New Yorker PVCG SERIES Service manual

INSTALLATION, OPERATING
AND
SERVICE INSTRUCTIONS
PVCG rMSERIES
GAS BOILER
BEFORE INSTALLATION: READ THIS MANUAL
SAVE THESE INSTRUCTIONS
Installing contractor and homeowner should read and be informed as to the proper installation and operation of this boiler. The
manufacturer will not be responsible for improper installation or operation. This manual and all associated instruction material should
be conspicuously posted near the boiler.
For service or repairs to boiler, call your heating contractor. When seeking information on boiler,
provide Boiler Model Number and Serial Number as shown on Rating Label.
|
Boiler Model Number IBoiler
I
PVCG
Heating Contractor
Serial Number
Address
IInstallation Date
Phone Number
®
RESIDENT_L H_TING BOILERS
8141975R14-11/09 Price -$3.00

IMPORTANT INFORMATION - READ CAREFULLY
NOTE: The equipment shall be installed in accordance with those installation regulations enforced in the area where the
installation is to be made. These regulations shall be carefully followed in all cases. Authorities having jurisdiction
shall be consulted before installations are made.
All wiring on boilers installed in the USA shall be made in accordance with the National Electrical Code and/or local
regulations.
The New York City Department of Buildings has approved the PVCG TM Series boiler: Approval No. MEA 318-99-E.
The City of New York requires a Licensed Master Plumber supervise the installation of this product.
The Massachusetts Board of Plumbers and Gas Fitters has approved the PVCG Series boiler. See the Massachusetts Board of
Plumbers and Gas Fitters website, http://license.reg.state.ma.us/pubLic/pb_pre_form.asp for the latest Approval Code or ask
your local Sales Representative.
The Colnlnonwealth of Massachusetts requires this product to be installed by a licensed Plumber or Gas Fitter.
The following terms are used throughout this manual to bring attention to the presence of hazards of various risk levels, or
to important information concerning product life.
Indicates a potentially hazardous situation which,
if not avoided, may result in moderate or minor
injury or property damage.
Indicates a potentially hazardous situation which,
if not avoided, could result in death, serious injury
or substantial property damage.
Indicates special instructions on installation,
operation, or maintenance which are important
but not related to personal injury hazards.
DO NOT store or use gasoline or other flammable vapors or liquids in the vicinity of this or any other
appliance.
If you smell gas vapors, NO NOT try to operate any appliance - DO NOT touch any electrical switch or use
any phone in the building. Immediately, call the gas supplier from a remotely located phone. Follow the gas
supplier's instructions or if the supplier is unavailable, contact the fire department.
2

This boiler requires regular maintenance and service to operate safely. Follow the instructions contained
in this manual.
Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal
injury or loss of life. Read and understand the entire manual before attempting installation, start-up
operation, or service. Installation and service must be performed only by an experienced, skilled, and
knowledgeable installer or service agency.
This boiler must be properly vented.
This boiler needs fresh air for safe operation and must be installed so there are provisions for adequate
combustion and ventilation air.
The interior of the venting system 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 venting system 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.
Installation is not complete unless a pressure relief valve is installed into the tapping located on top of
appliance. - See the Water Piping and Trim Section of this manual for details.
This boiler is supplied with safety devices 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 contains very hot water under high pressure. Do not unscrew any pipe fittings nor attempt
to disconnect any components of this boiler without positively assuring the water is cool and has no
pressure. Always wear protective clothing and equipment when installing, starting up or servicing this
boiler to prevent scald injuries. Do not rely on the pressure and temperature gauges to determine the
temperature and pressure of the boiler. This boiler contains components which become very hot when
the boiler is operating. Do not touch any components unless they are cool.
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 appliance.
Failure to follow all instructions inthe proper order can cause personal injury or death. Read all instructions,
including all those contained in component manufacturers manuals which are provided with the boiler
before installing, starting up, operating, maintaining or servicing.
Keep boiler area clear and free from combustible materials, gasoline and other flammable vapors or
liquids.
All cover plates, enclosures and guards must be in place at all times.

Table of Contents
I. Pre-Installation .................................. 5
II. Unpack Boiler ................................... 7
III. Venting ............................................. 8
IV. Water Piping and Trim .................... 14
V. Gas Piping ....................................... 18
VI.
VII.
VIII.
IX.
X.
Electrical ......................................... 20
System Start-up ............................... 22
Service ............................................. 29
Repair Parts ..................................... 36
Appendix
Low Water Cut Off ....................... 38
LgFW giDg vlgw FRONT VIEW RRIRT _InE V_F__
Figure 1: Dimensional Drawing
Table 1: Dimensional Data
Boiler Size
PVCG30
PVCG40
PVCG50
PVCG60
A
19-1/8
22-3/8
25-5/8
28-7/8
Dimensions [in inches]
B
12
15-1/4
18-1/2
21-3/4
C
9-5/8
10-5/8
13
14-5/8
D
15-5/8
15-5/8
15-1/4
15-1/4
Water Content
[Gallons]
3.2
4.0
4.7
5.5
Approximate
Shipping Weight
(Ibs.)
260
3O5
35O
415
4

I. Pre-lnstallation
Do not install boiler where gasoline or other I
flammable vapors or liquids, or sources of I
hydrocarbons (i.e. bleaches, cleaners, chemicals, I
sprays, paint removers, fabric softeners, etc.) are I
used or stored. I
Due to the low water content of the boiler, mis-
sizing of the boiler with regard to the heating
system load will result in excessive boiler cycling
and accelerated component failure. Manufacturer
DOES NOT warrant failures caused by mis-sized
boiler applications. DO NOT oversize the boiler
to the system.
i. Inspect shipment carefully for any signs of damage.
All equipment is carefully manufactured, inspected
and packed. Manufacturer's responsibility ceases upon
delivery of boiler to carrier in good condition. Any
claim for damage or shortage in shipment must be filed
1
,56"
6"
......4D.
iE!iii!,!ii}ii liliiiiiili iiiii/
TOP VtEW
•'--- CL©S£T
OUT/ NE
,.,_.__...T _
÷
FRONT _EW RIGHT SIDE ViEW
÷ VENT PP_}T MIb._MUM CI.EARANCE TO COMBUSTE.E MA1ER!AI. S
_IVE (5) _",_Ct¢_iS W N V{ilf,_I /S IF,_STAoU D t_".,_A tULLY D_CLOSi.iD
(C_¢ASE) APPLCA'ON OR FOL;R (4) NCNES WHEN VENT _S _iISTAI/ED
Wi]H Al LEAS[ ONE S©E OPEN, SIMILAR 0 A dOS[ [@A"re APPLICA] OR
Figure 2: Minimum Clearances to Combustible Material

Bo
Co
Do
Eo
E
Go
H.
Io
ilmnediately against carrier by consignee. No claims
for variances or shortages will be allowed by Boiler
Manufacturer, unless presented within sixty (60) days
after receipt of equipment.
Installation must conform to the requirements of the
authority having jurisdiction. In the absence of such
requirements, installation must conform to National
Fuel Gas ('ode, NFPA 54/ANSI Z223.1. Where
required by the authority having jurisdiction, the
installation must conform to the Standard for ('ontrols
and Safety Devices for Automatically Fired Boilers,
ANSI/ASME CSD- 1.
Do not install boiler where gasoline or other flalmnable
vapors or liquids, or sources of hydrocarbons (i.e.
bleaches, cleaners, chemicals, sprays, paint removers,
fabric softeners, etc.) are used or stored.
Appliance is design certified for installation on
combustible flooring. Do not install boiler on
carpeting.
Provide clearance between boiler jacket and
combustible material in accordance with local fire
ordinance. See Figure 2 for lninilnuln clearance from
combustible material for closet installation. For alcove
installation provide top clearance of 27 inches and
right side clearance of 6 inches. Recolmnended service
clearance is 24 inches from left side, right side and
front. Service clearances may be reduced to minilnuln
clearances to combustible materials.
Install on level floor. For basement installation provide
solid base, such as concrete, if floor is not level or if
water may be encountered on floor around boiler. Floor
must be able to support weight of boiler, water and all
additional system components.
Install near outside wall for through the wall venting.
Refer to Venting Section of this manual.
Protect gas ignition system components from water
(dripping, spraying, rain, etc.) during boiler operation
and service (circulator replacement, condensate trap,
control replacement, etc.).
Provide combustion and ventilation air in accordance
with applicable provisions of local building codes,
or National Fuel Gas ('ode, NFPA 54/ANSI Z223.1,
Section 5.3, Air for Combustion and Ventilation.
Adequate combustion and ventilation air must
be provided to assure proper combustion.
The following guideline is based on the National Fuel
Gas Code, NFPA 54/ANSI Z223.1.
1. Determine volume of space (boiler room). Rooms
communicating directly with space (through
openings not furnished with doors) are considered
part of space.
Volume [ft3]= Length [ft] x Width [ft] x Height [ft]
2. Determine Total Input of all appliances in space.
Round result to nearest 1,000 Btu per hour (Btuh).
3. Determine type of space. Divide Volume by Total
Input.
a. If result is greater than or equal to 50 ft3per
1,000 Btuh, space is considered an uncol_fined
space.
b. If result is less than 50 ft3per 1,000 Btuh, space
is considered a col_fined space.
4. Determine building type. A building of unusually
tight construction has the following characteristics:
a. Walls and ceiling exposed to outside atmosphere
have a continuous water vapor retarder with a
rating of 1 perln or less with openings gasketed
and sealed, and;
b. Weather-stripping has been added on openable
windows and doors, and;
c. Caulking or sealants applied in joints around
window and door frames, between sole
plates and floors, between wall-ceiling joints,
between wall panels, at plumbing and electrical
penetrations, and at other openings.
5. For boiler located in an uncol_fined space in a
building of other than unusually tight construction,
adequate combustion and ventilation air is normally
provided by fresh air infiltration through cracks
around windows and doors.
6. For boiler located within uncol_fined space in
building of unusually tight construction or within
confined space, provide outdoor air through two
permanent openings which COlmnunicate directly or
by duct with the outdoors or spaces (crawl or attic)
freely COlmnunicating 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 COlmnunication with outdoors. Minimum
free area of 1square 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 Bm 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.

7.
Alternate method for boiler located within col_[ined
space. Use indoor air if two permanent openings
communicate directly with additional space(s) of
sufficient volume such that combined volume of all
spaces meet criteria for unconfined space. Size each
opening for minimum free area of 1square inch per
1,000 Btu per hour input of all equipment in spaces,
but not less than 100 square inches.
Ventilation Duct Louvers and Grilles. Equip
outside openings with louvers to prevent entrance
of rain and snow, and screens to prevent entrance
of insects and rodents. Louvers and grilles must be
fixed in open position or interlocked with equipment
to open automatically before burner operation.
Screens must not be smaller than */4inch mesh.
Consider the blocking effect of louvers, grilles and
screens when calculating the opening size to provide
the required free area. If free area of 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.
Avoid operating this boiler in an environment where saw dust, loose insulation fibers, dry wall dust, etc.
are present. If boiler is operated under these conditions, the burner interior and ports must be cleaned and
inspected daily to insure proper operation.
II. Unpack Boiler
Ao
B.
C.
Move boiler to approximate installed position.
Remove all crate fasteners.
Lift outside container and remove with all other
inside protective spacers and bracing. Save two of the
wooden slats from the container sleeve for use in Steps
E and F.
D. Remove all boiler hold-down fasteners.
Installation of this boiler should be undertaken
only by trained and skilled personnel from a
qualified service agency.
E. Tilt the boiler to one side and slide a wooden slat under
the two raised feet.
IV. Tilt the boiler to the other side and slide another
wooden slat under the two raised feet.
G. Slide the boiler forward or backward offthe skid using
the two wooden slats as runners.
H. Move boiler to its permanent location.

III. Venting
Do not use this boiler with galvanized, Type 304 or Type 316 stainless steel, non metallic or any other
non AL29-4C ®based vent systems.
Do not use a barometric damper or drafthood with this boiler.
Do not use vent dampers with this boiler.
Moisture and ice may form on surfaces around termination. To prevent deterioration, surfaces should
be in good repair (sealed, painted, etc.).
This boiler needs fresh air for safe operation and must be installed so there are provisions for
adequate combustion and ventilation air.
Do not operate boiler where gasoline or other flammable vapors or liquids, or sources of hydrocarbons
(i.e. bleaches, cleaners, chemicals, sprays, paint removers, fabric softeners, etc.) are used, stored and/
or present in the air.
Do not exceed maximum vent length of 25 equivalent feet.
The gasketed vent system components pictured below in Figure A are being phased in and each vent
component is interchangeable with the previously supplied gasket-less venting components. The newer
vent components are generally quicker and easier to join, as they do not require the sealant application and
their clamp bands are attached. _ .............
In the event a gasketed vent component and a
gasket-less vent component must be intercon- _,.__,_..
nected, follow the instructions associated with ,_,._
Figure 4C or 4D. The two guiding principles of
these instructions are as follows:
1) Any joining of vent components
that involves at least one
gasket-less vent component
always requires the sealant
application.
2) The female end of a gasket-less
vent component always requires
a clamp band, regardless of the
design of the mating male vent
_dASKE_I ,,,LE:S$ (_ASKETI_I_)
VENT SY,_'I:TEM _ENT SYS_EM
component. Figure A: Vent
Each gasket-less vent component is supplied with a clamp band and sealant.
AVent Transition Kit, part number 6116302, is available that contains one clamp band and one 3 ounce tube
of sealant.

Table2:VentSystemComponents
Vent System Component Current Gasket-less Vent Part Number New Gasketed Vent Part Number
3" Dia. Pipe x 1 Ft 61160112 8116296U
3" Dia. Pipe x 3 Ft 61160101 8116298U
3" Dia. Pipe x 5 Ft 61160111 8116300U
3" Dia. Pipe x Adjustable N/A 8116319U
3" Dia. 90° Elbow 61160121 8116294U
3" Dia. 45° Elbow 61160131 8116292U
3" Dia. Horizontal Drain Tee 6116037 8116302U
3" Dia. Vertical Drain Tee 6116036 8116304U
A. General Guidelines. B.
1. Vent system installation must be in accordance with
National Fuel Gas' ('ode, NFPA 54/ANSI Z221.3,
Venting of Equipment or applicable provisions of
local building codes. Contact local building or fire
officials about restrictions and installation inspection
in your area.
2. This appliance requires a Special Gas Vent.
Use Vent Connector and Vent Terminal in Vent
Accessory Carton provided with boiler (See Repair
Parts). The product is designed to use factory
supplied AL 29-4C ®Stainless Steel vent system
components. The following lnanul_acturers offer
similar AL 29-4C _ components and are approved for
use with this product: Heat-Fab Inc. - Saf-T-Vent
(800-772-0739); Flex-L International Inc. - Star-34
(800-561-1980); Z-Flex U. S., Inc. - Z-Vent (800-
654-5600); and Protech Systems, Inc.- FasNSeal TM
(800-766-3473) or equivalent. The use of these
alternate lnanufacturer's venting systems will require
adapters to connect to the factory supplied vent
connector and vent terminal. These adapters are not
supplied with this unit and should be obtained from
the supplier of the alternate manufacturer's venting
system. See Table 2 for complete list of Vent
System Components.
3. Vent length restrictions are based on equivalent feet
of vent pipe (total length of straight pipe in feet plus
5 equivalent feet for each 45 ° or 90° elbow). Do
not exceed the lnaxilnuln certified vent length of 25
equivalent feet. The lninilnuln certified vent length
is 7 equivalent feet. Do not include vent terminal or
vent connector in equivalent feet calculations.
4. Do not install venting system components on
the exterior of the building except as specifically
required by these instructions.
5. This PVCG boiler may only be sidewall vented; it
may not be vertically vented, as through a roof.
Removal of Existing Boiler. For installations not
involving the replacement of an existing boiler, proceed
to Step C.
When an existing boiler is removed from a common
venting system, the common venting system is likely
to be too large for proper venting of the remaining
appliances. At the time ofrelnoval of an existing
boiler, the following steps shall be followed with each
appliance remaining connected to the colnlnon venting
system placed in operation, while the other appliances
remaining connected to the colnlnon venting system are
not in operation:
1. Seal any unused openings in the comlnon venting
system.
2. Visually inspect the venting system for proper
size and horizontal pitch and determine there is no
blockage or restriction, leakage, corrosion, and other
deficiencies which could cause an unsafe condition.
3. Insofar as is practical, close all building doors and
windows and all doors between the space in which
the appliances remaining connected to the colnlnon
venting system are located and other spaces of the
building. Turn on clothes dryers and any appliance
not connected to the common venting system.
Turn on any exhaust fans, such as range-hoods and
bathroom exhausts, so they will operate at lnaxilnuln
speed. Do not operate a sulmner exhaust fan. Close
fireplace dampers.
4. Place in operation the appliance being inspected.
Follow the Lighting (or Operating) Instructions.
Adjust thermostat so appliance will operate
continuously.
5. Test for spillage at the drafthood relief opening after
5 minutes of main burner operation. Use the flame
of a match or candle, or smoke from a cigarette,
cigar or pipe.

Co
6.
7.
After it has been determined that each appliance
remaining connected to the common venting system
properly vents when tested as outlined above, return
doors, windows, exhaust fans, fireplace dampers and
any other gas burning appliance to their previous
conditions of use.
Any improper operation of the common venting
system should be corrected so the installation
conforms with the National Fuel Gas Code, NFPA
54/ANSI Z223.1. When resizing any portion of the
common venting system, the common venting
system should be resized to approach the lninilnuln
size as determined in the National Fuel Gas ('ode,
NFPA 54/ANSI Z223.1.
Install Vent Connector.
1. Remove vent connector from vent accessory carton.
2. Remove gaskets, orifice plate and hardware from
blower outlet flange.
3. Assemble orifice plate gaskets, orifice plate, and
vent connector. See Figure 3.
4. Secure vent connector with washers and locknuts.
\
Figure 3: Vent Connector Installation
D. Install Vent Pipe, General.
1. Plan venting system to avoid possible contact with
plumbing or electrical wires. Start venting system at
vent connector and work toward the vent terminal.
2. Use non-combustible 3/4inch pipe strap to support
horizontal runs, maintain vent location and slope,
while preventing sags in pipe. Do not restrict
thermal expansion or movement of vent system.
Maximum support spacing is 5 feet. Do not
penetrate any part of the vent system with fasteners.
10
3.
4.
5.
Provide and maintain vent pipe lninilnuln clearance
to combustible materials. Vent pipe lninilnuln
clearance to combustible material is five (5)
inches when vent is installed in a fully enclosed
(chase) application or four (4) inches when vent is
installed with at least one side open, similar to a
joist bay application. Use thimble when penetrating
combustible wall.
a. PVCG30 and PVCG40 - Single wall thimble,
Factory Part No. 8116116. Other wall thimble
manufacturers are American Metal Products,
Hart & Cooley, and Metal Fab.
b. PVCG50 and PVCG60 - Double wall thimble,
Factory Part No. 8116115 (accommodates 5
inch to 8-3/4 inch wall thickness). Another wall
thimble manufacturer is Hart & Cooley.
Once a vent pipe manufacturer and system is chosen
never mix and match vent systems.
If a non-standard length pipe is required:
Gasketed Vent Svsteln: The use of the adjustable
length pipe (P/N 8116319U) is recommended to
complete a non-standard pipe length. This pipe
requires a lninilnuln installed length of 123¼inch
and can adjust across a 7 inch gap up to a lnaxilnuln
of 193/4inch long. (Note for the adjustable pipe
the installed length should be measured from the
centerline of the bead on the male end of the first
pipe to the end of the female pipe excluding the
locking band of the second pipe with a single
gasket.) Only in the event the adjustable length pipe
is not sufficient a standard length pipe may be cut
using the procedure outlined below for the Gasket-
Less Vent System.
Never exceed maximum installed length of 19%
inches for adjustable length pipe.
Risk of flue gas leakage is possible.
Gasket-Less Vent System: Carefully cut pipe to
length using a hacksaw with minilnuln 32 teeth
per inch or circular saw with metal abrasive wheel.
Remove male (bead) end only - female (bell) end
accepts next fitting or pipe.
I Cut must be with pipe and filed orI
square
sanded smooth before joining. Carefully ensure I
roundness of cut pipe by hand with gloves before I
installing. Seal joint with RTV specified in this I
manual. I
6. Seal all Gasket-Less vent, mixed vent (Gasket-
Less and Gasketed) and field cut joints using Dow
Coming Silastic 732 RTV, Dow Coming Silastic
736 RTV, GE RTV106, Polybac #500 RTV, Sil-

bondRTV4500(Acetoxy)andSil-bondRTV6500.
Donotuseotheradhesivesorsealants.
E. Install Vent Pipe, Gasket-Less Vent System.
1. Procedure for Joining Gasket-Less Vent Pipe and
Fittings. See Figure 4A.
/ii
Figure 4A: Gasket-Less Vent Joint Detail
a. Clean joints of pipe or fittings using an alcohol
pad to remove any dirt and grease.
b. Slip a locking band over female (bell) end of
pipe/fitting.
c. Apply a continuous */4inch bead of sealant
around male end of joint no more than 1/8 inch
from end.
d. Align weld seams and use a slight twisting
motion to FULLY insert male end into female
end of joint. Ensure bead in male end rest against
the end of the female pipe.
e. Smooth sealant around joint for a continuous
seal. Reapply sealant if necessary.
f. Slip the locking band over joint and align closest
bead in locking band with bead in male end of
pipe.
g. Tighten locking band by HAND with a 5/16"
nut driver until snug plus */4turn. DO NOT
SECURE JOINTS WITH SHEET METAL
SCREWS OR POP RIVETS. DO NOT
PUNCTURE THE VENT SYSTEM!
h.
F. Install
1.
Once the installation is complete, operate
appliance and inspect all joints to ensure that flue
gases and/or liquid condensate will not escape.
Vent Pipe, Gasketed Vent System.
Procedure for Joining Gasketed Vent Pipe and
Fittings. See Figure 4B.
a. Wipe the male end of each joint using an alcohol
pad to remove any dirt and grease.
b. Align weld seams in pipes and use a slight
twisting motion to FULLY insert male end into
female end of joint. Ensure bead in male end
of pipe is below locking band and rest against
the end of the female pipe. Verify the factory-
installed gasket is not dislodged or cut.
Figure 4B: Gasketed Vent Joint Detail
Tighten locking band by HAND with a 5/16" nut
driver until snug plus */4turn. DO NOT SECURE
JOINTS WITH SHEET METAL SCREWS OR
POP RIVETS. DO NOT PUNCTURE THE
VENT SYSTEM[
d. Once the installation is complete, operate
appliance and inspect all joints to ensure that flue
gases and/or liquid condensate will not escape.
G. Install Vent Pipe, Gasket-Less &Gasketed Vent
System.
1. Procedure for joining the male end of Gasket-Less
Vent with the female end of Gasketed Vent. See
Figure 4C.
Figure 4C: Gasket-Less Male and Gasketed
Female Vent Joint Detail
a. Clean the male end of each joint using an alcohol
pad to remove any dirt and grease.
b. Apply a continuous */4inch bead of sealant
around male end of joint no more than 1/8 inch
from end.
c. Align weld seams in pipes and use a slight
twisting motion to FULLY insert male end into
female end of joint. Ensure bead in male end
of pipe is below locking band and rest against
the end of the female pipe. Verify the factory-
installed gasket is not dislodged or cut.
d. Smooth sealant around joint for a continuous
seal. Reapply sealant if necessary.
e. Tighten locking band by HAND with a 5/16" nut
driver until snug plus *Aturn. DO NOT SECURE
JOINTS WITH SHEET METAL SCREWS OR
POP RIVETS. DO NOT PUNCTURE THE
VENT SYSTEM[
11

f. Once the installation is complete, operate
appliance and inspect all joints to ensure that flue
gases and/or liquid condensate will not escape.
2. Procedure for joining the female end of Gasket-
Less Vent with the male end of Gasketed Vent. See
Figure 4D.
,'_ _o_ T_,, , _ _>_ _;_
tL
::iN,,; }_ ? i I _......
/
/
_:_©_H _;_a_,_ _t4_) _)_N_¸ _o_
•/_ ¸__ g¸_¸_¸_2__,_#_
_,,_ _t?;_;_;
i¸_i_ii_iiiii/ii_i_iii_li_iiii/iit}
t_>:_ ¸ _ _ 1_4_ _
Figure 4D: Gasket-Less Female and
Gasketed Male Vent Joint Detail
a. Clean joints of pipe or fittings using an alcohol
pad to remove any dirt and grease.
b. Slip a locking band over female (bell) end of
pipe/fitting.
c. Apply a continuous */4inch bead of sealant
around male end of joint no more than 1/8 inch
from end.
d. Align weld seams in pipes and use a slight
twisting motion to FULLY insert male end into
female end of joint.
e. Smooth sealant around joint for a continuous
seal. Reapply sealant if necessary.
f. Slip the locking band over joint and align closest
bead in locking band with bead in male end of
pipe.
g. Tighten locking band by HAND with a 5/16"
nut driver until snug plus */4turn. DO NOT
SECURE JOINTS WITH SHEET METAL
SCREWS OR POP RIVETS. DO NOT
PUNCTURE THE VENT SYSTEM!
h. Once the installation is complete, operate
appliance and inspect all joints to ensure that flue
gases and/or liquid condensate will not escape.
H. Horizontal (Through Wall) Vent Installation.
2.
Maintain minilnuln */4inch per foot slope in
horizontal runs. Slope pipe down toward vent
terminal. Position weld seams in vent pipes in all
horizontal runs at the top to avoid condensate from
lying on the seams.
Vent terminal location restricted per following:
a. Minimum 12 inches above grade plus normally
expected snow accumulation level, or 7 feet
above grade if located adjacent to public
walkway. Do not install over public walkway
where local experience indicates condensate or
vapor from Category III appliances creates a
nuisance or hazard.
b. Minimum 3 feet above any forced air inlet
located within 10 feet.
c. Minimum 4 foot below, 4 foot horizontally from,
or 1foot above any door, window, or gravity air
inlet.
3.
d. Minimum 4 feet (6 feet in Canada) horizontally
from, and in no case above or below, unless a
4-foot horizontal distance is maintained, from
electric meters, gas meters, regulators and relief
equipment.
e. Minimum 12 inches from overhang or corner.
Use wall thimble when passing through combustible
outside wall (thimble use optional for noncolnbusti-
ble wall). Insert thimble through wall from outside.
Secure outside flange to wall with nails or screws,
and seal with adhesive material. Install inside flange
to inside wall, secure with nails or screws, and seal
with adhesive material.
4. For noncombustible wall when thimble is not
used, size opening such that female (bell) end with
locking band attached cannot pass through.
5. Join vent terminal to vent pipe. Locate vent
terminal 3 inches (lninilnuln) and 6 inches
(recolmnended) from wall when joined to inside
vent piping. See Figure 5. Vent terminal clearance
to vinyl wall surfaces is 6 inches.
6. Insert vent pipe through thimble/opening from
outside and join to vent system. Apply sealant
between vent pipe and opening/thimble to provide
weathertight seal.
12

Figure 5: Recommendations for Thimble and Wall Penetration

IV. Water Piping and Trim
Failure to properly pipe boiler may result in improper operation and damage to boiler or structure.
Oxygen contamination of boiler water will cause corrosion of iron and steel boiler components, and can
lead to boiler failure. Manufacturer'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.
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Design and install boiler and system piping to
prevent oxygen contamination of boiler water and
frequent water additions.
1. There are many possible causes of oxygen
contamination such as:
2.
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
must be eliminated. This can be accomplished by
taking the following measures:
a. Repairing system leaks to eliminate the need for
addition of make-up water.
b. Eliminating open tanks from the system.
c. Eliminating and/or repairing fittings which allow
oxygen absorption.
d. Use ofnon-perlneable materials in the
distribution system.
e. Isolating the boiler from the system water by
installing a heat exchanger.
f. Use properly designed and operating air
elimination devices in water piping.
Connect system supply and return piping to
boiler. See Figures 7 and 8. Also consult I=B=R
Installation and Piping Guides. Maintain lninilnuln ½
inch clearance from hot water piping to combustible
materials.
Install Circulator with flanges, gaskets and bolts
provided. Install system circulator on supply piping.
Connect harness to circulator and secure any excess
conduit.
Install Pressure Relief Valve. See Figure 7 or 8.
Pressure Relief Valve must be installed with spindle in
vertical position. Installation of the relief valve must
comply with the ANSI/ASME Boiler and Pressure
Vessel Code, Section IV.
Pressure relief valve discharge piping must be
piped such that the potential of severe burns
is eliminated. DO NOT pipe in any area where
freezing could occur. DO NOT install any shut-off
valves, plugs or caps. Consult Local Codes for
proper discharge piping arrangement.
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Install Drain Valve in 3/4inch NPT connection in tee
provided. See Figure 1.
Space heating and domestic water heating with
New Yorker Link SLTM indirect water heater. Install
New Yorker Link SLTM indirect water heater as a
separate heating zone. Refer to New Yorker Link SLTM
Installation, Operating and Service Instructions for
additional information.
If boiler is used in connection with refrigeration
systems, boiler must be installed with chilled medium
piped in parallel with the heating boiler using
appropriate valves to prevent chilled medium from
entering boiler, see Figure 6. Also consult I=B=R
Installation and Piping Guides.
SUP?_ Y I'4AIN l[} R£T'URN MAIN F'R8_t_
CI]MBIN{IB HEALING CGMSINE]] H[A'TZNG
S COOLING SYSTEM S COBLING SYSTES-
Figure 6: Recommended Piping for Combination
Heating & Cooling (Refrigeration) Systems
14

1¼
sUPPLY
VALVE
SYSTEM sUPPLY
AIR ScoOP
®
TO
ZONE I
FLOW cONTROL
-"VALVE
CIRCULATOR
sUPPLY
Figure 7: Recommended Water Piping for Circulator Zoned Heating Systems

Ob
VAL\_
_R VE_
FRON #DDmO_ ZONE
i_i_ _ FROMzo.E2
_'°_w_ _ FROM_JAN_EwA_R
HEATER OR ZONE I
SH_-OFF
1¼ VALV_
TO _CE TO
WATER HEA__R ZONE 1 Z_E 2
OF_)
_M
RETURN
P{PE _TH_N
6" OF FI,_OOR
S_EM SUPPLY
Figure 8: Recommended Water Piping for Zone Valve Zoned Heating Systems

H. If boiler is connected to heating coils located in
air handling units where they may be exposed to
refrigerated air, boiler piping must be equipped with
flow control valves to prevent gravity circulation of
boiler water during operation of cooling system.
Io Use aboiler bypass if the boiler is to be operated
in a system which has a large volume or excessive
radiation where low boiler water temperatures may be
encountered (i.e. converted gravity circulation system,
etc.).
Install pipe tee between circulator and boiler return
along with second tee in supply piping as shown in
Figures 7 and 8. Bypass should be same size as the
supply and return lines with valves located in bypass
and supply outlet as illustrated in Figures 7 and 8 in
order to regulate water flow to maintain higher boiler
water temperatures.
After the boiler is operational (reference System
Start-Up Section of this manual) set by-pass and boiler
supply valves to half throttle position to start. Operate
boiler until system water temperature reaches normal
operating range.
Adjust valves to provide 180° to 200°F supply water
temperature. Opening the boiler supply valve will raise
system temperature, while opening the by-pass valve
will lower system supply temperature.
J. A hot water boiler installed above radiation level
must be provided with a low water cut-off device as
part of installation.
K°
L°
Mo
If a low water cut-off is required, it must be mounted in
the system piping above the boiler.
The lninilnuln safe water level of a hot water boiler is
just above the highest water containing cavity of the
boiler; that is, a hot water boiler must be full of water to
operate safely.
Oil, grease, and other foreign materials which
accumulate in new hot water boilers and a new or
reworked system should be boiled out, and then
thoroughly flushed. A qualified water treatment
chemical specialist should be consulted for
recolnlnendations regarding appropriate chemical
compounds and concentrations which are compatible
with local environmental regulations.
After the boiler and system have been cleaned and
flushed, and before refilling the entire system, add
appropriate water treatment chemicals, if necessary, to
bring the pH between 7 and 11.
If it is required to perform a long term pressure
test of the hydronic system, the boiler should first be
isolated to avoid apressure loss due to the escape of air
trappedin the boiler.
To perforln along terlnpressure test including the
boiler, ALL trappedair must first be removed from the
boiler.
Aloss of pressure during such a test, with no visible
water leakage, is an indication thatthe boiler contained
trapped air.
17

V. Gas Piping
Failure to properly pipe gas supply to boiler may
result in improper operation and damage to the
boiler or structure. Always assure gas piping is
absolutely leak free and of the proper size and
type for the connected load.
An additional gas pressure regulator may be
needed. Consult gas supplier.
B. Connect boiler gas valve to gas supply system.
Ao Size gas piping. Design system to provide adequate gas
supply to boiler. Consider these factors:
1.
2.
Table
Allowable pressure drop from point of delivery to
boiler. Maximum allowable system pressure is */2
psig. Actual point of delivery pressure may be less;
contact gas supplier for additional information.
Minimum gas valve inlet pressure is listed on rating
label on front of boiler.
Maximum gas demand. Table 3 lists boiler input
rate. Also consider existing and expected future gas
utilization equipment (i.e. water heater, cooking
equipment).
3: Rated Input
Boiler
Model
Number
Input Rate
[cubic feet per hour] Gas
Connection
Size
Natural
Gas
62
96
130
164
LP/Propane
243A
38½
52
653A
PVCG30 ½
PVCG40 ½
PVCG50 ½
PVCG60 ½
3. Length of piping and number of fittings. Refer to
Table 4 for lnaxilnuln capacity of Schedule 40 pipe.
Table 5 lists equivalent pipe length for standard
fittings.
4. Specific gravity of gas. Corrections for the specific
gravity of natural gas can be found in Table 6.
For materials or conditions other than those listed
above, refer to National Fuel Gas ('ode, NFPA
54/ANSI Z223.1, or size system using standard
engineering methods acceptable to authority having
jurisdiction.
_
1. Use methods and materials in accordance with local
plumbing codes and requirements of gas supplier. In
absence of such requirements, follow National Fuel
Gas ('ode, NFPA 54/ANSI Z223.1.
2. Use thread (joint) compounds (pipe dope) resistant
to action of liquefied petroleum gas.
3. Install sediment trap, ground-joint union and manual
shut-off valve upstream of boiler gas control valve.
See Figure 10.
4.
I',11N,_..i................................[: °
C¢,pj, '/'
Figure 10: Recommended Gas Piping
All above ground gas piping upstream from manual
shut-off valve must be electrically continuous and
bonded to a grounding electrode. Do not use gas
piping as grounding electrode. Refer to National
Electrical ('ode, ANSI/NFPA 70.
18

Co Pressure test. The boiler and its gas connection must
be leak tested before placing boiler in operation.
Protect boiler gas control valve. For all testing over
*/2psig, boiler and its individual shutoff valve must
be disconnected from gas supply piping. For testing
at */2psig or less, isolate boiler from gas supply
piping by closing boiler's individual manual shutoff
valve.
2. Locate leaks using approved combustible gas
detector, soap and water, or similar nonflammable
solution.
Do not use matches, candles, open flames or
other ignition source to check for leaks.
Table 4:
Length
[Feet]
10
2O
3O
4O
5O
6O
7O
8O
9O
lO0
Maximum Capacity of Schedule 40 Pipe in CFH For Natural Gas Pressures of 0.5 psig or Less
½
132
92
73
63
56
50
46
43
40
38
0.3 Inch w.c. Pressure Drop 0.5 Inch w.c. Pressure Drop
¾
278
190
152
130
115
105
96
90
84
79
1
520
350
285
245
215
195
180
170
160
150
1%
1,050
730
590
500
440
400
370
350
320
305
½
175
120
97
82
73
66
61
57
53
50
¾
360
250
200
170
151
138
125
118
110
103
1
680
465
375
320
285
260
240
220
205
195
1%
1,400
950
770
660
580
530
490
460
430
400
Table 5: Fitting Equivalent Lengths
VALVES FULLY OPEN
Pipe I.D. Gate Globe Angle Swing
Size Inches Check
½" 06.22 0.35 18.6 9.3 4.3
3A" 0.824 0.44 23.1 11.5 5.3
1" 1.049 0.56 29.4 14.7 6.8
1¼" 1.380 0.74 38.6 19.3 8.9
90 ° 45 ° 90 ° Tee, Flow 90 ° Tee, Flow
Elbow Elbow Through Run Through Branch
1.6 0.78 1.0 3.1
2.1 0.97 1.4 4.1
2.6 1.23 1.8 5.3
3.5 1.60 2.3 6.9
Table 6: Specific Gravity Correction Factors
for Natural Gas
Specific Correction Specific Correction
Gravity Factor Gravity Factor
0.50 1.10 1.30 1.07
0.55 1.04 1.40 1.04
0.60 1.00 1.50 1.00
0.65 0.96 1.60 0.97
0.70 0.93 1.70 0.94
0.75 0.90 ......
0.80 0.87 ......
19

PVCG boilers built for installation at altitudes greater than 2,000 feet above sea level have been specially
orificed to reduce gas input rate. See rating label for gas orifice size. High
identifiable by the second digit in the model number suffix on the rating label:
PVCG O 1- 2 : Less than 2000 ft. elevation
PVCG O 1- 5 : 2000 to 5000 ft. elevation
altitude boiler models are
Vl. Electrical
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2O
Failure to properly wire electrical connections to the boiler may result in serious physical harm.
Electrical power may be from more than one source. Make sure all power is off before attempting any
electrical work.
Each boiler must be protected with a properly sized fused disconnect.
Never jump out or make inoperative any safety or operating controls.
The wiring diagrams contained in this manual are for reference purposes only. Each boiler is shipped
with a wiring diagram attached to the left side of the boiler. Refer to this diagram and the wiring diagram
of any controls used with the boiler. Read, understand and follow all wiring instructions supplied with
the controls.
General. Install wiring and ground boiler in accordance
with requirements of authority having jurisdiction, or in
absence of such requirements, the National Electrical
('ode, ANSI/NFPA 70.
Install thermostat. Locate on inside wall
approximately 4 feet above floor. Do not install on
outside wall, near fireplace, or where influenced by
drafts or restricted air flow, hot or cold water pipes,
lighting fixtures, television, or sunlight. Allow free air
movelnent by avoiding placement of furniture near
thermostat.
Wire thermostat. Provide Class II circuit between
thermostat and boiler. Run wires through grolmnet
in L8148E Combination Control. Set thermostat heat
anticipator to 0.4 amps. See Figure 11.
Wire boiler. Boiler is rated for 120 VAC, 60 hertz,
less than 12 amperes. A separate electrical circuit must
be run from the main electrical service with an over-
current device/disconnect in the circuit. A service
switch is recommended and may be required by some
local jurisdictions. Connect circuit to black and white
wires and green ground screw. See Figure 11.
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New Yorker Link SL TM indirect water heater (if
used). See Figure 11. Also refer to New Yorker Link
SLTM Installation, Operating and Service Instructions.
1. Zoning with Circulators, Domestic Hot Water
Priority. Provide DPDT relay. Connect coil to
New Yorker Link SLTM indirect water heater
thermostat. Connect normally open contacts to
L8148E Combination Control terlninals 'Z' and
'B'. Disconnect yellow circulator wire terminal
'CI' in L8148E Combination Control. Connect
normally closed contacts to 'C1' terminal and yellow
circulator wire.
2. Zoning with Circulators, Nonpriority. Connect New
Yorker Link SLTM indirect water heater circulator
zone control to L8148E Combination Control
terminals 'Z' and 'B'.
3. Zoning with Zone Valves. Connect New Yorker
Link SLTM indirect water heater thermostat to zone
valve. Connect zone valve end switch to L8148E
Combination Control terminals 'T' and 'TV'. See
Paragraph F.
For installations using zone valves provide separate
transformer for zone valve wiring. Consult zone valve
manufacturer for assistance.