U.S. Boiler Company MegaSteam MST Manuel d'instructions

103536-02 - 7/13 Price - $5.00 DNAGNITAREPO,NOITALLATSNIROFSNOITCURTSNIECIVRES™maetS

10A. CAST IRON SECTION ASSEMBLY TAPPINGS Refer to Table 3 "Purpose of Tappings and Bosses" and Figure 7. 1. All tappings have factory ins

11Figure 4: Boiler Removal from SkidSECTION II: UNIT-PAK BOILER ASSEMBLY (continued)

12Figure 5A: Partial Front View - Burner Swing Door Mounted to Boiler - Fully Closed and SecuredD. JACKET FRONT PANEL INSTALLATION. In order to

13Figure 5B: Top View - Burner Swing Door Mounted to Cast Iron Block Assembly (Jacket Removed for Clarity)10. Inspect burner swing door insulation f

1411. Upon inspection completion, lift door and place integral cast hinge pins into door mounting bracket slotted holes. Do not close and secure door

15Figure 6: Flueway Bafe Positioning/Orientationin Fluewaysueway on right side of boiler, hold bafe with word "Right" readable at the to

16Figure 7: Purpose of Tappings and BossesTABLE 3: PURPOSE OF TAPPINGS & BOSSESTapping Location Size, NPT Boss Location Thread Size UNCSteam Boi

177. Secure panel bottom to studs with acorn nuts hand tight.8. Align upper panel attachment holes with smokebox upper attachment bosses and install

189. Place the panel between side panels upper inside anges and slide it forward, until top panel front ange U-bend locks over front panel top ang

19Figure 9: Float-Type LWCO and Pressure Limit InstallationSECTION II: UNIT-PAK BOILER ASSEMBLY (continued)

2IMPORTANT INFORMATION - READ CAREFULLY The following terms are used throughout this manual to bring attention to the presence of hazards of vario

204. Pick-up the LWCO harness Molex end and feed it into the enclosure, thru external electrical enclosure top ange front left 7/8” hole; then, snap

21Figure 10: Oil Burner Installation (Beckett Burner Shown)3. Thread safety valve into the ¾” NPT black coupling. Pipe the safety valve discharge as

22g. Align holes and install two (2) remaining cap screws. Level burner and fully tighten all three (3) screws.h. Plug burner power cord into power

23Figure 11D: Turbulator SettingFigure 11E: Pump Connections and Port IdenticationWARNING: Do not operate a single line system with the by-pass

24 A. EVALUATE THE EXISTING STEAM SYSTEM. The single most important factor in determining the expected life cycle of a steam boiler, is the amou

25Figure 12: Recommended Boiler Piping for Gravity Return Steam BoilerSECTION III: STEAM BOILER PIPING & TRIM (continued)

26SECTION IV: TANKLESS & INDIRECT WATER HEATER PIPINGA. CONNECT TANKLESS HEATER PIPING as shown in Figure 13. See Table 4 for Tankl

27TABLE 4: TANKLESS HEATER DATA: Figure 13: Schematic Tankless Water Heater PipingBoiler Model Heater No.Heater Rating (GPM)Pressure Drop thru Heate

28Figure 14: Alliance SL™ Water Heater Piping with MegaSteam™ BoilerB. CONNECT ALLIANCE SL™ INDIRECT WATER HEATER PIPING as shown in Figure 14.

29A. CHIMNEY VENTING 1. Chimney venting is an important part of a safe and efcient oil red appliance system. Contact your local re and buildin

3DANGERDO NOT store or use gasoline or other ammable vapors or liquids in the vicinity of this or any other appliance. WARNINGImp

30Figure 15: Recommended Vent Pipe Arrangement and Chimney RequirementsFigure 16: Proper and Improper Locations of Draft RegulatorSECTION V: VENTIN

312. Type B Chimney Connector - a type B chimney connector can be used to transmit the ue gases provided ue gas temperature entering the chimney co

32a minimum, remove the bafes to increase the stack temperature. See Tables 7 thru 7B for temperature differential (∆T) with bafes IN and OUT. In

33A. GENERAL1. Install wiring and electrically ground boiler in accordance with requirements of the authority having jurisdiction, or in absence of

34Figure 18: Wiring Diagram, Hydrolevel CG450 Probe LWCOSECTION VI: ELECTRICAL (continued)(SEE FIGURE 19 FOR SCHEMATIC WIRING DIAGRAM OF APPROPRIAT

35Figure 18A: Wiring Diagram, McDonnell & Miller PS-801 Probe LWCOSECTION VI: ELECTRICAL (continued)(SEE FIGURE 19 FOR SCHEMATIC WIRING DIAGRAM

36Figure 18B: Wiring Diagram, McDonnell & Miller #67 Float LWCOSECTION VI: ELECTRICAL (continued)(SEE FIGURE 19 FOR SCHEMATIC WIRING DIAGRAM OF

37SECTION VI: ELECTRICAL (continued)Figure 19: Wiring Diagram, All Burner Options with Various Oil Primary Controls

38BOILER SEQUENCE OF OPERATION WITH PROBE LWCO (See Figure 18)When the thermostat calls for heat, it energizes the R8285C Control Center relay w

39Figure 21: Single Pipe Oil LineSECTION VII: OIL PIPINGA. GENERAL1. Use exible oil line(s) so the burner swing door can be opened without dis

4WARNINGThis boiler contains very hot water under high pressure. Do not unscrew any pipe ttings nor attempt to disconnect any components of this boi

40Figure 22: Two Pipe Oil LinesC. TWO PIPE OIL LINES1. For two piped systems, where more lift is required, the two-stage fuel unit is recommende

41SECTION VIII: SYSTEM START-UP1. SET ROOM THERMOSTAT about 10° above room temperature.2. PRESS RED RESET BUTTON on front of burner cover,

425. Adjust oil pressure.a. When checking a fuel unit's operating pressure, a reliable pressure gauge may be installed in either the bleeder po

43Figure 24: "L1" and "V1" Head Electrode Positioning and Gun Setting (Beckett AFG)SECTION VIII: SYSTEM START-UP (continued)

442. 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 w

45Figure 26: Cad Cell LocationSECTION VIII: SYSTEM START-UP (continued)c. Simulate Ignition or Flame Failure:• Follow procedure to turn on burner

46Important Product Safety InformationRefractory Ceramic Fiber ProductWarning:The Repair Parts list designates parts that contain refractory ceramic f

47SECTION IX: MAINTENANCE AND SERVICE INSTRUCTIONSA. MAINTENANCE OF LOW WATER CUT-OFF DEVICESWARNINGProbe and oat type low water cu

48 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 temporari

49open gate valve in Hartford Loop, then repeat Step 1 above.e. Make pH or Alkalinity Test. After boiler and system have been cleaned and relled as

5Figure 1: MST288 Thru MST629 Steam Boiler with and without Tankless Heater (Beckett Burner Shown)

50SECTION X: BOILER CLEANINGA. CLEAN THE FLUEWAYS (See Figure 27).1. For access to the combustion chamber remove the two (2) 3/8" - 16 cap

51Figure 27: Cleaning Boiler Flueways and Combustion Chamber SurfacesWARNINGThe boiler must be connected to an approved chimney in good condition. Se

52A. COMBUSTION1. NOZZLES — Although the nozzle is a relatively inexpensive device, its function is critical to the successful operation of the oil

53d. Excessive airow or draft causing ame to leave burner head.e. Excessive back pressure causing ame to be erratic.3. Control locks out after T

54SECTION XII: REPAIR PARTSAll MegaSteam™ Boiler Repair Parts may be obtained through your local U.S. Boiler Company Wholesale distributor. Should

55Item No.Description Part No. MST288 MST396 MST513 MST6291. BARE BOILER ASSEMBLY1ACast Iron Block Assembly - 3 Section (Non Heater) 100567-03 1 1 --

56Bare Boiler AssemblySECTION XII: REPAIR PARTS (continued)

57Item No.Description Part No. MST288 MST396 MST513 MST6291. BARE BOILER ASSEMBLY (Continued)1KBurner Swing Door Insulation (Less Pockets) 100039-01

58Jacket AssemblySECTION XII: REPAIR PARTS (continued)

59Item No.Description Part No. MST288 MST396 MST513 MST6292. JACKET ASSEMBLY2A Jacket Front Panel Assembly w/Insulation 100575-01 1 1 1 12B Power Out

6TABLE 1A: DIMENSIONAL DATA (SEE FIGURE 1)TABLE 1B: RATING DATABoiler Model No.Dimensions (See Figure 1)Water Content (To Normal Water Line) - Gall

60MST288 Thru MST629 Steam Boilers - Trim and ControlsSECTION XII: REPAIR PARTS (continued)

61Item No.Description Part No. MST288 MST396 MST513 MST6293. MST - TRIM AND CONTROLS3A6" RC-STD Draft Regulator 8116288 1 1 1 ---7" RC-STD

62Beckett AFG BurnerSECTION XII: REPAIR PARTS (continued)

63BECKETT OIL BURNER PART NOS. FOR MEGASTEAM™ SERIES BOILERSNOTE: When ordering parts always give the serial and model numbers shown on the boiler an

64NOTE: When ordering parts always give the serial and model numbers shown on the boiler and burner. Refer to Models F3 & F5 Installation Manua

65TABLE 7: BECKETT AFG BURNER SPECIFICATIONSBoiler ModelBurner Input (gph)Head Type (setting)Air Shutter (setting)Air Band (setting) NozzlePump Press

66Boiler ModelBurner Input (GPH)Burner ModelNozzleHead SettingAir SettingPump Pressure (PSI)Air Tube TypeInsertion Depth (Inch)Approx. Shipped CO2 (%)

67APPENDIX A - FIGURESFigure NumberPage Number DescriptionFigure 1 5 MST288 Thru MST629 Steam Boiler with and without Tan

68APPENDIX A - FIGURES (continued)Figure NumberPage Number DescriptionSection VIII - System Start-UpFigure 23 42 Adjustin

69APPENDIX B - TABLESTableNumberPage Number DescriptionTable 1A 6 Dimensional Data (See Figure 1)Table 1B 6 Rating DataSe

7Figure 2: Minimum Installation Clearances To Combustible Materials (Inches)A. INSPECT SHIPMENT carefully for any signs of damage.1. All equipment

70SERVICE RECORDDATE SERVICE PERFORMED

71SERVICE RECORDDATE SERVICE PERFORMED

72U.S. Boiler Company, Inc.P.O. Box 3020Lancaster, PA 176041-888-432-8887www.usboiler.net

8NOTICEClearance 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 m

9SECTION II: UNIT-PAK BOILER ASSEMBLYMegaSteam™ Unit-Pak Boiler Assembly ShipmentContent Check List (see Figure 3)1. ___ Cast Iron Section/Burner