PEERLESS SERIES 211A Instruction manual

211A
Boilers -Steam
Installation,
Operation
Maintenance
Manual
PEEI_LESS _
CAST IRON BOILERS

Factory Packaged, Hot Water or Steam
43 Sizes 4-46 Sections 630 to 9450 MBH Input 80% Combustion Efficiency
Natural or LP Gas
Natural Draft (chimney) Venting
Large Water Content
•Ideal for Steam and Large Volume Hot Water Jobs
Low Profile Design
•Horizontal to Vertical Draft Divel+ter
•Ideal.]br Installations with Low Ceilings
Individual Draw Rods
•For Ease of Assembly
Unique Fie_x-Sea! Flow Port Gaskets
•Injection Molded for SLq)eHor PerJ_)rmance and Flexibtlily
•Assures a Water Tight Seal Betweer_ Sections
•For Ease of Installation
Deluxe Insulated Enameled Steel Jacket
•Reduces Boiler Heat Loss
Tankless Coils
•For Domestic Hot Water Production on Hot Water Boilers
Safety Controls
•Low Water CubOJ]on
Steam Boilers •Honeywell Operating Controls
•Float and Probe Type LWCO on Steam Boilers
•Manual Reset High Limit Control
?•5' ¸¸
• Tankless Coils.for Hot Water Boilers
•Modulating Firing Systems
•Electronk: Control Systems
• FM and IRI Control Systems
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Peerless Heater Company • 231 North Walnut Street * Boyertown, PA 19512 1021 • 610-367-2153 • www.peerless-heater.com
FA[_ 211A (9/02 3MI
pnrlh (I ,fl U S A

READ THESE INSTRUCTIONS CAREFULLY BEFORE BEGINNING THE INSTALLATION
[_ STUDY THE CONTROL FOLDER AND CONSULT DRAWINGS
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 Nationa/ Fue/ Gas Code, ANSI
Z223.1/NFPA54.
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 Boi/ers, ANSI/ASME
CSD-1.
PEERLESS
CAST IRON BOILERS
PEERLESS HEATER COMPANY
231 NORTH WALNUT STREET • BOYERTOWN, PA 19512-1021 • PHONE [phone]
www.peerless-heater.com
THE PREFERRED HEATING CHOICE

TABLE OF CONTENTS
1. PREPARE THE BOILER LOCATION 3
ACCESSIBILITY CLEARANCES .................................. 3
COMBUSTIBLE CONSTRUCTION CLEARANCES..... 3
AIR FOR COMBUSTION AND VENTILATION ............. 3
CHIMNEY OR VENT .................................................... 4
BOILER SETTING ........................................................ 6
2. ASSEMBLE THE BASE 7
BASE ASSEMBLY ....................................................... 7
INSTALL THE PILOT BURNERS ................................. 8
3. PLACE THE BOILER SECTIONS 13
PREPARATION .......................................................... 13
PLACING THE SECTIONS ........................................ 13
HYDROSTATIC TEST THE BOILER ......................... 14
4. INSTALL THE FLUE COLLECTOR 15
5. PIPE THE BOILER 17
PREPARATION .......................................................... 17
SUPPLY PIPING ........................................................ 17
RETURN PIPING ........................................................ 17
MULTIPLE BOILER INSTALLATIONS ...................... 19
6. INSTALL THE JACKET _DRAFT HOOD 21
PREPARE THE PARTS .............................................. 21
APPLY CLEANOUT COVER PLATES ....................... 21
APPLY JACKET END ASSEMBLIES ........................ 21
211A-B4 through 211A-08 ONLY ............................. 21
211A-09 8LARGER ONLY ........................................ 21
APPLY JACKET TOP PANELS ................................. 22
APPLY LOWER END PANELS .................................. 22
APPLY PLATES AND LABELS ................................. 22
7. CONNECT GAS PIPING 27
INSTALL GAS TRAIN ............................................... 27
CONNECT PILOT GAS TUBING ............................... 27
INSTALL VENT AND BLEED PIPING ........................ 27
INSTALL GAS SUPPLY PIPING ................................ 28
TEST GAS SUPPLY PIPING ...................................... 28
8. INSTALL CONTROLS AND TRIM 30
INSTALL SAFETY VALVES ...................................... 30
INSTALL BLOWDOWN VALVES .............................. 30
INSTALL LOW WATER CUTOUT(S) ........................ 30
INSTALL PRESSURE CONTROLS ............................ 30
9. WIRE THE BOILER 35
CONNECT SUPPLY WIRING .................................... 35
PREPARE REMAINING CONTROLS ........................ 35
INSTALL CONTROL WIRING .................................... 35
10. STARTING THE BOILER 38
CHECK THE PIPING .................................................. 38
FILL THE BOILER ...................................................... 38
STUDY LIGHTING INSTRUCTIONS ......................... 38
RUN PILOT CHECK-OUT .......................................... 38
CHECK MAIN BURNER SYSTEM ............................. 38
CHECK BOILER CONTROLS .................................... 39
CLEAN THE BOILER ................................................. 39
11. LIGHTING INSTRUCTIONS - TYPICAL 40
TO LIGHT THE BOILER ............................................. 40
TO SHUT DOWN THE BOILER ................................. 40
PILOT FLAME FAILURE ............................................ 40
12. OPERATION _MAINTENANCE
13.
14.
15.
41
PLACING BOILER IN OPERATION ........................... 41
TO SHUT DOWN THE BOILER ................................. 41
MAINTENANCE - ANNUAL ..................................... 42
MONTHLY MAINTENANCE ..................................... 42
WEEKLY MAINTENANCE ......................................... 42
DAILY MAINTENANCE ............................................. 42
TROUBLESHOOTING - SERVICE TIPS 43
BOILER RATINGS _DIMENSIONS 45
REPAIR PARTS- SERIES 211A 48

USING THIS MANUAL
1. This boiler must be installed by a qualified contractor•
E. The boiler warranty can be voided if the boiler is not
installed, maintained and serviced correctly.
1. For new and existing installations, a Steam Installation
Survey is available from Peerless Heater Company• 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•
2. You can also use this survey to locate system problems
which will have to be corrected. To obtain copies of the
Steam Installation Survey, contact your Peerless
representative.
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 and brings in oxygen. Oxygen can cause
severe damage to the boiler through oxygen corrosion
pitting.
2. Clean the boiler as described in this manual Poor water
quality will cause foaming, priming and overfilling of the
system. Too much sediment in the water will cause
build-up in the boiler and could result in cracked sections
due to overheating.
3. If the condensate return time lag is too long, this boiler
may not work correctly with gravity return or with a
condensate return unit. Long time lags will cause
make+up water to be added to the boiler, resulting in
flooding of the boiler, carryover to the system, and
excessive make-up water addition. You will need to install
a boiler feed system to prevent problems in such cases.
4. Do not use chemicals or substances in the boiler
or system which contain petroleum or its
derivatives. This will damage the boiler seals.
i. We have provided suggested piping diagrams which will
cover most applications of this boiler.
2. Follow these guidelines to make sure the boiler will
operate correctly. Pay close attention to pipe sizing and
location of risers and returns.
]+This manual provides wlrmg diagrams and lighting
instructions for standard systems only.
2 Use the Lighting Instructions and Wiring Diagrams
provided with the boiler to make sure they represent fire
controls provided
I. Throughout this manual you will see special attention
boxes intended to supp]enrent the instructions and make
special notice of potential hazards. These categories
mean, in the judgment of Peerless Heater Company:
Indicates special attention is
needed, but not related to
potential personal injury or
property damage.
Indicates a condition or hazard
which will or can cause minor
personal injury or property
damage.
Indicates a condition or hazard
which could cause severe
personal injury, death or major
property damage.
Indicates a condition or hazard
which will cause severe personal
injury, death or major property
damage.

1, PREPARE THE BOILER LOCATION
|i
Vent,typcal _ 6j] 6',,
] P,p,ng,Typcal "-_ (3 if''_
II 1]
mm
(:-'--_ Front View C
Figure 1: Clearance Requirements
IThe following recommendations allow for reasonable
access to the boiler Local codes or special conditions
may require greater clearances•
•
a) For servicing the boiler: provide 48" between tile
conh'ol manifold and adjacent wall or other appliance
b) For access to draft hood or passage to access the boiler 4
control manifold(s): provide 48" between the side of
the boiler and adjacent wall or other appliance.
c) See Figure 1, Clearances with an "S" are minimum
clearances for service accessibility. 5.
1. This boiler is design certified for the following clearances
to combustible construction.
a 24" between the front, sides and rear of the jacket
• 6" from steam and hot water pipes
• 6" from vent connector
a See Figure I. Clearances with a "C" indicate
minimum clearances from combustible construction•
1. The installation must provide adequate air for
combustion, ventilation and draft hood dilution•
2. Provide air openings as recommended below• The
lower opening provides combustion air and dilution
air. The upper opening provides proper air circulation
to control the boiler room temperature and air quality•
Without the upper opening, the boiler room
temperature will be too high, causing problems with
control operation and life
The boiler room must never be under negative pressure.
Ifexhaust fans or other equipment can cause a negative
pressure in the boiler room, the air openings and
equipment design must be engineered to assure a neutral
or slightly positive pressure in the boiler room at all times
of operation If the equipment design and air openings
cannot assure this, then the boiler must be located in an
isolated room.
The following recommendations are in accordance with
the current edition of the National Fuel Gas Code, ANSI
Z223. I/NFPA54.
Ifall air for combustion and ventilation comes from inside
the building (Figure 2), the building must have adequate
A
TWO AIR OPENINGS:
Minimum
Free Area Each -
1 in _per 1000 Btu
at Least 100 in _
BOILER
3" rain
12"max
BUILDING
Aust communicate freely
with outdoors
Must not be under
negative pressure
3" min
[ ; 12" max
Figure 2: Air Openings -All Air from Inside
Building
3

1 :::xll
,/
TWO AIR OPENINGS:
MhlinqLim
Free Area Eacl_
1 in* per 4000 Btu
12" max
I
Figure 3: Air Openings - All Air Directly
from Outside
provision for outside air to assure the air supply needed
for the boiler room. Provide openings as follows:
• Provide two openings:
--one starting no closer than 3 inches nor further than
12 inches from the ceiling
one starting no closer than 3 inches nor further than
12 inches from the floor
• The openings must be into areas which have
unrestricted access to outside air
• Each opening must have a free area (after deduction
for louvers) of at least One square inch per 1000
Btu/Hr of total boiler and other appliance input. The
openings must never be smaller than 100 square
inches each.
6. If all air for combustion and ventilation comes directly
from outside the building:
3" min
_, 12" max
TWO AIR OPENINGS:
Minimum
Free Area Each -
1 in 2per 4000 Btu
• Provide two openings:
one starting no closer than 3 inches nor further than
12 inches from the ceiling
.... one starting no closer than 3 inches nor frlrther than
12 inches horn the floor
• If air openings are directly in an outside wall (Figure
3), each opening must have a free opening (after
louver reduction) of at least One square inch per 4000
BtuiHr of total boiler and other appliance input.
• Ifairissuppliedthroughverticalducts(Figure4).each
opening must have a free opening (after louver
reduction) of at least One square inch per 4000 Btu!Hr
of total boiler and other appliance input The cross
sectional area of the ducts must be at least as much as
the free area of the openings to which they connect.
TWO AIR OPENINGS:
Minimum
Free Area Each -
1 in zper 2000 Btu
Figure 5: Air Openings- All Air from
Outdoors through Horizontal Ducts
• If air is supplied through horizontal ducts (Figure 5),
each opening must have a free opening (after louver
reduction) ofat least One square inch per 2000 Btu/Hr
of total boiler and other appliance input. The cross
sectional area of the ducts must be at least as much as
the free area of the openings to which they connect.
7. Using combustion air dampers:
a) If motorized dampers are used on the combustion
and ventilation air openings, wire them such that
they must open when the boiler tries to operate.
They must include a switch which prevents the boiler
from operating if they do not open.
Figure 4: Air Openings -All Air from
Outdoors through Vertical Ducts
1.
2.
3.
Inspect the existing chimney or vent system. Make sure
it is in good condition. Inspect chimney liner and repair
or replace ifnecessary.
The vent system and installation must be in accordance
with Part 7, Venting of Equipment, of the current edition
of the National Fuel Gas Code, ANSI Z223.1/NFPA54,
or applicable provisions of the local building codes.
Chimney/Vent Operation: The vent system must be
sized and installed to provide the draft needed to remove

0
0
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 system,
the combustion and ventilation openings and make sure
the boiler room is never under negative pressure.
Failure to provide adequate
venting can result in severe
injury or death.
4. Exterior Vents
a) If the vent is outside, make sure it is insulated
sufficiently to ensure adequate draft.
5. Vent Sizing:
a) Individual vents: Use vent piping the same diameter
as the boiler vent connection. The minimum height
is I0 feet above the bottom of the draft hood (relief
opening). The vent must also extend above the roof
or any obstiructions as outlined in the current edition
of the National Fuel Gas Code, ANSI
Z223.1/NFPA54 or as required by local codes.
b) Combined vent- breeching:
•The recommended sizing in Section 14, "Boiler
Ratings and Dimensions", in this Manual is based
on a minimum chimney or vent height of 20 feet
and a maximum horizontal run of 6 feet to the
chimney with no more than one 90-degree
standard elbow.
• The minimum area of the chimney serving two or
more appliances must be at least the area of the
largest chimney connector plus 50% of the total
area of all other appliance connectors.
• The vent connector must be single wall steel or
Type B double wall vent pipe. The vent connector
must be Type B double wall if it is located in or
passes through cold areas. The vent connector
must extend into, but not beyond, the inside wall
of the chimney.
6. Vent Connection to Boiler (Figure 6):
a) Provide at least a three foot rise in the vent
connection on the boiler.
b) The vent system should provide a draft of at least
0.02" w.c. measured at the vent connections.
c) Support the weight of the vent system indepently of
the boiler draft hood. The draft hood is not designed
to carry structural loading.
d) Provide support ofthe vent connector (breeching] at
maximum 12 foot intervals to prevent sagging and
to provide a minimum upward slope of I/4" per foot.
e) Do not connect the vent for this boiler into any vent
system which operates with positive pressure.
f) Use Type B double-wall pipe for vents which run
through unheated spaces.
7. Removing an existing boiler from a common vent: At the
time for removal of an existing boiler, the following steps
shall be followed with each appliance connected to the
common venting system placed in operation, while the
other appliances remaining connected to the common
venting system are not in operation.
Recommendedsizingfor chimneyand connectorsis
based onmaximum 6 foot connector length and
maximumone 90 degree elbow.
Frovidesuppo_for I_lz_taJ secl_s to preventsagging •
Slopeve_t connectorupw_d min 1/4 inch perfoot --
T
Connlz_tor must notprotrudeinlo chimney •
Boi)erven_c0nnect0rshCuldbeh_ghet
than 0tha:connected app_ances
I_Do not obs_ct draft.hood openfn_
Figure 6: Vent Connection
a) Seal any unused openings in the common venting
system.
b) Visually inspect the venting system for proper size
and horizontal pitch and determine there is no
blockage or restriction, leakage, corrosion and other
deficiencies which could cause an unsafe condition.
c) Insofar as is practical, close all building doors and
windows and all doors between the space in which
the appliances remaining connected to the common
venting system are located and other spaces of the
building. 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.
d) Place in operation the appliance being inspected.
Follow the lighting instructions. Adjust the
thermostat so appliance will operate continuously.
e) Test for spillage at the draft hood relief opening after 5
minutes of main burner operation. Use the flame of a
match or candle, or smoke from a cigarette, cigar orpipe.
f) After it has been determined that each appliance
remaining connected to the common venting system
propedy vents when tested as outlined above, return
doors, windows, exhaust fans, fireplace dampers
and any other gas-burning appliance to their
previous condition of use.
g) Any improper operation of the common venting
system should be corrected so the installation
conforms with the current edition of the National
Fuel Gas Code, ANSI Z223.1/NFPA54. When
resizing any portion of the common venting system,
the common venting system should be resized to
approach the minimum size as determined using the
appropriate tables located in the chapter "Sizing of
Category I Venting Systems" in the current edition
ofthe National Fuel Gas Code, ANSIZ223.1/NFPA54.

1 Provid_ a good, levd foundation for the boi]el t_,.n mu
minimum dim_nsKJlm givun m Tahlf ] ThP fluulh _,--!
stlLwtura] SklI313olt _,t/stt,t3] RIU_t h( _ qUltdhlL' --
op_,_ating weif_ht o_ thu h_)dc, i dnd any conn_cIcc ....
2. Do not operate thin b()l}_ until the [ounoanon 11nett
concrete, has thoroughly cured• The high ternperuan_-
under the burners could cause major lamag_ ln_
concrete if it still contauled moisture.
Do not install this boiler on
carpeting or any combustible
flooring. A significant fire
hazard would result, with
potential for property damage,
personal injury or death.
3. If the boiler is installed in a penthouse or if wiring of any
sort is run undumeath the boiler foundation, construc_
the foundation with provision for air flow underneath
between the main floor and the' top of me boiisr
foundation.
a)
b)
Concrete block aligned with the openings connected
continuously would serve this purpose, for _'xampJe
If the foundation must be a concrete slab. use an air
cell high temperature insulating board, at least V_
inch thick, with aluminum backing, aiuminun slou
up One half inch Hi Temp millboard with aluminum
backing t_ould b_' acceptable as wall. PlaG, lnu
insulating board on thu slab inside tne 0ase
:z
l-
O uc
z I- :_
Lu {3 I-
zt_
zuJ 2
O-J LU
z < m
0
u.
Figure 7:
< BASE - 41" •
< JACKET - 45 _,' •
< FOUNDATION - 57 ,'
Foundation Layout
Table 1: Boiler Foundation Layout
Boiler Boiler Base Jackel Foundation
Model Length Length Length
2!1A 04 22 I 2 28 1 _ 40 1/8"
211A-05 28 1/8' 33 3/4 45 3/4
711A-06 33 3,4 39 3/_ 51 3 8'
211A-07 39 3/8 45' 57
211A 08 4[ 50 5/8' 62 5 8'
211A-09 50 5/8" 56 l/a, 68 1 4"
211A 10 56 1,,4 61 7/8' 73 7 8"
211A-11 61 7/8 67 1/2' 79 1/2"
211A-12 67 1/2 73 1/8' 85 1/8
211A-13 73 1/8 78 3/4" 90 3/4'
211A-14 78 3/4 84 3/8' 96 3/8'
211A-15 L84318 90" 1 102
211A-' 6 90' 95 5/8" 107 5/8"
211A-17 955/8 101 1/4' • 1131/4
211A-18 101 1/4- 106 7/8' 118 7 8'
211A-19 1067/8" 1121/2" _ 1241/2"
211A-20 112 1/2 118 1/8' 130 !/8"
211A-21 1181/8 1233/4" [ 1353/4"
211A-22 123 3/4 129 3/8" 141 3 8
211A-23 129 3/8 135" 147
211A-24 135' 140 5/8 152 5 8
211A-25 140 5/8 146 1/a' 158 1/4"
211A-2( 146 1,4 151 7/8 163 7 8'
211A-27 151 7/8 157 1/2" 169 1/2'
211A-28 157 1/2 163 1/8" 175 1/8
211A-29 163 1/8 168 3/4" 180 7/8
211A-30 168 7/8 174 3/8 186 3/8
211A-31 174 3/8" 180' 192"
211A-32 180 185 5/8 197 5/8'
211A-33 1855/8" 191 1/4 203 1/z1'
211A-34 191 lm 196 7/8 208 7/8'
T
211A-35 l 196 7/8" 202 1/2" 214 1/2'
211A-36 202 1/2' 208 '/8 220 1/8'
211A-37 208 1/8" 213 3/4" ] 225 3/4"
211A 38 213 3 4" 219 3/8 231 3/8"
211A-39 219 3/8" 225" I 237"
211A-40 225 230 5/8 242 5/8
211A-41 2305/8' 2361/4" J 2481/4"
211A-42 236 1/4" 241 7/8" 253 7/8"
211A-43 241 7 8" 247 I/2" 259 1/2"
211A-44 247 1/2' 253 1/8" 265 1/8"
211A-45 253 1/8' 258 3/4" 270 3/4"
211A 46 258 3 ,_ 264 3 8' 276 3/8

2. ASSEMBLE THE BASE
]. Co][_'cl the! cr_t_!s _onlaU/ing the 13as_Assemb[_; palts (able 2
shows the qu;_ntit'_ ¸¸at _ac]_ crate r_quired Th_ crates contain
the toi)owin9 pa_ts:
Crate i Right End Panel Sub-Assembly
2 Left End Panel Sub-Assembl r 90339
Burner SUB[_rt Channe[ 3s 121
Front Panel Sub-Assemo •
Back Panel Sub Assembl
Burner Support'C;nannelha_
2AA Anqle Tie Brace , _ 90340
Front Panel Support Bracket j
Section Assemb y Kit
Front Panel Sub Assemb .
Back Panel Sub-Assemo
Burner SuDi]ort Channe
2BB 90341
Angle Tie Brace
Front Pa_el Suaoort Bracket
Section Assert 3_y r,l[
' Front Panel Sub-Assemb LBack Panel Sub-Assera[3]
BurnerS@port Channel
Front Panel Support Bracket
1 Fsentctl_onAssemb,y Kit
Front Pane SubAssernb .
Back Panel Sub Assemb
Burner SUI]D_/t Channe
2DD _0343
Angle Tie Brace
ronl Paue ._ _..o_ Bracket
Sect on Assertlo _ lYE
Front Panel Sub-Assembl,_
_Back Panel Sub Assembl z
Items [ Sub-Assembly # Part #
2F E Burner Support Channel 90344
.. An£1e Tie Brace
Front Panel Support Bracket
Section Assemb tKi{
GG 2105
GG 2106
3G 207(
GG-2080
GG-2081
GG-206{
N/A
GG-2069
GG-1030
GG-2080-"
GG-2081 -"
GG-2066-"
30 2065
GG 2069
GG-103(
GG-2080-2
GG-208]-2
GG-2066-2
GG-2065
GG-2069
GG-103O-'
GG-2080 3
GG 2081 3
GG 2066 3
GG 206._
GG 2069
GG 1030 2
GG-2080-4
GG-208!-4
GG-2066-4
GG-2065
GG-2069
_ GG-1B30-3
2. Op_zn cl_t_' numb*'l 2 t£_mov_, the End P_llc]_ ,,zd
IllOUI]t a _tippor_ ChL_lllle] C]ip toward t}t_ I_al o_ ,:_1_ n
panel asshown in Figure 9 using _"-20 x L,," round humid
machine screws and _' lock washers provided
Figure 9: Steel Base Assembly
Figure 8: Boiler Base Assembly
Base BackPanelSub-Assembly,GG-2081 BaseBightEnd PanelSub-Assembly,GG-2105
.... T.......... T== BACK = ='T ......... T ....... T: T
a.S,d0 TOP VIEW Burner Po,ition Number t
RightSide
BurnerSupport Channel,GG-2066 Burner Support Channel Clip,06-2070
BaseLeftEndPanelSub-Assembly,GG-2106 BaseFrontPanelSub-Assembly,GG-20BO
FrontJacketSupportBracket,GG-2069 AngleTie Bracew/BurnerSupportChannel,GG-2065(whenrequired)
F.__ NT VI_V ! !1
•Assembly H Assembly b-• Assembly I=-• Assembly I_< Assembly •• Assembly I_• Assembly
ABCD E F G
•H(overaHlength) •
41"

3. Attach the Front Panel and Back Panel (Figure 9) to the
Left Hand End Panel using 5/16" -18 x 1" 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.
_ Front
Jacket •
Panel
Figure 11: Support Bracket Installation
5,
6,
7.
8,
9.
For 211 A-09 through 211 A-46 Only:
a) Attach a Front Panel Support Bracket to each Front
Panel as shown in Figure 11.
Attach an Angle Tie Brace at each panel joint to secure
the front and back panels as shown in Figure i0 using
5/16"48 x 1" cap screws and hex head nuts.
Bolt remaining Front and Back Panels together using
5/16"-18 x I" cap screws and hex head nuts. See Table
2 for panels required. Place the panels in the positions
shown in the table and Figure 8.
Complete the base assembly by attaching the Right Hand
End Panel using 5/16"-18 x i" cap screws and hex head
nuts.
Set the Burner Support Channels in place as shown in
Figure 8.
I,
,
3.
Check the location of the Burner Support Channels in
the Base Assembly. The dimensions should be:
a) Height above boiler foundation: 63/4"
b) Distance from back of Base: 33/4"
Remove the Gas Manifold and Pilot Line Assembly from
Box Number 7.
Place Manifold on front of Base. Bolt the hangers using
5/16"-18 x 1" long cap screws with 5/16" fiat washers.
See Figure 12.
Front Panel
Angle Tie Brace
3 3/4"
T
6 3/4"
Figure 10: Angle Tie Brace Installation
8

Overall Length
_r......... 7-
• Assembly I_• Assembly I_• Assembly I_• Assembly I_• Assembly Ib• Assembly I_• Assembly ip
A B C D E F 6
Model Overall
AB C DE F G
Number Length
211A 04 2AA 2434
211A O5 2BB -- -- -- 30 3/8"
211A 06 2CC 36'
211A 07 2DD -- 41 5/8"
211A 1)_ 2EE -- 47 1 4'
- - i 27/8
211A-09 2BB 2BB
211A 1 2CC 2BB 58 1'2'
211A 11 2CC 2CC .... 64 1/8
211A 12 2DE 2CC 693,4
] -- 75 3/8"
211A-13 2DD 2DD
ZIIA 14 2EE 2D[ 81"
-- -- _ -- 86518"
211A-15 2EE 2EE
2 ! 1A ] _ ?CC 2CC 2CC 92 !_4"
21IA 17 2DD 2CC 2CC -- 97 7/8
VllA 18 2EE 2CC 2CC 8 7 ]
EllA 19 2DD 2DD 2DD 9"-1 1,'8'
EllA d0 2EE ELL 2CC _) 634
211A-21 2EE 2EE 2DD -- -- 10L0 3/8 ''
211A 22 2EE 2LF 2EE I0' 6
211 A-23 2EE 2CC 2CC 2CC -- -- I0'-11 518
211A24 2DD 2DD 2DD 2CC -- 11 51'4
211A-25 2EE 2EE 2CC [ 2CC ] 1 -- 11' 107/8"
211A 26 2EE 2hE 2EE 2BB -- 12" 4 b2'
211A-27 2EE 2EE 2EE I2CC ] -- _ 12'-10 1/8"
211A-28 2BE 2EE 2EE 2DD 13"-3 :_4 '
2EE 2EE 2EE
211A-29
21 IA ,J* 2DD 2DD 2DD 2DD 2CC 14"-3'
211A-31 2DD 2DD 2DD 2DD 2DD -- [ [ 14'-85/8'
21 IA ," 2EE 2DD 2DD 2DD 2DD 15-2 1,4'
J 2BE 2EE 2BB 2EE 2EE
211A-33
211A-34 2EE 2EE 2BE 2EE 2CC -- 16" I U2'
21 IA-35 2EE 2EE 2EE 2EE 2DD 16'-7 1/8'
211A-36 2EE 2EE 2EE 2EE 2EL -- 17" 03/4
211A-37 2DD 2DD 2DD
21 IA-38 2EE 2DD 2DD 2DD 2DD 2DD 18' 0"
2EE 2EE 2DD 2DD -- I 18'-55/8'
211A-39 2DD 2DD
21 IA 41 2BB 2EE 2EE 2hE 2E£ 2EE 18' i i I/4
211A 41 2EE 2EE 2DD 2DD 2EE 2EE T -- J 19'4 7/8"
211A 42 2DD 2F[ 2hE 2EE 2EE 2EE 19'-10 1/2'
211A 43 2EE 2EE 2EE 2EE 2EE 2EE 20'4 1/8'
211A 44 2EF EBB 2EE Zhk 2hE 2BB 2EE )' 9 3/4'
21 IA-45 2CC 2BB 2EE 2EE 2EE 2EE 2EE 21'.3 3/8'
211A 41 2C( 2('C 2EL 2FL 2[-E 2EE 2EE 21 9
Table 2: Base Front and Back Panel Crates

_:1II:1/ill: I:f:T_'_
© ©
Mounting Clamp
GG-3052thru GG-3052-3
Manifold Weldment
GG-4084 thru GG-4084-46
Orifix_e4A0d3Pter\\ _
©
Imperial #68F
1/4" NPT x 3/8" O.D.
Tube Straight Connector
\\\
3/8" x 3/8" x 1/4" Tee
I 1/4" Street Elbow
3/8" Pipe Cap_
Pipe Cap _ 1/4" x1/8" 1/4" X 1 1/2" Nipple
\\\ Hex Bushing
Ignition Control _ Relay _\
Mounting Box Assembly
(Standard System, HSP-X-3O 11-3) PB-H91 BG-2 or
(Other panels mounted on Imperial #69F Elbow H-V8046C
jacket front, left side) 1/8' NPTx 1/4"O.D.Tubing Pilot Gas Valve
3/8" Pilotstatls)
H17CA
J
3/8" x I/4" Elbow
/
/
(21 5/16"-18 x 3/4" Square
Head Set Screw
Figure 12: Typical Gas Manifold and Pilot Line Assembly
4. Place only the Burners with pilots mounted in the
locations give in Table 3. Install the Burners 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 Burner Support Channel directly opposite
the orifice.
5. Cut and fit the I/4"aluminum tubing provided from the
pilot gas shut-off device(s) to the pilot burners.
6. Do not install the remaining burners until the Boiler
Sections are installed.
I0

Table 3: Pilot Burner Locations-Numbered Right to Left (See Figure 8)
Model Number of
Number Pilots
2ilA-04
NATURAL GAS ONLY
Total
Number Pilot Burnei Locations
of Positions Numbered Right [o Left)
Burners Electronic Pilots Standing Pilots
(Spark Ignited) IThermocouple)
5
PROPANE GAS ONLY
Pilot Burner Locations
Positions Numbered Right to Left
Electronic Pilots Standing Pilots
Manually Lighted Whermocoupte
5
211A 05 1 8 5
211A-06 1 10 5 --
"_7 1 1 12 5 I
211A-08 i 14 5
l211A-09 I 16 5 --
I211A-10 I 18 5 --
I
L
[ 211A-11 ,r 2 - 26 15 5
211A-12 2 22 15 5
211A 13 2 24 17 5 13
211A-14 i 2 _26 •. _.....17 5 t 9.19
211A-15 , 2 28 19 ] 5 ; 9.21
211A-16 3 30 25 5.15 5.15.23
211A-17 3 32 25 5. 15 5.15.25
211A-18
211A-19
211A-20
211A 21
211A-22
211A-23
211A-24
5
5
5
5
5
7
13 5
13 5
3
3
3
25 [ _ 15
34
36 29 5.17
38 35 5.21
5
I
]
9,19,27 1....... --
9.21.29 _ --
i
9 21.31
:3 40 {7 5.23 9.23.33
3
342 44 19 5.39 9.23.35 19 5.41 9.23.37
34_ 21 5.39 9 23.39
211A 25
211A-26
211A-27
211A-28
348 25
4 50 19
4 52 21
4 54 23
5.45 9.23.41
5.33.47 9.23.33.45
5.35.49 9.23.35.45
5.37.51 9.23.35.47
211A-29 4 56 27
211A-30 4 58 _ 29
211A-31 4 60 31
211A-32 4 62 33
211A 33 4 64 35
211A-34 [ 5 i 66 35
211A-35 5 68 37
211A-36 5 70 37
211A-37 5
2nA-38 [5
211A-39 ] 5
211A-40 5
211A 41 6
211A-43 ] 6
211A-44 6
211A-45 6
211A-46 6
72 37
74 25,55
76 I 23,49
78 25,55
80 19,45
82 ! 23,51
84 23,53
86 21,55
88 23,57
90 25,59
5.39.53 9.23.39.49
5.39.51 l 9.21,39,$1 1
/
5.41.53 9.23, 39, 53 J
9.25.41.55
9.25.41.57
9. 23.39.51.59
39.51.61 1
9. 23.
9.23.39.51.63
9.23.39.51.65
Models 21 IA-38 through 21 IA-46
Are Certified for Natural Gas Only
5.41.59
5.41.61
5.21.49.63
5.17.51.65
5 19.53.67
5.2347.65
5,43,67
5,35,69
5,33, 75
5,33,57,77
5,31,65,79
5,33,67,81
5, 33, 67, 83
5, 37.65.85
5, 39, 67, 87
11

J
C
D
F
r_
_o
o3
r_ r-
Lo
r_
oo
,r-
_O
%.
_o
o3 O0
%-
LO
A 3/4" npt Tapping
B 1/2" npt Tapping, Upper
C 1" npt Tapping, Upper
D 1/2" npt Tapping, Lower
E 3/4" npt Tapping, Probe LWCO
F 1" npt Tapping, Lower
TAPPINGS, EACH END SECTION
G 1 1/2" nptTapping, Back, Blowdown
H 3" npt Tapping, Pop Safety Valve(s) and
Upper Equalizer for Special Float
Controls (157, etc)
J 6" npt Tapping, Steam Riser
K6" npt Tapping, Return
Figure 13: Assembling Sections on Base
12

3. PLACE THE BOILER SECTIONS
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 I'16".
2 Check the area around the Flow Ports (Figure 14). Use
solvent and a clean cloth to thorougly clean the flat
surfaces and recesses• All foreign matter must be
removed to assure a proper seal when the sections are
drawn together•
Gaskets will be damaged by
petroleum or its derivatives.
Completely remove all solvent
residue before placing gaskets•
Do not use petroleum based
compounds in the boiler.
Flat Machined Recess Machined
Face Face
Flow Port
Gasket
Figure 14: Flow Port Machining b Gasket
I. Begin by placing the Left Hand End Section on the left
end of the base, The upper flow port goes toward the
front of the boiler as shown in Figure 15.
Figure 15: Placing the First Section on Base
2 Slide the section to the back of the base until the cast lug
on the bottom of the section under the lower flow port is
against the base back panel• Keep the section upright by
a supporting prop or other means•
The sections are heavy and
must be supported securely•
.
4.
S.
6.
Align the parting line of the section with the seam
between the Base End panel and the Base Front Panel
as shown in Figure 13.
Apply Hi-Temp rope seal by spreading a thin coat of
RopeAdhesive 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 _/' beyond
the top and bottom.
Place the Flow Port Gaskets in the recesses provided (see
Figure 14). Do not use adhesive.
The following steps must be followed to insure that no
damage is done to the tie rod lugs. A0 100 ft.-Ibs, torque
wrench is required•
a) Place an Intermediate Section on the base and slide
it carefully against the Left Hand End Section.
b) Align the flow ports from front to back, as close as
possible.
c) Insert a tie rod into each of the lugson each section
and app}y a nut and washer to each end of the tie
rod.
d) Before tightening, check the vertical alignment of the
sections using a spirit level (see Figure 16). Make
sure they are square with the Base
13

Spirit
Level
Left Hand
- " Et_d Section
Base
/Assembly
Figure 16: Align Sections Vertically
e)
f)
9)
Draw sections together evenly, alternating between
top lug and bottom lug in increments of 20 ft.-lbs.
Continu{, until both top and bottom lugs are
tightened to 60 It. lbs DO NOT EXCEED 60
FT -LBS
Check the level while tightening to make sure
alignment stays true Also make sure sections remain
square with the Base from front to back as the tie
rods are tightened and as additional sections are
installed.
If the sections tend to run out of plumb, this will
usually be at the bottom front. Loosen the upper nuts
slightly and tighten the lower ones to adjust•
7. Assemble the remaining sections in the same way for a
finished assembly as shown in Figure 13.
8. Some of the Intermediate Sections have tappings for
installing additional steam risers from the boiler. These
Tapped Intermediate Sections must be installed as shown
in Figure 17A. The placement order is left to right (Figure
17).
Left Hand End Section, Position Number 1
'!f!lf!!f'lI' lF'l'.... i=,
r;,1,,,,, - _ _ _ "
1 3 5 43 45
Figure 17: Section Positioning Numbering
Boiler Model Number
211A ]S
211A-19
211A 2{I
211A-21
211A _7
211A-23
211A 24
211A 25
211A 26
211A-27
211A 28
211A-29
211A 3(
211A-31
211A 32
Place Tapped Intermediate Sections
at Positions (Numbered Left to Right)
iU
10
H
11
& 16
9,17
7, 13, 19
7, 1:_ 20
7, 12, 17, 22
5 11,17 23
5. 10. 15.20.25
11. lb. 21.2b
6. 10. 14. 18.22. 26
o. 1] 15.19.23.27
11A- 3 " s.9.la.17Z-£TT-..... 1
211A 34
211A 35
211A 3(
211A-37
211A 38
5 9 13.17 22 26.30
5.9. 13. 18.23.27.31
5 9.13 17. 21 2[ 29.33
5.9. 13. 17.21.25.29.33 q
4 8 12 1722.27.31 35
211A-39 4 8. 12. 16.20.24.28.32:.36_ ]
ZllA4( 4 8 12 16.21 25.29.33.37
211A 41
211A-42
211A 43
211A-44
211A45
211A-46
4.8 12 16.19.23.26.30.34.38
a_ 12 16 2023 27 31 35.39
4.- 11.14.18.22.26.30.33.37.40
a - 12 16 19 23.26 29.33 37 41
4.- 11 14.18.21,25,28 32.35.39.42
4 11 14 18 22 25 29 33.36,40,43
Figure 17A: Section Positioning Numbering
1.
.
3.
4.
5.
6.
7.
The supply and return piping can be permanently
erected before applying the Boiler Jacket if the pipe
nipples applied to the boiler tappings are long enough to
clear the jacket.
Install a drain cock in the tapping provided at the bottom
rear of each section.
Provide a water supply line to the boiler.
Plug all open tappings in the boiler.
Provide a means to vent air as the boiler fills.
Fill the boiler with water, venting air as water level rises.
Pressurize boiler to 45 psig. Do not exceed this
plregsulre
a) Maintain pressure while checking all joints and
fittings for leaks
b) After inspection is complete, drain the boiler and
remove plugs from tappings that are to be used.
14

4. INSTALL THE FLUE COLLECTOR
1. ColDct the l:lu_' Coikzctor cartons. The Flue Cdlactot
sections are ]abal_,d on tile part and on the carton See HiTempRope AngleBracket,
Table 4 for the items needed. GG-50O5
2. Install Hi Tamp Rope for each collector section asshown
in Figure 18. The rope provides the seat 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 sea].
3. Place the Flue Collector sections in the positions given in
Table 4. These positions are numbered from left to
right when facing the front of the boiler•
4. Fasten an angle bracket, part number GO-5005, to the
top of each Collector section with two #10- Vi' sheet
metal screws. See Figure 19.
5. Insert a Long Hook Bolt, part number 00-5003, through
the angle bracket Slip the hook end over the tie rod.
Apply a W'-20 hex nut on the end of the rod and snug
against the bracket. See Figure 19. Do not tighten yet.
6. Insert a Short Hook Bolt, part number GO-5004, through
the flange in the rear of the flue collector. Catch the hook
around the spacer pads at the top of the boiler sections.
Apply a V4"-20 hex nut on the Bolt and snug against the
flange. See Figure 19. Do not tighten yet.
7. Draw the Flue Collector sections tight against the sealing
rope by tightening the nuts on the Hook Bolts. Draw the
nuts evenly, alternating tightening.
ShortHookBolt,
6G-5004
Figure 19:
'\ \\\
\\, \
LongHookBolt,
6G-5003
,\ TieRod
\X •
\\ \\ \\ \\
\\
Installing Flue Collector Sections
Figure 18: Applying Flue Collector Hi Temp Rope Gasket
15

Table 4: Flue Collector Section Location (From Left to Right Facing Front of Boiler) - Crates
Crate 14 = Part number GG-5000 Crate 14A = Part number GG-500O-1
Crate 14B =Part number GG-5000-2
Boiler
Model
Number
211A-04
F
Position ! Position
1 2
14
Position
3
i
Position ! Position Position
4 5 6 Position 7Position Position 8 9
211A-05 14A
211A-06 , 14B --- -- [ -- ] -- ! ii
211A-08 14A 14 -- - i --
211A 09 14A t4A
i 211A-11 _/ 14B _/ 14B k -- 1| -- _ Z ,/ -- J/ ---'-- [ --
211A-12 14 : -- -- --
14A i2i1AL13
211A-14
211A-15
21]A-I6
211A I7
211A-18
211A-19
211A 20
14A ! 14A
14A 14A
14B ---14A I
14B 14A
14B 14B
14A 14A
14B 14A
14A 14B
14B 14B
2iiA-21 14B 14B
211A-26
211A-27
211A-28
211A-29
211A-30
14B -- I __
14A 14A
_4B E 4A L --
14B i 14A -- --
14B ! i4B
211A23 14B _ i4B 14A _ 14A _ 14A
211A24 14B 14B 14B 14A 14A
211A25 ! i4B 14B IqB 14B 14A
_4B | 14B _4A -_ 14 A [
211A-31
211A 32
, 211A 33
I211A-34
_211A-35
211A-36 !
14B
1413
14B
14B
14B
14B
14B
14B
211A-37 14B
14B 14B 14B |
14B i4B l 14B l
14B l14B L14B L
T
14A [ --
14A
m i
14B 14B 14A
14B 14B 14B 14A
14B 14B 14B 14B
14B 14B 14B 14B |I
14B 14B 14B 14B
14B 14B 14B 14A
14A 14A -- i --
-B i I - I -
14B ! 14B I - I - / -
14A 14A 14A !
!4A 14A
14A 14A --
14B !4A --
14 2 14B
14A 14A 14A
211A-38
211A-39
211A40 14A 14B 14B 14B 14B
i/ 211A-4i 14B i 14B ,14B 14B 14B
2_ii_::ia_;- i_X 1 i4A-I i_g 14B
;211A_44 14A i4; 14B -- 54B IQB
211A-45 14A 14B 14B 14B 14B
i 2iiA_ i4B 14B
[ I 1
.A I.A 114B .B ].B I.B --
14A 14A 14B L14B 14B 14B 14B 14B --
14B 14B 14B .i
14B i4B 14B
14B 14B 1 1413 14B
14B 14B L 14B 14B
14B : 14B 14 2 14B
14B 14B 14B 14B
14B _i 14B i i4B I 14B • 14B ] 14B i 14B _i
16

5. PIPE THE BOILER
1 The boiler must be pressure tested as outlined in
Chapter 3. "Place the Boiler Sections", of this manual
2 TheSupplyandReturnpipingcanbeinstalledbeforethe
jacket is applied. Use nipples long enough to be sure they
will extend through the jacket.
1 Install End Riser connections sized per Table 5. The 3"
tappings in the tops of the end sections are not used for
steam boilers.
a) 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"
risers off of the tapped intermediate sections. See Table
5 for the number required.
4 Pipe the header at least 24 inches above the normal
boiler water line. This is required to prevent water from
carrying over into the header and then to the system.
5Figure 21 shows the Supply and Return piping for
Parallel Fk_w Gravity systems and all Pumped Return
Systems.
6. Counterflow Gravity systems require the boiler steam line
to enter the top of the steam main. See Figure 22 for this
special case.
Steam
Supply
7.
8.
9.
10.
11.
The piping in [hese 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 23, typical.
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 occur in the boiler, causing possible
overheating of some sections.
Pipe the Header with an offset as shown in the
drawings. This offset prevents the expansion and
contraction of the Header from damaging the boiler
sections.
Always locate the Steam Supply take-off between
the Equalizer and the last Boiler Riser. (See
Peerless Heater Company's "Steam installation Survey"
for discussion). Locating the Steam Supply between the
risers will cause water carryover to the system.
Do not use a bull head tee to provide steam supply and
equalizer connections. This will cause water level bounce
and carryover.
I.
.
We recommend the use of a Hartford loop in all
installations. The loop provides additional reliability for
the system. A check valve must still be installed on the
pump discharge of all pumped return systems.
On pumped return systems, install a boiler cock after the
pump to allow throttling of the pump discharge. The
pressure after the boiler cock should be no more than 5
psig above the boiler operating pressure. Pumping the
Steam Supply should always
be piped between last boiler
riser and equalizer.
BOILER HEADER -
Pipe with offset
to allow for header
expansion
\{
Water
ix
24"
Min.
" " ,.'Useclose YI" "
-- _--,. nipple on y JJ "
Hartford ,
Loop _! _
"Hartford q-"_
' , Loop
i
Figure 20: Supply and Return Positions, Skim Piping, Hartford Loop
17