PB Heat 211A manual

211A Boilers – Steam Series Gas Installation, Operation & Maintenance Manual[...]

USING THIS MANUAL 1 A . FOLL OW THE PIPING GUIDELINES . . . . . . .1 B . CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . .1 C. SPECIAL A TTENTION BO XES . . . . . . . . . . . .1 1. PREINST ALLA TION 2 A . ACCESSIBILITY CLEARANCES . . . . . . . . . . .2 B . COMBUSTIBLE CONSTRUCTION CLEARANCES . . . . . . . . . . . . . . . . . . . . . . [...]

1 USING THIS MANUAL A. FOLLOW THE PIPING GUIDELINES 1. W e have provided suggested piping diagrams which will cover most applications of this boiler . 2. F ollow these guidelines to make sure the boiler will operate correctly . B. CONTROLS 1. This manual provides wiring diagrams and lighting instructions for standard systems only . 2. Use the Light[...]

2 PREINST ALLA TION A. ACCESSIBILITY CLEARANCES 1. The following recommendations allow for r easonable access to the boiler . Local codes or special conditions may requir e greater clearances. a. F or ser vicing the boiler: provide 48" (1219 mm) between the control manifold and adjacent wall or other appliance. b. F or access to draft hood or [...]

3 PREINST ALLA TION 2. Requir ed Combustion Air V olume: The total requir ed volume of indoor air is to be the sum of the requir ed 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 consider[...]

4 i. Where communicating dir ectly or through ver tical ducts with the outdoors each opening shall have a minimum free ar ea of 1 in 2 per 4000 Btu/hr (22 cm 2 per 4000 W) of total input rating for all equipment in the space. See Figur e 1.4 for openings directly communicating with the outdoors or Figur e 1.5 for openings connected by ducts to the [...]

5. Combination Indoor and Outdoor Combustion Air: If the requir ed volume of indoor air e xceeds 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[...]

PREINST ALLA TION 3. Chimney/V ent 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 syst[...]

7 PREINST ALLA TION 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, e xhaust fans, fireplace dampers and any other gas-burning appliance to their previous condition of use. g. Any improper operation of the common venting system [...]

8 PREINST ALLA TION T able 1.1: Boiler Foundation Layout Boiler Boiler Base Length Jack et Length F oundation Length Model inches mm inches mm inches mm 211A -04 22-1/2 572 28-1/8 714 40-1/8 1,019 211A -05 28-1/8 714 33-3/4 857 45-3/4 1,162 211A -06 33-3/4 857 39-3/8 1,000 51-3/8 1,305 211A -07 39-3/8 1,000 45 1,143 57 1,448 211A -08 45 1,143 50-5/[...]

9 ASSEMBLE THE BASE A. BASE ASSEMBL Y 1. Collect the crates containing the Base Assembly par ts. T able 2.1 (on page 11) shows the quantity of each crate requir ed. The crates contain the following parts: 2. Open crate number 2. Remove the End P anels and mount a Suppor t Channel Clip toward the r ear on each panel as shown in Figur e 2.2 using 1/4[...]

10 ASSEMBLE THE BASE 3. Attach the F ront P anel and Back P anel (Figur e 2.2) to the Left Hand End P anel using 5/16"-18 x 1" (25 mm) long cap screws and he x head nuts provided. 4. F or 211A -04 through 211A -08 Only: a. Complete the base assembly by attaching the Right End P anel and setting the Bur ner Suppor t Channel on the clips. 5[...]

11 ASSEMBLE THE BASE T able 2.1: Base Front and Back P anel Crates Model ABC DE F G Number 211A -04 2AA —————— 24-3/4" 629 211A -05 2BB —————— 30-3/8" 771 211A -06 2CC —————— 3 6 " 9 1 4 211A -07 2DD —————— 41-5/8" 1,057 211A -08 2EE —————— 47-1/4" 1,200 211A -09 2[...]

12 ASSEMBLE THE BASE 4. Place only the Burners with pilots mounted in the locations given in T able 2.2. Install the Bur ners by slipping the opening on the front of the burner over the orifice adapter and slipping the pin on the end of the burner into the hole in the Bur ner Suppor t Channel directly opposite the orifice. 5. Cut and fit the 1/4&qu[...]

13 ASSEMBLE THE BASE T able 2.2: P ilot Burner Locations – Numbered Right to Left (See Figure 2.1) T otal Natural Gas Only Propane Gas Only Model Number of Number Pilot Burner Locations Pilot Burner Locations Number Pilots of (P ositions Numbered Right to Left (P ositions Numbered Right to Left Burners 211A -04 1 6 5 — 5 — 211A -05 1 8 5 — [...]

14 PLA CE THE BOILER SECTIONS A. PREP ARA TION 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 the area around the Flow P or ts (Figur e 3.1). Use solvent and a clean cloth to thoroughly clean the flat surfaces and recesses.[...]

15 Figure 3.3: Assembling Sections on Base PLA CE THE BOILER SECTIONS[...]

16 e. Draw sections together evenly , alter nating between top lug and bottom lug in increments of 20 ft.-lbs. (27 N · m). Continue until both top and bottom lugs are tightened to 60 ft.-lbs. (81 N · m). DO NOT EX CEED 60 FT .- LBS (81 N · m). f. Check the level while tightening to make sure alignment stays true. Also make sure sections remain s[...]

17 INST ALL THE FL UE COLLECT OR 1. Collect the Flue Collector car tons. The Flue Collector sections are labeled on the part and on the car ton. See T able 4.1 for the items needed. 2. Install Hi T emp Rope for each collector section as shown in Figur e 4.1. The rope provides the seal to prevent flue gases from leaking from the collector . Make cer[...]

18 INST ALL THE FL UE COLLECT OR Boiler P osition P osition P osition P osition P osition P osition P osition P osition P osition Model 123456789 Number 211A -04 14 ———————— 211A -05 14A ———————— 211A -06 14B ———————— 211A -07 14 14 ——————— 211A -08 14A 14 ——————— 211A -09 [...]

19 PIPE THE BOILER A. PREP ARA TION 1. The boiler must be pressur e tested as outlined in Chapter 3 , “Place 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 they will e xtend through the jacket. B. SUPPL Y PIPING 1. Install End Riser connecti[...]

20 PIPE THE BOILER Figure 5.2: Supply and Return Piping – P umped Return and P arallel Flow Gravity Systems[...]

21 PIPE THE BOILER 2. On pumped return systems, install a boiler cock after the pump to allow throttling of the pump discharge. The pressur e after the boiler cock should be no more than 5 psig (35 kP a) above the boiler operating pressur e. Pumping the water into the boiler too fast will cause collapse of the water level and level control problems[...]

22 PIPE THE BOILER Figure 5.6: Piping Multiple Boilers, T ypical, Pumped Return Systems Figure 5.5: Piping Multiple Boilers, T ypical, Gravity Return Systems[...]

23 INST ALL THE JA CKET & DRAFT HOOD A. PREP ARE THE P ARTS 1. Collect the Jacket car tons and Draft Hood cartons (numbers 12 and 13). 2. See Figur e 6.2 for the Jacket Assembly . Use these drawings for par t identification and location. 3. See Figure 6.3 for the quantity of each carton requir ed and placement of the jacket sections on the boil[...]

24 INST ALL THE JA CKET & DRAFT HOOD • Continue applying F ront P anels this way . • Slip the right edge of the last F ront P anel under the Right F ront Corner P anel. Line up the holes and secure with #10 x 1/2" (13 mm) long sheet metal screws. 5. Install the Jacket Rear P anels: • Slip the offset flange of the first Upper Rear P a[...]

25 INST ALL THE JA CKET & DRAFT HOOD T op P anel (GG -6024) P anel Support Angle (GG-6027) End P anel Cover Plate GG-6030 Draft Hood (GG-5001) Right Rear Corner P anel (GG-6017) Left Rear Corner P anel (GG-6018) Upper Rear P anel (GG-6025) Lower Rear P anel Guide (GG-6031) Lower Rear P anel (GG-6026) Rear P anel Support Leg (GG-6028) T op P ane[...]

26 INST ALL THE JA CKET & DRAFT HOOD Carton Contents Sub- Assembly P art Number Quantity Cleanout Cover Plates GG-6004 2 Jacket Corner P anel, Right F ront GG-6015 1 Jacket Corner P anel, Left Front GG-6016 1 Jacket Corner P anel, Right Rear GG-6017 1 Jacket Corner P anel, Left Rear GG-6018 1 Corner P anel Support Brackets GG-6029 4 12 Jacket U[...]

27 INST ALL THE JA CKET & DRAFT HOOD Figure 6.3: Jacket Assembly Sequence - Carton Numbers and Locations[...]

28 INST ALL THE JA CKET & DRAFT HOOD Boiler P osition P osition P osition P osition P osition P osition P osition P osition P osition Model 12 34 56 7 8 9 Number 211A -04 13 — — — — — — — — 211A -05 13A — — — — — — — — 211A -06 13C — — — — — — — — 211A -07 13 13 — — — — — — — 211A -0[...]

29 CONNECT GAS PIPING A. INST ALL GAS TRAIN 1. The Gas Control T rain(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 [...]

30 CONNECT GAS PIPING c. When piping bleed lines to outside, ter minate the tubing downward to prevent water from entering the tubing, and protect the tubing termination from any obstruction. T erminate the tubing above and well away from normal breathing level or building air intakes. D . INST ALL GAS SUPPL Y PIPING 1. Size the piping as requir ed[...]

31 CONNECT GAS PIPING T able 7.1: Capacity of Gas Supply P ipe in Cubic Feet (Cubic Meters) P er Hour of Natural Gas for 0.3 inch (75 P a) Drop. Above ratings based on natural gas with specific gravity of 0.60 allowing pressur e drop of 0.3 inches (75 P a). No allowance is needed for pipe fittings. Use the following multipliers on above capacities [...]

32 INST ALL CONTROLS AND TRIM A. INST ALL SAFETY V AL VE(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 r equirements. B. INST ALL BLOWDOWN V AL VES 1. Install a 1-1/2" full por t ball valve in each of the tappings provided at the lower ba[...]

33 INST ALL CONTROLS AND TRIM Figure 8.2: P ressure Control Piping (Fittings Included with Boiler)[...]

34 INST ALL CONTROLS AND TRIM Figure 8.4: Optional Feeder/Low W ater 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 T ype COntrol, Model 67PE2[...]

35 INST ALL CONTROLS AND TRIM Figure 8.5: Optional Float T ype Pump Control/Low W ater Cut-Off, Model 157[...]

36 INST ALL CONTROLS AND TRIM Figure 8.6: Optional Feeder/Low W ater Cut-Off, T ype 51-2 APPLICA TION OF 51 FEEDERS Models 211A-24 thru 211A-39 One 51-S -2 Feeder/Cutoff Models 211A-40 and Larger T wo 51-2 F eeder/Cutoffs Consult F actory for proper application of feeders. Always use a pump control and boiler feed system instead when possible. Norm[...]

37 WIRE THE BOILER A. CONNECT SUPPL Y WIRING 1. All wiring must be done in accordance with local codes, the National Electrical Code ANSI/NFP A70 and/or the Canadian Electrical Code P ar t I, CSA C22.1, Electrical Code and other controlling agencies or governing bodies. 2. Use #14 gauge or heavier wire for supply wiring. Protect the cir cuit with a[...]

38 WIRE THE BOILER Figure 9.2: T ypical Wiring – Standard Controls – Low V oltage Gas V alves[...]

39 WIRE THE BOILER Figure 9.3: T ypical Wiring – Standard Controls – 120- V olt Gas V alves[...]

ST ARTING THE BOILER A. CHECK THE PIPING 1. W ater and Steam P iping a. The Boiler must have been hydrostatically tested. b. Check the attached piping for joint tightness. c. Continue monitoring as you proceed through star t up. 2. Gas Piping a. Make sur e the gas system piping and the connections to the boiler Gas Control T rain(s) have been leak [...]

ST ARTING THE BOILER 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. Each of the burners is rated at 105,000 Btu/hr (30.8 kW) for Natural Gas with a 0.60 specific[...]

42 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 [...]

43 OPERA TIONS & MAINTENANCE 12. OPERA TION & MAINTENANCE W ARNING Product Saf ety Information Refractory Ceramic Fiber Product This appliance contains materials made from refractory ceramic fiber s (RCF). Airborne RCF , when inhaled, have been c lassified by the International Agency f or Researc h on Cancer (IARC), as a possible car cinoge[...]

44 OPERA TIONS & MAINTENANCE A. PLACING BOILER IN OPERA TION 1. Star t up the boiler per the Lighting Instructions shipped with the boiler . 2. Prove the correct operation of all controls on the boiler as outlined below . 3. Check the operation of the ignition and flame proving controls: a. Electronic Spark-Ignited P ilot System (S8610M Control[...]

45 OPERA TIONS & MAINTENANCE B. T O SHUT DOWN THE BOILER 1. Open main line power disconnect switch to boiler . 2. Close Main and Pilot gas shut-off valves. 3. T o take boiler out of ser vice if the boiler and system are not to be used when temperatur es are below freezing: a. Drain the boiler and system completely and shut off make-up water sup[...]

46 TROUBLESHOOTING – SERVICE TIPS 13. TROUBLESHOO TING – SERVICE TIPS Problem P ossible 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 V alve Check Main Gas Shut-Off V alve No Gas Check Manual Meter V [...]

47 TROUBLESHOOTING – SERVICE TIPS Problem P ossible Cause Suggested Remedy Main Gas V alve Opens Manual V alve Closed at Gas T rain Open V alve But No Gas Flows Manual V alve Closed at Meter Open V alve T est Firing V alve Closed (if Provided) Open V alve Sags in Steam Piping or not enough P itch Cor rect P iping Condition Concentric reducers cau[...]

48 BOILER RA TINGS & DIMENSIONS Natural Gas Ratings LP Gas (2500 Btu/cu ft.; 93,000 kJ/m 3 ) IBR Net Ratings IBR Net Ratings Input Output Steam EDR Steam Input Output Steam EDR Steam MBH kW MBH kW Sq. Ft. m 2 MBH kW MBH kW MBH kW Sq. Ft. m 2 MBH kW 211A -04 630 185 504 148 1,575 147 378 111 1.333 615 180 492 144 1,538 143 369 108 211A -05 860 2[...]

49 BOILER RA TINGS & DIMENSIONS[...]

50 BOILER RA TINGS & DIMENSIONS Boiler Length & Width Dimensions Boiler Intermediate Intermediate Supply/Return Locations Model Section Supply/Return (Dimensions are approximate) No. AB C Length DE F GH I JK LM N OP 211A-04 28 ¹⁄₈ 714 38 ³⁄₈ 975 63 160 21 ³⁄₄ 552 211A-05 33 ³⁄₄ 857 44 1,118 63 160 27 ³⁄₈ 695 211A-06[...]

51 BOILER RA TINGS & DIMENSIONS Boiler Flue Connection Center Lines Flue Connections V ent Chimney Model Connector Diameter x No . AA BB CC DD EE FF GG HH II JJ Size Diameter 20ft (6m) high 211A-04 10 ⁷⁄₈ 276 10 ⁷⁄₈ 276 1 12 305 12 305 12 305 211A-05 13 ³⁄₄ 349 13 ⁵⁄₈ 346 1 12 305 12 305 12 305 211A-06 16 ¹⁄₂ 419 16 [...]

52 REP AIR P ARTS – SERIES 211A 15. REP AIR P ARTS – SERIES 211A 1 Inter mediate Section 50 psig (345 kP a) W orking Pressur e 90356 2 L eft Hand End Section 50 psig (345 kP a) W orking Pressur e 90625 3 Right Hand End Section 50 psig (345 kP a) W orking Pr essure 90059 4 T apped Inter mediate Section 50 psig (345 kP a) W orking Pressur e 90065[...]

53 REP AIR P ARTS – SERIES 211A 14-3/4" (375 mm) Wide Base P anel 90316 20-3/8" (518 mm) Wide Base P anel 90318 17 Base F ront P anel Cover Plate 26" (660 mm) Wide Base P anel 90320 31-5/8" (803 mm) Wide Base P anel 90322 37-1/4" (946 mm) Wide Base P anel 90324 14-3/4" (375 mm) Wide Base P anel 90317 20-3/8" (51[...]

54 REP AIR P ARTS – SERIES 211A Figure 15.1: Boiler Assembly[...]

55 REP AIR P ARTS – SERIES 211A Figure 15.2: Base Assembly[...]

56 NOTES[...]

211A Boilers – Steam Series Gas Installation, Operation & Maintenance Manual TO THE INST ALLER: 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 of gama ASME GG8051 R13 (1/07-2M) Printed in U .S.A[...]