New Yorker CG20D Service manual

103710-03 - 10/12
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-D™ SERIES
GAS BOILER
Price - $3.00
9700609
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
CG D
Boiler Serial Number Installation Date
Heating Contractor Phone Number
Address

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
Dimensions [Inches] Recommended
Vent Size
[2]
Gas
Connection
[FPT]
Water
Content
[gallons]
Approx.
Shipping
Weight
[lb.]
'A' 'B' 'C' 'D' 'E' 'F' 'G'
20 20-1/4 10-3/4 6-3/8 4 45-5/8 8-1/2 10 [1] 4" Dia. 1/2 2.5 212
30 21-1/2 12 6 4 45-3/4 8-1/2 4-3/4 4" Dia. 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. 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. 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. 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. 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. 3/4 7.0 506
90 41 31-1/2 15-3/4 8 52 11 7-1/4 8" Dia. 3/4 7.7 550
100 44-1/4 34-3/4 17-3/8 8 52 11 7-1/4 8" Dia. 3/4 8.5 608
[1] CG20D only. Dimension 'G' includes allowance for 4" x 3" reducer furnished with boiler. See Figure 10.
[2] Refer to the National Fuel Gas Code for equivalent areas of circular and rectangular ue linings.
Maximum Allowable Working Pressure, Water - 50 PSI
Safety Relief Valve Pressure, Water - 30 PSI shipped from factory (std.)

3
Table of Contents
I. Pre-Installation .............................. 3
II. Unpack Boiler................................ 5
III. Water Piping and Trim................... 5
IV. Gas Piping ..................................... 9
V. Venting......................................... 11
VI. Electrical...................................... 14
VII. System Start-up and Checkout..... 18
VIII. Operation .................................... 22
IX. Service and Maintenance ............. 26
X. Troubleshooting........................... 28
XI. Repair Parts ................................. 33
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 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-D™ Series Boiler. See the Massachusetts Board of
Plumbers and Gas Fitters website, http://license.reg.state.ma.us/pubLic/pl_products/pb_pre_form.asp for the latest Approval
Code or ask your local Sales Representative.
The Commonwealth of Massachusetts requires this product to be 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.

5
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
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.
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 Residential Hydronic
Heating Installation and Design I=B=R Guide.
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.
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 Residential
Hydronic Heating Installation and Design I=B=R
Guide.
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.
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.

6
Figure 3: Recommended Water Piping for Zone Valve Zoned Heating Systems

7
Figure 4: Recommended Water Piping for Circulator Zoned Heating Systems

8
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.
Figure 5: Recommended Piping for Combination
Heating & Cooling (Refrigeration) Systems
J. Optional LWCO Installation
WARNING
DO NOT ATTEMPT to cut factory wires to
install an aftermarket Low Water Cut Off
(LWCO). Only use connections specically
identied for Low Water Cut Off.
In all cases, follow the Low Water Cut Off
(LWCO) manufacturer’s instructions.
Figure 6: Recommended Probe LWCO Location
1. A low water cutoff is required to protect
a gas-red hot water boiler when any
connected heat distributor (radiation) is
installed below the top of the hot water boiler
(i.e. baseboard on the same oor level as
the boiler). In addition, some jurisdictions
require the use of a LWCO with a hot water
boiler as a redundant safety control.
It is recommended that the LWCO control
is installed above the boiler to provide the
highest level of protection. However, where
the LWCO control is approved by the LWCO
control manufacturer for installation in a
high boiler tapping of a water boiler, the
use of the listed LWCO control is permitted
when it is installed according to the LWCO
manufacturer's instructions.
2. The recommended location for a LWCO on gas
hot water boilers is above the boiler, in the supply
piping. The minimum safe water level of a water
boiler is at the uppermost top of the boiler; that is, it
must be full of water to operate safely.
3. Typically, in residential applications, a probe type
LWCO is used instead of a oat type, due to their
relative costs and the simplicity of piping for a
probe LWCO.
4. Piping and ttings required to install LWCO are
eld supplied.
5. When constructing a piping tree to install LWCO
select ttings (tees, elbows etc) and nipples to have
the same size (NPT) as boiler supply connection.
At minimum, 1-1/4” tee with ¾” branch outlet is
required to connect the probe LWCO to the supply
piping. See Figure 6. DO NOT REDUCE THE
SIZE OF NEAR BOILER SUPPLY FITTINGS
AND NIPPLES.
6. Installation of manual shutoff valve located above
the LWCO and the boiler is recommended to allow
servicing. Thus LWCO probe can be removed for
inspection without draining the heating system. An
annual inspection of the probe is recommended.
7. The presence of water covering properly installed
LWCO probe will cause the normally open contact
of the LWCO to close, thus providing continuity of
the 24 VAC service to the boiler gas valve. When
water level drops below probe, LWCO contact
opens up breaking 24V supply to gas valve and
preventing the boiler to re.
8. 2012 compliant CG-D Series gas hot water boilers
have a “plug-in” provision in factory wiring that
will accept optional 24VAC probe LWCO harness
connector. The optional LWCO kit (P/N 104083-
01) includes 24VAC probe LWCO, Harness and
Instructions addressing piping, wiring and testing
after installation.

9
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).
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.
IV. Gas Piping
Table 2: Rated Input
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
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
Table 3: Maximum Capacity of Schedule 40 Pipe in CFH for Natural Gas Pressures of 0.5 psig or Less
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.
Table 4: Fitting Equivalent Lengths
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
Table 5: Specic Gravity Correction Factors for
Natural Gas
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

10
Figure 7: Pilot and Gas Piping
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 7.
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.

11
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 CG-D 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 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.
Figure 8: Blocked Vent Switch Installation
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
OPEN THE VENT DAMPER CARTON and remove
the Installation Instructions. READ THE INSTALLA-
TION INSTRUCTIONS THOROUGHLY before
proceeding.
The automatic gas control valve supplied on each
CG-D Series boiler provides the redundancy referenced
in the vent damper Installation Instructions.

12
CAUTION
Do not use one vent damper to control two heating
appliances.
1. The vent damper must be the same size as the outlet
of the Draft Hood supplied with the boiler (see
Figure 1). Unpack the damper carefully - DO NOT
FORCE IT CLOSED! Forcing the damper may
damage the gear train and void the warranty.
2. Mount the vent damper assembly after the draft
hood, as close to the draft hood as practicable
without modication to the draft hood or vent
damper. (Refer to Figure 9 and to instructions
packed with the vent damper for specic
instructions). This is a must for the wiring harness to
t and the damper position indicator to be visible to
the users.
NOTICE
Provide adequate clearance for servicing.
WARNING
Provide 6" (15.2cm) minimum clearance between
damper and combustible construction.
3. Plug the factory harness vent damper connector into
damper motor polarized receptacle and secure the
harness to the damper motor bracket with provided
strain relief bushing.
DANGER
Inspect existing chimney before installing boiler.
Failure to clean or replace perforated pipe or tile
lining will cause severe injury or death.
F. Install Vent Connector
1. Model CG20D only - Install provided 4" x 3" vent
reducer into vent damper outlet, then, install vent
connector from reducer outlet to chimney.
2. All other sizes - Install vent connector from vent
damper outlet to chimney.
3. Vent installation shall be in accordance with
local building codes; or the local authority
having jurisdiction; or the National Fuel Gas
Code, ANSI Z223.1/NFPA 54; or the Standard
for Chimneys, Fireplaces, Vents, and Solid Fuel
Burning Appliances, ANSI/NFPA 211. Both of
the aforementioned standards, ANSI Z223.1 and
ANSI/NFPA 211, specify Type B and Type L double
wall metal vents and re clay tile lined masonry
chimneys as suitable chimney constructions for
Category I, draft hood equipped appliances, such
as this CG-D Series boiler. Both standards prohibit
the use of unlined masonry construction as a
chimney, with the exception in ANSI Z223.1/NFPA
54 that "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." ANSI/NFPA 211 prohibits
the use of single wall metal vent as a chimney,
while ANSI Z223.1 allows it under very restrictive
conditions.
Figure 9: Vent Damper Installation

13
4. Do not connect into same leg of chimney serving an
open replace.
5. Inspect chimney for obstructions or restrictions and
remove. Clean chimney if necessary.
6. Vent pipe to chimney must not be smaller than outlet
on draft hood or damper. Although single wall vent
pipe may be used, Type B is recommended. The
venting system must be arranged so that only the
boiler is served by the damper device. Installation
per paragraph (C) complies with this provision.
7. Where two or more appliances vent into a common
vent, the area of the common vent should at least
equal the area of the largest vent plus 50% of the
area in the additional vents. Do not connect the vent
of this appliance into any portion of mechanical
draft system operating under positive pressure.
8. Vent pipe should have the greatest possible initial
rise above the draft hood consistent with the head
room available and the required clearance from
adjacent combustible building structure. Vent Pipe
should be installed above the bottom of chimney to
prevent blockage.
9. Vent pipe should slope upward from draft hood to
chimney not less than one inch in four feet. Doivent
présenter des tronçons horizontaux dont la pente
montante est d’au moins ¼ po par pied (21 mm/m)
entre la chaudière et l’évent. No portion of vent
pipe should run downward or have dips or sags.
Vent pipe must be securely supported. Les sections
horizontales doivent être supportées pour prévenir le
échissement.
10. Vent pipe must be inserted into but not beyond
inside wall of chimney liner. Seal tight between vent
pipe and chimney.
11. Do not install non-listed (AGA, CGA, CSA, ETL or
UL) vent damper or other obstruction in vent pipe.
WARNING
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, win dows, 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.
Figure 10: Typical Vent System Installation

14
VI. Electrical
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. 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.
C. Wire thermostat. Provide Class II circuit between
thermostat and boiler. Set thermostat heat anticipator to
0.3 amps. See Figure 14.
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.
D. New Yorker Link SL™ indirect water heater (if
used). See Figures 11 and 12. 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 15 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 Figures 11 and 12.
E. For installations using zone valves provide separate
transformer for zone valve wiring. Consult zone valve
manufacturer for assistance. See Figure 13.
CAUTION
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.

15
Figure 11: Wiring Schematic, Boiler Control

16
Figure 12: Wiring Schematic, Boiler Control

17
Figure 13: Wiring Schematic, Zone Valves
Figure 14: Wiring Schematic, Zone Circulators

18
VII. System Start-up and Checkout
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
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. Adequate
ventilation must be provided and no smoking or
open ame permitted.
7. Turn "ON" electric switch serving boiler.
8. Open Manual Shut-off Valve upstream of
Combination Gas Valve.
9. Loosen or remove Inlet Pressure Tap Plug in
Combination Gas Valve and when purging is
complete, tighten or replace plug. (See Figure 15).
10. Check pipe and ttings from meter to Combination
Gas Valve using soap solution or other approved
methods.
CAUTION
11. 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.
Figure 15: Top View of Honeywell Gas Valves

19
Figure 16: Operating Instructions

20
Figure 17: 40mm Main Burner Flame
C. 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.)
D. Check Main Burner Flame. See Figure 17 or 18.
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 valve
installed in the 1/8" outlet pressure tap in the gas
valve (See Figure 15). By installing gas valve
upstream of manometer, gas pressure can be
introduced gradually - without shut-off valve; 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 18: 1 Inch Main Burner Flame
NOTICE
CG-D Series boilers built for installation at altitudes
greater than 2,000 feet above sea level have been
specially oriced to reduce gas input rate 4 percent
per 1,000 feet above sea level per the National Fuel
Gas Code, 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_OD- _ _ 2: less than 2000 ft. elevation
CG_OD- _ _ 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.