Aerco MFC 4000 User manual

Brand: Aerco

Model: MFC 4000

Type: User manual

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MFC Series Boilers User Manual

OMM-0104_94 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 1 of 170

GF-146 Ph.: 800-526-0288 12/29/2015

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-146-IN, for preliminary

assembly and installation instructions and information.

Latest Update: 12/29/2015

MFC Series Boilers User Manual

CONTENTS

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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

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Pump Priming ............................................................................................................................. 39 6.7.1

6.8 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 ............................................................................................. 53

SECTION 7: MFC 3000 NATURAL GAS ONLY BURNER ....................................................54

7.1 Combustion Head Adjustment .......................................................................................................... 57

7.2 Gas Supply Pressure .......................................................................................................................... 59

Figuring Burner Output ............................................................................................................... 60 7.2.1

Figuring Required Burner Output ............................................................................................... 61 7.2.2

7.3 Adjustments Before First Firing (Gas) ............................................................................................... 62

7.4 Startup for MFC 3000 Gas Only Burner ............................................................................................ 64

Gas/Air Delivery Adjustment ...................................................................................................... 65

7.4.1

Air Pressure Switch Adjustment.................................................................................................. 66 7.4.2

Maximum Gas Pressure Switch Adjustment ............................................................................... 67 7.4.3

Minimum Gas Pressure Switch Adjustment ................................................................................ 67 7.4.4

7.5 Final Checks with Boiler in Operation ............................................................................................... 68

SECTION 8: MFC 4000 / 6000 DUAL FUEL BURNER ..........................................................69

8.1 MFC 4000-6000 Dual Fuel Burner Features ...................................................................................... 70

8.2 Burner Nozzle Setup .......................................................................................................................... 72

Recommended Nozzles .............................................................................................................. 72 8.2.1

Nozzle Assembly ......................................................................................................................... 72 8.2.2

8.3 Flow Rate Adjustment ....................................................................................................................... 73

8.4 Ignition Pilot Adjustment ................................................................................................................... 75

8.5 Combustion Head Setting .................................................................................................................. 75

8.6 Pump Adjustment .............................................................................................................................. 76

8.7 Air Damper Adjustment..................................................................................................................... 76

8.8 Electrode Positioning ......................................................................................................................... 77

8.9 Burner Setup...................................................................................................................................... 78

8.10 Hydraulic Connections ..................................................................................................................... 79

8.11 Pump ............................................................................................................................................... 80

Pump Priming ........................................................................................................................... 80 8.11.1

8.12 Gas Pressure .................................................................................................................................... 81

8.13 Burner Firing .................................................................................................................................... 82

8.14 Burner Calibration ........................................................................................................................... 83

8.15 Adjustments Before First Firing (Gas Operation) ............................................................................ 83

MFC Series Boilers User Manual

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Startup for MFC 4000 – 6000 Dual Fuel Burner ....................................................................... 85 8.15.1

Gas/Air Delivery Adjustment .................................................................................................... 86 8.15.2

Adjusting Oil/Air Delivery .......................................................................................................... 86 8.15.3

Air Pressure Switch Adjustment................................................................................................ 87 8.15.4

Maximum Gas Pressure Switch Adjustment ............................................................................. 88 8.15.5

Minimum Gas Pressure Switch Adjustment .............................................................................. 88 8.15.6

Low Oil Pressure Switch ............................................................................................................ 89 8.15.7

High oil pressure switch ............................................................................................................ 89 8.15.8

Burner Startup Sequence of Operation .................................................................................... 90 8.15.9

Normal Operation Sequence of Operation ............................................................................. 91 8.15.10

8.16 Firing Failure .................................................................................................................................... 92

8.17 Final Checks with Boiler in Operation ............................................................................................. 92

SECTION 9: MFC 4000-6000 GAS ONLY BURNER .............................................................93

9.1 Combustion Head Adjustment .......................................................................................................... 93

9.2 Gas Supply Pressure .......................................................................................................................... 95

Figuring Burner Output ............................................................................................................... 95 9.2.1

9.3 Adjustments Before First Firing ......................................................................................................... 96

9.4 Startup for MFC 4000-6000 Gas Only Burner ................................................................................... 98

Combustion Air Adjustment ....................................................................................................... 99 9.4.1

Gas/Air Delivery Adjustment ...................................................................................................... 99 9.4.2

Air/Fuel Control and Power Modulation System ..................................................................... 100 9.4.3

9.5 Final Calibration of the Pressure Switches ...................................................................................... 101

Air Pressure Switch Adjustment................................................................................................ 101 9.5.1

Maximum Gas Pressure Switch Adjustment ............................................................................. 102 9.5.2

Minimum Gas Pressure Switch Adjustment .............................................................................. 102

9.5.3

9.6 Final Checks with Boiler in Operation ............................................................................................. 103

SECTION 10: MFC 8000 / 10000 DUAL FUEL BURNER ...................................................... 104

10.1 MFC 8000-10000 Dual Fuel Burner Features ................................................................................ 105

10.2 Burner Nozzle Setup ...................................................................................................................... 107

Recommended Nozzles .......................................................................................................... 107 10.2.1

Nozzle Assembly ..................................................................................................................... 107 10.2.2

10.3 Combustion Head setting .............................................................................................................. 108

10.4 Hydraulic Connections ................................................................................................................... 110

10.5 Pressure Variator ........................................................................................................................... 111

10.6 Pump ............................................................................................................................................. 112

Pump Priming ......................................................................................................................... 112 10.6.1

10.7 Gas Train ........................................................................................................................................ 113

10.8 Gas Pressure .................................................................................................................................. 113

10.9 Adjustments before First Firing (Light Oil Operation) ................................................................... 114

10.10 Nozzles ......................................................................................................................................... 114

10.11 Combustion Head ........................................................................................................................ 114

10.12 Pump Pressure ............................................................................................................................ 115

10.13 Burner Firing ................................................................................................................................ 115

10.14 Changing Fuel Type ..................................................................................................................... 115

10.15 Adjustments before First Firing (Gas Operation) ........................................................................ 116

10.16 Burner Start-Up ........................................................................................................................... 117

Combustion Air Adjustment ................................................................................................. 118 10.16.1

Air Adjustment for Maximum Output .................................................................................. 118 10.16.2

Gas/Air Delivery Adjustment ................................................................................................ 118 10.16.3

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Adjusting Oil/Air Delivery ...................................................................................................... 119 10.16.4

Air/Fuel Control and Power Modulation System ................................................................. 119 10.16.5

10.17 Final Calibration of the Pressure Switches .................................................................................. 120

Air Pressure Switch Adjustment............................................................................................ 120 10.17.1

Maximum Gas Pressure Switch Adjustment ......................................................................... 121 10.17.2

Minimum Gas Pressure Switch Adjustment .......................................................................... 121 10.17.3

Low Oil Pressure Switch ........................................................................................................ 122 10.17.4

Burner Startup Sequence of Operation ................................................................................ 123 10.17.5

Normal Operation Sequence of Operation ........................................................................... 124 10.17.6

10.18 Firing Failure ................................................................................................................................ 124

10.19 Final Checks with Boiler in Operation ......................................................................................... 124

SECTION 11: MFC 8000-10000 GAS ONLY BURNER ......................................................... 125

11.1 MFC 8000-10000 Gas Only Burner Features ................................................................................. 125

11.2 Combustion Head Adjustment ...................................................................................................... 126

11.3 Rotation of the Fan Motor ............................................................................................................ 128

11.4 Gas Train ........................................................................................................................................ 128

11.5 Gas Pressure .................................................................................................................................. 129

11.6 Adjustments before First Firing ..................................................................................................... 130

11.7 Startup for MFC 8000-10000 Gas Only Burner ............................................................................. 132

Burner Firing ........................................................................................................................... 133 11.7.1

Combustion Air Adjustment ................................................................................................... 133 11.7.2

Gas/Air Delivery Adjustment .................................................................................................. 133 11.7.3

Air/Fuel Control and Power Modulation System.................................................................... 134 11.7.4

11.8 Final Calibration of the Pressure Switches .................................................................................... 135

Air Pressure Switch Adjustment.............................................................................................. 135 11.8.1

Maximum Gas Pressure Switch Adjustment ........................................................................... 136

11.8.2

Minimum Gas Pressure Switch Adjustment ............................................................................ 136 11.8.3

11.9 Final Checks with Boiler in Operation ........................................................................................... 137

SECTION 12: FLAME SIGNAL MEASUREMENT ................................................................. 138

Final Checks with Boiler in Operation ..................................................................................... 138 12.1.1

SECTION 13: MFC SERIES MAINTENANCE ....................................................................... 139

13.1 Preparation for Inspection and Maintenance ............................................................................... 139

13.2 Standard Maintenance .................................................................................................................. 140

13.3 Burner Maintenance ..................................................................................................................... 141

13.4 RS-120 / RS-160 Burner Maintenance (MFC 3000-6000) .............................................................. 141

Combustion ............................................................................................................................. 141 13.4.1

Gas Leaks ................................................................................................................................ 141 13.4.2

Flame inspection Window ...................................................................................................... 141 13.4.3

Combustion Head ................................................................................................................... 142 13.4.4

Nozzles (Fuel Oil) (Dual Fuel Models Only) ............................................................................. 142 13.4.5

Flexible Hoses (Fuel Oil) (Dual Fuel Models Only) .................................................................. 142 13.4.6

UV Scanner ............................................................................................................................. 142 13.4.7

Burner ..................................................................................................................................... 143 13.4.8

Combustion ............................................................................................................................. 143 13.4.9

13.5 RS-300 Burner Maintenance (MFC 8000-10000) .......................................................................... 143

Maintenance Frequency ......................................................................................................... 143 13.5.1

Combustion ............................................................................................................................. 143 13.5.2

Gas Leaks ................................................................................................................................ 143 13.5.3

Combustion Head ................................................................................................................... 143 13.5.4

MFC Series Boilers User Manual

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Measurement of Detector Current ......................................................................................... 143 13.5.5

Fan .......................................................................................................................................... 144 13.5.6

Burner ..................................................................................................................................... 144 13.5.7

Boiler ....................................................................................................................................... 144 13.5.8

13.6 Light Oil Operation (MFC 8000-10000 Dual Fuel Only) ................................................................. 144

Pump ....................................................................................................................................... 144 13.6.1

Filters ...................................................................................................................................... 144 13.6.2

Nozzles .................................................................................................................................... 144 13.6.3

Flexible Hoses ......................................................................................................................... 144 13.6.4

Fuel Tank ................................................................................................................................. 144 13.6.5

Combustion ............................................................................................................................. 144 13.6.6

13.7 Gas Operation (MFC 8000-10000 Only) ........................................................................................ 144

Gas Leaks ................................................................................................................................ 144 13.7.1

Gas filter.................................................................................................................................. 145 13.7.2

Combustion ............................................................................................................................. 145 13.7.3

APPENDIX A – OPERATIONAL SEQUENCE DIAGRAMS ................................................... 146

13.8 MFC 3000-6000 Sequence of Operation Diagram ........................................................................ 146

13.9 MFC 8000-10000 Sequence of Operation Diagram ...................................................................... 147

APPENDIX B – ELECTRICAL DIAGRAMS ........................................................................... 150

MFC 3000 / 4000 / 5000 / 6000 Electrical Diagrams 1-8 ...................................................................... 150

MFC 8000/10000 - ElectRICAL Diagrams 1-9 ........................................................................................ 159

MFC Series Boilers User Manual

FORWARD

OMM-0104_94 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 7 of 170

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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.

MFC Series Boilers User Manual

CHAPTER 1: SAFETY PRECAUTIONS

Page 8 of 170 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_94

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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.

MFC Series Boilers User Manual

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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.

MFC Series Boilers User Manual

CHAPTER 1: SAFETY PRECAUTIONS

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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.

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

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.

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)]

MFC Series Boilers User Manual

CHAPTER 2: INTRODUCTION

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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

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.

MFC Series Boilers User Manual

CHAPTER 2: INTRODUCTION

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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’’

3’’ (Flange)

Oil Connections

.375”

.5”

Max. Gas Pressure

2 psi

5 psi

2 psi

Min. Gas Pressure

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

25.8 FLA

Electrical Req. 460V/3PH/60Hz

2, 3

5.8 FLA

7.6 FLA

11.7 FLA

Electrical Req. 575V/3PH/60Hz

2,3

4.5 FLA

6.2 FLA

10.2 FLA

Control Circuit 120V/1PH/60Hz

2, 3

6.8 FLA

Water Connections (Flanged)

4’’

6”

8”

Dual Return Water Connection

Yes

Min. Water Flow (GPM)

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

14 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:

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.

See the MFC Electrical Power Guide, GF-148-E, for Service Disconnect Switch amperage

requirements.

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.

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.

MFC Series Boilers User Manual

CHAPTER 2: INTRODUCTION

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MFC Series – Dimensions

Model

(Width)

(Length)

(Height)

(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”

MFC Series Boilers User Manual

CHAPTER 3 - INSTALLATION P

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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 4

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

See Table A

Relief valve

See Table A

Pipe Nipple

See Table A

Bushing

123675-2

Tridicator

121700

Low Water Cut Off

24441

Condensate Trap

64115

Aquastat

64116

Manual Reset Aquastat

99235

Thermowell

MFC Series Boilers User Manual

CHAPTER 3 - INSTALLATION

Page 16 of 170 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_94

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Table A - MFC Series Accessories

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

MFC Series Boilers User Manual

CHAPTER 3 - INSTALLATION P

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MFC Factory Installed Parts

ITEM DESCRIPTION QTY

BODY BOILER

STAINLESS STEEL 4TH PASS

CONNECTION PIPE FRONT

CONNECTION PIPE REAR

EXPANSION JOINT

SCREW

NUTS

CONNECTION PIPE GASKETS

ELBOW

BOILER DRAIN PIPE

THERMOINSULATING MATERIAL

KIT FOR BURNER HEAD

SCREW BETWEEN STAINLESS STEEL 4TH PASS AND BOILER

LARGE WASHERS BETWEEN

STAINLESS STEEL 4TH PASS AND

CONN. PIPE SUPPORT

SCREWS

NUTS for CONN. PIPE

LOCK WASHERS for CONN. PIPE

TUBE CLEANING BRUSH

DOOR OPENING TOOL

Figure 2-1: MFC Factory Installed Parts

MFC Series Boilers User Manual

CHAPTER 3 - INSTALLATION

Page 18 of 170 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_94

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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

4000

RLS160

30.0

15.0

5000

RLS160

30.0

15.0

6000

RLS160

30.0

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

4000

RS100

15.0

5000

RS130

15.0

6000

RS190

20.0

15.0

8000

RS250

30.0

15.0

10000

RS300

30.0

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.

MFC Series Boilers User Manual

CHAPTER 3 - INSTALLATION P

OMM-0104_94 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 19 of 170

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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

MFC Series Boilers User Manual

CHAPTER 3 - INSTALLATION

Page 20 of 170 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_94

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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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