U.S. Boiler Company MegaSteam MST Installation, Operating And Service Instructions
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U.S. Boiler Company MegaSteam MST Installation, Operating And Service Instructions

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As an ENERGY STAR
®
U.S. Boiler Company
has determined that the
MST288, MST396, MST513 and
MST629 meet the
ENERGY STAR
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guidelines for Energy
efficiency established by the
United States Environmental
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Price - $5.00

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Summary of Contents for U.S. Boiler Company MegaSteam MST

  • Page 1 ™ As an ENERGY STAR Partner, ® U.S. Boiler Company has determined that the MST288, MST396, MST513 and MST629 meet the 9700609 ENERGY STAR ® guidelines for Energy efficiency established by the United States Environmental Protection Agency (EPA). 103536-01 - 3/11...
  • Page 2 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.
  • Page 3 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.

  • Page 4: Table Of Contents

    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.
  • Page 6 TABLE 1A: DIMENSIONAL DATA (SEE FIGURE 1) Dimensions (See Water Content (To Normal Heat Transfer Figure 1) Water Line) - Gallons Boiler Actual Shipping Surface Area Model No. Weight (LB.) With Tankless - sq. Ft. "A" "B" "C" Non-Heater Heater MST288 22-5/8"...

  • Page 7: Pre-Installation

    SECTION I: PRE-INSTALLATION A. INSPECT SHIPMENT carefully for any signs of • 30" for flueway cleaning (MST513) damage. • 36" for flueway cleaning (MST629) b. Clearance from Jacket Left Side Panel - 1. All equipment is carefully manufactured, inspected and packed. Our responsibility ceases upon delivery •...
  • Page 8 60-75 percent free area. a. Outdoor air for combustion may be provided c. Louvers and grilles must be fixed in the open with an optional U.S. Boiler Company V8H™ position, or interlocked with the equipment to open automatically during equipment operation.

  • Page 9: Unit-Pak Boiler Assembly

    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) –...
  • Page 10 SECTION II: UNIT-PAk BOILER ASSEMBLY (continued) A. CAST IRON SECTION ASSEMBLY TAPPINGS 6. For manual Cast Iron Section/Burner Swing Door/ Smoke Box Assembly removal prepare one piece of Refer to Table 3 "Purpose of Tappings and Bosses" and 4” x 4” x 16” lg. (or two pieces of 2” x 4” x 16” lg.) Figure 7.
  • Page 12 SECTION II: UNIT-PAk BOILER ASSEMBLY (continued) 2. Open Jacket Carton and locate jacket front panel D. JACkET FRONT PANEL INSTALLATION. (has factory attached 1” fiberglass insulation). See In order to install front jacket panel Burner Swing Door also “Repair Parts” Section, “Jacket Assembly” and door mounting bracket need to be removed.
  • Page 13 SECTION II: UNIT-PAk BOILER ASSEMBLY (continued) By design, door insulation on model MST629 will 10. Inspect burner swing door insulation for damage and have two by-pass pockets cast into the insulation proper type. centered on the bar between the combustion By design, for all models, cast bars on front section chamber and 3rd pass flueways.
  • Page 14 SECTION II: UNIT-PAk BOILER ASSEMBLY (continued) 11. Upon inspection completion, lift door and place NOTE: Read caution statement before proceeding. integral cast hinge pins into door mounting bracket slotted holes. Do not close and secure door at this CAUTION time, proceed to installing stainless steel flueway baffles.
  • Page 15 SECTION II: UNIT-PAk BOILER ASSEMBLY (continued) 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. NOTICE When securing burner swing door make sure door is drawn-in equally on both sides.
  • Page 16 SECTION II: UNIT-PAk BOILER ASSEMBLY (continued) Figure : Purpose of Tappings and Bosses TABLE 3: PURPOSE OF TAPPINGS & BOSSES Steam Boiler Tapping Location Size, NPT Boss Location Thread Size UNC With Heater Less Heater ¼" - 18 Pressure Gauge ¼"...
  • Page 17 SECTION II: UNIT-PAk BOILER ASSEMBLY (continued) 7. Secure panel bottom to studs with acorn nuts hand 3. Unfold Insulation Wrapper, position it over section tight. assembly centered left to right and align two wrapper upper holes with 2" NPT pipe tappings in 8.
  • Page 18 SECTION II: UNIT-PAk BOILER ASSEMBLY (continued) harness. Do not tighten the syphon by holding the 9. Place the panel between side panels upper inside limit case; apply a wrench to the brass hex below flanges and slide it forward, until top panel front the case.
  • Page 20 SECTION II: UNIT-PAk BOILER ASSEMBLY (continued) 4. Pick-up the LWCO harness Molex end and feed it top flange front left 7/8” hole; then, snap-in harness into the enclosure, thru external electrical enclosure BX connector into the hole, and, plug-in Molex top flange front left 7/8”...
  • Page 21 SECTION II: UNIT-PAk BOILER ASSEMBLY (continued) Figure 10: Oil Burner Installation (Beckett Burner Shown) 3. Thread safety valve into the ¾” NPT black coupling. 6. Install the drain valve into black tee ¾” NPT side Pipe the safety valve discharge as shown in Figure outlet.
  • Page 22 SECTION II: UNIT-PAk BOILER ASSEMBLY (continued) g. Align holes and install two (2) remaining cap screws. Level burner and fully tighten all three (3) screws. h. Plug burner power cord into power outlet receptacle located in lower right corner of front panel.
  • Page 23 SECTION II: UNIT-PAk BOILER ASSEMBLY (continued) Two PIPE CONNECTORS (4) are supplied with the burner for connection to either a single or two-line system. Also supplied are two ADAPTORS (3), two female ¼” NPT to adapt oil lines to burner pipe connectors.

  • Page 24: Steam Boiler Piping & Trim

    Oxygen contamination of boiler water will cause corrosion of iron and steel boiler components, and can lead to boiler failure. U.S. Boiler Company'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.

  • Page 26: Tankless & Indirect Water Heater Piping

    SECTION IV: TANkLESS & INDIRECT wATER HEATER PIPING A. CONNECT TANkLESS HEATER PIPING as possible by piping the hot water from the heater shown in Figure 13. See Table 4 for Tankless Heater prior to entering the mixing valve. The mixing valve Rating.
  • Page 27 SECTION IV: TANkLESS & INDIRECT wATER HEATER PIPING (cont'd) Figure 13: Schematic Tankless Water Heater Piping TABLE : TANKLESS HEATER DATA: Heater Rating Pressure Drop thru Boiler Model Heater No. (GPM) Heater (PSI) MST288 3.00 22.0 MST396 3.25 24.3 222A MST513 3.50 26.5...
  • Page 28 SECTION IV: TANkLESS & INDIRECT wATER HEATER PIPING (cont'd) Figure 1: 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: Venting & Air Intake Piping

    SECTION V: VENTING & AIR INTAkE PIPING a. Loose Mortar – Loose mortar could be an A. CHIMNEY VENTING indication of a prior history of condensing flue 1. Chimney venting is an important part of a safe gases upon the inside walls of the chimney. and efficient oil fired appliance system.
  • Page 30 SECTION V: VENTING & AIR INTAkE PIPING (continued) Figure 15: Recommended Vent Pipe Arrangement and Chimney Requirements Figure 16: Proper and Improper Locations of Draft Regulator...
  • Page 31 SECTION V: VENTING & AIR INTAkE PIPING (continued) 2. Type B Chimney Connector - a type B chimney 2. NFPA 31 has information to help the installer connector can be used to transmit the flue gases make an appropriate choice of venting materials. provided flue gas temperature entering the chimney In some cases a chimney may have to be lined to connector is greater than 310°F.
  • Page 32 SECTION V: VENTING & AIR INTAkE PIPING (continued) a minimum, remove the baffles to increase the stack minimum stack temperature outlined in this section temperature. See Tables 8 thru 8B for temperature can be maintained. (ONLY AVAILABLE wITH BECkETT BURNER). Refer to Section I, Paragraph differential (∆T) with baffles IN and OUT.

  • Page 33: Electrical

    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.
  • Page 40 SECTION VI: ELECTRICAL (continued) 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;...

  • Page 41: Oil Piping

    SECTION VII: OIL PIPING A. GENERAL WARNING 1. Use flexible oil line(s) so the burner swing door Under no circumstances can copper with sweat can be opened without disconnecting the oil supply style connectors be used. piping. 2. A supply line fuel oil filter is recommended as a minimum for all firing rates but a pleated paper fuel NOTICE oil filter is recommended for the firing rates below...
  • Page 42 SECTION VII: OIL PIPING (continued) C. TwO PIPE OIL LINES 3. Under no circumstances is a manual shutoff valve to be located on the return line of a two pipe system. 1. For two piped systems, where more lift is required, Accidental closure of the return line will rupture the the two-stage fuel unit is recommended.

  • Page 43: System Start-Up

    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.
  • Page 44 SECTION VIII: SYSTEM START-UP (continued) 5. Adjust oil pressure. all adjustments are made recheck for a draft of zero inches water column ("w.c.) in the canopy. Replace a. When checking a fuel unit's operating pressure, a plug at completion. reliable pressure gauge may be installed in either the bleeder port or the nozzle port.
  • Page 46 SECTION VIII: SYSTEM START-UP (continued) 2. IF NOZZLE CONTINUES TO DRIP, repeat iv. Limited Reset (Restricted Mode): In order Paragraph H, No. 1. If this does not stop the to limit the accumulation of unburned oil in dripping, remove cut-off valve and seat, and wipe the combustion area, the control can only be both with a clean cloth until clean, then replace reset three times.
  • Page 47 SECTION VIII: SYSTEM START-UP (continued) • • Check the piping to the oil tank. If safety switch shuts down burner and resistance is above 1600 OHMS, open line • Check the oil nozzle, oil supply and oil switch to boiler. Access cad cell under filter.
  • 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: Maintenance & Service Instructions

    SECTION Ix: MAINTENANCE AND SERVICE INSTRUCTIONS h. Clean the pipe threads of the probe to remove A. MAINTENANCE OF LOw wATER CUT- old, hardened pipe dope and other foreign matter. OFF DEVICES i. Apply a moderate amount of good quality pipe WARNING dope to the pipe threads on the probe, leaving the two end threads bare.
  • Page 50 SECTION Ix: MAINTENANCE AND SERVICE INSTRUCTIONS (cont'd) Operate the boiler with steam in the entire drain valves in return main and at boiler as system for a few days allowing the condensate shown in Figure 12 and proceed as follows: to return to the boiler.
  • Page 51 SECTION Ix: MAINTENANCE AND SERVICE INSTRUCTIONS (cont'd) open gate valve in Hartford Loop, then cast iron in that area gets extremely hot and eventually repeat Step 1 above. cracks. The presence of free oxygen or chloride salts in the boiler corrodes the cast iron from the inside. e.

  • Page 52: Boiler Cleaning

    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.
  • Page 53 SECTION x: BOILER CLEANING (continued) Figure : 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.

  • Page 54: Trouble Shooting

    SECTION xI: TROUBLE SHOOTING A. COMBUSTION 8. COLD OIL — If the oil temperature approaching the fuel pump is 40°F or lower, poor combustion or 1. NOZZLES — Although the nozzle is a relatively delayed ignition may result. Cold oil is harder to inexpensive device, its function is critical to the atomize at the nozzle.
  • Page 55 SECTION xI: TROUBLE SHOOTING (continued) d. Excessive airflow or draft causing flame to leave Note: The Safety Monitoring Circuit (SMC) is burner head. designed to provide lockout in the event of a stuck or welded motor relay. e. Excessive back pressure causing flame to be erratic.

  • Page 56: Repair Parts

    All MegaSteam™ Boiler Repair Parts may be obtained through your local Burnham product distributor. Should you require assistance in locating a Burnham product distributor in your area, or have questions regarding the availability of Burnham brand products or repair parts, please contact U.S. Boiler Company Customer Service at (717) 481-8400 or Fax (717) 481-8408.
  • Page 57 SECTION xII: REPAIR PARTS (continued) Item Description Part No. MST288 MST396 MST513 MST629 1. BARE BOILER ASSEMBLy Front Section, Machined 100569-01 Center Section, Machined 100571-01 Rear Section (Htr.), Steam, Machined 100573-01 Rear Section (Non-Htr.), Steam, Machined 100676-01 Slip Nipple, 22-B Steel 806600375 5"...
  • Page 59 SECTION xII: REPAIR PARTS (continued) Item Description Part No. MST288 MST396 MST513 MST629 1. BARE BOILER ASSEMBLy (Continued) Burner Swing Door Insulation (Less Pockets) 100039-01 Burner Swing Door Insulation (With Pockets) 100039-02 5/8" Dia. Rope Gasket - Burner Swing Door 100097-01 1/8"...
  • Page 61 SECTION xII: REPAIR PARTS (continued) Item Description Part No. MST288 MST396 MST513 MST629 . JACKET ASSEMBLy Jacket Front Panel Assembly w/Insulation 100575-01 Power Outlet Receptacle, w/Harness 100605-01 #8 x 1/2" Type AB Truss Head w/Shoulder, Sheet Metal 100038-01 Screw, Plated Jacket Rear Panel Assembly w/Insulation 100578-01 External Wiring Enclosure...
  • Page 63 SECTION xII: REPAIR PARTS (continued) Item Description Part No. MST288 MST396 MST513 MST629 3. MST - TRIM AND CONTROLS 6" RC-STD Draft Regulator 8116288 7" RC-STD Draft Regulator 8116289 Pressure Gauge 100325-01 Probe, Hydrolevel EL-1214 (for Hydrolevel CG450) 80160629 Low Water Cut-off, Hydrolevel CG450 (less Probe) 80160623 Low Water Cut-off, McDonnell &...
  • Page 65 SECTION xII: REPAIR PARTS (continued) 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...
  • Page 66 SECTION xII: REPAIR PARTS (continued) RIELLO OIL BURNER PART NUMBERS FOR 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 69: Appendix A - Figures

    APPENDIx A - FIGURES Figure Page Description Number Number Figure 1 MST288 Thru MST629 Steam Boiler with and without Tankless Heater (Beckett Burner Shown) Section I - Pre-Installation Figure 2 Minimum Installation Clearances to Combustible Materials (Inches) Section II - Unit-Pak Boiler Assembly Figure 3 MegaSteam Unit-Pak Boiler Shipment Contents (outiside container removed) Figure 4...
  • Page 70 APPENDIx A - FIGURES (continued) Figure Page Description Number Number Section VIII - System Start-Up Figure 23 Adjusting Fuel Pump Pressure Figure 24 "L1" and "V1" Head Electrode Positioning and Gun Setting (Beckett AFG) Figure 25 R7184 Terminals, LED and Reset Button Figure 26 Cad Cell Location Section X - Boiler Cleaning...

  • Page 71: Appendix B - Tables

    APPENDIx B - TABLES Table Page Description Number Number Table 1A Dimensional Data (See Figure 1) Table 1B Rating Data Section II - Unit-Pak Boiler Assembly Table 2 Baffle Usage Table 3 Purpose of Tappings and Bosses Section IV - Tankless & Indirect Water Heater Piping Table 4 Tankless Heater Data Section VII - Oil Piping...
  • Page 72 U.S. Boiler Company, Inc. P.O. Box 3020 Lancaster, PA 17604 (717) 397-4701 www.usboiler.burnham.com...

This manual is also suitable for:

Megasteam mst288Megasteam mst396Megasteam mst513Megasteam mst629Megasteam mst series

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