New Yorker CLW Series Service manual

1
INSTALLATION, OPERATING
AND SERVICE INSTRUCTIONS
"CLW" SERIES
CAST IRON OIL-FIRED BOILER
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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
DIFFER FROM THIS MANUAL. AUTHORITIES HAVING JURISDICTION SHOULD BE CONSULTED BEFORE
INSTALLATIONS 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
ATTEMPT INSTALLATION OF ANY BOILER.
5. THE BOILER MUST BE CONNECTED TO AN APPROVED CHIMNEY IN GOOD CONDITION. SERIOUS PROPERTY
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 HEAT-
ING 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 COR-
RECTLY 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. Have flueways cleaned at least once a year - preferably at the end of the heating season to remove soot and scale. Inside of firebox should also be
cleaned at the same time.
C. Have oil burner and controls checked at least once a year or as may be necessitated.
GNINRAW
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TABLE OF CONTENTS
I. General Information .............................. 3
II. Installation Instructions ......................... 6
III. Operating and Service Instructions ..... 13
IV. Boiler Cleaning ................................... 19
V. Repair Parts ......................................... 20
Burner Specifications .......................... 14
SECTION I: GENERAL INFORMATION
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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 filed 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 in front of final position before
removing crate. See Figures 1A and 1B.
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
solid base, such as concrete, if floor is not level, or
if water may be encountered on floor around boiler.
3. PROVIDE SERVICE CLEARANCE of at least 24”
on right side of boiler for cleaning flueways and for
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
must be sized so the boiler input will not exceed 4,000
BTUH/Sq. In. of free area. If other air consuming
appliances are near the boiler, the air inlet should be
larger. Consult respective manufacturers.

4
Figure 1A: CLW Series "P" Less Tankless Heater
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4-WLC"8/7-91"4/1-9"6'51x"8x"8'51x"79.51
5-WLC"8/7-32"4/1-11"7'51x"8x"8'51x"73.81
6-WLC"8/7-72"4/1-31"7'51x"8x"8'51x"87.02
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TABLE 1: DIMENSIONAL DATA (See Figures 1A and 1B)

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Figure 1B: CLW Series "PT" With Tankless Heater
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Figure 2: Minimum Installation Clearances To Combustible Materials (Inches)
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6
SECTION 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 carton containing relief valve,
circulator and fittings, drain valve and pipe fittings.
section, see Figures 1A or 1B.
d. 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 between the circulator and
boiler return along with a second tee in the
supply piping as shown in Figure 4. The bypass
should be the same size as the supply and return
lines. Locate valves in the bypass and supply
outlet as illustrated in Figure 4 for regulation of
water flow 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.
e. 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.
f. If this boiler is used in connection with
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 3. Remove
all bolts.
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 floor. 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
flashlight to inspect target wall secured to rear
section with silastic sealant. Inspect ceramic fiber
blanket secured to floor of boiler with water glass
adhesive. If either is damaged they must be replaced.
E. CONNECT SUPPLY AND RETURN PIPING TO
HEATING SYSTEM.
1. CLEARANCES — Hot water pipes shall have
clearances of at least ½” from all combustible
construction.
a. For Forced Circulation HOT WATER
HEATING. See Figure 4. Consult I=B=R
Installation and Piping Guide No. 200.
b. Screw drain valve into 1½" tapping in rear
section using 1½" x ¾" bushing.
c. Install relief valve and fittings in top of front
Figure 3: Removal of Boiler From Skid Figure 4: Recommended Boiler Piping For Series
Loop Hot Water System

7
Figure 5: Recommended Piping for Combination
Heating & Cooling (Refrigeration) Systems Water
Boilers
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 5. Also consult I=B=R
Installation and Piping Guides.
g. A hot water boiler installed above radiation level
must be provided with a low water cutoff device
as part of the installation.
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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.
In order to insure long product life, oxygen sources
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. 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
Figure 6: Schematic Tankless Heater Piping
installing a heat exchanger.
F. CONNECT TANKLESS HEATER PIPING AS
SHOWN IN Figure 6. See Table 2 for Tankless Heater
TABLE 2: TANKLESS HEATER DATA
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Ratings.
THE FOLLOWING GUIDELINES SHOULD BE FOL-
LOWED WHEN PIPING THE TANKLESS HEATER:
1. FLOW REGULATION — If flow 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 flow regulator
matching the heater rating should be installed in the
cold water line to the heater. The flow regulator
should preferably be located below the inlet to the
heater and a minimum 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 flow regulator also
limits the flow 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 fixtures. 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

8
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.
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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 beneficial to the
tankless heater but to piping and fixtures plus the
many other benefits derived from soft water.
G. INSTALL SMOKEPIPE — The CLW should be vented
into a fireclay tile-lined masonry chimney or chimney
constructed from type L vent or a factory built chimney
that complies with the type HT requirements of UL103.
The chimney and vent pipe shall have a sufficient draft
at all times, to assure safe proper operation of the
boiler. See Figure 7 for recommended installation.
1. Install a draft regulator (supplied with boiler)
following the instructions furnished with the
regulator. See Figure 8 for draft regulator locations.
2. Consider the chimney overall. Chimneys that have a
high heat loss may become less suitable as the heat
loss of the home goes down and the efficiency 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 coal fired or
an inefficient oil fired boiler built into a home
without insulation or storm windows. With
increasing fuel prices that home probably has been
insulated and fitted with storm windows so that the
heat loss of the home has been reduced. This
requires less fuel to be burned and sends less heat up
the chimney.
Figure 7: Recommended Smokepipe Arrangement
and Chimney Requirements
A new boiler probably has a higher efficiency than
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, reduced firing rate, reduced firing time,
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. In extreme cases, condensed water
may be visible on the outside of the breeching or
chimney. In those extreme cases, the chimney may
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.
A massive chimney on a cold, or exposed outside
wall may have produced adequate draft when it was
fired with a higher input and greater volumes of
heated gases. With reduced input and volume, the
draft may be severely affected. In one instance
research showed a new chimney of adequate sizing
produced only -.035" W.C. after 30 minutes of
continuous firing at 13.0% CO2. Outside wall
chimneys take longer to heat up and can have .00"
W.C. draft at burner startup. You may have to
consider a special alloy chimney flue liner with
insulation around it and a stabilizing draft cap or
even a draft inducing fan in severe cases.
3. For the same reasons as in 2. above, heat extractors
mounted into the breeching are not recommended.

9
Figure 8: Proper and Improper Locations of Draft Regulator
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 Figures 11 and 12.
I. FUEL UNITS AND OIL LINES
SINGLE-PIPE OIL LINES - Standard burners are
provided with single-stage 3450 rpm fuel units with the
by-pass plug removed for single-pipe installations.
The single-stage fuel unit may be installed single-pipe
with gravity feed or lift. Maximum allowable lift is 8
feet. See Figure 9.
TWO-PIPE OIL LINES - For two-pipe systems where
more lift is required, the two-stage fuel unit is
recommended. Table 3 (single-stage) and Table 4 (two-
stage) show allowable lift and lengths of 3/8-inch and
1/2-inch OD tubing for both suction and return lines.
Refer to Figure 10.
Be sure that all oil line connections are absolutely
airtight. Check all connections and joints. Flared
fittings are recommended. Do not use compression
fittings.
Figure 9
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10
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.
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11
Figure 11: Wiring Diagram for Water Boilers With Beckett AFG Burner and
Split Controls Less Tankless Heater
SEQUENCE OF OPERATION
A call for heat by the thermostat energizes the L8148A control which in turn energizes the R7184A primary control to turn on the
burner. If burner ignites within approximately 45 seconds and cad cell see flame, the burner will continue to operate until the call
for heat is satisfied or the setting of the high limit is reached. The circulator will operate as long as the thermostat is calling for
heat. If the thermostat is not satisfied and the high limit is reached, the circulator will continue to operate, and the burner will stop
until the high limit is closed by a drop in boiler water temperature.

12
Figure 12: Wiring Diagram for Water Boilers with Beckett AFG Burner and
Split Controls with Tankless Heater
SEQUENCE OF OPERATION
A call for heat by the thermostat energizes the L8124C control which in turn energizes the R7184A primary control to turn on the
burner. If burner ignites within approximately 45 seconds and the cad cell see flame, the burner will continue to operate until the
call for heat is satisfied. The circulator will also operate when the thermostat calls for heat if the boiler water temperature is up to
the setting of the low limit in the L8124C control. If boiler water temperature is below the low limit setting the burner will operate
but the circulator will not, giving preference to the domestic hot water demand.
On call for heat by the thermostat the burner will continue to operate until the thermostat is satisfied or the setting of the high limit
is reached. If the thermostat is not satisfied when the high limit is reached the burner will stop but the circulator will continue to
operate until the thermostat is satisfied.
Any time the boiler water temperature drops below the setting of the low limit the burner will be energized in order to maintain
domestic water temperature.

13
SECTION III: OPERATING AND SERVICE INSTRUCTIONS
3. ON UNITS WITHOUT TANKLESS HEATERS,
set high limit dial on L8148 at 210°F. This
temperature may be varied to suit requirements of
installation.
4. ON UNITS WITH TANKLESS HEATERS, set
operating control dial on L8124 at 190°F and high
limit dial at 210°F. Operating Control must be a
minimum of 20° below High Limit Setting. Set
Differential at 25°.
F. REMOVE GUN ASSEMBLY
1. CLW boilers are equipped with Beckett AFG
burners. Items to be checked are nozzle size, head
size, gun setting, and positioning of electrodes. This
information is shown in Figure 13 and Table 5.
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.
3. ATTACH A PLASTIC HOSE TO FUEL PUMP
VENT FITTING and provide a pan to catch the oil.
4. REMOVE GAUGE PORT PLUG from fuel pump
and install pressure gauge.
5. OPEN FLAME OBSERVATION DOOR on front of
boiler.
H. START OIL BURNER.
1. Open vent fitting on fuel pump.
2. TURN ‘ON’ BURNER service switch and allow
burner to run until oil flows from vent fitting in a
SOLID stream without air bubbles for approximately
10 seconds.
3. Close vent fitting and burner flame should start
immediately.
I. ADJUST OIL PRESSURE.
1. Locate oil pressure adjusting screw and turn screw
for appropriate pump pressure. (See Table 5)
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 DRAFT REGULATOR for a draft of
-.02" (water gauge) over the fire after chimney has
reached operating temperature and while burner is
running.
A. ALWAYS INSPECT INSTALLATION BEFORE
STARTING BURNER.
B. FILL HEATING SYSTEM WITH WATER.
1. Hot Water Boilers: Fill entire Heating System with
water and vent air from system. Use the following
procedure on a Series Loop System installed as per
Figure 4:
a. Close all but one zone valve.
b. Open drain valve on boiler.
c. Open fill valve.
d. Close purge valve.
e. Open relief valve on boiler.
f. Allow water to run out of drain valve until zone
has been purged of air and filled with water.
g. Open zone valve to the second zone to be
purged, then close the first. Repeat this step until
all zones have been purged but always have one
zone open. At completion open all zone valves.
h. Close drain valve.
i. When water discharges from relief valve, release
the lever on the top of the relief valve, allowing it
to close.
j. Continue filling the system until the pressure
gauge reads 12 psi. Close fill valve.
NOTE:
If make-up connections are tight and burner is rigid,
that all electrical connections have been completed
and fuses installed, and that oil tank is filled and oil
lines have been tested.
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
fuses installed, and that oil tank is filled and oil lines
have been tested.
D. LUBRICATION
1. 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 not require any field
lubrication. Water lubricated circulators do not need
field lubrication.
2. 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. SET ROOM THERMOSTAT about 10° above room
temperature.
2. PRESS RED RESET LEVER on R7184
Protectorelay and release.

14
3. READJUST AIR BANDS OR AIR SHUTTER on
burner for a light orange colored flame while the
draft over the fire is —.02”. Use a smoke tester and
adjust air for minimum smoke (not to exceed #1)
with a minimum of excess air. Make final check
using suitable instrumentation to obtain a CO2of
11.5 to 12.5% with draft of —.02” (water gauge) in
fire box. These settings will assure a safe and
efficient operating condition. If the flame appears
stringy instead of a solid fire, try another nozzle of
the same type. Flame should be solid and compact.
After all adjustments are made recheck for a draft of
—.02” over the fire.
4. TURN “OFF” BURNER and remove pressure
gauge. Install gauge port plug and tighten. Start
burner again.
5. CAD CELL LOCATION AND SERVICE
The burner is supplied with a cadmium sulfide flame
detector mounted at the factory, mounted on the Figure 14: Cad Cell Location
Figure 13: Beckett AFG Gun Setting and Electrode Positioning
TABLE 5: BECKETT AFG BURNER
bottom of the electronic ignitor. See Figure 14. 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.
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15
d. Jumper the quick connect terminals within 15 to
30 seconds. Burner should run.
e. Remove the quick connect terminals jumper.
Burner shuts down in approximately 15 to 60
seconds.
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.
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 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
AS OUTLINED ABOVE, REPLACE CONTROL
AND REPEAT CHECK-OUT PROCEDURES.
M. BOILER AND SYSTEM CLEANING
INSTRUCTIONS FOR TROUBLE FREE
OPERATION.
ECITON
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1. FILLING OF BOILER AND SYSTEM —
GENERAL — In a hot water heating system, the
boiler and entire system (other than the expansion
tank) must be full of water for satisfactory operation.
Water should be added to the system until the boiler
pressure gauge registers 12 psi. To insure that the
system is full, water should come out of all air vents
when opened.
2. BOILING OUT OF BOILER AND SYSTEM.The
oil and grease which accumulate in a new hot water
boiler can be washed out in the following manner:
a. Remove relief valve using extreme care to avoid
damaging it.
b. Add an appropriate amount of recommended boil
out compound.
c. Replace relief valve.
d. Fill the entire system with water.
e. Start firing the boiler.
f. Circulate the water through the entire system.
6. FLAME FAILURE
The CLW boiler controls operate the burner
automatically. If for unknown reasons the burner
ceases to fire and the reset button on the primary
control has tripped, the burner has experienced
ignition failure. Before pressing the reset button call
your heating contractor immediately.
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K. CHECK FOR CLEAN CUT OFF OF BURNER.
1. AIR IN THE OIL LINE between fuel unit and
nozzle will compress when burner is on and will
expand when burner stops, causing oil to squirt from
nozzle at low pressure as burner slows down and
causing nozzle to drip after burner stops. Usually
cycling the burner operation about 5 to 10 times will
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.
GNINRAW
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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
Instructions furnished with control or instructions as
follows:
CHECKOUT PROCEDURE
a. Check wiring connections. Close line switch.
Check power at control.
PRIMARY RELAY TEST
b. Disconnect cad cell leads from quick connects on
underside at primary control. Reset safety switch.
c. Set controller to call for heat. Burner should
start.

16
g. Vent the system, including the radiation.
h. Allow boiler water to reach operating
temperature, if possible.
i. Continue to circulate the water for a few hours.
j. Stop firing the boiler.
k. Drain the system in a manner and to a location
that hot water can be discharged with safety.
l. Remove plugs from all available returns and
wash the water side of the boiler as thoroughly as
possible, using a high-pressure water stream.
m.Refill the system with fresh water.
3. Add appropriate boiler water treatment compounds
as recommended by your qualified water treatment
company.
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 CLW boiler is the
result of extensive testing to obtain the best flame
shape and efficient 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. 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 fire hazard.
3. AIR LEAKS — Any such leaks should be repaired,
as they may cause erratic burning of the fuel and in
extreme cases may become a fire hazard.
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 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 fitting.
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 fittings put on. Just make sure you get the air out
before you leave.
Any air leaks in the fuel line will cause an unstable
flame and may cause delayed ignition noises. Use only
flare fittings in the fuel lines.
4. 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 firing rate the greater effect an air leak
can have on CO2readings.
5. DIRT — A fuel filter 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
firing rate, the smaller the slots become in the nozzle
and the more prone to plugging it becomes with the
same amount of dirt.
6. 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
flame and causes smoke and unburned fuel to pass
out of the combustion chamber and clog the
flueways of the boiler.
7. 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 flame shape gets longer. An outside
fuel tank that is above grade or has fuel lines in a
shallow bury is a good candidate for cold oil. The
best solution is to bury the tank and lines deep
enough to keep the oil above 40°F.
8. FLAME SHAPE — Looking into the combustion
chamber through the observation door, the flame
should appear straight with no sparklers rolling up
toward the crown of the chamber. If the flame 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 above.
9. HIGH ALTITUDE INSTALLATIONS
Air settings must be increased at high altitudes. Use
instruments and set for 11.5 to 12.5% CO2.
10. START-UP NOISE — Late ignition is the cause of
start-up noises. If it occurs recheck for electrode
settings, flame shape, air or water in the fuel lines.
11. SHUT DOWN NOISE — If the flame runs out of
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
trapped in the nozzle line. It may take several firing
cycles for that air to be fully vented through the
nozzle. Water in the fuel or poor flame shape can
also cause shut down noises.
A very good test for isolating fuel side problems is

17
to disconnect the fuel system and with a 2 ft. length
of tubing, fire out of an auxiliary five gallon pail of
clean, fresh, warm #2 oil from another source. If the
burner runs successfully when drawing out of the
auxiliary pail then the problem is isolated to the fuel
or fuel lines being used on the jobsite.
P. ATTENTION TO BOILER WHILE NOT IN
OPERATION
IM TNATROP
IF BOILER IS NOT USED DURING WINTER
TIME, IT MUST BE FULLY DRAINED TO
PREVENT FREEZE DAMAGE.
1. Spray inside surfaces with light lubricating or
crankcase oil using gun with extended stem so as to
reach all corners.
2. Always keep the manual fuel supply valve shut off if
the burner is shut down for an extended period of
time.
3. To recondition the heating system in the fall season
after a prolonged shut down, follow the instructions
outlined in Section III, Items A through L.
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18
AQUASTAT SWITCHING ACTION WITHIN L8124C
CONTROL
The switching action within the L8124C control has
three settings:
1. high limit
2. low limit
3. adjustable differential
HIGH LIMIT OPERATION —-
The high limit opens and turns off the burner when the
water temperature reaches the set point. The high limit
automatically resets after the water temperature drops past
the set point and through the 10°F differential.
Set the indicator at desired shutoff temperature.
LOW LIMIT OPERATION —-
On a temperature rise, with the adjustable differential at
the minimum setting of 10°F, the burner circuit (R-B) breaks
and the circulator circuit (R-W) makes at the low limit set
point. On a temperature drop of 10°F below the set point,
the R-B circuit makes and the R-W circuit breaks.
ADJUSTABLE DIFFERENTIAL —-
At any differential setting greater than 10°F, the R-B
make temperature and R-W break temperature will remain
the same-control setting minus 10°F. The R-B break and R-
W make temperature will be the set point temperature plus
the difference between the differential setting and 10°F.
EXAMPLE: Set point of 140°F; differential set at 25°F. On
a temperature rise, R-B will break and R-W will make at
155°F. On a temperature fall, R-B will make and R-W will
break at 130°F.
Set low limit indicator at the minimum temperature
recommended for domestic hot water supply. This setting
must be at least 20°F below high limit setting to prevent one
switch from locking out the other.
Set the differential the desired number of degrees. 25°F
differential gives longest burner cycles.
AQUASTAT SWITCHING ACTION WITHIN L8148A
CONTROLS
The switching action in the L8148A control has one
setting, the high limit. The switching relay is controlled by
the low voltage room thermostat. On a call for heat, the relay
contacts make to complete the line voltage circulator circuit
and also the burner circuit if the boiler water temperature is
below the high limit setting. The high limit switch shuts off
the burner if boiler water temperature exceeds the high limit
setting.
Set the indicator at the desired shutoff temperature.

19
SECTION IV: BOILER CLEANING
Figure 15: Cleaning of Boiler Flueways
A. CLEAN THE FLUEWAYS (See Figure 15).
1. Disconnect oil line(s) and remove burner and burner
mounting plate. See Figures 1A and 1B.
2. Lay protective cloth or plastic over combustion
chamber blanket.
3. On boilers with tankless heaters remove the control
from the tankless heater well. Unfasten the conduit
from the jacket panel and swing control away from
the jacket right side.
4. Remove the smokepipe as necessary to gain access
to the boiler canopy.
5. Remove the jacket top and right side panels.
NOTE: Top panel must be altered to be made
removable. Cut away left corner around supply
piping and relief valve. Top panel can be hinged
upward for access to canopy.
6. Remove the canopy being careful not to damage the
cerafelt gasket.
7. Loosen nuts securing the flue cleanout plates and
remove the plates. The insulation should be removed
with the plates taking care not to damage the
insulation.
8. Using a 1¼” diameter wire or fibre bristle brush
(30” handle) clean the flueways. Brush from the top
and side using horizontal and diagonal strokes for
best results. DO NOT allow brush to strike the target
wall or liner in the chamber.
B. CLEAN TOP OF BOILER SECTIONS.
1. Brush and vacuum the tops of the boiler sections.
C. CLEAN THE FIREBOX.
1. Using wire or fibre bristle brush, clean crown of
boiler 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, burner mounting plate and all flue plates are
secured in place.
1. Install the canopy taking care to align the gaskets
without blocking the flueways. If gasket is damaged,
replace as needed.
2. Bolt burner mounting plate to front section with
fasteners.
3. Bolt burner to burner mounting plate and connect oil
line(s).
4. Reinstall flue plates, making sure gasket on each
plate is in place and forms gas tight seal. If damaged
replace as needed.
5. Reinstall Right Side Jacket Panel and Top Panel and
secure with sheet metal screws.
6. Reinstall smokepipe on canopy and secure to collar
with sheet metal screws.
7. On boilers with tankless heaters place sensing
element of control well and bottom. Tighten screw.
secure cduit to jacket with plastic clips.
GNINRAW
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20
All CLW Series repair parts may be ordered through New Yorker®Boiler Company, or its authorized distributors.
Should you require assistance in locating a New Yorker Distributor in your area, or have questions regarding the availability of
New Yorker products or repair parts, please contact: New Yorker®Boiler Co., Inc., P.O. Box 295, Colmar, PA 18915, Phone:
[phone] Attn: Customer Service Department
SECTION V: REPAIR PARTS
Figure 16: Bare Boiler Assembly Exploded View