IN S TAL L AT ION , OP E R AT IN G AN D S E R V IC E IN S T R U C T ION S F OR Me g a S te a m™ 3 - PA S S O I L B O I L E R As an ENERGY STAR® Partner, Burnham Hydronics has determined that the MST288, MST396, MST513 and MST629 meet the ENERGY STAR® guidelines for Energy efficiency established by the United States Environmental Protection Agency (EPA). F o r s e rvi c e o r re p a i r s to b o i le r, c a ll yo ur he a ti ng c o ntr a c to r o r o i l s up p li e r.
IMPORTANT INFORMATION - READ CAREFULLY 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.
DANGER DO NOT store or use gasoline or other flammable vapors or liquids in the vicinity of this or any other appliance. WARNING Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury or loss of life. Failure to follow all instructions in the proper order can cause personal injury or death.
WARNING This boiler contains very hot water under high pressure. Do not unscrew any pipe fittings 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.
Figure 1: MST288 Thru MST629 Steam Boiler with and without Tankless Heater
TABLE 1A: DIMENSIONAL DATA (SEE FIGURE 1) Boiler Model No. Dimensions (See Figure 1) Water Content (To Normal Water Line) - Gallons With Tankless Non-Heater Heater Heat Transfer Surface Area - sq. Ft. Actual Shipping Weight (LB.) "A" "B" "C" MST288 22-5/8" 24" 6" 15.3 14.9 20.29 607 MST396 22-5/8" 24" 6" 15.3 14.9 20.29 607 MST513 28-5/8" 30" 6" 19.7 19.3 27.29 744 MST629 34-5/8" 36" 7" 24.1 23.8 34.
Section I: PRE-INSTALLATION 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 filed 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.
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. 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.
SECTION II: UNIT-PAK BOILER ASSEMBLY MegaSteam™ Unit-Pak Boiler Assembly Shipment Content Check List (see Figure 3) 1.
A. CAST IRON SECTION ASSEMBLY TAPPINGS Refer to Table 3 "Purpose of Tappings and Bosses" and Figure 7. 1. All tappings have factory installed thread protectors. The thread protectors must be removed prior to jacket and piping installation. 2. Depending of installation specifics and boiler build ordered, some tappings (front section Optional Front Return, rear section Indirect Heater Supply and Indirect Heater Limit) may not be used and must be plugged before jacket and piping installation.
Figure 4: Boiler Removal from Skid
1. To open/remove Burner Swing Door (mounted on Cast Iron Section/Burner Swing Door/Smoke Box Assembly) and door mounting bracket for front jacket panel installation: a. Loosen but not remove door left side latching hardware (3/8”-16 x 1-3/4” tap bolt). b. Loosen and remove door right side latching hardware (3/8”-16 x 1-3/4” tap bolt and 5/16” washer) and set aside. c. Remove door left side latching hardware (3/8”16 x 1-3/4” tap bolt and 5/16” washer) and set aside. d.
By design, door insulation on model MST629 will have two by-pass pockets cast into the insulation centered on the bar between the combustion chamber and 3rd pass flueways. By design, door insulation on models MST288, MST396 & MST513 will not have any by-pass pockets. If insulation is damaged, or, improper type regarding the pockets, it must be replaced. 11. Upon inspection completion, lift door and place integral cast hinge pins into door mounting bracket slotted holes.
Figure 5C: Top View - Burner Swing Door Fully Closed but Not Properly Secured or Sealed • Models MST396, MST513 and MST629 - To install flueway baffle in 2nd pass flueway on left side of boiler, hold baffle with word "Left" readable at the top. Slide baffle in flueway until position tab touches fins on right side of 2nd pass flueway. To install flueway baffle in 2nd pass flueway on right side of boiler, hold baffle with word "Right" readable at the top.
G. Jacket Rear Panel Installation. 1. Locate jacket rear panel (has factory attached 3” fiberglass insulation) inside Jacket Carton. See also “Repair Parts” Section, “Jacket Assembly” illustration for part identification. 2. Locate and remove from Hardware Bag rear panel mounting hardware – (2 pcs) 5/16”-18 x 3” lg. tap studs, (2 pcs) 5/16”-18 plated acorn nuts, (2 pcs) 5/8” x 2-9/32” round spacers and (2 pcs) 5/16”-18 x ½” Phillips pan head machine screws. 3.
Figure 7: Purpose of Tappings and Bosses Table 3: Purpose of Tappings & bosses 16 Tapping Location Size, NPT Boss Location Thread Size UNC Steam Boiler Less Heater With Heater A ¼" - 18 Pressure Gauge B ¼" - 18 Pressure Limit C ¾" - 14 Probe LWCO - Std.
6. Repeat above steps with right Cleanout Cover. 7. Apply the adhesive sealant to the underside of the collar, all around, at the inside corner of the collar outer ring. Insure adhesive bead is complete all around and without gaps. 8. Place the collar over smokebox tongue and align collar integral mounting ear slots with smokebox bosses. 9. Thread-in both 5/16”-18 – 7/8” hex head cap screws hand tight, then, alternately tighten them with open end or socket wrench. I.
L. Trim and Controls Installation. Pressure Limit Installation. 1. Locate and remove L404F Pressure Limit with factory attached harness from Control Carton. 2. Locate and remove 1/4" NPT x 1-7/8" x 4 x 90° syphon enclosed in Part Carton. 3. Review and locate pressure limit tapping on front section. See Table 3 “ Purpose of Tappings & Bosses” and Figure 7. 4. Thread 1-7/8" lg. syphon-threaded short end into the bottom of Pressure Limit with factory attached harness.
Figure 9: Float-Type LWCO and Pressure Limit Installation
7. Screw LWCO to External Wiring Enclosure wiring harness (end with fork and female disconnect terminals) connector into low water cut-off J-box top fitting, and attach wires to the terminals per LWCO wiring detail shown in Figure 9 "Float-Type LWCO and Gauge Glass Installation". 8. Re-install #67 LWCO J-box cover. 9.
f. Insert oil burner into the opening of burner swing door. Align and engage keyhole slot in burner flange over head of protruding cap screw installed in previous Step. Rotate burner to the right to lock flange behind head of cap screw. h. Plug burner power cord into power outlet receptacle located in lower right corner of front panel. g. Align holes and install two (2) remaining cap screws. Level burner and fully tighten all three (3) screws.
SECTION III: STEAM Boiler PIPING & TRIM WARNING Failure to properly pipe boiler may result in improper operation and damage to boiler or structure. Do not increase steam boiler input above the ratings. A. Evaluate the existing steam system. The single most important factor in determining the expected life cycle of a steam boiler, is the amount of fresh water added to the boiler during operation. Fresh water brings minerals and oxygen into the boiler.
Figure 11: Recommended Boiler Piping for Gravity Return Steam Boiler
SECTION IV: TANKLESS & Indirect Water HEATER PIPING A. CONNECT TANKLESS HEATER PIPING as shown in Figure 12. See Table 4 for Tankless Heater Rating. WARNING Install automatic mixing valve at tankless heater outlet to avoid risk of burns or scalding due to excessively hot water at fixtures. Adjust and maintain the mixing valve in accordance with the manufacturer's instructions. Do not operate tankless heater without mixing valve.
Figure 12: Schematic Tankless Water Heater Piping Table 4: TANKLESS HEATER DATA: Boiler Model Heater No. MST288 MST396 MST513 MST629 222A Heater Rating (GPM) Pressure Drop thru Heater (PSI) 3.00 22.0 3.25 24.3 3.50 26.5 4.00 31.
Figure 13: Alliance™ Water Heater Piping with MegaSteam™ Boiler B. CONNECT ALLIANCE™ INDIRECT WATER HEATER PIPING as shown in Figure 13. 26 1. Refer to Alliance™ manual for additional information.
SECTION V: VENTING & Air intake piping A. Chimney Venting 1. Chimney venting is an important part of a safe and efficient oil fired appliance system. Contact your local fire and building officials on specific requirements for restrictions and the installation of fuel oil burning equipment.
Figure 14: Recommended Vent Pipe Arrangement and Chimney Requirements 28 Figure 15: Proper and Improper Locations of Draft Regulator
2. Type B Chimney Connector - a type B chimney connector can be used to transmit the flue gases provided flue gas temperature entering the chimney connector is greater than 310°F. 3. Type L Chimney Connector - a type L vent or other suitable material shall be used for a chimney connector if the temperature or exiting temperature is less than 310°F. DANGER Any signs of condensate seepage at the base of the chimney shall be inspected immediately.
WARNING Remove the baffles if there are any signs of condensation in the chimney or chimney connector. Consult with your local chimney professional for recommendations. E. Minimum Clearances See Figure 2 for details regarding clearances to combustibles for the boiler. F.
c. Mount the vacuum relief valve into the tee and fasten with a screw and nut in collar tabs. To ensure proper operation, the gate must be level across the pivot point and plumb. Refer to vacuum relief valve manufacturer's instructions. 5. Install remainder of air intake, securing each joint with at least three (3) sheet metal screws evenly spaced. 7. Seal all external joints with weatherproof caulk.
SECTION VI: ELECTRICAL DANGER Positively assure all electrical connections are unpowered before attempting installation or service of electrical components or connections of the boiler or building. Lock out all electrical boxes with padlock once power is turned off. WARNING Failure to properly wire electrical connections to the boiler may result in serious physical harm. Electrical power may be from more than one source. Make sure all power is off before attempting any electrical work.
Figure 18: Wiring Diagram, Steam, Hydrolevel CG450 Probe LWCO
Figure 19: Wiring Diagram, Steam, McDonnell & Miller PS-801 Probe LWCO
Figure 20: Wiring Diagram, Steam, McDonnell & Miller #67 Float LWCO
BOILER SEQUENCE OF OPERATION WITH PROBE LWCO (See Figure 18) When the thermostat calls for heat, it energizes the R8285C Control Center relay which in turn energizes the cad cell primary control, bringing on the burner. The burner will operate in the following sequence: Prepurge for the first 10 seconds; fire until the thermostat is satisfied or the limit setting on the high limit is reached; post-purge for the last 10 seconds.
SECTION VII: OIL PIPING A. General 1. Use flexible oil line(s) so the burner swing door can be opened without disconnecting the oil supply piping. 2. A supply line fuel oil filter is recommended as a minimum for all firing rates but a pleated paper fuel oil filter is recommended for the firing rates below 1.0 gph to prevent nozzle fouling. 3. Use Flared fittings only. Cast iron fittings cannot be used. NOTICE WARNING Under no circumstances can copper with sweat style connectors be used.
C. Two Pipe Oil Lines 1. For two piped systems, where more lift is required, the two-stage fuel unit is recommended. Table 5 (two-stage) and Table 6 (single-stage) show allowable lift and lengths of 3/8 inch and 1/2 inch OD tubing for both suction and return lines. Refer to Figure 22. 2. Follow the oil pump manufacturer’s recommendations on the proper connections for a two pipe system. Some manufacturers require the insertion of a bypass plug.
Section VIII: SYSTEM START-UP WARNING All boilers equipped with burner swing door have a potential hazard which can cause severe property damage, personal injury or loss of life if ignored. Before opening swing door, turn off service switch to boiler to prevent accidental firing of burner outside the combustion chamber. Be sure to tighten swing door fastener completely when service is completed. 1. SET ROOM THERMOSTAT about 10° above room temperature. A. ALWAYS INSPECT INSTALLATION BEFORE STARTING BURNER.
See Table 8 (at rear of this manual) for details regarding the overfire pressure when baffles are both installed and removed. 5. Adjust oil pressure. a. When checking a fuel unit's operating pressure, a reliable pressure gauge may be installed in either the bleeder port or the nozzle port. See Figure 23. b. Locate oil pressure adjusting screw and turn screw to obtain proper pump pressure, refer to Table 8 at rear of manual. c.
Figure 24: "L1" and "V1" Head Electrode Positioning and Gun Setting (Beckett AFG)
vi. Diagnostic LED: The indicator light on oil primary control provides lockout, recycle and cad cell indications as follows: WARNING Before installation of the boiler is considered complete, the operation of all boiler controls must be checked, particularly the primary control and pressure limit control. 2. VERIFY PRIMARY CONTROL FEATURES using procedures outlined in Instructions furnished with control or instructions as follows: a. Features and Controls i. The R7184 is a microprocessor-based control.
• Place a jumper across cad cell terminals. • Follow procedure to turn on burner. • If safety switch shuts down burner and resistance is above 1600 OHMS, open line switch to boiler. Access cad cell under ignitor, clean face of cad cell and see that cell is securely in socket. Check gasket around perimeter of ignitor lid for proper seal. If gasket is missing or damaged, replace gasket. Room light can effect cad cell resistance. Reset safety switch.
Important Product Safety Information Refractory Ceramic Fiber Product Warning: The Repair Parts list designates parts that contain refractory ceramic fibers (RCF). RCF has been classified as a possible human carcinogen. When exposed to temperatures about 1805°F, such as during direct flame contact, RCF changes into crystalline silica, a known carcinogen. When disturbed as a result of servicing or repair, these substances become airborne and, if inhaled, may be hazardous to your health.
SECTION Ix: MAINTENANCE AND SERVICE INSTRUCTIONS A. MAINTENANCE OF LOW WATER CUTOFF DEVICES WARNING Probe and float type low water cut-off devices require annual inspection and maintenance. 1. PROBE TYPE LOW WATER CUT-OFF Although these devices are solid state in their operation, the probe is exposed to possible contamination in the boiler water and subject to fouling.
Operate the boiler with steam in the entire system for a few days allowing the condensate to return to the boiler. If the condensate can temporarily be wasted, operate boiler only for the length of time it takes for condensate to run clear. If the latter cannot be achieved or if the condensate is returned to the boiler, boil out the boiler using the SURFACE BLOW-OFF connection, see Figure 7. i. Drain boiler until 1” of water is visible in gauge glass.
by drawing a small sample of boiler water and testing with hydrion paper which is used in the same manner as litmus paper, except it gives specific readings. A color chart on the side of the small hydrion dispenser gives the reading in pH. Hydrion paper is inexpensive and obtainable from any chemical supply house or through your local druggist. The pH should be higher than 7, but lower than 11. Add some of the washout chemical (caustic soda), if necessary, to bring the pH within the specified range. f.
Section X: BOILER Cleaning WARNING All boiler cleaning must be completed with burner service switch turned off. Boilers equipped with burner swing door have a potential hazard which can cause severe property damage, personal injury or loss of life if ignored. Before opening swing door, turn off service switch to boiler to prevent accidental firing of burner outside the combustion chamber. Disconnect the burner plug from the receptacle in the front jacket.
Figure 27: Cleaning Boiler Flueways and Combustion Chamber Surfaces WARNING The boiler must be connected to an approved chimney in good condition. Serious property damage could result if the boiler is connected to a dirty or inadequate chimney. The interior of the chimney flue must be inspected and cleaned before the start of the heating season and should be inspected periodically throughout the heating season for any obstructions.
SECTION XI: TROUBLE SHOOTING A. COMBUSTION 1. NOZZLES — Although the nozzle is a relatively inexpensive device, its function is critical to the successful operation of the oil burner. The selection of the nozzle supplied with the MegaSteam™ boiler is the result of extensive testing to obtain the best flame shape and efficient combustion. Other brands of the same spray angle and spray pattern may be used but may not perform at the expected level of CO2 and smoke.
d. Excessive airflow or draft causing flame to leave burner head. e. Excessive back pressure causing flame to be erratic. Note: The Safety Monitoring Circuit (SMC) is designed to provide lockout in the event of a stuck or welded motor relay. NOTICE 3. Control locks out after Trial For Ignition (TFI). a. No oil to burner. If flame is not established within 15 seconds of oil valve actuation (known as Trial For Ignition [TFI]) lockout will occur.
Bare Boiler Assembly
Item No. Description Part No. MST288 MST396 MST513 MST629 1. BARE BOILER ASSEMBLY 1A Front Section, Machined 100569-01 1 1 1 1 1B Center Section, Machined 100571-01 1 1 2 3 1C1 Rear Section (Htr.), Steam, Machined 100573-01 1 1 1 1 1C2 Rear Section (Non-Htr.), Steam, Machined 100676-01 1 1 1 1 1D1 Slip Nipple, 22-B Steel 806600375 2 2 3 4 1D2 5" Cast Iron Slip Nipple 7066003 2 2 3 4 Upper Tie Rod, 3/8" -16 x 16" Lg.
Bare Boiler Assembly
Item No. Description Part No. MST288 MST396 MST513 MST629 1. BARE BOILER ASSEMBLY (Continued) Burner Swing Door Insulation (Less Pockets) 100039-01 1 1 1 --- Burner Swing Door Insulation (With Pockets) 100039-02 --- --- --- 1 1T 5/8" Dia. Rope Gasket - Burner Swing Door 100097-01 1 1 1 1 1U 1/8" Dia.
Jacket Assembly
Item No. Description Part No. MST288 MST396 MST513 MST629 2. JACKET ASSEMBLY 2A Jacket Front Panel Assembly w/Insulation 100575-01 1 1 1 1 2B Power Outlet Receptacle, w/Harness 100605-01 1 1 1 1 2C #8 x 1/2" Type AB Truss Head w/Shoulder, Sheet Metal Screw, Plated 100038-01 10 10 10 10 2D Jacket Rear Panel Assembly w/Insulation 100578-01 1 1 1 1 2E External Wiring Enclosure 100602-01 1 1 1 1 2F Tap End Stud, 5/16" -18 x 3" Lg.
MST288 Thru MST629 Steam Boilers - Trim and Controls
Item No. Description Part No. MST288 MST396 MST513 MST629 3. MST - TRIM AND CONTROLS 6" RC-STD Draft Regulator 8116288 1 1 1 --- 7" RC-STD Draft Regulator 8116289 --- --- --- 1 3B Pressure Gauge 8056010 1 1 1 1 3C Probe, Hydrolevel EL-1214 (for Hydrolevel CG450) 80160629 1 1 1 1 Low Water Cut-off, Hydrolevel CG450 (less Probe) 80160623 Low Water Cut-off, McDonnell & Miller PS-801 80160723 1 1 1 1 3E Nipple, 3/4" NPT x 3" Lg.
Beckett AFG Burner
BECKETT OIL BURNER PART NOS. FOR MegaSteam™ SERIES BOILERS NOTE: When ordering parts always give the serial and model numbers shown on the boiler and burner. Also provide the name of the part(s) and part number as listed below.
0.75 1.05 1.35 1.65 MST288 MST396 MST513 MST629 V1 (3) V1 (0) L1 L1 Head Type (setting) 7 7 7 61 Air Shutter (setting) 2 2 1 1 Air Band (setting) 150 150 150 150 0.60 x 60A Delavan 0.85 x 60B Delavan 1.10 x 60B Hago 1.35 x 60B Hago Nozzle 11.5 11.5 11.5 11.5 2nd 2nd 2nd --- 52 40 20 --- 0 0 0 0 0 0 0 0 0.050 0.040 0.040 --- Approx. Baffles Baffles Baffles Stack Temp. IN OUT IN Approx.
SERVICE RECORD DATE SERVICE PERFORMED 63
Limited Warranty FOR RESIDENTIAL CAST IRON STEAM BOILERS By this Warranty Statement the U.S. Boiler™ Company, Inc. of Lancaster, Pennsylvania issues limited warranties subject to the terms and conditions stated below. These limited warranties apply to residential cast iron boilers labeled Independence®, Independence® PV, V8H™ and MegaSteam™ Series, these warranties are issued only to the original homeowner at the original place of installation.
