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INSTALLATION, OPERATING AND
SERVICE INSTRUCTIONS FOR
MegaSteam™
3-PASS OIL BOILER
As an
®
ENERGY STAR Partner,
Burnham Hydronics
has determined that the
MST288, MST396, MST513 and
MST629 meet the
®
ENERGY STAR
guidelines for Energy
efficiency established by the
United States Environmental
Protection Agency (EPA).
For service or repairs to boiler, call your heating contractor or oil supplier. When seeking
information on boiler, provide Boil
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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, “
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DANGER DO NOT store or use gasoline or other flammable vapors or liquids in the vicinity of this or any other appliance. WARNING Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury or loss of life. Failure to follow all instructions in the proper order can cause personal injury or death. Read and understand all instructions, including all those contained in component manufacturers manuals which are provided with the appliance b
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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 whic
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5 Figure 1: MST88 Thru MST69 Steam Boiler with and without Tankless Heater
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TABLE 1A: DIMENSIONAL DATA (SEE FIGURE 1) Dimensions (See Water Content (To Normal Heat Transfer Figure 1) Water Line) - Gallons Boiler Actual Shipping Surface Area Model No. Weight (LB.) With Tankless - sq. Ft. "A" "B" "C" Non-Heater Heater MST288 22-5/8" 24" 6" 15.3 14.9 20.29 607 MST396 22-5/8" 24" 6" 15.3 14.9 20.29 607 MST513 28-5/8" 30" 6" 19.7 19.3 27.29 744 MST629 34-5/8" 36" 7" 24.1 23.8 34.29 881 NOTE: 1: Maximum Working Pressure: Steam - 15 PSI TABLE 1B: RATING DATA I=B=R N
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SECTION I: PRE-INSTALLATION A. INSPECT SHIPMENT carefully for any signs of • 30" for flueway cleaning (MST513) damage. • 36" for flueway cleaning (MST629) b. Clearance from Jacket Left Side Panel - 1. All equipment is carefully manufactured, inspected and packed. Our responsibility ceases upon delivery • 19" for burner swing door, if opened fully of crated boiler to the carrier in good condition. with burner mounted, otherwise 1" with burner removed 2. Any claims for damage or short
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a. Outdoor air for combustion may be provided NOTICE with an optional Burnham Inlet Air Accessory Kit, Part Number 611280031 (only available Clearance to venting is for single wall vent and suitable for use on Beckett AFG with pipe. If Type L vent is used, clearance may be burner enclosure cover burner). See Section V reduced to the minimum required by the vent pipe for installation details. manufacturer. or b. Outdoor air may be provided with the use of two C. PROVID
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SECTION II: UNIT-PAK BOILER ASSEMBLY MegaSteam™ Unit-Pak Boiler Assembly Shipment Content Check List (see Figure 3) 1. ___ Cast Iron Section/Burner Swing Door/Smoke Box Assembly Mounted on Shipping Skid: ____ MST3 (Rear Section, Heater) – Part # 100566-03 / 100045-01 / 100021-01 ____ MST4 (Rear Section, Heater) – Part # 100566-04 / 100045-01 / 100021-01 ____ MST5 (Rear Section, Heater) – Part # 100566-05 / 100045-02 / 100021-01 ____ MST3 (Rear Section, Non-Heater) – Part # 100567-03 / 10
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A. CAST IRON SECTION ASSEMBLY TAPPINGS 6. For manual Cast Iron Section/Burner Swing Door/ Smoke Box Assembly removal prepare one piece of Refer to Table 3 "Purpose of Tappings and Bosses" and 4” x 4” x 16” lg. (or two pieces of 2” x 4” x 16” lg.) Figure 7. and two pieces of 1” Sch. 40 black pipe to be used 1. All tappings have factory installed thread protectors. as handles. Suggested pipe length for each handle is The thread protectors must be removed prior to 72” (3-section); 78” (4-
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11 Figure 4: Boiler Removal from Skid
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1. To open/remove Burner Swing Door (mounted on 4. Place front jacket panel over front section Cast Iron Section/Burner Swing Door/Smoke Box attachment bosses and align jacket holes with front Assembly) and door mounting bracket for front section boss holes. jacket panel installation: 5. Firstly, install two 5/16”-18 x ½” Phillips pan head a. Loosen but not remove door left side latching machine screws hand tight to secure front jacket hardware (3/8”-16 x 1-3/4” tap bolt). panel right side t
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11. Upon inspection completion, lift door and place By design, door insulation on model MST629 will integral cast hinge pins into door mounting bracket have two by-pass pockets cast into the insulation slotted holes. Do not close and secure door at this centered on the bar between the combustion time, proceed to installing stainless steel flueway chamber and 3rd pass flueways. By design, door baffles. insulation on models MST288, MST396 & MST513 will not have any by-pass pockets. If in
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Figure 5C: Top View - Burner Swing Door Fully Closed but Not Properly Secured or Sealed • Models MST396, MST513 and MST629 - To E. FLUEWAY BAFFLE INSTALLATION. nd install flueway baffle in 2 pass flueway on Flueway baffles are enclosed into Part Carton. Baffle left side of boiler, hold baffle with word "Left" requirements differ by boiler model, see Table 2. readable at the top. Slide baffle in flueway until nd position tab touches fins on right side of 2 pass nd flueway. To inst
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G. JACKET REAR PANEL INSTALLATION. 1. Locate jacket rear panel (has factory attached 3” fiberglass insulation) inside Jacket Carton. See also “Repair Parts” Section, “Jacket Assembly” illustration for part identification. 2. Locate and remove from Hardware Bag rear panel mounting hardware – (2 pcs) 5/16”-18 x 3” lg. tap studs, (2 pcs) 5/16”-18 plated acorn nuts, (2 pcs) 5/8” x 2-9/32” round spacers and (2 pcs) 5/16”-18 x ½” Phillips pan head machine screws. 3. Locate rear panel two lo
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Figure : Purpose of Tappings and Bosses TABLE 3: PURPOSE OF TAPPINGS & BOSSES Steam Boiler Tapping Thread Size Size, NPT Boss Location Location UNC With Heater Less Heater A ¼" - 18 Pressure Gauge B ¼" - 18 Pressure Limit Probe LWCO - Std. C ¾" - 14 Plugged (Float LWO) Water Gauge Glass (Probe LWCO) D ½" - 14 Water Gauge Glass, Pressuretrol & LWCO (Float LWCO) E " - 11½" Supply (Front & Rear Tappings) F ¾" - 14 Safety Valve G 1½" - 11½ Condensate Return H 1¼" - 11½ Op
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6. Repeat above steps with right Cleanout Cover. 5. Pick up Molex end of Burner Harness stuffed between front panel insulation and insulation 7. Apply the adhesive sealant to the underside of the wrapper and feed it thru Right Side Jacket Panel collar, all around, at the inside corner of the collar front cutout, letting the harness connector to hang outer ring. Insure adhesive bead is complete all over the cutout edge temporarily. around and without gaps. 6. Place Right Side Jacket Panel,
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2. Install the probe into the appropriate front section L. TRIM AND CONTROLS INSTALLATION. tapping. See Figure 7 “Purpose of Tappings & Pressure Limit Installation. Bosses”. 1. Locate and remove L404F Pressure Limit with 3. Slip LWCO with factory attached harness over the factory attached harness from Control Carton. probe and clamp in place. Note that CG450 LWCO 2. Locate and remove 1/4" NPT x 1-7/8" x 4 x 90° will be positioned right side up, with diagnostic syphon enclosed in Part
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19 Figure 9: Float-Type LWCO and Pressure Limit Installation
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7. Screw LWCO to External Wiring Enclosure wiring nipple, ¾” NPT 90° black elbow and ¾” NPT black harness (end with fork and female disconnect coupling) from Part Carton. terminals) connector into low water cut-off J-box 2. Thread 3/4" NPT x 3” lg. black nipple into rear top fitting, and attach wires to the terminals per section safety valve tapping, install ¾” NPT 90° LWCO wiring detail shown in Figure 9 "Float-Type black elbow facing upward, then, thread 3/4" NPT LWCO and Gauge Glass In
