New Yorker CGS-C Series Service manual

104823-02 - 4/14 Price - $5.00
INSTALLATION, OPERATING
AND
SERVICE INSTRUCTIONS
CGS-C™ SERIES
GAS BOILER
BEFORE INSTALLATION: READ THIS MANUAL
SAVE THESE INSTRUCTIONS
Installing contractor and homeowner should read and be informed as to the proper installation and operation of this boiler.
The manufacturer will not be responsible for improper installation or operation. This manual and all associated instruction
material should be conspicuously posted near the boiler.
For service or repairs to boiler, call your heating contractor. When seeking information on boiler,
provide Boiler Model Number and Serial Number as shown on Rating Label.
Boiler Model Number
CGS _ 0C
Boiler Serial Number Installation Date
Heating Contractor Phone Number
Address
9700609

2
FOLLOW ALL INSTRUCTIONS and warnings
printed in this manual and posted on the boiler.
INSPECT THE BOILER ANNUALLY. To keep
your boiler safe and efcient, have a service
technician follow the Service checklist near the
end of this manual.
IF YOU ARE NOT QUALIFIED to install or
service boilers, do not install or service this one.
THE BOILER MAY LEAK WATER at the end of
its useful life. Be sure to protect walls, carpets,
and valuables from water that could leak from the
boiler.
PROTECT YOUR HOME IN FREEZING
WEATHER. A power outage, safety lockout,
or component failure will prevent your boiler
from lighting. In winter, your pipes may freeze
and cause extensive property damage. Do not
leave the heating system unattended during cold
weather unless alarms or other safeguards are in
place to prevent such damage
DO NOT BLOCK AIR FLOW into or around the
boiler. Insufcient air may cause the boiler to
produce carbon monoxide or start a re.
KEEP FLAMMABLE LIQUIDS AWAY from the
boiler, including paint, solvents, and gasoline.
The boiler may ignite the vapors from the liquids
causing explosion or re.
KEEP CHILDREN AND PETS away from hot
surfaces of the boiler, boiler piping, and vent pipe.
CARBON MONOXIDE (CO) is an odorless,
deadly gas that may be introduced into your
home by any malfunctioning fuel-burning product
or vent system failure. Consider installing CO
alarms near bedrooms in all levels of the building
to warn you and your family of potential CO
exposure.
WARNINGS FOR THE HOMEOWNER

33
READ THIS ENTIRE MANUAL before attempting
installation, start-up, or service. Improper
installation, adjustment, alteration, service,
or maintenance may cause serious property
damage, personal injury, or death.
DO NOT DISCONNECT PIPE FITTINGS on
the boiler or in the heating system without rst
verifying that the system is cool and free of
pressure and that your clothing will protect you
from a release of hot water or steam. Do not rely
solely on the boiler’s temperature and pressure
gage when making this judgment.
USE PROPER PERSONAL PROTECTION
EQUIPMENT when servicing or working near the
boiler. Materials of construction, ue products,
and fuel contain alumina, silica, heavy metals,
carbon monoxide, nitrogen oxides, and/or
other toxic or harmful substances that can are
hazardous to health and life and that are known
to the State of California to cause cancer, birth
defects, and other reproductive harm.
INSTALL ALL GUARDS, cover plates, and
enclosures before operating the boiler.
SIZE THE BOILER PROPERLY relative to the
design heat load or, if using domestic hot water
priority, the peak hot water load, whichever
is larger. A grossly oversized boiler will cycle
excessively and this will lead to premature failure
of the boiler and its components. Our warranty
does not apply to damage from excessive cycling.
ADHERE TO ALL LOCAL CODE
REQUIREMENTS. Contact your local code
inspector prior to installation. In the absence of a
local code, adhere to the National Fuel Gas Code
ANSI Z223.1/NFPA 54.
ALL WIRING must comply with the National
Electrical Code ANSI/NFPA 70.
WARNINGS FOR THE INSTALLER

4
 TheCGS-Cseriesboilersarelowpressurecastirongasredsteamboilersdesignedforuseinclosedsteamheating
systems. These boilers are Category I draft diverter equipped appliances, which must be vented by natural draft using a lined
masonryorlistedmetalchimneysystem.Anadequatesupplyofairforcombustion,ventilationanddilutionofuegases
must be available in the boiler room. These boilers are not designed for use in process or other “open” steam systems
TABLE OF CONTENTS
I. Product Description.................................................................................... 4
II. Specications............................................................................................ 5
III. Pre-Installation........................................................................................... 6
IV. Locating the Boiler..................................................................................... 6
V. Air for Combustion & Ventilation................................................................ 7
VI. Venting....................................................................................................... 11
VII. Gas Piping................................................................................................. 14
VIII. System Piping............................................................................................ 15
IX. Indirect Water Heater Piping...................................................................... 18
X. Electrical.................................................................................................... 19
XI. System Start-Up........................................................................................ 25
XII. Service Instructions................................................................................... 30
XIII. Troubleshooting.......................................................................................... 33
XIV. Repair Parts.............................................................................................. 40
Appendix A - Tapping Locations................................................................. 50
I. Product Description

55
TABLE 1: CGS-C SPECIFICATIONS
II. Specications
FIGURE 1: CGS-C BOILERS - GENERAL CONFIGURATION
Boiler
Model
Approx.
Shipping
Weight
Lbs.
Dimensions (in inches) Recommended Min.
Round
Chimney Size
(Diameter x Height)
(1)
Gas
Conn.
(NPT)
Water Volume
(Gal.)
'A' 'B' 'C' 'D' Steam
Boiler (2)
CGS30C 350 12¾
28
33-3/4 4 4" x 15 ft.
1/2"
5.1 3.9
CGS40C 420 16 34-3/4 5 5" x 15 ft. 6.5 5.0
CGS50C 485 19¼ 35-3/4 6 6" x 15 ft. 7.9 6.1
CGS60C 555 22½ 9.3 7.2
CGS70C 620 25¾ 30 36-3/4 7 7" x 15 ft. 3/4" 10.7 8.3
CGS80C 690 29 12.1 9.4
(1) 15' chimney height is from bottom of Draft Hood opening to top of Chimney.
(2) Steam boiler's "steamable water volume": water volume from NWL (normal water level) to low water cutoff level.
Heating Surface: 4.35 sq. ft. per ueway (steam); 5.72 sq. ft. per ueway (water)

6
1) Safe, reliable operation of this boiler depends upon installation by a professional heating contractor in strict accordance
with this manual and the requirements of the authority having jurisdiction.
• In the absence of an authority having jurisdiction, installation must be in accordance with this manual and the
National Fuel Gas Code, ANSI Z223.1/NFPA 54.
• Where required by the authority having jurisdiction, this installation must conform to the Standard for Controls and
Safety Devices for Automatically Fired Boilers (ANSI/ASME CSD-1).
2) Make sure that a properly sized chimney is available which is in good condition. Consult the authority having
jurisdiction, Part VI of this manual, and the National Fuel Gas Code for additional information on venting requirements.
3) Make sure that the boiler is correctly sized. Use an industry accepted sizing method such as the I=B=R Installation
Guide for Residential Hydronic Heating Systems (Pub. #200) and I=B=R Heat Loss Calculation Guide (Pub. #H21 or
#H22).
4)  Makesurethattheboilerreceivedisconguredforthecorrectgas(naturalorLP).
Warning
This Product Must be Installed By A Licensed Plumber Or Gas Fitter
when Installed Within The Commonwealth Of Massachusetts
IV. Locating the Boiler
1) Clearances:
•  Observe the minimum clearances shown below. These clearances apply to all combustible construction, as well as
noncombustible walls, ceilings and doors. Also see Figure 2.
Front – 18”
Right Side – 18”
Left Side – 6”
Rear – 6”
Top – 17”
•  A 24” service clearance from the jacket is recommended on the left, right, and front of the boiler. These clearances
maybereducedtothoseshowninFigure2,howeverservicingtheboilerwillbecomeincreasinglydifcultasthese
service clearances are reduced.
•  If the right side 24” service clearance is reduced, adequate clearance must be maintained to easily read and access the
controls. Alternatively, access may be provided using a door
2) This boiler may be installed directly over a non-carpetedcombustibleoor.
3) The boiler must be installed on a hard level surface.
I. Pre-Installation

77
4)  Donotinstallthisboilerinalocationwheregasolineorotherammablevaporsorliquidswillbestoredorused.Donot
install this boiler in an area where large amounts of airborne dust will be present, such as a workshop.
5) The boiler should be located as close to the chimney as possible.
FIGURE 2: CGS-C BOILERS - CLEARANCES TO
ALL TYPES OF COMBUSTIBLE CONSTRUCTION
AND NONCOMBUSTIBLE CEILINGS, WALLS,
AND DOORS.
V. Air for Combustion & Ventilation
6) Do not install this boiler directly on a surface that may get wet. Raise the boiler on a pad.
Sufcientfreshairmustbesuppliedforcombustion,ventilationanduegasdilution.Provisionsforcombustion,ventilationand
uegasdilutionairforgasutilizationequipmentventedbynaturaldraftmustbemadeinaccordancewithlocalbuildingcodesor,
in absence of such codes, in accordance with “Air for Combustion and Ventilation” of the National Fuel Gas Code, ANSI Z223.1/
NFPA 54.
Toensureanadequatesupplyofcombustion,ventilationanduegasdilutionairsupply,startbydeterminingwhether
theboileristobeinstalledinabuildingofunusuallytightconstruction.Agooddenitionofabuildingofunusuallytight
construction is one which has all of the following features:
• Walls and ceilings exposed to outside atmosphere have a continuous water vapor retarder with a rating of 1 perm or
less with openings gasketed and sealed
• Weather stripping has been added on openable windows and doors
• Caulking and sealants are applied to areas such as joints around window and door frames, between sole plates and
oors,betweenwall-ceilingjoints,betweenwallpanels,atpenetrationsforplumbing,electrical,andgaslines,and
at other openings.
IV. Locating the Boiler (continued)

8
For Buildings of Other than Unusually Tight Construction
1) Determinewhethertheboileristobeinstalledinaconnedspace-AconnedspaceisdenedbytheNational Fuel
Gas Code as having a volume less than 50 cubic feet per 1000 BTU/hr input of all appliances installed in that space. To
determinewhethertheboilerroomisaconnedspace:
a. Total the input of all appliances in the boiler room in thousands of BTU/hr. Round the result to the next highest 1000
BTU/hr.
b. Find the volume of the room in cubic feet. The volume of the room in cubic feet is:
Length (ft) x width (ft) x ceiling height (ft)
In calculating the volume of the boiler room, consider the volume of adjoining spaces only if no doors are installed
between them. If doors are installed between the boiler room and an adjoining space, do not consider the volume of
the adjoining space, even if the door is normally left open.
c. Divide the volume of the boiler room by the input in thousands of BTU/hr. If the result is less than 50, the boiler
room is a connedspace.
Example:
A CGS60C and a water heater are to be installed in a room measuring 6 ft - 3 in x 7 ft with an 8 ft ceiling. The water
heater has an input of 30000 BTU/hr:
Total input in thousands of BTU/hr = (172000 BTU/hr + 30000 BTU/hr)/1000 = 202
Volume of room = 6.25 ft x 7 ft x 8 ft = 350 ft3
350/202=1.73.Since1.73islessthan50,theboilerroomisaconnedspace.
2) UnconnedSpace-Naturalinltrationintotheboilerroomwillnormallyprovideadequateairforcombustionand
ventilation without additional louvers or openings into boiler room.
3) ConnedSpace-Providetwoopeningsintotheboilerroom,oneneartheoorandoneneartheceiling.Thetopedgeof
the upper opening must be within 12” of the ceiling and the bottom edge of the lower opening must be within 12” of the
oor(Figure3).
• Each opening must have a free area of 1 square inch per 1000 BTU/hr input of all gas burning appliances in the
boiler room. The minimum opening dimension is 3 inches. Minimum opening free area is 100 square inches per
opening.
• If the total volume of both the boiler room and the room to which the openings connect is less than 50 cubic feet per
1000 BTU/hr of total appliance input, install a pair of identical openings into a third room. Connect additional rooms
with openings until the total volume of all rooms is at least 50 cubic feet per 1000 BTU/hr of input.
• The “free area” of an opening takes into account the blocking effect of mesh, grills, and louvers. Where screens are
used,theymustbenonerthan¼”(4x4)mesh.
• If providing openings into adjacent rooms is undesirable, combustion and ventilation air can be brought into the
boiler room from outdoors. See the instructions under “For Buildings of Unusually Tight Construction”.
For Buildings of Unusually Tight Construction
1) Openings must be installed between the boiler room and the outdoors or a ventilated space, such as an attic or crawl
space, which communicates directly with the outdoors.
2) Two openings are required. The top edge of the upper opening must be within 12 inches of the ceiling. The bottom edge
oftheloweropeningmustbewithin12inchesoftheoor.
3) Size openings and ducts as follows:
• Vertical ducts or openings directly outdoors (Figure 4, Figure 5, and Figure 6) - Each opening must have a free cross
sectionalareaof1squareinchper4000BTU/hrofthetotalinputofallgas-redappliancesintheboilerroombut
not less than 100 square inches. Minimum opening size is 3 inches.
• Openings to outdoors via horizontal ducts (Figure 7) - Each opening must have a free cross sectional area of 1 square
inchper2000BTU/hrofthetotalinputofallgasredappliancesintheboilerroombutnotlessthan100square
inches. Minimum opening size is 3 inches.
• The “free area” of an opening takes into account the blocking effect of mesh, grills, and louvers. Where screens are
used,theymustbenonerthan¼”(4x4)mesh.
V. Air for Combustion & Ventilation (continued)

99
FIGURE 4: ALL AIR FROM OUTDOORS, VENTILATED CRAWL SPACE AND ATTIC
FIGURE 5: ALL AIR FROM OUTDOORS, VIA VENTILATED ATTIC
FIGURE 3: BOILER INSTALLED IN CONFINED SPACE, ALL AIR FROM INSIDE
V. Air for Combustion & Ventilation (continued)

10
FIGURE 6: ALL AIR FROM OUTDOORS, USING OPENINGS INTO BOILER ROOM
FIGURE 7: ALL AIR FROM OUTDOORS, USING HORIZONTAL DUCTS INTO BOILER ROOM
V. Air for Combustion & Ventilation (continued)

11 11
Vent installation must be in accordance with local building codes, or the local authority having jurisdiction, or the National
Fuel Gas Code, ANSI Z223.1/NFPA 54.
A typical vent installation is illustrated by Figure 8. The components of vent installation are the vent damper (if used), vent
connector and chimney.
1) Acceptable Chimneys - The following chimneys may be used to vent CGS-C series boilers:
•  Listed Type B or L gas vent - Install in accordance with the manufacturer’s instructions, the terms of its listing, and
applicable codes.
•  Masonry Chimney - The masonry chimney must be constructed in accordance with the Standard for Chimneys,
Fireplaces, Vents, and Solid Fuel Burning Appliances (NFPA 211) and lined with a clay liner or other listed lining
system. Do not vent a CGS-C series boiler into an unlined chimney.
2) Acceptable Vent Connectors - The following may be used for vent connectors:
•  Listed type B or L Gas Vent
•  Single Wall Galvanized Pipe - Use 0.018” (26 gauge or heavier). The size and location of the chimney may not
permit the use of a single wall connector in some cases. See the National Fuel Gas Code. Do not use single wall pipe
for vent connectors in attics.
•  Other Vent Connectors Permitted by the National Fuel Gas Code.
3) Chimney and Vent Connector Sizing - Size the chimney and vent connector in accordance with the National Fuel Gas
Code.
4) Exterior Chimneys - An exterior chimney has one or more sides exposed to the outdoors below the roof line. There are
two conditions under which an exterior chimney may be used:
•  In some very restrictive cases, CGS-C series boilers may be vented into an exterior ceramic lined masonry chimney.
See the National Fuel Gas Code for information on when exterior chimneys may be used.
•  An exterior masonry chimney may be used if it is lined with B vent or a listed chimney lining system.
5) This boiler may be vented using a listed power venter. The power venter must be sized and installed in accordance with
the power venter manufacturer’s instructions, the terms of the power venter listing, and applicable codes. The boiler
must be electrically interlocked with the power venter to prevent boiler operation if the power venter fails to operate.
Beforedecidingtouseapowerventer,makecertainthattheuegasexitingthepowerventerwillnotdamageadjacent
construction or other structures. Also make certain that the power venter terminal will not be subjected to winds which
could effect power venter operation.
6) Do not connect the vent of this appliance into any portion of a mechanical vent system operating under positive pressure.
7)  Donotconnecttheboilerintoachimneyueservinganopenreplaceorothersolidfuelappliance.
8) Prior to boiler installation, inspect chimney for obstructions or other defects and correct as required. Clean chimney as
necessary.
9) Vent pipe should slope upward from draft diverter not less than one inch in four feet. No portion of vent pipe should run
downward or have sags. Vent pipe must be securely supported.
10) The vertical section of vent pipe coming off the boiler should be as tall as possible, while still maintaining the proper
clearance from the horizontal vent connector to combustibles and the proper pitch called for in (9) above.
11) Vent pipe should be installed above the bottom of the chimney to prevent blockage.
12) Ventpipemustbeinsertedushwithinsidefaceofthechimneylinerandthespacebetweenventpipeandchimney
sealed tight.
13) Do not install the vent damper in any portion of the vent system which is used by appliances other than the boiler being
installed.
VI. Venting

12
14) Install vent damper (see Figure 9) as follows:
a) Open vent damper carton and remove installation instructions. Read the instructions thoroughly before proceeding.
Verify that vent damper is same size as draft diverter outlet. See Figure 1. Unpack vent damper carefully. Do not
force closed damper blade. Forcing vent damper closed may result in damaged gear train and void warranty.
b) Vent damper is factory shipped having approximately ¾” diameter hole in the vent damper blade, which must be left
open for boilers equipped with standing pilot, and should be plugged on boilers with an intermittent pilot system,
using the plug supplied with the damper.
Mounttheventdamperontheuecollarwithoutmodicationtoeitherandsecurewithsheetmetalscrews.Make
sure screws do not interfere with damper blade operation. Vent damper blade position indicator must be visible to
users.
c) The damper wire harness is shipped wired into the boiler junction box. Plug the loose end of this harness into the
damperandsecuretheexibleconduittothedamperusingaconnectornutprovided.
d) Installventconnectorpipeandventttingsfromventdamperoutlettochimneyorgasvent.Securewithsheetmetal
screws and support as required.
Removing an Existing Boiler from a Common Chimney
In some cases, when an existing boiler is removed from a common chimney, the common venting system may be too large
for the remaining appliances. 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 opening 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 practical, close all building doors and windows and all doors between the space in which all 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 instructions. Adjust thermostat so the appliance
will operate continuously.
e) Testforspillageatthedrafthoodreliefopeningafterve(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
appliances 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, ANSI Z223.1/NFPA 54. 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 Chapter 13 of the National Fuel Gas Code, ANSI Z223.1/NFPA 54.
VI. Venting (continued)

13 13
FIGURE 8: CGS-C BOILER TYPICAL VENT SYSTEM
INSTALLATION AND COMPONENTS
FIGURE 9: VENT DAMPER INSTALLATION DETAILS
VI. Venting (continued)

14
 Gaspipingtotheboilermustbesizedtodeliveradequategasfortheboilertoreatthenameplateinputataline
pressure between the minimum and maximum values shown on the rating plate. For more information on gas line sizing,
consult the utility or Chapter 2 of the National Fuel Gas Code.
Figure 10 shows typical gas piping connection to the CGS-C boiler. A sediment trap must be installed upstream of all gas
controls. Install a manual shut-off valve outside the jacket and ground joint union as shown.
The boiler and its gas connection must be leak tested before placing the boiler in operation. When doing this, the boiler
and its individual shut-off must be disconnected from the rest of the system during any pressure testing of that system at
pressures in excess of 1/2 psi. When pressure testing the gas system at pressures of 1/2 psi or less, isolate the boiler from the
gas supply system by closing its individual manual shut-off valve.
FIGURE 10: GAS CONNECTION TO BOILER
* State of Massachusetts Requires Manual
Shut-off Valve to be “T” Handle Type
*
VII. Gas Piping

15 15
CAUTION
• INSTALLBOILERSOTHATTHEGASIGNITIONSYSTEMCOMPONENTSAREPROTECTED
 FROMWATER(DRIPPING,SPRAYING,RAIN,ETC.)DURINGAPPLIANCEOPERATIONANDSERVICE
(CIRCULATOR REPLACEMENT, ETC.).
• OPERATIONOFTHISBOILERINASYSTEMHAVINGSIGNIFICANTAMOUNTSOFDISSOLVED
 OXYGENCANCAUSESEVEREHEATEXCHANGERCORROSIONDAMAGE.
VIII. System Piping
General Piping Notes
Figure 11 shows recommended near boiler piping for most common types of gravity return steam systems. Additional
information on steam system design may be found in Installation Guide for Residential Hydronic Heating Systems (Pub.
#200).
One of the primary purposes of this near boiler piping is to separate tiny water droplets from the steam exiting the boiler
so that “dry” steam is sent to the system. If the near boiler piping is not correct, wet steam will enter the system and the
following problems may occur:
• Short cycling on low water
• Boiler or system Flooding
• Hammering
• Failure to heat one or more radiators
Avoid the three common piping mistakes shown in Figure 12. This applies even if the existing boiler has one of the piping
mistakes shown in Figure 12 and appears to be working. If two or more steam mains must be connected to the boiler, connect
a separate take-off for each main into the header between the riser(s) and equalizer. Also note the following points:
1) A size reduction must be made to connect the header to the equalizer. This reduction must be made in the equalizer line.
Do not make this size reduction in the horizontal header.
2) One pipe steam systems require air vents on each radiator, as well as at the end of each main. For the system to work
properly, these vents must be properly installed, sized, and be in good condition. Inspect and replace any defective vents.
If there are no vents at the ends of the mains, install them.
3) Do not attempt to manifold multiple CGS-C boilers with gravity returns.
4) For installations with condensate or boiler feed pumps, follow the pump manufacturer’s piping instructions. Such
systems generally do not require Hartford loops.
5) Do not use a check valve in place of, or in addition to, a Hartford loop on a gravity return system.
6) Pipethellconnectionfromacleansourceofcoldwater.Whenthewatersupplyisfromawell,makesurethatastrainer
is installed in the well system.
7) Piping with a Chiller - If the boiler is used in conjunction with a chiller, pipe the boiler in parallel with chiller. Use
isolation valves to prevent chilled water from entering the boiler.

16
Piping Installation
1) Remove parts bag from boiler crate.
2) Install safety valve (spindle must be in vertical position) into tapping on boiler left side (see Figure 1) using the 3/4” NPT
nipple and elbow supplied.
3) Pipe the discharge of the safety relief valve to a location where water or steam will not create a hazard or cause property
damage if the valve opens. The end of the discharge pipe must terminate in an unthreaded pipe. If the safety valve
dischargeisnotpipedtoadrainitmustterminateatleast6inchesabovetheoor.Theterminationofthesafetyvalve
discharge piping must be in an area where it is not likely to become plugged by debris or subjected to freezing.
4) Install drain valve into tapping on boiler left side using the 2 x 3/4 bushing provided (see Figure 1).
5) Connect system supply and return to boiler. See Figure 11. CGS30C through CGS60C may be piped with one or two
risers. Install 2” plug in Tapping G if optional second supply A is not used. Two supply risers are required on the
CGS70C and CGS80C.
6) Piping with a Chiller - If the boiler is used in conjunction with a chiller, pipe the boiler in parallel with chiller. Use
isolation valves to prevent chilled water from entering the boiler.
DANGER
• PIPESAFETYVALVEDISCHARGETOASAFELOCATION.
• DONOTINSTALLAVALVEINTHESAFETYVALVEDISCHARGELINE.
• DONOTMOVESAFETYVALVEFROMFACTORYLOCATION.
• DONOTPLUGSAFETYVALVEDISCHARGE.
• DONOTINSTALLASAFETYVALVEWITHASETTINGGREATERTHAN15PSI.
VIII. System Piping (continued)

17 17
CGS30C /
CGS40C / CGS50C /
CGS60C
CGS70C /
CGS80C
A2** 2
B2 3
C1½ 1½
D1¼ ¼
** Optional
FIGURE 12: COMMON NEAR-BOILER PIPING MISTAKES
FIGURE 11: STEAM BOILER PIPING FOR GRAVITY RETURN
MINIMUM PIPE SIZE
VIII. System Piping (continued)

18
All CGS-C series boilers are equipped with tappings to permit the connection of a Link SL™ Indirect Water Heater,
or other indirect water heater. In this type of system, hot boiler water is drawn from below the water line and passed
through the heat exchanger in the indirect water heater. This section describes boiler-side piping only. Refer to Link SL™
Installation, Operating and Service Instructions for additional information. The components in this system and their
functions are as follows:
1) Circulator - Mount the circulator as shown in Figure 13. The circulator should be located as low and as close to the
boileraspractical.Donotinstallvalves,orotherdeviceshavingasignicantpressuredrop,betweentheboiler
and the circulator inlet. All piping between the boiler and the circulator inlet should be 1”, regardless of the size of
the piping required in the rest of the system. See Figure 15 in Part X for wiring information.
2) “Y”Strainer-Installa“Y”strainertopreventsedimentfromaccumulatinginsidetheindirectwaterheater.
3) Check Valve - Prevents gravity circulation through the indirect water heater when the boiler is responding to a call
for heat.
4) Boiler Limit Control - Use a SPST break-on-rise temperature limit control such as the Honeywell L4006A. Do not
set the limit above 180°F as doing so may cause the boiler to steam when there is no call for heat. See Figure 15
for wiring information.
5) Valves and Unions - Install shut-off valves, drain valves, and unions in locations that will facilitate maintenance of
the system. Do not install any valves between the boiler and circulator inlet.
IMPORTANT
•Some indirect water heaters may not be suitable for use with a steam boiler. Consult the water heater
manufacturer’s guidelines before installing it in this type of system.
•  Boilerwatertemperaturesandowratesinthistypeofsystemmaybeconsiderablylowerthanthoseupon
which the water heater manufacturer’s ratings are based. This may result in substantially longer water heater
recovery times.
FIGURE 13: INDIRECT WATER HEATER BOILER-SIDE PIPING
IX. Indirect Water Heater Piping

19 19
1) 120 Volt Wiring - The boiler should be provided with its own 15A branch circuit with fused disconnect. All 120 volt
connections are made inside the junction box on the left side of the boiler. Remove the transformer to gain access to this
box (also see Figures 16 and 17):
• Hot (“black”) - Wire nut to black transformer lead
• Neutral (“white”) - Wire nut to white transformer lead
• Ground (“green” or bare) - Ground screw inside junction box.
2) Thermostat Wiring - Follow thermostat manufacturer instructions. To insure proper thermostat operation, avoid
installation in areas of poor air circulation, hot spots (near any heat source or in direct sunlight), cold spots (outside
walls, walls adjacent to unheated areas, locations subject to drafts). Provide Class II circuit between thermostat and
boiler. Connect thermostat wire leads to the blue transformer lead and brown relay lead inside the junction box. Set the
heat anticipator to 0.2A.
Feeder Wiring for Boilers Equipped with Hydrolevel CG400A Low Water Cut-offs
1) Using Hydrolevel VXT-24 TWO-WIRE feeder - Do not alter factory boiler wiring. Connect VXT-24 to CG400A as
follows:
• Connect the BLACK lead on the feeder to terminal Aon the LWCO
• Connect the WHITE lead on the feeder to terminal 2on the LWCO
2) Using Hydrolevel VXT-24 THREE-WIRE feeder - Do not alter factory boiler wiring. Connect VXT-24 to CG400A as
follows:
• Connect the BLACK lead on the feeder to terminal 1on the LWCO
• Connect the WHITE lead on the feeder to terminal 2on the LWCO
• Connect the RED lead on the feeder to terminal Aon the LWCO
3) Using McDonnell & Miller WF2-U-24 feeder - Do not alter factory boiler wiring. Connect WF2-U-24 to CG400A as
follows:
• Connect terminal W on the feeder to terminal A on the LWCO
• Connect terminal Non the feeder to terminal 2on the LWCO
• Connect terminal Hon the feeder to terminal 1 on the LWCO
CAUTION
Do not attempt to connect a McDonnell & Miller model #101A feeder, or other feeder without a delay, to a CGS-C boiler
equippedwithaHydrolevelCG400lowwatercutoff.Doingsocoulddestroytheboilertransformerand/oroodthe
system.
WARNING
All wiring and grounding must be done in accordance with the authority having jurisdiction or, in the absence of such
requirements, with the National Electrical Code (ANSI/NFPA 70)
X. Electrical

20
Feeder Wiring for Boilers Equipped with McDonnell & Miller #67 Low Water Cut-offs
Figures 14a and 14b show feeder wiring for McDonnell & Miller #101A, McDonnell & Miller WF2-U-24 and Hydrolevel
VXT-24 feeders on boilers equipped with #67 low water cutoffs. The following points apply to all feeder wiring to #67 low
water cut-offs:
• Use a separate transformer to power the feeder. Do not use the transformer on the boiler.
• It is not necessary to touch any of the 24 volt factory boiler wiring when connecting a feeder to a #67 equipped
boiler.
• Do NOT install a jumper between terminals 2 and 3 on the #67 low water cutoff.
Indirect Water Heater Wiring
Figure15showseldwiringforanindirectwaterheater.AHoneywellR845AorequivalentDPSTrelayandtransformer
is required. The high limit described in Part IX must also be supplied by the installer. A call for heat from the indirect water
heater thermostat will energize the relay making both sets of contacts. One set of these contacts then energizes the circulator.
Theothersetofcontactswillmakethe“T”and“T”contactsontheburnerprimarycontrol,ringtheburner.Iftheboiler
water temperature exceeds the high limit setting of 180°F, the high limit will open the “T” - “T” circuit and the burner will
shut down.
Ifthereisacallforspaceheat,theheatingthermostatwillmakethe“T”-”T”circuitandtheboilerwillrewithoutregard
to the status of the indirect water heater. The low water cut-off and pressure limit control will interrupt 120 volt power to the
burner in the event of a low water or excessive pressure condition.
FIGURE 14a: WIRING MCDONNELL & MILLER 101A OR TWO-WIRE HYDROLEVEL
VXT-24 FEEDER TO BOILER EQUIPPED WITH #67 L.W.C.O.
CAUTION
DO NOT INSTALL
JUMPER BETWEEN 2 & 3
ON #67 L.W.C.O.
X. Electrical (continued)