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Burnham MST629 Boiler User Manual

1. Non sq Ft eight LB MST288 22 5 8 MST396 22 5 8 MST513 28 5 8 744 MST629 34 58 34 29 NOTE 1 Maximum Working Pressure Steam 15 PSI TABLE 1B RATING DATA I B R Minimum Chimney PES Ratings Requirements DOE Heating Steam Steam Round Rectangle Capacity MBH MBH 5 Ft In Dia In x In 2 7 ozs os o co 2 MST396 396 5 513 ws 57029 231 ae SECTION PRE INSTALLATION A INSPECT SHIPMENT carefully for any signs of 30 for flueway cleaning MST513 damage 36 for flueway cleaning MST629 1 All equipment is carefully manufactured inspected b Clearance from Jacket Left Side Panel and packed Our responsibility ceases upon delivery e 19 for burner swing door if opened fully of crated boiler to the carrier in good condition with burner mounted otherwise 1 with 2 Any claims for damage or shortage in shipment burner removed must be filed immediately against the carrier by the e 12 access clearance to service rear of consignee No claims for variances from or shortage boiler if right side clearance is less in orders will be allowed by the manufacturer than 12 unless presented within sixty 60 days after receipt e 1 minimum if right side clearance is 12 or of gonds larger to access and service rear of boiler B LOCATE BOILER front of final position before c Clearance from Jacket Right Side Panel
2. 4 Thread both 5 16 18 x 3 Ig 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 HI 7 Secure panel bottom to studs with acorn nuts hand tight 8 Align upper panel attachment holes with smokebox upper attachment bosses and install 5 16 18 x gt Phillips pan head machine screws hand tight Figure 6 Flueway Baffle Positioning Orientation in Flueways 9 Securely tighten rear jacket panel mounting hardware 10 Locate remove four 8 x shoulder sheet metal NOTICE screws from Hardware Bag then install them into is drawn in equally on both sides H FLUE CLEANOUT COVERS AND SMOKEBOX COLLAR INSTALLATION d Use a hand or socket wrench to tighten door 1 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 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 illustratio
3. 1 0 xo eis xoiddy SNOILVOISIDAdS OAV 1143948 8 318V1 62 DATE SERVICE RECORD 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 S
4. removing crate See Figure 1 e 6 minimum from external Electrical 1 LOCATE so that vent pipe connection to chimney Enclosure if left side clearance is 12 or will be short and direct larger to access and service rear of the boiler 2 BOILER IS SUITABLE FOR INSTALLATION e 24 minimum from rear tanklesss heater if ON COMBUSTIBLE FLOOR Boiler cannot be equipped for servicing and removal of the installed on carpeting heater 3 FOR BASEMENT INSTALLATION provide d Clearance from Jacket Rear Panel a solid elevated base such as concrete if floor is e 12 minimum for rear smokebox cleaning not level or if water may be encountered on floor Note This dimension will also be around boiler controlled by horizontal to vertical to 4 PROVIDE RECOMMENDED SERVICE horizontal smokepipe arrangement See CLEARANCE if applicable as follows Figures 2 and 14 Clearance from Jacket Front Panel 5 For minimum clearances to combustible materials 24 for servicing burner See Figure 2 24 for flueway cleaning MST288 amp MST396 KO FRONT VIEW RIGHT SIDE VIEW 50069 555555555 ete 6 250 ee 24225 55 252 ite lt gt 05 gt OOO 5559 NOTES Listed clearances cannot be reduced for alcove or closet 1 Listed clearances comply with American National Standard installations ANSI NFPA 31 Installation of Oil Burning Equipment 3
5. 1N Hex Nut 5 16 18 Serrated Flange Plated 80860443 1P Hinge Bracket 100014 01 Hinge Bracket 5 16 18 x 3 4 Lg Screw Plated 80861340 Mount Burner 1R Cast Iron Burner Swing Door Only 100071 01 53 54 Boiler Assembl Burner Swing Door Insulation With Pockets 100039 02 1X Socket Head Cap Screw 5 16 x 5 8 Lg Plated 100050 01 1 1 4 NPT Pipe Plug Square Head Brass 806603542 100093 01 1JJ 1 2 Dia Rope Gasket Clean Cut Cover 100095 01 Cap Screw 3 8 16 x 7 8 Lg Plated INN ASME Grade SA307B 80861337 DD 1EE 1PP 5 16 Flat Washer SAE Plated 80860647 ES ES CO RES p gt 2 p 3 2 2 3 2 aa a mew 100951 1 100084401 se en 3 2 z pa 2 3 gt p D gt p p ESSE E 55 Jacket Assembl 2 JACKET ASSEMBLY 2A Jacket Front Panel Assembly w Insulation 100575 01 2B Power Outlet Receptacle w Harness 100605 01 oe Tu AB Truss Head w Shoulder Sheet Metal Tap End Stud 5 16 18 x 3 Lg Plain 26 x 2 5 32 Lg Jacket Spacer 3 Thick Fiberglass Insulation Wrapper Z 20 2
6. 2 M31N39 AB aul TAA 1 15 098285 SSINYYH di Hi 5 gt 1 09 01 Beo ER 09 TAL Xa 11 21 4400 9NLLL3S 1 Pam J yes SH3HLO Ag j J NOLLO31OMd 5 AvZ M3INGH SSIDANVL HUM 553 3unss3ud 33AN3S DAN 3405534 vor 553 711919 MiMOd 01313 SNu13S _ uOlvdiouNy ath H Zo SH3H1O 48 AWLSOWHSHL AvZ M3TYVISNI AB ONIY MilV3H SS3DINVL 553 35 BOILER SEQUENCE OF OPERATION WITH 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 thermo stat is still calling for heat The probe low water cut off will shut down the burner after 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 eve
7. 24 222A COIL HIGH TEMPERATURE WATER FOR AUTOMATIC ASHERS ETC n v IN DUT TEMPERED HOT WATER FAUCETS AND SHOWERS AUTOMATIC MIXING VALVE eae A COLD WATER CHOSE BIBS A AND IN HOT AND SUPPLY COLD WATER LINES FOR PERIODIC FLUSHING OF SEDIMENT gt n GLOBE VALVE 4 BALL VALVE FLOW REGULATOR CIN COLD WATER LINE AT LEAST THREE SAFETY RELIEF VALVE FEET AHEAD OF TANKLESS HEATER Figure 12 Schematic Tankless Water Heater Pipin TABLE 4 TANKLESS HEATER DATA Heater Rating Pressure Drop thru Boiler Model Heater No GPM Heater PSI MST288 MST396 222A MST513 MST629 25 NPT LIMIT TAPPING L REAR OF BOILER WATER TEMPERATURE LIMIT CHONEYWELL L4006A OR EQUIVALENT TO ALLIANCE CIRCULATOR MEGASTEAM Y BOILER STRAINER 1 NPT nee LOCATE ALLIANCE SUPPLY SUPPLY TAPPING AS CLOSE TO FLOOR PIPING REAR OF BOILER LEVEL AS PRACTICAL FROM ALLIANCE WATER HEAT FLOW CONTROL VALVE TO BOILER RETURN 1 1 2 NPT RETURN TAPPING G CREAR OF BOILER Figure 13 Alliance Water Heater Piping with MegaSteam Boiler B CONNECT ALLIANCE INDIRECT WATER 1 Refer to Alliance manual for additional HEATER PIPING as shown in Figure 13 information 26 SECTION VENTING amp AIR A CHIMNEY VENTING 1 Chimney venting is an
8. 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 amp 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 gt Phillips pan head machine screws CAST DOOR HINGE W INTEGRAL PIN MOUNTING BRACKET POSITION FOR LEFT HAND HINGE AS SHIPPED 5 16 FLAT WASHER 5 8 16 X 1 3 4 LG HEX HEAD BOLT SECURE DOOR 7 5 16 18 X 3 4 LG HEX HEAD CAP SCREW BRACKET JACKET ATTACHMENT Z BURNER SWING DOOR AT REST FULLY CLOSED ea 10 Place front jacket panel over front section attachment bosses and align jacket holes with front section boss holes Firstly install two 5 16 18 x 1 2 Phillips pan head machine screws hand tight to secure front jacket panel right side to casting Secondly insert 5 16 18 27 hex head 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 cas
9. 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 GOHI3A uinjes 10 buidig
10. 1 Hz second on 12 second off system is locked out or in Restricted Mode Flashing at 4 Hz 2 seconds 2 seconds off control is in Recycle Mode On cad cell is sensing flame Off cad cell is not sensing flame 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 Cad Cell Resistance in ohms Less than 400 More than 400 and less than 800 More than 800 and less than 1600 More than 1600 and less than 5000 b CHECK OIL PRIMARY CONTROL CAUTION Due to the potential hazard of line voltage only atrained 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 supply Make sure power is on to the controls Make sure limit control is closed Check contacts between ignitor and the electrodes Check the oil pump pressure Check the piping to the oil tank Check the oil nozzle oil supply and oil filter ii Check Safety Features Safe Start iii Place a jumper acros
11. For reduced clearances to combustible material protection 2 MegaSteam boilers can be installed in rooms with must be provided as described in the above ANSI NFPA 31 clearances from combustible material as listed above standard Clearance to venting is for single wall vent pipe If Type L vent is used clearance 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 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 ft 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
12. LL oinbi4 WALSAS 43108 S3ATVA OL L3M NV31S M31vVM MO138 38 LSNW NOLO3NNOO GHO1LHVH 30 331 ATONOULS 54354 1538 03 310N 3Nn 40074 JAVA 31v9 8 4 16 8 1 1 31ddlN 5 YO 35012 E SNIdId TWN G33833333d OYOALYVH sv SNIVW AlddNS 40073 30 9 319NV HO ATIVOLLYSA M3Q0V3H NIHLIM OL 3S38VHOSIQ Jdid 30 01 330 N3XVL 38 OL NIVN 4144105 80 5531 LON 38 OL NIVW AlddNS 30 N30133 13M OLNI SNIV 30 SON3 4371108 HOIH NMOQ 34015 NIVN AlddnS Wv3ls N3lvM TVWHON OL 43114 431108 9100 3337 6Z91SN iSISN 96 1SA 88ZISN 3215 344 WAWININ 39NVWHOdM3d W31SAS Q3Q0N3WWOO3H 118 TVNOLLdO 83519 AlddNS QNOO3S 23 SECTION TANKLESS amp INDIRECT WATER HEATER PIPING A CONNECT TANKLESS HEATER PIPING 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 mainta
13. PIPE SHOULD SLOPE UPWARD NOT LESS THAN ONE INCH IN SLOPE UP FOUR FEET ril GAP APPROX DRAFT REGULATOR 120 H 10 O CLOCK 2 O CLOCK POSITION s POSITION e DILUTION AIR VENT LE 5 5 a 3 EN EE and MEGASTEAM BOILER FRONT CLEANOUT 6 O CLOCK POSITION SEE DETAIL A DETAIL RECOMMENDED SCREW LOCATIONS FOR CHIMNEY CONNECTORS mms LINE Fiqure 14 Recommended Vent Pipe Arrangement and Chimney Requirements PROPER LOCATIONS UNACCEPTABLE LOCATIONS CHIMNEY CHIMNEY CHIMNEY VENT PIPE BOILER BOILER BOILER REAR OUTLET BOILER BOILER BOILER REAR OUTLET CHIMNEY CHIMNEY CHIMNEY VENT PIPE BOILER BOILER BOILER ounce REAR u OUTLET Figure 15 Proper and Improper Locations of Draft Regulator 28 2 Chimney Connector a type chimney connector 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 ex
14. combustion chamber and 3rd pass flueways By design door insulation on models MST288 MST396 amp MST513 baffles will not have any by pass pockets If insulation is 12 Locate remove four 8 x 4 shoulder sheet metal damaged or improper type regarding the pockets it screws from Hardware Bag then install them into must be replaced front panel flange holes EQUAL COMPRESSION OF ROPE GASKET SEAL ROPE GASKET FRONT SECTION CUT AWAY SECURING BOLT AND WASHER RIGHT SIDE LATCH SECURING BOLT AND WASHER LEFT SIDE LATCH BURNER en SWING DOOR AIR TUBE POSITION 1 PROPERLY CLOSED AND SECURED JACKET SIDE PANEL 19 BURNER SWING DOOR CLEARANCE FULLY OPEN POSITION 2 90 MINIMUM FULL OPEN POSITION 3 150 MAXIMUM FULL OPEN POSITION 2 AND 3 SWING RADIUS TO FULL OPEN POSITION Figure 58 Top View Burner Swing Door Mounted to Cast Iron Block Assembly Jacket Removed for Clarit 13 ROPE GASKET LEFT SIDE OVER COMPRESSED FRONT SECTION CUT AWAY ROPE GASKET RIGHT SIDE NOT COMPRESSED SECURING BOLT SECURING BOLT AND WASHER AND WASHER LEFT SIDE HINGE BURNER A AIR TUBE N BEFORE RIGHT RIGHT SIDE LATCH BURNER SWING DOOR DO NOT TIGHTEN TORQUE THIS BOLT SIDE HARDWARE S TIGHTENED Figure 5C Top View Burner Swing Door Full Closed but Not Properly Secured or Seal
15. 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 re installing 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 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 pes 5 16 18 x V Phillips pan head machine screws 3 Locate rear panel two lower attachment bosses on rear section See Figure 7 Purpose of Tappings amp Bosses
16. 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 Burnham Hydronics
17. 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 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 CAUTION Use the chimney venting tables as a guide is highly recommended that 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 Und
18. 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 by products 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 t
19. input of all appliances in space If the result is greater than or equal to 50 ft 1000 BTU per hour then it is considered an unconfined space If the result is less than 50 ft 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 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 in
20. or consequential damages so the above limitation or exclusion may not apply to you 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 fi 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 9 5 Boiler Company Inc at Box 3079 Lancaster PA 17604 giving full particulars in support of the claim The homeowner is required to make available
21. or place accumulation of debris 1 Insert the baffles if originally installed into the 3 Remove the baffles if installed from the flue correct flue way The baffles are installed in the 2 passages There is a pair of baffles in each boiler pass two inner flue ways on the MST396 MST513 The baffles are installed in the 2 pass two inner and MST629 flue ways on the MST396 MST513 and MST629 2 Attach the smoke box clean out covers onto the 4 Clean the Pass Insert a 2 dia x 42 long rear of the boiler Verify that the rope gasket is wire or fiber bristle brush into each of the two in good working order before assembly Replace passes Using long strokes push the brush all the rope gasket if necessary Use the 3 8 hardware way through the boiler until the brush has exited originally removed Do not over tighten They the smoke box opening Pull the brush all the way should be snug but not bottomed out forward until it has exited the front of the boiler Continue this operation for the entire height of the NOTICE flue way until clean Repeat the operation for the other 34 pass flue way When securing burner swing door make sure door is drawn in equally on both sides 5 Clean the 2 Pass Insert a 2 dia x 42 long wire or fiber bristle brush into each of the two 2nd passes Tighten swing door hardware to provide adequate Using long strokes push the brush all the way seal to rope gasket around perimeter o
22. primary control Ignitor module defective Latch up will occur if the control locks out f CAD cell defective three 3 times during a call for heat This is indicated by steady on red and amber LED s g Oil valve stuck open or closed 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 INN Bare Boiler Assembl 1 Upper Rod 3 8 16 x 21 1 2 Lg 80861033 Upper Rod 3 8 16 x 27 1 2 Lg 80861014 Lower Rod 3 8 16 x 15 Lg 80861016 1 1 1 2 2 1 Lower Tie Rod 3 8 16 x 20 3 4 Lg 80861012 Lower Tie 3 8 16 x 27 Lg 80861018 1G 3 8 Flat Washer USS Plain 80860600 1H 3 8 16 Heavy Hex Nut Plain 80860400 Spanner Bar w Threaded Inserts 1 1 4 x 1 1 2 x 20 3 8 Lg 100012 02 Spanner Bar w Threaded Inserts 1 1 4 x 1 1 2 x 26 3 8 Lg Spanner Bar w Threaded Inserts 1 1 4 x 1 1 2 x 32 3 8 Lg 100012 04 1K Carriage Bolt 3 8 16 x 1 1 4 Lg Plated 100215 01 1L Cap Screw 5 16 18 x 7 8 Lg Plated 80861371 100012 03 1M Flat Washer 5 16 USS Plated 80860611
23. 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 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. 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 Color Terminals Terminals 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 sec onds primary control will shut burner down and enter into a recycle mode after 60 seconds will restart and repeat trial ignition If after three 3 trials for igni tion 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 amp Miller PS 801 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
25. 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 3 Use Flared fittings only Cast iron fittings cannot be used Do not use compression fittings B SINGLE PIPE OIL LINES Oil piping must be absolutely airtight or leaks 1 Standard burners are provided with single stage or loss of prime may result Bleed line and 3450 rpm fuel units with the bypass plug removed fuel unit completely for single pipe installations Refer to your local jurisdictions regarding 2 The single stage fuel unit may be installed single any special considerations for fuel supply pipe with gravity feed or lift Maximum allowable requirements In addition refer to NFPA 31 lift is 8 feet See Figure 21 Standard for the installation of Oil Burning 3 Fuel Oil Line Deaerator On many occasions Equipment 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 4 Use of a high efficiency micron filter Garber equivalent in addition to a conventional filter is highly recommended deaerator can be installed to eliminate air The 5 Piping used to connect the oil burner to the oil single line from the fuel tank is connected to the supply tank shall not be
26. water Seek immediate medical attention SECTION MAINTENANCE AND SERVICE INSTRUCTIONS A MAINTENANCE LOW WATER CUT OFF 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 wit
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28. 42015 3T Well 1 2 NPT x 3 Honeywell 123872A 80160497 3U Oil Primary Control Honeywell R7184P1064 80160848 3W 100042 01 Stainless Steel 2nd Pass Blueway Baffle Beckett AFG Oil Burner w Gasket for MST288 Spec No BCB7706 100625 01 MST396 Spec No BCB7703 100053 01 MST513 Spec No BCB7704 100054 01 1 MST629 Spec No BCB7705 100055 01 NOTE See Pages 60 and 61 for burner Parts Breakdown Fan Center Honeywell 8285 w Connectors 100640 01 59 943v TIVLAG 4117208 3lVid 2115 AISN3SSY 32 45 3045 M349S dAV19 300310313 M3ldvav 31ZZON rs 300419313 31220 A18W3ssv dWv19 300319313 300319313 MAIA LNOS MAIA 915 YSLLAHS QNV8 3 018 9 1359 YOLOW 3871 39NV 14 7304 YOLOANNOO ONILNNOW A18W3SSV 3QISNI 3144 8 3lVM ol 5 13HSV9 l L 3 X08 X E HOLIN9I OINOMI2313 QV3H LA 404 d 5 NO SdV3H 21 9 11 Q3Xi4 NOSHOLNOSS LAN Q3 TJA ND 1041409 60 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 list
29. 8144 38ONd 9NISN3S 3ovul M 3078 HM 18 N3NNnB ANOLOV 1Z1 13 T3A31080AH HA IA 9 39NVHD 90 39NY14 30118 18 NI using ANNONS AIM 0399md 31949 1MVWS NI 53 1 330 170 W3lVM SOME 0990 T3 3104QAH HANYOISNVAEL 2 M31N39 1OMINOO SUNSOTONS ONN YATIVISNI AB 0319905 268284 TI3MA3NOH 1 15 553 1 09 01 3 1 15 1 nao A8 OW 9NILI3S HOLVAIOLNY E T NOLL9310 d o SH3HLO A8 ANISONS3HL z 44 1 N3lV3H SS3DINVL uo HOLIMS 553 nsssug LAN 34055344 3214365 EL S3NNVH 33MOd 01313 vc S3TIVISNI AB M31V3H SSITINVL 5537 xmon 103NNOO 2501 NMV MAL OMY 3215 MOT 9 50 94 FIBVD XZ19 2 81 3215 39VL10A 2501 JVM MMV M3L NO 81 3215 INN 3215 INN MOLO3N
30. Chimney shall be free of all loose debris 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 Achimney 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 self drilling hex head TEK screws provided in appropriate Parts Carton Locate screws around perimeter of connector as shown in Figure 14 and approximately 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 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 FIRECLAY TILE LINED 5 288 629 LESS THAN 8 X 8 X 15 VENT 26 GA MIN NOTE ALL HORIZONTAL VENT
31. ERVATION PORT COVER on burner swing door START OIL BURNER l Open vent fitting on fuel pump line Refer to Fi No 1 2 PRESS RED RESET BUTTON on front of burner SR eee VOS cover hold for one 1 second and release to reset primary control 3 TURN ON BURNER service switch and The maximum operating pressure of this boiler is allow burner to run until oil flows from vent posted on the ASME Data Label located on the top fitting in SOLID stream without air bubbles for of the boiler Never exceed this pressure Do not approximately 10 seconds plug rslict valve NOTE For Primary Control Pump Priming C CHECK CONTROLS WIRING AND us details see Paragraph I No 2 Step a BURNER be sure that all connections are tight and burner is rigid that all electrical connections been 4 Close vent fitting and burner flame should start 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 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
32. FEATURES AND CONTROLS i 7184 is 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 DIAGNOSTIC LED Fiqure 25 R7184 Terminals LED and Reset Button 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 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 pre installed T T jumper Do not remove jumper See Figure 25 42 vi Diagnostic LED The indicator light on oil primary control provides lockout recycle and cad cell indications as follows Flashing at
33. FF connection see Figure 7 i Drain boiler until 1 of water is visible in gauge glass Run temporary 12 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 amp add solution to boiler water thru exposed tapping using a funnel Check with local authorities or consult local water treatment services for acceptable chemical cleaning compounds 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 qu
34. INSTALLATION OPERATING AND SERVICE INSTRUCTIONS FOR MegaSteam 3 PASS OIL BOILER WTERTE As an E ENERGY STAR Partner Burnham Hydronics B has determined that the 2 US 22 Listed MST288 MST396 MST513 and MST629 meet the ENERGY STAR guidelines for Energy efficiency established by the United States Environmental Protection Agency EPA For service or repairs to boiler call your heating contractor or oil supplier When seeking information on boiler provide Boiler Model Number and Serial Number as shown on Rating Label located on top of the boiler Boiler Model Number Boiler Serial Number Installation Date MST Heating Contractor Phone Number Burnham Hydronics U S Boiler Company Inc 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 Burning Equipment for recommended installation practices Current Edition of American National Standard ANSI NFPA 211 C
35. Jacket Right Side Panel 5 Section Jacket Top Panel 5 Section Beckett Burner Enclosure Backer Plate 1 Beckett Burner Enclosure Cover Knob Dimco 2 116 335 Sheet Metal Screw Plated Phillips Truss Head AB 8 x 1 2 Lg Sheet Metal Screw Plated Phillips Pan Head 2N 2P 2Q 24 s 20 57 5 pue WEIJS 6 91SIN uu p 8821567 NMOHS LON 9NIMS YINYNE HLIM ONLLNNOW 58 Description MST288 MST396 MST513 MST629 3 MST TRIM AND CONTROLS 6 RC STD Draft Regulator 8116288 7 RC STD Draft Regulator 8116289 3B 8056010 Pressure Gauge 3C Probe Hydrolevel EL 1214 for Hydrolevel CG450 80160629 Low Water Cut off Hydrolevel CG450 less Probe 80160623 Low Water Cut off McDonnell amp Miller PS 801 80160723 3E Nipple 3 4 NPT x 3 Lg 806600002 3F Elbow 3 4 NPT x 90 806601502 3J Syphon 1 4 NPT x 1 7 8 x 4 x 90 806603010 3K Pressure Limit Honeywell L404F 1367 80160369 3L Safety Valve 3 4 NPT 15 PSI Conbraco 13 511 08 81660530 3M Gauge Glass Set 6 Conbraco 20 104 10 8056091 3N Low Water Cut off McDonnell amp Miller 67 80160597 Nipple 1 1 2 NPT x 5 Lg 808600060 30 Tee 1 1 2 x 1 1 2 x 3 4 806601105 3R Drain Valve 3 4 NPT Conbraco 35 302 03 806603061 35 80160400 Limit Honeywell 114006
36. NOO iod ni 319V1d3238 193NNO9SIQ 33N3ng 1135938 HUM OMINOO ANNIE TI3WNOH o en YINYOISNVAL OMINOO 258084 iviSvnov Y90077 31H ama HW 18 HW y 3 an E H p 29 EN MO sans 38 a BEN Zo i A8 pay Ge UAN 01 WVAPVIC WN 34155344 34 7 1 103 HIND 250 3 IM 5 MMY M3L 9Mv 3215 39VL10A MOT 2504 54 NEYO UNIO 2 81 3215 MOT 250 NMV MAL NO OMY 3215 INN SMV 3215 INN WVHDVId OLLYVHAHNOS 553 193NNO9SIQ S M0193NNOO A 193NNO09SIQ TI 1133038 HUM AMVMhid m gt WOLLOB NI 340 10 QE 9 Et a ama HN 18
37. OR OIL BURNER GASKET 3 5 16 18 X 3 4 LG CAP SCREWS POWER OUTLET RECEPTACLE BURNER POWER CORD BECKETT AFG OIL BURNER SHOWN WITHOUT BACK PLATE FOR CLARITY BURNER COVER Figure 10 Oil Burner Installation 21 SECTION STEAM BOILER PIPING amp 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 The single most important factor in determining the 3 Install accurate water meter on the fresh water expected life cycle of a steam boiler is the amount of supply to the boiler fresh water added to the boiler during operation Fresh B CONNECT SYSTEM SUPPLY AND RETURN water brings minerals and oxygen into the boiler These contaminants greatly accelerate corrosion of the cast iron boiler sections PIPING BOILER See Figure 11 for piping details Also consult I B R Installation and Piping Guides 1 Assure that all system radiators piping and vents are absolutely leak tight CAUTION 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 Maintain minimum 7 inch clearance from hot water piping to combustible materials b Ifthe system contains hidden supply or return piping
38. S 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 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 B REMOVAL OF CAST IRON SECTION BURNER SWING DOOR SMOKE BOX ASSEMBLY FROM SKID WARNING 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 10 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 Remove all fast
39. TEAM 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 five 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 du
40. adjustable legs are elevated above the skid deck boards Remove the skid from underneath the Cast Iron Section Burner Swing Door Smoke Box Assembly Lower pipe handles until front adjustable legs touch the floor Place wood blocks under front legs if required before lowering to provide hand clearance 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 If wood blocks were placed under front legs lift pipe handles remove the blocks and lower front legs to floor Remove pipe handles Move Cast Iron Section Burner Swing Door Smoke Box Assembly to permanent position by sliding or walking CAUTION Do not drop boiler when removing from skid and moving to permanent position C PROCEDURE TO OPEN CLOSE AND SECURE BURNER SWING DOOR 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 JACKET FRONT PANEL INSTALLATION In order
41. alified 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 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 ope
42. ame contact RCF changes into crystalline silica a known carcinogen When disturbed as a result of servicing or repair these substances become airborne 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 Long sleeved loose fitting clothing Gloves 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 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
43. 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 9 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 insid
44. 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 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 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 e Excessive back pressure causing flame to be stuck or welded motor relay erratic 3 Control locks out after Trial For Ignition TFI No oil to burner If flame is not established within 15 seconds b Shorted electrodes of oil valve actuation known as Trial For Nozzle cl d Ignition TFI lockout will occur Lockout is b Pe TUM CERS indicated by red LED solid on located on the d Airflow too high oil
45. de the enclosure thru bushed hole at enclosure lower left corner next to transformer relay 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 Install 8 1 2 sheet metal screw thru enclosure base lower hole located to the right of transformer relay into right side panel to secure the enclosure 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 Do not install the enclosure cover yet proceed to control installation 17 AND CONTROLS INSTALLATION Pressure Limit Installation 1 Locate and remove L404F Pressure Limit with factory attached harness from Control Carton Locate and remove 1 4 NPT x 1 7 8 x 4 x 90 syphon enclosed in Part Carton Review and locate pressure limit tapping on front section See Table 3 Purpose of Tappings amp Bosses and Figure 7 Thread 1 7 8 12 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 Thread NPT x 4 Ig syphon threaded long end into pressure limi
46. details outlined in this section Do not reduce size of air intake pipe Read understand and follow combustion air instruction restrictions contained in the Pre Installation Section of this manual SUPPORT STRAPS HORIZONTAL RUN MUST SLOPE TOWARD TERMINAL 4 SLOPE DOWN PER FOOT MINIMUM 5 FT MAX VACUUM RELIEF VALVE VERTICAL ORIENTATION PREFERRED FOR DUSTY INSTALLATIONS FLOOR LINE 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 Assemb
47. e More make up water and higher concentrations of contaminants damage the boiler sooner Our warranty does not cover oxygen corrosion and sediment related 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
48. e 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 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 NPT tappings to the right of the probe LWCO See Figure 7 Purpose of Tappings amp Bosses 3 Thread the pressure gauge into 1 4 NPT tapping of the front section See Figure 7 Purpose of Tappings amp 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 FLOAT LWCO MCDONNELL MILLER 67 AND GAUGE GLASS INSTALLATION 1 Pre assemble float type LWCO per Figure 9 Float Type LWCO and Gauge Glass Installation 2 Install two 2 NPT x 22 long Sch 40 brass nipples supplied loose inside Control Carton disregard two NPT x 1 2 long brass nipples provided with 67 LWCO package and NPT brass unions into upper and lower front section tappings See Table 3 Purpose of Tappings amp Bosses and Figure 7 3 Install water gauge glass on low water cut off assembly tee fittin
49. e 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 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 TEST CONTROLS 1 Check thermostat operation Raise and lower thermostat setting as required to start and stop burner AVAH 629LSW ANV IGLSK 04 0 LV DNILLAS NOLLVNIBNOO 5 5201 3801 QW ANN NNOOV 31V1d ONLSNTOY 5 LAN Q3THON5 as ki 31V1d NOISN3NWIQ 2 ONILSNPOV AYYNIHd 3119 AYVA SS3NLIM NOILISOd O QV3H JO NOILV2O1 S130ON 303 TI LNAWLSACAY S3OONLOSTS 968LSW NV GHXI4 31ZZON Poe QV3H YO Qv3H 30 OL E dvo 31ZZON OL 01 300419313 41 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
50. ed 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 Baffle Usage Model MST396 T MSTS1S P N 100042 01 nape MST629 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 e Models MST396 MST513 and MST629 To install flueway baffle in 2 pass flueway 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 274 pass flueway To install flueway baffle in 2 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 2 pass flueway F CLOSING SECURING BURNER SWING DOOR 1 To close and secure Burner Swing Door a From fully open position rotate the
51. ed below MST513 AFG7OMLASN BCB7704 3492 4150 4198 3709 4198 2999 2454 Less 3666 5636 4 4219 5780 5992 MST629 AFG70MKASN BCB7705 3492 4150 4198 3709 4198 2999 2454 Less 3666 5636 4 4219 5780 5992 Boiler Model MST396 Air Tube Combination AFG70MMAQN Beckett s Spec No BCB7703 Air Band 3492 Air Band Nut 4150 Air Band Screw 4198 Air Shutter 3709 Air Shutter Screw 4198 Blower Wheel 2999 Coupling 2454 Low Firing Rate Baffle Less Bulkhead Knurled Locknut 3666 Connector Tube Assembly 5636 Electrode Clamp 149 Electrode Clamp Screw 4219 Electrode Insulator Assembly 5780 Support Spacer Assembly 5992 Escutcheon Plate Adjusting Plate Assembly 5941 5941 Head 5913 Head Screws 4221 Flange Gasket 3811 AFG Housing 5874GY Motor 21805E 218 Nozzle Adapter 213 Nozzle Line Electrode Assembly Pump Clean Cut 21844 21844 Single Stage Oil Pump Clean Cut 21941 21941 Two Stage Static Plate 3383 Ignitor 51771U Ignitor Hinge Screw 4217 Ignitor Holding Screw 4292 ignitor Gasket Kit 51304 Wire Guard 10251 Junction Box 3741 Flame Detector 7006Q Oil Solenoid Valve Coil 21775U Oil Solenoid Valve Cord 21807 5941 5913 4221 3811 5874GY 21805E 218 213 5941 5913 4221 3811 5874GY 21805E 218 213 NL70MD NL70MD 21844 21844 21941 21941 3383 51771U 4217 4292 51304 10251 3741 7006Q 21775U 21807 3383 51771U 4217 4292 51304 10251 3741 7006Q
52. en 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 1 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 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 72 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 fo
53. eners at crate skid Lift outside container Examine the skid contents for damage due to shipping and handling Remove Insulation Wrapper Control Carton Jacket Carton Part Carton and Oil Burner Carton from skid and set aside Instruction Label Bag is affixed to Section Assembly tie rod Remove the bag and locate MegaSteam Boiler Installation Operating and Service Instruc tion manual READ AND UNDERSTAND ALL INSTRUCTIONS BEFORE ATTEMPTING UNIT HANDLING AND INSTALLATION 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 11 12 13 14 15 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 Ig 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 Place wooden block s 12 from rear of skid as shown See Figure 4 Boiler Removal from Skid 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 For best leverage the pipe handles should extend 48 minimum beyond front section face Using the pipe handles lift the Cast Iron Section Burner Swing Door Smoke Box Assembly until
54. er no circumstances are other baffles to be used on this product The baffles are installed in the 2 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 AT with baffles IN and OUT In addition the lower the CO level the higher the stack temperature Figure 16 Smokebox Pressure Tapping for Checking Draft at Breech 29 WARNING Remove the baffles if there any signs of condensation in the chimney or chimney connector Consult with your local chimney professional for recommendations 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
55. f door 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 Use an alternating tightening method from right side to left side cap screw to pull door tight equally Continue this operation for the entire height of the flue way until clean Repeat the operation for the NOTICE other 274 pass flue way Do not overtighten The rope gasket will provide 6 Vacuum the loose debris in the bottom of the sufficient seal when the door is snugged into combustion chamber and smoke box place 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 FLUE BRUSH CLEAN OUT COVER sn gt VACUUM 3RD PASS 2ND PASS PARTIAL SIDE VIEW HOSE FLUEWAY FLUEWAY CUT A WAY THRU 3RD PASS FLUEWAY AND REAR SMOKEBOX FLUE BRUSH O5 COMBUSTION CHAMBER SOFT BRISTLE REVERSING CHAMBER VACUUM HOSE FRONT VIEW SIDE VIEW THRU COMBUSTION CHAMBER REVERSING CHAMBER AND 2ND PASS FLUEWAY 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 T
56. 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 of phosphoric acid H PO B BOILER AND SYSTEM CLEANING INSTRUCTIONS FOR TROUBLE FREE CAUTION OPERATION 1 STEAM BOILERS Exercise caution when handling phosphoric acid and follow the instruction label on its container a Oil greases amp sediments which accumulate ina 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 O
57. gs 4 Do not remove 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 uonej ejsuj 5 OOM12 TWNINYAL OL LOSNNOO 3MIM 1 TWNINYAL OL 103NNO2 ov18 3dld 14 8 TIddiN SSYY8 365010 X 2 1 3lddlN X l h 331 ldN B 2 1 1 X 1dN Z L ps 3103334 LAN HUM SSVU8 v 7 X TO 2 NoiSS3NdWOO 2 1 X 1dN 8 3033834 LAN HUM C 06 X 700 2 1 8 6 TiddiN 55 2 X LdN 2 1 NOINN LAN 2 be 31ddIN SSVU8 2 2 X LdN 55748 1 2 1 5 55 9 E 8 X LdN 2 1 135 55 19 39nv9 19 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 th
58. h 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 part h Clean the pipe threads of the probe to remove old hardened pipe dope and other foreign matter 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 Screw the probe into the boiler tapping k Mount the low water cut off control on the probe Reconnect the control to probe wiring c 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 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
59. he 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 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 50 NOZZLES Although the nozzle is 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 CO and smoke Nozzles are delicate and should be protected from dirt and abuse Nozzles are mass produced and from sample to sample For all of those reasons a spare nozzle is a desirable item for a serviceman to have 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 lea
60. he 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 Fuel Burning Appliances a Loose Mortar Loose mortar could be 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
61. himneys Fireplaces Vents and Solid Fuel Burning Appliances For Venting requirements 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 All wiring on boilers installed in the USA shall 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 Indicates an imminently hazardous situation which if not avoided will result in death serious injury or substantial property damage WARNING Indicates a potentially hazardous situation which if not avoided could result in death serious injury or substantial property damage CAUTION Indicates a potentially hazardous situation which if not avoided may result in moderate or minor injury or property damage NOTICE 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 section
62. ies are 3 On STEAM BOILERS turned off at the source and that the vent is clear a With an L404F1367 set cut out pressure from obstructions MAIN scale on the pressure limit for 1 PSI and differential pressure DIFF for 5 PSI WARNING These pressures may be varied to suit individual Completely read understand and follow all requirements of the system instructions in this manual before attempting 4 On STEAM BOILERS WITH TANKLESS 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 DOMESTIC WATER HEATERS set boiler water temperature dial on L4006 operating control at 190 F max Set differential at 10 ADJUST OIL BURNER BEFORE STARTING l CHECK BURNER AIR BAND AIR SHUTTER AND HEAD SETTING if applicable readjust if necessary see Table 8 at rear of manual OPEN ALL OIL LINE VALVES 3 Attach a plastic hose to fuel pump vent fitting and provide a pan to catch the oil OPEN FLAME OBS
63. ignition failure WARNING 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 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 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 40 and while burner is running At least five minutes See Table 8 at rear of manual for details 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 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 CO 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 expand when burner stops causing oil to squirt from nozzle at low pressure as th
64. 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 READJUST THE HEAD SETTING only if necessary a MST288 amp MST396 Beckett MB L1 Head burner has a fixed head which is non adjustable b MST513 amp MST629 Beckett MD V 1 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 readings See Figure 24 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 STING control has tripped the burner has experienced
65. in 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 15 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 CAUTION possible by piping the hot water from the heater prior to entering the mixing valve The mixing valve
66. ion 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 ___ MSTS Rear Section Heater Part 100566 05 100045 02 100021 01 MST3 Rear Section Non Heater Part 100567 03 100045 01 100021 01 222 MST4 Rear Section Non Heater Part 100567 04 100045 01 100021 01 MSTS Rear Section Non Heater Part 100567 05 100045 02 100021 01 2 __ Control Carton ___ CG450 LWCO W Tankless Heater Part 100608 01 ____ 58 1 LWCO W Tankless Heater Part 100622 01 __ 67 LWCO W Tankless Heater Part 100678 01 CG450 LWCO L Tankless Heater Part 100680 01 5 ___ Insulation Wrapper PS801 LWCO L Tankless Heater Part 100681 01 Part 100614 03 867 LWCO L Tankless Heater Part 100679 01 _ Part 100614 04 MSTS Part 100614 05 3 Jacket Carton ____ MST3 Part 100609 03 6 __ Instruction Label Bag MST4 Part 100609 04 ___ MST Models Part 100617 01 ___ 5 Part 100609 05 7 Oil Burner Carton 4 Part Carton __ Beckett MST288 Part 100625 01 MST3 amp 4 Part 100615 01 __ Beckett MST396 Part 100053 01 MSTS Part 100629 01 __ Beckett MST513 Part 100054 01 Beckett MST629 Part 100055 01 CASTIRON SECTION ASSEMBLY TAPPING
67. iting 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 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 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 4 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
68. ks air leaks water or dirt in the fuel as described above 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 AIR LEAKS Any such leaks should be repaired as they may cause erratic burning of the fuel and in extreme cases may become fire hazard GASKET LEAKS If 11 5 to 12 5 CO 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 CO reading in the breeching The smaller the firing rate the greater effect an air leak can have on CO readings 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 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 o
69. le the vacuum relief valve balance weight onto the gate Refer to the vacuum relief valve manufacturer s instructions WEATHERPROOF EXTERIOR JOINTS WITH SILICONE CAULK INTAKE TERMINAL SCREEN FACING DOWN el T Min 12 MIN L GRADE MAX SNOW ACCUMULATION 5 FT MAX Stl Sli FRONT VIEW Figure 17 Optional Air Intake Pipin Installation Only Available with Beckett Burner 30 Mount the vacuum relief valve into the tee and 7 Seal all external joints with weatherproof caulk fasten with a screw and nut in collar tabs To ensure proper operation the gate must be level WARNING across the pivot point and plumb Refer to vacuum relief valve manufacturer s instructions Donotlocate air intake where petroleum distillates detergents volatile vapors or any other chemicals are present Severe boiler corrosion and failure will result 5 Install remainder of air intake securing each joint with at least three 3 sheet metal screws evenly spaced 6 Install air intake terminal See Figure 17 NOTICE Intake terminal must be at least 12 inches above grade plus snow accumulation 31 SECTION 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 Failu
70. ll 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 18 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 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 44 Important Product Safety Information Refractory Ceramic Fiber Product Warning The Repair Parts list designates parts that contain refractory ceramic fibers RCF has been classified as a possible human carcinogen When exposed to temperatures about 1805 F such as during direct fl
71. n for part identification NEVER TIGHTEN LEFT SIDE TAP BOLT 2 Check the gasket factory attached to the FIRST OR EITHER PIECE OF HARDWARE Repair if the 15 damaged OT there is 100 WITHOUT USING THE ALTERNATING a gap between the rope ends METHOD DESCRIBED ABOVE See Figure 3 Locate remove four 5 16 18 7 8 hex head SB screws from Hardware Bag e Failure to follow the prescribed procedure could 4 Apply a drop of supplied Anti seize pouch provided cause thread damage to casting and or leak at in Part Carton to each of four 4 5 16 18 x 7 8 the door seal IF LEFT SIDE TAP BOLT IS hex head cap screws for rust protection and to TIGHTENED BEFORE RIGHT SIDE TAP facilitate easy removal for future service BOLT RIGHT SIDE OF THE DOOR CAN 5 Position left Cleanout Cover over rear section NOT BE DRAWN IN TO PROVIDE AN AIR cleanout opening align section boss holes with TIGHT SEAL as shown in Figure 5C Applying Cleanout Cover holes install both 5 16 18 7 8 excessive torque will only cause thread damage hex head cap screws hand tight then alternately tighten them with open end or socket wrench 15 4 VIEW d pem 4 1 _ p 9 x 4 a N 7 e v _ i 7 4 FRONT VIEW REAR VIEW Figure 7 Purpose of Tappings and Bosses TABLE 3 PURPOSE OF TAPPINGS amp BOSSES Tap
72. nsulation and insulation wrapper and feed it thru Right Side Jacket Panel front cutout letting the harness connector to hang over the cutout edge temporarily Place Right Side Jacket Panel clearing rear section tankless heater collar mounting flange over four 8 x 4 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 Slide the panel downwards to lock all screws securely Pick up Top Jacket Panel from Jacket Carton 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 Locate remove two 8 x gt sheet metal screws from Hardware Bag Install both screws into top panel rear flange to secure the top panel to rear jacket panel EXTERNAL ELECTRICAL ENCLOSURE MOUNTING 1 Remove two 8 x gt shoulder sheet metal screws and one 8 x gt sheet metal screw from Hardware Bag Install both Z8 x gt shoulder sheet metal screws into Right Side Jacket Panel at two upper corners of the panel front cutout Locate and remove External Electrical Enclosure assembly from Control Carton Remove the enclosure cover and set aside 5 Pick Molex connector end of Burner Harness and feed it insi
73. on 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 thermostat s temperature setting reduce heat anticipator setting by or 2 amps If system tends to short cycle without reaching desired room temperature increase heat anticipator setting by 1 or 2 amps OSMI 54014 06799 81 9Jnbi3 X310N Hi 193NNOO YANO ANN34IM 2501 5 MMV M3L OMY 81 3215 MOI 2901 94 JYI LINDYIO OMY 2 81 3215 JOVLIOA 250 ML OMY 8L 3215 9 INN ML OMY 3215 INN WVNDVIT 9 71132 Qvo 1 1 552 193NNO9SIQ Y3NYNE N YOLOJNNOD 5 1 nNOOVYIANS 3NTVA GION3 10S 1 9 YOLO T 193NNOOSIO YOLINSI YOLINS 113 239 HUM 33 9 ANVWhid 49
74. on the heating system to prevent damage if the boiler is inoperative 47 SECTION 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 AFTER CLEANING vacuum all remaining debris as necessary Inspect burner swing door insulation and rope gasket for signs of damage If damaged replace as 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 D REASSEMBLE BOILER the rear smoke box by removing the four 5 16 18 hex head bolts It is NOT necessary to remove the CAUTION vent connector from the smoke box to clean boiler Do not start the burner unless the burner swing door and canopy cover plates are secured in 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
75. ping Thread Size Steam Boiler Pressure Gauge Probe LWCO Std Plugged Float LWO Water Gauge Glass Probe LWCO 72 14 Water Gauge Glass Pressuretrol amp LWCO Float LWCO waa j Indirect Water Heater Limit Water Heater Limit 5 16 18 Jacket Panel Smoke Collar ees ees Covers w 18 Smokebox Pressure Smokebox Pressure Tapping L4006 12 14 Operating Plugged Control 112 Repeat above steps with right Cleanout Cover 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 Place the collar over smokebox tongue and align collar integral mounting ear slots with smokebox bosses Thread in both 5 16 18 7 8 hex head cap screws hand tight then alternately tighten them with open end or socket wrench INSULATION WRAPPER AND BURNER POWER OUTLET RECEPTACLE WITH HARNESS INSTALLATION 1 Insulation Wrapper is vacuum packed sealed in plastic bag at the factory Carefully cut the plastic bag and remove Insulation Wrapper The wrapper will expand upon removal 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 Insure wrapper fits snugly around rear section tankless heater colla
76. plied 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 TABLE DIMENSIONAL DATA SEE FIGURE 1 Dimensions See Water Content To Normal Boiler Figure 1 Water Line Gallons Heat Transfer Actual Shipping Surface Area Model No i Weight LB odel No A
77. 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 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 set ting for proper operation of the domestic water heater if equipped with optional tankless heater 36 SECTION OIL PIPING A GENERAL Pa WARNING Use flexible oil line s so the burner swing door can be opened without disconnecting the oil supply Under no circumstances can copper with sweat piping style connectors be used 2 Asupply 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 NOTICE 1 0 gph to prevent nozzle fouling Some jurisdictions require the use of a fusible shutoff valve at
78. pump seals TABLE 6 SINGLE STAGE UNITS 3450 RPM TWO PIPE SYSTEMS Maximum Length of Tubing Lift H H R See Figure 22 See Fig 21 3 8 OD Tubing 1 2 OD Tubing 3 3 100 100 100 100 100 100 100 100 100 100 100 100 83 62 OUTSIDE FUEL FILL AIR PIPE VENT LINE _ 7 RETURN H FLEXIBLE OIL PIPING RECOMMENDED NEAR BURNER SWING DOOR FUEL PUMP RECOMMENDED FILTER GARBER OR EQUIVALENT Figure 22 Two Pipe Oil Lines 38 SECTION 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 SET ROOM THERMOSTAT about 10 above room temperature 1 Verify that the venting water piping oil piping and 2 PRESS RED RESET BUTTON on front of electrical system are installed properly Refer to burner cover hold for one 1 second and release to Installation Instructions contained in this manual reset primary control 2 Confirm all electrical water and oil suppl
79. put 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 UNIT PAK ASSEMBLY MegaSteam Unit Pak Boiler Assembly Shipment Content Check List see Figure 3 1 ___ Cast Iron Sect
80. r additives which cause unusual deposits or corrosion in or on the heat exchanger This warranty applies only to boilers installed within the United States and Canada In order for this warranty to be effective 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 Boiler components must not have been damaged in handling during shipment or installation 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 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
81. r 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 Tack Insulation Wrapper bottom ends under section assembly between front and rear section legs Locate and remove Burner Power Outlet Receptacle with factory attached Burner Harness from Control Carton 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 SIDE AND JACKET PANEL INSTALLATION 1 Pick up Side Jacket Panel from Jacket Carton See also Repair Parts Section Jacket Assembly illustration for part identification Place Left Side Jacket Panel over four 8 x 2 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 Slide the panel downwards to lock all screws securely Pick up Right Side Jacket Panel from Jacket Carton See also Repair Parts Section Jacket Assembly illustration for part identification 10 11 Pick up Molex end of Burner Harness stuffed between front panel i
82. r 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 Transformer Relay then tighten screws securely Q SAFETY VALVE AND DRAIN VALVE INSTALLATION 1 Remove safety valve and related piping 3 4 NPT x 3 12 black nipple 3 4 NPT x 8 lg black nipple 34 NPT 90 black elbow and 34 NPT black coupling from Part Carton 2 Thread 3 4 NPT x 3 lg black nipple into rear section safety valve tapping install NPT 90 black elbow facing upward then thread 3 4 NPT x 8 lg black nipple into the elbow and install 34 NPT black coupling onto nipple end 3 Thread safety valve into the 34 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 x 5 Ig black nipple 1 1 2 x 1 1 2 3 2 NPT black tee and drain valve from Part Carton Lower section Tapping is used for
83. rating 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 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 Ifthe 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
84. re 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 32 Each boiler must be protected with a properly sized fused disconnect Never jump out or make inoperative any safety or operating controls 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 B 6 Ifan 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 INSTALL A ROOM THERMOSTAT onan 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 televisi
85. ring this period U S Boiler Company Inc will repair or replace at its option the cast iron section assembly ADDITIONAL TERMS AND CONDITIONS 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 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 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 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 insufficient water allowed to freeze subject to flood conditions or operated with water conditions and or fuels o
86. ry 10 minutes of firing time to allow water level to stabilize If the water level is too low the burnerwill 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 re turned 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 the high limit is reached Terminals be Lettered or for the last 10 seconds When the pressure limit control restores the circuit on a Numbered as Follows drop in pressure the burner will
87. s 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 Improperinstallation adjustment alteration serviceormaintenance 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 172 x NPT reducing bushing mounted into rear section boss a
88. s cad cell terminals Follow procedure to turn on burner Burner must not start indicator light turns on and control remains Idle Mode Remove jumper Simulate Ignition or Flame Failure Follow procedure to turn on burner Close hand valve in oil supply line Failure occurs device enters Recycle Mode Indicator light flashes at 1 4 Hz rate 2 seconds on 2 seconds off Device tries to restart system after approximately 60 seconds After third Recycle Mode trial safety switch locks out within safety switch timing indicated on label and control enters Restricted Mode Indicator light flashes at 1 Hz rate 7 second on second off Ignition and motor stop and oil valves closes Cad Cell Check See Figure 26 igure 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 1s good If safety switch shuts down burner and resistance is above 1600 OHMS open line switch to boiler Access cad cell under ignitor clean face of cad cell and see that cell is securely in socket Check gasket around perimeter of ignitor lid for proper seal If gasket 15 missing or damaged replace gasket Room light can effect cad cell resistance Reset safety switch Close line switch to boiler If burner starts and runs beyond safety switch cut off time cell is good If not install new ce
89. s 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 Aclean 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 sup
90. smaller than 3 8 iron pipe deaerator The burner pump must be connected or 3 8 OD copper tubing Copper tubing shall have to the deaerator as a two pipe system Follow the 032 minimum wall thickness oil pump manufacturer s recommendations for conversion to a two pipe system AIR VENT FILL FLEXIBLE PIPING RECOMMENDED PIPE NEAR BURNER SWING DOOR RECOMMENDED FILTER GARBER OR EQUIVALENT FUEL PUMP SHUT OFF VALVE MAXIMUM ONE PIPE diii FT MAIN FILTER Figure 21 Single Pipe Oil Line 37 TWO 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 recommenda tions 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 Maximum Length of Tubing Lift H R See Figure 22 See Fig 22 3 8 OD Tubing 1 2 OD Tubing 3 3 GPH 100 100 100 100 100 100 100 100 100 lt Q 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
91. standard condensate return on steam boilers 5 Thread 1 1 2 x 5 12 black nipple into lower rear section tapping then install 1 1 2 x 1 1 2 x 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 34 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 12 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 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 BURNER SWING DO
92. t tapping on front section See Figure 8 Pressure Limit Installation 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 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 M 18 Figure 8 Pressure Limit Installation PROBE LWCO HYDROLEVEL 450 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 2 Install the probe into the appropriate front section tapping See Figure 7 Purpose of Tappings amp 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 th
93. t the back of rear section See Unit Pak Boiler Assembly and Steam Boiler Trim amp 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 Alway
94. ting hand tight Thirdly insert 5 16 18 27 hex head 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 Finally tighten both sets of hardware to secure the bracket and front jacket panel Inspect fiberglass 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 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 BURNER SWING DOOR 5 16 18 X 1 2 LG PHILLIPS PAN HEAD MACHINE SCREW JACKET ATTACHMENT RIGHT SIDE CAST RAMP DOOR REST FRONT SECTION Figure 5A Partial Front View Burner Swing Door Mounted to Boiler Fully Closed and Secured 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 By design door insulation on model MST629 will have two by pass pockets cast into the insulation centered on the bar between the
95. 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 ON ASIA ACIS TVILYVd QIMS 3AOW3H 4315 30073 OL OL N3MO1 5018 ate 3SIVY das STIONYH 3did Lini 5 aas ON AJIA GIS TVILHVd ASIA LNOWHJ TVILEVd as WO33 21 SX2018 39V1d 4315 5931 1 5931 31108 TY NI Jdid NOH gas OL 831108 SNI8093S SM3HOS 9v1 das S310H HONOYHL AISN3SSY 5 5310 3did Y3NENE Ov HOS LMN3SNI NOIL93S NONI 18 0 g 4315 11 12 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 87 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 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 Remove two 5 16 18 27 hex head cap screws securing door mounting bracket to front section and set aside
96. ut of the combustion chamber and clog the flueways of the boiler 8 COLD OIL Ifthe 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 1s 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 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 SHUT DOWN NOISE Ifthe 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 CHECK TEST PROCEDURE 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

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