New Yorker CLS SERIES Service manual
INSTALLATION, OPERATING
AND SERVICE INSTRUCTIONS
CLS SERIES
CAST IRON OIL-FIRED BOILER
nonoitamrofnignikeesnehW.rotcartnocgnitaehruoyllac,reliobotsriaperroecivresroF
.lebaLgnitaRnonwohssarebmuNlaireSdnarebmuNledoMrelioBedivorp,reliob
rebmuNledoMrelioB rebmuNlaireSrelioB etaDnoitallatsnI
___P-_-SLC _______6
rotcartnoCgnitaeH rebmuNenohP
sserddA
M24350R6-11/09 Price - $3.00
2
IMPORTANT INFORMATION - PLEASE READ THIS PAGE CAREFULLY
1. THIS BOILER HAS LIMITED WARRANTIES, COPIES OF WHICH ARE PRINTED ON THE BACK COVER OF THIS
MANUAL.
2. THIS BOILER IS SUITABLE FOR INSTALLATION ON COMBUSTIBLE FLOORING. BOILER CANNOT BE IN-
STALLED ON CARPETING.
3. ALL BOILERS MUST BE INSTALLED IN ACCORDANCE WITH NATIONAL, STATE AND LOCAL PLUMBING,
HEATING AND ELECTRICAL CODES AND THE REGULATIONS OF THE SERVING UTILITIES WHICH MAY DIF-
FER FROM THIS MANUAL. AUTHORITIES HAVING JURISDICTION SHOULD BE CONSULTED BEFORE INSTAL-
LATIONS ARE MADE.
IN ALL CASES, REFERENCE SHOULD BE MADE TO THE FOLLOWING STANDARDS:
A. Current Edition of American National Standard ANSI/NFPA 31, “Installation of Oil Burning Equipment”, for clearances between boiler, vent connector and
combustible material.
B. Current Edition of American National Standard ANSI/NFPA 211, “Chimneys, Fireplaces, Vents, and Solid Fuel Burning Appliances”, For Chimney require-
ments, type of venting material and clearances between vent connector pipe and combustible materials.
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.
4. ALL HEATING SYSTEMS SHOULD BE DESIGNED BY COMPETENT CONTRACTORS AND ONLY PERSONS
KNOWLEDGEABLE IN THE LAYOUT AND INSTALLATION OF HYDRONIC HEATING SYSTEMS SHOULD AT-
TEMPT INSTALLATION OF ANY BOILER.
5. THE BOILER MUST BE CONNECTED TO AN APPROVED CHIMNEY IN GOOD CONDITION. SERIOUS PROP-
ERTY DAMAGE COULD RESULT IF THE BOILER IS CONNECTED TO A DIRTY OR INADEQUATE CHIMNEY.
THE INTERIOR OF THE CHIMNEY FLUE MUST BE INSPECTED AND CLEANED BEFORE THE START OF THE
HEATING SEASON AND SHOULD BE INSPECTED PERIODICALLY THROUGHOUT THE HEATING SEASON FOR
ANY OBSTRUCTIONS. A CLEAN AND UNOBSTRUCTED CHIMNEY FLUE 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 EFFICIENCY.
6. READ THE LITERATURE ENCLOSED BY THE MANUFACTURER WITH THE VARIOUS ACCESSORY DEVICES.
THESE ACCESSORY DEVICES MUST BE INSTALLED AND USED ACCORDING TO THE RECOMMENDATIONS OF
THE MANUFACTURER.
7. IT IS THE RESPONSIBILITY OF THE INSTALLING CONTRACTOR TO SEE THAT ALL CONTROLS ARE CORRECT-
LY INSTALLED AND ARE OPERATING PROPERLY WHEN THE INSTALLATION IS COMPLETED.
8. FOR OPTIMUM PERFORMANCE AND SERVICEABILITY FROM THIS BOILER ADHERE TO THE FOLLOWING
RECOMMENDATIONS:
A. DO NOT TAMPER WITH THE BOILER OR CONTROLS. Retain your contractor or a competent serviceman to assure that the boiler is properly adjusted
and maintained.
B. Haveuewayscleanedatleastonceayear-preferablyattheendoftheheatingseasontoremovesootandscale.Insideofreboxshouldalsobecleanedat
the same time.
C. Have oil burner and controls checked at least once a year or as may be necessitated.
WARNING
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) or
WARNING
3
Table of Contents
I. General Information.............................3
II. Installation Instructions .......................5
III. Operating & Service Instructions .......11
IV. Boiler Cleaning ..................................18
V. Repair Parts........................................20
Figure 1: CLS Line Drawing
TABLE 1: DIMENSIONAL DATA
WARNING
and posted near oil boiler for reference by owner and service technician.
Boiler
Model
Dimensions Minimum Chimney Size Water
Content -
Gallons
Heat Transfer
Surface Area -
Sq. Ft.
"A" "B" "C" "D" Rectangular Round
CLS-3 15-3/8" 8-3/8" --- 5-7/8" 8" x 8" x 15' 6" x 15' 10.8 14.0
CLS-4 19-3/8" 10-3/8" --- 5-7/8" 8" x 8" x 15' 6" x 15' 12.5 19.6
CLS-5 23-3/8" 12-3/8" --- 6-7/8" 8" x 8" x 15' 7" x 15' 14.3 25.3
CLS-6 27-3/8" 14-3/8" 21" 6-7/8" 8" x 8" x 15' 7" x 15' 16.0 31.0
CLS-7 31-3/8" 16-3/8" 25" 7-7/8" 8" x 8" x 15' 8" x 15' 17.8 36.7
CLS-8 35-3/8" 18-3/8" 29" 7-7/8" 8" x 12" x 15' 8" x 15" 19.6 42.4
Maximum Working Pressure: 15 PSI (Steam Only)
4
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
mustbeledimmediatelyagainstthecarrierbythe
consignee. No claims for variances from, or shortage
in orders, will be allowed by the manufacturer
unlesspresentedwithinsixty(60)daysafterreceipt
of goods.
B. LOCATEBOILERinfrontofnalpositionbefore
removing crate.
1. LOCATE so that smoke pipe connection to chimney
will be short and direct. BOILER IS SUITABLE
FOR INSTALLATION ON COMBUSTIBLE
FLOOR. Boiler cannot be installed on carpeting.
2. FOR BASEMENT INSTALLATION, provide a
solidbase,suchasconcrete,ifoorisnotlevel,or
ifwatermaybeencounteredonooraroundboiler.
3. PROVIDE SERVICE CLEARANCE of at least 24”
onrightsideofboilerforcleaninguewaysandfor
removal of rear tankless heater. Provide at least 24”
clearance from front jacket panel for servicing.
4. For minimum clearances to combustible materials.
See Figure 2.
C. PROVIDE AIR SUPPLY AND VENTILATION to
accommodate proper combustion. If natural ventilation
is inadequate, provide a screened opening or duct from
the boiler room to the outside. The opening or duct
mustbesizedsotheboilerinputwillnotexceed4,000
BTUH/Sq. In. of free area. If other air consuming
appliances are near the boiler, the air inlet should be
larger. Consult respective manufacturers.
C
A
Above
B
Front
Chimney
Connector
D
Rear
E
Sides
6 24 18 6 6
NOTE 1: Listed clearances comply with American
National Standard NFPA 31, Installation of Oil Burning
Equipment.
NOTE 2: CLS 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 mate-
rial, protection must be provided as described in the
ANSI/NFPA 31 standard.
5
II. 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 trim bag containing safety/relief
valve,andpipettings.
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. Remove all bolts.
2. Tilt boiler to right and to rear. Using right rear leg
aspivot,rotateboiler90°inaclockwisedirection,
andlowerleftsideofboilertooor.Tiltboiler
andremovecrateskid.Careshouldbeexercisedto
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.
Useashlighttoinspecttargetwallsecuredto
rear section with silastic sealant. Inspect ceramic
berblanketsecuredtooorofboilerwithwater
glass adhesive. If either is damaged they must be
replaced.
E. 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. Install Safety Valve in top ¾" tapping. Use ¾ NPT
x7"nippleand¾NPTcouplingincludedintrim
bag. Safety Valve must be installed with spindle in
vertical position.
3. OxygenContamination
CAUTION
can lead to boiler failure. New Yorker's standard
Therearemanypossiblecausesofoxygencontamination
such as:
a. Additionofexcessivemake-upwaterasaresult
of system leaks.
b. Absorptionthroughopentanksandttings.
c. Oxygenpermeablematerialsinthedistribution
system.
Inordertoinsurelongproductlife,oxygensources
should 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. Eliminatingand/orrepairingttingswhichallow
oxygenabsorption.
d. Use of non-permeable materials in the
distribution system.
e. Isolating the boiler from the system water by
installingaheatexchanger.
F. CONNECT TANKLESS HEATER PIPING AS
SHOWN IN Figure 3. See Table 2 for Tankless Heater
Ratings.
THE FOLLOWING GUIDELINES SHOULD BE FOL-
LOWED WHEN PIPING THE TANKLESS HEATER:
1. FLOWREGULATION—Ifowthroughtheheater
is greater than its rating, the supply of adequate hot
water may not be able to keep up with the demand.
NOTICE
1)
2)
3)
4)
if dielectric unions are not used.
6
Forthisreasonaowregulatormatchingtheheater
rating should be installed in the cold water line to
theheater.Theowregulatorshouldpreferablybe
located below the inlet to the heater and a minimum
of 3’ away from the inlet so that the regulator is not
subjectedtoexcesstemperaturesthatmayoccur
during “off” periods when it is possible for heat
to be conducted back through the supply line. The
owregulatoralsolimitstheowofsupplywater
regardless of inlet pressure variations in the range of
20to125psi.
2. TEMPERING OF HOT WATER — Installation
ofanautomaticmixingvalvewilllengthenthe
deliveryoftheavailablehotwaterbymixingsome
coldwaterwiththehot.Thispreventsexcessive
andpossiblyscaldinghotwateratthextures.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
waterfromtheheaterpriortoenteringthemixing
valve.Themixingvalveshouldbe“trapped”by
installing it below the cold water inlet to heater to
prevent lime formation in the valve.
WARNING
outlet to avoid risk of burns or scalding due to
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.Thisisnotonlybenecialtothe
tanklessheaterbuttopipingandxturesplusthe
manyotherbenetsderivedfromsoftwater.
NOTICE
G. INSTALL SMOKEPIPE — The CLS should be vented
intoareclaytile-linedmasonrychimneyorchimney
constructed from type L vent or a factory built chimney
thatcomplieswiththetypeHTrequirementsofUL103.
Thechimneyandventpipeshallhaveasufcientdraft
at all times, to assure safe proper operation of the boiler.
See Figure 5 for recommended installation.
1. Installadraftregulator(suppliedwithboiler)
following the instructions furnished with the
regulator. See Figure 6 for alternate draft regulator
locations.
2. Consider the chimney overall. Chimneys that have
a high heat loss may become less suitable as the
heatlossofthehomegoesdownandtheefciency
of the boiler installed goes up. Most homes have
a chimney appropriate for the fuel and the era in
which the home was built. That may have been a
coalredoraninefcientoilredboilerbuiltinto
a home without insulation or storm windows. With
increasing fuel prices that home probably has been
insulatedandttedwithstormwindowssothat
the heat loss of the home has been reduced. This
requires less fuel to be burned and sends less heat up
the chimney.
Boiler
Model Rating (GPM) Pressure Drop (PSI)
CLS-3
CLS-4
2¾
3
3.9
4.7
CLS-5
CLS-6
3¼
3½
5.6
6.4
CLS-7
CLS-8
3¾
4
7.2
8.0
7
Anewboilerprobablyhasahigherefciencythan
the boiler being replaced. That probably means that
the stack temperature from the new boiler will be
lower than that from the old boiler and with less
room air being drawn up the chimney to dilute the
stack gases. The combination of a large uninsulated
chimney,reducedringrate,reducedringtime,
lower stack temperature and less dilution air can,
in some cases, contribute to the condensing of
small amounts of water vapor in the chimney. Such
condensation, when it occurs, can cause chimney
deterioration.Inextremecases,condensedwater
may be visible on the outside of the breeching or
chimney.Inthoseextremecases,thechimneymay
have to be lined to insulate the chimney and thus
prevent the condensation. The addition of dilution
air into the chimney may assist in drying the
chimney interior surfaces.
Amassivechimneyonacold,orexposedoutside
wall may have produced adequate draft when it
wasredwithahigherinputandgreatervolumes
of heated gases. With reduced input and volume,
the draft may be severely affected. In one instance
research showed a new chimney of adequate
sizingproducedonly.035"W.C.after30minutes
ofcontinuousringat13.0%CO2. Outside wall
chimneystakelongertoheatupandcanhave.00"
W.C. draft at burner startup. You may have to
consideraspecialalloychimneyuelinerwith
9
Figure 7
Lift "H"
(See Figure)
Maximum Length of Tubing
"H" + "R" (See Figure)
3/8" OD
Tubing (3 GPH)
1/2" OD
Tubing (3 GPH)
0' 84' 100'
1' 78' 100'
2' 73' 100'
3' 68' 100'
4' 63' 100'
5' 57' 100'
6' 52' 100'
7' 47' 100'
8' 42' 100'
9' 36' 100'
10' 31' 100'
11' 26' 100'
12' 21' 83'
13' --- 62'
14' --- 41'
TABLE 3: SINGLE STAGE UNITS (3450 RPM)
TWO PIPE SYSTEMS
Lift "H"
(See Figure)
Maximum Length of Tubing
"H" + "R" (See Figure)
3/8" OD
Tubing (3 GPH)
1/2" OD
Tubing (3 GPH)
0' 93' 100'
2' 85' 100'
4' 77' 100'
6' 69' 100'
8' 60' 100'
10' 52' 100'
12' 44' 100'
14' 36' 100'
16' 27' 100'
18' --- 76'
TABLE 4: TWO-STAGE UNITS (3450 RPM)
TWO PIPE SYSTEMS
insulation around it and a stabilizing draft cap or
even a draft inducing fan in severe cases.
3. Forthesamereasonsasin(2.)above,heatextractors
mounted into the breeching are not recommended.
H. INSTALL ELECTRIC WIRING in accordance with
National Electrical Code and local regulations. A
separate ELECTRICAL CIRCUIT should be run from
meter with a Fused Disconnect Switch in the Circuit.
Wiring should conform to Figure 9.
I. FUEL UNITS AND OIL LINES
SINGLE-PIPE OIL LINES Standard burners are
providedwithsingle-stage3450rpmfuelunitswiththe
by-pass plug removed for single-pipe installations.
The single-stage fuel unit may be installed single-pipe
withgravityfeedorlift.Maximumallowableliftis8
feet. See Figure 7.
TWO-PIPE OIL LINES For two-pipe systems
where more lift is required, the two-stage fuel unit is
recommended.Table3(single-stage)andTable4(two-
stage)showallowableliftandlengthsof3/8-inchand
1/2-inch OD tubing for both suction and return lines.
Refer to Figure 8.
Be sure that all oil line connections are absolutely
airtight. Check all connections and joints. Flared
ttingsarerecommended.Donotusecompression
ttings.
Open the air-bleed valve and start the burner. For clean
bleed, slip a 3/16" ID hose over the end of the bleed
valve and bleed into a container. Continue to bleed for
15 seconds after oil is free of air bubbles. Stop burner
and close valve.
10
SEQUENCE OF OPERATION
When the thermostat calls for heat, it energizes the cad cell primary control. The burner will initiate ignition after com-
pleting 15 second pre-purge cycle. The burner will operate until the thermostat is satised or the limit setting on the
high limit is reached. When the high limit control restores the circuit on a drop in pressure, the burner will start if the
thermostat is still calling for heat. The low water cut off will shut down the burner if the water level in the boiler drops
too low. The control resets and restarts the burner with a call for heat a few seconds after the water is returned to its
normal level.
The McDonnell Miller low water cut off incorporates a 10 second delay to prevent nuisance burner cut-off due to rapid
water level uctuations. The LWCO also has a time delay of 15 seconds which allows additional ll time after water
touches the probe. Red LED indicates a low water condition.
On burner start, if the cad cell does not see ame within approximately 45 seconds, primary control will lock out on
safety and must be reset before burner can be restarted.
When there is no demand for heat, the operating control will maintain the boiler water temperature at the selected set-
ting for proper operation of the domestic water heater, if equipped with optional tankless heater.
11
III. Operating and Service Instructions
3. Attachaplastichosetofuelpumpventttingand
provide a pan to catch the oil.
4. REMOVE GAUGE PORT PLUG from fuel pump
and install pressure gauge capable of reading at least
150PSI.
5. OPEN FLAME OBSERVATION DOOR on front of
boiler.
H. START OIL BURNER.
1. Openventttingonfuelpump.
2. TURN ‘ON’ BURNER service switch and allow
burnertorununtiloilowsfromventtting
in a SOLID stream without air bubbles for
approximately10seconds.
3. Closeventttingandburnerameshouldstart
immediately after pre-purge is complete. Pre-purge
preventsburnerameuntil15secondshaselapsed
after initial power is applied to burner. During
pre-purge, the motor and ignitor will operate but the
oil valve will remain closed. Refer to Oil Primary
Control Instructions for more details.
I. ADJUST OIL PRESSURE.
1. Locate oil pressure adjusting screw and turn screw
toobtain140PSIpressure.
2. DO NOT REMOVE PRESSURE GAUGE until
later.
J. OTHER ADJUSTMENTS
1. ADJUST THE AIR BAND AND/OR AIR
SHUTTER.
Adjust air supply by loosening lock screws and
moving the air shutter and if necessary the air band.
Refer to Table 5 for preliminary settings.
2. ADJUST THE COMBUSTION HEAD.
CLS-3 thru CLS-7:
"F"headburnershaveaxedheadwhichisnon-
adjustable. To check combustion head location refer
toFigure10.
CLS-8:
“V1”(variable)headburnershavetheabilityto
control air by moving the head either forward or
back.
Loosen the adjusting plate assembly hold down
screw.Slidetheheadandplatetotherequiredring
rate setting as shown in Figure 11. Tighten the screw
and knurled nut.
It might be necessary to move the head forward or
back one position at a time to optimize the smoke
and CO2readings. See Figure 11.
3. ADJUST DRAFT REGULATOR for a draft
of—.02”(watergauge)overthereafterchimney
has reached operating temperature and while burner
is running.
A. ALWAYS INSPECT INSTALLATION BEFORE
STARTING BURNER.
B.FILL HEATING SYSTEM WITH WATER.
NOTE: It is important, especially in a steam system,
to properly remove the oil and dirt from the system.
Failure to clean the system can result in erratic water
lines and surging.
1. Clean heating system if boiler water or condensate
return water is dirty or if erratic water lines or
surgingexistafterafewdaysofboileroperation.
Refer to step "N" for proper cleaning instructions for
steam boilers.
2. Fill boiler to normal water line. Refer to Figure 1.
C. CHECK CONTROLS, WIRING AND BURNER to be
sure that all connections are tight and burner is rigid,
that all electrical connections have been completed and
fusesinstalled,andthatoiltankislledandoillines
have been tested.
D. LUBRICATION — Follow instruction on burner and
circulator label to lubricate, if oil lubricated. Most
motors currently used on residential type burners
employ permanently lubricated bearings and thus do
notrequireanyeldlubrication.Waterlubricated
circulatorsdonotneedeldlubrication.
Do not over-lubricate. This can cause as much trouble
as no lubrication at all.
E. SET CONTROLS with burner service switch turned
“OFF”.
1. SETROOMTHERMOSTATabout10°aboveroom
temperature.
2. PRESS RED RESET BUTTON on primary control
(R8184G)andrelease.
3. Setcut-inpressureonPA404pressuretrolforthree
(3)psianddifferentialpressurefortwo(2)psi.
These pressures may be varied to suit individual
requirements of installation.
4. On STEAM BOILERS WITH TANKLESS
DOMESTIC WATER HEATERS, set boiler water
temperaturedialonL4006operatingcontrolat
190°F(max.).Setdifferentialat10°.
F. REMOVE GUN ASSEMBLY
1. Items to be checked are nozzle size, type, and angle;
headsize(andsettingonMD(V1)head);gunsetting;
and positioning of electrodes. This informations is
showninFigures10and11andTable5.
2. Reinstall gun assembly.
G. ADJUST OIL BURNER BEFORE STARTING.
1. SET BURNER AIR BAND AND AIR SHUTTER,
see Table 5.
2. OPEN ALL OIL LINE VALVES.
12
Figure 10: "F" Head Electrode Positioning and Gun Setting (Beckett AFG)
Figure 11: "V1" Head Electrode Positioning and Gun Setting (Beckett AFG)
Boiler
Model
** Firing
Rate
Air Shutter
Setting
Air Band
Setting Head Static
Disc
Nozzle Data
GPH Angle Type Mfg.
CLS-3* 1.05 10 2 F3 3-3/8" 0.85 80° A Delavan
CLS-4 1.35 8 1 F4 3-3/8" 1.10 80° B Delavan
CLS-5 1.65 9 2 F6 2-3/4" 1.35 80° B Delavan
CLS-6 1.90 9 2 F12 2-3/4" 1.50 80° B Delavan
CLS-7 2.10 10 2 F16 NONE 1.75 80° B Delavan
CLS-8 2.35 10 6 V1 2-3/4" 2.00 80° B Delavan
* Low Firing Rate Bafe is Used on CLS-3
Settings are approximate and must be veried by smoke and CO2measurement.
Readjust where necessary. See Text of the Manual
** 140 PSI Pump Pressure
13
nozzle will compress when burner is on and will
expandwhenburnerstops,causingoiltosquirtfrom
nozzle at low pressure as burner slows down and
causing nozzle to drip after burner stops. Usually
cyclingtheburneroperationabout5to10timeswill
rid oil line of this air.
2. IF NOZZLE CONTINUES TO DRIP, repeat step
K.1. If this does not stop the dripping, remove
cutoff valve and seat, and wipe both with a clean
cloth until clean, then replace and readjust oil
pressure. If dripping or after burn persist replace
fuel pump.
L. TEST CONTROLS.
WARNING
Before installation of the boiler is considered
1. Check thermostat operation. Raise and lower
thermostat setting as required to start and stop
burner.
2. VERIFY PRIMARY CONTROL SAFETY
FEATURES using procedures outlined in
Instructionsfurnishedwithcontrol(Seebackof
controlcover)orinstructionsasfollows:
CHECKOUT PROCEDURE
CAUTION
a. Check wiring connections. Close line switch.
Check power at control.
PRIMARY RELAY TEST
b. Disconnect cad cell leads from quick connects
on underside of primary control. Reset safety
switch.
c. Set controller to call for heat. Burner should
start.
d. Jumper the quick connect terminals within 15 to
30seconds.Burnershouldrun.
e. Remove terminal Jumper. Burner shuts down in
approximately15to60seconds.
f. If burner operates as described, relay is good. If
not, install new relay.
CAD CELL TEST
g. Open line switch. Clean cell face and see that
cell is securely in socket. Reconnect leads. Reset
safety switch.
h. Close line switch. If burner starts and runs
beyond safety switch cut-out time, cell is good.
If not, install new cell.
4. READJUST AIR BANDS on burner for a light
orangecoloredamewhilethedraftoverthe
reis—.02”.Useasmoketesterandadjustair
forminimumsmoke(nottoexceed#1)witha
minimumofexcessair.Makenalcheckusing
suitable instrumentation to obtain a CO2of 11.5 to
12.5%withdraftof—.02”(watergauge)inre
box.Thesesettingswillassureasafeandefcient
operatingcondition.Iftheameappearsstringy
insteadofasolidre,tryanothernozzleofthesame
type. Flame should be solid and compact. After all
adjustmentsaremaderecheckforadraftof—.02”
overthere.
5. TURN “OFF” BURNER and remove pressure
gauge. Install gauge port plug and tighten. Start
burner again.
6. CAD CELL LOCATION AND SERVICE
Theburnerissuppliedwithacadmiumsuldeame
detector mounted at the factory, mounted on the
bottom of the ignitor. See Figure 12. To service cad
cell or to replace the plug in portion, swing open the
ignitor. After service is complete, be sure to fasten
down the ignitor.
Figure 12: Cad Cell Location
7. FLAME FAILURE
The CLS boiler controls operate the burner
automatically. If for unknown reasons the burner
ceasestoreandtheresetbuttonontheprimary
controlhastripped,theburnerhasexperienced
ignition failure. Before pressing the reset button call
your serviceman immediately.
WARNING
K. CHECK FOR CLEAN CUT OFF OF BURNER.
1. AIR IN THE OIL LINE between fuel unit and
FOR SERVICEMAN ONLY
14
3. WARNING — Check High Limit Control
— Jumper Thermostat Terminals. Allow burner to
operate until shut-down by limit. Installation is not
considered complete until this check has been made.
REMOVE JUMPER.
4. Check low water cut off control with water level at
normalwaterline(seeFigure1).Raisethermostat
setting to allow burner to operate. Open boiler drain
to allow water level to drop to bottom of sight glass
until burner operation is shut-down by low water
cutoff.
Closeboilerdrainandrelltonormalwaterline.
Burnershouldautomaticallyrestartduringll.
Lower thermostat setting.
5. Check operating control on boiler equipped with
tankless heaters. With burner off, draw hot water
until burner starts, then turn off hot water and check
burner shut-down.
IF CONTROLS DO NOT MEET REQUIREMENTS
OUTLINED IN PARAGRAPH L., REPLACE
CONTROL AND REPEAT CHECK-OUT
PROCEDURES.
M. MAINTENANCE OF PROBE LOW WATER CUTOFF
WARNING
1. Although these devices are solid state in their
operation,theprobeisexposedtopossible
contamination in the boiler water and subject to
fouling.
2. It is important to physically remove the probe from
the boiler tapping annually and inspect that probe
for accumulation of scale or sediment.
3. Follow these steps to inspect, clean and/or replace
the probe:
a. Turn off electric service to the boiler.
b. Drain boiler water to a level below the tapping
for the probe.
DANGER
pressure gauge to indicate that the boiler is at
all internal pressure prior to proceeding. Safety
c. Disconnect wiring connections between the low
water cutoff control and the probe.
d. Dismount the low water cutoff control from the
probe.
e. Unscrew the probe from the boiler tapping.
f. Inspectthatportionoftheprobethatisexposed
to the boiler water for a scale or sediment
buildup.
g. Light deposits may be removed by wiping the
probe with a damp cloth. Wiping the probe with
a cloth soaked in vinegar will remove more
tenacious lime deposits. The most stubborn
deposits may be removed from the probe by
using a diluted amount, 3 parts of water to 1 part
ofphosphoricacid(H2PO4).
CAUTION
and follow the instruction label on its container.
h. Clean the pipe threads of the probe to remove
old, hardened pipe dope and other foreign matter.
i. Apply a moderate amount of good quality pipe
dope to the pipe threads on the probe, leaving the
twoendthreadsbare.DonotusePTFE(Teon)
tape.
j. Screw the probe into the boiler tapping.
k. Mount the low water cutoff control on the probe.
l. Reconnect the control to probe wiring.
m. Fill the boiler to its normal waterline.
n. Add boiler water treatment compound as needed
(refertoparagraphN.).
o. Restore electric service to the boiler.
p. Fire burner to bring the water in the boiler to a
boiltodriveofffreeoxygen.
q. WARNING — BEFORE RETURNING
BOILER TO SERVICE: Follow the low water
cutoff check out procedure in step L.4.
N. BOILER AND SYSTEM CLEANING
INSTRUCTIONS FOR TROUBLE FREE
OPERATION
1. Oil, greases & sediments which accumulate in a new
boiler and piping must be removed from the system
in order to prevent an unsteady water line and carry
over of the water into the supply main above boiler.
Operate the boiler with steam in the entire system
for a few days allowing the condensate to return
to the boiler. If the condensate can temporarily be
wasted, operate boiler only for the length of time it
takes for condensate to run clear. If the latter cannot
be achieved or if the condensate is returned to the
boiler, boil out the boiler using the SURFACE
BLOWOFF connection.
15
b.Draw about 5 gallons of hot water from
boiler into a container and dissolve into it the
appropriate amount of a recommended boilout
compound. Remove safety valve from boiler and
pour this solution into boiler, then reinstall safety
valve.
c. Turn on oil burner and keep operating while
feeding water to boiler slowly. This will raise
water level in boiler slowly so that water will
be boiling hot and will rise slowly into supply
mainandbackthroughreturnmain,owing
fromdrainhoseatabout180°F.Continueuntil
waterrunsclearfromdrainhoseforatleast30
minutes.
d. Stop feeding water to boiler but continue
operatingoilburneruntilexcesswaterinboiler
owsoutthroughsupplymainandwaterlowers
(bysteaming)untilitreachesnormallevelin
boiler. Turn off oil burner. Drain boiler. Open
all radiator valves. Reinstall all supply main air
valves. Open gate valve in Hartford Loop.
e. Whenboilerhascooleddownsufciently(crown
sheetofsectionsarenottoohottotouch),close
the drain valves at boiler and in return main and
feed water slowly up to normal level in boiler.
Turn on oil burner and allow boiler to steam for
10minutes,thenturnoffburner.Drawoffone
quartofwaterfrombottomgaugeglasstting
and discard. Draw off another quart sample and
if this sample is not clear, repeat the cycle of
drainingtheboilerandreturnmainandrelling
the boiler until sample is clear.
f. If the boiler water becomes dirty again at a later
date due to additional sediment loosened up in
the piping, close gate valve in Hartford Loop,
open drain valve in return main, turn on oil
burnerandallowCondensatetoowtodrain
untilithasrunclearforatleast30minuteswhile
feeding water to boiler so as to maintain normal
water level. Turn off oil burner, drain boiler,
open gate valve in Hartford Loop, then repeat
step 1 above.
5. Make pH or Alkalinity Test.
After boiler and system have been cleaned and
relledaspreviouslydescribed,testthepHof
the water in the system. This can easily be done
by drawing a small sample of boiler water and
testing with hydrion paper which is used in the
samemanneraslitmuspaper,exceptitgives
specicreadings.Acolorchartonthesideofthe
small hydrion dispenser gives the reading in pH.
Hydrionpaperisinexpensiveandobtainablefrom
any chemical supply house or through your local
druggist. The pH should be higher than 7, but lower
than11.Addsomeofthewashoutchemical(caustic
soda),ifnecessary,tobringthepHwithinthe
speciedrange.
a. Drain boiler until 1” of water is visible in gauge
glass. Run temporary 1½” pipe line from the
surface blowoff connection to an open drain or
some other location where hot water may be
discharged safely. Do not install valve in this
line.
b. Drain about 5 gallons of hot water from
boiler into a container and dissolve into it
an appropriate amount of recommended boil
out compound. Remove safety valve and add
solutiontoboilerwaterthruexposedtapping
using a funnel.
NOTICE
Check with local authorities or consult local
c. Startburnerandoperatesufcientlytoboilthe
water without producing steam pressure. Boil for
about5hours.Openboilerfeedpipesufciently
to permit a steady trickle of water from the
surface blowoff pipe. Continue this slow boiling
andtrickleofoverowforseveralhoursuntilthe
watercomingfromtheoverowisclear.
d. Stop burner and drain boiler in a manner and to
a location that hot water can be discharged with
safety.
e. Rellboilertonormalwaterline.Ifwaterin
gauge glass does not appear to be clear, repeat
steps(a.thruc.)andboilouttheboilerfora
longer time.
2. Low pressure steam boilers such as the CLS Series
should be maintained with appropriate water
treatment compounds. Add suitable water treatment
compoundsasrecommendedbyyourqualiedwater
treatment company.
3. Remove temporary surface blowoff piping, plug
tapping and reinstall safety valve. Boil or bring
watertemperatureto180°Fpromptlyinorderto
drive off the dissolved gases in the fresh water.
4. If unsteady water line, foaming or priming persist,
install gate valve in Hartford Loop and drain valves
in return main and at boiler as shown in Figure 4
and proceed as follows:
a. Connecthosesfromdrainvalvestooordrain.
Close gate valve in Hartford Loop and open
drain valve in return main. Fill boiler to normal
water level, turn on oil burner and operate boiler
atthiswaterlevelforatleast30minutesafter
the condensate begins to run hot, then turn off
burner.
Close all radiator valves. Remove all supply
main air valves and plug the openings in supply
main.
16
6. Boiler is now ready to be put into service.
IMPORTANT
IF, DURING NORMAL OPERATION, IT IS
NECESSARY TO ADD MORE WATER PER
MONTH THAN INDICATED BELOW, CONSULT
A QUALIFIED SERVICE TECHNICIAN TO
CHECK YOUR SYSTEM FOR LEAKS.
EXCESSIVE WATER ADDITION:
(Gal/Month)
CLS-3: 5 CLS-4: 7 CLS-5: 8½
CLS-6: 10 CLS-7: 12 CLS-8: 13½
A leaky system will increase the volume of make-up
water supplied to the boiler which can signicantly
shorten the life of the boiler. Entrained in make-up
water are dissolved minerals and oxygen. When the
fresh, cool make-up water is heated in the boiler the
minerals fall out as sediment and the oxygen escapes
as a gas. Both can result in reduced boiler life. The
accumulation of sediment can eventually isolate
the water from contacting the cast iron. When this
happens the cast iron in that area gets extremely
hot and eventually cracks. The presence of free
oxygen in the boiler creates a corrosive atmosphere
which, if the concentration becomes high enough,
can corrode the cast iron through from the inside.
Since neither of these failure types are the result of a
casting defect the warranty does not apply. Clearly it
is in everyone’s best interest to prevent this type of
failure. The maintenance of system integrity is the
best method to achieve this.
O. HINTS ON COMBUSTION
1. NOZZLES — Although the nozzle is a relatively
inexpensive device, its function is critical to the
successful operation of the oil burner. The selection
of the nozzle supplied with the CLS boiler is the
result of extensive testing to obtain the best ame
shape and efcient combustion. Other brands of the
same spray angle and spray pattern may be used but
may not perform at the expected level of CO2and
smoke. Nozzles are delicate and should be protected
from dirt and abuse. Nozzles are mass-produced
and can vary from sample to sample. For all of
those reasons a spare nozzle is a desirable item for a
serviceman to have.
2. FLAME SHAPE — Looking into the combustion
chamber through the observation door, the ame
should appear straight with no sparklers rolling up
toward the crown of the chamber. If the ame drags
to the right or left, sends sparklers upward or makes
wet spots on the target wall, the nozzle should be
replaced. If the condition persists look for fuel leaks,
air leaks, water or dirt in the fuel as described in
following steps.
3. FUEL LEAKS — Any fuel leak between the
pump and the nozzle will be detrimental to good
combustion results. Look for wet surfaces in the air
tube, under the ignitor, and around the air inlet. Any
such leaks should be repaired as they may cause
erratic burning of the fuel and in the extreme case
may become a re hazard.
4. AIR LEAKS — Any such leaks should be repaired,
as they may cause erratic burning of the fuel and in
extreme cases may become a re hazard.
5. GASKET LEAKS — If 11.5 to 12.5% CO2with a
#1 smoke cannot be obtained in the breeching, look
for air leaks around the burner mounting gasket,
observation door, and canopy gasket. Such air leaks
will cause a lower CO2reading in the breeching. The
smaller the ring rate the greater effect an air leak
can have on CO2readings.
6. DIRT — A fuel lter is a good investment.
Accidental accumulation of dirt in the fuel system
can clog the nozzle or nozzle strainer and produce a
poor spray pattern from the nozzle. The smaller the
ring rate, the smaller the slots become in the nozzle
and the more prone to plugging it becomes with the
same amount of dirt.
7. WATER — Water in the fuel in large amounts will
stall the fuel pump. Water in the fuel in smaller
amounts will cause excessive wear on the pump,
but more importantly water doesn’t burn. It chills
the ame and causes smoke and unburned fuel to
pass out of the combustion chamber and clog the
ueways of the boiler.
8. COLD OIL — If the oil temperature approaching
the fuel pump is 40°F or lower poor combustion or
delayed ignition may result. Cold oil is harder to
atomize at the nozzle. Thus, the spray droplets get
larger and the ame shape gets longer. An outside
fuel tank that is above grade or has fuel lines in a
IMPORTANT
SUCTION LINE LEAKS - WHATEVER IT TAKES,
THE OIL MUST BE FREE OF AIR. This can be
a tough problem, but it must be resolved. Try
bleeding the pump through a clear tube. There
must be no froth visible. There are various test
kits available to enable you to look at the oil
through clear tubing adapted to the supply line at
the pump tting. Air eliminators are on the market
that have potential. Also, electronic sight glasses
are being used with good success. At times, new
tubing must be run to the tank or new ttings put
on. Just make sure you get the air out before you
leave.
Any air leaks in the fuel line will cause an unstable
ame and may cause delayed ignition noises. Use
only are ttings in the fuel lines.
17
shallow bury is a good candidate for cold oil. The
best solution is to bury the tank and lines deep
enoughtokeeptheoilabove40°F.
9. HIGH ALTITUDE INSTALLATIONS
Air settings must be increased at high altitudes. Use
instrumentsandsetfor11.5to12.5%CO2.
10.START-UPNOISE—Lateignitionisthecauseof
start-up noises. If it occurs recheck for electrode
settings,ameshape,airorwaterinthefuellines.
11.SHUTDOWNNOISE—Iftheamerunsoutof
air before it runs out of fuel, an after burn with
noise may occur. That may be the result of a faulty
cut-off valve in the fuel pump, or it may be air
trappedinthenozzleline.Itmaytakeseveralring
cycles for that air to be fully vented through the
nozzle.Waterinthefuelorpoorameshapecan
also cause shut down noises.
NOTICE
burner runs successfully when drawing out of the
P. ATTENTION TO BOILER WHILE NOT IN
OPERATION
1. IMPORTANT
IF BOILER IS NOT USED DURING WINTER
TIME, IT MUST BE FULLY DRAINED TO
PREVENT FREEZE DAMAGE.
2. Spray inside surfaces with light lubricating or
crankcaseoilusinggunwithextendedstemsoasto
reach all corners.
3. Withsteamboilers,atendofseasonaddsufcient
watertollboilertotopofwatercolumnandleave
it that way until fall when water should be drained
again to proper level. If at this time boiler water is
dirty,drainwater,ushoutboiler,andrellwith
clean water to prescribed water level.
4. Always keep the manual fuel supply valve shut off
iftheburnerisshutdownforanextendedperiodof
time.
5. To recondition the heating system in the fall season
after a prolonged shut down, follow the instructions
outlined in Section III, Items A through M.
CAUTION
boiler to shut down and not restart without service.
in cold weather; or appropriate safeguards and
IV. Boiler Cleaning
Figure 13: Cleaning of Boiler Flueways
A. CLEANTHEFLUEWAYS(SeeFigure13).
1. Prior to cleaning boiler, lay a protective cloth or
plastic over combustion chamber blanket to collect
debrisfallingfromueways.
2. Foraccesstorebox,removeburnerandburner
mounting plate.
NOTICE
thorough cleaning.
3. For cleaning from the side:
a. Lift the jacket's upper right side access panel off
toexposetheuecleanoutplates.
b. Loosennutssecuringtheuecleanoutplates
and remove the plates. The insulation should
be removed with the plates taking care not to
damage the insulation.
4. For cleaning from the top:
a. Lift the jacket's upper right side access panel off
to allow removal of the jacket top panel.
b. Remove as much smokepipe as necessary to
allow removal of the jacket top panel and canopy
(smokebox).
c. Remove the jacket top panel.
d. Remove the canopy, being careful not to damage
theceramicbergasket.
5. Usinga1½"diameterwireorbrebristlebrush
(30"handle)cleantheueways.Brushfromthetop
and/or side using horizontal and diagonal strokes
for best results. DO NOT allow brush to strike the
target wall or liner in the chamber.
B. CLEANTOPOFBOILERSECTIONS(ifcleaning
fromthetop).
Brush and vacuum the tops of the boiler sections.
C. CLEAN THE FIREBOX.
Usingwireorbrebristlebrush,cleancrownofboiler
and inside of water legs. DO NOT allow brush to strike
target wall or blanket in the combustion chamber.
D. AFTER CLEANING, remove protective cloth with
debris and vacuum as necessary, but be careful not
to damage blanket. Inspect target wall, combustion
chamber blanket and burner mounting plate insulation
for signs of damage. If damaged, replace as needed.
E. REASSEMBLE BOILER.
CAUTION: Do not start the burner unless canopy,
smokepipe,burnermountingplateandallueplatesare
secured in place.
1. Install the canopy taking care to align the gaskets
withoutblockingtheueways.Ifgasketisdamaged,
replace as needed.
2. Reinstallueplates,makingsuregasketoneach
plate is in place and forms gas tight seal. If damaged
replace as needed.
3. Reinstall split top panel and secure with sheet metal
screws. Replace jacket upper right side access panel.
4. Reinstall smokepipe on canopy and secure to collar
with sheet metal screws.
5. Reinstall burner mounting plate to front section with
fasteners.
6. Reinstall burner.
WARNING
WARNING
before the start of the heating season and
should be inspected periodically throughout the
heating season for any obstructions. A clean and
of life to vent safely and will contribute toward
19
DATE SERVICE PERFORMED
20
All CLS Series repair parts may be ordered through New Yorker Boiler Co., Inc. or its authorized distributors.
Should you require assistance in locating a New Yorker Distributor in your area, or have questions regarding the availability of
NewYorkerproductsorrepairparts,pleasecontact:NewYorkerBoilerCo.,Inc.,P.O.Box10,Hateld,PA19440-0010,
Phone:(215)855-8055Attn:CustomerServiceDepartment
V. Repair parts
BOILER ASSEMBLY
Other manuals for CLS SERIES
1
This manual suits for next models
6
Table of contents
Other New Yorker Boiler manuals
New Yorker
New Yorker CG20F Service manual
New Yorker
New Yorker CG-C Series Troubleshooting guide
New Yorker
New Yorker GHE Series Service manual
New Yorker
New Yorker GHE II Service manual
New Yorker
New Yorker PVCG-C Series Service manual
New Yorker
New Yorker M Service manual
New Yorker
New Yorker GHE2-120 Service manual
New Yorker
New Yorker CL3-105 Service manual
New Yorker
New Yorker GHE120HBII Service manual
New Yorker
New Yorker microTEKDV Service manual
New Yorker
New Yorker New Yorker CL Series Service manual
New Yorker
New Yorker CGS-A Series Service manual
New Yorker
New Yorker CG-C Series Service manual
New Yorker
New Yorker Classic CGS-A Series Service manual
New Yorker
New Yorker FR SERIES Service manual
New Yorker
New Yorker FR SERIES Service manual
New Yorker
New Yorker PVCG SERIES Service manual
New Yorker
New Yorker CLASSIC CG-A SERIES Service manual
New Yorker
New Yorker New Yorker CL Series User manual
New Yorker
New Yorker CGS-C Series Service manual
Popular Boiler manuals by other brands
Baxi
Baxi DUO-TEC COMPACT 30 GA Instructions for the end user
ACV
ACV Delta G25 Installation & operating guide
Instanta
Instanta InstaTap UCB Series Installation instructions manual
Burnham
Burnham K2WTC Installation, operating and service instructions
AMW
AMW 815 Installation, operation & service manual
Trianco
Trianco AZTEC 6 Installation, operation and servicing instructions
Legacy Stoves
Legacy Stoves SF170 Installation and operator's manual
Viessmann
Viessmann VITOCROSSAL CRU 800 kW Service instructions
Grant
Grant Spira 6-26kW Installation, commissioning and servicing instructions
Weishaupt
Weishaupt thermo condens WTC 15-A Installation and operating instructions
Kospel
Kospel GB-030AB installation manual
Nieco
Nieco 980 GAS owner's manual