Installation, Operating and Service Instructions for CG-F TM • Water Boiler • Cast Iron • Chimney Vent • Gas Fired Models: • CG30F • CG40F • CG50F • CG60F • CG70F • CG80F • CG90F Manual Contents Page Dimensional and Physical Data. . . . . . . . . . . . 3 Pre-Installation. . . . . . . . . . . . . . . . . . . . . . . . . . 5 Removing Existing Boiler. . . . . . . . . . . . . . . . . 6 Unpack Boiler . . . . . . . . . . . . . . . . . . .
CG-F Installation, Operating & Service Manual The City of New York requires a Licensed Master Plumber supervise the installation of this product. The Massachusetts Board of Plumbers and Gas Fitters has approved the CG-F™ Series Boiler. See the Massachusetts Board of Plumbers and Gas Fitters website, http://licensing.reg.state.ma.us/pubLic/pl_products/ pb_pre_form.asp for the latest Approval Code or ask your local Sales Representative.
Installation, Operating & Service Manual CG-F 1 Dimensional and Physical Data Table 1-1: Dimensions and Connections Boiler Model Depth Width Height Supply NPT (inch) Return NPT (inch) Vent (inch) Gas NPT (inch) Relief Valve NPT (inch) Drain NPT (inch) CG30F 32 14 40 1¼ 1¼ 4 ½ ¾ ¾ CG40F 32 16 40 1¼ 1¼ 5 ½ ¾ ¾ CG50F 32 19 40 1¼ 1¼ 6 ½ ¾ ¾ CG60F 32 22 40 1¼ 1¼ 6 ½ ¾ ¾ CG70F 32 25 40 1¼ 1¼ 7 ¾ ¾ ¾ CG80F 32 28 40 1¼ 1¼ 7 ¾ ¾ ¾ CG90F 32 31
CG-F Installation, Operating & Service Manual 1 Dimensional and Physical Data (continued) Model 'W' CG30E 14" CG40E 16" CG50E 19" CG60E 22" CG70E 25" CG80E 28" Figure 1-3: Minimum Closet Clearances Model 'W' CG90E 31" Figure 1-4: Minimum Alcove Clearances * Minimum radial clearance around vent pipe and breeching for single-wall metal pipe vent connector. Otherwise, follow vent connector manufacturer's recommended clearances.
CG-F Installation, Operating & Service Manual 2 Pre-Installation ! WARNING ! WARNING Carefully read all instructions before installing boiler. Failure to follow all instructions in proper order can cause personal injury or death. A. Inspect shipment carefully for any signs of damage. All equipment is carefully manufactured, inspected and packed. Our responsibility ceases upon delivery of boiler to carrier in good condition.
CG-F Installation, Operating & Service Manual 3 Removing Existing Boiler A. If an Existing Boiler is Removed: When an existing boiler is removed from a common venting system, the common venting system is likely to be too large for proper venting of the appliances remaining connected to it.
CG-F Installation, Operating & Service Manual 5 Venting A. Inspect chimney and remove any obstructions or restrictions. Clean chimney if previously used for solid or liquid fuel-burning appliances or fireplaces. B. Locate blocked vent switch on boiler draft hood. Verify connections are made. C. Install Vent Damper OPEN THE VENT DAMPER CARTON and remove Installation Instructions. READ THE INSTALLATION INSTRUCTIONS THOROUGHLY before proceeding.
CG-F Installation, Operating & Service Manual 5 Venting (continued) 4. Vent pipe to chimney must not be smaller than outlet on draft hood or vent damper. Arrange venting system so boiler is served by vent damper device. Figure 5-2: Vent Damper Position Indicator Exception: National Fuel Gas Code, ANSI Z223.1/NFPA 54, and allow vent downsizing when vent size determined by their Vent Sizing Tables is smaller than draft hood outlet/vent damper.
CG-F Installation, Operating & Service Manual 5 Venting (continued) F. Install vent termination (Masonry chimney and single wall metal pipe) 1. Termination shall extend at least 5 ft. in vertical height above highest connected appliance vent outlet. 2. Termination shall extend at least 3 ft. (2 ft. for single wall metal pipe) above roof penetration and at least 2 ft. above any portion of building within horizontal distance of 10 ft. G. Install vent termination: (Gas Vent) 1.
CG-F Installation, Operating & Service Manual 6 Water Piping ! WARNING Failure to properly pipe boiler may result in improper operation and damage to boiler or building. A. Design and install boiler and system piping to prevent oxygen contamination of boiler water. Oxygen contamination sources are system leaks requiring addition of makeup water, fittings, and oxygen permeable materials in distribution system.
0118-01 12/19 System Circulator Optional Zone Valve Controlled System System Zone Valves To System Optional Circulator Zone Controlled System Zone Circulators Flow Check To System Full Port Isolation Valves Expansion Tank Backflow Preventer Cold Water Return Fill Valve IWH Return Indirect Water Heater (IWH) Full Port Isolation Valve Unions Full Port Isolation Valves Figure 6-2: Recommended Water Piping for Direct Connection System Unions IWH Circulator Flow Check Full Port Isolation
System Circulator Optional Zone Valve Controlled System System Zone Valves To System Optional Circulator Zone Controlled System Zone Circulators Flow Check To System Full Port Isolation Valves Expansion Tank Backflow Preventer Cold Water Return Fill Valve IWH Return Safety Relief Valve Pipe within 6" of floor or drain Drain Valve Full Port Isolation Valves Drain Valve Circulator Full Port Isolation Valves Indirect Water Heater (IWH) Full Port Isolation Valve Unions 'A' From Syste
CG-F Installation, Operating & Service Manual 7 Gas Piping A. Size gas piping. Design system to provide adequate gas supply to boiler. Consider these factors: 1. Allowable pressure drop from point of delivery to boiler. Maximum allowable system pressure is ½ psig. Minimum gas valve inlet pressure is listed on rating label. See Table 7-1. Table 7-1: Gas Pressure Natural Gas Inlet Min (in w.c.) Inlet Max (in w.c.) Manifold (in w.c.) All Sizes 4.5 14.0 3.5 LP Gas Inlet Min (in w.c.
CG-F Installation, Operating & Service Manual 8 Electrical ! WARNING Electrical Shock Hazard. Wiring errors can cause improper or dangerous operation. Verify proper operation after installation. A. Install wiring so boiler is electrically bonded to ground in accordance with requirements of authority having jurisdiction, or in absence of such requirements, with the National Electrical Code, ANSI/NFPA 70. B. Install thermostat. Locate on inside wall approximately 4 feet above floor.
CG-F Installation, Operating & Service Manual 8 Electrical (continued) Figure 8-1: Wiring Connection Diagram 110118-01 12/19 15
CG-F Installation, Operating & Service Manual 8 Electrical (continued) Figure 8-2: Schematic Ladder Diagram 16 110118-01 12/19
CG-F Installation, Operating & Service Manual 8 Electrical (continued) Figure 8-3: Wiring Schematic, Zone Valves Figure 8-4: Wiring Schematic, Zone Circulators 110118-01 12/19 17
CG-F Installation, Operating & Service Manual 9 System Start-up and Checkout A. Visual Main Burner Check Inspect burners for dislodgement during shipment. Rear of burners should be in vertical slots in rear of burner tray and front of burners should be seated completely on orifices. B. Initial LWCO Test Before filling boiler with water, turn on power to boiler and set thermostat to call for heat. Both the green "POWER" LED and amber "LOW WATER" LED should illuminate (see Figure 9-1).
CG-F Installation, Operating & Service Manual 9 System Start-up and Checkout (continued) Figure 9-2: Operating Instructions 110118-01 12/19 19
Installation, Operating & Service Manual CG-F 9 System Start-up and Checkout (continued) 3. Locate and address leaks using listed combustible gas detector,a non corrosive leak detection fluid or other listed leak detection method. E. Perform gas leak test upstream of boiler shutoff valve. 1. Protect boiler gas valve. a. For all testing over ½ psig, boiler and manual shutoff valve must be disconnected from gas supply piping. b.
CG-F Installation, Operating & Service Manual 9 System Start-up and Checkout (continued) J. Check Main Burner Flame (see Figure 9-6) 1. NORMAL FLAME: a. Clearly defined inner cone with no yellow tipping. b. Orange-yellow streaks caused by dust should not be confused with true yellow tipping. 2. ABNORMAL FLAME (if found, check inlet and outlet gas pressure. Procedure found in following steps): a. Over fired - large flame b. Under fired - small flames c.
CG-F Installation, Operating & Service Manual 9 System Start-up and Checkout (continued) P. Check ignition system safety shut-off device. After control has finished sparking, remove ignitor/ flame sense wire from control. Burners will shut down. Q. Test LWCO functionality Press "TEST" button on IDL 1200. See Figure 9-1. Boiler should shut down. • Set thermostat to call for heat and push “TEST” button on IDL 1200 to simulate low water condition.
CG-F Installation, Operating & Service Manual 10 Operation A. Boiler Sequence of Operation (See Table 10-1) 1. When thermostat calls for heat, control starts system circulator. 2. If thermostat is not satisfied with residual heat in boiler, or boiler water temperature is less than start temperature (140oF) setpoint, start sequence continues by energizing vent damper. Once vent damper is fully open, ignition sequence is started. Damper must be in open position when appliance main burners are operating. 3.
Installation, Operating & Service Manual CG-F 10 Operation (continued) D. Viewing the Operating Mode Options Table 10-3 In operating mode, user may view (but not change) boiler operating status, settings and troubleshooting information. For example, when “I” key is pressed on control until “bt” is displayed, it will then flash three digit number (such as “180”) followed by “F” (or “C”). This indicates boiler water temperature is 180°F.
CG-F 10 Operation F. (continued) More Information About Adjustable Parameters 1. High Limit (HL_) Burner turns "off" when boiler water temperature (bt) is above this value. Operating setpoint (SP) equals high limit setpoint. 2. Differential (df_) Differential is number of degrees boiler temperature must decrease below the operating setpoint before boiler can restart. 3.
CG-F 10 Operation (continued) 7. Domestic Hot Water (DHW) Terminal Function () DHW Circulator output can be connected to a domestic hot water circulator or a second heating zone circulator. These applications are selected as follows: a. Indirect Water Heater (IWH) (dh_is set to Domestic Hot Water Demand (dh)) IWH limit is wired to "DHW" terminal on control. DHW circulator is wired to "DHW Circulator" on control wire harness.
CG-F Installation, Operating & Service Manual 11 Before Leaving Jobsite Before Leaving Jobsite: Boiler and system filled with water Performed gas leak test Checked pilot burner flame Checked main burner flames Checked gas input rate Checked gas inlet pressure Checked gas manifold pressure Checked CO level in vent Checked vent damper operation Check ignition system safety shut-off device Tested LWCO functionality Tested high limit operation Tested addition
CG-F Installation, Operating & Service Manual 12 Service and Maintenance Important Product Safety Information: Refractory Ceramic Fiber Product WARNING Some boiler components use materials that contain refractory ceramic fibers (RCF). RCF has been classified as a possible human carcinogen. When exposed to elevated temperatures, RCF may change into crystalline silica, a known carcinogen.
CG-F Installation, Operating & Service Manual 12 Service and Maintenance (continued) ! WARNING Service on this boiler should be undertaken only by trained and skilled personnel from a qualified service agency. Inspections should be performed at intervals specified in this manual. Maintain manual in a legible condition. • Keep boiler area clear and free of combustible materials, gasoline and other flammable vapors and liquids.
CG-F Installation, Operating & Service Manual 12 Service and Maintenance (continued) D. Clean Main Burners and Firebox. 1. To remove burners for cleaning, changing orifices, or repairs: a. Remove Jacket Front Panel. b. Disconnect pilot tubing at gas valve. c. Disconnect 3-wire plug at the gas valve. d. Remove wires to flame roll-out switch. e. Disconnect ignitor sensor cable at boiler control. f. Remove burner access panel. g.
CG-F Installation, Operating & Service Manual 12 Service and Maintenance (continued) Q. Test Vent Damper Operation Vent damper must be in open position when main burners are operating. R. Test Functionality of LWCO See "Start-up and Checkout - Check LWCO Functionality. S. Check High Limit Control See " Start-up and Checkout - Check High Limit Control". T. Check Thermostat Operation See "Start-up and Checkout - Check Thermostat Operation" U. Check CO detector operation (if available). V. Lubrication.
CG-F Installation, Operating & Service Manual 13 How It Works CG-F boilers are equipped with an Intelligent Hydronic Control. This control combines features such as ignition control, high limit switch, and circulator relays. Energy is saved by using a thermal purge feature that starts the circulator and delays burner start when residual heat is available in boiler. When thermostat calls for heat, control module starts system circulator, checks safety limits, and activates vent damper.
CG-F Installation, Operating & Service Manual 13 How It Works (continued) 4 3 3 B Rear of Boiler 7 (On rear of boiler) 3 8 2 1 5 6 A 4 UNLESS OTHERWISE N ALL DIMENSIONS IN IN TOLERANCES: X.X ±.1 X.XXX ±.0 X.XX ±.03 ANGLE PROP U.S. Boiler C LANC THIS DOCUMENT CONTAIN AND ITS CONTENTS ARE TH COMPANY, INC. ANY REP WHOLE WITHOUT THE WRIT COMPANY, INC.
CG-F Installation, Operating & Service Manual 14 Troubleshooting A. Before Troubleshooting When using troubleshooting tables, keep in mind: 1. Troubleshooting should be completed by a professional heating technician. 2. Before seeking technical assistance, the servicing technician should have a electrical meter and gas pressure gauge available for use. 3. Check electrical connections on boiler before proceeding (see Figure 8-1 and Figure 8-2). a.
Installation, Operating & Service Manual CG-F 14 Troubleshooting (continued) C. Use Control Display (ERROR) Number To Direct TroubleShooting Efforts If control detects an error it will flash “” (ERROR) followed by a number. Use this number to identify boiler problem and corrective action in table below.
CG-F Installation, Operating & Service Manual 14 Troubleshooting (continued) D. Use STA (STATUS) Number To Guide Troubleshooting The control will flash “” followed by a number. Use this number to identify the boiler problem in table below: 1. Boiler and Circulator Off Display / Status Recommended Corrective Action Boiler has not detected a call for heat (tt = off and dh = off).
Installation, Operating & Service Manual CG-F 14 Troubleshooting (continued) 5. Circulator is On But Damper is Not Open Display / Status Recommended Corrective Action Control is waiting for damper to open. Damper end switch has failed to close (end switch contact is stuck open). Combustion can never take place unless damper blade is in the fully open position. Check following: - During status “STA18" or “STA 20”, control terminal “P6 - 5” (yellow wire) is energized.
CG-F Installation, Operating & Service Manual 14 Troubleshooting (continued) 6. Circulator is On, Damper is Open But Boiler Fails to Start (continued) Display / Status Recommended Corrective Action 1. No Spark a. Can you hear sparking while is displayed? - If there is no spark noise, replace the control. b.
CG-F Installation, Operating & Service Manual 15 Service Parts All CG-F Series Repair Parts may be obtained through New Yorker Boiler Company, Inc. or its authorized distributors. Should you require assistance in locating a New Yorker Distributor in your area, or have questions regarding the availability of New Yorker Boiler Company products or repair parts, please contact New Yorker Customer Service at New Yorker Boiler Company, Inc., P.O.
CG-F Installation, Operating & Service Manual 15 Service Parts (continued) Key No.
CG-F Installation, Operating & Service Manual 15 Service Parts (continued) Natural Gas Only Key No.
CG-F Installation, Operating & Service Manual 15 Service Parts (continued) Key No.
CG-F Installation, Operating & Service Manual 15 Service Parts (continued) Key No.
Installation, Operating & Service Manual CG-F 15 Service Parts (continued) Key No.
CG-F Installation, Operating & Service Manual 15 Service Parts (continued) 7A 7B Part Number [Quantity] Key No. Description 7A Power Supply Harness 109639-01 [1] 7B Main Control Harness 109640-01 [1] CG30F CG40F CG50F CG60F CG70F CG80F CG90F CG80F CG90F Accessories: Key No.
CG-F Appendix: Installation, Operating & Service Manual Combination Refrigeration/ Heating System A. If boiler is used in connection with refrigeration systems, boiler must be installed with chilled medium piped in parallel with the heating boiler using appropriate valves to prevent chilled medium from entering boiler. See Figure A-1. Also consult Residential Hydronic Heating Installation and Design I=B=R Guide. Supply main to combined heating & cooling system B.
CG-F Appendix: Installation, Operating & Service Manual Low Return Water Temperatures Thermal Shock: Cast iron boilers are very robust. 110oF and below return water temperatures will not cause thermal shock to New Yorker Boiler castings. Condensation is a different matter: Cast iron boilers will tolerate intermittent periods of condensation, but are not designed for extended condensation periods. Water temperatures below 120oF cause condensation that damage cast iron, burners and other components.
CG-F Appendix: Installation, Operating & Service Manual Low Return Water Temperatures (continued) Primary-Secondary Pumping: This is an improvement over simple by-pass piping to reduce condensation. Again this is a fixed system. It can not adapt to variations in temperature and flow. Best Alternative: System by-pass kit [part number 107795-01] that addresses these situations. A strap on temperature sensor measures boiler inlet temperatures.
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CG-F 50 Installation, Operating & Service Manual 110118-01 12/19
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CG-F 52 Installation, Operating & Service Manual 110118-01 12/19
