New Yorker CI-HGS Series Service manual

ITALLATIO , OPE ATI G A
E VlCE IT CTI FOR
Label located on top of the boiler.
Boiler Model Number Boiler Serial Number
CI-HGS
Heating Contractor
Installation Date
Phone Number
Address
Yorker
RESIDENTIAL HEATING BOILERS
102408=02=12/10 Price - $3.00

IMPORTANT INFORMATION - READ CAREFULLY
All boilers must be installed in accordance with National, State and Local Plumbing, Heating
and Electrical Codes and the regulations of the serving utilities. These Codes and Regulations
may differ from this instruction manual. Authorities having jurisdiction should be consulted
before installations are made.
In all cases, reference should be made to the following Standards:
USA BOILERS
A. Current Edition of American National Standard ANSI/NFPA 31, "Installation of Oil
Burning Equipment", for recommended installation practices.
B. Current Edition of American National Standard ANSI/NFPA 211, "Chimneys, Fireplaces,
Vents, and Solid Fuel Burning Appliances", For Venting requirements.
C. Current Edition of American Society of Mechanical Engineers ASME CSD-1, "Controls and
Safety Devices for Automatically Fired Boilers", for assembly and operations of controls
and safety devices.
D. All wiring on boilers installed in the USA shall be made in accordance with the National
Electrical Code and/or Local Regulations.
CANADIAN BOILERS
A. Current Edition of Canadian Standards Association CSA B139, "Installation Code for Oil
Burning Equipment", for recommended Installation Practices.
B. All wiring on boilers installed in Canada shall be made in accordance with the Canadian
Electrical Code and/or Local Regulations.
The following terms are used throughout this manual to bring attention to the presence of hazards
of various risk levels, or to important information concerning product life.
indicates apotentially hazardous situation which,
if not avoided, could result in death, serious injury
or substantial property damage.
This boiler has a limited warranty, a copy of which is printed on the back of this manual.
The warranty for this boiler is valid only if the boiler has been installed, maintained and operated in
accordance with these instructions.
Surface rust on cast iron sections may be attributed to the manufacturing process as well as condensation
during storage. Surface rust is normal and does not affect the performance or longevity of a boiler.

Improperinstallation, adjustment, alteration, service or maintenance can cause property damage, personal
injury or loss of life. Failure to follow all instructions in the proper order can cause personal injury or
death. Read and understand all instructions, including all those contained in component manufacturers
manuals which are provided with the appliance before installing, starting-up, operating, maintaining or
servicing this appliance. Keep this manual and literature in legible condition and posted near appliance
for reference by owner and service technician.
This boiler requires regular maintenance and service to operate safely. Follow the instructions contained
in this manual.
Installation, maintenance, and service must be performed only by an experienced, skilled and knowledgeable
installer or service agency.
All heating systems should be designed by competent contractors and only persons knowledgeable in
the layout and installation of hydronic heating systems should attempt installation of any boiler.
Installation is not complete unless a pressure relief valve is installed into the 3/4" tapping located on
return piping that was installed into boss on top of rear section - See "Packaged Boiler Assy - Trim &
Controls" and "Water Boiler Piping" Sections of this manual for details.
It is the responsibility of the installing contractor to see that all controls are correctly installed and are
operating properly when the installation is complete including verifying that the limit sensor is fully
installed.
Failure to properly install Limit Sensor may result in property damage, personal injury or loss of life
due to elevated operating temperatures and/or pressures.
This boiler is suitable for installation on combustible flooring. Do not install boiler on carpeting.
Do not tamper with or alter the boiler or controls.
Inspect flueways at least once ayear - preferably at the start of the heating season. The inside of
the combustion chamber, the vent system and boiler flueways should be cleaned if soot or scale has
accumulated.
When cleaning this boiler, take precaution to avoid damage to burner swing door insulation. If damaged,
or if there is evidence of previous damage, burner swing door insulation must be replaced immediately.
Oil Burner and Controls must be checked at least once a year or as may be necessitated.
Do not operate unit with jumpered or absent controls or safety devices.
Do not operate unit if any control, switch, component, or device has been subject to water.
Appliance materials of construction, products of combustion and the fuel contain alumina, silica, heavy
metals, carbon monoxide, nitrogen oxides, aldehydes and/or other toxic or harmful substances which
can cause death or serious injury and which are known to the state of California to cause cancer, birth
defects and other reproductive harm. Always use proper safety clothing, respirators and equipment when
servicing or working nearby the appliance.

This boiler contains very hot water under high pressure. Do not unscrew any pipe fittings nor attempt
to disconnect any components of this boiler without positively assuring the water is cool and has no
pressure. Always wear protective clothing and equipment when installing, starting up or servicing this
boiler to prevent scald injuries. Do not rely on the pressure and temperature gauges to determine the
temperature and pressure of the boiler. This boiler contains components which become very hot when
the boiler is operating. Do not touch any components unless they are cool.
This boiler must be properly vented. The chimney must be inspected for any obstructions and cleaned
prior to each heating season. A clean and unobstructed chimney flue is necessary to produce the minimum
draft required to safely evacuate noxious fumes that could cause personal injury or loss of life. Evidence
of loose debris and or condensate induced stains at the base of the chimney flue, connector or smokepipe
joints may be signs of condensing flue gases. Flue gas condensate is corrosive, which requires special
consideration and must be addressed immediately. Refer to Section V, "Venting".
This boiler needs fresh air for safe operation and must be installed so there are provisions for adequate
combustion and ventilation air.
This boiler is supplied with controls which may cause the boiler to shut down and not re=start 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.
This boiler is designed to burn No. 2fuel oil only. Do not use gasoline, crankcase drainings, or any oil
containing gasoline. Never burn garbage or paper in this boiler. Do not convert to any solid fuel (i.e.
wood, coal). Do not convert to any gaseous fuel (i.e. natural gas, LP). All flammable debris, rags, paper,
wood scraps, etc., should be kept clear of the boiler at all times. Keep the boiler area clean and free of
fire hazards.
All boilers equipped with burner swing door have a potential hazard which, if ignored, can cause severe
property damage, personal injury or loss of life. Before opening swing door turn off service switch to
boiler to prevent accidental firing of burner outside the combustion chamber. Be sure to tighten swing
door fasteners completely when service is completed.
I, X.
II. XI.
III. XII.
XIII.
Pre-lnstallation ................................................ 7
Packaged Boiler Assy. - Trim & Controls ......... 10
Water Boiler Piping .......................................... 16
IV. Indirect Water Heater Piping ........................... 20
V. Venting ............................................................ 21
VI. Direct Venting/Air Intake Piping ...................... 25
VII. Electrical .......................................................... 32
VIII. Oil Piping ......................................................... 35
IX. System Start-up .............................................. 37
XIV.
XV.
Maintenance & Service Instructions ................ 47
Boiler Cleaning ................................................ 48
Trouble Shooting ............................................. 50
Repair Parts .................................................... 51
Appendix A 63
Low Water Cut Off ............................................
Appendix B
Blocked Vent Safety Switch .............................. 64
4

TOP _W H
a_N{
c{ L£GS
PJG_
F__igure1:CI-HGSTM-72 thru CI-HGSTM-163
O1

TABLE 1A:
Boiler Model
No.
CI-HGS-72
CI-HGS-101
CI-HGS-127
CI-HGS-163
NOTE:
DIMENSIONAL DATA (SEE FIGURE 1)
Dimensions See Figure 1
17"
17"
23"
29"
24"
24"
24"
30"
5"
5"
6"
6"
Water Content
- Gallons
7.70
7.70
11.08
14.46
1. Maximum Working Pressure: Water: 30 PSI Shipped From Factory (Standard),
40 PSI Optional, 50 PSI Optional
Heat Transfer
Surface Area
- Sq. Ft.
13.29
13.29
20.29
27.29
Actual
Shipping
Weight (LB.)
43O
430
545
658
TABLE 1B: RATING DATA
Boiler
Model No.
CI-HGS-72
CI-HGS-101
CI-HGS-127
CI-HGS-163
GPH
0.60
0.82
1.05
1.35
Burner Capacity
MBH
84
115
147
189
DOE Heating
Capacity MBH
72
101
127
163
I=B=R
NET Ratings
Water MBH
63
87
110
142
Minimum Chimney
Requirements
Round Rectangle Height
In. Dia. In. x In. Ft.
6 8x8 15
6 8x8 15
6 8x8 15
7 8x8 15
Direct Vent System
Model
N/A
N/A
FDVS-56
FDVS-56
Vent
Connector
Dia, Inch
N/A
N/A
5
5
AFUE %
Water
Boiler
86
86
86
86

SECTION I: PRE-INSTALLATION
A°
No
INSPECT SHIPMENT carefully for any signs of
damage.
2.
All equipment is carefully manufactured, inspected
and packed. Our responsibility ceases upon delivery
of crated boiler to the carrier in good condition.
Any claims for damage or shortage in shipment
must be filed inmlediately against the carrier by the
consignee. No claims for variances from, or shortage
in orders, will be allowed by the manufacturer
unless presented within sixty (60) days after receipt
of goods.
1.
2.
LOCATE BOILER in front of final position before
removing crate. See Figure 1.
LOCATE so that vent pipe connection to chinmey
will be short and direct.
3.
4.
BOILER IS SUITABLE FOR INSTALLATION
ON COMBUSTIBLE FLOOR. Boiler cannot be
installed on carpeting.
FOR BASEMENT INSTALLATION, provide
a solid elevated base, such as concrete, if floor is
not level, or if water may be encountered on floor
around boiler.
PROVIDE RECOMMENDED SERVICE
CLEARANCE, if applicable, as follows:
a. Clearance from Jacket Front Panel -
* 24" for servicing burner 5.
b.
* 24" for flueway cleaning (CI-HGS-72 thru
CI-HGS-127)
* 30" for flueway cleaning (CI-HGS-163)
Clearance from Jacket Left Side Panel -
* 19" for burner swing door, if opened fully
with burner mounted, otherwise 1" with
burner removed
* 12" access clearance to service rear of
boiler if right side clearance is less
than 12"
* 3" minimunl if right side clearance is 12" or
larger to access and service rear of boiler.
c. Clearance from Jacket Right Side Panel -
* 3" minimum if left side clearance is 12" or
larger to access and service rear of boiler.
d. Clearance from Jacket Rear Panel -
* 12" minimum for rear smokebox cleaning
(Note: This dimension will also be
controlled by horizontal to vertical to
horizontal smokepipe arrangement -
Chimney Vent (see Figures 2A and 10).
* 24" for rear smoke box cleaning and
disconnecting vent pipe from appliance
adaptor for servicing (if required) - Direct
Vent (see Figure 2B).
For minimum clearances to combustible materials.
See Figures 2A and 2B.
F=Ej_ure2A: Chimney_ Minimum installation Clearances To Combustible Materials
NOTES:
1. Listed clearances comply with American National Standard cannot be reduced t\_ralcove or closet installations.
ANSI/NFPA 31, Installationof Oil Burning Equipment. 3. For reduced clearances to combustible material, protection
2. CI-HGS boilers can be installed in rooms with clearances must be provided as described in the above ANSI/NFPA 31
from combustible material as listed above. Listed clearances standard.

Clearance to venting is for single wall vent
pipe. if Type Lvent is used, clearance may be
reduced to the minimum required by the vent pipe
manufacturer.
C. PROVIDE COMBUSTION AND VENTILATION
AIR. Local and National Codes may apply and should
be referenced.
Adequate combustion and ventilation air must
be provided to assure proper combustion and
to maintain safe ambient air temperatures.
Do not install boiler where gasoline or other
flammable vapors or liquids, or sources of
hydrocarbons (i.e. bleaches, fabric softeners,
etc.) are used or stored.
1. Determine volume of space (boiler room). Rooms
conmmnicating directly with the space in which
the appliances are installed, through openings not
furnished with doors, are considered a part of the
space.
Volume(ft 3) = Length(ft) x Width(ft) x Height(ft)
2. Determine total input of all appliances in the space.
Add inputs of all appliances in the space and round
the result to the nearest 1000 BTU per hour.
3. Determine type of space. Divide Volume by total
input of all appliances in space. If the result is
greater than or equal to 50 ft3/]000 BTU per hour,
then it is considered an unconfined space. If the
result is less than 50 ft3/]000 BTU per hour then the
space is considered a confined space.
FRONT VIEW
3"
4. For boiler located in an uneol_iined ,space of a
conventionally constructed building, the fresh
air infiltration through cracks around windows
and doors normally provides adequate air for
combustion and ventilation.
5.
RIGHT SIDE VIEW _
VENT 3"
(:_'_ PIPING
F;_:{%MLOVIETDy, _6" _ /-- _}
24"
For boiler located in a confined space or an
unconfined space in a building of unusually tight
construction, provide outdoor air.
a. Outdoor air may be provided with the use of two
permanent openings which conmmnicate directly
or by duct with the outdoors or spaces (crawl or
attic) freely conmmnicating 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:
i. Direct communication with outdoors.
Minimum free area of 1square inch per
4,000 BTU per hour input of all equipment
in space.
ii. 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.
iii. 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 jbr boiler located within
eo_iined ,space. Use indoor air if two
permanent openings comnmnicate directly
with additional space(s) of sufficient volume
such that combined volume of all spaces
meet criteria for unconfined 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.
FDVS
DIRECT
VENT
_AIR
INTAKE
PIPING
FEigure2B: Chimney_Minimum Installation Clearances To Combustible Materials

6. Louvers and Grilles of Ventilation Ducts
a. All outside openings should be screened and
louvered. Screens used should not be smaller
than 1/4 inch mesh. Louvers will prevent the
entrance of rain and snow.
b. Free area requirements need to consider the
blocking effect of louvers, grilles, or screens
protecting the openings. If the free area of the
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.
c. Louvers and grilles must be fixed in the open
position, or interlocked with the equipment to
open automatically during equipment operation.
Do DIRECT VENT CONFIGURATIONS requires:
1. Beckett NX Burner
2. Direct Vent conversion Kit
3. Double Wall Flex Oil Vent Pipe (FOVP)
TABLE 2: DIRECT VENT CONFiGURATiON
COMPONENTS
Boiler
Model No.
CI-HGS-127
CI-HGS-163
Beckett NX
Oil Burner
Part No.
103368-01
103369-01
Direct Vent
Conversion Kit
Part No.
103392-02
FOVP Carton Part
No.
100211-02- 5 ft.
100212-02-10 _.
100213-02- 15 _.
100214-02- 20 _.

SECTION II: PACKAGED BOILER ASSEMBLY-TRIM &CONTROLS
A. REMOVE CRATE. blocks under front legs before lowering to
provide hand clearance.
Step 7. To lower rear of boiler, tilt unit slightly
forward by pushing on smokebox collar or lift
pipes protruding through rear legs until wooden
blocks can be removed (see Figure 3). Slowly
allow the weight of the boiler to tilt backward
1. until rear legs rest on floor.
Step 8. If wood block was placed under front legs,
lift pipe handles, remove wooden block and
lower front legs to floor. Remove pipe handles.
g.
1. Remove all fasteners at crate skid.
2. Lift outside container and remove all other
inside protective spacers and bracing. Remove
miscellaneous parts carton.
REMOVE BOILER FROM SKID.
To reduce the risk of damage to boiler jacket, use
the following procedure to remove from skid, see
Figure 3:
Step L Boiler is secured to base with (4) 5/16" cap
screws, (2) in front and (2) in rear of shipping
skid, see Figure 3. Remove all securing
hardware.
Step Z Place wooden block(s) 12"from rear of
skid as shown (one piece 4" x 4" x 16" lg. or two
pieces Ùf2" x 4" x 16" lg.)
Step 3. Insert 1"Sch. 40 pipe handles through leg
hole in front and rear legs. Center end of pipe on
wooden blocks as shown in Figure 3.
NOTE: Pipe handles should extend a minimum
of 48" beyond jacket front panel for best
leverage.
Step 4. Using the pipe handles, lift boiler until
adjustable legs are elevated above the deck
boards.
Step 5. Remove skid from underneath the boiler.
Step 6. Lower pipe handles until front adjustable
legs touch floor. If necessary, place wooden
Do not drop boiler. Do not bump boiler jacket
against floor.
C.
D.
MOVE BOILER TO PERMANENT POSITION
by sliding or walking.
PROCEDURE TO OPEN CLOSE AND
SECURE BURNER SWING DOOR
Throughout this manual you wilt be instructed to open
and close the burner swing door for various reasons.
There is a proper and improper method to closing and
securing the burner swing door opened for inspection,
cleaning or field service.
1. TO OPEN BURNER SWING DOOR
(see Figures 4A and 4B).
Step 1. Loosen but do not remove left side latching
hardware (3/8" x 1-3/4" tg. tap bolt).
PARr:[A1 FRONT V_:EW PM_T_AL SH}E V'_F,;_ NO I
B ,C,8>f; 12"
:'_,@,,4 Si )
i!iii!i!i!i!ilili:i!iiii!iiiii!iiiiliiiiiililiiliiiiiliiiiiiiiiiiiiiiiiiiiiiiiiiii!iiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiii!i!ii!!i!i!ii iiiiii
10
P.aLRT_AL SIDE YIBW NO_ £
F=Ej=klure3: Packaged Boiler Removal from Skid

CAST DOOR N!NGE
W/INTEGRAL PIN ]URNER SW_NG DOOR
BURNER SW_NG DOOR ........
AT REST "_'-.
(_ULLY CLOSED) (FRONT SECTION}
MOUNTING BRACK£T
ROTATED 180_FOR
RIGHT HAND H_NGE
F=_ure 4A: Partial Front View - Burner Swinq Door Mounted to Boiler - Fully Closed and Secured
Step Z Loosen and remove right side latching
hardware (3/8" x 1-3/4" lg. tap bolt and washer).
Step 3. Remove left side latching hardware (3/8" x
1-3/4" lg. tap bolt and washer).
Step 4. Disconnect burner power cord from
receptacle located in lower right corner of jacket
front panel.
Step 5. Door can be swung to the fully open
position, approximately 90° to 120°, with the
burner mounted providing that there is 19" of
clearance to the adjacent wall, see Figure 1.
NOTE: If reduced clearance prevents the door
from opening fully, one of the following can
provide full access:
a. Burner can be removed to allow full rotation
of door.
b. Door with burner mounted can be lifted
off mounting bracket and set aside during
servicing.
c. The door mounting hardware is reversible
from left side hinge (as shipped) to right side
hinge.
To reverse hinge arrangement (see Figure
4A):
• Lift door off mounting bracket and set
aside.
• Remove mounting bracket and hardware
from left side.
2.
3.
* Remove upper jacket front panel retaining
screw (5/16" x 1/2" lg. Phillip Pan head
machine screw) from right side of door
and re-install in vacated upper mounting
bracket tapping. Do not tighten.
* Move lower jacket panel retaining screw
from right side to left tapping. Do not
tigNen.
* Rotate door mounting bracket 180°.
Insert 5/16" cap screw through top hole in
bracket and install in upper vacated jacket
hole on right side of door.
* Install second 5/16" cap through bracket
hole into lower vacated tapping on right
side.
* Tighten both sets of hardware to secure
jacket and mounting bracket.
* Lift door and place integral cast hinge
pins on door into slotted mounting bracket
holes.
Perform routine inspection, service or cleaning as
necessary.
To close Burner Swing Door (see Figures 4A and
4B):
Step l. From the fully open position, rotate Burner
Swing Door to the closed position.
Step 2. If necessary, place your right hand under
the burner air robe to lift upward. Lift the
door up unto the built-in cast ramp/door rest
11

EQUALCOMPRESSIONOF
ROP8 GASK£WSEAL
AiR TUBE SWING OOOR
POSITION i
(FR©PERLY Ch,OSE_ _ND SECURED)
;IACKET S_DE PANEL
POSliON 5 = _5o,
(MAXIMUMFULL OPffN}
POSITION £AND 8
(SWING RAD_:USTO FULL OP:EN POS [iON}
Figure 4B: Top View - Burner Swinq Door Mounted to Cast Iron Block Assembly(Jacket Removed for Clarit3L_
12

(protruding from the bottom of the front section
casting - see Figure 4A).
Step 3. Use one hand to help hold door in position
by lifting up on rear burner housing or applying
pressure directly to the door while re-installing
the securing hardware with your opposite hand.
Ahvays install right side latching hardware
(3/8"-16 x 1-3/4" lg. tap bolt and flat washer)
first, then install left side hinge hardware
(3/8"-16 x 1-3/4" lg. tap bolt and flat washer)
second. Apply additional pressure while hand
tightening the hardware as far as possible, then
release the pressure.
Step 4. Use a hand wrench to tighten door hardware
and always start with the right side ca__
screw first. Use an alternating tightening
method from right side tap bolt to left side tap
bolt to tighten door equally until sealed without
applying excessive torque. Never tighten left
side flange bolt first or tighten either piece of
hardware 100% without using the alternating
tightening method described above.
Failure to follow the prescribed procedure could
cause thread damage to casting or a leak in the
door seal. If left side tap bolt is tightened before
right side tap bolt, right side of door can not be
E.
E
drawn-in to provide an air tight seal, as shown in
Figure 4C. Applying excessive torque will only
cause thread damage.
INSPECT SWING DOOR INSULATION AND
ROPE GASKET.
].
2.
3.
4.
Open burner swing door using procedure previously
outlined in Paragraph D of this section.
Inspect fiberglass rope located on the swing door.
The rope must be evenly distributed around the
perimeter of the door groove and cannot bunch or
overhang. There must not be a gap where the two
ends of the rope meet. Repair or replace if the rope
is damaged or if there is a gap between the ends.
Inspect burner swing door insulation for damage and
proper type.
By design, cast bars on front section between the
combustion chamber and between the left and
right side 2*_and 3rdpass flueway should make an
impression in door insulation to seal the chambers.
If insulation is damaged or not of proper type
regarding pockets, it must be replaced.
Do not close and secure door at this time, proceed to
Field Assembly Details, Paragraph F.
FIELD ASSEMBLY OF BOILER TRIM AND
CONTROLS
Open miscellaneous parts carton and remove contents.
Identify the components using the illustrations (see
Figure 5A) throughout the assembly sequence outlined
below as it applies to your installation.
(cF -_AW,U'O
Figure 4C:
St!:}UR NO B©[_
{R {:/;HT SOL
Top_View - Burner Swing Door FulI_LClosed but Not Pro_ Secured or Sealed
13

1.
2.
Install supply piping and relief valve, refer to Figure
5A.
Step a. Locate the supply piping supplied with
boiler. Apply thread sealant to all joints prior
to assembly. Thread I*A"NPT x 6" long supply
nipple into 1'/2"NPT tapping on the topside
of the rear section. Thread ]1/2" X ]_" X 3_4"
NPT tee onto 6" nipple. Tighten all joints until
watertight and 3/4"NPT connection on tee is
positioned to allow clearance for relief valve
discharge.
Step b. Locate the relief valve piping supplied with
boiler. Apply thread sealant to all joints prior to
assembly. Thread the 3A"NPT street elbow onto
tee listed above. Install relief valve into street
elbow. Tighten all joints until watertight and
relief valve is positioned to allow clearance for
discharge. Installation of the relief valve must be
consistent with ANSI/ASME Boiler and Pressure
Vessel Code, Section IV.
Install Aquastat Control, refer to Figure 5A.
Step a. Locate the L7248C Aquastat Control/
Harness Assembly. Refer to Paragraph D for Swing
Door Hinge placement. Secure aquastat control to
the hinge side Side Panel with supplied sheet metal
screws as shown in Figure 5A.
Step b. Locate the aquastat sensor. Carefully
connect sensor into the L7248C Aquastat Control
circuit board by pressing connector on sensor unit
into mating connector on circuit board (refer to
Figure 16). Remove the center knockout from the
top of the control case. Fish the sensor tin'ouch
knockout; allow adequate slack in sensor cable.
Position sensor gronm_et over knockout to protect
sensor from sharp edges. Insert sensor into
inm_ersion well located in the front section until it
rests against the bottom of the well. Secure sensor
to immersion well with supplied well clamp.
3. Connect Field Wiring.
Step a. Connect the field wiring from the
circulator to the aquastat control. Make the wiring
connections as shown on Figure 13.
4. Installing stainless steel flueway baffles. Baffle
requirements differ from model to model, see
Table 3.
TABLE 3: BAFFLE USAGE
Boiler Model Baffle Usage
2ndPass 3rdPass
None
[2]
PIN 100081-01
CI-HGS-72 None
CI-HGS-101 [2]
PIN 102066-01
CI-HGS-127 None [2]
PIN 100081-01
CI-HGS-163 None None
NOTE: Read caution statement before proceeding.
These baffles will generate higher efficiencies
and lower stack temperatures. Under certain
conditions, a lower gross stack temperature
entering the chimney has the potential to be
cooled below the dew point and create condensate
on interior surfaces. Flue gas condensate is
corrosive, which requires special consideration
and must be addressed immediately.
DO NOT install baffles until you have read Section
V, "Venting" completely_
14 Figure 5A:

yf
/
//
,/
....s
(FULLY iNSERTED)
INCORRECT CORRECT
F_F_i__ure5B: Limit Sensor Insertion
Step a. Install stainless steel baffles provided in
miscellaneous parts carton as follows, refer to
Table 3 and Figure 6:
* Model CI-HGS-IOI - To install flueway
bane in 3rdpass on left side of boiler, hold
bane with word "Left" readable at the top.
Slide bane in flueway until position tab
touches fins on left side of 3rdpass flueway.
To install flueway bane in 3ldpass flueway
on right side of boiler, hold bane with word
"Right" readable at the top. Slide bane
in flueway until position tab touches fins
on right side of 31_pass flueway. To install
flueway bane in 2ndpass on left side of
boiler, hold bane with word "Left" readable
5.
at the top. Slide baffle in flueway until
position tab touches fins on left side of 3ld
pass flueway. To install flueway bane in
211dpass flueway on right side of boiler, hold
bane with word "Right" readable at the top.
Slide bane in flueway until position tab
touches fins on right side of 3rdpass flueway.
* Model CI-HGS-127 - To install flueway
bane in 31_pass flueway on left side of
boiler, hold bane with word "Left" readable
at the top. Slide bane in flueway until
position tab touches fins on left side of 3ld
pass flueway. To install flueway bane in
3ldpass flueway on right side of boiler, hold
baffle with word "Right" readable at the top.
Slide bane in flueway until position tab
touches fins on right side of 3rdpass flueway.
NOTE: 2ndand 3ldpass flueway bane are not
interchangeable.
Close the burner swing door and securely seal the
door to the boiler front section by reinstalling the
hardware and securing the door using procedure
previously outlined in Paragraph D of this section.
When securing burner swing door make sure door
is drawn=in equally on both sides.
2NDPAg$
LL_WAY
NOSiTi@_IN@
'tABS
F=jigure6: Baffle Orientation in Fluewa_Ls
15

SECTION III: WATER BOILER PIPING
A. EVALUATE THE EXISTING WATER
SYSTEM.
Design a piping system and install boiler which will
prevent oxygen contamination of boiler water and
frequent water additions.
1. There are many possible causes of oxygen
contamination such as:
a. Addition of excessive make-up water as a result
of system leaks.
b. Absorption through open tanks and fittings.
c. Oxygen permeable materials in the distribution
system.
2. In order to insure long product life, oxygen sources
must be eliminated. This can be accomplished by
taking the following measures:
a. Repairing system leaks to eliminate the need for
addition of make-up water.
b. Eliminating open tanks from the system.
c. Eliminating and/or repairing fittings which allow
oxygen absorption.
d. Use of non-permeable materials in the
distribution system.
e. Isolating the boiler from the system water by
installing a heat exchanger.
System supply and return piping must be con-
nected to correct boiler manifolds.
New Yorker recommends sizing the system
circulator to supply sufficient flow (GPM)
to allow a 20°F temperature differential
(maximum of a 30°F temperature differential)
in the system. When sizing the system
circulator, the most restrictive single zone
should be used to determine maximum
pressure drop.
g. CONNECT SYSTEM SUPPLY AND RETURN
PIPING TO BOILER. See Figures 7Aand 7B.
Also, consult I=B=R Installation and Piping Guides.
1. If this boiler is used in connection with refrigeration
systems, the boiler must be installed so that the
chilled medium is piped in parallel with the heating
boiler using appropriate valves to prevent the chilled
medium from entering the boiler. See Figure 8.
Also, consult I=B=R Installation and Piping Guides.
2. If this boiler is connected to heating coils located
in air handling units where they may be exposed
to refrigerated air, the boiler piping must be
equipped with flow control valves to prevent gravity
circulation of boiler water during the operation of
the cooling system.
3. If boiler is used with an Link SL TM Indirect-Fired
Domestic Water Heater, install the Link SLTM as
a separate heating zone. Refer to the Link SLTM
Installation, Operating, and Service Instructions for
additional information.
4. Use a system 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.).
The bypass should be the same size as the supply
and return lines with valves located in the bypass
and return line as illustrated in Figures 7A and 7B
in order to regulate water flow for maintenance of
higher boiler water temperature.
Set the by-pass and return valves to a half throttle
position to start. Operate boiler until the system
water temperature reaches its normal operating
range.
Adjust the valves to maintain 180°F to 200°F boiler
water temperature and greater than !50°F return
temperature. Adjust both valves simultaneously.
Closing the boiler return valve while opening
the by-pass valve will raise the boiler return
temperature. Opening the boiler return valve while
closing the by-pass valve will lower the boiler return
temperature.
16

SYSTEM RETURN ..........\
THERMOMETER \
RETURN _
VALVE
PURGE ........
VALVE .\.
BOILER RETURN _ 1_-,
THERMOMETER \,
\\\\
AIR VENT
SHUT-OFF
VALVE
\
PRESSURE _-...
RELIEF "----
VALVE
PIPE WITHIN 6" _ I _
o_oo_o_-- 1"1
SYSTEM RETURN ' 1_
DRAIN_
VALVE
FROM ADDITIONAL ZONES
_]_ _ FROM ZONE 2
_1_:_ _ FROM ZONE 1
i
SHUT-OFF
VALVES
%
18" MiN.
(IF CONVENTIONAL I
AIR SCOOP iS USED)
SUPPLY
VALVE
1TANK
-SYSTEM BYPASS
(SEE NOTE 2)
z BYPASS
VALVE
AIR VENT
SCOOP
TO 'LINK SL' TO
WATER HEATER ZONE 1
(IF USED)
VALVE
PRESSURE SHUT-OFF CHECK VALVE
REDUCING VALVE (IF REQUIRED)
VALVE
TO
ZONE2
t
_ FROM ADD'TL
BYPASSES
(_ CIRCULATOR
REDUCER
?
--IIID_
TO
ADDITIONAL
ZONES
T
NOTES:
1. FOR SINGLE ZONE HEATING ONLY SYSTEMS,
OMIT FLOW CONTROL VALVE.
2. SIZE SYSTEM BYPASS FOR THE HEAT LOAD
OF THE ZONES.
\\ \\ COLD W'ATE R
SUPPLY
m_
_4
F_ure 7A: Recommended Water _ for Circulator Zoned Heatin_stems

oo
AIR VENT
SYSTEM RETURN _ \
THERMOMETER _ \\\
RETURN VALVE
11
BOILER RETURN ..............\
THERMOMETER \
SHUT-OFF VALVE
PRESSURE .....
RELIEF ..........-
VALVE %'1
PIPE WITHIN 6"
OF FLOOR OR
DRAIN
SYSTEM RETURN 1 141
DRAIN
VALVE
FROM ADDITIONAL ZONES
_____41F_> _ _ FROM ZONE 2
SHUT-OFF
VALVES
FROM ZONE 1
j SYSTEM BYPASS
/
)_ (SEE NOTE 2)
PURGE
VALVE
11
AIR VENT
//
// ,,'J...........AIR SCOOP
18" MIN. _ /J//
(IF CONVENTIONAL I // /
AIR SCOOP IS USED) [_.///
11
SUPPLY
_ VALVE
t1®_1
11 SYSTEM
CIRCULATOR
&
PRESSURE
REDUCING
VALVE
TO 'LINK SL' TO
WATER HEATER ZONE 1
(IF USED)
TO
ZONE2
7
D
YPASS
2VALVEi-
T
[]
BALANCING VALVE
ZONE VALVE
REDUCER
TO
ADDITIONAL
ZONES
SHUT-OFF CHE -.
VALVE (IF REQUIRED) _ \\\\ " COLD WATER
SUPPLY
Lf o oj,
NOTES:
1. CHECK ZONE VALVE MANUFACTURER'S INSTRUCTIONS
PRIOR TO INSTALLATION. SOME ZONE VALVES DO NOT
WORK IN THE VERTICAL POSITION AS SHOWN.
2. SIZE SYSTEM BYPASS FOR THE HEAT LOAD OF
THEZONES.
F_jgure 7B: Recommended Water _ for Zone Valve Zoned Heating_S_ystems

Fi=E=_ure 8: Recommended _ for Combination Heating and Coolin_qeration) System
The use of alow water cut-off device, while not
required unless radiation level is below the boiler,
is highly recommended.
Ifa low water cut-off is required, it must be
mounted in the system piping above the boiler. The
mininmm safe water level of a hot water boiler is
just above the highest water containing cavity of
the boiler; that is, a hot water boiler nmst be full of
water to operate safely.
5. If it is required to perform a long term pressure
test of the hydronic system, the boiler should first
be isolated to avoid a pressure loss due to the escape
of air trapped must first be removed from the boiler.
To perform a long term pressure test including the
boilec ALL trapped air must first be removed from
the boiler.
A loss of pressure during such a test, with no visible
water leakage, is an indication that the boiler
contained trapped air.
19

SECTION IV: INDIRECT WATER HEATER PIPING
A° CONNECT an Link SLTM WATER HEATER
PIPING as shown in Figures 9A and 9B.
Also refer to Figures 7A and 7B.
1. Refer to Link SLTM instructions for additional
information.
gR{:)N?
[_(alL/:R "
gYNFF#P
R£ rUNN
RSAR OF
j,'f
F=_ure 9A: Link SL TM Water Heater Pi in w/Su I • Side Circulator
on Circulator Zoned Heatin_LSvSstem
?X_SSS',J
F=igure9B: Link SL TM Water Heater Pipin_ Side Circulator on Zone Valve Zoned Heatino___gSstem
20