3-PASS OIL BOILER
INSTALLATION, OPERATING AND SERVICE INSTRUCTIONS FOR
MegaSteam
DANGER
IMPORTANT INFORMATION - READ CAREFULLY
Do not tamper with or alter the boiler or controls
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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
2. Control Carton
SECTION II UNIT-PAK BOILER ASSEMBLY
MegaSteam Unit-Pak Boiler Assembly Shipment
Content Check List see Figure
D. Jacket Front Panel Installation
A. CAST IRON SECTION ASSEMBLY TAPPINGS
C. Procedure To Open, Close and Secure Burner Swing Door
Figure 4 Boiler Removal from Skid
Assembly and door mounting bracket for front jacket panel installation
Page
F. Closing / Securing Burner Swing Door
E. Flueway Baffle Installation
table 2 baffle USAGE
Figure 6 Flueway Baffle Positioning/Orientation in Flueways
G. Jacket Rear Panel Installation
H. Flue Cleanout Covers and Smokebox Collar Installation
Figure 7 Purpose of Tappings and Bosses
K. External Electrical Enclosure Mounting
J. Side and Top Jacket Panel Installation
O. Float LWCO McDonnell-Miller #67, AND Gauge Glass Installation
L. Trim and Controls Installation. Pressure Limit Installation
Figure 8 Pressure Limit Installation
N. Pressure Gauge and Gauge Glass Installation
Figure 9 Float-Type LWCO and Pressure Limit Installation
Do not install burner without gasket
P. Aquastat Controller Installation Boilers with Tankless Heater only
Q. Safety Valve and Drain Valve Installation
R. Oil Burner Installation
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
A. Chimney Venting
SECTION V VENTING & Air intake piping
B. Chimney Connector
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Figure 15 Proper and Improper Locations of Draft Regulator
Figure 14 Recommended Vent Pipe Arrangement and Chimney Requirements
Figure 16 Smokebox Pressure Tapping for Checking Draft at Breech
D. Stack Temperature
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C. Draft
Do not reduce size of air intake pipe
E. Minimum Clearances
6. Install air intake terminal. See Figure
A. General
SECTION VI ELECTRICAL
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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
B. Single Pipe Oil Lines
SECTION VII OIL PIPING
A. General
Figure 22 Two Pipe Oil Lines
C. Two Pipe Oil Lines
Table 5 Two-Stage Units 3450 RPM Two Pipe Systems
Table 6 Single-Stage Units 3450 RPM - Two Pipe Systems
B. FILL HEATING SYSTEM WITH WATER
Section VIII SYSTEM START-UP
A. ALWAYS INSPECT INSTALLATION BEFORE STARTING BURNER
E. ADJUST OIL BURNER BEFORE STARTING
I. TEST CONTROLS
Figure 23 Adjusting Fuel Pump Pressure
G. ADJUST OIL BURNER WHILE OPERATING. flame present
H. CHECK FOR CLEAN CUT OFF OF BURNER
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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
AVOID Breathing Fiber Particulates and Dust
Precautionary Measures
First Aid Procedures
Important Product Safety Information Refractory Ceramic Fiber Product
DANGER
SECTION Ix MAINTENANCE AND SERVICE INSTRUCTIONS
A. MAINTENANCE OF LOW WATER CUT- OFF DEVICES
B. BOILER AND SYSTEM CLEANING INSTRUCTIONS FOR TROUBLE FREE OPERATION
i Connect hoses from drain valves to floor
MST396
C. EXCESSIVE MAKE-UP WATER
EXCESSIVE WATER ADDITION Gallons / Month
MST288
D. REASSEMBLE BOILER
Section X BOILER Cleaning
A. CLEAN THE FLUEWAYS See Figure
B. Clean the Combustion Chamber
Figure 27 Cleaning Boiler Flueways and Combustion Chamber Surfaces
B. OIL PRIMARY CONTROL
SECTION XI TROUBLE SHOOTING
A. COMBUSTION
SECTION XII Repair Parts
Bare Boiler Assembly
1. BARE BOILER ASSEMBLY
Bare Boiler Assembly
MST396
1. BARE BOILER ASSEMBLY Continued
Description
MST288
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
DATE
SERVICE RECORD
SERVICE PERFORMED
SECOND THROUGH 10 YEAR - LIMITED WARRANTY FOR THE CAST IRON SECTION
FOR RESIDENTIAL CAST IRON STEAM BOILERS
Limited Warranty
FIRST YEAR - LIMITED WARRANTY FOR RESIDENTIAL CAST IRON STEAM BOILERS
