U.S. Boiler Company MPO - IQ Instrucciones de funcionamiento

103859-05 - 10/14 Price - $5.00

9700609

INSTALLATION, OPERATING AND

SERVICE INSTRUCTIONS FOR

MPO -IQ™

3-PASS OIL Boiler

For service or repairs to boiler, call your heating contractor. When seeking information on boiler, provide

Boiler Model Number and Serial Number as shown on Rating Label.

Boiler Model Number

MPO - IQ

Boiler Serial Number Installation Date

Heating Contractor Phone Number

Address

As an ENERGY STAR®Partner, U.S. Boiler Company has determined that the MPO-IQ™ boiler meets the ENERGY STAR®

guidelines for energy efciency established by the United States Environmental Protection Agency (EPA).

IMPORTANT INFORMATION - READ CAREFULLY

The following terms are used throughout this manual to bring attention to the presence of hazards

of various risk levels, or to important information concerning product life.

DANGER

Indicates an imminently hazardous situation which,

if not avoided, will result in death, serious injury or

substantial property damage.

WARNING

Indicates a potentially hazardous situation which, if

not avoided, could result in death, serious injury or

substantial property damage.

CAUTION

Indicates a potentially hazardous situation which, if

not avoided, may result in moderate or minor injury

or property damage.

NOTICE

Indicates special instructions on installation,

operation, or maintenance which are important but

not related to personal injury hazards.

NOTICE

This boiler has a limited warranty, a copy of which is included with this boiler.

The warranty for this boiler is valid only if the boiler has been installed, maintained and operated in

accordance with these instructions.

Surface rust on cast iron sections may be attributed to the manufacturing process as well as condensation

during storage. Surface rust is normal and does not affect the performance or longevity of a boiler.

All boilers must be installed in accordance with National, State and Local Plumbing, Heating

and Electrical Codes and the regulations of the serving utilities. These Codes and Regulations

may differ from this instruction manual. Authorities having jurisdiction should be consulted

before installations are made.

In all cases, reference should be made to the following Standards:

USA BOILERS

A. Current Edition of American National Standard ANSI/NFPA 31, “Installation of Oil

Burning Equipment”, for recommended installation practices.

B. Current Edition of American National Standard ANSI/NFPA 211, “Chimneys, Fireplaces,

Vents, and Solid Fuel Burning Appliances”, For Venting requirements.

C. Current Edition of American Society of Mechanical Engineers ASME CSD-1, “Controls and

Safety Devices for Automatically Fired Boilers”, for assembly and operations of controls

and safety devices.

D. All wiring on boilers installed in the USA shall be made in accordance with the National

Electrical Code and/or Local Regulations.

CANADIAN BOILERS

A. Current Edition of Canadian Standards Association CSA B139, “Installation Code for Oil

Burning Equipment", for recommended Installation Practices.

B. All wiring on boilers installed in Canada shall be made in accordance with the Canadian

Electrical Code and/or Local Regulations.

DANGER

DO NOT store or use gasoline or other ammable vapors or liquids in the vicinity of this or any other

appliance.

WARNING

Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal

injury or loss of life. Failure to follow all instructions in the proper order can cause personal injury or death.

Read and understand all instructions, including all those contained in component manufacturers manuals

which are provided with the boiler before installing, starting-up, operating, maintaining or servicing this

boiler. Keep this manual and literature in legible condition and posted near boiler for reference by owner

and service technician.

This boiler requires regular maintenance and service to operate safely. Follow the instructions contained

in this manual.

Installation, maintenance, and service must be performed only by an experienced, skilled and knowledgeable

installer or service agency.

All heating systems should be designed by competent contractors and only persons knowledgeable in

the layout and installation of hydronic heating systems should attempt installation of any boiler.

Installation is not complete unless a pressure relief valve is installed into the 3/4" tapping located on

return injector assembly that was installed into boss on top of rear section - See "Packaged Boiler Assy

- Trim & Controls", "Unit-Pak Boiler Assy - Trim & Controls" and "Water Boiler Piping" Sections of this

manual for details.

It is the responsibility of the installing contractor to see that all controls are correctly installed and are

operating properly when the installation is completed.

This boiler is suitable for installation on combustible ooring. Do not install boiler on carpeting.

Do not tamper with or alter the boiler or controls.

Inspect ueways at least once a year - preferably at the start of the heating season. The inside of

the combustion chamber, the vent system and boiler ueways should be cleaned if soot or scale has

accumulated.

When cleaning this boiler, take precaution to avoid damage to burner swing door insulation. If damaged,

or if there is evidence of previous damage, burner swing door insulation must be replaced immediately.

Oil Burner and Controls must be checked at least once a year or as may be necessitated.

Do not operate boiler with jumpered or absent controls or safety devices.

Do not operate boiler if any control, switch, component, or device has been subject to water.

Boiler construction materials, products of combustion and the fuel contain alumina, silica, heavy metals,

carbon monoxide, nitrogen oxides, aldehydes and/or other toxic or harmful substances which can cause

death or serious injury and which are known to the state of California to cause cancer, birth defects and

other reproductive harm. Always use proper safety clothing, respirators and equipment when servicing

or working nearby the appliance.

This boiler contains very hot water under high pressure. Do not unscrew any pipe ttings nor attempt

to disconnect any components of this boiler without positively assuring the water is cool and has no

pressure. Always wear protective clothing and equipment when installing, starting up or servicing this

boiler to prevent scald injuries. Do not rely on the pressure and temperature gauges to determine the

temperature and pressure of the boiler. This boiler contains components which become very hot when

the boiler is operating. Do not touch any components unless they are cool.

WARNING

This boiler must be properly vented. The chimney must be inspected for any obstructions and cleaned

prior to each heating season. A clean and unobstructed chimney ue is necessary to produce the minimum

draft required to safely evacuate noxious fumes that could cause personal injury or loss of life. Evidence

of loose debris and or condensate induced stains at the base of the chimney ue, connector or smokepipe

joints may be signs of condensing ue gases. Flue gas condensate is corrosive, which requires special

consideration and must be addressed immediately. Refer to Section V, "Venting" or Section VI "Direct

Venting / Air Intake Piping".

This boiler needs fresh air for safe operation and must be installed so there are provisions for adequate

combustion and ventilation air.

This boiler is supplied with controls which may cause the boiler to shut down and not re-start without

service. If damage due to frozen pipes is a possibility, the heating system should not be left unattended in

cold weather; or appropriate safeguards and alarms should be installed on the heating system to prevent

damage if the boiler is inoperative.

This boiler is designed to burn No. 2 fuel oil only. Do not use gasoline, crankcase drainings, or any oil

containing gasoline. Never burn garbage or paper in this boiler. Do not convert to any solid fuel (i.e.

wood, coal). Do not convert to any gaseous fuel (i.e. natural gas, LP). All ammable debris, rags, paper,

wood scraps, etc., should be kept clear of the boiler at all times. Keep the boiler area clean and free of

re hazards.

All boilers equipped with burner swing door have a potential hazard which, if ignored, can cause severe

property damage, personal injury or loss of life. Before opening swing door, unplug burner power cord

from receptacle located in lower right corner of jacket front panel and turn off service switch to boiler

to prevent accidental ring of burner outside the combustion chamber. Be sure to tighten swing door

fasteners completely when service is completed.

TABLE OF CONTENTS

I. Pre-Installation ........................................................................................ 8

II. Packaged Boiler Assy. - Trim & Controls ................................................. 11

III. Unit-Pak Boiler Assy. - Trim & Controls..................................................... 20

IV. Water Boiler Piping .................................................................................. 26

V. Natural Draft Venting ............................................................................... 30

VI. Direct Venting / Air Intake Piping.............................................................. 34

VII. Electrical .................................................................................................. 41

VIII. Oil Piping ................................................................................................. 45

IX. System Start-Up ...................................................................................... 47

X. Operating.................................................................................................. 52

XI. Maintenance & Service Instructions ....................................................... 57

XII. Boiler Cleaning ........................................................................................ 59

XIII. Trouble Shooting ..................................................................................... 61

XIV. Repair Parts ............................................................................................ 69

XV. Burner Specications................................................................................ 83

Appendix A - IQ Oil Control System.......................................................... 85

Appendix B - Figures................................................................................ 89

Appendix C - Tables.................................................................................. 91

Congratulations on your purchase of a new MPO-IQ™ boiler—designed and constructed to provide you with years

of reliable service.

• ENERGY STAR™ efciency – friendly on the environment and your wallet.

• Cast iron heat exchanger – for reliability and durability, nothing beats a cast iron heat exchanger.

• *IQ Control™ System– the most advanced and easiest to use controls available.

• System-friendly – built-in protection from condensation and thermal shock.

*IQ Control System Overview

MPO-IQ Boiler uses a microprocessor based control system called the "IQ Control System". This "IQ Control System"

consists of an IQ Oil Boiler Control (Boiler Control) in conjunction with an Oil Primary Control (Oil Primary)and an IQ Option

Panel (Option Panel) with optional "plug-in" IQ Option Cards (Option Card). The IQ Control System fully integrates both

factory and eld installed components, simplifying installation and troubleshooting. The IQ Control System is designed

to efciently operate the entire boiler system to save energy and installation and setup time, while ensuring adequate

supply of heat and domestic hot water.

What's in the crate?

Content Check List

1. MPO-IQ Boiler Assembly on Shipping Skid:

___ MPO-IQ84

___ MPO-IQ115

___ MPO-IQ147

___ MPO-IQ189

___ MPO-IQ231

2. Circulator & Gasket Kit:

___ Taco 007-2 - P/N 8056170

___ Grundfos UP-15 - P/N 102805-01

___ B & G NRF-22 - P/N 8056174

3. Parts Carton:

___ MPO-IQ84 - P/N 103088-01

___ MPO-IQ115 - P/N 103088-02

___ MPO-IQ147/231 - P/N 103088-03

4. Barometric Draft Regulator Carton

___ 5" Dia. - P/N 8116287

___ 6" Dia. - P/N 8116288

___ 7" Dia. - P/N 8116289

5. Instruction Envelope - P/N 103858-01

___ Installation & Operation Manual - P/N 103859-05

___ Boiler Warranty Sheet - P/N 103203-02

Warrantty Registration Tag - P/N 104409-01

Figure 1: MPO-IQ84 Thru MPO-IQ231 Water Boiler

TABLE 1A: DIMENSIONAL DATA (SEE FIGURE 1)

TABLE 1B: RATING DATA

Boiler Model

No.

Dimensions See Figure 1 Water Content

- Gallons

Heat Transfer

Surface Area

- Sq. Ft.

Actual

Shipping

Weight (LB.)

“A” “B” “C”

MPO-IQ84 16-5/8” 24” 5” 7.70 13.29 430

MPO-IQ115 16-5/8” 24” 5” 7.70 13.29 430

MPO-IQ147 22-5/8” 24” 6” 11.08 20.29 545

MPO-IQ189 28-5/8” 30” 6” 14.46 27.29 658

MPO-IQ231 34-5/8” 36” 7” 17.84 34.29 771

NOTE: 1. Maximum Working Pressure: Water: 30 PSI Shipped From Factory (Standard),

40 PSI Optional, 50 PSI Optional

Boiler

Model No.

Burner Capacity NET AHRI

Ratings AFUE % Minimum Chimney

Requirements Direct Vent System

GPH MBH DOE Heating

Capacity MBH Water MBH Water

Boiler

Round

In. Dia.

Rectangle

In. x In.

Height

Ft. Model

Vent

Connector

Dia. Inch

MPO-IQ84 0.60 84 74 64 87 6 8 x 8 15 N/A N/A

MPO-IQ115 0.82 115 101 87 87 6 8 x 8 15 N/A N/A

MPO-IQ147 1.05 147 129 112 87 6 8 x 8 15 FDVS-56 5

MPO-IQI89 1.35 189 167 145 87 7 8 x 8 15 FDVS-56 5

MPO-IQ231 1.65 231 203 177 87 7 8 x 8 15 FDVS-67 6

Figure 2A: Chimney Vented Boiler - Minimum Installation Clearances To Combustible Materials (Inches)

A. INSPECT SHIPMENT carefully for any signs of

damage.

1. All equipment is carefully manufactured, inspected and

packed. Our responsibility ceases upon delivery of crated

boiler to the carrier in good condition.

2. Any claims for damage or shortage in shipment must be

led immediately against the carrier by the consignee.

No claims for variances from, or shortage in orders, will

be allowed by the manufacturer unless presented within

sixty (60) days after receipt of goods.

B. LOCATE BOILER in front of nal position before removing

crate. See Figure 1.

1. LOCATE so that vent pipe connection to chimney will

be short and direct.

2. BOILER IS SUITABLE FOR INSTALLATION ON

COMBUSTIBLE FLOOR. Boiler cannot be installed

on carpeting.

3. FOR BASEMENT INSTALLATION, provide a solid

elevated base, such as concrete, if oor is not level, or if

water may be encountered on oor around boiler.

4. PROVIDE RECOMMENDED SERVICE CLEARANCE,

if applicable, as follows:

a. Clearance from Jacket Front Panel -

•24" for servicing burner

• 24" for ueway cleaning (MPO-IQ84 thru 147)

• 30" for ueway cleaning (MPO-IQ189)

• 36" for ueway cleaning (MPO-IQ231)

b. Clearance from Jacket Side Panels -

•19" for burner swing door, if opened fully with

burner mounted, otherwise 1" with b u r n e r

removed.

• 12" access clearance to service rear of

boiler if other side clearance is less

than 12".

• 3" minimum if other side clearance is 12" or

larger to access and service rear of boiler.

c. Clearance from Jacket Rear Panel -

• 12" minimum for rear smokebox cleaning

(Note: This dimension will also be controlled

by horizontal to vertical to horizontal smokepipe

arrangement - Chimney Vent (see Figures 2A

and 15).

• 24" for rear smokebox cleaning and disconnecting

vent pipe from appliance adapter for servicing (if

required) - Direct Vent (see Figure 2B).

5. For minimum clearances to combustible materials. See

Figures 2A and 2B.

NOTICE

Clearance to venting is for single wall vent pipe. If

Type L vent is used, clearance may be reduced to the

minimum required by the vent pipe manufacturer.

I. PRE-INSTALLATION

NOTES:

1. Listed clearances comply with American National Standard ANSI/

NFPA 31, Installation of Oil Burning Equipment.

2. MPO-IQ boilers can be installed in rooms with clearances from

combustible material as listed above. Listed clearances cannot be

reduced for alcove or closet installations.

3. For reduced clearances to combustible material, protection must be

provided as described in the above ANSI/NFPA 31 standard.

C. PROVIDE COMBUSTION AND VENTILATION

AIR. Local and National Codes may apply and should

be referenced.

WARNING

Adequate combustion and ventilation air must

be provided to assure proper combustion and to

maintain safe ambient air temperatures.

Do not install boiler where gasoline or other

flammable vapors or liquids, or sources of

hydrocarbons (i.e. bleaches, fabric softeners,

etc.) are used or stored.

1. Determine volume of space (boiler room). Rooms

communicating directly with the space in which the

appliances are installed, through openings not furnished

with doors, are considered a part of the space.

Volume(ft3) = Length(ft) x Width(ft) x Height(ft)

2. Determine total input of all appliances in the space.

Add inputs of all appliances in the space and round the

result to the nearest 1000 BTU per hour.

3. Determine type of space. Divide Volume by total input

of all appliances in space. If the result is greater than or

equal to 50 ft3/1000 BTU per hour, then it is considered

an unconned space. If the result is less than 50 ft3/1000

BTU per hour then the space is considered a conned

space.

4. For boiler located in an unconfined space of a

conventionally constructed building, the fresh air

inltration through cracks around windows and doors

normally provides adequate air for combustion and

ventilation.

5. For boiler located in a conned space or an unconned

space in a building of unusually tight construction,

provide outdoor air.

a. Outdoor air for combustion may be provided

with an optional Fresh Air Accessory Kit (ONLY

AVAILABLE WITH BECKETT BURNER).

Metal cover applications, P/N 611280031. Plastic

cover applications, P/N 102119-01. Refer to Fresh

Air Accessory Kit instructions for installation and air

intake piping details. See Section V for installation

details.

b. Outdoor air may be provided with the use of two

permanent openings which communicate directly or

by duct with the outdoors or spaces (crawl or attic)

freely communicating with the outdoors. Locate one

opening within 12 inches of top of space. Locate

remaining opening within 12 inches of bottom of

space. Minimum dimension of air opening is 3 inches.

Size each opening per following:

i. Direct communication with outdoors.

Minimum free area of 1 square inch per

4,000 BTU per hour input of all equipment

in space.

ii. Vertical ducts. Minimum free area of 1 square

inch per 4,000 BTU per hour input of all equipment

in space. Duct cross-sectional area shall be same

as opening free area.

iii. Horizontal ducts. Minimum free area of 1 square

inch per 2,000 BTU per hour input of all equipment

in space. Duct cross-sectional area shall be same

as opening free area.

Alternate method for boiler located within

conned space. Use indoor air if two permanent

openings communicate directly with additional

space(s) of sufcient volume such that combined

volume of all spaces meet criteria for unconned

space. Size each opening for minimum free area

of 1 square inch per 1,000 BTU per hour input

of all equipment in spaces, but not less than 100

square inches.

Figure 2B: Direct Vent Boiler - Minimum Installation Clearances To Combustible Materials (Inches)

I. PRE-INSTALLATION (continued)

6. Louvers and Grilles of Ventilation Ducts

a. All outside openings should be screened and louvered.

Screens used should not be smaller than 1/4 inch mesh.

Louvers will prevent the entrance of rain and snow.

b. Free area requirements need to consider the blocking

effect of louvers, grilles, or screens protecting the

openings. If the free area of the louver or grille is not

known, assume wood louvers have 20-25 percent free

area and metal louvers and grilles have 60-75 percent

free area.

c. Louvers and grilles must be xed in the open position, or

interlocked with the equipment to open automatically

during equipment operation.

D. DIRECT VENT CONFIGURATIONS requires:

1. Beckett NX Burner

2. Direct Vent Conversion Kit

3. Double Wall Flex Oil Vent Pipe (FOVP)

Boiler

Model No.

Beckett NX

Oil Burner

Part No.

Direct Vent

Conversion Kit

Part No.

FOVP Carton Part

No.

MPO-IQ147 103896-03

102130-02

100211-02 - 5 ft.

100212-02 - 10 ft.

MPO-IQ189 103897-04

100213-02 - 15 ft.

100214-02 - 20 ft.

MPO-IQ231 103898-05 102130-03

100211-03 - 5 ft.

100212-03 - 10 ft.

100213-03 - 15 ft.

100214-03 - 20 ft.

TABLE 2: DIRECT VENT CONFIGURATION

COMPONENTS

I. PRE-INSTALLATION (continued)

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