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MFC Series Boilers User Manual USER MANUAL Installation, Operation and Maintenance of: MFC Series Multi-Fuel Condensing Boilers MFC 10000 Applies to MFC Series Models: MFC 3000 MFC 4000 MFC 5000 MFC 6000 MFC 8000 MFC 10000 NOTE: Refer to the AERCO MFC Series Installation Manual, GF-148-IN, for preliminary assembly and installation instructions and information. Latest Update: 02/08/2016 OMM-0104_93 AERCO International, Inc. 100 Oritani Dr. Blauvelt, NY 10913 Page 1 of 168 GF-148 Ph.: 800-526-0288 02/08/2016

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MFC Series Boilers User Manual

USER MANUAL Installation, Operation and Maintenance of:

MFC Series Multi-Fuel Condensing Boilers

MFC 10000

Applies to MFC Series Models: • MFC 3000 • MFC 4000 • MFC 5000 • MFC 6000 • MFC 8000 • MFC 10000

NOTE: Refer to the AERCO MFC Series Installation Manual, GF-148-IN, for preliminary assembly and installation instructions and information.

Latest Update: 02/08/2016

OMM-0104_93 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 1 of 168 GF-148 Ph.: 800-526-0288 02/08/2016

MFC Series Boilers User Manual CONTENTS

TABLE OF CONTENTS

FOREWORD .................................................................................................................................... 7

SECTION 1: SAFETY PRECAUTIONS ................................................................................ 8 1.1 Warnings & Cautions ...................................................................................................................... 8 1.2 Emergency Shutdown..................................................................................................................... 9 1.3 Prolonged Shutdown ...................................................................................................................... 9 1.4 Massachusetts Installations .......................................................................................................... 10

SECTION 2: INTRODUCTION ........................................................................................... 12 2.1 General Features .......................................................................................................................... 12 2.2 Certification References and Compliance ..................................................................................... 12 2.3 General Technical Specifications .................................................................................................. 13

SECTION 3: INSTALLATION ............................................................................................ 15 3.1 Receiving The Unit ....................................................................................................................... 15 3.2 Moving & Unpacking the Unit....................................................................................................... 15 3.3 Site Preparation ........................................................................................................................... 18

Electrical Requirements ......................................................................................................... 18 3.3.1 Natural Gas Requirements ..................................................................................................... 18 3.3.2 Installation Clearances ........................................................................................................... 19 3.3.3

3.4 Installation - Site .......................................................................................................................... 20 3.5 Boiler Room ................................................................................................................................. 20 3.6 Flue .............................................................................................................................................. 21 3.7 Water Connections....................................................................................................................... 21 3.8 Sealed Hot Water Heating System w/ Expansion Vessel................................................................ 21 3.9 Electrical Connections .................................................................................................................. 22 3.10 Burner Door Opening Orientation .............................................................................................. 23 3.11 Reversing the Opening Direction of the Burner Door .................................................................. 23 3.12 Adjusting the Boiler Door – Vertical and Horizontal .................................................................... 26

SECTION 4: STARTUP ..................................................................................................... 28 4.1 Preliminary Checks ....................................................................................................................... 28 4.2 Water Treatment ......................................................................................................................... 28

Scaling ................................................................................................................................... 28 4.2.1 Corrosion on the Water Side .................................................................................................. 28 4.2.2

4.3 Filling the System ......................................................................................................................... 29

SECTION 5: BURNER INSTALLATION ............................................................................ 30 5.1 Burner Pre-Installation Procedures ............................................................................................... 30 5.2 Burner Installation........................................................................................................................ 30

SECTION 6: MFC 3000 DUAL FUEL BURNER ................................................................. 31 6.1 MFC 3000 Dual Fuel Burner Features............................................................................................ 32 6.2 Burner Nozzle Setup ..................................................................................................................... 34

Recommended Nozzles .......................................................................................................... 34 6.2.1 Nozzle Assembly .................................................................................................................... 34 6.2.2

6.3 Flow Rate adjustment .................................................................................................................. 35 6.4 Electrode Positioning.................................................................................................................... 36 6.5 Burner Setup ................................................................................................................................ 37 6.6 Hydraulic Connections.................................................................................................................. 38 6.7 Pump ........................................................................................................................................... 39

Page 2 of 168 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_93 02/08/2016 Ph.: 800-526-0288 GF-148

MFC Series Boilers User Manual CONTENTS

Pump Priming ........................................................................................................................ 39 6.7.16.8 Gas Pressure ................................................................................................................................ 40 6.9 Combustion Head Adjustment...................................................................................................... 42 6.10 Pump Adjustment ...................................................................................................................... 43 6.11 Air Damper Adjustment .............................................................................................................. 43 6.12 Ignition Pilot Adjustment ............................................................................................................ 43 6.13 Adjustments before First Firing (Gas Operation) ......................................................................... 44 6.14 Startup for MFC 3000 Dual Fuel Burner ..................................................................................... 46

Gas/Air Delivery Adjustment ................................................................................................ 47 6.14.1 Adjusting Oil/Air Delivery ..................................................................................................... 47 6.14.2 Air Pressure Switch Adjustment ........................................................................................... 48 6.14.3 Maximum Gas Pressure Switch Adjustment .......................................................................... 49 6.14.4 Minimum Gas Pressure Switch Adjustment .......................................................................... 49 6.14.5 Low Oil Pressure Switch ....................................................................................................... 50 6.14.6 High oil pressure switch........................................................................................................ 50 6.14.7 Burner Startup Sequence of Operation ................................................................................. 51 6.14.8 Normal Operation Sequence of Operation ........................................................................... 52 6.14.9

6.15 Final Checks with Boiler in Operation ......................................................................................... 52

SECTION 7: MFC 3000 NATURAL GAS ONLY BURNER ................................................. 53 7.1 Combustion Head Adjustment ...................................................................................................... 56 7.2 Gas Supply Pressure ..................................................................................................................... 58

Figuring Burner Output .......................................................................................................... 59 7.2.1 Figuring Required Burner Output ........................................................................................... 60 7.2.2

7.3 Adjustments Before First Firing (Gas) ........................................................................................... 61 7.4 Startup for MFC 3000 Gas Only Burner ........................................................................................ 63

Gas/Air Delivery Adjustment .................................................................................................. 64 7.4.1 Air Pressure Switch Adjustment ............................................................................................. 65 7.4.2 Maximum Gas Pressure Switch Adjustment ............................................................................ 66 7.4.3 Minimum Gas Pressure Switch Adjustment ............................................................................ 66 7.4.4

7.5 Final Checks with Boiler in Operation ........................................................................................... 67

SECTION 8: MFC 4000 / 6000 DUAL FUEL BURNER ....................................................... 68 8.1 MFC 4000-6000 Dual Fuel Burner Features................................................................................... 69 8.2 Burner Nozzle Setup ..................................................................................................................... 71

Recommended Nozzles .......................................................................................................... 71 8.2.1 Nozzle Assembly .................................................................................................................... 71 8.2.2

8.3 Flow Rate Adjustment .................................................................................................................. 72 8.4 Ignition Pilot Adjustment .............................................................................................................. 74 8.5 Combustion Head Setting ............................................................................................................. 74 8.6 Pump Adjustment ........................................................................................................................ 75 8.7 Air Damper Adjustment................................................................................................................ 75 8.8 Electrode Positioning.................................................................................................................... 76 8.9 Burner Setup ................................................................................................................................ 77 8.10 Hydraulic Connections ................................................................................................................ 78 8.11 Pump ......................................................................................................................................... 79

Pump Priming ...................................................................................................................... 79 8.11.18.12 Gas Pressure .............................................................................................................................. 80 8.13 Burner Firing............................................................................................................................... 81 8.14 Burner Calibration ...................................................................................................................... 82 8.15 Adjustments Before First Firing (Gas Operation) ......................................................................... 82

OMM-0104_93 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 3 of 168 GF-148 Ph.: 800-526-0288 02/08/2016

MFC Series Boilers User Manual CONTENTS

Startup for MFC 4000 – 6000 Dual Fuel Burner .................................................................... 84 8.15.1 Gas/Air Delivery Adjustment ................................................................................................ 85 8.15.2 Adjusting Oil/Air Delivery ..................................................................................................... 85 8.15.3 Air Pressure Switch Adjustment ........................................................................................... 86 8.15.4 Maximum Gas Pressure Switch Adjustment .......................................................................... 87 8.15.5 Minimum Gas Pressure Switch Adjustment .......................................................................... 87 8.15.6 Low Oil Pressure Switch ....................................................................................................... 88 8.15.7 High oil pressure switch........................................................................................................ 88 8.15.8 Burner Startup Sequence of Operation ................................................................................. 89 8.15.9

Normal Operation Sequence of Operation ......................................................................... 90 8.15.108.16 Firing Failure............................................................................................................................... 90 8.17 Final Checks with Boiler in Operation ......................................................................................... 90

SECTION 9: MFC 4000-6000 GAS ONLY BURNER .......................................................... 91 9.1 Combustion Head Adjustment ...................................................................................................... 91 9.2 Gas Supply Pressure ..................................................................................................................... 93

Figuring Burner Output .......................................................................................................... 93 9.2.19.3 Adjustments Before First Firing .................................................................................................... 94 9.4 Startup for MFC 4000-6000 Gas Only Burner ............................................................................... 96

Combustion Air Adjustment ................................................................................................... 97 9.4.1 Gas/Air Delivery Adjustment .................................................................................................. 97 9.4.2 Air/Fuel Control and Power Modulation System .................................................................... 98 9.4.3

9.5 Final Calibration of the Pressure Switches .................................................................................... 99 Air Pressure Switch Adjustment ............................................................................................. 99 9.5.1 Maximum Gas Pressure Switch Adjustment .......................................................................... 100 9.5.2 Minimum Gas Pressure Switch Adjustment .......................................................................... 100 9.5.3

9.6 Final Checks with Boiler in Operation ......................................................................................... 101

SECTION 10: MFC 8000 / 10000 DUAL FUEL BURNER ................................................... 102 10.1 MFC 8000-10000 Dual Fuel Burner Features ............................................................................. 103 10.2 Burner Nozzle Setup ................................................................................................................. 105

Recommended Nozzles ...................................................................................................... 105 10.2.1 Nozzle Assembly ................................................................................................................ 105 10.2.2

10.3 Combustion Head setting ......................................................................................................... 106 10.4 Hydraulic Connections .............................................................................................................. 108 10.5 Pressure Variator ..................................................................................................................... 109 10.6 Pump ....................................................................................................................................... 110

Pump Priming .................................................................................................................... 110 10.6.110.7 Gas Train .................................................................................................................................. 111 10.8 Gas Pressure ............................................................................................................................ 111 10.9 Adjustments before First Firing (Light Oil Operation) ................................................................ 112 10.10 Nozzles ................................................................................................................................... 112 10.11 Combustion Head ................................................................................................................... 112 10.12 Pump Pressure ....................................................................................................................... 113 10.13 Burner Firing ........................................................................................................................... 113 10.14 Changing Fuel Type ................................................................................................................ 113 10.15 Adjustments before First Firing (Gas Operation) ..................................................................... 114 10.16 Burner Start-Up ...................................................................................................................... 115

Combustion Air Adjustment ............................................................................................. 116 10.16.1 Air Adjustment for Maximum Output ............................................................................... 116 10.16.2 Gas/Air Delivery Adjustment ............................................................................................ 116 10.16.3

Page 4 of 168 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_93 02/08/2016 Ph.: 800-526-0288 GF-148

MFC Series Boilers User Manual CONTENTS

Adjusting Oil/Air Delivery ................................................................................................. 117 10.16.4 Air/Fuel Control and Power Modulation System............................................................... 117 10.16.5

10.17 Final Calibration of the Pressure Switches .............................................................................. 118 Air Pressure Switch Adjustment........................................................................................ 118 10.17.1 Maximum Gas Pressure Switch Adjustment ...................................................................... 119 10.17.2 Minimum Gas Pressure Switch Adjustment ...................................................................... 119 10.17.3 Low Oil Pressure Switch.................................................................................................... 120 10.17.4 Burner Startup Sequence of Operation ............................................................................. 121 10.17.5 Normal Operation Sequence of Operation ....................................................................... 122 10.17.6

10.18 Firing Failure........................................................................................................................... 122 10.19 Final Checks with Boiler in Operation ..................................................................................... 122

SECTION 11: MFC 8000-10000 GAS ONLY BURNER ...................................................... 123 11.1 MFC 8000-10000 Gas Only Burner Features ............................................................................. 123 11.2 Combustion Head Adjustment .................................................................................................. 124 11.3 Rotation of the Fan Motor ........................................................................................................ 126 11.4 Gas Train .................................................................................................................................. 126 11.5 Gas Pressure ............................................................................................................................ 127 11.6 Adjustments before First Firing................................................................................................. 128 11.7 Startup for MFC 8000-10000 Gas Only Burner .......................................................................... 130

Burner Firing ...................................................................................................................... 131 11.7.1 Combustion Air Adjustment ............................................................................................... 131 11.7.2 Gas/Air Delivery Adjustment .............................................................................................. 131 11.7.3 Air/Fuel Control and Power Modulation System................................................................. 132 11.7.4

11.8 Final Calibration of the Pressure Switches ................................................................................ 133 Air Pressure Switch Adjustment ......................................................................................... 133 11.8.1 Maximum Gas Pressure Switch Adjustment ........................................................................ 134 11.8.2 Minimum Gas Pressure Switch Adjustment ........................................................................ 134 11.8.3

11.9 Final Checks with Boiler in Operation ....................................................................................... 135

SECTION 12: FLAME SIGNAL MEASUREMENT .............................................................. 136 Final Checks with Boiler in Operation ................................................................................. 136 12.1.1

SECTION 13: MFC SERIES MAINTENANCE .................................................................... 137 13.1 Preparation for Inspection and Maintenance............................................................................ 137 13.2 Standard Maintenance ............................................................................................................. 138 13.3 Burner Maintenance ................................................................................................................ 139 13.4 RS-120 / RS-160 Burner Maintenance (MFC 3000-6000) ........................................................... 139

Combustion ....................................................................................................................... 139 13.4.1 Gas Leaks ........................................................................................................................... 139 13.4.2 Flame inspection Window .................................................................................................. 139 13.4.3 Combustion Head .............................................................................................................. 140 13.4.4 Nozzles (Fuel Oil) (Dual Fuel Models Only) ......................................................................... 140 13.4.5 Flexible Hoses (Fuel Oil) (Dual Fuel Models Only) ............................................................... 140 13.4.6 UV Scanner ........................................................................................................................ 140 13.4.7 Burner ............................................................................................................................... 141 13.4.8 Combustion ....................................................................................................................... 141 13.4.9

13.5 RS-300 Burner Maintenance (MFC 8000-10000) ....................................................................... 141 Maintenance Frequency .................................................................................................... 141 13.5.1 Combustion ....................................................................................................................... 141 13.5.2 Gas Leaks ........................................................................................................................... 141 13.5.3 Combustion Head .............................................................................................................. 141 13.5.4

OMM-0104_93 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 5 of 168 GF-148 Ph.: 800-526-0288 02/08/2016

MFC Series Boilers User Manual CONTENTS

Measurement of Detector Current ..................................................................................... 141 13.5.5 Fan .................................................................................................................................... 142 13.5.6 Burner ............................................................................................................................... 142 13.5.7 Boiler ................................................................................................................................. 142 13.5.8

13.6 Light Oil Operation (MFC 8000-10000 Dual Fuel Only) .............................................................. 142 Pump ................................................................................................................................. 142 13.6.1 Filters................................................................................................................................. 142 13.6.2 Nozzles .............................................................................................................................. 142 13.6.3 Flexible Hoses .................................................................................................................... 142 13.6.4 Fuel Tank ........................................................................................................................... 142 13.6.5 Combustion ....................................................................................................................... 142 13.6.6

13.7 Gas Operation (MFC 8000-10000 Only) .................................................................................... 142 Gas Leaks ........................................................................................................................... 142 13.7.1 Gas filter ............................................................................................................................ 143 13.7.2 Combustion ....................................................................................................................... 143 13.7.3

APPENDIX A – OPERATIONAL SEQUENCE DIAGRAMS ................................................. 144 13.8 MFC 3000-6000 Sequence of Operation Diagram ..................................................................... 144 13.9 MFC 8000-10000 Sequence of Operation Diagram ................................................................... 145

APPENDIX B – ELECTRICAL DIAGRAMS ........................................................................ 148 MFC 3000 / 4000 / 5000 / 6000 Electrical Diagrams 1-8 ................................................................... 148 MFC 8000/10000 - ElectRICAL Diagrams 1-9..................................................................................... 157

Page 6 of 168 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_93 02/08/2016 Ph.: 800-526-0288 GF-148

MFC Series Boilers User Manual FORWARD

Foreword The AERCO MFC Series boilers are modulating and condensing units. The MFC Series represents a true industry advancement that meets the needs of today's energy and environmental concerns. Designed for application in any closed loop hydronic system, the MFC Series modulating capability relates energy input directly to fluctuating system loads. The maximum turn down ratio for these units is 5:1. The MFC Series provides extremely high efficiency and makes it ideally suited for modern low temperature, as well as, conventional heating systems and higher temperature systems (up to 230°F).

The MFC Series operates within the following input and output ranges:

MFC Series INPUT and OUTPUT RANGES (Btu/Hr.)

MODEL INPUT RANGE (BTU/HR.) OUTPUT RANGE (BTU/HR.) at High Fire Rate*

Min. Max. Min. Max. MFC 3000 600,000 3,000,000 2,565,000 2,850,000

MFC 4000 800,000 4,000,000 3,420,000 3,800,000

MFC 5000 1,000,000 5,000,000 4,275,000 4,750,000

MFC 6000 1,200,000 6,000,000 5,130,000 5,700,000

MFC 8000 1,600,000 8,000,000 6,840,000 7,600,000

MFC 10000 2,000,000 10,000,000 8,550,000 9,500,000

* Output based on a supply temperature based 80°F incoming water with a 20F° rise.

Whether used in singular or modular arrangements, the MFC Series offers the maximum venting flexibility with minimum installation space requirements. These Boilers are Category II and IV, positive pressure appliances. Single and/or multiple breeched units are capable of operation in the following vent configurations:

• Room Combustion Air: o Vertical Discharge o Horizontal Discharge

• Ducted Combustion Air: o Vertical Discharge o Horizontal Discharge

These boilers are capable of being vented utilizing AL29-4C vent systems only.

The available burner’s advanced electronics are available with several selectable modes of operation offering the most efficient operating methods and energy management system integration.

IMPORTANT: Unless otherwise specified, all descriptions and procedures provided in this Installation, Operation & Maintenance Manual apply to the MFC Series boilers.

OMM-0104_93 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 7 of 168 GF-148 Ph.: 800-526-0288 02/08/2016

MFC Series Boilers User Manual CHAPTER 1: SAFETY PRECAUTIONS

SECTION 1: Safety Precautions

1.1 Warnings & Cautions Installers and operating personnel MUST, at all times, observe all safety regulations. The following warnings and cautions are general and must be given the same attention as specific precautions included in these instructions. In addition to all the requirements included in this AERCO Instruction Manual, the installation of units MUST conform with local building codes, or, in the absence of local codes, ANSI Z223.1 (National Fuel Gas Code Publication No. NFPA-54) for gas-fired boilers and ANSI/NFPASB for LP gas-fired boilers, as well as NFPA 31 “Standard for the Installation of Oil-Burning Equipment”, and NFPA 54 for gas piping compliance requirements. Where applicable, the equipment shall be installed in accordance with the current Installation Code for Gas Burning Appliances and Equipment, CSA B149.1, and applicable Provincial regulations for the class; which should be carefully followed in all cases. Authorities having jurisdiction should be consulted before installations are made.

See pages 14 and 15 for important information regarding installation of units within the Commonwealth of Massachusetts.

IMPORTANT: This Instruction Manual is an integral part of the product and must be maintained in legible condition. It must be given to the user by the installer and kept in a safe place for future reference.

WARNING: • Do not use matches, candles, flames, or other sources of ignition to check for gas leaks.

• Fluids under pressure may cause injury to personnel or damage to equipment when released. Be sure to shut off all incoming and outgoing water shutoff valves. Carefully decrease all trapped pressures to zero before performing any waterside maintenance or inspection.

• Before attempting to perform any maintenance on the unit, shut off all gas and electrical inputs to the unit.

• The exhaust vent pipe of the unit may operate under a positive pressure and therefore must be completely sealed to prevent leakage of combustion products into living spaces.

• Electrical voltages up to 575 VAC may be used in this equipment. Therefore the burner cover and all other junction boxes must be installed at all times, except during maintenance and servicing.

• A three-pole switch must be installed on the electrical supply line of the unit. The switch must be installed in an easily accessible position to quickly and safely disconnect electrical service. Do not affix switch to unit or burner enclosures.

CAUTION: • Many kinds of soap used for gas pipe leak testing are corrosive to metals. The piping must

be rinsed thoroughly with clean water after leak checks have been completed.

• DO NOT use this boiler if any part has been under water. Call a qualified service technician to inspect and replace any part that has been under water.

Page 8 of 168 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_93 02/08/2016 Ph.: 800-526-0288 GF-148

MFC Series Boilers User Manual CHAPTER 1: SAFETY PRECAUTIONS

1.2 Emergency Shutdown If overheating occurs or the gas supply fails to shut off, close the manual gas shutoff valve (Figure 1-1) located external to the unit.

NOTE: The Installer must identify and indicate the location of the emergency shutdown manual gas valve to operating personnel.

Figure 1-1: Manual Gas Shutoff Valve

1.3 Prolonged Shutdown If the boiler is to be taken out of service for an extended period of time (one year or more), perform the following procedure.

Shutting Boiler Down for Extended Period

1. Set ON/OFF switch on the front panel to the OFF position to shut down the boiler’s operating controls.

2. Disconnect AC power from the unit.

3. Close the water supply and return valves to isolate boiler. 4. Close external gas supply valve.

5. Open relief valve to vent water pressure.

To bring the boiler back into service after a prolonged shutdown (one year or more), the following procedures must be followed:

Placing Boiler in Service After Long Shutdown

1. Review installation requirements included in Chapter 3.

2. Inspect all piping and connections to the unit. 3. Inspect exhaust vent and air inlet duct work (if applicable).

4. Perform initial startup per Chapter 5.

5. Perform scheduled maintenance procedures per Chapters 6 of this manual.

OMM-0104_93 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 9 of 168 GF-148 Ph.: 800-526-0288 02/08/2016

MFC Series Boilers User Manual CHAPTER 1: SAFETY PRECAUTIONS

1.4 Massachusetts Installations Boiler installations within the Commonwealth of Massachusetts must conform to the following requirements:

• Boiler must be installed by a plumber or a gas fitter who is licensed within the Commonwealth of Massachusetts.

• Prior to unit operation, the complete gas train and all connections must be leak tested using a non-corrosive soap.

• AERCO provides an optional external CO Detector, part number 58092. It can be installed and conFigured to simply sound an alarm or to shut down the boiler(s) if CO concentrations rise above a configurable threshold. Contact your AERCO representative for details.

• The vent termination must be located a minimum of 4 feet above grade level. If side-wall venting is used, the installation must conform to the following requirements extracted from 248 CMR 5.08 (2):

(a) For all side wall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above finished grade in the area of the venting, including but not limited to decks and porches, the following requirements shall be satisfied:

• INSTALLATION OF CARBON MONOXIDE DETECTORS. At the time of installation of the side wall horizontal vented gas fueled equipment, the installing plumber or gasfitter shall observe that a hard wired carbon monoxide detector with an alarm and battery back-up is installed on the floor level where the gas equipment is to be installed. In addition, the installing plumber or gasfitter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling, building or structure served by the side wall horizontal vented gas fueled equipment. It shall be the responsibility of the property owner to secure the services of qualified licensed professionals for the installation of hard wired carbon monoxide detectors.

a. In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic, the hard wired carbon monoxide detector with alarm and battery back-up may be installed on the next adjacent floor level.

b. In the event that the requirements of this subdivision can not be met at the time of completion of installation, the owner shall have a period of thirty (30) days to comply with the above requirements; provided, however, that during said thirty (30) day period, a battery operated carbon monoxide detector with an alarm shall be installed.

1. APPROVED CARBON MONOXIDE DETECTORS. Each carbon monoxide detector as required in accordance with the above provisions shall comply with NFPA 720 and be ANSI/UL 2034 listed and IAS certified.

2. SIGNAGE. A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum height of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment. The sign shall read, in print size no less than one-half (1/2) inch in size, "GAS VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS".

3. INSPECTION. The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation unless, upon inspection, the inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR 5.08(2)(a)1 through 4.

Page 10 of 168 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_93 02/08/2016 Ph.: 800-526-0288 GF-148

MFC Series Boilers User Manual CHAPTER 1: SAFETY PRECAUTIONS

(b) EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08(2)(a)1 through 4:

1. The equipment listed in Chapter 10 entitled "Equipment Not Required To Be Vented" in the most current edition of NFPA 54 as adopted by the Board; and

2. Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from the dwelling, building or structure used in whole or in part for residential purposes.

(c) MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM PROVIDED. When the manufacturer of Product Approved side wall horizontally vented gas equipment provides a venting system design or venting system components with the equipment, the instructions provided by the manufacturer for installation of the equipment and the venting system shall include:

1. Detailed instructions for the installation of the venting system design or the venting system components; and

2. A complete parts list for the venting system design or venting system.

(d) MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED. When the manufacturer of a Product Approved side wall horizontally vented gas fueled equipment does not provide the parts for venting the flue gases, but identifies "special venting systems", the following requirements shall be satisfied by the manufacturer:

1. The referenced "special venting system" instructions shall be included with the appliance or equipment installation instructions; and

2. The "special venting systems" shall be Product Approved by the Board, and the instructions for that system shall include a parts list and detailed installation instructions.

(e) A copy of all installation instructions for all Product Approved side wall horizontally vented gas fueled equipment, all venting instructions, all parts lists for venting instructions, and/or all venting design instructions shall remain with the appliance or equipment at the completion of the installation.

____________________________________________________________________________ [End of Extracted Information From 248 CMR 5.08 (2)]

OMM-0104_93 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 11 of 168 GF-148 Ph.: 800-526-0288 02/08/2016

MFC Series Boilers User Manual CHAPTER 2: INTRODUCTION

SECTION 2: Introduction

2.1 General Features The AERCO Multi-Fuel Condensing (MFC) Fire Tube Water Boiler is designed for condensing application in any closed loop hydronic system. It features a proven 4-pass fire tube heat exchanger design for maximum heat transfer and efficiency. The heat exchanger’s combination of high quality carbon steel/316Ti stainless steel construction ensures the highest degree of durability. The 316Ti SS construction in the heat exchanger’s 4th pass offers superior corrosion resistance against acidic flue gas condensation. Likewise, it can be fired with multiple fuels including natural gas, propane or #2 fuel oil (as backup), offering dual fuel flexibility. Moreover, the MFC series features dual return connections standard for optimal application flexibility and seasonal efficiency gains of up to 12%. The heat exchanger’s maximum working temperature of 240°F allows for greater operating temperature range and meet the requirements of higher temperature applications when necessary, but allows for the building to reset water temperature for condensing in the shoulder months.

2.2 Certification References and Compliance Each boiler and Stainless Steel 4th Pass is provided with a manufacture plate that can be found in the envelope with the boiler documents. The plate lists:

Manufacturer Plate Information BOILER STAINLESS STEEL 4TH PASS

Serial Number Serial Number Minimum Relief Valve Capacity Maximum Water Temperature Heating Surface Area Maximum Operating Pressure Maximum Water Temperature Maximum Operating Pressure

The installation must be performed in compliance with the regulations in force by professionally qualified personnel. The term “professionally qualified personnel” means persons with specific technical skills in the sector of heating system components. Incorrect installation may cause damage to persons, animals or objects for which the manufacturer cannot be held responsible.

At the first start up, all regulation and control devices positioned on the control panel should be checked for proper operation.

The warranty shall be valid only upon compliance with the instruction given in this manual.

The AERCO MFC Series boilers have been built and tested in observance of ASME requirements and UL (In Process), when ordered with a factory supplied burner.

Page 12 of 168 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_93 02/08/2016 Ph.: 800-526-0288 GF-148

MFC Series Boilers User Manual CHAPTER 2: INTRODUCTION

2.3 General Technical Specifications MFC Series General Technical Specifications MFC 3000 MFC 4000 MFC 5000 MFC 6000 MFC 8000 MFC 10000 Boiler Category ASME Sect.IV

Max. Allowed Working Pressure 80 PSIG

Max. Working Temperature 240°F

Gas Connections (NPT) 2” 2” 2’’ 2’’ 3’’ (Flange) 3’’ (Flange) Oil Connections .375” .375” .5” .5” .5” .5” Max. Gas Pressure 2 psi 2 psi 2 psi 2 psi 5 psi 2 psi Min. Gas Pressure 1 5” 5” 5” 5” 5” 5” Max #2 Fuel Oil Consumption Flow rate (GPH) 21.4 28.6 35.7 42.9 57.1 71.4

#2 Fuel Oil Supply Flow Rate 85 150 150 150 218 218 Electrical Req. 208V/3PH/60Hz 2, 3 11.4 FLA 16.8 FLA 16.8 FLA 16.8 FLA 25.8 FLA 25.8 FLA Electrical Req. 460V/3PH/60Hz 2, 3 5.8 FLA 7.6 FLA 7.6 FLA 7.6 FLA 11.7 FLA 11.7 FLA Electrical Req. 575V/3PH/60Hz 2,3 4.5 FLA 6.2 FLA 6.2 FLA 6.2 FLA 10.2 FLA 10.2 FLA Control Circuit 120V/1PH/60Hz 2, 3 6.8 FLA Water Connections (Flanged) 4’’ 6” 6” 6” 8” 8” Dual Return Water Connection Yes Min. Water Flow (GPM)

4 0 / 19 0 / 25 0 / 31 0 / 38 0 / 50 0 / 62 Max. Water Flow (GPM) 350 520 610 700 890 1100 Water Volume Gallons 407 464 518 724 898 1043

Water Pressure Drop 2.4 PSIG @300 GPM

1 PSIG @400 GPM

1.3 PSIG @500 GPM

1.9 PSIG @600 GPM

1.1 PSIG @800 GPM

1.7 PSIG @1000 GPM

Turndown (Natural Gas/Propane) Up to 5:1 (20%) Turndown (#2 Fuel Oil) Progressive Vent/Air Intake Connections 10 Inch 12 Inch 12 Inch 14 Inch 16 Inch 16 Inch Vent Materials AL29-4C Type of Fuel Natural Gas, Propane, #2 Fuel Oil (backup) NOx Emiss <30ppm Capab* on Nat. Gas Yes Temperature Control Range 80ºF to 230ºF Ambient Temperature Range 32ºFto140ºF (Preliminary) Standard Listings & Approvals UL(pending), CUL(pending), CSD-1, ASME, AHRI(pending) Gas Train Operations FM Compliant Weight (dry) Lbs. 7,102 9,680 10,670 13,794 15,620 18,612

Weight (wet) Lbs. 10,462 13,780 15,134 18,926 23,639 26,723 Shipping Weight Lbs. (preliminary) 7,190 9,768 10,758 13,882 15,708 18,700

NOTES: 1 Values are for Natural Gas FM Compliant gas trains available with Riello Dual Fuel (light oil/gas) burners. See MFC Series Gas/Oil Components & Supply Design Guide GF-148-G for additional model gas train minimum gas pressure requirements. 2 See the MFC Electrical Power Guide, GF-148-E, for Service Disconnect Switch amperage requirements. 3 Values are for Riello Dual Fuel (light oil/gas) RLS 120-300 models. Consult MFC Electrical Power Guide, GF-148-E, for additional model and power requirements. 4 Zero flow allowed during warm-up period of 5 minutes maximum. The second number is the minimum flow after the warm-up period and represents the boiler firing at the minimum input with a 60 degree delta T across the heat exchanger.

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MFC Series Boilers User Manual CHAPTER 2: INTRODUCTION

MFC Series – Dimensions

Model

A (Width)

B (Length)

C (Height)

D

E

F

G

H

I

J

K

L

M

N

O

P

Q

R

S (REF)

MFC 3000

54.3”

167.6”

84.0”

63.0”

126.4”

6.6”

72.9”

0.6”

12.6”

35.2”

73.0”

48.9”

5.0”

0.6”

18.1”

6.5”

27.6”

6.9”

27.2”

MFC 4000

58.7"

170.1”

88.3”

66.1”

129.0”

7.3”

75.4”

4.5”

16.2”

36.2”

76.2”

48.9”

3.4”

0.5”

17.3”

6.4”

27.4”

6.9”

29.3”

MFC 5000

58.7"

182.3”

88.3”

66.1”

141.2”

7.3”

75.4”

4.5”

16.2”

36.2”

76.2”

49.3”

3.4”

0.5”

17.3”

6.4”

35.6”

6.9”

29.3”

MFC 6000

70.9"

185.0”

101.1”

76.8”

143.8”

8.5”

87.1”

3.1”

22.8”

40.9”

86.8”

50.8”

4.4”

1.1”

21.1”

6.6”

53.2”

6.7”

35.4”

MFC 8000

70.9"

216.3”

102.3”

76.8”

163.5”

8.5”

87.1”

7.8”

22.8”

40.9”

86.8”

53.8”

3.1”

1.1”

18.1”

7.2”

55.9”

7.1”

35.4”

MFC 10000

70.9”

236.0”

102.3”

76.8”

183.2”

8.5”

87.1”

7.8”

22.8”

40.9”

86.8”

52.7”

3.0”

1.1”

18.0”

7.2”

70.9”

7.9”

35.4”

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MFC Series Boilers User Manual CHAPTER 3 - INSTALLATION P

SECTION 3: Installation

3.1 Receiving The Unit Each MFC Series boiler is shipped as a double crated unit, comprised of boiler and Stainless Steel 4th Pass. The shipping weight for the MFC Series boiler is as follows for each model:

MFC 3000

MFC 4000 MFC 5000 MFC 6000 MFC 8000 MFC 10000 SHIPPING WEIGHT LBS. 7,190 9,768 10,758 13,882 15,708 18,700

The unit must be moved with the proper rigging equipment for safety and to avoid equipment damage. The unit should be completely inspected for evidence of shipping damage and shipment completeness at the time of receipt from the carrier and before the bill of lading is signed.

3.2 Moving & Unpacking the Unit While packaged in the shipping container, the unit can be moved using a forklift. Refer to the chart above in order to properly size forklift or other necessary equipment that may be required in order to move the unit.

Carefully unpack the unit taking care not to damage the unit enclosure when cutting away packaging materials

The following accessories come standard with each unit and are either factory installed on the unit or packed separately with the unit:

MFC Series Accessories ITEM QUANTITY PART NO. DESCRIPTION

1 See Table A See Table A Relief valve 2 See Table A See Table A Pipe Nipple 3 See Table A See Table A Bushing 4 1 123675-2 Tridicator 5 1 121700 Low Water Cut Off 6 1 24441 Condensate Trap 7 1 64115 Aquastat 8 1 64116 Manual Reset Aquastat 9 1 99235 Thermowell

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MFC Series Boilers User Manual CHAPTER 3 - INSTALLATION

Table A - MFC Series Accessories

Refer to the MFC Boiler Field Assembly (TID-0164) for more information.

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MFC Series Boilers User Manual CHAPTER 3 - INSTALLATION P

MFC Factory Installed Parts ITEM DESCRIPTION QTY

1 BODY BOILER 1 2 STAINLESS STEEL 4TH PASS 1 3 CONNECTION PIPE FRONT 1 4 CONNECTION PIPE REAR 1 5 EXPANSION JOINT 1 6 SCREW 32 7 NUTS 32 8 CONNECTION PIPE GASKETS 4 9 ELBOW 2

10 BOILER DRAIN PIPE 1 11 BOILER DRAIN PIPE 1 12 THERMOINSULATING MATERIAL KIT FOR BURNER HEAD 1 13 SCREW BETWEEN STAINLESS STEEL 4TH PASS AND BOILER 9 14 LARGE WASHERS BETWEEN STAINLESS STEEL 4TH PASS AND

9

15 CONN. PIPE SUPPORT 2 16 SCREWS 4 17 NUTS for CONN. PIPE 4 18 LOCK WASHERS for CONN. PIPE 8 19 TUBE CLEANING BRUSH 1 20 DOOR OPENING TOOL 1

Figure 2-1: MFC Factory Installed Parts

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MFC Series Boilers User Manual CHAPTER 3 - INSTALLATION

3.3 Site Preparation Electrical Requirements 3.3.1

(Refer to MFC Electrical Guide; GF-148-E / TAG-0077)

MFC Series boilers require 3∅ for the burner and include a step-down transformer as standard to provide 120VAC power to the control portion of the burner. Voltage requirements for each model are shown in the tables below:

Multi-Fuel (Gas-Oil) Power Requirements (Amperage) MFC Burner 208/3∅/60 460/3∅/60 575/3∅/60 3000 RLS120 20.0 15.0 15.0 4000 RLS160 30.0 15.0 15.0 5000 RLS160 30.0 15.0 15.0 6000 RLS160 30.0 15.0 15.0 8000 RLS300 40.0 20.0 15.0 10000 RLS300 40.0 20.0 15.0

Gas Burner Power Requirements (Amperage) MFC Burner 208/3∅/60 460/3∅/60 575/3∅/60 3000 RS70 15.0 15.0 15.0 4000 RS100 15.0 15.0 15.0 5000 RS130 15.0 15.0 15.0 6000 RS190 20.0 15.0 15.0 8000 RS250 30.0 15.0 15.0 10000 RS300 30.0 15.0 15.0

Natural Gas Requirements 3.3.2 (Refer to MFC Fuel Guide; GF-148-G / TAG-0078)

MFC boilers must have access to a Natural Gas line with the following minimum pressures with the unit at FULL FIRE:

• MFC 3000 = 14” W.C. • Other MFC Models = 1 psi.

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MFC Series Boilers User Manual CHAPTER 3 - INSTALLATION P

Installation Clearances 3.3.3 The MFC series boiler dimensions and minimum acceptable clearances are shown in Figures 4-1 and 4-2. The minimum clearance dimensions, required by AERCO, are listed below. However, if Local Building Codes require additional clearances, these codes shall supersede AERCO’s requirements. Minimum acceptable clearances required are as follows:

• FRONT: = 24 inches (610 mm) (From front of blower).

NOTE: This is a minimum requirement per NFPA. If a tube must be replaced, the following minimum front door clearances are required:

MFC 3000 80” (2032 mm) MFC 4000 - 5000 92” (2336.8 mm) MFC 6000 - 10000 133” (3378.2 mm)

• SIDES: = 24 inches (610 mm) • REAR: = 24 inches (610 mm) • TOP: = 12 inches (457 mm) from top of secondary inlet (high temp.) pipe connection.

NOTE: MFC Series boilers may be installed side by side with a minimum 6" side clearance, as long as there is access to the rear of the units. Note the necessary burner door orientation per Figure 3-2. The perimeter clearances still apply. The door hinge will need to be reversed on one of the paired units. Refer to Section 3.11 for instructions on how to reverse the opening direction of the door.

All gas piping, water piping and electrical conduit or cable must be arranged so that they do not interfere with the removal of any panels, or inhibit service or maintenance of the unit.

Figure 3-1: MFC Series – Single Unit Installation Clearances

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MFC Series Boilers User Manual CHAPTER 3 - INSTALLATION

Figure 3-2: MFC Series – Multiple Unit Installation Clearances

WARNING: Keep the unit area clear and free from all combustible materials and flammable vapors or liquids.

FOR MASSACHUSSETTS ONLY: For Massachusetts installations, the unit must be installed by a plumber or gas-fitter that is licensed within the Commonwealth of Massachusetts. In addition, the installation must comply with all requirements specified in Chapter 1 – Safety Precautions.

3.4 Installation - Site Before connecting the boiler, perform the following operations:

• Thoroughly clean all the system pipes in order to remove any foreign matter that could affect correct operation of the boiler.

• Check that the flue has an adequate draught, that there is no narrowing of passages and that it is free from debris; also check that other appliances do not discharge into the flue (unless designed to serve several utilities). See the regulations in force.

3.5 Boiler Room Current regulations must always be observed. Premises in which boilers will be installed should be sufficiently ventilated and permit access for maintenance operations.

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MFC Series Boilers User Manual CHAPTER 3 - INSTALLATION P

3.6 Flue The exhaust flue must be dimensioned as to applicable regulations. See the MFC Series Venting Guide, GF-148-V for venting installation instructions and guidelines.

3.7 Water Connections NOTE: Refer to Boiler Application Guide, GF-148-B for specific guidelines regarding installation of a variety of different water piping configurations and applications. The following are general guidelines only.

Refer to Figure 3-3 for component identification in a sealed hot water heating system with an expansion tank and Figure 2-1 for an example of MFC Series water connections. Ensure that the hydraulic pressure measured after the reduction valve on the supply pipe does not exceed the operating pressure specified on the rating plate of the boiler.

• As the water contained in the heating system increases in pressure during operation, ensure that its maximum value does not exceed the maximum hydraulic pressure specified on the component rating plate.

• Ensure that the safety valve outlets of the boiler and hot water tank, if any, have been connected to an exhaust funnel in order to prevent the valves from flooding the room if they open.

• Ensure that the pipes of the water and heating system are not used as an earth connection for the electrical system as this can seriously and very rapidly damage the pipes, boiler, heater and radiators.

• Once the heating system has been filled, you are advised to close the supply cock and keep it closed so that any leaks from the system will be identified by a drop in hydraulic pressure indicated on the system pressure gauge.

3.8 Sealed Hot Water Heating System w/ Expansion Vessel The boiler must be provided with the following:

• Safety valve(s),

• Expansion vessel

• Boiler Outlet Temperature Sensor with thermal well

• Operating Aquastat with thermal well

• Manual Reset Aquastat with thermal well

• Low-Water Cutoff Device

• Tridicator

• Condensate drain

• Boiler drain

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MFC Series Boilers User Manual CHAPTER 3 - INSTALLATION

Figure 3-3: MFC Series – Water Connections and Components Example

3.9 Electrical Connections Electrical systems of thermal plants designed only for heating purposes must comply with numerous legal regulations which apply in general as well as specifically to each application or fuel type.

Each unit must be connected to a dedicated electrical circuit. NO OTHER DEVICES SHOULD BE ON THE SAME ELECTRICAL CIRCUIT AS THE BOILER.

A three-pole switch must be installed on the electrical supply line in an easily accessible location to quickly and safely disconnect electrical service. DO NOT attach the switch to sheet metal enclosures of the unit.

After placing the unit in service, the ignition safety shutoff device must be tested. If an external electrical power source is used, the installed boiler must be electrically bonded to ground in accordance with the requirements of the authority having jurisdiction. In the absence of such requirements, the installation shall conform to National Electrical Code (NEC), ANSI/NFPA 70 and/or the Canadian Electrical Code (CEC) Part I, CSA C22.1 Electrical Code.

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MFC Series Boilers User Manual CHAPTER 3 - INSTALLATION P

3.10 Burner Door Opening Orientation The boiler door is installed at the factory with standard opening from the left and with functioning hinges on the right. Refer to Figure 3-4 and note the difference in door fixing hardware.

The opening-side features two large barrel nuts featuring a horizontal hole on the head for use with the door opening tool, as well as a washer under each. The hinge side features two large barrel nuts with keyed heads that are only removable using a wrench, and should never be removed unless the door opening is being reversed.

FACTORY INSTALLED DOOR CONFIGURATION

Opens from the left, with functioning hinges on the right.

Figure 3-4: Factory Installed Burner Door Hardware Configuration

3.11 Reversing the Opening Direction of the Burner Door Since there are already integral hinges on both sides of the door, the only procedures necessary to reverse the opening direction is to reverse the left and right side door fixing hardware, and then to ensure a tight seal and proper opening of the door, making adjustments if necessary. Instructions for reversing the door direction follow.

WARNING! The boiler door is very heavy and it is dangerous to inappropriately remove door hardware and risk the door detaching from the boiler, which can cause serious harm to persons and damage to property. The boiler door should be kept closed at all times while switching hardware and the instruction steps followed in the exact order as written.

HINGE-SIDE OPENING-SIDE

SAME HINGES ON BOTH SIDES

USES OPENING TOOL USES WRENCH

OPENING-SIDE WASHER & NUT

HINGE-SIDE NUT

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MFC Series Boilers User Manual CHAPTER 3 - INSTALLATION

Reversing the Opening Direction of the Burner Door (Left to Right)

1. Ensure all barrel nuts and door hardware are tightened appropriately and the door swings freely and fits properly when closed and all hardware is secure.

2. Check the adjustment nuts on all four hinges to assure they are secure. These adjusting nuts are used to adjust and level the boiler door during the procedure if needed. See Section 3.5 for more information about adjustments if needed.

NOTE: The main barrel nuts on the front should be switched in a “X” pattern, with one opening-side and one hinge-side nut always completely secured. Start by reversing the upper left (open-side) bolt with the lower right (hinge-side) nut, as shown in Figure 3-5.

WARNING! NEVER REMOVE ALL FOUR BARREL NUTS AT THE SAME TIME!

Figure 3-5: Switching Upper Left and Lower Right Bolts

3. Use the door opening tool to loosen upper left nut & washer and remove (Figure 3-6).

Figure 3-6: Removing Upper Left Nut and Washer with Door Opening Tool

4. Use a wrench to loosen and remove the lower right nut and remove it (Figure 3-7).

Figure 3-7: Removing lower Right Nut with Wrench

STEP 3:

STEP 4:

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MFC Series Boilers User Manual CHAPTER 3 - INSTALLATION P

Reversing the Opening Direction of the Burner Door (Left to Right) – Cont.

5. Insert the hinge-side nut just removed from the lower right position into the upper left hole as shown in Figure 3-8a. Tighten using the wrench, but do not tighten completely.

6. Insert the opening-side nut and washer just removed from the upper left position into the lower right hole as shown in Figure 3-8b. Tighten it with the door opening tool.

7. Now tighten the hinge-side nut in the upper left position completely with the wrench.

Figure 3-8a: Hinge Nut to Upper Left Figure 3-8b: open-Side Nut to Lower Right

8. Perform the same procedure above, only by reversing the lower left opening-side nut with the upper right hinge-side nut, as illustrated in Figure 3-9.

CAUTION: When cross-changing the barrel nuts, always make sure that the other two barrel nuts are fastened, so that they hold the door.

WARNING! NEVER REMOVE ALL FOUR BARREL NUTS AT THE SAME TIME!

Figure 3-9: Switching Upper Right and Lower Left Nuts

9. Check the correct adjustment of the hinges ensuring that, during door closure, the seal gasket of the boiler door is evenly pressed in the center on the whole circumference. If necessary, adjust as described in the next section.

STEP 5:

STEP 6:

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MFC Series Boilers User Manual CHAPTER 3 - INSTALLATION

3.12 Adjusting the Boiler Door – Vertical and Horizontal Reversing door hardware may cause slight shifts in weight, that may in turn cause the door to not close uniformly, or even shift enough to prevent the nuts from being inserted into the holes onto the hinge bolts. The following instructions show how to adjust the boiler door if necessary.

WARNING! Incorrect burner door adjustment may result in a dangerous situation for people and property.

Figure 3-10: Hinge Mechanical Features

If the boiler door is not seating over the boiler opening properly, or if there are problems inserting the barrel nuts over the hinge bolts, perform the following.

Adjusting the Boiler Door – Vertical Adjustment

1. Determine which hinges need adjustment.

2. With the door ajar, loosen the vertical adjustment locking nuts of the hinge.

3. Adjust the vertical adjustment nut as required to raise or lower the hinge bolt. 4. When satisfied with the adjustment, retighten the locking nut.

Figure 3-11: Example Problem for Adjusting Vertical Adjustment Nut on Hinge

VERTICLE ADJUSTMENT NUT

VERTICLE ADJUSTMENT LOCKING NUT

HINGE BOLT

HORIZONTAL ADJUSTMENT LOCKING NUT

WASHER

PROBLEM: Gap between hinge bolt and edge of door through-way preventing installation.

SOLUTION: Use wrench to adjust the vertical adjustment nut upward in order to lower hinge bolt.

Loosen locking nut first to adjust other nut. Retighten after adjustment.

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MFC Series Boilers User Manual CHAPTER 3 - INSTALLATION P

Adjusting the Boiler Door – Horizontal Adjustment

1. Close the door and check that there is equal distance, on both sides, between the stop plate of the door and the band surrounding the door opening.

2. With the door ajar, adjust the vertical adjustment nut as required to increase or decrease the distance the hinge joint projects into the door opening.

3. When satisfied with the adjustment, retighten the locking nut.

4. Check the proper adjustment in depth ensuring that the door, manually pushed up to the stop plate naturally returns to the slightly ajar position. This is to ensure the hinge side door seal.

Figure 3-12: Adjusting Horizontal Adjustment Nut on Hinge

For any problems related to the reversal and adjustment of the door, we recommend contacting AERCO technical support team at 1-800-526-0288.

PROBLEM: Hinge bolt does not reach far enough through, so door will not close entirely.

SOLUTION: Use wrench to adjust the horizontal adjustment nut.

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MFC Series Boilers User Manual CHAPTER 4 - STARTUP

SECTION 4: Startup

4.1 Preliminary Checks Before starting the boiler, check the following:

• The rating plate specifications and power supply network (electricity, water, gas or fuel oil) specifications correspond;

• The burner power range is compatible with the power of the boiler;

• There is a copy of the burner instructions in the boiler room;

• The flue gas exhaust pipe is correctly fitted;

• The air inlet supply is the correct size and free of any obstacles;

• The manhole, the exhaust flue and the burner plate are closed in order to provide a complete flue gas seal;

• The system is full of water and all air pockets have been eliminated;

• The anti-freeze protections are operative;

• The water circulation pumps are operating correctly;

• The expansion vessel and the safety valve(s) have been connected correctly and are properly operating.

• Check the electrical parts and thermostat operation.

4.2 Water Treatment The most common phenomena that occur in heating systems are described below.

Scaling 4.2.1 Scale reduces heat transfer between the combustion gases and the water, causing an abnormal increase in the temperature of the metal and therefore reducing the life of the boiler.

Scale is found mostly at the points where the wall temperature is highest and the best remedy, at construction level, is to eliminate areas that overheat.

Scale creates an insulating layer which reduces the thermal transfer of the boiler, affecting system efficiency. This means that the heat produced by burning the fuel is not fully exploited and is lost to the flue

Corrosion on the Water Side 4.2.2 Corrosion of the metal surfaces of the boiler on the water side is due to the passage of dissolved iron through its ions (Fe+). In this process the presence of dissolved gases and in particular of oxygen and carbon dioxide is very important. Corrosion often occurs with softened or demineralized water which has a more aggressive effect on iron (acid water with Ph <7): in these cases, although the system is protected from scaling, it is not protected against corrosion and the water must be treated with corrosion inhibitors.

For more information concerning water quality and requirements, see the MFC Boiler Application Guide, GF-148-B.

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MFC Series Boilers User Manual CHAPTER 4 - STARTUP P

4.3 Filling the System The water must enter the system as slowly as possible and in a quantity proportional to the air bleeding capacity of the components involved. Filling times vary depending on the capacity and characteristics of the system.

In the case of a sealed system with an expansion vessel, water is let in until the pressure gauge indicator reaches the static pressure value pre-set in the vessel.

Heat the water to maximum temperature. During this operation the air contained in the water is released through the automatic air separators. Once the air has been entirely released, reset the pressure to the pre-established value and close the manual and/or automatic filling valve.

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MFC Series Boilers User Manual CHAPTER 5 – BURNER INSTALLATION

SECTION 5: Burner Installation

5.1 Burner Pre-Installation Procedures Before installation you are advised to clean thoroughly the inside of all the fuel supply system pipes in order to remove any foreign matter that could affect correct operation of the burner. See technical specification tables in Appendix A of this manual, and check the maximum pressure value inside the furnace. The following actions should also be performed: • Check that there are no leaks in the fuel supply system; • Regulate the fuel flow according to the power required by the boiler; • Check that the boiler is fired by the correct type of fuel; • Check that the fuel supply pressure is within the values specified on the burner rating plate; • Check that the fuel supply system is sized for the maximum flow rate necessary for the

boiler and that it is provided with all control and safety devices provided for by the regulations referred to above.

In particular, when using gas: o Check that the gas supply pipe complies with the regulations in force; o Check that all the gas connections are sealed; o Check that the boiler room vents are of sufficient size to ensure the air flow dictated by

the regulations in NFPA 86; o Check that the gas pipes are not used as earth connections for electrical appliances. If

the boiler is not going to be used for some time, close the fuel supply cock or cocks.

5.2 Burner Installation Refer to section 11.1 of OMM-0108, MFC Series Boiler Installation Manual, GF-148-IN for burner installation instructions. Note that instructions are only applicable to Riello burner models RLS120, 160, 300 and RS 120, 160, 300 acquired through AERCO. For burners not acquired through AERCO, consult the respective burner manufacturer for proper installation instructions.

Burner setup and operating procedures are provided for the various MFC Series models are provided in the following sections.

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MFC Series Boilers User Manual CHAPTER 6 – MFC 3000 DUAL FUEL BURNER P

SECTION 6: MFC 3000 Dual Fuel Burner

NOTE: In order to guarantee that emissions do not vary, only the recommended and/or alternative nozzles as specified in these Instructions should be used.

CAUTION! It is advisable to replace nozzles every year during regular maintenance operations.

WARNING! The use of nozzles other than those specified by the manufacturer, and the inadequate regular maintenance of the boiler may result in emissions exceeding the limits set forth by the regulations in force, and can pose a potential serious hazard to people and property. The manufacturing company shall not be liable for any such damage arising from failure to observe all the safety warnings and requirements as set forth in this document.

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MFC Series Boilers User Manual CHAPTER 6 – MFC 3000 DUAL FUEL BURNER

6.1 MFC 3000 Dual Fuel Burner Features

Figure 6-1: MFC 3000 Dual Fuel Parts and Features

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MFC Series Boilers User Manual CHAPTER 6 – MFC 3000 DUAL FUEL BURNER P

Key to Figure 6-1: MFC 3000 Dual Fuel Burner Parts and Features 1. Combustion head 2. Ignition electrodes 3. Screw for combustion head adjustment 4. Sleeve 5. Fan motor 6. RWF 40 modulator (with analog output 4-20 mA) 7. Fan motor contactor with auxiliary contact and thermal relay with reset button 8. UV scanner 9. Burner terminal board for electrical wiring “X1” 10. Holes for cables grommets for electrical wirings, accessories and power supply (to be carried out by the installer) 11. Control box for checking flame and air/fuel ratio 12. Operator panel with LCD display 13. Flame inspection window 14. Low air pressure switch 15. Slide bars for opening the burner and inspecting the combustion head 16. Safety oil solenoid valve 17. Valve assembly with pressure regulator on nozzle return 18. Gas pressure test point and head fixing screw 19. Air pressure test point 20. Air servomotor 21. Pump motor 22. Low oil pressure switch 23. Pilot attachment 24. Pump 25. Gas train flange 26. Boiler mounting flange 27. Flame stability disk 28. Screw securing fan to sleeve 29. Max. gas pressure switch 30. Ignition transformers “T2” (for gas operation) 31. Lifting rings and extension bars 32. Oil/gas actuator 33. High oil pressure switch 34. Ignition transformer “T1” (for oil operation) 35. Terminal strip for oil valve “X2” 36. Timer module and relay “KO1” 37. Timer module and relay “KG1” 38. “K3” relay 39. “K1” relay 40. “KG2” relay 41. “K5” relay 42. “K2” relay 43. Horn 44. Auxiliary fuse 45. “OFF - ON” switch 46. “LOCAL-REMOTE” switch 47. “ALARM SILENCE” button 48. “OIL - OFF - GAS” switch 49. “POWER ON” signal 50. “CALL FOR HEAT signal 51. “ALARM ON” signal 52. “IGNITION ON” signal 53. “FUEL ON” signal 54. Optional holes 55. Ground terminals 56. Pump motor contactor and thermal relay with reset button 57. Delivery oil solenoid valve 58. Return oil solenoid valve 59. DIN bar for fuse holder, step-down transformer and OCI 412.10 (Available)

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MFC Series Boilers User Manual CHAPTER 6 – MFC 3000 DUAL FUEL BURNER

6.2 Burner Nozzle Setup Recommended Nozzles 6.2.1

• Bergonzo A4 45 • Delavan Variflo 45° and 60° • Fluidics KC2 30° and 45°

Nozzle Assembly 6.2.2 In order to assemble the nozzle, proceed as follows:

Assembling the Nozzle

1. Remove the screw (1) as shown in Figure 6-2

2. Remove the nozzle assembly (2) per the arrows in Figure 6-2.

Figure 6-2: Nozzle Assembly – Steps 1 and 2

3. Install the nozzle (1) per Figure 6-3.

Figure 6-3: Nozzle Assembly – Step 3 Figure 6-4: Nozzle Assembly – Step 4

4. Fit the wrench through the central hole in the flame stability disk and loosen screws (1) per Figure 6-4.

5. Remove disk (2) per Figure 6-4 and replace the nozzles using the wrench (3).

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MFC Series Boilers User Manual CHAPTER 6 – MFC 3000 DUAL FUEL BURNER P

WARNING! • Do not use any sealing products such as gaskets, sealing compound, or tape.

• Be careful to avoid damaging the nozzle sealing seat.

• The nozzles must be screwed into place tightly, but carefully.

• The nozzle for low fire operation is the one lying beneath the firing electrodes.

• Make sure that the electrodes are positioned as shown in Figure 6-7.

6.3 Flow Rate adjustment The nozzle flow rate varies according to the fuel pressure on the nozzle return. The chart in Figure 6-5 shows this relationship for type A4 return flow nozzles with a pump delivery pressure of 290 PSI.

The horizontal axis in the chart represents the PSI Nozzle Return Pressure, and the vertical axis the GPH Nozzle Flow Rate. The values indicated in the right side of Figure 6-5 refer to the data printed on the nozzle.

With a pump delivery pressure of 290 PSI, the pressure on the nozzle return must not exceed 246.5 PSI.

The pressure difference between pump delivery and nozzle return must be at least 43.5 PSI. With smaller pressure differences, the pressure on the nozzle return can be unstable.

Figure 6-5: Nozzle Pressure and Flow Rate Chart

The nozzle return pressure value is indicated by the pressure gauge (1) in Figure 6-6.

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MFC Series Boilers User Manual CHAPTER 6 – MFC 3000 DUAL FUEL BURNER

Figure 6-6: Flow Rate Controls and Gauges

The output and the pressure of the nozzle are at maximum when the servomotor is positioned at maximum.

The proper setting of the eccentric (6) is possible when its operation field matches the servomotor operation field (0° - 90°): so, that every variation of the servomotor position corresponds to a pressure variation.

If pressure fluctuations are detected on the gauge (1) (see Figure 6-6) at the maximum capacity of the nozzle (maximum pressure in the return line), slightly decrease the pressure in the return line until fluctuations are completely eliminated.

6.4 Electrode Positioning WARNING! Ensure that the electrodes are positioned as shown in Figure 6-7.

Figure 6-7: Electrode Positioning

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MFC Series Boilers User Manual CHAPTER 6 – MFC 3000 DUAL FUEL BURNER P

6.5 Burner Setup Reinstall the burner as follows:

Setting Up the Burner

1. Refit the burner to the slide bars (3) as shown in Figure 6-8 at approximately 4” from the sleeve (4) with burner positioned as shown in Figure 6-9.

Figure 6-8: Burner Reinstallation

Figure 6-9: Burner Positioning

2. Insert the ignition electrode cables. 3. Remove the extension bars (31) shown in Figure 6-1.

4. Slide the burner up to the sleeve so that it is positioned as shown in Figure 6-8.

5. Refit screws (2) shown in Figure 6-8 on slide bars (3) including the safety plate (15) per Figure 6-9.

6. Secure the burner to the sleeve by tightening screws (1) shown in Figure 6-8. 7. Connect the oil pipes again by screwing on the two connectors (6) shown in Figure 6-9.

8. Connect the swivel coupling (7) from the graduate sector shown in Figure 6-8.

WARNING! When fitting the burner on the two slide bars, it is advisable to gently draw out the high tension cables until they are slightly stretched.

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MFC Series Boilers User Manual CHAPTER 6 – MFC 3000 DUAL FUEL BURNER

6.6 Hydraulic Connections The pumps are equipped with a by-pass that separates return line and suction line. The pumps are installed on the burner with the by-pass closed by screw (6) shown in Figure 6-27. It is therefore necessary to connect both hoses to the pump.

CAUTION! Damage to the pump seal will occur immediately if it is run with the return line closed and the by-pass screw inserted. Remove the plugs from the suction and return connections of the pump.

Connecting the Hydraulics

1. Insert the hose connections with the supplied seals into the connections and screw them down. See Figure 6-10.

2. Take care that the hoses are not stretched or twisted during installation.

3. Install the hoses where they cannot be stepped on or come into contact with hot surfaces of the boiler and where they do not hamper the opening of the burner.

4. Now connect the other end of the hoses to the suction and return lines.

Figure 6-10: Connecting the Hydraulics

A

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MFC Series Boilers User Manual CHAPTER 6 – MFC 3000 DUAL FUEL BURNER P

6.7 Pump The pumps are equipped with a by-pass that separates return line and suction line.

Key to Pump Model J7C 1 Suction 1/2" NPT 2 Return 1/2" NPT 3 Pressure Gauge Attachment G 1/8" 4 Vacuum Gauge Attachment G 1/8" 5 Pressure Adjustment Screw 6 By-Pass Screw

Figure 6-11: J7C Pump Diagram

Pump Priming 6.7.1 WARNING!

Before starting the burner, make sure that the tank return line is not clogged. Obstructions in the line could cause the seal located on the pump shaft to break.

The time required for this operation depends upon the diameter and length of the suction tubing.

If the pump fails to prime at the first starting of the burner and the burner locks out, wait approximately 15 seconds, reset the burner, and then repeat the starting operation as often as required After 5 or 6 starting operations, then allow 2 or 3 minutes for the transformer to cool.

IMPORTANT NOTE: The priming operation is possible because the pump is already full of fuel when it leaves the factory. If the pump has been drained, fill it with fuel through the opening on the vacuum meter prior to starting; otherwise, the pump will seize.

Whenever the length of the suction piping exceeds 66 - 98 ft., the supply line must be filled using a separate pump.

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MFC Series Boilers User Manual CHAPTER 6 – MFC 3000 DUAL FUEL BURNER

6.8 Gas Pressure The following diagram is used to calculate manifold pressure taking into account combustion chamber pressure.

Figure 6-12: Burner Output Diagram

Gas manifold pressure measured at test point per 1 shown in Figure 6-13 with:

• Combustion chamber at 0” W.C.

• Burner operating at maximum output.

• Combustion head adjusted as indicated in diagram shown in Figure 6-15.

Figure 6-13: Gas Manifold Pressure Measuring Locations

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MFC Series Boilers User Manual CHAPTER 6 – MFC 3000 DUAL FUEL BURNER P

Calculate the approximate high fire output of the burner as follows:

Calculating the Approximate Boiler High Fire Rate

1. Subtract the combustion chamber pressure from the gas pressure measured at test point 1 shown in Figure 6-13.

2. Find the nearest pressure value to your result in Figure 6-12.

3. Read off the corresponding output on the left.

EXAMPLE: Maximum Output Operation (Natural Gas):

• Gas pressure at test point 1 (per Figure 6-13) = 4.41” WC • Pressure in combustion chamber = 0.79” WC

4.41 - 0.79 = 3.62” W.C.

A maximum output of 3616 MBtu/hr shown in the table below corresponds to 3.62” WC pressure, column 1, natural gas. This value serves as a rough guide. The effective delivery must be measured at the gas meter.

Maximum Output and WC Pressure Correlation Table

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MFC Series Boilers User Manual CHAPTER 6 – MFC 3000 DUAL FUEL BURNER

6.9 Combustion Head Adjustment WARNING! Before starting the burner, ensure that the tank return line is not clogged.

The setting of the combustion head depends on the maximum output of the burner.

Adjusting the Combustion Head

Turn screw (6) shown in Figure 6-14 until the notch shown in Figure 6-15 is level with the front surface of the flange (5).

Figure 6-14: Combustion Head Setting

EXAMPLE:

Maximum burner delivery = 23.1 GPH.

The chart shown in Figure 6-15 indicates that for this delivery, the combustion head must be adjusted using notch (3) shown in Figure 6-14.

Figure 6-15: Maximum Burner Output

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MFC Series Boilers User Manual CHAPTER 6 – MFC 3000 DUAL FUEL BURNER P

6.10 Pump Adjustment No settings are required for the pump, which is set to 360 PSI by the manufacturer. This pressure must be checked and adjusted (if required) after the burner has been ignited.

The only operation required in this phase is the application of a pressure gauge on the appropriate pump attachment.

6.11 Air Damper Adjustment The first time the burner is fired, leave the factory-set low and high fire settings unchanged.

6.12 Ignition Pilot Adjustment Position the pilot and electrode using the dimension shown in Figure 6-16. The pilot works correctly at pressures ranging from 3-4” W.C.

Figure 6-16: Ignition Pilot Adjustment

A = 1- 21/64”

Electrode

Pilot Flange

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MFC Series Boilers User Manual CHAPTER 6 – MFC 3000 DUAL FUEL BURNER

6.13 Adjustments before First Firing (Gas Operation) Adjustments Before First Firing

1. Ensure that the gas supply company has carried out the supply line vent operations, eliminating air or inert gases from the piping.

2. Slowly open the manual valves situated upstream of the gas train.

3. Adjust the minimum gas pressure switch shown in Figure 6-17 to the start of the scale.

Figure 6-17: Minimum Gas Pressure Switch

4. Adjust the maximum gas pressure switch shown in Figure 6-18 to the end of the scale.

Figure 6-18: Maximum Gas Pressure Switch

5. Adjust the air pressure switch shown in Figure 6-19 to the start of the scale.

Figure 6-19: Air Pressure Switch

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MFC Series Boilers User Manual CHAPTER 6 – MFC 3000 DUAL FUEL BURNER P

Adjustments Before First Firing

6. Purge the air from the gas line.

7. Fit a U-type manometer shown in Figure 6-20 to the gas pressure test point on the sleeve. The manometer readings are used to calculate the MAX. burner power using the diagram in Figure 6-12.

Figure 6-20: Manometer Insertion Point

NOTE: Before starting up the burner it is good practice to adjust the gas train so that ignition takes place in conditions of maximum safety, i.e., with gas delivery at the minimum.

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MFC Series Boilers User Manual CHAPTER 6 – MFC 3000 DUAL FUEL BURNER

6.14 Startup for MFC 3000 Dual Fuel Burner Starting the Burner

1. Turn on electricity to the burner by turning the power switch on the boiler panel to ON. 2. Close the thermostats/pressure switches and set the parameters on the RWF 40 regulator.

Please refer to the appropriate manual for instructions to perform this operation.

3. Turn the switch to the “ON” position shown in Figure 6-21 and turn the switch of to position “LOCAL” and turn the switch to position “OIL” for oil operation and “GAS” for gas operation.

Figure 6-21: Burner Controls Used for Startup

DANGER! Make sure that the lamps or testers connected to the solenoids, or indicator lights on the solenoids themselves, show that no voltage is present. If voltage is present, stop the burner immediately and check the electrical wiring.

NOTE: For the start-up procedure and the parameters calibration, refer to the specific instruction manual of the LMV37 electronic cam supplied with the burner.

DIRECTION OF MOTOR ROTATION

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MFC Series Boilers User Manual CHAPTER 6 – MFC 3000 DUAL FUEL BURNER P

Starting the Burner – Continued

CAUTION! Check Motor Rotation As the burner is not fitted with a device to check the sequence of the phases, the motor rotation may be incorrect. As soon as the burner starts up, go in front of the cooling fan of the fan motor and check it is rotating anticlockwise. See Figure 6-21. If this is not the case:

1. Place the On/Off switch in “OFF” position and wait for the control box to carry out the switch-off phase.

2. Disconnect the electrical supply from the burner.

3. Invert the phases on the three-phase power supply.

Gas/Air Delivery Adjustment 6.14.1

Adjusting Gas/Air Delivery

1. Slowly open butterfly gas valve to maximum open position.

2. Adjust the required maximum output with the gas pressure stabilizer.

3. Adjust the combustion parameters with the air servomotor and store the maximum combustion point.

4. Complete the procedure by synchronizing the combustion with the two servomotors and storing the different setting points.

Adjusting Oil/Air Delivery 6.14.2 Adjusting Oil/Air Delivery

1. Switch to the light oil operation.

2. During the ignition, slowly move oil servomotor to a maximum position of approximately 90°.

3. Adjust the maximum pressure on the return nozzle using the “nut and lock-nut” (5) shown in Figure 6-6.

4. Adjust the combustion parameter with the air servomotor and store the maximum combustion point.

5. To complete the procedure, synchronize the combustion with the two servomotors and store the different setting points.

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MFC Series Boilers User Manual CHAPTER 6 – MFC 3000 DUAL FUEL BURNER

Air Pressure Switch Adjustment 6.14.3 The air pressure switch is connected in differential (see Figure 6-23) and is activated by both the negative pressure of the air intake and the air pressure from the fan.

Adjust the air pressure switch shown in Figure 6-22 after having performed all other burner adjustments with the air pressure switch set to the minimum scale position.

Adjusting the Air Pressure Switch

1. With the burner operating at low fire, adjust the pressure switch by slowly turning the relative knob clockwise until the burner locks out.

2. Then turn the knob counter-clockwise about 20% of the set point and start-up the burner again to ensure the set point is correct.

3. If the burner locks out again, turn the knob counter-clockwise a little bit more.

Figure 6-22: Air Pressure Switch

Figure 6-23: Air Pressure Switch Connection

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Maximum Gas Pressure Switch Adjustment 6.14.4 Adjust the maximum gas pressure switch shown in Figure 6-24 after having performed all other burner adjustments with the maximum gas pressure switch set to the end of the scale.

Adjusting Maximum Gas Pressure Switch

1. With the burner operating at MAX output, reduce the adjustment pressure by slowly turning the adjustment dial anticlockwise until the burner locks out.

2. Then turn the dial clockwise by 0.8” WC and repeat burner firing.

3. If the burner locks out again, turn the dial again clockwise by 0.4” W.C.

Figure 6-24: Maximum Gas Pressure Switch

Minimum Gas Pressure Switch Adjustment 6.14.5 Adjust the minimum gas pressure switch shown in Figure 6-25 after having performed all the other burner adjustments with the pressure switch set at the start of the scale.

Adjusting the Minimum Gas Pressure Switch

1. With the burner operating at MAX output, increase adjustment pressure by slowly turning the relative dial clockwise until the burner locks out.

2. Then turn the dial anti-clockwise by 0.8” WC and repeat burner starting to ensure it is uniform.

3. If the burner locks out again, turn the dial anti-clockwise again by 0.4” W.C.

Figure 6-25: Minimum Gas Pressure Switch

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Low Oil Pressure Switch 6.14.6 The low oil pressure switch is factory set to 261 PSI (18 bar). If the oil pressure goes down this value in the delivery piping, the pressure switch stops the burner. Burner starts again automatically if the pressure goes above 261 PSI (18 bar) after burner start up.

High oil pressure switch 6.14.7 The high oil pressure switch is factory set to 43.5 PSI (3 bar). If the oil pressure goes above this value in the return piping, the pressure switch stops the burner. Burner starts again automatically if the pressure goes down under 43.5 PSI (3 bar) after burner shut down. If a loop circuit with Px pressure feeds the burner, the pressure switch should be adjusted to Px + 43.5 PSI. Figure 6-26 shows the location of this adjustment.

Figure 6-26: Maximum Gas Pressure Switch

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MFC Series Boilers User Manual CHAPTER 6 – MFC 3000 DUAL FUEL BURNER P

Burner Startup Sequence of Operation 6.14.8 Sequence of Operation:

• Operating control closes, the motor starts.

• The pump (3) in Figure 6-27 draws the fuel from the tank through the piping (1) and pumps it under pressure for delivery.

• The piston 4) rises and the fuel returns to the tank through the piping 5) - 7).

• The screw 6) closes the by-pass heading towards suction and the de-energized solenoid valves 8) - 9) - 2) close the passage to the nozzle.

• Air damper and pressure regulator are positioned on MIN output.

• Ignition electrode strikes a spark.

• Solenoid valves 8) - 9) - 2) open; the fuel passes through the piping 10) and filter 11), and enters the nozzle.

• A part of the fuel is then sprayed out through the nozzle, igniting when it comes into contact with the spark: flame at a low output level; the rest of the fuel passes through piping 12 at the pressure adjusted by the regulator 13, then, through piping 7), it goes back into the tank.

• The spark goes out.

• The starting cycle ends.

Figure 6-27: Burner Startup Sequence of Operation

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MFC Series Boilers User Manual CHAPTER 6 – MFC 3000 DUAL FUEL BURNER

Normal Operation Sequence of Operation 6.14.9 At the end of the starting cycle, the servo-motor control then passes to load control for boiler pressure or temperature.

Sequence of Operation:

• If the temperature or pressure is low (and the load control is consequently closed), the burner progressively increases output up to MAX.

• If subsequently the temperature or pressure increases until the load control opens, the burner progressively decreases output down to MIN.

• The burner shuts off when demand for heat is less than the heat supplied by the burner in the MIN output.

• The servomotor returns to the 0° angle limited by contact with cam 2. The air damper closes completely to reduce thermal dispersion to a minimum.

Every time output is changed, the servomotor automatically modifies oil delivery (pressure regulator) and air delivery (fan damper).

6.15 Final Checks with Boiler in Operation Perform the operations in the left column while the boiler is operating, and ensure the response in the right column are the result.

FINAL CHECK PROCEDURE DESIRED RESULT Open the control limit operation. Burner

Stops Open the high limit operation.

Turn down maximum gas pressure switch knob to the minimum position. Burner Stops

In Lockout Turn up the air pressure switch knob to the maximum position.

Turn down the maximum oil pressure switch at minimum position.

Switch burner to OFF and disconnect the electrical power. Burner Will Not Start Disconnect the minimum gas pressure switch.

Turn up the minimum low oil pressure switch to maximum position.

Cover the UV flame sensor. Burner Stops In Lockout Due To

Firing Failure

WARNING!

Ensure that all lockout and safety procedures concerning all controls and valves are strictly observed.

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MFC Series Boilers User Manual CHAPTER 7 – MFC 3000 GAS ONLY BURNER P

SECTION 7: MFC 3000 Natural Gas Only Burner

NOTE: In order to guarantee that emissions do not vary, only the recommended and/or alternative nozzles as specified in these Instructions should be used.

CAUTION! It is advisable to replace nozzles every year during regular maintenance operations.

WARNING! The use of nozzles other than those specified by the manufacturer, and the inadequate regular maintenance of the boiler may result in emissions exceeding the limits set forth by the regulations in force, and can pose a potential serious hazard to people and property. The manufacturing company shall not be liable for any such damage arising from failure to observe all the safety warnings and requirements as set forth in this document.

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MFC Series Boilers User Manual CHAPTER 7 – MFC 3000 GAS ONLY BURNER

Figure 7-1: MFC 3000 Gas Only Burner Parts and Features

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MFC Series Boilers User Manual CHAPTER 7 – MFC 3000 GAS ONLY BURNER P

Key to Figure 7-1 (1): Burner Parts and Features

1. Combustion head 2. Burner pilot 3. Screw for combustion head adjustment 4. Maximum gas pressure switch 5. Burner pilot attachment 6. Gas actuator 7. Ignition electrode 8. Fan motor contactor and thermal relay with reset button 9. Lifting ring 10. Terminal board for electrical wiring 11. Operator panel with LCD display 12. Control box for checking flame and air/fuel ratio 13. Auxiliary fuse 14. Signal “CALL FOR HEAT” 15. UV flame sensor 16. Ignition transformer 17. Holes for cable grommets for electrical wiring for accessories(to be carried out by the installer) 18. Air actuator 19. Air pressure switch 20. Sliding bars for opening the burner and inspecting the combustion head 21. Gas pressure test point and head fixing screw 22. Combustion head air pressure test point 23. Extension sliding bars 24. Switch “OFF - ON” 25. Fan air inlet 26. Screws to secure fan to pipe coupling 27. Switch “LOCAL REMOTE” 28. Gas butterfly valve 29. Boiler fixing flange 30. Flame stability disc 31. Horn 32. Button “ALARM SILENCE” 33. Signal “POWER ON” 34. Signal “IGNITION ON” 35. Signal “FUEL ON” 36. Signal “ALARM ON” 37. RWF40 modulator (with anolog output 4-20 mA) 38. Hight voltage lead 39. Din bar available for accessories 40. Optional holes 41. Din bar for fuse holder step-down transformer and OCI 412.10 42. Ground terminals 43. Din bar for thermal relay, fan motor contactor and available for accessories 44. Fan motor 45. k 1 relay 46. k 5 relay 47. k 3 relay 48. k 2 relay 49. Gas train flange 50. Air pressure switch test point

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MFC Series Boilers User Manual CHAPTER 7 – MFC 3000 GAS ONLY BURNER

7.1 Combustion Head Adjustment WARNING! Before starting the burner, ensure that the tank return line is not clogged.

The setting of the combustion head depends on the maximum output of the burner.

Adjusting the Combustion Head

Air Adjustment:

1. Turn screw (4) in Figure 7-2 until the notch identified is aligned with the front surface (5) in Figure 7-2 of the flange. To facilitate adjustment, loosen the screw ( 3) in Figure 7-2, adjust and then lock.

Gas Adjustment:

1. Loosen the 3 screws (4) in Figure 7-2 and turn ring (5) until the notch identified is aligned with index (6).

2. Tighten the 3 screws (1) fully down.

3. In the diagram in Figure 7-2, find the notch at which to adjust both air and central gas/air.

Figure 7-2: MFC 3000 Gas Only Burner Parts and Features

EXAMPLE: RS 120/E LN, burner output = 3750 MBtu/hr

Consult the diagram in Figure 7-3 to see that for this output the adjustments are: • AIR: R1 = notch 2 • GAS: R2 = notch 5

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Adjusting the Combustion Head – Continued

NOTE: The diagram in Figure 7-3 indicates an optimal calibration.

Figure 7-3: MFC 3000 Gas Only Burner Parts and Features

4. If the pressure of gas allows it, by closing ring nut a reduction of the formation of NOx is obtained.

5. Continuing with the previous example, Figure 7-6 indicates that for burner with output of 3750 MBtu/hr a pressure of approximately 2.8” is necessary at test point (3) in Figure 7-2. If this pressure cannot be reached, open the ring (5) in Figure 7-2 to notch 4 or 5.

6. Make sure that the combustion characteristics are satisfactory and free of pulsations. 7. Once the combustion head adjustment is completed:

• Push the burner on the sliding bars 3) at approximately 4” from the pipe coupling 4) - burner in the position shown in Figure 7-4.

• Insert the electrode cable, then slide the burner as far as the pipe coupling - burner in the position shown in Figure 7-4.

• Unscrew the 2 screws 2) from the extension 5) and reposition them as previously Figure 7-4 (19).

• Refit the screws 2) on the sliding bars 3).

• Fix the burner to the pipe coupling with the screws 1).

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Figure 7-4: MFC 3000 Gas Only Burner Reassembly

7.2 Gas Supply Pressure The diagram in Figure 7-6 shows minimum load losses at combustion head depending on the maximum burner output operation with natural gas (G 20).

Gas pressure is measured at the test point (1) in Figure 7-5, with:

• Combustion chamber at 0 mbar.

• Burner working at maximum output.

• Ring nut (2) in Figure 7-2 adjusted as in the diagram of Figure 7-3.

Figure 7-5: MFC 3000 Gas Only Gas Supply Pressure Test Points

NOTE: When fitting the burner on the two sliding bars, it is advisable to gently draw out the high voltage cable until it is slightly taut.

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Figuring Burner Output 7.2.1

Figuring Burner Output

To know the approximate output at which the burner is operating at its maximum:

1. Subtract the combustion chamber pressure from the gas pressure measured at test point (1) in Figure 7-5.

2. In the diagram in Figure 7-6 find the pressure value closest to the result you want; read the corresponding output on the left.

Figure 7-6: MFC 3000 Gas Only Burner Minimum Load Loss Chart

Maximum Output Formula Example, Natural gas:

• Gas ring 2) in Figure 7-3 • Gas pressure at test point 1) in Figure 7-5 = 5.11 “WC • Pressure in combustion chamber = 1.18 “WC

5.11 - 1.18 = 3.93 “WC A maximum output of 3030 MBtu/hr corresponds to 3.93“ WC pressure.

This value serves as a rough guide; the effective delivery must be measured at the gas meter.

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Figuring Required Burner Output 7.2.2

Figuring Required Burner Output

To know the required gas pressure at test point (1) in Figure 7-5, set the maximum output required from the burner operation, then:

1. Find the nearest output value in the table for the burner in question. See the diagram in Figure 7-6 for the pressure test point (1) in Figure 7-5.

2. Add this value to the estimated pressure in the combustion chamber.

Required Burner Output Formula Example:

• Maximum output required: 3750 MBtu/hr • Ring nut 2) in Figure 7-2 adjusted as in the diagram in Figure 7-3

• Gas pressure at output of 2815 MBtu/hr = 6 “WC

• Pressure in combustion chamber = 1.18 “WC

6 + 1.18 = 7.15 “WC (Pressure required at pressure test point 1 in Figure 7-5)

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7.3 Adjustments Before First Firing (Gas) Adjustments Before First Firing for (Gas)

1. Ensure that the gas supply company has carried out the supply line vent operations, eliminating air or inert gases from the piping.

2. Slowly open the manual valves situated upstream of the gas train.

3. Adjust the minimum gas pressure switch per Figure 7-7 to the start of the scale.

Figure 7-7: Minimum Gas Pressure Switch

4. Adjust the maximum gas pressure switch per Figure 7-8 to the end of the scale.

Figure 7-8: Maximum Gas Pressure Switch

5. Adjust the air pressure switch per Figure 7-9 to the start of the scale.

Figure 7-9: Air Pressure Switch

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Adjustments Before First Firing

8. Purge the air from the gas line.

9. Fit a U-type manometer per Figure 7-10 to the gas pressure test point on the sleeve. The manometer readings are used to calculate the maximum burner power.

Figure 7-10: Manometer insertion Point

NOTE: Before starting up the burner it is good practice to adjust the gas train so that ignition takes place in conditions of maximum safety, i.e. with gas delivery at the minimum.

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7.4 Startup for MFC 3000 Gas Only Burner Starting the Burner

1. Turn on electricity to the burner by turning the power switch on the boiler panel to ON.

2. Close the thermostats/pressure switches and set the parameters on the RWF 40 regulator. Please refer to the appropriate manual for instructions to perform this operation.

3. Turn the switch to position “ON” per Figure 7-11 and turn the switch of to position “LOCAL”.

Figure 7-11: Burner Controls Used for Startup

DANGER! Make sure that the lamps or testers connected to the solenoids, or indicator lights on the solenoids themselves, show that no voltage is present. If voltage is present, stop the burner immediately and check the electrical wiring.

NOTE: For the start-up procedure and the parameters calibration, refer to the specific instruction manual of the LMV37 electronic cam supplied with the burner.

DIRECTION OF MOTOR ROTATION

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Starting the Burner – Continued

CAUTION! Check Motor Rotation As the burner is not fitted with a device to check the sequence of the phases, the motor rotation may be incorrect. As soon as the burner starts up, go in front of the cooling fan of the fan motor and check it is rotating anticlockwise. See Figure 7-11.

If this is not the case:

1. Place the On/Off switch in the “OFF” position and wait for the control box to carry out the switch-off phase;

2. Disconnect the electrical supply from the burner;

3. Invert the phases on the three-phase power supply.

Gas/Air Delivery Adjustment 7.4.1

Adjusting Gas/Air Delivery

1. Slowly open butterfly gas valve to maximum open position.

2. Adjust the required maximum output with the gas pressure stabilizer.

3. Adjust the combustion parameters with the air servomotor and store the maximum combustion point.

4. Complete the procedure by synchronizing the combustion with the two servomotors and storing the different setting points.

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Air Pressure Switch Adjustment 7.4.2 The air pressure switch in Figure 7-12 is connected in differential (see Figure 7-13) and is activated by both the negative pressure of the air intake and the air pressure from the fan.

Adjust the air pressure switch after having performed all other burner adjustments with the air pressure switch set to the minimum scale position.

Adjusting the Air Pressure Switch

1. With the burner operating at low fire, adjust the pressure switch by slowly turning the relative knob clockwise until the burner locks out.

2. Then turn the knob counter-clockwise about 20% of the set point and start-up the burner again to ensure the set point is correct.

3. If the burner locks out again, turn the knob counter-clockwise in small increments until it does not.

Figure 7-12: Air Pressure Switch

Figure 7-13: Air Pressure Switch Connection

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Maximum Gas Pressure Switch Adjustment 7.4.3 Adjust the maximum gas pressure switch shown in Figure 7-14 after having performed all other burner adjustments with the maximum gas pressure switch set to the end of the scale.

Adjusting Maximum Gas Pressure Switch

1. With the burner operating at MAX output, reduce the adjustment pressure by slowly turning the adjustment dial anticlockwise until the burner locks out.

2. Then turn the dial clockwise by 0.8” WC and repeat burner firing.

3. If the burner locks out again, turn the dial again clockwise by 0.4” W.C.

Figure 7-14: Maximum Gas Pressure Switch

Minimum Gas Pressure Switch Adjustment 7.4.4 Adjust the minimum gas pressure switch shown in Figure 7-15 after having performed all the other burner adjustments with the pressure switch set at the start of the scale.

Adjusting the Minimum Gas Pressure Switch

1. With the burner operating at MAX output, increase adjustment pressure by slowly turning the relative dial clockwise until the burner locks out.

2. Then turn the dial anti-clockwise by 0.8” WC and repeat burner starting to ensure it is uniform.

3. If the burner locks out again, turn the dial anti-clockwise again by 0.4” W.C.

Figure 7-15: Minimum Gas Pressure Switch

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7.5 Final Checks with Boiler in Operation Perform the operations in the left column while the boiler is operating, and ensure the response in the right column are the result.

FINAL CHECK PROCEDURE DESIRED RESULT Open the control limit operation. Burner

Stops Open the high limit operation.

Turn down maximum gas pressure switch knob to the minimum position. Burner Stops

In Lockout Turn up the air pressure switch knob to the maximum position.

Turn down the maximum oil pressure switch at minimum position.

Switch burner to OFF and disconnect the electrical power. Burner Will Not Start Disconnect the minimum gas pressure switch.

Turn up the minimum low oil pressure switch to maximum position.

Cover the UV flame sensor. Burner Stops In Lockout Due To

Firing Failure

WARNING!

Ensure that all lockout and safety procedures concerning all controls and valves are strictly observed.

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MFC Series Boilers User Manual CHAPTER 8 – MFC 4000/6000 DUAL FUEL BURNER

SECTION 8: MFC 4000 / 6000 Dual Fuel Burner

NOTE: In order to guarantee that emissions do not vary, only the recommended and/or alternative nozzles as specified in these Instructions should be used.

CAUTION! It is advisable to replace nozzles every year during regular maintenance operations.

WARNING! The use of nozzles other than those specified by the manufacturer, and the inadequate regular maintenance of the boiler may result in emissions exceeding the limits set forth by the regulations in force, and can pose a potential serious hazard to people and property. The manufacturing company shall not be liable for any such damage arising from failure to observe all the safety warnings and requirements as set forth in this document.

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8.1 MFC 4000-6000 Dual Fuel Burner Features

Figure 8-1: MFC 4000-6000 Dual Fuel Parts and Features

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Key to Figure 8-1: Burner Parts and Features 1 Combustion head 2 Ignition electrodes 3 Screw for combustion head adjustment 4 Sleeve 5 Fan motor 6 RWF 40 modulator (with analog output 4-20 mA) 7 Fan motor contactor and thermal relay with reset button 8 UV scanner 9 Terminal strip x 1 10 Holes for cables grommets for electrical wirings, accessories and power supply (to be carried out by the installer) 11 Selectors and light signals 12 Operator panel with LCD display 13 Flame inspection window 14 Low air pressure switch (differential operating type) 15 Slide bars for opening the burner and inspecting the combustion head 16 Safety oil solenoid valve 17 Valve assembly with pressure regulator on nozzle return 18 Gas pressure test point and head fixing screw 19 Air pressure test point 20 Air servomotor 21 Pump motor 22 Low oil pressure switch 23 Pilot attachment 24 Pump 25 Gas train flange 26 Boiler mounting flange 27 Flame stability disk 28 Screw securing fan to sleeve 29 Max. gas pressure switch 30 Ignition transformers “TA2” (for gas operation) 31 Lifting rings and extension bars 32 Oil/gas actuator 33 High oil pressure switch 34 Ignition transformer “TA1” (for oil operation) 35 Terminal strip “X2” 36 Timer module and relay “KO1” 37 Timer module and relay “KG1” 38 “K3” relay 39 “K1” relay 40 “KG2” relay 41 “K5” relay 42 “K2” relay 43 Horn 44 Auxiliary fuse 45 Switch “OFF - ON” 46 Switch “LOCAL REMOTE” 47 Button “ALARM SILENCE” 48 Switch “OIL - OFF GAS” 49 Signal “POWER ON” 50 Signal “CALL FOR HEAT 51 Signal “ALARM ON” 52 Signal “IGNITION ON” 53 Signal “FUEL ON” 54 Optional holes 55 Ground terminals 56 Pump motor contactor and t hermal relay with reset button 57 Delivery oil solenoid valve 58 Return oil solenoid valve 59 DIN bar for fuse holder step-down transformer and OCI 412.10

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8.2 Burner Nozzle Setup Recommended Nozzles 8.2.1

• Bergonzo A4 45° • Delavan Variflo 45° and 60° • Fluidics KC2 30° and 45°

Nozzle Assembly 8.2.2 In order to assemble the nozzle, proceed as follows:

Assembling the Nozzle

1. Remove the screw (1) shown in Figure 8-2.

2. Remove the nozzle assembly (2) per the arrows in Figure 8-2.

Figure 8-2: Nozzle Assembly – Steps 1 and 2

3. Install the nozzle (1) in Figure 8-3.

Figure 8-3: Nozzle Assembly – Step 3 Figure 8-4: Nozzle Assembly – Step 4

4. Fit the wrench through the central hole in the flame stability disk and loosen screws (1) in Figure 8-4.

5. Remove disk (2) in Figure 8-4 and replace the nozzles using the wrench (3).

1

2

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WARNING! • Do not use any sealing products such as gaskets, sealing compound, or tape.

• Be careful to avoid damaging the nozzle sealing seat.

• The nozzles must be screwed into place tightly, but carefully.

• The nozzle for low fire operation is the one lying beneath the firing electrodes.

• Make sure that the electrodes are positioned as shown in Figure 8-11.

8.3 Flow Rate Adjustment The nozzle flow rate varies according to the fuel pressure on the nozzle return.

The diagram in Figure 8-5 indicates this relationship for type A4 return flow nozzles with pump delivery pressure of 290 PSI. See Figure 8-5:

• Horizontal axis: PSI, nozzle return pressure

• Vertical axis: GPH, nozzle flow rate

The values indicated in the right side of the diagram in Figure 8-5, refer to the data printed on the nozzle.

With a pump delivery pressure of 290 PSI, the pressure on the nozzle return must not exceed 246.5 PSI.

The pressure difference between pump delivery and nozzle return must be at least 43.5 PSI. With smaller pressure differences, the pressure on the nozzle return can be unstable. The nozzle return pressure value is indicated by the pressure gauge 1) in Figure 8-6, below.

The output and the pressure of the nozzle are at maximum when the servomotor is positioned on maximum.

The proper setting of the eccentric 6) is possible when its operation field follows the servomotor operation field (0° - 90°): so, that every variation of the servomotor position corresponds to a pressure variation.

If at the maximum capacity of the nozzle (maximum pressure in the return line) pressure fluctuations are detected on the gauge 1), slightly decrease the pressure in the return line until they are completely eliminated.

• Type A4 return flow nozzle (45°) • Delivery pressure 290 PSI

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NOTE: The values indicated in the right side of the diagram in Figure 8-5, refer to the data printed on the nozzle.

Figure 8-5: Nozzle Pressure and Flow Rate Chart

Figure 8-6: Flow Rate Controls and Gauges

The output and the pressure of the nozzle are at maximum when the servomotor is positioned at maximum.

The proper setting of the eccentric (6) is possible when its operation field matches the servomotor operation field (0° - 90°): so, that every variation of the servomotor position corresponds to a pressure variation.

If pressure fluctuations are detected on the gauge (1) in Figure 8-4 at the maximum capacity of the nozzle (maximum pressure in the return line), slightly decrease the pressure in the return line until fluctuations are completely eliminated.

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8.4 Ignition Pilot Adjustment Place the pilot and electrode as shown in Figure 8-7. The pilot works correctly at pressures ranging from 6 - 12” W.C.

Figure 8-7: Pilot and Electrode Figure 8-8: Pilot and Electrode

8.5 Combustion Head Setting The setting of the combustion head depends exclusively on the maximum delivery of the burner.

Turn the screw (6) in Figure 8-10 until the notch shown in diagram Figure 8-9 is level with the front surface of the flange (5) in Figure 8-10.

Figure 8-9: Burner Maximum Output

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EXAMPLE:

Maximum burner delivery = 7000 MBtu/hr.

Refer to the diagram in Figure 8-9 to find that for this delivery, the combustion head must be adjusted using notch 10, as shown in Figure 8-10.

Figure 8-10: Combustion Head Settings

For high altitude sites, consult the AERCO factory or Riello.

8.6 Pump Adjustment No settings are required for the pump, which is set to 360 PSI by the manufacturer. This pressure must be checked and adjusted (if required) after the burner has been ignited. The only operation required in this phase is the application of a pressure gauge on the appropriate pump attachment.

8.7 Air Damper Adjustment The first time the burner is fired leave the factory setting unchanged for both low and high fire operation.

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8.8 Electrode Positioning WARNING! Ensure that the electrodes are positioned as shown in Figure 8-11.

Figure 8-11: Electrode Positioning

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8.9 Burner Setup Reinstall the burner as follows:

Setting Up the Burner

1. Refit the burner to the slide bars (3) in Figure 8-12 at approximately 4” from the sleeve (4) - burner positioned as shown in Figure 8-13.

2. Insert the ignition electrode cables.

3. Remove the extension bars (31) in Figure 8-1.

4. Slide the burner up to the sleeve so that it is positioned as shown in Figure 8-12.

Figure 8-12: Burner Reinstallation

5. Refit screws (2) in Figure 8-12 on slide bars (3) including the safety plate (15) in Figure 8-13. 6. Secure the burner to the sleeve by tightening screws (1) and connectors (6).

7. Connect the oil pipes again by screwing on the two connectors (6) in Figure 13.

WARNING! When fitting the burner on the two slide bars, it is advisable to gently draw out the high tension cables until they are slightly stretched.

Figure 8-13: Securing the Burner to the Boiler

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8.10 Hydraulic Connections The pumps are equipped with a by-pass that separates return line and suction line in Figure 8-14. The pumps are installed on the burner with the by-pass closed by screw (6). It is therefore necessary to connect both hoses to the pump.

CAUTION! DO NOT run the pump with the return line closed and the by-pass screw inserted, or the pump will be quickly damaged. Remove the plugs from the suction and return connections of the pump.

Connecting the Hydraulics

1. Remove the plugs from the suction and return connections of the pump.

2. Insert the hose connections with the supplied seals into the connections and screw them down.

CAUTION! Take care that the hoses are not stretched or twisted during installation.

3. Install the hoses where they cannot be stepped on or come into contact with hot surfaces of the boiler.

4. Now connect the other end of the hoses to the suction and return lines.

Figure 8-14: Connecting the Hydraulics

A

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8.11 Pump The pumps are equipped with a by-pass that separates return line and suction line.

Key to Pump Model J7C 1 Suction 1/2" NPT 2 Return 1/2" NPT 3 Pressure Gauge Attachment G 1/4" 4 Vacuum Gauge Attachment G 1/4" 5 Pressure Adjustment Screw 6 By-Pass Screw

Figure 8-15: J7C Pump Diagram

Pump Priming 8.11.1 WARNING!

Before starting the burner, make sure that the tank return line is not clogged. Obstructions in the line could cause the seal located on the pump shaft to break.

The time required for this operation depends upon the diameter and length of the suction tubing.

If the pump fails to prime at the first starting of the burner and the burner locks out, wait approximately 15 seconds, reset the burner, and then repeat the starting operation as often as required After 5 or 6 starting operations, then allow 2 or 3 minutes for the transformer to cool.

IMPORTANT NOTE: The priming operation is possible because the pump is already full of fuel when it leaves the facto-ry. If the pump has been drained, fill it with fuel through the opening on the vacuum meter prior to starting; otherwise, the pump will seize.

Whenever the length of the suction piping exceeds 66 - 98 ft., the supply line must be filled using a separate pump.

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8.12 Gas Pressure The diagram blow is used to calculate manifold pressure, taking into account combustion chamber pressure.

Figure 8-16: Burner Output Chart

Gas manifold pressure measured at test point 1 per Figure 8-17 with:

• Combustion chamber at 0” W.C.

• Burner operating at maximum output.

• Combustion head adjusted as indicated in diagram shown in Figure 8-9.

Figure 8-17: Gas Manifold Pressure Measuring Locations

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Calculate the approximate high fire output of the burner as follows:

Calculating the Approximate Boiler High Fire Rate

1. Subtract the combustion chamber pressure from the gas pressure measured at test point 1 in Figure 8-17.

2. Find the nearest pressure value to your result in Figure 8-16.

3. Read off the corresponding output on the left.

EXAMPLE: Maximum Output Operation (Natural Gas):

• Gas pressure at test point 1 (per Figure 8-17) = 7.2” WC • Pressure in combustion chamber = 1.2” WC

7.2 – 1.2 = 6.0” W.C.

A maximum output of 6500 MBtu/hr shown in the table below corresponds to 6.0” WC pressure. This value serves as a rough guide. The effective delivery must be measured at the gas meter.

Maximum Output and WC Pressure Correlation Table

*The values refer to the butterfly gas valve.

8.13 Burner Firing Having completed the checks indicated in the previous heading, the pilot of the burner should fire. If the motor starts but the flame does not appear and the flame safeguard goes into lock-out, reset and wait for a new firing attempt.

Pilot adjustment has been illustrated in section 8.4.

Having adjusted the pilot, reconnect the main valve and ignite the main flame; it might require several attempts to purge the air from the gas lines or to adjust the valve with little gas.

Once the burner has fired, now proceed with calibration operations.

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MFC Series Boilers User Manual CHAPTER 8 – MFC 4000/6000 DUAL FUEL BURNER

8.14 Burner Calibration The optimum calibration of the burner requires an analysis of the flue gases at the boiler outlet. Adjust the following in order:

1) Firing output

2) Maximum burner output

3) Minimum burner output

4) Intermediate outputs between low and high fire 5) Air pressure switch

6) Minimum gas pressure switch

8.15 Adjustments Before First Firing (Gas Operation)

Adjustments Before First Firing

1. Ensure that the gas supply company has carried out the supply line vent operations, eliminating air or inert gases from the piping.

2. Slowly open the manual valves situated upstream of the gas train.

3. Adjust the minimum gas pressure switch shown in Figure 8-18 to the start of the scale.

Figure 8-18: Minimum Gas Pressure Switch

4. Adjust the maximum gas pressure switch shown in Figure 8-19 to the end of the scale.

Figure 8-19: Maximum Gas Pressure Switch

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Adjustments Before First Firing - Continued

5. Adjust the air pressure switch shown in Figure 8-20 to the start of the scale.

Figure 8-20: Air Pressure Switch

6. Purge the air from the gas line.

7. Fit a U-type manometer, shown in Figure 8-21, to the gas pressure test point on the sleeve. The manometer readings are used to calculate the MAX. burner power using the diagram on page 26.

Figure 8-21: Manometer insertion Point

NOTE: Before starting up the burner it is good practice to adjust the gas train so that ignition takes place in conditions of maximum safety, i.e., with gas delivery at the minimum.

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Startup for MFC 4000 – 6000 Dual Fuel Burner 8.15.1 Starting the Burner

1. Turn on electricity to the burner by turning the power switch on the boiler panel to ON.

2. Close the thermostats/pressure switches and set the parameters on the RWF 40 regulator.

Please refer to the appropriate manual for instructions to perform this operation.

3. Turn the switch shown on Figure 8-22 to the “ON” position and turn the switch of to position “LOCAL” and turn the switch to position “OIL” for oil operation and “GAS” for gas operation.

Figure 8-22: Burner Controls Used for Startup

DANGER! Make sure that the lamps or testers connected to the solenoids, or indicator lights on the solenoids themselves, show that no voltage is present. If voltage is present, stop the burner immediately and check the electrical wiring.

NOTE: For the start-up procedure and the parameters calibration, refer to the specific instruction manual of the LMV37 electronic cam supplied with the burner.

DIRECTION OF MOTOR ROTATION

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Starting the Burner – Continued

CAUTION! Check Motor Rotation As the burner is not fitted with a device to check the sequence of the phases, the motor rotation may be incorrect. As soon as the burner starts up, go in front of the cooling fan of the fan motor and check it is rotating anticlockwise. See Figure 8-22. If this is not the case:

4. Place the On/Off switch in the “OFF” position and wait for the control box to carry out the switch-off phase;

5. Disconnect the electrical supply from the burner;

6. Invert the phases on the three-phase power supply.

Gas/Air Delivery Adjustment 8.15.2

Adjusting Gas/Air Delivery

1. Slowly open butterfly gas valve to maximum open position.

2. Adjust the required maximum output with the gas pressure stabilizer.

3. Adjust the combustion parameters with the air servomotor and store the maximum combustion point.

4. Complete the procedure by synchronizing the combustion with the two servomotors and storing the different setting points.

Adjusting Oil/Air Delivery 8.15.3

Adjusting Oil/Air Delivery

1. Switch to the light oil operation.

2. During the ignition, slowly move oil servomotor to a maximum position of approximately 90°.

3. Adjust the maximum pressure on the return nozzle using the “nut and lock-nut” (5) shown in Figure 8-6.

4. Adjust the combustion parameter with the air servomotor and store the maximum combustion point.

5. To complete the procedure, synchronize the combustion with the two servomotors and store the different setting points.

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Air Pressure Switch Adjustment 8.15.4 The air pressure switch is connected in differential (see Figure 8-24) and is activated by both the negative pressure of the air intake and the air pressure from the fan.

Adjust the air pressure switch shown in Figure 8-23 after having performed all other burner adjustments with the air pressure switch set to the minimum scale position.

Adjusting the Air Pressure Switch

1. With the burner operating at low fire, adjust the pressure switch by slowly turning the relative knob clockwise until the burner locks out.

2. Then turn the knob counter-clockwise about 20% of the set point and start-up the burner again to ensure the set point is correct.

3. If the burner locks out again, turn the knob counter-clockwise a little bit more.

Figure 8-23: Air Pressure Switch

Figure 8-24: Air Pressure Switch Connection

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Maximum Gas Pressure Switch Adjustment 8.15.5 Adjust the maximum gas pressure switch shown in Figure 8-25 after having performed all other burner adjustments with the maximum gas pressure switch set to the end of the scale.

Adjusting Maximum Gas Pressure Switch

1. With the burner operating at MAX output, reduce the adjustment pressure by slowly turning the adjustment dial anticlockwise until the burner locks out.

2. Then turn the dial clockwise by 0.8” WC and repeat burner firing.

3. If the burner locks out again, turn the dial again clockwise by 0.4” W.C.

Figure 8-25: Maximum Gas Pressure Switch

Minimum Gas Pressure Switch Adjustment 8.15.6 Adjust the minimum gas pressure switch shown in Figure 8-26 after having performed all the other burner adjustments with the pressure switch set at the start of the scale.

Adjusting the Minimum Gas Pressure Switch

1. With the burner operating at MAX output, increase adjustment pressure by slowly turning the relative dial clockwise until the burner locks out.

2. Then turn the dial anti-clockwise by 0.8” WC and repeat burner starting to ensure it is uniform.

3. If the burner locks out again, turn the dial anti-clockwise again by 0.4” W.C.

Figure 8-26: Minimum Gas Pressure Switch

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Low Oil Pressure Switch 8.15.7 The low oil pressure switch is factory set to 261 PSI (18 bar). If the oil pressure goes down this value in the delivery piping, the pressure switch stops the burner. Burner starts again automatically if the pressure goes above 261 PSI (18 bar) after burner start up.

High oil pressure switch 8.15.8 The high oil pressure switch is factory set to 43.5 PSI (3 bar). If the oil pressure goes above this value in the return piping, the pressure switch stops the burner. Burner starts again automatically if the pressure goes down under 43.5 PSI (3 bar) after burner shut down. If a loop circuit with Px pressure feeds the burner, the pressure switch should be adjusted to Px + 43.5 PSI. Figure 8-27 shows the location of this adjustment.

Figure 8-27: Maximum Gas Pressure Switch

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Burner Startup Sequence of Operation 8.15.9 Sequence of Operation:

• Operating control closes, the motor starts.

• The pump (3) in Figure 8-28 draws the fuel from the tank through the piping (1) and pumps it under pressure for delivery.

• The piston 4) rises and the fuel returns to the tank through the piping (5) - 7).

• The screw 6) closes the by-pass heading towards suction and the de-energized solenoid valves 8) - 9) - 2) close the passage to the nozzle.

• Air damper and pressure regulator are positioned on MIN output.

• Ignition electrode strikes a spark.

• Solenoid valves (8) – (9) – (2) open; the fuel passes through the piping (10) and filter (11), and enters the nozzle.

• A part of the fuel is then sprayed out through the nozzle, igniting when it comes into contact with the spark: flame at a low output level; the rest of the fuel passes through piping (12) at the pressure adjusted by the regulator (13), then, through piping ( 7), it goes back into the tank.

• The spark goes out.

• The starting cycle ends.

Figure 8-28: Burner Startup Sequence of Operation

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Normal Operation Sequence of Operation 8.15.10 At the end of the starting cycle, the servo-motor control then passes to load control for boiler pressure or temperature.

Sequence of Operation:

• If the temperature or pressure is low (and the load control is consequently closed), the burner progressively increases output up to MAX.

• If subsequently the temperature or pressure increases until the load control opens, the burner progressively decreases output down to MIN.

• The burner shuts off when demand for heat is less than the heat supplied by the burner in the MIN output.

• The servomotor returns to the 0° angle limited by contact with cam 2. The air damper closes completely to reduce thermal dispersion to a minimum.

Every time output is changed, the servomotor automatically modifies oil delivery (pressure regulator) and air delivery (fan damper).

8.16 Firing Failure If the burner does not fire, it goes into lock-out within 3 sec. of the opening of the light oil valve. If the flame should go out for accidental reasons during operation, the burner will lock out in 1 second.

8.17 Final Checks with Boiler in Operation Perform the operations in the left column, while the boiler is operating, and ensure the response in the right column is the result.

FINAL CHECK PROCEDURE DESIRED RESULT Open the control limit operation. Burner

Stops Open the high limit operation.

Turn down maximum gas pressure switch knob to the minimum position. Burner Stops

In Lockout Turn up the air pressure switch knob to the maximum position.

Turn down the maximum oil pressure switch at minimum position.

Switch burner to OFF and disconnect the electrical power. Burner Will Not Start Disconnect the minimum gas pressure switch.

Turn up the minimum low oil pressure switch to maximum position.

Cover the UV flame sensor. Burner Stops In Lockout Due To

Firing Failure

WARNING!

Ensure that all lockout and safety procedures concerning all controls and valves are strictly observed.

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MFC Series Boilers User Manual CHAPTER 9 – MFC 4000/6000 GAS ONLY BURNER P

SECTION 9: MFC 4000-6000 Gas Only Burner

9.1 Combustion Head Adjustment WARNING! Before starting the burner, ensure that the tank return line is not clogged.

The setting of the combustion head depends on the maximum output of the burner.

Adjusting the Combustion Head

1. Outside Air Adjustment: Turn screw (4) in Figure 9-1 until the notch identified is aligned with the front surface (5) of the connector. In order to facilitate adjustment, loosen screw (6) in Figure 9-1, adjust, and then tighten.

2. Central Air Adjustment: Loosen the 3 screws (1) in Figure 9-1 and turn ring (2) until the notch identified is aligned with index (3).

3. Tighten the 3 screws (1) fully down.

4. In the diagram in Figure 9-2 find the notch at which to adjust both air and central gas/air.

Figure 9-1: Adjusting the Combustion Head

EXAMPLE: Maximum burner output = 5681 MBtu/hr.

Consult the diagram in Figure 9-2 to see that for this output the adjustments are: • Outside Air: R1 = notch 8.6. • Central Air: R2 = notch 0.

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Adjusting the Combustion Head (Continued)

NOTE: The diagram in Figure 9-2 indicates an optimal calibration example.

Figure 9-2: MFC 4000/6000 Gas Only Burner Parts and Features

NOTE: If possible, always keep the ring nut closed (notch 0). If air recovery is required, the nut may be opened per the indications in diagram. Make sure that the combustion characteristics are satisfactory and free of any pulsing behavior. Once the combustion head adjustment is completed:

5. Push the burner on the sliding bars 3) at approximately 4” from the pipe coupling 4) - burner in the position shown in Figure 9-3.

6. Insert the electrode cable, then slide the burner as far as the pipe coupling - burner in the position shown in Figure 9-4.

7. Unscrew the 2 screws 2) from the extension 5) and reposition them as shown in Figure 9-4. 8. Refit the screws 2) on the sliding bars 3). 9. Fix the burner to the pipe coupling with the screws 1).

Figure 9-3: Burner Reassembly Figure 9-4: Burner Reassembly

NOTE: When fitting the burner on the two sliding bars, it is advisable to gently draw out the high voltage cable until it is slightly taut.

Key to Figure 9-3 & 9-4 1 Screw 2 Screw 3 Sliding bars 4 Pipe coupling 5 Extension sliding bars 6 Lifting rings

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9.2 Gas Supply Pressure The table in Figure 9-5 shows minimum load losses at combustion head (∆p1) and gas butterfly valve (∆p2) depending on the maximum burner output operation with natural gas.

∆p1 - Gas pressure is measured at the test point (1) in Figure 9-5, with:

• Combustion chamber at 0 mbar.

• Burner working at maximum output.

• Ring nut (2) in Figure 9-3 adjusted as in the diagram of Figure 9-2.

∆p2 - Load loss at gas butterfly valve (2) in Figure 9-5 with maximum opening: 90°.

Figure 9-5: MFC 4000-6000 Natural Gas Supply Pressure Test Points and Chart

Figuring Burner Output 9.2.1

Figuring Burner Output

To know the approximate output at which the burner is operating at its maximum:

1. Subtract the combustion chamber pressure from the gas pressure measured at test point (1) in Figure 9-5.

2. In the table in Figure 9-5 find the pressure value closest to the result you want; read the corresponding output on the left.

Maximum Output Formula Example: • Natural gas

• Gas Pressure at Test Point 1 = 4.09” WC

• Pressure in combustion chamber = 1.14“ WC

4.09 – 1.14 = 2.95 “WC A maximum output of 4166 MBtu/hr corresponds to 2.95” W.C. pressure.

This value serves as a rough guide; the effective delivery must be measured at the gas meter.

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9.3 Adjustments Before First Firing WARNING! • The first start-up of the burner must be carried out by qualified personnel, as indicated in this

manual and in compliance with the standards and regulations of the laws in force.

• Ensure that all adjustment, command and safety devices are operating correctly

Adjustments Before First Firing

1. Ensure that the gas supply company has carried out the supply line vent operations, eliminating air or inert gases from the piping.

2. Slowly open the manual valves situated upstream of the gas train.

3. Adjust the minimum gas pressure switch shown in Figure 9-6 to the start of the scale.

Figure 9-6: Minimum Gas Pressure Switch

4. Adjust the maximum gas pressure switch shown in Figure 9-7 to the end of the scale.

Figure 9-7: Maximum Gas Pressure Switch

5. Adjust the air pressure switch shown in Figure 9-8 to the start of the scale.

Figure 9-8: Air Pressure Switch

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Adjustments Before First Firing - Continued

8. Purge the air from the gas line.

9. Fit a U-type manometer shown in Figure 9-9 to the gas pressure test point on the sleeve. The manometer readings are used to calculate the maximum burner power.

Figure 9-9: Manometer insertion Point

NOTE: Before starting up the burner it is good practice to adjust the gas train so that ignition takes place in conditions of maximum safety, i.e. with gas delivery at the minimum.

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9.4 Startup for MFC 4000-6000 Gas Only Burner Starting the Burner

1. Turn on electricity to the burner by turning the power switch on the boiler panel to ON.

2. Close the thermostats/pressure switches and set the parameters on the RWF 40 regulator. Please refer to the appropriate manual for instructions to perform this operation.

3. In Figure 9-10, turn the On/Off switch to the “ON” position and turn the other switch to “LOCAL”.

Figure 9-10: Burner Controls Used for Startup

DANGER! Make sure that the lamps or testers connected to the solenoids, or indicator lights on the solenoids themselves, show that no voltage is present. If voltage is present, stop the burner immediately and check the electrical wiring.

NOTE: For the start-up procedure and the parameters calibration, refer to the specific instruction manual of the LMV37 electronic cam, supplied with the burner.

DIRECTION OF MOTOR

ROTATION

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CAUTION! Check Motor Rotation As the burner is not fitted with a device to check the sequence of the phases, the motor rotation may be incorrect. As soon as the burner starts up, go in front of the cooling fan of the fan motor and check it is rotating anticlockwise. See Figure 9-10.

If this is not the case:

7. Place the On/Off switch in the “OFF” position and wait for the control box to carry out the switch-off phase;

8. Disconnect the electrical supply from the burner;

9. Invert the phases on the three-phase power supply.

Combustion Air Adjustment 9.4.1 Fuel/combustion air must be synchronized with the relevant servo-motors (air and gas) by storing a setting curve by means of the electronic cam.

To reduce pressure loss and to have a wider adjustment range, it is best to set the servomotor to the maximum output used, as near to maximum opening (90°) as possible.

On the gas butterfly valve, the fuel’s partial setting adjustment based on required output, with the servomotor fully open, is made by using the pressure stabilizer on the gas train.

With O2 control via the relative kit, follow the instructions about commissioning in the specific handbook for the LMV36.5.

Gas/Air Delivery Adjustment 9.4.2

Adjusting Gas/Air Delivery

1. Slowly open butterfly gas valve to maximum open position.

2. Adjust the required maximum output with the gas pressure stabilizer.

3. Adjust the combustion parameters with the air servomotor and store the maximum combustion point.

4. Complete the procedure by synchronizing the combustion with the two servomotors and storing the different setting points.

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Air/Fuel Control and Power Modulation System 9.4.3 The air/fuel and power modulation system installed on RS burner series provides, a set of integrated functions ensuring top level energy and operational performance from the burner, both for single and grouped burners (e.g. boiler with a double combustion chamber or several generators in parallel).

The system includes the following basic functions:

• Air and fuels are supplied in correct quantities by positioning the valves by direct servo-control, thus avoiding the possibility of play typical of systems used for traditional modulating burners, in which settings are obtained by levers and a mechanical cam.

• Burner power is modulated according to the load required by the system, while boiler pressure or temperature is maintained at set operating values.

• Fine, continuous correction of the airflow according to the analysis of the flue gases at the stack (O2); this function is associated with the O2 kit containing the PLL module and the QGO2 sensor.

• Measurement of the combustion efficiency; this function is associated with the O2 kit.

• A sequence (cascade control) of several boilers by suitably connecting different units.

Further interfaces and computer communication functions for remote control or integration in centrally supervised systems are available according to the system’s configuration.

NOTE: The first start-up and all further operations concerning internal settings of the control system or expansion of basic functions are accessed with a password and are reserved for technical service personnel specifically trained for internal programming of the instrument and for the specific application obtained with this burner. The first start-up and curve synchronization manual is supplied with the burner.

The complete manual for checking and setting all parameters will be provided on application.

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9.5 Final Calibration of the Pressure Switches Air Pressure Switch Adjustment 9.5.1

The air pressure switch shown in Figure 9-11 is connected in differential and is activated by both the negative pressure of the air intake and the air pressure from the fan.

Adjust the air pressure switch after having performed all other burner adjustments with the air pressure switch set to the minimum scale position.

Adjusting the Air Pressure Switch

1. With the burner operating at low fire, adjust the pressure switch by slowly turning the relative knob clockwise until the burner locks out.

2. Then turn the knob counter-clockwise about 20% of the set point and start-up the burner again to ensure the set point is correct.

3. If the burner locks out again, turn the knob counter-clockwise in small increments until it stops locking out.

Figure 9-11: Air Pressure Switch and Connection

Figure 9-12: Air Pressure Switch and Connection

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Maximum Gas Pressure Switch Adjustment 9.5.2 Adjust the maximum gas pressure switch shown in Figure 9-13 after having performed all other burner adjustments with the maximum gas pressure switch set to the end of the scale.

Adjusting Maximum Gas Pressure Switch

1. With the burner operating at MAX output, reduce the adjustment pressure by slowly turning the adjustment dial anticlockwise until the burner locks out.

2. Then turn the dial clockwise by 0.8” WC and repeat burner firing.

3. If the burner locks out again, turn the dial again clockwise by 0.4” W.C.

Figure 9-13: Maximum Gas Pressure Switch

Minimum Gas Pressure Switch Adjustment 9.5.3 Adjust the minimum gas pressure switch shown in Figure 9-14 after having performed all the other burner adjustments with the pressure switch set at the start of the scale.

Adjusting the Minimum Gas Pressure Switch

1. With the burner operating at MAX output, increase adjustment pressure by slowly turning the relative dial clockwise until the burner locks out.

2. Then turn the dial anti-clockwise by 0.8” WC and repeat burner starting to ensure it is uniform.

3. If the burner locks out again, turn the dial anti-clockwise again by 0.4” W.C.

Figure 9-14: Minimum Gas Pressure Switch

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9.6 Final Checks with Boiler in Operation Perform the operations in the left column, while the boiler is operating, and ensure the response in the right column is the result.

FINAL CHECK PROCEDURE DESIRED RESULT Open the control limit operation. Burner

Stops Open the high limit operation.

Turn down maximum gas pressure switch knob to the minimum position. Burner Stops

In Lockout Turn up the air pressure switch knob to the maximum position.

Turn down the maximum oil pressure switch at minimum position.

Switch burner to OFF and disconnect the electrical power. Burner Will Not Start Disconnect the minimum gas pressure switch.

Turn up the minimum low oil pressure switch to maximum position.

Cover the UV flame sensor. Burner Stops In Lockout Due To

Firing Failure

WARNING!

Ensure that all lockout and safety procedures concerning all controls and valves are strictly observed.

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MFC Series Boilers User Manual CHAPTER 10 – MFC 8000/10000 DUAL FUEL BURNER

SECTION 10: MFC 8000 / 10000 Dual Fuel Burner

NOTE: In order to guarantee that emissions do not vary, only the recommended and/or alternative nozzles as specified in these Instructions should be used.

CAUTION! It is advisable to replace nozzles every year during regular maintenance operations.

WARNING! The use of nozzles other than those specified by the manufacturer, and the inadequate regular maintenance of the boiler may result in emissions exceeding the limits set forth by the regulations in force, and can pose a potential serious hazard to people and property. The manufacturing company shall not be liable for any such damage arising from failure to observe all the safety warnings and requirements as set forth in this document.

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10.1 MFC 8000-10000 Dual Fuel Burner Features

Figure 10-1: MFC 8000-10000 Dual Fuel Parts and Features

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Key to Figure 10-1: MFC 8000-10000 Burner Parts and Features

1 Lifting eyebolts 2 Fan 3 Fan motor 4 Air gate valve servomotor 5 Gas pressure test point 6 Combustion head 7 Ignition pilot 8 Flame stability disk 9 Electric panel board - cover 10 Hinge for opening burner 11 Air inlet to fan 12 Manifold 13 Thermal insulation screen for securing burner to boiler 14 Gas train flange 15 Shutter 16 Lever for movement of combustion head 17 Gears for movement of air damper 18 Air pressure switch (differential operating type) 19 Air pressure test point 20 Max gas pressure switch with pressure test point 21 QRI flame detector 22 Air pressure test point “+” 23 Oil modulator and gas butterfly valve servomotor 24 Pump 25 Pump motor 26 Min oil pressure switch 27 Oil shutoff VOG valve 28 Nozzle delivery pressure gauge 29 Nozzle return pressure gauge 30 Oil modulator 31 Strainer 32 Check valve 33 Air pressure test point “-”

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10.2 Burner Nozzle Setup Recommended Nozzles 10.2.1

• Fluidics Type N2 angle 45°

NOTE: Intermediate flow rates may be obtained by choosing the nozzle with a nominal flow rate slightly higher than that actually required.

Nozzle Assembly 10.2.2 In order to assemble the nozzle, proceed as follows:

Assembling the Nozzle

1. Fit the nozzle with the box spanner, fitting the spanner through the central hole in the flame stability disk in Figure 10-2. Nozzles with no fuel shutoff needle must be fitted on the nozzle holder.

2. To set the delivery range within which the nozzle must work, nozzle return line fuel pressure must be adjusted according to section 4.9.1 of RLS 300 manual.

Figure 10-2: Nozzle Assembly

WARNING! • Do not use any sealing products such as gaskets, sealing compound, or tape.

• Be careful to avoid damaging the nozzle sealing seat.

• The nozzles must be screwed into place tightly, but carefully.

• The nozzle for low fire operation is the one lying beneath the firing electrodes.

• Make sure that the electrodes are positioned as shown in Figure 10-3, below.

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Figure 10-3: Electrode Adjustment

10.3 Combustion Head setting In addition to varying air flow depending on the output requested, the air gate valve servomotor (4) in Figure 10-1 varies the setting of the combustion head by means of a lifting assembly.

This system allows an optimal setting even at a minimum firing rate.

For the same servomotor rotation, combustion head opening can be varied by moving the tie rod onto holes 1-2-3, Figure 10-4.

The choice of the hole (1-2-3) to be used is decided on the basis of diagram in Figure 10-6 against the required maximum output.

Setting is pre-arranged in the plant for the maximum run (hole 3) in Figure 10-4.

When dealing with boilers featuring a strong back pressure, if air delivery is insufficient even with the damper fully open, you can use a different setting to that illustrated in diagram in Figure 10-6; do this by moving the tie rod onto the next highest index, thus increasing the combustion head’s opening and hence air delivery.

If combustion requirements require you to move spacer 1) in Figure 10-5 onto the first or second hole of the gear and, at the same time, the hinge is on the right, you need to fit the spacers 4) in Figure 10-5 supplied with the burner.

Proceed as follows:

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Fitting Spacers Supplied with Boiler

1. First unscrew nuts 2), remove tie rod 3), unscrew spacer 1) and position it on the hole you want in Figure 10-4.

Figure 10-4: Combustion Head Setting

2. Screw the spacers 4) onto spacer 1) and screw 5) respectively,

Figure 10-5: Combustion Head Setting

3. Once done, refit the tie rod and nuts.

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Fitting Spacers Supplied with Boiler – Continued

Figure 10-6: Maximum Burner Output Chart

10.4 Hydraulic Connections The pumps are equipped with a by-pass that separates return line and suction line in Figure 10-8. The pumps are installed on the burner with the by-pass closed by screw (6). It is therefore necessary to connect both hoses to the pump.

CAUTION! DO NOT run the pump with the return line closed and the by-pass screw inserted, or the pump will be quickly damaged. Remove the plugs from the suction and return connections of the pump.

Connecting the Hydraulics

1. Remove the plugs from the suction and return connections of the pump.

2. Insert the hose connections with the supplied seals into the connections and screw them down.

CAUTION! Take care that the hoses are not stretched or twisted during installation.

3. Install the hoses where they cannot be stepped on or come into contact with hot surfaces of the boiler.

4. Now connect the other end of the hoses to the suction and return lines.

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10.5 Pressure Variator The pressure variator, shown in Figure 10-7 of the oil circuit makes, it possible to vary the pressure on return of the nozzle depending on the flow rate required.

Governing of the pressure on return is obtained with the variation of a section by rotating the servomotor 23) shown in Figure 10-1, which simultaneously also controls the gas butterfly valve.

• Pressure governor at 0° (maximum opening) = minimum pressure on nozzle return.

• Pressure governor at 90° (minimum opening) = maximum pressure on nozzle return.

The servomotor is operated by the electronic cam; by means of this device it is possible to set different curves for oil and gas on the same servomotor (the air gate valve servomotor 4) shown in Figure 10-1 may be operated in the same way.

• In adjusting with gas it is advisable to set the servomotor at 90° in order to reduce losses from the gas butterfly valve.

In regulating with oil, setting is made depending on the type of nozzle used and on the modulation required. Under the conditions of minimum firing rate, 20° rotation may be sufficient.

Figure 10-7: Hydraulic Gauges and Indicators

KEY to Figure 10-7 1 = Nozzle pressure gauge 2 = Position indicator (0 - 90) of pressure variator

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10.6 Pump The pumps are equipped with a by-pass that separates return line and suction line.

Figure 10-8: TA3 Pump Technical Data

Pump Priming 10.6.1 WARNING!

Before starting the burner, make sure that the tank return line is not clogged. Obstructions in the line could cause the seal located on the pump shaft to break.

The time required for this operation depends upon the diameter and length of the suction tubing.

If the pump fails to prime at the first starting of the burner and the burner locks out, wait approximately 15 seconds, reset the burner, and then repeat the starting operation as often as required After 5 or 6 starting operations, then allow 2 or 3 minutes for the transformer to cool.

IMPORTANT NOTE: The priming operation is possible because the pump is already full of fuel when it leaves the facto-ry. If the pump has been drained, fill it with fuel through the opening on the vacuum meter prior to starting; otherwise, the pump will seize.

Whenever the length of the suction piping exceeds 66 - 98 ft., the supply line must be filled using a separate pump.

PUMP MODEL TA3

(RLS 300-400/E) Min. delivery rate at 300 PSI pressure GPH 218

Delivery pressure range PSI 102 - 580 Max. suction pressure PSI 7.0 Viscosity range cSt 3 - 75 Max. oil temperature °F 302 (150 °C) Max. return pressure PSI 73.0 Pressure calibration in the factory PSI 300

Key to Pump Model TA3 1 Suction 1/2" NPT 2 Return 1/2" NPT 3 Pressure Gauge Attachment G 1/4" 4 Vacuum Gauge Attachment G 1/4" 5 Pressure Adjustment Screw 6 By-Pass Screw

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RLS

300

/E

10.7 Gas Train The gas train is to be connected on the right of the burner, by flange (1) in Figure 10-9. If necessary connect it on the left, proceed as follows:

Switching Gas Train to Left Side Position

1. Loosen nuts and screws (3) and 4).

2. Remove blind flange (2) together with its gasket.

3. Fit them to flange (1) tightening the nuts and screws.

Figure 10-9: Gas Train Connection

10.8 Gas Pressure The Table J shows minimum pressure losses along the gas supply line depending on the maximum burner output operation.

The values shown in the Table J refer to natural gas (GCV).

Table J: Minimum Pressure Losses MBtu/hr (GCV) 1 ∆p (“WC) 2 ∆p (“WC)

5112 3.3 0.63 5680 3.7 0.79 7574 4.9 1.38 9467 5.4 2.13

11361 5.9 3 13254 7.9 4.2 14390 9 5.1

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COLUMN 1 Pressure loss at combustion head.

Gas pressure measured at the test point (1) in Figure 10-10, with:

• Combustion chamber at “WC;

• Burner working at maximum output;

• Combustion head adjusted as in the diagram in Figure 10-6.

COLUMN 2 Pressure loss at gas butterfly valve (2) in Figure 10-10 with maximum opening: 90°. Calculate the approximate maximum output of the burner as follows:

• Subtract the combustion chamber pressure from the gas pressure measured at test point 1) in Figure 10-10.

• In the Table J, above, find the pressure value closest to the result of the subtraction for the burner concerned.

Read off the corresponding output on the left.

Figure 10-10: Gas Manifold Pressure Measuring Locations

10.9 Adjustments before First Firing (Light Oil Operation) The optimum calibration of the burner requires an analysis of the flue gases at the boiler outlet and interventions on the following points.

10.10 Nozzles See Section 10.2.

10.11 Combustion Head The adjustment of the combustion head already carried out need not be altered unless the 2nd stage delivery of the burner is changed.

The setting of the combustion head depends exclusively on the maximum delivery of the burner. In case of high altitude site, consult the AERCO factory or Riello.

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10.12 Pump Pressure 300 psi: This is the pressure calibrated in the factory which is usually sufficient for most purposes. Sometimes, this pressure must be adjusted to:

145 psi: To reduce fuel delivery. This adjustment is possible only if the surrounding temperature remains above 0 °C.

In order to adjust pump pressure, use the screw (5) shown in Figure 10-8.

10.13 Burner Firing Having completed the checks indicated in the previous heading, the ignition pilot of the burner should fire.

Setting Burner to Fire Gas

1 Set switch (1) in Figure 10-11 to "LOCAL".

2 Set switch (2) in Figure 10-11 to "GAS".

Figure 10-11: Gas Manifold Pressure Measuring Locations

3 If the motor starts, but the flame does not appear and the flame safeguard goes into lock-out, reset and wait for a new firing attempt.

4 Adjust the pilot per Figure 10-3.

5 Having adjusted the pilot, reconnect the main valve and ignite the main flame. It may require several attempts to purge the air from the gas lines or to adjust the valve with little gas.

6 Once the burner has fired, now proceed with calibration operations.

10.14 Changing Fuel Type There are two possible options for changing fuel:

• Using switch (2) in Figure 10-11.

• Using a remote selector connected to the main terminal board.

By setting switch (1) in Figure 10-11 to “REMOTE” you activate the remote fuel selection facility.

In this position, if no remote selector is fitted, the display shows the priority fuel.

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10.15 Adjustments before First Firing (Gas Operation) Adjustment of the combustion head has been illustrated in Figures 10-4 and 10-5.

In addition, the following adjustments must also be made:

• Open manual valves up-stream from the gas train.

• Purge the air from the gas line.

• Adjust the minimum gas pressure switch shown in Figure 1016 to the start of the scale.

• Adjust the maximum gas pressure switch shown in Figure 10-15 to the upper limit of the scale.

• Adjust the air pressure switch shown in Figure 10-14 to the zero position of the scale.

• Fit a U-type manometer shown in Figure 10-12 to the gas pressure test point on the sleeve. The manometer readings are used to calculate MAX burner power using Table J, in section 10.8, above.

Figure 10-12: U-Type Manometer Test Points

CAUTION! Before starting up the burner it is good practice to adjust the gas train so that ignition takes place in conditions of maximum safety, i.e., with gas delivery at the minimum.

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10.16 Burner Start-Up Burner Start-Up

1. Turn on electricity to the burner by turning the power switch on the boiler panel to ON.

2. Close the thermostats and pressure switches. Please refer to the appropriate manual for instructions to perform this operation.

3. Turn the switch shown in Figure 10-13 to the “LOCAL” position and turn the other switch “OIL” for oil operation or “GAS” for gas operation.

Figure 10-13: Burner Controls Used for Startup

DANGER! Make sure that the lamps or testers connected to the solenoids, or indicator lights on the solenoids themselves, show that no voltage is present. If voltage is present, stop the burner immediately and check the electrical wiring.

NOTE: For the start-up procedure and the parameters calibration, refer to the specific instruction manual of the LMV37 electronic cam supplied with the burner.

DIRECTION OF MOTOR ROTATION

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CAUTION! Check Motor Rotation As the burner is not fitted with a device to check the sequence of the phases, the motor rotation may be incorrect. As soon as the burner starts up, go in front of the cooling fan of the fan motor and check it is rotating anticlockwise. See Figure 10-13.

If this is not the case:

10. Place the On/Off switch in the “OFF” position and wait for the control box to carry out the switch-off phase;

11. Disconnect the electrical supply from the burner;

12. Invert the phases on the three-phase power supply.

Combustion Air Adjustment 10.16.1 Fuel/combustion air must be synchronized with the relevant servo-motors (air and gas) by storing a setting curve by means of the electronic cam.

To reduce pressure loss and to have a wider adjustment range, it is best to set the servomotor to the maximum output used, as near to maximum opening (90°) as possible.

On the gas butterfly valve, the fuel’s partial setting adjustment based on required output, with the servomotor fully open, is made by using the pressure stabilizer on the gas train.

Air Adjustment for Maximum Output 10.16.2 Set the servomotor to maximum opening (near 90°) so that the air butterfly valves are fully open.

NOTE: To achieve the maximum output required manually, it is suggested to adjust intake to the partial setting, define gas pressure, and adjust the combustion head before completing the setting and storing the fuel/combustion air synchronization curves.

Gas/Air Delivery Adjustment 10.16.3

Adjusting Gas/Air Delivery

1. Slowly open butterfly gas valve to maximum open position.

2. Adjust the required maximum output with the gas pressure stabilizer.

3. Adjust the combustion parameters with the air servomotor and store the maximum combustion point.

4. Complete the procedure by synchronizing the combustion with the two servomotors and storing the different setting points.

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Adjusting Oil/Air Delivery 10.16.4

Adjusting Oil/Air Delivery

1. Switch to the light oil operation.

2. During the ignition, slowly move oil servomotor to a maximum position of approximately 90°.

3. Adjust the combustion parameter with the air servomotor and store the maximum combustion point.

4. To complete the procedure, synchronize the combustion with the two servomotors and store the different setting points.

Air/Fuel Control and Power Modulation System 10.16.5 The air/fuel and power modulation system installed on RLS burner series provides a set of integrated functions ensuring top level energy and operational performance from the burner, both for single and grouped burners (e.g. boiler with a double combustion chamber or several generators in parallel). The system includes the following basic functions:

• Air and fuels are supplied in correct quantities by positioning the valves by direct servo-control, thus avoiding the possibility of play typical of systems used for traditional modulating burners, in which settings are obtained by levers and a mechanical cam;

• Burner power is modulated according to the load required by the system, while boiler pressure or temperature is maintained at set operating values;

Further interfaces and computer communication functions for remote control or integration in centrally supervised systems are available according to the system’s configuration.

NOTE: The first start-up and all further operations concerning internal settings of the control system or expansion of basic functions are accessed with a password and are reserved for technical service personnel specifically trained for internal programming of the instrument and for the specific application obtained with this burner.

The first start-up and curve synchronization manual is supplied with the burner.

The complete manual for checking and setting all parameters will be provided on application.

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10.17 Final Calibration of the Pressure Switches Air Pressure Switch Adjustment 10.17.1

Adjust the air pressure switch shown in Figure 10-14 after having performed all other burner adjustments with the air pressure switch set to the minimum scale position.

Adjusting the Air Pressure Switch

1. With the burner operating at low fire, adjust the pressure switch by slowly turning the relative knob clockwise until the burner locks out.

2. Then turn the knob counter-clockwise about 20% of the set point and start-up the burner again to ensure the set point is correct.

3. If the burner locks out again, turn the knob counter-clockwise a little bit more.

Figure 10-14: Air Pressure Switch

WARNING! As a rule, the air pressure switch must prevent the formation of CO. To check this, insert a combustion analyzer into the chimney, slowly close the fan suction inlet (for example with cardboard) and check that the burner locks out, before the CO in the fumes exceeds 400 ppm.

To check this, insert a combustion analyzer into the chimney, slowly close the fan suction inlet (for example with cardboard) and check that the burner locks out, before the CO in the fumes exceeds 1%.

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Maximum Gas Pressure Switch Adjustment 10.17.2 Adjust the maximum gas pressure switch shown in Figure 10-15 after having performed all other burner adjustments with the maximum gas pressure switch set to the end of the scale.

Adjusting Maximum Gas Pressure Switch

1. With the burner operating at MAX output, reduce the adjustment pressure by slowly turning the adjustment dial anticlockwise until the burner locks out.

2. Then turn the dial clockwise by 0.8” WC and repeat burner firing.

3. If the burner locks out again, turn the dial again clockwise by 0.4” W.C.

Figure 10-15: Maximum Gas Pressure Switch

Minimum Gas Pressure Switch Adjustment 10.17.3 Adjust the minimum gas pressure switch shown in Figure 10-16 after having performed all the other burner adjustments with the pressure switch set at the start of the scale.

Adjusting the Minimum Gas Pressure Switch

1. With the burner operating at MAX output, increase adjustment pressure by slowly turning the relative dial clockwise until the burner locks out.

2. Then turn the dial anti-clockwise by 0.8” WC and repeat burner starting to ensure it is uniform.

3. If the burner locks out again, turn the dial anti-clockwise again by 0.4” W.C.

Figure 10-16: Minimum Gas Pressure Switch

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Low Oil Pressure Switch 10.17.4 The low oil pressure switch shown in Figure 10-17 is factory set to 261 PSI (18 bar). If the oil pressure goes down this value in the delivery piping, the pressure switch stops the burner. Burner starts again automatically if the pressure goes above 261 PSI (18 bar) after burner start up.

Figure 10-17: Maximum Gas Pressure Switch

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Burner Startup Sequence of Operation 10.17.5 Sequence of Operation:

• Operating control closes, the motor starts.

• The pump 18) in Figure 10-18 draws the fuel from the tank through the piping (1) and pumps it under pressure for delivery. The pump pressure governor 4) rises and the fuel returns to the tank through the piping (2).The screw 3) closes the by-pass heading towards suction and the de-energized solenoid valves (5) – (6) close the passage to the nozzle.

• Air damper and pressure regulator are positioned on MIN output.

• The ignition pilot starts.

• Solenoid valves (5) – (6) open; the fuel passes through the piping (19) and filter (12), and enters the nozzle. A part of the fuel is then sprayed out through the nozzle, igniting when it comes into contact with the pilot flame: flame at a low output level; the rest of the fuel passes through piping (20) at the pressure adjusted by the regulator (10), then, through piping 2), it goes back into the tank.

• The pilot flame goes out.

• The starting cycle ends.

Figure 10-18: Burner Startup Sequence of Operation

KEY TO FIGURE 50: 1 Pump suction 2 Pump and nozzle return 3 By-pass screw in pump 4 Pump pressure governor 5 Safety valve 6 Safety valve 7 Nozzle delivery 8 Nozzle without interception pin 9 Nozzle return 10 Pressure variator on nozzle return 11 Servomotor for pressure variator 12 Check valve (no dripping function) 13 Check valve (no dripping function) 14 Check valve 15 Pressure switch on pump delivery 16 Strainer 17 Security relief valve 18 Pump 19 Piping 20 Piping M Pressure gauge V Vacuometer

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Normal Operation Sequence of Operation 10.17.6 At the end of the starting cycle, the servo-motor control then passes to load control for boiler pressure or temperature.

Sequence of Operation:

• If the temperature or pressure is low (and the load control is consequently closed), the burner progressively increases output up to MAX.

• If subsequently the temperature or pressure increases until the load control opens, the burner progressively decreases output down to MIN.

• The burner shuts off when demand for heat is less than the heat supplied by the burner in the MIN output.

• The servomotor returns to the 0° angle. The air damper closes completely to reduce thermal dispersion to a minimum.

Every time output is changed, the servomotor automatically modifies oil delivery (pressure regulator) and air delivery (fan damper).

10.18 Firing Failure If the burner does not fire, it goes into lock-out within 3 sec. of the opening of the light oil valve. If the flame should go out for accidental reasons during operation, the burner will lock out in 1 second.

10.19 Final Checks with Boiler in Operation Perform the operations in the left column, while the boiler is operating, and ensure the response in the right column is the result.

FINAL CHECK PROCEDURE DESIRED RESULT Open the control limit operation. Burner

Stops Open the high limit operation.

Turn down maximum gas pressure switch knob to the minimum position. Burner Stops

In Lockout Turn up the air pressure switch knob to the maximum position.

Turn down the maximum oil pressure switch at minimum position.

Switch burner to OFF and disconnect the electrical power. Burner Will Not Start Disconnect the minimum gas pressure switch.

Turn up the minimum low oil pressure switch to maximum position.

Cover the UV flame sensor. Burner Stops In Lockout Due To

Firing Failure

WARNING!

Ensure that all lockout and safety procedures concerning all controls and valves are strictly observed.

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SECTION 11: MFC 8000-10000 Gas Only Burner

11.1 MFC 8000-10000 Gas Only Burner Features

Figure 11-1: MFC 8000-10000 Burner Parts and Features

Key to Figure 11-1 1 Lifting eyebolts 14 Gas butterfly valve 2 Fan 15 Shutter 3 Fan motor 16 Lever for movement of combustion head 4 Air gate valve servomotor 17 Gears for movement of air damper 5 Gas pressure test point 18 Air pressure switch (differential operating type) 6 Combustion head 19 Air pressure test point 7 Ignition pilot 20 Max gas pressure switch with pressure test point 8 Flame stability disk 21 QRI flame detector 9 Electric panel board - cover 22 Hinge for opening burner 10 Servomotor for gas butterfly valve 23 Air pressure test point “+” 11 Air inlet to fan 24 Air pressure test point “-” 12 Manifold 25 Ignition pilot attachment 13 Thermal insulation screen for securing

burner to boiler

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11.2 Combustion Head Adjustment WARNING! Before starting the burner, ensure that the tank return line is not clogged.

The setting of the combustion head depends on the maximum output of the burner.

Adjusting the Combustion Head

In addition to varying air flow depending on the output requested, the air gate valve servomotor (4) in Figure 11-1 by means of a lifting assembly varies the setting of the combustion head. This system allows an optimal setting even at a minimum firing rate.

For the same servomotor rotation, combustion head opening can be varied by moving the tie rod onto holes 1-2-3 in Figure 11-2.

Figure 11-2: Adjusting the Combustion Head

The choice of the hole (1-2-3) to be used is decided on the basis of the diagram in Figure 11-3 against the required maximum output. Setting is pre-arranged in the plant for the maximum run (hole 3) in Figure 11-2.

When dealing with boilers featuring a strong back pressure, if air delivery is insufficient even with the damper fully open, you can do this by using a different setting to the one illustrated in the diagram in Figure 11-3 by moving the tie rod onto the next highest hole numerically speaking, thus increasing the combustion head’s opening and hence air delivery.

Max burner output

Figure 11-3: Maximum Burner Output

MFC 8000 MFC 10000

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Adjusting the Combustion Head - Continued

If combustion requirements require you to move spacer 1) in Figure 11-4 onto the 1st or 2nd hole of the gear and, at the same time, the hinge is on the right, you need to fit the spacers 4) in Figure 11-4 supplied with the burner.

Proceed as follows:

1. First unscrew nuts (2), remove tie rod (3), unscrew spacer (1) and position it on the hole you want.

2. Screw the spacers (4) onto spacer (1) and screw (5) respectively.

3. Once done, refit the tie rod and nuts.

Figure 11-4: Adjusting the Combustion Head

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11.3 Rotation of the Fan Motor The correct motor rotation direction is indicated by the phase sequence relay (1) in Figure 11-5. After turning the power on to the burner, check that the green led lights up on the phase sequence relay. If the phase sequence is not correct, the burner does not fire.

Figure 11-5: Gas Train Connection

11.4 Gas Train The gas train is to be connected on the right of the burner, by flange (1) in Figure 11-6. If necessary connect it on the left, proceed as follows:

Switching Gas Train to Left Side Position

1. Loosen nuts and screws (3) and 4).

2. Remove blind flange (2) together with its gasket.

3. Fit them to flange (1) tightening the nuts and screws.

Figure 11-6: Gas Train Connection

CAUTION! Once assembled, the gas train should be checked for leaks.

1

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GCV MBtu/hr Combustion

Head “WC Gas butterfly + Adaptor “WC

RS

300/

E LN

5112 3.3 0.63 5680 3.7 0.79 7574 4.9 1.38 9467 5.4 2.13

11361 5.9 3 13254 7.9 4.2 14390 9 5.1

11.5 Gas Pressure IMPORTANT! The pressure at the head of the burner from table refers to zero in the combustion chamber; to obtain true pressure, measured by a U-type manometer shown in Figure 11-9 add the counter-pressure of the boiler.

NOTE: See the accompanying instructions for the adjustment of the gas train.

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11.6 Adjustments before First Firing WARNING! • The first start-up of the burner must be carried out by qualified personnel, as indicated in this

manual and in compliance with the standards and regulations of the laws in force.

• Ensure that all adjustment, command and safety devices are operating correctly

Adjustments Before First Firing

1. Ensure that the gas supply company has carried out the supply line vent operations, eliminating air or inert gases from the piping.

2. Slowly open the manual valves situated upstream of the gas train. 3. Adjust the minimum gas pressure switch shown in Figure 11-7 to the start of the scale.

Figure 11-7: Minimum Gas Pressure Switch

4. Adjust the maximum gas pressure switch shown in Figure 11-8 to the end of the scale.

Figure 11-8: Maximum Gas Pressure Switch

5. Adjust the air pressure switch shown in Figure 11-9 to the start of the scale.

Figure 11-9: Air Pressure Switch

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Adjustments Before First Firing - Continued

6. Purge the air from the gas line. Continue to purge the air (we recommend using a plastic tube routed outside the building) until the odor of gas is detected.

7. Fit a U-type manometer shown in Figure 11-10 to the gas pressure test point on the sleeve. The manometer readings are used to calculate MAX burner power using the table in section 11.5, above.

Figure 11-10: Manometer Insertion Point

NOTE: Before starting up the burner it is good practice to adjust the gas train so that ignition takes place in conditions of maximum safety, i.e., with gas delivery at the minimum.

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11.7 Startup for MFC 8000-10000 Gas Only Burner Starting the Burner

1. Turn on electricity to the burner by turning the power switch on the boiler panel to ON. 2. Close the thermostats and pressure switches.

3. Turn the switch shown in Figure 11-11 to “LOCAL”.

Figure 11-11: Burner Controls Used for Startup

DANGER! Make sure that the lamps or testers connected to the solenoids, or indicator lights on the solenoids themselves, show that no voltage is present. If voltage is present, stop the burner immediately and check the electrical wiring.

NOTE: For the start-up procedure and the parameters calibration, refer to the specific instruction manual of the LMV37 electronic cam supplied with the burner.

DIRECTION OF MOTOR ROTATION

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CAUTION! Check Motor Rotation As the burner is not fitted with a device to check the sequence of the phases, the motor rotation may be incorrect. As soon as the burner starts up, go in front of the cooling fan of the fan motor and check it is rotating anticlockwise. See Figure 11-11.

If this is not the case:

4. Place the On/Off switch in “OFF” position and wait for the control box to carry out the switch-off phase.

5. Disconnect the electrical supply from the burner.

6. Invert the phases on the three-phase power supply.

Burner Firing 11.7.1 Having completed the checks indicated in the previous heading, the burner should fire. If the motor starts, but the flame does not appear and the control box goes into lock-out, reset and wait for a new firing attempt.

If firing is still not achieved, it may be that gas is not reaching the combustion head within the safety time period of 3 seconds. In this case increase gas firing delivery.

The arrival of gas at the sleeve is indicated by the U-type manometer in Figure 11-10.

Once the burner has fired, proceed with global calibration operations.

When adjustments are complete, select the AUTOMATIC operating mode on the AZL display.

Combustion Air Adjustment 11.7.2 Fuel/combustion air must be synchronized with the relevant servomotors (air and gas) by storing a setting curve by means of the electronic cam.

To reduce pressure loss and to have a wider adjustment range, it is best to set the servomotor to the maximum output used, as near to maximum opening (90°) as possible.

On the gas butterfly valve, the fuel’s partial setting adjustment based on required output, with the servomotor fully open, is made by using the pressure stabilizer on the gas train.

Gas/Air Delivery Adjustment 11.7.3

Adjusting Gas/Air Delivery

1. Set the servomotor to maximum opening (near 90°) so that the air butterfly valves are fully open.

2. Loosen screw (2) shown in Figure 11-12 under the burner’s intake and close grille (1) progressively until you achieve the required output.

3. The only time reducing intake to a partial setting is not necessary is when the burner is working at the top of the operating range given in Figure 11-3.

CAUTION! We recommend you achieve the maximum output required manually, and adjust intake to the partial setting, define gas pressure and adjust the combustion head before completing the setting and storing the fuel/combustion air synchronization curves.

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Adjusting Gas/Air Delivery – Continued

Figure 11-12: Air Adjustment

Air/Fuel Control and Power Modulation System 11.7.4 The air/fuel and power modulation system installed on RS burner series provides, a set of integrated functions ensuring top level energy and operational performance from the burner, both for single and grouped burners (e.g. boiler with a double combustion chamber or several generators in parallel).

The system includes the following basic functions:

• Air and fuels are supplied in correct quantities by positioning the valves by direct servo-control, thus avoiding the possibility of play typical of systems used for traditional modulating burners, in which settings are obtained by levers and a mechanical cam.

• Burner power is modulated according to the load required by the system, while boiler pressure or temperature is maintained at set operating values.

• A sequence (cascade control) of several boilers by suitably connecting different units, and activation of internal software in the individual systems (optional item).

Further interfaces and computer communication functions for remote control or integration in centrally supervised systems are available according to the system’s configuration.

NOTE:

The first start-up and all further operations concerning internal settings of the control system or expansion of basic functions, are accessed with a password and are reserved for technical service personnel specifically trained for internal programming of the instrument and for the specific application obtained with this burner.

The first start-up and curve synchronization manual is supplied with the burner.

The complete manual for checking and setting all parameters will be provided on application.

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11.8 Final Calibration of the Pressure Switches Air Pressure Switch Adjustment 11.8.1

Adjust the air pressure switch after having performed all other burner adjustments with the air pressure switch set to the minimum scale position.

Adjusting the Air Pressure Switch

1. With the burner operating at low fire, adjust the pressure switch by slowly turning the relative knob clockwise until the burner locks out.

2. Then turn the knob counter-clockwise about 20% of the set point and start-up the burner again to ensure the set point is correct.

3. If the burner locks out again, turn the knob counter-clockwise in small increments until it stops locking out.

Figure 11-13: Air Pressure Switch

NOTE: As a rule, the air pressure switch must prevent the air pressure from lowering below 80% of the adjustment value as well as preventing the CO in the fumes from exceeding 1% (10,000 ppm).

To check this, insert a combustion analyzer into the chimney, slowly close the fan suction inlet (for example with cardboard) and check that the burner locks out, before the CO in the fumes exceeds 1%.

On RS 300-400-500/E burners the air pressure switch is fitted in a "differential" mode, that is, with two pipes connected to the specific pressure test points “+” and “-” 22) and 23) in Figure 11-1.

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Maximum Gas Pressure Switch Adjustment 11.8.2 Adjust the maximum gas pressure switch in Figure 11-14 after having performed all other burner adjustments with the maximum gas pressure switch set to the end of the scale.

Adjusting Maximum Gas Pressure Switch

1. With the burner operating at MAX output, reduce the adjustment pressure by slowly turning the adjustment dial anticlockwise until the burner locks out.

2. Then turn the dial clockwise by 0.8” WC and repeat burner firing.

3. If the burner locks out again, turn the dial again clockwise by 0.4” W.C.

Figure 11-14: Maximum Gas Pressure Switch

Minimum Gas Pressure Switch Adjustment 11.8.3 Adjust the minimum gas pressure switch in Figure 11-15 after having performed all the other burner adjustments with the pressure switch set at the start of the scale.

Adjusting the Minimum Gas Pressure Switch

1. With the burner operating at MAX output, increase adjustment pressure by slowly turning the relative dial clockwise until the burner locks out.

2. Then turn the dial anti-clockwise by 0.8” WC and repeat burner starting to ensure it is uniform.

3. If the burner locks out again, turn the dial anti-clockwise again by 0.4” W.C.

Figure 11-15: Minimum Gas Pressure Switch

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MFC Series Boilers User Manual CHAPTER 11 – MFC 8000/10000 GAS ONLY BURNER P

11.9 Final Checks with Boiler in Operation Perform the operations in the left column, while the boiler is operating, and ensure the response in the right column is the result.

FINAL CHECK PROCEDURE DESIRED RESULT Open the control limit operation. Burner

Stops Open the high limit operation.

Turn down maximum gas pressure switch knob to the minimum position. Burner Stops

In Lockout Turn up the air pressure switch knob to the maximum position.

Turn down the maximum oil pressure switch at minimum position.

Switch burner to OFF and disconnect the electrical power. Burner Will Not Start Disconnect the minimum gas pressure switch.

Turn up the minimum low oil pressure switch to maximum position.

Cover the UV flame sensor. Burner Stops In Lockout Due To

Firing Failure

WARNING!

Ensure that all lockout and safety procedures concerning all controls and valves are strictly observed.

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MFC Series Boilers User Manual CHAPTER 11 – MFC 8000/10000 GAS ONLY BURNER

SECTION 12: Flame Signal Measurement The flame signal is checked by accessing parameter 954 in the controller, as shown in Figure 12-1. The displayed value is expressed in percentage. The value during the operation must be higher than 24%.

The display shows parameter 954: flashing on the left. On the right, the flame’s intensity is displayed as a percentage. Example: 954: 0.0

If at the burner start-up the value is higher or equal of 18%, the burner locks out.

For further and specific information, please refer to the specific instruction manual.

Figure 12-1: Burner Startup Sequence of Operation

Final Checks with Boiler in Operation 12.1.1 Perform the operations in the left column while the boiler is operating, and ensure the response in the right column is the result.

FINAL CHECK PROCEDURE DESIRED RESULT

Open the control limit operation. Burner Stops Open the high limit operation.

Turn down maximum gas pressure switch knob to the minimum position. Burner Stops

In Lockout Turn up the air pressure switch knob to the maximum position.

Turn down the maximum oil pressure switch at minimum position.

Switch burner to OFF and disconnect the electrical power. Burner Will Not Start Disconnect the minimum gas pressure switch.

Turn up the minimum low oil pressure switch to maximum position.

Cover the UV flame sensor. Burner Stops In Lockout Due To

Firing Failure

WARNING!

Ensure that all lockout and safety procedures concerning all controls and valves are strictly observed.

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MFC Series Boilers User Manual CHAPTER 13 – MFC SERIES MAINTENANCE

SECTION 13: MFC Series Maintenance

IMPORTANT: Carry out thorough cleaning and periodic maintenance to ensure a correct and safe operation of the system. A perfectly clean tube bundle increases the thermal exchange between fumes and water contributing to energy saving and reducing air pollution.

13.1 Preparation for Inspection and Maintenance

CAUTION: Before carrying out any kind of maintenance, in order to avoid risks, the operator must be equipped with all the personal protection provided by the standards in force. WARNING: Before performing any cleaning and maintenance operation, it is first necessary to disconnect the device from both the fuel and the mains supply. Proper lockout/tagout procedures should be utilized when needed. Maintenance must be entrusted only to technically qualified personnel and can be either mechanical or electrical.

The preparation and status of the boiler may be different, depending on the operations to be performed:

• With the boiler running, to check the integrity of the boiler when hot (fume trace seal, water side gasket seal, flue draught, operation of adjustment and safety accessories),

• With switch-off and complete cooling of the boiler, when having to open the front door with inspection inside the furnace and fume chamber.

• With cooling complete, the boiler emptied and the electrical locked out when doing waterside inspections.

WARNING: Particular precautions must be taken to avoid the risk of electric shock since the system on the boiler has accessories powered at 120V and 208, 460 or 575V. CAUTION: Before performing any maintenance on the boiler, ensure that the electrical connections and grounds have been made according to current standards.

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13.2 Standard Maintenance • Carry out burner maintenance (as to the specific burner manufacturer’s instructions) and

have the calibration checked by duly qualified personnel.

• Check the tightness of flange bolts and the state of the gaskets;

• Analyze the system water and make sure it is treated in such a way that scaling does not occur, as scaling reduces performance and can cause premature failure of the boiler. Ensure the refractory is not damaged and the gaskets between the boiler and door are not damaged. Replace or repair as necessary.

• Periodically clean the burner tubes shown in Figure 13-1 as follows:

a. Access the burner tubes and inspect to determine if cleaning is necessary. (a). b. Remove the turbulator from each tube and clean of fouling.

NOTE: In general, gaseous fuels should not produce any carbon deposit. However, if liquid fuels are used, it is necessary to frequently clean to avoid substantial fouling.

c. Use a wire brush to internally clean each tube.

d. Reinsert the turbulators into the tubes and reassemble unit.

• If a more thorough cleaning is necessary, the Stainless Steel 4th Pass may be removed to allow cleaning from the backside of the boiler.

FIGURE 13-1: Burner Tube and Turbulator Maintenance

• Check the integrity of the electrical system on the boiler.

• Perform a combustion testing and adjust as necessary.

b a c

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MFC Series Boilers User Manual CHAPTER 13 – MFC SERIES MAINTENANCE

13.3 Burner Maintenance The periodic maintenance is essential for the good operation, safety, yield and duration of the burner. It allows you to reduce consumption and polluting emissions and to keep the product in a reliable state over time.

WARNING! The maintenance interventions and the calibration of the burner must only be carried out by qualified, authorized personnel, in accordance with the contents of this manual and in compliance with the standards and regulations of current laws.

WARNING! Before carrying out any maintenance, cleaning or checking operations:

• Disconnect the electricity supply from the burner by means of the main switch of the system.

• Close the fuel interception tap.

13.4 RS-120 / RS-160 Burner Maintenance (MFC 3000-6000) Combustion 13.4.1

The optimum calibration of the burner requires an analysis of the flue gases. Significant differences with respect to the previous measurements indicate the points where more care should be exercised during maintenance.

Gas Leaks 13.4.2 Make sure that there are no gas leaks on the pipework between the gas meter and the burner.

Flame inspection Window 13.4.3 Clean the flame inspection window (1) shown in Figure 13-2.

FIGURE 13-2: Flame Inspection Window

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Combustion Head 13.4.4 Open the burner and make sure that all components of the combustion head are in good condition, not deformed by the high temperatures, free of impurities from the surroundings and correctly positioned. If in doubt, disassemble the elbow fitting 1) in Figure 13-3.

FIGURE 13-3: Elbow Fitting

Nozzles (Fuel Oil) (Dual Fuel Models Only) 13.4.5 Do not clean the nozzle orifices. The nozzle filters however may be cleaned or replaced as required. Replace the nozzles every 2-3 years or whenever necessary. Combustion must be checked after the nozzles have been changed.

Flexible Hoses (Fuel Oil) (Dual Fuel Models Only) 13.4.6 Check to make sure that the flexible hoses are still in good condition and that they are not crushed or otherwise deformed.

UV Scanner 13.4.7 In order to reach the UV scanner, proceed as follows:

• Extract the UV scanner (2) Figure 13-4.

• Clean the glass cover from any dust that may have accumulated.

FIGURE 13-4: UV Scanner

1

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MFC Series Boilers User Manual CHAPTER 13 – MFC SERIES MAINTENANCE

Burner 13.4.8 Check for excess wear or loose screws. Also make sure that the screws securing the electrical leads in the burner connections are fully tightened.

Clean the outside of the burner.

Combustion 13.4.9 Adjust the burner if the combustion values found at the beginning of the operation do not comply with the regulations in force, or at any rate, do not correspond to good combustion.

13.5 RS-300 Burner Maintenance (MFC 8000-10000) Maintenance Frequency 13.5.1

The combustion system should be checked at least once a year by a representative of the manufacturer or another specialized technician.

Combustion 13.5.2 The optimum calibration of the burner requires an analysis of the flue gases. Significant differences with respect to the previous measurements indicate the points where more care should be exercised during maintenance.

Gas Leaks 13.5.3 Make sure that there are no gas leaks on the pipework between the gas meter and the burner.

Combustion Head 13.5.4 Open the burner and make sure that all components of the combustion head are in good condition, not deformed by the high temperatures, free of impurities from the surroundings and correctly positioned.

Measurement of Detector Current 13.5.5 Measurement of the detector’s signal with a Voltmeter is not normally required since the flame signal’s intensity is shown on the AZL...display and operating unit.

Min. value for a good work: 3.5 VDC (AZL display flame approx. 50%). If value is lower, it may be for one or more of the following reasons:

– Photocell positioned incorrectly

– Low current (lower than 96V)

– Bad regulation of the burner

To measure power, use a voltmeter with a 10 VDC scale, connected as illustrated in Figure 13-4.

FIGURE 13-4: Detector Current Measurement Connections

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Fan 13.5.6 Check to make sure that no dust has accumulated inside the fan or on its blades, as this condition will cause a reduction in the air flow rate and provoke polluting combustion.

Burner 13.5.7 Clean the outside of the burner.

Clean and grease the cam variable profile.

Boiler 13.5.8 Clean the boiler as indicated in its accompanying instructions in order to maintain all the original combustion characteristics intact, especially the flue gas temperature and combustion chamber pressure.

13.6 Light Oil Operation (MFC 8000-10000 Dual Fuel Only) Pump 13.6.1

Delivery pressure must correspond with the Tab. G on page 26. The depression must be less than 0.45 bar. Unusual noise must not be evident during pump operation.

If the pressure is found to be unstable or if the pump runs noisily, the flexible hose must be detached from the line filter and the fuel must be sucked from a tank located near the burner. This measure permits the cause of the anomaly to be traced to either the suction line or the pump.

If the problem lies in the suction line, check to make sure that the filter is clean and that air is not entering the piping.

Filters 13.6.2 Check the filtering baskets on line and at nozzle present in the system. Clean or replace if necessary. If rust or other impurities are observed inside the pump, use a separate pump to lift any water and other impurities that may have deposited on the bottom of the tank.

Nozzles 13.6.3 It is advisable to replace nozzles every year during regular maintenance operations. Do not clean the nozzle openings, and do not even open them.

Flexible Hoses 13.6.4 Check to make sure that the flexible hoses are still in good condition.

Fuel Tank 13.6.5 Approximately every 5 years, or whenever necessary, suck any water or other impurities present on the bottom of the tank using a separate pump.

Combustion 13.6.6 In case the combustion values found at the beginning of the intervention do not respect the standards in force or, in any case, do not correspond to a proper combustion, contact the Technical Assistant and have him carry out the necessary adjustments.

13.7 Gas Operation (MFC 8000-10000 Only) Gas Leaks 13.7.1

Make sure that there are no gas leaks on the pipework between the gas meter and the burner.

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Gas filter 13.7.2 Change the gas filter when it is dirty.

Combustion 13.7.3 In case the combustion values found at the beginning of the inspection do not comply with local standard, codes, and/or guidelines, or otherwise exhibits improper combustion, contact AERCO technical support, for guidance in carrying out the necessary adjustments.

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APPENDIX A – Operational Sequence Diagrams

13.8 MFC 3000-6000 Sequence of Operation Diagram

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MFC Series Boilers User Manual APPENDIX A – OPERATIONAL SEQUENCE DIAGRAMS

13.9 MFC 8000-10000 Sequence of Operation Diagram

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MFC Series Boilers User Manual APPENDIX A – OPERATIONAL SEQUENCE DIAGRAMS

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MFC Series Boilers User Manual APPENDIX B – ELECTRICAL DIAGRAMS

APPENDIX B – ELECTRICAL DIAGRAMS

MFC 3000 / 4000 / 5000 / 6000 Electrical Diagrams 1-8 DIAGRAM LEGEND MFC 3000 / 4000 / 5000 / 6000 Electrical Diagrams 1 - 8

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MFC Series Boilers User Manual APPENDIX A – OPERATIONAL SEQUENCE DIAGRAMS MFC 3000 / 4000 / 5000 / 6000 / 8000 - 1 of 8

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MFC Series Boilers User Manual APPENDIX B – ELECTRICAL DIAGRAMS MFC 3000 / 4000 / 5000 / 6000 / 8000 - 2 of 8

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MFC Series Boilers User Manual APPENDIX A – OPERATIONAL SEQUENCE DIAGRAMS MFC 3000 / 4000 / 5000 / 6000 / 8000 - 3 of 8

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MFC Series Boilers User Manual APPENDIX B – ELECTRICAL DIAGRAMS MFC 3000 / 4000 / 5000 / 6000 / 8000 - 4 of 8

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MFC Series Boilers User Manual APPENDIX A – OPERATIONAL SEQUENCE DIAGRAMS MFC 3000 / 4000 / 5000 / 6000 / 8000 - 5 of 8

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MFC Series Boilers User Manual APPENDIX B – ELECTRICAL DIAGRAMS MFC 3000 / 4000 / 5000 / 6000 / 8000 - 6 of 8

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MFC Series Boilers User Manual APPENDIX A – OPERATIONAL SEQUENCE DIAGRAMS MFC 3000 / 4000 / 5000 / 6000 / 8000 - 7 of 8

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MFC Series Boilers User Manual APPENDIX A – OPERATIONAL SEQUENCE DIAGRAMS

MFC 8000/10000 - ElectRICAL Diagrams 1-9

DIAGRAM LEGEND MFC 8000 / 10000 Electrical Diagrams 1-9

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MFC Series Boilers User Manual APPENDIX B – ELECTRICAL DIAGRAMS MFC 10000 - 1 of 9

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MFC Series Boilers User Manual APPENDIX A – OPERATIONAL SEQUENCE DIAGRAMS MFC 10000 - 2 of 9

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MFC Series Boilers User Manual APPENDIX A – ELECTRICAL DIAGRAMS MFC 10000 - 4 of 9

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MFC Series Boilers User Manual APPENDIX A – ELECTRICAL DIAGRAMS MFC 10000 - 6 of 9

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MFC Series Boilers User Manual APPENDIX A – ELECTRICAL DIAGRAMS MFC 10000 - 7 of 9

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MFC Series Boilers User Manual APPENDIX A – ELECTRICAL DIAGRAMS MFC 10000 - 8 of 9

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MFC Series Boilers User Manual APPENDIX A – ELECTRICAL DIAGRAMS MFC 10000 - 9 of 9

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MFC Series Boilers User Manual APPENDIX A – ELECTRICAL DIAGRAMS

NOTES:

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MFC Series Boilers User Manual Change Log: Date Description Changed By

02/05/2006 Rev-94: Removed AHRI pending cert and added new logo. No tech changes. Curtis Harvey

© AERCO International, Inc., 2016

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