New Yorker CL3-105 Service manual

INSTALLATION, OPERATING
AND SERVICE INSTRUCTIONS
CL™ SERIES
CAST IRON OIL-FIRED BOILER
103876-03 - 11/13 Price - $5.00
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As an
ENERGY
STAR®Partner,
New Yorker Boiler Co., Inc.
has determined that the
CL3-091, CL3-105, CL4-126
and CL5-168 water boilers
meet the ENERGY STAR®
guidelines for Energy
efciency established by the
United States Environmental
Protection Agency (EPA).
9700609

2
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.
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.
IMPORTANT INFORMATION - READ CAREFULLY
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.
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:
DANGER
Indicates an imminently hazardous situation
which, if not avoided, will 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.
NOTICE
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.

3
DANGER
DO NOT store or use gasoline or other ammable vapors or liquids in the vicinity of this or any other boiler.
WARNING
Improper installation, 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 boiler before installing, starting-up, operating, maintaining or servicing
this boiler. Keep this manual and literature in legible condition and posted near boiler 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 tapping located on top left
corner of front section- Refer to Figures 1A thru 1D and Section III "Installation Instructions" for additional
details.
It is the responsibility of the installing contractor to see that all controls are correctly installed and are
operating properly when installation is complete including verifying that the limit sensor is fully installed
(seated in bottom of Well).
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 ooring. DO NOT install boiler on carpeting.
DO NOT tamper with or alter the boiler or controls.
Inspect ueways at least once a year - preferably at the start of the heating season. The inside of
the combustion chamber, the vent system and boiler ueways should be cleaned if soot or scale has
accumulated.
When cleaning this boiler, DO NOT damage combustion chamber liner and/or rear target wall. If damaged,
combustion chamber 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 boiler with jumpered or absent controls or safety devices.
DO NOT operate boiler if any control, switch, component, or device has been subject to water.
Boiler 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 boiler.

4
TABLE OF CONTENTS
I. General Information ................................... 5
II. Pre-Installation ......................................... 10
III. Installation Instructions........................... 12
IV. Electrical ................................................... 24
V. System Start-Up ....................................... 30
VI. Operating .................................................. 37
VII. Maintenance & Service Instructions. .... 42
VIII. Boiler Cleaning........................................ 45
IX. Trouble Shooting..................................... 48
X. Repair Parts.............................................51
XI. Burner Specications.............................58
Appendix A - Low Water Cut-Off..........60
WARNING
This boiler contains very hot water under 12 - 15 PSI pressure. DO NOT unscrew any pipe ttings 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.
High water temperatures increase the risk of scalding injury. If this boiler is equipped with a tankless
heater for domestic water supply, a ow regulator and automatic mixing valve must be installed properly
in tankless heater piping. Refer to Section III "Installation Instructions" for additional details.
This boiler needs fresh air for safe operation and must be installed so there are provisions for adequate
combustion and ventilation air.
This boiler must be connected to an approved chimney or vent system in good condition. Serious
property damage could result if the boiler is connected to a dirty or inadequate chimney or vent system.
The interior of the chimney ue must be inspected and cleaned before the start of the heating season for
any obstructions. A clean and unobstructed chimney ue is necessary to allow noxious fumes that could
cause injury or loss of life to vent safely and will contribute toward maintaining the boiler's efciency.
DO NOT operate boiler with the absence of an approved vent system.
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. 2 fuel 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 ammable debris, rags,
paper, wood scraps, etc., should be kept clear of the boiler at all times. Keep the boiler area clean and
free of re 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 ring of burner outside the combustion chamber. Be sure to tighten swing
door fastener completely when service is completed.

5
Figure 1A: CL3 Thru CL5 Water Boiler without Tankless Heater, All Burner Options
Figure 1B: CL3 Thru CL5 Water Boiler With Tankless Heater, All Burner Options
I: GENERAL INFORMATION
'B'
'C'
DIA.

6
Figure 1C: CL3 Thru CL5 Steam Boiler with or without Tankless Heater,
McDonnell & Miller PS-801, Beckett Burner
Figure 1D: CL3 thru CL5 Steam Boiler with or without Tankless Heater,
McDonnell & Miller PS-801, Riello Burner
I: GENERAL INFORMATION (continued)
'A'
'B'
'C'
DIA.

7
TABLE 1: DIMENSIONAL DATA / GENERAL INFORMATION (SEE FIGURES 1A THRU 1D)
Boiler Model Dimensions Approx. Water Content
- Gallons
Heat Transfer Surface
Area - Sq. Ft.
"A" "B" "C"
CL3 17-3/8" 8-1/4" 5-7/8" 16 14.33
CL4 22-3/8" 10-7/8" 6-7/8" 20 20.90
CL5 27-3/8" 13-3/8" 7-7/8" 24 27.46
Maximum Working Pressure: Steam: 15 PSI; Water: 30 PSI Shipped Standard from Factory, 50 PSI Optional
I: GENERAL INFORMATION (continued)
TABLE 2: RATING DATA
Boiler Model
No. *
Burner
Capacity
DOE Heating
Capacity AHRI NET Ratings Minimum Chimney Requirements AFUE %
GPH MBH Water
MBH
Steam
MBH
Water
MBH
Steam
MBH
Steam
Sq. Ft.
Round
In. Dia.
Rectangle
In. x In.
Height
Ft. Water Steam
CL3-091(W) 0.65 91 80 --- 70 --- --- 6 8 x 8 15 86.1 ---
CL3-091(S) 0.65 91 --- 78 --- 56 233 6 8 x 8 15 --- 84.1
CL3-105(W) 0.75 105 91 --- 79 --- --- 6 8 x 8 15 86.0 ---
CL3-105(S) 0.75 105 --- 90 --- 68 283 6 8 x 8 15 --- 83.8
CL3-140(W) 1.00 140 120 --- 104 --- --- 6 8 x 8 15 84.3 ---
CL3-140(S) 1.00 140 --- 119 --- 89 370 6 8 x 8 15 --- 82.7
CL4-126(W) 0.90 126 111 --- 97 --- --- 7 8 x 8 15 86.0 ---
CL4-126(S) 0.90 126 --- 108 --- 81 338 7 8 x 8 15 --- 84.1
CL4-175(W) 1.25 175 152 --- 132 --- --- 7 8 x 8 15 85.1 ---
CL4-175(S) 1.25 175 --- 149 --- 112 467 7 8 x 8 15 --- 83.5
CL4-210(W) 1.50 210 179 --- 156 --- --- 7 8 x 8 15 84.0 ---
CL4-210(S) 1.50 210 --- 177 --- 133 554 7 8 x 8 15 --- 82.6
CL5-168(W) 1.20 168 147 --- 128 --- --- 8 8 x 8 15 85.9 ---
CL5-168(S) 1.20 168 --- 144 --- 108 450 8 8 x 8 15 --- 83.7
CL5-245(W) 1.75 245 210 --- 183 --- --- 8 8 x 8 15 85.1 ---
CL5-245(S) 1.75 245 --- 207 --- 155 646 8 8 x 8 15 --- 82.5
CL5-280(W) 2.00 280 238 --- 207 --- --- 8 8 x 8 15 84.7 ---
CL5-280(S) 2.00 280 --- 235 --- 176 733 8 8 x 8 15 --- 82.3
* Boiler Model Sufx: (W) = Water, (S) = Steam

8
Tapping
Location
Size,
NPT
Purpose
Less Heater With Heater
A 1½” Return
B ½” Limit Well Plug
C ¼” Temperature/Pressure
Gauge
D 1½” Supply
E 1½” Optional Return
F ¾” Relief Valve
G ¾” N/A DHW Outlet
H ¾” N/A Limit Well
I ¾” N/A DHW Inlet
TABLE 3A: PURPOSE OF TAPPINGS (WATER)
I: GENERAL INFORMATION (continued)
Figure 2A: Purpose of Tappings (Water)

9
Figure 2B: Purpose of Tappings (Steam)
TABLE 3B: PURPOSE OF TAPPINGS (STEAM)
Tapping
Location
Size,
NPT
Purpose
Less Heater With Heater
A 1½” Return
B ½” Pressure Limit
C ¼” Pressure Gauge
D 3” Supply
E 1½” Optional Return
F ¾” Relief Valve
G ¾” N/A DHW Outlet
H ¾” N/A Limit Well
I ¾” N/A DHW Inlet
J ¾” Drain
K ¾” LWCO
L ½” Water Gauge Glass
M ½” Water Gauge Glass
N 1” Indirect Water Heater Supply
O ½” Indirect Water Heater Limit
P 1½” Surface Blowoff
I: GENERAL INFORMATION (continued)

10
Figure 3: Minimum Installation Clearances To Combustible Materials (Inches)
NOTE 1: Listed clearances comply with American National
Standard NFPA 31, Standard for the Installation of Oil
Burning Equipment.
NOTE 2: CL Series boilers can be installed in rooms with
clearances from combustible material as listed above.
Listed clearances cannot be reduced for alcove or closet
installations.
NOTE 3: For reduced clearances to combustible material,
protection must be provided as described in the ANSI/NFPA
31 standard.
C
A
Above
B
Front
Chimney
Connector
D
Rear
E
Sides
6 24 18 6 6
4. PROVIDE SERVICE CLEARANCE of at least
24” clearance from front jacket panel for servicing
and removal of front tankless heater. If boiler is
equipped with a rear tankless heater, provide at
least 24" service clearance on the right side of the
boiler. Boiler ueways may be cleaned either from
the top or from the right side. Provide at least 24"
clearance from either the right side of the boiler or
the top of the boiler for cleaning ueways.
5. For minimum clearances to combustible materials.
See Figure 3.
NOTICE
Clearance to venting is for single wall vent
pipe. If Type L vent 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.
A. INSPECT SHIPMENT carefully for any signs of
damage.
1. All equipment is carefully manufactured, inspected
and packed. Our responsibility ceases upon delivery
of crated boiler to the carrier in good condition.
2. Any claims for damage or shortage in shipment
must be led immediately 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.
B. LOCATE BOILER near nal position before removing
crate. See Figures 1A thru 1D. Using hand truck or
pipe rollers under skid, move boiler into position along
side installation site.
1. LOCATE so that vent pipe connection to chimney
will be short and direct.
2. BOILER IS SUITABLE FOR INSTALLATION
ON COMBUSTIBLE FLOOR. Boiler cannot be
installed on carpeting.
3. FOR BASEMENT INSTALLATION, provide
a solid elevated base, such as concrete, if oor is
not level, or if water may be encountered on oor
around boiler.
II: PRE-INSTALLATION

11
II: PRE-INSTALLATION (continued)
WARNING
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
ammable 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
communicating directly with the space in which
the appliances are installed, through openings not
furnished with doors, are considered a part of the
space.
Volume(ft3) = 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 ft3/1000 BTU per hour,
then it is considered an unconned space. If the
result is less than 50 ft3/1000 BTU per hour then the
space is considered a conned space.
4. For boiler located in an unconned space of a
conventionally constructed building, the fresh
air inltration through cracks around windows
and doors normally provides adequate air for
combustion and ventilation.
5. For boiler located in a conned space or an
unconned space in a building of unusually tight
construction, provide outdoor air.
Outdoor air may be provided with the use of 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.
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 xed in the open
position, or interlocked with the equipment to
open automatically during equipment operation.

12
III: INSTALLATION INSTRUCTIONS
A. REMOVE CRATE
1. Remove all fasteners at crate skid.
2. Lift outside container and remove all other
inside protective spacers and bracing. Remove
miscellaneous steam or water trim carton.
B. REMOVAL OF BOILER FROM SKID
1. Boiler is secured to base with 4 carriage bolts, 2 on
left side and 2 on right side. See Figure 4. Remove
all bolts.
models, attached to the burner. Select the proper oil
nozzle for the installation. The lower input nozzle
will provide greater boiler efciency. However,
boiler output will be reduced. Refer to Table 2 for
ring rates. If the higher rate is desired, inspect
the installed nozzle and assure that the nozzle is
the correct size and type as specied in Burner
Specications, Tables 14A and 14B (at the rear of
this manual).
If a lower input is desired, remove the nozzle
which was factory installed. Locate the lower
ring rate nozzle that is supplied loose. Conrm
the nozzle is the proper size and type for the lower
ring rate as specied in Tables 14A and 14B (at the
rear of this manual). Install the proper nozzle in the
burner nozzle adaptor.
2. ON THE BECKETT AFG BURNER, use the
following procedure to complete the inspection,
check the settings and to change the nozzle to a
lower ring rate:
a. Loosen two (2) igniter latching screws, rotate
tabs and swing open igniter about hinge.
b. Loosen knurled nut and disconnect copper
connector tube.
c. Remove nozzle line electrode assembly.
d. If high ring rate is desired, conrm the nozzle
is the proper size and type, refer to Table 14A
(at rear of this manual), then proceed to Item i.
below.
e. If a lower input is desired, remove the nozzle
that was factory installed.
f. Remove Beckett MB(L1) or MD(V1) head.
g. Locate the desired nozzle. Refer to Table 14A
(at rear of this manual) for proper nozzle. The
nozzle must be securely installed to assure leak
free joints between the nozzle and adapter.
When installing the nozzle, be careful not to
bump or move the burner electrodes.
Note: On the CL3-091 (0.65 GPH) burner
application, a low ring rate bafe is required.
Bafe is shipped loose with nozzles. Install
bafe per Beckett Instruction included with
bafe.
h. Reinstall Beckett MB(L1) or MD(V1) Head.
i. Inspect and measure burner electrodes. Refer
to Figure 26 for the proper electrode setting.
Readjust electrode setting to the proper
dimensions if necessary. Refer to Figure 26.
j. Reinstall nozzle line electrode assembly.
k. Connect copper connector tube.
2. Tilt boiler to right and to rear. Using right rear leg
as pivot, rotate boiler 90° in a clockwise direction,
and lower left side of boiler to oor. Tilt boiler
and remove crate skid. Care should be exercised to
prevent damage to jacket or burner.
C. MOVE BOILER TO PERMANENT POSITION by
sliding or walking.
D. INSPECT COMBUSTION TARGET WALL AND
COMBUSTION CHAMBER LINER
1. OPEN FLAME OBSERVATION DOOR AND/
OR BURNER SWING DOOR on front of boiler.
Use ashlight to inspect target wall secured to
rear section with silastic sealant. Inspect ceramic
ber blanket secured to oor of boiler with water
glass adhesive. If either is damaged they must be
replaced.
E. INSPECT NOZZLE, ELECTRODES INSERTION
DEPTH AND TURBULATOR SETTING/CHANGE
FIRING RATE:
1. PACKAGED CL™ SERIES BOILERS are
shipped with the highest input oil nozzle installed
in the burner. Oil nozzles for lower ring rates
are shipped loose for the CL3-091 and CL4-175
Figure 4: Removal of Boiler From Skid

13
ii. Remove existing nozzle from nozzle adapter.
iii. Insert the proper NOZZLE into NOZZLE
ADAPTER and tighten securely (DO NOT
cover tighten), refer to Table 14B (at rear of
this manual).
iv. Replace adapter, with nozzle installed, into
drawer assembly and secure with screw (1).
c. Inspect and measure burner electrodes. Refer
to Figure 7 for the proper electrode settings.
d. Re-install Drawer Assembly into Combustion
Head per Step 3a above.
e. Insertion Depth, verify the distance between
the tip of the end cone is equal to the distance
specied in Table 14B (at rear of this manual).
f. Turbulator Setting, refer to Figure 8.
Figure 6: Riello Nozzle Replacement
III: INSTALLATION INSTRUCTIONS (continued)
Figure 5: Installation/Removal of
Riello Drawer Assembly
Figure 7: Riello Electrode Setting
Figure 8: Riello Turbulator Setting
l. Inspect Beckett head setting on left side of
burner by insuring the line on the label MB(L1)
or the blue line MD(V1) are aligned, readjust if
necessary. Refer to Figure 26.
m. Tighten knurled nut.
n. Swing igniter closed, rotate tabs and tighten two
(2) igniter screws.
3. ON THE RIELLO 40 SERIES OIL BURNER, use
the following procedure to complete the inspection,
check the settings and to change the nozzle to a
lower ring rate: Refer also to Model F3 & F5
Installation Manual, Riello 40 Series Residential
Oil Burners (C6501010) or Model F10 Installation
Manual, Riello 40 Series Residential Oil Burners
No. 2902554.
a. Installation/Removal of Drawer Assembly,
refer to Figure 5.
i. Removal:
• Disconnect oil delivery tube nut from
pump.
• Loosen SCREW (3), and then unplug
PRIMARY CONTROL (1) by carefully
pulling it back and then up.
• Remove the AIR TUBE COVER
PLATE (5) by loosening the retaining
SCREW (4) (Two SCREWS-Model F5).
• Loosen SCREW (2), and then slide the
complete drawer assembly out of the
combustion head as shown.
ii. Installation:
To insert drawer assembly, reverse the
procedure in Step i above.
b. Nozzle Replacement, refer to Figure 6.
i. Remove the NOZZLE ADAPTER (2) from
the DRAWER ASSEMBLY by loosening
the SCREW (1).

14
g. Pump Connections and Port Identication,
refer to Figure 9.
This burner is shipped with the oil pump set
to operate on a single line system. To operate
on a two-line system the bypass plug must be
installed.
WARNING: DO NOT operate a single
line system with the by-pass plug installed.
Operating a single line system with the by-pass
plug installed will result in damage to the pump
shaft seal.
Note: Pump pressure was factory pre-set but
must be checked at time of burner start-up. A
pressure gauge is attached to the PRESSURE/
BLEEDER PORT (7) for pressure readings.
Two PIPE CONNECTORS (4) are supplied
with the burner for connection to either a single
or two-line system. Also supplied are two
ADAPTORS (3), two female ¼” NPT to adapt
oil lines to burner pipe connectors. All pump
port threads are British Parallel Thread design.
Direct connection of NPT threads to the pump
will damage the pump body.
Riello manometers and vacuum gauges DO
NOT require any adapters, and can be safely
connected to the pump ports. An NPT x metric
adapter must be used when connecting other
gauge models.
h. Replace Burner Cover and Tighten Burner
Cover Screws.
F. INSTALL WATER BOILER TRIM AND CONTROLS,
(see Figures 1A and 1B)
1. Install return piping supplied with boiler. Apply
Teon or Sealant to all joints prior to assembly.
Thread 1½" NPT x 5" Lg. return nipple into 1½"
NPT tapping located in lower left corner of front
section. Thread 1½" x ¾" x 1½" NPT tee onto
5" nipple. Thread ¾" drain valve into ¾" NPT
connection on tee. Tighten all joints with wrench
Figure 9: Riello Pump Connections and Port Identication
until water tight and 1½" NPT return connection on
tee is facing away from boiler horizontally to allow
for proper burner swing door clearance, see Figures
1A, 1B, 11A and 11B.
Note: Vertical piping will prevent door from opening
fully for service and cleaning of boiler.
2. Thread relief valve onto factory installed ¾" NPT
x 7¼" nipple located in left rear corner on top
of boiler as shown in Figures 1A and 1B. Valve
spindle must be in vertical position. Tighten with
wrench. Pipe discharge as shown in Figures 11A
and 11B. Installation of the relief valve must be
consistent with ANSI/ASME Boiler and Pressure
Vessel Code, Section IV.
3. Connect Field Wiring
Connect the eld wiring to the Warm or Cold Start
Intelligent Oil Boiler Control (Boiler Control).
Make the wiring connections as shown in Figures 20
and 21.
a. On water boilers without rear tankless heater,
connect the eld wiring from the circulator to
the Cold Start Boiler Control and from the Cold
Start Boiler Control to the Burner Oil Primary
Control. Make the wiring connections as shown
on Figure 20.
Figure 10: Limit Sensor Insertion
III: INSTALLATION INSTRUCTIONS (continued)

15
b. On water boilers with rear tankless heater, the
factory wired Warm Start Boiler Control was not
installed in heater. Locate 3/4" NPT immersion
well, apply sealant, thread into 3/4" NPT tapping
on tankless heater and tighten with wrench.
Apply heat transfer paste (not furnished) to
limit sensor and fully insert limit sensor into
immersion well such that the tip on the limit
sensor touches the bottom of the immersion well.
See Figure 10. Tighten clamp screws to secure
Warm Start Boiler Control to immersion well.
Secure Boiler Control conduit to jacket right
side panel with 5/8" cable clamp provided, refer
to Figure 1B. Make the wiring connections as
shown on Figure 21.
G. INSTALL STEAM BOILER TRIM AND CONTROLS,
(see Figures 1C and 1D).
1. Thread ¾" MPT safety valve and ¾" NPT coupling
onto factory installed ¾" NPT x 7¼" nipple located
in left rear corner on top of boiler as shown in
Figures 1C and 1D. Tighten with wrench. Pipe
discharge as shown in Figure 12. Installation of the
relief valve must be consistent with ANSI/ASME
Boiler and Pressure Vessel Code, Section IV.
2. Install ¾" drain valve in wet return piping as shown
in Figure 12.
3. On boilers with rear tankless heater, factory wired
L4006A Aquastat Heater Control was not installed
in heater. Locate ¾" NPT Immersion Well, apply
sealant and thread into ¾" NPT tapping on heater.
Apply heat transfer paste (not furnished) to control
bulb and insert bulb into immersion well. Tighten
clamping screws to secure Boiler Control to
immersion well. Secure 18/2 Control Cable Wire
to jacket right side panel with 5/16" cable clamp
provided, refer to Figure 1C.
4. CONNECT FIELD WIRING
a. Connect the eld wiring to the pressure limit,
the R8239C Control Center, the LWCO and the
burner or primary control. If equipped with
tankless heater, connect eld wiring from the
Aquastat Control to the Oil Primary Control
"TT" terminals (Beckett Burner) or the R8239C
Control Center's "R-G" terminals (Riello
Burner). Make the wiring connections as shown
in Figure 22 or 23.
Note:
• The GeniSys 7505 Oil Primary Control has
pre-installed "T-T" jumper. To activate "T-T"
terminals, "T-T" jumper must be removed.
• DO NOT remove "T-T" jumper unless wiring
diagram indicates a direct connection from
III: INSTALLATION INSTRUCTIONS (continued)
thermostat and/or tankless heater aquastat
control to the oil burner primary control's "T-T"
terminal. Refer to Figures 22 and 23.
H. CONNECT SUPPLY AND RETURN PIPING TO
HEATING SYSTEM.
1. CLEARANCES — Steam and hot water pipes shall
have clearances of at least ½” from all combustible
construction.
2. WATER BOILER
a. For Forced Circulation HOT WATER HEATING.
See Figures 11A and 11B. Consult I=B=R,
"Residential Hydronic Heating Installation and
Design Guide".
b. Use a boiler water bypass if the boiler is to be
operated in a system which has a large volume
or excessive radiation where low boiler water
temperature may be encountered (i.e. converted
gravity circulation system, etc.).
Install a pipe tee in the boiler return piping along
with a second tee in the supply piping as shown
in Figures 11A and 11B. The bypass should
be the same size as the supply and return lines.
Locate valves in the bypass and supply outlet as
illustrated in Figures 11A and 11B for regulation
of water ow to maintain higher boiler water
temperature.
Set the by-pass and boiler supply valves to a half
throttle position to start. Operate boiler until the
system water temperature is a normal operating
range.
Adjust the valves to provide 180° to 200°F
supply water temperature. Opening the boiler
supply valves will raise the system temperature,
while opening the bypass valve will lower the
system supply temperature.
c. 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 ow control valves to prevent
gravity circulation of boiler water during the
operation of the cooling system.
d. 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 13. Also, consult I=B=R,
"Residential Hydronic Heating Installation and
Design Guide".
e. A hot water boiler installed above radiation level
must be provided with a low water cutoff device
as part of the installation. See Appendix A, Low
Water Cut-Off for additional details.

16
Figure 11A: Recommended Water Piping for Circulator Zoned Heating System - Supply Side Circulator
III: INSTALLATION INSTRUCTIONS (continued)

17
Figure 11B: Recommended Water Piping for Zone Valve Zoned Heating System - Supply Side Circulator
III: INSTALLATION INSTRUCTIONS (continued)

18
III: INSTALLATION INSTRUCTIONS (continued)
Figure 12: Recommended Boiler Piping for Gravity Return Steam Boiler

19
3. STEAM BOILER
a. For Recommended STEAM BOILER PIPING
refer to Figure 12. Also, consult I=B=R,
"Residential Hydronic Heating Installation and
Design Guide".
b. Evaluate the Existing Steam System.
The single most important factor in determining
the expected life cycle of a steam boiler, is
the amount of fresh water added to the boiler
during operation. Fresh water brings minerals
and oxygen into the boiler. These contaminants
greatly accelerate corrosion of the cast iron
boiler sections.
i. Assure that all system radiators, piping and
vents are absolutely leak tight.
• When a steam boiler is installed in an
existing system, ALL air vents should be
replaced at the same time. This assures
that the new boiler will not be
compromised by existing system leaks.
• If the system contains hidden supply or
return piping (hidden behind walls, buried
in concrete, etc.) pressure test this piping
to assure there are no leaks.
ii. Repair any leaks in the system.
iii. Install accurate water meter on the fresh
water supply to the boiler.
NOTICE
DO NOT use softened water in steam boilers.
Accelerated boiler corrosion will result. Tie in
fresh water supply to the boiler upstream of a
water softener.
4. OXYGEN CONTAMINATION:
a. There are many possible causes of oxygen
contamination such as:
i. Addition of excessive make-up water as a
result of system leaks.
ii. Absorption through open tanks and ttings.
iii. Oxygen permeable materials in the
distribution system.
b. In order to insure long product life, oxygen
sources should be eliminated. This can be
accomplished by taking the following measures:
i. Repairing system leaks to eliminate the need
for addition of make-up water.
ii. Eliminating open tanks from the system.
iii. Eliminating and/or repairing ttings which
allow oxygen absorption.
iv. Use of non-permeable materials in the
distribution system.
v. Isolating the boiler from the system water by
installing a heat exchanger.
See Section VII, Paragraph B, Step 3 for additional
details.
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.
III: INSTALLATION INSTRUCTIONS (continued)
Figure 13: Recommended Piping for Combination
Heating & Cooling (Refrigeration) Systems

20
CAUTION
Oxygen contamination of the boiler water
will cause corrosion of iron and steel boiler
components, and can lead to boiler failure. New
Yorker's Standard Warranty does not cover
problems caused by oxygen contamination of
boiler water or scale (lime) build-up caused by
frequent addition of water.
I. CONNECT TANKLESS HEATER PIPING AS
SHOWN IN Figure 14. See Table 4 for Tankless Heater
Ratings.
THE FOLLOWING GUIDELINES SHOULD BE
FOLLOWED WHEN PIPING THE TANKLESS HEATER:
1. FLOW REGULATION — If ow through the heater
is greater than its rating, the supply of adequate hot
water may not be able to keep up with the demand.
For this reason a ow regulator matching the heater
rating should be installed in the cold water line to
the heater. The ow regulator should preferably be
located below the inlet to the heater and a minimum
Boiler
Model
Rating (Gal/Min) Pressure Drop (PSI)
Steam Water Steam Water
CL3-091 2.25 2.75 2.3 3.9
CL3-105 2.25 3.00 2.3 4.7
CL3-140 2.50 3.25 3.1 5.6
CL4-126 2.50 3.25 3.1 5.6
CL4-175 2.75 3.75 3.9 7.2
CL4-210 3.00 4.00 4.7 8.0
CL5-168 2.75 3.50 3.9 6.4
CL5-245 3.25 4.25 5.6 8.8
CL5-280 3.50 4.75 6.4 9.6
TABLE 4: TANKLESS HEATER DATA
III: INSTALLATION INSTRUCTIONS (continued)
Figure 14: Schematic Tankless Heater Piping
of 3’ away from the inlet so that the regulator is not
subjected to excess temperatures that may occur
during “off” periods when it is possible for heat
to be conducted back through the supply line. The
ow regulator also limits the ow of supply water
regardless of inlet pressure variations in the range of
20 to 125 psi.
2. TEMPERING OF HOT WATER — Installation
of an automatic mixing valve will lengthen the
delivery of the available hot water by mixing some
cold water with the hot. This prevents excessive
and possibly scalding hot water at the xtures. In
addition, savings of hot water will be achieved since
the user will not waste as much hot water while
seeking water temperature to his liking. Higher
temperature hot water required by dishwashers and
automatic washers is possible by piping the hot
water from the heater prior to entering the mixing
valve. The mixing valve should be “trapped” by
installing it below the cold water inlet to heater to
prevent lime formation in the valve.
WARNING
Install automatic mixing valve at tankless heater
outlet to avoid risk of burns or scalding due to
excessively hot water at xtures. Adjust and
maintain the mixing valve in accordance with the
manufacturer's instructions.
3. FLUSHING OF HEATER — All water contains
some sediment which settles on the inside of the
coil. Consequently, the heater should be periodically
backwashed. This is accomplished by installing
hose bibs as illustrated and allowing water at city
pressure to run into hose bib A, through the heater,
and out hose bib B until the discharge is clear. The
tees in which the hose bibs are located should be
the same size as heater connections to minimize
pressure drop.
4. HARD WATER — A water analysis is necessary to
determine the hardness of your potable water. This
is applicable to some city water and particularly to
well water. An appropriate water softener should
be installed based on the analysis and dealer’s
recommendation. This is not only benecial to the
tankless heater but to piping and xtures plus the
many other benets derived from soft water.
J. INDIRECT WATER HEATER PIPING
1.CONNECT Indirect Water Heater Piping as
shown in Figures 11A and 11B for water boilers
and Figures 12 and 15 for steam boilers. Refer
to Indirect Water Heater Instruction Manual for
additional installation information.