Page 3 - servicing or working nearby the appliance.
3 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. Failure to follow all instructions in t...
Page 4 - WARNING; fasteners completely when service is completed.; TABLE OF CONTENTS
4 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...
Page 6 - TABLE 1B: RATING DATA
6 TABLE 1A: DIMENSIONAL DATA (SEE FIGURE 1) TABLE 1B: RATING DATA Boiler Model No. Dimensions (See Figure 1) Water Content (To Normal Water Line) - Gallons Heat Transfer Surface Area - sq. Ft. Actual Shipping Weight (LB.) "A" "B" "C" With Tankless Heater Non-Heater MST288 22-...
Page 8 - NOTICE; PROVIDE COMBUSTION AND VENTILATION; unconfined space; and suitable for use on Beckett AFG with; ii
8 NOTICE Clearance to venting is for single wall vent pipe. If Type L vent is used, clearance may be reduced to the minimum required by the vent pipe manufacturer. C. PROVIDE COMBUSTION AND VENTILATION AIR. Local and National Codes may apply and should be referenced. WARNING Adequate combustion and ...
Page 9 - MegaSteamTM Unit-Pak Boiler Assembly Shipment
9 SECTION II: UNIT-PAK BOILER ASSEMBLY MegaSteam™ Unit-Pak Boiler Assembly Shipment Content Check List (see Figure 3) 1. ___ Cast Iron Section/Burner Swing Door/Smoke Box Assembly Mounted on Shipping Skid: ____ MST3 (Rear Section, Heater) – Part # 100566-03 / 100045-01 / 100021-01 ____ MST4 (Rear Se...
Page 10 - SECURE BURNER SWING DOOR.
10 A. CAST IRON SECTION ASSEMBLY TAPPINGS Refer to Table 3 "Purpose of Tappings and Bosses" and Figure 7. 1. All tappings have factory installed thread protectors. The thread protectors must be removed prior to jacket and piping installation. 2. Depending of installation specifics and boiler...
Page 11 - Figure 4: Boiler Removal from Skid
Page 14 - before; CAUTION; Boiler; Pass; Pass; None
14 E. FLUEWAY BAFFLE INSTALLATION. Flueway baffles are enclosed into Part Carton. Baffle requirements differ by boiler model, see Table 2. TABLE : BAFFLE USAGE Figure 5C: Top View - Burner Swing Door Fully Closed but Not Properly Secured or Sealed NOTE: Read caution statement before proceeding. CAUT...
Page 15 - When securing burner swing door make sure door
15 Figure 6: Flueway Baffle Positioning/Orientation in Flueways 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 rig...
Page 18 - Do not apply pressure to gauge case, as this may
18 L. TRIM AND CONTROLS INSTALLATION. Pressure Limit Installation. 1. Locate and remove L404F Pressure Limit with factory attached harness from Control Carton. 2. Locate and remove 1/4" NPT x 1-7/8" x 4 x 90° syphon enclosed in Part Carton. 3. Review and locate pressure limit tapping on fron...
Page 20 - P. AqUASTAT CONTROLLER INSTALLATION; q. SAFETY VALVE AND DRAIN VALVE
0 7. Screw LWCO to External Wiring Enclosure wiring harness (end with fork and female disconnect terminals) connector into low water cut-off J-box top fitting, and attach wires to the terminals per LWCO wiring detail shown in Figure 9 "Float-Type LWCO and Gauge Glass Installation". 8. Re-ins...
Page 21 - Figure 10: Oil Burner Installation
1 Figure 10: Oil Burner Installation f. Insert oil burner into the opening of burner swing door. Align and engage keyhole slot in burner flange over head of protruding cap screw installed in previous Step. Rotate burner to the right to lock flange behind head of cap screw. g. Align holes and install...
Page 22 - EVALUATE THE ExISTING STEAM SYSTEM.; SECTION III: STEAM BOILER PIPING & TRIM; B. CONNECT SYSTEM SUPPLY AND RETURN; Maintain minimum 1⁄2 inch clearance from hot; chemistries if dielectric unions are not used.
A. EVALUATE THE ExISTING STEAM SYSTEM. The single most important factor in determining the expected life cycle of a steam boiler, is the amount of fresh water added to the boiler during operation. Fresh water brings minerals and oxygen into the boiler. These contaminants greatly accelerate corrosion...
Page 24 - SECTION IV: TANKLESS & INDIRECT WATER HEATER PIPING; CONNECT TANKLESS HEATER PIPING
4 SECTION IV: TANKLESS & INDIRECT WATER HEATER PIPING A . CONNECT TANKLESS HEATER PIPING as shown in Figure 12. See Table 4 for Tankless Heater Rating. WARNING Install automatic mixing valve at tankless heater outlet to avoid risk of burns or scalding due to excessively hot water at fixtures. Ad...
Page 25 - Figure 1: Schematic Tankless Water Heater Piping; Boiler Model
5 TABLE 4: TANKLESS HEATER DATA: Figure 1: Schematic Tankless Water Heater Piping Boiler Model Heater No. Heater Rating (GPM) Pressure Drop thru Heater (PSI) MST288 222A 3.00 22.0 MST396 3.25 24.3 MST513 3.50 26.5 MST629 4.00 31.0
Page 26 - as shown in Figure 13.
6 Figure 13: Alliance™ Water Heater Piping with MegaSteam™ Boiler B. CONNECT ALLIANCE™ INDIRECT WATER HEATER PIPING as shown in Figure 13. 1. Refer to Alliance™ manual for additional information.
Page 27 - A. Chimney Venting; Chimney venting is an important part of a safe; Do not de-rate the appliance. Failure to fire the; SeCtiOn V: Venting & Air intAke piping; the requirements of NFPA 211.; B. Chimney COnneCtOr; DANGER; failure and force flue gases into the living
27 A. Chimney Venting 1. Chimney venting is an important part of a safe and efficient oil fired appliance system. Contact your local fire and building officials on specific requirements for restrictions and the installation of fuel oil burning equipment. In addition, consult with a professional know...
Page 28 - Figure 15: Proper and Improper Locations of Draft Regulator
8 Figure 14: Recommended Vent Pipe Arrangement and Chimney Requirements Figure 15: Proper and Improper Locations of Draft Regulator
Page 29 - cannot
9 2. Type B Chimney Connector - a type B chimney connector can be used to transmit the flue gases provided flue gas temperature entering the chimney connector is greater than 310°F. 3. Type L Chimney Connector - a type L vent or other suitable material shall be used for a chimney connector if the te...
Page 30 - E. MINIMUM CLEARANCES
30 Figure 1: Optional Air Intake Piping Installation - Only Available with Beckett Burner WARNING Remove the baffles if there are any signs of condensation in the chimney or chimney connector. Consult with your local chimney professional for recommendations. E. MINIMUM CLEARANCES See Figure 2 for de...
Page 31 - Intake terminal must be at least 1 inches above; Do not locate air intake where petroleum distillates,
31 c. Mount the vacuum relief valve into the tee and fasten with a screw and nut in collar tabs. To ensure proper operation, the gate must be level across the pivot point and plumb. Refer to vacuum relief valve manufacturer's instructions. 5. Install remainder of air intake, securing each joint with...
Page 32 - GENERAL; SECTION VI: ELECTRICAL; B. INSTALL A ROOM THERMOSTAT; once power is turned off.
3 A. GENERAL 1. Install wiring and electrically ground boiler in accordance with requirements of the authority having jurisdiction, or in absence of such requirements the National Electrical Code, ANSI/ NFPA 70. 2. Refer to National Electric Code or Local Electric Codes for proper size and type of w...
Page 34 - WCO
34 Figure 19: W iring Diagram, Steam, McDonnell & Miller PS-801 Probe L WCO
Page 37 - SECTION VII: OIL PIPING; SINGLE PIPE OIL LINES
3 Figure 1: Single Pipe Oil Line SECTION VII: OIL PIPING A. GENERAL 1. Use flexible oil line(s) so the burner swing door can be opened without disconnecting the oil supply piping. 2. A supply line fuel oil filter is recommended as a minimum for all firing rates but a pleated paper fuel oil filter is...
Page 38 - Maximum Length of Tubing
38 TABLE 5: TWO-STAGE UNITS (3450 RPM) - TWO PIPE SySTEMS TABLE 6: SINGLE-STAGE UNITS (3450 RPM) - TWO PIPE SySTEMS Figure : Two Pipe Oil Lines C. TWO PIPE OIL LINES 1. For two piped systems, where more lift is required, the two-stage fuel unit is recommended. Table 5 (two-stage) and Table 6 (single...
Page 40 - ADJUST OIL BURNER WHILE; Do not loosen or remove any oil line fittings while; Do not attempt to start the burner when excess oil
40 5. Adjust oil pressure. a. When checking a fuel unit's operating pressure, a reliable pressure gauge may be installed in either the bleeder port or the nozzle port. See Figure 23. b. Locate oil pressure adjusting screw and turn screw to obtain proper pump pressure, refer to Table 8 at rear of man...
Page 41 - Figure
41 Figure 4: "L1" and "V1" Head Electrode Positioning and Gun Setting (Beckett AFG)
Page 42 - Flashes
4 WARNING Before installation of the boiler is considered complete, the operation of all boiler controls must be checked, particularly the primary control and pressure limit control. 2. VERIFY PRIMARY CONTROL FEATURES using procedures outlined in Instructions furnished with control or instructions a...
Page 43 - Figure 6: Cad Cell Location; Jumper must be removed after this check.
43 • Place a jumper across cad cell terminals. • Follow procedure to turn on burner. Burner must not start, indicator light turns on and control remains in Idle Mode. • Remove jumper. iii. Simulate Ignition or Flame Failure: • Follow procedure to turn on burner. • Close hand valve in oil supply line...
Page 44 - Warning; AVOID Breathing Fiber Particulates and Dust; Precautionary Measures
44 Important Product Safety Information Refractory Ceramic Fiber Product Warning : The Repair Parts list designates parts that contain refractory ceramic fibers (RCF). RCF has been classified as a possible human carcinogen. When exposed to temperatures about 1805°F, such as during direct flame conta...
Page 45 - SECTION Ix: MAINTENANCE AND SERVICE INSTRUCTIONS; MAINTENANCE OF LOW WATER CUT-; Do not attempt to repair mechanisms in the field.; BOILER AND SYSTEM CLEANING
45 SECTION Ix: MAINTENANCE AND SERVICE INSTRUCTIONS A. MAINTENANCE OF LOW WATER CUT- OFF DEVICES WARNING Probe and float type low water cut-off devices require annual inspection and maintenance. 1. PROBE TYPE LOW WATER CUT-OFF Although these devices are solid state in their operation, the probe is e...
Page 46 - Check with local authorities or consult local
46 Operate the boiler with steam in the entire system for a few days allowing the condensate to return to the boiler. If the condensate can temporarily be wasted, operate boiler only for the length of time it takes for condensate to run clear. If the latter cannot be achieved or if the condensate is...
Page 47 - ExCESSIVE MAKE-UP WATER; IMPORTANT; Our warranty
4 by drawing a small sample of boiler water and testing with hydrion paper which is used in the same manner as litmus paper, except it gives specific readings. A color chart on the side of the small hydrion dispenser gives the reading in pH. Hydrion paper is inexpensive and obtainable from any chemi...
Page 48 - SECTION x: BOILER CLEANING; CLEAN THE FLUEWAYS; Do not start the burner unless the burner swing; Do not overtighten. The rope gasket will provide
48 SECTION x: BOILER CLEANING A. CLEAN THE FLUEWAYS (See Figure 27). 1. For access to the combustion chamber remove the two (2) 3/8" - 16 cap screws. If boiler is equipped with flexible fuel line(s), swing door open. 2. Remove the two smoke box clean-out covers from the rear smoke box by removin...
Page 50 - COMBUSTION; SECTION xI: TROUBLE SHOOTING; OIL PRIMARY CONTROL
50 A. COMBUSTION 1. NOZZLES — Although the nozzle is a relatively inexpensive device, its function is critical to the successful operation of the oil burner. The selection of the nozzle supplied with the MegaSteam™ boiler is the result of extensive testing to obtain the best flame shape and efficien...
Page 51 - SECTION xII: REPAIR PARTS; If flame is not established within 15 seconds
51 d. Excessive airflow or draft causing flame to leave burner head. e. Excessive back pressure causing flame to be erratic. 3. Control locks out after Trial For Ignition (TFI). a. No oil to burner.b. Shorted electrodes.c. Nozzle clogged.d. Airflow too high.e. Ignitor module defective.f. CAD cell de...
Page 53 - BARE BOILER ASSEMBLy
53 Item No. Description Part No. MST288 MST396 MST513 MST629 1. BARE BOILER ASSEMBLy 1A Front Section, Machined 100569-01 1 1 1 1 1B Center Section, Machined 100571-01 1 1 2 3 1C1 Rear Section (Htr.), Steam, Machined 100573-01 1 1 1 1 1C2 Rear Section (Non-Htr.), Steam, Machined 100676-01 1 1 1 1 1D...
Page 61 - BECKETT OIL BURNER PART NOS. FOR MEGASTEAMTM SERIES BOILERS; provide the name of the part(s) and part number as listed below.
61 BECKETT OIL BURNER PART NOS. FOR MEGASTEAM™ SERIES BOILERS NOTE: When ordering parts always give the serial and model numbers shown on the boiler and burner. Also provide the name of the part(s) and part number as listed below. Boiler Model MST288 MST396 MST513 MST629 Air Tube Combination AFG70MM...
Page 63 - SERVICE RECORD; DATE
Page 64 - Limited Warranty; FOR RESIDENTIAL CAST IRON STEAM BOILERS
By this Warranty Statement the U.S. Boiler ™ Company, Inc. of Lancaster, Pennsylvania issues limited warranties subject to the terms and conditionsstated below. These limited warranties apply to residential cast iron boilerslabeled Independence ® , Independence ® PV, V8H ™ and MegaSteam ™ Series, th...