PB Heat 211A User Manual

Download

Page 1

211A

Boilers – Steam

Series

Gas

Installation, Operation & Maintenance Manual

Page 2

USING THIS MANUAL 1

A. FOLLOW THE PIPING GUIDELINES . . . . . . .1

B. CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . .1

C. SPECIAL ATTENTION BOXES . . . . . . . . . . . .1

1. PREINSTALLATION 2

A. ACCESSIBILITY CLEARANCES . . . . . . . . . . .2

B. COMBUSTIBLE CONSTRUCTION

CLEARANCES . . . . . . . . . . . . . . . . . . . . . . . .2

C. AIR FOR COMBUSTION & VENTILATION . . .2

D. CHIMNEY OR VENT . . . . . . . . . . . . . . . . . . . .5

E. BOILER SETTING . . . . . . . . . . . . . . . . . . . . . .7

F. WATER QUALITY AND MAKE-UP . . . . . . . . .7

G. INSTALLATION SURVEY . . . . . . . . . . . . . . . .7

2. ASSEMBLE THE BASE 9

A. BASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . .9

B. INSTALL THE PILOT BURNERS . . . . . . . . . .10

3. PLACE THE BOILER SECTIONS 14

A. PREPARATION . . . . . . . . . . . . . . . . . . . . . . .14

B. PLACING THE SECTIONS . . . . . . . . . . . . . .14

C. HYDROSTATIC TEST THE BOILER . . . . . . .16

4. INSTALL THE FLUE COLLECTOR 17

5. PIPE THE BOILER 19

A. PREPARATION . . . . . . . . . . . . . . . . . . . . . . .19

B. SUPPLY PIPING . . . . . . . . . . . . . . . . . . . . . .19

C. RETURN PIPING . . . . . . . . . . . . . . . . . . . . . .19

D. MULTIPLE BOILER INSTALLATIONS . . . . . .21

6. INSTALL THE JACKET & DRAFT HOOD 23

A. PREPARE THE PARTS . . . . . . . . . . . . . . . . .23

B. APPLY CLEANOUT COVER PLATES . . . . . .23

C. APPLY JACKET END ASSEMBLIES . . . . . .23

D. 211A-04 THROUGH 211A-08 ONLY . . . . . .23

E. 211A-09 AND LARGER ONLY . . . . . . . . . . .23

F. APPLY JACKET TOP PANELS . . . . . . . . . . .24

G. APPLY LOWER END PANELS . . . . . . . . . . .24

H. APPLY PLATES AND LABELS . . . . . . . . . . .24

7. CONNECT GAS PIPING 29

A. INSTALL GAS TRAIN . . . . . . . . . . . . . . . . .29

B. CONNECT PILOT GAS TUBING . . . . . . . . . .29

C. INSTALL VENT AND BLEED PIPING . . . . . .29

D. INSTALL GAS SUPPLY PIPING . . . . . . . . . .30

E. TEST GAS SUPPLY PIPING . . . . . . . . . . . . .30

8. INSTALL CONTROLS AND TRIM 32

A. INSTALL SAFETY VALVE(S) . . . . . . . . . . . .32

B. INSTALL BLOWDOWN VALVES . . . . . . . . .32

C. INSTALL LOW WATER CUT-OFF(S) . . . . . .32

D. INSTALL PRESSURE CONTROLS . . . . . . . .32

9. WIRE THE BOILER 37

A. CONNECT SUPPLY WIRING . . . . . . . . . . . .37

B. PREPARE REMAINING CONTROLS . . . . . .37

C. INSTALL CONTROL WIRING . . . . . . . . . . . .37

10. STARTING THE BOILER 40

A. CHECK THE PIPING . . . . . . . . . . . . . . . . . . .40

B. FILL THE BOILER . . . . . . . . . . . . . . . . . . . . .40

C. STUDY LIGHTING INSTRUCTIONS . . . . . . .40

D. RUN PILOT CHECK-OUT . . . . . . . . . . . . . . .40

E. CHECK MAIN BURNER SYSTEM . . . . . . . .40

F. CHECK BOILER CONTROLS . . . . . . . . . . . .41

G. CLEAN THE BOILER . . . . . . . . . . . . . . . . . . .41

11. LIGHTING INSTRUCTIONS - TYPICAL 42

A. TO LIGHT THE BOILER . . . . . . . . . . . . . . . .42

B. TO SHUT DOWN THE BOILER . . . . . . . . . .42

C. PILOT FLAME FAILURE . . . . . . . . . . . . . . . .42

12. OPERATION & MAINTENANCE 43

A. PLACING BOILER IN OPERATION . . . . . . . .44

B. TO SHUT DOWN THE BOILER . . . . . . . . . .45

C. ANNUAL MAINTENANCE . . . . . . . . . . . . . .45

D. MONTHLY MAINTENANCE . . . . . . . . . . . . .45

E. WEEKLY MAINTENANCE . . . . . . . . . . . . . .45

F. DAILY MAINTENANCE . . . . . . . . . . . . . . . . .45

13. TROUBLESHOOTING - SERVICE TIPS 46

14. BOILER RATINGS & DIMENSIONS 48

15. REPAIR PARTS - SERIES 211A 52

TABLE OF CONTENTS

Page 3

USING THIS MANUAL

A. FOLLOW THE PIPING GUIDELINES

1. We have provided suggested piping diagrams which will cover most applications of this boiler.

2. Follow these guidelines to make sure the boiler will operate correctly.

B. CONTROLS

1. This manual provides wiring diagrams and lighting instructions for standard systems only.

2. Use the Lighting Instructions and Wiring Diagrams provided with the boiler to make sure they represent the controls provided.

C. SPECIAL ATTENTION BOXES

1. Throughout this manual you will see special attention boxes intended to supplement the instructions and make special notice of potential hazards. These categories mean, in the judgment of PB Heat, LLC:

USING THIS MANUAL

Indicates special attention is needed, but not directly related to potential personal injury or property damage.

NOTICE

Indicates a condition or hazard which will or can cause minor personal injury or property damage.

CAUTION

DANGER

Indicates a condition or hazard which will cause severe personal injury, death or major property damage.

Indicates a condition or hazard which may cause severe personal injury, death or major property damage.

WARNING

Page 4

PREINSTALLATION

A. ACCESSIBILITY CLEARANCES

1. The following recommendations allow for reasonable access to the boiler. Local codes or special

conditions may require greater clearances.

a. For servicing the boiler: provide 48" (1219 mm)

between the control manifold and adjacent wall or other appliance.

b. For access to draft hood or passage to access the

boiler control manifold(s): provide 48" (1219 mm) between the side of the boiler and adjacent wall or other appliance.

c. See Figure 1.1. Clearances with an “S” are

minimum clearances for service accessibility.

B. COMBUSTIBLE CONSTRUCTION

CLEARANCES

1. This boiler is design certified for the following clearances to combustible construction.

• 24" (610 mm) between the front, top, sides and rear of the jacket.

• 6" (152 mm) from steam and hot water pipes

• 6" (152 mm) from vent connector

• See Figure 1.1. Clearances with a “C” indicate

minimum clearances from combustible construction.

C. AIR FOR COMBUSTION AND

VENTILATION

1. Adequate combustion air and ventilation air must be provided for this appliance in accordance with the section of the National Fuel Gas Code entitled, “Air for Combustion and Ventilation” or applicable provisions of the local building code. Subsections 2 through 8 as follows are based on the National Fuel Gas Code requirements.

1. PREINSTALLATION

The equipment shall be installed with those installation requirements of the authority having jurisdiction or, in the absence of such requirements, to the current edition of the

National Fuel Gas Code

, ANSI Z223.1/NFPA 54 and/or

CAN/CGA B149 Installation Codes.

Where required by the authority having jurisdiction, the installation must conform to

American Society of

Mechanical Engineers Safety Code for Controls and Safety Devices for Automatically Fired Boilers,

ASME CSD-1.

NOTICE

Read these instructions carefully before beginning the installation.

Study the control folder and consult drawings.

A shipping list is enclosed with each boiler, listing the items packed at the factory. Check the list as you unpack parts. If any parts are missing or damaged, report the problem to the delivering carrier immediately.

Figure 1.1: Clearance Requirements

Page 5

PREINSTALLATION

2. Required Combustion Air Volume: The total required volume of indoor air is to be the sum of the required volumes for all appliances located within the space. Rooms communicating directly with the space in which the appliances are installed and through combustion air openings sized as indicated in Subsection 3 are considered part of the required volume. The required volume of indoor air is to be determined by one of two methods.

a. Standard Method: The minimum required

volume of indoor air (room volume) shall be 50 cubic feet per 1000 BTU/Hr (4.8 m

/kW). This method is to be used if the air infiltration rate is unknown or if the rate of air infiltration is known to be greater than 0.6 air changes per hour. As an option, this method may be used if the air infiltration rate is known to be between 0.6 and

0.4 air changes per hour. If the air infiltration rate is known to be below 0.4 then the Known Air Infiltration Rate Method must be used. If the building in which this appliance is to be installed is unusually tight, PB Heat recommends that the air infiltration rate be determined.

b. Known Air Infiltration Rate Method:

Where the air infiltration rate of a structure is known, the minimum required volume of indoor air for appliances other than fan assisted and for the Series 211A Boiler shall be determined as follows:

where:

other

= Input of appliances other than fan

assisted in Btu/hr

ACH = air change per hour (percent of the

volume of the space exchanged per hour, expressed as a decimal)

For fan assisted appliances, calculate the required volume of air using the following equation:

fan

= Input of the fan assisted appliances in

Btu/hr

Note: These calculations are not to be used for infiltration rates greater than 0.60 ACH.

3. Indoor Air Opening Size and Location:

Openings

connecting indoor spaces shall be sized and located as follows:

a. Combining spaces on the same floor:

Provide two permanent openings communicating with additional spaces that have a minimum free area of 1 in

per 1000 Btu/hr (22 cm2per 1000 W) of the total input rating of all gas fired equipment but not less than 100 in

(645 cm2). One opening is to begin within 12 inches (305 mm) from the top of the space and the other is to begin within 12 inches (305 mm) from the floor. The minimum dimension of either of these openings shall be 3 inches (76 mm). See Figure

1.2 for an illustration of this arrangement.

b. Combining spaces on different floors:

Provide one or more permanent openings communicating with additional spaces that have a total minimum free area of 2 in

per 1000

Btu/hr (44 cm

per 1000 W) of total input rating of all equipment. See Figure 1.3 for an illustration of this arrangement.

4. Outdoor Combustion Air:

Outdoor combustion air is to be provided through one or two permanent openings. The minimum dimension of these air openings is 3 inches (76 mm).

a. Two Permanent Opening Method: Provide

two permanent openings. One opening is to begin within 12 inches (305 mm) of the top of the space and the other is to begin within 12 inches (305 mm) of the floor. The openings are to communicate directly or by ducts with the outdoors or with spaces that freely communicate with the outdoors. The size of the openings shall be determined as follows:

21 ft

other

ACH 1000

Btu

Required Volume

other

⎛ ⎜ ⎝

⎛

⎜

⎝

Figure 1.2: Air Openings – All Air from Indoors

on the Same Floor

Figure 1.3: Air Openings – All Air from Indoors

on Different Floors

15 ft

fan

ACH 1000

Btu

Required Volume

fan

⎛ ⎜ ⎝

⎛

⎜

⎝

Page 6

i. Where communicating directly or through

vertical ducts with the outdoors each opening shall have a minimum free area of 1 in

per

4000 Btu/hr (22 cm

per 4000 W) of total input rating for all equipment in the space. See Figure 1.4 for openings directly communicating with the outdoors or Figure

1.5 for openings connected by ducts to the outdoors.

ii. Where communicating with the outdoors

through horizontal ducts, each opening shall have a minimum free area of 1 in

per 2000

Btu/hr (22 cm

per 2000 W) of total rated input for all appliances in the space. See Figure 1.6.

b. One Permanent Opening Method: Provide

one permanent opening beginning within 12 inches (305 mm) of the top of the space. The opening shall communicate directly with the outdoors, communicate through a vertical or horizontal duct, or communicate with a space that freely communicates with the outdoors. The opening shall have a minimum free area of 1 in

per 3000 Btu/hr of total rated input for all appliances in the space and not less than the sum of the cross-sectional areas of all vent connectors in the space. The gas-fired equipment shall have clearances of at least 1 inch (25 mm) from the sides and back and 6 inches (150 mm) from the front of the appliance. See Figure 1.7 for this arrangement.

Figure 1.4: Air Openings – All Air Directly from

Outdoors

Figure 1.5: Air Openings – All Air from Outdoors

through Vertical Ducts

Figure 1.6: Air Openings – All Air from Outdoors

through Horizontal Ducts

Figure 1.7: Air Openings – All Air from Outdoors

through One Opening

PREINSTALLATION

Page 7

5. Combination Indoor and Outdoor Combustion Air: If the required volume of indoor air exceeds the available indoor air volume, outdoor air openings or ducts may be used to supplement the available indoor air provided:

a. The size and location of the indoor openings

comply with Subsection 3.

b. The outdoor openings are to be located in

accordance with Subsection 4.

c. The size of the outdoor openings are to be sized

as follows:

where:

req

= minimum area of outdoor openings.

full

= full size of outdoor openings calculated

in accordance with Subsection 4.

avail

=available indoor air volume

req

= required indoor air volume

6. Engineer

ed Installations: Engineered combustion air installations shall provide an adequate supply of combustion, ventilation, and dilution air and shall be approved by the authority having jurisdiction.

7. Mechanical Combustion Air Supply

a. In installations where all combustion air is

provided by a mechanical air supply system, the combustion air shall be supplied from the outdoors at the minimum rate of 0.35 ft

/min per

1000 Btu/hr (0.034 m

/min per 1000 W) of the

total rated input of all appliances in the space.

b. In installations where exhaust fans are installed,

additional air shall be provided to replace the exhaust air.

c. Each of the appliances served shall be

interlocked to the mechanical air supply to prevent main burner operation when the mechanical air supply system is not in operation.

d. In buildings where the combustion air is provided

by the mechanical ventilation system, the system shall provide the specified combustion air rate in addition to the required ventilation air.

8. Louvers & Grills:

a. The required size of openings for combustion,

ventilation, and dilution air shall be based on the net free area of each opening.

i. Where the free area through a louver or grille

is known, it shall be used in calculating the opening size required to provide the free area specified.

ii. Where the free area through a louver or grille

is not known, it shall be assumed that wooden louvers will have 25% free area and metal louvers and grilles will have 75% free area.

iii. Nonmotorized dampers shall be fixed in the

open position.

b. Motorized dampers shall be interlocked with the

equipment so that they are proven in the full open position prior to ignition and during operation of the main burner.

i. The interlock shall prevent the main burner

from igniting if the damper fails to open during burner startup.

ii. The interlock shall shut down the burner if

the damper closes during burner operation.

9. Combustion Air Ducts

a. Ducts shall be constructed of galvanized steel or

an equivalent corrosion- resistant material.

b. Ducts shall terminate in an unobstructed space,

allowing free movement of combustion air to the appliances.

c. Ducts shall serve a single space.

d. Ducts shall not serve both upper and lower

combustion air openings where both such openings are used. The separation between ducts serving upper and lower combustion air openings shall be maintained to the source of combustion air.

e. Ducts shall not be screened where terminating in

an attic space.

f. Horizontal upper combustion air ducts shall not

slope downward toward the source of the combustion air.

g. The remaining space surrounding a chimney

liner, gas vent, special gas vent, or plastic piping installed within a masonry, metal, or factory built chimney shall not be used to supply combustion air.

h. Combustion air intake openings located on the

exterior of buildings shall have the lowest side of the combustion air intake opening at least 12 inches (305 mm) above grade.

D. CHIMNEY OR VENT

1. Inspect the existing chimney or vent system. Make sure it is in good condition. Inspect chimney liner and repair or replace if necessary.

2. The vent system and installation must be in accordance with the current edition of the National Fuel Gas Code, ANSI Z223.1/NFPA 54, under “Venting of Equipment”, or CAN/CGA B149, Installation codes, under “Venting Systems and Air Supply for Appliances”, or applicable provisions of the local building codes.

PREINSTALLATION

avail

1 –

req

= A

full

⎛ ⎜ ⎝

⎛

⎜

⎝

Page 8

PREINSTALLATION

3. Chimney/Vent Operation: The vent system must be sized and installed to provide the draft needed to remove all combustion products. If the vent system does not provide enough draft, combustion products will spill into the building from the draft hood relief opening. If spillage of combustion products occurs, check the vent system, the combustion and ventilation openings and make sure the boiler room is never under negative pressure.

4. Exterior Vents

a. If the vent is outside, make sure it is insulated

sufficiently to ensure adequate draft.

5. Vent Sizing:

a. Individual vents: Use vent piping the same

diameter as the boiler vent connection. The minimum height is 10 feet (305 cm) above the bottom of the draft hood (relief opening). The vent must also extend above the roof or any obstructions as outlined in the current edition of the National Fuel Gas Code, ANSI Z223.1/NFPA 54 and/or CAN/CGA B149, Installation Codes or as required by local codes.

b. Combined vent breeching:

• The recommended sizing in Section 14, Boiler Ratings & Dimensions, in this Manual is based on a minimum chimney or vent height of 20 feet (610 cm) and a maximum horizontal run of 6 feet (183 cm) to the chimney with no more than one 90-degree standard elbow.

• The minimum area of the chimney serving two or more appliances must be at least the area of the largest chimney connector plus 50% of the total area of all other appliance connectors.

• The vent connector must be single wall steel or Type B double wall vent pipe. The vent connector must be Type B double wall if it is located in or passes through cold areas. The vent connector must extend into, but not beyond, the inside wall of the chimney.

6. Vent Connection to Boiler (Figure 1.8): a. Provide at least a 3 foot (91 cm) rise in the vent

connection on the boiler.

b. The vent system should provide a draft of at least

0.02" w.c. (5 Pa) measured at the vent connections.

c. Support the weight of the vent system

independently of the boiler draft hood. The draft hood is not designed to carry structural loading.

d. Provide support of the vent connector

(breeching) at maximum 12 foot (366 cm) intervals to prevent sagging and to provide a minimum upward slope of 1/4" per foot (21 mm per meter).

e. Do not connect the vent for this boiler into any

vent system which operates with positive pressure.

f. Use Type B double-wall pipe for vents which run

through unheated spaces.

7. Removing an existing boiler from a common vent:

At the time for removal of an existing boiler, the following steps shall be followed with each appliance connected to the common venting system placed in operation, while the other appliances remaining connected to the common venting system are not in operation.

a. Seal any unused openings in the common

venting system.

b. Visually inspect the venting system for proper size

and horizontal pitch and determine there is no blockage or restriction, leakage, corrosion and other deficiencies which could cause an unsafe condition.

c. Insofar as is practical, close all building doors

and windows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building. Turn on clothes dryers and any appliance not connected to the common venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they will operate at maximum speed. Do not operate a summer exhaust fan. Close fireplace dampers.

d. Place in operation the appliance being inspected.

Follow the lighting instructions. Adjust the thermostat so appliance will operate continuously.

e. Test for spillage at the draft hood relief opening

after 5 minutes of main burner operation. Use the flame of a match or candle, or smoke from a cigarette, cigar or pipe.

Failure to provide adequate venting can result in severe property damage, personal injury or death.

WARNING

Figure 1.8: Vent Connection

Page 9

PREINSTALLATION

f. After it has been determined that each appliance

remaining connected to the common venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers and any other gas-burning appliance to their previous condition of use.

g. Any improper operation of the common venting

system should be corrected so the installation conforms with the current edition of the National Fuel Gas Code, ANSI Z223.1/NFPA 54 and/or CAN/CGA B149, Installation Codes. When resizing any portion of the common venting system, the common venting system should be resized to approach the minimum size as determined using the appropriate tables located in the chapter Sizing of Category I Venting Systems in the current edition of the National Fuel Gas Code, ANSI Z223.1/NFPA 54 and/or CAN/CGA B149, Installation Codes.

E. BOILER SETTING

1. Provide a good, level foundation for the boiler with the minimum dimensions given in Figure 1.9 and Table 1.1. The flooring and structural support system must be suitable for the operating weight of the boiler and any connected piping.

2. Do not operate the boiler until the foundation, if new concrete, has thoroughly cured. The high temperature under the burners could cause major damage to the concrete if it still contains moisture.

3. If the boiler is installed in a penthouse or if wiring of any sort is run underneath the boiler foundation, construct the foundation with provision for airflow underneath between the main floor and the top of the boiler foundation.

a. Concrete block aligned with the openings

connected continuously would serve this purpose, for example.

b. If the foundation must be a concrete slab, use an

air cell high temperature insulating board, at least 1/2 inch (13 mm) thick, with aluminum backing, aluminum side up. One-half inch (13 mm) Hi Temp millboard with aluminum backing would be acceptable as well. Place the insulating board on the slab inside the base.

F. WATER QUALITY AND MAKE-UP

1. Check the system to make sure there are no leaks or overfilling problems which might cause excessive make-up water to be added. Make-up water causes liming in the boiler and brings in oxygen. Oxygen can cause severe damage to the boiler through oxygen corrosion pitting.

2. Clean the boiler as described in this manual. Poor water quality will cause foaming, priming and overfilling of the system. Too much sediment in the water will cause build-up in the boiler and could result in cracked sections due to overheating.

3. If the condensate return time lag is too long, this boiler may not work correctly with gravity return or with a condensate return unit. Long time lags will cause make-up water to be added to the boiler, resulting in flooding of the boiler, carryover to the system and excessive make-up water addition. You will need to install a boiler feed system to prevent problems in such cases.

4. Do not use chemicals or substances in the

boiler or system which contain petroleum or its derivatives. This will damage the boiler seals.

G. INSTALLATION SURVEY

For new and existing installations, a Steam Installation Survey is available from PB Heat. The survey will provide information on how a steam boiler works with your specific system and will provide an overview of steam system operation in general.

You can also use this survey to locate system problems which will have to be corrected. To obtain copies of the Steam Installation Survey, contact your PB Heat representative or download from PeerlessBoilers.com.

Figure 1.9: Foundation Layout

Do not install this boiler on carpeting or any combustible flooring. A significant fire hazard could result, with potential for property damage, personal injury or death.

WARNING

Page 10

PREINSTALLATION

Table 1.1: Boiler Foundation Layout

Boiler

Boiler Base Length Jacket Length Foundation Length

Model inches

mm inches mm inches mm

211A-04 22-1/2 572 28-1/8 714 40-1/8 1,019

211A-05 28-1/8 714 33-3/4 857 45-3/4 1,162

211A-06 33-3/4 857 39-3/8 1,000 51-3/8 1,305

211A-07 39-3/8 1,000 45 1,143 57 1,448

211A-08 45 1,143 50-5/8 1,286 62-5/8 1,591

211A-09 50-5/8 1,286 56-1/4 1,429 68-1/4 1,734

211A-10 56-1/4 1,429 61-7/8 1,572 73-7/8 1,876

211A-11 61-7/8 1,572 67-1/2 1,714 79-1/2 2,019

211A-12 67-1/2 1,714 73-1/8 1,857 85-1/8 2,162

211A-13 73-1/8 1,857 78-3/4 2,000 90-3/4 2,305

211A-14 78-3/4 2,000 84-3/8 2,143 96-3/8 2,448

211A-15 84-3/8 2,143 90 2,286 102 2,591

211A-16 90 2,286 95-5/8 2,429 107-5/8 2,734

211A-17 95-5/8 2,429 101-1/4 2,572 113-1/4 2,877

211A-18 101-1/4 2,572 106-7/8 2,715 118-7/8 3,019

211A-19 106-7/8 2,715 112-1/2 2,857 124-1/2 3,162

211A-20 112-1/2 2,857 118-1/8 3,000 130-1/8 3,305

211A-21 118-1/8 3,000 123-3/4 3,143 135-3/4 3,448

211A-22 123-3/4 3,143 129-3/8 3,286 141-3/8 3,591

211A-23 129-3/8 3,286 135 3,429 147 3,734

211A-24 135 3,429 140-5/8 3,572 152-5/8 3,877

211A-25 140-5/8 3,572 146-1/4 3,715 158-1/4 4,020

211A-26 146-1/4 3,715 151-7/8 3,858 163-7/8 4,162

211A-27 151-7/8 3,858 157-1/2 4,000 169-1/2 4,305

211A-28 157-1/2 4,000 163-1/8 4,143 175-1/8 4,448

211A-29 163-1/8 4,143 168-3/4 4,286 180-7/8 4,594

211A-30 168-3/4 4,286 174-3/8 4,429 186-3/8 4,734

211A-31 174-3/8 4,429 180 4,572 192 4,877

211A-32 180 4,572 185-5/8 4,715 197-5/8 5,020

211A-33 185-5/8 4,715 191-1/4 4,858 203-1/4 5,163

211A-34 191-1/4 4,858 196-7/8 5,001 208-7/8 5,305

211A-35 196-7/8 5,001 202-1/2 5,143 214-1/2 5,448

211A-36 202-1/2 5,143 208-1/8 5,286 220-1/8 5,591

211A-37 208-1/8 5,286 213-3/4 5,429 225-3/4 5,734

211A-38 213-3/4 5,429 219-3/8 5,572 231-3/8 5,877

211A-39 219-3/8 5,572 225 5,715 237 6,020

211A-40 225 5,715 230-5/8 5,858 242-5/8 6,163

211A-41 230-5/8 5,858 236-1/4 6,001 248-1/4 6,306

211A-42 236-1/4 6,001 241-7/8 6,144 253-7/8 6,448

211A-43 241-7/8 6,144 247-1/2 6,286 259-1/2 6,591

211A-44 247-1/2 6,286 253-1/8 6,429 265-1/8 6,734

211A-45 253-1/8 6,429 258-3/4 6,572 270-3/4 6,877

211A-46 258-3/4 6,572 264-3/8 6,715 276-3/8 7,020

Page 11

ASSEMBLE THE BASE

A. BASE ASSEMBLY

1. Collect the crates containing the Base Assembly parts. Table 2.1 (on page 11) shows the quantity of each crate required. The crates contain the following parts:

2. Open crate number 2. Remove the End Panels and mount a Support Channel Clip toward the rear on each panel as shown in Figure 2.2 using 1/4"-20 x 1/2" (13 mm) long round head machine screws and 1/4" lock washers provided.

2. ASSEMBLE THE BASE

2AA

2BB

2CC

2DD

2EE

Crate

Right End Panel Sub-Assembly

Left End Panel Sub-Assembly

Burner Support Channel Clips (2)

Front Panel Sub-Assembly Back Panel Sub-Assembly

Burner Support Channel

Front Panel Support Bracket

Section Assembly Kit Front Panel Sub-Assembly Back Panel Sub-Assembly

Burner Support Channel

Angle Tie Brace

Front Panel Support Bracket

Section Assembly Kit Front Panel Sub-Assembly Back Panel Sub-Assembly

Burner Support Channel

Angle Tie Brace

Front Panel Support Bracket

Section Assembly Kit Front Panel Sub-Assembly Back Panel Sub-Assembly

Burner Support Channel

Angle Tie Brace

Front Panel Support Bracket

Section Assembly Kit Front Panel Sub-Assembly Back Panel Sub-Assembly

Burner Support Channel

Angle Tie Brace

Front Panel Support Bracket

Section Assembly Kit

Items

90338

90340

90341

90342

90343

90344

Sub-Assembly #

GG-2105 GG-2106 GG-2070 GG-2080 GG-2081 GG-2066 GG-2069

GG-1030 GG-2080-1 GG-2081-1 GG-2066-1

GG-2065

GG-2069

GG-1030 GG-2080-2 GG-2081-2 GG-2066-2

GG-2065

GG-2069 GG-1030-1 GG-2080-3 GG-2081-3 GG-2066-3

GG-2065

GG-2069 GG-1030-2 GG-2080-4 GG-2081-4 GG-2066-4

GG-2065

GG-2069 GG-1030-3

Par t #

Figure 2.2: Steel Base Assembly

Figure 2.1: Boiler Base Assembly

Page 12

ASSEMBLE THE BASE

3. Attach the Front Panel and Back Panel (Figure 2.2) to the Left Hand End Panel using 5/16"-18 x 1" (25 mm) long cap screws and hex head nuts provided.

4. For 211A-04 through 211A-08 Only:

a. Complete the base assembly by attaching the

Right End Panel and setting the Burner Support Channel on the clips.

5. For 211A-09 through 211A-46 Only: a. Attach a Front Panel Support Bracket to each

Front Panel as shown in Figure 2.3.

6. Attach an Angle Tie Brace at each panel joint to

secure the front and back panels as shown in Figure

2.4 using 5/16"-18 x 1" (25 mm) long cap screws and hex head nuts.

7. Bolt remaining Front and Back Panels together using

5/16"-18 x 1" (25 mm) long cap screws and hex head nuts. See Table 2.1 for panels required. Place the panels in the positions shown in the table and Figure 2.1.

8. Complete the base assembly by attaching the Right

Hand End Panel using 5/16"-18 x 1" (25 mm) long cap screws and hex head nuts.

9. Set the Burner Support Channels in place as shown

in Figure 2.1.

B. INSTALL THE PILOT BURNERS

1. Check the location of the Burner Support Channels

in the Base Assembly. The dimensions should be:

a. Height above boiler foundation: 6-3/4" (171 mm)

b. Distance from back of Base: 3-3/4" (95 mm)

2. Remove the Gas Manifold and Pilot Line Assembly

from Box Number 7.

3. Place Manifold on front of Base. Bolt the hangers

using 5/16"-18 x 1" (25 mm) long long cap screws with 5/16" flat washers. See Figure 2.5.

Figure 2.3: Support Bracket Installation

Figure 2.4: Angle Tie Brace Installation

Page 13

ASSEMBLE THE BASE

Table 2.1: Base Front and Back Panel Crates

Model

ABCDEFG

Number

211A-04 2AA ——————24-3/4" 629 211A-05 2BB ——————30-3/8" 771 211A-06 2CC ——————36"914 211A-07 2DD ——————41-5/8" 1,057 211A-08 2EE ——————47-1/4" 1,200 211A-09 2BB 2BB —————52-7/8" 1,343 211A-10 2CC 2BB —————58-1/2" 1,486 211A-11 2CC 2CC —————64-1/8" 1,629 211A-12 2DD 2CC —————69-3/4" 1,772 211A-13 2DD 2DD —————75-3/8" 1,915 211A-14 2EE 2DD —————81"2,057 211A-15 2EE 2EE —————86-5/8" 2,200 211A-16 2CC 2CC 2CC ————92-1/4" 2,343 211A-17 2DD 2CC 2CC ————97-7/8" 2,486 211A-18 2EE 2CC 2CC ————8'-7-1/2" 2,629 211A-19 2DD 2DD 2DD ————9'-1-1/8" 2,772 211A-20 2EE 2EE 2CC ————9'-6-3/4" 2,915 211A-21 2EE 2EE 2DD ————10'-0-3/8" 3,058 211A-22 2EE 2EE 2EE ————10'-6" 3,200 211A-23 2EE 2CC 2CC 2CC — — — 10'-11-5/8" 3,343 211A-24 2DD 2DD 2DD 2CC — — — 11'-5-1/4" 3,486 211A-25 2EE 2EE 2CC 2CC — — — 11'-10-7/8" 3,629 211A-26 2EE 2EE 2EE 2BB — — — 12'-4-1/2" 3,772 211A-27 2EE 2EE 2EE 2CC — — — 12'-10-1/8" 3,915 211A-28 2EE 2EE 2EE 2DD — — — 13'-3-3/4" 4,058 211A-29 2EE 2EE 2EE 2EE — — — 13'-9-3/8" 4,201 211A-30 2DD 2DD 2DD 2DD 2CC — — 14'-3" 4,343 211A-31 2DD 2DD 2DD 2DD 2DD — — 14'-8-5/8" 4,486 211A-32 2EE 2DD 2DD 2DD 2DD — — 15'-2-1/4" 4,629 211A-33 2EE 2EE 2BB 2EE 2EE — — 15'-7-7/8" 4,772 211A-34 2EE 2EE 2EE 2EE 2CC — — 16'-1-1/2" 4,915 211A-35 2EE 2EE 2EE 2EE 2DD — — 16'-7-1/8" 5,058 211A-36 2EE 2EE 2EE 2EE 2EE — — 17'-0-3/4" 5,201 211A-37 2DD 2DD 2DD 2DD 2DD 2DD — 17'-6-3/8" 5,344 211A-38 2EE 2DD 2DD 2DD 2DD 2DD — 18'-0" 5,486 211A-39 2DD 2DD 2EE 2EE 2DD 2DD — 18'-5-5/8" 5,629 211A-40 2BB 2EE 2EE 2EE 2EE 2EE — 18'-11-1/4" 5,772 211A-41 2EE 2EE 2DD 2DD 2EE 2EE — 19'-4-7/8" 5,915 211A-42 2DD 2EE 2EE 2EE 2EE 2EE — 19'-10-1/2" 6,058 211A-43 2EE 2EE 2EE 2EE 2EE 2EE — 20'-4-1/8" 6,201 211A-44 2EE 2BB 2EE 2EE 2EE 2BB 2EE 20'-9-3/4" 6,344 211A-45 2CC 2BB 2EE 2EE 2EE 2EE 2EE 21'-3-3/8" 6,487 211A-46 2CC 2CC 2EE 2EE 2EE 2EE 2EE 21'-9" 6,629

feet/inches

Overall Length

Page 14

ASSEMBLE THE BASE

4. Place only the Burners with pilots mounted in the locations given in Table 2.2. Install the Burners by slipping the opening on the front of the burner over the orifice adapter and slipping the pin on the end of the burner into the hole in the Burner Support Channel directly opposite the orifice.

5. Cut and fit the 1/4" aluminum tubing provided from the pilot gas shut-off device(s) to the pilot burners.

6. Do not install the remaining burners until the Boiler Sections are installed.

Figure 2.5: Typical Gas Manifold and Pilot Line Assembly

Manifold Weldment

GG-4084 thru GG-4084-46

Imperial #68F

1/4" NPT x 3/8" O.D.

Tube Straight Connector

Orifice Spud

X-4026

Mounting Clamp

GG-3052 thru GG-3052-3

3/8" x 3/8" x 1/4" Tee

(2) 1/4" Street Elbow

3/8" Pipe Cap

Pipe Cap

Ignition Control & Relay

Mounting Box Assembly

(Standard HSP System, X-3011-3)

(Other panels mounted on

jacket front, left side)

1/4" x 1/8"

Hex Bushing

Imperial #69F Elbow

1/8" NPT x 1/4" O.D. Tubing

1/4" X 1-1/2"

(38 mm) long Nipple

PB-H91BG-2 or

H-V8046C

Pilot Gas Valve

Test Plug

3/8" Thermopilot

Valve(s) H17CA

(2) 5/16"-18 x 3/4" (19mm) long

Square Head Set Screw

3/8" x 1/4" Elbow

Page 15

ASSEMBLE THE BASE

Table 2.2: Pilot Burner Locations – Numbered Right to Left (See Figure 2.1)

Total

Natural Gas Only Propane Gas Only

Model Number of Number Pilot Burner Locations Pilot Burner Locations

Number Pilots of (Positions Numbered Right to Left (Positions Numbered Right to Left

Burners

211A-04 1 6 5 — 5 —

211A-05 1 8 5 — 5 —

211A-06 1 10 5 — 5 —

211A-07 1 12 5 — 5 —

211A-08 1 14 5 — 5 —

211A-09 1 16 5 — 5 —

211A-10 1 18 5 — 7 —

211A-11 2 20 15 5 13 5

211A-12 2 22 15 5 13 5

211A-13 2 24 17 5 13 5

211A-14 2 26 17 5 9, 19 —

211A-15 2 28 19 5 9, 21 —

211A-16 3 30 25 5, 15 5, 15, 23 —

211A-17 3 32 25 5, 15 5, 15, 25 —

211A-18 3 34 25 5, 15 9, 19, 27 —

211A-19 3 36 29 5, 17 9, 21, 29 —

211A-20 3 38 35 5, 21 9, 21, 31 —

211A-21 3 40 37 5, 23 9, 23, 33 —

211A-22 3 42 19 5, 39 9, 23, 35 —

211A-23 3 44 19 5, 41 9, 23, 37 —

211A-24 3 46 21 5, 39 9, 23, 39 —

211A-25 3 48 25 5, 45 9, 23, 41 —

211A-26 4 50 19 5, 33, 47 9, 23, 33, 45 —

211A-27 4 52 21 5, 35, 49 9, 23, 35, 45 —

211A-28 4 54 23 5, 37, 51 9, 23, 35, 47 —

211A-29 4 56 27 5, 39, 53 9, 23, 39, 49 —

211A-30 4 58 29 5, 39, 51 9, 23, 39, 51 —

211A-31 4 60 31 5, 41, 53 9, 23, 39, 53 —

211A-32 4 62 33 5, 41, 59 9, 25, 41, 55 —

211A-33 4 64 35 5, 41, 61 9, 25, 41, 57 —

211A-34 5 66 35 5, 21, 49, 63 9, 23, 39, 51, 59 —

211A-35 5 68 37 5, 17, 51, 65 9, 23, 39, 51, 61 —

211A-36 5 70 37 5, 19, 53, 67 9, 23, 39, 51, 63 —

211A-37 5 72 37 5, 23, 47, 65 9, 23, 39, 51, 65 —

211A-38 5 74 25, 55 5, 43, 67

211A-39 5 76 23, 49 5, 35, 69

211A-40 5 78 25, 55 5, 33, 75

211A-41 6 80 19, 45 5, 33, 57, 77

211A-42 6 82 23, 51 5, 31, 65, 79

211A-43 6 84 23, 53 5, 33, 67, 81

211A-44 6 86 21, 55 5, 33, 67, 83

211A-45 6 88 23, 57 5, 37, 65, 85

211A-46 6 90 25, 59 5, 39, 67, 87

Electronic Pilots Standing Pilots Electronic Pilots Standing Pilots

(Spark Ignited) (Thermocouple) (Manually Lighted) Thermocouple

Models 211A-38 through 211A-46 Are Certified for Natural Gas Only

Page 16

PLACE THE BOILER SECTIONS

A. PREPARATION

1. Check the level of the Boiler Base using a spirit level. Make sure the base is level and that the base panels are aligned within plus or minus 1/16" (2 mm).

2. Check the area around the Flow Ports (Figure 3.1). Use solvent and a clean cloth to thoroughly clean the flat surfaces and recesses. All foreign matter must be removed to assure a proper seal when the sections are drawn together.

B. PLACING THE SECTIONS

1. Begin by placing the Left Hand End Section on the left end of the base. The upper flow port goes toward the front of the boiler as shown in Figure 3.2.

2. Slide the section to the back of the base until the cast lug on the bottom of the section under the lower flow port is against the base back panel. Keep the section upright by a supporting prop or other means.

3. Align the parting line of the section with the seam between the Base End panel and the Base Front Panel as shown in Figure 3.3.

4. Apply Hi-Temp rope seal by spreading a thin coat of spray adhesive in the grooves on each end of the section. Place the rope in the grooves. Do not stretch the rope. The longer rope goes in the front groove. NOTE: The ends of each rope must extend 1/2" (13 mm) beyond the top and bottom.

5. Place the Flow Port Gaskets in the recesses provided (see Figure 3.1). Do not use adhesive.

6. The following steps must be followed to insure that no damage is done to the tie rod lugs. A 0-100 ft.-lbs. (0-136 N

m) torque wrench is required.

a. Place an Intermediate Section on the base and

slide it carefully against the Left Hand End Section.

b. Align the flow ports from front to back, as close

as possible.

c. Insert a tie rod into each of the lugs on each

section and apply a nut and washer to each end of the tie rod.

d. Before tightening, check the vertical alignment of

the sections using a spirit level (see Figure 3.4). Make sure they are square with the Base.

3. PLACE THE BOILER SECTIONS

Gaskets will be damaged by petroleum or its derivatives. Completely remove all solvent residue before placing gaskets.

Do not use petroleum based compounds in the boiler.

CAUTION

The sections are heavy and must be supported securely.

WARNING

Figure 3.1: Flow Port Machining & Gasket

Figure 3.2: Placing the First Section on Base

Page 17

Figure 3.3: Assembling Sections on Base

PLACE THE BOILER SECTIONS

Page 18

e. Draw sections together evenly, alternating

between top lug and bottom lug in increments of 20 ft.-lbs. (27 N

m). Continue until both top and

bottom lugs are tightened to 60 ft.-lbs. (81 N

m).

DO NOT EXCEED 60 FT.-LBS (81 N

m).

f. Check the level while tightening to make sure

alignment stays true. Also make sure sections remain square with the Base from front to back as the tie rods are tightened and as additional sections are installed.

g. If the sections tend to run out of plumb, this will

usually be at the bottom front. Loosen the upper nuts slightly and tighten the lower ones to adjust.

7. Assemble the remaining sections in the same way for a finished assembly as shown in Figure 3.3.

8. Some of the Intermediate Sections have tappings for installing additional steam risers from the boiler. These Tapped Intermediate Sections must be installed as shown in Figure 3.5A. The placement order is left to right (Figure 3.5).

C. HYDROSTATIC TEST THE BOILER

1. The supply and return piping can be permanently erected before applying the Boiler Jacket if the pipe nipples applied to the boiler tappings are long enough to clear the jacket.

2. Install a drain cock in the tapping provided at the bottom rear of each end section.

3. Provide a water supply line to the boiler.

4. Plug all open tappings in the boiler.

5. Provide a means to vent air as the boiler fills.

6. Fill the boiler with water, venting air as water level rises.

7. Pressurize boiler to 45 psig (310 kPa). Do not exceed this pressure.

a. Maintain pressure while checking all joints and

fittings for leaks.

b. After inspection is complete, drain the boiler and

remove plugs from tappings that are to be used.

Figure 3.4: Align Sections Vertically

Figure 3.5: Section Positioning Numbering

Boiler Model Number

Place Tapped Intermediate Sections

as Positions (numbered Left to Right)

211A-18 10 211A-19 10 211A-20 11 211A-21 11 211A-22 8, 16 211A-23 8, 16 211A-24 9, 17 211A-25 7, 13, 19 211A-26 7, 13, 20 211A-27 7, 12, 17, 22 211A-28 5, 11, 17, 23 211A-29 5, 10, 15, 20, 25 211A-30 6, 11, 16, 21, 26 211A-31 6, 10, 14, 18, 22, 26 211A-32 6, 11, 15, 19, 23, 27 211A-33 5, 9, 13, 17, 21, 25, 29 211A-34 5, 9, 13, 17, 22, 26, 30 211A-35 5, 9, 13, 18, 23, 27, 31 211A-36 5, 9, 13, 17, 21, 25, 29, 33 211A-37 5, 9, 13, 17, 21, 25, 29, 33 211A-38 4, 8, 12, 17, 22, 27, 31, 35 211A-39 4, 8, 12, 16, 20, 24, 28, 32, 36 211A-40 4, 8, 12, 16, 21, 25, 29, 33, 37 211A-41 4, 8, 12, 16, 19, 23, 26, 30, 34, 38 211A-42 4, 8, 12, 16, 20, 23, 27, 31, 35, 39 211A-43 4, 7, 11, 14, 18, 22, 26, 30, 33, 37, 40 211A-44 4, 8, 12, 16, 19, 23, 26, 29, 33, 37, 41 211A-45 4, 7, 11, 14, 18, 21, 25, 28, 32, 35, 39, 42 211A-46 4, 7, 11, 14, 18, 22, 25, 29, 33, 36, 40, 43

Figure 3.5A: Section Position Numbering

PLACE THE BOILER SECTIONS

Page 19

INSTALL THE FLUE COLLECTOR

1. Collect the Flue Collector cartons. The Flue Collector sections are labeled on the part and on the carton. See Table 4.1 for the items needed.

2. Install Hi Temp Rope for each collector section as shown in Figure 4.1. The rope provides the seal to prevent flue gases from leaking from the collector. Make certain that the rope is well under the bottom edges of each flue collector section in order to obtain a tight seal.

3. Place the Flue Collector sections in the positions given in Table 4.1. These positions are numbered

from left to right when facing the front of the boiler.

4. Fasten an angle bracket, part number GG-5005, to the top of each Collector section with two #10 x 1/2" (13 mm) long sheet metal screws. See Figure 4.2.

5. Insert a Long Hook Bolt, part number GG-5003, through the angle bracket. Slip the hook end over the tie rod. Apply a 1/4"-20 hex nut on the end of the rod and snug against the bracket. See Figure 4.2. Do not tighten yet.

6. Insert a Short Hook Bolt, part number GG-5004, through the flange in the rear of the flue collector. Catch the hook around the spacer pads at the top of the boiler sections. Apply a 1/4"-20 hex nut on the Bolt and snug against the flange. See Figure 4.2. Do not tighten yet.

7. Draw the Flue Collector sections tight against the sealing rope by tightening the nuts on the Hook Bolts. Draw the nuts evenly, alternating tightening.

4. INSTALL THE FLUE COLLECTOR

Figure 4.2: Installing Flue Collector Sections

Figure 4.1: Applying Flue Collector Hi Temp Rope Gasket

Page 20

INSTALL THE FLUE COLLECTOR

Boiler

Position Position Position Position Position Position Position Position Position

Model

123456789

Number

211A-04 14 ————————

211A-05 14A ————————

211A-06 14B ————————

211A-07 14 14 ———————

211A-08 14A 14 ———————

211A-09 14A 14A ———————

211A-10 14B 14A ———————

211A-11 14B 14B ———————

211A-12 14A 14A 14 ——————

211A-13 14A 14A 14A ——————

211A-14 14B 14A 14A ——————

211A-15 14B 14A 14B ——————

211A-16 14B 14B 14B ——————

211A-17 14A 14A 14A 14A —————

211A-18 14B 14A 14A 14A —————

211A-19 14A 14B 14B 14A —————

211A-20 14B 14B 14B 14A —————

211A-21 14B 14B 14B 14B —————

211A-22 14B 14A 14A 14A 14A ————

211A-23 14B 14B 14A 14A 14A ————

211A-24 14B 14B 14B 14A 14A ————

211A-25 14B 14B 14B 14B 14A ————

211A-26 14B 14B 14B 14B 14B ————

211A-27 14B 14B 14A 14A 14A 14A — — —

211A-28 14B 14B 14B 14A 14A 14A — — —

211A-29 14B 14B 14B 14B 14A 14A — — —

211A-30 14B 14B 14B 14B 14B 14A — — —

211A-31 14B 14B 14B 14B 14B 14B — — —

211A-32 14B 14B 14B 14A 14A 14A 14A — —

211A-33 14B 14B 14B 14B 14A 14A 14A — —

211A-34 14B 14B 14B 14B 14B 14A 14A — —

211A-35 14B 14B 14B 14B 14B 14B 14A — —

211A-36 14B 14B 14B 14B 14B 14B 14B — —

211A-37 14B 14B 14B 14B 14A 14A 14A 14A —

211A-38 14A 14A 14A 14B 14B 14B 14B 14B —

211A-39 14A 14A 14B 14B 14B 14B 14B 14B —

211A-40 14A 14B 14B 14B 14B 14B 14B 14B —

211A-41 14B 14B 14B 14B 14B 14B 14B 14B —

211A-42 14A 14A 14A 14A 14B 14B 14B 14B 14B

211A-43 14A 14A 14A 14B 14B 14B 14B 14B 14B

211A-44 14A 14A 14B 14B 14B 14B 14B 14B 14B

211A-45 14A 14B 14B 14B 14B 14B 14B 14B 14B

211A-46 14B 14B 14B 14B 14B 14B 14B 14B 14B

Table 4.1: Flue Collector Section Location (From Left to Right Facing Front of Boiler) – Crates

Crates 14 = Part number GG-5000 Crate 14A = Part number GG-5000-1 Crate 14B = Part number GG-5000-2

Page 21

PIPE THE BOILER

A. PREPARATION

1. The boiler must be pressure tested as outlined in Chapter 3, “Place the Boiler Sections,” of this manual.

2. The Supply and Return piping can be installed before the jacket is applied. Use nipples long enough to be sure they will extend through the jacket.

B. SUPPLY PIPING

1. Install End Riser connections sized per Table 5.1. The 3" tappings in the tops of the end sections are not used for steam boilers.

a. Install a reducing tee on one end riser. Install a 2"

valve, nipple and cap for skimming the boiler in the tee as shown in the piping drawings.

2. Models 211A-08 and larger require risers in both end sections.

3. Models 211A-18 and larger require additional 3" risers off of the tapped intermediate sections. See Table 5.1 for the number required.

4. Pipe the header at least 24 inches (610 mm) above the normal boiler water line. This is required to prevent water from carrying over into the header and then to the system.

5. Figure 5.2 shows the Supply and Return piping for Parallel Flow Gravity systems and all Pumped Return Systems.

6. Counterflow Gravity systems require the boiler steam line to enter the top of the steam main. See Figure

5.3 for this special case.

7. The piping in these drawings is shown off the right hand side of the boiler. The boiler may also be piped toward the left side as shown in Figure 5.4, typical.

8. Do not reduce the size or number of risers shown. These are required for reliable operation of the boiler. If the risers are undersized or incorrectly placed, a sloped water line can occur in the boiler, causing possible overheating of some sections.

9. Pipe the Header with an offset as shown in the drawings. This offset prevents the expansion and contraction of the Header from damaging the boiler sections. Use threaded fittings for swing joints.

10. Always locate the Steam Supply take-off

between the Equalizer and the last Boiler Riser. (See PB Heat’s “Steam Installation Survey”

for discussion). Locating the Steam Supply between the risers will cause water carryover to the system.

11. Do not use a bull head tee to provide steam supply and equalizer connections. This will cause water level bounce and carryover.

C. RETURN PIPING

1. The use of a Hartford loop in all installations is recommended. The loop provides additional reliability for the system. A check valve must still be installed on the pump discharge of all pumped return systems.

5. PIPE THE BOILER

Figure 5.1: Supply and Return Positions, Skim Piping, Hartford Loop

Page 22

PIPE THE BOILER

Figure 5.2: Supply and Return Piping – Pumped Return and Parallel Flow Gravity Systems

Page 23

PIPE THE BOILER

2. On pumped return systems, install a boiler cock after the pump to allow throttling of the pump discharge. The pressure after the boiler cock should be no more than 5 psig (35 kPa) above the boiler operating pressure. Pumping the water into the boiler too fast will cause collapse of the water level and level control problems.

3. Size the equalizer per Table 5.1.

4. Pipe the Hartford loop tee so the inside top of the close nipple is 2 to 4 inches (51 to 102 mm) below the boiler water line.

5. If the pump discharge is looped overhead, above the boiler water line, install spring-loaded check valves at both the pump discharge and the connection to the boiler return.

D. MULTIPLE BOILER INSTALLATIONS

1. Figure 5.5 shows typical piping for multiple boiler Gravity Return systems. Figure 5.6 shows typical piping for multiple boiler Pumped Return systems.

2. Provide separate feed lines for multiple boiler pumped return systems. Use either separate feed pumps or solenoid valves to isolate feeding of the boilers. This is needed to provide reliable level control and avoid nuisance performance problems.

3. Condensate return units are not effective for multiple boiler installations since they do not respond to the needs of the boilers. Always use Boiler feed units.

a. Install a Float and Thermostatic trap at the boiler

water level on each of the multiple boilers on a pumped return system. This prevents flooding of idle boilers due to condensation of steam.

Figure 5.4: Left Hand Piping Arrangement – Typical

Figure 5.3: Supply and Return Piping –

Counterflow Gravity Systems

Boiler Header

End Risers Interm. Risers Equalizers

Model Size

No. Size No. Size No. Size

211A-04 4" 1 4" - - 1 2-1/2" 211A-05 5" 1 5" - - 1 2-1/2" 211A-06 5" 1 5" - - 1 2-1/2" 211A-07 5" 1 5" - - 1 2-1/2" 211A-08 6" 2 5" - - 1 2-1/2" 211A-09 6" 2 5" - - 1 2-1/2" 211A-10 6" 2 5" - - 1 3" 211A-11 6" 2 5" - - 1 3" 211A-12 8" 2 5" - - 1 3" 211A-13 8" 2 5" - - 1 3" 211A-14 8" 2 5" - - 1 3" 211A-15 8" 2 6" - - 1 3" 211A-16 8" 2 6" - - 2 4" 211A-17 8" 2 6" - - 2 4" 211A-18 8" 2 6" 1 3" 2 4" 211A-19 8" 2 6" 1 3" 2 4" 211A-20 8" 2 6" 1 3" 2 4" 211A-21 8" 2 6" 1 3" 2 4" 211A-22 8" 2 6" 2 3" 2 4" 211A-23 8" 2 6" 2 3" 2 4" 211A-24 10" 2 6" 2 3" 2 4" 211A-25 10" 2 6" 3 3" 2 4" 211A-26 10" 2 6" 3 3" 2 4" 211A-27 10" 2 6" 4 3" 2 4" 211A-28 10" 2 6" 4 3" 2 5" 211A-29 10" 2 6" 5 3" 2 5" 211A-30 10" 2 6" 5 3" 2 5" 211A-31 10" 2 6" 6 3" 2 5" 211A-32 10" 2 6" 6 3" 2 5" 211A-33 10" 2 6" 7 3" 2 5" 211A-34 10" 2 6" 7 3" 2 5" 211A-35 10" 2 6" 7 3" 2 5" 211A-36 10" 2 6" 8 3" 2 5" 211A-37 10" 2 6" 8 3" 2 5" 211A-38 10" 2 6" 8 3" 2 5" 211A-39 10" 2 6" 9 3" 2 5" 211A-40 10" 2 6" 9 3" 2 5" 211A-41 10" 2 6" 10 3" 2 5" 211A-42 10" 2 6" 10 3" 2 5" 211A-43 10" 2 6" 11 3" 2 5" 211A-44 12" 2 6" 11 3" 2 5" 211A-45 12" 2 6" 12 3" 2 5" 211A-46 12" 2 6" 12 3" 2 5"

Table 5.1: Header, Risers & Equalizer Sizing

Page 24

PIPE THE BOILER

Figure 5.6: Piping Multiple Boilers, Typical, Pumped Return Systems

Figure 5.5: Piping Multiple Boilers, Typical, Gravity Return Systems

Page 25

INSTALL THE JACKET & DRAFT HOOD

A. PREPARE THE PARTS

1. Collect the Jacket cartons and Draft Hood cartons (numbers 12 and 13).

2. See Figure 6.2 for the Jacket Assembly. Use these drawings for part identification and location.

3. See Figure 6.3 for the quantity of each carton required and placement of the jacket sections on the boiler.

4. See Table 6.1 for the contents of each Jacket Carton and Draft Hood carton.

5. See Table 6.2 for the Draft Hood cartons required.

B. APPLY CLEANOUT COVER PLATES

1. Remove Cleanout Cover Plates from carton 12.

2. Install one cover plate on each End Section. Use four 5/16"-18 x 2" (51 mm) long studs, 5/16-18" hex nuts and 5/16" flat washers.

3. Seal around the cleanout plates using the furnace cement provided and apply between base and bottom of sections.

C. APPLY JACKET END ASSEMBLIES

1. Remove necessary knockouts from the Jacket End Panel pieces in carton 12.

2. Attach a Corner Panel Support Bracket (GG-6029) to each Corner Panel using two #10 x 1/2" (13 mm) long sheet metal screws.

3. Attach the four Corner Panels to the Base Ends using 1/4"-20 x 1/2" (13 mm) long machine screws and 1/4" flat washers. The locations are:

• Right Front – GG-6015

• Left Front – GG-6016

• Right Rear – GG-6017

• Left Rear – GG-6018

4. Attach an End Panel Cover Plate (GG-6030) to the opening on the Upper Left End Panel if the 6 inch tapping on that end is not used.

5. Attach Upper Left End Panel (GG-6032) to the left end corner panels with five #10 x 1/2" (13 mm) long sheet metal screws.

6. Place Top Left End Panel (GG-6020) over the Corner Panels and Upper Panel with flange pointing downward. Use four #10 x 1/2" (13 mm) long sheet metal screws.

7. Repeat for the Right End.

D. 211A-04 THROUGH 211A-08 ONLY

1. Apply Front and Rear Panels as follows.

2. Open Jacket Intermediate Section carton, 12A, B, C, D or E, per Table 6.1. Remove necessary knockouts from panels.

3. Insert Front Panel (GG-6023) flange (on right side of panel) under the edge of the Right Front Corner Panel. Place the left edge of the Front Panel over the offset flange of the Left Front Corner Panel. Line up the screw holes and secure with ten #10 x 1/2" (13 mm) long sheet metal screws.

4. Insert the offset flange of the Upper Rear Panel under the edge of the Left Rear Corner Panel. Place the left edge of the panel over the Right Rear Corner Panel. Line up the holes and secure with ten #10 x 1/2" (13 mm) long sheet metal screws.

5. Apply the Lower Rear Panel using the same procedure and secure with two #10 x 1/2" (13 mm) long sheet metal screws.

6. Install Rear Panel Support Leg (GG-6028) inside the Left Rear Corner Panel. The flanges extend toward the boiler. Line up the holes and secure with three #10 x 1/2" (13 mm) long sheet metal screws.

7. Attach the Lower Rear Panel Guide (GG-6031) to the Rear Base Panel as shown in Figure 6.2.

8. Install the Draft Hood. Work from the left side (facing the front) of the boiler to the right. Apply the Draft Hood Sections in the sequence given in Table 6.2. Attach the Hood sections to the Flue Collector with two #10 x 1/2" (13 mm) long sheet metal screws per collector section.

9. Insert the offset flange of the Jacket Top Panel under the Top Left End Panel. Place the right flange on the Top Right End Panel. The front edge flange goes over the Jacket Front Panel. Line up the holes and secure with #10 x 1/2" (13 mm) long sheet metal screws.

E. 211A-09 AND LARGER ONLY

1. The boilers have multiple intermediate jacket panels.

2. Collect the jacket cartons listed in Table 6.1. When installing the jacket panels, place them on boiler in the order shown in Figure 6.3.

3. Open the cartons in the order listed in Figure 6.3.

4. Install the Jacket Front Panels:

• Make sure to slip the Front Panels into the Front Panel Support Brackets (mounted on the base). See Figure 6.2.

• Install the first Front Panel with the left edge over the Left Front Corner Panel. Line up the holes and secure with #10 x 1/2" (13 mm) long sheet metal screws.

6. INSTALL THE JACKET & DRAFT HOOD

Page 26

INSTALL THE JACKET & DRAFT HOOD

• Continue applying Front Panels this way.

• Slip the right edge of the last Front Panel under

the Right Front Corner Panel. Line up the holes and secure with #10 x 1/2" (13 mm) long sheet metal screws.

5. Install the Jacket Rear Panels:

• Slip the offset flange of the first Upper Rear Panel under the edge of the Left Rear Corner Panel. Secure with #10 x 1/2" (13 mm) long sheet metal screws.

• Attach the first Lower Rear Panel in the same way.

• Attach a Rear Panel Support Leg on the inside of

the Upper Rear Panel. The flanges point toward the boiler. Attach with #10 x 1/2" (13 mm) long sheet metal screws.

• Install a Panel Support Angle on the inside top of the Upper Rear Panel (See Figure 6.2). Use #10 x 1/2" (13 mm) long sheet metal screws.

• Install the remaining Upper Rear and Lower Rear Panels in the same way.

• Place the edge of the last rear panel over the Right Rear Corner Panel.

6. Install the Draft Hood Sections:

• Start from the left of the boiler (facing the front). Apply the Draft Hood sections from left to right in the order given in Table 6.2.

• Use two #10 x 1/2" (13 mm) long sheet metal screws for each Flue Collector section.

F. APPLY JACKET TOP PANELS

1. Apply the jacket top panels working from left to right (facing front of boiler). Place the panels from the cartons in the sequence given in Figure 6.3.

2. Mount a Panel Support Angle (GG-6027) on the back bottom edge of each Top Panel with the long flange pointed down. Peel the insulation slightly away from the back edge of the panel for better contact. Secure with one #10 x 1/2" (13 mm) long sheet metal screw.

3. Slide the left hand offset flange of the first Top Panel under the Top Left End Panel. Place the front flange of the Top Panel over the Front Panel. Line up the holes and secure with #10 x 1/2" (13 mm) long sheet metal screws.

4. Slide the left hand edge of each additional panel under the panel to its left. Secure with #10 x 1/2" (13 mm) long sheet metal screws.

5. Apply the last Top Panel in the same way. Place its right hand edge over the Top Right End Panel. Secure with #10 x 1/2" (13 mm) long sheet metal screws.

6. Check for loose or missing screws as you complete the jacket assembly.

G. APPLY LOWER END PANELS

1. THIS APPLIES TO ALL BOILER SIZES.

2. The parts are packed in carton #12.

3. Attach an End Panel Cover Plate to the opening in the Lower End Panel (GG-6022) if the tapping in the boiler is not being used. Secure with two #10 x 1/2" (13 mm) long metal screws.

4. Apply a Lower End Panel to each end of the boiler, securing to the Corner Panels with eight #10 x ½” (13 mm) long sheet metal screws. Attach to the Upper End Panels with two #10 x ½” (13 mm) long sheet metal screws.

H. APPLY PLATES AND LABELS

1. Mount Boiler Rating Label, Agency Plates and Caution Labels in the Upper Right End Jacket Panel.

Plates to be field applied are packed in Box Number 7.

3. Place these plates as shown in Figure 6.1.

4. Secure metal plates with #6 x 6 mm (1/4") sheet metal screws. Apply all adhesive-backed labels.

FIGURE 28

Figure 6.1: Location of Rating, Agency and Instruction Plates on Upper Right End Panel

Page 27

INSTALL THE JACKET & DRAFT HOOD

Figure 6.2: Jacket Assembly

Top Panel (GG-6024) Top Right End Panel

(GG-6019)

Top Left End Panel (GG-6020)

Upper Left End Panel (GG-6032)

Lower End Panel (GG-6022)

Corner Panel Support Bracket (GG-6029)

Cleanout Cover Plate Assembly (GG-6004)

Draft Hood (GG-5001)

Front Panel

(GG-6023)

Right Front

Corner Panel

(GG-6015)

Front Jacket Panel

Support Bracket

(GG-2069) Left End Corner Panel (GG-6016)

Top Panel (GG-6024)

Panel Support Angle

(GG-6027)

Right Rear Corner Panel (GG-6017)

Upper Rear Panel (GG-6025)

Lower Rear Panel Guide (GG-6031)

Lower Rear Panel (GG-6026)

Rear Panel Support Leg (GG-6028)

End Panel Cover Plate GG-6030

Left Rear

Corner Panel

(GG-6018)

Page 28

INSTALL THE JACKET & DRAFT HOOD

Carton Contents Sub-Assembly Part Number Quantity

Cleanout Cover Plates GG-6004 2 Jacket Corner Panel, Right Front GG-6015 1 Jacket Corner Panel, Left Front GG-6016 1 Jacket Corner Panel, Right Rear GG-6017 1 Jacket Corner Panel, Left Rear GG-6018 1 Corner Panel Support Brackets GG-6029 4

Jacket Upper End Panel, Left GG-6032 1 Jacket Upper End Panel, Right GG6021 1 End Panel Cover Plates GG-6030 4 Jacket Lower End Panels GG-6022 2 Top Right End Panel GG-6019 1 Top Left End Panel GG-6020 1 Sheet Metal Screws — Machine Screws, Washers, Nuts — Jacket Intermediate Panel – Front GG-6023 1 Jacket Intermediate Panel – Top GG-6024 1 Jacket Intermediate Panel – Upper Rear GG-6025 1

12A

Jacket Intermediate Panel – Lower Rear GG-6026 1 Panel Support Angle GG-6027 2 Rear Panel Support Leg GG-6028 1 Lower Rear Panel Guide GG-6031 1 Sheet Metal Screws — 23 Jacket Intermediate Panel – Front GG-6023-1 1 Jacket Intermediate Panel – Top GG-6024-1 1 Jacket Intermediate Panel – Upper Rear GG-6025-1 1

12B

Jacket Intermediate Panel – Lower Rear GG-6026-1 1 Panel Support Angle GG-6027 2 Rear Panel Support Leg GG-6028 1 Lower Rear Panel Guide GG-6031 1 Sheet Metal Screws — 23 Jacket Intermediate Panel – Front GG-6023-2 1 Jacket Intermediate Panel – Top GG-6024-2 1 Jacket Intermediate Panel – Upper Rear GG-6025-2 1

12C

Jacket Intermediate Panel – Lower Rear GG-6026-2 1 Panel Support Angle GG-6027 2 Rear Panel Support Leg GG-6028 1 Lower Rear Panel Guide GG-6031 1 Sheet Metal Screws — 23 Jacket Intermediate Panel – Front GG-6023-3 1 Jacket Intermediate Panel – Top GG-6024-3 1 Jacket Intermediate Panel – Upper Rear GG-6025-3 1

12D

Jacket Intermediate Panel – Lower Rear GG-6026-3 1 Panel Support Angle GG-6027 2 Rear Panel Support Leg GG-6028 1 Lower Rear Panel Guide GG-6031 1 Sheet Metal Screws — 23 Jacket Intermediate Panel – Front GG-6023-4 1 Jacket Intermediate Panel – Top GG-6024-4 1 Jacket Intermediate Panel – Upper Rear GG-6025-4 1

12E

Jacket Intermediate Panel – Lower Rear GG-6026-4 1 Panel Support Angle GG-6027 2 Rear Panel Support Leg GG-6028 1 Lower Rear Panel Guide GG-6031 1 Sheet Metal Screws — 23

Draft Hood Section GG-5001 1 Sheet Metal Screws —

13A

Draft Hood Section GG-5001-1 1 Sheet Metal Screws —

13B

Draft Hood Section GG-5001-2 1 Sheet Metal Screws —

13C

Draft Hood Section GG-5001-3 1 Sheet Metal Screws —

GG-6033

GG-6034

GG-6034-1

GG-6034-2

GG-6034-3

GG-6034-4

GG-5001

GG-5001-1

GG-5001-2

GG-5001-3

Table 6.1: Jacket and Draft Hood Carton Contents – See Figure 6.2 for Placement of Jacket Sections

Page 29

INSTALL THE JACKET & DRAFT HOOD

Figure 6.3: Jacket Assembly Sequence - Carton Numbers and Locations

Page 30

INSTALL THE JACKET & DRAFT HOOD

Boiler

Position Position Position Position Position Position Position Position Position

Model

123456789

Number

211A-04 13 — — — — — — — —

211A-05 13A — — — — — — — —

211A-06 13C — — — — — — — —

211A-07 13 13 — — — — — — —

211A-08 13A 13 — — — — — — —

211A-09 13A 13A — — — — — — —

211A-10 13C 13B — — — — — — —

211A-11 13C 13C — — — — — — —

211A-12 13A 13A 13 — — — — — —

211A-13 13A 13A 13A — — — — — —

211A-14 13C 13B 13B — — — — — —

211A-15 13C 13B 13C — — — — — —

211A-16 13C 13C 13C — — — — — —

211A-17 13B 13B 13B 13B — — — — —

211A-18 13C 13B 13B 13B — — — — —

211A-19 13B 13C 13C 13B — — — — —

211A-20 13C 13C 13C 13B — — — — —

211A-21 13C 13C 13C 13C — — — — —

211A-22 13C 13B 13B 13B 13B — — — —

211A-23 13C 13C 13B 13B 13B — — — —

211A-24 13C 13C 13C 13B 13B — — — —

211A-25 13C 13C 13C 13C 13B — — — —

211A-26 13C 13C 13C 13C 13C — — — —

211A-27 13C 13C 13B 13B 13B 13B — — —

211A-28 13C 13C 13C 13B 13B 13B — — —

211A-29 13C 13C 13C 13C 13B 13B — — —

211A-30 13C 13C 13C 13C 13C 13B — — —

211A-31 13C 13C 13C 13C 13C 13C — — —

211A-32 13C 13C 13C 13B 13B 13B 13B — —

211A-33 13C 13C 13C 13C 13B 13B 13B — —

211A-34 13C 13C 13C 13C 13C 13B 13B — —

211A-35 13C 13C 13C 13C 13C 13C 13B — —

211A-36 13C 13C 13C 13C 13C 13C 13C — —

211A-37 13C 13C 13C 13C 13B 13B 13B 13B —

211A-38 13B 13B 13B 13C 13C 13C 13C 13C —

211A-39 13B 13B 13C 13C 13C 13C 13C 13C —

211A-40 13B 13C 13C 13C 13C 13C 13C 13C —

211A-41 13C 13C 13C 13C 13C 13C 13C 13C —

211A-42 13B 13B 13B 13B 13C 13C 13C 13C 13C

211A-43 13B 13B 13B 13C 13C 13C 13C 13C 13C

211A-44 13B 13B 13C 13C 13C 13C 13C 13C 13C

211A-45 13B 13C 13C 13C 13C 13C 13C 13C 13C

211A-46 13C 13C 13C 13C 13C 13C 13C 13C 13C

Table 6.2: Draft Hood Section Placement (from Left to Right Facing Front of Boiler)

Page 31

CONNECT GAS PIPING

A. INSTALL GAS TRAIN

1. The Gas Control Train(s) supplied with this boiler:

• Has been factory assembled and tested for tightness of joints.

• Must be re-tested after installation with a soap suds test to assure it is still leak-tight after assembly.

• Must be isolated from the gas supply piping during testing of the supply piping.

2. Assemble the Gas Control Train(s) to the Manifold with the ground joint union(s) provided. See Figure

7.1. Models 211A-04 through 211A-18 are supplied with a single Gas Control Train. Models 211A-19 and larger are supplied with two or more Gas Control Trains.

3. Support the Gas Control Train(s) with a permanent brace.

B. CONNECT PILOT GAS TUBING

1. Use 3/8" aluminum tubing or as required by local codes.

2. Connect the Pilot Line to the Pilot Cock Assembly supplied with the Gas Control Train.

3. Connect tubing to each pilot. a. Connect electronic pilots to the Pilot Gas Valves.

b. Connect standing pilots (when supplied – see

Table 2.2) to the thermopilot valves.

c. Install thermocouples in the standing pilots and

connect to the thermopilot valves.

C. INSTALL VENT AND BLEED PIPING

1. Gas Pressure Regulator a. Connect regulator vent outlet to outside

atmosphere using 1/4" tubing or as required by local codes.

b. Terminate the tubing downward to prevent water

from entering the tubing and protect from any obstruction.

c. Terminate the tubing above and well away from

normal breathing level or building air intakes.

2. Diaphragm Gas Valves a. Pipe diaphragm gas valve bleed lines to outside

atmosphere unless the boiler is equipped with a standing pilot. On standing pilot boilers, pipe the valve bleed lines to the bleed piping pre-installed to the pilot burner.

b. Use 1/4" tubing or as required by local codes.

Always pipe the bleed lines separate from the regulator vent lines.

7. CONNECT GAS PIPING

Figure 7.1: Gas Control Train and Burner Assembly, Single Natural Gas Control Train Shown

(Models 211A-19 and Larger Use Two or More Gas Control Trains)

Page 32

CONNECT GAS PIPING

c. When piping bleed lines to outside, terminate the

tubing downward to prevent water from entering the tubing, and protect the tubing termination from any obstruction. Terminate the tubing above and well away from normal breathing level or building air intakes.

D. INSTALL GAS SUPPLY PIPING

1. Size the piping as required by the National Fuel Gas Code, ANSI Z223.1/NFPA 54 and/or CAN/CGA B149 Installation Codes or as required by local codes.

a. Use Table 7.1 for sizing of natural gas for a

system pressure drop of 0.3 inch water column (75 Pa).

2. The standard gas train is designed for a maximum pressure of 1/2 psig (14 inches water column/3.5 kPa). Make sure the system regulator will not allow a higher pressure to the Gas Control Train under any conditions.

3. The minimum gas supply pressure is listed on the Boiler Rating Label. Make sure the system regulator and the piping are sized and adjusted properly to provide this pressure under all conditions.

4. Install a Service Valve, Sediment Trap and Ground Joint Union at the supply connection to the Gas Control Train as shown in Figure 7.2. These are not supplied with the boiler. Install them in accordance with local codes.

5. Use only pipe joint compounds rated for use with Liquefied Petroleum Gases. This is necessary because most natural gas contains propane as well as methane.

E. TEST GAS SUPPLY PIPING

1. ISOLATE THE BOILER GAS CONTROL TRAIN FROM THE SYSTEM DURING TEST:

a. Test pressure 1/2 psig (3.5 kPa) or less – Close

the Manual Shut-Off Valve on the Boiler Gas Control Train

b. Test pressure over 1/2 psig (3.5 kPa) – Disconnect

the gas supply piping upstream of the Boiler Manual Shut-Off Valve

Do not expose the Gas Control Train to excessive pressure. The gas valves can be damaged. This could result in explosion hazard and severe personal injury or death.

Do not test gas supply piping with open flame. Use a soap suds mixture brushed onto the pipe joints to test for leaks.

WARNING

Figure 7.2: Gas Supply Connection to Boiler

Page 33

CONNECT GAS PIPING

Table 7.1: Capacity of Gas Supply Pipe in Cubic Feet (Cubic Meters) Per Hour of Natural Gas for

0.3 inch (75 Pa) Drop.

Above ratings based on natural gas with specific gravity of 0.60 allowing pressure drop of 0.3 inches (75 Pa). No allowance is needed for pipe fittings. Use the following multipliers on above capacities for specific gravity other than 0.60:

Specific Gravity 0.50 0.55 0.60 0.65 0.70

Multiply Capacity by: 1.10 1.04 1.00 .962 .926

Pipe Length 1-1/4" Pipe 1-1/2" Pipe 2" Pipe 2-1/2" Pipe 3" Pipe 4" Pipe 6" Pipe

Feet Meters Foot3Meter3Foot3Meter3Foot3Meter3Foot3Meter3Foot3Meter3Foot3Meter3Foot3Meter

10 3.0 1050 30 1,600 45 3,050 86 4,800 136 8,500 241 17,500 496 44,000 1246

20 6.1 730 21 1,100 31 2,100 59 3,300 93 5,900 167 12,000 340 31,000 878

30 9.1 590 17 890 25 1,650 47 2,700 76 4,700 133 9,700 275 25,000 708

40 12.2 500 14 760 22 1,450 41 2,300 65 4,100 116 8,300 235 22,000 623

50 15.2 440 12 670 19 1,270 36 2,000 57 3,600 102 7,400 210 20,000 566

60 18.3 400 11 610 17 1,150 33 1,850 52 3,250 92 6,800 193 18,000 510

70 21.3 350 10 560 16 1,050 30 1,700 48 3,000 85 6,200 176 17,000 481

90 27.4 320 9 490 14 930 26 1,500 42 2,600 74 5,400 153 15,000 425

100 30.5 305 9 460 13 870 25 1,400 40 2,500 71 5,100 144 14,000 396

150 45.7 250 7 380 11 710 20 1,130 32 2,000 57 4,100 116 11,500 326

Page 34

INSTALL CONTROLS AND TRIM

A. INSTALL SAFETY VALVE(S)

1. Pipe the pop safety valve(s) in the 3" tappings located on the right or left end sections. Make sure the relief valve sizing meets local code requirements.

B. INSTALL BLOWDOWN VALVES

1. Install a 1-1/2" full port ball valve in each of the tappings provided at the lower back of the end sections. See Figure 8.1.

2. Pipe the valve discharge to a floor drain if available or apply a nipple and cap to close off when not in use.

C. INSTALL LOW WATER CUT-OFF(S)

1. Mount the float type low water cut-off and gauge glass in the tappings provided in the front of either end section.

2. Do not apply piping which would raise or lower the location of the cut-off relative to the tappings in the boiler. Raising the water level over the design height will cause water carryover to the system.

3. For correct location of typical low water cut-off/feeder or low water cut-off/pump control, see Figures 8.3 through 8.6.

4. Mount the probe type low water cut-off supplied with the boiler. The end sections have 3/4" tappings in the front for mounting the probe low water cut-off auxiliary control. See Figure 3.3.

a. The standard probe control is Hydrolevel Model

650P. This control is automatic reset type.

b. When a manual reset control is required, the boiler

can be supplied with Hydrolevel Model 550P.

5. Provide each float low water cut-off with a blowdown valve. Pipe the blowdown away from traffic to a floor drain if available. The blowdown valve is required for proper maintenance of the control.

6. Maintain a height of 40-1/2" (1029 mm) from boiler foundation to the normal water level.

7. When using multiple float type Controls: Always pipe the controls off of the same tappings to the boiler. Do not mount on different ends of the boiler or in different tappings. This can cause erratic operation and nuisance problems with the controls.

D. INSTALL PRESSURE CONTROLS

1. Pipe the Steam Pressure Gauge and Boiler Limit and Operating Pressure Controls as shown in Figure 8.2. Connect the control assembly to the 1/2" tapping on the right end of the boiler.

8. INSTALL CONTROLS AND TRIM

Pipe the discharge of the Safety Relief Valve(s) away from any traffic area, preferably to a floor drain. This is necessary to prevent injury should the valve discharge.

Pipe the discharge full size of valve outlet.

CAUTION

Make sure that the gas ignition system components, electrical controls, junction boxes and electrical panels are protected from water (dripping, spraying, rain, etc.) during boiler operation and service (circulator or pump servicing, control replacements or other).

CAUTION

Figure 8.1: Blowdown Valve Piping

Page 35

INSTALL CONTROLS AND TRIM

Figure 8.2: Pressure Control Piping (Fittings Included with Boiler)

Page 36

INSTALL CONTROLS AND TRIM

Figure 8.4: Optional Feeder/Low Water Cut-Off, Model 47-2 – Used Only on Models 211A-04

through 211A-08 – Capacity Not Adequate for Larger Boilers

Figure 8.3: Standard Float Type COntrol, Model 67PE2

Page 37

INSTALL CONTROLS AND TRIM

Figure 8.5: Optional Float Type Pump Control/Low Water Cut-Off, Model 157

Page 38

INSTALL CONTROLS AND TRIM

Figure 8.6: Optional Feeder/Low Water Cut-Off, Type 51-2

25-1/8" (638 mm)

36" (914 mm )

10-3/8"

264 mm)(

10-7/8" (276 mm)

4-1/8"

105 mm()

2" (51 mm)

6-11/16"

170 mm()

8-1/8"

206 mm)(

Normal Water Line

3/4"

19 mm)(

40-1/2"

(1029 mm)

Boiler Foundation

12-7/8"

327 mm)(

Control Center Line

Feeder Closing Level (Mark on Casting)

Burner Cut-Off Level is ( ) Below

Center Line on 51-2 and 51-S-2 Controls

[ ( ) Below Normal Water Line]

2-3/4" 70 mm

Install 1" Blowoff Valve

1-1/2" 38 mm

APPLICATION OF 51 FEEDERS

Models 211A-04 thru 211A-23

One 51-2 Feeder/Cutoff

Models 211A-24 thru 211A-39

One 51-S-2 Feeder/Cutoff

Models 211A-40 and Larger

Two 51-2 Feeder/Cutoffs

Consult Factory for proper application of feeders. Always use a pump control and boiler feed system instead when possible.

SUGGESTED FITTINGS LIST

A B C D E F G H J

1" Cross 1" Ground Joint Union 1" Plug

3" 76 mm

1" x ( ) long Nipple

5-1/2" 140 mm

1" x ( ) long Nipple

8" 203 mm

1" x ( ) long Nipple

8-1/4" 210 mm

1" x ( ) long Nipple

19-1/2" 495 mm

1" x ( ) long Nipple 3" x 1" Bushing

The connected fittings shown on this drawing are to be supplied by the installer.

Page 39

WIRE THE BOILER

A. CONNECT SUPPLY WIRING

1. All wiring must be done in accordance with local codes, the National Electrical Code ANSI/NFPA70 and/or the Canadian Electrical Code Part I, CSA C22.1, Electrical Code and other controlling agencies or governing bodies.

2. Use #14 gauge or heavier wire for supply wiring. Protect the circuit with a fused disconnect switch (by others) and a grounded neutral.

3. Mount an electrical junction box on the boiler Front Panel for connection of supply wiring and distribution to the boiler controls. See Figure 9.1.

B. PREPARE REMAINING CONTROLS

1. Mount the control transformer on the junction box as shown in Figure 9.1.

2. Mount a junction box near each Gas Control Train for connection of conduit and wiring distribution to the gas train components.

C. INSTALL CONTROL WIRING

1. Wire the boiler according to the wiring diagram supplied with the boiler (in the Control Envelope). Figure 9.1 is a typical layout of the components on the boiler. Figures 9.2 and 9.3 are examples of standard wiring systems. Use these drawings for general reference only.

2. Low Energy Safety Control wiring must follow the contour of the boiler. Some local codes may require that all wiring, even low voltage, be routed in conduit.

3. Install all line voltage wiring in conduit.

4. Do not install single pole switches, including safety controls, in a grounded line.

9. WIRE THE BOILER

The boiler/burner must be electrically grounded in accordance with the requirements of the authority having jurisdiction, or in the absence of such requirements, with the current edition of the National Electrical Code, ANSI/NFPA Number 70 and/or the Canadian Electrical Code Part I, CSA C22.1, Electrical Code.

NOTICE

Figure 9.1: Typical Control Layout and Wiring

Page 40

WIRE THE BOILER

Figure 9.2: Typical Wiring – Standard Controls – Low Voltage Gas Valves

Page 41

WIRE THE BOILER

Figure 9.3: Typical Wiring – Standard Controls – 120-Volt Gas Valves

Page 42

STARTING THE BOILER

A. CHECK THE PIPING

1. Water and Steam Piping a. The Boiler must have been hydrostatically tested.

b. Check the attached piping for joint tightness. c. Continue monitoring as you proceed through

start up.

2. Gas Piping a. Make sure the gas system piping and the

connections to the boiler Gas Control Train(s) have been leak tested.

b. After the boiler is in operation, check the

tightness of all joints in the boiler gas piping with a soap suds solution.

c. Purge the gas piping of all air up to the boiler

Gas Control Train.

B. FILL THE BOILER

1. Fill the boiler to the normal water line. a. Gravity Systems and Pumped Return with

Condensate Units Fill to 40-1/2" (103 cm) above the boiler foundation (center of gauge glass).

b. Pumped Return with Boiler Feed Unit–Fill the

boiler using the boiler feed unit. Fill level will depend on the control being used, but should be 40-1/2" (103 cm) above the boiler foundation (just below center of gauge glass) when the pump stops.

C. STUDY LIGHTING INSTRUCTIONS

1. Before starting the boiler, study the Lighting

Instructions supplied with the boiler.

D. RUN PILOT CHECK-OUT

1. Shut off all electrical power to the boiler.

2. Close Main and Pilot gas shut-off valves. Wait for

five (5) minutes.

3. Set the Operating and Limit Pressure Controls to

minimum setting so they will not call for heat.

4. Perform Pilot Check: a. Turn main electric disconnect switch to the ON

position.

b. Turn up the settings on the Operating and Limit

Pressure Controls so they will call for heat.

c. Check for a continuous spark at the electronic

spark-ignited pilot(s).

d. Electronic spark-ignited pilot systems–The control

will spark for 15 seconds (trial for ignition), then shut down for a 5 to 6 minute wait period before attempting another ignition.

e. Electronic standing pilot systems–Within 15

seconds the control will click, indicating a safety lockout.

f. Turn down the Operating Pressure Control to

stop the call for heat.

g. Wait 60 seconds to allow the control to reset

before proceeding with the next step.

5. Light Manual Pilots a. Follow the procedure in the Lighting Instructions

to manually light any standing pilots.

6. Electronic Spark-Ignited Pilot Ignition Check a. Turn up the Operating Pressure Control for a call

for heat. b. The electronic spark-ignited pilot(s) should ignite. c. Turn down the Operating Pressure Control to

stop the call for heat. d. The spark-ignited pilot(s) should shut off.

7. Check Main Burner Ignition a. With the Operating Pressure Control turned

down, open the main gas shut-off valve(s).

b. Turn up the Operating Pressure Control for a call

for heat. c. The electronic spark-ignited pilot(s) should ignite. d. The main gas valves will then open and the main

burners should ignite. e. Turn down the Operating Pressure Control to

stop the call for heat. f. The electronic spark-ignited pilot(s) and main

burners should shut off.

E. CHECK MAIN BURNER SYSTEM

1. Remove the pressure test plug at the Main gas shutoff valve. Attach a U-tube manometer.

2. Restart the boiler by turning up the Operating Pressure Control for a call for heat.

3. Leak test all gas train joints with a soap suds solution.

4. Check the gas pressure at the entrance to the Gas Control train.

a. The pressure reading under flow should be

between 5 and 14 inches water column (1.7 and

3.5 kPa).

b. If the pressure to the Gas Control Train exceeds

14 inches (3.5 kPa) under any conditions, the system must be provided with a lockup type gas pressure regulator to provide 14 inches (3.5 kPa) maximum.

5. Check the Manifold gas pressure.

a. Remove the 1/8" pipe plug from the manifold gas

pressure tapping. b. Attach a U-tube manometer. c. Adjust the Main Gas Pressure Regulator to obtain

3.5 inches water column (.9 kPa) on Natural Gas

10 inches water column (2.5 kPa) on Propane

(LP) Gas.

d. NOTE: If the pressure is adjusted to set the

nameplate input to the boiler, do not set it more

than 0.3 inches (75 Pa) plus or minus from the

specified settings. If more adjustment to the rate

is needed, it must be done by changing the

burner gas orifices.

10. STARTING THE BOILER

Page 43

STARTING THE BOILER

e. The Minimum input rate listed on the nameplate

applies to boilers with staged firing rate. This minimum rate is not adjustable. It is controlled by an orifice in the gas train.

6. Check the burner input by reading the gas meter. a. Each of the burners is rated at 105,000 Btu/hr

(30.8 kW) for Natural Gas with a 0.60 specific gravity.

b. Each of the burners is rated at 102,500 Btu/hr

(30 kW) for Propane (LP) Gas with a 1.56 specific gravity.

c. (U.S.) Determine the input by multiplying “F” –

Meter Reading (Cubic Feet of Gas) times “H” – Heating Value of Gas (Btu per Cubic Foot) times

3600. Divide by “T” – the time in seconds at the meter reading.

(Metric) Determine the input by multiplying “F”– Meter Reading (Cubic Meters of Gas) times “H” – Heating Value of Gas (Joules per Cubic Meter). Divide by “T” – the time in seconds of the meter reading.

d. Note: If the meter is not automatically corrected

for temperature and pressure, the meter reading must be corrected to actual conditions during the rate test.

7. Adjustment of Primary Air a. A bag of air adjustment screws is provided with

the boiler, attached to one of the burners with

pilot bracket. b. Primary air adjustment is not normally required. c. If primary air adjustment is needed, insert the

self-tapping screws into the holes located on the

top front of the burners. d. Turn the screws in all the way until yellow flame

tips appear. Turn the screws back out until the

yellow tips disappear.

F. CHECK BOILER CONTROLS

1. Limit and Operating Pressure Controls a. Lower the setting of each control until the

burners shut down.

2. Low Water Cut-offs a. Lower the water level in the boiler to below the

control cut-off level. The burners should shut down.

3. Main Burner Shut-Off Valve(s) a. Close Main Burner Shut-Off Valve(s).

b. The burners should shut down.

4. Check all controls to make sure they function correctly.

5. After all controls have been proven, set the Operating

and Limit Pressure Controls to the pressures desired.

G. CLEAN THE BOILER

1. Clean the boiler as described below no later than

one week after the initial start-up. Cleaning will be more effective if the boiler operates a day or two to loosen sediment and impurities in the system.

2. The boiler must be cleaned to remove any

accumulation of oil, grease, sludge, etc. that may be

in the system. These substances can cause foaming and surging of the boiler water, producing an unstable water line and water carryover to the system.

3. The piping for a skim valve must be done as shown in Section 5, “Pipe the Boiler,” of this manual, with the skim valve mounted off of one of the end riser connections.

4. Connect a 2 inch drain line off of the skim valve, run to a point of safe discharge.

5. Close all valves to the system. Provide a means of continuous fresh water to the boiler for the cleaning process.

6. Use common washing soda (such as Arm and Hammer Super Washing Soda). Mix the soda with water in a 10 quart (9.5 liter) pail and pour into the boiler through the safety valve tapping. Use a proportion of one (1) pound (.5 kg) of washing soda for each 800 square feet (74 m²) EDR net boiler rating.

7. Open the skim valve. Fill the boiler until water begins to flow out the valve.

8. Turn burners on and allow the boiler water to heat up to just below steaming [180 to 200ºF (82 to 93ºC)]. Cycle the burners to maintain temperature during skimming. Do not allow the boiler to steam. Steaming mixes up the contaminants in the water instead of floating them at the surface.

9. Open the make-up water valve to continuously feed water to the boiler. Allow water to flow out of the skim tapping.

10. Continue skimming the boiler until the water flowing from the skim tapping flows clear. This will take some time, possibly several hours for a dirty system.

11. After skimming is complete, close the skim valve and turn off the boiler.

12. Close the make-up water valve and open the boiler blowdown valves.

13. Drain the boiler completely. Then refill and drain again one or two times to make sure all of the soda has been washed out.

14. Restore piping to normal. Pipe a nipple and cap in the skim valve.

15. Note: If the gauge glass becomes dirty again, this indicates more contaminants have worked loose in the system. Repeat the cleaning and skimming process as needed to clean the system.

Rate, Btu/Hr =

F x H x 3600

Rate, Watts =

F x H

Cleaning the boiler requires the use of very hot water and corrosive chemicals. Use care when handling to prevent injury.

WARNING

Do not leave the boiler unattended while firing.

Take great care not to allow the water level to drop below the bottom of the gauge glass or to allow fresh water make-up to flow in too fast. This will avoid the possibility of causing the boiler sections to fracture.

CAUTION

Page 44

LIGHTING INSTRUCTIONS – TYPICAL

A. TO LIGHT THE BOILER

1. These instructions apply only to typical standard control systems (HSP System only). Use the Lighting Instructions supplied with the boiler to be sure they apply to the actual control system used.

2. Set Operating Control to lowest position.

3. Open main line power disconnect switch to boiler.

4. Close Main and Pilot gas shut-off valves.

5. Wait at least five (5) minutes.

6. With Main gas shut-off valve(s) closed, open Pilot gas shut-off valve.

7. Light standing (manual) pilots by depressing the red indicator button on the thermopilot valve. Manually light the pilot and hold the red button long enough for the thermocouple to heat up.

8. Open Main Gas shut-off valve.

9. Set Operating Control to desired setting.

10. Close main line power disconnect switch to boiler.

11. If all limit switches are closed, the spark pilot(s) will light, main gas valves will open and main burners will light.

12. The burners will continue to fire until the Operating Control is satisfied.

B. TO SHUT DOWN THE BOILER

1. Open main line power disconnect switch to boiler.

2. Close Main and Pilot gas shut-off valves.

C. PILOT FLAME FAILURE

1. If flame signal is lost at pilot, the ignition control will shut off the main gas valves and start sparking within

0.8 seconds.

2. The control will continue to spark for 15 seconds.

3. If a flame is not sensed, the control will shut down the pilot gas valve and wait 5 to 6 minutes.

4. It will then start sparking and open the pilot gas valve for another 15-second ignition trial.

5. The control will continue this sequence indefinitely.

6. Refer to Control Envelope supplied with the boiler for the specific system used.

7. Should a flame failure occur, causing a shut down of the main burners, turn off all electric power to the boiler and close Main and Pilot manual shut-off valves. Call a qualified service technician to inspect the boiler and correct the problem.

11. LIGHTING INSTRUCTIONS – TYPICAL

Figure 11.1: Typical Gas Control Train and Base - Single Gas Control Train - Standard Controls

Page 45

OPERATIONS & MAINTENANCE

12. OPERATION & MAINTENANCE

WARNING

Product Safety Information

Refractory Ceramic Fiber Product

This appliance contains materials made from refractory ceramic fibers (RCF). Airborne RCF, when inhaled, have been classified by the International Agency for Research on Cancer (IARC), as a possible carcinogen to humans. After the RCF materials have been exposed to temperatures above 1800°F (982°C), they can change into crystalline silica, which has been classified by the IARC as carcinogenic to humans. If particles become airborne during service or repair, inhalation of these particles may be hazardous to your health.

Avoid Breathing Fiber Particulates and Dust

Suppliers of RCF recommend the following precautions be taken when handling these materials:

Precautionar

y Measures: Provide adequate ventilation. Wear a NIOSH/MSHA approved respirator. Wear long sleeved, loose fitting clothing and gloves to prevent skin contact. Wear eye goggles. Minimize airborne dust prior to handling and removal by water misting the material and avoiding unnecessary disturbance of materials. Wash work clothes separately from others. Rinse washer thoroughly after use. Discard RCF materials by sealing in an airtight plastic bag.

Fir

st Aid Procedures: Inhalation: If breathing difficulty or irritation occurs, move to a location with fresh clean air. Seek immediate medical attention if symptoms persist. Skin Contact: Wash affected area gently with a mild soap and warm water. Seek immediate medical attention if irritation persists. Eye Contact: Flush eyes with water for 15 minutes while holding eyelids apart. Do not rub eyes. Seek immediate medical attention if irritation persists. Ingestion: Drink 1 to 2 glasses of water. Do not induce vomiting. Seek immediate medical attention.

Page 46

OPERATIONS & MAINTENANCE

A. PLACING BOILER IN OPERATION

1. Start up the boiler per the Lighting Instructions shipped with the boiler.

2. Prove the correct operation of all controls on the boiler as outlined below.

3. Check the operation of the ignition and flame proving controls:

a. Electronic Spark-Ignited Pilot System (S8610M

Control)

• With the boiler operating, close the Pilot manual shut-off valve.

• The ignition control should close the main gas valves within 1 second.

• The control will spark and attempt to relight the pilot burner.

• After 15 seconds, the control will shut down and wait 5 to 6 minutes for another ignition trial.

• Open the Pilot manual shut-off valve and restart the boiler per the Lighting Instructions. (Standing pilots will have to be manually relit per the Lighting Instructions.)

b. Electronic Standing Pilot System

• With the boiler operating, close the Pilot manual shut-off valve.

• The ignition control should close the main gas valves within 3 seconds after the pilot goes out.

• After 15 seconds, the control will lock out.

• Open the Pilot manual gas shut-off valve and

re-start the boiler per the Lighting Instructions. (Standing pilots will have to be manually re-lit per the Lighting Instructions.)

4. Check the manifold gas pressure and use a soap suds mixture to check the gas tightness of all gas joints.

5. Test the limit and operating controls to assure they are operating correctly.

6. Inspect and test all low water cut-offs. (Float type controls must be flushed (blown down) weekly to remove any sediment from the float chamber.)

7. Test the pop safety relief valve(s) using the procedure given by the valve manufacturer on the valve tag.

8. Visually inspect the burner and pilot flames.

a. See Figure 12.1.

b. The flame inner cone should be about 1-1/2"

(4 cm) high and should have a very sharp, blue color characteristic.

c. Poor flame conditions can be caused by dirty

burners, obstructed orifices, or incorrect gas pressure.

Figure 12.1: Pilot and Burner Flames

Do not store or allow combustible or flammable materials near the boiler. Substantial fire or explosion hazard could result, causing risk of personal injury, death or property damage.

Do not use this boiler if any part of it has been under water. Immediately call a qualified service technician to inspect the boiler. Any part of the control system, any gas control or any burner or gas component which has been under water must be replaced.

Should overheating occur or the fuel supply fail to shut off: Shut off the fuel supply at a location external to the boiler. Do not turn off or disconnect the electrical supply to the pump. Immediately call a qualified service technician to inspect the boiler for damage and defective components.

WARNING

Page 47

OPERATIONS & MAINTENANCE

B. TO SHUT DOWN THE BOILER

1. Open main line power disconnect switch to boiler.

2. Close Main and Pilot gas shut-off valves.

3. To take boiler out of service if the boiler and system are not to be used when temperatures are below freezing:

a. Drain the boiler and system completely and shut

off make-up water supply.

b. Open main line power disconnect switch to

boiler. Remove the fuses or secure the switch so that the power cannot be turned on accidentally.

c. Do not use ethylene glycol antifreeze in a steam

boiler or system.

d. Be certain that the boiler and system are refilled

before returning to service. Follow the Instructions in this manual and the Lighting Instructions to operate.

C. ANNUAL MAINTENANCE

1. Before the start of each heating season, inspect and make all necessary adjustments to insure proper boiler operation. Use the maintenance and inspection procedures following.

2. Inspect the Venting System

a. Check the chimney or vent to make sure it is

clean and free from cracks or potential leaks.

b. All joints must be tight and sealed.

c. The vent connector must extend into, but not

beyond, the inside edge of the chimney or vent.

3. Inspect the Boiler Area

a. The boiler area must be clean and free from

combustible materials, gasoline or any other flammable liquids or vapors.

b. The combustion air openings and the area

around the boiler must be unobstructed.

4. Inspect boiler flueways and burners for cleanliness. If cleaning is required, use the following procedure.

a. Turn off all electrical power to the boiler.

b. Remove top jacket panels, draft hood and flue

collector.

c. Remove side cleanout panels.

d. Brush the boiler tube spaces both horizontally

(through cleanout openings on ends) and vertically (from top of boiler).

e. Replace the flue collector, draft hood, jacket and

cleanout panels using the procedures given in this manual.

f. Remove the burners and brush the gas ports

lightly with a soft bristle brush.

5. Inspect the boiler base and insulation.

6. Inspect the boiler and piping for signs of leaks. Check to see if there are signs of heavy make-up water addition to the system.

7. When placing boiler into operation, follow Lighting Instructions shipped with the boiler and the instructions in this Chapter.

8. Test the operation of all limit controls, float controls, and ignition components as described in Part A, Placing Boiler in Operation, of this Chapter.

D. MONTHLY MAINTENANCE

1. Inspect the burner and pilot flames as for the annual inspection.

2. Inspect the boiler and system for any signs of leakage or excessive make-up water usage.

3. Inspect and check the operation of the venting system.

E. WEEKLY MAINTENANCE

1. Blow down the float type low water cut-offs and test for correct operation.

F. DAILY MAINTENANCE

1. Inspect the boiler area to make sure the area is free from combustible or flammable materials and that there are no obstructions to the flow of air to the boiler or combustion air openings to the room.

2. Make sure there are no signs of abnormal operation, such as overfilling or leakage.

Be very careful when adding water to a hot boiler. Add very slowly or, if possible, allow the boiler to cool naturally before adding water.

If an excessive loss of water occurs, check for a leak in the piping and correct the problem. Excessive make-up water will cause corrosion and damage to the boiler.

CAUTION

Before servicing the boiler:

• Turn off all electrical power to the boiler.

• Close the Gas Service Valve.

• Allow the boiler to cool if it has been operating.

• Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing.

CAUTION

Page 48

TROUBLESHOOTING – SERVICE TIPS

13. TROUBLESHOOTING – SERVICE TIPS

Problem Possible Cause Suggested Remedy

Defective Thermocouple Replace

Heavy Draft Blowing across Pilot Redirect Air Movement or Eliminate

Plugged Pilot Orifice Replace Orifice

Pilot Outage Check Manual Pilot Valve

Check Main Gas Shut-Off Valve

No Gas

Check Manual Meter Valve Consult Gas Company

Defective Thermopilot Valve Replace

Defective Ignition Control Replace

No Power

Check Power Source with Meter Check Fuses

Defective Gas Valve Replace

Defective Thermocouple Replace

Low Water Level in Boiler Check for Leaks

Main Gas Valve Will Not Open or System Causing Low Water Cut-off to Function Check Feeder (if Supplied)

(Standard Spark-Ignited Pilot System)

Defective Thermopilot Valve Replace

Defective Ignition Control Replace

High Gas Pressure Switch Open Check Switch Setting (if Provided) Check Manifold Gas Pressure

Low Gas Pressure Switch Open Check Switch Setting (if Provided) Check Manifold Gas Pressure

No Power

Check Power Source with Meter Check Fuses

Defective Gas Valve Replace

Relay Locked Out on Safety Check for Pilot Outage

Pilot Out

Relight Pilot (May have defective pilot valve or relay)

Main Gas Valve Will Not Open

Defective Relay Replace

(Electronic Standing Pilot System) Low Water in Boiler Check for Leaks

or System Causing Low Water Cut-off to Function Check Feeder (if Supplied)

Defective Thermopilot Valve(s) Replace

Defective Thermocouple(s) Replace

High Gas Pressure Switch Open Check Switch Setting (if Provided) Check Manifold Gas Pressure

Low Gas Pressure Switch Open Check Switch Setting (if Provided) Check Inlet Gas Pressure

Air Adjustment Screws Turned in Too Far Adjust Screws Out

Low Gas Pressure in Manifold Adjust Main Gas Pressure Regulator (Insufficient Air Injection) or Check Line Pressure

Burner Ports Partially Closed (Rust, Dirt, Lint, etc.) Replace Burners or Clean Ports

Burner(s) Burning with Yellow Flame Check Size of Combustion Air Openings to

Insufficient Air for Combustion Room, if Undersized, Correct as Required

Check for Negative Pressure in Boiler Room

Oversized Burner Orifice Install Correct Orifice

High Gas Pressure in Manifold Adjust Main Gas Pressure Regulator

Insufficient Draft – Chimney Too Low Increase Height or Add Induced Draft Fan

Insufficient Draft – Chimney Too Small Replace Chimney or Add Induced Draft Fan

Gas Spillage from

Insufficient Draft – Blockage in Chimney or Vent Repair Chimney or Vent

Insufficient Draft – Downdraft Caused by

Draft Hood Relief Opening

Chimney Location with Respect to Install Chimney Cap Other Buildings, Roofs, etc.

Negative Pressure in Boiler Room Remove Exhaust Fan (Due to Exhaust Fan or Duct System) or Isolate Fan From Boiler Room

Insufficient Combustion Air Openings

Provide Correctly Sized Combustion and Ventilation Air Openings

Page 49

TROUBLESHOOTING – SERVICE TIPS

Problem Possible Cause Suggested Remedy

Main Gas Valve Opens

Manual Valve Closed at Gas Train Open Valve

But No Gas Flows

Manual Valve Closed at Meter Open Valve

Test Firing Valve Closed (if Provided) Open Valve

Sags in Steam Piping or not enough Pitch Correct Piping Condition

Concentric reducers causing condensate pooling Correct Piping

Drip trap failed closed Replace Trap or Trap Element

Water Hammer On Start-Up

Dry returns wetted due to new boiler water line

Correct Piping or Install Feed System and Traps

higher than old boiler

No drip line on the back side of a back-pitched

Install Drip Line and Trap

motorized valve

Clogged returns on gravity system Clean or Re-Pipe Return Line(s)

Incorrect near-boiler piping causing wet steam

Correct Piping per Manual

to system

Trap failed open, allowing steam to enter returns Replace Trap or Trap Element

{Radiator Hammer} Large radiator may be

Use smaller Air Vent or Use Two Small Vents in

vented too quickly

Place of One Large Vent, One Mounted Higher than the Other

Long nipple at Hartford Loop Replace with Close Nipple

Water Hammer During Mid-Cycle Water leg or back slope in return line to receiver

Correct Piping

tank, causing water pocketing

Trap installed at receiver tank, causing water Remove Trap at Tank, Installing Drip Traps and trapping in return Radiator Traps where Required

Boiler feed pump or condensate pump feed rate

Throttle Flow Rate

too fast, causing spraying into equalizer

No drip on the inlet side of a forward pitched

Add Drip Line and Trap

motorized valve

Uninsulated steam piping, causing excessive

Insulate Steam Pipes

condensate loads

Close nipple on Hartford too high Repipe 2" to 4" (5cm to 10cm) Below Water Line

Water Hammer on Shut-Down

Uninsulated steam piping in boiler room, but system piping insulated, causing vacuum Insulate Steam Pipes condition on shut-down

Hammering in the Boiler

Poor circulation in the boiler due to sludge

Clean and Blowdown the Boiler

accumulation

Main vents not working

Replace Main Vents, Repiping away from End of Lines if Needed

Drip Traps failed closed Replace Traps or Trap Elements

No Heat or Poor Heat Distribution

Radiator traps failed open, allowing pressurization

Replace Traps or Trap Elements

of the returns

in the Building

Water legs or back slope in return lines to receiver

Correct Piping

tank, preventing air from venting out receiver vent

Boiler pressure too high, causing air vents to lock

Reduce Operating Pressure

up or blowing water loop seals

New boiler water content smaller than old boiler

Install Boiler Feed System with Receiver Tank Large enough for Condensate

Boiler water feed rate or pump rate too fast

System or Boiler Overfilling or Flooding causing water level to collapse (due to collapse of Reduce Feed Rate

steam bubbles in boiler water)

Foaming, priming or surging due to poor

Clean the Boiler

water quality

Poor water quality, causing foaming and surging Clean the Boiler

Excessive Water Level Bounce

Incorrect near-boiler piping, such as undersized

Pipe per Manual

or incorrectly placed risers

Boiler water feed rate or pump rate too fast Reduce Feed Rate

Air vents or traps not venting air, preventing steam from getting to radiation and pressurizing Replace Vents or Traps

Rapid Cycling

the air pocket

Pressure differential on pressure control too close Adjust Control Differential

Nuisance outages of water level control due to

See Excessive Water Level Bounce Above

boiler water level bounce

Page 50

BOILER RATINGS & DIMENSIONS

Natural Gas Ratings LP Gas (2500 Btu/cu ft.; 93,000 kJ/m3)

IBR Net Ratings IBR Net Ratings

Input Output Steam EDR Steam Input Output Steam EDR Steam

MBH kW MBH kW Sq. Ft. m2MBH kW MBH kW MBH kW Sq. Ft. m2MBH kW

211A-04 630 185 504 148 1,575 147 378 111 1.333 615 180 492 144 1,538 143 369 108

211A-05 860 252 672 197 2,100 195 504 148 1.333 820 240 656 192 2,050 191 492 144

211A-06 1,050 308 840 246 2,625 244 630 185 1.333 1,025 300 820 240 2,563 238 615 180

211A-07 1,260 369 1,008 295 3,150 293 756 222 1.333 1,230 361 984 288 3,075 286 738 216

211A-08 1,470 431 1,176 345 3,675 342 882 259 1.333 1,435 421 1,148 336 3,588 334 861 252

211A-09 1,680 492 1,344 394 4,229 393 1,015 298 1.324 1,640 481 1,312 385 4,121 384 991 290

211A-10 1,890 554 1,512 443 4,808 447 1,154 338 1.310 1,845 541 1,476 433 4,688 437 1,127 330

211A-11 2,100 616 1,680 492 5,392 501 1,294 379 1.298 2,050 601 1,640 481 5,258 490 1,263 370

211A-12 2,310 677 1,848 542 5,971 555 1,433 420 1.290 2,255 661 1,804 529 5,821 542 1,398 410

211A-13 2,520 739 2,016 591 6,521 607 1,565 459 1.288 2,460 721 1,968 577 6,367 593 1,528 448

211A-14 2,730 800 2,184 640 7,067 658 1,696 497 1.288 2,665 781 2,132 625 6,896 642 1,655 485

211A-15 2,940 862 2,352 689 7,608 708 1,826 535 1.288 2,870 841 2,296 673 7,429 692 1,783 522

211A-16 3,150 923 2,520 739 8,154 759 1,957 573 1.288 3,075 901 2,460 721 7,958 741 1,910 560

211A-17 3,360 985 2,688 788 8,696 810 2,087 612 1.288 3,280 961 2,624 769 8,488 790 2,037 597

211A-18 3,570 1,046 2,856 837 9,238 860 2,217 650 1.288 3,485 1,021 2,788 817 9,021 840 2,165 634

211A-19 3,780 1,108 3,024 886 9,783 911 2,348 688 1.288 3,690 1,082 2,952 865 9,550 889 2,292 672

211A-20 3,990 1,169 3,192 936 10,325 961 2,478 726 1.288 3,895 1,142 3,116 913 10,079 939 2,419 709

211A-21 4,200 1,231 3,360 985 10,871 1,012 2,609 765 1.288 4,100 1,202 3,280 961 10,613 988 2,547 746

211A-22 4,410 1,293 3,528 1,034 11,413 1,063 2,739 803 1.288 4,305 1,262 3,444 1,009 11,142 1,037 2,674 784

211A-23 4,620 1,354 3,696 1,083 11,958 1,113 2,870 841 1.288 4,510 1,322 3,608 1,058 11,671 1,087 2,801 821

211A-24 4,830 1,416 3,864 1,133 12,500 1,164 3,000 879 1.288 4,715 1,382 3,772 1,106 12,204 1,136 2,929 858

211A-25 5,040 1,477 4,032 1,182 13,042 1,214 3,130 918 1.288 4,920 1,442 3,936 1,154 12,733 1,186 3,056 896

211A-26 5,250 1,539 4,200 1,231 13,588 1,265 3,261 956 1.288 5,125 1,502 4,100 1,202 13,263 1,235 3,183 933

211A-27 5,460 1,600 4,368 1,280 14,129 1,316 3,391 994 1.288 5,330 1,562 4,264 1,250 13,796 1,284 3,311 970

211A-28 5,670 1,662 4,536 1,330 14,675 1,366 3,522 1,032 1.288 5,535 1,622 4,428 1,298 14,325 1,334 3,438 1,008

211A-29 5,880 1,723 4,704 1,379 15,217 1,417 3,652 1,070 1.288 5,740 1,682 4,592 1,346 14,854 1,383 3,565 1,045

211A-30 6,090 1,785 4,872 1,428 15,763 1,467 3,783 1,109 1.288 5,945 1,742 4,756 1,394 15,388 1,433 3,693 1,082

211A-31 6,300 1,847 5,040 1,477 16,304 1,518 3,913 1,147 1.288 6,150 1,803 4,920 1,442 15,917 1,482 3,820 1,120

211A-32 6,510 1,908 5,208 1,526 16,846 1,569 4,043 1,185 1.288 6,355 1,863 5,084 1,490 16,446 1,531 3,947 1,157

211A-33 6,720 1,970 5,376 1,576 17,392 1,619 4,174 1,223 1.288 6,560 1,923 5,248 1,538 16,979 1,581 4,075 1,194

211A-34 6,930 2,031 5,544 1,625 17,933 1,670 4,304 1,262 1.288 6,765 1,983 5,412 1,586 17,508 1,630 4,202 1,232

211A-35 7,140 2,093 5,712 1,674 18,479 1,720 4,435 1,300 1.288 6,970 2,043 5,576 1,634 18,038 1,680 4,329 1,269

211A-36 7,350 2,154 5,880 1,723 19,021 1,771 4,565 1,338 1.288 7,175 2,103 5,740 1,682 18,571 1,729 4,457 1,306

211A-37 7,560 2,216 6,048 1,773 19,567 1,822 4,696 1,376 1.288 7,380 2,163 5,904 1,730 19,100 1,778 4,584 1,344

211A-38 7,770 2,277 6,216 1,822 20,108 1,872 4,826 1,415 1.288

211A-39 7,980 2,339 6,384 1,871 20,654 1,923 4,957 1,453 1.288

211A-40 8,190 2,400 6,552 1,920 21,196 1,973 5,087 1,491 1.288

211A-41 8,400 2,462 6,720 1,970 21,738 2,024 5,217 1,529 1.288

211A-42 8,610 2,524 6,888 2,019 22,283 2,075 5,348 1,567 1.288

211A-43 8,820 2,585 7,056 2,068 22,825 2,125 5,478 1,606 1.288

211A-44 9,030 2,647 7,224 2,117 23,371 2,176 5,609 1,644 1.288

211A-45 9,240 2,708 7,392 2,167 23,913 2,227 5,739 1,682 1.288

211A-46 9,450 2,770 7,560 2,216 24,458 2,277 5,870 1,720 1.288

14. BOILER RATINGS & DIMENSIONS

Table 14.1: Boiler Rating Information

Models 211A-38 through 211A-46 Are Certified for Natural Gas Only

Steam Piping Factor

Boiler

Model

Number

Page 51

BOILER RATINGS & DIMENSIONS

Page 52

BOILER RATINGS & DIMENSIONS

Chart continues on page 51.

inch

(Dimensions are approximate)

Intermediate Supply/Return Locations

inch

SERIES 211A STEAM BOILER DIMENSIONS

inch

DEF GH I J KLMNOP

inch

Size

No.

Intermediate

Supply/Return

Boiler

Length

Section

inch

Length & Width Dimensions

AB C

inch

No.

Boiler

Model

211A-04 28¹⁄₈ 714 38³⁄₈ 975 63 160 21³⁄₄ 552

211A-05 33³⁄₄ 857 44 1,118 63 160 27³⁄₈ 695

211A-06 39³⁄₈ 1,000 50¹⁄₄ 1,276 65 165 33 838

211A-07 45 1,143 55⁷⁄₈ 1,419 63 160 38⁵⁄₈ 981

211A-08 50⁵⁄₈ 1,286 61³⁄₄ 1,568 63 160 44¹⁄₄ 1,124

211A-09 56¹⁄₄ 1,429 67⁵⁄₈ 1,718 63 160 49⁷⁄₈ 1,267

211A-10 61⁷⁄₈ 1,572 73¹⁄₄ 1,861 65 165 55¹⁄₂ 1,410

211A-11 67¹⁄₂ 1,715 80³⁄₄ 2,051 65 165 61¹⁄₈ 1,553

211A-12 73¹⁄₈ 1,857 86³⁄₈ 2,194 63 160 66³⁄₄ 1,695

211A-13 78³⁄₄ 2,000 91¹⁄₂ 2,324 63 160 72³⁄₈ 1,838

211A-14 84³⁄₈ 2,143 97¹⁄₈ 2,467 65 165 78 1,981

211A-15 90 2,286 102³⁄₄ 2,610 65 165 83⁵⁄₈ 2,124

211A-16 95⁵⁄₈ 2,429 108³⁄₈ 2,753 65 165 89¹⁄₄ 2,267

211A-17 101¹⁄₄ 2,572 114¹⁄₄ 2,902 65 165 94⁷⁄₈ 2,410

211A-18 106⁷⁄₈ 2,715 120³⁄₈ 3,058 65 165 100¹⁄₂ 2,553 53¹⁄₁₆ 1,348 47⁷₁₆ 1,205

211A-19 112¹⁄₂ 2,858 139¹⁄₈ 3,534 65 165 106¹⁄₈ 2,696 53¹⁄₁₆ 1,348 53¹₁₆ 1,348

211A-20 118¹⁄₈ 3,000 144³⁄₄ 3,677 65 165 111³⁄₄ 2,838 58¹¹⁄₁₆ 1,491 53¹₁₆ 1,348

211A-21 123³⁄₄ 3,143 150³⁄₈ 3,820 65 165 117³⁄₈ 2,981 58¹¹⁄₁₆ 1,491 58¹¹₁₆ 1,491

211A-22 129³⁄₈ 3,286 156 3,962 65 165 123 3,124 41¹³⁄₁₆ 1,062 45 1,143 36³₁₆ 919

211A-23 135 3,429 161⁵⁄₈ 4,105 65 165 128⁵⁄₈ 3,267 41¹³⁄₁₆ 1,062 45 1,143 41¹³₁₆ 1,062

211A-24 140⁵⁄₈ 3,572 166³⁄₈ 4,226 65 165 134¹⁄₄ 3,410 47⁷₁₆ 1,205 45 1,143 41¹³₁₆ 1,062

211A-25 146¹⁄₄ 3,715 172 4,369 65 165 139⁷⁄₈ 3,553 36³⁄₁₆ 919 33³⁄₄ 857 33³⁄₄ 857 36³₁₆ 919

211A-26 151⁷⁄₈ 3,858 177⁵⁄₈ 4,512 65 165 145¹⁄₂ 3,696 36³⁄₁₆ 919 33³⁄₄ 857 39³⁄₈ 1,000 36³₁₆ 919

211A-27 157¹⁄₂ 4,001 183¹⁄₄ 4,655 65 165 151¹⁄₈ 3,839 36³⁄₁₆ 919 28¹⁄₈ 714 28¹⁄₈ 714 28¹⁄₈ 714 30⁹₁₆ 776

211A-28 163¹⁄₈ 4,143 188⁷⁄₈ 4,797 65 165 156³⁄₄ 3,981 24¹⁵⁄₁₆ 633 33³⁄₄ 857 33³⁄₄ 857 33³⁄₄ 857 30⁹₁₆ 776

211A-29 168³⁄₄ 4,286 194¹⁄₂ 4,940 65 165 162³⁄₈ 4,124 2 3 24¹⁵⁄₁₆ 633 28¹⁄₈ 714 28¹⁄₈ 714 28¹⁄₈ 714 28¹⁄₈ 714 24¹⁵₁₆ 633

211A-30 174³⁄₈ 4,429 200¹⁄₈ 5,083 65 165 168 4,267 2 3 30⁹₁₆ 776 28¹⁄₈ 714 28¹⁄₈ 714 28¹⁄₈ 714 28¹⁄₈ 714 24¹⁵₁₆ 633

211A-31 180 4,572 205³⁄₄ 5,226 65 165 173⁵⁄₈ 4,410 2 3 30⁹₁₆ 776 22¹⁄₂ 572 22¹⁄₂ 572 22¹⁄₂ 572 22¹⁄₂ 572 22¹⁄₂ 572 30⁹₁₆ 776

211A-32 185⁵⁄₈ 4,715 211⁷⁄₈ 5,382 65 165 179¹⁄₄ 4,553 2 3 30⁹₁₆ 776 28¹⁄₈ 714 22¹⁄₂ 572 22¹⁄₂ 572 22¹⁄₂ 572 22¹⁄₂ 572 30⁹₁₆ 776

211A-33 191¹⁄₄ 4,858 217¹⁄₂ 5,525 65 165 184⁷⁄₈ 4,696 2 3 24¹⁵⁄₁₆ 633 22¹⁄₂ 572 22¹⁄₂ 572 22¹⁄₂ 572 22¹⁄₂ 572 22¹⁄₂ 572 22¹⁄₂ 572 24¹⁵₁₆ 633

211A-34 196⁷⁄₈ 5,001 223⁷⁄₈ 5,686 65 165 190¹⁄₂ 4,839 3 3 24¹⁵⁄₁₆ 633 22¹⁄₂ 572 22¹⁄₂ 572 22¹⁄₂ 572 28¹⁄₈ 714 22¹⁄₂ 572 22¹⁄₂ 572 24¹⁵₁₆ 633

211A-35 202¹⁄₂ 5,144 229¹⁄₂ 5,829 65 165 196¹⁄₈ 4,982 3 3 24¹⁵⁄₁₆ 633 22¹⁄₂ 572 22¹⁄₂ 572 28¹⁄₈ 714 28¹⁄₈ 714 22¹⁄₂ 572 22¹⁄₂ 572 24¹⁵₁₆ 633

211A-36 208¹⁄₈ 5,286 262 6,655 65 165 201³⁄₄ 5,124 3 3 24¹⁵⁄₁₆ 633 22¹⁄₂ 572 22¹⁄₂ 572 22¹⁄₂ 572 22¹⁄₂ 572 22¹⁄₂ 572 22¹⁄₂ 572 22¹⁄₂ 572 19⁵₁₆ 491

211A-37 213³⁄₄ 5,429 268 6,807 65 165 207³⁄₈ 5,267 3 3 24¹⁵⁄₁₆ 633 22¹⁄₂ 572 22¹⁄₂ 572 22¹⁄₂ 572 22¹⁄₂ 572 22¹⁄₂ 572 22¹⁄₂ 572 22¹⁄₂ 572 24¹⁵₁₆ 633

211A-38 219³⁄₈ 5,572 273¹⁄₂ 6,947 65 165 213 5,410 3 3 19⁵⁄₁₆ 491 22¹⁄₂ 572 22¹⁄₂ 572 28¹⁄₈ 714 28¹⁄₈ 714 28¹⁄₈ 714 22¹⁄₂ 572 22¹⁄₂ 572 19⁵₁₆ 491

211A-39 225 5,715 279¹⁄₂ 7,099 65 165 218⁵⁄₈ 5,553 3 3 19⁵⁄₁₆ 491 22¹⁄₂ 572 22¹⁄₂ 572 22¹⁄₂ 572 22¹⁄₂ 572 22¹⁄₂ 572 22¹⁄₂ 572 22¹⁄₂ 572 22¹⁄₂ 572 19⁵₁₆ 491

211A-40 230⁵⁄₈ 5,858 285 7,239 65 165 224¹⁄₄ 5,696 4 3 19⁵⁄₁₆ 491 22¹⁄₂ 572 22¹⁄₂ 572 22¹⁄₂ 572 28¹⁄₈ 714 22¹⁄₂ 572 22¹⁄₂ 572 22¹⁄₂ 572 22¹⁄₂ 572 19⁵₁₆ 491

211A-41 236¹⁄₄ 6,001 291 7,391 65 165 229⁷⁄₈ 5,839 4 3 19⁵⁄₁₆ 491 22¹⁄₂ 572 22¹⁄₂ 572 22¹⁄₂ 572 16⁷⁄₈ 429 22¹⁄₂ 572 16⁷⁄₈ 429 22¹⁄₂ 572 22¹⁄₂ 572 22¹⁄₂ 572 19⁵₁₆ 491

211A-42 241⁷⁄₈ 6,144 296¹⁄₂ 7,531 65 165 235¹⁄₂ 5,982 4 3 19⁵⁄₁₆ 491 22¹⁄₂ 572 22¹⁄₂ 572 22¹⁄₂ 572 22¹⁄₂ 572 16⁷⁄₈ 429 22¹⁄₂ 572 22¹⁄₂ 572 22¹⁄₂ 572 22¹⁄₂ 572 19⁵₁₆ 491

211A-43 247¹⁄₂ 6,287 302¹⁄₂ 7,684 65 165 241¹⁄₈ 6,125 5 3 19⁵⁄₁₆ 491 16⁷⁄₈ 429 22¹⁄₂ 572 16⁷⁄₈ 429 22¹⁄₂ 572 22¹⁄₂ 572 22¹⁄₂ 572 22¹⁄₂ 572 16⁷⁄₈ 429 22¹⁄₂ 572 16⁷⁄₈ 429 19⁵₁₆ 491

211A-44 253¹⁄₈ 6,429 308 7,823 65 165 246³⁄₄ 6,267 5 3 19⁵⁄₁₆ 491 22¹⁄₂ 572 22¹⁄₂ 572 22¹⁄₂ 572 16⁷⁄₈ 429 22¹⁄₂ 572 16⁷⁄₈ 429 16⁷⁄₈ 429 22¹⁄₂ 572 22¹⁄₂ 572 22¹⁄₂ 572 19⁵₁₆ 491

211A-45 258³⁄₄ 6,572 314 7,976 65 165 252³⁄₈ 6,410 5 3 19⁵⁄₁₆ 491 16⁷⁄₈ 429 22¹⁄₂ 572 16⁷⁄₈ 429 22¹⁄₂ 572 16⁷⁄₈ 429 22¹⁄₂ 572 16⁷⁄₈ 429 22¹⁄₂ 572 16⁷⁄₈ 429 22¹⁄₂ 572 16⁷⁄₈ 429 19⁵₁₆ 491

211A-46 264³⁄₈ 6,715 319¹⁄₂ 8,115 65 165 258 6,553 6 3 19⁵⁄₁₆ 491 16⁷⁄₈ 429 22¹⁄₂ 572 16⁷⁄₈ 429 22¹⁄₂ 572 22¹⁄₂ 572 16⁷⁄₈ 429 22¹⁄₂ 572 22¹⁄₂ 572 16⁷⁄₈ 429 22¹⁄₂ 572 16⁷⁄₈ 429 19⁵₁₆ 491

Page 53

BOILER RATINGS & DIMENSIONS

inch

20ft (6m) high

Vent Chimney

Connector Diameter x

inch

No.

inch

SERIES 211A STEAM BOILER DIMENSIONS

inch

Flue Connection Center Lines Flue Connections

inch

AA BB CC DD EE FF GG HH II JJ Size Diameter

Boiler

Model

No.

inch

211A-04 10⁷⁄₈ 276 10⁷⁄₈ 276 1 12 305 12 305 12 305

211A-05 13³⁄₄ 349 13⁵⁄₈ 346 1 12 305 12 305 12 305

211A-06 16¹⁄₂ 419 16¹⁄₂ 419 1 14 356 14 356 14 356

211A-07 10⁷⁄₈ 276 16⁷⁄₈ 429 10⁷⁄₈ 276 2 12 305 14 356 14 356

211A-08 13³⁄₄ 349 19⁵⁄₈ 498 10⁷⁄₈ 276 2 12 305 15 381 15 381

211A-09 13³⁄₄ 349 22¹⁄₂ 572 13⁵⁄₈ 346 2 12 305 16 406 16 406

211A-10 16¹⁄₂ 419 25³⁄₈ 645 13⁵⁄₈ 346 2 14 356 17 432 17 432

211A-11 16¹⁄₂ 419 28¹⁄₈ 714 16¹⁄₂ 419 2 14 356 18 457 18 457

211A-12 13³⁄₄ 349 22¹⁄₂ 572 19⁵⁄₈ 498 10⁷⁄₈ 276 3 12 305 18 457 18 457

211A-13 13³⁄₄ 349 22¹⁄₂ 572 22¹⁄₂ 572 13⁵⁄₈ 346 3 12 305 19 483 19 483

211A-14 16¹⁄₂ 419 25³⁄₈ 645 22¹⁄₂ 572 13⁵⁄₈ 346 3 14 356 20 508 20 508

211A-15 16¹⁄₂ 419 25³⁄₈ 645 25³⁄₈ 641 16¹⁄₂ 419 3 14 356 21 533 21 533

211A-16 16¹⁄₂ 419 28¹⁄₈ 714 28¹⁄₈ 714 16¹⁄₂ 419 3 14 356 21 533 21 533

211A-17 13³⁄₄ 349 22¹⁄₂ 572 22¹⁄₂ 572 22¹⁄₂ 572 13⁵⁄₈ 346 4 14 356 22 559 22 559

211A-18 16¹⁄₂ 419 25³⁄₈ 645 22¹⁄₂ 572 22¹⁄₂ 572 13⁵⁄₈ 346 4 14 356 23 584 23 584

211A-19 13³⁄₄ 349 25³⁄₈ 645 28¹⁄₈ 714 25³⁄₈ 641 13⁵⁄₈ 346 4 14 356 23 584 23 584

211A-20 16¹⁄₂ 419 28¹⁄₈ 714 28¹⁄₈ 714 25³⁄₈ 645 13⁵⁄₈ 346 4 14 356 24 610 24 610

211A-21 16¹⁄₂ 419 28¹⁄₈ 714 28¹⁄₈ 714 28¹⁄₈ 714 16¹⁄₂ 419 4 14 356 25 635 25 635

211A-22 16¹⁄₂ 419 25³⁄₈ 645 22¹⁄₂ 572 22¹⁄₂ 572 22¹⁄₂ 572 13⁵⁄₈ 346 5 14 356 25 635 25 635

211A-23 16¹⁄₂ 419 28¹⁄₈ 714 25³⁄₈ 645 22¹⁄₂ 572 22¹⁄₂ 572 13⁵⁄₈ 346 5 14 356 26 660 26 660

211A-24 16¹⁄₂ 419 28¹⁄₈ 714 28¹⁄₈ 714 25³⁄₈ 645 22¹⁄₂ 572 13⁵⁄₈ 346 5 14 356 26 660 26 660

211A-25 16¹⁄₂ 419 28¹⁄₈ 714 28¹⁄₈ 714 28¹⁄₈ 714 25³⁄₈ 645 13⁵⁄₈ 346 5 14 356 27 686 27 686

211A-26 16¹⁄₂ 419 28¹⁄₈ 714 28¹⁄₈ 714 28¹⁄₈ 714 28¹⁄₈ 714 16¹⁄₂ 419 5 14 356 27 686 27 686

211A-27 16¹⁄₂ 419 28¹⁄₈ 714 25³⁄₈ 645 22¹⁄₂ 572 22¹⁄₂ 572 22¹⁄₂ 572 13⁵⁄₈ 346 6 14 356 28 711 28 711

211A-28 16¹⁄₂ 419 28¹⁄₈ 714 28¹⁄₈ 714 25³⁄₈ 645 22¹⁄₂ 572 22¹⁄₂ 572 13⁵⁄₈ 346 6 14 356 29 737 29 737

211A-29 16¹⁄₂ 419 28¹⁄₈ 714 28¹⁄₈ 714 28¹⁄₈ 714 25³⁄₈ 645 22¹⁄₂ 572 13⁵⁄₈ 346 6 14 356 29 737 29 737

211A-30 16¹⁄₂ 419 28¹⁄₈ 714 28¹⁄₈ 714 28¹⁄₈ 714 28¹⁄₈ 714 25³⁄₈ 645 13⁵⁄₈ 346 6 14 356 30 762 30 762

211A-31 16¹⁄₂ 419 28¹⁄₈ 714 28¹⁄₈ 714 28¹⁄₈ 714 28¹⁄₈ 714 28¹⁄₈ 714 16¹⁄₂ 419 6 14 356 30 762 30 762

211A-32 16¹⁄₂ 419 28¹⁄₈ 714 28¹⁄₈ 714 25³⁄₈ 645 22¹⁄₂ 572 22¹⁄₂ 572 22¹⁄₂ 572 13⁵⁄₈ 346 7 14 356 31 787 31 787

211A-33 16¹⁄₂ 419 28¹⁄₈ 714 28¹⁄₈ 714 28¹⁄₈ 714 25³⁄₈ 645 22¹⁄₂ 572 22¹⁄₂ 572 13⁵⁄₈ 346 7 14 356 31 787 31 787

211A-34 16¹⁄₂ 419 28¹⁄₈ 714 28¹⁄₈ 714 28¹⁄₈ 714 28¹⁄₈ 714 25³⁄₈ 645 22¹⁄₂ 572 13⁵⁄₈ 346 7 14 356 32 813 32 813

211A-35 16¹⁄₂ 419 28¹⁄₈ 714 28¹⁄₈ 714 28¹⁄₈ 714 28¹⁄₈ 714 28¹⁄₈ 714 25³⁄₈ 645 13⁵⁄₈ 346 7 14 356 32 813 32 813

211A-36 16¹⁄₂ 419 28¹⁄₈ 714 28¹⁄₈ 714 28¹⁄₈ 714 28¹⁄₈ 714 28¹⁄₈ 714 28¹⁄₈ 714 16¹⁄₂ 419 7 14 356 33 838 33 838

211A-37 16¹⁄₂ 419 28¹⁄₈ 714 28¹⁄₈ 714 28¹⁄₈ 714 25³⁄₈ 645 22¹⁄₂ 572 22¹⁄₂ 572 22¹⁄₂ 572 13⁵⁄₈ 346 8 14 356 33 838 33 838

211A-38 13³⁄₄ 349 22¹⁄₂ 572 22¹⁄₂ 572 25³⁄₈ 641 28¹⁄₈ 714 28¹⁄₈ 714 28¹⁄₈ 714 28¹⁄₈ 714 16¹⁄₂ 419 8 14 356 34 864 34 864

211A-39 13³⁄₄ 349 22¹⁄₂ 572 25³⁄₈ 641 28¹⁄₈ 714 28¹⁄₈ 714 28¹⁄₈ 714 28¹⁄₈ 714 28¹⁄₈ 714 16¹⁄₂ 419 8 14 356 34 864 34 864

211A-40 13³⁄₄ 349 25¹⁄₄ 641 28¹⁄₈ 714 28¹⁄₈ 714 28¹⁄₈ 714 28¹⁄₈ 714 28¹⁄₈ 714 28¹⁄₈ 714 16¹⁄₂ 419 8 14 356 35 889 35 889

211A-41 16¹⁄₂ 419 28¹⁄₈ 714 28¹⁄₈ 714 28¹⁄₈ 714 28¹⁄₈ 714 28¹⁄₈ 714 28¹⁄₈ 714 28¹⁄₈ 714 16¹⁄₂ 419 8 14 356 35 889 35 889

211A-42 13³⁄₄ 349 22¹⁄₂ 572 22¹⁄₂ 572 22¹⁄₂ 572 25³⁄₈ 641 28¹⁄₈ 714 28¹⁄₈ 714 28¹⁄₈ 714 28¹⁄₈ 714 16¹⁄₂ 419 9 14 356 36 914 36 914

211A-43 13³⁄₄ 349 22¹⁄₂ 572 22¹⁄₂ 572 25³⁄₈ 641 28¹⁄₈ 714 28¹⁄₈ 714 28¹⁄₈ 714 28¹⁄₈ 714 28¹⁄₈ 714 16¹⁄₂ 419 9 14 356 36 914 36 914

211A-44 13³⁄₄ 349 22¹⁄₂ 572 25³⁄₈ 641 28¹⁄₈ 714 28¹⁄₈ 714 28¹⁄₈ 714 28¹⁄₈ 714 28¹⁄₈ 714 28¹⁄₈ 714 16¹⁄₂ 419 9 14 356 36 914 36 914

211A-45 13³⁄₄ 349 25¹⁄₄ 641 28¹⁄₈ 714 28¹⁄₈ 714 28¹⁄₈ 714 28¹⁄₈ 714 28¹⁄₈ 714 28¹⁄₈ 714 28¹⁄₈ 714 16¹⁄₂ 419 9 14 356 37 940 37 940

211A-46 16¹⁄₂ 419 28¹⁄₈ 714 28¹⁄₈ 714 28¹⁄₈ 714 28¹⁄₈ 714 28¹⁄₈ 714 28¹⁄₈ 714 28¹⁄₈ 714 28¹⁄₈ 714 16¹⁄₂ 419 9 14 356 37 940 37 940

Page 54

REPAIR PARTS – SERIES 211A

15. REPAIR PARTS – SERIES 211A

1 Intermediate Section 50 psig (345 kPa) Working Pressure 90356

2 Left Hand End Section 50 psig (345 kPa) Working Pressure 90625

3 Right Hand End Section 50 psig (345 kPa) Working Pressure 90059

4 Tapped Intermediate Section 50 psig (345 kPa) Working Pressure 90065

5 Tie Rod 2 Required Per Flueway 90090

6 Flow Port Gasket 2 Required Per Flueway 51670

7 Hi Temp Rope for Sections, 5/8" (16mm) 6-1/2 Feet (2 Meter) Required Per Flueway 55723

Base Right End Panel w/Insulation 1 Required Per Boiler GG2112

Base Left End Panel w/Insulation 1 Required Per Boiler GG2113

16-7/8" (429 mm) Wide GG2080

22-1/2" (571 mm) Wide GG2080-1

9 Base Front Panel Sub-Assembly w/Insulation 28-1/8" (714 mm) Wide GG2080-2

33-3/4" (857 mm) Wide GG2080-3

39-3/8" (1 m) Wide GG2080-4

16-7/8" (429 mm) Wide GG2081

22-1/2" (571 mm) Wide GG2081-1

10 Base Back Panel Sub-Assembly w/Insulation 28-1/8" (714 mm) Wide GG2081-2

33-3/4" (857 mm) Wide GG2081-3

39-3/8" (1 m) Wide GG2081-4

For 16-7/8" (429 mm) Wide Panel 50848

For 22-1/2" (571 mm) Wide Panel 50849

11 Base Front or Back Panel Insulation For 28-1/8" (714 mm) Wide Panel 50850

For 33-3/4" (857 mm) Wide Panel 50851

For 39-3/8" (1 m) Wide Panel 50852

12 Base Left/Right End Panel Insulation 1 Required Per Panel 50853

13 Insulation Fastener Specify Quantity Required GG2104

14 Burner Support Channel Clip 2 Required Per Boiler 90590

For 16-7/8" (429 mm) Wide Base Panel 90585

For 22-1/2" (571 mm) Wide Base Panel 90586

15 Burner Support Channel For 28-1/8" (714 mm) Wide Base Panel 90587

For 33-3/4" (857 mm) Wide Base Panel 90588

For 39-3/8

" (1 m) Wide Base Panel 90589

16 Angle Tie Brace Specify Quantity Required 90326

Item

Description Part Selection Information

Stock

No. Code

Repair parts are available from your installer or by contacting PB Heat, LLC, New Berlinville, PA. Use the Figures and Tables on Pages 52-55 to assist in ordering parts.

Note: Remember to include boiler model number and serial number when ordering parts.

Page 55

REPAIR PARTS – SERIES 211A

14-3/4" (375 mm) Wide Base Panel 90316

20-3/8" (518 mm) Wide Base Panel 90318

17 Base Front Panel Cover Plate 26" (660 mm) Wide Base Panel 90320

31-5/8" (803 mm) Wide Base Panel 90322

37-1/4" (946 mm) Wide Base Panel 90324

14-3/4" (375 mm) Wide Base Panel 90317

20-3/8" (518 mm) Wide Base Panel 90319

18 Base Back Panel Cover Plate 26" (660 mm) Wide Base Panel 90321

31-5/8" (803 mm) Wide Base Panel 90323

37-1/4" (946 mm) Wide Base Panel 90325

19 Manifold Weldment Specify Control System

20 Orifice Spud Specify Quantity Type of Gas and Altitude

21 Steel Burner Specify Quantity Required 51045

Steel Burner w/Pilot Mounting Clip Specify w/ or w/o Pilot and Pilot Number 51046

16" (406 mm) Wide 90557

22 Flue Collector 21-9/16" (548 mm) Wide 90558

27-1/8" (689 mm) Wide 90559

For GG-5000 w/ 12" (305 mm) Dia. Outlet 90399

For GG-5000-1 w/ 12" (305 mm) Dia. Outlet 90400

23 Draft Hood

For GG-5000-1 w/ 14" (356 mm) Dia. Outlet 90401

For GG-5000-2 w/ 14" (356 mm) Dia. Outlet 90402

24 Front Flue Collector Hook Bolt 1 Required Per Flue Collector GG5003

25 Black Flue Collector Hook Bolt 1 Required Per Flue Collector GG5004

26 Flue Collector Mounting Bracket 1 Required Per Flue Collector

27 Hi Temp Rope for Flue Collector, 5/8" (16 mm) Specify Quantity in Feet (Meters) Required 55723

28 Cleanout Cover Plate Sub-Assembly Set of 2 90489

29 Hi Temp Rope for Cleanout Cover Plate,

5/8

" (16 mm) Specify Quantity in Feet (Meters) Required 55723

Common End Panel and Cleanout Cover Plate Carton No. 12 90282

Assembly

Carton No. 12A 90283

Carton No. 12B 90284

Intermediate Panel Jacket Assembly Carton No. 12C 90285

Carton No. 12D 90286

Carton No. 12E 90287

Pilot Line Assembly Specify Control System

Pilot Line Support Bracket Specify Quantity Required

Gas Control Assembly Specify Control System

Steam Gauge Steam Boilers Only 51769

Gauge Glass Set Steam Boilers Only 50513

Lighting Instruction Plate Specify Control System

Hi Temp Sealing Cement Specify Quantity of Containers 55726

Spray Adhesive Specify Quantity of Containers 55485

¹⁄₄" O.D. Aluminum Tubing Specify Quantity in Feet (Meters) 718

³⁄₈" O.D. Aluminum Tubing Specify Quantity in Feet (Meters) 719

Item

Description Part Selection Information

Stock

No. Code

Page 56

REPAIR PARTS – SERIES 211A

Figure 15.1: Boiler Assembly

Page 57

REPAIR PARTS – SERIES 211A

Figure 15.2: Base Assembly

Page 58

NOTES

Page 59

211A

Boilers – Steam

Series

Gas

Installation, Operation & Maintenance Manual

TO THE INSTALLER:

This manual is the property of the owner and must be affixed near the boiler for future reference.

TO THE OWNER:

This boiler should be inspected annually by a Qualified Service Agency.

HI Division

of gama

ASME

GG8051 R13 (1/07-2M)

Printed in U.S.A.

PB HEAT, LLC

PO BOX 447 • NEW BERLINVILLE, PA 19545-0447