Installation, Operating and Service Instructions for CL Models: • CL3-105WE • CL3-140WE • CL4-168WE • CL4-210WE • CL5-245WE • CL5-266WE TM Residential Water • Water Boiler • Natural Draft • Oil-Fired • CL3-105WE-T • CL3-140WE-T • CL4-168WE-T • CL4-210WE-T • CL5-245WE-T • CL5-266WE-T Manual Contents Page 1. Dimensional Description, Specification & . Dimensional Data. . . . . . . . . . . . . . . . . . . . . 4 2. Pre-installation. . . . . . . . . . . . . . . . . . . . . . . 8 3.
CL Installation & Service Manual IMPORTANT INFORMATION - READ CAREFULLY All boilers must be installed in accordance with National, State and Local Plumbing, Heating and Electrical Codes and the regulations of the serving utilities. These Codes and Regulations may differ from this instruction manual. Authorities having jurisdiction should be consulted before installations are made. In all cases, reference should be made to the following Standards: A. B. C. D.
CL Installation & Service Manual ! DANGER DO NOT store or use gasoline or other flammable vapors or liquids in the vicinity of this or any other appliance. ! WARNING Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury or loss of life. Failure to follow all instructions in the proper order can cause personal injury or death.
CL ! Installation & Service Manual WARNING This boiler contains very hot water under high pressure. Do not unscrew any pipe fittings nor attempt to disconnect any components of this boiler without positively assuring the water is cool and has no pressure. Always wear protective clothing and equipment when installing, starting up or servicing this boiler to prevent scald injuries. Do not rely on the pressure and temperature gauges to determine the temperature and pressure of the boiler.
CL Installation & Service Manual 1 Product Description, Specification and Dimensional Data (continued) Table 1A: Dimensional Data Dimensions Boiler Series "A" "B" "C" Recommended Minimum Chimney Approx. Water Content Gallons Round in Dia. CL3 17-3/8" 8-1/4" 5-7/8" 16 6 CL4 22-3/8" 10-7/8" 6-7/8" 20 7 CL5 27-3/8" 13-3/8" 7-7/8" 24 8 Rectangle in. x in. Height ft.
CL Installation & Service Manual Figure 1-1: Water Boiler without Tankless Heater 'C' DIA.
CL Installation & Service Manual Figure 1-2: Water Boiler with Rear Tankless Heater 1 Product Description, Specification and Dimensional Data (continued) 110503-01 - 4/20 7
CL Installation & Service Manual 2 Pre-Installation A. INSPECT SHIPMENT carefully for any signs of damage. 1. All equipment is carefully manufactured, inspected and packed. Our responsibility ceases upon delivery of crated boiler to the carrier in good condition. 2. Any claims for damage or shortage in shipment must be filed immediately against the carrier by the consignee.
CL Installation & Service Manual 2 Pre-Installation (continued) NOTICE Clearance to venting is for single wall vent pipe. If Type L vent is used, clearance may be reduced to the minimum required by the vent pipe manufacturer. ! WARNING Adequate combustion and ventilation air must be provided to assure proper combustion and to maintain safe ambient air temperatures. DO NOT install boiler where gasoline or other flammable vapors or liquids, or sources of hydrocarbons (i.e. bleaches, fabric softeners, etc.
CL Installation & Service Manual 3 Packaged Boiler Assembly A. REMOVE CRATE. 1. Remove all fasteners at crate skid. 2. Lift outside container and remove all other inside protective spacers and bracing. Remove draft regulator box and miscellaneous trim bag containing safety or relief valve, and pipe fittings. B. REMOVE BOILER FROM SKID. 1. Boiler is secured to base with 4 bolts, 2 in front and 2 in rear of shipping skid, see Figure 3-1. Remove all bolts. 2. Tilt boiler to right and to rear.
CL Installation & Service Manual 4 Water Boiler Piping and Trim NOTICE Failure to pipe boiler as specified in this manual may result in excessive system noise, water line fluctuations and water carry over. A. EVALUATE THE EXISTING WATER SYSTEM. Design a piping system and install boiler which will prevent oxygen contamination of boiler water and frequent water additions. 1. There are many possible causes of oxygen contamination such as: a. Addition of excessive make-up water as a result of system leaks. b.
CL Installation & Service Manual 4 Water Boiler Piping and Trim (continued) To perform a long term pressure test including the boiler, ALL trapped air must first be removed from the boiler. A loss of pressure during such a test, with no visible water leakage, is an indication that the boiler contained trapped air.
Figure 4-2: Recommended Water Piping for Circulator Zoned Heating System - Supply Side Circulators CL 110503-01 - 4/20 Installation & Service Manual 4 Water Boiler Piping and Trim (continued) 13
Figure 4-3: Recommended Water Piping for Zone Valve Zoned Heating System ‑ Supply Side Circulator CL 14 Installation & Service Manual 4 Water Boiler Piping and Trim (continued) 110503-01 - 4/20
CL Installation & Service Manual 5 Tankless and Indirect Water Heater Piping A. CONNECT TANKLESS HEATER PIPING as shown in Figure 5-1. See Table 5-2 for Tankless Heater Rating. ! WARNING Install automatic mixing valve at tankless heater outlet to avoid risk of burns or scalding due to excessively hot water at fixtures. Adjust and maintain the mixing valve in accordance with the manufacturer's instructions. DO NOT operate tankless heater without mixing valve.
CL Installation & Service Manual 5 Tankless and Indirect Water Heater Piping (continued) Figure 5-1: Schematic Tankless Heater Piping Table 5-2: Tankless Heater Data Boiler Model Rating (Gal/Min) Pressure Drop (PSI) CL3-105WE-T CL3-140WE-T CL4-168WE-T CL4-210WE-T CL5-245WE-T CL5-266WE-T 3.00 3.25 3.75 4.00 4.25 4.75 4.7 5.6 7.2 8.0 8.8 9.
CL Installation & Service Manual 6 Venting ! WARNING Vent this boiler according to these instructions. Failure to do so may cause products of combustion to enter the home resulting in severe property damage, personal injury or death. • Insufficient Combustion Air Supply may result in the production and release of deadly carbon monoxide (CO) into the home which can cause severe personal injury or death.
CL Installation & Service Manual 6 Venting (continued) Figure 6-1: Recommended Vent Pipe Arrangement and Chimney Requirements Figure 6-2: Proper and Improper Locations of Draft Regulator 18 110503-01 - 4/20
CL Installation & Service Manual 6 Venting (continued) d. Clean Chimney – Chimney shall be free of all loose debris. 5. Draft Regulator – the draft regulator supplied with the boiler (or equivalent) must be used with this appliance. Refer to Figures 6-1 and 6-2. CHIMNEY CONNECTOR 1. A chimney connector (vent pipe) is used to connect the boiler to the base of the chimney. The chimney connector should be kept as short as possible.
CL Installation & Service Manual 7 Electrical ! DANGER Positively assure all electrical connections are unpowered before attempting installation or service of electrical components or connections of the boiler or building. Lock out all electrical boxes with padlock once power is turned off. ! WARNING Failure to properly wire electrical connections to the boiler may result in serious physical harm. • Electrical power may be from more than one source.
Figure 7-1: Schematic Wiring Diagram, Water Boiler, Hydrolevel Hydrostat (All Burners) CL 110503-01 - 4/20 Installation & Service Manual 7 Electrical (continued) 21
CL Installation & Service Manual 7 Electrical (continued) Figure 7-2: Schematic Wiring Diagrams For All Burner Options with Various Oil Primary Controls 22 110503-01 - 4/20
CL Installation & Service Manual 8 Oil Piping A. GENERAL ! WARNING 1. Use flexible oil line(s) so the burner swing door can be opened without disconnecting the oil supply piping. 2. A supply line fuel oil filter is recommended as a minimum for all firing rates but a pleated paper fuel oil filter is recommended for the firing rates below 1.0 GPH to prevent nozzle fouling. 3. Use Flared fittings only. Cast iron fittings cannot be used. NOTICE DO NOT use compression fittings.
CL Installation & Service Manual 8 Oil Piping (continued) C. TWO PIPE OIL LINES 1. For two piped systems, where more lift is required, the two-stage fuel unit is recommended. Table 8-2 (two-stage) and Table 8-3 (singlestage) show allowable lift and lengths of 3/8 inch and 1/2 inch OD tubing for both suction and return lines. Refer to Figure 8-4. Table 8-2: Two-Stage Units (3450 RPM) Two Pipe Systems Lift "H" (See Fig.
CL Installation & Service Manual 9 System Start-Up ! WARNING All boilers equipped with burner swing door have a potential hazard which can cause severe property damage, personal injury or loss of life if ignored. Before opening swing door, turn off service switch to boiler to prevent accidental firing of burner outside the combustion chamber. Be sure to tighten swing door fastener completely when service is completed. A. ALWAYS INSPECT INSTALLATION BEFORE STARTING BURNER. 1.
CL Installation & Service Manual 9 System Start-Up (continued) 3. CHECKOUT Put the system into operation and observe at least one complete cycle to make sure that the controller operates properly. See Troubleshooting Section to use LED to assist in determining system operation. E. ADJUST OIL BURNER BEFORE STARTING. 1. CHECK BURNER SETTINGS and readjust if necessary, see Burner Specifications, Tables 15-1 and 15-2 at the rear of this manual. F. START OIL BURNER. 1. Open vent fitting on fuel pump. 2.
CL Installation & Service Manual 9 System Start-Up (continued) 2. IF NOZZLE CONTINUES TO DRIP, repeat Paragraph H, No. 1 above. If this does not stop the dripping, remove cut-off valve and seat, and wipe both with a clean cloth until clean, then replace and readjust oil pressure. If dripping or after burn persist replace fuel pump. I. TEST CONTROLS. 1. Check thermostat operation. Raise and lower thermostat setting as required to start and stop burner.
CL Installation & Service Manual 10 Operating A. HydroStat 3250 PLUS SEQUENCE OF OPERATION IMPORTANT This boiler is equipped with a feature that saves energy by reducing the boiler water temperature as the heating load decreases. This feature is equipped with an override which is provided primarily to prevent the use of an external energy management system that serves the same function.
CL Installation & Service Manual 10 Operating (continued) 3. Degrees Fahrenheit or Celsius: The control has the ability to operate in degrees Fahrenheit or Celsius. When operating in Celsius, a c will appear in the display next to the temperature when ever the temperature is below 100 degrees. To change between degrees Fahrenheit and degrees Celsius • Turn the LO TEMP dial to access the Program Mode - indicated in the display as Pro. • Turn the HI TEMP dial to select feature 2.
CL Installation & Service Manual 10 Operating (continued) To change the well type • Turn the LO TEMP dial to access the Program Mode - indicated in the display as Pro. • Turn the HI TEMP dial to select feature 8. • Push the Test/Setting Button to select A for Electro-Well or b for Standard Well. NOTE: To ensure that the low water cut-off is always active when the control is installed on an ElectroWell, setting b will ONLY be available when installed on a standard well.
CL Installation & Service Manual 10 Operating (continued) Dial Setting Feature Options Description Default Setting 1 Thermal Pre-Pruge OFF ON Purge Inactive Purge Active OFF 2 Fahrenheit or Celsius F C Degrees Fahrenheit Degree Celcius F 3 LWCO Manual or Automatic Reset A b Automatic Reset Manual Reset A 4 Circulator Options A b c Circulator operation on TT call only Circulator operation on ZC/ZR call only Circulator operation on call from either A 5 Circulator Hold Off ON OFF
CL Installation & Service Manual 10 Operating (continued) ! WARNING Allow the boiler to fully cool before adding water. e. ECONOMY ACTIVE Indicates that the Thermal Targeting function is active and the Fuel Smart HydroStat will reduce boiler temperature to conserve fuel. The Economy feature is activated using the ECONOMY dial. (See “How Thermal Targeting Works” for more information). f.
CL Installation & Service Manual 10 Operating (continued) Important Product Safety Information: Refractory Ceramic Fiber Product WARNING Some boiler components contain refractory ceramic fibers (RCF). RCF has been classified as a possible human carcinogen. When exposed to temperatures above 1805°F, such as during direct flame contact, RCF changes into crystalline silica, a known carcinogen.
CL Installation & Service Manual 11 Maintenance and Service Instructions A. MAINTENANCE OF LOW WATER CUT-OFF DEVICES ! WARNING Probe and float type low water cut-off devices require annual inspection and maintenance. 1. PROBE TYPE LOW WATER CUT-OFF Although these devices are solid state in their operation, the probe is exposed to possible contamination in the boiler water and subject to fouling.
CL Installation & Service Manual 11 Maintenance and Service Instructions (continued) x. Stop firing the boiler. xi. Drain the system in a manner and to a location that hot water can be discharged with safety. xii. Remove plugs from all available returns and wash the water side of the boiler as thoroughly as possible, using a highpressure water stream. xiii. Refill the system with fresh water. c. Add appropriate boiler water treatment compounds as recommended by your qualified water treatment company. d.
CL Installation & Service Manual 12 Boiler Cleaning ! WARNING All boiler cleaning must be completed with burner service switch turned off. Boilers equipped with burner swing door have a potential hazard which can cause severe property damage, personal injury or loss of life if ignored. Before opening swing door, turn off service switch to boiler to prevent accidental firing of burner outside the combustion chamber. Be sure to tighten swing door fastener completely when service is completed. A.
CL Installation & Service Manual 12 Boiler Cleaning (continued) Figure 12-1: Cleaning of Boiler Flueways ! WARNING The boiler must be connected to an approved chimney in good condition. Serious property damage could result if the boiler is connected to a dirty or inadequate chimney. The interior of the chimney flue must be inspected and cleaned before the start of the heating season and should be inspected periodically throughout the heating season for any obstructions.
CL Installation & Service Manual 13 Troubleshooting A. COMBUSTION 1. NOZZLES — Although the nozzle is a relatively inexpensive device, its function is critical to the successful operation of the oil burner. The selection of the nozzle supplied with the CL boiler is the result of extensive testing to obtain the best flame shape and efficient combustion. Other brands of the same spray angle and spray pattern may be used but may not perform at the expected level of CO2 and smoke.
CL Installation & Service Manual 13 Troubleshooting (continued) NOTICE CHECK TEST PROCEDURE. A very good test for isolating fuel side problems is to disconnect the fuel system and with a 24" length of tubing, fire out of an auxiliary five gallon pail of clean, fresh, warm #2 oil from another source. If the burner runs successfully when drawing out of the auxiliary pail then the problem is isolated to the fuel or fuel lines being used on the jobsite. B. OIL PRIMARY CONTROL (Oil Primary) 1.
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CL Installation & Service Manual 14 Service Parts All CL™ Series repair parts may be ordered 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 products or service parts, please contact: New Yorker Boiler Company, Inc., P.O. Box 3005, Lancaster, PA 17604-3005, Attn: Customer Service Department. Visit our website at www.newyorkerboiler.
CL Installation & Service Manual Bare Boiler Assembly 14 Service Parts (continued) 42 110503-01 - 4/20
CL Installation & Service Manual 14 Service Parts (continued) Item No.
CL Installation & Service Manual Water Boilers - Trim and Controls 14 Service Parts (continued) 44 110503-01 - 4/20
CL Installation & Service Manual 14 Service Parts (continued) Item No.
CL Installation & Service Manual 14 Service Parts (continued) Item No.
CL Installation & Service Manual 15 Burner Specifications Table 15-1: Beckett Boiler Model CL3-105WE CL3-140WE CL4-168WE CL4-210WE CL5-245WE CL5-266WE Settings Firing Burner Rate Head Air Model GPH (Setting) Shutter 0.75 10 L1 1.00 5 1.20 10 AFG V1(0) 1.50 10 1.75 V1(3) 6 1.90 V1(4) 8 Air Band 2 2 0.5 6 6 4 Nozzle Shipped 0.65 X 60B (Hago) 0.85 x 60B (Hago) 1.00 x 60B (Hago) 1.25 x 60B (Hago) 1.50 x 45B (Hago) 1.
CL Installation & Service Manual Appendix - Aftermarket Low Water Cut Off (LWCO) ! WARNING DO NOT ATTEMPT to cut factory wires to install an aftermarket Low Water Cut Off (LWCO). Only use connections specifically identified for Low Water Cut Off. In all cases, follow the Low Water Cut Off (LWCO) manufacturer's instructions. When A low water cutoff is required to protect a hot water boiler when any connected heat distributor (radiation) is installed below the top of the hot water boiler (i.e.
CL Installation & Service Manual Appendix - Aftermarket Low Water Cut Off (LWCO) How to Test A 24 VAC LWCO is used primarily for gas fired boilers where a 24 volt control circuit exists within the boiler. However, a 24 VAC LWCO can only be used if the boiler manufacturer has provided piping and wiring connections and instructions to allow for this application. 110503-01 - 4/20 Shut off fuel supply. Lower water level until water level is BELOW the LWCO. Generate a boiler demand by turning up thermostat.
CL Installation & Service Manual SERVICE RECORD DATE 50 SERVICE PERFORMED 110503-01 - 4/20
CL Installation & Service Manual SERVICE RECORD DATE 110503-01 - 4/20 SERVICE PERFORMED 51
CL Installation & Service Manual New Yorker Boiler Company, Inc. P.O. Box 3005 Lancaster, Pennsylvania 17603-3005 Attn: Customer Service Department www.newyorkerboiler.
