U.S. Boiler Company MegaSteam MST758 Installation, Operating And Service Instructions
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U.S. Boiler Company MegaSteam MST758 Installation, Operating And Service Instructions

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Installation, Operating and Service Instructions for
MegaSteam
Models:
• MST288
• MST396
• MST513
• MST629
• MST758
• MST892
Manual Contents
1.
Pre-installation . . . . . . . . . . . . . . . . . . . . . . 5
2. Unit-Pak Boiler Assembly . . . . . . . . . . . . . . 9
3. Steam Boiler Piping & Trim . . . . . . . . . . . 21
5. Venting & Air Intake Piping . . . . . . . . . . . 30
6. Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . 34
7.
Oil Piping . . . . . . . . . . . . . . . . . . . . . . . . . . 39
8. System Start-up . . . . . . . . . . . . . . . . . . . . . 41
9. Maintenance & Service Instructions . . . . 46
10. Boiler Cleaning . . . . . . . . . . . . . . . . . . . . . 49
11. Troubleshooting . . . . . . . . . . . . . . . . . . . . 51
12. Service Parts . . . . . . . . . . . . . . . . . . . . . . . 53
(LWCO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
TO THE INSTALLER:
Affix these instructions adjacent to boiler.
TO THE CONSUMER:
Retain these instructions for future reference.
For service or repairs to boiler, call your heating contractor. When seeking information on boiler, provide
Boiler Model Number and Serial Number as shown on Rating Label.
103536-13 - 2/24
Page
TM
• Natural Draft
• Oil-Fired, 3 Pass
• Steam Boiler
• B20 Ready
9700609

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Summary of Contents for U.S. Boiler Company MegaSteam MST758

  • Page 1: Table Of Contents

    Installation, Operating and Service Instructions for MegaSteam • Natural Draft Models: • MST288 • Oil-Fired, 3 Pass • MST396 • Steam Boiler • MST513 • MST629 • B20 Ready • MST758 • MST892 Manual Contents Page Pre-installation ..... . 5 2.
  • Page 2 Installation & Service Manual MegaSteam IMPORTANT INFORMATION - READ CAREFULLY All boilers must be installed in accordance with National, State and Local Plumbing, All boilers must be installed in accordance with National, State and Local Plumbing, Heating and Electrical Codes and the regulations of the serving utilities. These Heating and Electrical Codes and the regulations of the serving utilities.
  • Page 3 Installation & Service Manual MegaSteam DANGER DO NOT store or use gasoline or other flammable vapors or liquids in the vicinity of this or any other appliance. WARNING Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury or loss of life.
  • Page 4 Installation & Service Manual MegaSteam WARNING This boiler contains very hot water under high pressure. DO NOT unscrew any pipe fittings nor attempt to disconnect any components of this boiler without positively assuring the water is cool and has no pressure. Always wear protective clothing and equipment when installing, starting up or servicing this boiler to prevent scald injuries.

  • Page 5: Pre-Installation

    Installation & Service Manual MegaSteam Pre-Installation 103536-13 - 2/24...
  • Page 6 Installation & Service Manual MegaSteam Pre-Installation (continued) Table 1-2: Dimensional (Data See Figure 1-1) Water Content (To Dimensions in. Boiler Normal Water Line) - Heat Transfer Surface Actual Shipping Model (See Figure 1-1) Gallons Area - sq. Ft. Weight (LB.) "A"...
  • Page 7 Installation & Service Manual MegaSteam Pre-Installation (continued) A. INSPECT SHIPMENT carefully for any signs of • 30 in. for flueway cleaning (MST513) damage. • 36 in. for flueway cleaning (MST629 thru 1. All equipment is carefully manufactured, MST892) inspected and packed. Our responsibility b.
  • Page 8 Installation & Service Manual MegaSteam Pre-Installation AVAILABLE WITH BECKETT BURNER - P/N (continued) 102119-01). Refer to Fresh Air Accessory 5. For minimum clearances to combustible Kit Instructions for installation and air intake materials. See Figure 1-4. piping details. NOTICE: Clearance to venting is for single wall vent pipe.

  • Page 9: Unit-Pak Boiler Assembly

    Installation & Service Manual MegaSteam Unit-Pak Boiler Assembly MegaSteam™ Unit-Pak Boiler Assembly Shipment Content Check List (see Figure 2-1) 1. ___ Cast Iron Section/Burner Swing Door/Smoke Box Assembly Mounted on Shipping Skid: ____ MST3 (Rear Section, Heater) – Part # 107242-03 / 102417-01 / 100021-01 ____ MST4 (Rear Section, Heater) –...
  • Page 10 Installation & Service Manual MegaSteam Unit-Pak Boiler Assembly (continued) as handles. Suggested pipe length for each 1. All tappings have factory installed thread handle is 72 in. (3-section); 78 in. (4-section) protectors. The thread protectors must be 84 in. (5-section); 90 in. (6-section). removed prior to jacket and piping installation.
  • Page 11 Installation & Service Manual MegaSteam Unit-Pak Boiler Assembly (continued) 103536-13 - 2/24...
  • Page 12 Installation & Service Manual MegaSteam Unit-Pak Boiler Assembly (continued) See also Figure 2-8 “Purpose of Tappings & Bosses”. D. JACKET FRONT PANEL INSTALLATION. 2. Open Jacket Carton and locate jacket front In order to install front jacket panel Burner Swing panel (has factory attached 1 in.
  • Page 13 Installation & Service Manual MegaSteam Unit-Pak Boiler Assembly (continued) 10. Inspect burner swing door insulation for into the insulation centered on the bar between damage and proper type. the combustion chamber and 3rd pass By design, for all models, cast bars on front flueways.
  • Page 14 Installation & Service Manual MegaSteam Unit-Pak Boiler Assembly (continued) 11. Upon inspection completion, lift door and place CAUTION integral cast hinge pins into door mounting These baffles will generate higher efficiencies bracket slotted holes. Do not close and secure and lower stack temperatures. Under certain door at this time, proceed to installing stainless conditions, a lower gross stack temperature steel flueway baffles.
  • Page 15 Installation & Service Manual MegaSteam Unit-Pak Boiler Assembly (continued) NOTICE: When securing burner swing door make sure door is drawn-in equally on both sides. d. Use a hand or socket wrench to tighten door hardware. ALWAYS START WITH RIGHT SIDE TAP BOLT FIRST. Use an alternating tightening method from right side tap bolt to left side tap bolt to tighten door equally, until sealed, without applying...
  • Page 16 Installation & Service Manual MegaSteam Unit-Pak Boiler Assembly (continued) Figure 2-8: Purpose of Tappings and Bosses Table 2-9: Purpose Of Tapping & Bosses Steam Boiler Tapping Boss Thread Size Size, NPT Location Location Less Heater With Heater ¼ in. - 18 Pressure Gauge ¼...
  • Page 17 Installation & Service Manual MegaSteam Unit-Pak Boiler Assembly (continued) 8. Align upper panel attachment holes with 2. Carefully cut the plastic bag and remove smokebox upper attachment bosses and install Insulation Wrapper. The wrapper will expand 5/16-18 in. x ½ in. Phillips pan head machine upon removal.
  • Page 18 Installation & Service Manual MegaSteam Unit-Pak Boiler Assembly (continued) L. TRIM AND CONTROLS INSTALLATION. 6. Place Right Side Jacket Panel, clearing rear section tankless heater collar/ mounting flange, Pressure Limit Installation. over four #8 x ½ in. shoulder sheet metal 1.
  • Page 19 Installation & Service Manual MegaSteam Unit-Pak Boiler Assembly (continued) 2. Remove the L4006A aquastat controller with M. PROBE LWCO (HYDROLEVEL CG450, factory attached harness from Control Carton. OR, MCDONNELL-MILLER PSE801-120) INSTALLATION. 3. Slip the bulb of the aquastat controller into the well and secure the controller in place with the 1.
  • Page 20 Installation & Service Manual MegaSteam Unit-Pak Boiler Assembly (continued) Figure 2-11: Oil Burner Installation (Beckett Burner Shown) e. Insert oil burner into the opening of burner 5. Thread 1-1/2 in. NPT x 5 in. lg. black nipple swing door. Align and engage keyhole slot into lower rear section tapping, then, install in burner flange over head of protruding cap 1-1/2 in.

  • Page 21: Steam Boiler Piping & Trim

    Installation & Service Manual MegaSteam Steam Boiler Piping & Trim WARNING Failure to properly pipe boiler may result in improper operation and damage to boiler or structure. Do not increase steam boiler input above the ratings. A. EVALUATE THE EXISTING STEAM SYSTEM. CAUTION The single most important factor in determining Maintain minimum ½...
  • Page 22 Installation & Service Manual MegaSteam Steam Boiler Piping & Trim (continued) 103536-13 - 2/24...
  • Page 23 Installation & Service Manual MegaSteam Steam Boiler Piping & Trim (continued) Table 3-2: Material for Boiler Models MST288, MST396 and MST513 Item Fittings Part Number Quantity 2 in. x 12 in. Nipple 806600330 2 in. Union 806604019 2 in. x 6 in. Nipple 806600204 2 in.
  • Page 24 Installation & Service Manual MegaSteam Steam Boiler Piping & Trim (continued) Table 3-4: Material for Boiler Model MST629 thru MST892 Item Fittings Part Number Quantity 2 in. x 12 in. Nipple 806600330 2 in. Union 806604019 2 in. x 6 in. Nipple 806600204 2 in.
  • Page 25 Installation & Service Manual MegaSteam Steam Boiler Piping & Trim (continued) Table 3-6: Dropped Header Material for Boiler Models MST288, MST396 and MST513 Item Fittings Part Number Quantity 2 in. x 12 in. Nipple 806600330 2 in. Union 806604019 2 in. x 6 in. Nipple 806600204 2 in.
  • Page 26 Installation & Service Manual MegaSteam Steam Boiler Piping & Trim (continued) Table 3-8: Dropped Header Material for Boiler Model MST629 thru MST892 Item Fittings Part Number Quantity 2 in. x 12 in. Nipple 806600330 2 in. Union 806604019 2 in. x 6 in. Nipple 806600204 2 in.

  • Page 27: Tankless & Indirect Water Heater Piping

    Installation & Service Manual MegaSteam Tankless & Indirect Water Heater Piping A. CONNECT TANKLESS HEATER PIPING as shown 3. FLUSHING OF HEATER — All water contains in Figure 4-1. See Table 4-2 for Tankless Heater some sediment which settles on the inside Rating.
  • Page 28 Installation & Service Manual MegaSteam Tankless & Indirect Water Heater Piping (continued) Figure 4-1: Schematic Tankless Water Heater Piping Table 4-2: Tankless Heater Data Boiler Model Heater No. Intermittent Draw (GPM) Pressure Drop thru Heater (PSI) MST288 3.00 19.5 MST396 3.25 28.7 MST513...
  • Page 29 Installation & Service Manual MegaSteam Tankless & Indirect Water Heater Piping (continued) Figure 4-3: Alliance SL™ Water Heater Piping with MegaSteam™ Boiler B. CONNECT ALLIANCE SL™ INDIRECT WATER 1. Refer to Alliance SL™ manual for additional HEATER PIPING as shown in Figure 4-3. information.

  • Page 30: Venting & Air Intake Piping

    Installation & Service Manual MegaSteam Venting & Air Intake Piping WARNING Vent this boiler according to these instructions. Failure to do so may cause products of combustion to enter the home resulting in severe property damage, personal injury or death. •...
  • Page 31 Installation & Service Manual MegaSteam Venting & Air Intake Piping (continued) Figure 5-1: Recommended Vent Pipe Arrangement and Chimney Requirements Figure 5-2: Proper and Improper Locations of Draft Regulator 103536-13 - 2/24...
  • Page 32 Installation & Service Manual MegaSteam Venting & Air Intake Piping (continued) c. Abandoned Openings – Openings through DANGER the chimney wall that are no longer used Any signs of condensate seepage at the base shall be sealed in accordance to NFPA 211. of the chimney shall be inspected immediately.
  • Page 33 Installation & Service Manual MegaSteam Venting & Air Intake Piping (continued) D. STACK TEMPERATURE WARNING 1. The temperature of the flue gases has a significant Remove the baffles if there are any signs effect on the amount of draft created in a vertical of condensation in the chimney or chimney chimney as well as the propensity to create connector.

  • Page 34: Electrical

    Installation & Service Manual MegaSteam Electrical DANGER Positively assure all electrical connections are unpowered before attempting installation or service of electrical components or connections of the boiler or building. Lock out all electrical boxes with padlock once power is turned off. WARNING Failure to properly wire electrical connections to the boiler may result in serious physical harm.
  • Page 35 Installation & Service Manual MegaSteam Electrical (continued) 103536-13 - 2/24...
  • Page 36 Installation & Service Manual MegaSteam Electrical (continued) 103536-13 - 2/24...
  • Page 37 Installation & Service Manual MegaSteam Electrical (continued) Figure 6-3: Schematic Wiring Diagram, Beckett 103536-13 - 2/24...
  • Page 38 Installation & Service Manual MegaSteam Electrical (continued) BOILER SEQUENCE OF OPERATION WITH PROBE LWCO (See Figure 6-1) When the thermostat calls for heat, it energizes the R8285C Control Center relay which in turn energizes the cad cell primary control, bringing on the burner. The burner will operate in the following sequence: Prepurge for the first 10 seconds;...

  • Page 39: Oil Piping

    Installation & Service Manual MegaSteam Oil Piping NOTICE: The National Oilheat Research Alliance 4. Use of a high efficiency micron filter (Garber or (NORA) recommends single pipe oil systems and equivalent) in addition to a conventional filter is high-quality filtration for all fuel types. This should highly recommended.
  • Page 40 Installation & Service Manual MegaSteam Oil Piping (continued) C. TWO PIPE OIL LINES 3. Under no circumstances is a manual shutoff valve to be located on the return line of a two 1. For two piped systems, where more lift pipe system.

  • Page 41: System Start-Up

    Installation & Service Manual MegaSteam System Start-Up WARNING All boilers equipped with burner swing door have a potential hazard which can cause severe property damage, personal injury or loss of life if ignored. Before opening swing door, turn off service switch to boiler to prevent accidental firing of burner outside the combustion chamber.
  • Page 42 Installation & Service Manual MegaSteam System Start-Up (continued) 5. Adjust oil pressure. will assure a safe and efficient operating condition. If the flame appears stringy instead a. When checking a fuel unit's operating of a solid fire, try another nozzle of the same pressure, a reliable pressure gauge may type.
  • Page 43 Installation & Service Manual MegaSteam System Start-Up (continued) CHECK THERMOSTAT OPERATION. c. Burner must not start. Verify that the SYS light is green, FLM light is yellow, and that Raise and lower thermostat setting as required to the control remains in Standby mode. start and stop burner.
  • Page 44 Installation & Service Manual MegaSteam System Start-Up (continued) f. Run: The flame is sustained until the call for heat is satisfied. The burner is then sent to Motor-Off Delay, if applicable, or it is shut down and sent to Standby. g.
  • Page 45 Installation & Service Manual MegaSteam System Start-Up (continued) Figure 8-4: Sequence of Operation, Beckett 7565 Primary Control M. ACTION Button (See Table 8-5) Table 8-5 – ACTION Button Operation Burner State/Status Pressing ACTION Button Results Lockout (soft) 1 Second Tap Reset Control Lockout (hard) 15+ Seconds...
  • Page 46 Installation & Service Manual MegaSteam System Start-Up (continued) Important Product Safety Information: Refractory Ceramic Fiber Product WARNING Some boiler components use materials that contain refractory ceramic fibers (RCF). RCF has been classified as a possible human carcinogen. When exposed to elevated temperatures, RCF may change into crystalline silica, a known carcinogen.
  • Page 47 Installation & Service Manual MegaSteam Maintenance and Service i. Apply a moderate amount of good quality A. MAINTENANCE OF LOW WATER CUT-OFF pipe dope to the pipe threads on the probe, DEVICES leaving the two end threads bare. Do not WARNING use PTFE (Teflon) tape.
  • Page 48 Installation & Service Manual MegaSteam Maintenance and Service (continued) iii. Turn on oil burner and keep operating NOTICE: Check with local authorities or consult while feeding water to boiler slowly. This local water treatment services for acceptable will raise water level in boiler slowly so chemical cleaning compounds.
  • Page 49 Installation & Service Manual MegaSteam Maintenance and Service (continued) oxygen or chloride salts in the boiler corrodes the e. Make pH or Alkalinity Test. cast iron from the inside. More make-up water and After boiler and system have been cleaned higher concentrations of contaminants damage and refilled as previously described, test the boiler sooner.

  • Page 50: Boiler Cleaning

    Installation & Service Manual MegaSteam Boiler Cleaning WARNING All boiler cleaning must be completed with burner service switch turned off. Boilers equipped with burner swing door have a potential hazard which can cause severe property damage, personal injury or loss of life if ignored.
  • Page 51 Installation & Service Manual MegaSteam Boiler Cleaning (continued) Figure 10-1: Cleaning Boiler Flueways and Combustion Chamber Surfaces WARNING The boiler must be connected to an approved chimney in good condition. Serious property damage could result if the boiler is connected to a dirty or inadequate chimney. The interior of the chimney flue must be inspected and cleaned before the start of the heating season and should be inspected periodically throughout the heating season for any obstructions.

  • Page 52: Troubleshooting

    Installation & Service Manual MegaSteam Troubleshooting A. COMBUSTION 7. WATER — Water in the fuel in large amounts will stall the fuel pump. Water in the fuel in 1. NOZZLES — Although the nozzle is a smaller amounts will cause excessive wear on relatively inexpensive device, its function is the pump, but more importantly water doesn’t critical to the successful operation of the oil...
  • Page 53 Installation & Service Manual MegaSteam Troubleshooting (continued) d. CAD assembly defective. e. Ignitor module defective. e. Control motor relay is stuck closed (see f. CAD cell defective. note below). g. Oil valve stuck open or closed. 2. Burner (control) will light, then shut down after Note: The Safety Monitoring Circuit (SMC) is a short time, then restart after one (1) minute.

  • Page 54: Service Parts

    All MegaSteam™ Boiler Service Parts may be obtained through your local U.S. Boiler Company Wholesale distributor. Should you require assistance in locating a U.S. Boiler Company Distributor in your area, or have questions regarding the availability of U.S. Boiler Company products or repair parts, please contact U.S. Boiler Company Customer Service at (717) 481-8400 or Fax (717) 481-8408.
  • Page 55 Installation & Service Manual MegaSteam Service Parts (continued) MST Bare Boiler Assembly Item Description Part Number MST288 MST396 MST513 MST629 MST758 MST892 109713-03 Heater Block Assembly 109713-04 Includes: Block Assembly and 109713-05 Smoke Box 109713-06 Smoke Box Includes: Sealant 109555-01 and Hardware 109556-01 Burner Swing Door Assembly...
  • Page 56 Installation & Service Manual MegaSteam Service Parts (continued) 103536-13 - 2/24...
  • Page 57 Installation & Service Manual MegaSteam Service Parts (continued) Steam Trim Item Description Part Number MST288 MST396 MST513 MST629 MST758 MST892 109725-03 109725-04 Complete Jacket Carton Includes: Labels and Hardware 109725-05 109725-06 109712-03 109712-04 Wrap Around Insulation 109712-05 109712-06 Pressure Gauge 109707-01 Burner Recepticle 109570-01...
  • Page 58 Installation & Service Manual MegaSteam Service Parts (continued) Oil Burners Item Description Part Number MST288 MST396 MST513 MST629 MST758 MST892 112210-01 112204-01 112205-01 Beckett Natural Draft 112206-01 112555-01 Shown 112556-01 Primary Becket 7565 Obtain Locally Burner Disconnect Harness 102115-01 103536-13 - 2/24...
  • Page 59 Installation & Service Manual MegaSteam Service Parts (continued) Table 12-1: Beckett AFG Burner Specifications Burner Pump Boiler Burner Head Type Air Shutter Air Band Input Nozzle Pressure Model Model (setting) (setting) (setting) (gph) (psi) MST288 0.75 0.60 x 60A Delavan MST396 1.05 0.75 x 60B Delavan...

  • Page 60: Appendix A: Steam Boiler Skimming

    Installation & Service Manual MegaSteam Appendix A Steam Boiler Skimming Steam Boiler Skimming ALL STEAM BOILERS REQUIRE PROPER SKIMMING. THIS NOTICE WILL HELP CONTRACTORS COMPLETE STEAM BOILER INSTALLATIONS AND AVOID CUSTOMER CALL-BACKS Background Skimming removes oil from the boiler water volume. If not removed properly oil can reduce steam generation and make the boiler surge.

  • Page 61: Appendix B: After Market Low Water Cut-Off

    Installation & Service Manual MegaSteam Appendix B After Market Low Water Cut-off (LWCO) WARNING DO NOT ATTEMPT to cut factory wires to install an aftermarket Low Water Cut Off (LWCO). Only use connections specifically identified for Low Water Cut Off. In all cases, follow the Low Water Cut Off (LWCO) manufacturer's instructions.
  • Page 62 Installation & Service Manual MegaSteam U.S. Boiler Company, LLC P.O. Box 3020 Lancaster, PA 17604 1-888-432-8887 www.usboiler.net 103536-13 - 2/24...

This manual is also suitable for:

Megasteam mst396Megasteam mst513Megasteam mst629Megasteam mst288Megasteam mst892

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