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

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Page 1

211A

Boilers - Steam

Installation, Operation

Maintenance Manual

PEEI_LESS _

CAST IRON BOILERS

Page 2

Factory Packaged, Hot Water or Steam

43 Sizes 4-46 Sections 630 to 9450 MBH Input 80% Combustion Efficiency

Natural or LP Gas

Natural Draft (chimney) Venting Large Water Content

• Ideal for Steam and Large Volume Hot Water Jobs

Low Profile Design

• Horizontal to Vertical Draft Divel+ter

• Ideal.]br Installations with Low Ceilings

Individual Draw Rods

• For Ease of Assembly

Unique Fie_x-Sea! Flow Port Gaskets

• Injection Molded for SLq)eHor PerJ_)rmance and Flexibtlily

• Assures a Water Tight Seal Betweer_ Sections

• For Ease of Installation

Deluxe Insulated Enameled Steel Jacket

• Reduces Boiler Heat Loss

Tankless Coils

• For Domestic Hot Water Production on Hot Water Boilers

Safety Controls

• Low Water CubOJ]on

Steam Boilers • Honeywell Operating Controls

• Float and Probe Type LWCO on Steam Boilers

• Manual Reset High Limit Control

? • 5' ¸¸

• Tankless Coils.for Hot Water Boilers

• Modulating Firing Systems

• Electronk: Control Systems

• FM and IRI Control Systems

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Peerless Heater Company • 231 North Walnut Street * Boyertown, PA 19512 1021 • 610-367-2153 • www.peerless-heater.com

FA[_ 211A (9/02 3MI

pnrlh (I ,fl U S A

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READ THESE INSTRUCTIONS CAREFULLY BEFORE BEGINNING THE INSTALLATION

[_ STUDY THE CONTROL FOLDER AND CONSULT DRAWINGS

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 Nationa/ Fue/ Gas Code, ANSI Z223.1/NFPA54.

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 Boi/ers, ANSI/ASME CSD-1.

PEERLESS

CAST IRON BOILERS

PEERLESS HEATER COMPANY

231 NORTH WALNUT STREET • BOYERTOWN, PA 19512-1021 • PHONE 610-367-2153

www.peerless-heater.com

THE PREFERRED HEATING CHOICE

Page 4

TABLE OF CONTENTS

1. PREPARE THE BOILER LOCATION 3

ACCESSIBILITY CLEARANCES .................................. 3

COMBUSTIBLE CONSTRUCTION CLEARANCES..... 3

AIR FOR COMBUSTION AND VENTILATION ............. 3

CHIMNEY OR VENT .................................................... 4

BOILER SETTING ........................................................ 6

2. ASSEMBLE THE BASE 7

BASE ASSEMBLY ....................................................... 7

INSTALL THE PILOT BURNERS ................................. 8

3. PLACE THE BOILER SECTIONS 13

PREPARATION .......................................................... 13

PLACING THE SECTIONS ........................................ 13

HYDROSTATIC TEST THE BOILER ......................... 14

4. INSTALL THE FLUE COLLECTOR 15

5. PIPE THE BOILER 17

PREPARATION .......................................................... 17

SUPPLY PIPING ........................................................ 17

RETURN PIPING ........................................................ 17

MULTIPLE BOILER INSTALLATIONS ...................... 19

6. INSTALL THE JACKET _ DRAFT HOOD 21

PREPARE THE PARTS .............................................. 21

APPLY CLEANOUT COVER PLATES ....................... 21

APPLY JACKET END ASSEMBLIES ........................ 21

211A-B4 through 211A-08 ONLY ............................. 21

211A-09 8 LARGER ONLY ........................................ 21

APPLY JACKET TOP PANELS ................................. 22

APPLY LOWER END PANELS .................................. 22

APPLY PLATES AND LABELS ................................. 22

7. CONNECT GAS PIPING 27

INSTALL GAS TRAIN ............................................... 27

CONNECT PILOT GAS TUBING ............................... 27

INSTALL VENT AND BLEED PIPING ........................ 27

INSTALL GAS SUPPLY PIPING ................................ 28

TEST GAS SUPPLY PIPING ...................................... 28

8. INSTALL CONTROLS AND TRIM 30

INSTALL SAFETY VALVES ...................................... 30

INSTALL BLOWDOWN VALVES .............................. 30

INSTALL LOW WATER CUTOUT(S) ........................ 30

INSTALL PRESSURE CONTROLS ............................ 30

9. WIRE THE BOILER 35

CONNECT SUPPLY WIRING .................................... 35

PREPARE REMAINING CONTROLS ........................ 35

INSTALL CONTROL WIRING .................................... 35

10. STARTING THE BOILER 38

CHECK THE PIPING .................................................. 38

FILL THE BOILER ...................................................... 38

STUDY LIGHTING INSTRUCTIONS ......................... 38

RUN PILOT CHECK-OUT .......................................... 38

CHECK MAIN BURNER SYSTEM ............................. 38

CHECK BOILER CONTROLS .................................... 39

CLEAN THE BOILER ................................................. 39

11. LIGHTING INSTRUCTIONS - TYPICAL 40

TO LIGHT THE BOILER ............................................. 40

TO SHUT DOWN THE BOILER ................................. 40

PILOT FLAME FAILURE ............................................ 40

12. OPERATION _ MAINTENANCE

13.

14.

15.

PLACING BOILER IN OPERATION ........................... 41

TO SHUT DOWN THE BOILER ................................. 41

MAINTENANCE - ANNUAL ..................................... 42

MONTHLY MAINTENANCE ..................................... 42

WEEKLY MAINTENANCE ......................................... 42

DAILY MAINTENANCE ............................................. 42

TROUBLESHOOTING - SERVICE TIPS 43

BOILER RATINGS _ DIMENSIONS 45

REPAIR PARTS- SERIES 211A 48

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USING THIS MANUAL

1. This boiler must be installed by a qualified contractor•

E. The boiler warranty can be voided if the boiler is not

installed, maintained and serviced correctly.

1. For new and existing installations, a Steam Installation Survey is available from Peerless Heater Company• 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•

2. 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 Peerless representative.

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.

i. 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. Pay close attention to pipe sizing and

location of risers and returns.

]+This manual provides wlrmg 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 fire controls provided

I. Throughout this manual you will see special attention

boxes intended to supp]enrent the instructions and make special notice of potential hazards. These categories

mean, in the judgment of Peerless Heater Company:

Indicates special attention is needed, but not related to potential personal injury or

property damage.

Indicates a condition or hazard which will or can cause minor

personal injury or property damage.

Indicates a condition or hazard which could cause severe

personal injury, death or major property damage.

Indicates a condition or hazard

which will cause severe personal

injury, death or major property damage.

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1, PREPARE THE BOILER LOCATION

Vent,typcal _ 6j] 6',,

] P,p,ng,Typcal "-_ (3 if''_

II 1]

(:-'--_ Front View C

Figure 1: Clearance Requirements

I 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" between tile

conh'ol manifold and adjacent wall or other appliance

b) For access to draft hood or passage to access the boiler 4

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

c) See Figure 1, Clearances with an "S" are minimum

clearances for service accessibility. 5.

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

a 24" between the front, sides and rear of the jacket

• 6" from steam and hot water pipes

• 6" from vent connector a See Figure I. Clearances with a "C" indicate

minimum clearances from combustible construction•

1. The installation must provide adequate air for

combustion, ventilation and draft hood dilution•

2. Provide air openings as recommended below• The

lower opening provides combustion air and dilution air. The upper opening provides proper air circulation

to control the boiler room temperature and air quality• Without the upper opening, the boiler room

temperature will be too high, causing problems with control operation and life

The boiler room must never be under negative pressure.

Ifexhaust fans or other equipment can cause a negative pressure in the boiler room, the air openings and equipment design must be engineered to assure a neutral or slightly positive pressure in the boiler room at all times of operation If the equipment design and air openings

cannot assure this, then the boiler must be located in an isolated room.

The following recommendations are in accordance with the current edition of the National Fuel Gas Code, ANSI

Z223. I/NFPA54. Ifall air for combustion and ventilation comes from inside

the building (Figure 2), the building must have adequate

TWO AIR OPENINGS:

Minimum Free Area Each - 1 in _per 1000 Btu

at Least 100 in _

BOILER

3" rain

12"max

BUILDING

Aust communicate freely

with outdoors

Must not be under

negative pressure

3" min

[ ; 12" max

Figure 2: Air Openings - All Air from Inside

Building

Page 7

1 :::xll

TWO AIR OPENINGS:

MhlinqLim

Free Area Eacl_

1 in* per 4000 Btu

12" max

Figure 3: Air Openings - All Air Directly

from Outside

provision for outside air to assure the air supply needed

for the boiler room. Provide openings as follows:

• Provide two openings:

--one starting no closer than 3 inches nor further than 12 inches from the ceiling

one starting no closer than 3 inches nor further than

12 inches from the floor

• The openings must be into areas which have unrestricted access to outside air

• Each opening must have a free area (after deduction for louvers) of at least One square inch per 1000

Btu/Hr of total boiler and other appliance input. The openings must never be smaller than 100 square

inches each.

6. If all air for combustion and ventilation comes directly from outside the building:

3" min

_, 12" max

TWO AIR OPENINGS:

Minimum

Free Area Each -

1 in 2per 4000 Btu

• Provide two openings: one starting no closer than 3 inches nor further than

12 inches from the ceiling

.... one starting no closer than 3 inches nor frlrther than

12 inches horn the floor

• If air openings are directly in an outside wall (Figure

3), each opening must have a free opening (after louver reduction) of at least One square inch per 4000 BtuiHr of total boiler and other appliance input.

• Ifairissuppliedthroughverticalducts(Figure4).each

opening must have a free opening (after louver reduction) of at least One square inch per 4000 Btu!Hr of total boiler and other appliance input The cross

sectional area of the ducts must be at least as much as the free area of the openings to which they connect.

TWO AIR OPENINGS:

Minimum

Free Area Each - 1 inzper 2000 Btu

Figure 5: Air Openings- All Air from

Outdoors through Horizontal Ducts

• If air is supplied through horizontal ducts (Figure 5), each opening must have a free opening (after louver

reduction) of at least One square inch per 2000 Btu/Hr of total boiler and other appliance input. The cross

sectional area of the ducts must be at least as much as the free area of the openings to which they connect.

7. Using combustion air dampers: a) If motorized dampers are used on the combustion

and ventilation air openings, wire them such that they must open when the boiler tries to operate.

They must include a switch which prevents the boiler

from operating if they do not open.

Figure 4: Air Openings - All Air from

Outdoors through Vertical Ducts

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

The vent system and installation must be in accordance with Part 7, Venting of Equipment, of the current edition

of the National Fuel Gas Code, ANSI Z223.1/NFPA54, or applicable provisions of the local building codes.

Chimney/Vent Operation: The vent system must be sized and installed to provide the draft needed to remove

Page 8

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.

Failure to provide adequate

venting can result in severe

injury or death.

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 I0 feet above the bottom of the draft hood (relief opening). The vent must also extend above the roof or any obstiructions as outlined in the current edition of the National Fuel Gas Code, ANSI Z223.1/NFPA54 or as required by local codes.

b) Combined vent- breeching:

• The recommended sizing in Section 14, "Boiler

Ratings and Dimensions", in this Manual is based on a minimum chimney or vent height of 20 feet

and a maximum horizontal run of 6 feet 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 6): a) Provide at least a three foot rise in the vent

connection on the boiler.

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

0.02" w.c. measured at the vent connections.

c) Support the weight of the vent system indepently of

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

d) Provide support ofthe vent connector (breeching] at

maximum 12 foot intervals to prevent sagging and to provide a minimum upward slope of I/4" per foot.

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.

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.

Recommendedsizingfor chimneyand connectorsis based on maximum 6 foot connectorlength and

maximumone 90 degree elbow.

Frovidesuppo_for I_lz_taJ secl_s to preventsagging• Slopeve_tconnectorupw_d min 1/4 inch perfoot --

Connlz_tor must notprotrudeinlo chimney •

Boi)erven_c0nnect0r shCuldbeh_ghet

than 0tha:connectedapp_ances

I_Do not obs_ct draft.hood openfn_

Figure 6: Vent Connection

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 orpipe.

f) After it has been determined that each appliance

remaining connected to the common venting system propedy 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/NFPA54. 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

ofthe National Fuel Gas Code, ANSIZ223.1/NFPA54.

Page 9

1 Provid_ a good, levd foundation for the boi]el t_,.n mu

minimum dim_nsKJlm givun m Tahlf ] ThP fluulh _ ,--!

stlLwtura] SklI313olt _,t/stt,t3] RIU_t h( _ qUltdhlL' --

op_,_ating weif_ht o_ thu h_)dc, i dnd any conn_cIcc ....

2. Do not operate thin b()l}_ until the [ounoanon 11nett

concrete, has thoroughly cured• The high ternperuan_- under the burners could cause major lamag_ ln_ concrete if it still contauled moisture.

Do not install this boiler on carpeting or any combustible flooring. A significant fire

hazard would result, with potential for property damage,

personal injury or death.

3. If the boiler is installed in a penthouse or if wiring of any sort is run undumeath the boiler foundation, construc_

the foundation with provision for air flow underneath between the main floor and the' top of me boiisr

foundation.

Concrete block aligned with the openings connected continuously would serve this purpose, for _'xampJe

If the foundation must be a concrete slab. use an air cell high temperature insulating board, at least V_

inch thick, with aluminum backing, aiuminun slou up One half inch Hi Temp millboard with aluminum

backing t_ould b_' acceptable as wall. PlaG, lnu

insulating board on thu slab inside tne 0ase

:z l- O uc z I- :_ Lu {3 I-

z t_

z uJ 2 O -J LU

z < m

Figure 7:

< BASE - 41" •

< JACKET - 45 _,' •

< FOUNDATION - 57 ,'

Foundation Layout

Table 1: Boiler Foundation Layout

Boiler Boiler Base Jackel Foundation Model Length Length Length

2!1A 04 22 I 2 28 1 _ 40 1/8"

211A-05 28 1/8' 33 3/4 45 3/4

711A-06 33 3,4 39 3/_ 51 3 8'

211A-07 39 3/8 45' 57 211A 08 4[ 50 5/8' 62 5 8' 211A-09 50 5/8" 56 l/a, 68 1 4"

211A 10 56 1,,4 61 7/8' 73 7 8"

211A-11 61 7/8 67 1/2' 79 1/2"

211A-12 67 1/2 73 1/8' 85 1/8 211A-13 73 1/8 78 3/4" 90 3/4'

211A-14 78 3/4 84 3/8' 96 3/8' 211A-15 L 84318 90" 1 102

211A-' 6 90' 95 5/8" 107 5/8" 211A-17 955/8 101 1/4' •

1131/4

211A-18 101 1/4- 106 7/8' 118 7 8' 211A-19 1067/8" 1121/2" _ 1241/2"

211A-20 112 1/2 118 1/8' 130 !/8" 211A-21 1181/8 1233/4" [ 1353/4"

211A-22 123 3/4 129 3/8" 141 3 8 211A-23 129 3/8 135" 147

211A-24 135' 140 5/8 152 5 8 211A-25 140 5/8 146 1/a' 158 1/4"

211A-2( 146 1,4 151 7/8 163 7 8'

211A-27 151 7/8 157 1/2" 169 1/2'

211A-28 157 1/2 163 1/8" 175 1/8 211A-29 163 1/8 168 3/4" 180 7/8

211A-30 168 7/8 174 3/8 186 3/8 211A-31 174 3/8" 180' 192" 211A-32 180 185 5/8 197 5/8'

211A-33 1855/8" 191 1/4 203 1/z1' 211A-34 191 lm 196 7/8 208 7/8'

211A-35 l 196 7/8" 202 1/2" 214 1/2'

211A-36 202 1/2' 208 '/8 220 1/8' 211A-37 208 1/8" 213 3/4" ] 225 3/4"

211A 38 213 3 4" 219 3/8 231 3/8" 211A-39 219 3/8" 225" I 237"

211A-40 225 230 5/8 242 5/8 211A-41 2305/8' 2361/4" J 2481/4"

211A-42 236 1/4" 241 7/8" 253 7/8" 211A-43 241 7 8" 247 I/2" 259 1/2" 211A-44 247 1/2' 253 1/8" 265 1/8"

211A-45 253 1/8' 258 3/4" 270 3/4" 211A 46 258 3 ,_ 264 3 8' 276 3/8

Page 10

2. ASSEMBLE THE BASE

]. Co][_'cl the! cr_t_!s _onlaU/ing the 13as_Assemb[_; palts (able 2

shows the qu;_ntit'_ ¸¸at _ac]_ crate r_quired Th_ crates contain the toi)owin9 pa_ts:

Crate i

Right End Panel Sub-Assembly

2 Left End Panel Sub-Assembl r 90339

Burner SUB[ _rt Channe[ 3s 121 Front Panel Sub-Assemo •

Back Panel Sub Assembl

Burner Support'C;nannelha_

2AA Anqle Tie Brace , _ 90340

Front Panel Support Bracket j

Section Assemb y Kit

Front Panel Sub Assemb .

Back Panel Sub-Assemo

Burner SuDi]ort Channe

2BB 90341

Angle Tie Brace

Front Pa_el Suaoort Bracket

Section Assert 3_y r,l[

' Front Panel Sub-Assemb LBack Panel Sub-Assera[3]

BurnerS@port Channel

Front Panel Support Bracket

1 Fsentctl_onAssemb,y Kit

Front Pane SubAssernb .

Back Panel Sub Assemb

Burner SUI]D_/t Channe

2DD _0343

Angle Tie Brace

ronl Paue ._ _..o_ Bracket

Sect on Assertlo _ lYE

Front Panel Sub-Assembl,_

_ Back Panel Sub Assembl z

Items [ Sub-Assembly # Part #

2F E Burner Support Channel 90344

.. An£1e Tie Brace

Front Panel Support Bracket

Section Assemb t Ki{

GG 2105 GG 2106

3G 207( GG-2080 GG-2081 GG-206{

N/A

GG-2069 GG-1030

GG-2080-" GG-2081 -"

GG-2066-"

30 2065 GG 2069

GG-103(

GG-2080-2 GG-208]-2

GG-2066-2

GG-2065 GG-2069

GG-103O-' GG-2080 3

GG 2081 3 GG 2066 3

GG 206._ GG 2069

GG 1030 2 GG-2080-4

GG-208!-4 GG-2066-4

GG-2065 GG-2069

_ GG-1B30-3

2. Op_zn cl_t_' numb*'l 2 t£_mov_, the End P_llc]_ ,,zd

IllOUI]t a _tippor_ ChL_lllle] C]ip toward t}t_ I_al o_ ,:_1_ n

panel as shown in Figure 9 using _"-20 x L,," round humid machine screws and _' lock washers provided

Figure 9: Steel Base Assembly

Figure 8: Boiler Base Assembly

Base BackPanelSub-Assembly,GG-2081 BaseBightEnd PanelSub-Assembly,GG-2105

.... T .......... T== BACK = ='T ......... T ....... T: T

a.S,d0 TOP VIEW Burner Po,ition Number t

RightSide

BurnerSupport Channel,GG-2066 Burner Support Channel Clip, 06-2070

BaseLeft EndPanelSub-Assembly,GG-2106 BaseFrontPanelSub-Assembly,GG-20BO

FrontJacketSupportBracket,GG-2069 AngleTieBracew/Burner SupportChannel,GG-2065(whenrequired)

F.__ NT VI_V ! !1

• Assembly H Assembly b-• Assembly I=-• Assembly I_< Assembly •• Assembly I_• Assembly A B C D E F G

• H(overaHlength) •

41"

Page 11

3. Attach the Front Panel and Back Panel (Figure 9) to the Left Hand End Panel using 5/16" -18 x 1" 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.

_ Front

Jacket •

Panel

Figure 11: Support Bracket Installation

For 211 A-09 through 211 A-46 Only:

a) Attach a Front Panel Support Bracket to each Front

Panel as shown in Figure 11.

Attach an Angle Tie Brace at each panel joint to secure

the front and back panels as shown in Figure i0 using

5/16"48 x 1" cap screws and hex head nuts.

Bolt remaining Front and Back Panels together using

5/16"-18 x I" cap screws and hex head nuts. See Table

2 for panels required. Place the panels in the positions shown in the table and Figure 8.

Complete the base assembly by attaching the Right Hand End Panel using 5/16"-18 x i" cap screws and hex head

nuts.

Set the Burner Support Channels in place as shown in Figure 8.

Check the location of the Burner Support Channels in the Base Assembly. The dimensions should be:

a) Height above boiler foundation: 63/4" b) Distance from back of Base: 33/4"

Remove the Gas Manifold and Pilot Line Assembly from Box Number 7.

Place Manifold on front of Base. Bolt the hangers using 5/16"-18 x 1" long cap screws with 5/16" fiat washers.

See Figure 12.

Front Panel

Angle Tie Brace

3 3/4"

6 3/4"

Figure 10: Angle Tie Brace Installation

Page 12

Overall Length

_r......... 7-

• Assembly I_• Assembly I_• Assembly I_• Assembly I_• Assembly Ib• Assembly I_• Assembly ip A B C D E F 6

Model Overall

A B C D E F G

Number Length 211A 04 2AA 2434 211A O5 2BB -- -- -- 30 3/8"

211A 06 2CC 36' 211A 07 2DD -- 41 5/8"

211A 1)_ 2EE -- 47 1 4'

- - i 27/8

211A-09 2BB 2BB

211A 1 2CC 2BB 58 1'2'

211A 11 2CC 2CC .... 64 1/8

211A 12 2DE 2CC 693,4

] -- 75 3/8"

211A-13 2DD 2DD

ZIIA 14 2EE 2D[ 81"

-- -- _ -- 86518"

211A-15 2EE 2EE 2 ! 1A ] _ ?CC 2CC 2CC 92 ! _4"

21IA 17 2DD 2CC 2CC -- 97 7/8 VllA 18 2EE 2CC 2CC 8 7 ] EllA 19 2DD 2DD 2DD 9"-1 1,'8' EllA d0 2EE ELL 2CC _) 634 211A-21 2EE 2EE 2DD -- -- 10L0 3/8 '' 211A 22 2EE 2LF 2EE I0' 6

211 A-23 2EE 2CC 2CC 2CC -- -- I0'-11 518 211A24 2DD 2DD 2DD 2CC -- 11 51'4

211A-25 2EE 2EE 2CC [ 2CC ] 1 -- 11' 107/8" 211A 26 2EE 2hE 2EE 2BB -- 12" 4 b2'

211A-27 2EE 2EE 2EE I 2CC ] -- _ 12'-10 1/8"

211A-28 2BE 2EE 2EE 2DD 13"-3 :_ 4 '

2EE 2EE 2EE

211A-29 21 IA ,J* 2DD 2DD 2DD 2DD 2CC 14"-3'

211A-31 2DD 2DD 2DD 2DD 2DD -- [ [

14'-85/8'

21 IA ," 2EE 2DD 2DD 2DD 2DD 15-2 1,4'

J 2BE 2EE 2BB 2EE 2EE

211A-33

211A-34 2EE 2EE 2BE 2EE 2CC -- 16" I U2' 21 IA-35 2EE 2EE 2EE 2EE 2DD 16'-7 1/8' 211A-36 2EE 2EE 2EE 2EE 2EL -- 17" 03/4

211A-37 2DD 2DD 2DD 21 IA-38 2EE 2DD 2DD 2DD 2DD 2DD 18' 0"

2EE 2EE 2DD 2DD -- I 18'-55/8'

211A-39 2DD

2DD

21 IA 41 2BB 2EE 2EE 2hE 2E£ 2EE 18' i i I/4 211A 41 2EE 2EE 2DD 2DD 2EE 2EE T -- J

19'4 7/8"

211A 42 2DD 2F[ 2hE 2EE 2EE 2EE 19'-10 1/2' 211A 43 2EE 2EE 2EE 2EE 2EE 2EE 20'4 1/8'

211A 44 2EF EBB 2EE Zhk 2hE 2BB 2EE )' 9 3/4'

21 IA-45 2CC 2BB 2EE 2EE 2EE 2EE 2EE 21'.3 3/8'

211A 41 2C( 2('C 2EL 2FL 2[-E 2EE 2EE 21 9

Table 2: Base Front and Back Panel Crates

Page 13

_ :1II:1/ill: I:f:T_'_

Mounting Clamp

GG-3052thru GG-3052-3

Manifold Weldment

GG-4084 thru GG-4084-46

Orifix_e4A0d3Pter\\ _

Imperial #68F

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

Tube Straight Connector

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

I 1/4" Street Elbow

3/8" Pipe Cap_

Pipe Cap _ 1/4" x 1/8" 1/4" X 1 1/2" Nipple

\\\ Hex Bushing

Ignition Control _ Relay _\

Mounting Box Assembly

(Standard System, HSP-X-3O 11-3) PB-H91 BG-2 or

(Other panels mounted on Imperial #69F Elbow H-V8046C

jacket front, left side) 1/8' NPT x 1/4"O.D.Tubing Pilot Gas Valve

3/8" Pilotstatls)

H17CA

3/8" x I/4" Elbow

(21 5/16"-18 x 3/4" Square

Head Set Screw

Figure 12: Typical Gas Manifold and Pilot Line Assembly

4. Place only the Burners with pilots mounted in the

locations give in Table 3. 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 I/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.

Page 14

Table 3: Pilot Burner Locations-Numbered Right to Left (See Figure 8)

Model Number of

Number Pilots

2ilA-04

NATURAL GAS ONLY

Total

Number Pilot Burnei Locations

of Positions Numbered Right [o Left)

Burners Electronic Pilots Standing Pilots

(Spark Ignited) IThermocouple)

PROPANE GAS ONLY

Pilot Burner Locations

Positions Numbered Right to Left

Electronic Pilots Standing Pilots

Manually Lighted Whermocoupte

211A 05 1 8 5

211A-06 1 10 5 --

"_7 1 1 12 5 I

211A-08 i 14 5

l 211A-09 I 16 5 -- I211A-10 I 18 5 --

[ 211A-11 ,r 2 - 26 15 5

211A-12 2 22 15 5 211A 13 2 24 17 5 13

211A-14 i 2 _26 •. _.....17 5 t 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 211A-19

211A-20 211A 21 211A-22

211A-23 211A-24

5 5

13 5 13 5

3 3

25 [ _ 15

36 29 5.17 38 35 5.21

]

9,19,27

1....... --

9.21.29 _ --

9 21.31 :3 40 {7 5.23 9.23.33 3

42 44

19 5.39 9.23.35 19 5.41 9.23.37

4_ 21 5.39 9 23.39

211A 25 211A-26

211A-27 211A-28

3 48 25 4 50 19

4 52 21

4 54 23

5.45 9.23.41

5.33.47 9.23.33.45

5.35.49 9.23.35.45

5.37.51 9.23.35.47

211A-29 4 56 27

211A-30 4 58 _ 29

211A-31 4 60 31 211A-32 4 62 33

211A 33 4 64 35

211A-34 [ 5 i 66 35

211A-35 5 68 37 211A-36 5 70 37

211A-37 5

2nA-38 [ 5

211A-39 ] 5

211A-40 5 211A 41 6

211A-43 ] 6 211A-44 6

211A-45 6 211A-46 6

72 37 74 25,55

76 I 23,49 78 25,55

80 19,45 82 ! 23,51

84 23,53 86 21,55 88 23,57

90 25,59

5.39.53 9.23.39.49

5.39.51 l 9.21,39,$1 1

5.41.53 9.23, 39, 53 J

9.25.41.55

9.25.41.57

9. 23.39.51.59

39.51.61 1

9. 23.

9.23.39.51.63

9.23.39.51.65

Models 21 IA-38 through 21 IA-46 Are Certified for Natural Gas Only

5.41.59

5.41.61

5.21.49.63

5.17.51.65 5 19.53.67

5.2347.65 5,43,67

5,35,69 5,33, 75

5,33,57,77 5,31,65,79

5,33,67,81 5, 33, 67, 83 5, 37.65.85

5, 39, 67, 87

Page 15

r_ r-

Lo r_

,r-

_O %.

_o o3 O0

A 3/4" npt Tapping

B 1/2" npt Tapping, Upper C 1" npt Tapping, Upper D 1/2" npt Tapping, Lower E 3/4" npt Tapping, Probe LWCO F 1" npt Tapping, Lower

TAPPINGS, EACH END SECTION

G 1 1/2" nptTapping, Back, Blowdown

H 3" npt Tapping, Pop Safety Valve(s) and

Upper Equalizer for Special Float

Controls (157, etc)

J 6" npt Tapping, Steam Riser

K 6" npt Tapping, Return

Figure 13: Assembling Sections on Base

Page 16

3. PLACE THE BOILER SECTIONS

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 I'16".

2 Check the area around the Flow Ports (Figure 14). Use

solvent and a clean cloth to thorougly clean the flat surfaces and recesses• All foreign matter must be

removed to assure a proper seal when the sections are

drawn together•

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.

Flat Machined Recess Machined

Face Face

Flow Port

Gasket

Figure 14: Flow Port Machining b Gasket

I. 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 15.

Figure 15: Placing the First Section on Base

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•

The sections are heavy and

must be supported securely•

Align the parting line of the section with the seam between the Base End panel and the Base Front Panel as shown in Figure 13.

Apply Hi-Temp rope seal by spreading a thin coat of RopeAdhesive 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 _/' beyond the top and bottom.

Place the Flow Port Gaskets in the recesses provided (see Figure 14). Do not use adhesive.

The following steps must be followed to insure that no

damage is done to the tie rod lugs. A 0 100 ft.-Ibs, 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 lugson each section

and app}y 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 16). Make sure they are square with the Base

Page 17

Spirit Level

Left Hand

- " Et_d Section

Base

/ Assembly

Figure 16: Align Sections Vertically

Draw sections together evenly, alternating between

top lug and bottom lug in increments of 20 ft.-lbs. Continu{, until both top and bottom lugs are tightened to 60 It. lbs DO NOT EXCEED 60

FT -LBS

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.

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 13.

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 17A. The placement order is left to right (Figure

17).

Left Hand End Section, Position Number 1

'!f!lf!!f'lI' lF'l'.... i=,

r;,1,,,,, - _ _ _ "

1 3 5 43 45

Figure 17: Section Positioning Numbering

Boiler Model Number

211A ]S

211A-19 211A 2{I

211A-21

211A _7

211A-23

211A 24

211A 25

211A 26

211A-27 211A 28

211A-29

211A 3( 211A-31

211A 32

Place Tapped Intermediate Sections

at Positions (Numbered Left to Right)

iU 10

& 16 9,17

7, 13, 19

7, 1:_ 20

7, 12, 17, 22 5 11,17 23

5. 10. 15.20.25

11. lb. 21.2b

6. 10. 14. 18.22. 26 o. 1] 15.19.23.27

11A- 3 " s.9.la.17Z-£TT-..... 1

211A 34 211A 35

211A 3( 211A-37 211A 38

5 9 13.17 22 26.30

5.9. 13. 18.23.27.31

5 9.13 17. 21 2[ 29.33

5.9. 13. 17.21.25.29.33 q 4 8 12 1722.27.31 35

211A-39 4 8. 12. 16.20.24.28.32:.36_ ] ZllA4( 4 8 12 16.21 25.29.33.37

211A 41 211A-42 211A 43 211A-44 211A45

211A-46

4.8 12 16.19.23.26.30.34.38 a _ 12 16 2023 27 31 35.39

4.- 11.14.18.22.26.30.33.37.40 a - 12 16 19 23.26 29.33 37 41

4.- 11 14.18.21,25,28 32.35.39.42 4 11 14 18 22 25 29 33.36,40,43

Figure 17A: Section Positioning Numbering

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.

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

Provide a water supply line to the boiler. Plug all open tappings in the boiler.

Provide a means to vent air as the boiler fills. Fill the boiler with water, venting air as water level rises.

Pressurize boiler to 45 psig. Do not exceed this

plregsulre

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.

Page 18

4. INSTALL THE FLUE COLLECTOR

1. ColDct the l:lu_' Coikzctor cartons. The Flue Cdlactot sections are ]abal_,d on tile part and on the carton See HiTempRope AngleBracket,

Table 4 for the items needed. GG-50O5

2. Install Hi Tamp Rope for each collector section asshown in Figure 18. The rope provides the seat 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 sea].

3. Place the Flue Collector sections in the positions given in Table 4. These positions are numbered from left to

right when facing the front of the boiler•

4. Fasten an angle bracket, part number GO-5005, to the top of each Collector section with two #10- Vi' sheet

metal screws. See Figure 19.

5. Insert a Long Hook Bolt, part number 00-5003, through the angle bracket Slip the hook end over the tie rod. Apply a W'-20 hex nut on the end of the rod and snug

against the bracket. See Figure 19. Do not tighten yet.

6. Insert a Short Hook Bolt, part number GO-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 V4"-20 hex nut on the Bolt and snug against the flange. See Figure 19. 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.

ShortHookBolt,

6G-5004

Figure 19:

LongHookBolt,

6G-5003

,\ TieRod

\X •

Installing Flue Collector Sections

Figure 18: Applying Flue Collector Hi Temp Rope Gasket

Page 19

Table 4: Flue Collector Section Location (From Left to Right Facing Front of Boiler) - Crates

Crate 14 = Part number GG-5000 Crate 14A = Part number GG-500O-1 Crate 14B = Part number GG-5000-2

Boiler Model

Number

211A-04

Position ! Position

1 2

Position

Position ! Position Position

4 5 6

Position

Position Position

8 9

211A-05 14A

211A-06 , 14B --- -- [ -- ] -- ! ii

211A-08 14A 14 -- - i -- 211A 09 14A t4A

i 211A-11 _/ 14B _/ 14B k -- 1| -- _ Z ,/ -- J/ ---'-- [ --

211A-12 14 : -- -- --

14A i2i1AL13

211A-14 211A-15

21]A-I6

211A I7 211A-18

211A-19 211A 20

14A ! 14A 14A 14A

14B ---14A I 14B 14A

14B 14B

14A 14A 14B 14A

14A 14B 14B 14B

2iiA-21 14B 14B

211A-26

211A-27

211A-28 211A-29

211A-30

14B -- I __ 14A 14A

_4B E 4A L -- 14B i 14A -- --

14B ! i4B

211A23 14B _ i4B 14A _ 14A _ 14A 211A24 14B 14B 14B 14A 14A

211A25 ! i4B 14B IqB 14B 14A

_4B | 14B _4A -_ 14 A [

211A-31

211A 32

, 211A 33 I 211A-34

_211A-35

211A-36 !

14B 1413 14B

14B

14B 14B

14B

211A-37 14B

14B 14B 14B | 14B i4B l 14B l

14B l 14B L 14B L

14A [ -- 14A

m i

14B 14B 14A 14B 14B 14B 14A 14B 14B 14B 14B

14B 14B 14B 14B |I 14B 14B 14B 14B

14B 14B 14B 14A

14A 14A -- i --

-B i I - I -

14B ! 14B I - I - / -

14A 14A 14A !

!4A 14A

14A 14A -- 14B !4A --

14 2 14B

14A 14A 14A 211A-38 211A-39

211A40 14A 14B 14B 14B 14B

i/ 211A-4i 14B i 14B , 14B 14B 14B

2_ii_::ia_;- i_X 1 i4A-I i_g 14B

; 211A_44 14A i4; 14B -- 54B IQB

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

i 2iiA_ i4B 14B

[ I 1

.A I.A 114B .B ].B I.B --

14A 14A 14B L 14B 14B 14B 14B 14B --

14B 14B 14B

14B i4B 14B

14B 14B 1 1413 14B 14B 14B L 14B 14B

14B : 14B 14 2 14B

14B 14B 14B 14B

14B _i 14B i i4B I 14B • 14B ] 14B i 14B _i

Page 20

5. PIPE THE BOILER

1 The boiler must be pressure tested as outlined in

Chapter 3. "Place the Boiler Sections", of this manual

2 TheSupplyandReturnpipingcanbeinstalledbeforethe

jacket is applied. Use nipples long enough to be sure they

will extend through the jacket.

1 Install End Riser connections sized per Table 5. 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 for the number required.

4 Pipe the header at least 24 inches 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 21 shows the Supply and Return piping for

Parallel Fk_w 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 22 for this

special case.

Steam Supply

10.

11.

The piping in [hese 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 23, typical.

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.

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.

Always locate the Steam Supply take-off between the Equalizer and the last Boiler Riser. (See

Peerless Heater Company's "Steam installation Survey" for discussion). Locating the Steam Supply between the risers will cause water carryover to the system.

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

We recommend the use of a Hartford loop in all

installations. The loop provides additional reliability for

the system. A check valve must still be installed on the

pump discharge of all pumped return systems. 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 above the boiler operating pressure. Pumping the

Steam Supply should always be piped between last boiler

riser and equalizer.

BOILER HEADER -

Pipe with offset

to allow for header

expansion

Water

24"

Min.

" " ,.'Useclose YI" "

-- _ --,. nipple on y JJ "

Hartford ,

Loop _! _

" Hartford q-"_

' , Loop

Figure 20: Supply and Return Positions, Skim Piping, Hartford Loop

Page 21

Steam Supply

Return

2" Skim

Connection

211A-04 TO 211A-07

SINGLE END RISER

Second Equalizer

1A-16 and Larger

i ] Steam

_ _Supply

2' Skim

Connection

Offset Header Required to Prevent Damage

to Boiler From Expansion of Header _, Return

E _ 211A-08 TO 211A-17

Second quaL:;ger _ND RISERS

Steam

Supply

211A-18 _ LARGER

TWO END RISERS

PLUS ONE OR MORE

3" INTERMEDIATE

RISERS

Offset Header Required to Prevent Damage to Boiler From Expansion of Header

Return

Figure 21: Supply and Return Piping - Pumped Return and Parallel Flow Gravity Systems

Page 22

Boiler Riser Piping enters TOP of main

on Counterflow System -,_

Counterflow

Steam Main

Pitch

Equalizer

I Figure 24 shows typica{ piping for multiple boiler Gravity

Return systems. Figure 25 shows typical piping for multiple boiler Pumped Return systems•

2. Provide separate feed lines for multiple boiler pumped

return systems• Use eithez 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•

2" Skim Connection

Figure 22: Supply and Return Piping -

Connterflow Gravity Systems

water into the boiler too fast will cause collapse of the water level and level control problems

3. Size the equalizer per Table 5.

4, Pipe the Hadford loop tee so the inside top of the close

nipple is 2 to 4 inches 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.

Figure 23: Left Hand Piping Arrangement -

Typical

Table 5: Header, Risers 8" Equalizer Sizing

il Boiler Header [=--End i:h-sers- ]interm._ Equalizers

I 211A-04 4" . 1 4" - : _ 1 i 2 1/2" ; :_211AL05 5" 1 5" - i - 1 12 1/2"

211A-06::_:5; ] 1 F 5': i :-[---_-[--1 121/2111

L211=_,-_- _" I 1 LEI - / - ! 1 /2t/z '

211A-08 6" 2 4" - - ' 1 2 1/2" I 211A-09 6 2 5 - , - 1 2 1/2

2t_A-lO[ 6" _ 2_:_ : I I 1 I aQ

211A-12 8" 2 5" - i - i 1 3" 211A-13 8" 2 5" _ - - ! I ] 3"

21iA:14 8;i V 2 V 5;', : "q : I " i - 3""

211A-15 8' I 2 1 6' _ -_ - [1 I 3" ]

211A:16 8" ' 2 6" " _ 2 [ 4" i

211A 17 . 8" _ 2 6" 2 4"

211A-19 8" I 2 6" L 3'_1 1 ____[_ I 4"

i 4. i

211A-20 8" _ 2 6" 3" 1 2 F J 211A-21 8" 2 6" 3" 1 2 4"

211A-22 8" I 2 I 6" I 3" 2 2 4"

21_A-2318" _ 2 I 6" I 3" 2 2 4,,

211A-24 t 10'; =: 2 -6" 3" 2 [ 2 4" 2iiA-25 10" 2 i 6" 3" 3 2 4"

21iA:;)61 10" ] 2 I 6;; [ 3" 3- ] 2 4"

L 211A-27 : 211A-28, 10" 2 6" 3" _ 4 i 2 5"

i_HA:29 !9" & i 6' _ 3" _ 2 5':..

! 211A-30 10" 2 6" 3" 5___ .__

211A-32 10 2 6 3" 6/ 2 5

, 211A-33 = 10" 2 : 6" 3" 7 i 2 5" : 211A-34 10" 2 6" 3" 7 2 5';-

: 211A 36 10" 2 6" 3" 8 2 5"

211A-37 _ 10" 2 " 6" 3" 8 2 5"

j21'IA-391 10 L 2 A 6 ! 3 I 9 1 2_ 5'

211A-40 10" 2 21tA41 10" 2 211A-42 : 10" ! 2

i 211A-43 I 10" 2

211A 44 12" 2 211A-45 12" 2

L _

,1211A-461 12" 2

[

6" 3" 9 2 5" , 6" 3" 10 2 5"

6" i 3;' I-3_- 2 [_

6" 3" 11 2 5"

o" 3" 12 2 _"

6. [ 3. I _2] 2 I-g! i

Page 23

Stop Steam

Valve Supply

Pipe All Headers Minimum 24" Above Boiler Water Line

Stop Valve

Stop t Valve

Return

Figure 24: Piping Multiple Boilers, Typical, Gravity Return Systems

Pipe All Headers Minimum 24" Above Boiler Water Line

Steam

stop Supply

Valve

":5

F/T Drip To recover

Trap

Valve

;olenoid or Motorized Valve

Boiler Cock for ThtotBing

Pump Pressure to Boilers

CheckValve TO Pump

Alternate Piping: Use two separate pumps, separate return lines and no solenoid valves

Figure 25: Piping Multiple Boilers, Typical, Pumped Return Systems

Page 24

6. INSTALL THE JACKET 8 DRAFT HOOD

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

2. See Figure 27 for the Jacket Assembly. Use these drawings for part identification and location.

3. See Figure 28 for the quantity of each carton required and placement of the jacket sections on the boiler.

4. See Table 6 for the contents of each Jacket Carton and Draft Hood carton.

5. See Table 7 for the Draft Hood cartons required.

i. Remove Cleanout Cover Plates from carton 12.

2. Install one cover plate on each End Section. Use four 5/16"-18 x 2" studs, 5/16"-18 hex nuts and 5/16" fiat

washers.

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

sections.

I. 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 Vi' sheet metal

screws,

3. Attach the four Corner Panels to the Base Ends using i. I/4-20 x V/' machine screws and V4" fiat washers. The

locations are: 2.

• Right Front- GG-6015

• Left Front GG+6016

• Right Rear GG-6017 3

• Left Rear GG-6018 4.

4. Attach an End Panel Cover Plate (GG 6030) to the opening on the Upper Left End Panel ifthe 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 V/' sheet metal screws

6. Place Top Left End Panel (GG-6020) over the Corner Panels and Upper Panel with flange pointing downward.

Use four #i0 x _/2"sheet metal screws.

7. Repeat for the Right End.

I. Apply Front and Rear Panels as follows.

2. Open Jacket Intermediate Section carton. 12A, B, C, D

or E, per Table 6. Remove necessary knockouts from

panels.

Inselt Front Panel (GG 60231 flange (on light side of panet) 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 _,z'"sheet metal screws.

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 _'>" sheet metal

screws.

Apply the Lower Rear Panel using the same procedure and secure with two #10 x !/_" sheet metal screws.

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 _//' sheet

metal screws.

Attach the Lower Rear Panel Guide (GG-6031} to the Rear Base Panel as shown in Figure 27.

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 7. Attach the

Hood sections to the Flue Collector with two #10 x _//' sheet metal screws per collector section.

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 9/' sheet metal screws.

The boilers have multiple intermediate jacket panels.

Collect the jacket cartons listed in Table 6. When installing the jacket panels, place them on boiler in the order shown in Figure 28.

Open the cartons in the order listed in Figure 28.

Install the Jacket Front Panels:

• Make sure to slip the Front Panels into the Front Panel

Support Brackets (mounted on the base). See Figure 27. Install the first Front Panel with the left edge over the

Left Front Corner Panel. Line up the holes and secure

with #10 x Vi' sheet metal screws.

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 V_"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 #I0 x Vi' sheet metal screws

• Attach the first Lower Rear Panel inthe 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 _ sheet metal screws.

Page 25

• InstallaPanelSupportAngleontheinsidetopofthe 5. UpperRearPanel(SeeFigure27).Use#I0 x _/"

sheetmetalscrews.

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

• Place the edge of the last rear panel ow, i 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 2.

given in Table 7. 3

• Use two #i0 x Vi' sheet metal screws for each Flue Collector section.

I. 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 28.

2. Mount a Panel Support Angle (GG-6027) on the back bottom edge of each Top Panel with the long flange pointed down. Peal the insulation slightly away from the back edge of the panel for better contact. Secure with one

#I0 x _" 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 Vi' sheetmetal screws.

4. Slide the left hand edge of each additional panel under the panel to its left. Secure with #I0 x _zi' sheet metal

screws.

Apply the last Top Panel in the same way. Place its right hand edge over the Top Right End Panel. Secure with

#i0 x Vi' sheet metal screws. Check for loose or missing screws as you complete the

jacket assembly

THIS APPLIES TO ALL BOILER SIZES.

The parts are packed in carton # 12. 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 V/' sheet metal

screws.

Apply a Lower End Panel to each end of the boiler. securing to the Corner Panels with eight #i0 x _/z"sheet

metal screws Attach to the Upper End Panels with two #10 x V./' sheet metal screws.

I. Mount Boiler Rating Plates, Agency Plates and Caution

Labels on the Upper Right End Jacket Panel.

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

3. Place these plates as shown in Figure 26.

4. Secure metal plates with #6 x V4" sheet metal screws. Apply all adhesive-backed labels.

Figure 26: Location of Rating, Agency and Instruction Plates on Upper Right End Panel

Page 26

Top Panel (GG-6024) Right End Panel

(GG-6019)

Top Left End Panel (GG-6020)

Upper Left End Panel (GG-6032

Lower End Panel (GG-6022)

I_ Front Panel

(GG-6023)

Right Front

Corner Panel

(GG-6015)

Corner Panel

Support Bracket (GG-6029)

Cleanout Cover

Plate Assembly (GG-60O4)

Draft Hood (GG-50Ol

Left End Corner Panel (GG-6016)

-- Front Jacket Panel Support Bracket

(GG-2069)

Top Panel (GG-6024)

Panel Support Angle

(GG-6027)

Right Rear Corner Panel (GG-6017)

Upper Rear Panel -- (GG-6025)

Lower Rear Panel Guida (GG-6031)

Lower Rear Panel (GG-6026)

Rear Panel Support Leg (GG-6028)

End Panel Cover Plate GG-6030

j-/

/- Left Rear

Corner Panel

(GG-6018)

Figure 27: Jacket Assembly

Page 27

• ' ,.::1 • '_._ oo_

Table 6: Jacket and Draft Hood Carton Contents - See Figure 27 for Placement of Jacket Sections

Ca_on No.

12A

Contents

' Cleanout Cover Plates

Jacket Corner Pane!, Right Front

Jack_'t Cumin Pan_'! Leit Front

Jacket Corner Panel. Right Rear Jacket Corner Panel, Left Rear

Corn_i Pan_l Support Brackets

• Jacket Upper End Pane!. Left Jacket Upper End Panel, Right

End Pane! Cover Plates Jacket Lower End Pane!s

Sheet Mete! Screws Machine Screws, Washers. Nuts

Jackefl l_ermediate Panel - Front 1 Jacket Intermediate Panel _

Jacket IntermP&ate Pane!- Upper Rear I Jacket Intermediate Panel Lower Rear

Panel Suppor_ _Angle Rear Panel Sup_o_ l_fl

Lower Rear Panel Guide Sheet Metal Screws

Sub-Assembly No. Part Number Quantity

GG-6004 1_ I

GG-6015 I

G(J 6016 l GG-6017 r 1

[ ....

GG-6018 _ 1 I

GG 6033 GG-6029 4

GG 603Z 1

_21 _ i -

GFG 6-6o3o 14-............z

, GG 6022 2

.... GG-6023GG_6024 A]il .......

GG 6025 1

GG-6034 GG-6026 I

GG-6027 [ 2

GG-6028 1 | GG 6031 1

...... J_acket Intermediate Panel - Fron-( ...... 0G-6023-I [ -i ...........

Jacket Intermediate Panel-To_ _ _ 1

Jacket [ntermedlate Panel - Upper Rein GG-6025 I I _I-- ....

12B Jacket Intermediate Panel Lower Rear GG-6026-I 1

Panel Suppor_ Angle GG-6034-1 _ GG-6027 I 2 Rear Panel Support Leg G[GG-6028 _ I

Lower Rear Panel Guide _,o-6031 1

[ +

Sheet Metal Screws .... 23

Jacket Intermediate Panel - Front Jacket Intermediate Panel - To_

Jacket Intermediate Panel - Upper Rear Jacket Intermedmte Panel - Lower Rear

12C Panel Support Angle GG-6034-2

Lower Rear Panel Grade Sheet Metal Screws

Jacket Intermediate Panel - Front Jacket Intermediate Panel - Top

Jacket Intermediate Panel - Upper Rear Jacket Intermediate Panel Lower Rear

12D GG 6034 3

Panel Support An_te

Rear Panel Support Lower Rear Panel Guide

Sheet Metal Screws

Jacket Intermediate Panel- Front

Jacket Intermediate Panel- Top

Jacket Intermediate Panel - Upper Rear Jacket Intermediate Panel Lower Rear

Lower Rear Panel Guide Sheet Metal Screws

Draft Hood Section

Sheet Metal Screw_ Draft Hood Section

13A ...... j She_ Met_ Scre_ ......

Draft Hood Section

13B

Sheet Metal Screw_

I Sheet Metal Screws

GG-6023-2 _ I

_2 I_ ___

GG 6025-2 i

GG-6026 2 GG-6027

GG-6028 GG-6031

GG-6023-3 GG-6024-3

GG-6025 3 GG-6026-3

GG_027 GG-6028

GG-6031

GG-60234

, 1

1 1

' 1

GG 6025-4 1

' 1

GG-6028

GG-6031

GG-5001

GG 5001

I 23

GG-5001-1

GG-5_I-I

GG-5001-2 1

..... ....

Page 28

Boiler

Model

Number

of Ca_ons

1 3 5 7 9 11 13 15 17 19

21 23 25 27

2iiA-O4 1 r ] F I A 211_ 1 L_ _ B

2! 1A 06 1 C 211A-07 1 D

211A-08 E 211A-09 B

211A-10 1 1 B 211A-1! 15

29 31 33

35 37 39 41 43 45

A I

A' !

Figure 28: Jacket Assembly Sequence - Carton Numbers and Locations

_J7

Page 29

Table 7: Draft Hood Section Placement (from Left to Right Facing Front of Boiler)

ModeIB°ilerli Position , Position2 Position3 Position4 Position5 Position6 Position7 Position8 Position9

211A 04 13

211A 05

=211A-06 [ 211A-07

! 2uA-os

L211A709 _ 13A ii 211A-10 13C

!i 211A-!! 13C i 211A-12 13A

, 211A 13 13A

211A-14 I 13C

211A-16 13C

13A

; L

13 13A , 13B "

13A 13 13A ! 13A

13B 13B l

13B 13C 13C 13C

211A-17 13B 13B 13B 211A-18

211A-19 211A-20 !

211A-211 211A-22 211A-23

13C

13B 13C

13C 13C 13C 13B

13C 13C

211A 24 13C 13C

211A-26 13C 13C 211A-27 13C 13C 211A-28 13C 13C

[

13B

13B 13B 13B 13C 13C 13B |

13C 13C 13B

13C 13C 13B 13B

13B 13B 13C 13B

13C 13C

13B 13B 13C 13B

i i

!-, i i

13B

13B 13B

13B 13C [

13B 13B I

13B 13B 211A-29 211A-30

211A-31 211A 32 211A-33

211A-34 211A45

13C 13C 13C 13C 13C 13C

13C 13C 13C

13C 13C 13C 13C 13C 13C

211A-38 I 13B

211A-39 13B 211A-40 13B 211A-41 13C

211A-42 13B 211A-43 13B

! 211A-44 13B

211A-45 13B

211A-36 : 13C 13C i 211A-37 13C i 13C

13B

13B 13C 13C

13B 13B

13B

13C

13C 13C

13B 13C

13C 13C 13B

13B

13C

13C 13C

13C

13B 13B

13C 13C 13C 13C

13C 13C 13C i 13B

13B 13B

13c 13cL

13B 13B 13B 13B

13C 13C

13B

13B 13C

13B 13B 13C I 13C

13c j 13c

13C 13C

13B

lac

13C

13C 13C

13C 13C 13C 13B 13C 13C 13C 13C 13C

13C 13C 13C 13C 13C 13C

13C 13C 13C 13C13C 13C

13C 13C 13C 13C 13C 13C

I i3d i

i 211A46 I 13C 13C _ 13C [ 13C _ 13C I 13C _ 13C 7 13C

Page 30

7. CONNECT GAS PIPING

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

s Has been factory assembled and tested for tightness

of joints,

• Mustbere-testedafterinstallationwithasoapsudstest 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 29

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.

I. 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

3) to the Pilotstats.

c) Install thermocouples in the standing pilots and

connect to the Pilotstats

1. Gas Pressure Regulator

a) Connect regulator vent outlet to outside atmosphere

using V4"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.

Vent lines separately. Connect Valve Bleed

line to bleed line to a standing pilot (when

supplied) or outside if required by local

codes

21 11 6 _---5

3 2 14

_1 15

1 _14

1 Pilot Gas Pressure Regulator

2 Pilot Cock 3 Line Gas Pressure Test Tapping

4 Pilotstat (One per Standing Pilot) 5 Red Pilotstat Indicator Button

6 PiiotGas Valve (One per Spark:ignited Piioti 7 Pilot Gas Line

8 Pilot Tubing, 3/8" OD Aluminum 9 Electronic Pilot (Spark Ignited), Typical

10. lgnit!gn/Sensing Cable to Pilot, Typical 11 i Electronic Pilot Ground Wire, Typical

12 Standing Pilot (Manually Lighted), Typical 13 Thermocouple to Standing Pilot, Typical

14 Manual Shut-Off Valve 15 Gas Pressure Regulator

16 Regulator Vent Line to Outside Atmosphere 17 Safety Gas Valve, Standard

18 Main Gas Valve, Standard 19 Gas Valve Bleed Line to Outside Atmosh #.

20 High Gas Pressure Switch (Over 2500 Btuh) 21 Ignition Control Panel

Figure 29: 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 31

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 _'F tubing or as required by local codes Always

pipe the bleed lines separate from the regulator vent

lines

When piping bleed lines to outside, terminate the tubing downward to prevent water from entering the

tubing, and protect the tubing teimination from any

obstruction. Terminate the tubing above and wel}

away from normal breathing level or building air intakes

To Gas Supply -_

Service Valve -_

Ground Joint Uni_i_

To Boiler Gas Control Train "n_

Sediment Trap _'_JT; !

Figure 30: Gas Supply Connection to Boiler

Size the piping as required by the National Fuel Gas Code. ANSI Z223 1,_FPA54 or as required by local

codes

a) Use Table {4 for sizing of natural gas for a system

pressure drop of 0 3 inch water column

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

The Minimum gas supply pressure is listed on the Boiler

Rating Plate. Make sure the system regulator and the piping are sized and adjusted properly to provide this pressure under all conditions.

Install a Service Valve. Sediment Trap and Ground Joint Union at the supply connection to the Gas Control Train as shown in Figure 30. These are not supplied with the

boiler. Install them in accordance with local codes.

Use only pipe joint compounds rated for use with Liquefied Petroleum Gases.

1. ISOLATE THE BOILER GAS CONTROL TRAIN FROM

THE SYSTEM DURING TEST: a) Test pressure _/bpsig or less - Close the Manual

Shut-Off Valve on the Boiler Gas Control Train

b) Test pressure over _/5psig 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.

Page 32

Table 8: Capacity of Gas Supply Pipe in Cubic Feet Per Hour of Natural Gas for 0.3 inch Drop

Pipe Length 1 V4"

(Feet) Pipe

1 1/2" Pipe

2_9

Pipe

21/2" 3" 4" 6"

Pipe Pipe Pipe Pipe

J 1

1(} 1050 1600 3050 4800 8500 17500 44000

_o _o ' ,,oo _!00 _3o0 5oo_I i_oooi[3,o0o

30 590 890 1650 2700 4700 9700 I

25000

4o 500 ! 145o1 I 4,0o 22oo0

50 440 670 1270 2000 3600 __1 7400 / 20000

T ........... t- [ --

60 , 4;0 ;]; _ 1150 _ 1850 J. 32;0 + 6800

1050 1700 3000 i 6200

[

490 930 1500 2600 5400

460 ' 870 1400 2500 i 5100

380 710 1130 2000 4i00

70 350 560

90 I 320

100 305

150 250

18000

17000

15000

14000 "

11500 ,:

............... J

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

--==SpecificGra;iU=_ 0.50 i_:55 i ] ;:6; ] 0.65 Multiply Capacity by: 110 1.04

....... i =

1.00 .962

0.70

.926

Page 33

8. INSTALL CONTROLS AND TRIM

1 Pipe the Pop Salety Valve(s) in the 3"" tappings located 1

on the right or left end sections Make sure the relief valve sizing meets local code requirements• 2.

Pipe the discharge of the Safety

Valve away from any traffic area,

preferably to a floor drain. This ts necessary to prevent injury

should the valve discharge. Pipe the discharge full size of

valve outlet.

1. [nstall a I V2" full port ball valve in each of the tappings

provided at the lower back of the end sections. See Figure 31

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

Install Boiler Pop Safety Relief

Valve(s) in 3" End Section Tapping(s)

Pipe Safety Valve Discharge

to safe location, preferably to

a floor drain

2" Skim

Connection

12) 1 W' Blowdown Valves

ip off

Figure 31: Blowdown Valve Piping

Mount the float type Low Water Cutout and Gauge Glass in the tappings provided in the front of either end section.

Do not apply piping which would raise or lower the location of the cutout relative to the tappmgs in the boiler. Raising the water level over the design height will cause water carryover to the system.

For correct location of typical low water cutout!feeder or low water cutout/pump control, see Figures 33 through

36. Mount the probe type low water cutout supplied with the

boiler. The end sections have %" tappings in the front for mounting the probe low water cutout auxiliary control. See Figure 13.

a) The standard probe control is either the Hydrolevel

Model 650P or McDonnell & Miller Model PS850. These controls are automatic reset type.

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

can be supplied with either the Hydrolevel Model 550P or the McDonnell & Miller Model PS850M.

Provide each float low water cutout 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. Maintain a height of 40 Vi' from boiler foundation to the

normal water level. 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.

Pipe the Steam Pressure Gauge and Boiler Lim:,t and Operating Pressure Controls as shown in Figure 32. Connect the control assembly to the Vi' tapping on the

right end of the boiler.

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 (trap servicing, control replacements

or other).

Page 34

Option 1

Option 2

B C D E F

3/4" X 3/4" X 1/4" Reducing Tee 3/4" Cross

3/4" Plug 3/4" x 1/2" Hex Bushing 3/4" x 1/4" Hex Bushing

1/4" x 3" Brass Nipple

G H

J K

3/4" x 3" Nipple 3/4" x 4" Nipple

3/4" x 5" Nipple

1/2" x 6" Brass Nipple

Steam Gauge

Pressuretrols

(Right Hand Shown, Left Hand Opposite)

(NOTE: Some local codes may require larger piping)

Figure 32: Pressure Control Piping (Fittings Included with Boiler)

Page 35

• t_lli_ -*_1_1JflhV_l

Burner Cut-Off Level --

1/2'_

Conduit

Connection

........... l.-|

8 1/2"

Water Line

1 3/4" ]_

f ......... 2"-

Figure 33: Standard Float Type Control, Model 67PE2

Figure 34: Optional Feeder/Low Water Cutout, Model 47-2 - Used Only on Models 211A-04

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

Page 36

12"

Burner Cutoff Level

(Mark on Casting)

Normal Water Line :

12 5/16"

Boiler Foundation

Install 1" Blowoff Valve

SUGGESTED FII-rlNGS LIST

A 1" Cross F 1" x 6" Nipple B 1" Ground Joint Union G 1" x 8" Nipple

C 1" Plug H 1" x 8 1/4" Nipple

D 1" x 2" Nipple J 1" x 14" Nipple E 1" x 3" Nipple K 3" x 1" Bushing

The connected fittings shown on this drawing are

to be supplied by the installer,

Figure 35: Optional Float Type Pump Control/Low Water Cutout, Model 157

Page 37

.i_ C

A H F

_' 4 1/8" -_ 8 1/8"

Normal Water Line

2 n

-. -

! • 3/4"

40 1/2"

12 7/8"

I' Boiler Foundation

Control Center Line

Feeder Closing Level (Mark on Casting)

Burner Cut4Off Level is 1 1/2" Below

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

(2 3/4" Below Normal Water Line)

D D

l, B

install 1" Biowoff Valve

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 FII-rlNGS LIST

B C D E

F G

H J

1" Cross 1" Ground Joint Union

1" Plug 1" x 3" Nipple 1" x 5 1/2" Nipple 1" x 8" Nipple 1" x 8 1/4" Nipple 1" x 19 1/2" Nipple 3" x 1" Bushing

The connected fittings shown on this drawing are

to be supplied by the installer.

Figure 36: Optional Feeder/Low Water Cutout, Type 51-2

Page 38

9. WIRE THE BOILER

1 All wiring must be done in accordance with local codes. 1

the National Electrical Code and other controlling agencies or governing bodies 2.

The boiler 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.

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 dectricaljunction box on the boiler Front Panel for connection of supply wiring and distribution to the boiler controls. See Figure 37.

Mount th_ conlrol transforma on the ]umlion box as shown in Figure 37

Mount a iunction box near each Gas Control Train for connection of conduit and wiring distribution to the gas

train components

Wire the boiler according to the wiring diagram supplied with the boi}er (in the Control Envelope). Figure 37 is a typical layout of the components on the boiler. Figures 38 and 39 are examples of standard wiring systems. Use these drawings for general reference only.

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.

Install all line voltage wiring in conduit• Do not install single pole switches, including safety

controls, in a grounded line.

Probe Type Low Water Cutout

Float Type Low Water Cutout

- u

• •.•/ •

. "x

/-/ x_

120-V/60hz Power

Transformer, 120v/24v

Operating and Limit

Pressure Controls

Gas Pressure Regulator

Control Box

Main Gas Valves

Pilot Gas Valve

High Gas Pressure

Switch (when req'd)

Figure 37: Typical Control Layout and Wiring

Page 39

120v/60hz (_)

Neutral

120 V'dO hz HOT

High Gas Pressure | Switch (H C645B)

(Modeis211A 13 = :_1_i I

Through 211A 18) Flame Rollout

Switch _l_ (When Req'd)

Float Type LowWater C_ \

Cutout _ i Spill Switch

(When Req'd) _ ,_

Operating Pressure r_ ' Control L/ _ J

Additional

Limit Switches (When Req'd)

Transformer

120V,24V 1OOva

gngion/Sensing

Lead

_ lectronic

Pilot

d Lead to Pilot Burner

(200° C Thermoplastic Onlyl

,goitio°Contro,!:T

{HSBdf0M 1Otq i .__ _ =%_

Pilot Gas Valve

High Limit Pf _ss[Jre Control

Probe Type Low Water

CtltolJt Hydrolevel

Model 650P Shown

L,!II] Valve Switching

Relay (H R8222A)

Low Voltage

_*_v. Main Gas Valve

Low Voltage

Safety Gas Valve

TYPICAL WIRING - HSP SYSTEM - SINGLE GAS CONTROL TRAIN, 24-VOLT GAS VALVES

120V/6Ohz [L2) 120 V/dO hz

Neutral HOT

High Gas Pressure i| Train 2 /Train 1 Switches Ooeper _ _(_ _ _

Gas Control Train ' _ _ Transformer

(H C645B) / L_ 120V/24V Flame Rotlout _ Additi°n, at/h _ I 4Ova

Switch _ Limit Switches ._, " J (When Req'd)

(When Req'd}

Float Type |_

Low Water O-- i Ignition Control

Cutout _ (H $8610M-1011)

Spill Switch (When Req'd)

Operating Pressure _ _ ' r l /_,_

Control , _'--

Pilot Gas Valve

High Limit Pressure Control

Probe Type Low Water Cutout - Hydroleve[

Model 650P Shown

r_-> :_ - Switching

• _ Relay !_ Transformer

_ (H R8222A} -- 120V/24v

I _ _ 1OOva

nition/Sensing i _i

Lead

_ Electronic

iiP,,ot ,,

/ A, U !

/--Ground Lead to Pilot Burner

(2go r' C Thermoplastic Only) _'_'_

Low Voltage

Main Gas

Valves

Low Voltage

Safety Gas

Valves

TYPICAL WIRING - HSP SYSTEM - TWO GAS CONTROL TRAINS, 24-VOLT GAS VALVES

120-V Hot Wires I -- 24 V Hot Wires I All wiring must comply with applicable codes, ordinances

..... 120 V Neutral Wires[ 24-V Neutral Wires ._ and regulations. If any of the original wire must be replaced,

All wiring 80" C Thermoplastic except as noted | it must be replaced with wire as shown or its equivalent.

Figure 38: Typical Wiring - Standard Controls - Low Voltage Gas Valves

Page 40

120V 60hz [L2) 120 V'60 hz Neutral HOT

Hi!tb Gas Pressure _| (ModeisSWitch(H21C645B)IA13 ' ':_} {I'_I) "_

Tbrough 211A 18) / Adddional

Flame Rollout Limit Switches Switch _ _ (When Req'd)

(When Req'd)

Float Type Low Water O_ \

Cutout _ Ignition Control

/ (HS8610M 1011)

Spill Switch {When Req'd) _

ControIOperatingPressure [_ 'i ' i

_ Pilot Gas Valve

High LimO

Pressure Control

Transformer

120V/24V

40 va

Probe Type Low Water Cutout Hydrolevel Model 650P Shown

Ignition/Sensin 0

_ Electronic

liP,o,

, €-7 II<Spar 'gnged>

/ A.V____J

Ground Lead to Pilot Burner

Valve Switching

Relay (H R8222A)

120 V Main

Gas Valve

120-V Safety

Gas Valve

(200 C Thermoplastic Only)

TYPICAL WIRING - HSP SYSTEM - SINGLE GAS CONTROL TRAIN, 120-VOLT GAS VALVES

120V_60hz L{_ 120 V/60 hz Neutral _ HOT

/ /

/ Train 2 / Train t

High

Gas Pressure

Switches One per _ _ fl _,_ GasControltrain _Rj @ @ (_ (_ _W)

; d 7'snawL ,..

Swl ch J-_ > _e), I

(When Req'd) O-- _ (When Req'd)

Float Type Low Water

Cutout _ Ignition Control

{H $8610M-1011

Spill Switch (When Req'd) -F_ ,'_

Operating Pressure [_ _"

Control ! : _--

Pitot Gas Valve

_--_"_ High Limit

_t" Pressure Control

Transformer Probe Type Low Water 120V/24V Cutout - Hydrolevel

40 va Model 650P Shown

I_= z _

Igndion/Sensing Lead , [

_ Pilot

{Spark Ignited)

fG:o Und Lead to PiIotBurner ii, t _

(20u ° C Thermoplastic Only)

Valve Switching

Relay (H R8222A)

"_ 120-V Main

Gas Valves

_ 120-V Safety

i Gas Valves

i i I Additional

i Gas Valves : Req'd on

Train 2 21 IA-36

211A 37

TYPICAL WIRING - HSP SYSTEM - TWO GAS CONTROL TRAINS, 120-VOLT GAS VALVES

120-V Hot Wires --24-V Hot Wires All wiring must comply with applicable codes, ordinances 120 V Neutral Wires 24-V Neutral Wires and regulations. If any of the original wire must be replaced,

All wiring 80 ° C Thermoplastic except as noted it must be replaced with wire as shown or its equivalent.

Figure 39: Typical Wiring - Standard Controls - 120-Volt Gas Valves

Page 41

10. STARTING THE BOILER

l) Turn down the Operatm 9 Pn_ssure Control to stop

fl_e call for heat.

I 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.

l Fill the boiler to the normal water line

a) Gravity Systems and Pumped Return with

Condensate Units Fill to 40 I/2" 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 i/2" above the boiler foundation (iust below center of gauge

glass) when the pump stops

i. Before starting the boiler, study the Lighting Instructions

supplied with the boiler.

g) Wait b0 seconds to allow the control to reset before

proceeding with the next step

Light Manual Pilots a) Follow the procedure in the Lighting Instructions to

manually light any standing pilots.

Electronic Spark-lgnited Pilot Ignition Check a) Turn up the Operating Pressure Control fora callforheat. 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. 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.

I. Shut off all electrical power to the boiler.

2. Close Main and Pilot 9as 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-ignit_d pilot systems The control

will spark for 15 sc_conds Ittial tot ignition), then shut down for a 5 to G minute wait period before attempting anoth_r ignition

e) E]ectronicstandingpilotsystems Within15seconds

the control will click, indicating a safety lockout.

1. Remove the pressure test plug at the Main gas shut-off

valve. Attach a U-tube manometer.

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

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

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

a) The pressure reading underflow should be between

7 and 14 inches water column (5 inches minimum ifgas train is sized for lower gas pressure).

b) If the pressure to the Gas Control Train exceeds 14

inches under any conditions, the system must be provided with a lock-up type gas pressure regulator

to provide 14 inches 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 on Natural Gas or 10 inches

water column 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 03 inches plus or minus from the specified settings.

Page 42

1] mole adjustment to the rate is needed it nlust be done by changing the, burner gas ()rifices

The Minimum input rak, listed on tl_e nameplate dpplies to boilers wifll staged fidng rate. Tbis

minimum rate is not adjustable It is controlled by an

odlk _, in the gas ham

b Ch_ck the burner input by reading lhe gas meter

a) Each of the burners is rated at ]05,000 Btuihr for

Natural Gas with a 060 specific gravity

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

Propane (LP) Gas with a [ 56 specific gravity.

c) 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.

F x H x 3600

Rate, Btu/Hr -

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.

]. Limit and Operating Pressure Controls

boiler wateL producing an unstable water line and water carryover to the system.

Cleaning the boiler requires the use of very hot water and

corrosive chemicals. Use care when handling to prevent injury.

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

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

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

process.

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

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

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.

a) Lower the setting of each control until the burners

shut down.

2 Low Water Cutouts

a) Lower the water level in the boiler to below the

control cutout 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 ConlTols to the pressures desired.

I 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

10.

11.

12.

13.

14.

t5.

Turn burners on and allow the boiler water to heat up to just below steaming (180 to 200 OF), 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. Open the make-up water valve to continuously feed

water to the boiler. Allow water to flow out of the skim tapping.

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.

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

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

Drain the boiler completely. Then refill and drain again

one or two times to make sure all of the soda has been washed out.

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

skim valve.

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.

Page 43

1 1. LIGHTING INSTRUCTIONS - TYPICAL

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 Pressure-,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 Pilotstat. 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 Pressure Conlrol to desired pressure 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.

1. Open main line power clisconnect switch to boiler.

2. Close Main and Pilot gas shut off valves.

If flame signal is lost at pilot, the ignition control will shut off the main gas valves and start sparking within 0 8 seconds.

The control will continue to spark for 15 seconds.

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

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

The control will continue this sequence indefinitely.

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

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.

3 2 14

f--_2_- PiiotGas Pressure Regulator

Pi/-o{ Cock

3 Line Gas Pressure Test Tapping

, 4 Pilotstat (One per Standing Pilot)

5 Red Pilotstat Indicator Button

6 Pilot Gas Valve (One per Spark-Ignited Pilot)

7 Pilot Gas Line 8 Pilot Tubin 9, 3/8" oD Aluminum

9 Electronic Pilot (Spark Ignited), Typical 10 1 !gn!ti°n/Sensin9 Cable to Pilot, Typical 11 Electronic Pilot Ground Wire, Typical

[ii - Standing PilOt (Manually Ei_hted); Typical , 13 Thermoeouple to Standing Pilot, Typical i 14 Manual Shut-Off Valve

,P'I5 Gas Pressure Regulator

1i 6 Fleguiator Vent Line to Outside Atmospheie

1/ Safety Gas Valve, standard

21i§ Main Gas Vaive, standard

16 GasValve Bleed Line to Outside Aimoshpl 20 High Gas Pressure Switch (Over 2500 Biuh)

Ignition Control Panel

Figure 40: Typical Gas Control Train and Base - Single Gas Control Train - Standard Controls

Page 44

12. OPERATION MAINTENANCE

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 gas supply fail to shut off:

Shut off the gas 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.

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:

Electronic Spark-lgnited Pilot System ($8610M 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 re-start the boiler per the Lighting Instructions, (Standing pilots will have to be manually re-lit per the Lighting Instructions.)

Electronic Standing Pilot System

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

• The ignHio;i control should close the m,_lin gil> valves wilhin _ seconds after tire pilot goe_ _tl_

• After i5 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 D>r

the Lighting Instructions.)

Check the manifold gas pressure and rise a soap suds mixture to check the gas tightness of all gas ioints

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

Inspect and test all low water cutouts. (Float type conhols

must be flushed (blown down) weekly to remove any sediment from the float chamber.)

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

Visually inspect the burner and pilot flames. a) See Figure 41 b) The flame inner cone should be about i _o"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

Open main line power disconnect switch to boiler. Close Main and Pilot gas shut-off valves.

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 used 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.

Before servicing the boiler:

• Turn off all electrical power to the boiler.

• Close the Gas Service Valve.

• Allowthe 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.

Page 45

I. Beforethestartof each heating seasom inspect and

make all necessary adjustments to insure proper boiler

nperation Use the n]aintenance and inspection procedures following

2. Inspect the Venting System a) Check the chimney or vent to make sure it is clean

and flee 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 flee 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

nlanual.

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.

F, Test the operation of all limit conh his float conhols and

igntion components as described in Pa_t A. *Placing Boiler in Operation", of this Chaptel

1. Inspect the burner and pilot flames as fol 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.

1. Blow down the float type low water cutouts and test for correct operation.

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.

Figure 41: Pilot and Burner Flames

Page 46

113. TROUBLESHOOTING - SERVICE TIPS

PROBLEM POSSIBLE CAUSE SUGGESTED REMEDY

Defective Thermocouple Replace

Heavy Draft Blowing across Prlot

Plugged Pdot Onhce

Redirect Air Movement or Ehmlnate

ReD ace Ordlce

Pilot Outage

No Gas

_efective Pdo:s[al

Check Manual Pilot Valve

Check Main Gas Shut Off Valve

Check Manual Meter Valve

Consult Gas Company

Re_ ac_

Main Gas Valve Will Not Open

(Standard Spark-Ignited Pilot System)

Defective rgnt[ton Control

No Power

Defective Gas Valve

3efective Thermocouole

Low Water Level in Boiler

or System Causing Low Water Cutout to Function

3efective Pilotstat

Reolace

Check Power Source w th Meter

Check Fuses

RePlace RePlace

Check for LeaKs

Check Feeder if SUD_ led

ReL_lacc

Defective Ignition Control Reotace

Check Switch Setting

_llgn Gas Pressure Switch Onen lif Prov ded Check Man fold Gas Pressure

Check Switch Setting

Low Gas Pressure Switch Ooen {if Provided)

Check Inlet Gas Pressure

No Power Check Power Source with Meter

Check Fuses

Defective Gas Valve RePlace

Main Gas Valve Will Not Open

(Electronic Standing Pilot Systeml

Relay Locked Out on Safel Check for Pilot Outage

Pilot Oul Relight Pilot

Ma_ have defective pilot valve or rela r

Defecnve ReJav Replace

.ow Water in Boiler Check for Leaks

or System Causing Low Water Cutout to Function Check Feeder if Supp.ea

Defective Pilotstat_s_ Re=31ace

Defective Thermocouc elsl Replace

Hign Gas Pressure Switch Ooen hf Provided Check Switch Setting

Check Manifold Gas Pressure

Low Gas Pressure Switch Open (if Provided Check Switch Setting

Check Inlet Gas Pressure

Air Ad ustment Screws Turned Too Far Adjust Screws Out

Low Gas Pressure in Manifold Adjust Main Gas Pressure Regulator

[nsufficient Air In ect_on or Check Line Pressure

Burner Ports Partial . Closed

ReoJace Burners or Clean Ports

Burner(s) Burning with Yellow Flame Rusl Dirt. Lint. etcl

Gas Spillage from

Draft Hood Relief Opening

nsufficient Air for Combustion

• k

Oversized Burner Onhce

High Gas Pressure in Manifold

nsufficient Draft - Chimnev Too Low

Insufficient Draft- Chimney Too Sma

Insufficient Draft Blockage inChimne, or vent

Insufficient Draft - Leaks in Chimne. or Vent

nsufficlent Draft Downdraft Caused h Chimney

Location with ResPect [o

Other Buildings, Roofs etc

Negative Pressure in Boiler Roorr

.Due to Exhaust Fan or Duct S,,stem]

Insufficient Combustton Air Openings

Check Size of Combustion Air Openings to Room

If Undersized Correct as Reauired

Check for Negative Pressure in Boiter Room

Install Correct Orifice

Adjust Main Gas Pressure Regulator

increase rlelgn[ or Add Induced Draft Fan

Replace Chimney or Add Induced Draft Fan

Remove BlocKage

Repair Chimney or Vent

nstall Chlmr ev CaD

Remove Exhaust Fan

or Isolate Fan From Boiler Roorr

ProvldeCorrectl Sized Combustion and

Vent lation Air Openings

Page 47

PROBLEM

POSSIBLE CAUSE

SUGGESTED REMEDY

Main Gas Valve Opens

But No Gas Flows

Manual Valve Closed at Gas Train

Manual Va ve Closed at Metel

Test Firing Valve Closec if Provided

aden Valve

_I tH] valve

Ooen Valve

S_gs i_l 5iedrll l_ i_lll(l c_r _1_31 _317o jR pll Ci;rrt,L:[ Pl I) rig CulldltlOtl

Water Hammer on Start-Up

Concentric reducers caum_ g condensate pooling

Dr iJ [r_ _ falIt!(J c ose(

_)rv -e[urns we[reel [lue [o new DC er water line

nlgner [Ran OlC113o er

Correct R pmg

Reuldcu Tral3 or Trap Element

Correct P 31ng or Install Feed System and Traps

Concentric reduce/s caus ng conaerlsaI_ DOOIIDg

No drio ne on [ne oacK Sicle of a DaCK-DltChed

mo[orlzecl valve

Clogged returlls d g_avqly s.sTem

Correct P ping

nstall Dr 3 Line and Trap

C ean or Re PqJe Return Lme(s)

Water Hammer During Mid-Cycle

Water Hammer on Shut-Down

Hammering in the Boiler

No Heat or Poor Heat Distribution in

the Building

System or Boiler Overfilling or Flooding

Incorrect near DoHer piping causing WeT steam to

system

Trao failed aden allowing s[ean3 to enter return_

{Radiator Hammer} Large raalator map be vented

too QUICKIV

_ong nip[ e at Har#ora LO00

Correct PIpmg per Manual

qeDlace TraD or Trap Element

Use Smaller Air Vent or Use Two Sma Vents in

Place of One Large Vent One Mounted Higher

than the Other

Rec ace with Close Nipple

Water leg or back SlODe in return line to receiver

tanK, causing water pocketing

Trae instal efJ at recewer [aRK Causing Hater

trapping irl return

Boiler feed Duma or conaensate pump feed rate

too fast. causmg spraymg rata equalizer

No drio on the nlet side ofaforwara oEtcnea

]qotorlzed valve

unlnsulateo steam OlD he, causlf_g excessive

;onclensate 3aas

Close n=DDI8 or7 Hdrtford too nlgr

unlnsulatea steam piping _ ooHer room but

System piping nsula[ec causlr ] vacuum

corlclltlOn on ShUt-down

Poor c_rculat on in the ha ler due to sludge

eccutl/ulat oil

Correct Piping

Remove Trac at Tank. Installing Drip Traps and

Radiator TraPs where Required

Throttle Flow Rate

Add Dr a Lme and Trap

Insulate Steam Pipes

ReD De 2" to 4" Be ow Normal Water Line

nsulate Steam Pipes

Clean and 8 owdown the Boiler

Rapid Cycling

Main vents not working Replace Main Vents, Repiping away from End of

, Lines if Needed

Drip traps failed closed Replace Traps or Trap Elements

i Radiator traps failed open, allowing pressur zat on

of the returns _ Replace Traps or Trap Elements

Water legs or back slope in return lines to

receiver tank, preventing air from venting out Correct Piping

receiver vent

Boiler pressure too high, causing air vents to lock

up or blowing water Ioopseals / Reduce Operating Pressure

New boiler water content smafler than old boiler Install Boiler Feed System with Receiver Tank

Large Enough for Condensate

Boiler water feed rate or pump rate too fast, /

causing water level to collapse (due to collapse of

s earn bubbles in boiler wa er) [

Foaming, priming or surging due to poor water

quality

water quality, causing foaming and surging I

Poor

Excessive Water Level Bounce Incorrect near-boiler piping, such as undersized

or incorrectly placed risers

I Boiler water rate or pump rate too fast

feed

Air vents or traps not ventrng air, preventing

steam from getting to radiation and pressurizing

the air pocket

Pressure differential on pressure control too close

Nuisance outages of water level control due to

boiler water level bounce

Reduce Feed Rate

Clean the Boiler

Pipe per Manual

Reduce Feed Rate

Replace Vents or Traps

Adjust Control Differential

See Excessive Water Level Bounce Above

Page 48

14. BOILER RATINGS f:lrDIMENSIONS

Table: Boiler Rating Information

i[ Natural Gas Ratings

Boiler i ; IBR Net Ratings Model i Input Output : T

= Steam i

Number MBH MBH i Steam Water

= MBH ; MBH

.[ , t

211A 04 630 804 1578 378 438 211A-05 660 672 2100 504 884

12iiA_06 1050 i 840 2625 I 630 ] 730

i?oo I ! 677

211A-08 1470 1176 3675 882 1028 211A 09 1680 1344 4229 1015 1169

Propane Gas (2500 Btu/Cu Ft)

[_ IBR Net Ratings

Steam _ r Sr_el_11 [ _a_ I Steam

Input Output Steam

P=pmg _ MBH | MBH r Piping

Factor Sq Ft ' Factor

EDR j

1333 615 492 1538 369 428 1.333 1333 820 656 2050 492 570 ] 1.333

1333[ 1025 8 0, 2663 _z13 ,383!

1.333 _ 1230 9843075 738 _ 8_ ] 1333 1435 1148 3588 861 | 998 1333

1324 1640 1312 4121 989 ! 1141 1327

! 211A=-!0 _.. 189n0 -_512 rT 4808 I-'!_4 11315 I ___3!.0 _1845 T 1476 ] 468811126 1283 1.312 ii

2!1A-! 1 _ 2100 11680 L 8_92 J !294 [ 1461 [ 1_298 _ 2050 I 1640 / 5258 | 126 _ 1426 [ _i_01]]]iI 211A 12 2310 1646 5971 1433 1607 1290 2255 1804 5821 1397 1669 1.291

211A-13 2520 2016 6521 1565 1753 1.288 2460 1968 6367 1528 17tl i 1.288

2940 t 2352 ! 7608 _ 22:: [_2___ 2132_ r _i,54 _ 1.2881

!i 211A-14 2730 2184 7067 _ 1696 I 18991.288 2665 6896 1655

:i_ 211A-15 i 1826 _ 2045 i 1. 2296 _ 7429 _ 1783 199711.288 I

211A 16 ; 3150 2520 8154 1957 2191 1.288 3075 2460 7958 1910 2139 . 1.288 211A-17 i 3360 2688 8696 2087 2337 1288 3280 i 2624 8488 2037 2282 1.288

211A_i8 _I 3570 2856 9738 ! " _ r _ I 11288_i

_ 37-- 211A-19 -_- 22172483 1.288 , 3486 2788 9021 . 2165 2424 i80 3024 _ 2348 + 2630 i 1.288 [ 36_£ + 29_ i 9550 j 2292 2587 ji_-_8

211A20 3990 3192 10825 2478 2776 1288 3895 3116 10078 2419 2710 1.288 211A21 4200 3360 10871 2509 2922 1288 4100 3280 10613 2547 2852 1.288

i 211A-22 _ 4410 T 3628 - 11413 i 2739 i 3068 [ 1.288 4305 ] 3444 ] 1ii42 2874 _- 2995 _288_

2!!A-23 ! 4620 i 3696 11858 [ 2870 _ 32!4 [ 1"288 45]O j 366_i-1167! 12801 _3137 [ ]28_ 211A24 4836 3864 12500 3000 3360 1.288 4715 i 3772 12204 2929 : 3280 1.288 211A-25 - 5040 4032 ! 13042 _ 3130 3506 1.288 !_ 4920 ! 3936 12733 _ 3056 _ 3423 - 1.288

!_ 21iA:265250 i 4200113588 _ 328i 13852 'i 1:288 _ 5125 _4100 _ 13263 T_665 [ i:2881

:' 211_7 ...... 5460 "] _4368 _1_3391_ 379811.288 _ 633014264 / 13796 i 3311 3708 11.288 :!

)11A-28 - 5670 4536 4675 3822 " 3944 " 288 "= 5535 _4428 * 4325 ' "343-8 .... 385013850--+"i288 ]!

i 211A-29 5880 4704 15217 3652 4090 1.288 ' 5740 I 4592 14854 _ 35664319936_3993 1.288 i

[ 2iiA-3; -60;0 ] 4872" 15763_ 3783 _ 4257 i _.288 _694614766 F18388 13693 .28s

[ 211A-3i "63;; I "5040 16304 ia 3913 / 4383 / --i)88. L 6150 ,14920 J 15917 [........3820-- 72784278I 1:1_288- !/i

211A-32 6510 5208 16846 4043 4529 1288 L 6355 5084 16446 3947 442 288

p ff 4

11 211A33 6720 | 5376 17392 4174 4675 _ 1.288_ .!I ............6560 5248 i 16979 4075 4563 _ 1.288 ]

i 211A=34 6930 _ 5544 17933 4304 4821 1.288 6765 5412 17508 4202 4706 | 1.288 .

5712 1_79 4435 4967 1288 6970 5576 180381 4329 4849 1288

• t _ t _ i _ , l ._!211A-35 7140

216 20108 4s26r5405 128s

: 211A-40 8190 . 211A-41 8400

21iA-4218610

211,,43

211A 44 9030 211A 45 9240

21,A46

6552 21196 5087 5697 1.288 6720 21738 5217 5843 ! 1.288

6888 22283115348 _ 5990 } 11288 -=

7056 22825 ] 5478 6136 ..... _-288--:

7224 23371 5609 6282 1.288 7392 23913 5739 6428 1.288

Models 211A-38 through 211A-46

Are Certified for Natural Gas Only

7560[ 124458] 88701 6574[ 1.2681

Page 49

(211A19 and Larger,Two Gas Control Trains))

1211A04thru 211A-18,Sngle Gas Control Train)

3% ° "AA- 3B - CC _ DD - EE " FF - GG "* HH - II M JJ . * 3_1_

O00O()O000

T3 T8

4f ; •

, I! i t.

331;" " D " E - c - G " _ " - J - K - L - rd .- N - O - P - -3_1;

Boiler Sectional Length

5 1/4"

32 5/8" 45 3/4"

TAPPING SCHEDULE

T1 End Supply Riser Taps,

6" each End Section

T2 Return Taps, 6" Each End T3 3" Tap, Top, Each End

Section

T4 3/4"Tap, One Each End

Section

T5 1/2" Tap, Two Each End

Section

T6 1"Tap, One Each End

Section

T7 1"Tap, One Each End

Section

T8 Intermediate Supply

Riser Taps, 3", in Tapped Intermediates

T9 3/4" Tap, One Each End

Section, For Probe LWCO

T10 1 1/2"Tap. Blowdown,

' Each End Section

Tll 3" Tap, Lower Rear,

Tapped Intermediate Sections Only, Not Used

[] [] [] [] [1 [] [J [1 [J [J

2nd End Riser

211A-08 _ LargeT'_ _1

T5 T9 T6

4 '

T7 _ U ProbekowW terCutout

2nd Equlizer _ l

211A-16_Larger,,-_ Ti1-_. ; .... [ r

_T10

FRONT VIEW

; 27

81"

i li

-- !IT2

', i 71o,

22 ,1oo 4 ,ii711

.... 41" - .

Base End Width

Page 50

BOILER DIMENSIONAL DATA (All Dimensions In Inches)

: Flue _

Boiler Length_ Width ! Boiler Intermediate RiserCenter Lines- 3" Tappings- Used In Additionto Two EndRisers FlueConnectio, Ce,te( Lines

Model Dimenslo,s 'SBgton i .... _ . : _ _ [ _ Connections _ • =

No. A _B C ! Lengtih D iT E I F , G H I J / K ;_ L M N O : P ; AA : BB CC _DD ' £E FF G6 HH : JJ No Size _ _ = /

2 1A04 291/2 _ 39% 63 ! 213/, ! . - - _ ! - " -_ - ' - : - L - [16•/8 _L - : _ ± _ - _ 10% 1 12 12 12 211A 05 33_ 44 63 27_ - 13_':_ i9_ I ]2 12 _2

211A06 398_ 50% 65 • 33 ..... 16!/2 161_ / 14 14 14

56 / 631 38% i I L _ _ r _ T _ - _ - T - / i 2

1 I " 13_/4 19% i - 19/8 2 12 i5 15

211AI0 61 _ 73_._ 65 553/2 16vz 25_% 135 2 14 17 17 211AI1 67_ 89%4 65 611/_ 16_ 28% 15 2 14 1_ 16 211A-12 73'_ 66_/_ 63 663/. 133/.. 2212 19% 10_, _ 12 I_ I_

211A-13 783/.. 9W_ 63 ! 723/s [ - ] - [ _ - ] [ .... 113_/_ 2211222V_ - 13% 3 12 19 19

' _ ! ' 16'/225% 22V=! - 13%

211A-14 843/2 97Ve i 65 I 78 3 14 20 20

--_ 3 14 21 21

211A-15 90 102_._ 65 i 83% 211A-16 95 s 108_._ 65 69V4 16!# 26_ 261.a 16' 2 ;4 21 21

211A17 161 _ 114% 65 94V8 13_4 22'/= 22_.2 22_ 13_ 4 i_ 22 22 211A 18 1OZa 120_/e 65 100V; 53ve 47_b !6_h 25% 221/2 22_.'2 13% 14 22 23

........ , T • i - ,

211A-191121/z 139'_ I 65 ' 1061_ 531/8 / - J - I • - ] - j - i 53_258/8_5%[ -_ _ q 13_e 14 23 23

_11A.20 [ 11iV,_q4__83!4_- _ C--_- -[_- --_ -_ -- ; i 153 i16Y= 28Yal28'4 25% - - -13% 14 24 24

: 4 ...... 158% 16V_ 284 I 28/_ 26/8 -- i -- : - 16,_ 14 25 25

211A-21 i 123_4 I 1 - , - : ; , . --'- , .... _

211A.22 129_B 156 65 123 41% 45 - 361/e 16!/2 253/2 22V2 22;/2 22V_ 13% !4 25 25 211A-23 135 161% 65 1993/8 41% 45 418/4 16Y_ 26% 25% 22_.£ 22_/2 13% 14 26 26 211A24 140% 16_ 65 134V.. 47V_ 45 * - _ = " _ - - 413/4 16V; 28% 26% 253/8 221'_ 13s, 14 26 26 "_ ^_ aml. I 7265 C1397/$ [36%[33_/._33_/4[ - [ _1 - [ C ] _ ! I , _ L 136,/8]i63/=F)8Ve 28,/a 28]/e]25% [ - - i - 13% 14 27 27

211A-26151, 177% '..65146" 36V_33_/, 39_a _ -__: ! _ _ _- 36/_ 16/, 28<,128" 26 _ 13% 1414" 282727 28

211A28 163% 188% 65 1563/4 25 33=/4 33_/4 33_/4 30vz 16_/2 26Ve 261/8 959& 22_ 22V2 13'_ 14 29 29 211A29 198_4 194V= 65 162_/2 25 261/_ 29Va 28V_ 29_',8 29Ve 16_/2 26% 261/_ 26_'8 25_'e 22Yz 13 _ ]4 2_ 29 211A.30 1748/_ 200_.6 65 169 30% 28V8 28V_ 28v8 28V_ - 24% 16Vz 28% 28*% 28% 28% 258/__ . 13 _ 14 30 30

211A-31 I" 1908 :' _-205_5 [17_73% 30% _22V_ 22V_'_221/= 22Vz_- _ - - _ _ _; ____13OV_- 16V_ : 68'/,8.[.28'/,,___28Y, 281/829'/., ;, _-; - 16'/=,- _4 - 30 30 211A-32 195% : 211% 6_w,/26,/,, 22,/= 22,/= 22v= 22w I - I _- , - 130Y=/16v=128v,,28,/, 25=/,122,/=1221/2122/= / 135/814 31 . 31

- 211A_3-33_91"V.:217V_'-65:184V_ 25 22_22_ V_ 22_ 22V2L_: ! : ! ] : × [2,,,,/o_Z_v,j28,>,._26_,/,.'253/,,4z21i2122,/= : :23o6. ,4 3, 3_

211A34 196_e 223_/e 65 190V2 25 22V222_/222'/228Ve 223/222V2 - 242/816'/228V8281/s:28'/228_/e 253/s 22'/_ T 13=_s 14 32 32 211A-35 9921; 229Vz 65 196_4_ 25 22Vz 22V= 29Ye 263/a 221/2 22'/2 - 24_/2 16_/226% 26V8 26Ve 28% 28_/_ 25% 13% 14 32 32 211A36 206e' 262 " 65 20¥._ 25 22V_ 22/_" 22_/_ 22/_" 224:22Vz 22_/, -- 193/416V2. 28_/s 28Vs. 29Va: 281/2'28Ve. . 28_ - 6'_z , 14 , 33 33

2nA:37 zl3_/,i 268%5;2o7_,, 29_22_/=22v=22y=22_/=I22Y_r2zv=_2v_/ ! -- _2_61_29_'/8 [ 221/'2 :.2_1/_221/2.i. _ + 195/B ._ _33 _33

211A-36219%" ___'_Y_F _- : [ : ' 19'/', : 13_ [22_ 221/2_j _'/8] 26% . !6V,: 143434

Wl=lA-39_ 225 __/2L22v_ 22!/2 - I C_3/4_223/, 25V4126Vs.26,/sL28'/828V828% 7 : ]6'/2 14 34 34

211A40 230% 295 65 228V4 193& 223/2 22V_ 22_ 29% 22Vz 22_/_ 22vz 22_ ;91/& 19_/_ 25_._ 28V_ . 28_._ 28!/8 28t/8 28_.e 28_'e 1612 14 35 35 211A41 236'_ 291 65 229% 19% 221/; 22!.# 221/_ 16% 22._ 16_.8 22_/z 22'# 22':_ 191._ 161.z 29_, 28% 28_ 28'8 26_ 261_ 29% ;61; 14 35 35 211A.42 241% 296'/2 65 239'/2193/_ 221/2 22v_ 221/2 22V2 16% 221h 221/# 22_.:, 22'_ 19V4 ;33/_ 221/) 221/_ 22t/_ 25_'4 281_ 281a 261.8 28'._ 16: 14 36 36

28% i 28Ya i 26Va 28% 16!/2 14 36

211A-43 2421/_ 902V_'_65941V'_93/e[16%_ 22V_16Va:_V=[22V=[22y=I29_'_16%22'/_163/° - 19V4 T 133/41821422V=_ 1283/_t 36

211A:44 _293,/8 ! _'19y8221/21122V= 22'/216"/e 22!/_16VsF!6% 22'/! 22'/_ 22'/2 L 191/4_ 221_ 51/428'/21126%28Ve;28'/8263/e-2#-16'/i 14 3s 36

"21_A-45 " 2563/4_ _252_/e : 193/8167/8291/z 167/8221/2 [ 16% 221/2_ 167/822 I/216'/822% 16% 161/4193/428_/4 : 961/8 961/,8 [ 8614291/826t/8261/e 281/s 16'2 14 37 37

2HA-46 264% 319t/; 65 256 ]9_& 16% 22'_ 16% 22_/z 221._ 16!% 22'; 22:. 1[_; 22' 16. 181. ]6 _ 26% 261'8 28_ 26% 28h_ 26 _ 29_, 28' 16'. 14 37 _H

Page 51

1 5. REPAIR PARTS - SERIES 21 1A

• REPAIR PARTS ARE AVAIIABI_E FROM YOUR INSTALLER OR BY CONTACTING PEERLESS HEATER

COMPANY, BOYERTOWN. PA 19512-t021

• PLEASE INCLUDE BOILER MODEL NUMBER AND SERIAL NUMBER WHEN ORDERING PARTS

• SEE FIGURE 42. BOILER ASSEMBLY AND FIGURE 43, BASE ASSEMBLY

o.sc°,.,o° 1 .OO,T,O°AL,. O°M.T,O.

GG-1000 50 lb. Working Pressure

1 Intermediate Section

GG-1000-1 80 lb. Working Pressure

2 _G:i023r_ _- 7 Left Hand End Section _ng Pressure

1 GG-1023_1 J ._ 80 !lm Working Pressure

GG-1024 i 50 lb. Working Pressure

3 Right Hand End Section

i GG-1024 1 ' 80 lb. Working Pressure

4_._["4 -_1 ] Tapped Intermediate Section _!g58_ ;bb" W_ ikkii__.._i _Ss._ ee_

5 GG-1012 Tie Rod 2 Required Per Flueway 6 GG 1013 Flow Port Gasket

GG-2105

8 GG: i05 T

GG 2080

2 Required Per Flueway

Hi Temp Rope for Sections, 5/8" - ..... 1 81/2

Feet

Required

Per

Flueway

Base Right End Panel w/insulation J_ 1 Required Per Boiler

Base Left End Panel w/insulation • 1 Required Per Boiler

167/8`` Wide

i 10

GG 2080 1 GG-2080-2 GG-2080-3 GG-2080-4

GG-2081

GG-2081-1 GG-2081-2

GG-2081-3 GG-2081-4

50848

; 50849 ! 11

50850 50851

50852

12 13

GG 2066

GG-2066-1

GG-2066 2

Base Front Panel Sub-Assembly w/insulation

Base BackPanel Sub-Assembly w/insulation

Base Front or Back Panel Insulation

50853 Base Left/Right End Panel Insulation

GG-2104 Insulation Washer GG-2070 Burner Support Channel Clip

Burner Support Channel

221/2" Wide 28_/8'' Wide

333/4" Wide 393/8" Wide 167/8" Wide

221/2 '' Wide

281/8" Wide 333/4" Wide

393/8`` Wide

For 167/8 " Wide Panel

For 221/2" Wide Panel

For 281/8" Wide Panel

For 333/4" Wide Panel

For 393/8 " Wide Panel (2 Per Panel)

1 Required Per Panel

Specify Quantity Required

2 Required Per Boiler

For 167/8'` Wide Base Panel For 221/2'' Wide Base Panel

For 281/8'' Wide Base Panel GG-2066 3 For 333/4 " Wide Base Panel GG-2066-4

16 ] GG-2065

For 393/8 " Wide Base Panel

Angle Tie Brace ] Specify Quantity Required

Page 52

ITEM DESCRIPTION

NO.

PART

NUMBER

GG-2053

GG 2053-2 GG-2053 4 GG 2053-6

Base Front Panel Cover Piate

ADDITIONAL INFORMATION

143/4" Wide 203/8" Wide

26" Wide

31 '8 Wide

GG-2053 8

i GG-2053-1 .

18 l GG-2053-3

GG-2053-5 GG-2053-7

[

Base Back Panel Cover Plate

371/4" Wide 143/4" Wide

203/8 " Wide

26" Wide

315/8 " Wide

GG-2053-9 ...... : 371/4" Wide

19 Manifold Weldment Specify Controt System 2O

! 21 I GG-3007

GG-3854 GG-5000

22 GG-5000 1

GG-5000-2

-- GG-5001 1

GG-8001-2 "t GG-5001-3 _

24 GG-5003

25 GG 5004

26 GG-5005

[ 27

Orifice Spud Specify Quantity Type of Gas and Altitude Steel Burner Specify Quantity Required

Steel Burner w/Pilot Mounting Clip

Flue Collector

DraR Hood

Front Flue Collector Hook Bolt

i 28 GG-6004 __

I 29 HiTemp Ropefor Cleanout Cover Plate, 5/8"

Back Flue Collector Hook Bolt

Flue Collector Mounting Bracket

Hi Temp Rope for Flue Collector, 5/8"

Cleanout Cover Plate Sub-Assembly

Common End Panel and Cleanout Cover Plate

Assembly

Intermediate Panel Jacket Assembly

i GG-6033

GG-6034

GG-6034-1 GG-6034-2

GG-6034-3 GG-6034-4

Specify w/or w/o Pilot and Pilot Number

16" Wide

219/16'` Wide

271/8'' Wide

For GG-50B0 w/12" Dia. Outlet For GG-5000-1 w/12" Dia. Outlet For GG-5000-1 w/14" Dia. Outlet

For GG-5000-2 w/14" Dia. Outlet

1 Required Per Flue Collector 1 Required Per Flue Collector 1 Required Per Flue Collector

Specify Quantity In Feet Required

Set of 2

Specify Quantity In Feet Required

Carton No. 12

Carton No. 12A .......... i

Carton No. 12B Carton No. 12C

Carton No. 12D Carton No. 12E

Pilot Line Assembly : Specify Control System

Pilot Line Support Bracket Specify Quantity Required

Gas Control Assembly I Specify Control System "

Theraltimeter Gauge / Water Boilers Only

ii "steam Gauge _ i/ Steam Boilers Only

Gauge Glass Set Steam Boilers Onlyi

! L,ghting Instruction Plate _ Specify Control System ]

i _ Hi Temp Sealing Cement | Specify Quantity of Containers

I i

Rope Seal Adhesive Specify Quantity of Containers

1/4" O.D. Aluminum Tubing Specify Quantity In Feet

i 3/8" O.D. Aluminum Tubing I Specify Quantity In Feet

Page 53

_'] 5.'] =1;1_=[.']v.lIEIr_,l

Figure 42: Boiler Assembly

Page 54

Page 55

Page 56

Series 21 1A

Gas Boilers - Steam

Installation, Operation Et

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.

gama

PEERLESS _

CAST IRON BOILERS

PEERLESS HEATER COMPANY

231 NORTH WALNUT STREET • BOYERTOWN, PA 19512-1021 • PHONE 610-367-2153

www.peerless-heater.com

THE PREFERRED HEATING CHOICE

@2002 Peerless Heater Company GG8051 R5 (2/02-1M)

Printed in U.S.A.