PeerlessBoilers 211A Series, Installation, Operation & Maintenance Manual

Page 1: ...211A Boilers Steam Series Gas Installation Operation Maintenance Manual ...

Page 2: ...TES AND LABELS 24 7 CONNECT GAS PIPING 29 A INSTALL GAS TRAIN 29 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 R...

Page 3: ...N BOXES 1 Throughout this manual you will see special attention boxes intended to supplement the instructions and make special notice of potential hazards These categories mean in the judgment of PB Heat LLC USING THIS MANUAL Indicates special attention is needed but not directly related to potential personal injury or property damage NOTICE Indicates a condition or hazard which will or can cause ...

Page 4: ...air and ventilation air must be provided for this appliance in accordance with the section of the National Fuel Gas Code entitled Air for Combustion and Ventilation or applicable provisions of the local building code Subsections 2 through 8 as follows are based on the National Fuel Gas Code requirements 1 PREINSTALLATION The equipment shall be installed with those installation requirements of the ...

Page 5: ...assisted appliances in Btu hr Note These calculations are not to be used for infiltration rates greater than 0 60 ACH 3 Indoor Air Opening Size and Location Openings connecting indoor spaces shall be sized and located as follows a Combining spaces on the same floor Provide two permanent openings communicating with additional spaces that have a minimum free area of 1 in2 per 1000 Btu hr 22 cm2 per ...

Page 6: ...he top of the space The opening shall communicate directly with the outdoors communicate through a vertical or horizontal duct or communicate with a space that freely communicates with the outdoors The opening shall have a minimum free area of 1 in2 per 3000 Btu hr of total rated input for all appliances in the space and not less than the sum of the cross sectional areas of all vent connectors in ...

Page 7: ... area through a louver or grille is not known it shall be assumed that wooden louvers will have 25 free area and metal louvers and grilles will have 75 free area iii Nonmotorized dampers shall be fixed in the open position b Motorized dampers shall be interlocked with the equipment so that they are proven in the full open position prior to ignition and during operation of the main burner i The int...

Page 8: ...at least 0 02 w c 5 Pa measured at the vent connections c Support the weight of the vent system independently of the boiler draft hood The draft hood is not designed to carry structural loading d Provide support of the vent connector breeching at maximum 12 foot 366 cm intervals to prevent sagging and to provide a minimum upward slope of 1 4 per foot 21 mm per meter e Do not connect the vent for t...

Page 9: ...inch 13 mm thick with aluminum backing aluminum side up One half inch 13 mm Hi Temp millboard with aluminum backing would be acceptable as well Place the insulating board on the slab inside the base F WATER QUALITY AND MAKE UP 1 Check the system to make sure there are no leaks or overfilling problems which might cause excessive make up water to be added Make up water causes liming in the boiler an...

Page 10: ...143 129 3 8 3 286 141 3 8 3 591 211A 23 129 3 8 3 286 135 3 429 147 3 734 211A 24 135 3 429 140 5 8 3 572 152 5 8 3 877 211A 25 140 5 8 3 572 146 1 4 3 715 158 1 4 4 020 211A 26 146 1 4 3 715 151 7 8 3 858 163 7 8 4 162 211A 27 151 7 8 3 858 157 1 2 4 000 169 1 2 4 305 211A 28 157 1 2 4 000 163 1 8 4 143 175 1 8 4 448 211A 29 163 1 8 4 143 168 3 4 4 286 180 7 8 4 594 211A 30 168 3 4 4 286 174 3 8 ...

Page 11: ...mbly Burner Support Channel Angle Tie Brace Front Panel Support Bracket Section Assembly Kit Front Panel Sub Assembly Back Panel Sub Assembly Burner Support Channel Angle Tie Brace Front Panel Support Bracket Section Assembly Kit Front Panel Sub Assembly Back Panel Sub Assembly Burner Support Channel Angle Tie Brace Front Panel Support Bracket Section Assembly Kit Front Panel Sub Assembly Back Pan...

Page 12: ... 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 8 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 9 Set the Burner Support Channels in place as shown in Figure 2 1 B INSTALL THE PILOT BURNERS 1 Check the location...

Page 13: ...211A 26 2EE 2EE 2EE 2BB 12 4 1 2 3 772 211A 27 2EE 2EE 2EE 2CC 12 10 1 8 3 915 211A 28 2EE 2EE 2EE 2DD 13 3 3 4 4 058 211A 29 2EE 2EE 2EE 2EE 13 9 3 8 4 201 211A 30 2DD 2DD 2DD 2DD 2CC 14 3 4 343 211A 31 2DD 2DD 2DD 2DD 2DD 14 8 5 8 4 486 211A 32 2EE 2DD 2DD 2DD 2DD 15 2 1 4 4 629 211A 33 2EE 2EE 2BB 2EE 2EE 15 7 7 8 4 772 211A 34 2EE 2EE 2EE 2EE 2CC 16 1 1 2 4 915 211A 35 2EE 2EE 2EE 2EE 2DD 16 7...

Page 14: ...l the Boiler Sections are installed 1 4 X 1 1 2 38 mm long Nipple 2 1 4 Street Elbow Imperial 69F Elbow 1 8 NPT x 1 4 O D Tubing PB H91BG 2 or H V8046C Pilot Gas Valve 1 4 x 1 8 Hex Bushing 3 8 Thermopilot Valve s H17CA 2 5 16 18 x 3 4 19mm long Square Head Set Screw 3 8 x 1 4 Elbow Imperial 68F 1 4 NPT x 3 8 O D Tube Straight Connector Ignition Control Relay Mounting Box Assembly Standard HSP Sys...

Page 15: ...7 211A 24 3 46 21 5 39 9 23 39 211A 25 3 48 25 5 45 9 23 41 211A 26 4 50 19 5 33 47 9 23 33 45 211A 27 4 52 21 5 35 49 9 23 35 45 211A 28 4 54 23 5 37 51 9 23 35 47 211A 29 4 56 27 5 39 53 9 23 39 49 211A 30 4 58 29 5 39 51 9 23 39 51 211A 31 4 60 31 5 41 53 9 23 39 53 211A 32 4 62 33 5 41 59 9 25 41 55 211A 33 4 64 35 5 41 61 9 25 41 57 211A 34 5 66 35 5 21 49 63 9 23 39 51 59 211A 35 5 68 37 5 1...

Page 16: ...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 10...

Page 17: ...15 Figure 3 3 Assembling Sections on Base PLACE THE BOILER SECTIONS ...

Page 18: ...nd section 3 Provide a water supply line to the boiler 4 Plug all open tappings in the boiler 5 Provide a means to vent air as the boiler fills 6 Fill the boiler with water venting air as water level rises 7 Pressurize boiler to 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...

Page 19: ...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 6 Insert a Short Hook Bolt part number GG 5004 through the flange in the rear of the flue co...

Page 20: ...4A 211A 29 14B 14B 14B 14B 14A 14A 211A 30 14B 14B 14B 14B 14B 14A 211A 31 14B 14B 14B 14B 14B 14B 211A 32 14B 14B 14B 14A 14A 14A 14A 211A 33 14B 14B 14B 14B 14A 14A 14A 211A 34 14B 14B 14B 14B 14B 14A 14A 211A 35 14B 14B 14B 14B 14B 14B 14A 211A 36 14B 14B 14B 14B 14B 14B 14B 211A 37 14B 14B 14B 14B 14A 14A 14A 14A 211A 38 14A 14A 14A 14B 14B 14B 14B 14B 211A 39 14A 14A 14B 14B 14B 14B 14B 14B 2...

Page 21: ...p 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 shown 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 oc...

Page 22: ...20 PIPE THE BOILER Figure 5 2 Supply and Return Piping Pumped Return and Parallel Flow Gravity Systems ...

Page 23: ...ds of the boilers Always use Boiler feed units a Install a Float and Thermostatic trap at the boiler water level on each of the multiple boilers on a pumped return system This prevents flooding of idle boilers due to condensation of steam Figure 5 4 Left Hand Piping Arrangement Typical Figure 5 3 Supply and Return Piping Counterflow Gravity Systems Boiler Header End Risers Interm Risers Equalizers...

Page 24: ...22 PIPE THE BOILER Figure 5 6 Piping Multiple Boilers Typical Pumped Return Systems Figure 5 5 Piping Multiple Boilers Typical Gravity Return Systems ...

Page 25: ...nel 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 4 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 t...

Page 26: ...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 3 Slide the left hand offset flange of the first Top Panel under the Top Left End Panel Place the front flange of the Top Panel over the Front Panel Line up the holes and secure with 10 x 1 2 13 mm long sheet metal screws 4 Slide the left hand edge...

Page 27: ...Panel Guide GG 6031 Lower Rear Panel GG 6026 Rear Panel Support Leg GG 6028 Top Panel GG 6024 Top Right End Panel GG 6019 Front Panel GG 6023 Right Front Corner Panel GG 6015 Front Jacket Panel Support Bracket GG 2069 Top Left End Panel GG 6020 Upper Left End Panel GG 6032 Lower End Panel GG 6022 Corner Panel Support Bracket GG 6029 Cleanout Cover Plate Assembly GG 6004 Left End Corner Panel GG 60...

Page 28: ...031 1 Sheet Metal Screws 23 Jacket Intermediate Panel Front GG 6023 2 1 Jacket Intermediate Panel Top GG 6024 2 1 Jacket Intermediate Panel Upper Rear GG 6025 2 1 12C Jacket Intermediate Panel Lower Rear GG 6026 2 1 Panel Support Angle GG 6027 2 Rear Panel Support Leg GG 6028 1 Lower Rear Panel Guide GG 6031 1 Sheet Metal Screws 23 Jacket Intermediate Panel Front GG 6023 3 1 Jacket Intermediate Pa...

Page 29: ...27 INSTALL THE JACKET DRAFT HOOD Figure 6 3 Jacket Assembly Sequence Carton Numbers and Locations ...

Page 30: ...13C 13C 13B 13B 13B 13B 211A 28 13C 13C 13C 13B 13B 13B 211A 29 13C 13C 13C 13C 13B 13B 211A 30 13C 13C 13C 13C 13C 13B 211A 31 13C 13C 13C 13C 13C 13C 211A 32 13C 13C 13C 13B 13B 13B 13B 211A 33 13C 13C 13C 13C 13B 13B 13B 211A 34 13C 13C 13C 13C 13C 13B 13B 211A 35 13C 13C 13C 13C 13C 13C 13B 211A 36 13C 13C 13C 13C 13C 13C 13C 211A 37 13C 13C 13C 13C 13B 13B 13B 13B 211A 38 13B 13B 13B 13C 13C ...

Page 31: ...ilots 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 wate...

Page 32: ... sized and adjusted properly to provide this pressure under all conditions 4 Install a Service Valve Sediment Trap and Ground Joint Union at the supply connection to the Gas Control Train as shown in Figure 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 mos...

Page 33: ... Foot3 Meter3 Foot3 Meter3 Foot3 Meter3 Foot3 Meter3 Foot3 Meter3 10 3 0 1050 30 1 600 45 3 050 86 4 800 136 8 500 241 17 500 496 44 000 1246 20 6 1 730 21 1 100 31 2 100 59 3 300 93 5 900 167 12 000 340 31 000 878 30 9 1 590 17 890 25 1 650 47 2 700 76 4 700 133 9 700 275 25 000 708 40 12 2 500 14 760 22 1 450 41 2 300 65 4 100 116 8 300 235 22 000 623 50 15 2 440 12 670 19 1 270 36 2 000 57 3 60...

Page 34: ... automatic reset type b When a manual reset control is required the boiler can be supplied with Hydrolevel Model 550P 5 Provide each float low water cut off with a blowdown valve Pipe the blowdown away from traffic to a floor drain if available The blowdown valve is required for proper maintenance of the control 6 Maintain a height of 40 1 2 1029 mm from boiler foundation to the normal water level...

Page 35: ...33 INSTALL CONTROLS AND TRIM Figure 8 2 Pressure Control Piping Fittings Included with Boiler ...

Page 36: ...L CONTROLS AND TRIM 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 Figure 8 3 Standard Float Type COntrol Model 67PE2 ...

Page 37: ...35 INSTALL CONTROLS AND TRIM Figure 8 5 Optional Float Type Pump Control Low Water Cut Off Model 157 ...

Page 38: ...iler Foundation 10 3 8 264 mm 10 7 8 276 mm 36 914 mm 4 1 8 105 mm 8 1 8 206 mm Install 1 Blowoff Valve Burner Cut Off Level is Below Center Line on 51 2 and 51 S 2 Controls Below Normal Water Line 1 1 2 38 mm 2 3 4 70 mm Control Center Line The connected fittings shown on this drawing are to be supplied by the installer J F A A A B B D D D C C C C C G H E Models 211A 04 thru 211A 23 One 51 2 Feed...

Page 39: ... components C INSTALL CONTROL WIRING 1 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 2 Low Energy Safety Control wiring must follow the contour of the boiler Some local codes may r...

Page 40: ...38 WIRE THE BOILER Figure 9 2 Typical Wiring Standard Controls Low Voltage Gas Valves ...

Page 41: ...39 WIRE THE BOILER Figure 9 3 Typical Wiring Standard Controls 120 Volt Gas Valves ...

Page 42: ...all for heat g 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 Pr...

Page 43: ...e sludge etc that may be 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 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 po...

Page 44: ...rs will light 12 The burners will continue to fire until the Operating Control is satisfied 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 f...

Page 45: ... Measures Provide adequate ventilation Wear a NIOSH MSHA approved respirator Wear long sleeved loose fitting clothing and gloves to prevent 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 ...

Page 46: ...use a soap suds mixture to check the gas tightness of all gas joints 5 Test the limit and operating controls to assure they are operating correctly 6 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 7 Test the pop safety relief valve s using the procedure given by the valve manufacturer on the valve tag 8 Vi...

Page 47: ...from top of boiler e Replace the flue collector draft hood jacket and cleanout panels using the procedures given in this manual f Remove the burners and brush the gas ports lightly with a soft bristle brush 5 Inspect the boiler base and insulation 6 Inspect the boiler and piping for signs of leaks Check to see if there are signs of heavy make up water addition to the system 7 When placing boiler i...

Page 48: ...aks or System Causing Low Water Cut off to Function Check Feeder if Supplied Defective Thermopilot Valve s Replace Defective Thermocouple s Replace High Gas Pressure Switch Open Check Switch Setting if Provided Check Manifold Gas Pressure Low Gas Pressure Switch Open Check Switch Setting if Provided Check Inlet Gas Pressure Air Adjustment Screws Turned in Too Far Adjust Screws Out Low Gas Pressure...

Page 49: ...sate loads Close nipple on Hartford too high Repipe 2 to 4 5cm to 10cm Below Water Line Water Hammer on Shut Down Uninsulated steam piping in boiler room but system piping insulated causing vacuum Insulate Steam Pipes condition on shut down Hammering in the Boiler Poor circulation in the boiler due to sludge Clean and Blowdown the Boiler accumulation Main vents not working Replace Main Vents Repip...

Page 50: ...1 087 2 801 821 211A 24 4 830 1 416 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 211A 25 5 040 1 477 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 5 250 1 539 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 5 460 1 600 4 368 1 280 14 129 1 316 3 391 994 1 288...

Page 51: ...49 BOILER RATINGS DIMENSIONS ...

Page 52: ...22 572 22 572 22 572 30 776 211A 32 185 4 715 211 5 382 65 165 179 4 553 2 3 30 776 28 714 22 572 22 572 22 572 22 572 30 776 211A 33 191 4 858 217 5 525 65 165 184 4 696 2 3 24 633 22 572 22 572 22 572 22 572 22 572 22 572 24 633 211A 34 196 5 001 223 5 686 65 165 190 4 839 3 3 24 633 22 572 22 572 22 572 28 714 22 572 22 572 24 633 211A 35 202 5 144 229 5 829 65 165 196 4 982 3 3 24 633 22 572 2...

Page 53: ...19 28 714 28 714 25 645 22 572 22 572 13 346 6 14 356 29 737 29 737 211A 29 16 419 28 714 28 714 28 714 25 645 22 572 13 346 6 14 356 29 737 29 737 211A 30 16 419 28 714 28 714 28 714 28 714 25 645 13 346 6 14 356 30 762 30 762 211A 31 16 419 28 714 28 714 28 714 28 714 28 714 16 419 6 14 356 30 762 30 762 211A 32 16 419 28 714 28 714 25 645 22 572 22 572 22 572 13 346 7 14 356 31 787 31 787 211A ...

Page 54: ...bly 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 50848 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 S...

Page 55: ...k 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 ...

Page 56: ...54 REPAIR PARTS SERIES 211A Figure 15 1 Boiler Assembly ...

Page 57: ...55 REPAIR PARTS SERIES 211A Figure 15 2 Base Assembly ...

Page 58: ...56 NOTES ...

Page 59: ...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 of gama ASME GG8051 R13 1 07 2M Printed in U S A 2007 PB HEAT LLC PO BOX 447 NEW BERLINVILLE PA 19545 0447 ...