U.S. Boiler Company STMX100 Quick Start Manual

Knock-down boiler assembly

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Installation, operating and service instructions (76 pages)

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Knock-Down Boiler Assembly

SteamMax KA, KS & Kl Boilers

Models:

• STMX200

• STMX100

• STMX125

• STMX250

• STMX150

• STMX299

• STMX350

• STMX175

Instruction Contents

1. Qualified Installer, Service Agency or Gas Supplier

Read Before Proceeding . . . . . . . . . . . . . . . . . . . . . . .3

2. Parts Check List . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

3. Single Base and Section Assembly . . . . . . . . . . . .10

4. Split Bases Assembly . . . . . . . . . . . . . . . . . . . . . . . .11

5. Split Section and Base Assembly . . . . . . . . . . . . . .13

6. Individual Sections Assembly . . . . . . . . . . . . . . . . .16

Hydro-Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

8. Single Canopy Assembly . . . . . . . . . . . . . . . . . . . . .21

9. Dual Canopy Assembly . . . . . . . . . . . . . . . . . . . . . . .22

10. Single Jacket Assembly . . . . . . . . . . . . . . . . . . . . . .23

11. Dual Jacket Assembly . . . . . . . . . . . . . . . . . . . . . . . .25

12. Controls Assembly . . . . . . . . . . . . . . . . . . . . . . . . . .28

13. Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

14. Label Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

WARNING

Attention Installer - Affix these instructions

adjacent to boiler. Provide model number and

serial number when seeking information and

support.

Attention Building Owner - Retain these

instructions for future reference. Contact a

qualified installer, service agency or gas

supplier for all issues and support.

This boiler must only be installed, serviced, and repaired by a qualified installer, service agency or gas

supplier. Improper installation, adjustment, alteration, service or maintenance can cause severe personal

injury, death, or substantial property damage. For assistance or additional information, consult a qualified

installer, service agency or gas supplier. Read these instruction carefully before installing.

111299-06 - 9/22

• STMX399

• STMX450

• STMX500

• STMX550

WARNING

• Steam Boiler

• Cast Iron

• Chimney Vent

• Gas Fired

Page

Video must be used in conjunction with this

Knock-down Boiler Assembly manual. REVIEW

all notices, cautions and warnings before

assembling boiler.

NOTICE: These assembly procedures should be

used in conjunction with Installation, Operating

and Service Instructions provided with boiler or

available on manufacturer's website.

QR code links to a video

illustrating split-base and

block assembly.

WARNING

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Summary of Contents for U.S. Boiler Company STMX100

Page 1: Table Of Contents
SteamMax KA, KS & Kl Boilers • Steam Boiler • Cast Iron • Chimney Vent Models: • Gas Fired • STMX200 • STMX399 • STMX100 • STMX125 • STMX250 • STMX450 • STMX150 • STMX299 • STMX500 • STMX350 • STMX550 •...
Page 2 Knock-Down Assembly Instructions SteamMax Important Definitions of Warnings Massachusetts Board of Plumbers and Gas Fitters has listed SteamMax Boilers. See Massachusetts Board of Plumbers and Gas Fitters website for latest Approval Code or ask your local Sales Representative. Commonwealth of Massachusetts requires this product to be installed by a licensed Plumber or Gas fitter. The following terms are used throughout this manual to bring attention to the presence of hazards of various risk levels, or to important information concerning product life.
Page 3: Qualified Installer, Service Agency Or Gas Supplier
Knock-Down Assembly Instructions SteamMax Qualified Installer, Service Agency or Gas Supplier Read Before Proceeding NOTICE: WARNING 1. Size boiler properly. A grossly oversized boiler Asphyxiation Hazard, Burn Hazard, Electrical will cycle excessively leading to premature Shock Hazard. failure of boiler and its components. Warranty •...
Page 4: Parts Check List
Knock-Down Assembly Instructions SteamMax Parts Check List Table 2-1: Knock-Down Boilers with Assembled Sections and Single Base Part Number [Quantity] Description STMX100 STMX125 STMX150 STMX175 STMX200 STMX250 STMX299 Base Assembly 110901-03 110901-04 110901-04 110901-05 110901-05 110901-06 110901-07 (BBMA) 110168-03 110168-04...
Page 5 Knock-Down Assembly Instructions SteamMax Parts Check List (continued) Table 2-2: Knock-Down Boilers with Split Sections and Split Base, NON CSD-1 Part Number [Quantity] Description STMX350 STMX399 STMX450 STMX500 STMX550 110908-04 110908-04 111236-05 111236-06 111236-06 Split Left Base Assembly (BBMA) 110909-04 110909-05 111237-05 111237-05...
Page 6 Knock-Down Assembly Instructions SteamMax Parts Check List (continued) Table 2-3: Knock-Down Boilers with Split Sections and Split Base, CSD-1 Part Number [Quantity] Description STMX450 STMX500 STMX550 111236-05 111236-06 111236-06 Split Left Base Assembly (BBMA) 111237-05 111237-05 111237-06 Split Right Base Assembly (BBMA) 110169-05 110169-06 110169-06...
Page 7 Knock-Down Assembly Instructions SteamMax Parts Check List (continued) Table 2-4: Knock-Down Boilers with Individual Sections and Single Base Part Number [Quantity] Description STMX100 STMX125 STMX150 STMX175 STMX200 STMX250 STMX299 110901-03 110901-04 110901-04 110901-05 110901-05 110901-06 110901-07 Base Assembly (BBMA) 110166-01...
Page 8 Knock-Down Assembly Instructions SteamMax Parts Check List (continued) Table 2-5 Knock-Down Boilers with Individual Sections and Split Base, NON CSD-1 Part Number [Quantity] Description STMX350 STMX399 STMX450 STMX500 STMX550 110908-04 110908-04 111236-05 111236-06 111236-06 Split Left Base Assembly (BBMA) 110909-04 110909-05 111237-05 111237-05...
Page 9 Knock-Down Assembly Instructions SteamMax Parts Check List (continued) Table 2-6: Knock-Down Boilers with Individual Sections and Split Base, CSD-1 Part Number [Quantity] Description STMX450 STMX500 STMX550 Split Left Base Assembly (BBMA) 111236-05 [1] 111236-06 [1] 111236-06 [1] Split Right Base Assembly (BBMA) 111237-05 [1] 111237-05 [1] 111237-06 [1]...
Page 10: Single Base And Section Assembly
Knock-Down Assembly Instructions SteamMax Single Base and Section Assembly B. Install on level floor. For basement installation DANGER provide concrete base if floor is not level or if • Use precautions and appropriate rigging water may be encountered on floor around apparatus when moving heavy objects.
Page 11: Split Bases Assembly
Knock-Down Assembly Instructions SteamMax Split Bases Assembly 3. Set aside rear air dams, not shown. Air dams will DANGER be installed after jacket attachment. • Use precautions and appropriate rigging 4. Set aside jacket top bracket, not shown, packed apparatus when moving heavy objects. with split left base assembly.
Page 12 Knock-Down Assembly Instructions SteamMax Split Bases Assembly (continued) Figure 4-1: Split Bases Assembly 111299-06 - 9/22...
Page 13: Split Section And Base Assembly
Knock-Down Assembly Instructions SteamMax Split Section and Base Assembly NOTICE: Do not loosen or remove draw rods until DANGER tie rods are secured. • Use precautions and appropriate rigging 14. Screw (2) 5/16-18 hex head bolts through base apparatus when moving heavy objects. holes and section assembly slots on right side.
Page 14 Knock-Down Assembly Instructions SteamMax Split Section and Base Assembly (continued) 111299-06 - 9/22...
Page 15 Knock-Down Assembly Instructions SteamMax Split Section and Base Assembly (continued) 111299-06 - 9/22...
Page 16: Individual Sections Assembly
Knock-Down Assembly Instructions SteamMax Individual Sections Assembly 14. Draw section assemblies together slowly and DANGER evenly. Alternately tighten upper and lower draw • Use precautions and appropriate rigging rods. Tighten each draw rod a little at a time apparatus when moving heavy objects. so sections are evenly spaced.
Page 17 Knock-Down Assembly Instructions SteamMax Individual Sections Assembly (continued) 7 7 7 Figure 6-1: Single Base and Individual Sections 111299-06 - 9/22...
Page 18 Knock-Down Assembly Instructions SteamMax Individual Sections Assembly (continued) Apply silicone here Apply silicone here Figure 6-2: Split Base and Individual Sections 111299-06 - 9/22...
Page 19 Knock-Down Assembly Instructions SteamMax Individual Sections Assembly (continued) 111299-06 - 9/22...
Page 20: Hydro-Test
Knock-Down Assembly Instructions SteamMax Hydro-Test NOTICE: It is essential that hydrostatic testing be done before canopy, jacket, controls or piping is installed. Hydro-Test per requirements of authority having jurisdiction. In the absence of such requirements, the following procedure can be used. 1.
Page 21: Single Canopy Assembly
Knock-Down Assembly Instructions SteamMax Single Canopy Assembly CAUTION Use proper Personal Protective Equipment (PPE) during assembly. See figures 8-1 and 8-2 for References. 1. Start washer and jam nut on ¼-20 carriage bolt, Item 1. 2. Insert assembly in slot between end sections and intermediate section.
Page 22: Dual Canopy Assembly
Knock-Down Assembly Instructions SteamMax Dual Canopy Assembly See Figure 9-1 for Reference. CAUTION 1. Follow steps in Single Canopy Assembly Section Use proper Personal Protective Equipment (PPE) for both canopies. during assembly. 2. See Figure 6-3 for canopy locations. 1 1 1 Figure 9-1: Dual Canopy Assembly 111299-06 - 9/22...
Page 23: Single Jacket Assembly
Knock-Down Assembly Instructions SteamMax Single Jacket Assembly NOTICE: Do not attach top panels until wiring is CAUTION complete. Use proper Personal Protective Equipment (PPE) 7. Attach front top jacket panel, Item 5, to side during assembly. jacket panels. 8. Attach rear top jacket panel, Item 6, to side jacket See Figures 10-1, 10-2 and 10-3 for References.
Page 24 Knock-Down Assembly Instructions SteamMax Single Jacket Assembly (continued) Figure 10-2: Single Jacket Assembly Figure 10-3: Rear Air Dam Installation 111299-06 - 9/22...
Page 25: Dual Jacket Assembly
Knock-Down Assembly Instructions SteamMax Dual Jacket Assembly 16. Install right rear air dam, Item 16, by hanging it on CAUTION stand-offs on right side of base tray. Use proper Personal Protective Equipment (PPE) 17. Install left rear air dam, not shown, by hanging it during assembly.
Page 26 Knock-Down Assembly Instructions SteamMax Dual Jacket Assembly (continued) 111299-06 - 9/22...
Page 27 Knock-Down Assembly Instructions SteamMax Dual Jacket Assembly (continued) Figure 11-2: Dual Jacket Assembly 111299-06 - 9/22...
Page 28: Controls Assembly
Knock-Down Assembly Instructions SteamMax Controls Assembly For location of controls, consult How it Works Section 2. Dual Pressure Limit Assembly of Installation, Operating,and Service Instructions See Figure 12-2 for References supplied with boiler or available on manufacturer’s Item 1: Auto Reset Pressure Limit website.
Page 29: Wiring
Knock-Down Assembly Instructions SteamMax Wiring Pressure limit(s), LWCO(s), control panel and WARNING junction box must be located on same side of Electrical Shock Hazard. boiler which could be either left or right side. All wiring and grounding must conform to requirements of authority having jurisdiction or, in absence of such requirements, DANGER...
Page 30 Knock-Down Assembly Instructions SteamMax Wiring (continued) Snap bushing (wires from limits/damper) 3-pin connector Green, white, black wires. 2-pin connector Relay plug 3-pin connector Orange wire (ignition cable) Blue wire Yellow wire Green wire (pilot ground) Figure 13-2: STMX075 through STMX299 Control Panel Wiring 2-pin connector Green Wire from main harness...
Page 31 Knock-Down Assembly Instructions SteamMax Wiring (continued) 111299-06 - 9/22...
Page 32 Knock-Down Assembly Instructions SteamMax Wiring (continued) 111299-06 - 9/22...
Page 33 Knock-Down Assembly Instructions SteamMax Wiring (continued) (snap bushing Fork terminals from behind control) main harness. Wires are interchangeable. Universal bushing Figure 13-6: Auto Reset Pressure Limit Wiring Snap bushing 2-pin connector (inside jacket) Fork terminals, wires are interchangeable Fork terminals, wires are interchangeable Snap...
Page 34 Knock-Down Assembly Instructions SteamMax Wiring (continued) Wires from lower bushing on rear of boiler. After control installed, connect ring terminal to probe. 3-pin connector from main harness Snap bushing Figure 13-8: Auto Reset M&M LWCO Wiring Wires from lower bushing on rear of boiler.
Page 35 Knock-Down Assembly Instructions SteamMax Wiring (continued) 3-pin connector Wires from from main harness lower bushing on rear of boiler. After control installed, connect ring terminal to probe. Snap bushing Figure 13-10: Auto Reset Hydrolevel LWCO Wiring 3-pin connector from main harness, Auto Reset plugs into LWCO harness.
Page 36 Knock-Down Assembly Instructions SteamMax Wiring (continued) 4-pin connector from main harness Strain relief bushing Snap bushing To LWCO Wires are interchangeable Figure 13-12: STMX075 through STMX299 Blocked Vent Switch (BVS) and Vent Damper Wiring 111299-06 - 9/22...
Page 37 Knock-Down Assembly Instructions SteamMax Wiring (continued) Weld Stud Draft Hood Rear Air Dam #6 SMS Wires are interchangeable Figure 13-13: STMX350 through STMX550 Dual Block Vent Switch (BVS) Wiring 111299-06 - 9/22...
Page 38: Label Locations
2. Low Water Level Plate, Item 2, screwed onto pre-drilled holes in either left or right side jacket panel. 3. Energy Guide Label, Item 3, affixed to left side jacket panel. For STMX100, STMX125, STMX150, STMX175, STMX200, STMX250 and STMX299 only. NOTICE: This installation is not complete until ASME Data Label, Low Water Level Plate and Energy Guide are attached to the jacket.
Page 39 Knock-Down Assembly Instructions SteamMax SERVICE RECORD DATE SERVICE PERFORMED 111299-06 - 9/22...
Page 40 Knock-Down Assembly Instructions SteamMax U.S. Boiler Company, LLC P.O. Box 3020 Lancaster, PA 17604 1-888-432-8887 www.usboiler.net 111299-06 - 9/22...

This manual is also suitable for:

Stmx200 Stmx399 Stmx125 Stmx250 Stmx450 Stmx150 ... Show all

U.S. Boiler Company STMX100 Quick Start Manual

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