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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).
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Price - $3.00
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Table of Contents
Related Manuals for Burnham MEGASTEAM MST513
Summary of Contents for Burnham MEGASTEAM MST513
- Page 1 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). 100618-01R5-4/09 ™ Price - $3.00...
- Page 2 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.
- Page 3 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.
- Page 4 IX. Maintenance & Service Instructions . . . 49 X. Boiler Cleaning ....XI. Trouble Shooting ....
- Page 6 TABLE 1A: DIMENSIONAL DATA (SEE FIGURE 1) Dimensions (See Figure 1) Boiler Model No. "A" "B" MST288 22-5/8" 24" MST396 22-5/8" 24" MST513 28-5/8" 30" MST629 34-5/8" 36" NOTE: 1: Maximum Working Pressure: Steam - 15 PSI TABLE 1B: RATING DATA...
- Page 7 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.
- Page 8 Outdoor air for combustion may be provided with an optional Burnham V8H™ Fresh /1000 BTU per hour, Air Accessory Kit, (ONLY AVAILABLE wITH BECkETT BURNER). Metal cover applications, P/N 611280031.
- Page 9 ____ MST3 – Part # 100609-03 ____ MST4 – Part # 100609-04 ____ MST5 – Part # 100609-05 Figure 3: MegaSteam™ Unit-Pak Boiler Shipment Contents (outside container removed) 4. ___ Part Carton ____ MST3 & 4 - Part # 100615-01...
- Page 10 (see Figure 4). Slowly allow the weight of boiler to tilt backward until rear legs rest on floor. 14. If wood blocks were placed under front legs, lift pipe handles;...
- Page 12 5/16”-18 x ½” Phillips pan head machine screws. Figure 5A: Partial Front View - Burner Swing Door Mounted to Boiler - Fully Closed and Secured 4. Place front jacket panel over front section attachment bosses and align jacket holes with front section boss holes.
- Page 13 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.
- Page 14 • Models MST396, MST513 and MST629 - To install flueway baffle in 2 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 2 flueway.
- Page 15 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.
- Page 16 Boss Location M (4 pcs) 5/16" - 18 N ( pcs) 3/8" - 16 P (10 pcs) 5/16" - 18 Steam Boiler With Heater Less Heater Pressure Gauge Pressure Limit Probe LWCO - Std. Plugged (Float LWCO) Water Gauge Glass (Probe LWCO) Water Gauge Glass, Pressuretrol &...
- Page 17 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.
- Page 18 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”...
- Page 20 3. Thread safety valve into the ¾” NPT black coupling. Pipe the safety valve discharge as shown in Figure 12 “ 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.
- Page 21 Figure 10: Oil Burner Installation (Beckett Burner Shown) f. Insert oil burner into the opening of burner swing door. Align and engage keyhole slot in burner flange over head of protruding cap screw installed in previous Step. Rotate burner to the right to lock flange behind head of cap screw.
- Page 22 Figure 11B: Nozzle Replacement b. Remove existing nozzle from nozzle adapter. c. Insert the proper NOZZLE into NOZZLE ADAPTER and tighten securely (Do not over tighten). d. Replace adapter, with nozzle installed, into drawer assembly and secure with screw (1). iii.
- Page 23 by-pass plug installed. Operating a single line system with the by-pass plug installed will result in damage to the pump shaft seal. NOTE: Pump pressure was factory pre-set but must be checked at time of burner start-up. A pressure gauge is attached to the PRESSURE/ BLEEDER PORT (7) for pressure readings.
- Page 24 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.
- Page 26 During summertime operation, the normal water line on a steam boiler can be raised 1", from 8-/8" to 9-/8" (see Figure 1) for improved tankless heater performance on steam boilers.
- Page 27 Figure 13: Schematic Tankless Water Heater Piping TABLE 4: TANKLESS HEATER DATA: Boiler Model Heater No. MST288 MST396 222A MST513 MST629 Heater Rating Pressure Drop thru (GPM) Heater (PSI) 3.00 22.0 3.25 24.3 3.50 26.5 4.00 31.0...
- Page 28 Figure 14: Alliance™ SL Water Heater Piping with MegaSteam™ Boiler B. CONNECT ALLIANCE™ SL INDIRECT 1. Refer to Alliance™ SL manual for additional wATER HEATER PIPING as shown in Figure 14. information.
- Page 29 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.
- Page 30 Figure 15: Recommended Vent Pipe Arrangement and Chimney Requirements Figure 16: Proper and Improper Locations of Draft Regulator...
- Page 31 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.
- Page 32 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...
- Page 33 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. Failure to properly wire electrical connections to the boiler may result in serious physical harm.
- Page 40 When the pressure limit control restores the circuit on a drop in pressure, the burner will start if the thermo- stat 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.
- Page 41 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.
- Page 42 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.
- Page 43 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.
- Page 44 Do not loosen or remove any oil line fittings while burner is operating. 6. 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.
- Page 46 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...
- Page 47 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.
- Page 48 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.
- Page 49 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...
- Page 50 Operate the boiler with steam in the entire system for a few days allowing the condensate to return to the boiler. If the condensate can temporarily be wasted, operate boiler only for the length of time it takes for condensate to run clear.
- Page 51 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.
- Page 52 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.
- Page 53 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.
- Page 54 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...
- Page 55 d. Excessive airflow or draft causing flame to leave burner head. e. Excessive back pressure causing flame to be erratic. 3. Control locks out after Trial For Ignition (TFI). a. No oil to burner. b. Shorted electrodes. c. Nozzle clogged. d.
- Page 56 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.
- Page 57 Item Description 1. BARE BOILER ASSEMBLy Front Section, Machined Center Section, Machined Rear Section (Htr.), Steam, Machined Rear Section (Non-Htr.), Steam, Machined Slip Nipple, 22-B Steel 5" Cast Iron Slip Nipple Upper Tie Rod, 3/8" -16 x 16" Lg. Upper Tie Rod, 3/8" -16 x 21-1/2" Lg.
- Page 59 Item Description 1. BARE BOILER ASSEMBLy (Continued) Burner Swing Door Insulation (Less Pockets) Burner Swing Door Insulation (With Pockets) 5/8" Dia. Rope Gasket - Burner Swing Door 1/8" Dia. Rope Gasket - Observation Port Observation Port Cover 5/16" Flat Washer, SAE, Plated Socket Head Cap Screw, 5/16"...
- Page 61 Item Description . JACKET ASSEMBLy Jacket Front Panel Assembly w/Insulation Power Outlet Receptacle, w/Harness #8 x 1/2" Type AB Truss Head w/Shoulder, Sheet Metal Screw, Plated Jacket Rear Panel Assembly w/Insulation External Wiring Enclosure Tap End Stud, 5/16" -18 x 3" Lg., Plain 5/8"...
- Page 63 Item Description 3. MST - TRIM AND CONTROLS 6" RC-STD Draft Regulator 7" RC-STD Draft Regulator Pressure Gauge Probe, Hydrolevel EL-1214 (for Hydrolevel CG450) Low Water Cut-off, Hydrolevel CG450 (less Probe) Low Water Cut-off, McDonnell & Miller PS-801 Nipple, 3/4" NPT x 3" Lg. Elbow, 3/4"...
- Page 65 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 Air Tube Combination Beckett's Spec. No. Air Band...
- Page 66 MEGASTEAM 3-PASS OIL BOILERS NOTE: When ordering parts always give the serial and model numbers shown on the boiler and burner. Refer to Models F3 & F5 Installation Manual, Riello 40 Series Residential Oil Burners (C6501010) for an exploded view of the burner and a list of spare parts.
- Page 68 Burnham Hydronics Repair Parts Pricing where the heat exchanger last appeared or the current retail price of the then nearest equivalent heat exchanger.