New Yorker CGS-A Series Service manual

8141953R17-1/10
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
CGS-A™ SERIES
GAS BOILER
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Price - $3.00

2
The New York City Department of Buildings has approved the Classic CGS-A Series boiler: Approval No. MEA 165-94-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 Classic CGS-A 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 Fitter.
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 (in inches)
Recommended Chimney * Gas
Connection
(NPT)
Approx.
Shipping
Weight
'A' 'B' 'C' 'D'
'E' 'F'
Nat LP Nat LP Round Square
30 12-3/16 4-3/4 4 6-1/8 53-1/8 53-1/8 9-3/4 9-3/4 4" Dia. x 15 ft. 8" x 8" x 15 ft. 3/4 305 LB
40 15-3/4 4-3/4 5 7-7/8 50-1/4 50-1/4 6 6 5" Dia. x 15 ft. 8" x 8" x 15 ft. 3/4 370 LB
50 19-3/8 5-1/4 6 9-3/4 52-1/8 55-1/8 7-1/4 10-1/4 6' Dia. x 15 ft. 8" x 8" x 15 ft. 3/4 440 LB
60 22-7/8 5-1/4 6 11-1/2 53-3/8 56-3/8 8-1/2 11-1/2 6' Dia. x 15 ft. 8" x 8" x 15 ft. 3/4 502 LB
70 26-1/2 7-1/2 7 13-1/4 55-7/8 58-7/8 9-3/4 12-3/4 7' Dia. x 15 ft. 8" x 8" x 15 ft. 3/4 566 LB
80 30 7-1/2 7 15 57-1/8 60-3/4 11 14-1/2 7' Dia. x 15 ft. 8" x 8" x 15 ft. 3/4 650 LB
* 15 Ft. Chimney height is from bottom of Draft Hood opening to top of chimney
Maximum Working Pressure: 15 PSIG, Steam
30 PSIG, Water

3
Table of Contents
I. Pre-Installation............................... 3
II. Unpack Boiler ................................ 5
III. Steam Piping and Trim ................... 5
IV. Gas Piping...................................... 8
V. Venting ......................................... 10
VI. Electrical....................................... 13
VII. System Start-up ............................ 18
VIII. Service ......................................... 23
IX. Repair Parts.................................. 28
Warranty ........................ Back Cover
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. Boiler is design certied for installation on
noncombustible ooring only. For installation on
combustible ooring only when installed on special
base listed in Table 2. 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 alcove installation.
Table 2: Special Base for Installation on
Combustible Flooring
Figure 2: Minimum Clearances to Combustible
Construction for Alcove Installation
Boiler Model Special Base Part Number
30 61812036
40 61812046
50 61812056
60 61812066
70 61812076
80 61812086

4
Recommended service clearance is 24 inches from
left side, right side and front. Service clearances may
be reduced to minimum clearances to combustible
materials.
E. 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.
F. Protect gas ignition system components from water
(dripping, spraying, rain, etc.) during boiler operation
and service (circulator replacement, condensate trap,
control replacement, etc.).
G. 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. 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.
H.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.

5
CAUTION
Do not drop boiler. Do not bump boiler jacket
against oor.
A. Move boiler to approximate installed position.
B. Remove crate.
1. Remove nails and staples from crate.
2. Remove four carriage bolts holding boiler to skid.
3. Remove boiler from skid using ¾ inch pipe rollers.
a. Roll boiler to rear of skid. Handle boiler jacket
carefully to avoid damage.
b. Lower rear of boiler to oor.
c. Tilt boiler, remove skid at front of boiler, and
lower front of boiler to oor. Do not drop boiler.
C. Move boiler to permanent location. When using special
base for installation on combustible oor:
III. Steam Piping and Trim
WARNING
Failure to properly pipe boiler may result in
improper operation and damage to boiler or
structure.
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.
II. Unpack Boiler
Figure 3: Special Base Installation
B. Boiler equipped with McDonnell & Miller 67 Low
Water Cutoff Only. Assemble gauge glass and low
water cutoff as shown in Figure 5. Follow instructions
packed with low water cutoff.
1. Afx Blow-Down Card to Jacket Left Side Panel
adjacent to low water cutoff.
2. Provide blow-down discharge piping.
C. Remove Jacket Front Panel. Remove parts bag from
vestibule area.
D. Install Safety Valve in Tapping 'E'. See Figure 4. Use
¾ NPT x 3" nipple and ¾ elbow provided. Safety Valve
must be installed with spindle in vertical position.
1. Place base on oor with insulated surface facing
upward and part number facing forward.
2. Position base to provide minimum clearances to
combustible walls. See Figure 3. Secure in place.
3. Place boiler on base. Center boiler on base to
provide minimum clearances to combustible walls
and ceiling. See Figure 2.
NOTICE
Before using copper for steam piping, consider the following characteristics of copper piping:
1) High coefcient of thermal expansion can induce mechanical stresses and cause expansion/
contraction noises if not accounted for in the piping system design and installation,
2) High heat transfer rate (heat loss) of un-insulated copper piping must be included in the normal piping
and pickup factors used to size the boiler,
3) Soldering or brazing pastes and uxes that end up in the system can cause poor heat transfer, surging,
an unsteady water line and wet steam if not thoroughly removed during boil out procedure and,
4) Galvanic corrosion of the adjoining metal may occur due to dissimilar metals in certain water chemistries
if dielectric unions are not used.

6
E. Install Drain Valve in Tapping 'F'. See Figure 4.
Figure 5: Assembly Diagram for McDonnell & Miller 67 Low Water Cutoff
Figure 4: Purpose of Tappings
Table 3: Purpose of Tappings
F. Connect system supply and return piping to boiler.
See Figure 7. Also consult I=B=R Installation and
Piping Guides. Maintain minimum ½ inch clearance
from hot water piping to combustible materials.
WARNING
Safety 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.
Tapping Size Purpose
A 2" 30 - 70: Plugged, Optional Second Supply
80: Second Supply
B ¾" Pressure Gauge (bushed to ¼)
C ½" Gauge Glass / Float LWCO
D 2" Return (Standard)
E ¾" Safety Valve
F 2" Drain Valve Return (Alternate)
G 2" Supply
H ¾" Limit
K ¾" Probe Low Water Cutoff
(Plugged with McDonnell & Miller 67 LWCO)

7
Figure 7: Recommended Boiler Piping for Gravity Return

8
Figure 9: Pilot and Gas Piping, Intermittent Ignition
(EI)
Figure 8: Pilot and Gas Piping, Continuous Ignition
(Standing Pilot)
IV. Gas Piping
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 4 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 5 for maximum capacity of Schedule 40 pipe.
Table 6 lists equivalent pipe length for standard
ttings.
4. Corrections for the specic gravity of natural gas
can be found in Table 7.
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 8 or 9.
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.
Table 4: Rated Input
Boiler
Model
Number
Input Rate
[cubic feet per hour] Gas
Connection
Size
Natural LP/Propane
30 70 28 ¾
40 105 42 ¾
50 140 56 ¾
60 175 70 ¾
70 210 84 ¾
80 245 98 ¾

9
Table 5: Maximum Capacity of Schedule 40 Pipe in CFH For Natural Gas Pressures of 0.5 psig or Less
Table 7: Specic Gravity Correction Factors for
Natural Gas
Table 6: Fitting Equivalent Lengths
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.
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

10
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, Part
7, Venting of Equipment. Install any of the following
for this Classic CGS-A 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. AGA 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. Pinch black strain relief bushing installed in Jacket
Right Side Panel to dislodge bushing from jacket.
Pull out enough power cord so Blocked Vent Switch
Assembly reaches near side of Draft Hood skirt. Do
not pull out more power cord than necessary.
3. 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 10.
4. Slide mounting bracket tight against lower edge of
Draft Hood skirt. Position #10 sheet metal screw
above skirt's stiffening rib.
5. Secure bracket in position by tightening #10 sheet
metal screw against outer surface of Draft Hood
skirt.
6. Insert excess power cord through Jacket Right Side
Panel hole. Remove slack.
7. Position strain relief bushing around power cord.
Pinch bushing's two halves together and snap back
into hole in Jacket Right Side Panel.
8. Verify power cord, mounting bracket and Blocked
Vent Switch are secure and located as shown in
Figure 10.
Figure 10: Blocked Vent Switch Installation

11
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.
CAUTION
Provide adequate clearance for servicing -
provide 6" minimum clearance between damper
and combustible construction.
CAUTION
Do not use one vent damper to control two heating
appliances.
Figure 11: Vent Damper Installation
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 11.
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.

12
F. Install Vent Connector from vent damper to chimney
or gas vent. See Figure 12.
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.
Figure 12: Typical Vent System Installation

13
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. Connect Vent Damper. See Figure 11.
1. Carefully remove Transformer from Junction Box.
2. Remove 7/8" knockout from top of Junction Box.
3. Attach Vent Damper wiring harness into top of
Junction Box.
4. Connect Vent Damper Wiring Harness to Vent
Damper Receptacle.
C. Wire Low Water Cutoff (McDonnell & Miller 67
Only). Attach Black wire to Terminal '1'. Attach Black-
White wire to Terminal '2'.
D. 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.
E. Wire thermostat. Provide Class II circuit between
thermostat and boiler. Connect to Blue transformer lead
and Brown relay lead. Set thermostat heat anticipator
to 0.4 amps. 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.
Figure 13: Vent Damper Schematic Wiring Diagram
Table 8: Wiring Diagrams
F. Wire boiler. Boiler is rated for 120 VAC, 60 hertz, less
than 12 amperes. Provide individual branch circuit with
fused disconnect. Connect to black and white wires and
green ground screw. Install Transformer on Junction
Box.
G. Vent Damper Sequence of Operation. See Figure 13.
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 gas control circuit through Terminal 2.
4. Call for heat ends. Vent Damper closes.
Note: After Vent Damper is installed and operated
through one cycle, the control circuit will operate only
when Vent Damper is connected in control circuit.
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.
Low Water
Cutoff
Ignition System
Figure No.
Continuous
(Standing
Pilot)
Intermittent
(EI)
24V Probe X 14
X 15
Float X 16
X 17

14
c.Blocked Vent Switch. Automatically interrupts
main burner operation when excessive vent
system blockage occurs. 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.
d.Flame Roll-out Switch. Automatically interrupts
boiler operation when ames or excessive heat
are present in vestibule. 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.
e. Thermocouple: senses pilot ame and causes gas
valve to turn off main burner and pilot burner gas
ow should pilot burner ame extinguish. Vent
Damper remains open with call for heat.
H. 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.Low Water Cutoff. Automatically interrupts main
burner operation when surface of boiler water
falls to lowest permissible operating level. Vent
damper closes. Normal operation resumes when
water returns to normal level.
b. Limit: Automatically interrupts main burner
operation when steam pressure exceeds set point.
Maximum allowable pressure is 15 psi. Vent
Damper closes. Normal operation resumes when
steam pressure falls below set point.
Figure 14: Wiring Diagram, Continuous Ignition (Standing Pilot) and Hydrolevel Model 400
or McDonnell & Miller PS-802-24 Cutoff

15
operation. The source of blockage must be
corrected by trained and skilled personnel from a
qualied service agency before resetting switch.
d.Flame Roll-out Switch. Automatically interrupts
boiler operation when ames or excessive heat
are present in vestibule. 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.
e. 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.
Vent Damper remains open with call for heat.
For Electronic Ignition Troubleshooting Guide, see
Pages 26-27.
I. Sequence of Operation with 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.Low Water Cutoff. Automatically interrupts main
burner operation when surface of boiler water
falls to lowest permissible operating level. Vent
damper closes. Normal operation resumes when
water returns to normal level.
b. Limit: Automatically interrupts main burner
operation when steam pressure exceeds set point.
Maximum allowable pressure is 15 psi. Vent
Damper closes. Normal operation resumes when
steam pressure falls below set point.
c.Blocked Vent Switch. Automatically interrupts
main burner operation when excessive vent
system blockage occurs. Vent Damper remains
open with call for heat. If blocked vent switch
is activated do not attempt to place boiler in
Figure 15: Wiring Diagram, Intermittent Ignition (EI) and Hydrolevel Model 400
or McDonnell & Miller PS-802-24 Low Water Cutoff

16
c.Blocked Vent Switch. Automatically interrupts
main burner operation when excessive vent
system blockage occurs. 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.
d.Flame Roll-out Switch. Automatically interrupts
boiler operation when ames or excessive heat
are present in vestibule. 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.
e. Thermocouple: senses pilot ame and causes gas
valve to turn off main burner and pilot burner gas
ow should pilot burner ame extinguish. Vent
Damper remains open with call for heat.
L. 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.Low Water Cutoff. Automatically interrupts main
burner operation when surface of boiler water
falls to lowest permissible operating level. Vent
damper closes. Normal operation resumes when
water returns to normal level.
b. Limit: Automatically interrupts main burner
operation when steam pressure exceeds set point.
Maximum allowable pressure is 15 psi. Vent
Damper closes. Normal operation resumes when
steam pressure falls below set point.
Figure 16: Wiring Diagram, Continuous Ignition (Standing Pilot) and McDonnell & Miller 67 Low Water Cutoff

17
K. Sequence of Operation with 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.Low Water Cutoff. Automatically interrupts main
burner operation when surface of boiler water
falls to lowest permissible operating level. Vent
damper closes. Normal operation resumes when
water returns to normal level.
b. Limit: Automatically interrupts main burner
operation when steam pressure exceeds set point.
Maximum allowable pressure is 15 psi. Vent
Damper closes. Normal operation resumes when
steam pressure falls below set point.
c.Blocked Vent Switch. Automatically interrupts
main burner operation when excessive vent
system blockage occurs. 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.
d.Flame Roll-out Switch. Automatically interrupts
boiler operation when ames or excessive heat
are present in vestibule. 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 rollout switch replaced by trained and
skilled personnel from a qualied service agency.
e. 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.
Vent Damper remains open with call for heat.
For Electronic Ignition Troubleshooting Guide, see
Pages 26-27.
Figure 17: Wiring Diagram, Intermittent Ignition (EI) and McDonnell & Miller 67 Low Water Cutoff

18
VII. System Start-up
Figure 19: Pilot Burner Flame, Intermittent Ignition
A. Safe operation and other performance criteria were
met with gas manifold and control assembly provided
on boiler when boiler underwent tests specied in
American National Standard for Gas-Fired Low-
Pressure Steam and Hot Water Boilers, ANSI Z21.13.
B. Check main burners. Rear of burner must be in
vertical slot in rear of burner tray. Front of burner must
be seated on orice.
C. Fill boiler with water to normal water line.
D. Prepare to check operation.
1. Obtain gas heating value (in Btu per cubic foot)
from gas supplier.
2. Adjust limit. Adjust cut-in pressure for 2 psi and
differential for 1 psi.
3. Connect manometer to outlet pressure tap on gas
valve.
4. For natural gas-red boiler, temporarily turn off all
other gas-red appliances.
E. Follow Lighting or Operating Instructions to place
boiler in operation. See Figure 21 for continuous
ignition (standing pilot) or Figure 22 for intermittent
ignition (EI).
F. Sequence of Operation is located under wiring
diagram. See Table 8. If boiler equipped with
intermittent ignition fails to operate properly, see
Troubleshooting Tree on Page 26-27.
G. Test gas piping and connections between Gas Valve
and Manifold, orices, and pilot tubing while boiler is
operating. 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.
Figure 18: Pilot Burner Flame, Continuous Ignition
H. Check pilot burner ame.
1. Continuous Ignition (standing pilot). See Figure
18. Pilot produces a single ame. Flame should be
steady, medium hard blue enveloping 3/8 to ½ inch
of thermocouple.
2. Intermittent Ignition (EI). See Figure 19. Pilot
produces three (3) ames. Center ame should be
steady, medium hard blue enveloping 3/8 to ½ inch
of sensing probe.
I. Check main burner ame. See Figure 20. Flame
should have clearly dened inner cone with no yellow
tipping. Orange-yellow streaks should not be confused
with true yellow tipping.
J. Check thermostat operation. Raise and lower
temperature setting to start and stop boiler operation.
K. Check ignition system shutoff.
1. Continuous Ignition (standing pilot). Disconnect
thermocouple.
2. Intermittent Ignition (EI). Disconnect sensor cable
from Terminal 4 SENSE. Gas valve should close
and pilot and main burners should extinguish.
L. Low Water Cutoff.
1. Adjust thermostat to highest setting.
2. With boiler operating, open drain valve and slowly
drain boiler.
CAUTION
Do not drain below gauge glass.

19
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.
3. Main burners and pilot burner will extinguish when
water level falls below low water cutoff (water
should still be visible in gauge glass). Verify limit,
thermostat or other controls have not shut off boiler.
4. Adjust thermostat to lowest setting. Rell boiler to
normal water line.
M. Check limit.
1. Adjust thermostat to highest setting.
2. Observe pressure gauge. When pressure is indicated,
adjust limit to setting below observed pressure.
Main burners should extinguish.
3. Adjust limit to setting above observed pressure.
Ignition sequence should begin.
4. Adjust thermostat to lowest setting. Adjust limit to
desired setting.
N. Check Vent Damper Operation. Vent Damper must be
in open position when main burners are ignited.
O. Adjust gas input rate to boiler (Natural Gas).
1. Adjust thermostat to highest setting.
2. Check manifold gas pressure. Manifold pressure
is listed on rating label. Adjust gas valve pressure
regulator as necessary (turn adjustment screw
counterclockwise to decrease manifold pressure, or
clockwise to increase manifold pressure). If pressure
can not be attained, check gas valve inlet pressure.
Figure 20: Main Burner Flame Table 9: Gas Flow Rate in Cubic Feet per Hour
Seconds
for One
Revolution
Size of Gas Meter Dial
One-Half
Cu. Ft.
One
Cu. Ft.
Two
Cu. Ft.
Five
Cu. Ft.
30 60 120 240 600
32 56 113 225 563
34 53 106 212 529
36 50 100 200 500
38 47 95 189 474
40 45 90 180 450
42 43 86 172 430
44 41 82 164 410
46 39 78 157 391
48 37 75 150 375
50 36 72 144 360
52 35 69 138 346
54 33 67 133 333
56 32 64 129 321
58 31 62 124 310
60 30 60 120 300
62 29 58 116 290
64 29 56 112 281
66 29 54 109 273
68 28 53 106 265
70 26 51 103 257
72 25 50 100 250
74 24 48 97 243
76 24 47 95 237
78 23 46 92 231
80 22 45 90 225
NOTICE
CGS-A 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,
Section 8.1.2 and Appendix F. High altitude
boiler models are identiable by the third digit in
the model number sufx on the rating label:
CGS _ OA _ _ - _ _ 2: less than 2000 ft. elevation
CGS _ OA _ _ - _ _ 5: 2000 to 5000 ft. elevation
If less than minimum gas supply pressure listed on
rating label, contact gas supplier for assistance.
3. Clock gas meter for at least 30 seconds. Use Table 9
to determine gas ow rate in Cubic Feet per Hour.

20
ii. Remove gas orices. Drill one (1) drill size
larger (drill size is stamped on orice, or see
Section IX. Repair Parts).
iii. Reinstall gas orices and main burners.
Measure input rate.
6. Recheck Main Burner Flame.
7. Follow instructions to TURN OFF GAS TO
APPLIANCE. See Figure 21 for continuous
ignition (standing pilot) or Figure 22 for intermittent
ignition (EI). Remove manometer.
8. Follow Lighting or Operating Instructions to place
boiler in operation. See Figure 21 for continuous
ignition (standing pilot) or Figure 22 for intermittent
ignition (EI). Adjust thermostat to normal setting.
4. Determine Input Rate. Multiply gas ow rate by gas
heating value.
5. Compare measured input rate to input rate listed on
rating label.
a. Boiler must not be overred. Reduce input
rate by decreasing manifold pressure. Do not
reduce more than 0.3 inch w.c. If boiler is still
overred, contact New Yorker Boiler Company
for replacement Gas Orices.
b. Increase input rate if less than 98% of rating
label input. Increase manifold gas pressure no
more than 0.3 inch w.c. If measured input rate is
still less than 98% of rated input:
i. Remove Main Burners per procedure in
Section VIII. Service.
Figure 21: Lighting Instructions