U.S. Boiler Company SteamMax STMX100, Quick Start Manual

Page 1: ...ure reference Contact a qualified installer service agency or gas supplier for all issues and support Steam Boiler Cast Iron Chimney Vent Gas Fired Instruction Contents Page 1 Qualified Installer Serv...

Page 2: ...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 th...

Page 3: ...rature and pressure gauge when making this judgement Install all guards cover plates and enclosures before leaving boiler in operation Disconnect electrical supply before installing or performing main...

Page 4: ...110898 03 1 110898 04 1 110898 04 1 110898 05 1 110898 05 1 110898 06 1 110898 07 1 Draft Hood Carton 110900 03 1 110900 04 1 110900 04 1 110900 05 1 110900 05 1 110900 06 1 110900 07 1 Parts Carton M...

Page 5: ...1 110899 05 1 110899 06 2 110899 06 1 110899 05 1 110899 06 1 110899 06 1 110899 07 1 Split Left Jacket Carton 110906 04 1 110906 04 1 110906 05 1 110906 06 1 110906 06 1 Split Right Jacket Carton 110...

Page 6: ...70 06 1 Draw Up Carton 111239 01 1 111239 01 1 111239 01 1 Canopy Carton 110899 05 1 110899 06 2 110899 06 1 110899 06 1 110899 07 1 Split Left Jacket Carton 110906 05 1 110906 06 1 110906 06 1 Split...

Page 7: ...05 1 111238 06 1 111238 07 1 Tie Rod Bundle 111364 03 1 111364 04 1 111364 04 1 111364 05 1 111364 05 1 111364 06 1 111364 07 1 Canopy Carton 110899 03 1 110899 04 1 110899 04 1 110899 05 1 110899 05...

Page 8: ...364 08 1 111364 09 1 111364 10 1 111364 11 1 111364 12 1 Canopy Carton 110899 04 1 110899 04 1 110899 05 1 110899 06 2 110899 06 1 110899 05 1 110899 06 1 110899 06 1 110899 07 1 Split Left Jacket Car...

Page 9: ...py Carton 110899 05 1 110899 06 2 110899 06 1 110899 06 1 110899 07 1 Split Left Jacket Carton 110906 05 1 110906 06 1 110906 06 1 Split Right Jacket Carton 110907 05 1 110907 05 1 110907 06 1 Draft H...

Page 10: ...ere is a leak If boiler must be located in an area sensitive to water damage install drain pan underneath boiler and pipe to a suitable drain location Manufacturer will not be held responsible for wat...

Page 11: ...ter damage in case there is a leak If boiler must be located in an area sensitive to water damage install drain pan underneath boiler and pipe to a suitable drain location Manufacturer will not be hel...

Page 12: ...12 111299 06 9 22 SteamMax Knock Down Assembly Instructions 4 Split Bases Assembly continued Figure 4 1 Split Bases Assembly 1 2 5 4 4 3 3 7 6 4 4...

Page 13: ...assemblies Items 2 and 5 draw plates washers nuts Item 7 on both sides Two draw rods are required one through upper nipple port and other through lower nipple port 11 Keep draw rod threads lubricated...

Page 14: ...9 22 SteamMax Knock Down Assembly Instructions 5 Split Section and Base Assembly continued Figure 5 2 Split Section and Base Assembly 7 7 7 7 2 5 Apply silicone here Apply silicone here Apply silicon...

Page 15: ...15 111299 06 9 22 SteamMax Knock Down Assembly Instructions 5 Split Section and Base Assembly continued Figure 5 3 Push Nipple and Tie Rods Detail 4 6 8 9 9...

Page 16: ...ation of intermediate section with and without riser tappings 12 Screw together enough 3 4 10 x 11 draw rod using coupling nuts to pass through section assemblies Items 3 and 6 draw plates washers nut...

Page 17: ...17 111299 06 9 22 SteamMax Knock Down Assembly Instructions 6 Individual Sections Assembly continued Figure 6 1 Single Base and Individual Sections 7 7 7 6 3 2 4 4 7 7 5 1 1...

Page 18: ...18 111299 06 9 22 SteamMax Knock Down Assembly Instructions Figure 6 2 Split Base and Individual Sections 6 Individual Sections Assembly continued Apply silicone here 9 8 Apply silicone here...

Page 19: ...Down Assembly Instructions 6 Individual Sections Assembly continued Figure 6 3 Arrangement of Sections and Canopies 3 Section 4 Section 5 Section 6 Section 8 Section 9 Section 10 Section 7 Section 11...

Page 20: ...supplied with this boiler or located on manufacturer s website for size and purpose of tappings NOTICE Limit controls LWCOs and junction box must be installed on same side of boiler Otherwise wiring...

Page 21: ...d sections and intermediate section 3 Tighten jam nut to set carriage bolt Item 1 in slot 4 Place washer Item 2 on top of Item 1 5 Repeat Steps 1 through 3 for other three carriage bolts 1 1 1 3 5 5 4...

Page 22: ...Use proper Personal Protective Equipment PPE during assembly 9 Dual Canopy Assembly See Figure 9 1 for Reference 1 Follow steps in Single Canopy Assembly Section for both canopies 2 See Figure 6 3 fo...

Page 23: ...se tray and rear jacket panel 6 Attach vestibule panel Item 4 to side jacket panels Figure 10 1 Single Jacket Assembly 1 3 2 4 NOTICE Do not attach top panels until wiring is complete 7 Attach front t...

Page 24: ...24 111299 06 9 22 SteamMax Knock Down Assembly Instructions 10 Single Jacket Assembly continued Figure 10 2 Single Jacket Assembly 5 6 8 7 9 Figure 10 3 Rear Air Dam Installation 9...

Page 25: ...e vestibule panel Item 6 NOTICE Do not attach top panels until wiring is installed 10 Attach top front left side jacket panel Item 8 to left jacket panel Item 2 and jacket upper bracket Item 5 11 Atta...

Page 26: ...26 111299 06 9 22 SteamMax Knock Down Assembly Instructions 11 Dual Jacket Assembly continued Figure 11 1 Dual Jacket Assembly 2 1 3 6 7 4 5...

Page 27: ...27 111299 06 9 22 SteamMax Knock Down Assembly Instructions 11 Dual Jacket Assembly continued Figure 11 2 Dual Jacket Assembly 8 10 11 9 12 13 14 15 16...

Page 28: ...boiler Otherwise wiring harness will not fit configuration 1 Single Pressure Limit Assembly See Figure 12 1 for References Item 1 Auto Reset Pressure Limit Item 2 180 Degree Syphon Item 3 Brass Bushi...

Page 29: ...rom more than one circuit Lock out all electrical boxes with padlock once power in turned off WARNING Electrical Shock Hazard All wiring and grounding must conform to requirements of authority having...

Page 30: ...hite black wires 3 pin connector Relay plug 2 pin connector 3 pin connector Green wire pilot ground Yellow wire Blue wire Orange wire ignition cable Figure 13 2 STMX075 through STMX299 Control Panel W...

Page 31: ...el Wiring Non CSD 1 Snap bushing wires from limits BVS Green white black wires 3 pin connector 2 pin connector Relay plug 3 pin connector Orange wire ignition cable Yellow wire Green wire pilot ground...

Page 32: ...imit BVS Green white black wires 3 pin connector Relay plug 2 pin connector 3 pin connector Orange wires alarm wires are interchangeable Orange wire igntion cable Yellow wire Green wire pilot ground R...

Page 33: ...Universal bushing snap bushing behind control Fork terminals from main harness Wires are interchangeable Manual Reset Snap bushing Fork terminals wires are interchangeable Snap bushing Fork terminals...

Page 34: ...ect ring terminal to probe Snap bushing 3 pin connector from main harness Wires from lower bushing on rear of boiler Auto Reset Manual Reset After control installed connect ring terminal to probe 3 pi...

Page 35: ...nnector from main harness Figure 13 10 Auto Reset Hydrolevel LWCO Wiring Manual Reset Auto Reset After control installed connect ring terminal to probe 3 pin connector Snap bushing 3 pin connector fro...

Page 36: ...Down Assembly Instructions 13 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...

Page 37: ...9 22 SteamMax Knock Down Assembly Instructions 13 Wiring continued Draft Hood Rear Air Dam Weld Stud BVS 6 SMS Wires are interchangeable BVS Figure 13 13 STMX350 through STMX550 Dual Block Vent Switc...

Page 38: ...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 STMX...

Page 39: ...39 111299 06 9 22 SteamMax Knock Down Assembly Instructions SERVICE RECORD SERVICE PERFORMED DATE...

Page 40: ...40 111299 06 9 22 SteamMax Knock Down Assembly Instructions U S Boiler Company LLC P O Box 3020 Lancaster PA 17604 1 888 432 8887 www usboiler net...