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103759-02 - 11/12

Price - $5.00

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

   

PVCG_ _A

  

Boiler Serial Number

 

 Installation Date

Heating Contractor

  

Phone Number

Address

INSTALLATION, OPERATING

AND

SERVICE INSTRUCTIONS

PVCG-A™ 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.

9700609

Содержание PVCG-A

Страница 1: ...ntractor Phone Number Address INSTALLATION OPERATING AND SERVICE INSTRUCTIONS PVCG A SERIES GAS BOILER BEFORE INSTALLATION READ THIS MANUAL SAVE THESE INSTRUCTIONS Installing contractor and homeowner...

Страница 2: ...e http license reg state ma us pubLic pl_products pb_pre_form asp for the latest Approval Code or ask your local Sales Representative The Commonwealth of Massachusetts requires this product to be inst...

Страница 3: ...l be permanently mounted to the exterior of the building at a minimum height of eight 8 feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating...

Страница 4: ...f the boiler is inoperative 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...

Страница 5: ...ater Piping and Trim 21 V Gas Piping 26 VI Electrical 29 VII Modular Installation 34 VIII System Start up 36 IX Operation 40 X Troubleshooting 44 XI Service 49 XII Repair Parts 54 Warranty Back Cover...

Страница 6: ...G30A 1 NPT 1 NPT 3 NPT PVCG40A 1 NPT 1 NPT 3 NPT PVCG50A 1 NPT 1 NPT 3 NPT PVCG60A 1 NPT 1 NPT 3 NPT PVCG70A 1 NPT 1 NPT 3 NPT PVCG80A 1 NPT 1 NPT 4 NPT PVCG90A 1 NPT 1 NPT 4 NPT PVCG A DIMENSIONAL DA...

Страница 7: ...ment condensate trap control replacement etc I Pre Installation F Provide combustion and ventilation air in accordance with applicable provisions of local building codes or USA National Fuel Gas Code...

Страница 8: ...ncy E Tilt the boiler to its front side or back side and slide a wooden slat under the three raised feet F Tilt the boiler in the opposite direction and slide another wooden slat under the three raise...

Страница 9: ...erate appliance where gasoline or other flammable vapors or liquids or sources of hydro carbons i e bleaches cleaners chemicals sprays paint removers fabric softeners etc are used stored and or presen...

Страница 10: ...179 01 3 Dia 90 Elbow 8116294U 5 4 Dia 90 Elbow 100180 01 3 Dia 45 Elbow 8116292U 5 4 Dia 45 Elbow 100181 01 3 Dia Horizontal Drain Tee 8116302U 2 4 Dia Horizontal Drain Tee 100182 01 3 Dia Vertical D...

Страница 11: ...ent system installation must be in accordance with National Fuel Gas Code NFPA 54 ANSI Z221 3 CAN CSA B149 1 Natural Gas or Propane Installation Code or applicable provisions of local building codes C...

Страница 12: ...d match vent systems 12 If a non standard length pipe is required Gasketed Vent System The use of the adjustable length pipe P N 8116319U is recommended to complete a non standard pipe length This pip...

Страница 13: ...s of vent being sloped down inch per foot away from boiler See Figure 4A See Figure 4B for an alternate horizontal installation 4 Use appropriate designed thimbles when passing through combustible wal...

Страница 14: ...14 Figure 4A Recommended Horizontal Vent Installation III Venting continued...

Страница 15: ...15 Figure 4B Alternate Horizontal Vent Installation III Venting continued...

Страница 16: ...16 Figure 5 Horizontal Vent Terminal Configuration 3 or 4 Vent III Venting continued...

Страница 17: ...he vent pipe and the structure E Separate Vertical Venting System See Figures 6 7 8 and 9 NOTICE Roof penetrations require the use of roof flashing and storm collar not supplied with boiler 5 Whenever...

Страница 18: ...18 Figure 7 Attic Offset Figure 6 Vertical Vent Installation III Venting continued...

Страница 19: ...Termination Extend Vent Piping to maintain minimum vertical X and minimum horizontal Y distance of twelve 12 inches from roof sur face Allow additional vertical X distance for expected snow accumulat...

Страница 20: ...nt pipe installation F Optional Exterior Separate Horizontal Vent Terminal Mounting See Figure 9 b After penetrating wall thimble install an AL29 4C 90 elbow so that elbow leg is in the up direction c...

Страница 21: ...cturer s instructions 2 The recommended location for a LWCO on gas hot water boilers is above the boiler in the supply piping The minimum safe water level of a water boiler is at the uppermost top of...

Страница 22: ...spindle in vertical position Installation of the relief valve must comply with the ASME Boiler and Pressure Vessel Code Section IV WARNING Pressure relief valve discharge piping must be piped such tha...

Страница 23: ...r flow to maintain higher boiler water temperatures After the boiler is operational reference Section VIII System Start Up set by pass and boiler supply valves to half throttle position to start Opera...

Страница 24: ...24 Figure 13 Recommended Boiler Piping For Circulator Zoned Heating Systems IV Water Piping and Trim continued...

Страница 25: ...25 Figure 14 Recommended Water Piping for Zone Valve Zoned Heating Systems IV Water Piping and Trim continued...

Страница 26: ...ter cooking equipment 3 Length of piping and number of fittings Refer to Table 7 for maximum capacity of Schedule 40 pipe Table 8 lists equivalent pipe length for standard fittings 4 Corrections for t...

Страница 27: ...grounding electrode Do not use gas piping as grounding electrode Refer to National Electrical Code NFPA 70 or Canadian Electrical Code CSA C22 1 Table 7 Maximum Capacity of Schedule 40 Pipe in CFH Fo...

Страница 28: ...l shutoff valve must be disconnected from gas supply piping For testing at psig or less isolate boiler from gas supply piping by closing boiler s individual manual shutoff valve 2 Locate leaks using a...

Страница 29: ...er and circulator amperage must not exceed 15 amps Install over current protection in accordance with authority having jurisdiction or in the absence of such requirements follow the National Electric...

Страница 30: ...30 Figure 16 Wiring Connection Diagram VI Electrical continued...

Страница 31: ...agram VI Electrical continued NOTICE All wire wire nuts controls etc are installer supplied unless otherwise noted If an additional system limit is used install in series with the auxiliary limit jump...

Страница 32: ...32 Figure 18 Circulator Zoned System Wiring Diagram VI Electrical continued...

Страница 33: ...33 Figure 19 Zone Valve Zoned System Wiring Schematic VI Electrical continued...

Страница 34: ...be made Each vent termination must be one 1 foot from other terminations D Water Piping See Table 9 and Figure 20 Installing a low water cutoff in the system piping of modular systems is strongly reco...

Страница 35: ...35 Figure 20 Modular Boiler Piping VII Modular Installation continued...

Страница 36: ...n piping 5 Open hose bib VIII System Start up 6 Open fill valve Make up water line should be located directly after full port ball valve in system supply piping between air scoop and expansion tank 7...

Страница 37: ...37 Figure 21 Operating Instructions VIII System Start up continued...

Страница 38: ...other controls have not shut off boiler 4 Adjust thermostat to lowest setting Refill boiler M Check limit Jumper Thermostat connections in boiler wiring harness Allow burners to operate until shutdown...

Страница 39: ...butor or Regional Office for replacement Gas Orifice 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 stil...

Страница 40: ...atus codes that are reported RefertotheTroubleshootingSectionformoreinformation C Using Display The control is located inside the boiler front door Figure 24 Figure 24 Boiler Control Status Codes disp...

Страница 41: ...STA status display code has the below listed values This list is also available on the control cover Status Code Displayed in STA Mode 1 Standby 2 Waiting for Pressure Switch to Open 3 Waiting for Pre...

Страница 42: ...eat ends The Circulator Overrun Time is adjustable between 0 through 10 minutes 4 Circulator Pre purge Time When the boiler is warm boiler water temperature higher than 140 F adjustable using StartTem...

Страница 43: ...ol a second heating zone This is particularly helpful when the home uses only two heating zones The control replaces the need for a two circulator zone panel When DHW Terminal Function is set to the c...

Страница 44: ...he boiler are tested at least once in the manufacturing process and a defective control or component is generally the least likely cause Before replacing a component try to rule out all other possible...

Страница 45: ...l in excess of 40 mph Replace blower Err 32 Temperature Sensor Failure Temperature sensor or interface failure open or short connection increased connection resistance dual sensor mismatch or control...

Страница 46: ...ff for a DHW call for heat Wiring Circulator Issue Check wiring for loose connection miswiring Check circulator Use STA status Number To guide TroubleShooting The control will flash followed by a numb...

Страница 47: ...ted and the one hour time delay is completed Boiler can be restarted sooner than the time delay by entering Adjustment Mode and selecting the reset button see Adjustment Mode instructions or by cyclin...

Страница 48: ...ly tubes of air b If no gas flow check the following 24 volts across PV and MV PV at gas valve if voltage ok replace defective gas valve Check for break in wiring harness to gas valve 24 volts across...

Страница 49: ...tube to drain fitting providing gas tight and watertight seal 7 If pipe must be disassembled for removal of obstructions or resealing of joint see Section III Paragraph C D Boiler Flue Passages Inspec...

Страница 50: ...Vacuum firebox Exercise care do not damage base insulation 2 Clean main burners Brush top of burners with soft bristle brush See Figure 28 Vacuum to remove any dirt and lint 3 Vacuum tip of pilot bur...

Страница 51: ...51 Figure 28 Flue and Burner Cleanout 1 Burner XI Service continued...

Страница 52: ...with Pilot Bracket Pilot Burner Located Between Main Burners PVCG30A 2 2 3 PVCG40A 3 3 4 PVCG50A 4 4 5 PVCG60A 5 5 6 PVCG70A 6 6 7 PVCG80A 7 7 8 PVCG90A 8 8 9 Main burners numbered left to right as vi...

Страница 53: ...53 SERVICE RECORD DATE SERVICE PERFORMED...

Страница 54: ...l New Yorker Wholesale distributor 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 p...

Страница 55: ...001 1B Center Section 1 71707003 2 71707003 3 71707003 4 71707003 5 71707003 6 71707003 7 71707003 1C Right End Section 71707002 1D Slip Nipple 3 4 806600009 6 806600009 8 806600009 10 806600009 12 80...

Страница 56: ...56 XII Repair Parts continued...

Страница 57: ...08 102705 09 2E Burner Access Panel 102707 03 102707 04 102707 05 102707 06 102707 07 102707 08 102707 09 2F Cerafelt Gasket 1 2 x 2 6206002 2G Cerafelt Gasket 1 2 x 2 6206002 2H Base Side Insulation...

Страница 58: ...A PVCG50A PVCG60A PVCG70A PVCG80A PVCG90A 3 BASE ASSEMBLY 3A Burner Cover Natural Gas Only 102033 03 102033 04 102033 05 102033 06 102033 07 102033 08 102033 09 3B Manifold Support Bracket 718070001 3...

Страница 59: ...mbly Sea Level 61107031 61107041 61107051 61107061 61107071 61107081 61107091 Canopy Assembly High Altitude 61107032 61107042 61107052 61107062 61107072 61107082 61107092 4B Cerafelt 9206005 4C U Clip...

Страница 60: ...60 XII Repair Parts continued...

Страница 61: ...82207031 82207041 82207051 82207061 Gas Manifold 82207071 82207081 82207091 5C Burner Orifices Natural Gas 47 4 822710 6 822710 8 822710 10 822710 12 822710 14 822710 16 822710 Burner Orifices LP Gas...

Страница 62: ...r Control Induced Draft Honeywell S9361A2075 103968 01 6D Control Panel 103727 01 6E Temperature Sensor Clip 102422 01 6F Differential Pressure Switch Sea Level 0 4999 80160762 80160761 80160760 80160...

Страница 63: ...771 04 103771 05 103771 06 103771 07 103771 08 103771 09 7D Vestibule Panel 103773 03 103773 04 103773 05 103773 06 103773 07 103773 08 103773 09 7E Top Panel 103772 03 103772 04 103772 05 103772 06 1...

Страница 64: ...VCG60A PVCG70A PVCG80A PVCG90A 8 MISCELLANEOUS PARTS CARTON 8A Water Manifold 80607001 8B Temperature Pressure Gauge 100282 01 8C Circulator Wiring Harness 6130701 8D Safety Relief Valve 81660363 8E B...

Страница 65: ...Long sleeved loose fitting clothing 3 Gloves 4 Eye Protection Take steps to assure adequate ventilation Wash all exposed body areas gently with soap and water after contact Wash work clothes separatel...

Страница 66: ...66 SERVICE RECORD DATE SERVICE PERFORMED...

Страница 67: ...67 SERVICE RECORD DATE SERVICE PERFORMED...

Страница 68: ...68...

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