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installation, operating and service instructions cl™ series cast iron

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3. Sun b Loosen knurled nut and disconnect copper connector tube c Remove nozzle line electrode assembly d If high firing rate is desired confirm the nozzle is the proper size and type refer to Table 14A at rear of this manual then proceed to Item i 3 8 CARRIAGE BOLT WASHER amp NUT Figure 4 Removal of Boiler From Skid 2 Tilt boiler to right and to rear Using right rear leg below as pivot rotate boiler 90 in a clockwise direction e If a lower input is desired remove the nozzle and lower left side of boiler to floor Tilt boiler that was factory installed and remove crate skid Care should be exercised to f Remove Beckett MB L1 or MD V1 head prevent damage to jacket or burner g Locate the desired nozzle Refer to Table 14 C MOVE BOILER TO PERMANENT POSITION by at rear of this manual for proper nozzle The sliding or walking nozzle must be securely installed to assure leak D INSPECT COMBUSTION TARGET WALL AND free joints between the nozzle and adapter COMBUSTION CHAMBER LINER When installing the nozzle be careful not to 1 OPEN FLAME OBSERVATION DOOR AND Dumper move the burner electrodes OR BURNER SWING DOOR on front of boiler Note On the CL3 091 0 65 burner Use flashlight to inspect target wall secured to application a low firing rate baffle is required rear section with silastic sealant Inspect ceramic Baffle is shippe
4. 0 901 OMV 81 2215 ONISIM QN393 33IIA NOILdO 1OH LNOO ex 3 1VIdOSHddV INVHOVIG OLIVIN3HOS O4 vc 331914 OL 4343 ALON 335 710 LO3NNOO lt TWNINSYL MANOS 2 ONILLAS YOLWdIOLLNY LW3H I A8 1 i 7 wA 33TIV1SNI A8 M3lV3H SS3TMNV1 SS31 N HOLVdIOLLNV 1 V3H 70 Ir A8 1VISOWM3HL 17 33TIV1SNI I 1 LVLSVNOV d A 5 Y90071 TI3MA3NOH W31V3H SS3 DINVIL W QN3931 DILVIN3HOS Seu pejene1 pejequinN 5 0 0 1 se pejequinN Jo eg 3UHM HM 108 5 191 8 qaq 9 30105 3HIM ALON 33S 1 TIO agoud G3TIV1SNI WV4Ls HM TISMASNOH N H M HOSN3S gt 330 119 108 54 a TI3NNOG9N es
5. YOLIND OINOHLO3 T3 QV3H LA A18IW3SSV SLV1d LAN Q3 THONM SQV3H 1 NOSHOLNOSA ponuyu0d SLUVd 4 BECKETT AFG OIL BURNER PART NOS FOR CL SERIES BOILERS NOTE When ordering parts always give the serial and model numbers shown on the boiler and burner Also provide the name of the part s and part number as listed below Air Tube Combination AFG70MLAS emwmemm Pump Clean Cut 2184404U 2184404U 2184404U 2184404U 2184404U Single Stage De 1 5880 used on CL3 091 firing rate only A e 57 XI BURNER SPECIFICATIONS TABLE 14A BECKETT AFG BURNER SPECIFICATIONS Beckett AFG Firing Rate 3 Pump Boiler Model Head Air GPH 2 Setting Shutter GPH x Angle Type Shipped Pressure Cum sel T omm om 1 Beckett low firing rate baffle required on CL3 091 0 65 GPH application only shipped loose with nozzle 5 Nozzle s for alternate boiler model firing rate s are shipped loose in bag attached to the burner designated by corresponding symbol i e A CL3 105 3 Single stage fuel pump is standard two stage fuel pump is optional Burner manufacturer has preset single stage fuel pump to settings shown in table above 58 XI BURNER SPECIFICATIONS continued RIELLO 40 SERIES OIL BURNER PART NUMBERS
6. 1 1 6 2 W i QN3931 9ILVW3H2S HOLIMS i LO9 OZ I SOINNSS I 31IHM HM X0v18 ii 30705 LOANNOOSIG i I B L w 6 YATIVLSNI SWALI HOLIMS 3OI H3S penunuo TVORLLOWT AI N Jeuung 94 11932eg OOM 94044 08 54 9 Sso yue 40 5491 6 zz 4 CIOHLNOO OL LVLSOWYSHL SNIHOV LLV N3HM TVOINVHO3NW SAOWSY 9 001 WAWINIW V GALVY SHIM IWYS 39nvo 3WVS ONIAVH LSNW LI LSNW AHL SV 38IM LNAWdINOA dl L SALON 97315 0 80 OMY 81 3215 AHOLOV4J SOVLIOA INIT 91315
7. 68 f 5 2 Y37109 OL NMOG 5 NYNLIY 13AFWV31S ONldld 21 1 1 d 3ATVA 440 10 8 9 NOILO3NNOO NYNLIY 44O LNHS 38010 3ATVA 40 101 8 43108 NOLLO3NNOO NYN L3Y 31VNH31T1V uaznvnoa v 35010 ONLLLIJ 220 ONIdid 319NV Sp HO ATWOILYSA H3Q0V3H dOl 330 38 5 3AO8V 82 5531 38 OL LON dO LNIOd LIM OLNI SNIVW dO SANA 331108 LNIOd NMOG 38075 5 Wv3lS SNOLLOQLLSNI NOLLV T TV LSNI INSTALLATION INSTRUCTIONS continued If the system contains hidden supply or 4 WATER 277 return piping hidden behind walls buried in concrete etc pressure test this piping to assure there are no leaks HEATING Repai mib SHUT DFF BOILER SHUT OFF ii epair any leaks in the system VALVES VALVES iii Install accurate water meter on the fresh 1 L L water supply to the boiler HH Ski AIR CUSHION NOTICE 1 A TANK 1 Ii DO NOT use softened water in steam boilers as Accelerate
8. Locate oil pressure adjusting screw and turn screw to obtain proper pump pressure refer to Tables 14A and 14B at the rear of this manual To check the cutoff pressure deadhead a reliable pressure gauge onto the copper connector tube attached to the nozzle port Run the burner for a short period of time Shut the burner off The pressure should drop and hold Remove the gauge and install bleeder port and or reconnect the nozzle port line 31 SYSTEM START UP continued BLEEDER PORT Figure 25 Adjusting Fuel Pump Pressure G ADJUST OIL BURNER WHILE OPERATING flame present 32 SET ROOM THERMOSTAT about 10 F below room temperature PRESS RED RESET BUTTON on Oil Primary Control and release Beckett Burners READJUST THE HEAD SETTING only if necessary a CL3 091 thru CL4 126 Beckett MB L1 Head burners have a fixed head which are non adjustable b CL4 175 thru CL5 280 Beckett MD V1 variable Head burners have the ability to control air by moving the head It might be necessary to move the head forward or back one position at a time to optimize the smoke and CO readings See Figure 26 and Table 14A at the rear of this manual Riello Burners READJUST THE TURBULATOR SETTING only if necessary a CL3 through CL5 All Models Move the turbulator setting forward or back one position at a time to optimize the smoke and CO2 readings Refer to Figure 8 and
9. Area Sq Ft Maximum Working Pressure Steam 15 PSI Water 30 PSI Shipped Standard from Factory 50 PSI Optional TABLE 2 RATING DATA Burner DOE Heating AHRI NET Ratings Minimum Chimney Boiler Model Capacity Capacity Requirements Water Steam Water Steam Steam Round Rectangle Height MBH MBH MBH MBH Sq Ft In Dia AFUE Water Steam In x In Ft 8x8 15 8x8 15 8x8 15 8x8 15 8x8 15 8x8 15 8x8 15 8x8 15 8x8 15 8x8 15 8x8 15 8x8 15 8x8 15 8x8 15 8x8 15 8x8 15 8x8 15 8x8 15 21309107 oss 91 asore oss 5 CL3 105 S 05 CL3 140 W 14 CL3 140 40 EUM uet 152 BENI s al 12 Co i CL4 126 S 0 90 CL4 175 W 1 25 14 175 8 1 25 175 210 210 CL4 126 W 0 90 126 1 CL4 210 1 CL4 210 CL5 168 W CL5 168 S CLS 245 W CL5 245 S 245 0 8 CL5 280 W 28 15 280 5 200 280 Boiler Model Suffix W Water S Steam 9 e 42 4 147 N N 3 3 0 8 7 0 2 2 3 3 4 5 4 6 1 1 1 6 REZES 28 23 29 sess 8 3o 11 t 338 52 112 467 7 221 33 554 108
10. The GeniSys 7505 Oil Primary Control has pre installed T T jumper To activate T T terminals T T jumper must be removed DO NOT remove T T jumper unless wiring diagram indicates a direct connection from the boiler see Figure 13 Also consult I B R Residential Hydronic Heating Installation and Design Guide A hot water boiler installed above radiation level must be provided with a low water cutoff device as part of the installation See Appendix A Low Water Cut Off for additional details 15 epis Ajddng Bune H 5 Buldig V LL 941164 ACIS 1 40073 hi 3ATVA 40074 40 9 NIHLIM 2202 YNI HMI 131545 M3IV3H JAVA 153 OIIS3WOQ 1939IONI 2 eK a ES ES JUNSSAYd 440 100 q3sn M3lv3H M3lVM 3ATVA LS MOJIVIDOMIO L OLLS3AOQ 103MIQNI 440 41 5 Y gt K M3IVM LOH OLLSAWOG W31SAS 5 5 N NOISNVdX3 tl L 1 1 00 3ATVA x 3ATVA 3ATVA Alddns 140 10
11. 1 Using wire or fibre bristle brush clean crown of boiler and inside of water legs DO NOT allow brush to strike target wall or blanket in the combustion chamber D AFTER CLEANING remove protective cloth with debris and vacuum as necessary but be careful not to damage blanket Inspect target wall combustion chamber blanket and burner mounting plate insulation for signs of damage If damaged replace as needed E REASSEMBLE BOILER CAUTION DO NOT start the burner unless canopy smokepipe and burner swing door are secured in place 1 Install the canopy taking care to align the gaskets without blocking the flueways If gasket is damaged replace as needed 2 Close and secure burner swing door to front section with fasteners 3 Reconnect oil line s 4 Reinstall Top Panels and secure with sheet metal Screws 5 Reinstall smokepipe on canopy and secure to collar with sheet metal screws WARNING The boiler must be connected to an approved chimney in good condition Serious property damage could result if the boiler is connected to a dirty or inadequate chimney The interior of the chimney flue must be inspected and cleaned before the start of the heating season and should be inspected periodically throughout the heating season for any obstructions A clean and unobstructed chimney flue is necessary to allow noxious fumes that could cause injury or loss of life to vent safely and will contribute toward maintaining
12. 4mm 13 64 5mm L 5 23 BEEN gt 5 64 to 7 64 or 2 to2 5m Figure 7 Riello Electrode Setting Figure 8 Riello Turbulator Setting 13 INSTALLATION INSTRUCTIONS continued PUMP LEGEND PUMP COVER PUMP COVER O RING BSPP NPT ADAPTERS SUPPLY AND RETURN OIL LINES RETURN PORT BY PASS SCREW NOZZLE PORT PUMP OULET TO NOZZLE PUMP PRESSURE PORT AND BLEEDER PORT PUMP SUPPLY PORT PUMP RETURN PORT 10 PUMP PRESSURE REGULATING SCREW 11 VACUUM PORT 12 PUMP VALVE STEM DONON A ton uw Figure 9 Riello Pump Connections and Port Identification g Pump Connections and Port Identification refer to Figure 9 This burner is shipped with the oil pump set to operate on a single line system To operate on a two line system the bypass plug must be installed WARNING DO NOT operate a single line system with the by pass plug installed Operating a single line system with the by pass plug installed will result in damage to the pump shaft seal Note Pump pressure was factory pre set but must be checked at time of burner start up A pressure gauge is attached to the PRESSURE BLEEDER PORT 7 for pressure readings Two PIPE CONNECTORS 4 are supplied with the burner for connection to either a single or two line system Also supplied are two ADAPTORS 3 two female 4 NPT to adapt oil lines to burner pipe connectors All pump port threads are British Parallel Thre
13. PROPER LOCATIONS UNACCEPTABLE LOCATIONS CHIMNEY CHIMNEY SMOKEPIPE CHIMNEY SMOKEPIPE CHIMNEY CHIMNEY Figure 17 Proper and Improper Locations of Draft Regulator lower stack temperature and less dilution air can in some cases contribute to the condensing of small amounts of water vapor in the chimney Such condensation when it occurs can cause chimney deterioration In extreme cases condensed water may be visible on the outside of the breeching or chimney In those extreme cases the chimney may have to be lined to insulate the chimney and thus prevent the condensation The addition of dilution air into the chimney may assist in drying the chimney interior surfaces A massive chimney on a cold or exposed outside wall may have produced adequate draft when it was fired with a higher input and greater volumes of heated gases With reduced input and volume the draft may be severely affected In one instance research showed a new chimney of adequate sizing produced only 035 W C after 30 minutes of continuous firing at 13 0 CO Outside wall chimneys take longer to heat up and can have 00 W C draft at burner startup You may have to consider a special alloy chimney flue liner with insulation around it and a stabilizing draft cap or even a draft inducing fan in severe cases For the same reasons as in 2 above heat extractors mounted into the breeching are not recommen
14. See Figure 1 2 inch OD tubing for both suction and return lines See Figure 3 8 OD 1 2 OD Refer to Figure 19 Tu v GPH Tubing 3 GPH Be sure that all oil line connections are absolutely airtight Check all connections and joints Flared fittings are recommended DO NOT use compression fittings 100 100 100 Open the air bleed valve and start the burner For clean 100 bleed slip a 3 16 ID hose over the end of the bleed 100 valve and bleed into a container Continue to bleed for 100 15 seconds after oil is free of air bubbles Stop burner 100 and close valve 100 100 23 IV ELECTRICAL DANGER Positively assure all electrical connections are unpowered before attempting installation or service of electrical components or connections of the boiler or building Lock out all electrical boxes with padlock once power is turned off WARNING Failure to properly wire electrical connections to the boiler may result in serious physical harm Electrical power may be from more than one source Make sure all power is off before attempting any electrical work Each boiler must be protected with a properly sized fused disconnect Never jump out or make inoperative any safety or operating controls WARNING The primary control may be damaged or may not function properly if 120 volt power supply is NOT wired into control as follows The 120V interrupted hot black wire must be connected
15. T T T TERMINALS CONTROL SCHEMATIC REFER x2 gt 12 gt TO FIGURES 20 THRU 23 OIL SOLENOID VALVE gt gt VALVE CAD WH CELL L2 T gt 12 A BURNER 5 E T T JUMPER SCHEMATIC DIAGRAM LEGEND J BOX SCREW TREMINAL GAD CELE QUICK CONNECT RECEPTACLE BECKETT AFG BURNER WITH GeniSys OIL PRIMARY CONTROL WIRE COLORS BK BLACK BL WH BLUE W WHITE TRACER WH WHITE VI VIOLET YE YELLOW OR ORANGE RD RED WIRE TYPE LEGEND LOW VOLTAGE FACTORY WIRING SIZE 18 AWG 105 C LOW VOLTAGE FIELD WIRING NOTES 1 IF ANY ORIGINAL EQUIPMENT WIRE AS SUPPLIED WITH THE APPLIANCE MUST BE REPLACED IT MUST BE REPLACED WITH WIRE HAVING THE SAME WIRE GAUGE AWG SAME WIRE TYPE AND RATED FOR A MINIMUM OF 105 C NOTE APPLY THIS BURNER SCHEMATIC TO APPROPRIATE STEAM OR WATER BOILER CONTROL SCHEMATIC REFER TO FIGURES 20 THRU 23 LINE VOLTAGE FACTORY WIRING SIZE 18 AWG 105 C RIELLO OIL PRIMARY LINE VOLTAGE FIELD WIRING L RIELLO 40 SERIES BURNER WITH RIELLO OIL PRIMARY CONTROL Figure 24 Schematic Wiring Diagrams For All Burner Options w Various Oil Primary Controls 29 SYSTEM START UP WARNING All boilers equipped with burner swing door have a potential hazard which can cause severe property damage personal injury or loss of life if ignored Before opening swing door turn off serv
16. o of o on B STEAM BOILERS SEQUENCE OF OPERATION Upon a thermostat call for heat when provided the R8239A Control Center Relay or the Oil Primary Control is energized when the steam pressure is below the L404F Pressure Limit and water level is above the Low Water Cut Off When energized the Oil Primary Control starts the burner as follows blower is started and operates for a pre purge time spark is energized and fuel valve is opened for ignition trail time the fuel valve remains open when flame is proven The burner fires until the thermostat is satisfied or the Pressure Limit setting is reached The Oil Primary Control stops the burner by closing the fuel valve and operating the blower for post purge time Upon a drop in pressure steam pressure below the L404F Pressure Limit the burner will re start if the thermostat is still calling for heat When there is a tankless heater included and there is no demand for heat the L4006A operating control will maintain the boiler water temperature at the selected setting for proper operation of the domestic water heater The probe low water cut off will shut down the burner after a 10 15 second delay if the water level in the boiler drops below the probe level The Hydrolevel CG450 low water cut off will shut down the burner for 90 seconds every 10 minutes of firing time to allow water level to stabilize If the water level is too low the burner will not be allowed to restart T
17. 3T10V1d3O3M LO3NNOO lt 8 A 9 M 3llHM HM 2 HO A Am 30705 JAIM GN3931 Wv39VIG 9ILVW3H2S MATIN 9 TISNNOGOW 2 ds TOULNOS TI3MA3NOH lvisvnov Y20077 TISMA3NOH xog 198 MH3TIVISNI 2 lt as HO ONILLAS A 9 M ya YOLVdIOLLNY HN 10 HM A8 5 23 3 HM LVLSOWYSHL 210 C E Pese YATIVLSNI Ad SWALI M31V3H SSSTHNVL HLIM wars 2 HOLIMS NOLLO31O d A ONILLAS YOLVIOLLNV 35 1V3H 10 5 SS ToS Ua LVLSOWYSHL MATIVISNI oc mci rc ue M31V3H SS3 DINVIL SS31 2 TVOIMLOATA AI N IV ELECTRICAL continued BECKETT GeniSys OIL PRIMARY IGNITOR BLWH IGNITOR WH 3 L2 IGN BURNER gt L2 GN MOTOR OR gt MOTOR WH FACTORY gt L2 MTR L INSTALLED eee L LIMIT JUMPER L1 BOARD NOTE APPLY THIS BURNER dn dic SCHEMATIC TO APPROPRIATE x1 LIMIT STEAM OR WATER BOILER
18. 450 sent 155 66 r 56 3 8 7 81 3 112 6 33 5 08 5 55 4 176 73 N e N e N e gt w N EN N A e 733 I GENERAL INFORMATION continued TABLE 3A PURPOSE OF TAPPINGS WATER Tapping Size Location NPT Less Heater With Heater mwa Pus F Ce Temperature Pressure Gauge Supply Optional Return Relief Valve DHW a Limit Well pe NA _ HW net TOP VIEW E TANKLESS 1 m B HEATER ee a o pepe o E o TANKLESS HEATER OPENING NOT PRESENT ON NON HEATER BUILDS 24 FRONT VIEW REAR VIEW Figure 2A Purpose of Tappings Water I GENERAL INFORMATION continued TABLE 3B PURPOSE OF TAPPINGS STEAM Location NPT A s Spy TA lt lt 000 1 1 x NA DHWinlet_ J Ga Indirect Water Heater Limit m spes Surface Blowoff TOP VIEW K TANKLESS B HEATER AUR ma G TANKLESS HEATER OPENING NOT PRESENT ON NON HEATER BUILDS FRONT VIEW REAR VIEW Figure 2B Purpose of Tappings Steam PRE INSTALLATION A INSPECT SHIPMENT carefully for any signs of damage 1 All equipmen
19. FRONT VIEW BURNER SWING DOOR RIGHT SIDE VIEW CLEARANCE OPEN 907 NOTES 1 CIRCULATOR SUPPLIED LOOSE BE INSTALLED ON SUPPLY OR RETURN 2 RETURN FITTINGS AND DRAIN VALVE SHIPPED LOOSE 3 PIPING SHOWN HIDDEN NOT FURNISHED WITH BOILER Figure 1A CL3 Thru CL5 Water Boiler without Tankless Heater All Burner Options 248 L lt A RELIEF VALVE 57 B H a e 14 SUPPLY me FLUE ra COLLAR NN n i DIA T BUILT IN DOMESTIC TEMP ZL RESSURE e WATER HEATER W Os 3 4 CONNECTIONS FLAME 2 OBSERVATION e zi PORT o o BOILER 5 CONTROL 313 OIL BURNER a ra 2 W PRIMARY 12 RETURN 4 11 e Oo e Suto 5 N 1 2 SE FLOOR J i i LINE DRAIN VALVE FRONT VIEW e 2 SEE NOTE 2 RIGHT SIDE VIEW BURNER SWING DOOR CLEARANCE OPEN 90 NOTES 1 CIRCULATOR SUPPLIED LOOSE MAY BE INSTALLED ON SUPPLY OR RETURN 2 RETURN FITTINGS AND DRAIN VALVE SHIPPED LOOSE 3 PIPING SHOWN HIDDEN NOT FURNISHED WITH BOILER Figur
20. furnished with doors are considered a part of the space Volume ft Length ft x Width ft x Height ft 2 Determine total input of all appliances in the space Add inputs of all appliances in the space and round the result to the nearest 1000 BTU per hour 3 Determine type of space Divide Volume by total input of all appliances in space If the result is greater than or equal to 50 ft 1000 BTU per hour then it is considered an unconfined space 1f the result is less than 50 ft 1000 BTU per hour then the space is considered a confined space 4 For boiler located in an unconfined space of a conventionally constructed building the fresh air infiltration through cracks around windows and doors normally provides adequate air for combustion and ventilation 5 For boiler located in a confined space or an unconfined space in a building of unusually tight construction provide outdoor air Outdoor air may be provided with the use of two permanent openings which communicate directly or by duct with the outdoors or spaces crawl or attic freely communicating with the outdoors Locate one opening within 12 inches of top of space Locate remaining opening within 12 inches of bottom of space Minimum dimension of air opening is 3 inches Size each opening per following a Direct communication with outdoors Minimum free area of 1 square inch per 4 000 BTU per hour input of all equipment in space b Vertical du
21. the thermal purge circulator pre purge time maybe added adjusting the Circulator Pre purge time parameter This feature saves energy by starting the circulator and delaying the burner start when there is residual heat available in the boiler TABLE 7 SEQUENCE OF OPERATION Status Codes Displayed Mode a No call for heat detected burner off pump off Either condition is true a Call for heat detected and boiler temperature higher than operating setpoint b Call for heat detected and boiler temperature higher than 140 F and Pump Pre Purge Time has not expired Standby burner off pump on The burner runs until the call for heat is satisfied Self Test Control internal checking Running VI OPERATING continued d Ifthe thermostat is not satisfied and the Operating Setpoint SP is reached the system circulator will continue to operate and the burner will stop When the boiler water temperature drops below the setpoint less the differential setting the burner will restart e After the thermostat is satisfied the burner and circulator are stopped f The Warm Start Boiler Control also includes a low limit control function When the boiler water temperature falls below the Low Limit Setpoint less the Low Limit Differential the ZC terminal and System Circulator outputs are de energized and the oil primary is energized to start the burner As temperature rises above the Low Li
22. Add boiler water treatment compound as needed refer to Paragraph B o Restore electric service to the boiler p Fire burner to bring the water in the boiler to a boil to drive off free oxygen q WARNING BEFORE RETURNING BOILER TO SERVICE Follow the low water cut off check out procedure in Section V System Start Up Paragraph I Step 5 B BOILER AND SYSTEM CLEANING INSTRUCTIONS FOR TROUBLE FREE OPERATION 1 STEAM BOILERS a Oil greases amp sediments which accumulate in a new boiler and piping must be removed from the system in order to prevent an unsteady water line and carry over of the water into the supply main above boiler Operate the boiler with steam in the entire system for a few days allowing the condensate to return to the boiler If the condensate can temporarily be wasted operate boiler only for the length of time it takes for condensate to run clear If the latter cannot be achieved or if the condensate is returned to the boiler boil out the boiler using the SURFACE BLOW OFF connection i Drain boiler until 1 of water is visible in gauge glass Run temporary 1 NPT pipe line from the surface blow off connection to an open drain or some other location where hot water may be discharged safely DO NOT install valve in this line ii Drain about 5 gallons of hot water from boiler into a container and dissolve into it an appropriate amount of recommended boil out compound Remove safety v
23. Co Inc at P O Box 10 Hatfield PA 19440 0010 giving full particulars in support of the claim The original consumer purchaser is required to make available for inspection by New Yorker or its representative the parts claimed to be defective and if requested by New Yorker to ship those parts prepaid to New Yorker at the above address for inspection or repair In addition the original consumer purchaser agrees to make all reasonable efforts to settle any disagreement arising in connection with any warranty claim before resorting to legal remedies in the courts THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE Yorker RESIDENTIAL HEATING BOILERS 02 04
24. FOR CL SERIES BOILERS TABLE 14 RIELLO BURNER SPECIFICATIONS ir 3 Boiler Model Burner 506 Pump Combustion Insertion Model Air Air Gate Turbulator Type Shipped Pressure Depth CL3 105 40F5 Installed SBT 6 0 CL3 140 40F5 s s Installed 150 CL4 126 40F5 Installed 2 3 8 SBT 6 0 2 1 4 SBT 6 0 2 3 8 CL4 210 40F10 228 Installed 150 SBT 5 0 2 1 2 Delavan CL5 168 40F5 100 80B Installed 145 Set 6 0 2 1 4 Delavan 1 35 x 45B EB SBT 5 0 2 1 2 1 65 x 45B y x CL5 280 Delavan Installed 3 Single stage fuel pump is standard two stage fuel pump is optional Burner manufacturer has preset 2 Nozzle s for alternate boiler model firing rate s are shipped loose in bag attached to the single stage fuel pump to settings shown in table above CL4 175 1 25 40F5 Se Installed Delavan KENN burner by corresponding symbol i e A CL3 105 NOTE When ordering parts always give the serial and model numbers shown on the boiler and burner Refer to Models amp F5 Installation Manual Riello 40 Series Residential Oil Burners C6501010 Model F10 Installation Manual Riello 40 Series Residential Oil Burners 2902554 for an exploded view of the burner and a list of spare parts For replacement Riello oil burner parts contact your wholesaler or the burner manufacturer Riello Corporation of America Riello Cana
25. JiVid ONILSAPAV NO 5 IV QV3H 40 NOILVOOT LNHWISOfGV ig 1 GQV3H LA HO able 10804193 3 o8v t 9 1 81220 01 ol F penunuo INW LLSAS A 33 SYSTEM START UP continued GASKET L IGNITOR Figure 27 Cad Cell Location H CHECK FOR CLEAN CUT OFF OF BURNER 1 AIR IN THE OIL LINE between fuel unit and nozzle will compress when burner is on and will expand when burner stops causing oil to squirt from nozzle at low pressure as burner slows down and causing nozzle to drip after burner stops Usually cycling the burner operation about 5 to 10 times will rid oil line of this air 2 IF NOZZLE CONTINUES TO DRIP repeat Paragraph H Step 1 above If this does not stop the dripping remove cut off valve and seat and wipe both with a clean cloth until clean then replace and readjust oil pressure If dripping or after burn persist replace fuel pump I TEST CONTROLS 1 Check thermostat operation Raise and lower thermostat setting as required to start and stop burner WARNING Before installation of the boiler is considered complete the operation of all boiler controls must be checked particularly the primary control and high limit control 2 VERIFY OIL PRIMARY CONTROL FEATURES using procedures outl
26. The CL boiler controls operate the burner automatically If for unknown reasons the burner ceases to fire and the reset button on the primary control has tripped the burner has experienced ignition failure Refer to Oil Primary Control features Paragraph I Step 2 of this Section and Section IX Troubleshooting Paragraph B If the failure re occurs call your heating contractor immediately before pressing the reset button WARNING DO NOT attempt to start the burner when excess oil has accumulated when the boiler is full of vapor or when the combustion chamber is very hot 10 CAD CELL LOCATION AND SERVICE The burner is supplied with a cadmium sulfide flame detector mounted at the factory mounted on the bottom of the electronic ignitor See Figure 27 To service cad cell or to replace the plug in portion swing open the ignitor After service is complete be sure to fasten down the ignitor 54V 5 pue Buruonisod A 17 92 9 1614 ONILSAPAVY AYVGNOOSS on AYYNINd Y ieee e M3HSVM 201 NMNOOV dlv ld AN Q3 T40N jlV ld AAYAN SSANLIM 112201 0 LV DNILLYS M3MOS Qv3H 318VIMJVA
27. adjustable between 140 F and 180 F h Priority Time _ When the Priority Time parameter is set to on and Domestic Hot Water DHW call for heat is on the DHW demand will take Priority over home heating demand and the system circulator will be forced Priority Time ends and the system circulator is released to service home heating demand when Domestic Hot Water call for heat is over When Priority Time parameter is set to Off the DHW call for heat does not force off the system circulator The Priority Time has a factory setting of On and is field adjustable between On and Off Refer to Table 9A TABLE 9A DOMESTIC HOT WATER DEMAND PARAMETER dH Call for Heat Circulator Status Priority System DHW uh 2 Circulator Circulator E ZC Output on of n input terminal for the IWH Aquastat and ZC output terminal for the DHW Circulator When there is a DHW call for heat the System Circulator 1s forced off the DHW Circulator terminal is energized and the circulator pre purge time delay control logic is bypassed to allow the boiler to fire without delay When DHW demand ends the System Circulator force off is removed the circulator can respond normally and the DHW Circulator is de energized The DHW call for heat is detected by a voltage on to the ZR terminal When a Priority Time parameter is set to off the
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29. boiler and in return main and feed water slowly up to normal level in boiler Turn on oil burner and allow boiler to steam for 10 minutes then turn off burner Draw off one quart of water from bottom gauge glass fitting and discard Draw off another quart sample and if this sample is not clear repeat the cycle of draining the boiler and return main and refilling the boiler until sample is clear vi Ifthe boiler water becomes dirty again at a later date due to additional sediment loosened up in the piping close gate valve in Hartford Loop open drain valve in return main turn on oil burner and allow Condensate to flow to drain until it has run clear for at least 30 minutes while feeding water to boiler so as to maintain normal water level Turn off oil burner drain boiler open gate valve in Hartford Loop then repeat the full Boiler and System Cleaning procedure outlined in Paragraph B starting on Page 30 Make pH or Alkalinity Test After boiler and system have been cleaned and refilled as previously described test the pH of the water in the system This can easily be done by drawing a small sample of boiler water and testing with hydrion paper which is used in the same manner as litmus paper except it gives specific readings A color chart on the side of the small hydrion dispenser gives the reading in pH Hydrion paper is inexpensive and obtainable from any chemical supply house or through your local druggist The pH shou
30. bottom of sight glass until burner operation is shut down by low water cut off Close boiler drain and refill to normal water line Burner should automatically restart during fill Lower thermostat setting b Water Boiler Refer to Appendix A at the rear of this manual 6 CHECK OPERATING CONTROL on boiler applications equipped with tankless heater s With burner off draw hot water until burner starts then turn off hot water and check burner shut down IF_ CONTROLS MEET REQUIREMENT outlined in Paragraph I 1 Allow boiler to operate for approximately 30 minute confirm the boiler and system have no leaks IF CONTROLS DO NOT MEET REQUIREMENTS outlined in Paragraphs I 1 thru I 6 replace control and repeat checkout procedures VI OPERATING A WATER BOILERS SEQUENCE OF OPERATION 1 a Water Boilers Without Tankless Heaters Cold Start Sequence Of Operation The CL Boiler is equipped with an Intelligent Oil Boiler Control Cold Start Boiler Control The boiler control replaces the traditional electronic aquastat and circulator relays and adds energy saving thermal purge features Energy is saved by starting the circulator and delaying the burner start when there is residual heat available in the boiler The boiler s sequence of operation is shown as Status Codes on Boiler Control display See Table 7 and Figure 29 When the thermostat calls for heat the boiler control starts the system circulator and
31. cast iron in that area gets extremely hot and eventually cracks The presence of free oxygen or chloride salts in the boiler corrodes the cast iron from the inside More make up water and higher concentrations of contaminants damage the boiler sooner Our warranty does not cover corrosion and sediment related damage Clearly it is in everyone s best interest to prevent this type of failure You can do your part by ensuring that your system is leak free keeping leakage to less than 2 percent of the total water volume each month IMPORTANT IF DURING NORMAL OPERATION IT IS NECESSARY TO ADD MORE WATER THAN INDICATED BELOW CONSULT A QUALIFIED SERVICE TECHNICIAN TO CHECK YOUR SYSTEM FOR LEAKS Gallons Per Gallons Per 05 C ATTENTION TO BOILER WHILE NOT IN OPERATION 1 IMPORTANT IF BOILER IS NOT USED DURING WINTER TIME IT MUST BE FULLY DRAINED TO PREVENT FREEZE DAMAGE MAINTENANCE AND SERVICE INSTRUCTIONS continued 2 Spray inside surfaces with light lubricating or crankcase oil using gun with extended stem so as to reach all corners 3 With steam boilers at end of season add sufficient water to fill boiler to top of water column and leave it that way until fall when water should be drained again to proper level If at this time boiler water is dirty drain water flush out boiler and refill with clean water to prescribed water level 4 Alway
32. clearance on the right side of the boiler Boiler flueways may be cleaned either from the top or from the right side Provide at least 24 clearance from either the right side of the boiler or the top of the boiler for cleaning flueways 5 For minimum clearances to combustible materials See Figure 3 NOTICE Clearance to venting is for single wall vent pipe Type L vent is used clearance may be reduced to the minimum required by the vent pipe manufacturer PROVIDE COMBUSTION AND VENTILATION AIR Local and National Codes may apply and should be referenced a ass SIDE UF BOILER 27 NOTE 2 CL Series boilers can be installed in rooms with clearances from combustible material as listed above Listed clearances cannot be reduced for alcove or closet installations NOTE 3 For reduced clearances to combustible material protection must be provided as described in the ANSI NFPA 31 standard H PRE INSTALLATION continued WARNING Adequate combustion and ventilation air must be provided to assure proper combustion and to maintain safe ambient air temperatures DO NOT install boiler where gasoline or other flammable vapors or liquids or sources of hydrocarbons i e bleaches fabric softeners etc are used or stored 1 Determine volume of space boiler room Rooms communicating directly with the space in which the appliances are installed through openings not
33. flow through the indirect water heater called for by the indirect water heater manufacturer Refer to the indirect water heater instruction manual for additional details CL SERIES STEAM BOILER All CL Series steam boilers are equipped with tappings to permit the connect of an indirect water heater see Figures 2B and 15 In this type of system hot boiler water is drawn from below the water line and passed through the heat exchanger in the indirect water heater This section describes boiler side piping only Refer to the indirect water heater instruction manual for additional details K INSTALL SMOKEPIPE The CL Series boiler FIRECLAY TILE LINED CHIMNEY S VENT PIPE 26 GA MIN NOTE THIMBLE ALL HORIZONTAL VENT PIPE SHOULD SLOPE UPWARD NOT LESS THAN ONE INCH IN SLOPE UP FOUR FEET r AIR GAP DRAFT REGULATOR SYSTEM DILUTION AIR 1 18 MIN l x Ni Ep qo CLEANOUT LL I I Dd I 3 eI Ti l FLOOR LINE Figure 16 Recommended Smokepipe Arrangement and Chimney Requirements should be vented into a fireclay tile lined masonry chimney or chimne
34. left corner of front section Refer to Figures 1A thru 1D and Section Installation Instructions for additional details It is the responsibility of the installing contractor to see that all controls are correctly installed and are operating properly when installation is complete including verifying that the limit sensor is fully installed seated in bottom of Well Failure to properly install Limit Sensor may result in property damage personal injury or loss of life due to elevated operating temperatures and or pressures This boiler is suitable for installation on combustible flooring DO NOT install boiler on carpeting DO NOT tamper with or alter the boiler or controls Inspect flueways at least once a year preferably at the start of the heating season The inside of the combustion chamber the vent system and boiler flueways should be cleaned if soot or scale has accumulated When cleaning this boiler DO NOT damage combustion chamber liner and or rear target wall If damaged combustion chamber insulation must be replaced immediately Oil Burner and Controls must be checked at least once a year or as may be necessitated DO NOT operate boiler with jumpered or absent controls or safety devices DO NOT operate boiler if any control switch component or device has been subject to water Boiler materials of construction products of combustion and the fuel contain alumina silica heavy metals carbon monoxide nitrogen oxides
35. off the dissolved gases in the fresh water If unsteady water line foaming or priming persist install gate valve in Hartford Loop and drain valves in return main and at boiler as shown in Figure 10 and proceed as follows i Connect hoses from drain valves to floor drain Close gate valve in Hartford Loop and open drain valve in return main Fill boiler to normal water level turn on oil burner and operate boiler at this water level for at least 30 minutes after the condensate begins to run hot then turn off burner Close all radiator valves Remove all supply main air valves and plug the openings in supply main Draw about 5 gallons of hot water from boiler into a container and dissolve into it the appropriate amount of a recommended boilout compound Remove safety valve from boiler and pour this solution into boiler then reinstall safety valve iii Turn on oil burner and keep operating while feeding water to boiler slowly This will raise water level in boiler slowly so that water will be boiling hot and will rise slowly operating oil burner until excess water in boiler flows out through supply main and water lowers by steaming until it reaches normal level in boiler Turn off oil burner Drain boiler Open all radiator valves Reinstall all supply main air valves Open gate valve in Hartford Loop v When boiler has cooled down sufficiently crown sheet of sections are not too hot to touch close the drain valves at
36. the thermal purge circulator pre purge time begins If the time is completed or boiler temperature is less than the Start Temperature 140 F default the start sequence continues by energizing the oil primary to operate the following sequence blower is started and operates for pre purge time spark is energized and fuel valve is opened for ignition trial time burner fires until the thermostat is satisfied If the thermostat is not satisfied and the Operating Setpoint SP is reached the system circulator will continue to operate and the burner will stop When the boiler water temperature drops below the setpoint less the differential setting the burner will restart After the thermostat is satisfied the burner and circulator are stopped When an indirect water heater aquastat call for heat is wired to the ZR terminal the Boiler Control starts a domestic hot water circulator connected to the ZC terminal and when the boiler temperature is less than Operating Setpoint SP the boiler control energizes the oil primary to turn on the burner without circulator pre purge delay On burner start if the CAD cell does not see flame within approximately 15 seconds primary control will shut down the burner and enter into a lockout mode A lockout is reset by pressing the reset button located on the primary control If the flame is lost while the burner is firing the primary control shuts down the burner enters a 60 second recy
37. to fuel pump vent fitting and provide a pan to catch the oil OPEN FLAME OBSERVATION PORT COVER on burner swing door Riello Burners Inspect Riello head setting on left side of burner by reading the scale embossed on the housing cover Refer to Figure 8 Inspect Riello burner air damper and turbulator setting Readjust if necessary see Table 14B at the rear of this manual OPEN ALL OIL LINE VALVES Provide a pan to catch oil Remove pressure port bleeder plug from fuel pump and install Riello Combination Pressure Gauge and Bleeder Valve Assembly OPEN FLAME OBSERVATION PORT COVER on burner swing door START BURNER Open vent fitting on fuel pump TURN ON BURNER service switch and allow burner to run until oil flows from vent fitting ina SOLID stream without air bubbles for approximately 10 seconds Close vent fitting and burner flame should start immediately after prepurge is completed Prepurge prevents burner flame until 10 seconds has elapsed after initial power is applied to burner During prepurge the motor and igniter will operate but the oil valve will remain closed Refer to Oil Primary Control Instructions for more details a Adjust oil pressure When checking a fuel unit s operating pressure a reliable pressure gauge may be installed in either the bleeder port or the nozzle port For Beckett burner refer to Figure 25 Refer to Figure 9 for Riello burner
38. 0 1600 ohms Limited 1600 ohms to lockout 3 CHECK OIL PRIMARY CONTROL CAUTION Check contacts between ignitor and the electrodes Check the oil pump pressure Check the piping to the oil tank Check the oil nozzle oil supply and oil filter Check Safety Features Safe Start Place a jumper across cad cell terminals Follow procedure to turn on burner Burner must not start indicator light turns on and control remains in Idle Mode Remove jumper Simulate Ignition or Flame Failure Follow procedure to turn on burner Check cad cell resistance If resistance 1s below 1600 OHMS and burner runs beyond safety cut out time cad cell is good If safety switch shuts down burner and resistance is above 1600 OHMS open line switch to boiler Access cad cell under ignitor clean face of cad cell and see that cell is securely in socket Check gasket around perimeter of ignitor lid for proper seal If gasket is missing or damaged replace gasket Room light can effect cad cell resistance Reset safety switch Close line switch to boiler If burner starts and runs beyond safety switch cut off time cell is good If not install new cell Close hand valve in oil supply line Failure occurs device enters Recycle Mode Device tries to restart system after approximately 60 seconds After third Recycle Mode trial safety switch locks out within safety switch timing indicated on label and
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40. INSTALLATION OPERATING AND SERVICE INSTRUCTIONS CL SERIES CAST IRON OIL FIRED BOILER ENERGY STAR H As ENERGY STAR Partner New Yorker Boiler Co Inc US has determined that the Listed CL3 091 CL3 105 CL4 126 and CL5 168 water boilers Intertek meet the ENERGY STAR guidelines for Energy efficiency established by the United States Environmental A LID i Protection Agency lt all E RTI FI E www ahridirectory org 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 Boiler Serial Number Installation Date CL Heating Contractor Phone Number New Yorker RESIDENTIAL HEATING BOILERS 103876 02 11 12 Price 5 00 IMPORTANT INFORMATION READ CAREFULLY All boilers must be installed in accordance with National State and Local Plumbing Heating and Electrical Codes and the regulations of the serving utilities These Codes and Regulations may differ from this instruction manual Authorities having jurisdiction should be consulted before installations are made In all cases reference should be made to the following Standards USA BOILERS A Current Edition of American National Standard ANSI NFPA 31 Installation of Oil Burning Equipment for recommended installation practices B Current Edition of American
41. M31v3H M31VM MO QNV n L OILSSWOd LOAYIGNI Alddhs 3ATVA MO3H WALSAS 3ATVA 40 3ATVA agate W31SAS jJO 1nHS JAVA 3ATVA 3ATVA q3MInO3M 40 JAYA NOISNVdX3 440 LNHS Adans JAVA MO3HO 440 10 5 3unss3uq T MALVM 10 7 JAVA Tyg tl SATIVA YOLVINOMIO 0 934 4 WALSAS M3OnQq3M M313WOWs3H 435 SI 40025 TVNOLLIN3ANOO Jl SSVdAH JAYA 3NOZ TE 331108 YI S3ATVA JAVA SNIONYTVS IN3A 440 101 5 39Mfd S3ATVA ONION IVE PI Z 3NOZ 3NOZ SJAA 3NOZ LINO SW3lSAS 3NOZ 319 5 7 OL OL NMOHS SV NOILISOd TWOILYSA NI Z 10 OG S3AlVA 3NOZ 3WOS NOLLVTIVISNI OL SNOILONULSNI S YSYNLOVANNVW SATIVA INOZ 93H9 71 SALON 3 07 TIWNOILIGGV SNOLLONULSNI NOLLVTIVLSNI III 17 1 iog weas APAeID 2 91 4 4 4 209 3NI1331VM z OL aamia 53708 4 15 3337 p OL 30073 t NIHLIM OL ASYVHOSIC 3ATVA Al133VS 719 519 3ZIS WNWININ 59 WALSAS 437108 41 303 S3ATVA
42. NG OF SEDIMENT 1 ke D T I GLOBE VALVE OR BALL VALVE FLOW REGULATOR T IN COLD WATER LINE AT LEAST THREE SAFETY RELIEF VALVE FEET AHEAD OF TANKLESS HEATER Figure 14 Schematic Tankless Heater Piping TABLE 4 TANKLESS HEATER DATA Boiler Mode Foo 40 ar 350 55 64 96 CAUTION Oxygen contamination of the boiler water will cause corrosion of iron and steel boiler components and can lead to boiler failure New Yorker 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 I CONNECT TANKLESS HEATER PIPING AS SHOWN IN Figure 14 See Table 4 for Tankless Heater Ratings THE FOLLOWING GUIDELINES SHOULD BE FOLLOWED WHEN PIPING THE TANKLESS HEATER 1 FLOW REGULATION If flow through the heater is greater than its rating the supply of adequate hot water may not be able to keep up with the demand For this reason a flow regulator matching the heater rating should be installed in the cold water line to the heater The flow regulator should preferably be located below the inlet to the heater and a minimum 20 of 3 away from the inlet so that the regulator is not subjected to excess temperatures that may occur during off periods when it is possible for heat to be conducted back through the supply line The flow regulator also limits the flow of supp
43. National Standard ANSI NFPA 211 Chimneys Fireplaces Vents and Solid Fuel Burning Appliances For Venting requirements C Current Edition of American Society of Mechanical Engineers ASME CSD 1 Controls and Safety Devices for Automatically Fired Boilers for assembly and operations of controls and safety devices D All wiring on boilers installed in the USA shall be made in accordance with the National Electrical Code and or Local Regulations The following terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or to important information concerning product life DANGER Indicates an imminently hazardous situation which if not avoided will result in death serious injury or substantial property damage WARNING Indicates a potentially hazardous situation which if not avoided could result in death serious injury or substantial property damage CAUTION Indicates a potentially hazardous situation which if not avoided may result in moderate or minor injury or property damage NOTICE Indicates special instructions installation operation or maintenance which are important but not related to personal injury hazards NOTICE This boiler has a limited warranty a copy of which is printed on the back of this manual The warranty for this boiler is valid only if the boiler has been installed maintained and operated in accordance with these instructi
44. S 801 Beckett Burner 248 X 5 jm SAFTEY VALVE supPLY 3 8 La T PRESSURE McDONNELL amp MILLER GAUGE 5 801 120 L W C O PRESSURETROL WATER GAUGE GLASS HONEYWELL R8239C CONTROL CENTER BUILT IN DOMESTIC WATER HEATER W 3 4 CONNECTIONS numm OIL BURNER GERA IN W PRIMARY o AQUASTAT 318 PORT CONTROL N HEATER CONTROL OPTIONAL o 257 o bi 9 i Y FLOOR LINE 1 14 WET RETURN 14 RETURN CONNECTIO 11 2 SEE NOTE 3 BURNER SWING DOOR FRONT VIEW CLEARANCE OPEN 90 RIGHT SIDE VIEW OTES 1 TANKLESS COIL OPENING NOT PRESENT ON LESS COIL BOILERS 2 PIPING SHOWN HIDDEN NOT FURNISHED WITH BOILER 3 DRAIN VALVE SHIPPED LOOSE NOT SHOWN Figure 1D CL3 thru CL5 Steam Boiler with or without Tankless Heater McDonnell amp Miller PS 801 Riello Burner I GENERAL INFORMATION continued TABLE 1 DIMENSIONAL DATA GENERAL INFORMATION SEE FIGURES 1 THRU 1D I Dimensions Approx Water Content Heat Transfer Surface Boiler Model
45. System Circulator is not forced off for a DHW call for heat Refer to Table 9A When an Outdoor Air Reset Option Card is installed and there is a DHW call for heat there 1s an adjustable DHW Temperature Setpoint and Priority Timer included Refer to Table 9B TABLE 9B DOMESTIC HOT WATER DEMAND PARAMETER 27 _ dH Outdoor Air Reset Option Card Installed Outdoor Air Reset Option Card P N 102294 01 Call for Heat Circulator Status ZR zc Input Input Input time Time Output Output Expired of Le n e of gt o m of on on gt o m er en om gt o ys en VI OPERATING continued TABLE 10 ZONE REQUEST PARAMETER cr Call for Heat Circulator Status T T ZR C1 ZC Input Input Output Output o of o of o o o o ii When is set equal to Zone Request 27 When there is no IWH the Cold Start Boiler Control ZC output may be configured to control a second heating zone This is particularly helpful when the home uses only two heating zones The boiler control replaces the need for a two circulator zone panel When DHW Terminal Function dh_ is set to cr the boiler control s two circulator outputs are used to control two independent heating zones Refer to Table 10 A TT input causes a call for heat and energizes the System Circulator output to service heating zone 1 A sec
46. T Bushing Black Steel 1 4 _ fo 3 4 NPT x 3 Immersion Well Honeywell 123871 80160452 6 Steam Gauge 1 4 NPT x 2 1 2 Dia x 7 8 Shank 100325 01 10 Gauge Glass Set Conbraco 22 171 10 1 1 1 10085401 1 1 2 Male Female NPT Brass Extension Piece 1 2 NPT Brass Street Elbow 1 1 1 1 10085254 s wewPTKTWig Nppe Bak 31 34 NPT 15 PSI Safety Valve 9135115 1 519955 3 4 NPT Coupling Malleable 1 1 1 806602561 11 34 Ball Drain Valve Conbraco 35 302 03 J 1 55 Jauing WIZZON 21118 AT8IW3SSV 13OVdS YAdIdS dINV TO 39044195713 Yaldvdv 31ZZON Z s A18Wassv 390519575 11220 ATgW3SSV 10313 19414 1 4 MAIA ACIS H3LLRHS YOLOW 1914 YOLOANNOO ONILNNOW ag AT8W3SSV E BA OS 99 310H 5 o 5 A ONISNOH 3GISNI dl4d4v8 YOLIND
47. TER TRIM CARTON CL3 Thru CL5 Water Boilers Trim and Controls Item Description Boiler Size Quantity Part No No CL3 Thru CL5 Water Boilers Trim and Controls Beckett GeniSys 7505B Oil Primary Control 103447 01 Honeywell L7248L1090 Hi Limit Circ Relay WL 103850 01 2 OR 1 1 1 Honeywell L7224C1010 Hi amp Lo Limit Circ Relay WT 103854 01 1 2 NPT x 1 1 2 Immersion Well Honeywell 123869A WL OR 1 1 1 x 3 Immersion Well Honeywell 123871A WT ERENENE Temperature Pressure Gauge NPT x 2 1 2 Dia x 1 1 2 Lg Shank 1 1 1 1002821 3 4 NPT x 7 1 4 Lg Nipple SCH 80 Black 1 1 100839 01 31 8169315 _ 3 806600060 171 3 4 NPT Ball Drain Valve Conbraco 35 302 03 007 Hex Nut 7 16 14 Taco 00 Series Flange Gasket Gasket Only 2 5 142 54 x 2 NPT Tee Bak ao X REPAIR PARTS continued INTERIOR PART BEHIND JACKET gt INSTRUCTIONS ENVELOPE WN 2 STEAM TRIM CARTON 8 oU CL3 Thru CL5 Steam Boilers Trim and Controls Item D ipti Boiler Size Quantity CL3 Thru CL5 Steam Boilers Trim and Controls Beckett GeniSys 7505B Oil Primary Control 1 1 1044701 McDonnell amp Miller PS801 120 LWCO With Probe 1 1 1 8016072 Honeywell PA404A1009 Pressuretrol 1 1 1 80160300 1 2 x 1 4 NP
48. Table 14B at the rear of this manual ADJUST DRAFT REGULATOR for a draft of 0 02 water gauge over the fire after chimney has reached operating temperature and while burner is running READJUST THE AIR DAMPER SETTING air Band Air Shutter Air Gate on the burner for a light orange colored flame while the draft over the fire is 0 02 Use a smoke tester and adjust air for minimum smoke not to exceed Z1 with a minimum of excess air Make final check using suitable instrumentation to obtain a CO of 11 5 to 12 5 with draft of 0 02 water gauge in fire box These settings will assure a safe and efficient operating condition If the flame appears stringy instead of a solid fire try another nozzle of the same type Flame should be solid and compact After all adjustments are made recheck for a draft of 0 02 over the fire 7 ONLY READJUST THE HEAD TURBULATOR SETTING if necessary through CLS Models Move the setting forward or back one position at a time to optimize the smoke and CO readings b Steps outlined in Paragraph 5 and 6 above must be repeated every time the Head Turbulator or Air Damper Setting is readjusted 8 Turn OFF burner and remove Riello Combination Pressure Gauge and Bleeder Valve Assembly Install pressure port bleeder plug and tighten Start burner again WARNING DO NOT loosen or remove any oil line fittings while burner is operating 9 FLAME FAILURE
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50. a Close full port ball valve in boiler system piping b Isolate all zones by closing zone valves or shut off valves in supply and return of each zone s c Attach a hose to vertical purge valve in boiler system piping Note Terminate hose in five gallon bucket at a suitable floor drain or outdoor area d Starting with one zone at a time open zone valve or shut off valve in boiler supply and return piping 30 e Open purge valve f Open shut off valve in cold water supply piping located between the air scoop and expansion tank g Allow water to overflow from bucket until discharge from hose is bubble free for 30 seconds h When zone is completely purged of air close zone valve or shut off valve Open zone valve to the next zone to be purged Repeat this step until all zones have been purged At completion open all zone valves 1 Close purge valve continue filling the system until the pressure gauge reads 12 psi Close shut off valve in cold water supply piping WARNING The maximum operating pressure of this boiler is posted on the ASME Data Label located on the top of the boiler Never exceed this pressure DO NOT plug safety or relief valve NOTICE make up water line is equipped with pressure reducing valve system will automatically fill to 12 psi Follow fill valve manufacturer s instructions j Open full port ball valve in boiler system piping k Remove hose from purge valve 1 Con
51. able if the boiler has been damaged as a result of being improperly serviced or operated including but not limited to the following operated with insufficient water allowed to freeze subjected to flood conditions or operated with water conditions and or fuels or additives which causes unusual deposits or corrosion in or on the pressure vessel or associated controls 6 Geographic Limitations these warranties apply only to boilers installed within the 48 contiguous United States 7 Installation Requirements in order for these warranties to be effective a The boiler must be installed in a single or two family residential dwelling This warranty does not apply to boilers installed in ts for commercial or industrial applications b The boiler must be installed in strict compliance with New Yorker s Installation Operating and Service Instructions by an installer regularly engaged in boiler installations c Boiler sections must not have been damaged during shipment or installation d The boiler must be vented in accordance with chimney recommendations set forth in New Yorker s Installation Operating and Service Instructions 8 Exclusive Remedy New Yorker s obligation in the event of any breach of these warranties is expressly limited to the repair or replacement of any part found to be defective under conditions of normal use 9 Limitation of Damages Under no circumstances will New Yorker be liable for incidental indirect speci
52. acom terminal is shorted to ground or line voltage Check wiring to EnviraCOM terminals 1 2 and 3 Wiring to external EnviraCom device is incorrect Error detected with AC power supply frequency or boiler control failure Cycle power to the control Replace control if problem persists B1 output sensed powered during safety output relay check sequence or un powered during running or powered in idle in combination with water temperature above 264 F limit Cycle power to the control Replace control if problem persists AC voltage out of specification high or low check L1 L2 110 VAC Internal fuse is blown or missing The fuse protects the Aquastat from miswiring the 11 and L2 on Oil Primary When the Oil Primary is correctly wired the fuse is useless and not detected If Primary is wired incorrectly the fuse is blown out and Aquastat report error 6 EnviraCOM message is sent when the wiring is fixed and the error disappears to indicate the end of the error state Check wiring and replace fuse Warning Generated if user adjustments are lost and the device uses factory default values Error is cleared by entering and exiting the Adjustment mode Replace control if problem persists Set if E r was invoked four times a row Check wiring and clear Lockout by pressing all three user keys for 30 seconds X REPAIR PARTS All CL Series repair parts may be ordered through New Yorker Boiler Co Inc or its authorized distributor
53. ad design Direct connection of NPT threads to the pump will damage the pump body Riello manometers and vacuum gauges DO NOT require any adapters and can be safely connected to the pump ports An NPT x metric adapter must be used when connecting other gauge models h Replace Burner Cover and Tighten Burner Cover Screws INSTALL WATER BOILER TRIM AND CONTROLS see Figures 1A and 1B 1 Install return piping supplied with boiler Apply Teflon or Sealant to all joints prior to assembly Thread 1 NPT x 5 Lg return nipple into 172 NPT tapping located in lower left corner of front section Thread 15 4 1 NPT tee onto 5 nipple Thread 32 drain valve into 34 NPT connection on tee Tighten all joints with wrench 14 until water tight and 1 NPT return connection on tee is facing away from boiler horizontally to allow for proper burner swing door clearance see Figures 1A IB 11A and 11B Note Vertical piping will prevent door from opening fully for service and cleaning of boiler 2 Thread relief valve onto factory installed 94 NPT x 74 nipple located in left rear corner on top of boiler as shown in Figures 1A and 1B Valve spindle must be in vertical position Tighten with wrench Pipe discharge as shown in Figures 11A and 11B Installation of the relief valve must be consistent with ANSI ASME Boiler and Pressure Vessel Code Section IV 3 Connect Field Wiring Connect the field wiring to the Warm o
54. al or consequential damages of any kind under these warranties including without limitation injury or damage to persons or property and damages for loss of use inconvenience or loss of time New Yorker s liability under these warranties shall under no circumstances exceed the purchase price paid for the boiler involved Some states do not allow the exclusion or limitation of incidental or consequential damages so the above limitation or exclusion may not apply to you 10 Limitation of Warranty these limited warranties are given in lieu of all other express warranties and set forth the entire obligation of New Yorker with respect to any defect in a residential water boiler New Yorker shall have no express obligations responsibilities or liabilities of any kind other than those set forth herein ALL APPLICABLE IMPLIED WARRANTIES IF ANY INCLUDING ANY WARRANTY OF MERCHANT ABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY LIMITED DURATION TO A PERIOD OF ONE YEAR EXCEPT THAT IMPLIED WARRANTIES IF ANY APPLICABLE TO THE PRESSURE VESSEL OF A RESIDENTIAL WATER BOILER SHALL BE LIMITED IN DURATION TO THE LESSER OF THE DURATION OF SUCH IMPLIED WARRANTY OR A PERIOD EQUAL TO THE TERM OF THE APPLICABLE EXPRESS WARRANTY Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply to you PROCEDURE FOR OBTAINING WARRANTY SERVICE Upon discovery of a condition believed to be related t
55. aldehydes and or other toxic or harmful substances which can cause death or serious injury and which are known to the state of California to cause cancer birth defects and other reproductive harm Always use proper safety clothing respirators and equipment when servicing or working nearby the boiler WARNING This boiler contains very hot water under 12 15 PSI pressure DO NOT unscrew any pipe fittings nor attempt to disconnect any components of this boiler without positively assuring the water is cool and has no pressure Always wear protective clothing and equipment when installing starting up or servicing this boiler to prevent scald injuries DO NOT rely on the pressure and temperature gauges to determine the temperature and pressure of the boiler This boiler contains components which become very hot when the boiler is operating DO NOT touch any components unless they are cool High water temperatures increase the risk of scalding injury If this boiler is equipped with a tankless heater for domestic water supply a flow regulator and automatic mixing valve must be installed properly in tankless heater piping Refer to Section Installation Instructions for additional details This boiler needs fresh air for safe operation and must be installed so there are provisions for adequate combustion and ventilation air This boiler must be connected to an approved chimney or vent system in good condition Serious property damage could resul
56. alve amp add solution to boiler water thru exposed tapping using a funnel MAINTENANCE AND SERVICE INSTRUCTIONS continued into supply main and back through return NOTICE main flowing from drain hose at about 180 F Continue until water runs clear from drain hose for at least 30 minutes Check with local authorities or consult local water treatment services for acceptable chemical cleaning compounds iv Stop feeding water to boiler but continue Start burner and operate sufficiently to boil the water without producing steam pressure Boil for about 5 hours Open boiler feed pipe sufficiently to permit a steady trickle of water from the surface blow off pipe Continue this slow boiling and trickle of overflow for several hours until the water coming from the overflow is clear _ iv Stop burner and drain boiler in a manner and to a location that hot water can be discharged with safety v Refill boiler to normal water line If water in gauge glass does not appear to be clear repeat steps i thru iii and boil out the boiler for a longer time Low pressure steam boilers such as the CL Series should be maintained with appropriate water treatment compounds Add suitable water treatment compounds as recommended by your qualified water treatment company Remove temporary surface blow off piping plug tapping and reinstall safety valve Boil or bring water temperature to 180 F promptly in order to drive
57. an also cause shut down noises NOTICE CHECK TEST PROCEDURE A very good test for isolating fuel side problems is to disconnect the fuel system and with a 24 length of tubing fire out of an auxiliary five gallon pail of clean fresh warm 2 oil from another source If the burner runs successfully when drawing out of the auxiliary pail then the problem is isolated to the fuel or fuel lines being used on the jobsite IX TROUBLESHOOTING continued B OIL PRIMARY CONTROL Oil Primary g Oil valve stuck open or closed 1 Burner Oil Primary will not come on Note The Safety Monitoring Circuit SMC is a No power to Oil Primary designed to provide lockout in the event of a b Oil Primary is in lockout or restricted mode stuck or welded motor relay Press reset button for one 1 second to exit lockout If control has recycled three times NOTICE within the same call for heat it will enter into restricted mode To reset from restricted mode refer to Section V Paragraph I Step 2 for details CAD cell seeing light CAD assembly defective control If flame is not established within 15 seconds of oil valve actuation known as Trial For Ignition lockout will occur Lockout is indicated by a red LED solid on located on the oil primary e Control motor relay is stuck closed see note Hard Lockout will occur if the Oil Primary below Control locks out three 3 times during a call 2 Burner contro
58. cidental firing of burner outside the combustion chamber Be sure to tighten swing door fastener completely when service is completed TABLE OF CONTENTS General Information 5 Maintenance amp Service Instructions 42 Pre Installation 10 VIII Boiler Cleaning 45 Installation Instructions 12 IX Trouble Shooting 48 Electrical ee enn 24 X Repair 51 V System Start Up 30 Burner Specifications 58 Operating 37 Appendix A Low Water Cut Off 60 I GENERAL INFORMATION 33 144 P TN _ RELIEF VALVE 5 B 2i a sue MIS 0001124 aeque S 3 DIA i TEMP PRESSURE FLAME OBSERVATION PORT 1 e ST BOILER CONTROL 1 1 RETURN OIL BURNER ME W PRIMARY l CONTROL ME M Le pus FLOOR N D ap LINE SEE NOTE 2 DRAIN VALVE 117
59. cle delay and repeats the ignition sequence If after three 3 trials for ignition flame is not detected primary control will enter into restricted mode Restricted mode is reset by holding down the reset button for 15 seconds I BUTTO DISPLAY CAPACITOR DOWN BUTTON SFORMER UP BUTTON me THERMOSTAT SENSOR HOLE TERMINALS VERTICAL MOUNT RELAYS ENVIRACOM TERMINALS SENSOR CONNECTOR FIELD TERMINALS SENSOR HOLE HORIZONTAL MOUNT Figure 29 Intelligent Oil Boiler Control 2 Water Boilers with Tankless Heaters Warm Start Sequence Of Operation a The CL Boiler is equipped with a Warm Start Intelligent Oil Boiler Control Warm Start Boiler Control The Warm Start Boiler Control replaces the traditional high and low limit aquastat and circulator relays b The boiler s sequence of operation is shown as Status Codes on Boiler Control display See Table 7 and Figure 29 c When the thermostat calls for heat the boiler control starts the system circulator and the start sequence continues by energizing the oil primary to operate the following sequence blower is started and operates for pre purge time spark is energized and fuel valve is opened for ignition trial time burner fires until the thermostat is satisfied Optionally
60. control Due to the potential hazard of line voltage only a trained experienced service technician should perform the following safety checks d This control contains no field serviceable parts DO NOT attempt to take it apart Replace entire control if operation is not as described enters Restricted Mode Ignition and motor stop and oil valves closes Power Failure Check After Flame is established turn the power off to the control burner The burner should shut down safely When power is restored a normal ignition sequence should be started a Preliminary Steps Check wiring connections and power supply WARNING Cad Cell Jumper must be removed after this check 35 Make sure power is on to the controls Make sure limit control is closed SYSTEM START UP continued 4 CHECK HIGH LIMIT a Adjust system thermostat s to highest setting b Allow burner to run until boiler water temperature exceeds high limit setting The burner should shut down and circulators continue running Allow the temperature to drop below control setting The burner must restart Boiler installation is not considered complete until this check has been made 5 CHECK LOW WATER CUT OFF CONTROL a Steam Boiler Check Low Water Cut off Control with water level at normal water line see Figure 1D Raise thermostat setting to allow burner to operate Open boiler drain to allow water level to drop to
61. ct the proper oil nozzle for the installation The lower input nozzle will provide greater boiler efficiency However 2 Lift outside container and remove all other boiler output will be reduced Refer to Table 2 for inside protective spacers and bracing Remove firing rates If the higher rate is desired inspect miscellaneous steam or water trim carton the installed nozzle and assure that the nozzle is B REMOVAL OF BOILER FROM SKID the correct size and type as specified in Burner Specifications Tables 14A and 14B at the rear of this manual 1 Remove all fasteners at crate skid 1 Boiler is secured to base with 4 carriage bolts 2 on left side and 2 on right side See Figure 4 Remove all bolts If a lower input is desired remove the nozzle which was factory installed Locate the lower firing rate nozzle that is supplied loose Confirm the nozzle is the proper size and type for the lower EX 2 firing rate as specified in Tables 14A and 14 at the a y 2 rear of this manual Install the proper nozzle in the burner nozzle adaptor 2 ON THE BECKETT AFG BURNER use the 9 following procedure to complete the inspection S E 149 check the settings and to change the nozzle to A 79 lower firing rate a Loosen two 2 igniter latching screws rotate s tabs and swing open igniter about hinge 1
62. cts Minimum free area of 1 square inch per 4 000 BTU per hour input of all equipment in space Duct cross sectional area shall be same as opening free area c Horizontal ducts Minimum free area of 1 square inch per 2 000 BTU per hour input of all equipment in space Duct cross sectional area shall be same as opening free area 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 Louvers and Grilles of Ventilation Ducts a All outside openings should be screened and louvered Screens used should not be smaller than 1 4 inch mesh Louvers will prevent the entrance of rain and snow b Free area requirements need to consider the blocking effect of louvers grilles or screens protecting the openings If the free area of the louver or grille is not known assume wood louvers have 20 25 percent free area and metal louvers and grilles have 60 75 percent free area Louvers and grilles must be fixed in the open position or interlocked with the equipment to open automatically during equipment operation 11 INSTALLATION INSTRUCTIONS A REMOVE CRATE models attached to the burner Sele
63. d boiler corrosion will result Tie fresh water supply to the boiler upstream of a SUPPLY MAIN TO RETURN MAIN FROM water softener COMBINED HEATING COMBINED HEATING amp COOLING SYSTEM amp COOLING SYSTEM 4 OXYGEN CONTAMINATION Figure 13 Recommended Piping for Combination Heating amp Cooling Refrigeration Systems joa contamination such as 3 STEAM BOILER i Addition of excessive make up water as a a For Recommended STEAM BOILER PIPING result of system leaks refer to Figure 12 Also consult I B R ii Absorption through open tanks and fittings Residential Hydronic Heating Installation and Oxygen permeable materials in the Design Guide distribution system b Evaluate the Existing Steam System b In order to insure long product life oxygen The single most important factor in determining sources should be eliminated This can be the expected life cycle of a steam boiler is accomplished by taking the following measures the amount of fresh water added to the boiler i Repairing system leaks to eliminate the need during operation Fresh water brings minerals for addition of make up water and oxygen into the boiler These contaminants ii Eliminating open tanks from the system greatly accelerate corrosion of the cast iron iii Eliminating and or repairing fittings which boiler sections allow oxygen absorption i Assure that all system radiators piping and iv Use of non permeable materials in the ven
64. d is adjustable between 10 F and 30 F WATER BOILERS WITH TANKLESS HEATERS are equipped with a Warm Start Intelligent Oil Boiler Control Warm Start Boiler Control The Warm Start Boiler Control is factory programmed with a High Limit setpoint of 180 F The High Limit setpoint is adjustable between 140 F and 240 High Limit Differential is factory programmed at 10 F Additionally the Warm Start Boiler Control is factory programmed with a Low Limit setpoint of 110 The Low Limit setpoint is adjustable between 110 F and 220 F These temperatures may be varied to suit the installation requirements CHECKOUT Put the system into operation and observe at least one complete cycle to make sure that the controller operates properly See Troubleshooting Section to use LED to assist in determining system operation E ADJUST OIL BURNER BEFORE STARTING 1 CHECK BURNER SETTINGS and readjust if necessary see Burner Specifications Tables 14A and 14B at rear of manual Beckett Burners a Inspect Beckett head setting on left side of burner housing by insuring the blue line MD V1 or the line on the label MB L1 are aligned readjust if necessary Refer to Figure 26 and Table 14 at the rear of this manual b Check burner air band and air shutter settings Readjust if necessary see Burner Specifications Table 14 at the rear of this manual a OPEN ALL OIL LINE VALVES Attach a plastic hose
65. d loose with nozzles Install fiber blanket secured to floor of boiler with water baffle per Beckett Instruction included with glass adhesive If either is damaged they must be baffle replaced h Reinstall Beckett MB L1 or MD V1 Head E INSPECT NOZZLE ELECTRODES INSERTION i Inspect and measure burner electrodes Refer DEPTH AND TURBULATOR SETTING CHANGE to Figure 26 for the proper electrode setting FIRING RATE Readjust electrode setting to the proper 1 PACKAGED CL SERIES BOILERS are dimensions if necessary Refer to Figure 26 shipped with the highest input oil nozzle installed in the burner Oil nozzles for lower firing rates k Connect copper connector tube are shipped loose for the CL3 091 and CL4 175 Reinstall nozzle line electrode assembly c 12 1 Inspect Beckett head setting on left side of burner by insuring the line on the label MB L1 or the blue line MD V1 are aligned readjust if necessary Refer to Figure 26 m Tighten knurled nut n Swing igniter closed rotate tabs and tighten two 2 igniter screws ON THE RIELLO 40 SERIES OIL BURNER use the following procedure to complete the inspection check the settings and to change the nozzle to a lower firing rate Refer also to Model F3 amp F5 Installation Manual Riello 40 Series Residential Oil Burners C6501010 or Model 10 Installation Manual Riello 40 Series Residential Oil Burners No 2902554 a Installation Removal of Drawer Assembly r
66. d with good success At times new tubing must be run to the tank or new fittings put on Just make sure you get the air out before you leave Any air leaks in the fuel line will cause an unstable flame and may cause delayed ignition noises Use only flare fittings in the fuel lines GASKET LEAKS If 11 5 to 12 5 CO with a 1 smoke cannot be obtained in the breeching look for air leaks around the burner mounting gasket observation door and canopy gasket Such air leaks will cause a lower CO reading in the breeching The smaller the firing rate the greater effect an air leak can have on CO readings DIRT A fuel filter is a good investment Accidental accumulation of dirt in the fuel system can clog the nozzle or nozzle strainer and produce a poor spray pattern from the nozzle The smaller the firing rate the smaller the slots become in the nozzle and the more prone to plugging it becomes with the same amount of dirt 6 WATER Water in the fuel in large amounts will stall the fuel pump Water in the fuel in smaller amounts will cause excessive wear on the pump but more importantly water doesn t burn It chills the flame and causes smoke and unburned fuel to pass out of the combustion chamber and clog the flueways of the boiler 7 COLD OIL If the oil temperature approaching the fuel pump is 40 F or lower poor combustion or delayed ignition may result Cold oil is harder to atomize at the nozzle Thus
67. da Inc 35 Pond Park Road 2165 Meadowpine Blvd Hingham Massachusetts 02043 Mississauga Ontario L5N 6H6 Telephone 617 749 8292 Telephone 905 542 0303 Facsimile 617 740 2069 Facsimile 905 542 1525 Toll Free outside Massachusetts Toll Free 800 387 3898 800 992 7637 59 APPENDIX A LOW WATER CUT OFF LWCO 60 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 1 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 baseboard on the same floor level as the boiler In addition some jurisdictions require the use of a LWCO with a hot water boiler Where The universal location for a LWCO on oil hot water boilers is above the boiler in either the supply or return piping The minimum safe water level of a water boiler is at the uppermost top of the boiler that is it must be full of water to operate safely It is recommended that the LWCO control is installed above the boiler to provide the highest level of protection However where the LWCO control is approved by the LWCO control manufacturer for installation in a high boiler tapping of a water boiler the use of the listed LWCO control is per
68. ded AIR VENT 11 MIN FILL PIPE FUEL PUMP AUX FILTER SHUT OFF MAXIMUM VALVE ONE PIPE LIFT 8 FT ys Figure 18 Single Pipe Oil Line IMPORTANT Single pipe installations must be absolutely airtight or leaks or loss of prime may result Bleed line and fuel unit completely INSTALLATION INSTRUCTIONS continued TABLE 5 SINGLE STAGE UNITS 3450 RPM OUTSIDE TANK FUEL PUMP ABOVE TWO PIPE SYSTEMS BOTTOM OF TANK Maximum i Lift S FILL AIR FUEL PUMP See Figure 3 8 OD B Tubing Tubing 3 GPH PIPE VENT AUX FILTER RETURN a o p oa 2 4 en 5 LINE 6 7 Figure 19 Two Pipe Oil Lines 21 9 L FUEL UNITS AND OIL LINES SINGLE PIPE OIL LINES Standard burners provided with single stage 3450 rpm fuel units with the 2 by pass plug removed for single pipe installations The single stage fuel unit may be installed single pipe with gravity feed or lift Maximum allowable lift is 8 feet See Figure 18 TABLE 6 TWO STAGE UNITS 3450 RPM TWO PIPE OIL LINES For two pipe systems TWO PIPE SYSTEMS where more lift is required the two stage fuel unit is recommended Table 5 single stage and Table 6 two Maximum Length of Tubing stage show allowable lift and lengths of 3 8 inch and Lift H R
69. e 1B CL3 Thru CL5 Water Boiler With Tankless Heater All Burner Options I GENERAL INFORMATION continued m 248 x 145 SAFTEY VALVE 5 2 5 N 3 SUPPLY 3 Lod ped m 4 PRESSURE McDONNELL amp MILLER GAUGE ME C 5 801 120 BAA DAA DIA Ag PRESSURETROL i I e 2 4 BUILT IN DOMESTIC WATER HEATER W mise Pe 3 4 CONNECTIONS B o 3 12 j FLAME Q o OIL BURNER SM BU 25 1 4006 AQUASTAT W PRIMARY 318 PORT CONTROL o 253 E Li od e 9 m p E 5 A 1 1 IL FLOOR i LINE 14 WET RETURN 14 RETURN CONNECTION 11 SEE NOTE 3 BURNER SWING DOOR FRONT VIEW CLEARANCE OPEN 90 RIGHT SIDE VIEW NOTES 1 TANKLESS COIL OPENING NOT PRESENT ON LESS COIL BOILERS 2 PIPING SHOWN HIDDEN NOT FURNISHED WITH BOILER 3 DRAIN VALVE SHIPPED LOOSE NOT SHOWN Figure 1 CL3 Thru CL5 Steam Boiler with or without Tankless Heater McDonnell amp Miller P
70. e relevant display code and its corresponding value Operating Mode Options Status Numbers Standby B Running Self Test bt Boiler Temperature 5P Operating Setpoint Outdoor Reset HL High Limit Setting HdF High Limit Differential LL Low Limit Setpoint warm start only LdF Low Limit Differential warm start only hr Heat Request Status dh DHW Request Status Err Boiler Error For example when the 2 key is pressed on the Boiler Control until is displayed it will then flash a three digit number such as 180 followed by either or This indicates that the boiler water temperature 15 180 F Other operating parameters display the information in a similar fashion _ gi Sample or Display Please note that in operating mode to hold the display on the value the user can press and hold either the Up or Down keys and the value will be continuously shown This may be helpful in watching a value live 5 Changing the Adjustable Parameters To adjust parameters such as the High Limit Setpoint and High Limit Differential a Using the Boiler Control display access the adjustment mode by pressing and holding the Up 1 Down and if keys simultaneously for three 3 seconds This procedure is intended to discourage unauthorized changes or accidental changes to limit settings b Press the key to d
71. ecure Boiler Control conduit to Jacket right side panel with 5 8 cable clamp provided refer to Figure 1B Make the wiring connections as shown on Figure 21 see Figures 1C and 1D See Figures 11A and 11B Consult I B R Residential Hydronic Heating Installation and Design Guide Use boiler water bypass if the boiler is to be operated in a system which has a large volume or excessive radiation where low boiler water 1 Thread 4 MPT safety valve and 3 4 NPT coupling temperature may be encountered i e converted onto factory installed 34 NPT x 714 nipple located gravity circulation system etc in left rear corner on top of boiler as shown in Install a pipe tee in the boiler return piping along Figures 1 and 1D Tighten with wrench Pipe with a second tee in the supply piping as shown discharge as shown in Figure 12 Installation of the in Figures 11A and 11B The bypass should relief valve must be consistent with ANSI ASME be the same size as the supply and return lines Boiler and Pressure Vessel Code Section IV Locate valves in the bypass and supply outlet as 2 Install 34 drain valve in wet return piping as shown illustrated in Figures 11A and 11B for regulation in Figure 12 of water flow to maintain higher boiler water temperature 3 On boilers with rear tankless heater factory wired Set the b d boil L4006A Aquastat Heater Control was not installed S ee in heater Locate 54 NPT Immer
72. ed may be hazardous to your health AVOID Breathing Fiber Particulates and Dust Precautionary Measures Do not remove or replace RCF parts or attempt any service or repair work involving RCF without wearing the following protective gear A National Institute for Occupational Safety and Health NIOSH approved respirator Long sleeved loose fitting clothing Gloves Eye Protection Take steps to assure adequate ventilation Wash all exposed body areas gently with soap and water after contact Wash work clothes separately from other laundry and rinse washing machine after use to avoid contaminating other clothes Discard used RCF components by sealing in an airtight plastic bag RCF and crystalline silica are not classified as hazardous wastes in the United States and Canada First Aid Procedures If contact with eyes Flush with water for at least 15 minutes Seek immediate medical attention if irritation persists If contact with skin Wash affected area gently with soap and water Seek immediate medical attention if irritation persists If breathing difficulty develops Leave the area and move to a location with clean fresh air Seek immediate medical attention if breathing difficulties persist Ingestion Do not induce vomiting Drink plenty of water Seek immediate medical attention 47 IX TROUBLESHOOTING A COMBUSTION 48 1 NOZZLES Although the nozzle is a relatively inexpensive de
73. efer to Figure 5 i Removal Disconnect oil delivery tube nut from pump Loosen SCREW 3 and then unplug PRIMARY CONTROL 1 by carefully pulling it back and then up Remove the AIR TUBE COVER PLATE 5 by loosening the retaining SCREW 4 Two SCREWS Model 5 Loosen SCREW 2 and then slide the complete drawer assembly out of the combustion head as shown ii Installation To insert drawer assembly reverse the procedure in Step above b Nozzle Replacement refer to Figure 6 i Remove the NOZZLE ADAPTER 2 from the DRAWER ASSEMBLY by loosening the SCREW 1 Figure 5 Installation Removal of Riello Drawer Assembly INSTALLATION INSTRUCTIONS continued ii Remove existing nozzle from nozzle adapter iii Insert the proper NOZZLE into NOZZLE ADAPTER and tighten securely DO NOT cover tighten refer to Table 14B at rear of this manual iv Replace adapter with nozzle installed into drawer assembly and secure with screw 1 c Inspect and measure burner electrodes Refer to Figure 7 for the proper electrode settings d Re install Drawer Assembly into Combustion Head per Step 3a above e Insertion Depth verify the distance between the tip of the end cone is equal to the distance specified in Table 14B at rear of this manual f Turbulator Setting refer to Figure 8 Figure 6 Riello Nozzle Replacement IMPORTANT THESE DIMENSIONS MUST BE OBSERVED AND VERIFIED 5 32
74. efore removing the LWCO probe DO NOT rely on the pressure gauge to indicate that the boiler is at zero pressure Open the safety valve to relieve all internal pressure prior to proceeding Safety valve discharge piping must be piped such that the potential for burns is eliminated c Disconnect wiring connections between the low water cut off control and the probe d Remove the low water cut off control from the probe e Unscrew the probe from the boiler tapping f Inspect that portion of the probe that is exposed to the boiler water for a scale or sediment buildup g Light deposits may be removed by wiping the probe with a damp cloth Wiping the probe with a cloth soaked in vinegar will remove more tenacious lime deposits The most stubborn deposits may be removed from the probe by using a diluted amount 3 parts of water to part of phosphoric acid H PO CAUTION Exercise caution when handling phosphoric acid and follow the instruction label on its container 42 h Clean the pipe threads of the probe to remove old hardened pipe dope and other foreign matter i Apply a moderate amount of good quality pipe dope to the pipe threads on the probe leaving the two end threads bare DO NOT use PTFE Teflon tape Screw the probe into the boiler tapping k Mount the low water cut off control on the probe Reconnect the control to probe wiring c m Fill the boiler to its normal waterline n
75. ermostat 120 Vac at B1 B2 f no replace control If yes check burner and wiring Referto Erron depay Boiler is hot house is Display is ON 120 Vac at C1 C2 check wiring to cold pump 120 Vac at C1 C2 Wiring OK is pump running If not replace the pump If pump is running check for trapped air or closed zone valves Boiler below the Low Limit temperature wait for boiler to go above Low Limit temperature If no 120 Vac replace control If yes check zone relays circulators and wiring Boiler above LL If yes check for 120 Vac between ZC and L2 IX TROUBLESHOOTING continued b Ifthe Boiler Control detects an error it will flash Err boiler control error followed by a number Use this text and number to identify the boiler problem and corrective action in Table 13 below TABLE 13 BOILER CONTROL ERROR NUMBERS Display Recommended Corrective Actions Temperature Sensor Fault Communication Fault Internal Hardware Fault Burner Output B1 Fault Line Voltage Fault 80 Vac Fuse missing User settings lost reset to factory defaults Manual Reset Lockout resettable 50 Temperature sensor failure wire harness loose or shorted connection or control hardware failure Check sensor is securely attached to boiler control Check that sensor wire is not damaged If secure and in good condition replace sensor If problem persists replace control Envir
76. firm that the boiler and system have no water leaks C CHECK CONTROLS WIRING AND BURNER be sure that all connections are tight and burner is rigid that all electrical connections have been completed and fuses installed and that oil tank is filled and oil lines have been tested D ADJUST CONTROL SETTINGS with burner service switch turned ON 1 SET ROOM THERMOSTAT about 10 F below room temperature 2 PRESS RED RESET BUTTON on front of burner cover Beckett Riello burners or Oil Primary Control with burner cover removed Hold button for one 1 second and release to reset primary control SYSTEM START UP continued STEAM BOILERS With an PA404A Pressure Limit set cut out pressure MAIN scale on the pressure limit for 1 PSI and differential pressure DIFF for 5 PSI These pressures may be varied to suit individual requirements of the system STEAM BOILERS WITH TANKLESS DOMESTIC WATER HEATERS set boiler water temperature dial on L4006 operating control at 190 F max Set differential at 10 WATER BOILERS WITHOUT TANKLESS HEATERS are equipped with an Intelligent Oil Boiler Control Boiler Control The Boiler Control is factory programmed with a High Limit setpoint of 180 F The High Limit setpoint is adjustable between 140 F and 240 This temperature may be varied to suit the installation requirements HIGH LIMIT DIFFERENTIAL is factory programmed at 15 F an
77. g water flow through the boiler The Low Limit Differential is adjustable between 10 F and 25 F Circulator Overrun Time Circulator Overrun Time also called circulator off delay or circulator post purge continues circulator operation after a call for heat has ended sending excess heat from the boiler into the priority zone Ensure system piping and zone panel settings allow water flow to the priority zone after the call for heat ends The Circulator Overrun Time has a factor setting of 0 minutes and 15 field adjustable between 0 and 10 minutes Circulator Pre Purge Time FF_ When the boiler is warm boiler water temperature higher than 140 F adjustable using Start Temperature parameter and there is a thermostat call for heat the system circulator is started and boiler firing is delayed pre purge minutes If the temperature drops below 140 F or there is a DHW Call for Heat the boiler is started without delay Additionally the boiler is started without delay if the thermostat call for heat is initiated when the boiler water temperature is less than 140 F This feature helps save energy by satisfying home heating needs with residual boiler heat rather than cycling the boiler The Circulator Pre purge time has a factory setting of 2 minutes and is field adjustable between 2 and 20 minutes Refer to Table 8 The Warm Start Boiler Control Pre purge Time is factor set to 0 minutes 39 VI OPERATING cont
78. h year and beyond warranty claim homeowner pays 75 EXCEPTIONS AND EXCLUSIONS 1 Components Manufactured by Others following the expiration of the foregoing one year limited warranty all component parts of a boiler which are manufactured by others such as burners burner controls circulator tankless water heater and New Yorker Link shall be subject only to the manufacturer s warranty if any 2 Removal and Replacement Costs these warranties do not cover expenses of removal or reinstallation The consumer purchaser will be responsible for the cost of removing and replacing any defective part and all labor and related materials connected therewith Replacement parts will be invoiced to the distributor in the usual manner and will be subject to adjustment upon proof of defect 3 Proper Installation these warranties are conditioned upon the installation of the boiler in strict compliance with New Yorker s Installation Operating and Service Instructions New Yorker specifically disclaims any liability of any kind which arises from or relates to improper installation 4 Improper 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 maintained in accordance with New Yorker s Installation Operating and Service Instructions and hydronics industry standards 5 Improper Operation these warranties will not be applic
79. he low water cut off will reset and restart the burner with a call for heat a few seconds after the water is returned to its normal level On burner start if the CAD cell does not see flame within approximately 15 seconds primary control will shut down the burner and enter into a lockout mode A lockout is reset by pressing the reset button located on the primary control If the flame is lost while the burner is firing the primary control shuts down the burner enters a 60 second recycle delay and repeats the Ignition sequence If after three 3 trials for ignition flame is not detected primary control will enter into restricted mode Restricted mode is reset by holding down the reset button for 15 seconds 41 MAINTENANCE AND SERVICE INSTRUCTIONS A MAINTENANCE OF LOW WATER CUT OFF DEVICES WARNING Probe and float type low water cut off devices require annual inspection and maintenance 1 Although these devices are solid state in their operation the probe is exposed to possible contamination in the boiler water and subject to fouling 2 It is important to physically remove the probe from the boiler tapping annually and inspect that probe for accumulation of scale or sediment 3 Follow these steps to inspect clean and or replace the probe a Turn off electric service to the boiler b Drain boiler water to a level below the tapping for the probe DANGER Assure that the boiler is at zero pressure b
80. ice switch to boiler to prevent accidental firing of burner outside the combustion chamber Be sure to tighten swing door fastener completely when service is completed A ALWAYS INSPECT INSTALLATION BEFORE STARTING BURNER 1 Verify that the venting water piping oil piping and electrical system are installed properly Refer to Installation Instructions contained in this manual 2 Confirm all electrical water and oil supplies are turned off at the source and that the vent is clear from obstructions WARNING Completely read understand and follow all instructions in this manual before attempting start up B FILL HEATING SYSTEM WITH WATER NOTICE It is important especially in a steam system to properly remove the oil and dirt from the system Failure to clean the system can result in erratic water lines and surging CLEAN HEATING SYSTEM if boiler water or condensate return water is dirty or if erratic water lines or surging exist after a few days of boiler operation Refer to Maintenance and Service Instructions Section of this manual for proper cleaning instructions for steam and water boilers 1 STEAM BOILERS Fill boiler to normal water line Refer to Figures 1C and 1D 2 HOT WATER BOILERS Fill entire heating system with water and vent air from system Use the following procedure on a series loop or multi zoned system installed as per Figures 11A and 11B to remove air from system when filling
81. ined in Instructions furnished with control or instructions as follows a GeniSys 7505 Control Features see Figure 28 i GeniSys 7505 15 microprocessor based control The indicator light provides diagnostic information for lockout recycling and cad cell status There is a manual reset button to exit the Lockout Mode Pump Priming Cycle To facilitate purging air from the oil lines and filters the 7505 can be placed in a purge routine by 34 After the burner starts press and hold the reset button for 15 seconds until the yellow light turns on This indicates that the button has been held long enough Release the reset button The yellow light will turn off and the burner will start up again At burner start up click the reset button while the igniter is till on This will transition the control to a dedicated Pump Prime mode during which the motor igniter and valve are powered for four 4 minutes The yellow light will be on At the end of four 4 minutes the yellow light will turn off and the control will automatically return to standby mode iii Limited Recycle This feature limits the number of recycle trials for each call for heat to a maximum of three trials If the flame is lost three times and does not successfully satisfy a call for heat the 7505 locks out iv Limited Reset Restricted Mode In order to limit the accumulation of unburned oil in the combustion area the control can on
82. inued TABLE 8 CIRCULATOR PRE PURGE TIME EXAMPLE i ZC and ZR Terminal Function EL _ PARAMETER PP_ 2 MINUTES ZC ZR for Terminal Boiler Heat Function Temp 20 The boiler control allows configuration of the ZC output functionality to help the CL integrate into each installation more effectively The ZC output can be connected to a domestic hot water circulator or a second heating zone circulator or be used to enable pumps in a warm start application These applications are selected as follows Boiler Status B1 Output e lt o Startwithno delay 22 2 5140 Start after 2 minute delay 22 4 lt 140 Startwithno delay 22 524 540 Startwithno delay i When is set equal to Domestic Hot Water Demand dh When there is an Indirect Water Heater IWH the boiler control provides a ZR g Start Temperature 5E The amount of Heat available is calculated by taking the difference between measured boiler water temperature and the Start Temperature setting Useful Heat Available is dependent on the type of heating emitter installed in the home Heat emitters require a certain minimum temperature to operate effectively Our default settings reflect cast iron radiators Fan Coils may require a start temperature setting of 180 F or 160 F before providing heat to the home The Start Temperature has a factory setting of 140 F and is field
83. irements of the control to which it is connected 4 Use anti short bushings on all wiring passing See Figures 20 thru 24 for desired system and heat through boiler jacket junction boxes and or control anticipator setting If system tends to overheat above boxes the thermostat s temperature setting reduce heat 5 Use armored cable BX over all exposed line anticipator setting by 1 or 2 amps If system tends to voltage wiring short cycle without reaching desired room temperature 6 If an indirect domestic water heater is used use increase heat anticipator setting by 1 or 2 amps 24 priority zoning DO NOT use priority zoning for Hydro Air Systems oj or pue 04409 14616 5 lt 02 9 1614 NOILLVOITddV SIHL TONLNOD NO SAOWSY TON OG ONIMIM 39VLIOA 93801 JO VCIAINIW VO ONY 0 901 81 2715 ANOLOW4 39V L10A AWS 39nvo OT IWYS ONIAVH 38 15 LSNIW 5 SV TVNIOIHO S3LON QN3931 SNILL3S 1V3H 303 TIVO MO11VNH31X3 N YOLVdIOLLNY 1V3H TIVO INOZ GNOO3S TERN 1V3H
84. isplay available Adjustment Mode options Select an option VI OPERATING continued Adjustment Mode Options 140 240 F Adjust High Limit Setting 10 30 F Adjust High Limit Differential dh er or ELL ZC and ZR Terminal Function 0 10 minutes Pump Overrun Time 2 20 minutes Pump Pre purge Time 140 180 F Start Temperature Gn or Priority Time Fort Select degrees F or C Mode Back to Operating Mode Adjustment Mode Options 140 240 F Adjust High Limit Setting 110 220 F Adjust Low Limit Setting Adjust Low Limit Differential Setting er or dh ZC and ZR Terminal Function 0 10 minutes Pump Overrun Time 0 20 minutes Pump Pre purge Time 140 180 F Start Temperature Un Priority Time Fort Select degrees F or C Mode Back to Operating Mode 10 25 F Press the Up 1 and Down keys to adjust the displayed setpoint to the desired value d To return to the normal operating mode from the Adjustment Mode when the option is displayed press either the Up f or Down key If no keys are pressed after five 5 minutes the Boiler Control will automatically return to the Operating Mode 6 More Information about Adjustable Parameters a High Limit HL _ The Boiler Control is factory programmed with a High Limit Setpoint of 180 F The boiler turns off when the boiler water temperature is above this value The High Limit setpoint is adjustable between 140 and 240 The Operati
85. ject only to the manufacturer s warranty if any 2 Removal and Replacement Costs These warranties do not cover expenses of removal or reinstallation The consumer purchaser will be responsible for the cost of removing and replacing any defective part and all labor and related materials connected therewith Replacement parts will be invoiced to the distributor in the usual manner and will be subject to adjustment upon proof of defect 3 Proper Installation These warranties are conditioned upon the installation of the boiler in strict compliance with New Yorker s Installation Operating and Service Instructions New Yorker specifically disclaims any liability of any kind which arises from or relates to improper installation 4 Improper 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 maintained 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 damaged as a result of being improperly serviced or operated including but not limited to the following operated with insufficient water allowed to freeze subjected to flood conditions or operated with water conditions and or fuels or additives which cause unusual deposits or corrosion in or on the pressure vessel or associated c
86. ker warrants to the original consumer purchaser at the original installation address that its residential cast iron steam boilers will be free of defects in material and workmanship under normal usage for a period of one year from the date of original installation In the event that any defect in material or workmanship is found during the one year period following the date of installation New Yorker will at its option repair the defective part or provide a replacement free of charge F O B its factory TEN YEAR LIMITED WARRANTY Ten Year Pressure Vessel Limited Warranty for Residential Cast Iron Steam Boilers New Yorker warrants to the original consumer purchaser at the original installation address that the pressure vessel of its residential cast iron steam boilers will be free of defects in material and workmanship under normal usage for a period of 10 years from the date of original installation In the event that any defect in material or workmanship is found during the ten year period following the date of installation New Yorker will at its option repair the defective pressure vessel or provide a replacement free of charge F O B its factory EXCEPTIONS AND EXCLUSIONS 1 Components Manufactured by Others Following the expiration of the foregoing one year limited warranty all component parts of a boiler which are manufactured by others such as burners burner controls circulator tankless water heater and New Yorker Link shall be sub
87. l will light then shut down after a for heat This is indicated by red light reset short time then restart after one 1 minute button solid on a CAD cell is defective b Air leaking into oil line causing flame out INTELLIGENT OIL BOILER CONTROL c Defective nozzle causing flame to be erratic Cold Start Boiler Control is used on Boilers without d Excessive airflow or draft causing flame to leave Tankless Heaters burner head Warm Start Boiler Control is used on Boilers with e Excessive back pressure causing flame to be Tankless Heaters erratic 1 When a problem occurs with the boiler operation 3 Control locks out after Trial For Ignition TFI the Boiler Control easily provides specific valuable information to help resolve the issue quickly The a No oil to burner display on the Boiler Control should be the first b Shorted electrodes place to check c Nozzle clogged a Ifan Error Code Err IS NOT displayed on d Airflow too high the Boiler Control In this circumstance Table 12 be used to determine the problem and e Ignitor module defective possible causes f CAD cell defective TABLE 12 TROUBLESHOOTING GUIDE System Condition Diagnostic Condition Boiler is cold house is Display is OFF 120 Vac System power Turn system power on cold Display is ON 24 Vac T T No 24 V replace control 24 V present disconnect is thermostat short T T Boiler starts check wiring and th
88. ld be higher than 7 but lower than 11 Add some of the washout chemical caustic soda 1f necessary to bring the pH within the specified range Boiler is now ready to be put into service 43 MAINTENANCE AND SERVICE INSTRUCTIONS continued 44 2 WATER BOILERS a Filling of boiler and system GENERAL In hot water heating system the boiler and entire system other than the expansion tank must be full of water for satisfactory operation Water should be added to the system until the boiler pressure gauge registers 12 psi To insure that the system is full water should come out of all air vents when opened b BOILING OUT OF BOILER AND SYSTEM The oil and grease which accumulate in a new hot water boiler can be washed out in the following manner i Remove relief valve using extreme care to avoid damaging it ii Add an appropriate amount of recommended boil out compound iii Replace relief valve iv Fill the entire system with water v Start firing the boiler vi Circulate the water through the entire system vii Vent the system including the radiation viii Allow boiler water to reach operating temperature 1f possible ix Continue to circulate the water for a few hours x Stop firing the boiler xi Drain the system in a manner and to a location that hot water can be discharged with safety xii Remove plugs from all available returns and wash the water side of the boiler as th
89. ler will be free of defects in material and workmanship under normal usage for the lifetime of the original consumer purchaser In the event that any defect in material or workmanship is found during the ten year period following the date of installation New Yorker will at its option repair the defective pressure vessel or provide a replacement free of charge F O B its factory In the event that any defect in material or workmanship is found after the tenth year following the date of installation New Yorker will provide a replacement pressure vessel upon payment by the original consumer purchaser of an amount equal to a percentage of the then current retail price of the model boiler involved or in the event that such model is not then in production the most comparable model then in production as follows 11th year warranty claim homeowner pays 5 12th year warranty claim homeowner pays 10 13th year warranty claim homeowner pays 15 14th year warranty claim homeowner pays 20 15th year warranty claim homeowner pays 25 16th year warranty claim homeowner pays 30 17th year warranty claim homeowner pays 35 18th year warranty claim homeowner pays 40 19th year warranty claim homeowner pays 45 20th year warranty claim homeowner pays 50 21st year warranty claim homeowner pays 55 22nd year warranty claim homeowner pays 60 23rd year warranty claim homeowner pays 65 24th year warranty claim homeowner pays 70 25t
90. ly be reset three times The reset count returns to Reset Button with Red Light Yellow Light Green Light Terminals Wiring Connections Cad Cell Connections Figure 28 GeniSys 7505 Oil Primary Terminals LED s and Reset Button SYSTEM START UP continued zero each time a call for heat is successfully completed T T Jumper Select models have pre installed T T jumper DO NOT remove jumper Note DO NOT remove T T jumper unless wiring diagram indicates a direct connection from thermostat and or tankless heater aquastat control to the oil burner primary control s terminal Refer to appropriate wiring diagram see Figure 20 21 22 or 23 vi Diagnostic LED The indicator light on oil primary control provides lockout recycle and cad cell indications as follows Flashing at 1 Hz second on second off system is locked out or in Restricted Mode Flashing at V4 Hz 2 seconds on 2 seconds off control is in Recycle Mode On cad cell is sensing flame Off cad cell is not sensing flame vii Cad Cell Resistance Check For proper operation it is important that the cad cell resistance is below 1600 ohms During a normal call for heat the cad cell leads can be unplugged from the control and the resistance measured with a meter in the conventional way Conduct these tests with flame present see chart below Flame Detection Range Normal
91. ly water regardless of inlet pressure variations in the range of 20 to 125 psi 2 TEMPERING OF HOT WATER Installation of an automatic mixing valve will lengthen the delivery of the available hot water by mixing some cold water with the hot This prevents excessive and possibly scalding hot water at the fixtures In addition savings of hot water will be achieved since the user will not waste as much hot water while seeking water temperature to his liking Higher temperature hot water required by dishwashers and automatic washers is possible by piping the hot water from the heater prior to entering the mixing valve The mixing valve should be trapped by installing it below the cold water inlet to heater to prevent lime formation in the valve WARNING Install automatic mixing valve at tankless heater outlet to avoid risk of burns or scalding due to excessively hot water at fixtures Adjust and maintain the mixing valve in accordance with the manufacturer s instructions 3 FLUSHING OF HEATER All water contains some sediment which settles on the inside of the coil Consequently the heater should be periodically backwashed This is accomplished by installing hose bibs as illustrated and allowing water at city pressure to run into hose bib A through the heater and out hose bib B until the discharge is clear The tees in which the hose bibs are located should be the same size as heater connections to minimize pressure d
92. mit Setpoint the burner is stopped the ZC output is energized and the System Circulator is enabled to run in response to a call for heat g On burner start if the CAD cell does not see flame within approximately 15 seconds primary control will shut down the burner and enter into a lockout mode A lockout is reset by pressing the reset button located on the primary control If the flame is lost while the burner is firing the primary control shuts down the burner enters a 60 second recycle delay and repeats the ignition sequence If after three 3 trials for ignition flame is not detected primary control will enter into restricted mode Restricted mode is reset by holding down the reset button for 15 seconds 3 Using Boiler Control The Boiler Control is located on front of boiler The Boiler Control display along with Up Down 2 keys may be used to view boiler operating status Figure 30 4 Viewing the Operating Mode Options In operating mode the user may view but not change boiler operating status settings and troubleshooting information To view Boiler Control display information I BUTTON DISPLAY DOWN BUTTON UP BUTTON Figure 30 Boiler Control Key Function amp Orientation 38 Press and release the 2 key on the Boiler Control to change from one parameter to the next Each setting will alternately flash between th
93. mitted when it is installed according to the LWCO manufacturer s instructions What Kind Typically in residential applications a probe type LWCO is used instead of a float type due to their relative costs and the simplicity of piping for a probe LWCO How to Pipe A tee is commonly used to connect the probe LWCO in the supply or return piping as shown below SYSTEM SYSTEM SUPPLY MINIMUM SAFE WATER LINE ABOVE UPPERMOST TOP a OF HEAT EXCHANGER _ IF AVAILAB pu 2 Figure 1 LWCO Location Select the appropriate size tee using the LWCO manufacturer s instructions Often the branch connection must have a minimum diameter to prevent bridging between the probe and the tee Also the run of the tee must have a minimum diameter to prevent the end of the probe from touching or being located too close to the inside wall of the run of the tee Ideally manual shutoff valves should be located above the LWCO and the boiler to allow for servicing This will allow probe removal for inspection without draining the heating system Many probe LWCO manufacturers recommend an annual inspection of the probe How to Wire LWCO s are available in either 120 VAC or 24 VAC configurations The 120 VAC configuration must be applied to oil boilers by wiring it in the line voltage service to the boiler after the service switch if so equipped Refer to Figure A2 The presence of water in a properly in
94. ng Setpoint 5P will equal the High Limit Setpoint b High Limit Differential i The Cold Start Boiler Control is factory programmed with a Differential of 15 F The Differential is the number of degrees the boiler temperature must decrease below the Operating Setpoint before the boiler can restart The differential is adjustable between 10 and 30 F On Warm Start Boiler Control the High Limit Differential is not adjustable and is fixed at 10 F c Low Limit LL_ The Warm Start Boiler Control is factory programmed with a Low Limit Setpoint of 110 F On falling temperature the boiler turns on and the ZC terminal and System Circulator outputs are de energized when the boiler temperature is less than the Low Limit Setpoint less the differential On a rising temperature when the boiler temperature is above the Low Limit Setpoint the boiler turns off the ZC terminal output is energized and the System circulator is enabled to respond to a call for heat The Low Limit Setpoint is adjustable between 110 F and 220 F d Low Limit Differential L The Warm Start Boiler Control is factory programmed with a Low Limit Differential Setpoint of 10 F The Low Limit Differential is the number of degrees the boiler temperature must decrease below the Low Limit Setpoint before the Warm Start Boiler Control takes actions to warm the boiler These actions include starting the burner and stoppin
95. o a defect in material or workmanship covered by these warranties the original consumer purchaser should notify the installer who will in turn notify the distributor If this action is not possible or does not produce a prompt response the original consumer purchaser should write to New Yorker Boiler Co Inc at P O Box 10 Hatfield PA 19440 0010 giving full particulars in support of the claim The original consumer purchaser is required to make available for inspection by New Yorker or its representatives the parts claimed to be defective and if requested by New Yorker to ship those parts prepaid to New Yorker at the above address for inspection or repair In addition the original consumer agrees to make all reasonable efforts to settle any disagreement arising in connection with any warranty claim before resorting to legal remedies in the courts THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE NEW YORKER BOILER CO INC Limited Warranties For Residential Cast Iron Steam 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 steam boilers labeled with the New Yorker brand which are sold on or after March 1 2004 ONE YEAR LIMITED WARRANTY One Year Limited Warranty for Residential Cast Iron Steam Boilers New Yor
96. ond zone s thermostat may be wired to the ZR input to energize heating zone 2 circulator wired to the ZC output Both outputs function independently TT input controls only the System Circulator output and the ZR input controls only the ZC output Both inputs cause a boiler call for heat The Warm Start Boiler Control with 2 _ set equal to Zone Request Zr energizes the ZC terminal while the boiler is warm as described earlier in this section refer to Paragraph A 2 f The ZR input is a call for heat that starts the boiler External Low Limit Parameter 20 ELL The Cold Start Boiler Control is capable of functioning as a warm start control when external limit control is installed that closes a contact when boiler water temperature falls below a setpoint When an external limit contact closes boiler water is cold the boiler is started and the ZC and C1 output terminals are de energized When the ZR terminal is de energized boiler water temperature is above setpoint the call for heat is ended and the C1 terminal is released to operation and the ZC terminal is energized An External Low Limit Request is detected by sensing a voltage on the ZR terminal The Warm Start Boiler Control does not have the External Low Limit Option Refer to Table 11 TABLE 11 EXTERNAL LOW LIMIT PARAMETER Call for Heat Circulator Status T T ZR Input Input n n Output Output of of on
97. ons Surface rust on cast sections may be attributed to the manufacturing process as well as condensation during storage Surface rust is normal and does not affect the performance or longevity of a boiler DANGER DO NOT store or use gasoline or other flammable vapors or liquids in the vicinity of this or any other boiler WARNING Improper installation adjustment alteration service or maintenance can cause property damage personal injury or loss of life Failure to follow all instructions in the proper order can cause personal injury or death Read and understand all instructions including all those contained in component manufacturers manuals whichare provided with the boiler before installing starting up operating maintaining or servicing this boiler Keep this manual and literature in legible condition and posted near boiler for reference by owner and service technician This boiler requires regular maintenance and service to operate safely Follow the instructions contained in this manual Installation maintenance and service must be performed only by an experienced skilled and knowledgeable installer or service agency All heating systems should be designed by competent contractors and only persons knowledgeable in the layout and installation of hydronic heating systems should attempt installation of any boiler Installation is not complete unless a pressure relief valve is installed into the tapping located on top
98. ontrols 6 Geographic Limitations These warranties apply only to boilers installed within the 48 contiguous United States 7 Installation Requirements In order for these warranties to be effective a The boiler must be installed in a single or two family residential dwelling This warranty does not apply to boilers installed in apartments or for commercial or industrial applications b The boiler must be installed in strict compliance with New Yorker s Installation Operating and Service Instructions including the installation of a low water cut off by an installer regularly engaged in boiler installations C Boiler sections must not have been damaged during shipment or installation d The boiler must be vented in accordance with chimney recommendations set forth in New Yorker s Installation Operating and Service Instructions 8 Exclusive Remedy New Yorker s obligation in the event of any breach of these warranties is expressly limited to the repair or replacement of any part found to be defective under conditions of normal use 9 Limitation of Damages Under no circumstances will New Yorker be liable for incidental indirect special or consequential damages of any kind under these warranties including without limitation injury or damage to persons or property and damages for loss of use inconvenience or loss of time New Yorker s liability under these warranties shall under no circumstances exceed the purcha
99. oroughly as possible using a high pressure water stream xiii Refill the system with fresh water c Add appropriate boiler water treatment compounds as recommended by your qualified water treatment company d Make pH or Alkalinity Test After boiler and system have been cleaned and refilled as previously described test the pH of the water in the system This can easily be done by drawing a small sample of boiler water and testing with hydrion paper which is used in the same manner as litmus paper except it gives specific readings A color chart on the side of the small hydrion dispenser gives the reading pH Hydrion paper is inexpensive and obtainable from any chemical supply house or through your local druggist The pH should be higher than 7 but lower than 11 Add some of the washout chemical caustic soda if necessary to bring the PH within the specified range e Boiler is now ready to be put into service 3 EXCESSIVE MAKE UP WATER A leaky system will increase the volume of make up water supplied to the boiler which can significantly shorten the life of the boiler Entrained in make up water are dissolved minerals salts and oxygen When the fresh cool make up water is heated in the boiler the minerals fall out as sediment the salts coat the inside of the boiler and the oxygen escapes as a gas The accumulation of sediment eventually isolates the water from contacting the cast iron When this happens the
100. r Cold Start Intelligent Oil Boiler Control Boiler Control Make the wiring connections as shown in Figures 20 and 21 a On water boilers without rear tankless heater connect the field wiring from the circulator to the Cold Start Boiler Control and from the Cold Start Boiler Control to the Burner Oil Primary Control Make the wiring connections as shown on Figure 20 FULLY INSERTED INCORRECT CORRECT Figure 10 Limit Sensor Insertion INSTALLATION INSTRUCTIONS continued b On water boilers with rear tankless heater the factory wired Warm Start Boiler Control was not installed in heater Locate 3 4 NPT immersion well apply sealant thread into 3 4 NPT tapping on tankless heater and tighten with wrench Apply heat transfer paste not furnished to limit sensor and fully insert limit sensor into immersion well such that the tip on the limit sensor touches the bottom of the immersion well See Figure 10 Tighten clamp screws to secure Warm Start Boiler Control to immersion well thermostat and or tankless heater aquastat control to the oil burner primary control s T T terminal Refer to Figures 22 and 23 H CONNECT SUPPLY AND RETURN PIPING TO HEATING SYSTEM 1 CLEARANCES Steam and hot water pipes shall have clearances of at least gt from all combustible construction 2 WATER BOILER a For Forced Circulation HOT WATER HEATING G INSTALL STEAM BOILER TRIM AND CONTROLS S
101. rip 1 2 x 1 1 4 x 10 in Poly Bag 6206001 Canopy Assembly 3 Section 5 7 8 Dia Collar 100827 03 20 Canopy Assembly 4 Section 6 7 8 Dia Collar 100827 04 Canopy Assembly 5 Section 7 7 8 Dia Collar 100827 05 1 1 4 20 x 3 Lg Carriage Bolt Plated 2 0860119 1 4 20 x 3 1 2 Lg Carriage Bolt Plated 1 4 Flat Washer Plated 1 4 20 Wing Nut Plated V1 2 Heater Carton WT R amp ST R Rear Heater 5 16 Flat Washer Plated 8 3 8 16 x 7 8 Lg Cap Screw ASME Grade Marked SA307B 1 4 0860603 0860910 036058 036031 80860611 ES 80861337 00838 01 N N X REPAIR PARTS continued 3 N N Jacket Assembly Exploded View Item Boiler Size Quantity Size Boiler Size Quantity No Description aa s Part No Jacket Components Items 1 thru 6 Include Insulation as Part of Assembly 1 Packet Front PanerAssemby r 2 ucketRearPameAwem y 1 j Jacket Reversible Side Panel Assembly 1810 _ no 5 _ 5 Jacket Split Rear Top Panel Assembly 1 ax 102204 10082205 53 X REPAIR PARTS continued GASKET ONLY INSTRUCTIONS ENVELOPE ASSEMBLY WA
102. rop 4 HARD WATER A water analysis is necessary to determine the hardness of your potable water This is applicable to some city water and particularly to well water An appropriate water softener should be installed based on the analysis and dealer s recommendation This is not only beneficial to the tankless heater but to piping and fixtures plus the many other benefits derived from soft water J INDIRECT WATER HEATER PIPING 1 CONNECT Indirect Water Heater Piping as shown in Figures 11A and 11B for water boilers and Figures 12 and 15 for steam boilers Refer to Indirect Water Heater Instruction Manual for additional installation information INSTALLATION INSTRUCTIONS continued 3 4 RETURN CONNECTION FLOW CONTROL OR SWING CHECK VALVE INDIRECT BACK OF CL SERIES WATER HEATER STEAM BOILER LIMIT CONTROL IN 2 1 0 TAPPING 1 SUPPLY CONNECTION CIRCULATOR BOILER SUPPLY CONNECTION STRAINER BOILER RETURN CONNECTION Figure 15 Indirect Water Heater Piping on CL Series Steam Boiler CL SERIES WATER BOILER Figures and 11B show indirect water heater piping on typical hot water heating system Boiler piping is the same as for any two zone system Figures 11A and 11B show circulator zoning which is usually preferred for indirect water heaters Size the circulator and indirect water heater piping to obtain the boiler water
103. s 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 Box 10 Hatfield PA 19440 0010 Phone 215 855 8055 Attn Customer Service Department Bare Boiler Assembly Exploded View 51 X REPAIR PARTS continued Item Boiler Size Quantity Description art No Bare Boiler Assembly Front Section Non Htr Machined Water 71720103 OR 1 1 1 Front Section Non Htr Machined Steam 71720104 Center Section 71720301 Rear Section Non Htr Machined Water 71720201 OR Rear Section Non Htr Machined Steam i 71720202 Rear Heater Section Machined Water 71720203 OR Rear Heater Section Machined Steam 71720204 Rear Target Wallinsulaton 8202000 Tie Rod 3 8 16 x 12 1 2 Lg 2 80861010 7 Rod 3 8 16 17 3 4 Lg 2 80861032 Tie Rod 3 8 16 x 23 Lg 2 80861049 8 3 8 Flat Washer 5 80960423 Combustion Chamber Liner 1 2 19 1 2 x 9 3 4 1 82020031 10 Combustion Chamber Liner 1 2 x 19 1 2 14 3 4 4 82020041 Combustion Chamber Liner 1 2 x 19 1 2 x 19 3 4 1 82020051 2 80861349 100793 01 82020001 11728004 5 16 18 3 4 Lg Cap Screw Plated 80861340 Canopy Sealing St
104. s keep the manual fuel supply valve shut off if the burner is shut down for an extended period of time 5 To recondition the heating system in the fall season after a prolonged shut down follow the instructions outlined in Section V Paragraphs A through K WARNING This boiler contains controls which may cause the boiler to shut down and not restart without service 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 BOILER CLEANING WARNING All boiler cleaning must be completed with burner service switch turned off A CLEAN THE FLUEWAYS See Figure 31 1 Disconnect oil line s and remove burner and burner mounting plate See Figures 1A thru 1D 2 Lay protective cloth or plastic over combustion chamber blanket 3 Remove the smokepipe as necessary to gain access to the boiler canopy 4 Remove the jacket top panels 5 Remove the canopy being careful not to damage the cerafelt gasket 6 Using 114 diameter wire or fibre bristle brush 30 handle clean the flueways Brush from the top using diagonal strokes for best results DO NOT allow brush to strike the target wall or liner in the chamber B CLEAN TOP OF BOILER SECTIONS 1 Brush and vacuum the tops of the boiler sections CLEAN THE FIREBOX
105. se price paid for the boiler involved Some states do not allow the exclusion or limitation of incidental or consequential damages so the above limitation or exclusion may not apply to you 10 Limitation of Warranty These limited warranties are given in lieu of all other express warranties and set forth the entire obligation of New Yorker with respect to any defect in a residential cast iron steam boiler New Yorker shall have no express obligations responsibilities or liabilities of any kind other than those set forth herein ALL APPLICABLE IMPLIED WARRANTIES IF ANY INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY LIMITED IN DURATION TO A PERIOD OF ONE YEAR EXCEPT THAT IMPLIED WARRANTIES IF ANY APPLICABLE TO THE PRESSER VESSEL OF A RESIDENTIAL CAST IRON STEAM BOILER SHALL BE LIMITED IN DURATION TO THE LESSER OF THE DURATION OF SUCH IMPLIED WARRANTY OR A PERIOD OF TEN YEARS Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply to you PROCEDURE FOR OBTAINING WARRANTY SERVICE Upon discovery of a condition believed to be related to a defect in material or workmanship covered by these warranties the original consumer purchaser should notify the installer who will in turn notify the distributor If this action is not possible or does not produce a prompt response the original consumer purchaser should write to New Yorker Boiler
106. sion Well apply throttle position to start Operate boiler until the sealant and thread into 34 NPT tapping on heater Apply heat transfer paste not furnished to control Pad 2 bulb and insert bulb into immersion well Tighten Adjust the valves to provide 180 to 200 clamping screws to secure Boiler Control to supply water temperature Opening the boiler immersion well Secure 18 2 Control Cable Wire supply valves will raise the system temperature to jacket right side panel with 5 16 cable clamp while opening the bypass valve will lower the provided refer to Figure 1C system supply temperature 4 CONNECT FIELD WIRING If this boiler is connected to heating coils located C in air handling units where they may be exposed RE ice 5 ed h to refrigerated air the boiler piping must be 2 et 21 211 equipped with flow control valves to prevent tankless heater connect field wiring from the BIS CRON a s 2 operation of the cooling system Aquastat Control to the Oil Primary Control 5 2 Ps a TT terminals Beckett Burner or the R8239C If this boiler is used in connection with Control Center s R G terminals Riello refrigeration systems the boiler must be installed Burner Make the wiring connections as shown so that the chilled medium is piped in parallel in Figure 22 or 23 with the heating boiler using appropriate valves Kar to prevent the chilled medium from entering ote
107. stalled 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 recommended to supply power to the probe LWCO with the same line voltage servicing the boiler as shown below OAD Figure A2 Wiring of Typical LWCO APPENDIX A LOW WATER CUT OFF LWCO continued How to Test Shut off fuel supply Close shut off valves in system supply and return piping located in near boiler piping above LWCO as shown in Figure Al Open drain valve to lower water level until water is below the LWCO probe It may be necessary to open relief valve seat to allow air into system for the water to drain close drain valve and relief valve once completed Generate a boiler demand by turning up thermostat Boiler should not attempt to operate Open fill valve to increase the water level by filling the system It may be necessary to open relief valve to allow air to escape during filling process The boiler should attempt to operate once the water level is above the LWCO 61 SERVICE RECORD DATE SERVICE PERFORMED 62 NEW YORKER BOILER CO INC Limited Warranties For Residential Cast and Steel Water Boilers By this Warranty Statement New Yorker Boiler Co Inc New Yorker issues limited warranties subject to the terms and conditions s
108. t if the boiler is connected to a dirty or inadequate chimney or vent system The interior of the chimney flue must be inspected and cleaned before the start of the heating season for any obstructions Aclean and unobstructed chimney flue is necessary to allow noxious fumes that could cause injury or loss of life to vent safely and will contribute toward maintaining the boiler s efficiency DO NOT operate boiler with the absence of an approved vent system This boiler is supplied with controls which may cause the boiler to shut down and not re start 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 This boiler is designed to burn No 2 fuel oil only DO NOT use gasoline crankcase drainings or any oil containing gasoline Never burn garbage or paper in this boiler DO NOT convert to any solid fuel i e wood coal DO NOT convert to any gaseous fuel i e natural gas LP All flammable debris rags paper wood scraps etc should be kept clear of the boiler at all times Keep the boiler area clean and free of fire hazards All boilers equipped with burner swing door have a potential hazard which if ignored can cause severe property damage personal injury or loss of life Before opening swing door turn off service switch to boiler to prevent ac
109. t is carefully manufactured inspected and packed Our responsibility ceases upon delivery of crated boiler to the carrier in good condition 2 Any claims for damage or shortage in shipment must be filed immediately against the carrier by the consignee No claims for variances from or shortage in orders will be allowed by the manufacturer unless presented within sixty 60 days after receipt of goods B LOCATE BOILER near final position before removing crate See Figures 1A thru 1D Using hand truck or pipe rollers under skid move boiler into position along side installation site 1 LOCATE so that vent pipe connection to chimney will be short and direct 2 BOILER IS SUITABLE FOR INSTALLATION ON COMBUSTIBLE FLOOR Boiler cannot be installed on carpeting 3 FOR BASEMENT INSTALLATION provide a solid elevated base such as concrete if floor is not level or if water may be encountered on floor around boiler HERE Z Figure 3 Minimum Installation Clearances To Combustible Materials Inches C A B Chimney D E Above Front Connector Rear Sides 6 24 18 6 6 NOTE 1 Listed clearances comply with American National Standard NFPA 31 Standard for the Installation of Oil Burning Equipment 10 4 PROVIDE SERVICE CLEARANCE of at least 24 clearance from front jacket panel for servicing and removal of front tankless heater If boiler is equipped with a rear tankless heater provide at least 24 service
110. tated 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 prs YEAR pus br proie imite ers New Yorker warrants to the original consumer purchaser at the original installation address that its residential cast iron and steel water boilers will be free from defects in material and workmanship under normal usage for a period of one year from the date of original installation In the event that any defect in material or workmanship is found during the one year period following the date of installation New Yorker will at its option repair the defective part or provide a replacement free of charge F O B its factory WARNTE New Yorker warrants to the original consumer PR at the installation address that the pressure vessel of the boiler will be free of defects in material and workmanship under normal usage for a period of five years following the date of installation In the event that any defect in material or workmanship is found during the five year period following the date of installation New Yorker will at its option repair the defective pressure vessel or provide a replacement free of charge F O B its factory LIFETIME WARRANTY ant Boilers New Yorker warrants to the original consumer purchaser at the original installation address that the pressure vessel component of the boi
111. the boiler s efficiency 45 BOILER CLEANING continued NOTES SOFT BRISTLE BRUSH 1 PRIOR TO CLEANING BOILER LAY A PROTECTIVE CLOTH OR PLASTIC OVER THE BLANKET TO TR COLLECT DEBRIS FALLING FROM gt gt lt lt MV 4 FLUEWAYS 2 AFTER CLEANING INSPECT TARGET WALL COMBUSTION CHAMBER BLANKET AND BURNER SWING DOOR INSULATION FOR SIGNS OF DAMAGE IF DAMAGED REPLACE AS NEEDED VENT PIPE 3 REPLACE CANOPY GASKET STRIPS AS NEEDED IF DAMAGED CANOPY ASSEMBLY GASKET STRIPS FLUE BRUSH WALL INSULATION COMBUSTION CHAMBER BLANKET Figure 31 Cleaning of Boiler Flueways 46 Important Product Safety Information Refractory Ceramic Fiber Product Warning The Repair Parts list designates parts that contain refractory ceramic fibers RCF RCF has been classified as a possible human carcinogen When exposed to temperatures about 1805 F such as during direct flame contact RCF changes into crystalline silica a known carcinogen When disturbed as a result of servicing or repair these substances become airborne and if inhal
112. the spray droplets get larger and the flame shape gets longer An outside fuel tank that is above grade or has fuel lines in a shallow bury is a good candidate for cold oil The best solution is to locate the tank near the boiler in the basement utility room or bury the tank and lines deep enough to keep the oil above 40 F Check environmental issues with local authorities having jurisdiction 8 FLAME SHAPE Looking into the combustion chamber through the observation port the flame should appear straight with no sparklers rolling up toward the crown of the chamber If the flame drags to the right or left sends sparklers upward or makes wet spots on the target wall the nozzle should be replaced If the condition persists look for fuel leaks air leaks water or dirt in the fuel as described above 9 HIGH ALTITUDE INSTALLATIONS Air openings must be increased at higher altitudes Use instruments and set for 11 5 to 12 5 CO 10 START UP NOISE Late ignition is the cause of start up noises If it occurs recheck for electrode settings flame shape air or water in the fuel lines 11 SHUT DOWN NOISE If the flame runs out of air before it runs out of fuel an after burn with noise may occur That may be the result of a faulty cut off valve in the fuel pump or it may be air trapped in the nozzle line It may take several firing cycles for that air to be fully vented through the nozzle Water in the fuel or poor flame shape c
113. to the primary control black wire the 120V neutral white wire must be connected to the primary control white wire and the 120V constant hot red wire must be connected to the primary control red wire A GENERAL I Install wiring and electrically ground boiler in accordance with requirements of the authority having jurisdiction or in absence of such requirements the National Electrical Code ANSI NFPA 70 and or the CSA C22 1 Electric Code 7 If boiler is installed in Canada a blocked vent safety switch must be installed Refer to Blocked Vent Safety Switch Instruction Supplement provided with boiler Canada only 8 Wiring should conform to Figures 20 through 24 INSTALL A ROOM THERMOSTAT on an 2 Refer to National Electric Code or Local Electric mE Codes for proper size and type of wire required inside wall about four feet above floor Never install Follow Code thermostat on an outside wall or where it will be influenced by drafts hot or cold water pipes lighting 3 Aseparate electrical circuit must be run from the main electrical service with an over current device disconnect in the circuit A service switch is recommended and may be required by some local jurisdictions fixtures television rays of the sun or near a fireplace Keep large furniture away from thermostat so there will be free movement of room air around this control Heat Anticipator in Thermostat should be set to match the requ
114. ts are absolutely leak tight distribution system When a steam boiler is installed in an v Isolating the boiler from the system water by existing system ALL air vents should be installing a heat exchanger replaced at the same time This assures See Section VII Paragraph B Step 3 for additional that the new boiler will not be details compromised by existing system leaks NOTICE Before using copper for steam piping consider the following characteristics of copper piping High coefficient of thermal expansion can induce mechanical stresses and cause expansion contraction noises if not accounted for in the piping system design and installation High heat transfer rate heat loss of un insulated copper piping must be included in the normal piping and pickup factors used to size the boiler Soldering or brazing pastes and fluxes that end up in the system can cause poor heat transfer surging an unsteady water line and wet steam if not thoroughly removed during boil out procedure and Galvanic corrosion of the adjoining metal may occur due to dissimilar metals in certain water chemistries if dielectric unions are not used INSTALLATION INSTRUCTIONS continued HIGH TEMPERATURE WATER FOR AUTOMATIC WASHERS ETC TEMPERED HOT WATER 4 TO FAUCETS AND SHOWERS 5 AUTOMATIC MIXING Oy 1 COLD WATER HOSE 965 AND B IN HOT AND SUPPLY COLD WATER LINES FOR PERIODIC 1 FLUSHI
115. vice its function 18 critical to the successful operation of the oil burner The selection of the nozzle supplied with the CL boiler is the result of extensive testing to obtain the best flame shape and efficient combustion Other brands of the same spray angle and spray pattern may be used but may not perform at the expected level of CO and smoke Nozzles are delicate and should be protected from dirt and abuse Nozzles are mass produced and can vary from sample to sample For all of those reasons a spare nozzle is a desirable item for a serviceman to have FUEL LEAKS Any fuel leak between the pump and the nozzle will be detrimental to good combustion results Look for wet surfaces in the air tube under the ignitor and around the air inlet Any such leaks should be repaired as they may cause erratic burning of the fuel and in the extreme case may become a fire hazard SUCTION LINE LEAKS Any such leaks should be repaired as they may cause erratic burning of the fuel and in extreme cases may become a fire hazard Whatever it takes The Oil Must Be Free of Air This can be a tough problem but it must be resolved Try bleeding the pump through a clear tube There must be no froth visible There are various test kits available to enable you to look at the oil through clear tubing adapted to the supply line at the pump fitting Air eliminators are on the market that have potential Also electronic sight glasses are being use
116. y constructed from type L vent or a factory built chimney that complies with the type HT requirements of UL103 The chimney and vent pipe shall have a sufficient draft at all times to assure safe proper operation of the boiler See Figure 16 for recommended installation 1 Install a draft regulator supplied by installer following the instructions furnished with the regulator See Figure 17 for draft regulator locations 2 Consider the chimney overall Chimneys that have a high heat loss may become less suitable as the heat loss of the home goes down and the efficiency of the boiler installed goes up Most homes have a chimney appropriate for the fuel and the era in which the home was built That may have been a coal fired or an inefficient oil fired boiler built into a home without insulation or storm windows With increasing fuel prices that home probably has been insulated and fitted with storm windows so that the heat loss of the home has been reduced This requires less fuel to be burned and sends less heat up the chimney A new boiler probably has a higher efficiency than the boiler being replaced That probably means that the stack temperature from the new boiler will be lower than that from the old boiler and with less room air being drawn up the chimney to dilute the stack gases The combination of a large uninsulated chimney reduced firing rate reduced firing time 21 INSTALLATION INSTRUCTIONS continued 22

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installation, operating and service instructions cl™ series cast iron