INSTALLATION, OPERATING AND SERVICE INSTRUCTIONS CGS-A™ Series GAS BOILER 9700609 BEFORE INSTALLATION: READ THIS MANUAL SAVE THESE INSTRUCTIONS Installing contractor and homeowner should read and be informed as to the proper installation and operation of this boiler. The manufacturer will not be responsible for improper installation or operation. This manual and all associated instruction material should be conspicuously posted near the boiler.
The New York City Department of Buildings has approved the Classic CGS-A™ Series boiler: Approval No. MEA 165-94-E. 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 Classic CGS-A™ Series boiler. See the Massachusetts Board of Plumbers and Gas Fitters website, http://license.reg.state.ma.us/pubLic/pl_products/pb_pre_form.
Table of Contents I. Pre-Installation................................ 3 VI. Electrical........................................ 13 II. Unpack Boiler................................. 5 VII. System Start-up............................. 16 III. Steam Piping and Trim.................... 5 VIII. Service .......................................... 21 IV. Gas Piping....................................... 8 IX. Repair Parts................................... 27 V. Venting......................................
I. Pre-Installation (continued) Recommended service clearance is 24 inches from left side, right side and front. Service clearances may be reduced to minimum clearances to combustible materials. E. Install on level floor. For basement installation provide concrete base if floor is not level or if water may be encountered on floor around boiler. F. Protect gas ignition system components from water (dripping, spraying, rain, etc.
II. Unpack Boiler CAUTION 1. Place base on floor with insulated surface facing upward and part number facing forward. Do not drop boiler. Do not bump boiler jacket against floor. 2. Position base to provide minimum clearances to combustible walls. See Figure 3. Secure in place. 3. Place boiler on base. Center boiler on base to provide minimum clearances to combustible walls and ceiling. See Figure 2. A. Move boiler to approximate installed position. B. Remove crate. 1.
III. Steam Piping and Trim (continued) WARNING Safety valve discharge piping must be piped near floor to eliminate potential of severe burns. Do not pipe in any area where freezing could occur. Do not install any shut-off valves. E. Install Drain Valve in Tapping 'F'. See Figure 4.
III.
IV. Gas Piping A. Size gas piping. Design system to provide adequate gas For materials or conditions other than those listed above, refer to National Fuel Gas Code, NFPA 54/ANSI Z223.1, or size system using standard engineering methods acceptable to authority having jurisdiction. supply to boiler. Consider these factors: 1. Allowable pressure drop from point of delivery to boiler. Maximum allowable system pressure is ½ psig.
IV. Gas Piping (continued) Table 6: Fitting Equivalent Lengths Fitting Table 7: Specific Gravity Correction Factors for Natural Gas Nominal Pipe Size ½ ¾ 1 1¼ 45° Ell 0.7 1.0 1.2 1.6 90° Ell 1.6 2.1 2.6 3.5 Tee (As Elbow) 3.1 4.1 5.2 6.9 4. All above ground gas piping upstream from manual shut-off valve must be electrically continuous and bonded to a grounding electrode. Do not use gas piping as grounding electrode. Refer to National Electrical Code, ANSI/NFPA 70. C. Pressure test.
V. Venting A. Install vent system in accordance with local building codes; or local authority having jurisdiction; or National Fuel Gas Code, ANSI Z223.1/NFPA 54, Part 7, Venting of Equipment. Install any of the following for this Classic CGS-A Series Category I, draft hood equipped appliance: 1. Type B or Type L gas vent. Install in accordance with listing and manufacturer's instructions. 2. Masonry or metal chimney.
V. Venting (continued) WARNING Failure to properly install and use this Blocked Vent Switch may result in property damage, personal injury or loss of life. E. Install Vent Damper. See Figure 9. 1. Open Vent Damper Carton and remove Installation Instructions. Read Installation Instructions thoroughly before proceeding. NOTICE Please refer to the specifications, installation instructions and troubleshooting guide packed in the vent damper carton for complete detailed installation instructions. 2.
V. Venting (continued) F. Install Vent Connector from vent damper to chimney or gas vent. See Figure 10. 1. Do not connect into same leg of chimney serving an open fireplace. 2. Vent connector must not be smaller than vent damper outlet. Type B is recommended, but singlewall vent pipe may be used. Arrange venting system so only the boiler is served by vent damper device. 3.
VI. Electrical A. General. Install wiring and ground boiler in accordance with requirements of authority having jurisdiction, or in absence of such requirements the National Electrical Code, ANSI/NFPA 70. B. Connect Vent Damper. See Figure 9. Table 8: Wiring Diagrams Intermittent (EI) 24V Probe X 15 Float X 17 1. Carefully remove Transformer from Junction Box. 2. Remove 7/8" knockout from top of Junction Box. 3. Attach Vent Damper wiring harness into top of Junction Box.
VI. Electrical (continued) I. 14 Figure 12: Wiring Diagram, Intermittent Ignition (EI) and Hydrolevel Model 400 or McDonnell & Miller PS-802-24 Low Water Cutoff do not attempt to place boiler in operation. The Sequence of Operation with Intermittent Ignition source of blockage must be corrected by trained and (EI). skilled personnel from a qualified service agency 1. Normal Operation before resetting switch. d. Flame Roll-out Switch. Automatically interrupts a. Thermostat calls for heat.
VI. Electrical (continued) Figure 13: Wiring Diagram, Intermittent Ignition (EI) and McDonnell & Miller 67 Low Water Cutoff K. Sequence of Operation with Intermittent Ignition (EI). 1. Normal Operation a. Thermostat calls for heat. Vent Damper opens. b. Ignition Module energized. Pilot Valve opens. Igniter energized to ignite Pilot Burner. c. Sensor proves presence of pilot flame. Main Valve opens and ignites Main Burners. d. Call for heat ends. Ignition Module is de-energized.
VII. System Start-up A. Safe operation and other performance criteria were met with gas manifold and control assembly provided on boiler when boiler underwent tests specified in American National Standard for Gas-Fired LowPressure Steam and Hot Water Boilers, ANSI Z21.13. B. Check main burners. Rear of burner must be in vertical slot in rear of burner tray. Front of burner must be seated on orifice. C. Fill boiler with water to normal water line. D. Prepare to check operation. 1.
VII. System Start-up (continued) CAUTION NOTICE Avoid operating this boiler in an environment where saw dust, loose insulation fibers, dry wall dust, etc. are present. If boiler is operated under these conditions, the burner interior and ports must be cleaned and inspected daily to insure proper operation.
VII. System Start-up (continued) Figure 16: Operating Instructions i. Remove Main Burners per procedure in Section VIII. Service. ii. Remove gas orifices. Drill one (1) drill size larger (drill size is stamped on orifice, or see Section IX. Repair Parts). iii. Reinstall gas orifices and main burners. Measure input rate. 6. Recheck Main Burner Flame. 7. Follow instructions to TURN OFF GAS TO APPLIANCE. See Figure 16 for intermittent ignition (EI). Remove manometer. 8.
VII. System Start-up (continued) 4. Follow instructions to TURN OFF GAS TO APPLIANCE. See Figure 16 for intermittent ignition (EI). Remove manometer. 5. Follow Lighting or Operating Instructions to place boiler in operation. See Figure 16 for intermittent ignition (EI). Adjust thermostat to normal setting. Q. Clean Heating System.
VII. System Start-up (continued) 11. Drain boiler. Open all radiator valves. Reinstall all supply main air valves. Open shut off valve in Hartford Loop. 12. When boiler has cooled down sufficiently (iron sections are not too hot to touch), close the drain valves at boiler and in return main and feed water slowly up to normal level in boiler. 13. Follow Lighting or Operating Instructions to place boiler in operation. See Figure 16 for intermittent ignition (EI). 14.
VIII. Service 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. Do not place any obstructions in boiler room that will hinder flow of combustion and ventilation air. A. General.
VIII. Service (continued) Table 10: Ignition Module Terminal CrossReference 5. For reliable operation the flame current should be 2 μAmp or greater. Ignition Module Terminal Designation Wiring Ladder Diagram Terminal Number MV 1 MV/PV 2 PV 3 GND 4 24V (GND) 5 24V 6 SPARK 9 6. To ensure adequate flame current: a. Turn off boiler power at circuit breaker or fuse box. b. Clean the flame rod with emery cloth if required c.
VIII. Service (continued) e. Check the pilot flame. It must be blue, steady and envelop the flame sensing rod 3/8” to ½”. f. If needed, adjust pilot flame by turning the gas valve pilot adjustment screw clockwise to decrease or counterclockwise to increase pilot flame. Always reinstall pilot adjustment screw cover and tighten securely upon completion to assure proper gas valve operation. 7. Reconnect MV lead wire to the module upon satisfactory completion of pilot flame current measurement. 8.
VIII. Service (continued) Figure 18: Jacket Front Panel and Vestibule Panel Removal 7. Install canopy a. Verify that sealing surfaces between canopy and heat exchanger are clean. b. Secure canopy to heat exchanger with carriage bolts, nuts, and washers. c. Seal gap between canopy and heat exchanger with high temperature boiler cement or Dow Corning Silastic 732 RTV, Dow Corning Silastic 736 RTV, Polybac #500 RTV, or Sil-bond RTV 4500 (Acetoxy). Do not use other adhesives or sealants. 8.
VIII. Service (continued) Table 12: Pilot Burner Location Boiler Model I. Check operation. Follow steps D through P from Main Burner with Pilot Burner Located Pilot Bracket * Between Main Burners * CGS-30 2 2&3 CGS-40 2 2&3 CGS-50 4 4&5 CGS-60 6 6&7 CGS-70 7 7&8 CGS-80 9 9 & 10 Section VII: System Start-up. J. Lubrication. There are no parts requiring lubrication by service technician or owner. * Main burners numbered left to right as viewed from front of boiler.
VIII. Service (continued) "CALL FOR HEAT." POWER TO MODULE? (24 V NOMINAL) NO CHECK LINE VOLTAGE POWER, LOW VOLTAGE TRANSFORMER, LIMIT CONTROLLER, THERMOSTAT (CONTROLLER), AND WIRING. ALSO, CHECK AIR PROVING SWITCH ON COMBUSTION AIR BLOWER SYSTEM (IF USED) AND THAT THE VENT DAMPER END SWITCH (IF USED) IS MADE. YES 30 SECOND PREPURGE DELAY?(S8670 ONLY) NO REPLACE S8670 YES PULL IGNITION LEAD AND CHECK SPARK AT MODULE.
IX. Repair Parts All CGS-A™ Series repair parts may be obtained through your local New Yorker Boiler Co., Inc. authorized distributor. Should you require assistance in locating a New Yorker distributor in your area, or have questions regarding the availability of New Yorker products or repair parts, please contact New Yorker's main office: New Yorker Boiler Co., Inc. P.O. Box 10 Hatfield, PA 19440-0010 Phone: (215) 855-8055 Attn: Customer Service Department Description Part No.
IX. Repair Parts (continued) Description Part No. Quantity 30 40 50 60 70 80 Main Burner Orifice, #45 (Pink) (Natural Gas) 822711 --- 5 7 --- --- --- Main Burner Orifice, #48 (Natural Gas) 822726 4 --- --- 10 12 --- Main Burner Orifice, #49 (Yellow) (Natural Gas) 822709 --- --- --- --- --- 15 Main Burner Orifice, 1.
IX. Repair Parts (continued) Description Part No.
Important Product Safety Information Refractory Ceramic Fiber Product Warning: The Repair Parts list designates parts that contain refractory ceramic fibers (RCF). RCF has been classified as a possible human carcinogen. When exposed to temperatures about 1805°F, such as during direct flame contact, RCF changes into crystalline silica, a known carcinogen. When disturbed as a result of servicing or repair, these substances become airborne and, if inhaled, may be hazardous to your health.
SERVICE RECORD DATE SERVICE PERFORMED 31
NEW YORKER BOILER CO., INC. Limited Warranties For Residential Cast Iron Steam Boilers By this Warranty Statement New Yorker Boiler Co., Inc. (“New Yorker”) issues limited warranties subject to the terms and conditions stated below.
