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  5. Service Instructions Manual

U.S. Boiler Company MPO - IQ Service Instructions Manual

Summary of MPO - IQ

  • Page 1

    103859-05 - 10/14 price - $5.00 9700609 installation, operating and service instructions for mpo - iq™ 3-pass oil boiler for service or repairs to boiler, call your heating contractor. When seeking information on boiler, provide boiler model number and serial number as shown on rating label. Boiler ...

  • Page 2

    2 important information - read carefully the following terms are used throughout this manual to bring attention to the presence of hazards of various risk levels, or to important information concerning product life. Danger indicates an imminently hazardous situation which, if not avoided, will resul...

  • Page 3

    3 danger do not store or use gasoline or other flammable vapors or liquids in the vicinity of this or any other appliance. Warning improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury or loss of life. Failure to follow all instructions in t...

  • Page 4

    4 warning this boiler must be properly vented. The chimney must be inspected for any obstructions and cleaned prior to each heating season. A clean and unobstructed chimney flue is necessary to produce the minimum draft required to safely evacuate noxious fumes that could cause personal injury or lo...

  • Page 5

    5 congratulations on your purchase of a new mpo-iq™ boiler—designed and constructed to provide you with years of reliable service. • energy star™ efficiency – friendly on the environment and your wallet. • cast iron heat exchanger – for reliability and durability, nothing beats a cast iron heat exch...

  • Page 6

    6 figure 1: mpo-iq84 thru mpo-iq231 w ater boiler.

  • Page 7

    7 table 1a: dimensional da ta (see figure 1) table 1b: ra ting da ta boiler model no. Dimensions see figure 1 w ater content - gallons heat t ransfer surface area - sq. Ft. Actual shipping w eight (lb.) “a” “b” “c” mpo-iq84 16-5/8” 24” 5” 7.70 13.29 430 mpo-iq1 15 16-5/8” 24” 5” 7.70 13.29 430 mpo-i...

  • Page 8

    8 figure 2a: chimney vented boiler - minimum installation clearances to combustible materials (inches) a. Inspect shipment carefully for any signs of damage. 1. All equipment is carefully manufactured, inspected and packed. Our responsibility ceases upon delivery of crated boiler to the carrier in g...

  • Page 9

    9 c. Provide combustion and ventilation air. Local and national codes may apply and should be referenced. Warning adequate combustion and ventilation air must be provided to assure proper combustion and to maintain safe ambient air temperatures. Do not install boiler where gasoline or other flammabl...

  • Page 10

    10 6. Louvers and grilles of ventilation ducts a. All outside openings should be screened and louvered. Screens used should not be smaller than 1/4 inch mesh. Louvers will prevent the entrance of rain and snow. B. Free area requirements need to consider the blocking effect of louvers, grilles, or sc...

  • Page 11

    11 ii. Packaged boiler assembly - trim & controls a. Remove crate. 1. Remove all fasteners at crate skid. 2. Lift outside container and remove all other inside protective spacers and bracing. Remove miscellaneous parts carton. B. Remove boiler from skid. 1. To reduce the risk of damage to boiler jac...

  • Page 12

    12 figure 4a: partial front view - burner swing door mounted to boiler - fully closed and secured step 4. Disconnect burner power cord from receptacle located in lower right corner of jacket front panel. Step 5. Door can be swung to the fully open position, approximately 90° to 120°, with the burner...

  • Page 13

    13 figure 4b: top view - burner swing door mounted to cast iron block assembly (jacket removed for clarity) ii. Packaged boiler assembly - trim & controls (cont'd).

  • Page 14

    14 step 2. If necessary, place your right hand under the burner air tube to lift upward. Lift the door up unto the built-in cast ramp/door rest (protruding from the bottom of the front section casting - see figure 4a). Step 3. Use one hand to help hold door in position by lifting up on rear burner h...

  • Page 15

    15 figure 5: return injector piping and relief valve assembly details ii. Packaged boiler assembly - trim & controls (cont'd) figure 4d: burner swing door insulation 1. Install return injector piping and relief valve, refer to figure 5. Step a. Locate the return pipe fittings and injector. Apply sea...

  • Page 16

    16 • 1-1/2" npt horizontal left or right side return piping - install relief valve vertically in 3/4" npt tapping on tee. See figure 5. Step c. Pipe discharge of relief valve as shown in figures 13a and 13b. Installation of the relief valve must be consistent with ansi/asme boiler and pressure vesse...

  • Page 17

    17 figure 7: internal junction box and wiring harness details table 3: baffle usage boiler model baffle usage 2 nd pass 3 rd pass mpo-iq84 none [2] p/n 100081-01 mpo-iq115 [2] p/n 102066-01 mpo-iq147 [2] p/n 100042-01 none mpo-iq189 mpo-iq231 warning wire an additional safety limit such as a low wat...

  • Page 18

    18 figure 8: baffle orientation in flueways step a. Install stainless steel baffles provided in miscellaneous parts carton as follows, refer to table 3 and figure 8: • model mpo-iq84 - to install flueway baffle in 3 rd pass on left side of boiler, hold baffle with word "left" readable at the top. Sl...

  • Page 19

    19 figure 9: oil burner installation (beckett shown) 7. Install oil burner. (see figure 9) step a. Open burner carton and remove contents. Step b. Place oil burner gasket on burner and align holes. Caution do not install burner without gasket. Step c. Remove three (3) 5/16-18 x 3/4 lg. Cap screw fro...

  • Page 20

    20 iii. Unit-pak boiler assembly - trim & controls mpo-iq unit-pak boiler assembly shipment (-llu) content check list (see figure 10) 1. ___ cast iron section/burner swing door/smoke box assembly mounted on shipping skid: ____ mpo-iq84/115 – part # 103071-02 / 100045-01 / 100021-01 ____ mpo-iq147 – ...

  • Page 21

    21 a. Removal of cast iron section/burner swing door / smoke box assembly from skid. Warning the cast iron section/burner swing door/smoke box assembly has a substantial weight. Insure the travel path to permanent location, as well as mounting surface at boiler permanent location, are structurally s...

  • Page 22

    22 figure 1 1: boiler removal from skid iii. Unit -p ak boiler assembl y - trim & controls (continued).

  • Page 23

    23 front section right side. These four front section bosses are front jacket panel and door mounting bracket attachment points. 2. Open jacket carton and locate jacket front panel (has factory attached 1” fiberglass insulation). See also “repair parts” section, “jacket assembly” illustration for pa...

  • Page 24

    24 5. Position left cleanout cover over rear section cleanout opening, align section boss holes with cleanout cover holes, install both 5/16”-18 – 7/8” hex head cap screws hand tight, then, alternately tighten them with open end or socket wrench. 6. Repeat above steps with right cleanout cover. 7. A...

  • Page 25

    25 figure 12: immersion well probe insertion 11. Locate the jacket front cover from control carton. See also "repair parts" section, "jacket assembly" illustration for parts identification. 12. Align jacket front cover mounting holes with side panel holes and secure with four #8 x ½" oval sheet meta...

  • Page 26

    26 a. Evaluate the existing water system. Design a piping system and install boiler which will prevent oxygen contamination of boiler water and frequent water additions. 1. There are many possible causes of oxygen contamination such as: a. Addition of excessive make-up water as a result of system le...

  • Page 27

    27 figure 13a: recommended w ater piping for circulator zoned heating systems iv . W ater b oiler piping (continued).

  • Page 28

    28 figure 13b: recommended w ater piping for zone v alve zoned heating systems iv . W ater b oiler piping (continued).

  • Page 29

    29 5. See figure 14 for suggested near boiler piping of option card controls. Warning the use of a low water cut-off device, while not required unless radiation level is below the boiler, is highly recommended. If a low water cut-off is required, it must be mounted in the supply piping above the boi...

  • Page 30

    30 a. Chimney venting 1. Chimney venting is an important part of a safe and efficient oil fired appliance system. Contact your local fire and building officials on specific requirements for restrictions and the installation of fuel oil burning equipment. In addition, consult with a professional know...

  • Page 31

    31 figure 15: recommended vent pipe arrangement and chimney requirements figure 16: proper and improper locations of draft regulator v. Natural draft venting (continued).

  • Page 32

    32 danger any signs of condensate seepage at the base of the chimney shall be inspected immediately. The discoloration may be a sign of chimney damage and must be remedied immediately. C. Draft 1. The natural draft generated through a chimney is dependent on several factors including, chimney height...

  • Page 33

    33 e. Minimum clearances see figure 2a for details regarding clearances to combustibles for the boiler. F. Optional air intake piping installation - all air for combustion can be supplied directly to the burner from outdoors providing that the criteria for chimney, vent connector and minimum stack t...

  • Page 34

    34 vi. Direct venting / air intake piping (boiler models mpo-iq147 thru 231 only) a. General guidelines 1. Direct vent system must be installed in accordance with these instructions and applicable provisions of local building codes. Contact your local fire and building officials on specific requirem...

  • Page 35

    35 e. Not less than 3 ft (as measured to side of vent termination) from an inside corner of an l-shaped structure. F. Not less than 1 ft from the nearest surface of the terminal to a roof soffit. G. Not directly above, or, not less than 6 ft horizontally from an oil tank vent or gas meter. H. Not le...

  • Page 36

    36 c. Installation of vent hood tee 1. Assemble the vent hood tee body to the vent hood outer pipe, and, rotate the tee, so air intake inlet collar is in the desired position. See figure 21. 2. Attach the vent hood tee body to the vent hood outer pipe with at least tree sheet metal screws (installer...

  • Page 37

    37 boiler model no. Boiler flue outlet collar od (inch) vent hood inner pipe diameter (inch) flex oil vent pipe inner pipe diameter (inch) * flue outlet collar to vent pipe adapter (inch) mpo-iq147 6 5 6 to 5 mpo-iq189 mpo-iq231 7 6 7 to 6 note: * the model specific direct vent (fdvs) kit cartons co...

  • Page 38

    38 f. Connecting flex oil vent pipe to appliance adapter and direct vent termination 1. Flexible double wall oil vent pipe is available pre-cut from 5 ft to 20 ft long. If necessary, the vent pipe may be cut to required length with a hacksaw or cutoff saw. Caution use safety glasses and other approp...

  • Page 39

    39 figure 26: vent pipe assembly to vent termination inner pipe & appliance adapter figure 27: oil burner installation (beckett shown) g. Installing the air intake piping from direct vent termination to burner outside air adapter 1. Use 4" diameter galvanized single wall vent pipe and fittings, avai...

  • Page 40

    40 12. Assemble the vacuum relief valve balance weight onto the gate. Refer to the vacuum relief valve manufacturer’s instructions for details. 13. Mount the assembled vacuum relief valve gate with balance weight into the tee and fasten with a screw and nut in collar tabs. To insure proper operation...

  • Page 41

    41 a. General 1. Install wiring and electrically ground boiler in accordance with requirements of the authority having jurisdiction, or in absence of such requirements the national electrical code, ansi/nfpa 70, and/or the csa c22.1 electric code. 2. Refer to national electric code or local electric...

  • Page 42

    42 figure 28a: schematic w iring diagram vii. Electrical (continued).

  • Page 43

    43 figure 28b: schematic w iring diagram, burner options vii. Electrical (continued).

  • Page 44

    44 figure 28c: ladder diagram vii. Electrical (continued).

  • Page 45

    45 figure 29: single pipe oil line viii. Oil piping a. General 1. Use flexible oil line(s) so the burner swing door can be opened without disconnecting the oil supply piping. 2. A supply line fuel oil filter is recommended as a minimum for all firing rates but a pleated paper fuel oil filter is reco...

  • Page 46

    46 figure 30: two pipe oil lines c. Two pipe oil lines 1. For two piped systems, where more lift is required, the two-stage fuel unit is recommended. Table 7 (two-stage) and table 8 (single-stage) show allowable lift and lengths of 3/8 inch and 1/2 inch od tubing for both suction and return lines. R...

  • Page 47

    47 ix. System start-up warning all boilers equipped with burner swing door have a potential hazard which can cause severe property damage, personal injury or loss of life if ignored. Before opening swing door, turn off service switch to boiler to prevent accidental firing of burner outside the combu...

  • Page 48

    48 ix. System start-up (continued) d. Start oil burner. 1. Open oil supply to burner and vent fitting on fuel pump. 2. Turn 'on' electrical service switch to boiler. 3. Press "i" button on front of primary control, hold for ten (10) seconds and release to reset primary control. 4. Allow burner to ru...

  • Page 49

    49 ix. System start-up (continued) warning before installation of the boiler is considered complete, the operation of all boiler controls must be checked, particularly the primary control and high limit control. J. Verify honeywell oil primary features using procedures outlined in instructions furni...

  • Page 50

    50 figure 32: cad cell location ix. System start-up (continued) • if safety switch shuts down burner and resistance is above 1600 ohms, open line switch to boiler. Access cad cell under ignitor, clean face of cad cell and see that cell is securely in socket, see figure 32. Check gasket around perime...

  • Page 51

    51 important product safety information refractory ceramic fiber product warning : the repair parts list designates parts that contain refractory ceramic fibers (rcf). Rcf has been classified as a possible human carcinogen. When exposed to temperatures above 1805°f, such as during direct flame conta...

  • Page 52

    52 figure 33: boiler control & option panel orientation x. Operating a. Boiler sequence of operation 1. The boiler's sequence of operation is shown in table 9. 2. When there is a call for heat the boiler control starts the system circulator and the thermal purge (circulator pre- purge time) begins. ...

  • Page 53

    53 x. Operating (continued) the trial for ignition, the oil primary control will shut the burner down and enter into a hard lockout. The oil primary must be reset manually before the burner can be restarted. B. Using boiler control the boiler control is located under the jacket front cover, to the l...

  • Page 54

    54 x. Operating (continued) call for heat zc and zr terminal function ( zc_ ) boiler temp. Boiler status, (b1 output) tt = on -- start with no delay tt = on -- >140 start after 2 minute delay zr = on zc_ = zr start with no delay zr = on zc_ = zr >140 start after 2 minute delay zr = on zc_ = dh start...

  • Page 55

    55 table 11b: domestic hot water demand, (parameter zc_ = dh ) outdoor air reset option card installed. Call for heat outdoor air reset option card p/n 102294-01 circulator status t-t input zr input dhw input priority time priority time expired? C1 output zc output off -- off > 0 no off off on -- of...

  • Page 56

    56 x. Operating (continued) c. External low limit, parameter zc = ell the boiler control is capable of functioning as a warm start control when external limit control is installed that closes a contact when boiler water temperature falls below a setpoint. When an external limit contact closes (boile...

  • Page 57

    57 xi. Maintenance and service instructions a. Maintenance of low water cut-off devices (when installed) see instructions provided with low water cut-off option card for installation instructions. Warning probe type low water cut-off devices require annual inspection and maintenance. 1. Probe type l...

  • Page 58

    58 c. Remove relief valve using extreme care to avoid damaging it. D. Add an appropriate amount of recommended boil out compound. E. Replace relief valve. F. Fill the entire system with water. G. Start firing the boiler. H. Circulate the water through the entire system. I. Vent the system, including...

  • Page 59

    59 xii. Boiler cleaning a. Clean the flueways (see figure 35). 1. For access to the combustion chamber remove the two (2) 3/8" - 16 cap screws. If boiler is equipped with flexible fuel line(s), swing door open. 2. Remove the two smoke box clean-out covers from the rear smoke box by removing the four...

  • Page 60

    60 figure 35: cleaning of boiler flueways warning the boiler must be connected to an approved chimney in good condition. Serious property damage could result if the boiler is connected to a dirty or inadequate chimney. The interior of the chimney flue must be inspected and cleaned before the start o...

  • Page 61

    61 a. Combustion 1. Nozzles — although the nozzle is a relatively inexpensive device, its function is critical to the successful operation of the oil burner. The selection of the nozzle supplied with the mpo-iq boiler is the result of extensive testing to obtain the best flame shape and efficient co...

  • Page 62

    62 xiii. Trouble shooting (continued) possible err (boiler control error) values: err value description 1 temperature sensor fault 2 communications fault 3 internal hardware fault 4 burner output (b1) fault 5 line voltage fault ( 6 fuse missing 7 user setting lost, (reset to factory defaults) 8 manu...

  • Page 63

    63 possible erp (external error) values: display status recommended corrective actions err 1 temperature sensor fault temperature sensor failure, wire harness loose or shorted connection or control hardware failure: - check sensor is securely attached to boiler control - check that sensor wire is no...

  • Page 64

    64 xiii. Trouble shooting (continued) e. Use boiler control display err and erp numbers to direct troubleshooting (continued) display status recommended corrective actions erp 4 warning, cad cell resistance high (service required) the cad cell resistance is higher than normal while running, the syst...

  • Page 65

    65 xiii. Trouble shooting (continued) e. Use boiler control display err and erp numbers to direct troubleshooting (continued) display status recommended corrective actions erp 23 flame out of sequence, during pre-purge flame was proven during the valve on delay period. Check the oil valve for proper...

  • Page 66

    66 xiii. Trouble shooting (continued) f. Use boiler control display sta (status) number to guide troubleshooting the boiler control will flash “ sta ” followed by a number. Use this number to identify the boiler problem in the table below: 1. Burner and circulator off display / status recommended co...

  • Page 67

    67 6. Burner will light, then shut down after a short time, then restart xiii. Trouble shooting (continued) 5. Burner will not come on display / status recommended corrective action sta10 recycle / retry delay the burner loses flame during running mode ( sta code “ 8 ”). After a recycle delay the oi...

  • Page 68

    68 xiii. Trouble shooting (continued) g. Use option panel display to direct troubleshooting if boiler control shows status code “ sta 15 ": the boiler control is “waiting for limit to close and option panel display (display to right) will show one of the following status codes: option panel display ...

  • Page 69

    69 xiv. Repair parts all mpo-iq™ boiler repair parts may be obtained through your local u.S. Boiler company wholesale distributor. Should you require assistance in locating a u.S. Boiler company distributor in your area, or have questions regarding the availability of u.S. Boiler company products or...

  • Page 70

    70 bare boiler assembly xiv . R ep air p arts (continued).

  • Page 71

    71 item no. Description part no. Mpo-iq84 mpo-iq115 mpo-iq147 mpo-iq189 mpo-iq231 1. Bare boiler assembly 1a cast iron block assembly - 2 section 103071-02 1 1 --- --- --- cast iron block assembly - 3 section 103071-03 --- --- 1 --- --- cast iron block assembly - 4 section 103071-04 --- --- --- 1 --...

  • Page 72

    72 jacket assembly xiv . R ep air p arts (continued).

  • Page 73

    73 item no. Description part no. Mpo-iq84 mpo-iq115 mpo-iq147 mpo-iq189 mpo-iq231 2. Jacket assembly 2a jacket front panel assembly w/insulation 103053-01 1 1 1 1 1 2b power outlet receptacle, heyco #0937 8136522 1 1 1 1 1 2c #8 x 1/2” sheet metal screw, black oxide 80860061 33 33 33 33 33 2d jacket...

  • Page 74

    74 mpo-iq84 thru mpo-iq231 w ater boilers - t rim and controls xiv . R ep air p arts (continued).

  • Page 75

    75 item no. Description part no. Mpo-iq84 mpo-iq115 mpo-iq147 mpo-iq189 mpo-iq231 3. Mpo-iq84 thru mpo-iq231 water boilers - trim and controls 3a beckett afg oil burner w/gasket for: natural draft mpo-iq84 spec no. Bcb9502 104506-02 1 --- --- --- --- mpo-iq115 spec no. Bcb9503 104507-02 --- 1 --- --...

  • Page 76

    76 item no. Description part no. Mpo-iq84 mpo-iq115 mpo-iq147 mpo-iq189 mpo-iq231 4. Controls 4a iq oil boiler control 103851-01 1 1 1 1 1 4b iq option control panel 102291-01 1 1 1 1 1 4c line voltage harness 103058-02 1 1 1 1 1 4d low voltage harness 103059-03 1 1 1 1 1 4e burner-ecom harness 1030...

  • Page 77

    77 item no. Description part no. Mpo-iq147 mpo-iq189 mpo-iq231 5. Direct vent kits and parts 5a direct vent conversion kit , 5-6 102130-02 1 1 --- direct vent conversion kit, 6-7 102130-03 --- --- 1 5b appliance adapter, fdvs, 5-6 100234-02 1 1 --- appliance adapter, fdvs, 6-7 100234-03 --- --- 1 5c...

  • Page 78

    78 beckett afg burner xiv . R ep air p arts (continued).

  • Page 79

    79 beckett afg oil burner part nos. For mpo-iq series boilers natural draft applications note: when ordering parts always give the serial and model numbers shown on the boiler and burner. Also provide the name of the part(s) and part number as listed below. Boiler model mpo-iq84 mpo-iq115 mpo-iq147 ...

  • Page 80

    80 beckett n x burner xiv . R ep air p arts (continued).

  • Page 81

    81 beckett nx oil burner part nos. For mpo-iq series boilers direct vent applications note: when ordering parts always give the serial and model numbers shown on the boiler and burner. Also provide the name of the part(s) and part number as listed below. Item no. Part description mpo-iq147 mpo-iq189...

  • Page 82

    82 riello oil burner part numbers for mpo-iq series boilers note: when ordering parts always give the serial and model numbers shown on the boiler and burner. Refer to models f3 & f5 installation manual, riello 40 series residential oil burners (c6501010) or model f10 installation manual, riello 40 ...

  • Page 83

    83 boiler model burner input (gph) burner model nozzle air shutter (setting) air band (setting) pump pressure (psi) head type (setting) insertion depth (inch) approx. Shipped co 2 (%) baffle location (pass) approx. Stack temp. Increase without baffles °f (2) approx. Breech pressure (" w.C.) (3) baff...

  • Page 84

    84 boiler model burner input (gph) burner model nozzle head setting air setting pump pressure (psi) air tube type insertion depth (inch) approx. Shipped co 2 (%) baffle location (pass) approx. Stack temp. Increase without baffles °f (2) approx. Breech pressure (" w.C.) (3) baffles in approx. Overfir...

  • Page 85

    85 appendix a – oil boiler iq control system iq control system overview mpo-iq boiler uses a microprocessor based control system called the "iq control system". This "iq control system" consists of an iq oil boiler control in conjunction with an oil primary control and an iq option panel with option...

  • Page 86

    86 appendix a – oil boiler iq control system (continued) installing the outdoor reset iq option card is the simplest way to maximize the efficiency of any mpo-iq boiler. The outdoor reset iq option card is a microprocessor-based control that regulates the water temperature of the heating system base...

  • Page 87

    87 high limit iq option cards add auxiliary temperature limit-rated controls to mpo-iq boilers. High limit iq option cards plug into the iq option panel and connect to a system-mounted probe with a single molex connection. High limit iq option cards feature an adjustable set point and differential, ...

  • Page 88

    88 part number item description 102723-01 outside reset iq option card kit , domestic hot water priority, for use with iq option panel, with outside air temperature sensor, instructions, unit pack 102294-01 outdoor reset iq option card, domestic hot water priority, for use with iq option panel, less...

  • Page 89

    89 appendix b – figures figure number page number description figure 1 6 mpo-iq84 thru mpo-iq231 water boiler section i - pre-installation figure 2a 8 chimney vented boiler - minimum installation clearances to combustible materials (inches) figure 2b 9 direct vent boiler - minimum installation clear...

  • Page 90

    90 appendix b – figures (continued) figure number page number description section vii - electrical figure 28a 42 schematic wiring diagram figure 28b 43 schematic wiring diagram, burner options figure 28c 44 ladder diagram section viii - oil piping figure 29 45 single pipe oil line figure 30 46 two p...

  • Page 91

    91 appendix c – tables table number page number description 1a 7 dimensional data 1b 7 rating data section i - pre-installation table 2 10 direct vent configuration components section ii - packaged boiler assembly - trim & controls table 3 17 baffle usage section iv - water boiler piping table 4 26 ...

  • Page 92

    92 u.S. Boiler company, inc. P.O. Box 3020 lancaster, pa 17604 1-888-432-8887 www.Usboiler.Net.