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New Yorker CGS-C Series, Installation, Operating And Service Instructions

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New Yorker CGS-C Series Installation, Operating And Service Instructions Download Page 1

104823-02 - 4/14

Price - $5.00

INSTALLATION, OPERATING

AND

SERVICE INSTRUCTIONS

CGS-C™ 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.

For service or repairs to boiler, call your heating contractor.  When seeking information on boiler, 

provide Boiler Model Number and Serial Number as shown on Rating Label.
Boiler Model Number

      

CGS  _ 0C

  

Boiler Serial Number

  Installation Date

Heating Contractor

  Phone Number

Address

9700609

Summary of Contents for CGS-C Series

Page 1: ...is 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 For service...

Page 2: ...se extensive property damage Do not leave the heating system unattended during cold weather unless alarms or other safeguards are in place to prevent such damage DO NOT BLOCK AIR FLOW into or around t...

Page 3: ...noxide nitrogen oxides and or other toxic or harmful substances that can are hazardous to health and life and that are known to the State of California to cause cancer birth defects and other reproduc...

Page 4: ...nd dilution of flue gases must be available in the boiler room These boilers are not designed for use in process or other open steam systems TABLE OF CONTENTS I ProductDescription 4 II Specifications...

Page 5: ...350 12 28 33 3 4 4 4 x 15 ft 1 2 5 1 3 9 CGS40C 420 16 34 3 4 5 5 x 15 ft 6 5 5 0 CGS50C 485 19 35 3 4 6 6 x 15 ft 7 9 6 1 CGS60C 555 22 9 3 7 2 CGS70C 620 25 30 36 3 4 7 7 x 15 ft 3 4 10 7 8 3 CGS80C...

Page 6: ...stems Pub 200 and I B R Heat Loss Calculation Guide Pub H21 or H22 4 Make sure that the boiler received is configured for the correct gas natural or LP Warning This Product Must be Installed By A Lice...

Page 7: ...accordance with local building codes or in absence of such codes in accordance with Air for Combustion and Ventilation of the National Fuel Gas Code ANSI Z223 1 NFPA 54 To ensure an adequate supply of...

Page 8: ...h per 1000 BTU hr input of all gas burning appliances in the boiler room The minimum opening dimension is 3 inches Minimum opening free area is 100 square inches per opening If the total volume of bot...

Page 9: ...ALL AIR FROM OUTDOORS VENTILATED CRAWL SPACE AND ATTIC FIGURE 5 ALL AIR FROM OUTDOORS VIA VENTILATED ATTIC FIGURE 3 BOILER INSTALLED IN CONFINED SPACE ALL AIR FROM INSIDE V Air for Combustion Ventilat...

Page 10: ...10 FIGURE 6 ALL AIR FROM OUTDOORS USING OPENINGS INTO BOILER ROOM FIGURE 7 ALL AIR FROM OUTDOORS USING HORIZONTAL DUCTS INTO BOILER ROOM V Air for Combustion Ventilation continued...

Page 11: ...rior chimneys may be used An exterior masonry chimney may be used if it is lined with B vent or a listed chimney lining system 5 This boiler may be vented using a listed power venter The power venter...

Page 12: ...r appliances remaining connected to the common venting system are not in operation a Seal any unused opening in the common venting system b Visually inspect the venting system for proper size and hori...

Page 13: ...13 13 FIGURE 8 CGS C BOILER TYPICAL VENT SYSTEM INSTALLATION AND COMPONENTS FIGURE 9 VENT DAMPER INSTALLATION DETAILS VI Venting continued...

Page 14: ...a manual shut off valve outside the jacket and ground joint union as shown The boiler and its gas connection must be leak tested before placing the boiler in operation When doing this the boiler and i...

Page 15: ...king If two or more steam mains must be connected to the boiler connect a separate take off for each main into the header between the riser s and equalizer Also note the following points 1 A size redu...

Page 16: ...debris or subjected to freezing 4 Install drain valve into tapping on boiler left side using the 2 x 3 4 bushing provided see Figure 1 5 Connect system supply and return to boiler See Figure 11 CGS30C...

Page 17: ...0C CGS40C CGS50C CGS60C CGS70C CGS80C A 2 2 B 2 3 C 1 1 D 1 Optional FIGURE 12 COMMON NEAR BOILER PIPING MISTAKES FIGURE 11 STEAM BOILER PIPING FOR GRAVITY RETURN MINIMUM PIPE SIZE VIII System Piping...

Page 18: ...tall a Y strainer to prevent sediment from accumulating inside the indirect water heater 3 Check Valve Prevents gravity circulation through the indirect water heater when the boiler is responding to a...

Page 19: ...o not alter factory boiler wiring Connect VXT 24 to CG400A as follows Connect the BLACK lead on the feeder to terminal A on the LWCO Connect the WHITE lead on the feeder to terminal 2 on the LWCO 2 Us...

Page 20: ...cribed in Part IX must also be supplied by the installer A call for heat from the indirect water heater thermostat will energize the relay making both sets of contacts One set of these contacts then e...

Page 21: ...NELL MILLER WF2 U 24 FEEDER OR THREE WIRE HYDROLEVEL VXT 24 FEEDER TO BOILER EQUIPPED WITH 67 L W C O CAUTION DO NOT INSTALL JUMPER BETWEEN 2 3 ON 67 L W C O FIGURE 15 WIRING INDIRECT WATER HEATER TO...

Page 22: ...urrent flows through the boiler to the GND BURNER connection on the ignition module For the ignition module to recognize that a pilot flame is present the DC current flowing into this terminal must be...

Page 23: ...ich must be pressed to restore normal burner operation An open blocked vent switch is indicative of a problem with the vent system If the blocked vent switch opens the cause of the venting problem mus...

Page 24: ...24 FIGURE 17 WIRING DIAGRAM McDONNELL MILLER MODEL 67 LOW WATER CUTOFF X Electrical continued...

Page 25: ...shed Once a flame has been established for the first time subsequent calls for burner operation should result in a flame on the first try 10 Observe pilot burner flame Pilot burner produces three flam...

Page 26: ...ect a manometer to the manifold outlet pressure tap on the gas valve see Figures 21 d Read the manifold pressure It should be set at Natural Gas LP Gas Manifold Press inches w c 3 5 10 0 e If a manifo...

Page 27: ...27 27 FIGURE 19 OPERATING INSTRUCTIONS XI System Start up continued...

Page 28: ...ose accumulated scale from the system During the first week of operation blow down the 67 low water cut off at least three times following the blow down instructions on the yellow sticker adjacent to...

Page 29: ...Turn off gas supply to boiler per the Operating Instructions see Figure 19 Drain hot water from boiler through boiler drain valve to a location where hot water can be safely discharged Refill the boi...

Page 30: ...through the venturi opening 5 Inspect the pilot assembly Clean any deposits found on the electrode and grounding strap The ideal gap between the electrode and the ground strap is 1 8 Inspect the porc...

Page 31: ...re the boiler and allow it to steam until 2 5 psi is registered on the gauge e Turn off the burners and immediately fully open the 1 1 4 valve f Allow the boiler to blow down until either the water ru...

Page 32: ...ich boiler is installed Crooked or out of round orifice holes never attempt to drill orifice for this boiler in the field Partially plugged flue passages Improper manifold pressure Foreign material in...

Page 33: ...he beginning of the troubleshooting process With the 120 volts applied to the boiler and no call for heat the damper should go to the closed position If it does not do the following Confirm that 120 v...

Page 34: ...34 Troubleshooting Chart for CGS C Boilers Equipped with Hydro level CG400A Low Water Cut offs and Vent Dampers Caution Read page 33 before attempting to use this chart XIII Troubleshooting continued...

Page 35: ...35 35 XIII Troubleshooting continued...

Page 36: ...36 Troubleshooting Chart for CGS C Boilers Equipped with McDonnell Miller 67 Low Water Cut offs and Vent Dampers Caution Read page 33 before attempting to use this chart XIII Troubleshooting continued...

Page 37: ...37 37 XIII Troubleshooting continued...

Page 38: ...38 Ignition System Troubleshooting Chart Caution Read page 33 before attempting to use this chart XIII Troubleshooting continued...

Page 39: ...39 39...

Page 40: ...Exchanger Assembly 1 1 1 1 1 1 Left End Section 717100022 1 1 1 1 1 1 Right End Section 717100011 1 1 1 1 1 1 Center Section 717100031 1 2 3 4 5 6 Slip Nipple 5 7066003 2 3 4 5 6 7 Slip Nipple 22B 806...

Page 41: ...41 41 XIV Repair Parts continued...

Page 42: ...18 1 1 1 1 1 1 14 8 x 3 4 Self Tapping Screw 80860030 1 1 1 1 1 1 15 10 x 1 2 Sheet Metal Screw 808600492 2 2 2 2 2 2 16 Washer 5 16 USS 80860611 4 4 4 4 4 4 17 Hex Lock Nut 5 16 18 80860464 4 4 4 4 4...

Page 43: ...43 43 XIV Repair Parts continued...

Page 44: ...neywell VR8204C3007 81660145 1 1 1 1 Gas Valve Nat Gas Honeywell VR8304P4306 81660161 1 1 Gas Valve LP Gas Honeywell VR8204C3015 81660146 1 1 1 1 Gas Valve LP Gas Honeywell VR8304P4314 81660160 1 1 46...

Page 45: ...45 45 XIV Repair Parts continued...

Page 46: ...83 1 80 Upper Front Jacket Panel 704193036 1 704193046 1 704193056 1 704193066 1 704193076 1 704193086 1 81 Diverter Panel 704193035 1 704193045 1 704193055 1 704193065 1 704193075 1 704193085 1 82 Ve...

Page 47: ...47 47 XIV Repair Parts continued...

Page 48: ...Float LWCO Only 8056020 1 1 1 1 1 1 90 Low Water Cutoff McDonnell Miller 67 BC 1 Float Type 80160517 1 1 1 1 1 1 90a Low Water Cutoff Hydrolevel CG400 2090 includes Probe 104975 01 1 1 1 1 1 1 Probe f...

Page 49: ...49 49 XIV Repair Parts continued...

Page 50: ...ety Relief Valve F 2 Bush to Drain Valve and or Optional Return Bush to Drain Valve and or Optional Return G 2 Optional Supply CGS30C CGS60C Required Supply CGS70C CGS80C Optional Supply CGS30C CGS60C...

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