INSTALLATION, OPERATING AND SERVICE INSTRUCTIONS FOR
MegaSteam
3-PASS OIL BOILER
DANGER
IMPORTANT INFORMATION - READ CAREFULLY
Do not tamper with or alter the boiler or controls
DANGER
TABLE OF CONTENTS
Page
TABLE 1B RATING DATA
TABLE 1A DIMENSIONAL DATA SEE FIGURE
Section I PRE-INSTALLATION
C. PROVIDE COMBUSTION AND VENTILATION AIR. Local and National Codes may apply and should be referenced
MegaSteam Unit-Pak Boiler Assembly Shipment
SECTION II UNIT-PAK BOILER ASSEMBLY
Content Check List see Figure
2. Control Carton
A. CAST IRON SECTION ASSEMBLY TAPPINGS
C. Procedure To Open, Close and Secure Burner Swing Door
D. Jacket Front Panel Installation
Figure 4 Boiler Removal from Skid
Assembly and door mounting bracket for front jacket panel installation
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E. Flueway Baffle Installation
table 2 baffle USAGE
F. Closing / Securing Burner Swing Door
G. Jacket Rear Panel Installation
H. Flue Cleanout Covers and Smokebox Collar Installation
Figure 6 Flueway Baffle Positioning/Orientation in Flueways
Figure 7 Purpose of Tappings and Bosses
K. External Electrical Enclosure Mounting
J. Side and Top Jacket Panel Installation
Figure 8 Pressure Limit Installation
L. Trim and Controls Installation. Pressure Limit Installation
N. Pressure Gauge and Gauge Glass Installation
O. Float LWCO McDonnell-Miller #67, AND Gauge Glass Installation
Figure 9 Float-Type LWCO and Pressure Limit Installation
Q. Safety Valve and Drain Valve Installation
P. Aquastat Controller Installation Boilers with Tankless Heater only
R. Oil Burner Installation
Do not install burner without gasket
Figure 10 Oil Burner Installation
A. Evaluate the existing steam system
SECTION III STEAM Boiler PIPING & TRIM
Figure 11 Recommended Boiler Piping for Gravity Return Steam Boiler
SECTION IV TANKLESS & Indirect Water HEATER PIPING
Table 4 TANKLESS HEATER DATA
Figure 12 Schematic Tankless Water Heater Piping
B. CONNECT ALLIANCE INDIRECT WATER HEATER PIPING as shown in Figure
Figure 13 Alliance Water Heater Piping with MegaSteam Boiler
B. Chimney Connector
SECTION V VENTING & Air intake piping
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A. Chimney Venting
Figure 15 Proper and Improper Locations of Draft Regulator
Figure 14 Recommended Vent Pipe Arrangement and Chimney Requirements
C. Draft
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D. Stack Temperature
Figure 16 Smokebox Pressure Tapping for Checking Draft at Breech
Do not reduce size of air intake pipe
E. Minimum Clearances
6. Install air intake terminal. See Figure
SECTION VI ELECTRICAL
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A. General
Figure 18 Wiring Diagram, Steam, Hydrolevel CG450 Probe LWCO
Figure 19 Wiring Diagram, Steam, McDonnell & Miller PS-801 Probe LWCO
Figure 20 Wiring Diagram, Steam, McDonnell & Miller #67 Float LWCO
Jumper
SECTION VII OIL PIPING
A. General
B. Single Pipe Oil Lines
Table 5 Two-Stage Units 3450 RPM Two Pipe Systems
C. Two Pipe Oil Lines
Table 6 Single-Stage Units 3450 RPM - Two Pipe Systems
Figure 22 Two Pipe Oil Lines
A. ALWAYS INSPECT INSTALLATION BEFORE STARTING BURNER
Section VIII SYSTEM START-UP
E. ADJUST OIL BURNER BEFORE STARTING
B. FILL HEATING SYSTEM WITH WATER
G. ADJUST OIL BURNER WHILE OPERATING. flame present
Figure 23 Adjusting Fuel Pump Pressure
H. CHECK FOR CLEAN CUT OFF OF BURNER
I. TEST CONTROLS
Page
Table 7 Cad Cell Resistance When Sensing Flame
Figure 25 R7184 Terminals, LED and Reset Button
Jumper must be removed after this check
Figure 26 Cad Cell Location
First Aid Procedures
Precautionary Measures
Important Product Safety Information Refractory Ceramic Fiber Product
AVOID Breathing Fiber Particulates and Dust
A. MAINTENANCE OF LOW WATER CUT- OFF DEVICES
SECTION Ix MAINTENANCE AND SERVICE INSTRUCTIONS
B. BOILER AND SYSTEM CLEANING INSTRUCTIONS FOR TROUBLE FREE OPERATION
DANGER
i Connect hoses from drain valves to floor
EXCESSIVE WATER ADDITION Gallons / Month
C. EXCESSIVE MAKE-UP WATER
MST288
MST396
A. CLEAN THE FLUEWAYS See Figure
Section X BOILER Cleaning
B. Clean the Combustion Chamber
D. REASSEMBLE BOILER
Figure 27 Cleaning Boiler Flueways and Combustion Chamber Surfaces
SECTION XI TROUBLE SHOOTING
A. COMBUSTION
B. OIL PRIMARY CONTROL
SECTION XII Repair Parts
Bare Boiler Assembly
1. BARE BOILER ASSEMBLY
Bare Boiler Assembly
Description
1. BARE BOILER ASSEMBLY Continued
MST288
MST396
Jacket Assembly
2. JACKET ASSEMBLY
MST288 Thru MST629 Steam Boilers - Trim and Controls
3. MST - TRIM AND CONTROLS
Beckett AFG Burner
BECKETT OIL BURNER PART NOS. FOR MegaSteam SERIES BOILERS
Stack Temp
Table 8 BECKETT AFG Burner specifications
SERVICE RECORD
SERVICE PERFORMED
DATE
Limited Warranty
FOR RESIDENTIAL CAST IRON STEAM BOILERS
FIRST YEAR - LIMITED WARRANTY FOR RESIDENTIAL CAST IRON STEAM BOILERS
SECOND THROUGH 10 YEAR - LIMITED WARRANTY FOR THE CAST IRON SECTION
