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