211A-36 Peerless Gas Steam Boiler Series 211A

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211A Boilers - Steam Installation , Operation Maintenance Manual PEEI _ LESS _ CAST IRON BOILERS
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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 â€¢ Ideal for Steam and Large Volume Hot Water Jobs Low Profile Design â€¢ Horizontal to Vertical Draft Divel + ter â€¢ Ideal . ] br Installations with Low Ceilings Individual Draw Rods â€¢ For Ease of Assembly Unique Fie _ x - Sea ! Flow Port Gaskets â€¢ Injection Molded for SLq ) eHor PerJ _ ) rmance and Flexibtlily â€¢ Assures a Water Tight Seal Betweer _ Sections â€¢ For Ease of Installation Deluxe Insulated Enameled Steel Jacket â€¢ Reduces Boiler Heat Loss Tankless Coils â€¢ For Domestic Hot Water Production on Hot Water Boilers Safety Controls â€¢ Low Water CubOJ ] on Steam Boilers â€¢ Honeywell Operating Controls â€¢ Float and Probe Type LWCO on Steam Boilers â€¢ Manual Reset High Limit Control ? â€¢ 5 ' Â¸ Â¸ â€¢ Tankless Coils . for Hot Water Boilers â€¢ Modulating Firing Systems â€¢ Electronk : Control Systems â€¢ 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 â€¢ 231 North Walnut Street * Boyertown , PA 19512 1021 â€¢ 610 - 367 - 2153 â€¢ 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 â€¢ BOYERTOWN , PA 19512 - 1021 â€¢ PHONE 610 - 367 - 2153 www . peerless - heater . com THE PREFERRED HEATING CHOICE
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TABLE OF CONTENTS 1 . PREPARE THE BOILER LOCATION 3 8 . INSTALL CONTROLS AND TRIM 30 ACCESSIBILITY CLEARANCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 INSTALL SAFETY VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 COMBUSTIBLE CONSTRUCTION CLEARANCES . . . . . 3 INSTALL BLOWDOWN VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 AIR FOR COMBUSTION AND VENTILATION . . . . . . . . . . . . . 3 INSTALL LOW WATER CUTOUT ( S ) . . . . . . . . . . . . . . . . . . . . . . . . 30 CHIMNEY OR VENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 INSTALL PRESSURE CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 BOILER SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 9 . WIRE THE BOILER 35 2 . ASSEMBLE THE BASE 7 CONNECT SUPPLY WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 BASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 PREPARE REMAINING CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . 35 INSTALL THE PILOT BURNERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 INSTALL CONTROL WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 3 . PLACE THE BOILER SECTIONS 13 10 . STARTING THE BOILER 38 PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 CHECK THE PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 PLACING THE SECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 FILL THE BOILER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 HYDROSTATIC TEST THE BOILER . . . . . . . . . . . . . . . . . . . . . . . . . 14 STUDY LIGHTING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . 38 4 . INSTALL THE FLUE COLLECTOR 15 RUN PILOT CHECK - OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 CHECK MAIN BURNER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 5 . PIPE THE BOILER 17 CHECK BOILER CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 CLEAN THE BOILER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 SUPPLY PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 RETURN PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 11 . LIGHTING INSTRUCTIONS - TYPICAL 40 MULTIPLE BOILER INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . 19 TO LIGHT THE BOILER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 6 . INSTALL THE JACKET _ DRAFT HOOD 21 TO SHUT DOWN THE BOILER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 PILOT FLAME FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 PREPARE THE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 APPLY CLEANOUT COVER PLATES . . . . . . . . . . . . . . . . . . . . . . . 21 12 . OPERATION _ MAINTENANCE 41 APPLY JACKET END ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . 21 211A - B4 through 211A - 08 ONLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 PLACING BOILER IN OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 211A - 09 8 LARGER ONLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 TO SHUT DOWN THE BOILER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 APPLY JACKET TOP PANELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 MAINTENANCE - ANNUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 APPLY LOWER END PANELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 MONTHLY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 APPLY PLATES AND LABELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 WEEKLY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 DAILY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 7 . CONNECT GAS PIPING 27 INSTALL GAS TRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 13 . TROUBLESHOOTING - SERVICE TIPS 43 CONNECT PILOT GAS TUBING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 INSTALL VENT AND BLEED PIPING . . . . . . . . . . . . . . . . . . . . . . . . 27 14 . BOILER RATINGS _ DIMENSIONS 45 INSTALL GAS SUPPLY PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 15 . REPAIR PARTS - SERIES 211A 48 TEST GAS SUPPLY PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
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USING THIS MANUAL 1 . This boiler must be installed by a qualified contractor â€¢ ] + This manual provides wlrmg diagrams and lighting instructions for standard systems only . E . The boiler warranty can be voided if the boiler is not installed , maintained and serviced correctly . 2 Use the Lighting Instructions and Wiring Diagrams provided with the boiler to make sure they represent fire controls provided 1 . For new and existing installations , a Steam Installation Survey is available from Peerless Heater Company â€¢ The survey will provide information on how a steam boiler works with your specific system and will provide an I . Throughout this manual you will see special attention overview of steam system operation in general â€¢ boxes intended to supp ] enrent the instructions and make special notice of potential hazards . These categories 2 . You can also use this survey to locate system tproblemshe mean , in the judgment of Peerless Heater Company : which will have to be corrected . To obtain copies of Steam Installation Survey , contact your Peerless representative . Indicates special attention is needed , but not related to 1 . Check the system to make sure there are no leaks or potential personal injury or overfilling problems which might cause excessive property damage . 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 Indicates a condition or hazard quality will cause foaming , priming and overfilling of the which will or can cause minor system . Too much sediment in the water will cause personal injury or property build - up in the boiler and could result in cracked sections damage . 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 Indicates a condition or hazard flooding of the boiler , carryover to the system , and which could cause severe excessive make - up water addition . You will need to install personal injury , death or major a boiler feed system to prevent problems in such cases . property damage . 4 . Do not use chemicals or substances in the boiler or system which contain petroleum or its derivatives . This will damage the boiler seals . Indicates a condition or hazard which will cause severe personal i . We have provided suggested piping diagrams which will injury , death or major property cover most applications of this boiler . damage . 2 . Follow these guidelines to make sure the boiler will operate correctly . Pay close attention to pipe sizing and location of risers and returns .
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1 , PREPARE THE BOILER LOCATION | Vent , typcal _ 6j ] 6 ' , , i ] P , p , ngT , ypcal " - _ ( 3 if ' ' _ II 1 ] mm ( : - ' - - _ Front View C Figure 1 : Clearance Requirements â€¢ 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 I The following recommendations allow for reasonable equipment design must be engineered to assure a neutral access to the boiler Local codes or special conditions or slightly positive pressure in the boiler room at all times may require greater clearances â€¢ of operation If the equipment design and air openings a ) For servicing the boiler : provide 48 " between tile cannot assure this , then the boiler must be located in an conh'ol manifold and adjacent wall or other appliance isolated room . b ) For access to draft hood or passage to access the boiler 4 The following recommendations are in accordance withSI control manifold ( s ) : provide 48 " between the side of the current edition of the National Fuel Gas Code , AN the boiler and adjacent wall or other appliance . Z223 . I / NFPA54 . c ) See Figure 1 , Clearances with an " S " are minimum Ifall air for combustion and ventilation comes from inside clearances for service accessibility . 5 . the building ( Figure 2 ) , the building must have adequate 3 " rain 1 . This boiler is design certified for the following clearances to combustible construction . 12 " max A a 24 " between the front , sides and rear of the jacket TWO AIR OPENINGS : â€¢ 6 " from steam and hot water pipes BUILDING Minimum â€¢ 6 " from vent connector Free Area Each - a See Figure I . Clearances with a " C " indicate 1 in _ per 1000 Btu Aust communicate freely minimum clearances from combustible construction â€¢ at Least 100 in _ with outdoors Must not be under negative pressure 1 . The installation must provide adequate air for BOILER combustion , ventilation and draft hood dilution â€¢ 3 " min 2 . Provide air openings as recommended below â€¢ The [ ; 12 " max lower opening provides combustion air and dilution air . The upper opening provides proper air circulation to control the boiler room temperature and air quality â€¢ Without the upper opening , the boiler room Figure 2 : Air Openings - All Air from Inside temperature will be too high , causing problems with Building control operation and life 3
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â€¢ Provide two openings : one starting no closer than 3 inches nor further than 12 inches from the ceiling 1 : : : xll . . . . one starting no closer than 3 inches nor frlrther than TWO AIR OPENINGS : 12 inches horn the floor MhlinqLim â€¢ If air openings are directly in an outside wall ( Figure , / Free Area Eacl _ 3 ) , each opening must have a free opening ( after 1 in * per 4000 Btu louver reduction ) of at least One square inch per 4000 BtuiHr of total boiler and other appliance input . â€¢ 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 crossas sectional area of the ducts must be at least as much the free area of the openings to which they connect . 12 " max I TWO AIR OPENINGS : Minimum Figure 3 : Air Openings - All Air Directly from Outside Free Area Each - 1 in zper 2000 Btu provision for outside air to assure the air supply needed for the boiler room . Provide openings as follows : â€¢ 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 â€¢ The openings must be into areas which have unrestricted access to outside air â€¢ Each opening must have a free area ( after deduction for louvers ) of at least One square inch per 1000he Btu / Hr of total boiler and other appliance input . T Figure 5 : Air Openings - All Air fromntal openings must never be smaller than 100 square Outdoors through Horizo Ducts inches each . â€¢ If air is supplied through horizontal ducts ( Figure 5 ) , 6 . If all air for combustion and ventilation comes directly each opening must have a free opening ( after louverr from outside the building : reduction ) of at least One square inch per 2000 Btu / H of total boiler and other appliance input . The acrosss sectional area of the ducts must be at least as much the free area of the openings to which they connect . 3 " min 7 . Using combustion air dampers : _ , 12 " max a ) If motorized dampers are used on the combustion and ventilation air openings , wire them such that TWO AIR OPENINGS : they must open when the boiler tries to operate . Minimum They must include a switch which prevents the boiler Free Area Each - from operating if they do not open . 1 in 2per 4000 Btu 1 . Inspect the existing chimney or vent system . Make sure it is in good condition . Inspect chimney liner and repair or replace if necessary . 2 . The vent system and installation must be in accordance with 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 . Figure 4 : Air Openings - All Air from 3 . Chimney / Vent Operation : The vent system must be Outdoors through Vertical Ducts sized and installed to provide the draft needed to remove
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Recommendedsizingfor chimneyand connectorsis all combustion products . If the vent system does not based onmaximum 6 foot connector length and provide enough draft , combustion products will spill into maximum one 90 degree elbow . the building from the draft hood relief opening . If spillage 0 of combustion products occurs , check the vent system , T the combustion and ventilation openings and make sure the boiler room is never under negative pressure . Frovidesuppo _ for I _ lz _ taJ secl _ s to preventsagging â€¢ Slopeve _ t connectorupw _ d min 1 / 4 inch perfoot - - 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 Connlz _ otr must notprotrudeinlo chimney â€¢ sufficiently to ensure adequate draft . 5 . Vent Sizing : Boi ) erven _ c0nnect0r shCuldbeh _ ghet than 0tha : connected app _ ances 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 I _ Do not obs _ ct draft . hood openfn _ 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 . Figure 6 : Vent Connection b ) Combined vent - breeching : â€¢ The recommended sizing in Section 14 , " Boiler a ) Seal any unused openings in the common venting Ratings and Dimensions " , in this Manual is based system . on a minimum chimney or vent height of 20 feete and a maximum horizontal run of 6 feet to th b ) Visually inspect the venting system for proper sizeo and horizontal pitch and determine there is n chimney with no more than one 90 - degree standard elbow . blockage or restriction , leakage , corrosion and other deficiencies which could cause an unsafe condition . â€¢ The minimum area of the chimney serving two or more appliances must be at least the area of the c ) Insofar as is practical , close all building doors and largest chimney connector plus 50 % of the total windows and all doors between the space in which area of all other appliance connectors . the appliances remaining connected to the commonthe venting system are located and other spaces of â€¢ The vent connector must be single wall steel or building . Turn on clothes dryers and any appliance Type B double wall vent pipe . The vent connector not connected to the common venting system . Turn must be Type B double wall if it is located in or on any exhaust fans , such as range hoods andat passes through cold areas . The vent connectorall bathroom exhausts , so they will operate must extend into , but not beyond , the inside w maximum speed . Do not operate a summer exhaust of the chimney . fan . Close fireplace dampers . 6 . Vent Connection to Boiler ( Figure 6 ) : d ) Place in operation the appliance being inspected . a ) Provide at least a three foot rise in the vent Follow the lighting instructions . Adjust the connection on the boiler . thermostat so appliance will operate continuously . b ) The vent system should provide a draft of at least e ) Test for spillage at the draft hood relief opening after 5 0.02 " w . c . measured at the vent connections . minutes of main burner operation . Use the flame of a match or candle , or smoke from a cigarette , cigar or pipe . c ) Support the weight of the vent system indepently of the boiler draft hood . The draft hood is not designed f ) After it has been determined that each appliance to carry structural loading . remaining connected to the common venting system propedy vents when tested as outlined above , return d ) Provide support ofthe vent connector ( breeching ] at doors , windows , exhaust fans , fireplace dampers maximum 12 foot intervals to prevent sagging and and any other gas - burning appliance to their to provide a minimum upward slope of I / 4 " per foot . previous condition of use . e ) Do not connect the vent for this boiler into any vent system which operates with positive pressure . g ) Any improper operation of the common venting system should be corrected so the installational f ) Use Type B double - wall pipe for vents which run conforms with the current edition of the Nation through unheated spaces . Fuel Gas Code , ANSI Z223 . 1 / NFPA54 . When 7 . Removing an existing boiler from a common vent : At the resizing any portion of the common venting system , time for removal of an existing boiler , the following steps the common venting system should be resized to 0 shall be followed with each appliance connected to the approach the minimum size as determined using the common venting system placed in operation , while the appropriate tables located in the chapter " Sizing of other appliances remaining connected to the common Category I Venting Systems " in the current edition venting system are not in operation . of the National Fuel Gas Code , ANSIZ223 . 1 / NFPA54 .
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Table 1 : Boiler Foundation Layout Boiler Boiler Base Jackel Foundation 1 Provid _ a good , levd foundation for the boi ] el t _ , . n mu Model Length Length Length minimum dim _ nsKJlm givun m Tahlf ] ThP fluulh _ , - - ! stlLwtura ] SklI313olt _ , t / stt , t3 ] RIU _ t h ( _ qUltdhlL ' - - 2 ! 1A 04 22 I 2 28 1 _ 40 1 / 8 " op _ , _ ating weif _ ht o _ thu h _ ) dc , i dnd any conn _ cIcc . . . . 211A - 05 28 1 / 8 ' 33 3 / 4 45 3 / 4 2 . Do not operate thin b ( ) l } _ until the [ ounoanon 11nett 711A - 06 33 3,4 39 3 / _ 51 3 8 ' concrete , has thoroughly cured â€¢ The high ternperuan _ - 211A - 07 39 3 / 8 45 ' 57 under the burners could cause major lamag _ ln _ concrete if it still contauled moisture . 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 " Do not install this boiler on carpeting or any combustible 211A - 11 61 7 / 8 67 1 / 2 ' 79 1 / 2 " flooring . A significant tfireh 211A - 12 67 1 / 2 73 1 / 8 ' 85 1 / 8 hazard would result , wi 211A - 13 73 1 / 8 78 3 / 4 " 90 3 / 4 ' potential for property damage , 211A - 14 78 3 / 4 84 3 / 8 ' 96 3 / 8 ' personal injury or death . 211A - 15 L 84318 90 " 1 102 211A - ' 6 90 ' 95 5 / 8 " 107 5 / 8 " 3 . If the boiler is installed in a penthouse or if wiring of any sort is run undumeath the boiler foundation , construc _ 1131 / 4 211A - 17 955 / 8 101 1 / 4 ' â€¢ the foundation with provision for air flow underneath 211A - 18 101 1 / 4 - 106 7 / 8 ' 118 7 8 ' between the main floor and the ' top of me boiisr foundation . 211A - 19 1067 / 8 " 1121 / 2 " _ 1241 / 2 " a ) Concrete block aligned with the openings connected 211A - 20 112 1 / 2 118 1 / 8 ' 130 ! / 8 " continuously would serve this purpose , for _ ' xampJe 211A - 21 1181 / 8 1233 / 4 " [ 1353 / 4 " If the foundation must be a concrete slab . use an air b ) 211A - 22 123 3 / 4 129 3 / 8 " 141 3 8 cell high temperature insulating board , at least V _ inch thick , with aluminum backing , aiuminun slou 211A - 23 129 3 / 8 135 " 147 up One half inch Hi Temp millboard with aluminum 211A - 24 135 ' 140 5 / 8 152 5 8 backing t _ ould b _ ' acceptable as wall . PlaG , lnu 211A - 25 140 5 / 8 146 1 / a ' 158 1 / 4 " insulating board on thu slab inside tne 0ase 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 : z l - 211A - 31 174 3 / 8 " 180 ' 192 " O uc z I - : _ Lu { 3 I - 211A - 32 180 185 5 / 8 197 5 / 8 ' z t _ z uJ 2LU 211A - 33 1855 / 8 " 191 1 / 4 203 1 / z1 ' O - J 211A - 34 191 lm 196 7 / 8 208 7 / 8 ' T 211A - 35 l 196 7 / 8 " 202 1 / 2 " 214 1 / 2 ' z < m 211A - 36 202 1 / 2 ' 208 ' / 8 220 1 / 8 ' 0 u . 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 " < BASE - 41 " â€¢ 211A - 43 241 7 8 " 247 I / 2 " 259 1 / 2 " < JACKET - 45 _ , ' â€¢ 211A - 44 247 1 / 2 ' 253 1 / 8 " 265 1 / 8 " < FOUNDATION - 57 , ' 211A - 45 253 1 / 8 ' 258 3 / 4 " 270 3 / 4 " 211A 46 258 3 , _ 264 3 8 ' 276 3 / 8 Figure 7 : Foundation Layout
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2 . ASSEMBLE THE BASE 2 . Op _ zn cl _ t _ ' numb * ' l 2 t Â£ _ 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 ] . Co ] [ _ ' cl the ! cr _ t _ ! s _ onlaU / ing the 13as _ Assemb [ _ ; palts ( able 2 machine screws and _ ' lock washers provided shows the qu ; _ ntit ' _ Â¸ Â¸ at _ ac ] _ crate r _ quired Th _ crates contain the toi ) owin9 pa _ ts : Crate i Items [ Sub - Assembly # Part # GG 2105 Right End Panel Sub - Assembly 2 Left End Panel Sub - Assembl r 90339 GG 2106 Burner SUB [ _ rt Channe [ 3s 121 3G 207 ( Front Panel Sub - Assemo â€¢ GG - 2080 Back Panel Sub Assembl GG - 2081 Burner Support'C ; nannelha _ GG - 206 { N / A 2AA Anqle Tie Brace , _ 90340 GG - 2069 Front Panel Support Bracket j Section Assemb y Kit GG - 1030 Front Panel Sub Assemb . GG - 2080 - " Back Panel Sub - Assemo GG - 2081 - " Burner SuDi ] ort Channe GG - 2066 - " 2BB 90341 Angle Tie Brace 30 2065 Front Pa _ el Suaoort Bracket GG 2069 GG - 103 ( Section Assert 3 _ y r , l [ GG - 2080 - 2 ' FBroanctk PPaanneell SSuubb - - AAsssseerma [ b3 ] L GG - 208 ] - 2 BurnerS @ port Channel GG - 2066 - 2 GG - 2065 Front Panel Support Bracket GG - 2069 1 Fsentctl _ onAssemb , y Kit GG - 103O - ' Front Pane SubAssernb . GG - 2080 3 Back Panel Sub Assemb GG 2081 3 Burner SUI ] D _ / t Channe GG 2066 3 2DD _ 0343 GG 206 . _ Angle Tie Brace ronl Paue . _ _ . . o _ Bracket GG 2069 Sect on Assertlo _ lYE GG 1030 2 Front Panel Sub - Assembl , _ GG - 2080 - 4 _ Back Panel Sub Assembl z GG - 208 ! - 4 GG - 2066 - 4 2F E Burner Support Channel 90344 GG - 2065 . . An Â£ 1e Tie Brace GG - 2069 Figure 9 : Steel Base Assembly Front Panel Support Bracket Section Assemb t Ki { _ GG - 1B30 - 3 Figure 8 : Boiler Base Assembly Base BackPanelSub - AssemblyG , G - 2081 BaseBightEnd PanelSub - AssemblyG , G - 2105 . . . . T . . . . . . . . . . T = = BACK = = ' T . . . . . . . . . T . . . . . . . T : T 41 " a . S , d0 TOP VIEW Burner Po , ition Number t RightSide Burner Support Channel , GG - 2066 Burner Support Channel Clip , 06 - 2070 BaseLeft EndPanelSub - AssemblyG , G - 2106 BaseFrontPanelSub - AssemblyG , G - 20BO FrontJacketSupportBracket , GG - 2069 AngleTie Bracew / Burner SupportChannel , GG - 2065 ( whenrequired ) F . _ _ NT VI _ V ! ! 1 â€¢ Assembly H Assembly b - â€¢ Assembly I = - â€¢ Assembly I _ < Assembly â€¢ â€¢ Assembly I _ â€¢ Assembly A B C D E F G â€¢ H ( overaHlength ) â€¢
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5 , 3 . Attach the Front Panel and Back Panel ( Figure 9 ) to the For 211 A - 09 through 211 A - 46 Only : Left Hand End Panel using 5 / 16 " - 18 x 1 " cap screws a ) Attach a Front Panel Support Bracket to each Front and hex head nuts provided . Panel as shown in Figure 11 . 4 . For 211A - 04 through 211A - 08 Only : 6 , Attach an Angle Tie Brace at each panel joint to secureg the front and back panels as shown in Figure i0 usin a ) Complete the base assembly by attaching the Right 5 / 16 " 48 x 1 " cap screws and hex head nuts . End Panel and setting the Burner Support Channel on the clips . 7 . Bolt remaining Front and Back Panels together usingle 5 / 16 " - 18 x I " cap screws and hex head nuts . See Tab 2 for panels required . Place the panels in the positions shown in the table and Figure 8 . _ Frontet Jack â€¢ 8 , Complete the base assembly by attaching the Right Hand Panel End Panel using 5 / 16 " - 18 x i " cap screws and hex head nuts . 9 . Set the Burner Support Channels in place as shown in Figure 8 . I , 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 . 3 . 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 . Figure 11 : Support Bracket Installation Front Panel 3 3 / 4 " Angle Tie Brace T 6 3 / 4 " Figure 10 : Angle Tie Brace Installation 8
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Overall Length _ r . . . . . . . . . 7 - â€¢ Assembly I _ â€¢ Assembly I _ â€¢ Assembly I _ â€¢ Assembly I _ â€¢ Assembly Ib â€¢ Assembly I _ â€¢ 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 ' 211A - 09 2BB 2BB - - i 27 / 8 211A 1 2CC 2BB 58 1 ' 2 ' 211A 11 2CC 2CC . . . . 64 1 / 8 211A 12 2DE 2CC 693,4 211A - 13 2DD 2DD ] - - 75 3 / 8 " ZIIA 14 2EE 2D [ 81 " 211A - 15 2EE 2EE - - - - _ - - 86518 " 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 ' 211A - 29 2EE 2EE 2EE 21 IA , J * 2DD 2DD 2DD 2DD 2CC 14 " - 3 ' 14 ' - 85 / 8 ' 211A - 31 2DD 2DD 2DD 2DD 2DD - - [ [ 21 IA , " 2EE 2DD 2DD 2DD 2DD 15 - 2 1,4 ' 211A - 33 J 2BE 2EE 2BB 2EE 2EE 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 " 211A - 39 2DD 2DD 2EE 2EE 2DD 2DD - - I 18 ' - 55 / 8 ' 21 IA 41 2BB 2EE 2EE 2hE 2E Â£ 2EE 18 ' i i I / 4 19 ' 4 7 / 8 " 211A 41 2EE 2EE 2DD 2DD 2EE 2EE T - - J 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
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_ : 1II : 1 / ill : I : f : T _ ' _ Â© Â© Â© Manifold Weldment GG - 4084 thru GG - 4084 - 46 Imperial # 68F 1 / 4 " NPT x 3 / 8 " O . D . Tube Straight Connector \ \ \ Orifix _ e4A0d3Pter \ \ _ Mounting Clamp GG - 3052thru GG - 3052 - 3 3 / 8 " x 3 / 8 " x 1 / 4 " Tee I 1 / 4 " Street Elbow J 3 / 8 " Pipe Cap _ Pipe Cap _ 1 / 4 " x 1 / 8 " 1 / 4 " X 1 1 / 2 " Nipple 3 / 8 " x I / 4 " Elbow 3 / 8 " Pilotstatls ) / H17CA \ \ \ Hex Bushing Ignition Control _ Relay _ \ Mounting Box Assembly3O / ( Standard System , HSP - X - 11 - 3 ) PB - H91 BG - 2 or ( Other panels mounted on Imperial # 69F Elbow H - V8046C ( 21 5 / 16 " - 18 x 3 / 4 " Square jacket front , left side ) 1 / 8 ' NPT x 1 / 4 " O . D . Tubing Pilot Gas Valve Head Set Screw Figure 12 : Typical Gas Manifold and Pilot Line Assembly 4 . Place only the Burners with pilots mounted in the 5 . Cut and fit the I / 4 " aluminum tubing provided from the locations give in Table 3 . Install the Burners by slipping pilot gas shut - off device ( s ) to the pilot burners . the opening on the front of the burner over the orifice 6 . Do not install the remaining burners until the Boiler adapter and slipping the pin on the end of the burner into Sections are installed . the hole in the Burner Support Channel directly opposite the orifice . I0
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Table 3 : Pilot Burner Locations - Numbered Right to Left ( See Figure 8 ) NATURAL GAS ONLY PROPANE GAS ONLY Total Pilot Burner Locations Number Pilot Burnei Locations Model Number of Positions Numbered Right to Left of Positions Numbered Right [ o Left ) Number Pilots Burners Electronic Pilots Standing Pilots Electronic Pilots Standing Pilots ( Spark Ignited ) IThermocouple ) Manually Lighted Whermocoupte 2ilA - 04 5 5 211A 05 1 8 5 5 211A - 06 1 10 5 - - 5 " _ 7 1 1 12 5 I 5 5 211A - 08 i 14 5 l 211A - 09 I 16 5 - - 5 I I211A - 10 I 18 5 - - 7 L 13 5 [ 211A - 11 , r 2 - 26 15 5 211A - 12 2 22 15 5 13 5 211A 13 2 24 17 5 13 5 I 211A - 14 i 2 _ 26 â€¢ . _ . . . 1 . . 7 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 3 34 25 [ _ 15 9,19,27 1 . . . . . . . - - i 211A - 19 3 36 29 5.17 9.21.29 _ - - 3 211A - 20 38 35 5.21 9 21.31 211A 21 : 3 40 { 7 5.23 9.23.33 211A - 22 3 42 19 5.39 9.23.35 211A - 23 3 44 19 5.41 9.23.37 211A - 24 3 4 _ 21 5.39 9 23.39 211A 25 3 48 25 5.45 9.23.41 211A - 26 4 50 19 5.33.47 9.23.33.45 211A - 27 4 52 21 5.35.49 9.23.35.45 211A - 28 4 54 23 5.37.51 9.23.35.47 211A - 29 4 56 27 5.39.53 9.23.39.49 5.39.51 l 9.21,39 , $ 1 1 / 211A - 30 4 58 _ 3291 211A - 31 4 60 5.41.53 9.23 , 39 , 53 J 211A - 32 4 62 33 5.41.59 9.25.41.55 211A 33 4 64 35 5.41.61 9.25.41.57 5.21.49.63 9 . 23.39.51.59 211A - 34 [ 5 i 66 3357 211A - 35 5 68 5.17.51.65 9 . 23 . 39.51.61 1 211A - 36 5 70 37 5 19.53.67 9.23.39.51.63 211A - 37 5 72 37 5.2347.65 9.23.39.51.65 74 25,55 5,43,67 2nA - 38 [ 5 76 I 23,49 5,35,69 211A - 39 ] 5 211A - 40 5 78 25,55 5,33 , 75 211A 41 6 80 19,45 5,33,57,77 Models 21 IA - 38 through 21 IA - 46 82 ! 23,51 5,31,65,79 Are Certified for Natural Gas Only 211A - 43 ] 6 84 23,53 5,33,67,81 211A - 44 6 86 21,55 5 , 33 , 67 , 83 211A - 45 6 88 23,57 5 , 37.65.85 211A - 46 6 90 25,59 5 , 39 , 67 , 87 11
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J C oo D , r - r _ _ O _ oo3 % . _ o3 o O0 F % - LO Lo r _ r _ r - TAPPINGS , EACH END SECTION A 3 / 4 " npt Tapping G 1 1 / 2 " nptTapping , Back , Blowdown B 1 / 2 " npt Tapping , Upper H 3 " npt Tapping , Pop Safety Valve ( s ) and C 1 " npt Tapping , Upper Upper Equalizer for Special Float D 1 / 2 " npt Tapping , Lower Controls ( 157 , etc ) E 3 / 4 " npt Tapping , Probe LWCO J 6 " npt Tapping , Steam Riser F 1 " npt Tapping , Lower K 6 " npt Tapping , Return Figure 13 : Assembling Sections on Base 12
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3 . PLACE THE BOILER SECTIONS 1 Check the level of the Boiler Base using a spirit level â€¢ 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 â€¢ All foreign matter must be removed to assure a proper seal when the sections are drawn together â€¢ Gaskets will be damaged by petroleum or its derivatives . Completely remove all solvent residue before placing gaskets â€¢ Do not use petroleum based compounds in the boiler . Figure 15 : Placing the First Section on Base Flat Machined Recess Machined Face Face 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 â€¢ Keep the section upright by a supporting prop or other means â€¢ The sections are heavy and must be supported securely â€¢ . Align the parting line of the section with the seam Flow Port between the Base End panel and the Base Front Panel Gasket as shown in Figure 13 . 4 . Apply Hi - Temp rope seal by spreading a thin coat of â€¢ 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 â€¢ NOTE : The ends of each rope must extend _ / ' beyond the top and bottom . S . Place the Flow Port Gaskets in the recesses provided ( see Figure 14 ) . Do not use adhesive . 6 . The following steps must be followed to insure that no damage is done to the tie rod lugs . A 0 100 ft . - Ibs , torque wrench is required â€¢ a ) Place an Intermediate Section on the base and slide it carefully against the Left Hand End Section . Figure 14 : Flow Port Machining b Gasket b ) Align the flow ports from front to back , as close as possible . c ) Insert a tie rod into each of the lugs on each section and app } y a nut and washer to each end of the tie rod . I . Begin by placing the Left Hand End Section on the left end of the base , The upper flow port goes toward the d ) Before tightening , check the vertical alignment of the front of the boiler as shown in Figure 15 . sections using a spirit level ( see Figure 16 ) . Make sure they are square with the Base 13
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Place Tapped Intermediate Sections Boiler Model Number at Positions ( Numbered Left to Right ) 211A ] S iU 211A - 19 10 211A 2 { I H 211A - 21 11 211A _ 7 211A - 23 & 16 211A 24 9,17 Spirit 211A 25 7 , 13 , 19 Level 211A 26 7 , 1 : _ 20 211A - 27 7 , 12 , 17 , 22 211A 28 5 11,17 23 211A - 29 5 . 10 . 15.20.25 211A 3 ( 11 . lb . 21.2b Left Hand 6 . 10 . 14 . 18.22 . 26 211A - 31 - " Et _ d Section 211A 32 o . 1 ] 15.19.23.27 11A - 3 " s . 9 . la . 17Z - Â£ TT - . . . . . 1 211A 34 5 9 13.17 22 26.30 Base / Assembly 5.9 . 13 . 18.23.27.31 211A 35 211A 3 ( 5 9.13 17 . 21 2 [ 29.33 5.9 . 13 . 17.21.25.29.33 q 211A - 37 211A 38 4 8 12 1722.27.31 35 Figure 16 : Align Sections Vertically 211A - 39 4 8 . 12 . 16.20.24.28.32 : . 36 _ ] ZllA4 ( 4 8 12 16.21 25.29.33.37 e ) 211A 41 4.8 12 16.19.23.26.30.34.38 Draw sections together evenly , alternating between top lug and bottom lug in increments of 20 ft . - lbs . 211A - 42 a _ 12 16 2023 27 31 35.39 Continu { , until both top and bottom lugs are 211A 43 4 . - 11.14.18.22.26.30.33.37.40 tightened to 60 It . lbs DO NOT EXCEED 60 FT - LBS 211A - 44 a - 12 16 19 23.26 29.33 37 41 4 . - 11 14.18.21,25,28 32.35.39.42 211A45 f ) Check the level while tightening to make sure 211A - 46 4 11 14 18 22 25 29 33.36,40,43 alignment stays true Also make sure sections remain square with the Base from front to back as the tie Figure 17A : Section Positioning Numbering rods are tightened and as additional sections are installed . 9 ) 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 â€¢ 1 . The supply and return piping can be permanently erected before applying the Boiler Jacket if the pipe 7 . Assemble the remaining sections in the same way for a nipples applied to the boiler tappings are long enough to finished assembly as shown in Figure 13 . clear the jacket . 8 . Some of the Intermediate Sections have tappings for . Install a drain cock in the tapping provided at the bottom installing additional steam risers from the boiler . These rear of each section . Tapped Intermediate Sections must be installed as shown 3 . in Figure 17A . The placement order is left to right ( Figure Provide a water supply line to the boiler . 17 ) . 4 . Plug all open tappings in the boiler . Left Hand End Section , Position Number 1 5 . Provide a means to vent air as the boiler fills . 6 . Fill the boiler with water , venting air as water level rises . 7 . Pressurize boiler to 45 psig . Do not exceed this plregsulre ' ! f ! lf ! ! f ' ' l . I ' . l . F . ' l i = , a ) Maintain pressure while checking all joints and r ; 1 , , , , , , - _ _ _ " fittings for leaks b ) After inspection is complete , drain the boiler and 1 3 5 43 45 remove plugs from tappings that are to be used . Figure 17 : Section Positioning Numbering 14
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4 . INSTALL THE FLUE COLLECTOR 1 . ColDct the l : lu _ ' Coikzctor cartons . The Flue Cdlactot LongHookBolt , sections are ] abal _ , d on tile part and on the carton See HiTempRope AngleBracket , Table 4 for the items needed . GG - 50O5 6G - 5003 2 . Install Hi Tamp Rope for each collector section as shown in Figure 18 . The rope provides the seat to prevent flue ' \ gases from leaking from the collector . Make certain that \ , \ TieRod \ \ X â€¢ 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 \ ShortHookBolt , right when facing the front of the boiler â€¢ 6G - 5004 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 . Figure 19 : Installing Flue Collector Sections 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 . Figure 18 : Applying Flue Collector Hi Temp Rope Gasket 15
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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 i F Boiler Position Position ! Position Position Position ! Position Position Position Position Model 3 1 2 4 5 6 7 8 9 Number 211A - 04 14 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 14A ! 14A 14 : - - - - - - 2i1AL13 14A i 14A 14A 211A - 14 14B - - - 14A I 211A - 15 14B 14A 21 ] A - I6 14B 14B 14B - - I _ _ 14A 14A 211A I7 14A 14A 211A - 18 14B 14A 211A - 19 14A 14B _ 4B E 4A L - - 14B i 14A - - - - 211A 20 14B 14B 2iiA - 21 14B 14B 14B ! i4B 211A23 14B _ i4B 14A _ 14A _ 14A 211A24 14B 14B 14B 14A 14A m i 211A25 ! i4B 14B IqB 14B 14A T 211A - 26 211A - 27 14A [ - - _ 4B | 14B _ 4A - _ 14 A [ 211A - 28 14A 211A - 29 14B 14A 14A - - i - - 14B 14B 14B | 211A - 30 1413 14B i4B l 14B l - B i I - I - 211A - 31 14B 14B l 14B L 14B L 14B ! 14B I - I - / - 211A 32 14B 14B 14B 14A 14A 14A 14A ! , 211A 33 14B 14B 14B 14B 14A ! 4A 14A 14B 14B 14B 14B 14B I 211A - 34 14A 14A - - 14B 14B 14B 14B 14B | I _ 211A - 35 14B ! 4A - - 211A - 36 ! 14B 14B 14B 14B 14B 14 2 14B 211A - 37 14B 14A 14A 14A 14B 14B 14B 14A 211A - 38 . AI . A 114B . B ] . B I . B - - 211A - 39 14A 14A 14B L 14B 14B 14B 14B 14B - - 211A40 14A 14B 14B 14B 14B 14B 14B 14B . i 14B i4B 14B i / 211A - 4i 14B i 14B , 14B 14B 14B 14B 14B 1 1413 14B 2 _ ii _ : : ia _ ; - i _ X 1 i4A - I i _ g 14B 14B 14B L 14B 14B ; 211A _ 44 14A i4 ; 14B - - 54B IQB 14B : 14B 14 2 14B 211A - 45 14A 14B 14B 14B 14B 14B 14B 14B 14B i 2iiA _ i4B 14B 14B _ i 14B i i4B I 14B â€¢ 14B ] 14B i 14B _ i [ I 1 16
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5 . PIPE THE BOILER 7 . 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 . 1 The boiler must be pressure tested as outlined in Chapter 3 . " Place the Boiler Sections " , of this manual 8 . Do not reduce the size or number of risers shown These are required for reliable operation of the boiler . If 2 TheSupplyandReturnpipingcanbeinstalledbeforethe the risers are undersized or incorrectly placed , a sloped jacket is applied . Use nipples long enough to be sure they water line can occur in the boiler , causing possible will extend through the jacket . overheating of some sections . 9 . Pipe the Header with an offset as shown in the drawings . This offset prevents the expansion and 1 Install End Riser connections sized per Table 5 . The 3 " contraction of the Header from damaging the boiler tappings in the tops of the end sections are not used for sections . steam boilers . 10 . Always locate the Steam Supply take - off between a ) Install a reducing tee on one end riser . Install a 2 " the Equalizer and the last Boiler Riser . ( See valve , nipple and cap for skimming the boiler in the Peerless Heater Company's " Steam installation Survey " tee as shown in the piping drawings . for discussion ) . Locating the Steam Supply between the risers will cause water carryover to the system . 2 . Models 211A - 08 and larger require risers in both end sections . 11 . Do not use a bull head tee to provide steam supply and equalizer connections . This will cause water level bounce 3 . Models 211A - 18 and larger require additional 3 " and carryover . 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 I . We recommend the use of a Hartford loop in all carrying over into the header and then to the system . installations . The loop provides additional reliability fore the system . A check valve must still be installed on th 5 Figure 21 shows the Supply and Return piping for pump discharge of all pumped return systems . Parallel Fk _ w Gravity systems and all Pumped Return Systems . . On pumped return systems , install a boiler cock after thee pump to allow throttling of the pump discharge . Th 6 . Counterflow Gravity systems require the boiler steam line pressure after the boiler cock should be no more than 5 to enter the top of the steam main . See Figure 22 for this psig above the boiler operating pressure . Pumping the special case . Steam Steam Supply should always Supply be piped between last boiler riser and equalizer . ix BOILER HEADER - Pipe with offset to allow for header expansion 24 " Min . \ { Water " " , . ' Useclose YI " " - - _ - - , . nipple on y JJ " Hartford , Loop _ ! _ " Hartford q - " _ ' , Loop i Figure 20 : Supply and Return Positions , Skim Piping , Hartford Loop 17
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Steam Second Equalizer Supply 1A - 16 and Larger i ] Steam _ _ Supply Return Connection 2 " Skim Connection 2 ' Skim 211A - 04 TO 211A - 07 SINGLE END RISER 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 18
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Boiler Riser Piping enters TOP of main I Figure 24 shows typica { piping for multiple boiler Gravity on Counterflow Return systems . Figure 25 shows typical piping for multiple boiler Pumped Return systems â€¢ System - , _ 2 . Provide separate feed lines for multiple boiler pumped return systems â€¢ Use eithez separate feed pumps or Counterflow solenoid valves to isolate feeding of the boilers . This is Steam Main needed to provide reliable level control and avoid nuisance performance problems . 3 . Condensate return units are not effective for multiple Pitch boiler installations since they do not respond to the needs T of the boilers â€¢ Always use Boiler feed units â€¢ Equalizer 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 â€¢ Table 5 : Header , Risers 8 " Equalizer Sizing il Boiler Header [ = - - End i : h - sers - ] interm . _ Equalizers 2 " Skim Connection 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 Figure 22 : Supply and Return Piping - L211 = _ - , - _ _ " I 1 LEI - / - ! 1 / 2t / z ' Connterflow Gravity Systems 211A - 08 6 " 2 4 " - - ' 1 2 1 / 2 " I 211A - 09 6 2 5 - , - 1 2 1 / 2 water into the boiler too fast will cause collapse of the 2t _ A - lO [ 6 " _ 2 _ : _ : I I 1 I aQ water level and level control problems 211A - 12 8 " 2 5 " - i - i 1 3 " 3 . Size the equalizer per Table 5 . 211A - 13 8 " 2 5 " _ - - ! I ] 3 " 4 , Pipe the Hadford loop tee so the inside top of the close 21iA : 14 8 ; i V 2 V 5 ; ' , : " q : I " i - 3 " " nipple is 2 to 4 inches below the boiler water line . 211A - 15 8 ' I 2 1 6 ' _ - _ - [ 1 I 3 " ] 211A : 16 8 " ' 2 6 " " _ 2 [ 4 " i 5 . If the pump discharge is looped overhead â€¢ above the 211A 17 . 8 " _ 2 6 " 2 4 " boiler water line , install spring - loaded check valves at both the pump discharge and the connection to the boiler 211A - 19 8 " I 2 6 " L 3 ' _ 1 1 _ _ _ _ [ _ I 4 " return . i 4 . iJ 211A - 20 8 " _ 2 6 " 3 " 1 2 F 211A - 21 8 " 2 6 " 3 " 1 2 4 " 211A - 22 8 " I 2 I 6 " I 3 " 2 2 4 " 21 _ A - 2381 " _ 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 6 " 3 " 9 2 5 " , 21tA41 10 " 2 6 " 3 " 10 2 5 " % 211A - 42 : 10 " ! 2 6 " i 3 ; ' I - 3 _ - 2 [ _ i 211A - 43 I 10 " 2 211A 44 12 " 2 6 " 3 " 11 2 5 " 211A - 45 12 " 2 o " 3 " 12 2 _ " Figure 23 : Left Hand Piping Arrangement - L _ [ Typical , 1211A - 461 12 " 2 6 . [ 3 . I _ 2 ] 2 I - g ! i 19
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Stop Steam Valve Supply Pipe All Headers Minimum 24 " Above Boiler Water Line Stop t Valve Stop Valve Return Figure 24 : Piping Multiple Boilers , Typical , Gravity Return Systems Steam stop Supply Valve Pipe All Headers Minimum 24 " Above Boiler Water Line " : 5 F / T Drip To recover Trap Valve ; olenoid or Motorized Valve Boiler Cock for ThtotBing Pump Pressure to Boilers ChecVkalve TO Pump Alternate Piping : Use two separate pumps , separate return lines and no solenoid valves Figure 25 : Piping Multiple Boilers , Typical , Pumped Return Systems 20
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6 . INSTALL THE JACKET 8 DRAFT HOOD 3 . 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 1 . Collect the Jacket cartons and Draft Hood cartons flange of the Left Front Corner Panel . Line up the wscrews . ( numbers 12 and 13 ) . holes and secure with ten # 10 x _ , z ' " sheet metal scre 2 . See Figure 27 for the Jacket Assembly . Use these 4 . Insert the offset flange of the Upper Rear Panel under the drawings for part identification and location . edge of the Left Rear Corner Panel . Place the left edge 3 . See Figure 28 for the quantity of each carton required of the panel over the Right Rear Corner Panel . Line up the holes and secure with ten # 10 x _ ' > " sheet metal and placement of the jacket sections on the boiler . screws . 4 . See Table 6 for the contents of each Jacket Carton and Draft Hood carton . 5 . Apply the Lower Rear Panel using the same procedure and secure with two # 10 x ! / _ " sheet metal screws . 5 . See Table 7 for the Draft Hood cartons required . 6 . Install Rear Panel Support Leg ( GG 6028 ) inside the Left Rear Corner Panel . The flanges extend toward the boiler . Line up the holes and secure with three # 10 x _ / / ' sheet metal screws . i . Remove Cleanout Cover Plates from carton 12 . 7 . Attach the Lower Rear Panel Guide ( GG - 6031 } to the 2 . Install one cover plate on each End Section . Use four Rear Base Panel as shown in Figure 27 . 5 / 16 " - 18 x 2 " studs , 5 / 16 " - 18 hex nuts and 5 / 16 " fiat washers . 8 . Install the Draft Hood . Work from the left side ( facing the front ) of the boiler to the right . Apply the Draft Hood 3 . Seal around the cleanout plates using the furnace cement Sections in the sequence given in Table 7 . Attach the provided . Also apply between base and bottom of Hood sections to the Flue Collector with two # 10 x _ / / ' sections . sheet metal screws per collector section . 9 . Insert the offset flange of the Jacket Top Panel under the Top Left End Panel . Place the right flange on the Top I . Remove necessary knockouts from the Jacket End Panel Right End Panel . The front edge flange goes over the pieces in carton 12 . Jacket Front Panel . Line up the holes and secure with # 10 x 9 / ' sheet metal screws . 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 . The boilers have multiple intermediate jacket panels . I / 4 - 20 x V / ' machine screws and V4 " fiat washers . The locations are : 2 . Collect the jacket cartons listed in Table 6 . When installing the jacket panels , place them on boiler in the â€¢ Right Front - GG - 6015 order shown in Figure 28 . â€¢ Left Front GG + 6016 Open the cartons in the order listed in Figure 28 . â€¢ Right Rear GG - 6017 3 Install the Jacket Front Panels : â€¢ Left Rear GG - 6018 4 . â€¢ Make sure to slip the Front Panels into the Front Panel 4 . Attach an End Panel Cover Plate ( GG 6030 ) to the Support Brackets ( mounted on the base ) . See Figure 27 . opening on the Upper Left End Panel ifthe 6 inch tapping on that end is not used . Install the first Front Panel with the left edge over the Left Front Corner Panel . Line up the holes and secure 5 . Attach Upper Left End Panel ( GG 6032 ) to the left end with # 10 x Vi ' sheet metal screws . corner panels with five # 10 x V / ' sheet metal screws Continue applying Front Panels this way . 6 . Place Top Left End Panel ( GG - 6020 ) over the Corner Slip the right edge of the last Front Panel under the Panels and Upper Panel with flange pointing downward . Right Front Corner Panel . Line up the holes and Use four # i0 x _ / 2 " sheet metal screws . secure with # 10 x V _ " sheet metal screws . 7 . Repeat for the Right End . 5 . Install the Jacket Rear Panels : â€¢ 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 I . Apply Front and Rear Panels as follows . â€¢ Attach the first Lower Rear Panel inthe same way . 2 . Open Jacket Intermediate Section carton . 12A , B , C , D â€¢ Attach a Rear Panel Support Leg on the inside of the or E , per Table 6 . Remove necessary knockouts from Upper Rear Panel . The flanges point toward the panels . boiler . Attach with # 10 x _ sheet metal screws . 21
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â€¢ Instaall PaneSl upporAt ngleontheinsidetopofthe 5 . Apply the last Top Panel in the same way . Place its right UpperRearPanel ( SeeFigure27 ) . Use # I0 x _ / " hand edge over the Top Right End Panel . Secure with sheemt etasl crews . # i0 x Vi ' sheet metal screws . â€¢ Install the remaining Upper Rear and Lower Rear 6 . Check for loose or missing screws as you complete the Panels in the same way . jacket assembly â€¢ Place the edge of the last rear panel ow , i the Right Rear Corner Panel . 6 . Install the Draft Hood Sections : 1 . THIS APPLIES TO ALL BOILER SIZES . â€¢ Start from the left of the boiler ( facing the front ) Apply the Draft Hood sections from left to right in the order 2 . The parts are packed in carton # 12 . given in Table 7 . 3 Attach an End Panel Cover Plate to the opening in the â€¢ Use two # i0 x Vi ' sheet metal screws for each Flue Lower End Panel ( GG - 6022 ) if the tapping in the boiler Collector section . is not being used . Secure with two # 10 x V / ' sheet metal screws . 4 . Apply a Lower End Panel to each end of the boiler . securing to the Corner Panels with eight # i0 x _ / z " sheeto I . Apply the jacket top panels working from left to right metal screws Attach to the Upper End Panels with tw ( facing front of boiler ) . Place the panels from the cartons # 10 x V . / ' sheet metal screws . 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 I . Mount Boiler Rating Plates , Agency Plates and Caution back edge of the panel for better contact . Secure with one Labels on the Upper Right End Jacket Panel . # I0 x _ " sheet metal screw . 2 . Plates to be field applied are packed in Box Number 7 . 3 . Slide the left hand offset flange of the first Top Panel 3 . Place these plates as shown in Figure 26 . under the Top Left End Panel , Place the front flange of the Top Panel over the Front Panel . Line up the holes 4 . Secure metal plates with # 6 x V4 " sheet metal screws . and secure with # 10 x Vi ' sheet metal screws . Apply all adhesive - backed labels . 4 . Slide the left hand edge of each additional panel under the panel to its left . Secure with # I0 x _ zi ' sheet metal screws . Figure 26 : Location of Rating , Agency and Instruction Plates on Upper Right End Panel 22
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Top Panel ( GG - 6024 ) Right End Panel ( GG - 6019 ) Top Left End Panel ( GG - 6020 ) i - Upper Left End Panel ( GG - 6032 ( GG - 6023 ) I _ Front Panel Lower End E . Right Front Panel Corner Panel ( GG - 6022 ) ( GG - 6015 ) Corner Panel Support Bracket - - Front Jacket Panel ( GG - 6029 ) Support Bracket ( GG - 2069 ) Left End Corner Cleanout Cover Panel ( GG - 6016 ) Plate Assembly ( GG - 60O4 ) Top Panel ( GG - 6024 ) Panel Support Angle ( GG - 6027 ) Draft Hood ( GG - 50Ol Right Rear Corner Panel ( GG - 6017 ) Upper Rear Panel - - ( GG - 6025 ) Lower Rear Panel Guida ( GG - 6031 ) Lower Rear Panel ( GG - 6026 ) j - / / - Left Rear Rear Panel Support Leg Corner Panel End Panel Cover Plate ( GG - 6028 ) GG - 6030 ( GG - 6018 ) Figure 27 : Jacket Assembly 23
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â€¢ ' , . : : 1 â€¢ ' _ . _ oo _ Table 6 : Jacket and Draft Hood Carton Contents - See Figure 27 for Placement of Jacket Sections Ca _ on No . Contents Sub - Assembly No . Part Number Quantity ' Cleanout Cover Plates GG - 6004 1 _ I GG - 6015 I Jacket Corner Pane ! , Right Front Jack _ ' t Cumin Pan _ ' ! Leit Front G ( J 6016 l GG - 6017 r 1 Jacket Corner Panel . Right Rear [ . . . . GG - 6018 _ 1 I Jacket Corner Panel , Left Rear Corn _ i Pan _ l Support Brackets GG 6033 GG - 6029 4 12 GG 603Z 1 â€¢ Jacket Upper End Pane ! . Left Jacket Upper End Panel , Right _ 21 _ i - GFG 6 - 6o3o 14 - . . . . . . . . . z . . . End Pane ! Cover Plates Jacket Lower End Pane ! s , GG 6022 2 Sheet Mete ! Screws Machine Screws , Washers . Nuts Jackefl l _ ermediate Panel - Front 1 Jacket Intermediate Panel _ . . . . GG - 6023GG _ 6024 A ] il . . . . . . . Jacket IntermP & ate Pane ! - Upper Rear I GG 6025 1 Jacket Intermediate Panel Lower Rear 12A GG - 6034 GG - 6026 I Panel Suppor _ _ Angle GG - 6027 [ 2 GG - 6028 1 | Rear Panel Sup _ o _ l _ fl Lower Rear Panel Guide GG 6031 1 23 Sheet Metal Screws . . . . . . 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 GG - 6023 - 2 _ I Jacket Intermediate Panel - To _ _ 2 I _ _ _ _ GG 6025 - 2 i Jacket Intermediate Panel - Upper Rear I Jacket Intermedmte Panel - Lower Rear GG - 6026 2 2 12C Panel Support Angle GG - 6034 - 2 GG - 6027 GG - 6028 Lower Rear Panel Grade GG - 6031 , 1 Sheet Metal Screws 23 Jacket Intermediate Panel - Front GG - 6023 - 3 GG - 6024 - 3 Jacket Intermediate Panel - Top 1 GG - 6025 3 1 Jacket Intermediate Panel - Upper Rear GG - 6026 - 3 1 Jacket Intermediate Panel Lower Rear 12D GG 6034 3 GG _ 027 Panel Support An _ te GG - 6028 Rear Panel Support Lower Rear Panel Guide GG - 6031 ' 1 23 Sheet Metal Screws Jacket Intermediate Panel - Front GG - 60234 Jacket Intermediate Panel - Top GG 6025 - 4 1 Jacket Intermediate Panel - Upper Rear ' 1 Jacket Intermediate Panel Lower Rear GG - 6028 I Lower Rear Panel Guide GG - 6031 Sheet Metal Screws 23 GG 5001 I Draft Hood Section 13 GG - 5001 Sheet Metal Screw _ GG - 5001 - 1 Draft Hood Section GG - 5 _ I - I 13A . . . . . . j She _ Met _ Scre _ . . . . . . Draft Hood Section GG - 5001 - 2 1 13B Sheet Metal Screw _ . . . . . . . . . I Sheet Metal Screws 24
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35 37 39 41 43 45 21 23 25 27 29 31 33 1 3 5 7 9 11 13 15 17 19 Number of Ca _ ons Boiler Model _ m 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 25 45 A I A ' ! A Figure 28 : Jacket Assembly Sequence - Carton Numbers and Locations _ J7
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Table 7 : Draft Hood Section Placement ( from Left to Right Facing Front of Boiler ) ModeIB Â° ilelirPosition , Position2 Position3 Position4 Position5 Position6 Position7 Position8 Position9 211A 04 13 211A 05 13A I = 211A - 06 [ 211A - 07 ; L 13A 13 ! 2uA - os 13A , L 211A709 _ 13A ii 211A - 10 13C 13B " ! i 211A - ! ! 13C 13A 13 i 211A - 12 13A 13A ! 13A , 211A 13 13A t 211A - 14 I 13C 13B 13B l 13B 13C 211A - 16 13C 13C 13C [ 13B 211A - 17 13B 13B 13B i i i 211A - 18 13C 13B 13B 13B ! - , i i 211A - 19 13B 13C 13C 13B | 211A - 20 ! 13C 13C 13C 13B 13C 13C 211A - 211 13C 13C 211A - 22 13C 13B 13B 13B 13B 211A - 23 13B 13B 13B 13C 13C 13C 13B 13B 211A 24 13C 13C 13C 13C 13B 13C [ 13C 13C 211A - 26 13C 13C 211A - 27 13C 13C 13B 13B 13B 13B I 211A - 28 13C 13C 13C 13B 13B 13B 13C 13B 13B 211A - 29 13C 13C 13C 13C 211A - 30 13C 13C 13C 13C 211A - 31 13C 13C 13C 13c 13cL 211A 32 13C 13C 13C 13B 13B 13B 13B 211A - 33 13B 13B 13C 13C 13C 13C 13C 13B 211A - 34 13C 13C 13C 13B 211A45 13C 13C 13C 13C 13C 13C 13C 13C 13C 13C 13C 211A - 36 : 13C 13C i 13C i 13B 13B 13B 13B 211A - 37 13C i 13C 13C i 13B 13B 13C 13C 13C I 13C 211A - 38 I 13BB 13C 13C 13C 211A - 39 13 13B lac 13c j 13c 13C 13C 13C 13C 13C 211A - 40 13B 13C 13C 13C 13C 211A - 41 13C 13C 13C 13C 13C 13C 13B 13B 13C 13C 13C 13C 13C 211A - 42 13B 13B 211A - 43 13B 13B 13B 13C 13C 13C 13C 13C 13C ! 211A - 44 13B 13B 13C 13C 13C 13C 13C 13C 13C 13C 13C 13C 13C 13C 13C 13C 13C 211A - 45 13B I i3d i i 211A46 I 13C 13C _ 13C [ 13C _ 13C I 13C _ 13C 7 13C 26
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7 . CONNECT GAS PIPING 2 Connect the Pilot Line to the , Pilot Cock Assembly supplied with the Gas Control Train 1 The Gas Control Train ( s ) supplied with this boiler : 3 Connect tubing to each pilot s Has been factory assembled and tested for tightness a ) Connect electronic pilots to the Pilot Gas Valves . of joints , b ) Connect standing pilots ( when supplied see Table â€¢ Mustbere - testedafterinstallationwithasoapsudstest 3 ) to the Pilotstats . to assure it is still leak tight after assembly . c ) Install thermocouples in the standing pilots and â€¢ Must be isolated from the gas supply piping during connect to the Pilotstats 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 1 . Gas Pressure Regulator Models 211A - 04 through 211A 18 are supplied with a single Gas Control Train . Models 211A - 19 and larger are a ) Connect regulator vent outlet to outside atmosphere supplied with two or more Gas Control Trains . using V4 " tubing or as required by local codes . b ) Terminate the tubing downward to prevent water 3 . Support the Gas Control Train ( s ) with a permanent brace . 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 . I . Use 3 / 8 " aluminum tubing or as required by local codes 3 2 14 1 Pilot Gas Pressure Regulator 2 Pilot Cock 3 Line Gas Pressure Test Tapping 4 Pilotstat ( One per Standing Pilot ) _ 1 15 5 Red Pilotstat Indicator Button 6 PiiotGas Valve ( One per Spark : ignited Piioti 7 Pilot Gas Line Vent lines separately . Connect Valve Bleed 8 Pilot Tubing , 3 / 8 " OD Aluminum line to bleed line to a 9 Electronic Pilot ( Spark Ignited ) , Typical standing pilot ( when 10 . lgnit ! gn / Sensing Cable to Pilot , Typical supplied ) or outside if required by local 11 i Electronic Pilot Ground Wire , Typical codes 12 Standing Pilot ( Manually Lighted ) , Typical 13 Thermocouple to Standing Pilot , Typical g 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 8 1 _ 14 19 Gas Valve Bleed Line to Outside Atmosh # . 20 High Gas Pressure Switch ( Over 2500 Btuh ) 21 Ignition Control Panel 21 11 6 _ - - - 5 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 ) 27
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2 Diaphragm Gas Valves a ) Pipe diaphragm gas valve bleed lines to outside 1 , atmosphere unless the boiler is equipped with a Size the piping as required by the National Fuel Gas standing pilot . On standing pilot boilers , pipe the Code . ANSI Z223 1 , _ FPA54 or as required by local valve bleed lines to the bleed piping pre - installed to codes the pilot burner a ) Use Table { 4 for sizing of natural gas for a system b ) Use _ ' F tubing or as required by local codes Always pressure drop of 0 3 inch water column pipe the bleed lines separate from the regulator vent 2 . The standard gas train is designed for a Maximum lines pressure of _ / 2psig ( 14 inches water column ) Make sure c ) When piping bleed lines to outside , terminate the the system regulator will not allow a higher pressure to tubing downward to prevent water from entering the the Gas Control Train under any conditions tubing , and protect the tubing teimination from any 3 . obstruction . Terminate the tubing above and wel } The Minimum gas supply pressure is listed on the Boiler away from normal breathing level or building air Rating Plate . Make sure the system regulator and the intakes piping are sized and adjusted properly to provide this pressure under all conditions . 4 , Install a Service Valve . Sediment Trap and Ground Joint Union at the supply connection to the Gas Control Train as shown in Figure 30 . These are not supplied with the To Gas Supply - _ boiler . Install them in accordance with local codes . . Use only pipe joint compounds rated for use with Liquefied Petroleum Gases . Service Valve - _ 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 Ground Joint Uni _ i _ b ) Test pressure over _ / 5psig Disconnect the gas supply piping upstream of the Boiler Manual Shut - Off Valve J Do not expose the Gas Control Train to excessive pressure . The gas valves can be damaged . This could result in To Boiler Gas Control Train " _ n explosion hazard and severe personal injury or death . Do not test gas supply piping Sediment Trap _ ' _ JT ; ! with open flame . Use a soap suds mixture brushed onto the Figure 30 : Gas Supply Connection to Boiler pipe joints to test for leaks . 28
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Table 8 : Capacity of Gas Supply Pipe in Cubic Feet Per Hour of Natural Gas for 0.3 inch Drop 1 1 / 2 " 2 _ 9 21 / 2 " 3 " 4 " 6 " Pipe Length 1 V4 " ( Feet ) Pipe Pipe Pipe Pipe Pipe Pipe Pipe J 1 1 ( } 1050 1600 3050 4800 8500 17500 44000 _ o _ o ' , , oo _ ! 00 _ 3o0 5oo _ I i _ ooo3i [ , o0o l 30 590 890 1650 2700 4700 9700 I 25000 4o 500 ! 1451o I 4,0o 22oo0 50 440 670 1270 2000 3600 _ _ 1 7400 / 20000 T . . . . . . . . . . . t - [ - - 18000 60 , 4 ; 0 ; ] ; _ 1150 _ 1850 J . 32 ; 0 + 6800 70 350 560 1050 1700 3000 i 6200 17000 [ 490 930 1500 2600 5400 15000 90 I 320 100 305 460 ' 870 1400 2500 i 5100 14000 " i 380 710 1130 2000 4i00 11500 , : 150 250 . . . . . . . . . . . . . . . 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 : 0.70 - - = = SpecificGra ; iU = _ 0.50 i _ : 55 i ] ; : 6 ; ] 0.65 1.00 . 962 . 926 Multiply Capacity by : 110 1.04 I . . . . . . . i = 29
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8 . INSTALL CONTROLS AND TRIM 1 Pipe the Pop Salety Valve ( s ) in the 3 " " tappings located 1 Mount the float type Low Water Cutout and Gauge Glass on the right or left end sections Make sure the relief valve in the tappings provided in the front of either end section . sizing meets local code requirements â€¢ 2 . 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 Pipe the discharge of the Safety water carryover to the system . Valve away from any traffic area , . For correct location of typical low water cutout ! feeder or preferably to a floor drain . Thisy low water cutout / pump control , see Figures 33 through ts necessary to prevent injur 36 . should the valve discharge . 4 . Mount the probe type low water cutout supplied with the Pipe the discharge full size of boiler . The end sections have % " tappings in the front valve outlet . 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 1 . [ nstall a I V2 " full port ball valve in each of the tappings can be supplied with either the Hydrolevel Model provided at the lower back of the end sections . See Figure 31 550P or the McDonnell & Miller Model PS850M . 5 . Provide each float low water cutout with a blowdown 2 . Pipe the valve discharge to a floor drain if available or valve . Pipe the blowdown away from traffic to a floor apply a nipple and cap to close off when not in use . drain if available â€¢ The blowdown valve is required for proper maintenance of the control . 6 . Maintain a height of 40 Vi ' from boiler foundation to the Install Boiler Pop Safety Relief normal water level . Valve ( s ) in 3 " End Section Tapping ( s ) 7 . When using Multiple Float Type Controls : Always pipeott Pipe Safety Valve Discharge the controls off of the same tappings to the boiler . Do rnen to safe location , preferably to mount on different ends of the boiler or in diffe a floor drain tappings . This can cause erratic operation and nuisance 2 " Skim problems with the controls . Connection I . 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 12 ) 1 W ' Blowdown Valves operation and service ( trap ip off servicing , control replacements or other ) . Figure 31 : Blowdown Valve Piping 30
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S Option 1 F D C D S C Option 2 C S A \ C G A 3 / 4 " x 3 " Nipple 3 / 4 " X 3 / 4 " X 1 / 4 " Reducing Tee B H 3 / 4 " Cross 3 / 4 " x 4 " Nipple C J 3 / 4 " x 5 " Nipple 3 / 4 " Plug K D 1 / 2 " x 6 " Brass Nipple 3 / 4 " x 1 / 2 " Hex Bushing P E Steam Gauge 3 / 4 " x 1 / 4 " Hex Bushing S F Pressuretrols 1 / 4 " x 3 " Brass Nipple ( Right Hand Shown , Left Hand Opposite ) ( NOTE : Some local codes may require larger piping ) Figure 32 : Pressure Control Piping ( Fittings Included with Boiler ) 31
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â€¢ t _ lli _ - * _ 1 _ 1JflhV _ l . . . . . . . . . . . l . - | 8 1 / 2 " Burner Cut - Off Level - - Water Line t 4 " ! 1 3 / 4 " ] _ _ r f . . . . . . . . . 2 " - 1 / 2 ' _ 5 " Conduit Connection J i 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 32
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C C B D H C A J Burner Cutoff Level ( Mark on Casting ) Normal Water Line : / 12 5 / 16 " 4 _ 4 12 " E Install 1 " Blowoff Valve Boiler Foundation 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 33
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C C D G . i _ C B A H F J H Normal Water Line 2 n - . - Control Center Line r - ! â€¢ 3 / 4 " Feeder Closing Level ( Mark on Casting ) 12 7 / 8 " Burner Cut4Off Level is 1 1 / 2 " Below Center Line on 51 - 2 and 51 - S - 2 Controls E ( 2 3 / 4 " Below Normal Water Line ) D D 40 1 / 2 " l , B _ ' 4 1 / 8 " - _ 8 1 / 8 " install 1 " Biowoff Valve iJ I ' Boiler Foundation APPLICATION OF 51 FEEDERS SUGGESTED FII - rlNGS LIST Models 211A - 04 thru 211A - 23 A 1 " Cross One 51 - 2 Feeder / Cutoff B 1 " Ground Joint Union C 1 " Plug Models 211A - 24 thru 211A - 39 D 1 " x 3 " Nipple One 51 - S - 2 Feeder / Cutoff E 1 " x 5 1 / 2 " Nipple F 1 " x 8 " Nipple Models 211A - 40 and Larger G 1 " x 8 1 / 4 " Nipple Two 51 - 2 Feeder / Cutoffs H 1 " x 19 1 / 2 " Nipple J 3 " x 1 " Bushing Consult Factory for proper application of feeders . Always use a pump control and boiler feed system The connected fittings shown on this drawing are instead when possible . to be supplied by the installer . Figure 36 : Optional Feeder / Low Water Cutout , Type 51 - 2 34
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9 . WIRE THE BOILER 1 All wiring must be done in accordance with local codes . 1 Mount th _ conlrol transforma on the ] umlion box as the National Electrical Code and other controlling shown in Figure 37 agencies or governing bodies 2 . Mount a iunction box near each Gas Control Train for connection of conduit and wiring distribution to the gas train components The boiler must be electrically grounded in accordance with the requirements of the authority having jurisdiction , Wire the boiler according to the wiring diagram supplied or in the absence of such with the boi } er ( in the Control Envelope ) . Figure 37 is a requirements , with the typical layout of the components on the boiler . Figures current edition of the National 38 and 39 are examples of standard wiring systems . Use Electrical Code , ANSI / NFPA these drawings for general reference only . Number 70 . 2 . Low Energy Safety Control wiring must follow the contour of the boiler . Some local codes may require that all wiring , even low voltage , be routed in conduit . 2 . Use # 14 gauge or heavier wire for supply wiring â€¢ Protect the circuit with a fused disconnect switch ( by others ) and 3 . Install all line voltage wiring in conduit â€¢ a grounded neutral . 4 . Do not install single pole switches , including safety 3 . Mount an dectricaljunction box on the boiler Front Panel controls , in a grounded line . for connection of supply wiring and distribution to the boiler controls . See Figure 37 . - u â€¢ â€¢ . â€¢ / â€¢ 120 - V / 60hz Power . " x / - / x _ / / Probe Type Low Water Cutout Transformer , 120v / 24v Float Type Operating and Limit Low Water Cutout Pressure Controls Gas Pressure Regulator Control Box Main Gas Valves High Gas Pressure Pilot Gas Valve Switch ( when req'd ) Figure 37 : Typical Control Layout and Wiring 35
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120 V'dO hz 120v / 60hz ( _ ) HOT Neutral High Limit / Pf _ ss [ Jre Control High Gas Pressure | Switch ( H C645B ) Transformer Probe Type Low Water Through 211A 18 ) Additional 120V , 24V ( Modeis211A 13 = : _ 1 _ i I CtltolJt Hydrolevel Limit Switches Model 650P Shown Flame Rollout 1OOva ( When Req'd ) Switch _ l _ ( When Req'd ) I Float Type 4 - LowWater C _ \ , goitCioo Â° ntr ! o : T , { HSBdf0M 1Otq i . _ _ _ = % _ Cutout _ i Relay ( H R8222A ) Spill Switch ( When Req'd ) _ , _ gngion / Sensing Low Voltage Lead L , ! II ] Valve Switching Operating Pressure r _ ' Control L / _ J ! _ lectronic Pilot Pilot Gas Valve _ * _ v . Main Gas eValve Low Voltag 1 Safety Gas Valve d Lead to Pilot Burner ( 200 Â° C Thermoplastic Onlyl TYPICAL WIRING - HSP SYSTEM - SINGLE GAS CONTROL TRAIN , 24 - VOLT GAS VALVES 120V / 6Ohz [ L2 ) 120 V / dO hz Neutral HOT @ High Limit Pressure Control High Gas Pressure i | Train 2 / Train 1 Switches Ooeper _ _ ( _ _ _ Gas Control Train ' _ _ Transformer Probe Type Low Water Cutout - Hydroleve [ ( H C645B ) / L _ 120V / 24V Model 650P Shown Flame Rotlout _ Additi Â° n , at / h _ I 4Ova Switch _ Limit Switches . _ , " J ( When Req'd ) ( When Req'd } / Float Type | _ r _ - > : _ - Switching Cutout _ ( H $ 8610M - 1011 ) Low Water O - - i Ignition Control â€¢ _ Relay ! _ Transformer _ ( H R8222A } - - 120V / 24v Spill Switch ( When Req'd ) I _ _ 1OOva Lead Operating Pressure _ _ ' r l / _ , _ Control , _ ' - - _ Electronic Low Voltage Pilot Gas Valve Main Gas iPi , , ot , , Valves nition / Sensing i _ i / A , U ! Low Voltage / - - Ground Lead to Pilot Burner Safety Gas ( 2go r ' C Thermoplastic Only ) _ ' _ ' _ 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 36
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120V 60hz [ L2 ) 120 V ' 60 hz Neutral HOT ( _ High LimO / Pressure Control Hi ! tb Gas Pressure _ | ( ModeisS ( WH2it1chC64153B ) IA ' ' : _ } { I ' _ I ) " _ Transformer Probe Type Low Water 120V / 24V Cutout Hydrolevel Tbrough 211A 18 ) / wAdddionalitches Model 650P Shown Flame Rollout Limit S 40 va Switch _ _ ( When Req'd ) I ( When Req'd ) Ii Float Type Low Water O _ \ Cutout _ Ignition Control Valve 2SwitchingA ) / ( HS8610M 1011 ) Relay ( H R822 Spill Switcheq'd ) { When R _ Ignition / Sensin 0 120 V Main Gas Valve _ Electronico , liP , ControIOperaPtirnegssure [ _ ' i ' ailve _ Pilot Gas V 120 - V vSafetye Gas Val , â‚¬ - 7 II < Spar ' gnged > / A . V _ _ _ _ J Ground Lead to Pilot Burner ( 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 _ - - _ " _ High Limit / / Gas Pressure / Train 2 / Train t High ! _ t " Pressure Control J Switches One per _ _ fl _ , _ GasControltrain _ Rj @ @ ( _ ( _ _ W ) Transformer Probe Type Low Water 120V / 24V Cutout - Hydrolevel 40 va Model 650P Shown Swl ch J - _ > _ e ) , aI , ; d 7 ' sn w . . L t Float Type ( When Req'd ) O - - _ ( When Req'd ) Low Water Cutout _ Ignition Control Valve Switching { H $ 8610M - 1011 I _ = z _ Relay ( H R8222A ) 1 Spill Switch ( When Req'd ) - F _ , ' _ i Igndion / Sensing " _ 120 - V Main Lead , [ Gas Valves Operating Pressure [ _ _ " Control ! : _ - - _ Pilot Pitot Gas Valve t { Spark Ignited ) _ 120 - V Safety i Gas Valves i i I Additional i Gas Valveson fG : o Und Lead to PiIotBurner ii , t _ : Req'd ( 20u Â° C Thermoplastic Only ) Train 2 21 IA - 36A 211 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 Â° 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 37
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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 g ) Wait b0 seconds to allow the control to reset before proceeding with the next step a ) The Boiler must have been hydrostatically tested . 5 . b ) Check the attached piping for joint tightness Light Manual Pilots c ) Continue monitoring as you proceed through start a ) Follow the procedure in the Lighting Instructions to up . manually light any standing pilots . 6 . 2 Gas Piping Electronic Spark - lgnited Pilot Ignition Check a ) Make sure the gas system piping and the connections a ) Turn up the Operating Pressure Control for a callfor heat . to the boiler Gas Control Train ( s ) have been leak b ) The electronic spark - ignited pilot ( s ) should ignite . tested . c ) Turn down the Operating Pressure Control to stop b ) After the boiler is in operation , check the tightness of the call for heat . all joints in the boiler gas piping with a soap suds d ) The spark - ignited pilot ( s ) should shut off . solution . 7 . Check Main Burner Ignition c ) Purge the gas piping of all air up to the boiler Gas Control Train . 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 . l Fill the boiler to the normal water line c ) The electronic spark - ignited pilot ( s ) should ignite . a ) Gravity Systems and Pumped Return ewithr d ) The main gas valves will then open and the main Condensate Units Fill to 40 I / 2 " above the boil burners should ignite . foundation ( center of gauge glass ) . e ) Turn down the Operating Pressure Control to stop b ) Pumped Return with Boiler Feed Unit Fill the boiler the call for heat . using the boiler feed unit . Fill level will depend on the control being used . but should be 40 i / 2 " above f ) The electronic spark ignited pilot ( s ) and main burners should shut off . the boiler foundation ( iust below center of gauge glass ) when the pump stops 1 . Remove the pressure test plug at the Main gas shut - off valve . Attach a U - tube manometer . i . Before starting the boiler , study the Lighting Instructions supplied with the boiler . 2 . Restart the boiler by turning up the Operating Pressure Control for a call for heat . 3 . Leak test all gas train joints with a soap suds solution . I . Shut off all electrical power to the boiler . 4 . Check the gas pressure at the entrance to the Gas Control train . 2 . Close Main and Pilot 9as shut off valves . Wait for five ( 5 ) minutes . a ) The pressure reading underflow should be betweenm 7 and 14 inches water column ( 5 inches minimu 3 . Set the Operating and Limit Pressure Controls to if gas train is sized for lower gas pressure ) . minimum setting so they will not call for heat . b ) If the pressure to the Gas Control Train exceeds 14 4 . Perform Pilot Check : inches under any conditions , the system must be a ) Turn main electric disconnect switch to the " ON " provided with a lock - up type gas pressure regulator position . to provide 14 inches maximum . b ) Turn up the settings on the Operating and Limit 5 . Check the Manifold gas pressure . Pressure Controls so they will call for heat . a ) Remove the 1 / 8 " pipe plug from the manifold gas c ) Check for a continuous spark at the electronic pressure tapping . spark ignited pilot ( s ) b ) Attach a U - tube manometer . d ) Electronic spark - ignit _ d pilot systems The control c ) Adjust the Main Gas Pressure Regulator to obtaines will spark for 15 sc _ conds Ittial tot ignition ) , then shut 3 5 inches water column on Natural Gas or 10 inch down for a 5 to G minute wait period before water column on Propane ( LP ) Gas . attempting anoth _ r ignition d ) NOTE : If the pressure is adjusted to set the e ) E ] ectronicstandingpilotsystems Within15seconds nameplate input to the boiler , do not set it more than the control will click , indicating a safety lockout . 03 inches plus or minus from the specified settings . 38
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boiler wateL producing an unstable water line and water 1 ] mole adjustment to the rate is needed it nlust be done by changing the , burner gas ( ) rifices carryover to the system . The Minimum input rak , listed on tl _ e nameplate Cleaning the boiler requires the dpplies to boilers wifll staged fidng rate . Tbis minimum rate is not adjustable It is controlled by an use of very hot water andre corrosive chemicals . Use ca odlk _ , in the gas ham when handling to prevent injury . b Ch _ ck the burner input by reading lhe gas meter a ) Each of the burners is rated at ] 05,000 Btuihr for 3 . The piping for a skim valve must be done as shown in Natural Gas with a 060 specific gravity Section 5 , " Pipe the Boiler " , of this manual , with the skim b ) Each of the burners is rated at 102,500 Btu / hr for valve mounted off of one of the end riser connections Propane ( LP ) Gas with a [ 56 specific gravity . 4 . Connect a 2 inch drain line off of the skim valve , run to c ) Determine the input by multiplying " F " Meter a point of safe discharge . Reading ( Cubic Feet of Gas ) times " ' H " - Heating Value of Gas ( Btu per Cubic Foot ) times 3600 . Divide 5 , Close all valves to the system . Provide a means of by " T " - the time in seconds at the meter reading . continuous fresh water to the boiler for the cleaning process . F x H x 3600 6 . Open the skim valve . Fill the boiler until water begins to Rate , Btu / Hr - flow out the valve . T 7 . Use common washing soda ( such as Arm and Hammer Super Washing Soda ) . Mix the soda with water in a 10 d ) Note : If the meter is not automatically corrected for quart pail and pour into the boiler through the safety valve temperature and pressure , the meter reading mustt . tapping . Use a proportion of one ( I ) pound of washing be corrected to actual conditions during the rate tes soda for each 800 square feet EDR net boiler rating . 7 . Adjustment of Primary Air a ) A bag of air adjustment screws is provided with the Do not leave the boiler boiler , attached to one of the burners with pilot unattended while firing . bracket . b ) Primary air adjustment is not normally required . Take great care not to allow the water level to drop below c ) If primary air adjustment is needed , insert the self - tapping screws into the holes located on the top the bottom of the gauge glass front of the burners . or to allow fresh water make up to flow in too fast , This will d ) Turn the screws in all the way until yellow flame tips appear . Turn the screws back out until the yellow tips avoid the possibility of causing disappear . the boiler sections to fracture . 8 . Turn burners on and allow the boiler water to heat up to just below steaming ( 180 to 200 OF ) , Cycle the burners ] . Limit and Operating Pressure Controls to maintain temperature during skimming . Do not allow a ) Lower the setting of each control until the burners the boiler to steam . Steaming mixes up the contaminants shut down . in the water instead of floating them at the surface . 2 Low Water Cutouts 9 . Open the make - up water valve to continuously ifeedm water to the boiler . Allow water to flow out of the sk a ) Lower the water level in the boiler to below the . tapping . control cutout level . The burners should shut down 10 . Continue skimming the boiler until the water flowing 3 . Main Burner Shut - Off Valve ( s ) from the skim tapping flows clear . This will take some a ) Close Main Burner Shut - Off Valve ( s ) . time , possibly several hours for a dirty system . b ) The burners should shut down . 11 . After skimming is complete , close the skim valve and turn off the boiler . 4 . Check all controls to make sure they function correctly . 12 . 5 . After all controls have been proven , set the Operating and Close the make * up water valve and open the boiler Limit Pressure ConlTols to the pressures desired . blowdown valves . 13 . Drain the boiler completely . Then refill and drain eagainn one or two times to make sure all of the soda has be washed out . I Clean the boiler as described below no later than one 14 . week after the initial start - up . Cleaning will be more Restore piping to normal . Pipe a nipple and cap in the effective if the boiler operates a day or two to loosen skim valve . sediment and impurities in the system . t5 . Note : If the gauge glass becomes dirty again , hthise 2 The boiler must be cleaned to remove any accumulation indicates more contaminants have worked loose in t of oil , grease , sludge , etc . that may be in the system . system . Repeat the cleaning and skimming process as These substances can cause foaming and surging of the needed to clean the system . 39
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1 1 . LIGHTING INSTRUCTIONS - TYPICAL 1 These instructions apply only to typical standard control 1 . Open main line power clisconnect switch to boiler . systems ( HSP System only ) . Use the Lighting Instructions 2 . Close Main and Pilot gas shut off valves . 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 1 . If flame signal is lost at pilot , the ignition control will shut off the main gas valves and start sparking within 0 8 4 . Close Main and Pilot gas shut - off valves . seconds . 5 , Wait at least five ( 5 ) minutes . 2 . The control will continue to spark for 15 seconds . 6 . With Main gas shut off valve ( s ) closed , open Pilot gas 3 . shut - off valve . If a flame is not sensed , the control will shut down the pilot gas valve and wait 5 to 6 minutes . 7 . Light standing ( manual ) pilots by depressing the red indicator button on the Pilotstat . Manually light the pilot 4 . It will then start sparking and open the pilot gas valve for and hold the red button long enough for the another 15 - second ignition trial thermocouple to heat up . 5 . The control will continue this sequence indefinitely . 8 . Open Main Gas shut - off valve . 6 . Refer to Control Envelope supplied with the boiler for 9 . Set Operating Pressure Conlrol to desired pressure setting . the specific system used , 10 . Close main line power disconnect switch to boiler . 7 . Should a flame failure occur , causing a shut down of the 11 . If all limit switches are closed , the spark pilot ( s ) will light , main burners , turn off all electric power to the boiler and close Main and Pilot manual shut - off valves . Call a main gas valves will open and main burners will light . qualified service technician to inspect the boiler and 12 . The burners will continue to fire until the Operating correct the problem . Control is satisfied . 3 2 14 f - - _ 2 _ - PiiotGas Pressure Regulator Pi / - o { Cock 3 Line Gas Pressure Test Tapping 15 , 4 Pilotstat ( One per Standing Pilot ) 5 Red Pilotstat Indicator Button 6 Pilot Gas Valve ( One per Spark - Ignited Pilot ) 7 Pilot Gas Line 17 8 Pilot Tubin 9 , 3 / 8 " oD Aluminum 9 Electronic Pilot ( Spark Ignited ) , Typical 10 1 ! gn ! ti Â° 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 16 GasValve Bleed Line to Outside Aimoshpl 20 High Gas Pressure Switch ( Over 2500 Biuh ) 21i Â§ Main Gas Vaive , standard Ignition Control Panel Figure 40 : Typical Gas Control Train and Base - Single Gas Control Train - Standard Controls 40
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12 . OPERATION MAINTENANCE â€¢ The ignHio ; i control should close the m , _ lin gil > Do not store or allow valves wilhin _ seconds after tire pilot goe _ _ tl _ combustible or flammable â€¢ After i5 seconds , the control will lock out materials near the boiler . â€¢ Open the Pilot manual gas shut - off valve and Substantial fire or explosion re - start the boiler per the Lighting Instructions . hazard could result , causing ( Standing pilots will have to be manually re lit D > r risk of personal injury , death the Lighting Instructions . ) or property damage . 4 . Check the manifold gas pressure and rise a soap suds mixture to check the gas tightness of all gas ioints Do not use this boiler if any part of it has been under 5 . Test the limit and operating controls to assure they are water . Immediately call a operating correctly qualified service technician 6 . Inspect and test all low water cutouts . ( Float type conhols to inspect the boiler . Any part must be flushed ( blown down ) weekly to remove any of the control system , any sediment from the float chamber . ) gas control or any burner or gas component which bhase 7 . Test the pop safety relief valve ( s ) using the procedure been under water must given by the valve manufacturer on the valve tag replaced . 8 , Visually inspect the burner and pilot flames . Should overheating occur or a ) See Figure 41 the gas supply fail to shut off : b ) The flame inner cone should be about i _ o " high and Shut off the gas supply at a . should have a very sharp , blue color characteristic location external to the boiler c ) Poor flame conditions can be caused by dirty Do not turn off or disconnect burners , obstructed orifices or incorrect gas pressure the electrical supply to the pump . Immediately call a qualified service technician to inspect the boiler for damage I . Open main line power disconnect switch to boiler . and defective components . 2 . Close Main and Pilot gas shut - off valves . 3 . To take boiler out of service if the boiler and system are not to be used when temperatures are below freezing : a ) Drain the boiler and system completely and shut off 1 . Start up the boiler per the Lighting Instructions shipped make - up water supply . with the boiler . b ) Open main line power disconnect switch to boiler . 2 . Prove the correct operation of all controls on the boiler Remove the fuses or secure the switch so that the as outlined below . power cannot be turned on accidentally 3 . Check the operation of the ignition and flame proving c ) Do not used ethylene glycol antifreeze in a steam controls : boiler or system . a ) Electronic Spark - lgnited Pilot System ( $ 8610M d ) Be certain that the boiler and system are refilled Control ) before returning to service . Follow the Instructions in this manual and the Lighting Instructions to operate . â€¢ With the boiler operating , close the Pilot manual shut - off valve . â€¢ The ignition control should close the main gas Before servicing the boiler : valves within 1 second . â€¢ Turn off all electrical power to the boiler . â€¢ The control will spark and attempt to relight the â€¢ Close the Gas Service Valve . pilot burner . â€¢ Allowthe boiler to cool if â€¢ After 15 seconds , the control will shut down and it has been operating . wait 5 to 6 minutes for another ignition trial . â€¢ Label all wires prior to â€¢ Open the Pilot manual shut - off valve and re - start disconnection when the boiler per the Lighting Instructions , ( Standing servicing controls . Wiring pilots will have to be manually re - lit per the errors can cause improper Lighting Instructions . ) and dangerous operation . b ) Electronic Standing Pilot System Verify proper operation â€¢ With the boiler operating , close the Pilot manual after servicing . shut - off valve . 41
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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 I . Beforethestart of each heating seasom inspect and make all necessary adjustments to insure proper boiler nperation Use the n ] aintenance and inspection procedures following 1 . Inspect the burner and pilot flames as fol the annual 2 . Inspect the Venting System inspection . a ) Check the chimney or vent to make sure it is clean 2 Inspect the boiler and system for any signs of leakage or and flee from cracks or potential leaks . excessive make - up water usage b ) All joints must be tight and sealed . 3 . Inspect and check the operation of the venting system . c ) The vent connector must extend into , but not beyond , the inside edge of the chimney or vent . 3 . Inspect the Boiler Area 1 . Blow down the float type low water cutouts and test for a ) The boiler area must be clean and flee from correct operation . combustible materials , gasoline or any other flammable liquids or vapors . b ) The combustion air openings and the area around the boiler must be unobstructed . 1 . Inspect the boiler area to make sure the area is free fromare 4 . Inspect boiler flueways and burners for cleanliness . If combustible or flammable materials and that there cleaning is required , use the following procedure . no obstructions to the flow of air to the boiler or combustion air openings to the room a ) Turn off all electrical power to the boiler . b ) Remove top jacket panels , draft hood and flue collector 2 . Make sure there are no signs of abnormal operation , such as overfilling or leakage . c ) Remove side cleanout panels . d ) Brush the boiler tube spaces both horizontally ( through cleanout openings on ends ) and vertically Be very careful when addingdd ( from top of boiler ) . water to a hot boiler . A e ) Replace the flue collector , draft hood . jacket and very slowly or , if possible , cleanout panels using the procedures given in this allow the boiler to cool nlanual . naturally before adding f ) Remove the burners and brush the gas ports lightly water . with a soft bristle brush . If an excessive loss of water 5 . Inspect the boiler base and insulation . occurs , check for a leak in the 6 . Inspect the boiler and piping for signs of leaks . Check to piping and correct the see if there are signs of heavy make - up water addition to problem . Excessive make - upn the system . water will cause corrosio and damage to the boiler . 7 . When placing boiler into operation , follow Lighting Instructions shipped with the boiler and the instructions in this Chapter . II Figure 41 : Pilot and Burner Flames 42
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113 . TROUBLESHOOTING - SERVICE TIPS PROBLEM POSSIBLE CAUSE SUGGESTED REMEDY Defective Thermocouple Replace Redirect Air Movement or Ehmlnate Heavy Draft Blowing across Prlot ReD ace Ordlce Plugged Pdot Onhce Check Manual Pilot Valve Pilot Outage Check Main Gas Shut Off Valve No Gas Check Manual Meter Valve Consult Gas Company _ efective Pdo : s [ al Re _ ac _ Reolace Defective rgnt [ ton Control Check Power Source w th Meter No Power Check Fuses Defective Gas Valve RePlace 3efective Thermocouole RePlace Low Water Level in Boiler Check for LeaKs Main Gas Valve Will Not Open Check Feeder if SUD _ led or System Causing Low Water Cutout to Function ( Standard Spark - Ignited Pilot System ) 3efective Pilotstat ReL _ lacc Defective Ignition Control Reotace Check Switch rSettingessure _ llgn Gas Pressure Switch Onen lif Prov ded Check Man fold Gas P 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 Relay Locked Out on Safel Check for Pilot Outage Pilot Oul Relight Pilot Ma _ have defective pilot valve or rela r Defecnve ReJav Replace Main Gas Valve Will Not Open ( Electronic Standing Pilot Systeml . 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 Settingsure Check Inlet Gas Pres 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 Check Size of Combustion Air Openings to Room nsufficient Air for Combustion If Undersized Correct as Reauired Check for Negative Pressure in Boiter Room â€¢ k Oversized Burner Onhce Install Correct Orifice High Gas Pressure in Manifold Adjust Main Gas Pressure Regulator nsufficient Draft - Chimnev Too Low increase rlelgn [ or Add Induced Draft Fan Insufficient Draft - Chimney Too Sma Replace Chimney or Add Induced Draft Fan Insufficient Draft Blockage inChimne , or vent Remove BlocKage Insufficient Draft - Leaks in Chimne . or Vent Repair Chimney or Vent Gas Spillage from nsufficlent Draft Downdraft Caused h Chimney Draft Hood Relief Opening Location with ResPect [ o nstall Chlmr ev CaD Other Buildings , Roofs etc Negative Pressure in Boiler Roorr Remove Exhaust Fan . Due to Exhaust Fan or Duct S , , stem ] or Isolate Fan From Boiler Roorr ProvldeCorrectl Sized Combustion and Insufficient Combustton Air Openings Vent lation Air Openings 43
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POSSIBLE CAUSE PROBLEM SUGGESTED REMEDY Manual Valve Closed at Gas Train aden Valve Main Gas Valve Opens Manual Va ve Closed at Metel _ I tH ] valve But No Gas Flows Test Firing Valve Closec if Provided 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 Concentric reducers caum _ g condensate pooling Correct R pmg Dr iJ [ r _ _ falIt ! ( J c ose ( Reuldcu Tral3 or Trap Element Water Hammer on Start - Up _ ) rv - e [ urns we [ reel [ lue [ o new DC er water line Correct P 31ng or Install Feed System and Traps nlgner [ Ran OlC113o er Concentric reduce / s caus ng conaerlsaI _ DOOIIDg Correct P ping No drio ne on [ ne oacK Sicle of a DaCK - DltChed nstall Dr 3 Line and Trap mo [ orlzecl valve Clogged returlls d g _ avqly s . sTem C ean or Re PqJe Return Lme ( s ) Incorrect near DoHer piping causing WeT steam to Correct PIpmg per Manual system Trao failed aden allowing s [ ean3 to enter return _ qeDlace TraD or Trap Element Use Smaller Air Vent or Use Two Sma Vents in { Radiator Hammer } Large raalator map be vented Place of One Large Vent One Mounted Higher too QUICKIV than the Other _ ong nip [ e at Har # ora LO00 Rec ace with Close Nipple Water Hammer During Mid - Cycle Water leg or back SlODe in return line to receiver Correct Piping tanK , causing water pocketing Trae instal efJ at recewer [ aRK Causing Hater Remove Trac at Tank . Installing Drip Traps and trapping irl return Radiator TraPs where Required Boiler feed Duma or conaensate pump feed rate Throttle Flow Rate too fast . causmg spraymg rata equalizer No drio on the nlet side ofaforwara oEtcnea Add Dr a Lme and Trap ] qotorlzed valve unlnsulateo steam OlD he , causlf _ g excessive Insulate Steam Pipes ; onclensate 3aas ReD De 2 " to 4 " Be ow Normal Water Line Close n = DDI8 or7 Hdrtford too nlgr Water Hammer on Shut - Down unlnsulatea steam piping _ ooHer room but System piping nsula [ ec causlr ] vacuum nsulate Steam Pipes corlclltlOn on ShUt - down Poor c _ rculat on in the ha ler due to sludge Clean and 8 owdown the Boiler Hammering in the Boiler eccutl / ulat oil Main vents not working Replace Main Vents , Repiping away from End of , Lines if Needed Drip traps failed closed Replace Traps or Trap Elements r i Radiator traps failed open , allowing pressur zat on No Heat or Poor Heat Distribution in of the returns _ Replace Traps or Trap Elements the Building Water legs or back slope in return lines to receiver tank , preventing air from venting out Correct Piping receiver vent 1 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 , / System or Boiler Overfilling or Flooding Reduce Feed Rate causing water level to collapse ( due to collapse of s earn bubbles in boiler wa er ) [ Foaming , priming or surging due to poor water Clean the Boiler quality I Poor Clean the Boiler water quality , causing foaming and surging I ! Excessive Water Level Bounce Incorrect near - boiler piping , such as undersized Pipe per Manual or incorrectly placed risers feed Reduce Feed Rate I Boiler water rate or pump rate too fast Air vents or traps not ventrng air , preventing steam from getting to radiation and pressurizing Replace Vents or Traps the air pocket Rapid Cycling Pressure differential on pressure control too close Adjust Control Differential Nuisance outages of water level control due to See Excessive Water Level Bounce Above boiler water level bounce 44
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14 . BOILER RATINGS f : lrDIMENSIONS Table ï¿½ : Boiler Rating Information Propane Gas ( 2500 Btu / Cu Ft ) l Boiler i ; IBR Net Ratings [ _ IBR Net Ratings Model i Input Output : Tas = Steam i Input Output Steam i [ Natural G Ratings Number MBH MBH i Steam Water SPt = epammg _ _ MBH | MBH r Sr _ el _ 11 [ _ a _ r I SPtiepainmg Factor Sq Ft ' Factor = MBH ; MBH EDR j L . [ , t 211A 04 630 804 1578 378 438 1333 615 492 1538 369 428 1.333 1333 820 656 2050 492 570 ] 1.333 211A - 05 660 672 2100 504 884 1333 [ 1025 8 0 , 2663 _ z13 , 383 ! 12iiA _ 06 1050 i 840 2625 I 630 ] 730 1.333 _ 1230 9843075 738 _ 8 _ ] i ? ooI ! 677 211A - 08 1470 1176 3675 882 1028 1333 1435 1148 3588 861 | 998 1333 211A 09 1680 1344 4229 1015 1169 1324 1640 1312 4121 989 ! 1141 1327 ! 211A = - ! 0 _ . . 189n0 - _ 512 Tr 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 ! i 211A - 14 2730 2184 7067 _ 1696 I 18991.288 2665 6896 1655 2940 t 2352 ! 7608 _ 22 : : [ _ 2 _ _ _ 2132 _ r _ i , 54 _ 1.2881 : 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 - - 211A - 19 - _ _ - 3780 3024 _ 222314782483 + 2630 i 11 . . 228888 , [ 33468 _ 6 Â£ + 22798 _ 8 i 99052510 . j 22126952 22452847 jii _ - _ 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 [ . . . . . . 3 . . 820 - - 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 . . . 6 . . 5 . . 6 . . 0 . . . 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 _ ! 211A - 35 7140 â€¢ t _ t _ i _ , l . 216 201048s26r5405128s : 211A - 40 8190 6552 21196 5087 5697 1.288 . 211A - 41 8400 6720 21738 5217 5843 ! 1.288 Models 211A - 38 through 211A - 46 21iA - 4218610 Are Certified for Natural Gas Only 211 , , 43 6888 22283115348 _ 5990 } 11288 - = 7056 22825 ] 5478 6136 . . . . . _ - 288 - - : 211A 44 9030 7224 23371 5609 6282 1.288 211A 45 9240 7392 23913 5739 6428 1.288 21 , A46 7560 [ 124 ] 45888701 657 [ 4 1.2681 45
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O3 B TAPPING SCHEDULE ( 211A 19 and Larger , Two Gas Control Trains ) ) B T1 End Supply Riser Taps , 6 " each End Section 1211A04thru 211A - 18 , Sngle Gas Control Train ) T2 Return Taps , 6 " Each End A T3 3 " Tap , Top , Each End Section 3 % Â° " AA - 3B - CC _ DD - EE " FF - GG " * HH - II M JJ . * 3 _ 1 _ T4 3 / 4 " Tap , One Each End Section T5 1 / 2 " Tap , Two Each End Section O00O ( ) O000 T6 1 " Tap , One Each End Section T7 1 " Tap , One Each End 5 1 / 4 " Section T8 Intermediate Supply C Riser Taps , 3 " , in Tapped " 1 Intermediates T3 T8 T3 32 5 / 8 " 45 3 / 4 " T9 3 / 4 " Tap , One Each End Section , For Probe LWCO T10 1 1 / 2 " Tap . Blowdown , ' Each End Section 4f ; â€¢ Tll 3 " Tap , Lower Rear , Tapped Intermediate , I ! i t . Sections Only , Not Used 331 ; " " D " E - c - G " _ " - J - K - L - rd . - N - O - P - - 3 _ 1 ; Boiler Sectional Length [ ] [ ] [ ] [ ] [ 1 [ ] [ J [ 1 [ J [ J 2nd End Riser 211A - 08 _ LargeT ' _ _ 1 T5 T9 ; 27 T6 4 ' T7 _ U ProbekowW terCutout 81 " i li 2nd Equlizer _ l - - ! IT2 211A - 16 _ Larger , , - _ Ti1 - _ . ; . . . . [ r ' , i 71o , _ T10 22 , 1oo 4 , i7i 11 . . . . 41 " - . FRONT VIEW Base End Width
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BOILER DIMENSIONAL DATA ( All Dimensions In Inches ) : Flue _ Boiler Length _ Width ! Boiler Intermediate Riser Center Lines - 3 " Tappings - Used In Additionto Two EndRisers FlueConnectio , Ce , te ( Lines Model Dimenslo , s ' SBgton i . . . . _ . : _ _ [ _ Connections _ â€¢ = No . A _ B C ! Lengtih D iT E I F , G H I J / K ; _ L M N O : P ; AA : BB CC _ DD ' Â£ E FF G6 HH : JJ No Size _ _ = / 2 1A04 291 / 2 _ 39 % 63 ! 213 / , ! . - - _ ! - " - _ - ' - : - L - [ 16 â€¢ / 8 _ L - : _ Â± _ - _ 10 % 1 12 12 12 211A 05 33 _ 44 63 27 _ - 13 _ ' : _ i9 _ I ] 2 12 _ 2 211A06 398 _ 50 % 65 â€¢ 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 ï¿½ Za 120 _ / e 65 100V ; 53ve 47 _ b ! 6 _ h 25 % 221 / 2 22 _ . ' 2 13 % 14 22 23 . . . . . . . . , T â€¢ i - , 211A - 191121 / z 139 ' _ I 65 ' 1061 _ 531 / 8 / - J - I â€¢ - ] - 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 _ . Â£ 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 " 2V1 . : 7V _ ' - 65 : 184V _ 25 22 _ 22 _ V _ 22 _ 22V2L _ : ! : ! ] : Ã— [ 2 , , , , / o _ Z _ jv2 , 8 , > , . _ 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 t 211A36 206e ' 262 " 65 20 Â¥ . _ 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 / Â° - 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
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1 5 . REPAIR PARTS - SERIES 21 1A â€¢ REPAIR PARTS ARE AVAIIABI _ E FROM YOUR INSTALLER OR BY CONTACTING PEERLESS HEATER COMPANY , BOYERTOWN . PA 19512 - t021 â€¢ PLEASE INCLUDE BOILER MODEL NUMBER AND SERIAL NUMBER WHEN ORDERING PARTS â€¢ SEE FIGURE 42 . BOILER ASSEMBLY AND FIGURE 43 , BASE ASSEMBLY o . sc Â° , . , o Â° 1 . OO , T , O Â° AL , . O Â° M . T , O . GG - 1000 50 lb . Working Pressure 1 Intermediate Section GG - 1000 - 1 80 lb . Working Pressure 2 _ G : i02 _ 3r _ - 7 Left Hand End Section _ ng Pressurere 1 GG - 1023 _ 1 J . _ 80 ! lm Working Pressu 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 2 Required Per Flueway Feet Per Hi Temp Rope for Sections , 5 / 8 " - . . . . . 1 81 / 2 Required Flueway / / GG - 2105 Base Right End Panel w / insulation J _ 1 Required Per Boiler / 8 GG : i05 T Base Left End Panel w / insulation â€¢ 1 Required Per Boiler GG 2080 167 / 8 ` ` Wide GG 2080 1 221 / 2 " Wide Base Front Panel Sub - Assembly w / insulation GG - 2080 - 2 28 _ / 8 ' ' Wide GG - 2080 - 3 333 / 4 " Wide GG - 2080 - 4 393 / 8 " Wide GG - 2081 167 / 8 " Wide GG - 2081 - 1 221 / 2 ' ' Wide i 10 Base BackPanel Sub - Assembly w / insulation GG - 2081 - 2 281 / 8 " Wide GG - 2081 - 3 333 / 4 " Wide GG - 2081 - 4 393 / 8 ` ` Wide i 50848 For 167 / 8 " Wide Panel ; 50849 For 221 / 2 " Wide Panel Base Front or Back Panel Insulation ! 11 50850 For 281 / 8 " Wide Panel 50851 For 333 / 4 " Wide Panel I 50852 For 393 / 8 " Wide Panel ( 2 Per Panel ) 12 50853 Base Left / Right End Panel Insulation 1 Required Per Panel 13 GG - 2104 Insulation Washer Specify Quantity Required 14 GG - 2070 Burner Support Channel Clip 2 Required Per Boiler GG 2066 For 167 / 8 ' ` Wide Base Panel GG - 2066 - 1 For 221 / 2 ' ' Wide Base Panel 15 Burner Support Channel GG - 2066 2 For 281 / 8 ' ' Wide Base Panel GG - 2066 3 For 333 / 4 " Wide Base Panel GG - 2066 - 4 For 393 / 8 " Wide Base Panel i 16 ] GG - 2065 Angle Tie Brace ] Specify Quantity Required 48
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PART ITEM DESCRIPTION ADDITIONAL INFORMATION NO . NUMBER 143 / 4 " Wide GG - 2053 203 / 8 " Wide GG 2053 - 2 Base Front Panel Cover Piate 17 26 " Wide GG - 2053 4 5 31 ' 8 Wide GG 2053 - 6 371 / 4 " Wide GG - 2053 8 143 / 4 " Wide i GG - 2053 - 1 . 203 / 8 " Wide 18 l GG - 2053 - 3 Base Back Panel Cover Plate 26 " Wide GG - 2053 - 5 315 / 8 " Wide GG - 2053 - 7 [ GG - 2053 - 9 . . . . . . : 371 / 4 " Wide 19 Manifold Weldment Specify Controt System i 2O Orifice Spud Specify Quantity Type of Gas and Altitude t ! 21 I GG - 3007 Steel Burner Specify Quantity Required GG - 3854 Steel Burner w / Pilot Mounting Clip Specify w / or w / o Pilot and Pilot Number 16 " Wide GG - 5000 Flue Collector 219 / 16 ' ` Wide 22 GG - 5000 1 271 / 8 ' ' Wide GG - 5000 - 2 For GG - 50B0 w / 12 " Dia . Outlet - - GG - 5001 1 For GG - 5000 - 1 w / 12 " Dia . Outlet DraR Hood For GG - 5000 - 1 w / 14 " Dia . Outlet GG - 8001 - 2 " t For GG - 5000 - 2 w / 14 " Dia . Outlet GG - 5001 - 3 _ 24 GG - 5003 Front Flue Collector Hook Bolt 1 Required Per Flue Collector Back Flue Collector Hook Bolt 25 GG 5004 1 Required Per Flue Collector 26 GG - 5005 Flue Collector Mounting Bracket 1 Required Per Flue Collector Specify Quantity In Feet Required Hi Temp Rope for Flue Collector , 5 / 8 " [ 27 Set of 2 Cleanout Cover Plate Sub - Assembly i 28 GG - 6004 _ _ Specify Quantity In Feet Required I 29 HiTemp Ropefor Cleanout Cover Plate , 5 / 8 " Common End Panel and Cleanout Cover Plate Carton No . 12 i GG - 6033 Assembly ! , GG - 6034 Carton No . 12A . . . . . . . . . . i Carton No . 12B GG - 6034 - 1 Intermediate Panel Jacket Assembly GG - 6034 - 2 Carton No . 12C Carton No . 12D GG - 6034 - 3 Carton No . 12E GG - 6034 - 4 J 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 i Gauge Glass Set Steam Boilers Only ! 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 49
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_ ' ] 5 . ' ] = 1 ; 1 _ = [ . ' ] v . lIEIr _ , l Figure 42 : Boiler Assembly 50
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$ g _ w _ D Â® @
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52
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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 â€¢ BOYERTOWN , PA 19512 - 1021 â€¢ 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 .