New Yorker CG-C Series Installation, Operating And Service Instructions Download | Manualshive

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Summary of Contents for CG-C Series

Page 1: ... 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 IBoiler Serial Number Installation Date I CG C Heating...

Page 2: ...4 8 1 2 4 3 4 40 24 3 4 15 1 4 7 5 8 5 47 1 8 9 1 8 4 3 4 50 28 18 1 2 9 1 4 6 48 1 2 9 3 4 5 1 4 60 31 1 4 21 3 4 10 7 8 6 48 1 2 9 3 4 5 1 4 70 34 1 2 25 12 1 2 7 50 1 8 10 3 8 6 5 8 80 37 3 4 28 1 4 14 1 8 7 50 1 8 10 3 8 6 5 8 90 41 31 1 2 15 3 4 8 52 11 7 1 4 100 44 1 4 34 3 4 17 3 8 8 52 11 7 1 4 Recommended Gas Water Vent Size 1 Conn Content Round Dia in x Ht ft FPT Gallons 4 Dia x 15 1 2 2...

Page 3: ...be filed ilmnediately 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 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 Where required by...

Page 4: ...ing of other than unusually tight construction adequate combustion and ventilation air is normally provided by fresh air infiltration through cracks around windows and doors 6 For boiler located within uncol_fined space in building of unusually tight construction or within co_fined space provide outdoor air through two permanent openings which colmnunicate directly or by duct with the outdoors or ...

Page 5: ...ove boiler to its permanent location III Water Piping and Trim Ao Design and install boiler and system piping to prevent oxygen contamination of boiler water Oxygen contamination sources are system leaks requiring addition of makeup water fittings and oxygen Bo Co permeable materials in distribution system Eliminate oxygen contamination by repairing system leaks repairing fittings and using nonper...

Page 6: ...iler water temperatures Set by pass and boiler supply valves to half throttle position to start Operate boiler until system water temperature reaches normal operating range Adjust valves to provide 180 to 200 F supply water temperature Opening the boiler supply valve will raise system temperature while opening by pass valve will lower system supply temperature If it is required to perform a long t...

Page 7: ...aterials in accordance with local plumbing codes and requirements of gas supplier In absence of such requirements follow National Fuel Gas ode NFPA 54 ANSI Z223 1 Use thread joint compounds pipe dope resistant to action of liquefied petroleum gas Install sediment trap ground joint union and manual shut off valve upstream of boiler gas control valve See Figure 6 or 7 Table 5 Specific Gravity Correc...

Page 8: ...d when an appliance is replaced by an appliance of similar type input rating and efficiency Single wall metal vent Allowed by ANSI Z223 1 NFPA 54 under very restrictive conditions Inspect chimney and remove any obstructions or restrictions Clean chimney if previously used for solid or liquid fuel burning appliances or fireplaces Inspect existing chimney before installing boiler Failure to clean or...

Page 9: ...eeding Please refer to the specifications installation instructions and troubleshooting guide packed in the vent damper carton for complete detailed installation instructions 2 Vent damper should be same size as draft hood outlet See Figure 1 Unpack vent damper carefully DO NOT FORCE CLOSED Forcing vent damper may damage gear train and void warranty Vent damper assembly includes pre wired connecti...

Page 10: ...ance remaining connected to the colnlnon venting system placed in operation while the other appliances remaining connected to the colnlnon venting system are not in operation a Seal any unused openings in the colnlnon venting system b Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restriction leakage corrosion and other deficiencies w...

Page 11: ...stat heat anticipator to 0 3 amps See Figure 12 for continuous ignition standing pilot or Figure 13 for intermittent ignition EI Eo 17 Go If system tends to overheat above therlnostat s temperature setting reduce heat anticipator setting by 0 1 or 0 2 amps If system tends to shortcycle without reaching desired room temperature increase heat anticipator setting by 0 1 or 0 2 amps New Yorker Link SL...

Page 12: ...2 4 Call for heat ends Vent Damper closes This boiler contains controls which may cause the boiler to shut down and not restart without service If damage due to frozen pipes is a possibility the heating system should not be left unattended in cold weather or appropriate safeguards and alarms should be installed on the heating system to prevent damage if the boiler is inoperative _L _R WIRING Figur...

Page 13: ... heat Vent Damper opens b Gas Valve energized allowing main gas flow and ignition of Main Burners c Call for heat ends Gas Calvede energized extinguishing main flame Vent Damper closes 2 Safety Shutdown a Limit Automatically interrupts main burner operation when water temperature exceeds set point Maximum allowable telnperamre is 250 F Circulator continues to operate with call for heat and Vent Da...

Page 14: ...r in operation The source of blockage must be corrected by trained C d and skilled personnel from a qualified service agency before resetting switch Flame Roll out Switch Automatically interrupts boiler operation when flames or excessive heat are present in vestibule Circulator continues to operate and Vent Damper remains open with call for heat Control is single use device If flame roll out switc...

Page 15: ...ve globe valve open j Open isolation valve in boiler supply piping k Remove hose from hose bib 2 Turn ROOM THERMOSTAT to lowest setting 3 Be sure that gas to pilot and main burners has been off for at least five minutes and vent damper has been in the open position 4 Turn OFF the electric switch serving boiler 5 Open valve on main gas line at meter 6 PURGE AIR FROM GAS PIPING This procedure will v...

Page 16: ...ction Heartbeat Normal Flame Signal N A Weak Flame Signal System will operate reliably but flame signal is less than desired Note This indication may flash temporarily during or shortly after lightoff on some applications Marginal Flame Signal less than 1 1 HA System may not operate reliably over time Service call recommended 1 Note This indication may flash temporarily during or shortly after lig...

Page 17: ...t due to error ON detected during self check sequences _Flash Code Descriptions Flash Fast rapid blinking Heartbeat Constant second bright second dim cycles Control auto resets from soft lockout after one hour If system fails to light on next trial for ignition check gas supply pilot burner spark and flame sense wir ing flame rod contamination or out of position burner ground connec tion If system...

Page 18: ... under water OPERATING INSTRUCTIONS 1 STOP Read the safety information above on this label 6 Rotate gas control knob clockwise S_ from ON position to OFF Make sure knob rests against stop 2 3 4 5 Set the thermostat to lowest setting Turn off all electric power to the appliance This appliance is equipped with an ignition device which automatically lights the pilot Do not try to light the pilot by h...

Page 19: ...ower to the appliance 5 Set the room thermostat to lowest setting 6 Locate the gas control POSITION _ _ GAS CONTROL valve at theend of the ga_ IDICATOR supply pipe going into the 1 _ I I boiler The gas control _ 11 I I I knob is the blue or brown _ _ I plastic knob located on top GAS _ __ I I INLET of the gas control valve _ I I o 7 Rotate gas control knob RED RESET BUTTON14 clockwise _ from ON po...

Page 20: ...tor on Gas Calve so that manifold pressure is three and a half 31 2 inches water column three inches water colullln for high altitude Turning Regulator Adjusting Screw Clockwise increases pressure Counter clockwise rotation decreases pressure If more accurate check on input is necessary see b For minor input changes readjust Regulator Gas Calveto increase or decrease manifold pressure to obtain co...

Page 21: ... valve 2 Intermittent Ignition EI Disconnect sensor wire from Terminal 4 SENSE on Ignition Module H Check Vent Damper Operation Vent Damper must be in open position when main burners are ignited I Check Limit 1 Adjust thermostat to highest setting 2 Observe temperature gauge When temperature is indicated adjust limit to setting below observed temperature Main burners should extinguish 3 Adjust lim...

Page 22: ...oting Guide J Y_s _OT_ IFCO_KROL G_S _N O LOCr _j_r _ _ O_LAY RESETTNE Ja_L FOR HEA CLF_ FIJ_ RO0 CHECK _EC_CAL CONNECTS _ F_ _ _ MOOb_ C_CK FORCRACK_ CERAMP3 _ _ME _ _U_OFL _ OUST _L_ F_ Y_s YES I CAt FORHEAT _ _S F_ OPeRATiON _SC_T_O _ I 22 ...

Page 23: ...iler is exposed If piping or wall prevent full rotation of top panel for access to canopy cut slot into safety relief valve opening and remove top panel 3 Remove carriage bolts securing Canopy to Section Assembly For high efficiency models CG CH remove flue baffles 4 Using flashlight examine all flue passageways a If passageways are free of soot and obstruction replace canopy secure and seal b If ...

Page 24: ...Rollout Switch wires 17 G Check Operation Follow steps C through J from Section VII System Start up 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 E 1 1 To replace orifice disconnect pilot tubing a Continuous Ignition Standing Pilot and Intermittent Igniti...

Page 25: ...ew Yorker products or repair parts please contact New Yorker Boiler Co Inc RO Box l0 Hatfield Pennsylvania 19440 0010 Phone 215 855 8055 Attn Customer Service Department Section Assembly and Canopy Assembly 26 Base Assembly 28 Manifold and Main Burners 1 Inch Main Burners 30 40mm Main Burners 32 Pilot Burner and Gas Valve Continuous Ignition Standing Pilot 34 Electronic Ignition 34 Jacket Assembl ...

Page 26: ... b 3 a b 4 a b 5 a b 6 b 7 c 8 c 9 c Footnote to Flue Baffle a CG CH Models El only b Standing Pilot LP 1 Burners only c Standing Pilot Natural LP Gas 1 Burners only d Standing Pilot Natural LP 1 40mm Burners 61117022 1 611170302 1 611170402 l a 100310 01 l b 611170502 1 611170602 l a 100310 02 l b 6111706010 1 c 611170702 1 611170802 l a 100310 03 l b 611170902 1 611171002 l a 100310 04 l b Footn...

Page 27: ...J J J J J J J f Section Assembly and Canopy Group 27 ...

Page 28: ...1 718600791 1 718600891 1 718600991 1 718601091 1 718600211 1 718600311 1 718600411 1 718600511 1 718600611 1 718600711 1 718600811 1 718600911 1 718601011 1 720601 2 2 2 2 2 2 2 2 2 72060025 1 72060035 1 72060045 1 72060055 1 72060065 1 72060075 1 72060085 1 72060095 1 72060105 1 618600241 1 618600341 1 618600441 1 618600541 1 618600641 1 618600741 1 618600841 1 618600941 1 618601041 1 6186001 4 ...

Page 29: ...lt Sealing Strip x 2 x 10 19 Section Assembly to Base Part CG C MODEL Number 20 30 40 50 60 70 80 90 100 718600261 1 718600361 1 718600461 1 718600561 1 718600661 1 718600761 1 718600861 1 718600961 1 718601061 1 80860700 20 20 20 20 20 21 21 21 21 80860717 4 4 4 4 4 4 4 4 4 80860601 4 4 4 4 4 4 4 4 4 80860464 4 4 4 4 4 4 4 4 4 6206002 1 1 1 1 1 1 1 1 1 29 ...

Page 30: ...1 Standing Pilot Natural Gas 22 Main Burner w 45 Pilot Brackets Q350 Standing Pilot LP Gas 1 1 1 8236120 Main Burner w 45 Pilot Bracket Q327 Standing Pilot LP Gas Main Burner w 60 Pilot Bracket 8236118 El Natural LP Gas 82219021 82219031 82219041 82219051 23 Manifold 82219061 82219071 82219081 82219091 82219101 Burner Gas Orifice Natural Gas Sea Level to 2000 Ft Main Burner Orifice 45 Pink 822711 ...

Page 31: ...SEE PILOT BURNER AND GAS VALVE GROUP MTD ON BASE SIDE PANELS Manifold and Main Burners 1 Inch Main Burners 31 ...

Page 32: ... 1 82219052 1 82219062 1 82219072 1 82219082 1 82219092 1 82219102 1 Burner Gas Orifice Natural Gas 2000 5000 Ft USA Only Main Burner Orifice 39 822727 2 3 29 Main Burner Orifice 38 822720 4 5 6 7 8 9 Burner Gas Orifice LP Gas 2000 5000 Ft USA Only 29IMa nBurnerOrif ce_53 822722 I I 2 I 3 4 5 16 17 18 9 Burner Gas Orifice Natural Gas 5000 9000 Ft USA Only Main Burner Orifice 41 822729 2 3 29 Main ...

Page 33: ...ORIFICE BRACKET FLUSH WETH SmDE TYP BOTH SIDES TAB PILOT BURNER I I ORIFICE BRACKET SLIP TAB BETWEEN ORIFICE BRACKET FLARED END OF VENTURI TUBE WP BOTH SIDES VENTU RI TUBE Manifold and Main Burners 40mm Main Burners 33 ...

Page 34: ...r 81660143 1 1 1 1 1 81660154 100333 01 1 1 1 1 1 100334 01 81660144 1 1 1 1 1 81660163 8236024 1 1 1 1 1 8236004 8236122 1 1 1 1 8236123 1 8236042 Footnote to Continuous Ignition 24V Standing Pilot 1 1 inch Burner Only 1 40mm Burner Only 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 34 Key Description No Part Number CG C MODEL 01301401 01601701801 I 00 100331 0...

Page 35: ...35 ...

Page 36: ...et Assembly Complete 41 Jacket Assembly Complete CG C MODEL Part Number _o I 3o 14o I _o I 6o I 7o I 8o I _o 1lOO 100294 01 1 100294 02 1 100294 03 1 100294 04 1 100294 05 1 100294 06 1 100294 07 1 100294 08 1 100294 09 1 36 ...

Page 37: ...TOP PANEL 0 0 FRONT DOOR 0 0 VESTI B ULE WRAP AROUNB LOWER BAR 37 ...

Page 38: ... Honeywell L4080B 80160736 1 1 1 1 1 1 1 1 1 50 Circulator w Gaskets and Hardware Taco 007 8056182 1 1 1 1 1 1 1 1 1 8131706 1 1 1 1 1 51 24V El Vestibule Harness 8131707 1 1 1 1 52 Ignition Module Honeywell S8610M3009 100958 01 1 1 1 1 1 1 1 1 1 53 J Box 4 x 4 x 1 1 2 8136259 1 1 1 1 1 1 1 1 1 54 Transformer Relay Honeywell R8285D5001 50VA 80160155U 1 1 1 1 1 1 1 1 1 55 Replacement Relay Honeywel...

Page 39: ...V_ _ _I DAMP _R CAI _ Ol DRAi I HOOD CAi_ CiN 39 ...

Page 40: ...DATE SERVICE RECORD SERVICE PERFORMED 40 ...

Page 41: ...DATE SERVICE RECORD SERVICE PERFORMED 41 ...

Page 42: ...DATE SERVICE RECORD SERVICE PERFORMED 42 ...

Page 43: ...oil boilers by wiring it in the line voltage service to the boiler after the service switch if so equipped The presence of water in a properly installed LWCO will cause the normally open contact of the LWCO to close thus providing continuity of the 120 VAC service to the boiler It is recolmnended to supply power to the probe LWCO with the same line voltage boiler service as shown below v _T _OE 20...

Page 44: ...oper Use or Maintenance These warranties will not be applicable if the boiler is used or operated over its rated capacity is installed for uses other than home heating or is not maimained in accordance with New Yorker s Installation Operating and Service Instructions and hydronics industry standards 5 Improper Operation These warranties will not be applicable if the boiler has been unaged as a res...

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