Instruction/ maintenance manual of the product MST396 Burnham
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100618-01R4-5/08 As an ENERGY ST AR ® Partner , Burnham Hydronics has determined that the MST288, MST396, MST513 and MST629 meet the ENERGY ST AR ® guidelines for Energy efciency established by the United States Environmental Protection Agency (EP A).
2 IMPOR T ANT INFORMA TION - READ CAREFULL Y The following terms are used thr oughout this manual to bring attention to the pr esence of hazards of various risk levels, or to important information concerning pr oduct life.
3 DANGER DO NOT store or use gasoline or other ammable vapors or liquids in the vicinity of this or any other appliance. W ARNING Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury or loss of life.
4 W ARNING This boiler contains very hot water under high pressure. Do not unscrew any pipe ttings nor attempt to disconnect any components of this boiler without positively assuring the water is cool and has no pressure.
5 Figure 1: MST288 Thru MST629 Steam Boiler with and without T ankless Heater.
6 T ABLE 1A: DIMENSIONAL DA T A (SEE FIGURE 1) T ABLE 1B: RA TING DA T A Boiler Model No. Dimensions (See Figure 1) W ater Content (T o Normal W ater Line) - Gallons Heat T ransfer Surface Area - sq. Ft. Actual Shipping Weight (LB.) "A" "B" "C" With T ankless Heater Non-Heater MST288 22-5/8" 24" 6" 15.
7 Figure 2: Minimum Installation Clearances T o Combustible Materials (Inches) A. INSPECT SHIPMENT carefully for any signs of damage. 1. All equipment is carefully manufactured, inspected and packed. Our responsibility ceases upon delivery of crated boiler to the carrier in good condition.
8 NOTICE Clearance to venting is for single wall vent pipe. If T ype L vent is used, clearance may be reduced to the minimum required by the vent pipe manufacturer . C. PROVIDE COMBUSTION AND VENTILA TION AIR. Local and National Codes may apply and should be referenced.
9 SE CTI ON II : U N IT -P A K BOILER ASSE M BL Y MegaSteam™ Unit-Pak Boiler Assembly Shipment Content Check List (see Figure 3) 1. ___ Cast Iron Section/Burner Swing Door/Smoke Box Assembly Mounted.
10 A. CAST IRON SECTION ASSEMBL Y T APPINGS Refer to T able 3 "Purpose of T appings 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.
1 1 Figure 4: Boiler Removal from Skid.
12 Figure 5A: Partial Front View - Burner Swing Door Mounted to Boiler - Fully Closed and Secured 1. T o 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.
13 Figure 5B: T op View - Burner Swing Door Mounted to Cast Iron Block Assembly (Jacket Removed for Clarity) By design, door insulation on model MST629 will have two by-pass pockets cast into the insulation centered on the bar between the combustion chamber and 3rd pass ueways.
14 E. FLUEW A Y BAFFLE INST ALLA TION. Flueway bafes are enclosed into Part Carton. Bafe requirements differ by boiler model, see T able 2. T ABLE 2: BAFFLE USAGE Figure 5C: T op View - Burner Swing Door Fully Closed but Not Properly Secured or Sealed NOTE: Read caution statement before proceeding.
15 Figure 6: Flueway Bafe Positioning/Orientation in Flueways NOTICE When securing burner swing door make sure door is drawn-in equally on both sides. d. Use a hand or socket wrench to tighten door hardware. AL W A YS ST AR T WITH RIGHT SIDE T AP BOL T FIRST .
16 Figure 7: Purpose of T appings and Bosses T ABLE 3: PURPOSE OF T APPINGS & BOSSES T apping Location Size, NPT Boss Location Thread Size UNC Steam Boiler Less Heater With Heater A ¼" - 18 Pressure Gauge B ¼" - 18 Pressure Limit C ¾" - 14 Probe L WCO - Std.
17 6. Repeat above steps with right Cleanout Cover . 7. Apply the adhesive sealant to the underside of the collar , all around, at the inside corner of the collar outer ring. Insure adhesive bead is complete all around and without gaps. 8. Place the collar over smokebox tongue and align collar integral mounting ear slots with smokebox bosses.
18 L. TRIM AND CONTROLS INST ALLA TION. Pressur e Limit Installation. 1. Locate and remove L404F Pressure Limit with factory attached harness from Control Carton. 2. Locate and remove 1/4" NPT x 1-7/8" x 4 x 90° syphon enclosed in Part Carton.
19 Figure 9: Float-T ype L WCO and Pressure Limit Installation.
20 7. Screw L WCO to External W iring Enclosure wiring harness (end with fork and female disconnect terminals) connector into low water cut-off J-box top tting, and attach wires to the terminals per L WCO wiring detail shown in Figure 9 "Float-T ype L WCO and Gauge Glass Installation".
21 Figure 10: Oil Burner Installation f. Insert oil burner into the opening of burner swing door . Align and engage keyhole slot in burner ange over head of protruding cap screw installed in previous Step. Rotate burner to the right to lock ange behind head of cap screw .
22 A. EV ALUA TE THE EXISTING STEAM SYSTEM. The single most important factor in determining the expected life cycle of a steam boiler , is the amount of fresh water added to the boiler during operation. Fresh water brings minerals and oxygen into the boiler .
23 Figure 1 1: Recommended Boiler Piping for Gravity Return Steam Boiler.
24 SECTION IV : T ANKLESS & INDIRECT W A TER HEA TER PIPING A . CONNECT T ANKLESS HEA TER PIPING as shown in Figure 12. See T able 4 for T ankless Heater Rating. W ARNING Install automatic mixing valve at tankless heater outlet to avoid risk of burns or scalding due to excessively hot water at xtures.
25 T ABLE 4: T ANKLESS HEA TER DA T A: Figure 12: Schematic T ankless W ater Heater Piping Boiler Model Heater No. Heater Rating (GPM) Pressure Drop thru Heater (PSI) MST288 222A 3.
26 Figure 13: Alliance™ W ater Heater Piping with MegaSteam™ Boiler B. CONNECT ALLIANCE™ INDIRECT W A TER HEA TER PIPING as shown in Figure 13. 1.
27 A. Chimney Venting 1. Chimney venting is an important part of a safe and efcient oil red appliance system. Contact your local re and building ofcials on specic requirements for restrictions and the installation of fuel oil burning equipment.
28 Figure 14: Recommended V ent Pipe Arrangement and Chimney Requirements Figure 15: Proper and Improper Locations of Draft Regulator.
29 2. T ype B Chimney Connector - a type B chimney connector can be used to transmit the ue gases provided ue gas temperature entering the chimney connector is greater than 310°F .
30 Figure 17: Optional Air Intake Piping Installation - Only A vailable with Beckett Burner W ARNING Remove the bafes if there are any signs of condensation in the chimney or chimney connector . Consult with your local chimney professional for recommendations.
31 c. Mount the vacuum relief valve into the tee and fasten with a screw and nut in collar tabs. T o ensure proper operation, the gate must be level across the pivot point and plumb.
32 A. GENERAL 1. Install wiring and electrically ground boiler in accordance with requirements of the authority having jurisdiction, or in absence of such requirements the National Electrical Code, ANSI/ NFP A 70. 2. Refer to National Electric Code or Local Electric Codes for proper size and type of wire required.
33 Figure 18: Wiring Diagram, Steam, Hydrolevel CG450 Probe L WCO.
34 Figure 19: Wiring Diagram, Steam, McDonnell & Miller PS-801 Probe L WCO.
35 Figure 20: Wiring Diagram, Steam, McDonnell & Miller #67 Float L WCO.
36 B O I L E R SEQUENCE OF OPERA TION WITH PROBE L WCO (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 .
37 Figure 21: Single Pipe Oil Line SECTION VII: OIL PIPING A. GENERAL 1. Use exible oil line(s) so the burner swing door can be opened without disconnecting the oil supply piping. 2. A supply line fuel oil lter is recommended as a minimum for all ring rates but a pleated paper fuel oil lter is recommended for the ring rates below 1.
38 T ABLE 5: TWO-ST AGE UNITS (3450 RPM) - TWO PIPE SYSTEMS T ABLE 6: SINGLE-ST AGE UNITS (3450 RPM) - TWO PIPE SYSTEMS Figure 22: T wo Pipe Oil Lines C. TWO PIPE OIL LINES 1. For two piped systems, where more lift is required, the two-stage fuel unit is recommended.
39 SECTION VIII: SYSTEM ST AR T -UP 1. S E T ROOM THERMOST A T about 10° above room temperature. 2. P R E S S RED RESET BUTTON on front of burner cover , hold for one (1) second and release to reset primary control.
40 5. Adjust oil pressure. a. When checking a fuel unit's operating pressure, a reliable pressure gauge may be installed in either the bleeder port or the nozzle port. See Figure 23. b. Locate oil pressure adjusting screw and turn screw to obtain proper pump pressure, refer to T able 8 at rear of manual.
41 Figure 24: "L1" and "V1" Head Electrode Positioning and Gun Setting (Beckett AFG).
42 W ARNING 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 .
43 • Place a jumper across cad cell terminals. • Follow procedure to turn on burner . Burner must not start, indicator light turns on and control remains in Idle Mode. • Remove jumper . iii. Simulate Ignition or Flame Failure: • Follow procedure to turn on burner .
44 Important Produc t Safety Information Refractory Ceram ic Fiber Product Warning : The Repair Parts list designates parts that contain refractory ceramic fibers (RCF).
45 SECTION IX: MAINTENANCE AND SER VICE INSTRUCTIONS A. MAINTENANCE OF LOW WATER CUT- O F F DEVICES W ARNING Probe and oat type low water cut-off devices require annual inspection and maintenance.
46 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 .
47 by drawing a small sample of boiler water and testing with hydrion paper which is used in the same manner as litmus paper , except it gives specic readings.
48 SECTION X: BOILER CLEANING A. CLEAN THE FLUEWAYS (See Figure 27). 1. For access to the combustion chamber remove the two (2) 3/8" - 16 cap screws. If boiler is equipped with exible fuel line(s), swing door open. 2. Remove the two smoke box clean-out covers from the rear smoke box by removing the four 5/16"-18 hex head bolts.
49 Figure 27: Cleaning Boiler Flueways and Combustion Chamber Surfaces W ARNING 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 .
50 A. COMBUSTION 1. N O Z Z L E S — Although the nozzle is a relatively inexpensive device, its function is critical to the successful operation of the oil burner . The selection of the nozzle supplied with the MegaSteam™ boiler is the result of extensive testing to obtain the best ame shape and efcient combustion.
51 d. Excessive airow or draft causing ame to leave burner head. e. Excessive back pressure causing ame to be erratic. 3. Control locks out after T rial For Ignition (TFI). a. No oil to burner . b. Shorted electrodes. c. Nozzle clogged. d. Airow too high.
52 Bare Boiler Assembly.
53 Item No. Description Part No. MST288 MST396 MST513 MST629 1. BARE BOILER ASSEMBL Y 1A Front Section, Machined 100569-01 1 1 1 1 1B Center Section, Machined 100571-01 1 1 2 3 1C1 Rear Section (Htr .), Steam, Machined 100573-01 1 1 1 1 1C2 Rear Section (Non-Htr .
54 Bare Boiler Assembly.
55 Item No. Description Part No. MST288 MST396 MST513 MST629 1. BARE BOILER ASSEMBL Y (Continued) 1S Burner Swing Door Insulation (Less Pockets) 100039-01 1 1 1 --- Burner Swing Door Insulation (With Pockets) 100039-02 --- --- --- 1 1T 5/8" Dia. Rope Gasket - Burner Swing Door 100097-01 1 1 1 1 1U 1/8" Dia.
56 Jacket Assembly.
57 Item No. Description Part No. MST288 MST396 MST513 MST629 2. JACKET ASSEMBL Y 2A Jacket Front Panel Assembly w/Insulation 100575-01 1 1 1 1 2B Power Outlet Receptacle, w/Harness 100605-01 1 1 1 1 2.
58 MST288 Thru MST629 Steam Boilers - T rim and Controls.
59 Item No. Description Part No. MST288 MST396 MST513 MST6 29 3. MST - TRIM AND CONTROLS 3A 6" RC-STD Draft Regulator 81 16288 1 1 1 --- 7" RC-STD Draft Regulator 81 16289 --- --- --- 1 3B P.
60 Beckett AFG Burner.
61 BECKETT OIL BURNER P ART NOS. FOR MEGASTEAM™ SERIES BOILERS NOTE: When ordering parts always give the serial and model numbers shown on the boiler and burner .
62 T ABLE 8: BECKETT AFG B U R N E R S P E C I F I C A T I O N S Boiler Model Burner Input (gph) Head T ype (setting) Air Shutter (setting) Air Band (se tti ng) Nozzle Pump Pressure (psi) Approx. Shipped CO 2 (%) Bafe Location (pass) Approx. Stack T emp.
63 SER VICE RECORD DA TE SERVICE PERFORMED.
By this Warranty Statement the U.S. Boiler ™ Company, Inc. of Lancaster, Pennsylvania issues limited warranties subject to the terms and conditions stated below.
An important point after buying a device Burnham MST396 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Burnham MST396 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Burnham MST396 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Burnham MST396 you will learn all the available features of the product, as well as information on its operation. The information that you get Burnham MST396 will certainly help you make a decision on the purchase.
If you already are a holder of Burnham MST396, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Burnham MST396.
However, one of the most important roles played by the user manual is to help in solving problems with Burnham MST396. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Burnham MST396 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
