Install Instructions

30
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.
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. Disconnect vent connector from blower discharge
flange.
2. Remove sheet metal screws securing Jacket Top
Panel. Lift panel and rotate about relief valve
piping until top of boiler is exposed. If piping or
wall prevent full rotation of top panel for access
to canopy, cut slot into relief valve opening and
remove top panel.
3. Disconnect blower connection from wiring harness.
4. Remove bolts securing canopy to boiler sections.
Cut silastic sealant around base of canopy, pry
canopy from boiler sections and remove canopy/
blower assembly from boiler.
5. Using flashlight, examine all flue passageways.
a. If passageways are free of soot and obstruction,
replace canopy, secure and seal using kit
available from New Yorker Distributors, Part No.
6111716.
b. If passageways need cleaning, remove burners
as described in Paragraph F below. Using long
handle wire or bristle flue brush and vacuum,
brush flueways thoroughly from top of boiler
as illustrated in Figure 20. Replace canopy
and seal using kit available from New Yorker
Distributors, Part No. 6111716.
WARNING
Canopy must be resealed with RTV-732 Silicone
Rubber Sealant (500°F Intermittent Duty).
6. Reinstall jacket top panel, vent pipe and vent
connector in reverse manner. Reconnect electrical
connector to blower.
F. Clean Main Burners and Firebox.
1. To remove burners for cleaning, changing orifice
plugs, or repairs:
a. Remove jacket burner cover.
b. Disconnect pilot tubing at gas valve.
c. Disconnect igniter/sensor cable and ground wire
at Ignition Module.
d. Disconnect Flame Rollout Switch wires.
e. Remove Burner Access Panel.
f. Mark Pilot Main Burner location on Manifold.
g. Hold burner on throat. Lift slightly to clear
orifice. Pull burner from combustion chamber.
Pilot Main Burner can only be removed by
lifting at 45° angle after adjacent burner to right
is removed.
2. Brush top of burners with a soft bristle brush. See
Figure 20. Vacuum burners.
3. Check orifices. Drilled passageways must be free of
lint or dirt.
4. Vacuum tip of Pilot Burner.
5. Clean firebox by vacuuming. Exercise care not to
disturb insulation inside base.
6. Install burners by reversing procedure used to
remove burners. Burner with pilot assembly must be
in same location as original installation. See Table
11. Burners must be properly located on support
bracket at rear of burner. Slide burner over orifice.
Table 11: Pilot Burner Location
7. Reconnect pilot gas supply, igniter/sensor cable,
and ground wire. Reinstall Burner Access Panel.
Reconnect Flame Rollout Switch wires.
G. Check operation. Follow Steps G through P from
System Start-up Section.
H. Removal or replacement of pilot assembly or pilot
assembly parts. If pilot assembly, sensor or pilot orifice
need replacing, remove main burner with pilot using
procedure described in Paragraph F.1.
1. To replace orifice.
a. Disconnect pilot tubing. Pilot orifices screw
into Pilot Burner. Replace with Honeywell
388146NE (Natural Gas) or Honeywell
388146KP (LP/Propane).
b. Reconnect pilot tubing and check for leaks.
2. To adjust or check spark gap between electrode and
hood on Honeywell Q348A intermittent pilot. See
Figure 19.
a. Use round wire gauge to check spark gap.
Boiler
Model
Main Burner with
Pilot Bracket *
Pilot Burner
Located Between
Main Burners *
PVCG30 1 1 & 2
PVCG40 2 2 & 3
PVCG50 3 3 & 4
PVCG60 4 4 & 5
* Main burners numbered left to right as viewed from front
of boiler.