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

...

Download

211A

Boilers - Steam

Installation, Operation

Maintenance Manual

PEEI_LESS _

CAST IRON BOILERS

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

Ill IIll' lll(_ll>,II'l]. All [)('_'/[('_,:_ {'o/llnlt'Ill(ll ((I._/ II_Jll ])olhffN i/l('hld('_l ]Jill. oIIt" {l('(u IptlFI'(IIII{]. A

[[llllll'(_. /I'll ]]<'(11 IIl(lll'(lllll] 011 lilt' I tl:_l I1011 _,l "l /l(Jl[_ i.% _)lOl_itl('([ 101 (ll[ ('Ollllll('l('l(l[ lI{ll [p(I{('I CIII(I

%1('(1111 [)Oil['l_, [.'HI(, (llttl I('11 !]t't4l t'\llqltlt'(] II'(dll(llllit'_ Oil I)(l!'lF; (llJ(/ l(lt)(ll (ll_, llOlp (IlyUI(I[)I(,, CAST IRON BOILENS

1_1('(1_" ( I)IL'.,Illl /)('('l!(,.%N l [_'(lll'l ( (t?!lt)(l!l{ j [OI ( ll!l{[)_('!<" Ip(lll(l?lll] II!tOl'lll(l[[(lll

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

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

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

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.

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

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

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.

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

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"

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

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

_ :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.

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

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

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

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.

+ 39 hidden pages

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

Specifications and Main Features

Frequently Asked Questions

User Manual