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PeerlessBoilers 211A Series Installation, Operation & Maintenance Manual

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Series
211A
Gas
Boilers – Steam
I n s t a l l a t i o n ,
O p e r a t i o n &
M a i n t e n a n c e
M a n u a l

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Summary of Contents for PeerlessBoilers 211A Series

  • Page 1 Series 211A Boilers – Steam I n s t a l l a t i o n , O p e r a t i o n & M a i n t e n a n c e M a n u a l...

  • Page 2: Table Of Contents

    D. 211A-04 THROUGH 211A-08 ONLY ..23 E. 211A-09 AND LARGER ONLY ...23 F. APPLY JACKET TOP PANELS ...24 G.

  • Page 3: Using This Manual

    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 DANGER Indicates a condition or hazard which will cause severe personal injury, death or major property damage.

  • Page 4: Preinstallation

    PREINSTALLATION 1. PREINSTALLATION 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 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.
  • Page 5 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 ft Required Volume other =...
  • Page 6 PREINSTALLATION i. Where communicating directly or through vertical ducts with the outdoors each opening shall have a minimum free area of 1 in 4000 Btu/hr (22 cm input rating for all equipment in the space. See Figure 1.4 for openings directly communicating with the outdoors or Figure 1.5 for openings connected by ducts to the outdoors.

  • Page 7: Chimney Or Vent

    5. Combination Indoor and Outdoor Combustion Air: If 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.
  • Page 8 Turn on clothes dryers and any appliance not connected to the common venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they will operate at maximum speed. Do not operate a summer exhaust fan. Close fireplace dampers.

  • Page 9: Boiler Setting

    This will damage the boiler seals. G. INSTALLATION SURVEY For new and existing installations, a Steam Installation Survey is available from PB Heat. The survey will provide information on how a steam boiler works with your specific system and will provide an overview of steam system operation in general.
  • Page 10 PREINSTALLATION Table 1.1: Boiler Foundation Layout Boiler Base Length Boiler Model inches 211A-04 22-1/2 211A-05 28-1/8 211A-06 33-3/4 211A-07 39-3/8 1,000 211A-08 1,143 211A-09 50-5/8 1,286 211A-10 56-1/4 1,429 211A-11 61-7/8 1,572 211A-12 67-1/2 1,714 211A-13 73-1/8 1,857 211A-14 78-3/4...

  • Page 11: Assemble The Base

    2. ASSEMBLE THE BASE A. BASE ASSEMBLY 1. Collect the crates containing the Base Assembly parts. Table 2.1 (on page 11) shows the quantity of each crate required. The crates contain the following parts: Crate Items Sub-Assembly # Right End Panel Sub-Assembly Left End Panel Sub-Assembly Burner Support Channel Clips (2) Front Panel Sub-Assembly...

  • Page 12: Install The Pilot Burners

    Left Hand End Panel using 5/16"-18 x 1" (25 mm) long cap screws and hex head nuts provided. 4. For 211A-04 through 211A-08 Only: a. Complete the base assembly by attaching the Right End Panel and setting the Burner Support Channel on the clips.
  • Page 13 Table 2.1: Base Front and Back Panel Crates Model Number 211A-04 — 211A-05 — 211A-06 — 211A-07 — 211A-08 — 211A-09 211A-10 211A-11 211A-12 211A-13 211A-14 211A-15 211A-16 211A-17 211A-18 211A-19 211A-20 211A-21 211A-22 211A-23 211A-24 211A-25 211A-26 211A-27 211A-28...
  • Page 14 ASSEMBLE THE BASE Mounting Clamp GG-3052 thru GG-3052-3 3/8" Pipe Cap Pipe Cap Hex Bushing Ignition Control & Relay Mounting Box Assembly (Standard HSP System, X-3011-3) (Other panels mounted on Imperial #69F Elbow jacket front, left side) 1/8" NPT x 1/4" O.D. Tubing Figure 2.5: Typical Gas Manifold and Pilot Line Assembly 4.
  • Page 15 — 9, 25, 41, 57 — 9, 23, 39, 51, 59 — 9, 23, 39, 51, 61 — 9, 23, 39, 51, 63 — 9, 23, 39, 51, 65 — Models 211A-38 through 211A-46 Are Certified for Natural Gas Only...

  • Page 16: Place The Boiler Sections

    PLACE THE BOILER SECTIONS 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.
  • Page 17 PLACE THE BOILER SECTIONS Figure 3.3: Assembling Sections on Base...

  • Page 18: Hydrostatic Test 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). Figure 3.5: Section Positioning Numbering Boiler Model Number 211A-18 211A-19 211A-20 211A-21 211A-22 211A-23...

  • Page 19: Install The Flue Collector

    4. INSTALL THE FLUE COLLECTOR 1. Collect the Flue Collector cartons. The Flue Collector sections are labeled on the part and on the carton. See Table 4.1 for the items needed. 2. Install Hi Temp Rope for each collector section as shown in Figure 4.1.
  • Page 20 Table 4.1: Flue Collector Section Location (From Left to Right Facing Front of Boiler) – Crates Crates 14 = Part number GG-5000 Crate 14B = Part number GG-5000-2 Boiler Position Position Model Number 211A-04 — 211A-05 — 211A-06 — 211A-07 211A-08...

  • Page 21: Pipe The Boiler

    Install a reducing tee on one end riser. Install a 2" valve, nipple and cap for skimming the boiler in the tee as shown in the piping drawings. 2. Models 211A-08 and larger require risers in both end sections. 3. Models 211A-18 and larger require additional 3"...
  • Page 22 PIPE THE BOILER Figure 5.2: Supply and Return Piping – Pumped Return and Parallel Flow Gravity Systems...

  • Page 23: Multiple Boiler Installations

    This prevents flooding of idle boilers due to condensation of steam. Table 5.1: Header, Risers & Equalizer Sizing End Risers Interm. Risers Boiler Header Model Size Size 211A-04 4" 4" 211A-05 5" 5" 211A-06 5" 5" 211A-07 5"...
  • Page 24 PIPE THE BOILER Figure 5.5: Piping Multiple Boilers, Typical, Gravity Return Systems Figure 5.6: Piping Multiple Boilers, Typical, Pumped Return Systems...

  • Page 25: Install The Jacket & Draft Hood

    7. Repeat for the Right End. INSTALL THE JACKET & DRAFT HOOD D. 211A-04 THROUGH 211A-08 ONLY 1. Apply Front and Rear Panels as follows. 2. Open Jacket Intermediate Section carton, 12A, B, C, D or E, per Table 6.1. Remove necessary knockouts from panels.

  • Page 26: Apply Jacket Top Panels

    INSTALL THE JACKET & DRAFT HOOD • 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.
  • Page 27 Top Panel (GG-6024) 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) Draft Hood (GG-5001) Right Rear Corner Panel (GG-6017) Upper Rear Panel (GG-6025) Lower Rear Panel Guide (GG-6031) Lower Rear Panel (GG-6026)
  • Page 28 INSTALL THE JACKET & DRAFT HOOD Table 6.1: Jacket and Draft Hood Carton Contents – See Figure 6.2 for Placement of Jacket Sections Carton Cleanout Cover Plates Jacket Corner Panel, Right Front Jacket Corner Panel, Left Front Jacket Corner Panel, Right Rear Jacket Corner Panel, Left Rear Corner Panel Support Brackets Jacket Upper End Panel, Left...
  • Page 29 INSTALL THE JACKET & DRAFT HOOD Figure 6.3: Jacket Assembly Sequence - Carton Numbers and Locations...
  • Page 30 INSTALL THE JACKET & DRAFT HOOD Table 6.2: Draft Hood Section Placement (from Left to Right Facing Front of Boiler) Boiler Position Position Model Number 211A-04 — 211A-05 — 211A-06 — 211A-07 211A-08 211A-09 211A-10 211A-11 211A-12 211A-13 211A-14 211A-15...

  • Page 31: Connect Gas Piping

    Gas Control Train. 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) CONNECT GAS PIPING 3. Connect tubing to each pilot.

  • Page 32: Install Gas Supply Piping

    CONNECT GAS PIPING c. When piping bleed lines to outside, terminate the tubing downward to prevent water from entering the tubing, and protect the tubing termination from any obstruction. Terminate the tubing above and well away from normal breathing level or building air intakes. D.
  • Page 33 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 Feet Meters Foot Meter Foot 1050 1,600 1,100 12.2 15.2 18.3 21.3 27.4 30.5...

  • Page 34: Install Controls And Trim

    INSTALL CONTROLS AND TRIM 8. INSTALL CONTROLS AND TRIM A. INSTALL SAFETY VALVE(S) 1. Pipe the pop safety valve(s) in the 3" tappings located on the right or left end sections. Make sure the relief valve sizing meets local code requirements. CAUTION Pipe the discharge of the Safety Relief Valve(s) away from any traffic area, preferably to a floor drain.
  • Page 35 INSTALL CONTROLS AND TRIM Figure 8.2: Pressure Control Piping (Fittings Included with Boiler)
  • Page 36 INSTALL CONTROLS AND TRIM Figure 8.3: Standard Float Type COntrol, Model 67PE2 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...
  • Page 37 INSTALL CONTROLS AND TRIM Figure 8.5: Optional Float Type Pump Control/Low Water Cut-Off, Model 157...
  • Page 38 170 mm 8-1/8" 206 mm) 4-1/8" 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.

  • Page 39: Wire The Boiler

    9. WIRE THE BOILER A. CONNECT SUPPLY WIRING 1. All wiring must be done in accordance with local codes, the National Electrical Code ANSI/NFPA70 and/or the Canadian Electrical Code Part I, CSA C22.1, Electrical Code and other controlling agencies or governing bodies. NOTICE The boiler/burner must be electrically grounded in accordance with the requirements of the authority...
  • Page 40 WIRE THE BOILER Figure 9.2: Typical Wiring – Standard Controls – Low Voltage Gas Valves...
  • Page 41 WIRE THE BOILER Figure 9.3: Typical Wiring – Standard Controls – 120-Volt Gas Valves...

  • Page 42: Starting The Boiler

    STARTING THE BOILER 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.

  • Page 43: Check Boiler Controls

    e. The Minimum 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.

  • Page 44: Lighting Instructions - Typical

    LIGHTING INSTRUCTIONS – TYPICAL 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.

  • Page 45: Operation & Maintenance

    OPERATIONS & MAINTENANCE 12. OPERATION & 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.

  • Page 46: Placing Boiler In Operation

    OPERATIONS & 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.

  • Page 47: To Shut Down The Boiler

    B. TO SHUT DOWN THE BOILER 1. Open main line power disconnect switch to boiler. 2. Close Main and Pilot gas shut-off valves. 3. To take boiler out of service if the boiler and system are not to be used when temperatures are below freezing: a.

  • Page 48: Troubleshooting - Service Tips

    TROUBLESHOOTING – SERVICE TIPS 13. TROUBLESHOOTING – SERVICE TIPS Problem Pilot Outage Main Gas Valve Will Not Open (Standard Spark-Ignited Pilot System) Main Gas Valve Will Not Open (Electronic Standing Pilot System) Burner(s) Burning with Yellow Flame Gas Spillage from Draft Hood Relief Opening Possible Cause Defective Thermocouple...
  • Page 49 Problem Manual Valve Closed at Gas Train Main Gas Valve Opens Manual Valve Closed at Meter But No Gas Flows Test Firing Valve Closed (if Provided) Sags in Steam Piping or not enough Pitch Concentric reducers causing condensate pooling Drip trap failed closed Water Hammer On Start-Up Dry returns wetted due to new boiler water line higher than old boiler...

  • Page 50: Boiler Ratings & Dimensions

    5,821 1,968 6,367 2,132 6,896 2,296 7,429 2,460 7,958 2,624 8,488 9,021 9,550 10,079 939 10,613 988 Models 211A-38 through 211A-46 Are Certified for Natural Gas Only Steam 1,127 1,263 1,398 1,528 1,655 1,783 1,910 2,037 2,165 2,292 2,419 2,547...
  • Page 51 BOILER RATINGS & DIMENSIONS...
  • Page 52 BOILER RATINGS & DIMENSIONS...
  • Page 53 BOILER RATINGS & DIMENSIONS...

  • Page 54: Repair Parts - Series 211A

    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.
  • Page 55 Hi Temp Sealing Cement Spray Adhesive " O.D. Aluminum Tubing " O.D. Aluminum Tubing REPAIR PARTS – SERIES 211A Part Selection Information 14-3/4" (375 mm) Wide Base Panel 20-3/8" (518 mm) Wide Base Panel 26" (660 mm) Wide Base Panel 31-5/8"...
  • Page 56 REPAIR PARTS – SERIES 211A Figure 15.1: Boiler Assembly...
  • Page 57 REPAIR PARTS – SERIES 211A Figure 15.2: Base Assembly...
  • Page 58 NOTES...
  • Page 59 Series HI Division of gama PB HEAT, LLC PO BOX 447 • NEW BERLINVILLE, PA 19545-0447 ©2007 211A Boilers – Steam I n s t a l l a t i o n , O p e r a t i o n &...

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