New Yorker CG-C Series Troubleshooting guide

100291-01R7-1/09
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.
INSTALLATION, OPERATING
AND
SERVICE INSTRUCTIONS
CG-C™ SERIES
GAS BOILER
Price - $3.00
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2
Table 1: Dimensional Data
Figure 1: Dimensional Drawing
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.
CAUTION
Indicates a potentially hazardous situation which,
if not avoided, may result in moderate or minor
injury or property damage.
WARNING
Indicates a potentially hazardous situation which,
if not avoided, could result in death, serious injury
or substantial property damage.
NOTICE
Indicates special instructions on installation,
operation, or maintenance which are important
but not related to personal injury hazards.
Boiler
Size 'A' 'B' 'C' 'D' 'E' 'F' 'G' Recommended
Vent Size [1] Gas
Conn.
(FPT)
Water
Content
(Gallons)
Approx.
Shipping
Weight (LB.)
Round Dia. (in) x Ht. (ft.)
20 20-1/4 10-3/4 6-3/8 4 45-5/8 8-1/2 10** 4" Dia. x 15' 1/2 2.5 212
30 21-1/2 12 6 4 45-3/4 8-1/2 4-3/4 4" Dia. x 15' 1/2 3.2 254
40 24-3/4 15-1/4 7-5/8 5 47-1/8 9-1/8 4-3/4 5" Dia. x 15' 1/2 4.0 298
50 28 18-1/2 9-1/4 6 48-1/2 9-3/4 5-1/4 6" Dia. x 15' 1/2 4.7 346
60 31-1/4 21-3/4 10-7/8 6 48-1/2 9-3/4 5-1/4 6" Dia. x 15' 1/2 5.5 408
70 34-1/2 25 12-1/2 7 50-1/8 10-3/8 6-5/8 7" Dia. x 15' 3/4 6.2 450
80 37-3/4 28-1/4 14-1/8 7 50-1/8 10-3/8 6-5/8 7" Dia. x 15' 3/4 7.0 506
90 41 31-1/2 15-3/4 8 52 11 7-1/4 8" Dia. x 15' 3/4 7.7 550
100 44-1/4 34-3/4 17-3/8 8 52 11 7-1/4 8" Dia. x 15' 3/4 8.5 608
**CG20 only. Dimension 'G' includes allowance for 4" x 3" size reducer furnished with boiler. See Figure 10.
[1] 15' chimney height is from bottom of draft hood opening to top of chimney.
Maximum Allowable Working Pressure (Water only): 30 PSI

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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. System Start-up............................15
EI Trouble Shooting Guide ..........22
VIII. Service.......................................... 23
IX. Repair Parts ................................. 25
X. Appendix
Low Water Cut Off....................... 43
I. Pre-Installation
WARNING
Carefully read all instructions before installing
boiler. Failure to follow all instructions in proper
order can cause personal injury or death.
A. 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 led
immediately 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.
B. 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 Controls and Safety
Devices for Automatically Fired Boilers, ANSI/ASME
CSD-1.
C. Appliance is design certied for installation on
combustible ooring. The boiler must not be installed
on carpeting.
D. Provide clearance between boiler jacket and
combustible material in accordance with local re
ordinance. Refer to Figure 2 for minimum clearance
from combustible material for closet installation. Figure 2: Minimum Clearances to Combustible
Construction for Closet Installation
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 Commonwealth of Massachusetts requires this product to be installed by a licensed Plumber or Gas tter.
For alcove or unconned 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".

4
5. For boiler located in an unconned space in a
building of other than unusually tight construction,
adequate combustion and ventilation air is normally
provided by fresh air inltration through cracks
around windows and doors.
6. For boiler located within unconned space in
building of unusually tight construction or within
conned space, provide outdoor air through 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 ducts. 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 conned
space. Use indoor air if two permanent openings
communicate directly with additional space(s) of
sufcient volume such that combined volume of all
spaces meet criteria for unconned 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.
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 xed in
open position or interlocked with equipment to open
automatically before burner operation. Screens must
not be smaller than ¼ inch 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.
I.Do not install boiler where gasoline or other
ammable vapors or liquids, or sources of
hydrocarbons (i.e. bleaches, cleaners, chemicals, sprays,
paint removers, fabric softeners, etc.) are used or stored.
E. 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".
F. Install on level oor. For basement installation provide
concrete base if oor is not level or if water may be
encountered on oor around boiler.
G. Protect gas ignition system components from water
(dripping, spraying, rain, etc.) during boiler operation
and service (circulator replacement, condensate trap,
control replacement, etc.).
H. Provide combustion and ventilation air in accordance
with applicable provisions of local building codes,
or National Fuel Gas Code, NFPA 54/ANSI Z223.1,
Section 5.3, Air for Combustion and Ventilation.
WARNING
Adequate combustion and ventilation air must be
provided to assure proper combustion.
The following guideline is based on the National Fuel
Gas Code, NFPA 54/ANSI Z223.1.
1. Determine volume of space (boiler room). Rooms
communicating directly with space (through
openings not furnished with doors) are considered
part of space.
Volume [ft³] = 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 ft³ per
1,000 Btuh, space is considered an unconned
space.
b. If result is less than 50 ft³ per 1,000 Btuh, space
is considered a conned 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 1 perm 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 oors, between wall-ceiling joints,
between wall panels, at plumbing and electrical
penetrations, and at other openings.

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III. Water Piping and Trim
WARNING
Failure to properly pipe boiler may result in
improper operation and damage to boiler or
building.
A. 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, ttings, and oxygen
Figure 3: Recommended Water Piping for Zone Valve Zoned Heating Systems
permeable materials in distribution system. Eliminate
oxygen contamination by repairing system leaks,
repairing ttings, and using nonpermeable materials in
distribution system.
B. Install circulator with anges, 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.
C. Install Safety Relief Valve. See Figure 1. Safety Relief
Valve must be installed with spindle in vertical position.
II. Unpack Boiler
CAUTION
Do not drop boiler. Do not bump boiler jacket
against oor.
A. Move boiler to approximate installed position.
B. Remove all crate fasteners.
C. 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 F.
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.

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WARNING
Safety relief valve discharge piping must be piped
near oor 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 minimum ½ inch clearance
from hot water piping to combustible materials.
E. Space heating and domestic water heating with the
New Yorker Link SL™ indirect water heater. Install
the New Yorker Link SL™ indirect water heater as a
separate heating zone. Refer to the New Yorker Link
SL™ Indirect Water Heater Installation, Operating and
Service Instructions for additional information.
Figure 4: Recommended Piping for Combination
Heating & Cooling (Refrigeration) Systems
A. 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 ½
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).
IV. Gas Piping
Table 2: Rated Input
F. If 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.
G. 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
ow control valves to prevent gravity circulation of
boiler water during operation of cooling system.
H. 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 ow to maintain
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.
I. If it is required to perform a long term pressure
test of the hydronic system, the boiler should rst be
isolated to avoid a pressure loss due to the escape of air
trapped in the boiler.
To perform a long term pressure test including the
boiler, ALL trapped air must rst 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
trapped air.
Boiler
Model
Number
Input Rate
[cubic feet per hour] Gas
Connection
Size
Natural Gas LP/Propane
20 37.5 15.0 ½
30 62.0 24.8 ½
40 96.0 38.4 ½
50 130.0 52.0 ½
60 164.0 65.6 ½
70 198.0 79.2 ¾
80 232.0 92.8 ¾
90 266.0 106.4 ¾
100 299.0 119.6 ¾

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Table 3: Maximum Capacity of Schedule 40 Pipe in CFH for Natural Gas Pressures of 0.5 psig or Less
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 Code, ANSI/NFPA 70.
C. Pressure test. The boiler and its gas connection must
be leak tested before placing boiler in operation.
1. Protect boiler gas control valve. For all testing over
½ psig, boiler and its individual shutoff valve must
be disconnected from gas supply piping. For testing
at ½ psig or less, isolate boiler from gas supply
piping by closing boiler's individual manual shutoff
valve.
2. Locate leaks using approved combustible gas
detector, soap and water, or similar nonammable
solution. Do not use matches, candles, open ames,
or other ignition source.
3. Length of piping and number of ttings. Refer to
Table 3 for maximum capacity of Schedule 40 pipe.
Table 4 lists equivalent pipe length for standard
ttings.
4. Specic gravity of gas. Corrections for the specic
gravity of natural gas can be found in Table 5.
For materials or conditions other than those listed
above, refer to National Fuel Gas Code, 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.
1. Use methods and materials in accordance with local
plumbing codes and requirements of gas supplier. In
absence of such requirements, follow National Fuel
Gas Code, NFPA 54/ANSI Z223.1.
2. Use thread (joint) compounds (pipe dope) resistant
to action of liqueed petroleum gas.
3. Install sediment trap, ground-joint union and manual
shut-off valve upstream of boiler gas control valve.
See Figure 6 or 7.
Table 4: Fitting Equivalent Lengths Table 5: Specic Gravity Correction Factors for
Natural Gas
Length
[Feet] 0.3 inch w.c. Pressure Drop 0.5 inch w.c. Pressure Drop
½ ¾ 1 1¼ ½ ¾ 1 1¼
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
Fitting Nominal Pipe Size
½ ¾ 1 1¼
45° Ell 0.7 1.0 1.2 1.6
90° Ell 1.6 2.1 2.6 3.5
Tee
(As Elbow) 3.1 4.1 5.2 6.9
Specic
Gravity Correction Factor Specic Gravity Correction 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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Figure 6: Pilot and Gas Piping, Continuous Ignition
(Standing Pilot) Figure 7: Pilot and Gas Piping, Intermittent Ignition
(EI)
V. Venting
A. 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. Type B or Type L gas vent. Install in accordance
with listing and manufacturer's instructions.
2. Masonry or metal chimney. Build and install in
accordance with local building codes; or local
authority having jurisdiction; or Standard for
Chimneys, Fireplaces, Vents, and Solid Fuel
Burning Appliances, ANSI/NFPA 211.
Masonry chimney must be lined with approved
clay ue 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 efciency.
3. Single wall metal vent. Allowed by ANSI Z223.1/
NFPA 54 under very restrictive conditions.
B. Inspect chimney and remove any obstructions or
restrictions. Clean chimney if previously used for solid
or liquid fuel-burning appliances or replaces.
DANGER
Inspect existing chimney before installing boiler.
Failure to clean or replace perforated pipe or tile
lining will cause severe injury or death.
C. Install Draft Hood without modication on outlet of
ue collector. See Figure 1. Secure with sheet metal
screws.
WARNING
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 certication will become void.
D. 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 SwitchAssembly 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.

9
3. Slide mounting bracket tight against lower edge of
Draft Hood skirt. Position #10 sheet metal screw
above skirt's stiffening rib.
4. Secure bracket in position by tightening #10 sheet
metal screw against outer surface of Draft Hood
skirt.
5. Verify power cord, mounting bracket and Blocked
Vent Switch are secure and located as shown in
Figure 8.
WARNING
Failure to properly install and use this Blocked
Vent Switch may result in property damage,
personal injury or loss of life.
E. Install Vent Damper. See Figure 9.
1. Open Vent Damper Carton and remove Installation
Instructions. Read Installation Instructions
thoroughly before proceeding.
NOTICE
Please refer to the specications, 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
modication to either. Refer to instructions packed
with vent damper for specic instructions. Vent
damper position indicator to be visible to users.
Figure 8: Blocked Vent Switch Installation
Figure 9: Vent Damper Installation

10
NOTICE
Provide adequate clearance for servicing.
WARNING
Provide 6" minimum clearance between damper
and combustible construction.
CAUTION
Do not use one vent damper to control two heating
appliances.
F. Install Vent Connector from vent damper to chimney
or gas vent. See Figure 10.
1. Do not connect into same leg of chimney serving an
open replace.
2. Vent connector must not be smaller than vent
damper outlet. Type B is recommended, but single-
wall vent pipe may be used. Arrange venting system
so only the boiler is served by vent damper device.
3. Where two or more appliances vent into a common
vent, the area of the common 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.
4. Vent connector should have greatest possible initial
rise above vent damper consistent with headroom
available and required clearance from adjacent
combustible building structure.
5. Vent connector should slope upward from vent
damper to chimney 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.
6. 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.
G. If an Existing Boiler is Removed:
When an existing boiler is removed from a common
venting system, the common venting system is likely
to be too large for proper venting of the appliances
remaining connected to it.
At the time of removal of an existing boiler, the
following steps shall be followed with each appliance
remaining connected to the common venting system
placed in operation, while the other appliances
remaining connected to the common venting system are
not in operation:
a. Seal any unused openings in the common 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
deciencies 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 common
venting system are located and other spaces of the
building. Turn on clothes dryers and any appliance
not connected to the common venting system.
Turn on any exhaust fans, such as range-hoods and
bathroom exhausts, so they will operate at maximum
speed. Do not operate a summer exhaust fan. Close
replace 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 ame
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 common venting system
properly vents when tested as outlined above, return
doors, windows, exhaust fans, replace dampers and
any other gas-burning appliance to their previous
condition of use.
g. Any improper operation of the common venting
system should be corrected so the installation
conforms with the National Fuel Gas Code, NFPA
54/ANSI Z223.1. When resizing any portion of
the common venting system, the common venting
system should be resized to approach the minimum
size as determined using the appropriate tables in
Part 11 in the National Fuel Gas Code, NFPA 54/
ANSI Z223.1.

11
Figure 10: Typical Vent System Installation
A. General. Install wiring and ground boiler in accordance
with requirements of authority having jurisdiction, or
in absence of such requirements the National Electrical
Code, ANSI/NFPA 70.
B. Connect Vent Damper. See Figure 9.
Install the 90° BX connector attached to the exible
conduit in the 7/8" hole on the right side of the jacket.
Plug the factory wired Vent Damper Harness into
polarized receptacle.
C. Install thermostat. Locate on inside wall
approximately 4 feet above oor. Do not install on
outside wall, near replace, or where inuenced by
drafts or restricted air ow, hot or cold water pipes,
lighting xtures, television, or sunlight. Allow free air
movement by avoiding placement of furniture near
thermostat.
D. 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).
VI. Electrical
If system tends to overheat above thermostat'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.
E. New Yorker Link SL™ 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 SL™ Indirect Water
Heater Installation, Operating and Service Instructions.
F. 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 recommended 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).
G. For installations using zone valves provide separate
transformer for zone valve wiring. Consult zone valve
manufacturer for assistance.

12
Figure 11: Vent Damper Schematic Wiring Diagram
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.
CAUTION
This boiler contains controls which may cause the
boilertoshutdownandnotrestartwithoutservice.
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.

13
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 ow and
ignition of Main Burners.
c.Call for heat ends. Gas Valve de-energized,
extinguishing main ame. 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 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 qualied service
agency before resetting switch.
c.Flame Roll-out Switch. Automatically interrupts
boiler operation when ames 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 ame
roll-out switch is activated do not attempt to
place boiler in operation. The source of blockage
must be corrected and the ame roll-out switch
replaced by trained and skilled personnel from a
qualied service agency.
d. Thermocouple: senses pilot ame and causes gas
valve to turn off main burner and pilot burner
gas ow should pilot burner ame extinguish.
Circulator continues to operate and Vent Damper
remains open with call for heat.
Figure 12: Wiring Diagram, Continuous Ignition (Standing Pilot)

14
J. Sequence of Operation, Electronic Intermittent
Ignition (EI).
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 ame. 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 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 qualied service
agency before resetting switch.
c.Flame Roll-out Switch. Automatically interrupts
boiler operation when ames 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 ame
roll-out switch is activated do not attempt to
place boiler in operation. The source of blockage
must be corrected and the ame roll-out switch
replaced by trained and skilled personnel from a
qualied service agency.
d. Sensor: senses pilot ame and causes ignition
module to turn off main burner and pilot burner
gas ow should pilot burner ame extinguish.
Ignition module will try to relight pilot for
approximately 85 seconds after pilot burner
ame is extinguished. If pilot burner ame
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 ame
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 21.
Figure 13: Wiring Diagram, Electronic Intermittent Ignition (EI)

15
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 specied in American National Standard for Gas-Fired Low-Pressure Steam and Hot Water Boilers,
ANSI Z21.13.
A.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 orices.
B. 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 ve gallon bucket, at a
suitable oor drain, or outdoor area).
d. Starting with one circuit, open zone valve.
e. Open hose bib.
f. Open ll valve (Make-up water line should be
located directly above isolation valve in boiler
supply piping).
g. Allow water to overow 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 rst. 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 lling the system
until the pressure gauge reads 12 psi. Close ll
valve. (Note - If make-up water line is equipped
with pressure reducing valve, system will
automatically ll 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 ve 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 ame permitted.
a. Standing Pilot Models, see Figures 6 and 16.
i. Keep electric switch "OFF".
ii. Open Manual Shut-off Valve 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
ttings 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-off Valve 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).
Figure 14: Top View of Honeywell Gas Valves
iv. Check pipe and ttings from meter to
Combination Gas Valve using soap solution
or other approved methods.
CAUTION
v. Test gas piping and connections between
Combination Gas Valve and manifold,
orices, and pilot piping for leaks after
boiler is operating. Use soap solution or
other approved method.

16
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 status of the ame, see Table 7.
The green LED indicates the status of the system,
see Table 8.. See Figure 15 for LED locations.
2. See Figure 16 for Continuous Ignition System
(standing pilot).
Ignition Module
Terminal Designation Wiring Ladder Diagram
Terminal Number
MV 1
MV/PV 2
PV 3
GND 4
24V (GND) 5
24V 6
SPARK 9
Table 6: Ignition Module Terminal Cross-Reference
Table 7: Yellow LED Flame Codes
Yellow LED
Flash CodeaIndicates Recommended
Service Action
Heartbeat Normal Flame Signal N/A
2
Weak Flame Signal -
System will operate reliably but ame signal is
less than desired.
Note: This indication may ash temporarily
during or shortly after lightoff on some
applications.
Perform routine
maintenance to
assure optimum
ame signal.
1
Marginal Flame Signal (less than 1.1 µA) -
System may not operate reliably over time.
Service call recommended.
Note: This indication may ash temporarily
during or shortly after lightoff on some
applications.
Check gas supply,
pilot burner, ame
sense wiring, con-
tamination of ame
rod, burner ground
connection.
OFF No Flame or Flame Signal -
below minimum threshold for system operation. N/A
aFlash Code Descriptions
- Heartbeat: Constant ½ second bright, ½ second dim cycles.
- The ash code number signies that the LED ashes X times at 2Hz,
remains off for two seconds, and then repeats sequence.
Figure 15: LED Locations

17
Green LED
Flash Code
(X + Y)aIndicates Next System Action Recommended Service Action
OFF No “Call for Heat” N/A None
Flash Fast Startup - Flame sense
calibration N/A None
Heartbeat Normal operation N/A None
25 minute Retry Delay- Pilot ame not detected
during trial for ignition
Initiate new trial for ignition after retry
delay completed.
If system fails to light on next trial
for ignition check gas supply, pilot
burner, spark and ame sense wir-
ing, ame rod contamination or out
of position, burner ground connec-
tion.
3Recycle- Flame failed
during run
Initiate new trial for ignition. Flash
code will remain through the ignition
trial until ame is proved.
If system fails to light on next trial
for ignition check gas supply, pilot
burner, ame sense wiring, ame
rod contamination, burner ground
connection.
4Flame sensed out of
sequence
If situation self corrects within 10
seconds, control returns to normal
sequence. If ame out of sequence re-
mains longer than 10 seconds, control
goes to Flash code 6+4 (see below)
Check for pilot ame. Replace gas
valve if pilot ame present. If no
pilot ame, cycle “Call for Heat.” If
error repeats, replace control.
7Flame sense leakage to
ground
Control remains in wait mode. When
the fault corrects, control resumes nor-
mal operation after a one minute delay.
Check ame sense lead wire for
damage or shorting. Check that
ame rod is in proper position.
Check ame rod ceramic for cracks,
damage or tracking.
8Low secondary voltage
supply- (below 15.5 Vac)
Control remains in wait mode. When
the fault corrects, control resumes nor-
mal operation after one minute delay.
Check transformer and AC line for
proper input voltage to the control.
Check with full system load on the
transformer.
6 + 2 5 minute Retry Delay- On every third retry on
same “Call for Heat”
Initiate new trial for ignition after retry
delay completed.
Check gas supply, pilot burner, spark
and ame sense wiring, ame rod
contamination or out of position,
burner ground connection.
6 + 3 On every 6th ame failure during run on the
same “Call for Heat”
5 minute retry delay, then initiate new
trial for ignition.
Check gas supply, pilot burner, ame
sense wiring, contamination of ame
rod, burner ground connection.
6 + 4 Flame sensed out of sequence- longer than
10 seconds
Control waits until ame is no longer
sensed and then goes to soft lockout.
Flash code continues. Control auto
resets from soft lockout after one hour.
Check for pilot ame. Replace gas
valve if pilot ame present. If no
pilot ame, cycle “Call for Heat.” If
error repeats, replace control.
ON Soft lockout due to error detected during self
check sequences
Control auto resets from soft lockout
after one hour. Reset by cycling “Call for Heat.” If error repeats, replace the control
aFlash Code Descriptions:
- Flash Fast: rapid blinking
- Heartbeat: Constant ½ second bright, ½ second dim cycles.
- A single ash code number signies that the LED ashes X times at 2Hz, remains off for two seconds, and then
repeats the sequence.
- X + Y ash codes signify that the LED ashes X times at 2Hz, remains off for two seconds, ashes Y times at 2
Hz, remains off for three seconds, and then repeats the sequence.
Table 8: Green LED Status Codes

18
Figure 16: Operating Instructions

19
Figure 17: Lighting Instructions

20
Figure 18: 40mm Main Burner Flame
D.Check Gas Input to Boiler rst 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 ow 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.)
E. Check Main Burner Flame. See Figure 18 or 18a.
Flame should have a clearly dened inner cone with no
yellow tipping. Orange-yellow streaks caused by dust
should not be confused with true yellow tipping.
1. Input Rate and Maximum Inlet Pressure shown on
Rating Label must not be exceeded. Inlet pressure
must not be lower than minimum inlet pressure
shown on Rating Label.
2. All Rate checks and all adjustments are to be made
while boiler is ring - all other appliances connected
to the same meter as the boiler must be off.
3. With boiler off, water Manometer or water
column 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 nished.
4. 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.
5. Natural Gas Input
a. Approx. Input - Adjust regulator on Gas Valve
so that manifold pressure is three and a half (3½)
inches water column (three inches water column
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
Valve to increase or decrease manifold pressure
to obtain corresponding increase manifold
pressure more than 0.3" of water to obtain rated
input, remove orices and drill one size larger.
Reinstall and recheck input rate.
b. Additional Check on Input - Since input is a
function of heating value, specic gravity, and
volume of gas ow contact your utility for the
Figure 18a: 1 Inch Main Burner Flame
NOTICE
CG-Cboilersbuiltforinstallationataltitudesgreater
than2,000 feetabove sea levelhave beenspecially
oriced to reduce gas input rate 4 percent per 1,000
feetabovesealevelpertheNationalFuelGasCode,
NFPA 54/ANSI Z223.1. High altitude boiler models
are identiable by the third digit in the model number
sufx on the rating label:
CG_OC- _ _ 2: less than 2000 ft. elevation
CG_OC- _ _ 5: 2000 to 5000 ft. elevation
CAUTION
Avoid operating this boiler in an environment
where saw dust, loose insulation bers, 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.