New Yorker CG-C Series Service manual

INSTALLATION, OPERATING
AND
SERVICE INSTRUCTIONS
CG-CrM SERIES
GAS BOILER
JS
Intertek
BEFORE INSTALLATION: READ THIS MANUAL
SAVE THESE INSTRUCTIONS
Installing contractor and homeowner should read and be informed as to the proper installation and operation of this boiler.
The manufacturer will not be responsible for improper installation or operation. This manual and all associated instruction
material should be conspicuously posted near the boiler.
For service or repairs to boiler, call your heating contractor. When seeking information on
boiler, provide Boiler Model Number and Serial Number as shown on Rating Label.
Boiler Model Number IBoiler Serial Number Installation Date
I
CG C
Heating Contractor Phone Number
Address
®
RESIDENTIAL HG_.TING BOILERS
100291-01 R10-6/10 Price -$3.00

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.
Indicates a potentially hazardous situation which,
if not avoided, could result in death, serious injury
or substantial property damage.
Indicates special instructions on installation,
operation, or maintenance which are important
but not related to personal injury hazards.
5.62 --_
TE_P/
PRE_URE
_NTROL
e4
l
_ SIDE V_W
CONTROL
\
1_25
CONNECT_N
Figure 1:
ALLOWANCEFOR
Table 1: Dimensional Data
Boiler 'A' 'B' 'C' 'D' 'E' 'F' 'G'
Size
20 20-1/4 10-3/4 6-3/8 4 45-5/8 8-1/2 10"*
30 21-1/2 12 6 4 45-3/4 8-1/2 4-3/4
40 24-3/4 15-1/4 7-5/8 5 47-1/8 9-1/8 4-3/4
50 28 18-1/2 9-1/4 6 48-1/2 9-3/4 5-1/4
60 31-1/4 21-3/4 10-7/8 6 48-1/2 9-3/4 5-1/4
70 34-1/2 25 12-1/2 7 50-1/8 10-3/8 6-5/8
80 37-3/4 28-1/4 14-1/8 7 50-1/8 10-3/8 6-5/8
90 41 31-1/2 15-3/4 8 52 11 7-1/4
100 44-1/4 34-3/4 17-3/8 8 52 11 7-1/4
Recommended Gas Water
Vent Size [1] Conn. Content
Round Dia. (in) x Ht. (ft.) (FPT) (Gallons)
4" Dia. x 15' 1/2 2.5
4" Dia. x 15' 1/2 3.2
5" Dia. x 15' 1/2 4.0
6" Dia. x 15' 1/2 4.7
6" Dia. x 15' 1/2 5.5
7" Dia. x 15' 3/4 6.2
7" Dia. x 15' 3/4 7.0
8" Dia. x 15' 3/4 7.7
8" Dia. x 15' 3/4 8.5
Approx.
Shipping
Weight (LB.)
212
254
298
346
408
450
506
550
608
**CG20 only. Dimension 'G' includes allowance for 4"x 3" size reducer furnished with boiler. See Figure 10.
[1] 15' chimney height isfrom bottom of draft hood opening to top of chimney.
Maximum Allowable Working Pressure (Water only): 30 PSI
2

The New York City Department of Buildings has approved the CG-C Series boiler: Approval No. MEA 40-94-E.
The City of New York requires a Licensed Master Plumber supervise the installation of this product.
The Massachusetts Board of Plumbers and Gas Fitters has approved the CG-C Series Boiler. See the Massachusetts Board of
Plumbers and Gas Fitters website, http://license.reg.state.ma.us/pubLic/pb_pre_form.asp for the latest Approval Code or ask
your local Sales Representative.
The Colnlnonwealth of Massachusetts requires this product to be installed by a licensed Plumber or Gas fitter.
Table of Contents
I. Pre-Installation .............................. 3
II. Unpack Boiler ................................ 5
III. Water Piping and Trim ................... 5
IV. Gas Piping ..................................... 6
V. Venting ........................................... 8
VI. Electrical ...................................... 11
VII.
VIII.
IX.
X.
System Start-up ............................ 15
EI Trouble Shooting Guide .......... 22
Service .......................................... 23
Repair Parts ................................. 25
Appendix
Low Water Cut Off. ...................... 43
I. Pre-lnstallation
Carefully read all instructions before installing
boiler. Failure to follow all instructions in proper
order can cause personal injury or death.
A.
B.
C.
n.
Inspect shipment carefully for any signs of damage.
All equipment is carefully manufactured, inspected
and packed. Our responsibility ceases upon delivery
of boiler to carrier in good condition. Any claim
for damage or shortage in shipment must be filed
ilmnediately against carrier by consignee. No claims
for variances or shortages will be allowed by Boiler
Manufacturer, unless presented within sixty (60) days
after receipt of equipment.
Installation must conform to the requirements of the
authority having jurisdiction. In the absence of such
requirements, installation must conform to National
Fuel Gas Code, NFPA 54/ANSI Z223.1 Where required
by the authority having jurisdiction, the installation
must conform to the Standard for ('ontrols and Safety
Devices for Automatically Fired Boilers, ANSI/ASME
CSD-1.
Appliance is design certified for installation on
combustible flooring. The boiler must not be installed
on carpeting.
Provide clearance between boiler jacket and
combustible material in accordance with local fire
ordinance. Refer to Figure 2 for lninilnuln clearance
from combustible material for closet installation.
For alcove or unconfined space installations height
clearance maybe reduced to 27". Subject to boiler and
system piping, left side clearance may be reduced to 1"
if right side clearance is increased to 9".
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TOP VIEW
CGg0C 3*250
ZOO g,O0-_-
FRONT VIEW RIGHT S|D£ ViEW
÷ M{NM,*M {_?_DAL C:L[:ARANCE ANOUNO {)RA_T HOOD AND {)REg(;: {{NO,
÷ A{)[ Hg{g_il RSQU:t:gFO IO MA/N[A:N 6' C:{['XRANCE r-iOM A{{ BR/:EOHING
_- _R _ OR(MP(:),iENfS VEI41 }AM:'ER _'t' B: IN.>: _, I}', 7. ,I..Ao
HO_Z),_rA SF:C'/I(I', O: B_[:EC_ _"(:; W:HiN A:'_C}_ O!" CO'qTRO[ IARN:5;S,
Figure 2: Minimum Clearances to Combustible
Construction for Closet Installation

Eo
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Provide practical service clearances. A minimum
of 24" from the left side and front jacket panels is
recommended for servicing but may be reduced to
minimums shown in Figure 2. Subject to boiler and
system piping, left side clearance may be reduced to 1"
if right side clearance is increased to 9".
Install on level floor. For basement installation provide
concrete base if floor is not level or if water may be
encountered on floor around boiler.
Protect gas ignition system components from water
(dripping, spraying, rain, etc.) during boiler operation
and service (circulator replacement, condensate trap,
control replacement, etc.).
Provide combustion and ventilation air in accordance
with applicable provisions of local building codes,
or National Fuel Gas ('ode, NFPA 54/ANSI Z223.1,
Section 5.3, Air for Combustion and Ventilation.
Adequate combustion and ventilation air must be
provided to assure proper combustion.
The following guideline is based on the National Fuel
Gas' ('ode, NFPA 54/ANSI Z223.1.
1. Determine volume of space (boiler room). Rooms
colmnunicating directly with space (through
openings not furnished with doors) are considered
part of space.
Volume [fig] = Length [ft] x Width [ft] x Height [ft]
2. Determine Total Input of all appliances in space.
Round result to nearest 1,000 Btu per hour (Btuh).
3. Determine type of space. Divide Volume by Total
Input.
a. If result is greater than or equal to 50 ft3per
1,000 Btuh, space is considered an unconJined
space.
b. If result is less than 50 ft3per 1,000 Btuh, space
is considered a confined space.
4. Determine building type. A building of unusually
tight construction has the following characteristics:
a. Walls and ceiling exposed to outside atmosphere
have a continuous water vapor retarder with a
rating of 1perln or less with openings gasketed
and sealed, and;
b. Weather-stripping has been added on openable
windows and doors, and;
c. Caulking or sealants applied in joints around
window and door frames, between sole
plates and floors, between wall-ceiling joints,
between wall panels, at plumbing and electrical
penetrations, and at other openings.
4
I.
5. For boiler located in an uncol_fined space in a
building of other than unusually tight construction,
adequate combustion and ventilation air is normally
provided by fresh air infiltration through cracks
around windows and doors.
6. For boiler located within uncol_fined space in
building of unusually tight construction or within
co_fined space, provide outdoor air through two
permanent openings which colmnunicate directly or
by duct with the outdoors or spaces (crawl or attic)
freely colmnunicating 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 colmnunication with outdoors. Minimum
free area of 1 square inch per 4,000 Btu per hour
input of all equipment in space.
b. Vertical ducts. Minimum free area of 1 square
inch per 4,000 Bm 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 col_fined
space. Use indoor air if two permanent openings
colnlnunicate directly with additional space(s) of
sufficient volume such that combined volume of all
spaces meet criteria for unconfined space. Size each
opening for minilnuln free area of 1square inch per
1,000 Btu per hour input of all equipment in spaces,
but not less than 100 square inches.
7. Ventilation Duct Louvers and Grilles. Equip outside
openings with louvers to prevent entrance of rain
and snow, and screens to prevent entrance of insects
and rodents. Louvers and grilles must be fixed in
open position or interlocked with equipment to open
automatically before burner operation. Screens must
not be smaller than V4inch mesh.
Consider the blocking effect of louvers, grilles and
screens when calculating the opening size to provide
the required free area. If free area of 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.
Do not install boiler where gasoline or other
flamlnable vapors or liquids, or sources of
hydrocarbons (i.e. bleaches, cleaners, chemicals, sprays,
paint removers, fabric softeners, etc.) are used or stored.

II. Unpack Boiler
Do not drop boiler.
against floor.
Ao
B.
C.
Do not bump boiler jacket
Move boiler to approximate installed position.
Remove all crate fasteners.
Lift outside container and remove with all other
inside protective spacers and bracing. Save two of the
wooden slats from the container sleeve for use in Steps
E and E
D. Remove all boiler hold-down fasteners.
E. Tilt the boiler to one side and slide a wooden slat under
the two raised feet.
F. Tilt the boiler to the other side and slide another
wooden slat under the two raised feet.
G. Slide the boiler forward or backward off the skid using
the two wooden slats as runners.
H. Move boiler to its permanent location.
III. Water Piping and Trim
Ao Design and install boiler and system piping to
prevent oxygen contamination of boiler water.
Oxygen contamination sources are system leaks
requiring addition of makeup water, fittings, and oxygen
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permeable materials in distribution system. Eliminate
oxygen contamination by repairing system leaks,
repairing fittings, and using nonperlneable materials in
distribution system.
Install circulator with flanges, gaskets and bolts
provided. Five foot long circulator harness allows
circulator to be mounted on supply or return. Connect
harness to circulator and secure any excess conduit.
Install Safety Relief Valve. See Figure 1. Safety Relief
Valve must be installed with spindle in vertical position.
Figure 3: Recommended Water Piping for Zone Valve Zoned Heating Systems

Safety relief valve discharge piping must be piped
near floor to eliminate potential of severe burns.
Do not pipe in any area where freezing could
occur. Do not install any shut-off valves.
D. Connect system supply and return piping to boiler.
Refer to Figure 3. Also consult I=B=R Installation and
Piping Guides. Maintain lninilnuln */2inch clearance
from hot water piping to combustible materials.
E. Space heating and domestic water heating with the
New Yorker Link SLTM indirect water heater. Install
the New Yorker Link SLTM indirect water heater as a
separate heating zone. Refer to the New Yorker Link
SLTM Indirect Water Heater Installation, Operating and
Service Instructions for additional information.
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If boiler is connected to heating coils located in
air handling units where they may be exposed to
refrigerated air, boiler piping must be equipped with
flow control valves to prevent gravity circulation of
boiler water during operation of cooling system.
Use a boiler bypass if the boiler is to be operated
in a system which has a large volume or excessive
radiation where low boiler water temperatures may be
encountered (i.e. converted gravity circulation system,
etc.).
Remove circulator and install pipe tee between
circulator and boiler return along with second tee in
supply piping as shown in Figure 3. Bypass should be
same size as the supply and return lines with valves
located in bypass and supply outlet as illustrated in
Figure 3 in order to regulate water flow to maintain
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Figure 4: Recommended Piping for Combination
Heating & Cooling (Refrigeration) Systems
I,
higher boiler water temperatures.
Set by-pass and boiler supply valves to half throttle
position to start. Operate boiler until system water
temperature reaches normal operating range.
Adjust valves to provide 180° to 200°F supply water
temperature. Opening the boiler supply valve will raise
system temperature, while opening by-pass valve will
lower system supply temperature.
If it is required to perform a long term pressure
test of the hydronic system, the boiler should first be
isolated to avoid a pressure loss due to the escape of air
trapped in the boiler.
EIf boiler is used in connection with refrigeration
systems, boiler must be installed with chilled medium
piped in parallel with the heating boiler using
appropriate valves to prevent chilled medium from
entering boiler. See Figure 4. Also consult I=B=R
Installation and Piping Guides.
IV. Gas Piping
A,
To perforln a long terln pressure test including the
boiler, ALL trapped air must first be removed from the
boiler.
A loss of pressure during such a test, with no visible
water leakage, is an indication that the boiler contained
Size gas piping. Design system to provide adequate gas
supply to boiler. Consider these factors:
1. Allowable pressure drop from point of delivery to
boiler. Maximum allowable system pressure is */2
psig. Actual point of delivery pressure may be less;
contact gas supplier for additional information.
Minimum gas valve inlet pressure is listed on rating
label.
2. Maximum gas demand. Table 2 lists boiler input
rate. Also consider existing and expected future gas
utilization equipment (i.e. water heater, cooking
equipment).
Table 2:
Boiler
Model
Number
2O
3O
4O
5O
6O
7O
8O
9O
100
Rated Input
Input Rate
[cubic feet per hour]
Natural Gas
37.5
62.0
96.0
130.0
164.0
198.0
232.0
266.0
299.0
LP/Propane
15.0
24.8
38.4
52.0
65.6
79.2
92.8
106.4
119.6
Gas
Connection
Size
½
½
½
½
½
¾
¾
¾
¾
trapped air.

Table 3: Maximum Capacity of Schedule 40 Pipe in CFH for Natural Gas Pressures of 0.5 psig or Less
Length 0.3 inch w.c. Pressure Drop 0.5 inch w.c. Pressure Drop
[Feet] ½¾ 1 1% ½ ¾ 1 1%
10 132 278 520 1,050 175 360 680 1,400
20 92 190 350 730 120 250 465 950
30 73 152 285 590 97 200 375 770
40 63 130 245 500 82 170 320 660
50 56 115 215 440 73 151 285 580
60 50 105 195 400 66 138 260 530
70 46 96 180 370 61 125 240 490
80 43 90 170 350 57 118 220 460
90 40 84 160 320 53 110 205 430
100 38 79 150 305 50 103 195 400
Table 4: Fitting Equivalent Lengths
Fitting
45 ° Ell
90° Ell
Tee
(As Elbow)
½
0.7
1.6
3.1
Nominal Pipe Size
¾ 1
1.0 1.2
2.1 2.6
4.1 5.2
1%
1.6
3.5
6.9
3. Length of piping and number of fittings. Refer to
Table 3 for lnaxilnuln capacity of Schedule 40 pipe.
Table 4 lists equivalent pipe length for standard
fittings.
4. Specific gravity of gas. Corrections for the specific
gravity of natural gas can be found in Table 5.
For materials or conditions other than those listed
above, refer to National Fuel Gas ('ode, NFPA
54/ANSI Z223.1, or size system using standard
engineering methods acceptable to authority having
jurisdiction.
B. Connect boiler gas valve to gas supply system.
2.
3.
Use methods and materials in accordance with local
plumbing codes and requirements of gas supplier. In
absence of such requirements, follow National Fuel
Gas'('ode, NFPA 54/ANSI Z223.1.
Use thread (joint) compounds (pipe dope) resistant
to action of liquefied petroleum gas.
Install sediment trap, ground-joint union and manual
shut-off valve upstream of boiler gas control valve.
See Figure 6 or 7.
Table 5: Specific Gravity Correction Factors for
Natural Gas
Specific Correction Specific Correction
Gravity Factor Gravity Factor
0.50 1.10 1.30 1.07
0.55 1.04 1.40 1.04
0.60 1.00 1.50 1.00
0.65 0.96 1.60 0.97
0.70 0.93 1.70 0.94
0.75 0.90
0.80 0.87
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4. All above ground gas piping upstream from manual
shut-off valve must be electrically continuous and
bonded to a grounding electrode. Do not use gas
piping as grounding electrode. Refer to National
Electrical ('ode, ANSI/NFPA 70.
Pressure test. The boiler and its gas connection must
be leak tested before placing boiler in operation.
1.
2.
Protect boiler gas control valve. For all testing over
*/2psig, boiler and its individual shutoff valve must
be disconnected from gas supply piping. For testing
at */2psig or less, isolate boiler from gas supply
piping by closing boiler's individual manual shutoff
valve.
Locate leaks using approved combustible gas
detector, soap and water, or similar nonflalmnable
solution. Do not use snatches, candles, open flames,
or other ignition source.

Figure 6: Pilot and Gas Piping, Continuous Ignition
(Standing Pilot) Figure 7: Pilot and Gas Piping, Intermittent Ignition
(El)
V. Venting
Ao
Bo
Install vent system in accordance with local building
codes; or local authority having :jurisdiction; or
National Fuel Gas Code, ANSI Z223.1/NFPA 54.
Install any of the following for this Classic CG-C Series
Category I, draft hood equipped appliance:
1.
2.
3.
Type B or Type L gas vent. Install in accordance
with listing and manufacturer's instructions.
Masonry or metal chimney. Build and install in
accordance with local building codes; or local
authority having jurisdiction; or Standard for
('himneys, Fireplaces, Vents, and Solid Fuel
Burning Appliances', ANSI/NFPA 211.
Masonry chimney must be lined with approved
clay flue lining or listed chimney lining system
except as provided in ANSI Z223.1/NFPA 54,
Paragraph 7.5.4(a): Exception." Where permitted by
the authority having jurisdiction, existing chimneys
shall be permitted to have their use continued when
an appliance is replaced by an appliance of similar
type, input rating, and efficiency.
Single wall metal vent. Allowed by ANSI Z223.1/
NFPA 54 under very restrictive conditions.
Inspect chimney and remove any obstructions or
restrictions. Clean chimney if previously used for solid
or liquid fuel-burning appliances or fireplaces.
Inspect existing chimney before installing boiler.
Failure to clean or replace perforated pipe or tile
lining will cause severe injury or death.
Co
Do
Install Draft Hood without modification on outlet of
flue collector. See Figure 1. Secure with sheet metal
screws.
Do not alter boiler draft hood or place any
obstruction or non-approved damper in the
breeching or vent system. Flue gas spillage can
occur. ETL certification will become void.
Install Blocked Vent Switch. The Blocked Vent Switch
Assembly shipped taped to top of boiler includes power
cord and switch attached to mounting bracket.
1. Untape Blocked Vent Switch Assembly from top of
boiler. Uncoil power cord.
2. Position mounting bracket onto lower edge of Draft
Hood skirt. Locate center tooth (with #10 sheet
metal screw) on outside and other two teeth inside
Draft Hood skirt. See Figure 8.

3.
4.
5.
Slide mounting bracket tight against lower edge of
Draft Hood skirt. Position #10 sheet metal screw
above skirt's stiffening rib.
Secure bracket in position by tightening #10 sheet
metal screw against outer surface of Draft Hood
skirt.
Verify power cord, mounting bracket and Blocked
Vent Switch are secure and located as shown in
Figure 8.
Figure 8: Blocked Vent Switch Installation
Failure to properly install and use this Blocked
Vent Switch may result in property damage,
personal injury or loss of life.
Eo Install Vent Damper. See Figure 9.
1. Open Vent Damper Carton and remove Installation
Instructions. Read Installation Instructions
thoroughly before proceeding.
Please refer to the specifications, installation
instructions and troubleshooting guide packed
in the vent damper carton for complete detailed
installation instructions.
2. Vent damper should be same size as draft hood
outlet. See Figure 1. Unpack vent damper carefully
-DO NOT FORCE CLOSED! Forcing vent
damper may damage gear train and void warranty.
Vent damper assembly includes pre-wired
connection harness with polarized plug for use on all
24V standing pilot or EI control systems.
3. Mount vent damper assembly on draft hood without
modification to either. Refer to instructions packed
with vent damper for specific instructions. Vent
damper position indicator to be visible to users.
SUPPLY-
PER POSmON INDICATOR
D_F HOOD BLOCKED VENT
SWITCH
O
O
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4P_N POLARIZED
CONNECTOR
CABLE C_P
LF1W 8lDg Vi_ U
FRONT VIEW
Figure 9: Vent Damper Installation
DETAIL 'A_

Provide 6" minimum clearance between damper
and combustible construction.
Do not use one vent damper to control two heating
appliances.
E
Go
Install Vent Connector from vent damper to chimney
or gas vent. See Figure 10.
1.
2.
3.
4.
5.
6.
Do not connect into same leg of chimney serving an
open fireplace.
Vent connector must not be smaller than vent
damper outlet. Type B is recolmnended, but single-
wall vent pipe may be used. Arrange venting system
so only the boiler is served by vent damper device.
Where two or more appliances vent into a colmnon
vent, the area of the colnlnon vent should be at least
equal to the area of the largest vent plus 50% of the
area in the additional vent(s). Do not connect the
vent of this appliance into any portion of mechanical
draft systems operating under positive pressure.
Vent connector should have greatest possible initial
rise above vent damper consistent with headroom
available and required clearance from adjacent
combustible building structure.
Vent connector should slope upward from vent
damper to chilnney or gas vent not less than one
inch in four feet. No portion of vent connector
should run downward or have dips or sags. Vent
connector must be securely supported.
Vent connector should be installed above bottom
of chimney to prevent blockage. Inserted into but
not beyond inside wall of chimney liner. Seal tight
between vent connector and chimney.
If an Existing Boiler is Removed:
When an existing boiler is removed from a colnlnon
venting system, the colnlnon venting system is likely
to be too large for proper venting of the appliances
remaining connected to it.
At the time of relnoval of an existing boiler, the
following steps shall be followed with each appliance
remaining connected to the colnlnon venting system
placed in operation, while the other appliances
remaining connected to the colnlnon venting system are
not in operation:
a. Seal any unused openings in the colnlnon venting
system.
b. Visually inspect the venting system for proper
size and horizontal pitch and determine there is no
blockage or restriction, leakage, corrosion, and other
deficiencies which could cause an unsafe condition.
c. Insofar as is practical, close all building doors and
windows and all doors between the space in which
the appliances remaining connected to the colnlnon
venting system are located and other spaces of the
building. Turn on clothes dryers and any appliance
not connected to the colnlnon venting system.
Turn on any exhaust fans, such as range-hoods and
bathroom exhausts, so they will operate at lnaxilnuln
speed. Do not operate a sulnlner exhaust fan. Close
fireplace dampers.
d. Place in operation the appliance being inspected.
Follow the Lighting (or Operating) Instructions.
Adjust thermostat so appliance will operate
continuously.
e. Test for spillage at the draft hood relief opening after
5 minutes of main burner operation. Use the flame
of a match or candle, or smoke from a cigarette,
cigar or pipe.
f. After it has been determined that each appliance
remaining connected to the colnlnon venting system
properly vents when tested as outlined above, return
doors, windows, exhaust fans, fireplace dampers and
any other gas-burning appliance to their previous
condition of use.
g. Any improper operation of the colnlnon venting
system should be corrected so the installation
conforms with the National Fuel Gas ('ode, NFPA
54/ANSI Z223.1. When resizing any portion of
the colnlnon venting system, the colnlnon venting
system should be resized to approach the lninilnuln
size as determined using the appropriate tables in
Part 11 in the National Fuel Gas ('ode, NFPA 54/
ANSI Z223.1.
10

FRECLAY TILE LINED CHIMNEY
t/_ THIMBLE
/f--HOR/ZONTA!: dENT CONNECTOR,
AIR GAP // ;/ SLOPE SECTIONS PWARD NOT
...........
,oRi,Fr HOOD
CLEANOUT--,-_ f7:i{i77"' ......
:LOOR
lINE
Figure 10: Typical Vent System Installation
FEE T
Vl. Electrical
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General. Install wiring and ground boiler in accordance
with requirements of authority having ;jurisdiction, or
in absence of such requirements the National Electrical
('ode, ANSI/NFPA 70.
Connect Vent Damper. See Figure 9.
Install the 90 ° BX connector attached to the flexible
conduit in the 7/8" hole on the right side of the jacket.
Plug the factory wired Vent Damper Harness into
polarized receptacle.
Install thermostat. Locate on inside wall
approximately 4 feet above floor. Do not install on
outside wall, near fireplace, or where influenced by
drafts or restricted air flow, hot or cold water pipes,
lighting fixtures, television, or sunlight. Allow free air
movelnent by avoiding placement of furniture near
thermostat.
Wire thermostat. Provide Class II circuit between
thermostat and boiler. Set thermostat heat anticipator
to 0.3 amps. See Figure 12 for continuous ignition
(standing pilot) or Figure 13 for intermittent ignition
(EI).
Eo
17.
Go
If system tends to overheat above therlnostat's
temperature setting, reduce heat anticipator setting by
0.1 or 0.2 amps. If system tends to shortcycle without
reaching desired room temperature, increase heat
anticipator setting by 0.1 or 0.2 amps.
New Yorker Link SLTM indirect water heater (if
used). See Figure 12 for continuous ignition (standing
pilot) or Figure 13 for intermittent ignition (EI). Also
refer to the New Yorker Link SLTM Indirect Water
Heater Installation, Operating and Service Instructions.
Wire boiler. Boiler is rated for 120 VAC, 60 hertz,
less than 12 amperes. A separate electrical circuit
must be run from the main electrical service with an
over-current device/disconnect in the circuit. A service
switch is recolmnended and may be required by some
local jurisdictions. Connect to black and white wires
and green ground screw. See Figure 12 for continuous
ignition (standing pilot) or Figure 13 for intermittent
ignition (EI).
For installations using zone valves provide separate
transformer for zone valve wiring. Consult zone valve
manufacturer for assistance. 11

H. Vent Damper Sequence of Operation. See Figure 11.
1. Vent Damper continuously powered at Terminal 1.
2. Call for heat energizes Vent Damper through
Terminal 5.
3. Vent Damper reaches fully open position. Power is
sent back to Limit through Terminal 2.
4. Call for heat ends. Vent Damper closes.
This boiler contains controls which may cause the
boiler to shut down and not restart without service.
If damage due to frozen pipes is a possibility, the
heating system should not be left unattended
in cold weather; or appropriate safeguards and
alarms should be installed on the heating system
to prevent damage if the boiler is inoperative.
_L-._R WIRING
Figure 11: Vent Damper Schematic Wiring Diagram
12

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C IRC ULA:C;R
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I RELAY
?- !+>-- G_
./ \
DU_L LIMIT OPTON
6I
I
i
i
) hONI2Y3cZL[ VR8200C/
r- ............................s '¢R83G#_O _AS VALVE
NOTES:
SCHEMATIC DIAGRAM _GEND HARNESS
............ VOLTAGZ SZE 18 AWG TYPZ 7ZW/AWM ST_NDZO W_RZ: - O_+C,
..... LO_ VOLIAGE SZE i8/2 AWG YY_ C) 2X OR POWFR /2MI_D CRCUI1 CAB),E "o 75 05+C
NE 'COL,TAG S_ZE 14 AWG FYPE fW OR EW,/A_ WRE
.... LNE VOITA,GE SZE 16 AWG TYPE TW OR T£W/AWM WRE
"----------- UNE VOE1AGE S_ZE I8 ##_tG (YPE _W OR 7EWiA@_M WRE
@K/W - B/,_,CK WiTH WHITE }'RACE
BL -@L:UE
GR GREEN
OR -_ OR@@_GE
P - PINK
RD - RZO
WN- WHITE
YE - YELLOW
GY G_AY
_iW -GRAY, '_/'W_('_E TRACE
_DDER DIAGRAM LEGEND
................24V WRNC
.................. 12RV WIRINO
I, IF ANY OF TNE OR_GNAL _RE AS SUPPLED /_(TH THE APPLIANCE MUST BE
R PLACED, IT MUS1 8F REPLACED WITH WIRE AS SHOWN OR /lS EQ/JIVAt._-:NT,
Si _n _es _o_d_cteur_ _o_rn_ _ve¢ i'_p_rei! _@t _tre rernp_c@, utiise_ un
oo_d_JAeu de type,, c_mme n_iquS, ou '@q_lent
2, COLMAR ONLY -- G_REZN GROUND WRE: ATIACHED FROM TRARSFORM£R
TERMINAL "C' TO dAC_E] SCREW N VES[BU_:.
:L iNDRECT WAFER FATER CONTROUS SUPPHEB BY NSTAUER (S4OWN FOR
DO#EST_C _Ol _'A_ER _R_ORI[Y AND CRCNLA1OR ZONNG},
4, REVERSe ACT)NG ©RCUbCTOR CONTROL. Y USED, SUPPL)EO BY NS_4,LER.
Figure 12: Wiring Diagram, Continuous Ignition (Standing Pilot)
I, Sequence of Operation, Continuous Ignition
(Standing Pilot).
1. Normal Operation
a. Thermostat calls for heat. Vent Damper opens.
b. Gas Valve energized allowing main gas flow and
ignition of Main Burners.
c. Call for heat ends. Gas "Calvede-energized,
extinguishing main flame. Vent Damper closes.
2. Safety Shutdown
a. Limit: Automatically interrupts main burner
operation when water temperature exceeds set
point. Maximum allowable telnperamre is 250°F.
Circulator continues to operate with call for
heat and Vent Damper closes. Normal operation
resumes when water temperature falls below set
point.
b. Blocked Vent Switch. Automatically interrupts
main burner operation when excessive vent
system blockage occurs. Circulator continues
to operate and Vent Damper remains open with
call for heat. If blocked vent switch is activated
do not attempt to place boiler in operation. The
source of blockage must be corrected by trained
and skilled personnel from a qualified service
agency before resetting switch.
Flame Roll-out Switch. Automatically interrupts
boiler operation when flames or excessive heat
are present in vestibule. Circulator continues to
operate and Vent Damper remains open with call
for heat. Control is single use device. If flame
roll-out switch is activated do not attempt to
place boiler in operation. The source of blockage
must be corrected and the flame roll-out switch
replaced by trained and skilled personnel from a
qualified service agency.
Therlnocouple: senses pilot flame and causes gas
valve to turn off main burner and pilot burner
gas flow should pilot burner flame extinguish.
Circulator continues to operate and Vent Damper
remains open with call for heat.
13

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14
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...... GRO4._N6 +- C©_ N£NIA/. SRGX@O0 _>Z[: 8 A_( _,qlR '° g_)O
Figure 13: Wiring Diagram, Electronic Intermittent Ignition (El)
Sequence of Operation, Electronic Intermittent
Ignition (El).
1. Normal Operation
a. Thermostat calls for heat. Vent Damper opens.
b. Ignition Module energized. Pilot Valve opens.
Igniter energized to ignite Pilot Burner.
c. Sensor proves presence of pilot flame. Main
Valve opens and ignites Main Burners.
d. Call for heat ends. Ignition Module is de-
energized. Main Valve and Pilot Valve close,
extinguishing pilot and main burners. Vent
Damper closes.
2. Safety Shutdown
a. Limit: Automatically interrupts main burner
operation when water temperature exceeds set
point. Maximum allowable temperature is 250°F.
Circulator continues to operate with call for
heat and Vent Damper closes. Normal operation
resumes when water temperature Palls below set
point.
b. Blocked Vent Switch. Automatically interrupts
main burner operation when excessive vent
system blockage occurs. Circulator continues
to operate and Vent Damper remains open with
call for heat. If blocked vent switch is activated
do not attempt to place boiler in operation. The
source of blockage must be corrected by trained
C.
d.
and skilled personnel from a qualified service
agency before resetting switch.
Flame Roll-out Switch. Automatically interrupts
boiler operation when flames or excessive heat
are present in vestibule. Circulator continues to
operate and Vent Damper remains open with call
for heat. Control is single use device. If flame
roll-out switch is activated do not attempt to
place boiler in operation. The source of blockage
must be corrected and the flame roll-out switch
replaced by trained and skilled personnel from a
qualified service agency.
Sensor: senses pilot flame and causes ignition
module to turn off main burner and pilot burner
gas flow should pilot burner flame extinguish.
Ignition module will try to relight pilot for
approximately 85 seconds after pilot burner
flame is extinguished. If pilot burner flame
can not be reestablished, Ignition Module will
shutdown.
Five to six minutes after shutdown, Ignition
Module automatically restarts ignition sequence.
Sequence continues until pilot burner flame
is reestablished or call for heat ends. Ignition
Module can be manually reset by adjusting
thermostat to end call for heat for one minute.
Circulator continues to operate and Vent Damper
remains open with call for heat.
For Electronic Ignition Troubleshooting Guide,
see Page 22.

VII. System Start-up
Safe lighting and other performance criteria were met with the gas manifold and control assembly provided on the boiler when
the boiler underwent tests specified in American National Standard for Gas-Fired Low-Pressure Steam and Hot Water Boilers,
ANSI Z21.13.
A.
B,
Main Burner Check - Check main burners to see
that they were not dislodged during shipment. Rear
of burners should be in the vertical slots in the rear of
burner tray and the front of the burners should be seated
completely on the orifices.
Initial start -
1. Fill entire heating system with water and vent
air from system. Use the following procedure on a
Series Loop System equipped with zone valves. (See
Figure 3).
a. Close isolation valve in boiler supply piping.
b. Isolate all circuits by closing zone valves or
balancing valves.
c. Attach a hose to hose bib located just below
isolation valve in boiler supply piping. (Note
- Terminate hose in five gallon bucket, at a
suitable floor drain, or outdoor area).
d. Starting with one circuit, open zone valve.
e. Open hose bib.
f. Open fill valve (Make-up water line should be
located directly above isolation valve in boiler
supply piping).
g. Allow water to overflow from bucket until
discharge from hose is bubble free for 30
seconds.
h. Open zone valve to the second zone to be
purged, then close the first. Repeat this step until
all zones have been purged, but always have one
zone open. At completion, open all zone valves.
i. Close hose bib, continue filling the system
until the pressure gauge reads 12 psi. Close fill
valve. (Note - If make-up water line is equipped
with pressure reducing valve, system will
automatically fill to 12 psi. Leave globe valve
open).
j. Open isolation valve in boiler supply piping.
k. Remove hose from hose bib.
2. Turn ROOM THERMOSTAT to lowest setting.
3. Be sure that gas to pilot and main burners has been
off for at least five minutes and vent damper has
been in the open position.
4. Turn "OFF" the electric switch serving boiler.
5. Open valve on main gas line at meter.
6. PURGE AIR FROM GAS PIPING. This procedure
will vary with ignition system furnished but in all
cases adequate ventilation must be provided and
no smoking or open flame permitted.
a. Standing Pilot Models, see Figures 6 and 16.
i. Keep electric switch "OFF".
ii. Open Manual Shut-offValve upstream of
Combination Gas Valve.
iii. Disconnect Pilot Tubing at gas valve (Purge
must not be into combustion chamber).
iv. Turn Main Gas Knob on Combination Gas
Valve to "Pilot" Position. Depress and hold
in this position until purging is complete.
Turn Main Gas Knob to "off' position.
v. Reconnect pilot tubing and check pipe and
fittings from meter to combination Gas
Valve for leaks using soap solution or other
approved method.
b. Intermittent Ignition Models, see Figures 7 and
17.
i. Turn "ON" electric switch serving boiler.
ii. Open Manual Shut-offValve upstream of
Combination Gas Valve.
iii. Loosen or remove Inlet Pressure Tap Plug in
Combination Gas Valve and when purging
is complete, tighten or replace plug. (See
Figure 14).
PRESSURE REGJL_,rOR
A/),USSMENT "'\\
UNOR CA CRD@ s
GAS COHX<?L
K ,,_08
(SL£,N}II'G ;#_ ONLY)
_:.C, RES_.T S/ii"lOrl -_, ,,, pot! AD, uSV_,_e:r,,I?
(S!Ai,,Oi_,_OPI_O O'aY] (uq;!;R CA;,_ SCi;{EW)
Figure 14: Top View of Honeywell Gas Valves
iv. Check pipe and fittings from meter to
Combination Gas Valve using soap solution
or other approved methods.
V. Test gas piping and connections between
Combination Gas Valve and manifold,
orifices, and pilot piping for leaks after
boiler is operating. Use soap solution or
other approved method.
15

C. Instructions to Put the Boiler in Operation.
1. Electronic Ignition Modules with LED indicators.
Table 6 cross-references the ignition module
terminal designations to the ignition terminal
numbers in the wiring ladder diagrams. The yellow
LED indicates the stares of the flame, see Table 7.
The green LED indicates the status of the system,
see Table 8.. See Figure 15 for LED locations.
2. See Figure 17 for Continuous Ignition System
(standing pilot).
Table 6:
Ignition Module
Terminal Designation
MV
MV/PV
PV
GND
24V (GND)
24V
SPARK
Ignition Module Terminal Cross-Reference
Wiring Ladder Diagram
Terminal Number
1
2
3
4
5
6
9
Table 7: Yellow LED Flame Codes
Yellow LED Recommended
Flash Code aIndicates Service Action
Heartbeat Normal Flame Signal N/A
Weak Flame Signal -
System will operate reliably but flame signal is
less than desired.
Note: This indication may flash temporarily
during or shortly after lightoff on some
applications.
Marginal Flame Signal (less than 1.1 HA) -
System may not operate reliably over time.
Service call recommended.
1Note: This indication may flash temporarily
during or shortly after lightoff on some
applications.
No Flame or Flame Signal -
OFF below minimum threshold for system operation.
aFlash Code Descriptions
Heartbeat: Constant ½ second bright, ½ second dim cycles.
Perform routine
maintenance to
assure optimum
flame signal.
Check gas supply,
pilot burner, flame
sense wiring, con-
tamination of flame
rod, burner ground
connection.
N/A
The flash code number signifies that the LED flashes X times at 2Hz,
remains off for two seconds, and then repeats sequence.
N1ATUN L_D
Figure 15: LED Locations
16

Table 8: Green LED Status Codes
Green LED
Flash Code Indicates Next System Action Recommended Service Action
(X + y)a
OFF No "Call for Heat" N/A None
Flash Fast Startup - Flame sense N/A None
calibration
Heartbeat Normal operation N/A None
6+2
6+3
6+4
5 minute Retry Delay-
Pilot flame not detected
during trial for ignition
Recycle- Flame failed
during run
Flame sensed out of
sequence
Flame sense leakage to
ground
Low secondary voltage
supply- (below 15.5 Vac)
5 minute Retry Delay-
On every third retry on
same "Call for Heat"
On every 6th flame
failure during run on the
same "Call for Heat"
Flame sensed out of
sequence- longer than
10 seconds
Initiate new trial for ignition after retry
delay completed.
Initiate new trial for ignition. Flash
code will remain through the ignition
trial until flame is proved.
If situation self corrects within 10
seconds, control returns to normal
sequence. If flame out of sequence re-
mains longer than 10 seconds, control
goes to Flash code 6+4 (see below)
Control remains in wait mode. When
the fault corrects, control resumes nor-
mal operation after a one minute delay.
Control remains in wait mode. When
the fault corrects, control resumes nor-
mal operation after one minute delay.
Initiate new trial for ignition after retry
delay completed.
5 minute retry delay, then initiate new
trial for ignition.
Control waits until flame is no longer
sensed and then goes to soft lockout.
Flash code continues. Control auto
resets from soft lockout after one hour.
Soft lockout due to error
ON detected during self
check sequences
_Flash Code Descriptions:
Flash Fast: rapid blinking
Heartbeat: Constant ½ second bright, ½ second dim cycles.
Control auto resets from soft lockout
after one hour.
If system fails to light on next trial
for ignition check gas supply, pilot
burner, spark and flame sense wir-
ing, flame rod contamination or out
of position, burner ground connec-
tion.
If system fails to light on next trial
for ignition check gas supply, pilot
burner, flame sense wiring, flame
rod contamination, burner ground
connection.
Check for pilot flame. Replace gas
valve if pilot flame present. If no
pilot flame, cycle "Call for Heat." If
error repeats, replace control.
Check flame sense lead wire for
damage or shorting. Check that
flame rod is in proper position.
Check flame rod ceramic for cracks,
damage or tracking.
Check transformer and AC line for
proper input voltage to the control.
Check with full system load on the
transformer.
Check gas supply, pilot burner, spark
and flame sense wiring, flame rod
contamination or out of position,
burner ground connection.
Check gas supply, pilot burner, flame
sense wiring, contamination of flame
rod, burner ground connection.
Check for pilot flame. Replace gas
valve if pilot flame present. If no
pilot flame, cycle "Call for Heat." If
error repeats, replace control.
Reset by cycling "Call for Heat." If
error repeats, replace the control
A single flash code number signifies that the LED flashes X times at 2Hz, remains off for two seconds, and then
repeats the sequence.
X + Y flash codes signify that the LED flashes X times at 2Hz, remains off for two seconds, flashes Y times at 2
Hz, remains off for three seconds, and then repeats the sequence.
17

FOR YOUR SAFETY READ BEFORE OPERATING
WARNING: If you do not follow these instructions exactly, a fire or explosion may result
causing property damage, personal injury, or loss of life.
A.
B,
This appliance is equipped with an ignition device
which automatically lights the pilot. Do not try to light
the pilot by hand.
BEFORE OPERATING smell all around the appliance
area for gas. Be sure to smell next to the floor
because some gas is heavier than air and will settle
on the floor.
C,
I_ If you cannot reach your gas supplier, call the fire
department.
Use only your hand to push in or turn the gas control
knob. Never use tools. If the knob will not push in or
turn by hand, don't try to repair it, call a qualified
service technician. Force or attempted repair may
result in a fire or explosion.
WHAT TO DO IF YOU SMELL GAS
I_ Do not try to light any appliance.
I_ Do not touch any electric switch; do not use any
phone in your building.
I_ Immediately call your gas supplier from a neigh-
bor's phone. Follow the gas supplier's instructions.
D. Do not use this appliance if any part has been under
water. Immediately call a qualified service technician
to inspect the appliance and to replace any part of the
control system and any gas control which has been
under water.
OPERATING INSTRUCTIONS
1. STOP! Read the safety information above on this
label. 6. Rotate gas control knob clockwise S_ from "ON" position to "OFF". Make sure knob rests against stop.
2.
3.
4.
5.
Set the thermostat to lowest setting.
Turn off all electric power to the appliance.
This appliance is equipped with an ignition device
which automatically lights the pilot. Do not try to
light the pilot by hand,
Locate the gas control
valve at the end of the
gas supply pipe going
into the boiler. The
gas control knob is the
brown or blue plastic
knob located on top of
the gas control valve.
GAS CONTROL KNOB
POSITION INDICATOR _
7,
8.
9,
10.
11.
Wait five (5) minutes to clear out any gas. Then smell
for gas, including near the floor. If you smell gas,
STOPt Follow "B" in the safety information above on
this label. If you do not smell gas, go to the next step.
Rotate gas control knob counterclockwise _h from
"OFF" to "ON". Make sure knob rest against stop. Do
not force.
Turn on all electric power to the appliance.
Set thermostat to desired setting.
If the appliance will not operate, follow the
instructions "TO TURN OFF GAS TO APPLIANCE" and
call your service technician or gas supplier.
TO TURN OFF GAS TO APPLIANCE
1. Set the thermostat to lowest setting.
2. Turn off all electric power to the appliance if service is
to be performed,
3. Rotate gas control knob clockwise (_ from "ON"
position to "OFF". Make sure knob rests against stop.
Figure 16: Operating Instructions
18

A. This appliance has a pilot which must be lighted by
hand. When lighting the pilot, follow these instruc-
tions exactly.
B. BEFORE LIGHTING smell all around the appliance for
gas, Be sure to smell next to the floor because some
gas is heavier than air and will settle on the floor.
WHAT TO DO IF YOU SMELL GAS
I_ Do not try to light any appliance.
I_ Do not touch any electric switch; do not use any
phone in your building.
I_ Immediately call your gas supplier from a neigh-
bor's phone. Follow the gas supplier's instructions.
I_ If you cannot reach your gas supplier, call the fire
department.
C. Use only your hand to push in or turn the gas control
knob. Never use tools. If the knob will not push in or
turn by hand, don't try to repair it, call a qualified
service technician, Force or attempted repair may
result in a fire or explosion.
D. Do not use this appliance if any part has been under
water. Immediately call a qualified service technician
to inspect the appliance and to replace any part of the
control system and any gas control which has been
under water.
LIGHTING INSTRUCTIONS
1. STOP! Read the safety information above. 11. Find the pilot by following _[_ PILOT BURNER
the aluminum tube from the /%.._
2. Read the lighting instructions all the way through gas control valve to the pilot /_1 I_ THERMO¢OUPLE
before starting the procedure, located between the steel _IF
tube burners, I I
3, If equipped with a vent damper, set the room thermo- ' '
stat to highest setting and wait two (2) minutes for the 12. Turn gas control knob counterclockwise _-_ to
damper to open. "PILOT" position.
4. Turn off all electric power to the appliance.
5. Set the room thermostat to lowest setting.
6. Locate the gas control POSITION _ _ GAS CONTROL
valve at theend of the ga_ IDICATOR
supply pipe going into the 1 _ I I
boiler. The gas control _\11 I I I
knob is the blue or brown [- _ _ I
plastic knob located on top GAS / // _ __ I I
INLET
of the gas control valve. / _ I I
o
7, Rotate gas control knob --RED RESET BUTTON14.
clockwise _from "ON" position to "OFF" position. t5.
8. Wait five (5) minutes to clear out any gas. Then smell
for gas, including near the floor. If you smell gas, 16,
STOP! Follow "B" in the safety information above on
this label, If you do not smell gas, go to the next step.
NOTE: Vent damper must be open during this five (5)
minute wait period. 17.
13. Push in red reset button and hold in. Immediately light
the pilot with a match. Continue to hold the red reset
button for about one (1) minute after the pilot is lit.
Release button and it will pop back up. Pilot should
remain lit. If it goes out, repeat Steps 8 -13.
I_ If button does not pop up when released, stop and
immediately call your service technician or gas
supplier.
I_ If the pilot will not stay lit after several tries, turn
gas control knob clockwise F-_ to "OFF" and call
your service technician or gas s_upplier.
Replace bumer access panel.
Replace front door.
Turn gas control knob counterclockwise Ir_ to "ON"
position. Knob can be turned to "ON" onl_ if red reset
button is up.
Turn on all electric power to the appliance.
9. Remove front door. 18. Set room thermostat to desired setting,
10. Remove the burner access panel located above the
burners.
TO TURN OFF GAS TO APPLIANCE
1. Set the thermostat to lowest setting. 3. Turn gas control knob clockwise ,_ to "OFF". Do
2. Turn off all electric power to the appliance if service is not force.
to be performed.
Figure 17: Lighting Instructions 19

D. Check Gas Input to Boiler
CG-C boilers built for installation at altitudes greater
than 2,000 feet above sea level have been specially
orificed to reduce gas input rate 4 percent per 1,000
feet above sea level per the National Fuel Gas Code,
NFPA 54/ANSI Z223A. High altitude boiler models
are identifiable by the third digit inthe model number
suffix on the rating label:
CG OC- 2:
CG OC- 5: less than 2000 ft. elevation 2000 to 5000 ft. elevation
1. Input Rate and Maximum Inlet Pressure shown on
Rating Label must not be exceeded. Inlet pressure
must not be lower than lninilnuln inlet pressure
shown on Rating Label.
2. All Rate checks and all adjustlnents are to be made
while boiler is firing - all other appliances connected
to the same meter as the boiler must be off.
3.
4.
5.
With boiler off, water Manometer or water
colulnn gauge should be connected to a shut-off
cock installed in the 1/8" outlet pressure tap in
the gas valve (See Figure 14). By installing gas
cock upstream of manometer, gas pressure can be
introduced gradually - without shut-off cock; surge
of pressure when boiler is turned on, could blow
liquid out of manometer. Replace plug in gas valve
when rate check is finished.
LP Gas Input:
Adjust Regulator on Gas Valve so that manifold
pressure is 10 inches water column. Turning
Regulator Adjusting Screw Clockwise increases
pressure. Counterclockwise rotation decreases
pressure.
Natural Gas Input
a. Approx. Input -Adjust regulator on Gas "Calve
so that manifold pressure is three and a half (31/2)
inches water column (three inches water colullln
for high altitude). Turning Regulator Adjusting
Screw Clockwise increases pressure, Counter-
clockwise rotation decreases pressure. If more
accurate check on input is necessary see (b).
For minor input changes readjust Regulator Gas
"Calveto increase or decrease manifold pressure
to obtain corresponding increase manifold
pressure more than 0.3" of water to obtain rated
input, remove orifices and drill one size larger.
Reinstall and recheck input rate.
b. Additional Check on Input - Since input is a
function of heating value, specific gravity, and
volume of gas flow contact your utility for the
Eo
first two items in order to utilize the formula
below. The gas meter should then be clocked
for three (3) minutes with stop watch and
substituting the appropriate values in the formula
below, determine what the gas flow should be in
this 3 minute period to give the input shown on
the Rating Label:
Gas Input cu. ft. Btuh Input
per 3 min. = Heating Value Multiplier from
of Gas X Table 5
(Btu /cu. ft.)
Check Main Burner Flame. See Figure 18 or 18a.
Flame should have a clearly defined inner cone with no
yellow tipping. Orange-yellow streaks caused by dust
should not be confused with true yellow tipping.
Figure 18: 40mm Main Burner Flame
OIITER CONE
Figure 18a: 1 Inch Main Burner Flame
Avoid operating this boiler in an environment
where saw dust, loose insulation fibers, dry wall
dust, etc. are present. If boiler is operated under
these conditions, the burner interior and ports
must be cleaned and inspected daily to insure
proper operation.
2O