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Series 211A
Gas Boilers – Steam
Installation,
Operation &
Maintenance
Manual
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TABLE OF CONTENTS TABLE OF CONTENTS B. CONNECT PILOT GAS TUBING . . . . . . . . . .29 USING THIS MANUAL 1 C. INSTALL VENT AND BLEED PIPING . . . . . .29 A. FOLLOW THE PIPING GUIDELINES . . . . . . .1 D. INSTALL GAS SUPPLY PIPING . . . . . . . . . .30 B. CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . .1 E. TEST GAS SUPPLY PIPING . . . . . . . . . . . . .30 C. SPECIAL ATTENTION BOXES . . . . . . . . . . . .1 8. INSTALL CONTROLS AND TRIM 32 1. PREINSTALLATION 2 A. INSTALL SAFETY VALVE
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USING THIS MANUAL USING THIS MANUAL A. FOLLOW THE PIPING GUIDELINES 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 B. CONTROLS Indicates a condition or hazard which may cause severe personal injury, death or major property 1. This manual provides wiring d
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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 the authority having jurisdiction, the installation must conform to American Society of Mechanical Engineers Safety Code for Controls and Safety Devices for Automatically Fired B
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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. The required volume of indoor air is to be determined by one of two methods. a. Standard Method: The minimum required volume o
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PREINSTALLATION i. Where communicating directly or through vertical ducts with the outdoors each opening 2 shall have a minimum free area of 1 in per 2 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 outdoors. Figure 1.6: Air Openings – All Air from Outdoors through Horizontal Ducts b. One Permanent Opening Method: Provide one permanent o
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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. Motorized dampers shall be interlocked with the indoor air provided: equipment so that they are proven in the full open position prior to ignition and during a. The size and location of the indoor openings operation of t
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PREINSTALLATION 3. Chimney/Vent Operation: The vent system must be • The vent connector must be single wall steel 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. The will spill into the building from the draft hood relief vent connector must extend into, but not op
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PREINSTALLATION f. After it has been determined that each appliance F. 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. Make-up water causes appliance to their previous condition of use. liming in the boiler and brin
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PREINSTALLATION Table 1.1: Boiler Foundation Layout Boiler Base Length Jacket Length Foundation Length Boiler 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 50-5/8 1,286 62-5/8 1,591 211A-09 50-5/8 1,286 56-1/4 1,429 68-1/4 1,734 211A-10 56-1/4 1,429 61-7/8 1,572 73-7/8 1,876 211A-11 61-7/8 1,572 67-1/2 1,714 79-1/2 2,019
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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" (13 mm) long round head machine screws and Table 2.1 (on page 11) shows the quantity of each 1/4" lock washers provided. crate required. The crates contain the following parts: Crate Items Sub-Assembly # Part # Right End Panel Sub-As
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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. Front Panel as shown in Figure 2.3. 4. For 211A-04 through 211A-08 Only: 6. Attach an Angle Tie Brace at each panel joint to a. Complete the base assembly by attaching the secure the front and back panels as shown in Figure Right End Panel and
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ASSEMBLE THE BASE Table 2.1: Base Front and Back Panel Crates Overall Length Model AB C D E F G Number mm feet/inches 211A-04 2AA —————— 24-3/4" 629 211A-05 2BB —————— 30-3/8" 771 211A-06 2CC —————— 36" 914 211A-07 2DD —————— 41-5/8" 1,057 211A-08 2EE —————— 47-1/4" 1,200 211A-09 2BB 2BB ————— 52-7/8" 1,343 211A-10 2CC 2BB ————— 58-1/2" 1,486 211A-11 2CC 2CC ————— 64-1/8" 1,629 211A-12 2DD 2CC ————— 69-3/4" 1,772 211A-13 2DD 2DD ————— 75-3/8" 1,915 211A-14 2EE 2DD ————— 81" 2,057 211A-15 2EE 2EE
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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" 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 & Relay Mounting Box Assembly (Standard HSP System, X-3011-3) PB-H91BG-2 or (2) 5/16"-18 x 3/4" (19mm) long (Other panel
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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 of (Positions Numbered Right to Left (Positions Numbered Right to Left Burners Electronic Pilots Standing Pilots Electronic Pilots Standing Pilots (Spark Ignited) (Thermocouple) (Manually Lighted) Thermocouple 211A-04 1 6 5 — 5 — 211A-05 1 8 5 — 5 — 211A-06 1 10 5 — 5 — 211A-07 1 12
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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. Check the 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 pe
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PLACE THE BOILER SECTIONS Figure 3.3: Assembling Sections on Base 15
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PLACE THE BOILER SECTIONS Place Tapped Intermediate Sections Boiler 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 211A-25 7, 13, 19 211A-26 7, 13, 20 211A-27 7, 12, 17, 22 211A-28 5, 11, 17, 23 211A-29 5, 10, 15, 20, 25 211A-30 6, 11, 16, 21, 26 211A-31 6, 10, 14, 18, 22, 26 211A-32 6, 11, 15, 19, 23, 27 211A-33 5, 9, 13, 17, 21, 25, 29 211A-34 5, 9, 13, 17, 22, 26, 30 211A-35 5, 9, 13, 18, 23, 27, 31 211A
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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. 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. 3. Place the Flue
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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 Position Position Position Position Position Model 123456789 Number 211A-04 14 ———————— 211A-05 14A ———————— 211A-06 14B ———————— 211A-07 14 14 ——————— 211A-08 14A 14 ——————— 211A-09 14A 14A ——————— 211A-10 14B 14A ———————
