Burnham MEGASTEAM MST629 User Manual

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 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

Address

Price - $3.00

100618-01R4-5/08

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,serviceormaintenancecancausepropertydamage,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,andservicemustbeperformedonlybyanexperienced,skilledandknowledgeable

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 1½"" x ¾"" NPT reducing bushing,

mounted into rear section boss, at the back of rear section. See Unit-Pak Boiler Assembly and Steam

Boiler Trim & Piping Sections of this manual for details.

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. Always 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

priortoeachheatingseason.Acleanandunobstructedchimneyﬂueisnecessarytoproducetheminimum

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 supplied 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. ꢀ 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

I. Pre-Installation . . . . . . . . . . . . . . . . . . . .

II. Unit-Pak Boiler Assy . . . . . . . . . . . . . . .

VII. Oil Piping . . . . . . . . . . . . . . . . . . . . . . . 37

VIII. System Start-Up . . . . . . . . . . . . . . . . . . 39

IX. Maintenance & Service Instructions . . . 45

X. Boiler Cleaning . . . . . . . . . . . . . . . . . . . 48

XI. Trouble Shooting . . . . . . . . . . . . . . . . . 50

XII. Repair Parts . . . . . . . . . . . . . . . . . . . . . 51

III. Steam Boiler Trim & Piping . . . . . . . . . . . 22

IV. Tankless & Indirect Water Heater Piping . 24

V. Venting & Air Intake Piping . . . . . . . . . . 27

VI. Electrical . . . . . . . . . . . . . . . . . . . . . . . . 32

TABLE 1A: DIMENSIONAL DATA (SEE FIGURE 1)

Dimensions (See

Figure 1)

Water Content (To Normal

Water Line) - Gallons

With Tankless

Heat Transfer

Surface Area

- sq. Ft.

Boiler

Model No.

Actual Shipping

Weight (LB.)

"A"

"B"

"C"

Non-Heater

Heater

MST288

MST396

MST513

MST629

22-5/8"

28-5/8"

34-5/8"

24"

30"

36"

15.3

14.9

19.3

23.8

20.29

27.29

34.29

607

744

881

15.3

19.7

24.1

NOTE: 1: Maximum Working Pressure: Steam - 15 PSI

TABLE 1B: RATING DATA

I=B=R NET

Ratings

Steam Steam

Minimum Chimney

Requirements

Burner Capacity

DOE Heating

Boiler

Model

No.

AFUE

Round Rectangle Height

GPH MBH

Capacity MBH

MBH

Sq. Ft.

In. Dia.

In. x In.

Ft.

MST288

MST396

MST513

MST629

0.75

1.05

1.35

1.65

105

147

189

231

288

8 X 8

86.0

127

164

201

396

8 X 8

123

151

513

8 X 8

629

8 X 8

SECTION I: PRE-INSTALLATION

A. INSPECT SHIPMENT carefully for any signs of

•

30" for ﬂueway cleaning (MST513)

36" for ﬂueway cleaning (MST629)

damage.

b. Clearance from Jacket Left Side Panel -

1. All equipment is carefully manufactured, inspected

and packed. Our responsibility ceases upon delivery

of crated boiler to the carrier in good condition.

•

19" for burner swing door, if opened fully

with burner mounted, otherwise 1" with

burner removed

2. Any claims for damage or shortage in shipment

must be ﬁled immediately against the carrier by the

consignee. No claims for variances from, or shortage

in orders, will be allowed by the manufacturer

unless presented within sixty (60) days after receipt

of goods.

12" access clearance to service rear of

boiler if right side clearance is less

than 12"

1" minimum if right side clearance is 12" or

larger to access and service rear of boiler.

B. LOCATE BOILER in front of ﬁnal position before

c. Clearance from Jacket Right Side Panel -

removing crate. See Figure 1.

•

6" minimum from external Electrical

Enclosure if left side clearance is 12" or

larger to access and service rear of the boiler

1. LOCATE so that vent pipe connection to chimney

will be short and direct.

•

24" minimum from rear tanklesss heater (if

equipped) for servicing and removal of the

heater

2. BOILER IS SUITABLE FOR INSTALLATION

ON COMBUSTIBLE FLOOR. Boiler cannot be

installed on carpeting.

d. Clearance from Jacket Rear Panel -

3. FOR BASEMENT INSTALLATION, provide

a solid elevated base, such as concrete, if ﬂoor is

not level, or if water may be encountered on ﬂoor

around boiler.

•

12" minimum for rear smokebox cleaning

(Note: This dimension will also be

controlled by horizontal to vertical to

horizontal smokepipe arrangement - See

Figures 2 and 14.)

4. PROVIDE RECOMMENDED SERVICE

CLEARANCE, if applicable, as follows:

a. Clearance from Jacket Front Panel -

5. For minimum clearances to combustible materials.

•

24" for servicing burner

See Figure 2.

24" for ﬂueway cleaning (MST288 &

MST396)

Figure ꢀ: Minimum Installation Clearances To Combustible Materials (Inches)

NOTES:

Listed clearances cannot be reduced for alcove or closet

installations.

1. Listed clearances comply with American National Standard

ANSI/NFPA 31, Installation of Oil Burning Equipment.

3. For reduced clearances to combustible material, protection

must be provided as described in the above ANSI/NFPA 31

standard.

2. MegaSteam™ boilers can be installed in rooms with

clearances from combustible material as listed above.

ꢁ

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.

NOTICE

Clearance to venting is for single wall vent

pipe. If Type L vent is used, clearance may be

reduced to the minimum required by the vent pipe

manufacturer.

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:

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.

i. Direct communication with outdoors.

Minimum free area of 1 square inch per

4,000 BTU per hour input of all equipment

in space.

Do not install boiler where gasoline or other

ﬂammable vapors or liquids, or sources of

hydrocarbons (i.e. 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.

ii. Vertical ducts. Minimum free area of 1

square inch per 4,000 BTU per hour input 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.

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.

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.

Volume(ft³) = 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

input of all appliances in space. If the result is

greater than or equal to 50 ft³/1000 BTU per hour,

then it is considered an unconﬁned space. If the

result is less than 50 ft³/1000 BTU per hour then the

space is considered a conﬁned space.

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.

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.

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.

5. For boiler located in a conﬁned space or an

unconﬁned space in a building of unusually tight

construction, provide outdoor air.

c. Louvers and grilles must be ﬁxed in the open

position, or interlocked with the equipment to

open automatically during equipment operation.

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 / 100045-01 / 100021-01

____ MST4 (Rear Section, Non-Heater) – Part # 100567-04 / 100045-01 / 100021-01

____ MST5 (Rear Section, Non-Heater) – Part # 100567-05 / 100045-02 / 100021-01

2. ___ Control Carton

____ CG450 LWCO; W/Tankless Heater - Part # 100608-01

____ PS801 LWCO; W/Tankless Heater - Part # 100622-01

____ #67 LWCO; W/Tankless Heater - Part # 100678-01

5. ____ Insulation Wrapper

____ CG450 LWCO; L/Tankless Heater - Part # 100680-01

____ MST3 - Part #100614-03

____ PS801 LWCO; L/Tankless Heater - Part # 100681-01

____ #67 LWCO; L/Tankless Heater - Part # 100679-01

____ MST4 - Part #100614-04

____ MST5 - Part #100614-05

3. ___ Jacket Carton

6. ___ Instruction/Label Bag

____ MST3 – Part # 100609-03

____ MST4 – Part # 100609-04

____ MST5 – Part # 100609-05

____ MST (All Models) – Part # 100617-01

7. ___ Oil Burner Carton

____ Beckett MST288 – Part # 100625-01

____ Beckett MST396 – Part # 100053-01

____ Beckett MST513 – Part # 100054-01

____ Beckett MST629 – Part # 100055-01

4. ___ Part Carton

____ MST3 & 4 - Part # 100615-01

____ MST5 - Part # 100629-01

Figure 3: MegaSteam™ Unit-Pak Boiler Shipment Contents (outside container removed)

6. 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” lg.)

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).

A. CAST IRON SECTION ASSEMBLY TAPPINGS

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.

7. Place wooden block(s) 12” from rear of skid as

2. 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.

shown. See Figure 4 “ Boiler Removal from Skid”.

8. 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.

9. For best leverage, the pipe handles should extend

48” minimum beyond front section face.

10. Using the pipe handles, lift the Cast Iron Section/

Burner Swing Door/Smoke Box Assembly until

adjustable legs are elevated above the skid deck

boards.

11. Remove the skid from underneath the Cast Iron

B. REMOVAL OF CAST IRON SECTION/

BURNER SWING DOOR / SMOKE BOx

ASSEMBLY FROM SKID.

Section/Burner Swing Door/Smoke Box Assembly.

12. Lower pipe handles until front adjustable legs touch

the ﬂoor. Place wood blocks under front legs, if

required, before lowering, to provide hand clearance.

WARNING

13. 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.

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.

14. If wood blocks were placed under front legs, lift pipe

handles; remove the blocks and lower front legs to

ﬂoor. Remove pipe handles.

15. Move Cast Iron Section/Burner Swing Door/Smoke

Box Assembly to permanent position by sliding or

walking.

1. 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.

CAUTION

Do not drop boiler when removing from skid and

moving to permanent position.

2. Remove all fasteners at crate skid. Lift outside

container. Examine the skid contents for damage due

to shipping and handling.

C. PROCEDURE TO OPEN, CLOSE AND

SECURE BURNER SWING DOOR.

3. Remove Insulation Wrapper, Control Carton, Jacket

Carton, Part Carton and Oil Burner Carton from skid

and set aside.

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.

4. 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.

5. The Cast Iron Section/Burner Swing Door/Smoke

Box Assembly is secured to shipping skid with four

lag screws. Remove the screws and discard.

D. JACKET FRONT PANEL INSTALLATION.

In order 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.

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:

4. Place front jacket panel over front section

attachment bosses and align jacket holes with front

section boss holes.

5. Firstly, install two 5/16”-18 x ½” Phillips pan head

machine screws hand tight to secure front jacket

panel right side to casting

a. Loosen but not remove door left side latching

hardware (3/8”-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.

6. Secondly, insert 5/16”-18 – ¾” hex head cap

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

casting hand tight.

c. Remove door left side latching hardware (3/8”-

16 x 1-3/4” tap bolt and 5/16” washer) and set

aside.

7. Thirdly, insert 5/16”-18 – ¾” hex head cap

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.

d. Lift the door off mounting bracket and set aside.

e. Remove two 5/16”-18 – ¾” hex head cap screws

securing door mounting bracket to front section

and set aside.

8. Finally, tighten both sets of hardware to secure the

bracket and front jacket panel.

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.

9. Inspect ﬁberglass rope 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.

See also Figure 7 “Purpose of Tappings & Bosses”.

10. Inspect burner swing door insulation for damage and

proper type.

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.

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.

3. Open Part Carton, locate Hardware Bag, remove

two 5/16”-18 x ½” Phillips pan head machine

screws.

Figure 5A: Partial Front View - Burner Swing Door Mounted to Boiler - Fully Closed and Secured

1ꢀ

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

bafﬂes.

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 ﬂueways. By design, door

insulation on models MST288, MST396 & MST513

will not have any by-pass pockets. If insulation is

damaged, or, improper type regarding the pockets, it

must be replaced.

12. Locate/remove four #8 x ½” shoulder sheet metal

screws from Hardware Bag, then, install them into

front panel ﬂange holes.

Figure 5B: Top View - Burner Swing Door Mounted to Cast Iron Block Assembly (Jacket Removed for Clarity)

Figure 5C: Top View - Burner Swing Door Fully Closed but Not Properly Secured or Sealed

•

Models MST396, MST513 and MST629 - To

install ﬂueway bafﬂe in 2^ndpass ﬂueway on

left side of boiler, hold bafﬂe with word "Left"

readable at the top. Slide bafﬂe in ﬂueway until

position tab touches ﬁns on right side of 2^ndpass

ﬂueway. To install ﬂueway bafﬂe in 2^ndpass

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^ndpass ﬂueway.

E. FLUEWAY BAFFLE INSTALLATION.

Flueway bafﬂes are enclosed into Part Carton. Bafﬂe

requirements differ by boiler model, see Table 2.

TABLE ꢀ: BAFFLE USAGE

Boiler

Model

Bafﬂe Usage

2^ndPass 3^rdPass

MST288

MST396

MST513

MST629

None

F. CLOSING / SECURING BURNER SWING

DOOR.

(2)

P/N 100042-01

None

1. To close and secure Burner Swing Door:

a. From fully open position, rotate the door to the

closed position.

NOTE: Read caution statement before proceeding.

b. Lift door upward into the build-in cast ramp/door

rest (protruding from the bottom of the front

section casting – see Figure 5A).

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.

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.

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:

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 lower attachment bosses on

rear section. See Figure 7 “Purpose of Tappings &

Bosses”.

4. Thread both 5/16”-18 x 3” lg. 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.

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 ½”

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 ½” shoulder sheet metal

screws from Hardware Bag, then, install them into

rear panel ﬂange holes.

NOTICE

When securing burner swing door make sure door

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

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.

NEVER TIGHTEN LEFT SIDE TAP BOLT

FIRST, OR, EITHER PIECE OF HARDWARE

100% WITHOUT USING THE ALTERNATING

METHOD DESCRIBED ABOVE. See Figure

5B.

1. Remove two cast iron Cleanout Covers, cast iron

Smokebox Collar and the tube of hi-temperature

silicon adhesive sealant from Part Carton. See also

“Repair Parts” Section, “Bare Boiler Assembly”

illustration for part identiﬁcation.

2. Check the rope gasket factory attached to the covers.

Repair or replace, if the rope is damaged, or, there is

a gap between the rope ends.

3. Locate/remove four 5/16”-18 – 7/8” hex head cap

screws from Hardware Bag.

e. Failure to follow the prescribed procedure could

cause thread damage to casting and /or leak at

the door seal. IF LEFT SIDE TAP BOLT IS

TIGHTENED BEFORE RIGHT SIDE TAP

BOLT, RIGHT SIDE OF THE DOOR CAN

NOT BE DRAWN-IN TO PROVIDE AN AIR-

TIGHT SEAL, as shown in Figure 5C. Applying

excessive torque will only cause thread damage.

4. Apply a drop of supplied Anti-seize (pouch provided

in Part Carton) to each of four (4) 5/16”-18 x 7/8”

hex head cap screws for rust protection and to

facilitate easy removal for future service.

5. Position left Cleanout Cover over rear section

cleanout opening, align section boss holes with

Cleanout Cover holes, install both 5/16”-18 – 7/8”

hex head cap screws hand tight, then, alternately

tighten them with open end or socket wrench.

Figure ꢁ: Purpose of Tappings and Bosses

TABLE 3: PURPOSE OF TAPPINGS & BOSSES

Steam Boiler

With Heater

Tapping

Location

Thread Size

UNC

Size, NPT

Boss Location

Less Heater

¼" - 18

Pressure Gauge

Pressure Limit

Probe LWCO - Std.

Plugged (Float LWO)

¾" - 14

Water Gauge Glass (Probe LWCO)

Water Gauge Glass, Pressuretrol &

LWCO (Float LWCO)

½" - 14

ꢀ" - 11½"

¾" - 14

Supply (Front & Rear Tappings)

Safety Valve

1½" - 11½

1¼" - 11½

1½" - 11½

1" - 11½

½" - 14

Condensate Return

Optional Front Return

Surface Blowoff (Plugged)

Indirect Water Heater Supply

Indirect Water Heater Limit

Jacket Front Panel, Burner Swing

Door Mounting Bracket

M (4 pcs)

N (ꢀ pcs)

P (10 pcs)

5/16" - 18

3/8" - 16

5/16" - 18

Burner Swing Door

Jacket Rear Panel, Smoke Box Collar,

Cleanout Covers

¼" - 18

½"-14

Smokebox Pressure Tapping

L4006

Operating

Control

Plugged

6. Repeat above steps with right Cleanout Cover.

5. Pick up Molex end of Burner Harness stuffed

between front panel insulation and insulation

wrapper and feed it thru Right Side Jacket Panel

front cutout, letting the harness connector to hang

over the cutout edge temporarily.

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.

6. Place Right Side Jacket Panel, clearing rear section

tankless heater collar/ mounting ﬂange, over four

#8 x ½” 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.

8. Place the collar over smokebox tongue and align

collar integral mounting ear slots with smokebox

bosses.

9. Thread-in both 5/16”-18 – 7/8” hex head cap screws

hand tight, then, alternately tighten them with open

end or socket wrench.

7. Slide the panel downwards to lock all screws

securely.

I. INSULATION WRAPPER AND BURNER

POWER OUTLET RECEPTACLE WITH

HARNESS INSTALLATION.

8. Pick up Top Jacket Panel from Jacket Carton.

9. 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.

1. Insulation Wrapper is vacuum packed/sealed in

plastic bag at the factory.

2. Carefully cut the plastic bag and remove Insulation

Wrapper. The wrapper will expand upon removal.

3. 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.

10. Locate/remove two #8 x ½” sheet metal screws from

Hardware Bag.

11. Install both screws into top panel rear ﬂange to

secure the top panel to rear jacket panel.

4. Insure wrapper ﬁts snugly around rear section

tankless heater collar/ mounting ﬂange (if boiler

is equipped with tankless heater) and trim the

insulation at tankless heater cutout. Do not trim off

insulation on boilers having non-heater rear section.

K. ExTERNAL ELECTRICAL ENCLOSURE

MOUNTING.

1. Remove two #8 x ½” shoulder sheet metal screws

and one #8 x ½” sheet metal screw from Hardware

Bag.

5. Tack Insulation Wrapper bottom ends under section

assembly, between front and rear section legs.

2. Install both #8 x ½” shoulder sheet metal screws

into Right Side Jacket Panel, at two upper corners of

the panel front cutout.

6. Locate and remove Burner Power Outlet Receptacle

with factory attached Burner Harness from Control

Carton.

3. Locate and remove External Electrical Enclosure

assembly from Control Carton.

7. 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.

4. Remove the enclosure cover and set aside.

5. Pick Molex connector end of Burner Harness and

feed it inside the enclosure, thru bushed hole at

enclosure lower left corner, next to transformer/

relay.

6. 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.

J. SIDE AND TOP JACKET PANEL

INSTALLATION.

1. Pick up Left Side Jacket Panel from Jacket Carton.

See also “Repair Parts” Section, “Jacket Assembly”

illustration for part identiﬁcation.

7. Install #8 x ½” sheet metal screw thru enclosure

base lower hole, located to the right of transformer/

relay, into right side panel to secure the enclosure.

2. Place Left Side Jacket Panel over four #8 x ½”

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.

8. 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.

3. Slide the panel downwards to lock all screws

securely.

9. Do not install the enclosure cover yet; proceed to

control installation.

4. Pick up Right Side Jacket Panel from Jacket Carton.

See also “Repair Parts” Section, “Jacket Assembly”

illustration for part identiﬁcation.

1ꢁ

2. Install the probe into the appropriate front section

tapping. See Figure 7 “Purpose of Tappings &

Bosses”.

L. TRIM AND CONTROLS INSTALLATION.

Pressure Limit Installation.

1. Locate and remove L404F Pressure Limit with

factory attached harness from Control Carton.

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.

2. Locate and remove 1/4" NPT x 1-7/8" x 4 x 90°

syphon enclosed in Part Carton.

3. Review and locate pressure limit tapping on front

section. See Table 3 “ Purpose of Tappings &

Bosses” and Figure 7.

4. Thread 1-7/8" lg. 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.

4. Pick-up the 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.

5. Thread ¼" NPT x 4" lg. syphon-threaded long end

into pressure limit tapping on front section. See

Figure 8 "Pressure Limit Installation.

6. L404F pressure limit does not require leveling. The

pressure limit ﬁnal orientation must be parallel to

boiler front, having the harness on the right side.

N. PRESSURE GAUGE AND GAUGE GLASS

INSTALLATION.

1. Remove the 6” water gauge glass set from Part

Carton.

7. 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.

2. Install the gauge glass using the two ½” NPT

tappings to the right of the probe LWCO. See Figure

7 “Purpose of Tappings & Bosses”.

3. Thread the pressure gauge into 1/4” NPT tapping of

the front section. See Figure 7 “Purpose of Tappings

& 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.

O. 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 ½” NPT x 2½" long Sch 40 brass nipples,

supplied loose inside Control Carton (disregard two

½" NPT x 1½" long brass nipples provided with

#67 LWCO package) and ½" NPT brass unions into

upper and lower front section tappings. See Table 3

"Purpose of Tappings & Bosses" and Figure 7.

3. Install water gauge glass on low water cut-off

Figure 8: Pressure Limit Installation

assembly tee ﬁttings.

M. PROBE LWCO (HYDROLEVEL CG450,

OR, MCDONNELL-MILLER PS801-120)

INSTALLATION.

4. Do not remove ¼” 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.

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.

6. Remove #67 LWCO J-box cover.

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".

nipple, ¾” NPT 90° black elbow and ¾” NPT black

coupling) from Part Carton.

2. Thread 3/4" NPT x 3” lg. black nipple into rear

section safety valve tapping, install ¾” NPT 90°

black elbow facing upward, then, thread 3/4" NPT

x 8” lg. black nipple into the elbow, and, install ¾”

NPT black coupling onto nipple end.

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; 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.

3. Thread safety valve into the ¾” 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

10. 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.

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" NPT x 5” lg. black nipple, 1-1/2”

x 1-1/2” x ¾” NPT black tee and drain valve from

Part Carton.

P. AqUASTAT CONTROLLER INSTALLATION

NOTICE

(BOILERS WITH TANKLESS HEATER ONLY).

1. On boilers with tankless heater, install the L4006A

aquastat controller well (found in Part Carton) into

½” NPT tapping in tankless heater plate.

Lower rear section Tapping "H" is used for

standard condensate return on steam boilers.

5. Thread 1-1/2" NPT x 5” lg. black nipple into lower

rear section tapping, then, install 1-1/2” x 1-1/2” x

¾” NPT black tee onto nipple end. Black tee side

outlet may be oriented to either left, or, right side.

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.

6. Install the drain valve into black tee ¾” NPT side

outlet.

WARNING

R. OIL BURNER INSTALLATION.

1. Install oil burner, refer to Figure 10.

a. Open burner carton and remove contents.

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.

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.

5. See Figures 18, 19 and 20 (whichever applicable)

for tankless heater aquastat connection details.

CAUTION

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.

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.

q. SAFETY VALVE AND DRAIN VALVE

INSTALLATION.

e. Thread (1) 5/16-18 x 3/4 lg. cap screw,

approximately three (3) full turns, into tapping

located at 12:00 o'clock on burner swing door.

1. Remove safety valve and related piping (3/4”

NPT x 3” lg. black nipple, 3/4” NPT x 8” lg. black

ꢀ0

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.

h. Plug burner power cord into power outlet

receptacle located in lower right corner of front

panel.

g. Align holes and install two (2) remaining cap

screws. Level burner and fully tighten all three

(3) screws.

Figure 10: Oil Burner Installation

ꢀ1

SECTION III: STEAM BOILER PIPING & 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

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. These

contaminants greatly accelerate corrosion of the cast

iron boiler sections.

3. Install accurate water meter on the fresh water

supply to the boiler.

B. CONNECT SYSTEM SUPPLY AND RETURN

PIPING TO 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 ½ inch clearance from hot

water piping to combustible materials.

b. If the system contains hidden supply or return

piping (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,

ꢀ) 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.

ꢀꢀ

ꢀ3

SECTION IV: TANKLESS & INDIRECT WATER HEATER PIPING

A. CONNECT TANKLESS HEATER PIPING as

shown in Figure 12. See Table 4 for Tankless Heater

Rating.

possible by piping the hot water from the heater

prior to entering the mixing valve. The mixing valve

should be “trapped” by installing it below the cold

water inlet to heater to prevent lime formation in the

valve. Refer to Figure 12.

WARNING

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.

Install automatic mixing valve at tankless heater

outlet to avoid risk of burns or scalding due to

excessively hot water at ﬁxtures. Adjust and

maintain 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:

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.

1. FLOW REGULATION — If ﬂow through the

heater is 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.

NOTICE

During summertime operation, the normal

water line on a steam boiler can be raised

1", from ꢀ8-ꢁ/8" to ꢀ9-ꢁ/8" (see Figure 1) for

improved tankless heater performance on

steam boilers.

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

Use street elbow ﬁttings in tankless in and out

connections to assure adequate clearance of

piping.

CAUTION

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.

ꢀ4

Figure 1ꢀ: Schematic Tankless Water Heater Piping

TABLE 4: TANKLESS HEATER DATA:

Heater Rating

(GPM)

Pressure Drop thru

Heater (PSI)

Boiler Model

Heater No.

MST288

MST396

MST513

MST629

3.00

3.25

3.50

4.00

22.0

24.3

26.5

31.0

222A

ꢀ5

Figure 13: Alliance™ Water Heater Piping with MegaSteam™ Boiler

B. CONNECT ALLIANCE™ INDIRECT WATER

HEATER PIPING as shown in Figure 13.

1. Refer to Alliance™ manual for additional

information.

ꢀ6

SeCtiOn V: Venting & Air intAke piping

a. Loose Mortar – Loose mortar could be an

A. Chimney Venting

indication of a prior history of condensing ﬂue

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.

1. Chimney venting is an 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

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.

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.

d. Clean Chimney – 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.

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.

B. Chimney COnneCtOr

1. A chimney connector (vent pipe) is used to connect

the boiler to the base of the chimney. The chimney

connector should be kept as short as possible. The

horizontal length of the chimney connector shall not

be greater than 10 feet.

NOTE: Secure chimney connector to cast iron

smokebox collar with three (3) #10 x ½" self drilling

hex head TEK screws provided in appropriate

Parts Carton. Locate screws around perimeter of

connector as shown in Figure 14 and approximately

½" in from edge. Use drill with 5/16" hex bit to

drive screws through connector and smokebox

collar.

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, the 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.

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.

A 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.

Figure 14: Recommended Vent Pipe Arrangement and Chimney Requirements

Figure 15: Proper and Improper Locations of Draft Regulator

ꢀ8

2. Type B Chimney Connector - a type B chimney

connector can be used to transmit the ﬂue gases

provided ﬂue gas temperature entering the chimney

connector is greater than 310°F.

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.

3. Type L Chimney Connector - a type L vent or

other suitable material shall be used for a chimney

connector if the temperature or exiting temperature

is less than 310°F.

CAUTION

DANGER

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.

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.

C. DRAFT

CAUTION

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.

Use the chimney venting tables as a guide. It

is highly recommended that any 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.

2. Minimum Draft at Breech (Canopy) – The draft

induced by a chimney must create at least a

pressure of 0 (zero) inches water column (“ 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 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. Bafﬂes – The efﬁciency of the boiler is based on the

insertion of ﬂue bafﬂes supplied with your product.

Under no circumstances are other bafﬂes to be used

on this product. The bafﬂes are installed in the 2^nd

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 (∆T) with bafﬂes IN and OUT. In

addition, the lower the CO₂level the higher the

stack temperature.

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.

Figure 16: Smokebox Pressure Tapping for

Checking Draft at Breech

ꢀ9

1. General

a. Use 4" dia., single wall galvanized metal pipe

WARNING

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.

Remove the bafﬂes if there are any signs

of condensation in the chimney or chimney

connector. Consult with your local chimney

professional for recommendations.

E. MINIMUM CLEARANCES

WARNING

See Figure 2 for details regarding clearances to

combustibles for the boiler.

Do not exceed maximum allowable air intake

length.

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.

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.

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 details outlined in this

section.

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

Do not reduce size of air intake pipe.

evenly spaced around the burner inlet ring.

Read, understand and follow combustion air

instruction restrictions contained in the Pre-

Installation Section of this manual.

b. Assemble the vacuum relief valve balance

weight onto the gate. Refer to the vacuum relief

valve manufacturer's instructions.

Figure 1ꢁ: Optional Air Intake Piping Installation - Only Available with Beckett Burner

c. Mount the vacuum relief valve into the tee and

fasten with a screw and nut in collar tabs. To

ensure proper operation, the gate must be level

across the pivot point and plumb. Refer to

vacuum relief valve manufacturer's instructions.

7. Seal all external joints with weatherproof caulk.

WARNING

Donotlocateairintakewherepetroleumdistillates,

CFC's, 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 1ꢀ inches above

grade plus snow accumulation.

SECTION VI: ELECTRICAL

DANGER

Positively assure all electrical connections are unpowered before attempting installation or service of

electrical components or connections of the boiler or building. Lock out all electrical boxes with padlock

once power is turned off.

WARNING

Failure to properly wire electrical connections to the boiler may result in serious physical harm.

Electrical power may be from more than one source. Make sure all power is off before attempting any

electrical work.

Each boiler must be protected with a properly sized fused disconnect.

Never jump out or make inoperative any safety or operating controls.

A. GENERAL

1. Install wiring and electrically ground boiler in

6. If an Alliance™ indirect water heater is used, use

priority zoning. Do not use priority zoning for

Hydro-Air Systems.

accordance with requirements of the authority

having jurisdiction, or in absence of such

requirements the National Electrical Code, ANSI/

NFPA 70.

7. Wiring should conform to Figure 18.

B. INSTALL A ROOM THERMOSTAT on an

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, television, 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.

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.

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 the

thermostat's temperature setting, reduce heat anticipator

setting by .1 or .2 amps. If system tends to short cycle

without reaching desired room temperature, increase

heat anticipator setting by .1 or .2 amps.

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.

3ꢀ

BOILER SEQUENCE OF OPERATION WITH PROBE LWCO (See Figure 18)

When the thermostat calls for heat, it energizes the R8285C Control Center relay which in turn energizes the cad cell

primary control, bringing on the burner. The burner will operate in the following sequence: Prepurge for the ﬁrst 10

seconds; 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 a 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 every 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 on the high limit is reached; post-purge

for the last 10 seconds. When the pressure limit control restores the circuit on a

McDonnell & Miller PS-801

Terminals May be Lettered or

Numbered as Follows:

Wire

Color

Numbered Lettered

Terminals Terminals

drop in pressure, the burner will 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

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 burner 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.

Jumper

1-3

H-C

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 FLOAT LWCO (See Figure ꢀ0)

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 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.

SECTION VII: OIL PIPING

A. GENERAL

1. Use ﬂexible oil line(s) so the burner swing door

WARNING

Under no circumstances can copper with sweat

style connectors be used.

can be opened without disconnecting the oil supply

piping.

2. A supply line fuel oil ﬁlter is recommended as a

minimum for all ﬁring rates but a pleated paper fuel

oil ﬁlter is recommended for the ﬁring rates below

1.0 gph to prevent nozzle fouling.

NOTICE

Some jurisdictions require the use of a fusible

shutoff valve at 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.

NOTICE

B. SINGLE PIPE OIL LINES

Do not use compression ﬁttings.

1. Standard burners are provided with single-stage

3450 rpm fuel units with the bypass plug removed

for single-pipe installations.

Oil piping must be absolutely airtight or leaks

or loss of prime may result. Bleed line and

fuel unit completely.

2. The single-stage fuel unit may be installed single-

pipe with gravity feed or lift. Maximum allowable

lift is 8 feet. See Figure 21.

Refer to your local jurisdictions regarding

any special considerations for fuel supply

requirements. In addition, refer to NFPA 31,

Standard for the installation of Oil-Burning

Equipment.

3. Fuel Oil Line Deaerator – On many occasions a

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

deaerator can be installed to eliminate air. The

single line from the fuel tank is connected to the

deaerator. The burner pump must be connected

to the deaerator as a two pipe system. Follow the

oil pump manufacturer’s recommendations for

conversion to a two pipe system.

4. Use of a high efﬁciency micron ﬁlter (Garber or

equivalent) in addition to a conventional ﬁlter is

highly recommended.

5. Piping used to connect the oil burner to the oil

supply tank shall not be smaller than 3/8" iron pipe

or 3/8" OD copper tubing. Copper tubing shall have

a .032" minimum wall thickness.

Figure ꢀ1: Single Pipe Oil Line

3ꢁ

C. TWO PIPE OIL LINES

3. Under no circumstances is a manual shutoff valve to

be located on the return line of a two pipe system.

Accidental closure of the return line will rupture the

oil pump seals.

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.

TABLE 6: SINGLE-STAGE UNITS (3450 RPM) -

TWO PIPE SySTEMS

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.

Maximum Length of Tubing

"H" + "R" (See Figure 22)

3/8" OD Tubing 1/2" OD Tubing

(3 GPH) (3 GPH)

Lift "H"

(See Fig. 21)

TABLE 5: TWO-STAGE UNITS (3450 RPM) -

84'

78'

73'

68'

63'

57'

52'

47'

42'

36'

31'

26'

21'

---

100'

83'

TWO PIPE SySTEMS

Maximum Length of Tubing

"H" + "R" (See Figure 22)

3/8" OD Tubing 1/2" OD Tubing

(3 GPH) (3 GPH)

Lift "H"

(See Fig. 22)

93'

85'

77'

69'

60'

52'

44'

36'

27'

---

100'

76'

10'

11'

12'

13'

14'

10'

12'

14'

16'

18'

62'

---

41'

Figure ꢀꢀ: Two Pipe Oil Lines

SECTION VIII: SYSTEM START-UP

WARNING

All boilers equipped with burner swing door have a potential hazard which can cause severe property damage,

personal injury or loss of life if ignored. Before opening swing door, turn off service switch to boiler to

prevent accidental ﬁring of burner outside the combustion chamber. Be sure to tighten swing door fastener

completely when service is completed.

1. SET ROOM THERMOSTAT about 10° above

A. ALWAYS INSPECT INSTALLATION

BEFORE STARTING BURNER.

room temperature.

2. PRESS RED RESET BUTTON on front of

burner cover, hold for one (1) second and release to

reset primary control.

1. Verify that the venting, water piping, oil piping, and

electrical system are installed properly. Refer to

Installation Instructions contained in this manual.

3. On STEAM BOILERS:

2. Conﬁrm all electrical, water and oil supplies are

turned off at the source and that the vent is clear

from obstructions.

a. With an L404F1367 - set cut-out pressure

(MAIN scale) on the pressure limit for (1) PSI

and differential pressure (DIFF.) for .5 PSI.

These pressures may be varied to suit individual

requirements of the system.

WARNING

Completely read, understand and follow all

instructions in this manual before attempting

start up.

4. On STEAM BOILERS WITH TANKLESS

DOMESTIC WATER HEATERS, set boiler

water temperature dial on L4006 operating control

at 190°F (max.). Set differential at 10°.

B. FILL HEATING SYSTEM WITH WATER.

E. ADJUST OIL BURNER BEFORE

STARTING.

NOTICE

1. CHECK BURNER AIR BAND, AIR SHUTTER

AND HEAD SETTING (if applicable), readjust if

necessary, see Table 8 at rear of manual.

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.

2. OPEN ALL OIL LINE VALVES.

3. Attach a plastic hose to fuel pump vent ﬁtting and

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.

provide a pan to catch the oil.

4. OPEN FLAME OBSERVATION PORT COVER

on burner swing door.

Refer to Maintenance and Service Instructions Section

of this manual for proper cleaning instructions for

steam and water boilers.

F. START OIL BURNER.

1. Open vent ﬁtting on fuel pump.

1. STEAM BOILERS — Fill boiler to normal water

2. PRESS RED RESET BUTTON on front of burner

cover, hold for one (1) second and release to reset

primary control.

line. Refer to Figure No. 1.

WARNING

3. TURN ‘ON’ BURNER service switch and

allow burner to run until oil ﬂows from vent

ﬁtting in a SOLID stream without air bubbles for

approximately 10 seconds.

The maximum operating pressure of this boiler is

posted on the ASME Data Label located on the top

of the boiler. Never exceed this pressure. Do not

plug relief valve.

NOTE: For Primary Control "Pump Priming

Cycle" details, see Paragraph I, No. 2., Step a.,

Item ii .

C. CHECK CONTROLS, WIRING AND

BURNER to be sure that all connections are tight and

burner is rigid, that all electrical connections have been

completed and fuses installed, and that oil tank is ﬁlled

and oil lines have been tested.

4. Close vent ﬁtting and burner ﬂame should start

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.

D. SET CONTROLS with burner service switch turned

“OFF”.

See Table 8 (at rear of this manual) for details

regarding the overﬁre pressure when bafﬂes are both

installed and removed.

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.

3. READJUST THE HEAD SETTING only if

necessary.

b. Locate oil pressure adjusting screw and turn

screw to obtain proper pump pressure, refer to

Table 8 at rear of manual.

a. MST288 & MST396:

Beckett MB(L1) Head burner has a ﬁxed head

which is non-adjustable.

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.

b. MST513 & MST629:

Beckett MD(V1) (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 CO₂readings. See Figure 24.

d. Remove the gauge and install bleeder port and/or

reconnect the nozzle port line.

4. 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

control has tripped, the burner has experienced

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 ꢀ3: Adjusting Fuel Pump Pressure

G. ADJUST OIL BURNER WHILE

H. CHECK FOR CLEAN CUT OFF OF

BURNER.

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

and while burner is running. (At least ﬁve minutes)

See Table 8 at rear of manual for details.

1. AIR IN THE OIL LINE between fuel unit and

nozzle will compress when burner is on and will

expand when burner stops, causing oil to squirt from

nozzle at low pressure as the 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.

2. 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 a

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 CO₂of 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.

2. 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.

I. TEST CONTROLS.

1. Check thermostat operation. Raise and lower

thermostat setting as required to start and stop

burner.

vi. Diagnostic LED: The indicator light on oil

primary control provides lockout, recycle

and cad cell indications as follows:

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.

• Flashing at 1 Hz (½ second on, ½ second

off): system is locked out or in Restricted

Mode.

• Flashing at ¼ Hz (2 seconds on, 2 seconds

2. VERIFY PRIMARY CONTROL FEATURES

using procedures outlined in Instructions furnished

with control or instructions as follows:

off): control is in Recycle Mode.

• On: cad cell is sensing ﬂame.

• Off: cad cell is not sensing ﬂame.

a. FEATURES AND CONTROLS

i. The R7184 is a 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).

vii. Cad 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 ꢁ: CAD CELL RESISTANCE WHEN

SENSING FLAME

Flashes

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

Figure ꢀ5: Rꢁ184 Terminals, LED and Reset Button

ii. 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.

CAUTION

Due to the potential hazard of line voltage,

only a trained, 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.

iii. 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.

i. Preliminary Steps

• Check wiring connections and power

supply.

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.

• Make sure power is on to the controls.

• Make sure limit control is closed.

• Check contacts between ignitor and the

electrodes.

• To reset from Restricted Mode: Press and

hold the reset button for 30 seconds.

When the LED ﬂashes twice, the device

has reset.

• 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:

v. T-T Jumper: Select models have pre-

installed T-T jumper. Do not remove

jumper. See Figure 25.

4ꢀ

• Place a jumper across cad cell terminals.

• 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 is missing or damaged,

replace gasket. Room light can effect cad

cell resistance. Reset safety switch.

• 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.

• Close hand valve in oil supply line.

• Close line switch to boiler. If burner starts

and runs beyond safety switch cut-off

time, cell is good. If not, install new cell.

• Failure occurs, device enters Recycle

Mode. Indicator light ﬂashes at ¼ Hz rate

2 seconds on, 2 seconds off).

• Device tries to restart system after

approximately 60 seconds.

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.

• 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 (½ second on, ½

second off). Ignition and motor stop and

oil valves closes.

3. WARNING — Check Pressure Limit Control

— Jumper Thermostat Terminals. Allow burner to

operate until shut-down by limit. Installation is not

considered complete until this check has been made.

iv.

Cad Cell Check: See Figure 26.

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.

Figure ꢀ6: Cad Cell Location

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.

• 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 is

good.

J. IF CONTROLS DO NOT MEET

REqUIREMENTS outlined in Paragraph I.,

replace control and repeat checkout procedures.

Important Product Safety Information

Refractory Ceramic Fiber Product

Warning:

The Repair Parts list designates parts that contain refractory ceramic fibers

(RCF). RCF has been classified as a possible human carcinogen. When

exposed to temperatures about 1805°F, such as during direct flame contact,

RCF changes into crystalline silica, a known carcinogen. When disturbed as a

result of servicing or repair, these substances become airborne and, 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

2. Long sleeved, loose fitting clothing

3. Gloves

4. 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 water. Seek

immediate medical attention.

SECTION Ix: MAINTENANCE AND SERVICE INSTRUCTIONS

h. Clean the pipe threads of the probe to remove

old, hardened pipe dope and other foreign matter.

i. 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.

j. Screw the probe into the boiler tapping.

k. Mount the low water cut-off control on the

probe.

A. MAINTENANCE OF 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.

l. Reconnect the control to probe wiring.

m. Fill the boiler to its normal waterline.

n. Add boiler water treatment compound as needed

(refer to Paragraph B.).

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.

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.

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.

2. 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.

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.

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 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.

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 with 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 1 part

of phosphoric acid (H₂PO₄).

B. BOILER AND SYSTEM CLEANING

INSTRUCTIONS FOR TROUBLE FREE

OPERATION

CAUTION

1. STEAM BOILERS

Exercise caution when handling phosphoric acid

and follow the instruction label on its container.

a. Oil, greases & sediments which accumulate in a

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.

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.

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-OFF

connection, see Figure 7.

i. Drain boiler until 1” of water is visible in

gauge glass. Run temporary 1½” 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. 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.

iii. 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.

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 & add

solution to boiler water thru exposed tapping

using a funnel.

NOTICE

iv. Stop feeding water to boiler but continue

operating 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.

Check with local authorities or consult local

water treatment services for acceptable chemical

cleaning compounds.

iii. 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.

v. 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. If the 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.

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 qualiﬁed 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:

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

Connect hoses from drain valves to ﬂoor

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.

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

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.

D. ATTENTION TO BOILER WHILE NOT IN

OPERATION.

NOTICE

f. Boiler is now ready to be put into service.

If boiler is not used during winter time, it must be

fully drained to prevent freeze damage.

C. ExCESSIVE MAKE-UP WATER

1. Spray inside surfaces with light lubricating or

crankcase oil using gun with extended stem so as to

reach all corners.

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.

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.

EXCESSIVE WATER ADDITION:

(Gallons / Month)

3. Always keep the manual fuel supply valve shut off

if the burner is shut down for an extended period of

time.

MSTꢀ88: 6

MST396: 8

MST6ꢀ9: 11

MST513: 9½

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.

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 inside.

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 on the heating system

to prevent damage if the boiler is inoperative.

4ꢁ

SECTION x: BOILER CLEANING

WARNING

All boiler cleaning must be completed with burner service switch turned off. Boilers equipped with burner

swing door have a potential hazard which can cause severe property damage, personal injury or loss of life

if ignored. Before opening swing door, turn off service switch to boiler to prevent accidental ﬁring of burner

outside the combustion chamber. 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).

C. AFTER CLEANING, vacuum all remaining debris

as necessary. Inspect burner swing door insulation, and

rope gasket for signs of damage. If damaged, replace as

needed.

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.

D. REASSEMBLE BOILER.

2. Remove the two smoke box clean-out covers from

the rear smoke box by removing the four 5/16"-18

hex head bolts. It is NOT necessary to remove the

vent connector from the smoke box to clean boiler.

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 or

accumulation of debris.

CAUTION

Do not start the burner unless the burner swing

door and canopy cover plates are secured in

place.

1 Insert the bafﬂes (if originally installed) into the

correct ﬂue way. The bafﬂes are installed in the 2^nd

pass (two inner ﬂue ways) on the MST396, MST513

and MST629.

3. Remove the bafﬂes (if installed) from the ﬂue

passages. There is a pair of bafﬂes in each boiler.

The bafﬂes are installed in the 2^ndpass (two inner

ﬂue ways) on the MST396, MST513 and MST629.

4. Clean the 3^rdPass – Insert a 2" dia. x 42" long

wire or ﬁber bristle brush into each of the two 3^rd

passes. Using long strokes push the brush all the

way through the boiler until the brush has exited

the smoke box opening. Pull the brush all the way

forward until it has exited the front of the boiler.

Continue this operation for the entire height of the

ﬂue way until clean. Repeat the operation for the

other 3^rdpass ﬂue way.

5. Clean the 2^ndPass - Insert a 2" dia. x 42" long wire

or ﬁber bristle brush into each of the two 2^ndpasses.

Using long strokes push the brush all the way

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.

Continue this operation for the entire height of the

ﬂue way until clean. Repeat the operation for the

other 2^ndpass ﬂue way.

2. Attach the smoke box clean-out covers onto the

rear of the boiler. Verify that the rope gasket is

in good working order before assembly. Replace

rope gasket if necessary. Use the 3/8" hardware

originally removed. Do not over tighten. They

should be snug but not bottomed out.

NOTICE

When securing burner swing door make sure door

is drawn-in equally on both sides.

Tighten swing door hardware to provide adequate

seal to rope gasket around perimeter of door.

Use an alternating tightening method from right side

to left side cap screw to pull door tight equally.

NOTICE

Do not overtighten. The rope gasket will provide

sufﬁcient seal when the door is snugged into

place.

6. Vacuum the loose debris in the bottom of the

combustion chamber and smoke box.

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.

Figure ꢀꢁ: Cleaning Boiler Flueways and Combustion Chamber Surfaces

WARNING

The boiler must be connected to an approved chimney in good condition. Serious property damage could

result if the boiler is connected to a dirty or inadequate chimney. The interior of the chimney ﬂue must be

inspected and cleaned before the start of the heating season and should be inspected periodically throughout

the heating season for any obstructions. Aclean 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.

SECTION xI: TROUBLE SHOOTING

A. COMBUSTION

8. COLD OIL — If the oil temperature approaching

the fuel pump is 40°F or lower, poor combustion or

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 is to bury the tank and lines deep

enough to keep the oil above 40°F.

1. NOZZLES — 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

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

CO₂and smoke. Nozzles are delicate and should be

protected from dirt and abuse. Nozzles are mass-

produced and can vary from sample to sample. For

all of those reasons a spare nozzle is a desirable item

for a serviceman to have.

9. HIGH ALTITUDE INSTALLATIONS — Air

openings must be increased at higher altitudes. Use

instruments and set for 11.5 to 12.5% CO₂.

10.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.

2. 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

leaks, air leaks, water or dirt in the fuel as described

above.

11. SHUT DOWN NOISE — If the 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.

3. 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.

NOTICE

CHECK TEST PROCEDURE. A 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 #ꢀ oil from another source. If the 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.

4. AIR LEAKS — Any such leaks should be repaired,

as they may cause erratic burning of the fuel and in

extreme cases may become a ﬁre hazard.

5. GASKET LEAKS — If 11.5 to 12.5% CO₂with 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 CO₂reading in the breeching. The

smaller the ﬁring rate the greater effect an air leak

can have on CO₂readings.

B. OIL 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.

6. 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.

c. CAD cell seeing light.

d. CAD assembly defective.

e. Control motor relay is stuck closed (see note

below).

7. 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 out of the combustion chamber and clog the

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.

ﬂueways of the boiler.

Note: The Safety Monitoring Circuit (SMC) is

designed to provide lockout in the event of a

stuck or welded motor relay.

d. Excessive airﬂow or draft causing ﬂame to leave

burner head.

e. Excessive back pressure causing ﬂame to be

erratic.

NOTICE

3. Control locks out after Trial For Ignition (TFI).

a. No oil to burner.

If ﬂame is not established within 15 seconds

of oil valve actuation (known as Trial For

Ignition [TFI]) lockout will occur. Lockout is

indicated by a red LED solid-on located on the

oil primary control.

b. Shorted electrodes.

c. Nozzle clogged.

d. Airﬂow too high.

e. Ignitor module defective.

f. CAD cell defective.

Latch-up will occur if the control locks-out

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.

5ꢀ

Item

No.

Description

Part No. MST288 MST396 MST513 MST629

1. BARE BOILER ASSEMBLy

Front Section, Machined

100569-01

100571-01

100573-01

100676-01

806600375

7066003

Center Section, Machined

1C1

1C2

1D1

1D2

Rear Section (Htr.), Steam, Machined

Rear Section (Non-Htr.), Steam, Machined

Slip Nipple, 22-B Steel

5" Cast Iron Slip Nipple

Upper Tie Rod, 3/8" -16 x 16" Lg.

Upper Tie Rod, 3/8" -16 x 21-1/2" Lg.

Upper Tie Rod, 3/8" -16 x 27-1/2" Lg.

Lower Tie Rod, 3/8" -16 x 15" Lg.

Lower Tie Rod, 3/8" -16 x 20-3/4" Lg.

Lower Tie Rod, 3/8" -16 x 27" Lg.

3/8" Flat Washer, USS, Plain

80861075

80861033

80861014

80861016

80861012

80861018

80860600

80860400

---

3/8" -16 Heavy Hex Nut, Plain

Spanner Bar w/Threaded Inserts,

1-1/4" x 1-1/2" x 20-3/8" Lg.

100012-02

100012-03

100012-04

---

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.

---

Carriage Bolt, 3/8" -16 x 1-1/4" Lg., Plated

Cap Screw, 5/16" -18 x 7/8" Lg., Plated

Flat Washer, 5/16", USS, Plated

Hex Nut, 5/16 -18, Serrated Flange, Plated

Hinge Bracket

100215-01

80861371

80860611

80860443

100014-01

Hinge Bracket

Mount Burner

5/16" -18 x 3/4" Lg. Cap Screw, Plated

Cast Iron Burner Swing Door (Only)

80861340

100071-01

Item

No.

Description

Part No. MST288 MST396 MST513 MST629

1. BARE BOILER ASSEMBLy (Continued)

Burner Swing Door Insulation (Less Pockets)

100039-01

100039-02

100097-01

100096-01

100074-01

80860647

100050-01

100102-01

80860611

100021-01

80860611

80861340

806603542

---

Burner Swing Door Insulation (With Pockets)

5/8" Dia. Rope Gasket - Burner Swing Door

1/8" Dia. Rope Gasket - Observation Port

Observation Port Cover

5/16" Flat Washer, SAE, Plated

Socket Head Cap Screw, 5/16" x 5/8" Lg., Plated

Tap Bolt, 3/8" -16 x 1-3/4" Lg., Plated

5/16" Flat Washer, USS, Plated

1AA Smokebox

1BB

5/16" Flat Washer, USS, Plated

1CC Cap Screw, 5/16" -18 x 3/4" Lg., Plated

1DD 1/4" NPT Pipe Plug, Square Head, Brass

6" Dia.

7" Dia.

100093-01

100094-01

---

1EE

1FF

Smokebox Collar

---

5/16" Flat Washer, USS, Plated

80860611

80861371

100104-01

100095-01

6036036

1GG Cap Screw, 5/16" -18 x 7/8" Lg., Plated

1HH Cast Iron Clean-Cut Cover (only)

1JJ

1KK

1LL

1/2" Dia. Rope Gasket - Clean-Cut Cover

222A Heater Carton Assembly

Tapped Heater Cover Plate - Rear Heater

7036031

1MM Heater Cover Plate Gasket

8036068

Cap Screw, 3/8" -16" x 7/8" Lg., Plated,

ASME Grade SA307B

1NN

80861337

80860647

1PP

5/16" Flat Washer, SAE, Plated

Item

No.

Description

Part No. MST288 MST396 MST513 MST629

ꢀ. JACKET ASSEMBLy

Jacket Front Panel Assembly w/Insulation

Power Outlet Receptacle, w/Harness

100575-01

100605-01

#8 x 1/2" Type AB Truss Head w/Shoulder, Sheet Metal

Screw, Plated

100038-01

Jacket Rear Panel Assembly w/Insulation

External Wiring Enclosure

100578-01

100602-01

100046-01

100035-01

100047-01

100614-03

100614-04

100614-05

100581-03

100581-04

100581-05

100583-03

100583-04

100583-05

100585-03

100585-04

100585-05

60228001

60228002

80860955

Tap End Stud, 5/16" -18 x 3" Lg., Plain

5/8" O.D. x 2-5/32" Lg. Jacket Spacer

Acorn Nut, 5/16" -18, Plated

---

3" Thick Fiberglass Insulation Wrapper

---

Jacket Left Side Panel - 3 Section

Jacket Left Side Panel - 4 Section

Jacket Left Side Panel - 5 Section

Jacket Right Side Panel - 3 Section

Jacket Right Side Panel - 4 Section

Jacket Right Side Panel - 5 Section

Jacket Top Panel - 3 Section

---

Jacket Top Panel - 4 Section

---

Jacket Top Panel - 5 Section

---

Beckett Burner Enclosure Backer Plate

Beckett Burner Enclosure Cover

Knob, Dimco #2-116-335

Sheet Metal Screw, Plated, Phillips Truss Head,

Type AB, #8 x 1/2" Lg.

80860000

80860019

Sheet Metal Screw, Plated, Phillips Pan Head,

Type B, #8 x 1/2" Lg.

5ꢁ

Item

No.

Description

Part No.

MST288 MST396 MST513 MST629

3. MST - TRIM AND CONTROLS

6" RC-STD Draft Regulator

8116288

8116289

---

7" RC-STD Draft Regulator

Pressure Gauge

8056010

Probe, Hydrolevel EL-1214 (for Hydrolevel CG450)

Low Water Cut-off, Hydrolevel CG450 (less Probe)

Low Water Cut-off, McDonnell & Miller PS-801

Nipple, 3/4" NPT x 3" Lg.

80160629

80160623

80160723

806600002

806601502

806603010

80160369

81660530

8056091

---

Elbow, 3/4" NPT x 90

Syphon, 1/4" NPT x 1-7/8" x 4" x 90

Pressure Limit, Honeywell L404F1367

Safety Valve, 3/4" NPT, 15 PSI, Conbraco 13-511-08

Gauge Glass Set, 6", Conbraco 20-104-10

Low Water Cut-off, McDonnell & Miller 67

Nipple, 1-1/2" NPT x 5" Lg.

80160597

808600060

806601105

806603061

80160400

80160497

80160848

100042-01

Tee, 1-1/2' x 1-1/2" x 3/4"

Drain Valve, 3/4" NPT, Conbraco 35-302-03

Limit, Honeywell L4006A2015

Well, 1/2" NPT x 3", Honeywell 123872A

Oil Primary Control, Honeywell R7184P1064

Stainless Steel 2nd Pass Blueway Bafﬂe

Beckett AFG Oil Burner w/Gasket for:

MST288 Spec. No. BCB7706

100625-01

100053-01

---

MST396 Spec. No. BCB7703

---

MST513 Spec. No. BCB7704

MST629 Spec. No. BCB7705

100054-01

100055-01

---

(NOTE: See Pages 60 and 61 for burner Parts Breakdown)

Fan Center, Honeywell R8285C w/Connectors

100640-01

BECKETT OIL BURNER PART NOS. FOR MEGASTEAM™ SERIES BOILERS

NOTE: When ordering parts always give the serial and model numbers shown on the boiler and burner. Also

provide the name of the part(s) and part number as listed below.

Boiler Model

MST288

AFG70MMAQN

BCB7706

3492

MST396

AFG70MMAQN

BCB7703

3492

MST513

AFG70MLASN

BCB7704

3492

MST629

AFG70MKASN

BCB7705

3492

Air Tube Combination

Beckett's Spec. No.

Air Band

Air Band Nut

4150

Air Band Screw

4198

Air Shutter

3709

Air Shutter Screw

Blower Wheel

4198

2999

Coupling

2454

Low Firing Rate Bafﬂe

Bulkhead Knurled Locknut

Connector Tube Assembly

Electrode Clamp

Electrode Clamp Screw

Electrode Insulator Assembly

Support / Spacer Assembly

Escutcheon Plate

Adjusting Plate Assembly

Head

Less

3666

5636

149

4219

5780

5992

---

5941

5913

Head Screws

4221

Flange Gasket

3811

AFG Housing

5874GY

21805E/218

213

5874GY

21805E/218

213

5874GY

21805E/218

213

5874GY

21805E/218

213

Motor

Nozzle Adapter

Nozzle Line

Electrode Assembly

NL70MD

21844

NL70MD

21844

NL70MD

21844

NL70MD

21844

Oil Pump, Clean Cut,

Single Stage

Oil Pump, Clean Cut,

Two-Stage

21941

Static Plate

3383

51771U

42176

4292

3383

51771U

4217

3383

51771U

4217

3383

51771U

4217

Ignitor

Ignitor Hinge Screw

Ignitor Holding Screw

Ignitor Gasket Kit

Wire Guard

4292

51304

10251

3741

51304

10251

3741

51304

10251

3741

51304

10251

3741

Junction Box

Flame Detector

Oil Solenoid Valve Coil

Oil Solenoid Valve Cord

7006Q

21775U

21807

7006Q

21775U

21807

7006Q

21775U

21807

7006Q

21775U

21807

6ꢀ

SERVICE RECORD

DATE

SERVICE PERFORMED

Limited Warranty

FOR RESIDENTIAL CAST IRON STEAM BOILERS

By this Warranty Statement the U.S. Boiler^™Company, Inc. of Lancaster,

5. This warranty applies only to boilers installed within the United States, and

Canada.

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.

6. In order for this warranty to be effective:

a.) 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.

FIRSTYEAR - LIMITED WARRANTY FOR

RESIDENTIAL CAST IRON STEAM BOILERS

b.) The boiler must have been assembled in strict compliance with

installation instructions furnished with the boiler by U.S. Boiler Company, Inc.

c.) Boiler components must not have been damaged in handling during

shipment or installation.

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.

7. 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.

8. 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 or

consequential damages so the above limitation or exclusion may not apply

to you.

SECOND THROUGH 10YEAR - LIMITED

WARRANTY FOR THE CAST IRON SECTION

ASSEMBLY OF RESIDENTIAL CAST IRON STEAM 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.

9. 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  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.

FIRST THROUGH 5YEAR - LIMITED WARRANTY AGAINST

WATERSIDE CORROSION IN THE MEGASTEAM SERIES

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.

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 ve 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.

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.

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 during this period, U.S.

Boiler Company, Inc. will repair or replace at its option, the cast iron section

assembly.

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 U.S. Boiler Company, Inc., at P.O. Box 3079, Lancaster, PA 17604 giving full

particulars in support of the claim.

ADDITIONAL TERMS AND CONDITIONS

The homeowner is required to make available 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.

1. 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.

2. 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 GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY

ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE.

3. 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.

4. 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 insufcient water, allowed to freeze; subject

to ood conditions; or operated with water conditions and/or fuels or

additives which cause unusual deposits or corrosion in or on the heat

exchanger.

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