INSTALLATION, OPERATING AND SERVICE INSTRUCTIONS PVCG™ SERIES GAS BOILER 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.
IMPORTANT INFORMATION - READ CAREFULLY NOTE: The equipment shall be installed in accordance with those installation regulations enforced in the area where the installation is to be made. These regulations shall be carefully followed in all cases. Authorities having jurisdiction shall be consulted before installations are made. All wiring on boilers installed in the USA shall be made in accordance with the National Electrical Code and/or local regulations.
WARNING This boiler requires regular maintenance and service to operate safely. Follow the instructions contained in this manual. Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury or loss of life. Read and understand the entire manual before attempting installation, start-up operation, or service. Installation and service must be performed only by an experienced, skilled, and knowledgeable installer or service agency.
Table of Contents I. Pre-Installation................................... 5 VI. Electrical.......................................... 20 II. Unpack Boiler.................................... 7 VII. System Start-up................................ 22 III. Venting.............................................. 8 VIII. Service.............................................. 29 IV. Water Piping and Trim..................... 14 IX. Repair Parts...................................... 36 V. Gas Piping............
I. Pre-Installation WARNING NOTICE Carefully read all instructions before installing boiler. Failure to follow all instructions in proper order can cause personal injury or death. Due to the low water content of the boiler, missizing of the boiler with regard to the heating system load will result in excessive boiler cycling and accelerated component failure. Manufacturer DOES NOT warrant failures caused by mis-sized boiler applications. DO NOT oversize the boiler to the system.
immediately against carrier by consignee. No claims for variances or shortages will be allowed by Boiler Manufacturer, unless presented within sixty (60) days after receipt of equipment. B. Installation must conform to the requirements of the authority having jurisdiction. In the absence of such requirements, installation must conform to National Fuel Gas Code, NFPA 54/ANSI Z223.1.
Alternate method for boiler located within confined space. Use indoor air if two permanent openings communicate directly with additional space(s) of sufficient volume such that combined volume of all spaces meet criteria for unconfined space. Size each opening for minimum free area of 1 square inch per 1,000 Btu per hour input of all equipment in spaces, but not less than 100 square inches. of insects and rodents.
III. Venting WARNING Do not use this boiler with galvanized, Type 304 or Type 316 stainless steel, non metallic or any other non AL29-4C® based vent systems. Do not use a barometric damper or drafthood with this boiler. Do not use vent dampers with this boiler. Moisture and ice may form on surfaces around termination. To prevent deterioration, surfaces should be in good repair (sealed, painted, etc.).
Table 2: Vent System Components Vent System Component Current Gasket-less Vent Part Number New Gasketed Vent Part Number 3” Dia. Pipe x 1 Ft 61160112 8116296U 3” Dia. Pipe x 3 Ft 61160101 8116298U 3” Dia. Pipe x 5 Ft 61160111 8116300U 3” Dia. Pipe x Adjustable N/A 8116319U 3” Dia. 90° Elbow 61160121 8116294U 3” Dia. 45° Elbow 61160131 8116292U 3” Dia. Horizontal Drain Tee 6116037 8116302U 3” Dia. Vertical Drain Tee 6116036 8116304U A. General Guidelines. 1.
6. After it has been determined that each appliance remaining connected to the common venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers and any other gas burning appliance to their previous conditions of use. 7. Any improper operation of the common venting system should be corrected so the installation conforms with the National Fuel Gas Code, NFPA 54/ANSI Z223.1.
bond RTV 4500 (Acetoxy) and Sil-bond RTV 6500. Do not use other adhesives or sealants. E. Install Vent Pipe, Gasket-Less Vent System. 1. Procedure for Joining Gasket-Less Vent Pipe and Fittings. See Figure 4A. Figure 4B: Gasketed Vent Joint Detail c. Tighten locking band by HAND with a 5/16" nut driver until snug plus ¼ turn. DO NOT SECURE JOINTS WITH SHEET METAL SCREWS OR POP RIVETS. DO NOT PUNCTURE THE VENT SYSTEM! d.
f. Once the installation is complete, operate appliance and inspect all joints to ensure that flue gases and/or liquid condensate will not escape. 2. Procedure for joining the female end of GasketLess Vent with the male end of Gasketed Vent. See Figure 4D. H. Horizontal (Through Wall) Vent Installation. 1. Maintain minimum ¼ inch per foot slope in horizontal runs. Slope pipe down toward vent terminal.
Figure 5: Recommendations for Thimble and Wall Penetration
IV. Water Piping and Trim WARNING Failure to properly pipe boiler may result in improper operation and damage to boiler or structure. Oxygen contamination of boiler water will cause corrosion of iron and steel boiler components, and can lead to boiler failure. Manufacturer’s Standard Warranty does not cover problems caused by oxygen contamination of boiler water or scale (lime) build-up caused by frequent addition of water. A.
Figure 7: Recommended Water Piping for Circulator Zoned Heating Systems
Figure 8: Recommended Water Piping for Zone Valve Zoned Heating Systems
H. If boiler is connected to heating coils located in air handling units where they may be exposed to refrigerated air, boiler piping must be equipped with flow control valves to prevent gravity circulation of boiler water during operation of cooling system. I. Use a boiler bypass if the boiler is to be operated in a system which has a large volume or excessive radiation where low boiler water temperatures may be encountered (i.e. converted gravity circulation system, etc.).
V. Gas Piping B. Connect boiler gas valve to gas supply system. WARNING Failure to properly pipe gas supply to boiler may result in improper operation and damage to the boiler or structure. Always assure gas piping is absolutely leak free and of the proper size and type for the connected load. An additional gas pressure regulator may be needed. Consult gas supplier. A. Size gas piping. Design system to provide adequate gas supply to boiler. Consider these factors: 1.
C. Pressure test. The boiler and its gas connection must 2. Locate leaks using approved combustible gas detector, soap and water, or similar nonflammable solution. be leak tested before placing boiler in operation. 1. Protect boiler gas control valve. For all testing over ½ psig, boiler and its individual shutoff valve must be disconnected from gas supply piping. For testing at ½ psig or less, isolate boiler from gas supply piping by closing boiler's individual manual shutoff valve.
NOTICE PVCG boilers built for installation at altitudes greater than 2,000 feet above sea level have been specially orificed to reduce gas input rate. See rating label for gas orifice size. High altitude boiler models are identifiable by the second digit in the model number suffix on the rating label: PVCG_O_1-_2_: Less than 2000 ft. elevation PVCG_O_1-_5_: 2000 to 5000 ft. elevation VI.
Figure 11: Wiring Diagram
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. Verify that the venting, water piping, gas piping and electrical system are installed properly. Refer to installation instructions contained in this manual. C.
Figure 13: Operating Instructions 23
H. Operating Instructions 1. See Figure 13 to place boiler in operation. 2. Electronic Ignition Modules with LED indicators. Table 7 cross-references the ignition module terminal designations to the ignition terminal numbers in the wiring ladder diagrams. The yellow LED indicates the status of the flame, see Table 8. The green LED indicates the status of the system, see Table 9. See Figure 14 for LED locations. See Figure 15 for Troubleshooting Guide.
Table 9: Green LED Status Codes Green LED Flash Code (X + Y)a Next System Action Recommended Service Action No “Call for Heat” N/A None Flash Fast Startup - Flame sense calibration N/A None Heartbeat Normal operation N/A None OFF 5 minute Retry DelayPilot flame not detected during trial for ignition Initiate new trial for ignition after retry delay completed.
Honeywell Electronic Ignition Troubleshooting Guide 26 Figure 15: Troubleshooting Guide
I. Sequence of Operation. See Figure 16. If boiler fails to operate properly, see Troubleshooting Guides in Service Section. J. Check pilot burner flame. See Figure 17. Flame should be steady, medium hard blue enveloping 3/8 to 1/2 inch of sensing probe. Figure 17: Pilot Burner Flame K. Check main burner flame. See Figure 18. Flame should have clearly defined inner cone with no yellow tipping. Orange-yellow streaks should not be confused with true yellow tipping. Figure 18: Main Burner Flame L.
3. Main burners and pilot burner will extinguish and blower stop when water level drops below low water cut-off probe. Verify limit, thermostat or other controls have not shut off boiler. b. Increase input rate if less than 98% of rating plate input. Increase manifold gas pressure no more than 0.3 inch w.c. If measured input rate is still less than 98% of rated input: i. 4. Adjust thermostat to lowest setting. Refill boiler. Remove Main Burners per procedure in Service Section. ii. Remove gas orifices.
VIII. Service DANGER This boiler uses flammable gas, high voltage electricity, moving parts, and very hot water under high pressure. Assure that all gas and electric power supplies are off and that the water temperature is cool before attempting any disassembly or service. Assure that all gas valves and electrical disconnect switches are off before attempting any disassembly or service. Do not attempt any service work if gas is present in the air in the vicinity of the boiler.
2. Terminal and wall thimble (if used) must be weathertight. 3. Pipe must be full round shape, and show no damage from impact or excessive temperature. 4. Pipe must be supported at minimum five (5) foot intervals and must not sag. d. e. f. g. 5. All vent joints must be secure and watertight. 6. If pipe must be disassembled for removal of obstructions or resealing of joint, see Venting Section. E. Inspect Boiler Flue Passages for blockage or soot accumulation. See Figure 20. 1.
b. Spark gap should be 1/8 inch for optimum performance. 3. To replace complete pilot assembly. a. Remove two machine screws holding pilot burner to pilot bracket. b. Disconnect pilot tubing. c. Disconnect all other leads to pilot. d. Select pilot assembly with identical model number, reconnect leads and pilot tubing. Resecure to pilot bracket. 4. Reinstall main burner following procedure described in Paragraph F.1.
I. Lubrication. There are no parts requiring lubrication by service technician or owner. Circulator bearings are water lubricated. Blower motor bearings are factory sealed. J. Procedure for measuring fan inlet pressure. See Figure 21. 1. With boiler off, remove hoses at pressure switch. 2. With tee connect water manometer as shown with additional tubing. 3. Start boiler and read Pressure on Manometer when boiler water temperature reaches operating temperature. Refer to Table 12 for minimum readings.
THIS PAGE LEFT INTENTIONALLY BLANK 33
Troubleshooting Guide
Troubleshooting Guide 35
IX. Repair Parts All PVCG™ Series Repair Parts may be ordered through New Yorker Boiler Co., 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 repair parts, please contact: New Yorker Boiler Co., Inc. P.O.
Description [Quantity] Part Number PVCG30 PVCG40 PVCG50 Pilot Assembly, Natural Gas, Honeywell Q348A1002 8236072 Pilot Assembly, LP Gas, Honeywell Q348A1010 8236081 Pilot Tubing, 1/4" OD x 40" 8236123 Gas Valve, 1/2 x 1/2, Natural Gas, Honeywell VR8204C3007 81660145 Gas Valve, 1/2 x 1/2, LP/Propane, Honeywell VR8204C3015 81660146 Igniter/Sensor Cable, 36", Honeywell 394803-2 8236121 Ground Wire Assembly 6130403 Safety Relief Valve, 30 psi, 3/4 NPT, Conbraco 10-408-05 81660319 Combination
X. Low Water Cut Off (LWCO) on Hot Water Boilers 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.
SERVICE RECORD DATE SERVICE PERFORMED 39
NEW YORKER BOILER CO., INC. Limited Warranties For Residential Cast Iron and Steel Water Boilers By this Warranty Statement New Yorker Boiler Co., Inc. ("New Yorker"), issues limited warranties subject to the terms and conditions stated below. These limited warranties apply to residential cast iron and steel water boilers labeled with the New Yorker® brand which are sold on or after March 1, 2004.
