TABLE OF CONTENTS TABLE OF CONTENTS B. CONNECT PILOT GAS TUBING ..29 USING THIS MANUAL C. INSTALL VENT AND BLEED PIPING ..29 A. FOLLOW THE PIPING GUIDELINES ..1 D.
USING THIS MANUAL USING THIS MANUAL DANGER A. FOLLOW THE PIPING GUIDELINES 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.
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.
Page 5
PREINSTALLATION 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.
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 per 4000 W) of total 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...
PREINSTALLATION 5. Combination Indoor and Outdoor Combustion Air: If iii. Nonmotorized dampers shall be fixed in the the required volume of indoor air exceeds the open position. available indoor air volume, outdoor air openings or ducts may be used to supplement the available b.
Page 8
PREINSTALLATION • The vent connector must be single wall steel 3. Chimney/Vent Operation: The vent system must be sized and installed to provide the draft needed to or Type B double wall vent pipe. The vent remove all combustion products. If the vent system connector must be Type B double wall if it is does not provide enough draft, combustion products located in or passes through cold areas.
PREINSTALLATION f. After it has been determined that each appliance WATER QUALITY AND MAKE-UP remaining connected to the common venting system properly vents when tested as outlined 1. Check the system to make sure there are no leaks or above, return doors, windows, exhaust fans, overfilling problems which might cause excessive fireplace dampers and any other gas-burning make-up water to be added.
ASSEMBLE THE BASE 2. ASSEMBLE THE BASE 2. Open crate number 2. Remove the End Panels and A. BASE ASSEMBLY mount a Support Channel Clip toward the rear on each panel as shown in Figure 2.2 using 1/4"-20 x 1. Collect the crates containing the Base Assembly parts. 1/2"...
ASSEMBLE THE BASE 3. Attach the Front Panel and Back Panel (Figure 2.2) to 5. For 211A-09 through 211A-46 Only: the Left Hand End Panel using 5/16"-18 x 1" (25 mm) a. Attach a Front Panel Support Bracket to each long cap screws and hex head nuts provided.
Page 13
ASSEMBLE THE BASE Table 2.1: Base Front and Back Panel Crates Overall Length Model Number feet/inches 211A-04 — — — — — — 24-3/4" 211A-05 — — — — — — 30-3/8" 211A-06 — — — — — — 36" 211A-07 —...
Page 14
ASSEMBLE THE BASE Manifold Weldment GG-4084 thru GG-4084-46 Imperial #68F 1/4" NPT x 3/8" O.D. Tube Straight Connector Orifice Spud X-4026 Mounting Clamp GG-3052 thru GG-3052-3 Test Plug 3/8" x 3/8" x 1/4" Tee (2) 1/4" Street Elbow 3/8" Pipe Cap 1/4"...
Page 15
ASSEMBLE THE BASE Table 2.2: Pilot Burner Locations – Numbered Right to Left (See Figure 2.1) Natural Gas Only Propane Gas Only Total Model Number of Number Pilot Burner Locations Pilot Burner Locations Number Pilots (Positions Numbered Right to Left (Positions Numbered Right to Left Burners Electronic Pilots...
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...
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
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 14B = Part number GG-5000-2 Boiler Position Position Position Position...
PIPE THE BOILER 5. PIPE THE BOILER 6. Counterflow Gravity systems require the boiler steam A. PREPARATION line to enter the top of the steam main. See Figure 5.3 for this special case. 1. The boiler must be pressure tested as outlined in Chapter 3, “Place the Boiler Sections,”...
Page 22
PIPE THE BOILER Figure 5.2: Supply and Return Piping – Pumped Return and Parallel Flow Gravity Systems...
PIPE THE BOILER D. MULTIPLE BOILER INSTALLATIONS 1. Figure 5.5 shows typical piping for multiple boiler Gravity Return systems. Figure 5.6 shows typical piping for multiple boiler Pumped Return systems. 2. Provide separate feed lines for multiple boiler pumped return systems. Use either separate feed pumps or solenoid valves to isolate feeding of the boilers.
INSTALL THE JACKET & DRAFT HOOD 6. INSTALL THE JACKET & DRAFT HOOD A. PREPARE THE PARTS D. 211A-04 THROUGH 211A-08 ONLY 1. Collect the Jacket cartons and Draft Hood cartons 1. Apply Front and Rear Panels as follows. (numbers 12 and 13). 2.
INSTALL THE JACKET & DRAFT HOOD • Continue applying Front Panels this way. 3. Slide the left hand offset flange of the first Top Panel under the Top Left End Panel. Place the front flange • Slip the right edge of the last Front Panel under of the Top Panel over the Front Panel.
Page 27
INSTALL THE JACKET & DRAFT HOOD Top Panel (GG-6024) Top Right End Panel (GG-6019) Top Left End Panel (GG-6020) Upper Left End Front Panel Panel (GG-6032) (GG-6023) Lower End Right Front Panel Corner Panel (GG-6022) (GG-6015) Corner Panel Support Bracket Front Jacket Panel (GG-6029) Support Bracket...
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 Contents Sub-Assembly Part Number Quantity Cleanout Cover Plates GG-6004 Jacket Corner Panel, Right Front GG-6015 Jacket Corner Panel, Left Front GG-6016 Jacket Corner Panel, Right Rear GG-6017...
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 Position Position Position Position Position Position Position Model Number 211A-04 — — — — — — — —...
CONNECT GAS PIPING 7. CONNECT GAS PIPING 3. Connect tubing to each pilot. A. INSTALL GAS TRAIN a. Connect electronic pilots to the Pilot Gas Valves. 1. The Gas Control Train(s) supplied with this boiler: b. Connect standing pilots (when supplied – see •...
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.
Page 33
CONNECT GAS PIPING 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 6"...
INSTALL CONTROLS AND TRIM 8. INSTALL CONTROLS AND TRIM A. INSTALL SAFETY VALVE(S) 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.
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
INSTALL CONTROLS AND TRIM Normal Water Line 2" (51 mm) Control Center Line 3/4" Feeder Closing Level 19 mm) (Mark on Casting) 12-7/8" 327 mm) Burner Cut-Off Level is 1-1/2" 38 mm ) Below 6-11/16" 170 mm Center Line on 51-2 and 51-S-2 Controls 40-1/2"...
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. Mount the control transformer on the junction box as codes, the National Electrical Code ANSI/NFPA70 shown in Figure 9.1.
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...
STARTING THE BOILER 10. STARTING THE BOILER 5. Light Manual Pilots A. CHECK THE PIPING a. Follow the procedure in the Lighting Instructions 1. Water and Steam Piping to manually light any standing pilots. a. The Boiler must have been hydrostatically tested. 6.
STARTING THE BOILER e. The Minimum input rate listed on the nameplate in the system. These substances can cause foaming applies to boilers with staged firing rate. This and surging of the boiler water, producing an minimum rate is not adjustable. It is controlled unstable water line and water carryover to the system.
LIGHTING INSTRUCTIONS – TYPICAL 11. LIGHTING INSTRUCTIONS – TYPICAL A. TO LIGHT THE BOILER B. TO SHUT DOWN THE BOILER 1. These instructions apply only to typical standard 1. Open main line power disconnect switch to boiler. control systems (HSP System only). Use the Lighting 2.
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.
OPERATIONS & MAINTENANCE • Open the Pilot manual shut-off valve and re- WARNING start the boiler per the Lighting Instructions. (Standing pilots will have to be manually re- Do not store or allow combustible or flammable lit per the Lighting Instructions.) materials near the boiler.
OPERATIONS & MAINTENANCE c. Remove side cleanout panels. B. TO SHUT DOWN THE BOILER 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.
TROUBLESHOOTING – SERVICE TIPS 13. TROUBLESHOOTING – SERVICE TIPS Problem Possible Cause Suggested Remedy Defective Thermocouple Replace Heavy Draft Blowing across Pilot Redirect Air Movement or Eliminate Plugged Pilot Orifice Replace Orifice Pilot Outage Check Manual Pilot Valve Check Main Gas Shut-Off Valve No Gas Check Manual Meter Valve Consult Gas Company...
Page 49
TROUBLESHOOTING – SERVICE TIPS Problem Possible Cause Suggested Remedy Manual Valve Closed at Gas Train Open Valve Main Gas Valve Opens Manual Valve Closed at Meter Open Valve But No Gas Flows Test Firing Valve Closed (if Provided) Open Valve Sags in Steam Piping or not enough Pitch Correct Piping Condition Concentric reducers causing condensate pooling...
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.
Page 55
REPAIR PARTS – SERIES 211A Item Stock Description Part Selection Information Code 14-3/4" (375 mm) Wide Base Panel 90316 20-3/8" (518 mm) Wide Base Panel 90318 Base Front Panel Cover Plate 26" (660 mm) Wide Base Panel 90320 31-5/8" (803 mm) Wide Base Panel 90322 37-1/4"...
Page 56
REPAIR PARTS – SERIES 211A Figure 15.1: Boiler Assembly...
Page 57
REPAIR PARTS – SERIES 211A Figure 15.2: Base Assembly...
Page 59
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 TO T H E I N S TA L L E R : This manual is the property of the owner and must be affixed near the boiler for future reference.
Need help?
Do you have a question about the 211A series and is the answer not in the manual?
Questions and answers