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PB Heat 211A User's Manual

1. 4 Jin wo your uou uu your yu unu aig pu yu your N P I H 9 4 umjog i ddng 2 9 Y pon ayewxordde suorsuounq 6 suoisuauitq 73 suome2oT umjay A ddng SNOISNAWIC HATIOd WVALS 531935 2 a J 7 a lt ce 50 15 15 946 VI 99114 LE LE 995 SDVITS 9 9 966 9 9 995 h VII 95 95 966 SE 946 VI 46 46 966 OD VITS TC TC 966 6E VITS ve ve 966 8E VITS 966 LEVITS 946 VI 96 112 oe 26 966 SEVITS 26 26 966 VI DEVITS 966 KEY LLZ LC LC 946 VI 0 0 946 VI TEVITS 06 06 966 06 112 66 66 966 DCV LLE 66 66 966 809112 82 82 946 129112 42
2. CN SF lt 00 00 60 r 10 82 11 LO cN 17116 9C VLLC SF co m GC VLLC ve vile N EZ VLLZ ccv IC Ve vile 002 7112 6L VLLC SLY LLE cN co 91 SLY LLC VL VLLE EL VLLC 01 7112 DUY LLE 80 112 LO VLLE BUY LLC GO VLLC 70 116 12 120 12 12 12 gy t Lp 66 LE GE E 66 L6 6 6l L Sl LL 6 2 Jo 19109 Figure 6 3 Jacket Assembly Sequence Carton Numbers and Locations 27 INSTALL THE JACKET amp DRAFT HOOD Table 6 2 Draft Hood Section Placement from Left to Right Facing Front of Boiler Boiler Model Number Position Position Position Position Position Positio
3. Low Energy Safety Control wiring must follow the contour of the boiler Some local codes may require that all wiring even low voltage be routed in conduit Install all line voltage wiring in conduit Do not install single pole switches including safety controls in a grounded line 120V 60Hz Power Transformer 120V 24V Operating and Limit Pressure Controls yl Gas Pressure Regulator d P mmr gS Main Gas Valves High Gas Pressure Switch when req d 37 WIRE THE BOILER 120V 60hz 120 V 60 hz Neutral HOT High Limit Pressure High Gas Pressure Control M R Switch C6097B lE Models 211A 13 n 00000 ou Probe Type Low Water Through 211A 18 Additional 120V 24V Cutoff Hydrolevel Limit Switches 09000 100 Model 650P Shown When Req d TN Float Type Low Water Cutoff When Req d Valve Switching Relay H R8222A Ignition Sensing Operating Lead Low Voltage Pressure Main Gas Valve Control Electronic Pilot Gas Valve Pilot 3 Low Voltage Spark Ignited Auxiliary Gas Valve Z Ground Lead to Pilot Burner 200 C Thermoplastic Only TYPICAL WIRING HSP SYSTEM SINGLE GAS CONTROL TRAIN 24 VOLT GAS VALVES 120V 60hz 120 V 60 hz Neutral HOT High Limit S 1 Pressure High Gas Pressure Train 2 Train 1 Control M R Switches One per Gas Control Train Transformer Probe Type Low Water C6097B 120V 24V Cut
4. 11 After skimming is complete close the skim valve and turn off the boiler 12 Close the make up water valve and open the boiler blowdown valves 13 Drain the boiler completely Then refill and drain again one or two times to make sure all of the soda has been washed out 14 Restore piping to normal Pipe a nipple and cap in the skim valve 15 Note If the gauge glass becomes dirty again this indicates more contaminants have worked loose in the system Repeat the cleaning and skimming process as needed to clean the system 41 11 LIGHTING INSTRUCTIONS TYPICAL A TO LIGHT THE BOILER 1 These instructions apply only to typical standard control systems HSP System only Use the Lighting Instructions supplied with the boiler to be sure they apply to the actual control system used 2 Set Operating Control to lowest position 3 Open main line power disconnect switch to boiler 4 Close Main and Pilot gas shut off valves 5 Wait at least five 5 minutes 6 With Main gas shut off valve s closed open Pilot gas shut off valve 7 Light standing manual pilots by depressing the red indicator button on the thermopilot valve Manually light the pilot and hold the red button long enough for the thermocouple to heat up 8 Open Main Gas shut off valve 9 Set Operating Control to desired setting 10 Close main line power disconnect switch to boiler 11 If all limit switches are closed the spark pilot s wil
5. Check the manifold gas pressure and use a soap suds mixture to check the gas tightness of all gas joints Test the limit and operating controls to assure they are operating correctly Inspect and test all low water cut offs Float type controls must be flushed blown down weekly to remove any sediment from the float chamber Test the pop safety relief valve s using the procedure given by the valve manufacturer on the valve tag Visually inspect the burner and pilot flames a See Figure 12 1 b The flame inner cone should be about 1 1 2 4 cm high and should have a very sharp blue color characteristic c Poor flame conditions can be caused by dirty burners obstructed orifices or incorrect gas pressure Figure 12 1 Pilot and Burner Flames 44 OPERATIONS 8 MAINTENANCE B TO SHUT DOWN THE BOILER c Remove side cleanout panels d Brush the boiler tube spaces both horizontally 1 Open main line power disconnect switch to boiler through cleanout openings on ends and vertically from top of boiler 2 Close Main and Pilot gas shut off valves e Replace the flue collector draft hood jacket and 3 To take boiler out of service if the boiler and system cleanout panels using the procedures given in are not to be used when temperatures are below this manual freezing f Remove the burners and brush the gas ports a Drain the boiler and system completely and shut lightly with a soft bristle brush
6. REPAIR PARTS SERIES 211A 15 REPAIR PARTS SERIES 211A Repair parts are available from your installer or by contacting PB Heat LLC New Berlinville PA Use the Figures and Tables on Pages 52 55 to assist in ordering parts Note Remember to include boiler model number and serial number when ordering parts 52 Intermediate Section 50 psig 345 kPa Working Pressure 90356 2 Left Hand End Section 50 psig 345 kPa Working Pressure 90625 3 Right Hand End Section 50 psig 345 kPa Working Pressure 90059 4 Tapped Intermediate Section 50 psig 345 kPa Working Pressure 90065 5 Tie Rod 2 Required Per Flueway 90090 6 Flow Port Gasket 2 Required Per Flueway 51670 7 Hi Temp Rope for Sections 5 8 16mm 6 1 2 Feet 2 Meter Required Per Flueway 55723 4 Base Right End Panel w Insulation 1 Required Per Boiler GG2112 Base Left End Panel w Insulation 1 Required Per Boiler GG2113 16 7 8 429 mm Wide GG2080 22 1 2 571 mm Wide GG2080 1 9 Base Front Panel Sub Assembly w Insulation 28 1 8 714 mm Wide GG2080 2 33 3 4 857 mm Wide GG2080 3 39 3 8 1 m Wide GG2080 4 16 7 8 429 mm Wide GG2081 22 1 2 571 mm Wide GG2081 1 10 Base Back Panel Sub Assembly w Insulation 28 1 8 714 mm Wide GG2081 2 33 3 4 857 mm Wide GG2081 3 39 3 8 1 m Wide GG2081 4 For 16 7 8 429 mm Wide Panel 50
7. off make up water supply b Open main line power disconnect switch to 5 Inspect the boiler base and insulation boiler Remove the fuses or secure the switch so that the power cannot be turned on accidentally 6 Inspect the boiler and piping for signs of leaks Check to see if there are signs of heavy make up c Do not use ethylene glycol antifreeze in a steam water addition to the system boiler or system 7 When placing boiler into operation follow Lighting Instructions shipped with the boiler and the instructions in this Chapter d Be certain that the boiler and system are refilled before returning to service Follow the Instructions in this manual and the Lighting Instructions to operate P 8 Test the operation of all limit controls float controls and ignition components as described in Part A CAUTION Placing Boiler in Operation of this Chapter Before servicing the boiler D MONTHLY MAINTENANCE Turn off all electrical power to the boiler 1 Inspect the burner and pilot flames as for the annual Close the Gas Service Valve l inspection Allow the boiler to cool if it has been operating 2 Inspect the boiler and system for any signs of leakage or excessive make up water usage Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation Verify proper 3 operation after servicing Inspect and check the operation of the venting
8. 3 485 1 021 2 788 817 9 021 840 2 165 634 211 19 3 024 886 9783 911 2 348 688 1 288 3 690 1 082 2 952 865 9 550 889 2 292 672 211 20 3 192 936 10325 961 2 478 726 1 288 3 895 1 142 3 116 913 10 079 939 2 419 709 211 21 3 360 985 10 871 1 012 2 609 765 1 288 4 100 1 202 3 280 961 10613 988 2 547 746 211 22 3 528 1 034 11 413 1 063 2 739 803 1 288 4 305 1 262 3 444 1 009 11 142 1 037 2 674 784 211 23 3 696 1 083 11 958 1 113 2 870 841 1 288 4 510 1 322 3 608 1 058 11 671 1 087 2 801 821 211 24 3 864 1 133 12 500 1 164 3 000 879 1 288 4 715 1 382 3 772 1 106 12 204 1 136 2 929 858 211 25 4 032 1 182 13 042 1 214 3 130 918 1 288 4 920 1 442 3 936 1 154 12 733 1 186 3 056 896 211A 26 4 200 1 231 13 588 1 265 3 261 956 1 288 5 125 1 502 4 100 1 202 13 263 1 235 3 183 933 211A 27 4 368 1 280 14 129 1 316 3 391 994 1 288 5 330 1 562 4 264 1 250 13 796 1 284 3 311 970 211A 28 4 536 1 330 14 675 1 366 3 522 1 032 1 288 5 535 1 622 4 428 1 298 14325 1 334 3 438 1 008 211A 29 4 704 1 379 15 217 1 417 3 652 1 070 1 288 5 740 1 682 4 592 1 346 14854 1 383 3 565 1 045 211A 30 4 872 1 428 15 763 1 467 3 783 1 109 1 288 5 945 1 742 4 756 1 394 15 388 1 433 3 693 1 082 211A 31 5 040 1 477 16 304 1 518 3 913 1 147 1 288 6 150 1 803 4 920 1 442 15 917 1 482
9. 33 5 9 13 17 21 25 29 211 34 5 9 13 17 22 26 30 211 35 5 9 13 18 23 27 31 211 36 5 9 13 17 21 25 29 33 211 37 5 9 13 17 21 25 29 33 211 38 4 8 12 17 22 27 31 35 211 39 4 8 12 16 20 24 28 32 36 211 40 4 8 12 16 21 25 29 33 37 211 41 4 8 12 16 19 23 26 30 34 38 211 42 4 8 12 16 20 23 27 31 35 39 211 43 4 7 11 14 18 22 26 30 33 37 40 211 44 4 8 12 16 19 23 26 29 33 37 41 211 45 4 7 11 14 18 21 25 28 32 35 39 42 211 46 4 7 11 14 18 22 25 29 33 36 40 43 Figure 3 5A Section Position Numbering C HYDROSTATIC TEST THE BOILER 1 Ow JO 592 The supply and return piping can be permanently erected before applying the Boiler Jacket if the pipe nipples applied to the boiler tappings are long enough to clear the jacket Install a drain cock in the tapping provided at the bottom rear of each end section Provide a water supply line to the boiler Plug all open tappings in the boiler Provide a means to vent air as the boiler fills Fill the boiler with water venting air as water level rises Pressurize boiler to 45 psig 310 kPa Do not exceed this pressure a Maintain pressure while checking all joints and fittings for leaks b After inspection is complete drain the boiler and remove plugs from tappings that are to be u
10. 41 230 5 8 236 1 4 248 1 4 6 306 2114 42 236 1 4 241 7 8 253 7 8 6 448 211 43 241 7 8 247 12 259 12 6 591 211 44 247 1 2 253 18 265 1 8 6 734 211 45 253 18 258 3 4 270 3 4 6 877 211 46 258 3 4 264 3 8 276 3 8 7 020 2 ASSEMBLE THE BASE BASE ASSEMBLY 2 Open crate number 2 Remove the End Panels and mount a Support Channel Clip toward the rear on 1 Collect the crates containing the Base Assembly parts each panel as shown in Figure 2 2 using 1 4 20 x Table 2 1 on page 11 shows the quantity of each 1 2 13 mm long round head machine screws and crate required The crates contain the following parts 1 4 lock washers provided Sub Assembly Right End Panel Sub Assembly GG 2105 Left End Panel Sub Assembly GG 2106 Burner Support Channel Clips 2 GG 2070 Front Panel Sub Assembly GG 2080 Back Panel Sub Assembly GG 2081 Burner Support Channel GG 2066 Front Panel Support Bracket GG 2069 Section Assembly Kit GG 1030 Front Panel Sub Assembly GG 2080 1 Back Panel Sub Assembly GG 2081 1 Burner Support Channel GG 2066 1 Angle Tie Brace GG 2065 Front Panel Support Bracket GG 2069 Section Assembly Kit GG 1030 Front Panel Sub Assembly GG 2080 2 Back Panel Sub Assembly GG 2081 2 Burner Support Channel GG 2066 2 Angle Tie Brace GG 2065 Front Panel Sup
11. 42 956 902 5112 42 42 966 4059112 96 96 966 VI DEVITS 96 96 966 ES VITS 55 959 55 946 229112 GS 959 GS 946 16 7116 vo 019 vo 966 02 112 EZ 789 62 966 6r VII EZ 789 EZ 966 TL 8I VITS 22 6959 22 946 VI LI VITS Ic EES LZ 946 9r VIIZ LZ EES LZ 966 SL VIIG 06 808 06 966 TL DIVITS 61 58 61 406 T VIIG SI LSD SI 406 CIVILIS 81 LSD SI 946 IT VITS LI LI 995 01 7112 9I 907 9I 406 605112 SI 182 ST 406 80 112 TL 946 SOE 405112 VI 995 VI 946 90 112 ZI 406 ZI 406 40 112 406 21 406 N CN c cN eo sh sit 10 10 10 SO O oo oo co O DIA DOVITS yout your yout yout yout yout w9 305 X JayaWeIG uuruo 2216 2 99 dd quan suomnoeuuo sour 1910971 uor ouuo eni SNOISNAWIC YATIOd WVALS 531935 51
12. Burners Natural Gas Only Propane Gas Only Pilot Burner Locations Positions Numbered Right to Left Pilot Burner Locations Positions Numbered Right to Left Standing Pilots Thermocouple Electronic Pilots Spark Ignited Electronic Pilots Standing Pilots Manually Lighted Thermocouple 211A 04 211A 05 211A 06 211A 07 211A 08 211A 09 211A 10 211A 11 2114 12 211A 13 211A 14 9 19 211A 15 9 21 211A 16 5 15 5 15 23 211 17 5 15 5 15 25 211 18 5 15 9 19 27 211 19 5 17 9 21 29 211 20 5 21 9 21 31 211 21 5 23 9 23 33 211 22 5 39 9 23 35 211 23 5 41 9 23 37 211 24 5 39 9 23 39 211 25 5 45 9 23 41 211 26 5 33 47 9 23 33 45 211 27 5 35 49 9 23 35 45 211 28 5 37 51 9 23 35 47 211 29 5 39 53 9 23 39 49 211 30 5 39 51 9 23 39 51 211 31 5 41 53 9 23 39 53 211 32 5 41 59 9 25 41 55 211 33 5 41 61 9 25 41 57 211 34 5 21 49 63 9 23 39 51 59 211 35 5 17 51 65 9 23 39 51 61 211 36 5 19 53 67 9 23 39 51 63 211 37 5 23 47 65 9 23 39 51 65 211 38 5 43 67 211 39 5 35 6
13. GAS PIPING 29 INSTALL GAS TRAIN 29 TABLE OF CONTENTS B CONNECT PILOT GAS TUBING 29 C INSTALL VENT AND BLEED PIPING 29 D INSTALL GAS SUPPLY PIPING 30 E TEST GAS SUPPLY PIPING 30 8 INSTALL CONTROLS AND TRIM 32 A INSTALL SAFETY VALVE S 32 B INSTALL BLOWDOWN VALVES 32 C INSTALL LOW WATER CUT OFF S 32 D INSTALL PRESSURE CONTROLS 32 9 WIRE THE BOILER 37 A CONNECT SUPPLY WIRING 37 B PREPARE REMAINING CONTROLS 37 C INSTALL CONTROL WIRING 37 10 STARTING THE BOILER 40 A CHECK THE PIPING 40 B FILE THE BOILER Rem 40 C STUDY LIGHTING INSTRUCTIONS 40 D RUN PILOT CHECK OUT 40 E CHECK MAIN BURNER SYSTEM 40 CHECK BOILER CONTROLS 41 G CLEAN THE BOILER 41 TO LIGHT THE BOILER 42 TO SHUT DOWN THE BOILER 42 C PILOT FLAME FAILURE 42 12 OPERATION amp MAINTENANCE 43 A PLACING BOILER IN OPERATION 44 B TO SHUT DOWN THE BOILER 45 C ANNUAL MAINTENANCE 45 D MONTHLY MAINTENANCE 45 E WEEKLY MAINTENANCE 45 DAILY 45 13 TROUBLESHOOTING SERVICE TIPS 46 14 BOILER RATINGS 8 DIMENSIONS 48 15 REPAIR PARTS SERIES 211A 52 USING THIS MANUAL USIN
14. Repair Chimney or Vent Insufficient Draft Downdraft Caused by Chimney Location with Respect to Other Buildings Roofs etc Install Chimney Cap Negative Pressure in Boiler Room Due to Exhaust Fan or Duct System Remove Exhaust Fan or Isolate Fan From Boiler Room Insufficient Combustion Air Openings Provide Correctly Sized Combustion and Ventilation Air Openings TROUBLESHOOTING SERVICE TIPS Problem Possible Cause Suggested Remedy Main Gas Valve Opens But No Gas Flows Manual Valve Closed at Gas Train Open Valve Manual Valve Closed at Meter Open Valve Test Firing Valve Closed if Provided Open Valve Water Hammer On Start Up Sags in Steam Piping or not enough Pitch Correct Piping Condition Concentric reducers causing condensate pooling Correct Piping Drip trap failed closed Replace Trap or Trap Element Dry returns wetted due to new boiler water line higher than old boiler Correct Piping or Install Feed System and Traps No drip line on the back side of a back pitched motorized valve Install Drip Line and Trap Water Hammer During Mid Cycle Clogged returns on gravity system Clean or Re Pipe Return Line s Incorrect near boiler piping causing wet steam to system Correct Piping per Manual Trap failed open allowing steam to enter returns Replace Trap or Trap Element Radiator Hammer Large radiator may be v
15. Right End Panel and setting the Burner Support Channel on the clips Front Panel Front Support Bracket Jacket GG 2069 e e En Figure 2 3 Support Bracket Installation Figure 2 4 Angle Tie Brace Installation For 211A 09 through 211A 46 Only a Attach a Front Panel Support Bracket to each Front Panel as shown in Figure 2 3 Attach an Angle Tie Brace at each panel joint to secure the front and back panels as shown in Figure 2 4 using 5 16 18 x 1 25 mm long cap screws and hex head nuts Bolt remaining Front and Back Panels together using 5 16 18 x 1 25 mm long cap screws and hex head nuts See Table 2 1 for panels required Place the panels in the positions shown in the table and Figure 2 1 Complete the base assembly by attaching the Right Hand End Panel using 5 16 18 x 1 25 mm long cap screws and hex head nuts Set Burner Support Channels in place as shown in Figure 2 1 B INSTALL THE PILOT BURNERS 1 Check the location of the Burner Support Channels in the Base Assembly The dimensions should be a Height above boiler foundation 6 3 4 171 mm b Distance from back of Base 3 3 4 95 mm Remove the Gas Manifold and Pilot Line Assembly from Box Number 7 Place Manifold on front of Base Bolt the hangers using 5 16 18 x 1 25 mm long long cap screws
16. chimney or vent height of 20 feet 610 cm and a maximum horizontal run of 6 feet 183 cm to the chimney with no more than one 90 degree standard elbow Recommended sizing for chimney and connectors is based on maximum 6 foot 183 cm connector length and maximum one 90 degree elbow Provide support for horizontal sections to prevent sagging Slope vent connector upward min 1 4 inch per foot 21 mm per meter CHIMNEY HEIGHT a 1 4 6 mm Hole for draft reading Riser at least 3 feet 91 cm preferred Connector must not protrude into chimney L Boiler vent connector should be higher DRAFT HOOD than other connected appliances gt Do not obstruct draft hood opening Figure 1 8 Vent Connection The minimum area of the chimney serving two or more appliances must be at least the area of the largest chimney connector plus 50 of the total area of all other appliance connectors PREINSTALLATION The vent connector must be single wall steel or Type B double wall vent pipe The vent connector must be Type B double wall if it is located in or passes through cold areas The vent connector must extend into but not beyond the inside wall of the chimney Vent Connection to Boiler Figure 1 8 a Provide at least a 3 foot 91 cm rise in the vent connection on the boiler b The vent system should provide a draft of at least 0 02 w c 5 Pa measured at the vent connections c Support the we
17. d The main gas valves will then open and the main burners should ignite e Turn down the Operating Pressure Control to stop the call for heat f The electronic spark ignited pilot s and main burners should shut off E CHECK MAIN BURNER SYSTEM 1 Remove the pressure test plug at the Main gas shut off valve Attach a U tube manometer 2 Restart the boiler by turning up the Operating Pressure Control for a call for heat 3 Leak test all gas train joints with a soap suds solution 4 Check the gas pressure at the entrance to the Gas Control train a The pressure reading under flow should be between 5 and 14 inches water column 1 7 and 3 5 kPa b If the pressure to the Gas Control Train exceeds 14 inches 3 5 kPa under any conditions the system must be provided with a lockup type gas pressure regulator to provide 14 inches 3 5 kPa maximum 5 Check the Manifold gas pressure a Remove the 1 8 pipe plug from the manifold gas pressure tapping b Attach a U tube manometer c Adjust the Main Gas Pressure Regulator to obtain 3 5 inches water column 9 kPa on Natural Gas 10 inches water column 2 5 kPa on Propane LP Gas d NOTE If the pressure is adjusted to set the nameplate input to the boiler do not set it more than 0 3 inches 75 Pa plus or minus from the specified settings If more adjustment to the rate is needed it must be done by changing the burner gas orifices e The Minimum
18. disappear CHECK BOILER CONTROLS 1 Limit and Operating Pressure Controls a Lower the setting of each control until the burners shut down 2 Low Water Cut offs a Lower the water level in the boiler to below the control cut off level The burners should shut down 3 Main Burner Shut Off Valve s a Close Main Burner Shut Off Valve s b The burners should shut down Check all controls to make sure they function correctly After all controls have been proven set the Operating and Limit Pressure Controls to the pressures desired G CLEAN THE BOILER 1 Clean the boiler as described below no later than one week after the initial start up Cleaning will be more effective if the boiler operates a day or two to loosen sediment and impurities in the system 2 The boiler must be cleaned to remove any accumulation of oil grease sludge etc that may be 8 Turn burners on and allow the boiler water to heat up to just below steaming 180 to 200 F 82 to 93 C Cycle the burners to maintain temperature during skimming Do not allow the boiler to steam Steaming mixes up the contaminants in the water instead of floating them at the surface 9 Open the make up water valve to continuously feed water to the boiler Allow water to flow out of the skim tapping 10 Continue skimming the boiler until the water flowing from the skim tapping flows clear This will take some time possibly several hours for a dirty system
19. evviIc 6684 8622 S9 1681 165 IPVIIZ 9694 bee S9 6521 S86 Or VIIC 6546 8812 S9 660 6 2 6E VITS 0176 EIZ S9 69 6 2 SEVITS 1926 402 59 1089 892 LEVITS vols 104 59 9999 292 9EVITS 286 4961 59 6086 602 GEVITS 668 A06T S9 9896 9522 PEVITS 969 8 S9 9299 LIS CEVITS 969 6 1 S9 7864 ITS ELT S9 9706 lt 02 TEVITS 1967 891 S9 2805 002 0 VIIC 29 S9 0 7 VOT 609114 1866 951 S9 L6L 9881 8e VIIC 6686 ATST S9 9997 AEST LOVITS 9696 ASHI S9 929114 6666 6 69 696 ZLI 429114 0176 69 9407 594991 19026 821 S9 SOUP I9I 629114 EZI S9 2965 9ST 229112 1862 4 S9 0086 OSI 86827 69 1 96 02 112 9692 94901 S9 VESE 6 6TVIIZ 6462 4001 S9 8406 001 8TVIIZ 0172 96 S9 27062 LI VITS 1922 A68 S9 lt 47 594801 919112 volo 5468 S9 0192 ZOT SrVIIG 1861 8 S9 9 46 DIVITS 8281 AZL 9 262 l6 ST VITS S69 l 99 69 v6l z 98 6991 19 S9 1402 08 SS S9 1981 MEL 1961 67 69 SILT 9 60 VITS bell Abb 69 8981 19 80 VIIC 186 948 69 SS LOVITS 828 5 59 9 51 08 90 VITS 969 24 9 SIIT bv SO VIIC 6599 elo 9 SL6 88 DOVITS
20. flow port goes toward the front of the boiler as shown in Figure 3 2 14 PLACE THE BOILER SECTIONS w m MAI B C amp E C u 2 T ps 9 amp n 1 e s E E oad N E E B o HE e E 1 is oo 9 Align parting line of left hand js end section with seam between EE base front panel amp base end panel E D Q 0 Y m Y Y Y Y TAPPINGS EACH END SECTION A 3 4 NPT Tapping 1 1 2 Tapping Back Blowdown B 1 2 Tapping Upper H 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 Tapping Steam Riser F 1 Tapping Lower K 6 NPT Tapping Return Figure 3 3 Assembling Sections on Base 15 PLACE THE BOILER SECTIONS Intermediate _ Section Spirit inn Left Hand End Section Base Figure 3 4 Align Sections Vertically e Draw sections together evenly alternating b
21. if the air infiltration rate is unknown or if the rate of air infiltration is known to be greater than 0 6 air changes per hour an option this method may be used if the air infiltration rate is known to be between 0 6 and 0 4 air changes per hour If the air infiltration rate is known to be below 0 4 then the Known Air Infiltration Rate Method must be used If the building in which this appliance is to be installed is unusually tight PB Heat recommends that the air infiltration rate be determined b Knoun Air Infiltration Rate Method Where the air infiltration rate of a structure is known the minimum required volume of indoor air for appliances other than fan assisted and for the Series 211A Boiler shall be determined as follows 21 ff loth Required Volumeother ACH where lother Input of appliances other than fan assisted in Btu hr ACH air change per hour percent of the volume of the space exchanged per hour expressed as a decimal For fan assisted appliances calculate the required volume of air using the following equation 15 8 Ifan ACH 10008 Required Volume nput of the fan assisted appliances Btu hr Note These calculations are not to be used for infiltration rates greater than 0 60 ACH Indoor Air Opening Size and Location Openings connecting indoor spaces shall be sized and located as follows a Combining spaces on the same floor Provide two permanent o
22. input rate listed on the nameplate applies to boilers with staged firing rate This minimum rate is not adjustable It is controlled by an orifice in the gas train 6 Check the burner input by reading the gas meter a Each of the burners is rated at 105 000 Btu hr 30 8 kW for Natural Gas with a 0 60 specific gravity b Each of the burners is rated at 102 500 Btu hr 30 kW for Propane LP Gas with a 1 56 specific gravity c 0 5 Determine the input by multiplying Meter Reading Cubic Feet of Gas times Heating Value of Gas Btu per Cubic Foot times 3600 Divide by T the time in seconds at the meter reading Rate Btu Hr Fx Hx 3609 Metric Determine the input bv multiplying F Meter Reading Cubic Meters of Gas times Heating Value of Gas Joules per Cubic Meter Divide bv T the time in seconds of the meter ding Rate Watts d Note If the meter is not automatically corrected for temperature and pressure the meter reading must be corrected to actual conditions during the rate test 7 Adjustment of Primary Air a bag of air adjustment screws is provided with STARTING THE BOILER in the system These substances can cause foaming and surging of the boiler water producing an unstable water line and water carryover to the system WARNING Cleaning the boiler requires the use of very hot water and corrosive chemicals
23. mm Wide 90557 22 Flue Collector 21 9 16 548 mm Wide 90558 27 1 8 689 mm Wide 90559 For GG 5000 w 12 305 mm Dia Outlet 90399 Assembly For GG 5000 1 w 12 305 mm Dia Outlet 90400 23 Draft Hood For GG 5000 1 w 14 356 mm Dia Outlet 90401 For GG 5000 2 w 14 356 mm Dia Outlet 90402 24 Front Flue Collector Hook Bolt 1 Required Per Flue Collector GG5003 25 Black Flue Collector Hook Bolt 1 Required Per Flue Collector GG5004 26 Flue Collector Mounting Bracket 1 Required Per Flue Collector 27 Hi Temp Rope for Flue Collector 5 8 16 mm Specify Quantity in Feet Meters Required 55723 28 Cleanout Cover Plate Sub Assembly Set of 2 90489 29 Hi Temp Rope for Cleanout Cover Plate 5 8 16 mm Specify Quantity in Feet Meters Required 55723 Common End Panel and Cleanout Cover Plate Carton No 12 90282 Intermediate Panel Jacket Assembly Carton No 12A 90283 Carton No 12B 90284 Carton No 12C 90285 Carton No 12D 90286 Carton No 12E 90287 Pilot Line Assembly Specify Control System Pilot Line Support Bracket Specify Quantity Required Gas Control Assembly Specify Control System Steam Gauge Steam Boilers Only 51769 Gauge Glass Set Steam Boilers Only 50513 Lighting Instruction Plate Specify Control Syst
24. system E WEEKLY MAINTENANCE C ANNUAL MAINTENANCE 1 Blow down the float type low water cut offs and test 1 Before the start of each heating season inspect for correct operation and make all necessary adjustments to insure proper boiler operation Use the maintenance and DAILY MAINTENANCE inspection procedures following 1 Inspect the boiler area to make sure the area is free 2 Inspect the Venting System from combustible or flammable materials and that a Check the chimney or vent to make sure it is there are no obstructions to the flow of air to the clean and free from cracks or potential leaks boiler or combustion air openings to the room b All joints must be tight and sealed 2 Make sure there are no signs of abnormal operation The vent connector must extend into but not such as overfilling or leakage beyond the inside edge of the chimney or vent 3 Inspect the Boiler Area VN CAUTION a The boiler area must be clean and free from combustible materials gasoline or any other flammable liquids or vapors Be very careful when adding water to a hot boiler Add very slowly or if possible allow the boiler to cool naturally before adding water b The combustion air openings and the area around the boiler must be unobstructed If an excessive loss of water occurs check for a leak in the piping and correct the problem Excessive make up water will cause corrosion and damage to 4 Inspect boiler flueways an
25. the authority having jurisdiction the installation must conform to American Society of Mechanical Engineers Safety Code for Controls and Safety Devices for Automatically Fired Boilers ASME CSD 1 Read these instructions carefully before beginning the installation Study the control folder and consult drawings A shipping list is enclosed with each boiler listing the items packed at the factory Check the list as you unpack parts If any parts are missing or damaged report the problem to the delivering carrier immediately Vent typical min Piping Typical e 152 mm C e c min 152 mm it Vent ll 610m am gt mr z 24 24 _ min e 610 610 lt gt m a Front View EE End View in y a 48 C uc G Me 48 min 1219 lt 5 lt o ln 5 on 1219 mm S ontre boil Figure 1 1 Clearance Requirements A ACCESSIBILITY CLEARANCES 1 The following recommendations allow for reasonable access to the boiler Local codes or special conditions may require greater clearances a For servicing the boiler provide 48 1219 mm between the control manifold and adjacent wall or other appliance b For access to draft hood or passage to access the boiler control manifold s provide 48 1219 mm between the side of the boiler and adjacent wall or other applia
26. they will extend through the jacket B SUPPLY PIPING 1 Install End Riser connections sized per Table 5 1 The 3 tappings in the tops of the end sections are not used for steam boilers a Install a reducing tee on one end riser Install a 2 valve nipple and cap for skimming the boiler in the tee as shown in the piping drawings 2 Models 2114 08 and larger require risers in both end sections 3 Models 211A 18 and larger require additional 3 risers off of the tapped intermediate sections See Table 5 1 for the number required 4 Pipe the header at least 24 inches 610 mm above the normal boiler water line This is required to prevent water from carrying over into the header and then to the system 5 Figure 5 2 shows the Supply and Return piping for Parallel Flow Gravity systems and all Pumped Return Systems Threaded Fittings Steam Supply BOILER HEADER m Pipe with offset to allow for header expansion Use threaded fittings for swing joints BOILER RISER 4 6 7 Water Line 40 1 2 1029 mm H Equalizer a 2 Skim Connection ys 20047 5110 102mm 6 Counterflow Gravity systems require the boiler steam line to enter the top of the steam main See Figure 5 3 for this special case 7 The piping in these drawings is shown off the right hand side of the boiler The boiler may also be piped toward the left side as sh
27. with 5 16 flat washers See Figure 2 5 Front Panel Back Panel gt gt 3 3 4 95 mm lt 7 Angle Tie Brace Assembly Burner Support Channel A x 2 with Gusset Plates 6 3 4 171 mm Y ASSEMBLE THE BASE Table 2 1 Base Front and Back Panel Crates E3 Ed Ed m Ez lt Overall Length gt lt Assembly AN Na ptm Na ii dd 4 etr Assembly Model Overall Length Number feet inches 211A 04 24 3 4 211A 05 30 3 8 211A 06 36 211A 07 41 5 8 211A 08 47 1 4 211A 09 52 7 8 211A 10 58 1 2 211A 11 64 1 8 211A 12 69 3 4 211A 13 75 3 8 211A 14 81 211A 15 86 5 8 211A 16 92 1 4 211A 17 97 7 8 211 18 8 7 1 2 211 19 9 1 1 8 211A 20 9 6 3 4 211A 21 10 0 3 8 211A 22 10 6 211A 23 10 11 5 8 211 24 11 5 1 4 2114 25 11 10 7 8 2114 26 12 4 1 2 211A 27 12 10 1 8 211A 28 13 3 3 4 211A 29 13 9 3 8 211A 30 14 3 211 31 14 8 5 8 211 32 15 2 1 4 211A 33 15 7 7 8 211A 34 16 1 1 2 211 35 16 7 1 8 211A 36 17 0 3 4 211A 37 17 6 3 8 211A 38 18 0 211A 39 18 5 5 8 2114 40 18 11 1 4 211 41 19 4 7 8 211A 42 19 10 1 2 211A 43 20 4 1 8 211A 44 20 9 3 4 2114 45 21 3 3 8 211 46 21 9 11 ASSEMBLE THE BASE Manif
28. 2 13 mm long sheet metal screws per collector section Insert the offset flange of the Jacket Top Panel under the Top Left End Panel Place the right flange on the Top Right End Panel The front edge flange goes over the Jacket Front Panel Line up the holes and secure with 10 x 1 2 13 mm long sheet metal screws E 211A 09 AND LARGER ONLY 1 2 The boilers have multiple intermediate jacket panels Collect the jacket cartons listed in Table 6 1 When installing the jacket panels place them on boiler in the order shown in Figure 6 3 Open the cartons in the order listed in Figure 6 3 Install the Jacket Front Panels Make sure to slip the Front Panels into the Front Panel Support Brackets mounted on the base See Figure 6 2 Install the first Front Panel with the left edge over the Left Front Corner Panel Line up the holes and secure with 10 x 1 2 13 mm long sheet metal screws 23 Continue applying Front Panels this way Slip the right edge of the last Front Panel under the Right Front Corner Panel Line up the holes and secure with 10 x 1 2 13 mm long sheet metal screws Install the Jacket Rear Panels Slip the offset flange of the first Upper Rear Panel under the edge of the Left Rear Corner Panel Secure with 10 x 1 2 13 mm long sheet metal screws Attach the first Lower Rear Panel in the same way Attach a Rear Panel Support Leg on the inside of the Upper Rear Pa
29. 211A CE Boilers Steam Installation Operation amp Maintenance Manual USING THIS MANUAL 1 A FOLLOW THE PIPING GUIDELINES 1 B CONTROLS 1 C SPECIAL ATTENTION BOXES 1 1 PREINSTALLATION 2 A ACCESSIBILITY CLEARANCES 2 B COMBUSTIBLE CONSTRUCTION CLEARANCES 2 C AIR FOR COMBUSTION amp VENTILATION 2 D CHIMNEY OR VENT 5 E BOILER SETTING 7 WATER QUALITY AND MAKE UP 7 INSTALLATION SURVEY 7 2 ASSEMBLE THE BASE 9 BASE ASSEMBLY 9 B INSTALL THE PILOT BURNERS 10 3 PLACE THE BOILER SECTIONS 14 A PREPARATION 14 B PLACING THE SECTIONS 14 C HYDROSTATIC TEST THE BOILER 16 4 INSTALL THE FLUE COLLECTOR 17 5 PIPE THE BOILER 19 A PREPARATION 19 B SUPPLY PIPING 19 C RETURN PIPING 19 D MULTIPLE BOILER INSTALLATIONS 21 6 INSTALL THE JACKET amp DRAFT HOOD 23 A PREPARE THE PARTS 23 B APPLY CLEANOUT COVER PLATES 23 C APPLY JACKET END ASSEMBLIES 23 D 211 04 THROUGH 211 08 ONLY 23 E 2114 09 AND LARGER ONLY 23 APPLY JACKET TOP PANELS 24 APPLY LOWER END PANELS 24 H APPLY PLATES AND LABELS 24 7 CONNECT
30. 211A 16 and Larger Threaded Fittings Return 2 Skim Connection 211A 04 TO 211A 07 SINGLE END RISER Offset Header Required to Prevent Damage to Boiler From Expansion of Header Use threaded fittings for swing joints 211A 08 TO 211A 17 Second Equalizer TWO END RISERS 22 2 q Threaded 1 J d gt Fittings PSAN 211A 18 amp LARGER TWO END RISERS PLUS ONE OR MORE 3 INTERMEDIATE RISERS Offset Header Required to Prevent Damage to Boiler From Expansion of Header Use threaded fittings for swing joints Return Figure 5 2 Supply and Return Piping Pumped Return and Parallel Flow Gravity Systems 20 PIPE THE BOILER Soller Miser Piping D MULTIPLE BOILER INSTALLATIONS enters TOP of main on Counterflow 1 Figure 5 5 shows typical piping for multiple boiler System lE Gravity Return systems Figure 5 6 shows typical piping for multiple boiler Pumped Return systems Counterflow 2 Provide separate feed lines for multiple boiler Steam Main pumped return systems Use either separate feed pumps or solenoid valves to isolate feeding of the boilers This is needed to provide reliable level Pitch T control and avoid nuisance performance problems 3 Condensate return units are not effective for multiple boiler installations since they do not respond to the needs of the boilers Always use Boiler feed units a Install a Float and Thermostatic trap at the boiler water level on each o
31. 3 820 1 120 211A 32 5 208 1 526 16 846 1 569 4 043 1 185 1 288 6 355 1 863 5 084 1 490 16 446 1 531 3 947 1 157 211A 33 5 376 1 576 17 392 1 619 4 174 1 223 1 288 6 560 1 923 5 248 1 538 16 979 1 581 4 075 1 194 211A 34 5 544 1 625 17 933 1 670 4 304 1 262 1 288 6 765 1 983 5 412 1 586 17 508 1 630 4 202 1 232 211A 35 5 712 1 674 18 479 1 720 4 435 1 300 1 288 6 970 2 043 5 576 1 634 18 038 1 680 4 329 1 269 211A 36 5 880 1 723 19 021 1 771 4 565 1 338 1 288 7 175 2 103 5 740 1 682 18 571 1 729 4 457 1 306 211A 37 6 048 1 773 19 567 1 822 4 696 1 376 1 288 7 380 2 163 5 904 1 730 19 100 1 778 4 584 1 344 211A 38 6 216 1 822 20 108 1 872 4 826 1 415 1 288 211A 39 6 384 1 871 20 654 1 923 4957 1 453 1 288 211A 40 6 552 1 920 21 196 1 973 5 087 1 491 1 288 2114 41 6 720 1 970 21 738 2 024 5 217 1 529 1 288 Models 211A 38 through 211A 46 2114 42 6 888 2 019 22 283 2 075 5 348 1 567 1288 Are Certified for Natural Gas Only 211A 43 7 056 2 068 22 825 2 125 5 478 1 606 1 288 211A 44 7 224 2 117 23 371 2 176 5 609 1 644 1 288 211A 45 7 392 2 167 23 913 2 227 5 739 1 682 1288 211 46 7 560 2 216 24 458 2 277 5 870 1 720 1 288 48
32. 848 For 22 1 2 571 mm Wide Panel 50849 11 Base Front or Back Panel Insulation For 28 1 8 714 mm Wide Panel 50850 For 33 3 4 857 mm Wide Panel 50851 For 39 3 8 1 m Wide Panel 50852 12 Base Left Right End Panel Insulation 1 Required Per Panel 50853 13 Insulation Fastener Specify Quantity Required GG2104 14 Burner Support Channel Clip 2 Required Per Boiler 90590 For 16 7 8 429 mm Wide Base Panel 90585 For 22 1 2 571 mm Wide Base Panel 90586 15 Burner Support Channel For 28 1 8 714 mm Wide Base Panel 90587 For 33 3 4 857 mm Wide Base Panel 90588 For 39 3 8 1 m Wide Base Panel 90589 Angle Tie Brace Specify Quantity Required 90326 REPAIR PARTS SERIES 211A Base Front Panel Cover Plate 14 3 4 375 mm Wide Base Panel 20 3 8 518 mm Wide Base Panel 26 660 mm Wide Base Panel Base Back Panel Cover Plate 31 5 8 803 mm Wide Base Panel 90322 37 1 4 946 mm Wide Base Panel 90324 14 3 4 375 mm Wide Base Panel 90317 20 3 8 518 mm Wide Base Panel 26 660 mm Wide Base Panel 31 5 8 803 mm Wide Base Panel 37 1 4 946 mm Wide Base Panel 19 Manifold Weldment Specify Control System 20 Orifice Spud Specify Quantity Type of Gas and Altitude 21 Steel Burner Specify Quantity Required 51045 Steel Burner w Pilot Mounting Clip Specify w or w o Pilot and Pilot Number 51046 16 406
33. 9 211 40 5 33 75 211 41 5 33 57 77 211 42 5 31 65 79 211 43 5 33 67 81 211 44 5 33 67 83 211 45 5 37 65 85 211 46 1 1 1 1 1 1 1 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 4 4 4 4 4 4 4 4 5 5 5 5 5 5 5 6 6 6 6 6 6 5 39 67 87 Models 211A 38 through 211A 46 Are Certified for Natural Gas Only 13 3 PLACE THE BOILER SECTIONS A PREPARATION 1 Check the level of the Boiler Base using a spirit level Make sure the base is level and that the base panels are aligned within plus or minus 1 16 2 mm 2 Check area around the Flow Ports Figure 3 1 Use solvent and a clean cloth to thoroughly clean the flat surfaces and recesses All foreign matter must be removed to assure a proper seal when the sections are drawn together CAUTION Gaskets will be damaged by petroleum or its derivatives Completely remove all solvent residue before placing gaskets Do not use petroleum based compounds in the boiler Figure 3 2 Placing the First Section on Base Flat Machined Recess Machined 2 Slide the section to the back of the base until the cast Face Face lug on the bottom of the section under the lower flow port is against the base back panel Keep the section upright by a supporting prop or other means WARNING Yoo o o ooooooooooo Y loooooooooooo Qo000000000 Lo
34. ACCORDING TO LOCAL CODE B GNITED PILOT SAFETY GAS VALVE BLEED G N TUBING S MAIN GAS VALVE HIGH GAS PRESSURE SWITCH UAL SHUT OFF VALVE i 3 8 O D TUBING CUT TO FIT BY INSTALLER L PILOT LINE THERMOCOUPLE L THERMOPILOT VALVE RED INDICATOR BUTTON Figure 7 1 Gas Control Train and Burner Assembly Single Natural Gas Control Train Shown Models 211A 19 and Larger Use Two or More Gas Control Trains 29 CONNECT GAS PIPING c When piping bleed lines to outside terminate the 2 The standard gas train is designed for a maximum tubing downward to prevent water from entering pressure of 1 2 psig 14 inches water column 3 5 kPa the tubing and protect the tubing termination Make sure the system regulator will not allow a higher from any obstruction Terminate the tubing pressure to the Gas Control Train under any above and well away from normal breathing conditions level or building air intakes 3 The minimum gas supply pressure is listed on the Boiler Rating Label Make sure the system regulator and the piping are sized and adjusted properly to 1 Size the piping as required by the National Fuel Gas provide this pressure under all conditions Code ANSI Z223 1 NFPA 54 and or CAN CGA B149 Installation Codes or as required by local codes a Use Table 7 1 for sizing of natural gas for a system pressure drop of 0 3 inch water column 75 Pa 4 Install a Ser
35. Air from Outdoors through Vertical Ducts BOILER from front ii Where communicating with the outdoors no LI through horizontal ducts each opening shall s have a minimum free area of 1 in per 2000 Btu hr 22 cm per 2000 W of total rated Figure 1 7 Air Openings All Air from Outdoors input for all appliances in the space See through One Opening Figure 1 6 the required volume of indoor air exceeds the available indoor air volume outdoor air openings or ducts may be used to supplement the available indoor air provided a The size and location of the indoor openings comply with Subsection 3 b The outdoor openings are to be located in accordance with Subsection 4 c The size of the outdoor openings are to be sized as follows Areq L 2 req where minimum area of outdoor openings Af il full size of outdoor openings calculated in accordance with Subsection 4 Vavail available indoor air volume Vreq required indoor air volume Engineered Installations Engineered combustion air installations shall provide an adequate supply of combustion ventilation and dilution air and shall be approved by the authority having jurisdiction 7 Mechanical Combustion Air Supply a In installations where all combustion air is provided by a mechanical air supply system the combustion air shall be supplied from the outdoors at the minimum rate of 0 35 ft8 mi
36. Assembly Use these drawings for part identification and location See Figure 6 3 for the quantity of each carton required and placement of the jacket sections on the boiler See Table 6 1 for the contents of each Jacket Carton and Draft Hood carton See Table 6 2 for the Draft Hood cartons required B APPLY CLEANOUT COVER PLATES 1 2 Remove Cleanout Cover Plates from carton 12 Install one cover plate on each End Section Use four 5 16 18 x 2 51 mm long studs 5 16 18 hex nuts and 5 16 flat washers Seal around the cleanout plates using the furnace cement provided and apply between base and bottom of sections APPLY JACKET END ASSEMBLIES 1 Remove necessarv knockouts from the Jacket End Panel pieces in carton 12 Attach a Corner Panel Support Bracket GG 6029 to each Corner Panel using two 10 x 1 2 13 mm long sheet metal screws Attach the four Corner Panels to the Base Ends using 1 4 20 x 1 2 13 mm long machine screws and 1 4 flat washers The locations are Right Front GG 6015 Left Front GG 6016 Right Rear 6017 Left Rear GG 6018 Attach an End Panel Cover Plate GG 6030 to the opening on the Upper Left End Panel if the 6 inch tapping on that end is not used Attach Upper Left End Panel GG 6032 to the left end corner panels with five 10 x 1 2 13 mm long sheet metal screws Place Top Left End Panel GG 6020 over the Corner Panels and Upper Panel with fl
37. BOILER RATINGS amp DIMENSIONS p sn ION Ajuo suonoes je9H 190 LLL uonoes u e3 Z L L OLL 9q0Jd 104 uono s euo del p E 61 sejeipauuo u pedde ui sde Ajddng ejeipeuiueju 81 uonoes pu3uoe3eugo dey LL uonoes pug 3 del 91 uonoes pug uoe3 omy dej z L GL uonoes dej p E uonoes pug 6 L 223 9 5 uonoes pug uoea 9 sdej Aj ddng pu3 LL s o 002 8 4 99 91 9 22 r 5 i MO Mg 419 002 91 6 12 4 L 196127 8 80 112 Jasiy jeuonoes 191109 gt 91 g d ON WT AP H 000000000 8 18 Ue II HH 99 4 34 od 20 gg V gt 2 seo ejBurs 8L YLLZ naui 90 112 9 1 Sute14 104405 sec OM pue 6 vV L 12 a 49 aded uo senunuoo 6969 892 S9 SII 8 OTE 979114 0179 ZSZ S9 9 64 IE Sv VIIC 1929 9 S9 6787 80 12 6019 1 69 897 206 v VIIC 2864 ASEZ S9 1647 4967
38. Free Area S PIG in 4000 Btuh 22 cm per 4000 W Figure 1 6 Air Openings Air from Outdoors through Horizontal Ducts 7 b One Permanent Opening Method Provide 3 76mm ne t ina beqin i ithin 12 REA 7 permanent opening beginning within lt BOILER inches 805 mm of the top of the space The 12 305mm opening shall communicate directly with the max outdoors communicate through a vertical or z T horizontal duct or communicate with a space that freely communicates with the outdoors L E The opening shall have a minimum free area of Figure 1 4 Air Openings All Air Directly from 1 in per 3000 Btu hr of total rated input for all Outdoors appliances in the space and not less than the sum of the cross sectional areas of all vent RY IE connectors in the space The gas fired equipment shall have clearances of at least 1 inch 25 mm y from the sides and back and 6 inches 150 mm 127 305mm from the front of the appliance See Figure 1 7 max for this arrangement A TWO AIR OPENINGS 76mm aie wee UMEN d PRIM dl ect LOCATION min 1 in per 4000 Btuh 22 cm per 4000 W X 27 12 305mm SSNN max i ONE AIR OPENING 5 E Mniam E E BOILER 2 1 in per 3000 Btuh gt 22 cm per 3000 W p Pat the e et purs E all vent connectors Ei ares 4 WS MINIMUM CLEARANCES i 25mm From Figure 1 5 Openings
39. G THIS MANUAL N DANGER 1 We have provided suggested piping diagrams which Indicates a condition or hazard which will cause will cover most applications of this boiler Severe personal injury death or major property damage 2 Follow these guidelines to make sure the boiler will operate correctly WARNING Indicates a condition or hazard which may cause 1 This manual provides wiring diagrams and lighting severe personal injury death or major property instructions for standard systems only damage 2 Use the Lighting Instructions and Wiring Diagrams provided with the boiler to make sure they represent VN CAUTION the controls provided Indicates a condition or hazard which will or can SPECIAL ATTENTION BOXES cause minor personal injury or property damage 1 Throughout this manual you will see special attention boxes intended to supplement the VN instructions and make special notice of potential hazards These categories mean in the judgment of Indicates special attention is needed but not directly PB Heat LLC related to potential personal injury or property damage PREINSTALLATION 1 PREINSTALLATION NOTICE The equipment shall be installed with those installation requirements of the authority having jurisdiction or in the absence of such requirements to the current edition of the National Fuel Gas Code ANSI Z223 1 NFPA 54 and or CAN CGA B149 Installation Codes Where required by
40. GG 6019 Top Left End Panel GG 6020 Upper Left End Panel GG 6032 Front Panel A GG 6023 lt lt Right Front Corner Panel GG 6015 Lower End Panel GG 6022 Corner Panel Support Bracket GG 6029 Front Jacket Panel Support Bracket GG 2069 Left End Corner Cleanout Cover Panel GG 6016 Plate Assembly GG 6004 Top Panel GG 6024 Panel Support Angle GG 6027 Draft Hood GG 5001 E Right Rear Corner Panel GG 6017 Upper Rear Panel GG 6025 Lower Rear Panel i gt lt L C GG 6026 eft Rear orner Panel GG 6018 25 Rear Panel Support Leg GG 6028 End Panel Cover Plate GG 6030 Figure 6 2 Jacket Assembly INSTALL THE JACKET amp DRAFT HOOD Table 6 1 Jacket and Draft Hood Carton Contents See Figure 6 2 for Placement of Jacket Sections Contents Sub Assembly Part Number Quantity Cleanout Cover Plates GG 6004 2 Jacket Corner Panel Right Front 6015 Jacket Corner Panel Left Front GG 6016 Jacket Corner Panel Right Rear GG 6017 Jacket Corner Panel Left Rear GG 6018 Corner Panel Support Brackets GG 6029 Jacket Upper End Panel Left GG 6033 GG 6032 Jacket Upper End Panel Right GG6021 End Panel Cover Plates GG 6030 Jacket Lower End Panels GG 6022 Top Right End Panel GG 6019 Top Left End Panel GG 6020 Sheet Metal Screws Machine Screws Washers Nuts Jacket Intermediate Panel Front GG 6023 Jack
41. INSTALLATION Table 1 1 Boiler Foundation Layout Boiler Boiler Base Length Jacket Length Foundation Length Model inches inches inches mm 211A 04 22 1 2 28 1 8 40 1 8 1 019 211A 05 28 1 8 33 3 4 45 3 4 1 162 211A 06 33 3 4 39 3 8 51 3 8 1 305 211A 07 39 3 8 45 57 1 448 211A 08 45 50 5 8 62 5 8 1 591 211A 09 50 5 8 56 1 4 68 1 4 1 734 2114 10 56 1 4 61 7 8 73 7 8 1 876 211A 11 61 7 8 67 1 2 79 1 2 2 019 2114 12 67 1 2 73 1 8 85 1 8 2 162 2114 13 73 1 8 78 3 4 90 3 4 2 305 211A 14 78 3 4 84 3 8 96 3 8 2 448 211 15 84 3 8 90 102 2 591 211 16 90 95 5 8 107 5 8 2 734 211 17 95 5 8 101 1 4 113 1 4 2 877 211A 18 101 1 4 106 7 8 118 7 8 3 019 2114 19 106 7 8 112 1 2 124 1 2 3 162 211A 20 112 1 2 118 1 8 130 1 8 3 305 211A 21 118 1 8 123 3 4 135 3 4 3 448 2114 22 123 3 4 129 3 8 141 3 8 3 591 211A 23 129 3 8 135 147 3 734 211A 24 135 140 5 8 152 5 8 3 877 2114 25 140 5 8 146 1 4 158 1 4 4 020 211A 26 146 1 4 151 7 8 163 7 8 4 162 211A 27 151 7 8 157 1 2 169 1 2 4 305 211A 28 157 1 2 163 1 8 175 1 8 4 448 211A 29 163 1 8 168 3 4 180 7 8 4 594 211A 30 168 3 4 174 3 8 186 3 8 4 734 211A 31 174 3 8 180 192 4 877 211A 32 180 185 5 8 197 5 8 5 020 211A 33 185 5 8 191 1 4 203 1 4 5 163 2114 34 191 1 4 196 7 8 208 7 8 5 305 211A 35 196 7 8 202 1 2 214 1 2 5 448 2114 36 202 1 2 208 1 8 220 1 8 5 591 211A 37 208 1 8 213 3 4 225 3 4 5 734 211A 38 213 3 4 219 3 8 231 3 8 5 877 211A 39 219 3 8 225 237 6 020 211 40 225 230 5 8 242 5 8 6 163 211A
42. NT TO OUTSIDE ATMOSPHERE IGNITED REGULATOR WELL ABOVE NORMAL BREATHING V 2C G CAL COD PILOT n Y LEVEL AND ACCORDING TO LOCAL CODE IGNITED PILOT H SAFETY GAS VALVE TUBING 2 im MAIN GAS VALVE HIGH GAS PRESSURE SWITCH MANUAL SHUT OFF VALVE 3 8 0 0 TUBING CUT TO FIT BY INSTALLER ics THERMOCOUPLE Ly IERMOPILOT VALVE 1 L PILOT LINE INDICATOR BUTTON Figure 11 1 Typical Gas Control Train and Base Single Gas Control Train Standard Controls 42 12 OPERATION amp MAINTENANCE WARNING Product Safety Information Refractory Ceramic Fiber Product This appliance contains materials made from refractory ceramic fibers RCF Airborne RCF when inhaled have been classified by the International Agency for Research on Cancer IARC as a possible carcinogen to humans After the RCF materials have been exposed to temperatures above 1800 F 982 C they can change into crystalline silica which has been classified by the IARC as carcinogenic to humans If particles become airborne during service or repair inhalation of these particles may be hazardous to your health Avoid Breathing Fiber Particulates and Dust Suppliers of RCF recommend the following precautions be taken when handling these materials Precautionary Measures Provide adequate ventilation Wear a NIOSH MSHA approved respirator Wear long sleeved loose fitting clothing and gloves to preve
43. See Figure 4 2 Do not tighten yet 7 Draw the Flue Collector sections tight against the sealing rope by tightening the nuts on the Hook Bolts Draw the nuts evenly alternating tightening Figure 4 1 Applying Flue Collector Hi Temp Rope Gasket 17 INSTALL THE FLUE COLLECTOR Table 4 1 Flue Collector Section Location From Left to Right Facing Front of Boiler Crates Crates 14 Part number GG 5000 Crate 14A Part number GG 5000 1 Crate 148 Part number GG 5000 2 Boiler Model Number Position Position Position Position Position Position Position Position Position 1 2 3 4 5 6 7 8 211A 04 14 211A 05 211A 06 211A 07 211A 08 211A 09 211A 10 211 11 211 12 211 13 211 14 211 15 211 16 211 17 211 18 211 19 211 20 211 21 211 22 211 23 211 24 211 25 211 26 211 27 211 28 211 29 211 30 211 31 211 32 211 33 211 34 211 35 211 36 211 37 211 38 211 39 211 40 211 41 211 42 211 43 211 44 211 45 211 46 18 PIPE THE BOILER 5 PIPE THE BOILER A PREPARATION 1 The boiler must be pressure tested as outlined in Chapter 3 the Boiler Sections of this manual 2 The Supply and Return piping can be installed before the jacket is applied Use nipples long enough to be sure
44. Use care when handling to prevent injury 3 The piping for a skim valve must be done as shown in Section 5 Pipe the Boiler of this manual with the skim valve mounted off of one of the end riser connections 4 Connect a 2 inch drain line off of the skim valve run to a point of safe discharge 5 Close all valves to the system Provide a means of continuous fresh water to the boiler for the cleaning process 6 Use common washing soda such as Arm and Hammer Super Washing Soda Mix the soda with water in a 10 quart 9 5 liter pail and pour into the boiler through the safety valve tapping Use a proportion of one 1 pound 5 kg of washing soda for each 800 square feet 74 m EDR net boiler rating 7 Open the skim valve Fill the boiler until water begins to flow out the valve N CAUTION the boiler attached to one of the burners with Do not leave the boiler unattended while firing pilot bracket b Primary air adjustment is not normally required Take great care not to allow the water level to drop below the bottom of the gauge glass or to allow fresh water make up to flow in too fast This will avoid the possibility of causing the boiler sections to fracture c If primary air adjustment is needed insert the self tapping screws into the holes located on the top front of the burners d Turn the screws in all the way until yellow flame tips appear Turn the screws back out until the yellow tips
45. Valve Switching Relay H R8222A Ignition Sensing 5 Lead 120 V Main Opaning N Gas Valve ressure i Control Electronic Pilot Gas Valve 120 V Auxiliary Spark Ignited Gas Valve 4 Ground Lead to Pilot Burner 200 Thermoplastic Only TYPICAL WIRING HSP SYSTEM SINGLE GAS CONTROL TRAIN 420 VOLT GAS VALVES 120V 60hz 120 V 60 hz Neutral HOT High Limit Pressure High Gas Pressure Train 2 Control M R Switches One per Gas Control Train 00000 Transformer Probe Type Low Water C6097B 120V 24V Cutoff Hydrolevel 59000 40 Model 650P Shown Additional Limit Switches SS id When Req d Float Low Water C E Wien Req d Ignition Control L gt Valve Switching 9 98010 1011 2225 Ms Relay H R8222A 1 WR Ignition Sensing Lead 120 V Main Operating Pressure D 2 Gas Valves Control Electronic 120 Pilot Gas Valve Pilot Aundii Spark Ignited uxiliary Gas Valves Additional Ground Lead to Pilot Burner Rai 200 C Thermoplastic Only 211A 36 amp 211A 37 TYPICAL WIRING HSP SYSTEM TWO GAS CONTROL TRAINS 120 VOLT GAS VALVES 120 V Hot Wires 24 V Hot Wires All wiring must comply with applicable codes ordinances and 120 V Neutral Wires 24 V Neutral Wires regulations If any of the original wire must be replaced it must wiring 80 C Thermopla
46. anel Guide GG 6031 Sheet Metal Screws Draft Hood Section GG 5001 GG 5001 Sheet Metal Screws Draft Hood Section GG 5001 1 GG 5001 1 Sheet Metal Screws Draft Hood Section GG 5001 2 GG 5001 2 Sheet Metal Screws I Draft Hood Section GG 5001 3 Sheet Metal Screws GG 50013 Ka l Kal KO l Kal Kal d Ka l Kal Kal Ka Ka l Ka l Ka Ka l Ka l Ka 1 1 1 1 2 1 1 Ka l Ka l Ka Ka l Ka l Ka 26 INSTALL THE JACKET DRAFT HOOD SY LLE lt lt lt lt EV VLLC LLE UY L LZ DEY LLC lt lt lt lt lt lt lt lt lt lt NI CN St 09 CO 10 00 8E VLLC BEY LLE BEY LLE PEY LLE ta EEN LLE 12 OOo 06 112 7112
47. ange pointing downward Use four 10 x 1 2 13 mm long sheet metal screws Repeat for the Right End 1 2 Apply Front and Rear Panels as follows Open Jacket Intermediate Section carton 12A B C D or E per Table 6 1 Remove necessary knockouts from panels Insert Front Panel GG 6023 flange on right side of panel under the edge of the Right Front Corner Panel Place the left edge of the Front Panel over the offset flange of the Left Front Corner Panel Line up the screw holes and secure with ten 10 x 1 2 13 mm long sheet metal screws Insert the offset flange of the Upper Rear Panel under the edge of the Left Rear Corner Panel Place the left edge of the panel over the Right Rear Corner Panel Line up the holes and secure with ten 10 x 1 2 13 mm long sheet metal screws Apply the Lower Rear Panel using the same procedure and secure with two 10 x 1 2 13 mm long sheet metal screws Install Rear Panel Support Leg GG 6028 inside the Left Rear Corner Panel The flanges extend toward the boiler Line up the holes and secure with three 10 x 1 2 13 mm long sheet metal screws Attach the Lower Rear Panel Guide GG 6031 to the Rear Base Panel as shown in Figure 6 2 Install the Draft Hood Work from the left side facing the front of the boiler to the right Apply the Draft Hood Sections in the sequence given in Table 6 2 Attach the Hood sections to the Flue Collector with two 10 x 1
48. ate at maximum speed Do not operate a summer exhaust fan Close fireplace dampers d Place in operation the appliance being inspected Follow the lighting instructions Adjust the thermostat so appliance will operate continuously e Test for spillage at the draft hood relief opening after 5 minutes of main burner operation Use the flame of a match or candle or smoke from a cigarette cigar or pipe PREINSTALLATION f After it has been determined that each appliance remaining connected to the common venting system properly vents when tested as outlined above return doors windows exhaust fans fireplace dampers and any other gas burning appliance to their previous condition of use g Any improper operation of the common venting system should be corrected so the installation conforms with the current edition of the National Fuel Gas Code ANSI Z223 1 NFPA 54 and or CAN CGA B149 Installation Codes When resizing any portion of the common venting system the common venting system should be resized to approach the minimum size as determined using the appropriate tables located in the chapter Sizing of Category I Venting Systems in the current edition of the National Fuel Gas Code ANSI Z223 1 NFPA 54 and or CAN CGA B149 Installation Codes E BOILER SETTING 1 Provide a good level foundation for the boiler with the minimum dimensions given in Figure 1 9 and Table 1 1 The flooring and structural support system must be su
49. ck valves at both the pump discharge and the connection to the boiler return SD ro PD D D Connection CO 60 1 1 DI A i Co Aal S eS 1 n e n mm ro ro PB ro D PD PD D D D D PIPE THE BOILER Pipe All Headers Minimum 24 610 mm Above Boiler Water Line 2 Skim Connection 2 Skim Connection Z 4 Return Figure 5 5 Piping Mlultiple Boilers Typical Gravity Return Systems STEAM SUPPLY STOP VALVE PIPE ALL HEADERS MINIMUM 24 610 mm ABOVE BOILER WATER LINE STOP VALVE TRAP F T DRIP TRAP TO RECEIVER PIPE OVERFLOW F T TRAPS 2 51 mm ABOVE NORMAL WATER LINE STOP VALVE SOLENOID OR MOTORIZED VALVE TO PUMP CHECK VALVE 2 SKIM TO RECEIVER CONNECTION STOP VALVE BOILER COCK FOR THROTTLING PUMP PRESSURE TO BOILERS SOLENOID OR MOTORIZED VALVE Figure 5 6 Piping Multiple Boilers Typical Pumped Return Systems 22 6 INSTALL THE JACKET amp DRAFT HOOD 211 04 THROUGH 211A 08 ONLY A PREPARE THE PARTS 1 5 Collect the Jacket cartons and Draft Hood cartons numbers 12 and 13 See Figure 6 2 for the Jacket
50. contains moisture provide information on how a steam boiler works with your specific system and will provide an overview of steam system operation in general WARNING Do not install this boiler on carpeting or any You can also use this survey to locate system problems which will have to be corrected To obtain copies of the Steam Installation Survey contact your PB Heat representative or download from PeerlessBoilers com combustible flooring A significant fire hazard could result with potential for property damage personal injury or death 3 If the boiler is installed in a penthouse or if wiring of x any sort is run underneath the boiler foundation construct the foundation with provision for airflow underneath between the main floor and the top of the boiler foundation a Concrete block aligned with the openings connected continuously would serve this purpose for example b If the foundation must be a concrete slab use an air cell high temperature insulating board at least 1 2 inch 13 mm thick with aluminum backing aluminum side up One half inch 13 mm Hi Temp millboard with aluminum backing would Y be acceptable as well Place the insulating board on the slab inside the base FOUNDATION LENGTH JACKET LENGTH BASE LENGTH lt BASE 41 1041 mm N JACKET 45 3 4 1162 mm lt FOUNDATION 57 3 4 1467 mm gt Figure 1 9 Foundation Layout PRE
51. d burners for cleanliness If ihe boiler cleaning is required use the following procedure a Turn off all electrical power to the boiler b Remove top jacket panels draft hood and flue collector 45 13 TROUBLESHOOTING SERVICE TIPS Problem Possible Cause Suggested Remedy Pilot Outage Defective Thermocouple Replace Heavy Draft Blowing across Pilot Redirect Air Movement or Eliminate Plugged Pilot Orifice Replace Orifice No Gas Check Manual Pilot Valve Check Main Gas Shut Off Valve Check Manual Meter Valve Consult Gas Company Defective Thermopilot Valve Replace Defective Ignition Control Replace Main Gas Valve Will Not Open Standard Spark Ignited Pilot System No Power Check Power Source with Meter Check Fuses Defective Gas Valve Replace Defective Thermocouple Replace Low Water Level in Boiler or System Causing Low Water Cut off to Function Check for Leaks Check Feeder if Supplied Defective Thermopilot Valve Replace Defective Ignition Control Replace High Gas Pressure Switch Open if Provided Check Switch Setting Check Manifold Gas Pressure Low Gas Pressure Switch Open if Provided Check Switch Setting Check Manifold Gas Pressure Main Gas Valve Will Not Open Electronic Standing Pilot System No Power Check Power Source with Meter Check Fuses Defective Gas Valve Replace Re
52. e ANSI NFPA70 and or the Canadian Electrical Code Part I CSA C22 1 Electrical Code and other controlling 2 agencies or governing bodies NOTICE The boiler burner must be electrically grounded in accordance with the requirements of the authority 1 having jurisdiction or the absence of such requirements with the current edition of the National Electrical Code ANSI NFPA Number 70 and or the Canadian Electrical Code Part I CSA C22 1 Electrical Code 2 Use 14 gauge or heavier wire for supply wiring Protect the circuit with a fused disconnect switch by others and a grounded neutral 3 Mount an electrical junction box on the boiler Front 3 Panel for connection of supply wiring and distribution to the boiler controls See Figure 9 1 4 Probe Type s K Low Water Cut off Ec P KNN U Float Type Low Water Cut off Control Box Pilot Gas Valve Figure 9 1 Typical Control Layout and Wiring Mount the control transformer on the junction box as shown in Figure 9 1 Mount a junction box near each Gas Control Train for connection of conduit and wiring distribution to the gas train components INSTALL CONTROL WIRING Wire the boiler according to the wiring diagram supplied with the boiler in the Control Envelope Figure 9 1 is a typical layout of the components on the boiler Figures 9 2 and 9 3 are examples of standard wiring systems Use these drawings for general reference only
53. em Hi Temp Sealing Cement Specify Quantity of Containers 55726 Spray Adhesive Specify Quantity of Containers 55485 OD Aluminum Tubing Specify Quantity in Feet Meters 718 38 O D Aluminum Tubing Specify Quantity in Feet Meters 53 REPAIR PARTS SERIES 211A Figure 15 2 Base Assembly NOTES 56 Series 211A Gas Boilers Steam Installation Operation amp Maintenance Manual TO THE INSTALLER This manual is the property of the owner and must be affixed near the boiler for future reference TO THE OWNER This boiler should be inspected annually by a Qualified Service Agency HI Division ASME of gama p D PeerlessBoilers com PB HEAT LLC PO BOX 447 NEW BERLINVILLE PA 19545 0447 2007 GG8051 R13 1 07 2M Printed in U S A
54. enings All Air from Indoors on Different Floors 4 Outdoor Combustion Air Outdoor combustion air is to be provided through one or two permanent openings The minimum dimension of these air openings is 3 inches 76 mm a Two Permanent Opening Method Provide two permanent openings One opening is to begin within 12 inches 305 mm of the top of the space and the other is to begin within 12 inches 305 mm of the floor The openings are to communicate directly or by ducts with the outdoors or with spaces that freely communicate with the outdoors The size of the openings shall be determined as follows PREINSTALLATION i Where communicating directly or through vertical ducts with the outdoors each opening shall have a minimum free area of 1 in per te oon 4000 Btu hr 22 cm per 4000 W of total TWO AIR OPENINGS E Z Minimum input rating for all equipment in the space Z 3 76mm Free Area Each See Figure 1 4 for openings directly 2 min 1 in per 2000 Btuh communicating with the outdoors or Figure i VEDO 1 5 for openings connected by ducts to the outdoors N Z 3 76 12 305mm 7 BOILER max 12 305mm Z TWO AIR OPENINGS 3 76mm p Minimum
55. ented too quickly Use smaller Air Vent or Use Two Small Vents in Place of One Large Vent One Mounted Higher than the Other Long nipple at Hartford Loop Replace with Close Nipple Water leg or back slope in return line to receiver tank causing water pocketing Correct Piping Trap installed at receiver tank causing water trapping in return Remove Trap at Tank Installing Drip Traps and Radiator Traps where Required Boiler feed pump or condensate pump feed rate too fast causing spraying into equalizer Throttle Flow Rate No drip on the inlet side of a forward pitched motorized valve Add Drip Line and Trap Uninsulated steam piping causing excessive condensate loads Insulate Steam Pipes Water Hammer on Shut Down Close nipple on Hartford too high Repipe 2 to 4 bcm to 10cm Below Water Line Uninsulated steam piping in boiler room but system piping insulated causing vacuum condition on shut down Insulate Steam Pipes Hammering in the Boiler Poor circulation in the boiler due to sludge accumulation Clean and Blowdown the Boiler No Heat or Poor Heat Distribution in the Building Main vents not working Replace Main Vents Repiping away from End of Lines if Needed Drip Traps failed closed Replace Traps or Trap Elements Radiator traps failed open allowing pressurization of the returns Replace Traps or Trap Elements Water legs or back slope in re
56. et Intermediate Panel Top GG 6024 Jacket Intermediate Panel Upper Rear GG 6025 Jacket Intermediate Panel Lower Rear GG 6034 GG 6026 Panel Support Angle GG 6027 Rear Panel Support Leg GG 6028 Lower Rear Panel Guide GG 6031 Sheet Metal Screws SM Jacket Intermediate Panel Front GG 6023 1 Jacket Intermediate Panel Top GG 6024 1 Jacket Intermediate Panel Upper Rear GG 6025 1 Jacket Intermediate Panel Lower Rear GG 6026 1 Panel Support Angle CRDI GG 6027 Rear Panel Support Leg GG 6028 Lower Rear Panel Guide GG 6031 Sheet Metal Screws Jacket Intermediate Panel Front GG 6023 2 Jacket Intermediate Panel Top GG 6024 2 Jacket Intermediate Panel Upper Rear GG 6025 2 Jacket Intermediate Panel Lower Rear GG 6034 2 GG 6026 2 Panel Support Angle GG 6027 Rear Panel Support Leg GG 6028 Lower Rear Panel Guide GG 6031 Sheet Metal Screws Jacket Intermediate Panel Front GG 6023 3 Jacket Intermediate Panel Top GG 6024 3 Jacket Intermediate Panel Upper Rear GG 6025 3 Jacket Intermediate Panel Lower Rear GG 6034 3 GG 6026 3 Panel Support Angle GG 6027 Rear Panel Support Leg GG 6028 Lower Rear Panel Guide GG 6031 Sheet Metal Screws Jacket Intermediate Panel Front GG 6023 4 Jacket Intermediate Panel Top GG 6024 4 Jacket Intermediate Panel Upper Rear GG 6025 4 Jacket Intermediate Panel Lower Rear GG 6034 4 GG 6026 4 Panel Support Angle GG 6027 Rear Panel Support Leg GG 6028 Lower Rear P
57. etween top lug and bottom lug in increments of 20 ft Ibs 27 N m Continue until both top and bottom lugs are tightened to 60 ft Ibs 81 N m DO NOT EXCEED 60 FT LBS 81 N m f Check the level while tightening to make sure alignment stays true Also make sure sections remain square with the Base from front to back as the tie rods are tightened and as additional sections are installed g If the sections tend to run out of plumb this will usually be at the bottom front Loosen the upper nuts slightly and tighten the lower ones to adjust 7 Assemble the remaining sections in the same way for a finished assembly as shown in Figure 3 3 8 Some of the Intermediate Sections have tappings for installing additional steam risers from the boiler These Tapped Intermediate Sections must be installed as shown in Figure 3 5A The placement order is left to right Figure 3 5 Left Hand End Section Position Number 1 Figure 3 5 Section Positioning Numbering 16 Boiler Place Tapped Intermediate Sections Model Number as Positions numbered Left to Right 211A 18 10 211A 19 10 211A 20 11 211A 21 11 211A 22 8 16 211A 23 8 16 211A 24 9 17 2114 25 7 13 19 211 26 7 13 20 211 27 7 12 17 22 211 28 5 11 17 23 211 29 5 10 15 20 25 211 30 6 11 16 21 26 211 31 6 10 14 18 22 26 211 32 6 11 15 19 23 27 211
58. f Model 157 3b INSTALL CONTROLS AND TRIM Normal Water Line 2 51 mm 36 914 mm 10 7 8 276 mm 25 1 8 638 mm 10 3 8 264 mm 19 mm 12 7 8 327 mm 4 1 8 206 mm 105 mm APPLICATION OF 51 FEEDERS Models 211A 04 thru 211A 23 One 51 2 Feeder Cutoff Models 211A 24 thru 211A 39 One 51 S 2 Feeder Cutoff Models 211A 40 and Larger Two 51 2 Feeder Cutoffs Consult Factory for proper application of feeders Always use a pump control and boiler feed system instead when possible Figure 8 6 Optional Feeder Low Water Cut Off Type 51 2 36 NE E ee Control Center Line Feeder Closing Level Mark on Casting Burner Cut Off Level is 1 1 2 38 mm Below Center Line on 51 2 and 51 S 2 Controls 2 3 4 70 mim Below Normal Water Line Install 1 Blowoff Valve Y Boiler Foundation SUGGESTED FITTINGS LIST 1 Cross 1 Ground Joint Union 1 Plug 1 x 3 76 mm long Nipple 1 x 5 1 2 140 mm long Nipple 1 x 8 203 mm long Nipple 1 x 8 1 4 210 mm long Nipple 1 x 19 1 2 495 mm long Nipple 3 x 1 Bushing K TH HHOH The connected fittings shown on this drawing are to be supplied by the installer WIRE THE BOILER 9 WIRE THE BOILER A CONNECT SUPPLY WIRING B PREPARE REMAINING CONTROLS 1 All wiring must be done in accordance with local 1 codes the National Electrical Cod
59. f the multiple boilers on a pumped return system This prevents flooding of idle boilers due to condensation of steam Equalizer 2 Skim Connection Table 5 1 Header Risers amp Equalizer Sizing Figure 5 3 Supply and Return Piping Boiler Header End Risers Interm Risers Equalizers Counterflow Gravity Systems Model Size No Size Size No Size 211A04 4 2 1 2 2 On pumped return systems install a boiler cock after 211A 05 5 5 2 1 2 the pump to allow throttling of the pump discharge 2114 06 2 1 2 The pressure after the boiler cock should be no more than 5 psig 35 kPa above the boiler operating pressure Pumping the water into the boiler too fast will cause collapse of the water level and level 2114 10 control problems 211 11 211 12 3 Size the equalizer per Table 5 1 2114 13 2114 14 211A 15 211A 16 211A 17 2114 18 211A 19 211A 20 211A 21 211A 22 211A 23 211A 24 211A 25 211A 26 211A 27 211A 28 211A 29 211A 30 211A 31 211A 32 211A 33 2114 34 211A 35 211A 36 211A 37 211 38 211 39 211 40 211 41 211 42 211 43 211 44 211 45 Figure 5 4 Left Hand Piping Arrangement Typical 211A 46 4 Pipe the Hartford loop tee so the inside top of the close nipple is 2 to 4 inches 51 to 102 mm below the boiler water line 5 If the pump discharge is looped overhead above the boiler water line install spring loaded che
60. he Operating and Limit Pressure Controls to minimum setting so they will not call for heat 4 Perform Pilot Check a Turn main electric disconnect switch to the ON position b Turn up the settings on the Operating and Limit Pressure Controls so they will call for heat c Check for a continuous spark at the electronic spark ignited pilot s d Electronic spark ignited pilot systems The control will spark for 15 seconds trial for ignition then shut down for a 5 to 6 minute wait period before attempting another ignition e Electronic standing pilot systems Within 15 seconds the control will click indicating a safety lockout f Turn down the Operating Pressure Control to stop the call for heat Wait 60 seconds to allow the control to reset before proceeding with the next step 5 Light Manual Pilots a Follow the procedure in the Lighting Instructions to manually light any standing pilots 6 Electronic Spark Ignited Pilot Ignition Check a Turn up the Operating Pressure Control for a call for heat b The electronic spark ignited pilot s should ignite c Turn down the Operating Pressure Control to stop the call for heat d The spark ignited pilot s should shut off 7 Check Main Burner Ignition a With the Operating Pressure Control turned down open the main gas shut off valve s b Turn up the Operating Pressure Control for a call for heat c The electronic spark ignited pilot s should ignite
61. ht Hand Shown Left Hand Opposite NOTE Some local codes may require larger piping 3 4 Plug m w gt Figure 8 2 Pressure Control Piping Fittings Included with Boiler 33 INSTALL CONTROLS AND TRIM Burner Cut Off Level 1 2 Pipe Tap Conduit Connection 13 330 mm 8 1 2 216 mm Water Line 4 102 E 76 mm 57 mm l em o I 7 135 Feeder Closing Level ae Mark on Casting Figure 8 4 Optional Feeder Low Water Cut Off Model 47 2 Used Only on Models 211A 04 through 211A 08 Capacity Not Adequate for Larger Boilers 34 INSTALL CONTROLS AND TRIM lR X RI 16 11 16 _ 424 mm Burner Cutoff Level Mark on Casting Normal Water Line 7 s eite en cg 8 1 2 38 mm be gt Ac xmas 2 as i 12 5 16 313 4 E 40 1 2 RE 1029 mm i ii i 2 lt 12 305 mm Install 1 Blowoff Valve Y Boiler Foundation SUGGESTED FITTINGS LIST A 1 Cross F 1 x 6 152 mm long Nipple B 1 Ground Joint Union G 1 x 8 203 mm long Nipple C 1 Plug H 1 x 8 1 4 210 mm long Nipple D 1 x 2 51 mm long Nipple J 1 x 14 356 mm long Nipple E 1 x 3 76 mm long Nipple K 3 x 1 Bushing The connected fittings shown on this drawing are to be supplied by the installer Figure 8 5 Optional Float Type Pump Control Low Water Cut Of
62. ich would raise or lower the location of the cut off relative to the tappings in the boiler Raising the water level over the design height N CAUTION Pipe the discharge of the Safety Relief Valve s away will cause water carryover to the system from any traffic area preferably to a floor drain This is necessary to prevent injury should the valve 3 For correct location of typical low water cut off feeder discharge or low water cut off pump control see Figures 8 3 Pipe the discharge full size of valve outlet through 8 6 4 Mount the probe type low water cut off supplied with the boiler The end sections have 3 4 tappings in the INSTALL BLOWDOWN VALVES front for mounting the probe low water cut off auxiliary control See Figure 3 3 a The standard probe control is Hydrolevel Model 650P This control is automatic reset type 1 Install a 1 1 2 full port ball valve in each of the tappings provided at the lower back of the end sections See Figure 8 1 b When a manual reset control is required the boiler 2 Pipe the valve discharge to a floor drain if available or can be supplied with Hydrolevel Model 550P apply a nipple and cap to close off when not in use 5 Provide each float low water cut off with a blowdown valve Pipe the blowdown away from traffic to a floor Install Boiler Pop Safety Relief drain if available The blowdown valve is required for Valve s in 3 End Section Tapping s proper maintenance of the con
63. ight of the vent system independently of the boiler draft hood The draft hood is not designed to carry structural loading d Provide support of the vent connector breeching at maximum 12 foot 366 cm intervals to prevent sagging and to provide a minimum upward slope of 1 4 per foot 21 mm per meter e Do not connect the vent for this boiler into any vent system which operates with positive pressure f Use Type B double wall pipe for vents which run through unheated spaces Removing an existing boiler from a common vent At the time for removal of an existing boiler the following steps shall be followed with each appliance connected to the common venting system placed in operation while the other appliances remaining connected to the common venting system are not in operation a Seal any unused openings in the common venting system b Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restriction leakage corrosion and other deficiencies which could cause an unsafe condition c Insofar as is practical close all building doors and windows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building Turn on clothes dryers and any appliance not connected to the common venting system Turn on any exhaust fans such as range hoods and bathroom exhausts so they will oper
64. itable for the operating weight of the WATER QUALITY AND MAKE UP 1 Check the system to make sure there are no leaks or overfilling problems which might cause excessive make up water to be added Make up water causes liming in the boiler and brings in oxygen Oxygen can cause severe damage to the boiler through oxygen corrosion pitting Clean the boiler as described in this manual Poor water quality will cause foaming priming and overfilling of the system Too much sediment in the water will cause build up in the boiler and could result in cracked sections due to overheating If the condensate return time lag is too long this boiler may not work correctly with aravity return or with a condensate return unit Long time lags will cause make up water to be added to the boiler resulting in flooding of the boiler carryover to the system and excessive make up water addition You will need to install a boiler feed system to prevent problems in such cases Do not use chemicals or substances in the boiler or system which contain petroleum or its derivatives This will damage the boiler seals boiler and any connected piping 2 Do not operate the boiler until the foundation if new G INSTALLATION SURVEY concrete has thoroughly cured The high For new and existing installations a Steam Installation temperature under the burners could cause major Survey is available from PB Heat The survey will damage to the concrete if it still
65. ition of the National Fuel Gas Code ANSI Z223 1 NFPA 54 under Venting of Equipment or CAN CGA 8149 Installation codes under Venting Systems and Air Supply for Appliances or applicable provisions of the local building codes 3 Chimney Vent Operation The vent system must be sized and installed to provide the draft needed to remove all combustion products If the vent system does not provide enough draft combustion products will spill into the building from the draft hood relief opening If spillage of combustion products occurs check the vent system the combustion and ventilation openings and make sure the boiler room is never under negative pressure A WARNING Failure to provide adequate venting can result in severe property damage personal injury or death 4 Exterior Vents a Ifthe vent is outside make sure it is insulated sufficiently to ensure adequate draft 5 Vent Sizing a Individual vents Use vent piping the same diameter as the boiler vent connection The minimum height is 10 feet 305 cm above the bottom of the draft hood relief opening The vent must also extend above the roof or any Obstructions as outlined in the current edition of the National Fuel Gas Code ANSI Z223 1 NFPA 54 and or CAN CGA 8149 Installation Codes or as required by local codes b Combined vent breeching The recommended sizing in Section 14 Boiler Ratings amp Dimensions in this Manual is based on a minimum
66. l light main gas valves will open and main burners will light 12 The burners will continue to fire until the Operating Control is satisfied SPARK SENSING PROBE IGNITION CONTROL CABLE J 1 4 PILOT GAS VALVE IGNITION RED NOTES REQUIRED ON BOILERS WITH INPUT OF 2500 MBH 733kw OR MORE PILOT GAS PRESSURE BLEED B TO SHUT DOWN THE BOILER 1 Open main line power disconnect switch to boiler 2 Close Main and Pilot gas shut off valves C PILOT FLAME FAILURE 1 If flame signal is lost at pilot the ignition control will shut off the main gas valves and start sparking within 0 8 seconds 2 The control will continue to spark for 15 seconds 3 If a flame is not sensed the control will shut down the pilot gas valve and wait 5 to 6 minutes 4 It will then start sparking and open the pilot gas valve for another 15 second ignition trial 5 The control will continue this sequence indefinitely 6 Refer to Control Envelope supplied with the boiler for the specific system used 7 Should a flame failure occur causing a shut down of the main burners turn off all electric power to the boiler and close Main and Pilot manual shut off valves Call a qualified service technician to inspect the boiler and correct the problem GAS PRESSURE TEST TAPPING p PILOT COCK MANUA SHUT OFF VALVE GAS PRESSURE REGULATOR VE
67. lay Locked Out on Safety Check for Pilot Outage Pilot Out Relight Pilot May have defective pilot valve or relay Defective Relay Replace Low Water in Boiler or System Causing Low Water Cut off to Function Check for Leaks Check Feeder if Supplied Defective Thermopilot Valve s Replace Defective Thermocouple s Replace High Gas Pressure Switch Open if Provided Check Switch Setting Check Manifold Gas Pressure Low Gas Pressure Switch Open if Provided Check Switch Setting Check Inlet Gas Pressure Burner s Burning with Yellow Flame Air Adjustment Screws Turned in Too Far Adjust Screws Out Low Gas Pressure in Manifold Insufficient Air Injection Adjust Main Gas Pressure Regulator or Check Line Pressure Burner Ports Partially Closed Rust Dirt Lint etc Replace Burners or Clean Ports Insufficient Air for Combustion Check Size of Combustion Air Openings to Room if Undersized Correct as Required Check for Negative Pressure in Boiler Room Oversized Burner Orifice Install Correct Orifice High Gas Pressure in Manifold Adjust Main Gas Pressure Regulator Gas Spillage from Draft Hood Relief Opening 46 Insufficient Draft Chimney Too Low Increase Height or Add Induced Draft Fan Insufficient Draft Chimney Too Small Replace Chimney or Add Induced Draft Fan Insufficient Draft Blockage in Chimney or Vent
68. m EDR Steam Piping Input Output Steam EDR Steam MBH kW Sq Ft m MBH kW Factor MBH kW MBH kW Sq Ft m MB kW 211A 04 504 148 1 575 147 378 111 1333 615 180 492 144 1538 143 369 108 211A 05 672 197 2 100 195 504 148 1 333 820 240 656 192 2 050 191 492 144 211A 06 840 246 2625 244 630 185 1 333 1 025 300 820 240 2563 238 615 180 211A 07 1 008 295 3 150 293 756 222 1 333 1 230 361 984 288 3 075 286 738 216 211A 08 1 176 345 3 675 342 882 259 1 333 1 435 421 1 148 336 3 588 334 861 252 211A 09 1 344 394 4229 393 1 015 298 14324 1 640 481 1312 385 4121 384 991 290 211 10 1 512 443 4 808 447 1154 338 1 310 1 845 541 1 476 433 4 688 437 1 127 330 211 11 1 680 492 5 392 501 1 294 379 1 298 2 050 601 1 640 481 5 258 490 1 263 370 211 12 1 848 542 5 971 555 1433 420 1290 2 255 661 1 804 529 5 821 542 1 398 410 211 13 2 016 591 6521 607 1 565 459 1288 2 460 721 1 968 577 6 367 593 1 528 448 211 14 2 184 640 7 067 658 1 696 497 1 288 2665 781 2 132 625 6 896 642 1 655 485 211 15 2 352 689 7 608 708 1 826 535 1 288 2 870 841 2 296 673 7 429 692 1 783 522 211 16 2 520 739 8 154 759 1 957 573 1 288 3 075 901 2 460 721 7 958 741 1 910 560 211 17 2 688 788 8696 810 2 087 612 1 288 3 280 961 2 624 769 8 488 790 2 037 597 211 18 2 856 837 9238 860 2 217 650 1 288
69. n Position Position Position 1 2 3 4 5 6 7 8 211A 04 13 211A 05 211A 06 211A 07 211A 08 211A 09 211A 10 211A 11 211 12 211 13 211 14 211 15 211 16 211 17 211 18 211 19 211 20 211A 21 211A 22 211A 23 211A 24 211A 25 211A 26 211A 27 211A 28 211A 29 211A 30 211A 31 211A 32 211A 33 211A 34 211A 35 211A 36 211A 37 211A 38 211A 39 211A 40 211 41 211 42 211 43 211 44 211 45 211 46 28 7 CONNECT GAS PIPING INSTALL GAS TRAIN 1 2 B CONNECT PILOT GAS TUBING 1 The Gas Control Train s supplied with this boiler Has been factory assembled and tested for tightness of joints Must be re tested after installation with a soap suds test to assure it is still leak tight after assembly Must be isolated from the gas supply piping during testing of the supply piping Assemble the Gas Control Train s to the Manifold with the ground joint union s provided See Figure 7 1 Models 211A 04 through 2114 18 are supplied with a single Gas Control Train Models 211A 19 and larger are supplied with two or more Gas Control Trains Support the Gas Control Train s with a permanent brace Use 3 8 aluminum tubing or as required by local codes Connect the Pilot Line to the Pilot Cock Assembly supplied with the Gas Cont
70. n per 1000 Btu hr 0 034 m3 min per 1000 W of the total rated input of all appliances in the space b In installations where exhaust fans are installed additional air shall be provided to replace the exhaust air c Each of the appliances served shall be interlocked to the mechanical air supply to prevent main burner operation when the mechanical air supply system is not in operation d In buildings where the combustion air is provided by the mechanical ventilation system the system shall provide the specified combustion air rate in addition to the required ventilation air 8 Louvers amp Grills a The required size of openings for combustion ventilation and dilution air shall be based on the net free area of each opening i Where the free area through a louver or grille is known it shall be used in calculating the opening size required to provide the free area specified Where the free area through a louver or grille is not known it shall be assumed that wooden louvers will have 25 free area and metal louvers and arilles will have 75 free area PREINSTALLATION 5 Combination Indoor and Outdoor Combustion Air If iii Nonmotorized dampers shall be fixed in the open position b Motorized dampers shall be interlocked with the equipment so that thev are proven in the full open position prior to ignition and during operation of the main burner i The interlock shall prevent the main burner from igniti
71. nce c See Figure 1 1 Clearances with an S are minimum clearances for service accessibility B COMBUSTIBLE CONSTRUCTION CLEARANCES 1 This boiler is design certified for the following clearances to combustible construction 24 610 mm between the front top sides and rear of the jacket 6 152 mm from steam and hot water pipes 6 152 mm from vent connector See Figure 1 1 Clearances with a C indicate minimum clearances from combustible construction AIR FOR COMBUSTION AND VENTILATION 1 Adequate combustion air and ventilation air must be provided for this appliance in accordance with the section of the National Fuel Gas Code entitled Air for Combustion and Ventilation or applicable provisions of the local building code Subsections 2 through 8 as follows are based on the National Fuel Gas Code requirements 2 Required Combustion Air Volume The total required volume of indoor air is to be the sum of the required volumes for all appliances located within the space Rooms communicating directly with the space in which the appliances are installed and through combustion air openings sized as indicated in Subsection 3 are considered part of the required volume The required volume of indoor air is to be determined by one of two methods a Standard Method The minimum required volume of indoor air room volume shall be 50 cubic feet per 1000 BTU Hr 4 8 m kW This method is to be used
72. nel The flanges point toward the boiler Attach with 10 x 1 2 13 mm long sheet metal screws Install a Panel Support Angle on the inside top of the Upper Rear Panel See Figure 6 2 Use 10 x 1 2 13 mm long sheet metal screws Install the remaining Upper Rear and Lower Rear Panels in the same way Place the edge of the last rear panel over the Right Rear Corner Panel Install the Draft Hood Sections Start from the left of the boiler facing the front Apply the Draft Hood sections from left to right in the order given in Table 6 2 Use two 10 x 1 2 13 mm long sheet metal screws for each Flue Collector section F APPLY JACKET TOP PANELS 1 Apply the jacket top panels working from left to right facing front of boiler Place the panels from the cartons in the sequence given in Figure 6 3 Mount a Panel Support Angle GG 6027 on the back bottom edge of each Top Panel with the long flange pointed down Peel the insulation slightly away from the back edge of the panel for better contact Secure with one 10 x 1 2 13 mm long sheet metal screw Lighting Instructions Plate NYC MEA Plate When Required gt L INSTALL THE JACKET amp DRAFT HOOD Slide the left hand offset flange of the first Top Panel under the Top Left End Panel Place the front flange of the Top Panel over the Front Panel Line up the holes and secure with 10 x 1 2 13 mm long sheet metal screw
73. ng if the damper fails to open during burner startup i The interlock shall shut down the burner if the damper closes during burner operation 9 Combustion Air Ducts a Ducts shall be constructed of galvanized steel or an equivalent corrosion resistant material b Ducts shall terminate in an unobstructed space allowing free movement of combustion air to the appliances c Ducts shall serve a single space d Ducts shall not serve both upper and lower combustion air openings where both such openings are used The separation between ducts serving upper and lower combustion air openings shall be maintained to the source of combustion air e Ducts shall not be screened where terminating in an attic space f Horizontal upper combustion air ducts shall not slope downward toward the source of the combustion air g The remaining space surrounding a chimney liner gas vent special gas vent or plastic piping installed within a masonry metal or factory built chimney shall not be used to supply combustion air h Combustion air intake openings located on the exterior of buildings shall have the lowest side of the combustion air intake opening at least 12 inches 305 mm above grade D CHIMNEY OR VENT T Inspect the existing chimney or vent system Make sure it is in good condition Inspect chimney liner and repair or replace if necessary The vent system and installation must be in accordance with the current ed
74. nt skin contact Wear eye goggles Minimize airborne dust prior to handling and removal by water misting the material and avoiding unnecessary disturbance of materials Wash work clothes separately from others Rinse washer thoroughly after use Discard RCF materials by sealing in an airtight plastic bag First Aid Procedures Inhalation If breathing difficulty or irritation occurs move to a location with fresh clean air Seek immediate medical attention if symptoms persist Skin Contact Wash affected area gently with a mild soap and warm water Seek immediate medical attention if irritation persists Eye Contact Flush eyes with water for 15 minutes while holding eyelids apart Do not rub eyes Seek immediate medical attention if irritation persists Ingestion Drink 1 to 2 glasses of water Do not induce vomiting Seek immediate medical attention 43 OPERATIONS 8 MAINTENANCE WARNING Do not store or allow combustible or flammable materials near the boiler Substantial fire or explosion hazard could result causing risk of personal injury death or property damage Do not use this boiler if any part of it has been under water Immediately call a qualified service technician to inspect the boiler Any part of the control system any gas control or any burner or gas component which has been under water must be replaced Should overheating occur or the fuel supply fail to shut off Shut off the fuel supply at a l
75. ocation external to the boiler Do not turn off or disconnect the electrical supply to the pump Immediately call a qualified service technician to inspect the boiler for damage and defective components A PLACING BOILER OPERATION 1 Start up the boiler per the Lighting Instructions shipped with the boiler Prove the correct operation of all controls on the boiler as outlined below Check the operation of the ignition and flame proving controls a Electronic Spark Ignited Pilot System S8610M Control With the boiler operating close the Pilot manual shut off valve The ignition control should close the main gas valves within 1 second The control will spark and attempt to relight the pilot burner After 15 seconds the control will shut down and wait 5 to 6 minutes for another ignition trial Open the Pilot manual shut off valve and re start the boiler per the Lighting Instructions Standing pilots will have to be manually re lit per the Lighting Instructions b Electronic Standing Pilot System With the boiler operating close the Pilot manual shut off valve The ignition control should close the main gas valves within 3 seconds after the pilot goes out After 15 seconds the control will lock out Open the Pilot manual gas shut off valve and re start the boiler per the Lighting Instructions Standing pilots will have to be manually re lit per the Lighting Instructions
76. off Hydrolevel Model 650P Shown 40 va Additional Limit Switches 4 When Req d Float Type Low Water 1 gt N Tq itchi sod cc 193 Ignition Control i Swing Transformer When Req d HS8610M 1011 2528 Relay MO 120V 24V H R8222A 10059 Operating Pressure Control Low Voltage Main Gas Valves Pilot Gas Valve 9 Low Voltage m b Auxiliary Train 1 Train 2 TYPICAL WIRING HSP SYSTEM TWO GAS CONTROL TRAINS 24 VOLT GAS VALVES CNN Lead to Pilot Burner 200 C Thermoplastic Only m 120 V Hot Wires 24 Hot Wires All wiring must comply with applicable codes ordinances and 120 Neutral Wires 24 V Neutral Wires regulations If any of the original wire must be replaced it must wiring 80 Thermoplastic except as noted be replaced with wire as shown its equivalent Figure 9 2 Typical Wiring Standard Controls Low Voltage Gas Valves 38 WIRE THE BOILER 120V 60hz 1 120 v 60 hz Neutral 5 HOT High Limit CN Pressure High Gas Pressure Control M R Switch C6097B Models 2114 53 Y 100000 Transformer Probe Type Low Water Through 211A 18 Additional 120 24 Cutoff Hydrolevel Limit Switches f000001 40 va Model 650P Shown When Req d n Float Type Low Water Cutoff Ignition Control When Req d L H S8610M 1011
77. old Weldment GG 4084 thru GG 4084 46 Imperial 68F 1 4 NPT x 3 8 O D Tube Straight Connector Ne Orifice Spud 4026 T Mounting Clamp GG 3052 thru GG 3052 3 Test Plug 3 8 x 3 8 x 1 4 Tee po 4 DUE rcm gt ma N Codd Street Elbow 3 8 Pipe Cap 1 4 X 1 1 2 Pipe Cap 1 4 x 1 8 38 mm long Nipple 3 8 Thermopilot 3 8 x 1 4 Elbow Hex Bushing Valve s H17CA Ignition Control amp Relay Mounting Box Assembly Standard HSP System X 3011 3 PB H91BG 2 or Other panels mounted on Imperial 69F Elbow H V8046C 2 5 16 18 x 3 4 19mm long jacket front left side 1 8 NPT x 1 4 O D Tubing Pilot Gas Valve Square Head Set Screw Figure 2 5 Typical Gas Manifold and Pilot Line Assembly 4 Place only the Burners with pilots mounted in the 5 Cut and fit the 1 4 aluminum tubing provided from locations given in Table 2 2 Install the Burners by the pilot gas shut off device s to the pilot burners slipping the opening on the front of the burner over the orifice adapter and slipping the pin on the end of 6 Do not install the remaining burners until the Boiler the burner into the hole in the Burner Support Sections are installed Channel directly opposite the orifice 12 ASSEMBLE THE BASE Table 2 2 Pilot Burner Locations Numbered Right to Left See Figure 2 1 Model Number Number of Pilots Total Number of
78. ooooooooooo 90000000000 0000000000 00000000000 00000000000 000000000000 The sections are heavy and must be supported securely 00000000000 3 Align the parting line of the section with the seam between the Base End panel and the Base Front Panel as shown in Figure 3 3 Flow Port Gasket 4 Apply Hi Temp rope seal by spreading a thin coat of spray adhesive in the grooves on each end of the section Place the rope in the grooves Do not stretch the rope The longer rope goes in the front groove NOTE The ends of each rope must extend 1 2 13 mm beyond the top and bottom 5 Place the Flow Port Gaskets in the recesses provided see Figure 3 1 Do not use adhesive 6 The following steps must be followed to insure that no damage is done to the tie rod lugs A 0 100 ft Ibs 0 136 N m torque wrench is required a Place an Intermediate Section on the base and slide it carefully against the Left Hand End Section b Align the flow ports from front to back as close as possible Figure 3 1 Flow Port Machining amp Gasket c Insert a tie rod into each of the lugs on each section and apply a nut and washer to each end of the tie rod PLACING THE SECTIONS d Before tightening check the vertical alignment of the sections using a spirit level see Figure 3 4 1 Begin by placing the Left Hand End Section on the Make sure they are square with th Base left end of the base The upper
79. oot Meter Foot Meter Foot Meter Foot Meter Foot Meter 10 3 0 1050 30 1 600 45 3 050 86 4 800 136 8 500 241 17 500 496 20 6 1 730 21 1 100 31 2 100 59 3 300 93 5 900 167 12 000 340 30 9 1 590 17 890 25 1 650 47 2 700 76 4 700 133 9 700 275 40 12 2 500 14 760 22 1 450 41 2 300 65 4 100 116 8 300 235 50 15 2 440 12 670 19 1 270 36 2 000 57 3 600 102 7 400 210 60 18 3 400 11 610 17 1 150 33 1 850 52 3 250 92 6 800 193 70 21 3 350 10 560 16 1 050 30 1 700 48 3 000 85 6 200 176 90 27 4 320 490 14 930 26 1 500 42 2 600 74 5 400 153 30 5 305 460 13 870 25 1 400 40 2 500 71 5 100 144 45 7 250 380 11 710 20 1 130 32 2 000 57 4 100 Above ratings based on natural gas with specific gravity of 0 60 allowing pressure drop of 0 3 inches 75 Pa No allowance is needed for pipe fittings Use the following multipliers on above capacities for specific gravity other than 0 60 Specific Gravity Multiply Capacity by 31 8 INSTALL CONTROLS AND TRIM A INSTALL SAFETY 5 C INSTALL LOW WATER CUT OFF S 1 Pipe the pop safety valve s in the 3 tappings 1 Mount the float type low water cut off and gauge located on the right or left end sections Make sure glass in the tappings provided in the front of either the relief valve sizing meets local code requirements end section 2 Do not apply piping wh
80. own in Figure 5 4 typical 8 Do not reduce the size or number of risers shown These are required for reliable operation of the boiler If the risers are undersized or incorrectly placed a sloped water line can occur in the boiler causing possible overheating of some sections 9 Pipe the Header with an offset as shown in the drawings This offset prevents the expansion and contraction of the Header from damaging the boiler sections Use threaded fittings for swing joints 10 Always locate the Steam Supply take off between the Equalizer and the last Boiler Riser See PB Heat s Steam Installation Survey for discussion Locating the Steam Supply between the risers will cause water carryover to the system 11 Do not use a bull head tee to provide steam supply and equalizer connections This will cause water level bounce and carryover C RETURN PIPING 1 The use of a Hartford loop in all installations is recommended The loop provides additional reliability for the system A check valve must still be installed on the pump discharge of all pumped return systems Steam Supply should always be piped between last boiler riser and equalizer 24 610 mm Min SL lt Use close URL x s p Ras nipple only Hartford 4 Loop mm Hartford Loop y Figure 5 1 Supply and Return Positions Skim Piping Hartford Loop 19 PIPE THE BOILER Second Equalizer
81. penings communicating with additional spaces that have a minimum free area of 1 in per 1000 Btu hr 22 cm per 1000 W of the total input rating of all gas fired equipment but not less than 100 in 645 cm2 One opening is to begin within 12 inches 305 mm from the top of the space and the other is to begin within 12 inches 305 mm from the floor The minimum dimension of either of these openings shall be 3 inches 76 mm See Figure 1 2 for an illustration of this arrangement PREINSTALLATION f 1 12 305mm TWO AIR OPENINGS Ms Minimum 7 Free Area Z 3 76mm 1 in per 1000 Btuh 7 min 22 cm per 1000 W i a ae e n BUILDING M SPACES ON SAME STORY Must not be under negative pressure 3 76mm Z min BOILER i 12 305mm max a 4 2 avs Figure 1 2 Air Openings Air from Indoors on the Same Floor b Combining spaces on different floors Provide one or more permanent openings communicating with additional spaces that have a total minimum free area of 2 in per 1000 Btu hr 44 cm per 1000 W of total input rating of all equipment See Figure 1 3 for an illustration of this arrangement BUILDING SPACES ON DIFFERENT STORY Must not be under negative pressure SS R ONE OR MORE AIR OPENINGS Minimum Total Free Area 2 in per 1000 Btuh 44 cm per 1000 w BOILER Figure 1 3 Air Op
82. port Bracket GG 2069 Section Assembly Kit GG 1030 1 Front Panel Sub Assembly GG 2080 3 Back Panel Sub Assembly GG 2081 3 Burner Support Channel GG 2066 3 Angle Tie Brace GG 2065 Front Panel Support Bracket GG 2069 Section Assembly Kit GG 1030 2 Front Panel Sub Assembly GG 2080 4 Back Panel Sub Assembly GG 20814 Figure 2 2 Steel Base Assembly Burner Support Channel GG 2066 4 Angle Tie Brace GG 2065 Front Panel Support Bracket GG 2069 Section Assembly Kit GG 1030 3 Base Back Panel Sub Assembly GG 2081 x Base Right End Panel Sub Assembly GG 2105 r ma T TI P a T i 41 Left Side VI EW Burner Position Number 1 1041 mm Right Side 4 2 SES i SERONT L zw k Y Burner Support Channel GG 2066 Base Left End Panel Sub Assembly GG 2106 Base Front Panel Sub Assembly GG 2080 Front Jacket Support Bracket GG 2069 Angle Tie Brace w Burner Support Channel GG 2065 when required Es Es FRONT VIEW n oA i ipfe lt Assembly 4 Assembly 4 Assembly 4 Assembly 4 Assembly 4 Assembly Assembly A B D E F G lt H overall length Figure 2 1 Boiler Base Assembly ASSEMBLE THE BASE Attach the Front Panel and Back Panel Figure 2 2 to the Left Hand End Panel using 5 16 18 x 1 25 mm long cap screws and hex head nuts provided For 211A 04 through 211A 08 Only a Complete the base assembly by attaching the
83. rol Train SENSING PROBE IGNITION CONTROL Z IGNITION CABLE 1 4 PILOT GAS VALVE NOTES REQUIRED ON BOILERS WITH AN INPUT OF 2500 MBH 733kw OR MORE PILOT GAS PRESSURE REGULATOR MANUALLY 3 Connect tubing to each pilot a Connect electronic pilots to the Pilot Gas Valves b Connect standing pilots when supplied see Table 2 2 to the thermopilot valves c Install thermocouples in the standing pilots and connect to the thermopilot valves C INSTALL VENT AND BLEED PIPING 1 Gas Pressure Regulator a Connect regulator vent outlet to outside atmosphere using 1 4 tubing or as required by local codes b Terminate the tubing downward to prevent water from entering the tubing and protect from any obstruction c Terminate the tubing above and well away from normal breathing level or building air intakes 2 Diaphragm Gas Valves a Pipe diaphragm gas valve bleed lines to outside atmosphere unless the boiler is equipped with a standing pilot On standing pilot boilers pipe the valve bleed lines to the bleed piping pre installed to the pilot burner b Use 1 4 tubing or as required by local codes Always pipe the bleed lines separate from the regulator vent lines GAS PRESSURE TEST TAPPING OT COCK La MANUAL SHUT OFF VALVE GAS PRESSURE REGULATOR 97 VENT TO OUTSIDE ATMOSPHERE WELL ABOVE NORMAL BREATHING 9 EVEL AND
84. s Slide the left hand edge of each additional panel under the panel to its left Secure with 10 x 1 2 13 mm long sheet metal screws Apply the last Top Panel in the same way Place its right hand edge over the Top Right End Panel Secure with 10 x 1 2 13 mm long sheet metal screws Check for loose or missing screws as you complete the jacket assembly G APPLY LOWER END PANELS 1 2 3 THIS APPLIES TO ALL BOILER SIZES The parts are packed in carton Z12 Attach an End Panel Cover Plate to the opening in the Lower End Panel GG 6022 if the tapping in the boiler is not being used Secure with two 10 x 1 2 13 mm long metal screws Apply a Lower End Panel to each end of the boiler securing to the Corner Panels with eight 10 x Y 13 mm long sheet metal screws Attach to the Upper End Panels with two 10 x 2 13 mm long sheet metal screws H APPLY PLATES AND LABELS 1 Mount Boiler Rating Label Agency Plates and Caution Labels in the Upper Right End Jacket Panel Plates to be field applied are packed in Box Number 7 Place these plates as shown in Figure 6 1 Secure metal plates with 6 x 6 mm 1 4 sheet metal screws Apply all adhesive backed labels Figure 6 1 Location of Rating Agency and Instruction Plates on Upper Right End Panel INSTALL THE JACKET amp DRAFT HOOD Top Panel GG 6024 Top Right End Panel
85. sed INSTALL THE FLUE COLLECTOR 4 INSTALL THE FLUE COLLECTOR 1 Collect the Flue Collector cartons The Flue Collector Hi Temp Rope Angle Bracket Long Hook Bolt sections are labeled on the part and on the carton N GG 5005 066 5003 See Table 4 1 for the items needed K 2 Install Hi Temp Rope for each collector section as shown in Figure 4 1 The rope provides the seal to prevent flue gases from leaking from the collector Make certain that the rope is well under the bottom edges of each flue collector section in order to obtain a tight seal Short Hook Bolt GG 5004 3 Place the Flue Collector sections in the positions given in Table 4 1 These positions are numbered from left to right when facing the front of the boiler Spacer 4 Fasten an angle bracket part number GG 5005 to the top of each Collector section with two 10 x 1 2 13 mm long sheet metal screws See Figure 4 2 5 Insert a Long Hook Bolt part number GG 5003 through the angle bracket Slip the hook end over the tie rod Apply a 1 4 20 hex nut on the end of the rod and snug against the bracket See Figure 4 2 Do not tighten yet Figure 4 2 Installing Flue Collector Sections 6 Insert a Short Hook Bolt part number GG 5004 through the flange in the rear of the flue collector Catch the hook around the spacer pads at the top of the boiler sections Apply a 1 4 20 hex nut on the Bolt and snug against the flange
86. stic except as noted be replaced with wire as shown or its equivalent Figure 9 3 Typical Wiring Standard Controls 120 Volt Gas Valves 39 10 STARTING THE BOILER A CHECK THE PIPING 1 Water and Steam Piping a The Boiler must have been hydrostatically tested b Check the attached piping for joint tightness c Continue monitoring as you proceed through start up 2 Gas Piping a Make sure the gas system piping and the connections to the boiler Gas Control Train s have been leak tested b After the boiler is in operation check the tightness of all joints in the boiler gas piping with a soap suds solution Purge the gas piping of all air up to the boiler Gas Control Train B FILL THE BOILER 1 Fill the boiler to the normal water line a Gravity Systems and Pumped Return with Condensate Units Fill to 40 1 2 103 cm above the boiler foundation center of gauge glass b Pumped Return with Boiler Feed Unit Fill the boiler using the boiler feed unit Fill level will depend on the control being used but should be 40 1 2 103 cm above the boiler foundation just below center of gauge glass when the pump stops STUDY LIGHTING INSTRUCTIONS 1 Before starting the boiler study the Lighting Instructions supplied with the boiler D RUN PILOT CHECK OUT 40 1 Shut off all electrical power to the boiler 2 Close Main and Pilot gas shut off valves Wait for five 5 minutes 3 Set t
87. trol 6 Maintain a height of 40 1 2 1029 mm from boiler foundation to the normal water level Pipe Safety Valve Discharge to safe location preferably to a floor drain 2 Skim gt 7 When using multiple float type Controls Always pipe Connection the controls off of the same tappings to the boiler Do not mount on different ends of the boiler or in different tappings This can cause erratic operation and nuisance problems with the controls D INSTALL PRESSURE CONTROLS 1 Pipe the Steam Pressure Gauge and Boiler Limit and Operating Pressure Controls as shown in Figure 8 2 Connect the control assembly to the 1 2 tapping on the right end of the boiler gt N CAUTION install 2 1 1 2 Blowdown Valves Pipe to floor drain or cap off Make sure that the gas ignition system components electrical controls junction boxes and electrical panels are protected from water dripping spraying rain etc during boiler operation and service circulator or pump servicing control replacements or other Figure 8 1 Blowdown Valve Piping 32 INSTALL CONTROLS AND TRIM Option 1 Option 2 C G 3 4 x 3 76 mm long Nipple 3 4 Cross H 3 4 x 4 102 mm long Nipple J K P 3 4 X 3 4 X 1 4 Reducing Tee 3 4 x 5 127 mm long Nipple 3 4 x 1 2 Hex Bushing 1 2 x 6 152 mm long Brass Nipple 3 4 x 1 4 Hex Bushing Steam Gauge 1 4 x 3 76 mm long Brass Nipple S Pressuretrols Rig
88. turn lines to receiver tank preventing air from venting out receiver vent Correct Piping Boiler pressure too high causing air vents to lock up or blowing water loop seals Reduce Operating Pressure System or Boiler Overfilling or Flooding New boiler water content smaller than old boiler Install Boiler Feed System with Receiver Tank Large enough for Condensate Boiler water feed rate or pump rate too fast causing water level to collapse due to collapse of steam bubbles in boiler water Reduce Feed Rate Foaming priming or surging due to poor water quality Clean the Boiler Excessive Water Level Bounce Poor water quality causing foaming and surging Clean the Boiler Incorrect near boiler piping such as undersized or incorrectly placed risers Pipe per Manual Boiler water feed rate or pump rate too fast Reduce Feed Rate Rapid Cycling Air vents or traps not venting air preventing steam from getting to radiation and pressurizing the air pocket Replace Vents or Traps Pressure differential on pressure control too close Adjust Control Differential Nuisance outages of water level control due to boiler water level bounce See Excessive Water Level Bounce Above 47 14 BOILER RATINGS amp DIMENSIONS Table 14 1 Boiler Rating Information Natural Gas Ratings LP Gas 2500 Btu cu ft 93 000 kJ m3 Boiler IBR Net Ratings Steam IBR Net Ratings 42 Output Stea
89. vice Valve Sediment Trap and Ground Joint Union at the supply connection to the Gas Control Train as shown in Figure 7 2 These are not supplied with the boiler Install them in accordance with local codes 5 Use only pipe joint compounds rated for use with Liquefied Petroleum Gases This is necessary because most natural gas contains propane as well as methane E TEST GAS SUPPLY PIPING 1 ISOLATE THE BOILER GAS CONTROL TRAIN FROM THE SYSTEM DURING TEST a Test pressure 1 2 psig 3 5 kPa or less Close the Manual Shut Off Valve on the Boiler Gas Control Train Ground Joint Union b Test pressure over 1 2 psig 3 5 kPa Disconnect the gas supply piping upstream of the Boiler Manual Shut Off Valve WARNING Do not expose the Gas Control Train to excessive pressure The gas valves can be damaged This could result in explosion hazard and severe personal injury or death To Gas Supply gt Service Valve gt To Boiler Gas Control Train Do not test gas supply piping with open flame Use a Sediment Trap soap suds mixture brushed onto the pipe joints to test for leaks Figure 7 2 Gas Supply Connection to Boiler 30 Table 7 1 Capacity of Gas Supply Pipe in Cubic Feet Cubic Meters Per Hour of Natural Gas for 0 3 inch 75 Pa Drop Pipe Length 1 1 4 Pipe 1 1 2 Pipe 2 Pipe 2 1 2 Pipe 3 Pipe 4 Pipe Feet Meters Foot Meter F

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