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. W he n s e e k i ng i nfo rma ti o n o n b o i le r, p r o vi d e B o i le r Mo d e l Numb e r a nd S e ri a l Num b e r a s s ho wn o n Ra ti ng L a b e l lo c a te d o n to p o f the b o i le r. B o i l e r M o d e l N um b e r B o i l e r S e r i a l N um b e r Ins ta lla ti o n D a te MS T He a ti ng C o ntra c to r P ho ne Numb e r A d d re s s 100618-01R4-5/08 Price - $3.00 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. Current Edition of American National Standard ANSI/NFPA 31, “Installation of Oil Burning Equipment”, for recommended installation practices. B. Current Edition of American National Standard ANSI/NFPA 211, “Chimneys, Fireplaces, Vents, and Solid Fuel Burning Appliances”, For Venting requirements. C. Current Edition of American Society of Mechanical Engineers ASME CSD-1, “Controls and Safety Devices for Automatically Fired Boilers”, for assembly and operations of controls and safety devices. D. All wiring on boilers installed in the USA shall be made in accordance with the National Electrical Code and/or Local Regulations. The following terms are used throughout this manual to bring attention to the presence of hazards of various risk levels, or to important information concerning product life. DANGER CAUTION Indicates an imminently hazardous situation which, if not avoided, will result in death, serious injury or substantial property damage. Indicates a potentially hazardous situation which, if not avoided, may result in moderate or minor injury or property damage. WARNING NOTICE Indicates a potentially hazardous situation which, if not avoided, could result in death, serious injury or substantial property damage. Indicates special instructions on installation, operation, or maintenance which are important but not related to personal injury hazards. NOTICE This boiler has a limited warranty, a copy of which is printed on the back of this manual. The warranty for this boiler is valid only if the boiler has been installed, maintained and operated in accordance with these instructions. Surface rust on cast iron sections may be attributed to the manufacturing process as well as condensation during storage. Surface rust is normal and does not affect the performance or longevity of a boiler. 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. Read and understand all instructions, including all those contained in component manufacturers manuals which are provided with the appliance before installing, starting-up, operating, maintaining or servicing this appliance. Keep this manual and literature in legible condition and posted near appliance for reference by owner and service technician. This boiler requires regular maintenance and service to operate safely. Follow the instructions contained in this manual. Installation, maintenance, and service must be performed only by an experienced, skilled and knowledgeable installer or service agency. All heating systems should be designed by competent contractors and only persons knowledgeable in the layout and installation of hydronic heating systems should attempt installation of any boiler. Installation is not complete unless a safety valve is installed into 1½"" x ¾"" NPT reducing bushing, mounted into rear section boss, at the back of rear section. See Unit-Pak Boiler Assembly and Steam Boiler Trim & Piping Sections of this manual for details. It is the responsibility of the installing contractor to see that all controls are correctly installed and are operating properly when the installation is completed. This boiler is suitable for installation on combustible flooring. Do not install boiler on carpeting. Do not tamper with or alter the boiler or controls. Inspect flueways at least once a year - preferably at the start of the heating season. The inside of the combustion chamber, the vent system and boiler flueways should be cleaned if soot or scale has accumulated. When cleaning this boiler, take precaution to avoid damage to burner swing door insulation. If damaged, or if there is evidence of previous damage, burner swing door insulation must be replaced immediately. Oil Burner and Controls must be checked at least once a year or as may be necessitated. Do not operate unit with jumpered or absent controls or safety devices. Do not operate unit if any control, switch, component, or device has been subject to water. Appliance materials of construction, products of combustion and the fuel contain alumina, silica, heavy metals, carbon monoxide, nitrogen oxides, aldehydes and/or other toxic or harmful substances which can cause death or serious injury and which are known to the state of California to cause cancer, birth defects and other reproductive harm. Always use proper safety clothing, respirators and equipment when servicing or working nearby the appliance. 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. This boiler contains components which become very hot when the boiler is operating. Do not touch any components unless they are cool. This boiler must be properly vented. The chimney must be inspected for any obstructions and cleaned prior to each heating season. A clean and unobstructed chimney flue is necessary to produce the minimum draft required to safely evacuate noxious fumes that could cause personal injury or loss of life. Evidence of loose debris and or condensate induced stains at the base of the chimney flue, connector or smokepipe joints may be signs of condensing flue gases. Flue gas condensate is corrosive, which requires special consideration and must be addressed immediately. Refer to Section V, "Venting and Air Intake Piping". This boiler needs fresh air for safe operation and must be installed so there are provisions for adequate combustion and ventilation air. This boiler is supplied with controls which may cause the boiler to shut down and not re-start without service. If damage due to frozen pipes is a possibility, the heating system should not be left unattended in cold weather; or appropriate safeguards and alarms should be installed on the heating system to prevent damage if the boiler is inoperative. This boiler is designed to burn No. 2 fuel oil only. Do not use gasoline, crankcase drainings, or any oil containing gasoline. Never burn garbage or paper in this boiler. Do not convert to any solid fuel (i.e. wood, coal). Do not convert to any gaseous fuel (i.e. natural gas, LP). All flammable debris, rags, paper, wood scraps, etc., should be kept clear of the boiler at all times. Keep the boiler area clean and free of fire hazards. All boilers equipped with burner swing door have a potential hazard which, if ignored, can cause severe property damage, personal injury or loss of life. Before opening swing door, unplug burner power cord from receptacle located in lower right corner of jacket front panel and turn off service switch to boiler to prevent accidental firing of burner outside the combustion chamber. Be sure to tighten swing door fasteners completely when service is completed. TABLE OF CONTENTS I. Pre-Installation . . . . . . . . . . . . . . . . . . . . 7 VII. Oil Piping . . . . . . . . . . . . . . . . . . . . . . . 37 II. Unit-Pak Boiler Assy . . . . . . . . . . . . . . . 9 VIII. System Start-Up . . . . . . . . . . . . . . . . . . 39 III. Steam Boiler Trim & Piping . . . . . . . . . . . 22 IX. Maintenance & Service Instructions . . . 45 IV. Tankless & Indirect Water Heater Piping . 24 X. Boiler Cleaning . . . . . . . . . . . . . . . . . . . 48 V. Venting & Air Intake Piping . . . . . . . . . . 27 XI. Trouble Shooting . . . . . . . . . . . . . . . . . 50 VI. Electrical . . . . . . . . . . . . . . . . . . . . . . . . 32 XII. Repair Parts . . . . . . . . . . . . . . . . . . . . . 51 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 34.29 881 NOTE: 1: Maximum Working Pressure: Steam - 15 PSI TABLE 1B: RATING DATA Burner Capacity Boiler Model No. GPH MBH DOE Heating Capacity MBH MST288 0.75 105 92 MST396 1.05 147 MST513 1.35 189 MST629 1.65 231 I=B=R NET Ratings Steam Steam MBH Sq. Ft. Minimum Chimney Requirements Round Rectangle Height In. Dia. In. x In. Ft. AFUE % 69 288 6 8X8 15 86.0 127 95 396 6 8X8 15 86.0 164 123 513 7 8X8 15 86.0 201 151 629 7 8X8 15 86.0 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. LOCATE BOILER in front of final position before removing crate. See Figure 1. 1. LOCATE so that vent pipe connection to chimney will be short and direct. • 30" for flueway cleaning (MST513) • 36" for flueway cleaning (MST629) b. Clearance from Jacket Left Side Panel • 19" for burner swing door, if opened fully with burner mounted, otherwise 1" with burner removed • 12" access clearance to service rear of boiler if right side clearance is less than 12" • 1" minimum if right side clearance is 12" or larger to access and service rear of boiler. c. Clearance from Jacket Right Side Panel • 6" minimum from external Electrical Enclosure if left side clearance is 12" or larger to access and service rear of the boiler 24" minimum from rear tanklesss heater (if equipped) for servicing and removal of the heater 2. BOILER IS SUITABLE FOR INSTALLATION ON COMBUSTIBLE FLOOR. Boiler cannot be installed on carpeting. • 3. FOR BASEMENT INSTALLATION, provide a solid elevated base, such as concrete, if floor is not level, or if water may be encountered on floor around boiler. d. Clearance from Jacket Rear Panel - 4. PROVIDE RECOMMENDED SERVICE CLEARANCE, if applicable, as follows: a. Clearance from Jacket Front Panel • 24" for servicing burner • 24" for flueway cleaning (MST288 & MST396) • 12" minimum for rear smokebox cleaning (Note: This dimension will also be controlled by horizontal to vertical to horizontal smokepipe arrangement - See Figures 2 and 14.) 5. For minimum clearances to combustible materials. See Figure 2. Figure 2: Minimum Installation Clearances To Combustible Materials (Inches) NOTES: 1. Listed clearances comply with American National Standard ANSI/NFPA 31, Installation of Oil Burning Equipment. 2. MegaSteam™ boilers can be installed in rooms with clearances from combustible material as listed above. Listed clearances cannot be reduced for alcove or closet installations. 3. For reduced clearances to combustible material, protection must be provided as described in the above ANSI/NFPA 31 standard. 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.e. bleaches, fabric softeners, etc.) are used or stored. Do not install boiler in laundry room, or, in vicinity of clothes dryer to prevent inadequate air supply to burner and lint contamination of burner air intake openings. 1. Determine volume of space (boiler room). Rooms communicating directly with the space in which the appliances are installed, through openings not furnished with doors, are considered a part of the space. Volume(ft3) = Length(ft) x Width(ft) x Height(ft) 2. Determine total input of all appliances in the space. Add inputs of all appliances in the space and round the result to the nearest 1000 BTU per hour. 3. Determine type of space. Divide Volume by total input of all appliances in space. If the result is greater than or equal to 50 ft3/1000 BTU per hour, then it is considered an unconfined space. If the result is less than 50 ft3/1000 BTU per hour then the space is considered a confined space. 4. For boiler located in an unconfined space of a conventionally constructed building, the fresh air infiltration through cracks around windows and doors normally provides adequate air for combustion and ventilation. 5. For boiler located in a confined space or an unconfined space in a building of unusually tight construction, provide outdoor air. a. Outdoor air for combustion may be provided with an optional Burnham Inlet Air Accessory Kit, Part Number 611280031 (only available and suitable for use on Beckett AFG with burner enclosure cover burner). See Section V for installation details. or b. Outdoor air may be provided with the use of two permanent openings which communicate directly or by duct with the outdoors or spaces (crawl or attic) freely communicating with the outdoors. Locate one opening within 12 inches of top of space. Locate remaining opening within 12 inches of bottom of space. Minimum dimension of air opening is 3 inches. Size each opening per following: i. Direct communication with outdoors. Minimum free area of 1 square inch per 4,000 BTU per hour input of all equipment in space. ii. Vertical ducts. Minimum free area of 1 square inch per 4,000 BTU per hour input of all equipment in space. Duct cross-sectional area shall be same as opening free area. iii. Horizontal ducts. Minimum free area of 1 square inch per 2,000 BTU per hour input of all equipment in space. Duct cross-sectional area shall be same as opening free area. Alternate method for boiler located within confined space. Use indoor air if two permanent openings communicate directly with additional space(s) of sufficient volume such that combined volume of all spaces meet criteria for unconfined space. Size each opening for minimum free area of 1 square inch per 1,000 BTU per hour input of all equipment in spaces, but not less than 100 square inches. 6. Louvers and Grilles of Ventilation Ducts a. All outside openings should be screened and louvered. Screens used should not be smaller than 1/4 inch mesh. Louvers will prevent the entrance of rain and snow. b. Free area requirements need to consider the blocking effect of louvers, grilles, or screens protecting the openings. If the free area of the louver or grille is not known, assume wood louvers have 20-25 percent free area and metal louvers and grilles have 60-75 percent free area. c. Louvers and grilles must be fixed in the open position, or interlocked with the equipment to open automatically during equipment operation. SECTION II: UNIT-PAK BOILER ASSEMBLY 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 / 100045-01 / 100021-01 ____ MST5 (Rear Section, Heater) – Part # 100566-05 / 100045-02 / 100021-01 ____ MST3 (Rear Section, Non-Heater) – Part # 100567-03 / 100045-01 / 100021-01 ____ MST4 (Rear Section, Non-Heater) – Part # 100567-04 / 100045-01 / 100021-01 ____ MST5 (Rear Section, Non-Heater) – Part # 100567-05 / 100045-02 / 100021-01 2. ___ Control Carton ____ CG450 LWCO; W/Tankless Heater - Part # 100608-01 ____ PS801 LWCO; W/Tankless Heater - Part # 100622-01 ____ #67 LWCO; W/Tankless Heater - Part # 100678-01 ____ CG450 LWCO; L/Tankless Heater - Part # 100680-01 ____ PS801 LWCO; L/Tankless Heater - Part # 100681-01 ____ #67 LWCO; L/Tankless Heater - Part # 100679-01 3. ___ Jacket Carton ____ MST3 – Part # 100609-03 ____ MST4 – Part # 100609-04 ____ MST5 – Part # 100609-05 4. ___ Part Carton ____ MST3 & 4 - Part # 100615-01 ____ MST5 - Part # 100629-01 5. ____ Insulation Wrapper ____ MST3 - Part #100614-03 ____ MST4 - Part #100614-04 ____ MST5 - Part #100614-05 6. ___ Instruction/Label Bag ____ MST (All Models) – Part # 100617-01 7. ___ Oil Burner Carton ____ Beckett MST288 – Part # 100625-01 ____ Beckett MST396 – Part # 100053-01 ____ Beckett MST513 – Part # 100054-01 ____ Beckett MST629 – Part # 100055-01 Figure 3: MegaSteam™ Unit-Pak Boiler Shipment Contents (outside container removed) 6. For manual Cast Iron Section/Burner Swing Door/ Smoke Box Assembly removal prepare one piece of 4” x 4” x 16” lg. (or two pieces of 2” x 4” x 16” lg.) and two pieces of 1” Sch. 40 black pipe to be used as handles. Suggested pipe length for each handle is 72” (3-section); 78” (4-section) and 84” (5-section). 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. 7. Place wooden block(s) 12” from rear of skid as shown. See Figure 4 “ Boiler Removal from Skid”. 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. The appropriate size plugs for above mentioned tappings, as well as rear section Surface Blowoff and front section probe type LWCO tappings, are enclosed into Part Cartons (100615-01 or 100629-01) and Control Cartons (100678-01 and 100679-01), supplied as part of MegaSteam™ Unit-Pak Boiler shipment. 8. Insert 1” Sch. 40 black pipe handles thru leg holes in front and rear section legs. Center rear pipe ends on wooden block(s). See Figure 4. 9. For best leverage, the pipe handles should extend 48” minimum beyond front section face. 10. Using the pipe handles, lift the Cast Iron Section/ Burner Swing Door/Smoke Box Assembly until adjustable legs are elevated above the skid deck boards. 11. Remove the skid from underneath the Cast Iron Section/Burner Swing Door/Smoke Box Assembly. B. Removal of Cast Iron Section/ Burner Swing Door / Smoke Box Assembly from Skid. 12. Lower pipe handles until front adjustable legs touch the floor. Place wood blocks under front legs, if required, before lowering, to provide hand clearance. WARNING 13. To lower rear of the Cast Iron Section/Burner Swing Door/Smoke Box Assembly tilt unit slightly forward by pushing on smokebox, or, lift pipes protruding thru rear legs, until wooden block(s) can be removed (see Figure 4). Slowly allow the weight of boiler to tilt backward until rear legs rest on floor. The Cast Iron Section/Burner Swing Door/Smoke Box Assembly has a substantial weight. Insure the travel path to permanent location, as well as mounting surface at boiler permanent location, are structurally sound and rated to handle the boiler weight and water content (refer to Table 1A). Otherwise, a potentially hazardous situation could result in death, serious injury and substantial property damage. 14. If wood blocks were placed under front legs, lift pipe handles; remove the blocks and lower front legs to floor. Remove pipe handles. 15. Move Cast Iron Section/Burner Swing Door/Smoke Box Assembly to permanent position by sliding or walking. 1. Move crated Cast Iron Section/Burner Swing Door/Smoke Box Assembly and part cartons on the shipping skid as close to final permanent location as possible. 2. Remove all fasteners at crate skid. Lift outside container. Examine the skid contents for damage due to shipping and handling. 3. Remove Insulation Wrapper, Control Carton, Jacket Carton, Part Carton and Oil Burner Carton from skid and set aside. CAUTION Do not drop boiler when removing from skid and moving to permanent position. C. Procedure To Open, Close and Secure Burner Swing Door. 4. Instruction/Label Bag is affixed to Section Assembly tie rod. Remove the bag and locate MegaSteam™ Boiler Installation, Operating and Service Instruction manual. READ AND UNDERSTAND ALL INSTRUCTIONS BEFORE ATTEMPTING UNIT HANDLING AND INSTALLATION. 5. The Cast Iron Section/Burner Swing Door/Smoke Box Assembly is secured to shipping skid with four lag screws. Remove the screws and discard. 10 Throughout this manual you will be instructed to open and close Burner Swing Door for various reasons. There is a proper and improper method of closing and securing the door opened for front jacket panel installation, inspection, cleaning or field service. Refer to Figures 5A, 5B, 5C and paragraphs D “Jacket Front Panel Installation”, and, F “Closing/Securing Burner Swing Door” for details. D. Jacket Front Panel Installation. In order to install front jacket panel Burner Swing Door and door mounting bracket need to be removed. As shipped, the door would open to the left side. 11 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. Lift the door off mounting bracket and set aside. e. Remove two 5/16”-18 – ¾” hex head cap screws securing door mounting bracket to front section and set aside. f. Remove door mounting bracket and set aside. g. Note/mark cap screw bosses on front section left side; locate/mark similar two bosses directly opposite on front section right side. These four front section bosses are front jacket panel and door mounting bracket attachment points. See also Figure 7 “Purpose of Tappings & Bosses”. 2. Open Jacket Carton and locate jacket front panel (has factory attached 1” fiberglass insulation). See also “Repair Parts” Section, “Jacket Assembly” illustration for part identification. 3. Open Part Carton, locate Hardware Bag, remove two 5/16”-18 x ½” Phillips pan head machine screws. 12 4. Place front jacket panel over front section attachment bosses and align jacket holes with front section boss holes. 5. Firstly, install two 5/16”-18 x ½” Phillips pan head machine screws hand tight to secure front jacket panel right side to casting 6. Secondly, insert 5/16”-18 – ¾” hex head cap screw thru door mounting bracket upper hole and upper hole on left side of front jacket panel simultaneously, and, fasten the bracket and panel to casting hand tight. 7. Thirdly, insert 5/16”-18 – ¾” hex head cap screw thru door mounting bracket lower hole and lower hole on left side of front jacket panel simultaneously, and, fasten the bracket and panel to casting hand tight. 8. Finally, tighten both sets of hardware to secure the bracket and front jacket panel. 9. Inspect fiberglass rope located on the swing door. The rope must be evenly distributed around the perimeter of the door groove and cannot bunch or overhang. Repair or replace, if the rope is damaged, or, there is a gap between the rope ends. 10. Inspect burner swing door insulation for damage and proper type. By design, for all models, cast bars on front section between the combustion chamber, and, between the left and right side 2nd and 3rd pass flueways should make an impression in door insulation to seal the chambers. Figure 5A: Partial Front View - Burner Swing Door Mounted to Boiler - Fully Closed and Secured 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. Do not close and secure door at this time, proceed to installing stainless steel flueway baffles. 12. Locate/remove four #8 x ½” shoulder sheet metal screws from Hardware Bag, then, install them into front panel flange holes. Figure 5B: Top View - Burner Swing Door Mounted to Cast Iron Block Assembly (Jacket Removed for Clarity) 13 Figure 5C: Top View - Burner Swing Door Fully Closed but Not Properly Secured or Sealed E. Flueway Baffle Installation. Flueway baffles are enclosed into Part Carton. Baffle requirements differ by boiler model, see Table 2. table 2: baffle USAGE Boiler Model Baffle Usage 2nd Pass 3rd Pass MST288 None MST396 MST513 MST629 (2) P/N 100042-01 None NOTE: Read caution statement before proceeding. CAUTION These baffles will generate higher efficiencies and lower stack temperatures. Under certain conditions, a lower gross stack temperature entering the chimney has the potential to be cooled below the dew point and create condensate on interior surfaces. Flue gas condensate is corrosive, which requires special consideration and must be addressed immediately. DO NOT install baffles until you have read Section V, "Venting" completely. 1.To install flueway baffles, provided in miscellaneous part cartons, as follows, refer to Figure 6 and Table 2: 14 • 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. Slide baffle in flueway until position tab touches fins on left side of 2nd pass flueway. F. Closing / Securing Burner Swing Door. 1. To close and secure Burner Swing Door: a. From fully open position, rotate the door to the closed position. b. Lift door upward into the build-in cast ramp/door rest (protruding from the bottom of the front section casting – see Figure 5A). c. Use one hand to apply pressure directly to the door to hold it in closed position while reinstalling earlier removed door-latching hardware (3/8”-16 x 1-3/4” tap bolt and 5/16” washer). Prior to re-installation, apply a drop of supplied Anti-seize (pouch provided in Part Carton) to both tap bolts for rust protection and to facilitate easy removal, if burner door is to be open for inspection and service. ALWAYS INSTALL RIGHT SIDE LATCHING HARDWARE FIRST, THEN INSTALL EARLIER REMOVED LEFT SIDE HINGE HARDWARE (3/8”-16 X 1-3/4” TAP BOLT AND 5/16” WASHER) SECOND. Apply additional pressure while hand tightening the hardware as far as possible and then release the pressure. 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. Locate rear panel two lower attachment bosses on rear section. See Figure 7 “Purpose of Tappings & Bosses”. 4. Thread both 5/16”-18 x 3” lg. tap studs, with short threaded end, into lower attachment bosses on rear section. 5. Install both 5/8” x 2-9/32” round spacers over tap studs. 6. Place rear jacket panel over rear section, so both tap studs clear thru lower panel holes, rear section cleanout openings clear thru matching panel cutouts and brass sample port plug clears panel matching hole. 7. Secure panel bottom to studs with acorn nuts hand tight. Figure 6: Flueway Baffle 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. ALWAYS START WITH RIGHT SIDE TAP BOLT FIRST. Use an alternating tightening method from right side tap bolt to left side tap bolt to tighten door equally, until sealed, without applying excessive torque. NEVER TIGHTEN LEFT SIDE TAP BOLT FIRST, OR, EITHER PIECE OF HARDWARE 100% WITHOUT USING THE ALTERNATING METHOD DESCRIBED ABOVE. See Figure 5B. e. Failure to follow the prescribed procedure could cause thread damage to casting and /or leak at the door seal. IF LEFT SIDE TAP BOLT IS TIGHTENED BEFORE RIGHT SIDE TAP BOLT, RIGHT SIDE OF THE DOOR CAN NOT BE DRAWN-IN TO PROVIDE AN AIRTIGHT SEAL, as shown in Figure 5C. Applying excessive torque will only cause thread damage. 8. Align upper panel attachment holes with smokebox upper attachment bosses and install 5/16”-18 x ½” Phillips pan head machine screws hand tight. 9. Securely tighten rear jacket panel mounting hardware. 10. Locate/remove four #8 x ½” shoulder sheet metal screws from Hardware Bag, then, install them into rear panel flange holes. H. Flue Cleanout Covers and Smokebox Collar Installation. 1. Remove two cast iron Cleanout Covers, cast iron Smokebox Collar and the tube of hi-temperature silicon adhesive sealant from Part Carton. See also “Repair Parts” Section, “Bare Boiler Assembly” illustration for part identification. 2. Check the rope gasket factory attached to the covers. Repair or replace, if the rope is damaged, or, there is a gap between the rope ends. 3. Locate/remove four 5/16”-18 – 7/8” hex head cap screws from Hardware Bag. 4. Apply a drop of supplied Anti-seize (pouch provided in Part Carton) to each of four (4) 5/16”-18 x 7/8” hex head cap screws for rust protection and to facilitate easy removal for future service. 5. Position left Cleanout Cover over rear section cleanout opening, align section boss holes with Cleanout Cover holes, install both 5/16”-18 – 7/8” hex head cap screws hand tight, then, alternately tighten them with open end or socket wrench. 15 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. Plugged (Float LWO) D ½" - 14 Water Gauge Glass (Probe LWCO) Water Gauge Glass, Pressuretrol & LWCO (Float LWCO) E 2" - 11½" Supply (Front & Rear Tappings) F ¾" - 14 Safety Valve G 1½" - 11½ Condensate Return H 1¼" - 11½ Optional Front Return J 1½" - 11½ Surface Blowoff (Plugged) K 1" - 11½ Indirect Water Heater Supply L ½" - 14 Indirect Water Heater Limit Q ¼" - 18 R ½"-14 M (4 pcs) 5/16" - 18 Jacket Front Panel, Burner Swing Door Mounting Bracket N (2 pcs) 3/8" - 16 Burner Swing Door P (10 pcs) 5/16" - 18 Jacket Rear Panel, Smoke Box Collar, Cleanout Covers Smokebox Pressure Tapping L4006 Operating Control Plugged 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. Insulation Wrapper and Burner Power Outlet Receptacle with Harness Installation. 1. Insulation Wrapper is vacuum packed/sealed in plastic bag at the factory. 2. Carefully cut the plastic bag and remove Insulation Wrapper. The wrapper will expand upon removal. 3. Unfold Insulation Wrapper, position it over section assembly centered left to right and align two wrapper upper holes with 2" NPT pipe tappings in front and rear section top. 4. Insure wrapper fits snugly around rear section tankless heater collar/ mounting flange (if boiler is equipped with tankless heater) and trim the insulation at tankless heater cutout. Do not trim off insulation on boilers having non-heater rear section. 5. Tack Insulation Wrapper bottom ends under section assembly, between front and rear section legs. 6. Locate and remove Burner Power Outlet Receptacle with factory attached Burner Harness from Control Carton. 7. Feed Molex end of Burner Harness thru front jacket panel right side outlet receptacle cutout. Insure that the receptacle middle prong opening is facing down. Snap the receptacle into front jacket panel. Temporarily, stuff Molex end of Burner Harness between front panel insulation and insulation wrapper near boiler top. J. Side and Top Jacket Panel Installation. 1. Pick up Left Side Jacket Panel from Jacket Carton. See also “Repair Parts” Section, “Jacket Assembly” illustration for part identification. 2. Place Left Side Jacket Panel over four #8 x ½” shoulder sheet metal screws, earlier installed at Front and Rear Jacket Panel side flanges, so teardrop cutouts in the side panel inside flanges engage all four screws simultaneously. 3. Slide the panel downwards to lock all screws securely. 4. Pick up Right Side Jacket Panel from Jacket Carton. See also “Repair Parts” Section, “Jacket Assembly” illustration for part identification. 5. Pick up Molex end of Burner Harness stuffed between front panel insulation and insulation wrapper and feed it thru Right Side Jacket Panel front cutout, letting the harness connector to hang over the cutout edge temporarily. 6. Place Right Side Jacket Panel, clearing rear section tankless heater collar/ mounting flange, over four #8 x ½” shoulder sheet metal screws, previously installed at Front and Rear Jacket Panel side flanges, so teardrop cutouts in the side panel inside flanges engage all four screws simultaneously. 7. Slide the panel downwards to lock all screws securely. 8. Pick up Top Jacket Panel from Jacket Carton. 9. Place the panel between side panels upper inside flanges and slide it forward, until top panel front flange U-bend locks over front panel top flange, and, top panel rear flange is positioned over rear jacket panel. 10. Locate/remove two #8 x ½” sheet metal screws from Hardware Bag. 11. Install both screws into top panel rear flange to secure the top panel to rear jacket panel. K. External Electrical Enclosure Mounting. 1. Remove two #8 x ½” shoulder sheet metal screws and one #8 x ½” sheet metal screw from Hardware Bag. 2. Install both #8 x ½” shoulder sheet metal screws into Right Side Jacket Panel, at two upper corners of the panel front cutout. 3. Locate and remove External Electrical Enclosure assembly from Control Carton. 4. Remove the enclosure cover and set aside. 5. Pick Molex connector end of Burner Harness and feed it inside the enclosure, thru bushed hole at enclosure lower left corner, next to transformer/ relay. 6. Place the enclosure over installed shoulder sheet metal screws, so teardrop cutouts in the enclosure base engage both screws simultaneously, then, slide the enclosure downwards to lock it in place. 7. Install #8 x ½” sheet metal screw thru enclosure base lower hole, located to the right of transformer/ relay, into right side panel to secure the enclosure. 8. Plug-in burner harness Molex connector into dedicated burner harness receptacle inside the enclosure (lower left off transformer/relay). See “ Control Plug-In Diagram” label attached to inside of the enclosure cover for details. 9. Do not install the enclosure cover yet; proceed to control installation. 17 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. Do not tighten the syphon by holding the limit case; apply a wrench to the brass hex below the case. 5. Thread ¼" NPT x 4" lg. syphon-threaded long end into pressure limit tapping on front section. See Figure 8 "Pressure Limit Installation. 6. L404F pressure limit does not require leveling. The pressure limit final orientation must be parallel to boiler front, having the harness on the right side. 7. Pick-up the pressure limit harness Molex end and feed it into the enclosure, thru top flange rear left 7/8” hole; then, snap-in harness BX connector into the hole, and, plug Molex connector into dedicated pressure limit receptacle inside the enclosure (upper left off transformer/relay). See “ Control Plug-In Diagram” label attached to inside of the enclosure cover for details. 2. Install the probe into the appropriate front section tapping. See Figure 7 “Purpose of Tappings & Bosses”. 3. Slip LWCO with factory attached harness over the probe and clamp in place. Note that CG450 LWCO will be positioned right side up, with diagnostic LED(s) on the top flange, while PS801 LWCO will be positioned upside down, with diagnostic LED(s) on the bottom flange. Connect the wire(s) between the probe and control per manufacturer’s instructions. 4. Pick-up the LWCO harness Molex end and feed it into the enclosure, thru external electrical enclosure top flange front left 7/8” hole; then, snap-in harness BX connector into the hole, and, plug-in Molex connector into dedicated LWCO receptacle inside the enclosure (middle left off transformer/relay). See “ Control Plug-In Diagram” label attached to inside of the enclosure cover for details. N. Pressure Gauge and Gauge Glass Installation. 1. Remove the 6” water gauge glass set from Part Carton. 2. Install the gauge glass using the two ½” NPT tappings to the right of the probe LWCO. See Figure 7 “Purpose of Tappings & Bosses”. 3. Thread the pressure gauge into 1/4” NPT tapping of the front section. See Figure 7 “Purpose of Tappings & Bosses”. Tighten with wrench applied to the square shank of the gauge. CAUTION Do not apply pressure to gauge case, as this may result in inaccurate readings. O. Float LWCO (McDonnell-Miller #67), AND Gauge Glass Installation. 1. Pre-assemble float-type LWCO per Figure 9 "FloatType LWCO and Gauge Glass Installation". 2. Install two ½” NPT x 2½" long Sch 40 brass nipples, supplied loose inside Control Carton (disregard two ½" NPT x 1½" long brass nipples provided with #67 LWCO package) and ½" NPT brass unions into upper and lower front section tappings. See Table 3 "Purpose of Tappings & Bosses" and Figure 7. Figure 8: Pressure Limit Installation M. Probe LWCO (Hydrolevel CG450, or, McDonnell-Miller PS801-120) Installation. 1. Remove either Hydrolevel CG450 LWCO with factory attached harness and Hydrolevel probe #EL1214, or, McDonnell-Miller PS801-120 with factory attached harness and #153875 probe from Control Carton. 18 3. Install water gauge glass on low water cut-off assembly tee fittings. 4. Do not remove ¼” NPT plug factory installed on top of #67 LWCO. 5. Insure that 3/8" NPT plug (provided within #67 LWCO package) is installed at bottom of #67 LWCO. 6. Remove #67 LWCO J-box cover. 19 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. Pick-up the LWCO harness Molex end and feed it into the enclosure, thru external electrical enclosure top flange front left 7/8” hole; then, snap-in harness BX connector into the hole, and, plug-in Molex connector into dedicated LWCO receptacle inside the enclosure (middle left off transformer/relay). See “ Control Plug-In Diagram” label attached to inside of the enclosure cover for details. 10.Pick-up the pressure limit harness Molex end and feed it into the enclosure, thru External Electrical Enclosure top flange rear left 7/8” hole; then, snap-in harness BX connector into the hole, and, plug-in Molex connector into dedicated pressure limit receptacle inside the enclosure (upper left off transformer/relay). See “ Control Plug-In Diagram” label attached to inside of the enclosure cover for details. P. Aquastat Controller Installation (Boilers with Tankless Heater only). 1. On boilers with tankless heater, install the L4006A aquastat controller well (found in Part Carton) into ½” NPT tapping in tankless heater plate. 2. Remove the L4006A aquastat controller with factory attached harness from Control Carton. 3. Slip the bulb of the aquastat controller into the well and secure the controller in place with the set screw. WARNING Aquastat bulb must be fully inserted into the well. 4. Feed the L4006A aquastat controller harness end thru external electrical enclosure top flange middle right bushed hole. See “ Control Plug-In Diagram” label attached to inside of the enclosure cover for details. 5. See Figures 18, 19 and 20 (whichever applicable) for tankless heater aquastat connection details. 6. Using needle nose pliers form hook on harness each stripped end and wrap hooks around screws under terminals "R" and "G" of the R8285C TransformerRelay; then, tighten screws securely. Q. Safety Valve and Drain Valve Installation. 1. Remove safety valve and related piping (3/4” NPT x 3” lg. black nipple, 3/4” NPT x 8” lg. black 20 nipple, ¾” NPT 90° black elbow and ¾” NPT black coupling) from Part Carton. 2. Thread 3/4" NPT x 3” lg. black nipple into rear section safety valve tapping, install ¾” NPT 90° black elbow facing upward, then, thread 3/4" NPT x 8” lg. black nipple into the elbow, and, install ¾” NPT black coupling onto nipple end. 3. Thread safety valve into the ¾” NPT black coupling. Pipe the safety valve discharge as shown in Figure 11 “ Recommended Boiler Piping For Gravity Return Steam Boiler” shown in Section III of this manual. Installation of the safety valve must be consistent with ANSI/ASME Boiler and Pressure Vessel Code, Section IV. WARNING Safety valve discharge piping must be piped near floor to eliminate potential of severe burns. Do not pipe in any area where freezing could occur. Do not install any shut-off valves, plugs or caps. 4. Remove 1-1/2" NPT x 5” lg. black nipple, 1-1/2” x 1-1/2” x ¾” NPT black tee and drain valve from Part Carton. NOTICE Lower rear section Tapping "H" is used for standard condensate return on steam boilers. 5. Thread 1-1/2" NPT x 5” lg. black nipple into lower rear section tapping, then, install 1-1/2” x 1-1/2” x ¾” NPT black tee onto nipple end. Black tee side outlet may be oriented to either left, or, right side. 6. Install the drain valve into black tee ¾” NPT side outlet. R. Oil Burner Installation. 1. Install oil burner, refer to Figure 10. a. Open burner carton and remove contents. b. Check oil nozzle in burner for size, angle and type, inspect electrode settings, check head setting, check air band and air shutter settings, refer to Table 8 at rear of this manual. c. Place oil burner gasket on burner and align holes. CAUTION Do not install burner without gasket. d. Remove three (3) 5/16-18 x 3/4 lg. cap screw from burner swing door used for mounting burner. e. Thread (1) 5/16-18 x 3/4 lg. cap screw, approximately three (3) full turns, into tapping located at 12:00 o'clock on burner swing door. 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. Figure 10: Oil Burner Installation 21 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. 2. Repair any leaks in the system. 3. Install accurate water meter on the fresh water supply to the boiler. 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. Assure that all system radiators, piping and vents are absolutely leak tight. a. When a steam boiler is installed in an existing system, ALL air vents should be replaced at the same time. This assures that the new boiler will not be compromised by existing system leaks. B. Connect system supply and return piping to boiler. See Figure 11 for piping details. Also consult I=B=R Installation and Piping Guides. CAUTION Maintain minimum ½ inch clearance from hot water piping to combustible materials. b. If the system contains hidden supply or return piping (hidden behind walls, buried in concrete, etc.) pressure test this piping to assure there are no leaks. NOTICE Do not use softened water in steam boilers. Accelerated boiler corrosion will result. Tie in fresh water supply to the boiler upstream of a water softener. Oxygen contamination of boiler water will cause corrosion of iron and steel boiler components, and can lead to boiler failure. Burnham's Standard Warranty does not cover problems caused by oxygen contamination of boiler water or scale (lime) build-up caused by frequent addition of water. Before using copper for steam piping, consider the following characteristics of copper piping: 1) high coefficient of thermal expansion can induce mechanical stresses and cause expansion/ contraction noises if not accounted for in the piping system design and installation, 2) high heat transfer rate (heat loss) of uninsulated copper piping must be included in the normal piping and pickup factors used to size the boiler, 3) soldering or brazing pastes and fluxes that end up in the system can cause poor heat transfer, surging, an unsteady water line and wet steam if not thoroughly removed during the boil out procedure and, 4) galvanic corrosion of the adjoining metal may occur due to dissimilar metals in certain water chemistries if dielectric unions are not used. 22 23 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. THE FOLLOWING GUIDELINES SHOULD BE FOLLOWED WHEN PIPING THE TANKLESS HEATER: 1. FLOW REGULATION — If flow through the heater is greater than its rating, the supply of adequate hot water may not be able to keep up with the demand. For this reason a flow regulator matching the heater rating should be installed in the cold water line to the heater. The flow regulator should preferably be located below the inlet to the heater and a minimum of 3’ away from the inlet so that the regulator is not subjected to excess temperatures that may occur during “off” periods when it is possible for heat to be conducted back through the supply line. The flow regulator also limits the flow of supply water regardless of inlet pressure variations in the range of 20 to 125 psi. 2. TEMPERING OF HOT WATER — Installation of an automatic mixing valve will lengthen the delivery of the available hot water by mixing some cold water with the hot. This prevents the possibility of scalding hot water at the fixtures. In addition, savings of hot water will be achieved since the user will not waste as much hot water while seeking a water temperature. Higher temperature hot water required by dishwashers and automatic washers is possible by piping the hot water from the heater prior to entering the mixing valve. The mixing valve should be “trapped” by installing it below the cold water inlet to heater to prevent lime formation in the valve. Refer to Figure 12. 3. FLUSHING OF HEATER — All water contains some sediment which settles on the inside of the coil. Consequently, the heater should be periodically back washed. This is accomplished by installing hose bibs as illustrated and allowing water at city pressure to run into hose bib A, through the heater, and out hose bib B until the discharge is clear. The tees in which the hose bibs are located should be the same size as heater connections to minimize pressure drop. 4. HARD WATER — A water analysis is necessary to determine the hardness of your potable water. This is applicable to some city water and particularly to well water. An appropriate water softener should be installed based on the analysis and dealer’s recommendation. This is not only beneficial to the tankless heater but to piping and fixtures plus the many other benefits derived from soft water. NOTICE During summertime operation, the normal water line on a steam boiler can be raised 1", from 28-7/8" to 29-7/8" (see Figure 1) for improved tankless heater performance on steam boilers. Use street elbow fittings in tankless in and out connections to assure adequate clearance of piping. CAUTION Use of hard water with a tankless coil will, over a short period of time, reduce the output of the coil and reduce the useful life of the coil. 24 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 31.0 25 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. Loose Mortar – Loose mortar could be an indication of a prior history of condensing flue gases upon the inside walls of the chimney. Colder climates are more susceptible to this condition. Under no circumstances shall a chimney of this condition be used until it meets the requirements of NFPA 211. b. Unlined Chimney – Under no circumstances shall a chimney constructed of brick only be used. Only approved clay liners or listed chimney lining systems shall be used as specified in NFPA 31. c. Abandoned Openings – Openings through the chimney wall that are no longer used shall be sealed in accordance to NFPA 211. Often abandoned openings are improperly sealed and usually covered by a gypsum wall covering. d. Clean Chimney – Chimney shall be free of all loose debris. 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. In addition, consult with a professional knowledgeable on the requirements of NFPA 31 – Standard for the Installation of Oil-Burning Equipment and NFPA 211 - Standard for Chimneys, Fireplaces, Vents, and Solid Fuel-Burning Appliances for installations in the United States 2. The safe venting of oil fired boilers is dependent on many factors. Some of these factors include: a. sufficient draft during the entire heating season to allow for the safe discharge of combustion byproducts and; b. suitable corrosion protection in the event of condensing flue gases. Only a trained and qualified contractor may install this product. 3. The MegaSteam™ can be vented into a fireclay tile-lined masonry chimney that meets requirements outlined in Paragraph 4 below. It can also be vented into a chimney constructed from type L vent or a factory built chimney that complies with the type HT requirements of UL 103. The chimney and vent pipe shall have a sufficient draft at all times, to assure safe proper operation of the boiler. See Figure 14 for recommended installation. WARNING Do not de-rate the appliance. Failure to fire the unit at it's designed input may cause excessive condensation upon the interior walls of the chimney. In addition, the lower input may not create enough draft to adequately evacuate the by-products of combustion. 4. Chimney Inspection – Prior to the installation of any new or replacement fuel burning equipment the chimney shall be inspected by a qualified installer. The chimney shall be inspected for integrity as well as for proper draft and condensate control. Some jurisdictions require the use of a liner when changing fuel types. Some jurisdictions require the use of a liner even when the same fuel is used. At a minimum, the chimney shall be examined by a qualified person in accordance with the requirements of Chapter 11 of NFPA 211, Standard for Chimneys, Fireplaces, Vents, and Solid FuelBurning Appliances. 5. Draft Regulator – the draft regulator supplied with the boiler must be used with this appliance. No other draft regulator shall be used. Refer to Figures 14 and 15. B. Chimney Connector 1. A chimney connector (vent pipe) is used to connect the boiler to the base of the chimney. The chimney connector should be kept as short as possible. The horizontal length of the chimney connector shall not be greater than 10 feet. NOTE: Secure chimney connector to cast iron smokebox collar with three (3) #10 x ½" self drilling hex head TEK screws provided in appropriate Parts Carton. Locate screws around perimeter of connector as shown in Figure 14 and approximately ½" in from edge. Use drill with 5/16" hex bit to drive screws through connector and smokebox collar. DANGER The chimney and connector shall be inspected annually for signs of debris and corrosion. Loose mortar at the base of the chimney may be a sign of condensate damage to the chimney. A chimney professional shall be contacted immediately to examine the damage and recommend a solution. Long term operation while in this condition may cause a venting failure and force flue gases into the living space. If the chimney is to be relined use the recommendations in NFPA 31, Appendix E. 27 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. The discoloration may be a sign of chimney damage and must be remedied immediately. C. Draft 1. The natural draft generated through a chimney is dependent on several factors including, chimney height, temperature of flue gases, cross section area of chimney, chimney wall insulation value, dilution air and total volume of flue gases, to name a few. Make sure that the boiler has been running for at least 5 minutes before measuring the draft. 2. Minimum Draft at Breech (Canopy) – The draft induced by a chimney must create at least a pressure of 0 (zero) inches water column (“ w.c.) at the pressure tapping on the canopy mounted on rear of boiler (see Figure 16). The pressure at the canopy cannot be positive since this could create a condition that allows flue gas by-products to escape from the draft regulator. A negative pressure reading up to -.03 inches water column is acceptable for proper operation. (See Table 8, Burner Specifications at the rear of this manual for more details) 3. Minimum Overfire Pressure – The overfire pressure is another piece of information that is often measured, however this should be done for observation purposes only! The breech pressure must be used to qualify the draft condition. See Table 8 for more details as a guide. Actual draft and temperature measurements may be different then those values in the table. 2. NFPA 31 has information to help the installer make an appropriate choice of venting materials. In some cases a chimney may have to be lined to create sufficient draft. In other cases, the chimney may have to be lined to prevent the corrosion of a masonry chimney. Consult with a chimney specialist knowledgeable on the requirements for chimney requirements in your area. CAUTION Any doubt on the condition of a chimney or it's ability to prevent the generation and accumulation of flue gas condensate, must be relined according to NFPA31. CAUTION Use the chimney venting tables as a guide. It is highly recommended that any borderline application should result in the relining of the chimney with a suitable liner that creates sufficient draft and to protect against corrosion caused by flue gas condensate. 3. Baffles – The efficiency of the boiler is based on the insertion of flue baffles supplied with your product. Under no circumstances are other baffles to be used on this product. The baffles are installed in the 2nd pass (two inner flueways) on the MST396, MST513 and MST629 Refer to Section II, Item E, Paragraph 1 for baffle installation. If there is any doubt on the application of this boiler on the intended chimney, consult with your local code officials. At a minimum, remove the baffles to increase the stack temperature. See Table 8 for temperature differential (∆T) with baffles IN and OUT. In addition, the lower the CO2 level the higher the stack temperature. D. Stack Temperature 1. The temperature of the flue gases has a significant effect on the amount of draft created in a vertical chimney as well as the propensity to create condensate. The higher the stack temperature, the greater the amount of draft that can be generated. A lower stack temperature not only reduces the amount of draft that can be created but it also increases the possibility that the flue gases could condense in the chimney connector or stack. Figure 16: Smokebox Pressure Tapping for Checking Draft at Breech 29 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. OPTIONAL AIR INTAKE PIPING INSTALLATION - All air for combustion can be supplied directly to the burner from outdoors providing that the criteria for chimney, vent connector and minimum stack temperature outlined in this section can be maintained. (ONLY AVAILABLE WITH BECKETT BURNER). See Figure 17. WARNING Using outdoor air in the middle of winter may result in lower stack temperatures and chimney degradation. Any signs of condensate seepage or discoloration at the base of chimney must be remedied immediately per the details outlined in this section. Do not reduce size of air intake pipe. Read, understand and follow combustion air instruction restrictions contained in the PreInstallation Section of this manual. 1. General a. Use 4" dia., single wall galvanized metal pipe and fittings available at most heating distributors for air intake piping. Maximum allowable air intake length is 50 equivalent feet. Each elbow is equal to 6 equivalent feet. WARNING Do not exceed maximum allowable air intake length. b. Start at burner. Work toward air intake terminal. c. Maintain minimum of 1/4 inch per foot slope in horizontal run to air intake terminal. Slope down toward air intake terminal. d. Seal all joints gas-tight, using silicone caulk or self-adhesive aluminum tape. 2. After determining location, cut a hole in the wall to accept 4 inch air intake pipe. See Figure 15. 3. Remove the metal knockout in right side of burner cover. Install Burnham Inlet Air Accessory Kit, Part Number 611280031. 4. Mount the Vacuum Relief Valve Tee Assembly (P/N 8116268 included with Kit) or 90° elbow into the burner inlet ring. See Figure 16. a. Secure with at least three (3) sheet metal screws evenly spaced around the burner inlet ring. b. Assemble the vacuum relief valve balance weight onto the gate. Refer to the vacuum relief valve manufacturer's instructions. Figure 17: Optional Air Intake Piping Installation - Only Available with Beckett Burner 30 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. WARNING Do not locate air intake where petroleum distillates, CFC's, detergents, volatile vapors or any other chemicals are present. Severe boiler corrosion and failure will result. 6. Install air intake terminal. See Figure 17. NOTICE Intake terminal must be at least 12 inches above grade plus snow accumulation. 31 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. Each boiler must be protected with a properly sized fused disconnect. Never jump out or make inoperative any safety or operating controls. 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/ NFPA 70. 2. Refer to National Electric Code or Local Electric Codes for proper size and type of wire required. Follow Code. 3. A separate electrical circuit must be run from the main electrical service with an over-current device/disconnect in the circuit. A service switch is recommended and may be required by some local jurisdictions. 4. Use anti-short bushings on all wiring passing through boiler jacket, junction boxes and/or control boxes. 5. Use armored cable (BX) over all exposed line voltage wiring. 32 6. If an Alliance™ indirect water heater is used, use priority zoning. Do not use priority zoning for Hydro-Air Systems. 7. Wiring should conform to Figure 18. B. Install A room thermostat on an inside wall about four feet above floor. Never install thermostat on an outside wall or where it will be influenced by drafts, hot or cold water pipes, lighting fixtures, television, rays of the sun or near a fireplace. Keep large furniture away from thermostat so there will be free movement of room air around this control. Heat Anticipator in Thermostat should be set to match the requirements of the control to which it is connected. See Figure 20 for desired system and heat anticipator setting. If system tends to overheat above the thermostat's temperature setting, reduce heat anticipator setting by .1 or .2 amps. If system tends to short cycle without reaching desired room temperature, increase heat anticipator setting by .1 or .2 amps. 33 Figure 18: Wiring Diagram, Steam, Hydrolevel CG450 Probe LWCO 34 Figure 19: Wiring Diagram, Steam, McDonnell & Miller PS-801 Probe LWCO 35 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. When the pressure limit control restores the circuit on a drop in pressure, the burner will start if the thermostat is still calling for heat. The probe low water cut-off will shut down the burner after a 10-15 second delay, if the water level in the boiler drops below the probe level. The Hydrolevel CG450 low water cut-off will shut down the burner for 90 seconds every 10 minutes of firing time to allow water level to stabilize. If the water level is too low the burner will not be allowed to restart. The probe low water cut-off will reset and restart the burner with a call for heat a few seconds after the water is returned to its normal level. On burner start, if the cad cell does not see flame within approximately 15 seconds, primary control will shut burner down and enter into a recycle mode, after 60 seconds burner will restart and repeat trial for ignition. If after three (3) trials for ignition, flame is not detected, control will enter into restricted mode and must be reset manually before burner can be restarted. When there is no demand for heat, the operating control will maintain the boiler water temperature at the selected setting for proper operation of the domestic water heater, if equipped with optional tankless heater. BOILER SEQUENCE OF OPERATION WITH PROBE LWCO (See Figure 19) 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. When the pressure limit control restores the circuit on a drop in pressure, the burner will start if the thermostat is still calling for heat. The probe low water cut-off will shut down the burner after a 10-15 second delay, if the water level in the boiler drops below the probe level. The probe low water cut-off will reset and restart the burner with a call for heat a few seconds after the water is returned to its normal level. On burner start, if the cad cell does not see flame within approximately 15 seconds, primary control will shut burner down and enter into a recycle mode, after 60 seconds burner will restart and repeat trial ignition. If after three (3) trials for ignition, flame is not detected, control will enter into restricted mode and must be reset manually before burner can be restarted. When there is no demand for heat, the operating control will maintain the boiler water temperature at the selected setting for proper operation of the domestic water heater, if equipped with optional tankless heater. McDonnell & Miller PS-801 Terminals May be Lettered or Numbered as Follows: Wire Color Numbered Lettered Terminals Terminals RD 5 B BK 1 H WH 2 N Jumper 1-3 H-C BOILER SEQUENCE OF OPERATION WITH FLOAT LWCO (See Figure 20) 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. When the pressure limit control restores the circuit on a drop in pressure, the burner will start if the thermostat is still calling for heat. The low water cut-off will shut down the burner if the water level in the boiler drops too low. The control resets and restarts the burner with a call for heat a few seconds after the water is returned to its normal level. On burner start, if the cad cell does not see flame within approximately 15 seconds, primary control will shut burner down and enter into a recycle mode, after 60 seconds burner will restart and repeat trial for ignition. If after three (3) trials for ignition, flame is not detected, control will enter into restricted mode and must be reset manually before burner can be restarted. When there is no demand for heat, the operating control will maintain the boiler water temperature at the selected setting for proper operation of the domestic water heater, if equipped with optional tankless heater. 36 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. NOTICE Some jurisdictions require the use of a fusible shutoff valve at the tank and/or the burner. In addition, some jurisdictions require the use of a fusible electrical interlock with the burner circuit. Check your local Codes for special requirements. B. Single Pipe Oil Lines Do not use compression fittings. Oil piping must be absolutely airtight or leaks or loss of prime may result. Bleed line and fuel unit completely. Refer to your local jurisdictions regarding any special considerations for fuel supply requirements. In addition, refer to NFPA 31, Standard for the installation of Oil-Burning Equipment. 4. Use of a high efficiency micron filter (Garber or equivalent) in addition to a conventional filter is highly recommended. 5. Piping used to connect the oil burner to the oil supply tank shall not be smaller than 3/8" iron pipe or 3/8" OD copper tubing. Copper tubing shall have a .032" minimum wall thickness. 1. Standard burners are provided with single-stage 3450 rpm fuel units with the bypass plug removed for single-pipe installations. 2. The single-stage fuel unit may be installed singlepipe with gravity feed or lift. Maximum allowable lift is 8 feet. See Figure 21. 3. Fuel Oil Line Deaerator – On many occasions a leaky oil delivery line can introduce air into the fuel oil supply system. This often creates a rough starting condition and can create a burner lockout state. In addition to fixing the leak, a fuel line deaerator can be installed to eliminate air. The single line from the fuel tank is connected to the deaerator. The burner pump must be connected to the deaerator as a two pipe system. Follow the oil pump manufacturer’s recommendations for conversion to a two pipe system. Figure 21: Single Pipe Oil Line 37 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. Table 5: Two-Stage Units (3450 RPM) Two Pipe Systems Lift "H" (See Fig. 22) Maximum Length of Tubing "H" + "R" (See Figure 22) 3/8" OD Tubing (3 GPH) 1/2" OD Tubing (3 GPH) 0' 93' 100' 2' 85' 100' 4' 77' 100' 6' 69' 100' 8' 60' 100' 10' 52' 100' 12' 44' 100' 14' 36' 100' 16' 27' 100' 18' --- 76' 3. Under no circumstances is a manual shutoff valve to be located on the return line of a two pipe system. Accidental closure of the return line will rupture the oil pump seals. Table 6: Single-Stage Units (3450 RPM) Two Pipe Systems Lift "H" (See Fig. 21) 3/8" OD Tubing (3 GPH) 1/2" OD Tubing (3 GPH) 0' 84' 100' 1' 78' 100' 2' 73' 100' 3' 68' 100' 4' 63' 100' 5' 57' 100' 6' 52' 100' 7' 47' 100' 8' 42' 100' 9' 36' 100' 10' 31' 100' 11' 26' 100' 12' 21' 83' 13' --- 62' 14' --- 41' Figure 22: Two Pipe Oil Lines 38 Maximum Length of Tubing "H" + "R" (See Figure 22) 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. A. ALWAYS INSPECT INSTALLATION BEFORE STARTING BURNER. 1. SET ROOM THERMOSTAT about 10° above room temperature. 1. Verify that the venting, water piping, oil piping, and electrical system are installed properly. Refer to Installation Instructions contained in this manual. 2. PRESS RED RESET BUTTON on front of burner cover, hold for one (1) second and release to reset primary control. 2. Confirm all electrical, water and oil supplies are turned off at the source and that the vent is clear from obstructions. 3. On STEAM BOILERS: a. With an L404F1367 - set cut-out pressure (MAIN scale) on the pressure limit for (1) PSI and differential pressure (DIFF.) for .5 PSI. These pressures may be varied to suit individual requirements of the system. WARNING Completely read, understand and follow all instructions in this manual before attempting start up. B. FILL HEATING SYSTEM WITH WATER. NOTICE It is important, especially in a steam system, to properly remove the oil and dirt from the system. Failure to clean the system can result in erratic water lines and surging. CLEAN HEATING SYSTEM if boiler water or condensate return water is dirty or if erratic water lines or surging exist after a few days of boiler operation. Refer to Maintenance and Service Instructions Section of this manual for proper cleaning instructions for steam and water boilers. 1. STEAM BOILERS — Fill boiler to normal water line. Refer to Figure No. 1. WARNING The maximum operating pressure of this boiler is posted on the ASME Data Label located on the top of the boiler. Never exceed this pressure. Do not plug relief valve. C. CHECK CONTROLS, WIRING AND BURNER to be sure that all connections are tight and burner is rigid, that all electrical connections have been completed and fuses installed, and that oil tank is filled and oil lines have been tested. D. SET CONTROLS with burner service switch turned “OFF”. 4. On STEAM BOILERS WITH TANKLESS DOMESTIC WATER HEATERS, set boiler water temperature dial on L4006 operating control at 190°F (max.). Set differential at 10°. E. ADJUST OIL BURNER BEFORE STARTING. 1. CHECK BURNER AIR BAND, AIR SHUTTER AND HEAD SETTING (if applicable), readjust if necessary, see Table 8 at rear of manual. 2. OPEN ALL OIL LINE VALVES. 3. Attach a plastic hose to fuel pump vent fitting and provide a pan to catch the oil. 4. OPEN FLAME OBSERVATION PORT COVER on burner swing door. F. START OIL BURNER. 1. Open vent fitting on fuel pump. 2. PRESS RED RESET BUTTON on front of burner cover, hold for one (1) second and release to reset primary control. 3. TURN ‘ON’ BURNER service switch and allow burner to run until oil flows from vent fitting in a SOLID stream without air bubbles for approximately 10 seconds. NOTE: For Primary Control "Pump Priming Cycle" details, see Paragraph I, No. 2., Step a., Item ii . 4. Close vent fitting and burner flame should start immediately after prepurge is completed. Prepurge prevents burner flame until 15 seconds has elapsed after initial power is applied to burner. During prepurge the motor and igniter will operate but the oil valve will remain closed. Refer to Oil Primary Control Instructions for more details. 39 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. To check the cut-off pressure, deadhead a reliable pressure gauge onto the copper connector tube attached to the nozzle port. Run the burner for a short period of time. Shut the burner off. The pressure should drop and hold. d. Remove the gauge and install bleeder port and/or reconnect the nozzle port line. See Table 8 (at rear of this manual) for details regarding the overfire pressure when baffles are both installed and removed. 3. READJUST THE HEAD SETTING only if necessary. a. MST288 & MST396: Beckett MB(L1) Head burner has a fixed head which is non-adjustable. b. MST513 & MST629: Beckett MD(V1) (variable) Head burners have the ability to control air by moving the head. It might be necessary to move the head forward or back one position at a time to optimize the smoke and CO2 readings. See Figure 24. 4. TURN “OFF” BURNER and remove pressure gauge. Install gauge port/bleeder plug and tighten. Start burner again. WARNING Do not loosen or remove any oil line fittings while burner is operating. 5. FLAME FAILURE The MegaSteam™ boiler controls operate the burner automatically. If for unknown reasons the burner ceases to fire and the reset button on the primary control has tripped, the burner has experienced ignition failure. WARNING Figure 23: Adjusting Fuel Pump Pressure G. ADJUST OIL BURNER WHILE OPERATING. (flame present) 1. ADJUST DRAFT REGULATOR for a draft of zero inches (water gauge) in the canopy (see Figure 18) after chimney has reached operating temperature and while burner is running. (At least five minutes) See Table 8 at rear of manual for details. 2. READJUST THE AIR BAND on burner for a light orange colored flame while the draft in the canopy is zero inches water column ("w.c.). Use a smoke tester and adjust air for minimum smoke (not to exceed #1) with a minimum of excess air. Make final check using suitable instrumentation to obtain a CO2 of 11.5 to 12.5% with draft of zero inches water column ("w.c.) (water gauge) in canopy. These settings will assure a safe and efficient operating condition. If the flame appears stringy instead of a solid fire, try another nozzle of the same type. Flame should be solid and compact. After all adjustments are made recheck for a draft of zero inches water column ("w.c.) in the canopy. Replace plug at completion. 40 Do not attempt to start the burner when excess oil has accumulated, when the unit is full of vapor, or when the combustion chamber is very hot. H. CHECK FOR CLEAN CUT OFF OF BURNER. 1. AIR IN THE OIL LINE between fuel unit and nozzle will compress when burner is on and will expand when burner stops, causing oil to squirt from nozzle at low pressure as the burner slows down and causing nozzle to drip after burner stops. Usually, cycling the burner operation about 5 to 10 times will eliminate air from the oil line. 2. IF NOZZLE CONTINUES TO DRIP, repeat Paragraph H, No. 1. If this does not stop the dripping, remove cut-off valve and seat, and wipe both with a clean cloth until clean, then replace and readjust oil pressure. If dripping or after burn persist replace fuel pump. I. TEST CONTROLS. 1. Check thermostat operation. Raise and lower thermostat setting as required to start and stop burner. 41 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. The indicator light provides diagnostic information for lockout, recycling and patented cad cell status. There is a manual reset button to exit the Lockout Mode and enter the Idle Mode (see Figure 25). • Flashing at 1 Hz (½ second on, ½ second • Flashing at ¼ Hz (2 seconds on, 2 seconds • On: cad cell is sensing flame. • Off: cad cell is not sensing flame. off): system is locked out or in Restricted Mode. off): control is in Recycle Mode. vii. Cad Cell Resistance Check: For proper operation it is important that the cad cell resistance is below 1600 ohms. During a normal call for heat, once the control has entered the Run Mode, press and release the reset button. Indicator light will flash 1 to 4 flashes. See Table 7 for equivalent cad cell resistance. Table 7: Cad Cell Resistance When Sensing Flame Flashes Figure 25: R7184 Terminals, LED and Reset Button ii. Pump Priming Cycle: To facilitate purging air from the oil lines and filters, the R7184 can be placed in a purge routine by pressing and releasing the reset button during the safety check, delayed valve-on, ignition or carry-over periods. iii. Limited Recycle: This feature limits the number of recycle trials (for each call for heat) to a maximum of three trials. If the flame is lost three times and does not successfully satisfy a call for heat, the R7184 locks out. iv. Limited Reset (Restricted Mode): In order to limit the accumulation of unburned oil in the combustion area, the control can only be reset three times. The reset count returns to zero each time a call for heat is successfully completed. • To reset from Restricted Mode: Press and hold the reset button for 30 seconds. When the LED flashes twice, the device has reset. v. T-T Jumper: Select models have preinstalled T-T jumper. Do not remove jumper. See Figure 25. 42 Cad Cell Resistance in ohms 1 Less than 400 2 More than 400 and less than 800 3 More than 800 and less than 1600 4 More than 1600 and less than 5000 b. Check Oil Primary Control CAUTION Due to the potential hazard of line voltage, only a trained, experienced service technician should perform the following safety checks. This control contains no field-serviceable parts. Do not attempt to take it apart. Replace entire control if operation is not as described. i. Preliminary Steps • Check wiring connections and power • Make sure power is on to the controls. • Make sure limit control is closed. • Check contacts between ignitor and the • Check the oil pump pressure. • Check the piping to the oil tank. • Check the oil nozzle, oil supply and oil supply. electrodes. filter. ii. Check Safety Features Safe Start: • Place a jumper across cad cell terminals. • Follow procedure to turn on burner. • If safety switch shuts down burner and • Close line switch to boiler. If burner starts 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 line. • Failure occurs, device enters Recycle • Device tries to restart system after • After third Recycle Mode trial, safety Mode. Indicator light flashes at ¼ Hz rate 2 seconds on, 2 seconds off). approximately 60 seconds. iv. switch locks out within safety switch timing indicated on label and control enters Restricted Mode. Indicator light flashes at 1 Hz rate (½ second on, ½ second off). Ignition and motor stop and oil valves closes. Cad Cell Check: See Figure 26. 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. and runs beyond safety switch cut-off time, cell is good. If not, install new cell. v. Power Failure Check: After Flame is established, turn the power off to the control/ burner. The burner should shut down safely. When power is restored a normal ignition sequence should be started. 3. WARNING — Check Pressure Limit Control — Jumper Thermostat Terminals. Allow burner to operate until shut-down by limit. Installation is not considered complete until this check has been made. WARNING Jumper must be removed after this check. 4. Check low water cut off control with water level at normal water line (see Figure 1). Raise thermostat setting to allow burner to operate. Open boiler drain to allow water level to drop to bottom of sight glass until burner operation is shut-down by low water cut-off. Close boiler drain and refill to normal water line. Burner should automatically restart during fill. Lower thermostat setting. Figure 26: Cad Cell Location • Perform cad cell resistance check as outlined in control feature. If resistance is below 1600 OHMS and burner runs beyond safety cut-out time, cad cell is good. 5. Check operating control on boiler equipped with tankless heaters. With burner off, draw hot water until burner starts, then turn off hot water and check burner shut-down. J. IF CONTROLS DO NOT MEET REQUIREMENTS outlined in Paragraph I., replace control and repeat checkout procedures. 43 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. AVOID Breathing Fiber Particulates and Dust Precautionary Measures: Do not remove or replace RCF parts or attempt any service or repair work involving RCF without wearing the following protective gear: 1. A National Institute for Occupational Safety and Health (NIOSH) approved respirator 2. Long sleeved, loose fitting clothing 3. Gloves 4. Eye Protection • • • • Take steps to assure adequate ventilation. Wash all exposed body areas gently with soap and water after contact. Wash work clothes separately from other laundry and rinse washing machine after use to avoid contaminating other clothes. Discard used RCF components by sealing in an airtight plastic bag. RCF and crystalline silica are not classified as hazardous wastes in the United States and Canada. First Aid Procedures: • • • • 44 If contact with eyes: Flush with water for at least 15 minutes. Seek immediate medical attention if irritation persists. If contact with skin: Wash affected area gently with soap and water. Seek immediate medical attention if irritation persists. If breathing difficulty develops: Leave the area and move to a location with clean fresh air. Seek immediate medical attention if breathing difficulties persist. Ingestion: Do not induce vomiting. Drink plenty of water. Seek immediate medical attention. 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. It is important to physically remove the probe from the boiler tapping annually and inspect that probe for accumulation of scale or sediment. Follow these steps to inspect, clean and/or replace the probe: a. Turn off electric service to the boiler. b. Drain boiler water to a level below the tapping for the probe. c. Disconnect wiring connections between the low water cut-off control and the probe. d. Remove the low water cut-off control from the probe. DANGER Assure that the boiler is at zero pressure before removing the LWCO probe. Do not rely on the pressure gauge to indicate that the boiler is at zero pressure. Open the safety valve to relieve all internal pressure prior to proceeding. Safety valve discharge piping must be piped such that the potential for burns is eliminated. e. Unscrew the probe from the boiler tapping. f. Inspect that portion of the probe that is exposed to the boiler water for a scale or sediment buildup. g. Light deposits may be removed by wiping the probe with a damp cloth. Wiping the probe with a cloth soaked in vinegar will remove more tenacious lime deposits. The most stubborn deposits may be removed from the probe by using a diluted amount, 3 parts of water to 1 part of phosphoric acid (H2PO4). CAUTION Exercise caution when handling phosphoric acid and follow the instruction label on its container. h. Clean the pipe threads of the probe to remove old, hardened pipe dope and other foreign matter. i. Apply a moderate amount of good quality pipe dope to the pipe threads on the probe, leaving the two end threads bare. Do not use PTFE (Teflon) tape. j. Screw the probe into the boiler tapping. k. Mount the low water cut-off control on the probe. l. Reconnect the control to probe wiring. m.Fill the boiler to its normal waterline. n. Add boiler water treatment compound as needed (refer to Paragraph B.). o. Restore electric service to the boiler. p. Fire burner to bring the water in the boiler to a boil to drive off free oxygen. q. WARNING — BEFORE RETURNING BOILER TO SERVICE: Follow the low water cut-off check out procedure in Section VIII, Paragraph I, No. 4. 2. FLOAT TYPE LOW WATER CUT-OFF During the heating season, if an external low water cut-off is on the boiler, the blow off valve should be opened once a month (use greater frequency where conditions warrant), to flush out the sediment chamber so the device will be free to function properly. Low water cut-offs and water feeders should be dismantled annually by qualified personnel, to the extent necessary to insure freedom from obstructions and proper functioning of the working parts. Inspect connecting lines to boiler for accumulation of mud, scale, etc., and clean as required. Examine all visible wiring for brittle or worn insulation and make sure electrical contacts are clean and that they function properly. Give special attention to solder joints on bellows and float when this type of control is used. Check float for evidence of collapse and check mercury bulb (where applicable) for mercury separation or discoloration. Do not attempt to repair mechanisms in the field. Complete replacement mechanisms, including necessary gaskets and installation instructions are available from the manufacturer. B. BOILER AND SYSTEM CLEANING INSTRUCTIONS FOR TROUBLE FREE OPERATION 1. STEAM BOILERS a. Oil, greases & sediments which accumulate in a new boiler and piping must be removed in order to prevent an unsteady water line and carry over of the water into the supply main above boiler. 45 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. Run temporary 1½” NPT pipe line from the surface blow-off connection to an open drain or some other location where hot water may be discharged safely. Do not install valve in this line. ii. Drain about 5 gallons of hot water from boiler into a container and dissolve into it an appropriate amount of recommended boil out compound. Remove safety valve & add solution to boiler water thru exposed tapping using a funnel. NOTICE Check with local authorities or consult local water treatment services for acceptable chemical cleaning compounds. iii. Start burner and operate sufficiently to boil the water without producing steam pressure. Boil for about 5 hours. Open boiler feed pipe sufficiently to permit a steady trickle of water from the surface blow-off pipe. Continue this slow boiling and trickle of overflow for several hours until the water coming from the overflow is clear. iv. Stop burner and drain boiler in a manner and to a location that hot water can be discharged with safety. v. Refill boiler to normal water line. If water in gauge glass does not appear to be clear, repeat steps (i. thru iii.) and boil out the boiler for a longer time. b. Low pressure steam boilers such as the MegaSteam™, should be maintained with appropriate water treatment compounds. Add suitable water treatment compounds as recommended by your qualified water treatment company. c. Remove temporary surface blow-off piping, plug tapping and reinstall safety valve. Boil or bring water temperature to 180°F promptly in order to drive off the dissolved gases in the fresh water. d. If unsteady water line, foaming or priming persist, install gate valve in Hartford Loop and drain valves in return main and at boiler as shown in Figure 11 and proceed as follows: i Connect hoses from drain valves to floor 46 drain. Close gate valve in Hartford Loop and open drain valve in return main. Fill boiler to normal water level, turn on oil burner and operate boiler at this water level for at least 30 minutes after the condensate begins to run hot, then turn off burner. Close all radiator valves. Remove all supply main air valves and plug the openings in supply main. ii. Draw about 5 gallons of hot water from boiler into a container and dissolve into it the appropriate amount of a recommended boilout compound. Remove safety valve from boiler and pour this solution into boiler, then reinstall safety valve. iii. Turn on oil burner and keep operating while feeding water to boiler slowly. This will raise water level in boiler slowly so that water will be boiling hot and will rise slowly into supply main and back through return main, flowing from drain hose at about 180°F. Continue until water runs clear from drain hose for at least 30 minutes. iv. Stop feeding water to boiler but continue operating oil burner until excess water in boiler flows out through supply main and water lowers (by steaming) until it reaches normal level in boiler. Turn off oil burner. Drain boiler. Open all radiator valves. Reinstall all supply main air valves. Open gate valve in Hartford Loop. v. When boiler has cooled down sufficiently (crown sheet of sections are not too hot to touch), close the drain valves at boiler and in return main and feed water slowly up to normal level in boiler. Turn on oil burner and allow boiler to steam for 10 minutes, then turn off burner. Draw off one quart of water from bottom gauge glass fitting and discard. Draw off another quart sample and if this sample is not clear, repeat the cycle of draining the boiler and return main and refilling the boiler until sample is clear. vi. If the boiler water becomes dirty again at a later date due to additional sediment loosened up in the piping, close gate valve in Hartford Loop, open drain valve in return main, turn on oil burner and allow Condensate to flow to drain until it has run clear for at least 30 minutes while feeding water to boiler so as to maintain normal water level. Turn off oil burner, drain boiler, open gate valve in Hartford Loop, then repeat Step 1 above. e. Make pH or Alkalinity Test. After boiler and system have been cleaned and refilled as previously described, test the pH of the water in the system. This can easily be done 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. Boiler is now ready to be put into service. C. EXCESSIVE MAKE-UP WATER IMPORTANT IF, DURING NORMAL OPERATION, IT IS NECESSARY TO ADD MORE WATER THAN INDICATED BELOW, CONSULT A QUALIFIED SERVICE TECHNICIAN TO CHECK YOUR SYSTEM FOR LEAKS. EXCESSIVE WATER ADDITION: (Gallons / Month) MST288: 6 MST396: 8 MST513: 9½ MST629: 11 A leaky system will increase the volume of make-up water supplied to the boiler, which can significantly shorten the life of the boiler. Entrained in make-up water are dissolved minerals, salts and oxygen. When the fresh, cool make-up water is heated in the boiler, the minerals fall out as sediment, the salts coat the inside of the boiler, and the oxygen escapes as a gas. The accumulation of sediment eventually isolates the water from contacting the cast iron. When this happens the cast iron in that area gets extremely hot and eventually cracks. The presence of free oxygen or chloride salts in the boiler corrodes the cast iron from the inside. More make-up water and higher concentrations of contaminants damage the boiler sooner. Our warranty does not cover oxygen corrosion and sedimentrelated damage. Clearly it is in everyone’s best interest to prevent this type of failure. You can do your part by ensuring that your system is leak-free. D. ATTENTION TO BOILER WHILE NOT IN OPERATION. NOTICE If boiler is not used during winter time, it must be fully drained to prevent freeze damage. 1. Spray inside surfaces with light lubricating or crankcase oil using gun with extended stem so as to reach all corners. 2. With steam boilers, at end of season add sufficient water to fill boiler to top of water column and leave it that way until fall when water should be drained again to proper level. If at this time boiler water is dirty, drain water, flush out boiler, and refill with clean water to prescribed water level. 3. Always keep the manual fuel supply valve shut off if the burner is shut down for an extended period of time. 4. To recondition the heating system in the fall season after a prolonged shut down, follow the instructions outlined in Section VIII, Paragraphs A through J. WARNING This boiler contains controls which may cause the boiler to shut down and not restart without service. If damage due to frozen pipes is a possibility, the heating system should not be left unattended in cold weather; or appropriate safeguards and alarms should be installed on the heating system to prevent damage if the boiler is inoperative. 47 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. Be sure to tighten swing door fastener completely when service is completed. 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 flexible 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 NOT necessary to remove the vent connector from the smoke box to clean boiler. If necessary, remove the vent connector if there is evidence of heavy soot accumulation in the boiler or to inspect base of chimney for condensate or accumulation of debris. 3. Remove the baffles (if installed) from the flue passages. There is a pair of baffles in each boiler. The baffles are installed in the 2nd pass (two inner flue ways) on the MST396, MST513 and MST629. 4. Clean the 3rd Pass – Insert a 2" dia. x 42" long wire or fiber bristle brush into each of the two 3rd passes. Using long strokes push the brush all the way through the boiler until the brush has exited the smoke box opening. Pull the brush all the way forward until it has exited the front of the boiler. Continue this operation for the entire height of the flue way until clean. Repeat the operation for the other 3rd pass flue way. 5. Clean the 2nd Pass - Insert a 2" dia. x 42" long wire or fiber bristle brush into each of the two 2nd passes. Using long strokes push the brush all the way through the boiler until the brush hits the back wall of the reversing chamber. Pull the brush all the way forward until it has exited the front of the boiler. Continue this operation for the entire height of the flue way until clean. Repeat the operation for the other 2nd pass flue way. 6. Vacuum the loose debris in the bottom of the combustion chamber and smoke box. B. Clean the Combustion Chamber – Use a wire or fiber bristle brush to clean the surfaces of the combustion chamber. Vacuum all of the loose debris in the bottom of the combustion chamber. 48 C. AFTER CLEANING, vacuum all remaining debris as necessary. Inspect burner swing door insulation, and rope gasket for signs of damage. If damaged, replace as needed. D. REASSEMBLE BOILER. CAUTION Do not start the burner unless the burner swing door and canopy cover plates are secured in place. 1 Insert the baffles (if originally installed) into the correct flue way. The baffles are installed in the 2nd pass (two inner flue ways) on the MST396, MST513 and MST629. 2. Attach the smoke box clean-out covers onto the rear of the boiler. Verify that the rope gasket is in good working order before assembly. Replace rope gasket if necessary. Use the 3/8" hardware originally removed. Do not over tighten. They should be snug but not bottomed out. NOTICE When securing burner swing door make sure door is drawn-in equally on both sides. Tighten swing door hardware to provide adequate seal to rope gasket around perimeter of door. Use an alternating tightening method from right side to left side cap screw to pull door tight equally. NOTICE Do not overtighten. The rope gasket will provide sufficient seal when the door is snugged into place. 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. A clean and unobstructed chimney flue is necessary to allow noxious fumes that could cause injury or loss of life to vent safely and will contribute toward maintaining the boiler's efficiency. 49 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. Nozzles are delicate and should be protected from dirt and abuse. Nozzles are massproduced and can vary from sample to sample. For all of those reasons a spare nozzle is a desirable item for a serviceman to have. 2. FLAME SHAPE — Looking into the combustion chamber through the observation port, the flame should appear straight with no sparklers rolling up toward the crown of the chamber. If the flame drags to the right or left, sends sparklers upward or makes wet spots on the chamber walls, the nozzle should be replaced. If the condition persists look for fuel leaks, air leaks, water or dirt in the fuel as described above. 3. FUEL LEAKS — Any fuel leak between the pump and the nozzle will be detrimental to good combustion results. Look for wet surfaces in the air tube, under the ignitor, and around the air inlet. Any such leaks should be repaired as they may cause erratic burning of the fuel and in the extreme case may become a fire hazard. 4. AIR LEAKS — Any such leaks should be repaired, as they may cause erratic burning of the fuel and in extreme cases may become a fire hazard. 5. GASKET LEAKS — If 11.5 to 12.5% CO2 with a #1 smoke cannot be obtained in the breeching, look for air leaks around the burner mounting gasket, observation door, and canopy gasket. Such air leaks will cause a lower CO2 reading in the breeching. The smaller the firing rate the greater effect an air leak can have on CO2 readings. 6. DIRT — A fuel filter is a good investment. Accidental accumulation of dirt in the fuel system can clog the nozzle or nozzle strainer and produce a poor spray pattern from the nozzle. The smaller the firing rate, the smaller the slots become in the nozzle and the more prone to plugging it becomes with the same amount of dirt. 50 7. WATER — Water in the fuel in large amounts will stall the fuel pump. Water in the fuel in smaller amounts will cause excessive wear on the pump, but more importantly water doesn’t burn. It chills the flame and causes smoke and unburned fuel to pass out of the combustion chamber and clog the flueways of the boiler. 8. COLD OIL — If the oil temperature approaching the fuel pump is 40°F or lower, poor combustion or delayed ignition may result. Cold oil is harder to atomize at the nozzle. Thus, the spray droplets get larger and the flame shape gets longer. An outside fuel tank that is above grade or has fuel lines in a shallow bury is a good candidate for cold oil. The best solution is to bury the tank and lines deep enough to keep the oil above 40°F. 9. HIGH ALTITUDE INSTALLATIONS — Air openings must be increased at higher altitudes. Use instruments and set for 11.5 to 12.5% CO2. 10.START-UP NOISE — Late ignition is the cause of start-up noises. If it occurs recheck for electrode settings, flame shape, air or water in the fuel lines. 11.SHUT DOWN NOISE — If the flame runs out of air before it runs out of fuel, an after burn with noise may occur. That may be the result of a faulty cut-off valve in the fuel pump, or it may be air trapped in the nozzle line. It may take several firing cycles for that air to be fully vented through the nozzle. Water in the fuel or poor flame shape can also cause shut down noises. NOTICE CHECK TEST PROCEDURE. A very good test for isolating fuel side problems is to disconnect the fuel system and with a 24" length of tubing, fire out of an auxiliary five gallon pail of clean, fresh, warm #2 oil from another source. If the burner runs successfully when drawing out of the auxiliary pail then the problem is isolated to the fuel or fuel lines being used on the jobsite. B. OIL PRIMARY CONTROL 1. Burner (control) will not come on. a. No power to control. b. Control is in lockout or restricted mode. Press reset button for one (1) second to exit lockout. If control has recycled three times within the same call for heat, it will enter into restricted mode. To reset from restricted mode, refer to Section VIII, Paragraph I, No. 2 for details. c. CAD cell seeing light. d. CAD assembly defective. e. Control motor relay is stuck closed (see note below). 2. Burner (control) will light, then shut down after a short time, then restart after one (1) minute. a. CAD cell is defective. b. Air leaking into oil line causing flame out. c. Defective nozzle causing flame to be erratic. 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. Lockout is indicated by a red LED solid-on located on the oil primary control. b. Shorted electrodes. c. Nozzle clogged. d. Airflow too high. e. Ignitor module defective. f. CAD cell defective. g. Oil valve stuck open or closed. Latch-up will occur if the control locks-out three (3) times during a call for heat. This is indicated by steady-on red and amber LED's. SECTION XII: Repair Parts 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 Customer Service at (717) 481-8400 or Fax (717) 481-8408. 51 52 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. 80861075 1 1 --- --- Upper Tie Rod, 3/8" -16 x 21-1/2" Lg. 80861033 --- --- 1 --- Upper Tie Rod, 3/8" -16 x 27-1/2" Lg. 80861014 --- --- --- 1 Lower Tie Rod, 3/8" -16 x 15" Lg. 80861016 1 1 --- --- Lower Tie Rod, 3/8" -16 x 20-3/4" Lg. 80861012 --- --- 1 --- Lower Tie Rod, 3/8" -16 x 27" Lg. 80861018 --- --- --- 1 1G 3/8" Flat Washer, USS, Plain 80860600 4 4 4 4 1H 3/8" -16 Heavy Hex Nut, Plain 80860400 4 4 4 4 Spanner Bar w/Threaded Inserts, 1-1/4" x 1-1/2" x 20-3/8" Lg. 100012-02 2 2 --- --- Spanner Bar w/Threaded Inserts, 1-1/4" x 1-1/2" x 26-3/8" Lg. 100012-03 --- --- 2 --- Spanner Bar w/Threaded Inserts, 1-1/4" x 1-1/2" x 32-3/8" Lg. 100012-04 --- --- --- 2 1K Carriage Bolt, 3/8" -16 x 1-1/4" Lg., Plated 100215-01 4 4 4 4 1L Cap Screw, 5/16" -18 x 7/8" Lg., Plated 80861371 4 4 4 4 1M Flat Washer, 5/16", USS, Plated 80860611 4 4 4 4 1N Hex Nut, 5/16 -18, Serrated Flange, Plated 80860443 4 4 4 4 1P Hinge Bracket 100014-01 1 1 1 1 1Q 5/16" -18 x 3/4" Lg. Cap Screw, Plated 2 2 2 2 3 3 3 3 1R Cast Iron Burner Swing Door (Only) 1 1 1 1 1E 1F 1J Hinge Bracket Mount Burner 80861340 100071-01 53 54 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. Rope Gasket - Observation Port 100096-01 1 1 1 1 1V Observation Port Cover 100074-01 1 1 1 1 1W 5/16" Flat Washer, SAE, Plated 80860647 2 2 2 2 1X Socket Head Cap Screw, 5/16" x 5/8" Lg., Plated 100050-01 2 2 2 2 1Y Tap Bolt, 3/8" -16 x 1-3/4" Lg., Plated 100102-01 2 2 2 2 1Z 5/16" Flat Washer, USS, Plated 80860611 2 2 2 2 1AA Smokebox 100021-01 1 1 1 1 1BB 5/16" Flat Washer, USS, Plated 80860611 4 4 4 4 1CC Cap Screw, 5/16" -18 x 3/4" Lg., Plated 80861340 4 4 4 4 1DD 1/4" NPT Pipe Plug, Square Head, Brass 806603542 1 1 1 1 1EE Smokebox Collar 1FF 1S 6" Dia. 100093-01 1 1 1 --- 7" Dia. 100094-01 --- --- --- 1 5/16" Flat Washer, USS, Plated 80860611 2 2 2 2 1GG Cap Screw, 5/16" -18 x 7/8" Lg., Plated 80861371 2 2 2 2 1HH Cast Iron Clean-Cut Cover (only) 100104-01 2 2 2 2 1JJ 1/2" Dia. Rope Gasket - Clean-Cut Cover 100095-01 2 2 2 2 1KK 222A Heater Carton Assembly 6036036 1 1 1 1 1LL Tapped Heater Cover Plate - Rear Heater 7036031 1 1 1 1 1MM Heater Cover Plate Gasket 8036068 1 1 1 1 1NN Cap Screw, 3/8" -16" x 7/8" Lg., Plated, ASME Grade SA307B 80861337 6 6 6 6 1PP 5/16" Flat Washer, SAE, Plated 80860647 6 6 6 6 55 56 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., Plain 100046-01 2 2 2 2 2G 5/8" O.D. x 2-5/32" Lg. Jacket Spacer 100035-01 2 2 2 2 2H Acorn Nut, 5/16" -18, Plated 100047-01 2 2 2 2 100614-03 1 1 --- --- 100614-04 --- --- 1 --- 100614-05 --- --- --- 1 Jacket Left Side Panel - 3 Section 100581-03 1 1 --- --- Jacket Left Side Panel - 4 Section 100581-04 --- --- 1 --- Jacket Left Side Panel - 5 Section 100581-05 --- --- --- 1 Jacket Right Side Panel - 3 Section 100583-03 1 1 --- --- Jacket Right Side Panel - 4 Section 100583-04 --- --- 1 --- Jacket Right Side Panel - 5 Section 100583-05 --- --- --- 1 Jacket Top Panel - 3 Section 100585-03 1 1 --- --- Jacket Top Panel - 4 Section 100585-04 --- --- 1 --- Jacket Top Panel - 5 Section 100585-05 --- --- --- 1 2N Beckett Burner Enclosure Backer Plate 60228001 1 1 1 1 2P Beckett Burner Enclosure Cover 60228002 1 1 1 1 2Q Knob, Dimco #2-116-335 80860955 4 4 4 4 2R Sheet Metal Screw, Plated, Phillips Truss Head, Type AB, #8 x 1/2" Lg. 80860000 2 2 2 2 2S Sheet Metal Screw, Plated, Phillips Pan Head, Type B, #8 x 1/2" Lg. 80860019 1 1 1 1 2J 2K 2L 2M 3" Thick Fiberglass Insulation Wrapper 57 58 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. 806600002 1 1 1 1 3F Elbow, 3/4" NPT x 90 806601502 1 1 1 1 3J Syphon, 1/4" NPT x 1-7/8" x 4" x 90 806603010 1 1 1 1 3K Pressure Limit, Honeywell L404F1367 80160369 1 1 1 1 3L Safety Valve, 3/4" NPT, 15 PSI, Conbraco 13-511-08 81660530 1 1 1 1 3M Gauge Glass Set, 6", Conbraco 20-104-10 8056091 1 1 1 1 3N Low Water Cut-off, McDonnell & Miller 67 80160597 1 1 1 1 3P Nipple, 1-1/2" NPT x 5" Lg. 808600060 1 1 1 1 3Q Tee, 1-1/2' x 1-1/2" x 3/4" 806601105 1 1 1 1 3R Drain Valve, 3/4" NPT, Conbraco 35-302-03 806603061 1 1 1 1 3S Limit, Honeywell L4006A2015 80160400 1 1 1 1 3T Well, 1/2" NPT x 3", Honeywell 123872A 80160497 1 1 1 1 3U Oil Primary Control, Honeywell R7184P1064 80160848 1 1 1 1 3W Stainless Steel 2nd Pass Blueway Baffle 100042-01 --- 1 1 1 MST288 Spec. No. BCB7706 100625-01 1 --- --- --- MST396 Spec. No. BCB7703 100053-01 --- 1 --- --- MST513 Spec. No. BCB7704 100054-01 --- --- 1 --- MST629 Spec. No. BCB7705 100055-01 --- --- --- 1 100640-01 1 1 1 1 3A 3D Beckett AFG Oil Burner w/Gasket for: 3X (NOTE: See Pages 60 and 61 for burner Parts Breakdown) 3Y Fan Center, Honeywell R8285C w/Connectors 59 60 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. Boiler Model MST288 MST396 MST513 MST629 AFG70MMAQN AFG70MMAQN AFG70MLASN AFG70MKASN BCB7706 BCB7703 BCB7704 BCB7705 Air Band 3492 3492 3492 3492 Air Band Nut 4150 4150 4150 4150 Air Band Screw 4198 4198 4198 4198 Air Shutter 3709 3709 3709 3709 Air Shutter Screw 4198 4198 4198 4198 Blower Wheel 2999 2999 2999 2999 Coupling 2454 2454 2454 2454 Air Tube Combination Beckett's Spec. No. Low Firing Rate Baffle Less Less Less Less Bulkhead Knurled Locknut 3666 3666 3666 3666 Connector Tube Assembly 5636 5636 5636 5636 Electrode Clamp 149 149 149 149 Electrode Clamp Screw 4219 4219 4219 4219 Electrode Insulator Assembly 5780 5780 5780 5780 Support / Spacer Assembly 5992 5992 5992 5992 --- --- --- --- Adjusting Plate Assembly 5941 5941 5941 5941 Head 5913 5913 5913 5913 Head Screws 4221 4221 4221 4221 Escutcheon Plate Flange Gasket 3811 3811 3811 3811 AFG Housing 5874GY 5874GY 5874GY 5874GY 21805E/218 21805E/218 21805E/218 21805E/218 213 213 213 213 NL70MD NL70MD NL70MD NL70MD Oil Pump, Clean Cut, Single Stage 21844 21844 21844 21844 Oil Pump, Clean Cut, Two-Stage 21941 21941 21941 21941 Static Plate 3383 3383 3383 3383 51771U 51771U 51771U 51771U Ignitor Hinge Screw 42176 4217 4217 4217 Ignitor Holding Screw 4292 4292 4292 4292 Ignitor Gasket Kit 51304 51304 51304 51304 Wire Guard 10251 10251 10251 10251 Junction Box 3741 3741 3741 3741 Flame Detector 7006Q 7006Q 7006Q 7006Q Oil Solenoid Valve Coil 21775U 21775U 21775U 21775U Oil Solenoid Valve Cord 21807 21807 21807 21807 Motor Nozzle Adapter Nozzle Line Electrode Assembly Ignitor 61 62 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. Increase Minimum Minimum Minimum Pump Shipped Baffle Without Breech Breech Overfire Pressure CO2 Location Baffles Pressure Pressure Pressure (psi) (%) (pass) (F)2 ("w.c.)3 ("w.c.)3 ("w.c.)3 0.030 0.030 0.020 0.010 Baffles OUT Minimum Overfire Pressure ("w.c.)3 2) The increased stack temperature with the baffles removed is an approximation, based on a constant supply temperature of 212°F and 11.5% CO2. Actual field conditions may be different. 3) These values are minimum and could be as much as -.03" w.c., more without impacting performance. Pressures based on 11.5% CO2. Example: MST629 could have a breech pressure of -.03" w.c. and an overfire pressure of .020" w.c. 4) Single stage fuel pump is standard, two stage fuel pump is optional. Burner manufacturer has preset single stage fuel pump to settings shown in table above. Two stage fuel pump is factory set at 140 PSI and must be readjusted to settings shown above during burner start-up. 1) MST288 at 0.75 GPH firing rate utilizes a low fire baffle. Notes Burner Input (gph) Boiler Model Table 8: BECKETT AFG Burner specifications 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. FIRST YEAR - LIMITED WARRANTY FOR RESIDENTIAL CAST IRON STEAM BOILERS U.S. Boiler Company, Inc. warrants its residential cast iron steam boilers labeled Independence, Independence PV, V8H and MegaSteam Series to be free of defects in material and workmanship when shipped and to remain free of such defects under normal usage for a period of one year from the date of original installation. In the event that any part of such a steam boiler is found to be defective in material or workmanship during the one-year period, then U.S. Boiler Company, Inc. will repair or replace, at its option, the defective part. SECOND THROUGH 10 YEAR - LIMITED WARRANTY FOR THE CAST IRON SECTION ASSEMBLY OF RESIDENTIAL CAST IRON STEAM BOILERS U.S. Boiler Company, Inc. warrants the cast iron section assembly of its residential cast iron steam boilers labeled Independence, Independence PV, V8H and MegaSteam Series, to be free of defects in material and workmanship when shipped and to remain free of such defects under normal usage for a period of 10 years from the date of original boiler installation. In the event that such cast iron section assembly is found to be defective in material or workmanship during this period, U.S. Boiler Company, Inc. will repair or replace, at its option, the defective cast iron section assembly. FIRST THROUGH 5 YEAR - LIMITED WARRANTY AGAINST WATERSIDE CORROSION IN THE MEGASTEAM SERIES U.S. Boiler Company, Inc. warrants the cast iron sections of the MegaSteam boiler to resist TEMPERATURE INDUCED CHLORIDE ACTIVATED GRAPHITIC CORROSION for a period of ve years from the date of original installation. In the event that any cast iron section of a MegaSteam boiler fails due to this corrosion mechanism during this period, U.S. Boiler Company, Inc. will repair or replace, at its option, the failed cast iron section assembly. LIFETIME NIPPLE LEAKAGE WARRANTY U.S. Boiler Company, Inc. warrants the cast iron and steel nipples that join the sections to be free from defects in material and workmanship for the lifetime of the original owner at the time of installation. In the event that such nipples are found to be defective in material or workmanship during this period, U.S. Boiler Company, Inc. will repair or replace at its option, the cast iron section assembly. ADDITIONAL TERMS AND CONDITIONS 1. This warranty does not cover expenses for removal or reinstallation. The homeowner will be responsible for the cost of removing and reinstalling the defective part or its replacement and all labor and material connected therewith. Replacement material will be invoiced to the distributor in the usual manner and will be subject to adjustment upon proof of defect. 2. This warranty, in no way, can be considered as a guarantee of workmanship of an installer connected with the installation of the U.S. Boiler Company, Inc. boiler or as imposing on U.S. Boiler Company, Inc. liability of any nature for unsatisfactory performance as a result of faulty workmanship in the installation, which liability is expressly disclaimed. 3. This warranty will not be applicable if the boiler is used or operated over its rated capacity; or installed for uses other than home heating; or is not maintained in accordance with U.S. Boiler Company, Inc. recommendation or accepted good practice as determined by hydronics industry standards. 4. This warranty will not be applicable if the boiler has been damaged as a result of being improperly serviced or operated, including but not limited to the following: operated with insufcient water, allowed to freeze; subject to ood conditions; or operated with water conditions and/or fuels or additives which cause unusual deposits or corrosion in or on the heat exchanger. 5. This warranty applies only to boilers installed within the United States, and Canada. 6. In order for this warranty to be effective: a.) The boiler must have been properly installed in a single or two-family residential dwelling. This warranty does not apply to boilers installed in apartments or to commercial or industrial installation. b.) The boiler must have been assembled in strict compliance with installation instructions furnished with the boiler by U.S. Boiler Company, Inc. c.) Boiler components must not have been damaged in handling during shipment or installation. 7. The foregoing provisions of this warranty shall be effective to the maximum extent permitted by applicable law, and, to the extent that any such provision would otherwise be inconsistent with applicable law, such provision shall be limited in effect to the minimum extent necessary to avoid such unconscionable result or inconsistency with applicable law. 8. The remedy for breach of this warranty is expressly limited to the repair or replacement of any part found to be defective under conditions of normal use; and the remedy for breach of this warranty or for negligence does not extend to liability for incidental, special or consequential damages or losses such as loss of the use of the materials, inconvenience or loss of time. Some states do not allow the exclusion or limitation of incidental or consequential damages so the above limitation or exclusion may not apply to you. 9. This warranty is in lieu of all others, and any and all express or implied warranties (including, without limitation, any implied warranties of merchantability or tness for a particular purpose) are expressly limited in duration to the period of the warranty as previously stated herein. Some states do not allow limitation on how long an implied warranty lasts, so the above limitation may not apply to you. 10.Not withstanding any of the above provisions, U.S. Boiler Company, Inc. liability under this warranty shall not exceed the selling price of the product found to be defective. PROCEDURE FOR OBTAINING WARRANTY SERVICE In order to assure prompt warranty service the homeowner is requested to complete and mail the attached Warranty Card within ten days after the installation of the boiler, although failure to comply with this request will not void the homeowner’s rights under this warranty. Upon discovery of a condition believed to be related to a defect in material or workmanship covered by this warranty statement, the homeowner should notify the installer who will in turn notify the distributor. If this action is not possible or does not produce a prompt response, the homeowner should write to U.S. Boiler Company, Inc., at P.O. Box 3079, Lancaster, PA 17604 giving full particulars in support of the claim. The homeowner is required to make available for inspection by U.S. Boiler Company, Inc. or its representative the parts claimed to be defective and, if requested by U.S. Boiler Company, Inc., to ship said parts prepaid to Burnham Hydronics at the above address for inspection or repair. In addition, the homeowner agrees to make all reasonable efforts to settle any disagreement arising in connection with his claim before resorting to legal remedies in the courts. THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE.