New Yorker CG-E SERIES Installation, Operating And Service Instructions
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New Yorker CG-E SERIES Installation, Operating And Service Instructions

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INSTALLATION, OPERATING
SERVICE 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
CG _ _ E
Heating Contractor
Address
106213-01- 11/15
AND
CG-E™ SERIES
GAS BOILER
BEFORE INSTALLATION: READ THIS MANUAL
SAVE THESE INSTRUCTIONS
Boiler Serial Number
9700609
Installation Date
Phone Number
Price - $5.00

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  • Page 1 INSTALLATION, OPERATING SERVICE INSTRUCTIONS CG-E™ SERIES GAS BOILER 9700609 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.
  • Page 2 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 CG-E™ Series Boiler. See the Massachusetts Board of Plumbers and Gas Fitters website, http://license.reg.state.ma.us/pubLic/pl_products/pb_pre_form.asp for the latest Approval Code or ask your local Sales Representative.
  • Page 3 Table 1A: Dimensions and Connections Boiler Supply NPT Return NPT Vent Gas NPT Relief Valve Drain Depth Width Height Model (inch) (inch) (inch) (inch) NPT (inch) NPT (inch) CG30E 1¼ 1¼ ½ ¾ ¾ CG40E 1¼ 1¼ ½ ¾ ¾ CG50E 1¼...
  • Page 4 Figure 1: Minimum Clearance to Combustible Materials and Alcove Dimensions...
  • Page 5 I. Pre-Installation Install on level floor. For basement installation provide WARNING concrete base if floor is not level or if water may be encountered on floor around boiler. Carefully read all instructions before installing boiler. Failure to follow all instructions in proper CAUTION order can cause personal injury or death.
  • Page 6 III. Water Piping and Trim WARNING Failure to properly pipe boiler may result in improper operation and damage to boiler or building. Design and install boiler and system piping to prevent oxygen contamination of boiler water. Oxygen contamination sources are system leaks requiring addition of makeup water, fittings, and oxygen permeable materials in distribution system.
  • Page 7 LWCO control the boiler to fire. is permitted when it is installed according to the 8. CG-E Series gas hot water boilers have a “plug- LWCO manufacturer's instructions. in” provision in factory wiring that will accept 2.
  • Page 10 Z223.1/NFPA 54, or applicable provisions of local c. Insofar as is practical, close all building doors and building codes. The CG-E Series boiler is a Category I, windows and all doors between the space in which draft hood equipped appliance.
  • Page 11 building. Turn on clothes dryers and any appliance f. After it has been determined that each appliance not connected to the common venting system. remain ing connected to the common venting system Turn on any exhaust fans, such as range hoods and properly vents when tested as outlined above, return bathroom exhausts, so they will operate at maxi mum doors, win dows, exhaust fans, fireplace dampers and...
  • Page 12 V. Gas Piping 3. Install sediment trap, ground-joint union and manual Size gas piping. Design system to provide adequate gas shut-off valve upstream of boiler gas control valve. supply to boiler. Consider these factors: See Figure 8. 1. Allowable pressure drop from point of delivery to boiler.
  • Page 13 VI. Electrical General. Install wiring and electrically bond boiler to For installations using zone valves provide separate ground in accordance with requirements of authority transformer for zone valve wiring. Consult zone valve having jurisdiction, or in absence of such requirements, manufacturer for assistance.
  • Page 14 Figure 9: Wiring Connection Diagram...
  • Page 15 Figure 10: Schematic Ladder Diagram...
  • Page 16 Figure 11: Wiring Schematic, Zone Valves Figure 12: Wiring Schematic, Zone Circulators...
  • Page 17 VII. System Start-up and Checkout . Main Burner Check - Check main burners to see that they were not dislodged during shipment. Rear of burners should be in the vertical slots in the rear of burner tray and the front of the burners should be seated completely on the orifices.
  • Page 18 Figure 14: Operating Instructions...
  • Page 19 4. With boiler off, water Manometer or water column gauge should be connected to a shut-off valve installed in the 1/8" outlet pressure tap in the gas valve (see Figure 13). By installing gas valve upstream of manometer, gas pressure can be introduced gradually - without shut-off valve;...
  • Page 20 In the event the boiler fails to start, the control provides NORMAL OPERATION status information to help determine the cause of the 1. The CG-E Series Boilers are equipped with an problem. Table 3 from Section X: Troubleshooting Integrated Boiler Control (IBC). This IBC replaces...

  • Page 21: Outdoor Reset

    1. High limit setpoint 2. Outdoor Reset Differential Setpoint (when outdoor sensor installed) The High Limit Setpoint is user adjustable by turning the top knob labeled “BOILER TEMP”. The Outdoor Reset Differential Setpoint is user Adjustment range is 140°F to 220°F. During adjustable by turning the bottom knob labeled normal operation the LED display will show boiler “OUTDOOR RESET DIFF”.
  • Page 22 IX. Service and Maintenance Important Product Safety Information Refractory Ceramic Fiber Product Warning: The Repair Parts list designates parts that contain refractory ceramic fibers (RCF). RCF has been classified as a possible human carcinogen. When exposed to temperatures above 1805°F, such as during direct flame contact, RCF changes into crystalline silica, a known carcinogen.
  • Page 23 WARNING Service on this boiler should be undertaken only by trained and skilled personnel from a qualified service agency. Inspections should be performed at intervals specified in this manual. Maintain manual in a legible condition. Keep boiler area clear and free of combustible materials, gasoline and other flammable vapors and liquids.
  • Page 24 30 VAC) and polarity is correct. tables the following should be kept in mind: 4. All controls on the CG-E Series are tested at least 1. This information is only meant to be used by once in the manufacturing process and a defective...
  • Page 25 UsE COnTROl lEDS TO DIRECT TROUBlEsHOOTIng EFFORTs If the control detects an error, the lEDs will flash. Use the lEDs to identify the boiler problem and corrective action in the table below. If lEDs are not flashing, proceed to paragraph C: Flashing Status Recommended Corrective Action...
  • Page 26 USE STATUS LEDS TO GUIDE TROUBLESHOOTING The control LEDs will light to indicate status. Use these LEDs to identify the boiler problem in the table below: 1. Boiler and Circulator Off LED / Status Recommended Corrective Action The boiler has not detected a call for heat Check that the thermostat: - POWER - When a thermostat call for heat is detected control TSTAT/CIRC LED will be lit.
  • Page 27 4. Circulator is On But Damper is Not Open LED / Status Recommended Corrective Action The control is waiting for the damper to open. Damper end switch has failed to close (end switch contact is stuck open). Combustion can never take place unless the damper blade is in the fully open position. Check the following: - POWER - Confirm if control terminal “P6 - 5”...
  • Page 28 5. Circulator is On, Damper is Open But Boiler Fails to Start (continued) LED / Status Recommended Corrective Action 1. No Spark a. Can you hear sparking? - If there is no spark noise replace the control. b. If you can hear spark noise check the following: - Loose connection in ignition cable or ground wire - Continuity of ignition cable - Break in ignition cable insulation...
  • Page 29 All CG-E™ Series repair parts may be ordered through New Yorker Boiler Company, 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 New Yorker products or repair parts, please contact: New Yorker Boiler Company, Inc.
  • Page 30 CG-E MODEL Description Part Number 102287-03 102287-04 102287-05 Cast Iron Section Assembly (Complete) 102287-06 102287-07 102287-08 102287-09 Canopy Gasket Kit 6201001 102254-03 102254-04 102254-05 Canopy Assembly 102254-06 102254-07 102254-08 102254-09 Blocked Vent Switch (not shown) 80160157...
  • Page 31 Section Assembly and Canopy Group...
  • Page 32 CG-E MODEL Description Part Number 71807031 71807041 71807051 Base Wrapper 71807061 71807071 71807081 71807091 102543-03 102543-04 102543-05 Base Tray 102543-06 102543-07 102543-08 102543-09 61807031 61807041 61807051 Burner Tray/Burner Tray Assembly 61807061 61807071 61807081 61807091 102705-03 102705-04 102705-05 Base Front Panel 102705-06 102705-07 102705-08...
  • Page 33 CG-E MODEL Description Part Number 72007032 72007042 72007052 Base Front Insulation 72007062 72007072 72007082 72007092 Base Leg Assembly 6186001 Flame Roll-out Switch 80160044 Manifold Support Bracket 718070001 103718-03 103718-04 103718-05 Front Air Dam 103718-06 103718-07 103718-08 103718-09...
  • Page 34 CG-E MODEL Description Part Number Burners, Manifold and Gas Valve (Natural & LP Gas) Gas Valve, Honeywell VR8204P1171 81660282 (Nat. Gas) Gas Valve, Honeywell VR8304P4496 81660283 (Nat. Gas) Gas Valve, Honeywell VR8204C3015 (LP) 81660146 Gas Valve, Honeywell VR8304P4314 (LP) 81660160 82207031 82207041 82207051...
  • Page 35 CG-E MODEL Description Part Number Controls Boiler Control, Atmospheric Draft, 106541-01 UTEC 1135-630 Transformer, 40 VA, modified Honeywell 106529-01 AT140B1297 Limit Rated Temperature Sensor, 12" Lg., 106643-01 Tasseron Temperature Sensor Clip, Honeywell 102422-01 32002656-001 (not shown)
  • Page 36 CG-E MODEL Description Part Number Jacket Assembly, Complete 106707-03 106707-04 106707-05 Jacket Assembly, Complete 106707-06 106707-07 106707-08 106707-09...
  • Page 37 CG-E MODEL Description Part Number Trim and Vent Damper Supply Water Manifold 8060700 Temperature / Pressure Gauge 100282-01 Safety Relief Valve, 30 psi 81660363 Drain Valve 102802-01 Vent Damper - 4" Dia. 102284-01 Vent Damper - 5" Dia. 102284-02 Vent Damper - 6" Dia. 102284-03 Vent Damper - 7"...

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