U.S. Boiler Company SteamMax STMX075, Installation, Operating And Service Instructions

Page 1: ...ing 15 7 Steam Piping 18 8 Gas Piping 22 9 Electrical 24 10 System Start Up and Checkout 31 11 Operation 39 12 Before Leaving Jobsite 40 13 Service and Maintenance 41 14 How it Works 45 15 Troubleshoo...

Page 2: ...t if not avoided could result in death or serious injury Important Definitions of Warnings DANGER Explosion Hazard DO NOT store or use gasoline or other flammable vapors or liquids in the vicinity of...

Page 3: ...ect you from a release of hot water or steam Do not rely solely on boiler temperature and pressure gauge when making this judgement Install all guards cover plates and enclosures before leaving boiler...

Page 4: ...r may leak water or steam at the end of its useful life Be sure to protect walls carpets and valuables from water or steam that could leak from boiler WARNING Asphyxiation Hazard Fire Hazard A qualifi...

Page 5: ...5 517 124 82 0 STMX250 250 206 646 155 82 0 STMX299 299 246 771 185 82 0 STMX350 350 284 890 213 81 0 82 5 STMX399 399 323 1012 242 81 0 82 5 STMX450 450 365 1143 274 81 0 82 5 STMX500 500 405 1269 30...

Page 6: ...21 3 8 30 1 2 2 6 1 2 3 4 103 STMX150 4 41 21 3 8 30 1 2 2 6 1 2 3 4 124 STMX175 5 41 26 7 16 30 2 2 2 7 3 4 3 4 144 STMX200 5 41 26 7 16 30 2 2 2 7 3 4 3 4 165 STMX250 6 41 31 1 2 30 2 2 2 8 3 4 3 4...

Page 7: ...6 6 1 2 11 STMX175 26 7 16 7 7 13 1 2 STMX200 26 7 16 7 7 13 1 2 STMX250 31 1 2 8 7 1 2 16 STMX299 36 9 16 8 7 1 2 18 1 2 Left Side Right Side Front 6 1 2 A 8 3 16 D 8 3 16 5 3 8 2 Riser Required STMX...

Page 8: ...3 16 16 27 1 2 8 8 Left Side Right Side Front 6 1 2 A 8 3 16 8 3 16 B C 5 3 8 2 Riser All sizes 3 1 2 26 20 16 1 2 26 5 8 NWL BVS Gauge Glass Auto Reset Pressure Limit Gas Line Opening Auto Reset LWC...

Page 9: ...ushed Down for Drain C 2 Skimming Connection or Bushed Down for Auto Reset Pressure Limit Manual Reset Pressure Limit and Pressure Gauge D 1 2 Gauge Glass E 3 4 Auto Reset LWCO F 1 Relief Valve G 3 4...

Page 10: ...combustible materials gasoline or other flammable liquids from area around boiler 8 Check for and remove any potential combustion air contaminants from area around boiler See Table 4 1 Clearances 1 P...

Page 11: ...nded from left side right side and front 4 Locating Boiler continued Figure 4 2 Minimum Alcove Clearances STMX075 through STMX299 Boiler A STMX075 16 5 16 STMX100 16 5 16 STMX125 21 3 8 STMX150 21 3 8...

Page 12: ...continued Figure 4 3 Minimum Alcove Clearances STMX350 through STMX550 Boiler A STMX350 41 5 8 STMX399 46 11 16 STMX450 51 3 4 STMX500 56 13 16 STMX550 61 7 8 NOTICE 24 in service clearance recommende...

Page 13: ...fans such as range hoods and bathroom exhausts so they will operate at maxi mum speed Do not operate a summer exhaust fan Close fireplace dampers Before Removing Existing Boiler Take pictures and mea...

Page 14: ...miscellaneous parts carton from outer shipping carton Unpack Boiler Figure 5 1 Packaged STMX100 through STMX250 DANGER Use precautions and appropriate rigging apparatus when moving heavy objects Reli...

Page 15: ...fireplace or other solid fuel appliance 5 Prior to boiler installation inspect chimney for obstructions or other defects and correct as required Clean chimney as necessary 6 The vertical section of v...

Page 16: ...nd Black BVS FRS quick connects to BVS Wires are interchangeable 4 Install vent piping A See Figure 3 4 for vent sizes and locations See Figure 4 2 for clearances B Install vent piping from vent dampe...

Page 17: ...es and locations See Figure 4 3 for clearances B Install vent piping from vent damper outlets to chimney See Figure 6 6 for typical vent installation WARNING This installation is not complete until re...

Page 18: ...n Figure 7 1 This applies even if existing boiler has one of the piping mistakes shown in Figure 7 1 and appears to be working If two or more steam mains must be connected to boiler connect a separate...

Page 19: ...llation Operating Service Instructions 7 Steam Piping continued Figure 7 1 Common Near Boiler Piping Mistakes WRONG Take off between risers WRONG Header bullheaded into take off and equalizer WRONG Ta...

Page 20: ...on boiler right side using nipple and elbow supplied See Figures 3 4 and 3 5 3 6 and Table 3 7 DANGER Pipe relief valve discharge to a safe location Do not install any valves between boiler and relief...

Page 21: ...2 2 2 D 1 1 4 1 1 2 1 1 2 1 1 2 1 3 2 indicates three 2 inch risers 7 Steam Piping continued A B A A B Supply Main to be taken off top of header vertically Boiler Fill Gate Valve Steam wet return pit...

Page 22: ...tant to action of liquefied petroleum gas D Install sediment trap ground joint union and manual shut off valve upstream of combination gas valve within 6 ft of boiler See Figure 8 2 E All above ground...

Page 23: ...lve 8 Gas Piping continued Figure 8 4 STMX350 through STMX550 Gas Manifold and Control Assembly Dual Combination Gas Valves Combination Gas Valve Pilot Tubing Manifold Assembly Ignitor Sensor Pilot Bu...

Page 24: ...after installation DANGER Electrical Shock Hazard Disconnect electrical supply before installing or performing maintenance Electrical power may be supplied from more than one circuit Lock out all elec...

Page 25: ...25 111043 03 9 21 SteamMax Installation Operating Service Instructions 9 Electrical continued Figure 9 1 Wiring Diagram STMX075 through STMX299...

Page 26: ...26 SteamMax Installation Operating Service Instructions 111043 03 9 21 9 Electrical continued Figure 9 2 Ladder Diagram STMX075 through STMX299...

Page 27: ...27 111043 03 9 21 SteamMax Installation Operating Service Instructions 9 Electrical continued Figure 9 3 Wiring Diagram STMX350 through STMX550 Non CSD 1...

Page 28: ...28 SteamMax Installation Operating Service Instructions 111043 03 9 21 9 Electrical continued Figure 9 4 Ladder Diagram STMX350 through STMX550 NON CSD 1...

Page 29: ...YE BL GY GY WH GY WH GY WH YE GND Service Switch Optional by Installer Overcurrent Protection Disconnect by Installer L2 Power Supply 120 60 1 L1 1 2 1 2 3 3 WH BK Thermostat By others GY WH GY Wire...

Page 30: ...24V Gnd Ignition Module 1 Alarm 2 Alarm 1 Ignition Module 2 Alarm 2 Alarm 1 Gas Valve 1 Gas Valve 2 B or P2 H or 1 N or 2 Auto Reset LWCO H or 1 N or 2 B or P2 C or P1 Manual Reset LWCO L1 L2 Gnd Pow...

Page 31: ...lot flame signal must be 1 A microampere DC direct current For reliable operation flame signal should be 2 A or greater Flame current can be determined by flashing green STATUS LED on ignition module...

Page 32: ...32 SteamMax Installation Operating Service Instructions 111043 03 9 21 10 System Start Up and Checkout continued Figure 10 1 Operating Instructions...

Page 33: ...0 System Start Up and Checkout continued Figure 10 3 Pilot Burner Flame Top Panels Rear Panel Step 1 Up Step 2 Forward Step 3 Down Lower Front Tie Bar Front Removable Door Figure 10 2 Front Door Remov...

Page 34: ...seconds control returns to normal sequence If flame out of sequence remains longer than 10 seconds control will resume normal operation 1 hour after error is corrected Check for pilot flame Replace g...

Page 35: ...System Start Up and Checkout continued Figure 10 5 Main Burner Flame Incandescent Outer Mantle Blue with occasional orange flashing Outer Cone Darker transparent blue Inner Cone Sharply outlined with...

Page 36: ...eration while boiler is running Slowly open drain valve and drain boiler until water level drops below auto reset LWCO line Water should be visible in gauge glass when auto reset LWCO shuts down both...

Page 37: ...37 111043 03 9 21 SteamMax Installation Operating Service Instructions 10 System Start Up and Checkout continued Figure 10 6 Combination Gas Valve Detail...

Page 38: ...e from shutoff valve to combination gas valve s Add 5 cubic inches for each combination gas valve 2 Determine test time per Figure 10 7 3 Turn off gas to boiler 4 Install pressure tap on combination g...

Page 39: ...applied across MV and MV PV terminals opening valve and establishing main burner flame Control Operation LWCO Interrupts burner operation when water in boiler drops below cut off level Power is resto...

Page 40: ...flame Checked main burner flames Checked gas input rate Checked gas inlet pressure Checked gas manifold pressure Checked vent damper operation Performed combination gas valve shutdown test Tested aut...

Page 41: ...that is sufficiently tight around potential entry points for RCF dust 3 Gloves 4 Eye protection such as goggles safety glasses with side shields or full facepiece Take steps to assure adequate ventil...

Page 42: ...d chimney Inspect masonry chimney liner Repair or replace defects and or deterioration B If masonry chimney is lined verify lining is in good condition and there are no openings into chimney C Remove...

Page 43: ...iping A Check all system piping for leaks B Repair any leaks before placing back into service 6 Inspect Pressure Gauge A Needle should move with variation in pressure B Replace gauge if needed 7 Opera...

Page 44: ...STMX299 0 02 0 21 STMX350 0 02 0 23 STMX399 0 02 0 25 STMX450 0 02 0 27 STMX500 0 02 0 29 STMX550 0 03 0 31 Based on maximum leak rate of 2 steamable water per month NOTICE When substantial amount of...

Page 45: ...vel is returned to normal 6 Flame Rollout Switch FRS If flames roll out of burner tubes switch will open requiring replacement and cause burners to shut down If switch trips determine cause of flame r...

Page 46: ...46 SteamMax Installation Operating Service Instructions 111043 03 9 21 14 How It Works continued Figure 14 1 Controls Location STMX075 through STMX299 8 7 6 11 1 2 9 4 5 10 3...

Page 47: ...47 111043 03 9 21 SteamMax Installation Operating Service Instructions Figure 14 2 Controls Location STMX350 through STMX550 Non CSD 1 14 How It Works continued 7 8 7 8 6 6 1 2 11 1 4 5 10 4 3 3...

Page 48: ...48 SteamMax Installation Operating Service Instructions 111043 03 9 21 Figure 14 3 Controls Location STMX450 through STMX550 CSD 1 14 How It Works continued 7 8 7 8 6 6 1 2 11 1 5 10 4 14 12 13 3 3 4...

Page 49: ...rical meter and gas pressure gauge available for use 3 Check electrical connections on boiler before proceeding See Figures 9 1 9 3 or 9 5 A Ensure 120VAC power polarity is correct and boiler is prope...

Page 50: ...50 SteamMax Installation Operating Service Instructions 111043 03 9 21 15Troubleshooting continued Figure 15 1 Troubleshooting Flow Diagram STMX075 through STMX299...

Page 51: ...51 111043 03 9 21 SteamMax Installation Operating Service Instructions 15Troubleshooting continued Figure 15 1 Troubleshooting Flow Diagram STMX075 through STMX299 continued from previous page...

Page 52: ...52 SteamMax Installation Operating Service Instructions 111043 03 9 21 15Troubleshooting continued Figure 15 2 Troubleshooting Flow Diagram STMX350 through STMX550 Non CSD 1...

Page 53: ...3 111043 03 9 21 SteamMax Installation Operating Service Instructions 15Troubleshooting continued Figure 15 2 Troubleshooting Flow Diagram STMX350 through STMX550 Non CSD 1 continued from previous pag...

Page 54: ...54 SteamMax Installation Operating Service Instructions 111043 03 9 21 15Troubleshooting continued Figure 15 3 Troubleshooting Flow Diagram STMX450 through STMX550 CSD 1...

Page 55: ...55 111043 03 9 21 SteamMax Installation Operating Service Instructions Figure 15 3 Troubleshooting Flow Diagram STMX450 through STMX550 CSD 1 continued from previous page 15Troubleshooting continued...

Page 56: ...d 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...

Page 57: ...ssembly includes both canopy and base gaskets 111268 03 1 111268 03 1 111268 04 1 111268 04 1 111268 05 1 111268 05 1 111268 06 1 111268 07 1 1B Baffles set of 3 111263 01 1 111263 01 2 1C Canopy Gask...

Page 58: ...58 SteamMax Installation Operating Service Instructions 111043 03 9 21 16 Service Parts continued 2A 2B 2C 2D 2E 2G 2H 2F...

Page 59: ...D Canopy Gasket 6206001 2 2E Left Side Canopy 111290 04 1 111290 04 1 111290 05 1 111290 06 1 111290 06 1 2F Right Side Canopy 111290 05 1 111290 06 1 111290 06 1 111290 06 1 111290 07 1 2G Left Side...

Page 60: ...Part Number Quantity STMX075 STMX100 STMX125 STMX150 STMX175 STMX200 STMX250 STMX299 3A Complete Base Assembly Base Gasket included Consult Factory 110901 03 1 110902 04 1 110901 04 1 110902 05 1 1109...

Page 61: ...500 STMX550 4A Complete Left Half Base Assembly 110908 04 1 110908 04 1 111236 05 1 111236 06 1 111236 06 1 4B Complete Right Half Base Assembly 110909 04 1 110909 05 1 111237 05 1 111237 05 1 111237...

Page 62: ...1 5C Pilot 111279 01 1 5D 1 4 Pilot Tubing 109611 01 1 Key No Description Part Number Quantity STMX350 STMX399 STMX450 STMX500 STMX550 5A Left Manifold Burners Pilot Insulation Assembly 111277 04 1 11...

Page 63: ...nstructions 16 Service Parts continued 6A 6A Key No Description Part Number Quantity STMX075 STMX100 STMX125 STMX150 STMX175 STMX200 STMX250 STMX299 6A Jacket Set 110898 03 1 110898 03 1 110898 04 1 1...

Page 64: ...ce Parts continued 7A 7A 7B 7B Key No Description Part Number Quantity STMX350 STMX399 STMX450 STMX500 STMX550 7A Left Side Jacket Set 110906 04 1 110906 04 1 110906 05 1 110906 06 1 110906 06 1 7B Ri...

Page 65: ...X200 STMX250 STMX299 8A Non CSD 1 Ignition Module Honeywell 109633 01 1 8B Transformer 106034 01 1 8C Relay 111282 01 1 Key No Description Part Number Quantity STMX350 STMX399 STMX450 STMX500 STMX550...

Page 66: ...9634 04 1 109634 04 1 109634 05 1 109634 05 1 9B Pressure Gauge 109707 01 1 9C Gauge Glass 111271 01 1 9D Relief Valve 111267 01 1 9E Pressure Limit Auto Reset Honeywell 111280 01 1 9F Pressure Limit...

Page 67: ...Relief Valve 111267 01 1 111304 01 1 9E Pressure Limit Auto Reset Honeywell 111280 01 1 9F CSD 1 Pressure Limit Manual Reset Honeywell N A 111281 01 1 9G LWCO Auto Reset M M 111275 01 1 LWCO Auto Res...

Page 68: ...68 SteamMax Installation Operating Service Instructions 111043 03 9 21 16 Service Parts continued 10B 10C 10D 10E 10A...

Page 69: ...X200 STMX250 STMX299 10A Main Harness Power Harness 111264 01 1 10B Pilot Ground Wire 111278 01 1 10C Ignition Cable 111274 01 1 Key No Description Part Number Quantity STMX350 STMX399 STMX450 STMX500...

Page 70: ...ressure Limit Manual Reset Honeywell 111281 01 1 Key No Description Part Number Quantity STMX350 STMX399 STMX450 STMX500 STMX550 Not Shown M M CSD 1 Kit 111294 01 1 N A Not Shown Hydrolevel CSD 1 Kit...

Page 71: ...This valve is a just in case valve You will not close this after the skimming process starts This pipe nipple must be horizontal and must come straight out It can not elbow up We are trying to skim th...

Page 72: ...their functions are as follows 1 Circulator Mount circulator as shown in Figure B 1 Circulator should be located as low and as close to boiler as practical Do not install valves or other devices havin...

Page 73: ...call for heat from the IWH thermostat will energize relay making both sets of contacts One contact energizes the circulator Other contact will make boiler T T circuit firing burners If boiler water t...

Page 74: ...111294 01 or PARTS CARTON CONTROLS 110918 01 Wire blue lead to terminal 5 and gray white lead to terminal 6 in 150S MD See Electrical Section for complete boiler wiring diagram Figure C 2 Auto Reset...

Page 75: ...75 111043 03 9 21 SteamMax Installation Operating Service Instructions SERVICE RECORD SERVICE PERFORMED DATE...

Page 76: ...76 SteamMax Installation Operating Service Instructions 111043 03 9 21 U S Boiler Company Inc P O Box 3020 Lancaster PA 17604 1 888 432 8887 www usboiler net...