Burnham MEGASTEAM MST513 manual

100618-01R5-4/09 As an ENERGY ST AR ® Partner , Burnham Hydronics has determined that the MST288, MST396, MST513 and MST629 meet the ENERGY ST AR ® guidelines for Energy efciency established by the United States Environmental Protection Agency (EP A). Price - $3.00 D N A G N I T A R E P O , N O I T A L L A T S N I R O F S N O I T C U R T S N I[...]

2 IMPOR T ANT INFORMA TION - READ CAREFULL Y The following terms are used thr oughout this manual to bring attention to the pr esence of hazards of various risk levels, or to important information concerning pr oduct life. DANGER Indicates an imminently hazardous situation which, if not avoided, will result in death, serious injury or substantial p[...]

3 DANGER DO NOT store or use gasoline or other ammable vapors or liquids in the vicinity of this or any other appliance. W ARNING 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 dea[...]

4 W ARNING 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[...]

5 Figure 1: MST288 Thru MST629 Steam Boiler with and without T ankless Heater (Beckett Burner Shown)[...]

6 T ABLE 1A: DIMENSIONAL DA T A (SEE FIGURE 1) T ABLE 1B: RA TING DA T A Boiler Model No. Dimensions (See Figure 1) W ater Content (T o Normal W ater Line) - Gallons Heat T ransfer Surface Area - sq. Ft. Actual Shipping Weight (LB.) "A" "B" "C" With T ankless Heater Non-Heater MST288 22-5/8" 24" 6" 15.3 [...]

7 Figure 2: Minimum Installation Clearances T o 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 ?[...]

8 NOTICE Clearance to venting is for single wall vent pipe. If T ype L vent is used, clearance may be reduced to the minimum required by the vent pipe manufacturer . C. PROVIDE COMBUSTION AND VENTILA TION AIR. Local and National Codes may apply and should be referenced. W ARNING Ade quat e com bus tion and vent ilat ion air must be provi ded to ass[...]

9 SE CTI ON II : U N IT -P A K BOILER ASSEMBL Y MegaSteam™ Unit-Pak Boiler Assembly Shipment Content Check List (see Figure 3) 1. ___ Cast Iron Section/Burner Swing Door/Smoke Box Assembly Mounted on Shipping Skid: ____ MST3 (Rear Section, Heater) – Part # 100566-03 / 100045-01 / 100021-01 ____ MST4 (Rear Section, Heater) – Part # 100566-04 /[...]

10 A. CAST IRON SECTION ASSEMBL Y T APPINGS Refer to T able 3 "Purpose of T appings 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 specics and boiler build ordered, some tappings (front sectio[...]

1 1 Figure 4: Boiler Removal from Skid[...]

12 Figure 5A: Partial Front View - Burner Swing Door Mounted to Boiler - Fully Closed and Secured 1. T o 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 [...]

13 Figure 5B: T op View - Burner Swing Door Mounted to Cast Iron Block Assembly (Jacket Removed for Clarity) 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 ueways. By design, door insulation on models MST288, MST396 & MST513 wil[...]

14 E. FLUEW A Y BAFFLE INST ALLA TION. Flueway bafes are enclosed into Part Carton. Bafe requirements differ by boiler model, see T able 2. T ABLE 2: BAFFLE USAGE Figure 5C: T op View - Burner Swing Door Fully Closed but Not Properly Secured or Sealed NOTE: Read caution statement before proceeding. CAUTION These bafes will generate higher [...]

15 Figure 6: Flueway Bafe Positioning/Orientation in Flueways NOTICE When securing burner swing door make sure door is drawn-in equally on both sides. d. Use a hand or socket wrench to tighten door hardware. AL W A YS ST AR T WITH RIGHT SIDE T AP BOL T FIRST . Use an alternating tightening method from right side tap bolt to left side tap bolt to[...]

16 Figure 7: Purpose of T appings and Bosses T ABLE 3: PURPOSE OF T APPINGS & BOSSES T apping 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 L WCO - Std. Plugged (Float L WCO) D ½" - 14 W ater Gauge Glass (Probe L WCO[...]

17 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. Th[...]

18 L. TRIM AND CONTROLS INST ALLA TION. Pressur e 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 T able 3 “ Purpose of T app[...]

19 Figure 9: Float-T ype L WCO and Pressure Limit Installation[...]

20 7. Screw L WCO to External W iring Enclosure wiring harness (end with fork and female disconnect terminals) connector into low water cut-off J-box top tting, and attach wires to the terminals per L WCO wiring detail shown in Figure 9 "Float-T ype L WCO and Gauge Glass Installation". 8. Re-install #67 L WCO J-box cover . 9. Pick-up t[...]

21 Figure 10: Oil Burner Installation (Beckett Burner Shown) f. Insert oil burner into the opening of burner swing door . Align and engage keyhole slot in burner ange over head of protruding cap screw installed in previous Step. Rotate burner to the right to lock ange behind head of cap screw . g. Align holes and install two (2) remaining cap[...]

22 b. Remove existing nozzle from nozzle adapter . c. Insert the proper NOZZLE into NOZZLE ADAPTER and tighten securely (Do not over tighten). d. Replace adapter , with nozzle installed, into drawer assembly and secure with screw (1). iii. Inspect/Measure Burner Electrodes . Refer to Figure 1 1C. iv . Re-install Drawer Assembly into Combustion Head[...]

23 W ARNING : Do not operate a single line system with the by-pass plug installed. Operating a single line system with the by-pass plug installed will result in damage to the pump shaft seal. NOTE : Pump pressure was factory pre-set but must be checked at time of burner start-up. A pressure gauge is attached to the PRESSURE/ BLEEDER POR T (7) for p[...]

24 A. EV ALUA TE 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 . These contaminants greatly accelerate corrosion of the cast iron boiler sections. 1. Assur[...]

25 Figure 12: Recommended Boiler Piping for Gravity Return Steam Boiler[...]

26 SECTION IV : T ANKLESS & INDIRECT W A TER HEA TER PIPING A . CONNECT T ANKLESS HEA TER PIPING as shown in Figure 13. See T able 4 for T ankless Heater Rating. W ARNING Install automatic mixing valve at tankless heater outlet to avoid risk of burns or scalding due to excessively hot water at xtures. Adjust and maintain the mixing valve in [...]

27 T ABLE 4: T ANKLESS HEA TER DA T A: Figure 13: Schematic T ankless W ater Heater Piping Boiler Model Heater No. Heater Rating (GPM) Pressure Drop thru Heater (PSI) MST288 222A 3.00 22.0 MST396 3.25 24.3 MST513 3.50 26.5 MST629 4.00 31.0[...]

28 Figure 14: Alliance™ SL W ater Heater Piping with MegaSteam™ Boiler B. CONNECT ALLIANCE™ SL INDIRECT W A TER HEA TER PIPING as shown in Figure 14. 1. Refer to Alliance™ SL manual for additional information.[...]

29 A. CHIMNEY VENTING 1. Chimney venting is an important part of a safe and efcient oil red appliance system. Contact your local re and building ofcials on specic requirements for restrictions and the installation of fuel oil burning equipment. In addition, consult with a professional knowledgeable on the requirements of NFP A 31 –[...]

30 Figure 15: Recommended V ent Pipe Arrangement and Chimney Requirements Figure 16: Proper and Improper Locations of Draft Regulator[...]

31 2. T ype B Chimney Connector - a type B chimney connector can be used to transmit the ue gases provided ue gas temperature entering the chimney connector is greater than 310°F . 3. T ype 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 th[...]

32 W ARNING Remove the bafes 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 . OPTIONAL AIR INTAKE PIPING INSTALLATION - All air for combustion can [...]

33 A. GENERAL 1. Install wiring and electrically ground boiler in accordance with requirements of the authority having jurisdiction, or in absence of such requirements the National Electrical Code, ANSI/ NFP A 70. 2. Refer to National Electric Code or Local Electric Codes for proper size and type of wire required. Follow Code. 3. A separate electri[...]

34 Figure 18: Wiring Diagram, Steam, Hydrolevel CG450 Probe L WCO[...]

35 Figure 18A: Wiring Diagram, Riello 40 Series Burner , Steam, Hydrolevel CG450 Probe L WCO[...]

36 Figure 19: Wiring Diagram, Steam, McDonnell & Miller PS-801 Probe L WCO[...]

37 Figure 19A: Wiring Diagram, Riello 40 Series Burner , Steam, McDonnell & Miller PS-801 Probe L WCO[...]

38 Figure 20: Wiring Diagram, Steam, McDonnell & Miller #67 Float L WCO[...]

39 Figure 20A: Wiring Diagram, Riello 40 Series Burner , Steam, McDonnell & Miller #67 Float L WCO[...]

40 B O I L E R SEQUENCE OF OPERA TION WITH PROBE L WCO (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 rst 10 seconds; re until the thermostat is sa[...]

41 Figure 21: Single Pipe Oil Line SECTION VII: OIL PIPING A. GENERAL 1. Use exible oil line(s) so the burner swing door can be opened without disconnecting the oil supply piping. 2. A supply line fuel oil lter is recommended as a minimum for all ring rates but a pleated paper fuel oil lter is recommended for the ring rates below 1.0[...]

42 T ABLE 5: TWO-ST AGE UNITS (3450 RPM) - TWO PIPE SYSTEMS T ABLE 6: SINGLE-ST AGE UNITS (3450 RPM) - TWO PIPE SYSTEMS Figure 22: T wo Pipe Oil Lines C. TWO PIPE OIL LINES 1. For two piped systems, where more lift is required, the two-stage fuel unit is recommended. T able 5 (two-stage) and T able 6 (single-stage) show allowable lift and lengths o[...]

43 SECTION VIII: SYSTEM ST AR T -UP 1. S E T ROOM THERMOST A T about 10° above room temperature. 2. P R E S S RED RESET BUTTON on front of burner cover , hold for one (1) second and release to reset primary control. 3 . On STEAM BOILERS: a. W ith an L404F1367 - set cut-out pressure (MAIN scale) on the pressure limit for (1) PSI and differential pr[...]

44 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 T able 8 at rear of manual. c. T o check the cut-off pressure, dead[...]

45 Figure 24: "L1" and "V1" Head Electrode Positioning and Gun Setting (Beckett AFG)[...]

46 I. TEST CONTROLS. 1. Check thermostat operation. Raise and lower thermostat setting as required to start and stop burner . W ARNING 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 [...]

47 ii. Check Safety Features Safe Start: • Place a jumper across cad cell terminals. • Follow procedure to turn on burner . Burner must not start, indicator light turns on and control remains in Idle Mode. • Remove jumper . iii. Simulate Ignition or Flame Failure: • Follow procedure to turn on burner . • Close hand valve in oil supply lin[...]

48 Important Produc t Safety Information Refractory Ceram ic 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 know[...]

49 SECTION IX: MAINTENANCE AND SER VICE INSTRUCTIONS A. MAINTENANCE OF LOW WATER CUT- O F F DEVICES W ARNING Probe and oat 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 boil[...]

50 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 us[...]

51 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 specic 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[...]

52 SECTION X: BOILER CLEANING A. CLEAN THE FLUEWAYS (See Figure 27). 1. For access to the combustion chamber remove the two (2) 3/8" - 16 cap screws. If boiler is equipped with exible fuel line(s), swing door open. 2. Remove the two smoke box clean-out covers from the rear smoke box by removing the four 5/16"-18 hex head bolts. It is N[...]

53 Figure 27: Cleaning Boiler Flueways and Combustion Chamber Surfaces W ARNING 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 ue must be inspected and cleaned before the start of the heating seas[...]

54 A. COMBUSTION 1. N O Z Z L E S — 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 ame shape and efcient combustion. Other brands of the sam[...]

55 d. Excessive airow or draft causing ame to leave burner head. e. Excessive back pressure causing ame to be erratic. 3. Control locks out after T rial For Ignition (TFI). a. No oil to burner . b. Shorted electrodes. c. Nozzle clogged. d. Airow too high. e. Ignitor module defective. f. CAD cell defective. g. Oil valve stuck open or clo[...]

56 SECTION XII: REP AIR P AR TS All MegaSteam™ Boiler Repair Parts may be obtained through your local U.S. Boiler Co., Inc. Wholesale Distributor . Should you require assistance in locating a Wholesale Distributor in your area, or have questions regarding the availability of U.S. Boiler Co., Inc. products or repair parts, please contact Burnham C[...]

57 Item No. Description Part No. MST288 MST396 MST513 MST629 1. BARE BOILER ASSEMBL Y 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 806 6003 75 2 2 3 4 1[...]

58 Bare Boiler Assembly[...]

59 Item No. Description Part No. MST288 MST396 MST513 MST629 1. BARE BOILER ASSEMBL Y (Continued) 1S 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. Rope Gasket - Observation Port [...]

60 Jacket Assembly[...]

61 Item No. Description Part No. MST288 MST396 MST513 MST629 2. JACKET ASSEMBL Y 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" T ype AB T russ Head w/Shoulder , Sheet Metal Screw , Plated 100038-01 10 10 10 10 2D Jacket Rear Panel Assembly w/Insulation 100578-[...]

62 MST288 Thru MST629 Steam Boilers - T rim and Controls[...]

63 Item No. Description Part No. MST288 MST396 MST513 MST6 29 3. MST - TRIM AND CONTROLS 3A 6" RC-STD Draft Regulator 81 16288 1 1 1 --- 7" RC-STD Draft Regulator 81 16289 --- --- --- 1 3B Pressure Gauge 100325-01 1 1 1 1 3C Probe, Hydrolevel EL-1214 (for Hydrolevel CG450) 80160629 1 1 1 1 3D Low W ater Cut-off, Hydrolevel CG450 (less Pro[...]

64 Beckett AFG Burner[...]

65 BECKETT OIL BURNER P ART 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 . Boiler Model MST288 MST396 MST513 MST629 Air T ube Combination AFG70MMAQN AFG70MMAQN AFG70MLASN AFG70MKASN Beckett[...]

66 NOTE: When ordering parts always give the serial and model numbers shown on the boiler and burner . Refer to Models F3 & F5 Installation Manual, Riello 40 Series Residential Oil Burners (C6501010) for an exploded view of the burner and a list of spare parts. RIELLO OIL BURNER P AR T NUMBERS FOR MEGASTEAM 3-P ASS OIL BOILERS For replacement R[...]

67 T ABLE 8: BECKETT AFG B U R N E R S P E C I F I C A T I O N S Boiler Model Burner Input (gph) Head T ype (setting) Air Shutter (setting) Air Band (se tti ng) Nozzle Pump Pressure (psi) Approx. Shipped CO 2 (%) Bafe Location (pass) Approx. Stack T emp. Increase Without Bafes (F) 2 Bafes IN Minimum Breech Pressure ("w .c.) 3 Bafes[...]

68 L L i i m m i i t t e e d d W W a a r r r r a a n n t t y y F F o o r r R R e e s s i i d d e e n n t t i i a a l l G G r r a a d d e e W W a a t t e e r r a a n n d d S S t t e e a a m m B B o o i i l l e e r r s s Using Cast Iron, Carbon Steel, Cast Aluminum, or Stainless Steel Heat Exchangers a a n n d d P P a a r r t t s s / / A A c c c c e [...]