PeerlessBoilers 211A-04, 211A-05, 211A-06, 211A-07, 211A-08 Installation Manual

...

211A

Boilers – Water

Series

Gas

Installation, Operation & Maintenance Manual

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 AND RETURN PIPING . . . . . . . . . .19

C. LOW SYSTEM TEMPERATURE . . . . . . . . . .21

D. CHILLED WATER SYSTEMS . . . . . . . . . . . .23

E. HIGH FLOW RATE PIPING . . . . . . . . . . . . . .23

F. MULTIPLE BOILER INSTALLATIONS . . . . . .23

6. INSTALL THE JACKET & DRAFT HOOD 27

A. PREPARE THE PARTS . . . . . . . . . . . . . . . . .27

B. APPLY CLEANOUT COVER PLATES . . . . . .27

C. APPLY JACKET END ASSEMBLIES . . . . . .27

D. 211A-04 THROUGH 211A-08 ONLY . . . . . .27

E. 211A-09 AND LARGER ONLY . . . . . . . . . . .27

F. APPLY JACKET TOP PANELS . . . . . . . . . . .28

G. APPLY LOWER END PANELS . . . . . . . . . . .28

H. APPLY PLATES AND LABELS . . . . . . . . . . .28

7. CONNECT GAS PIPING 33

A. INSTALL GAS TRAIN . . . . . . . . . . . . . . . . .33

B. CONNECT PILOT GAS TUBING . . . . . . . . . .33

C. INSTALL VENT AND BLEED PIPING . . . . . .33

D. INSTALL GAS SUPPLY PIPING . . . . . . . . . .34

E. TEST GAS SUPPLY PIPING . . . . . . . . . . . . .34

8. INSTALL CONTROLS AND TRIM 36

A. INSTALL SAFETY RELIEF VALVE(S) . . . . . .36

B. INSTALL BLOWDOWN VALVES . . . . . . . . .36

C. INSTALL LOW WATER CUT-OFF(S) . . . . . .36

D. INSTALL CONTROLS AND TRIM . . . . . . . .36

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 . . . . . . . .41

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

G. PURGE AIR FROM SYSTEM . . . . . . . . . . . .41

H. CHECK SYSTEM PRESSURE . . . . . . . . . . . .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. DAILY MAINTENANCE . . . . . . . . . . . . . . . . .45

13. TROUBLESHOOTING - SERVICE TIPS 46

14. BOILER RATINGS & DIMENSIONS 48

15. REPAIR PARTS - SERIES 211A 52

TABLE OF CONTENTS

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

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

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

⎛ ⎜ ⎝

⎛

⎜

⎝

15 ft

fan

ACH 1000

Btu

Required Volume

fan

⎛ ⎜ ⎝

⎛

⎜

⎝

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

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

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

⎛ ⎜ ⎝

⎛

⎜

⎝

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

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, 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 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 air flow 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. 1/2 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. Make sure the expansion tank and automatic fill valve (if used) are operating correctly. If either of these causes high pressure in the system, the boiler relief valve will weep or open, allowing fresh water to enter the system.

3. Make sure the system controls don’t subject the boiler to excessively low water temperatures, which would cause condensation of flue gases and corrosion of the boiler.

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 Water Installation Survey is available from PB Heat, LLC. The survey will provide information on how a water boiler works with your specific system and will provide an overview of water 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 Water Installation Survey, contact your PB Heat representative or download it from PeerlessBoilers.com.

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

Figure 1.9: Foundation Layout

PREINSTALLATION

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 1019

211A-05 28-1/8 714 33-3/4 857 45-3/4 1162

211A-06 33-3/4 857 39-3/8 1000 51-3/8 1305

211A-07 39-3/8 1000 45 1143 57 1448

211A-08 45 1143 50-5/8 1286 62-5/8 1591

211A-09 50-5/8 1286 56-1/4 1429 68-1/4 1734

211A-10 56-1/4 1429 61-7/8 1572 73-7/8 1876

211A-11 61-7/8 1572 67-1/2 1714 79-1/2 2019

211A-12 67-1/2 1714 73-1/8 1857 85-1/8 2162

211A-13 73-1/8 1857 78-3/4 2000 90-3/4 2305

211A-14 78-3/4 2000 84-3/8 2143 96-3/8 2448

211A-15 84-3/8 2143 90 2286 102 2591

211A-16 90 2286 95-5/8 2429 107-5/8 2734

211A-17 95-5/8 2429 101-1/4 2572 113-1/4 2877

211A-18 101-1/4 2572 106-7/8 2715 118-7/8 3019

211A-19 106-7/8 2715 112-1/2 2857 124-1/2 3162

211A-20 112-1/2 2857 118-1/8 3000 130-1/8 3305

211A-21 118-1/8 3000 123-3/4 3143 135-3/4 3448

211A-22 123-3/4 3143 129-3/8 3286 141-3/8 3591

211A-23 129-3/8 3286 135 3429 147 3734

211A-24 135 3429 140-5/8 3572 152-5/8 3877

211A-25 140-5/8 3572 146-1/4 3715 158-1/4 4020

211A-26 146-1/4 3715 151-7/8 3858 163-7/8 4162

211A-27 151-7/8 3858 157-1/2 4000 169-1/2 4305

211A-28 157-1/2 4000 163-1/8 4143 175-1/8 4448

211A-29 163-1/8 4143 168-3/4 4286 180-7/8 4594

211A-30 168-3/4 4286 174-3/8 4429 186-3/8 4734

211A-31 174-3/8 4429 180 4572 192 4877

211A-32 180 4572 185-5/8 4715 197-5/8 5020

211A-33 185-5/8 4715 191-1/4 4858 203-1/4 5163

211A-34 191-1/4 4858 196-7/8 5001 208-7/8 5305

211A-35 196-7/8 5001 202-1/2 5143 214-1/2 5448

211A-36 202-1/2 5143 208-1/8 5286 220-1/8 5591

211A-37 208-1/8 5286 213-3/4 5429 225-3/4 5734

211A-38 213-3/4 5429 219-3/8 5572 231-3/8 5877

211A-39 219-3/8 5572 225 5715 237 6020

211A-40 225 5715 230-5/8 5858 242-5/8 6163

211A-41 230-5/8 5858 236-1/4 6001 248-1/4 6306

211A-42 236-1/4 6001 241-7/8 6144 253-7/8 6448

211A-43 241-7/8 6144 247-1/2 6286 259-1/2 6591

211A-44 247-1/2 6286 253-1/8 6429 265-1/8 6734

211A-45 253-1/8 6429 258-3/4 6572 270-3/4 6877

211A-46 258-3/4 6572 264-3/8 6715 276-3/8 7020

Table 1.1: Boiler Foundation Layout

A. BASE ASSEMBLY

1. Collect the crates containing the Base Assembly parts. Table 2.1 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) round head machine screws and 1/4" lock washers provided.

ASSEMBLE THE BASE

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-2112 GG-2113 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

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 2.4.

6. Bolt remaining Front and Back Panels together

using 5/16"-18 x 1" (25 mm) 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.

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

secure the front and back panels as shown in Figure

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

8. Complete the base assembly by attaching the Right

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

ASSEMBLE THE BASE

Figure 2.4: Support Bracket Installation

Figure 2.3: Angle Tie Brace Installation

ASSEMBLE THE BASE

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" 1057 211A-08 2EE ——————47-1/4" 1200 211A-09 2BB 2BB —————52-7/8" 1343 211A-10 2CC 2BB —————58-1/2" 1486 211A-11 2CC 2CC —————64-1/8" 1629 211A-12 2DD 2CC —————69-3/4" 1772 211A-13 2DD 2DD —————75-3/8" 1915 211A-14 2EE 2DD —————81"2057 211A-15 2EE 14A —————86-5/8" 2200 211A-16 2CC 2CC 2CC ————92-1/4" 2343 211A-17 2DD 2CC 2CC ————97-7/8" 2486 211A-18 2EE 2CC 2CC ————8'-7-1/2" 2629 211A-19 2DD 2DD 2DD ————9'-1-1/8" 2772 211A-20 2EE 2EE 2CC ————9'-6-3/4" 2915 211A-21 2EE 2EE 2DD ————10'-0-3/8" 3058 211A-22 2EE 2EE 2EE ————10'-6" 3200 211A-23 2EE 2CC 2CC 2CC — — — 10'-11-5/8" 3343 211A-24 2DD 2DD 2DD 2CC — — — 11'-5-1/4" 3486 211A-25 2EE 2EE 2CC 2CC — — — 11'-10-7/8" 3629 211A-26 2EE 2EE 2EE 2BB — — — 12'-4-1/2" 3772 211A-27 2EE 2EE 2EE 2CC — — — 12'-10-1/8" 3915 211A-28 2EE 2EE 2EE 2DD — — — 13'-3-3/4" 4058 211A-29 2EE 2EE 2EE 2EE — — — 13'-9-3/8" 4201 211A-30 2DD 2DD 2DD 2DD 2CC — — 14'-3" 4343 211A-31 2DD 2DD 2DD 2DD 2DD — — 14'-8-5/8" 4486 211A-32 2EE 2DD 2DD 2DD 2DD — — 15'-2-1/4" 4629 211A-33 2EE 2EE 14B 2EE 2EE — — 15'-7-7/8" 4772 211A-34 2EE 2EE 2EE 2EE 2CC — — 16'-1-1/2" 4915 211A-35 2EE 2EE 2EE 2EE 2DD — — 16'-7-1/8" 5058 211A-36 2EE 2EE 2EE 2EE 2EE — — 17'-0-3/4" 5201 211A-37 2DD 2DD 2DD 2DD 2DD 2DD — 17'-6-3/8" 5344 211A-38 2EE 2DD 2DD 2DD 2DD 2DD — 18'-0" 5486 211A-39 2DD 2DD 2EE 2EE 2DD 2DD — 18'-5-5/8" 5629 211A-40 2BB 2EE 2EE 2EE 2EE 2EE — 18'-11-1/4" 5772 211A-41 2EE 2EE 2DD 2DD 2EE 2EE — 19'-4-7/8" 5915 211A-42 2DD 2EE 2EE 2EE 2EE 2EE — 19'-10-1/2" 6058 211A-43 2EE 2EE 2EE 2EE 2EE 2EE — 20'-4-1/8" 6201 211A-44 2EE 2BB 2EE 2EE 2EE 2BB 2EE 20'-9-3/4" 6344 211A-45 2CC 2BB 2EE 2EE 2EE 2EE 2EE 21'-3-3/8" 6487 211A-46 2CC 2CC 2EE 2EE 2EE 2EE 2EE 21'-9" 6629

Table 2.1: Base Front and Back Panel Crates

feet/inches

Overall Length

ASSEMBLE THE BASE

4. Place only the Burners with pilots mounted in the locations given in Table 2.2. Install each Burner 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

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

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 is 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 Rope Adhesive or 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

PLACE THE BOILER SECTIONS

Figure 3.3: Assembling Sections on Base

PLACE THE BOILER SECTIONS

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 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).

9. After all sections are mounted, apply the furnace cement provided between the Base and the bottoms of the sections.

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 one of the tappings 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:

• 75 psig (517 kPa) for 50 psig (345 kPa) sections.

Do not exceed this pressure.

• 120 psig (827 kPa) for 80 psig (552 kPa)

sections. 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.

211A-29

211A-30

211A-31

211A-32

211A-33

211A-34

211A-35

211A-36

211A-37

211A-38

211A-39

211A-40

211A-41

211A-42

211A-43

211A-44

211A-45

211A-46

Boiler Model Number

Place Tapped Intermediate

Sections at Positions

(Numbered Left to Right)

10, 20

11, 21

10, 22

11, 23

13, 25

9, 17, 26

9, 18, 27

13, 21, 29

12, 22, 31

12, 20, 28

8, 16, 25, 33

12, 19, 26, 34

12, 20, 27, 35

7, 14, 22, 30, 37

8, 16, 23, 29, 37

7, 14, 21, 32, 39

7, 14, 22, 29, 36, 43

Figure 3.5: Section Positioning Numbering

Figure 3.5A: Section Position Numbering

Figure 3.4: Align Sections Vertically

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