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INSTALLATION, OPERATING
AND SERVICE INSTRUCTIONS
CAST IRON OIL-FIRED BOILER
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M24350R6-11/09
CLS SERIES
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Price - $3.00
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Summary of Contents for New Yorker CLS Series
- Page 1 INSTALLATION, OPERATING AND SERVICE INSTRUCTIONS CLS SERIES CAST IRON OIL-FIRED BOILER M24350R6-11/09 Price - $3.00...
- Page 2 IMPORTANT INFORMATION - PLEASE READ THIS PAGE CAREFULLY 1. THIS BOILER HAS LIMITED WARRANTIES, COPIES OF WHICH ARE PRINTED ON THE BACK COVER OF THIS MANUAL. 2. THIS BOILER IS SUITABLE FOR INSTALLATION ON COMBUSTIBLE FLOORING. BOILER CANNOT BE IN- STALLED ON CARPETING. 3. ALL BOILERS MUST BE INSTALLED IN ACCORDANCE WITH NATIONAL, STATE AND LOCAL PLUMBING, HEATING AND ELECTRICAL CODES AND THE REGULATIONS OF THE SERVING UTILITIES WHICH MAY DIF- FER FROM THIS MANUAL. AUTHORITIES HAVING JURISDICTION SHOULD BE CONSULTED BEFORE INSTAL- LATIONS ARE MADE. IN ALL CASES, REFERENCE SHOULD BE MADE TO THE FOLLOWING STANDARDS: A. Current Edition of American National Standard ANSI/NFPA 31, “Installation of Oil Burning Equipment”, for clearances between boiler, vent connector and combustible material. B. Current Edition of American National Standard ANSI/NFPA 211, “Chimneys, Fireplaces, Vents, and Solid Fuel Burning Appliances”, For Chimney require- ments, type of venting material and clearances between vent connector pipe and combustible materials. C. Current Edition of American Society of Mechanical Engineers ASME CSD-1, “Controls and Safety Devices for Automatically Fired Boilers”, for assembly and operations of controls and safety devices. 4. ALL HEATING SYSTEMS SHOULD BE DESIGNED BY COMPETENT CONTRACTORS AND ONLY PERSONS KNOWLEDGEABLE IN THE LAYOUT AND INSTALLATION OF HYDRONIC HEATING SYSTEMS SHOULD AT- TEMPT INSTALLATION OF ANY BOILER. 5. THE BOILER MUST BE CONNECTED TO AN APPROVED CHIMNEY IN GOOD CONDITION. SERIOUS PROP- ERTY DAMAGE COULD RESULT IF THE BOILER IS CONNECTED TO A DIRTY OR INADEQUATE CHIMNEY. THE INTERIOR OF THE CHIMNEY FLUE MUST BE INSPECTED AND CLEANED BEFORE THE START OF THE HEATING SEASON AND SHOULD BE INSPECTED PERIODICALLY THROUGHOUT THE HEATING SEASON FOR ANY OBSTRUCTIONS. A CLEAN AND UNOBSTRUCTED CHIMNEY FLUE IS NECESSARY TO ALLOW NOXIOUS FUMES THAT COULD CAUSE INJURY OR LOSS OF LIFE TO VENT SAFELY AND WILL CONTRIBUTE TOWARD MAINTAINING THE BOILER’S EFFICIENCY.
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Page 3: Table Of Contents
WARNING Before starting to install this oil boiler, read these instructions carefully. Keep instructions in legible condition and posted near oil boiler for reference by owner and service technician. Table of Contents I. General Information ......3 IV. Boiler Cleaning ........18 II. Installation Instructions .......5 V. Repair Parts ........20 III. Operating & Service Instructions ..11 I. - Page 4 Figure 2: Minimum Installation Clearances To Combustible Materials (Inches) NOTE 1: Listed clearances comply with American National Standard NFPA 31, Installation of Oil Burning Equipment. Chimney NOTE 2: CLS Series boilers can be installed in rooms Above Front Connector Rear...
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Page 5: Installation Instructions
Oxygen contamination of the boiler water will cause 2. Lift outside container and remove all other corrosion of iron and steel boiler components, and inside protective spacers and bracing. Remove can lead to boiler failure. New Yorker's standard miscellaneous trim bag containing safety/relief warranty does not cover problems caused by valve, and pipe fittings. oxygen contamination of boiler water. - Page 6 WARNING Install automatic mixing valve at tankless heater outlet to avoid risk of burns or scalding due to excessively hot water at fixtures. Adjust and maintain the mixing valve in accordance with the manufacturer's instructions. 3. FLUSHING OF HEATER — All water contains some sediment which settles on the inside of the coil. Consequently, the heater should be periodically backwashed. This is accomplished by installing hose bibs as illustrated and allowing water at city pressure to run into hose bib A, through the heater, and out hose bib B until the discharge is clear. The...
- Page 8 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, Figure 5: recommended Smokepipe Arrangement the draft may be severely affected. In one instance and Chimney requirements research showed a new chimney of adequate sizing produced only .035" W.C. after 30 minutes A new boiler probably has a higher efficiency than of continuous firing at 13.0% CO . Outside wall the boiler being replaced. That probably means that chimneys take longer to heat up and can have .00" the stack temperature from the new boiler will be W.C. draft at burner startup. You may have to lower than that from the old boiler and with less consider a special alloy chimney flue liner with Figure 6: Proper and Improper Locations of Draft regulator...
- Page 9 insulation around it and a stabilizing draft cap or TABLE 3: SINGLE STAGE UNITS (3450 RPM) even a draft inducing fan in severe cases. TWO PIPE SYSTEMS 3. For the same reasons as in (2.) above, heat extractors Maximum Length of Tubing mounted into the breeching are not recommended. "H" + "R" (See Figure) Lift "H" H. INSTALL ELECTRIC WIRING in accordance with (See Figure) National Electrical Code and local regulations. A 3/8" OD 1/2" OD separate ELECTRICAL CIRCUIT should be run from Tubing (3 GPH) Tubing (3 GPH) meter with a Fused Disconnect Switch in the Circuit.
- Page 10 Figure 9: Wiring Diagram SEQUENCE OF OPERATION When the thermostat calls for heat, it energizes the cad cell primary control. The burner will initiate ignition after com- pleting 15 second pre-purge cycle. The burner will operate until the thermostat is satisfied or the limit setting on the high limit is reached.
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Page 11: Operating & Service Instructions
III. Operating and Service Instructions 3. Attach a plastic hose to fuel pump vent fitting and A. ALWAYS INSPECT INSTALLATION BEFORE provide a pan to catch the oil. STARTING BURNER. 4. REMOVE GAUGE PORT PLUG from fuel pump FILL HEATING SYSTEM WITH WATER. and install pressure gauge capable of reading at least NOTE: It is important, especially in a steam system, 150 PSI. to properly remove the oil and dirt from the system. 5. OPEN FLAME OBSERVATION DOOR on front of Failure to clean the system can result in erratic water boiler. lines and surging. H. START OIL BURNER. 1. Clean heating system if boiler water or condensate return water is dirty or if erratic water lines or 1. Open vent fitting on fuel pump. surging exist after a few days of boiler operation. 2. TURN ‘ON’ BURNER service switch and allow Refer to step "N" for proper cleaning instructions for burner to run until oil flows from vent fitting steam boilers. in a SOLID stream without air bubbles for approximately 10 seconds. 2. Fill boiler to normal water line. Refer to Figure 1. 3. Close vent fitting and burner flame should start C. CHECK CONTROLS, WIRING AND BURNER to be immediately after pre-purge is complete. Pre-purge... - Page 12 TABLe 5: BeCKeTT AFG Burner Nozzle Data Boiler ** Firing Air Shutter Air Band Static Head Model Rate Setting Setting Disc Angle Type Mfg. CLS-3* 1.05 3-3/8" 0.85 80° Delavan CLS-4 1.35 3-3/8" 1.10 80° Delavan CLS-5 1.65 2-3/4" 1.35 80°...
- Page 13 4. READJUST AIR BANDS on burner for a light nozzle will compress when burner is on and will orange colored flame while the draft over the expand when burner stops, causing oil to squirt from nozzle at low pressure as burner slows down and fire is —.02”. Use a smoke tester and adjust air for minimum smoke (not to exceed #1) with a causing nozzle to drip after burner stops. Usually minimum of excess air. Make final check using cycling the burner operation about 5 to 10 times will rid oil line of this air. suitable instrumentation to obtain a CO of 11.5 to 12.5% with draft of —.02” (water gauge) in fire 2. IF NOZZLE CONTINUES TO DRIP, repeat step box. These settings will assure a safe and efficient K.1. If this does not stop the dripping, remove operating condition. If the flame appears stringy cutoff valve and seat, and wipe both with a clean instead of a solid fire, try another nozzle of the same cloth until clean, then replace and readjust oil type. Flame should be solid and compact. After all pressure. If dripping or after burn persist replace adjustments are made recheck for a draft of —.02” fuel pump. over the fire. L. TEST CONTROLS. 5. TURN “OFF” BURNER and remove pressure gauge. Install gauge port plug and tighten. Start WARNING burner again. Before installation of the boiler is considered 6. CAD CELL LOCATION AND SERVICE complete, the operation of all boiler controls must The burner is supplied with a cadmium sulfide flame...
- Page 14 3. WARNING — Check High Limit Control d. Dismount the low water cutoff control from the — Jumper Thermostat Terminals. Allow burner to probe. operate until shut-down by limit. Installation is not e. Unscrew the probe from the boiler tapping. considered complete until this check has been made. f. Inspect that portion of the probe that is exposed REMOVE JUMPER. to the boiler water for a scale or sediment 4. Check low water cut off control with water level at buildup. normal water line (see Figure 1). Raise thermostat g. Light deposits may be removed by wiping the setting to allow burner to operate. Open boiler drain probe with a damp cloth. Wiping the probe with to allow water level to drop to bottom of sight glass a cloth soaked in vinegar will remove more until burner operation is shut-down by low water tenacious lime deposits. The most stubborn cutoff. deposits may be removed from the probe by Close boiler drain and refill to normal water line. using a diluted amount, 3 parts of water to 1 part Burner should automatically restart during fill. of phosphoric acid (H Lower thermostat setting. CAUTION 5. Check operating control on boiler equipped with tankless heaters. With burner off, draw hot water exercise caution when handling phosphoric acid until burner starts, then turn off hot water and check and follow the instruction label on its container.
- Page 15 b. Draw about 5 gallons of hot water from a. Drain boiler until 1” of water is visible in gauge boiler into a container and dissolve into it the glass. Run temporary 1½” pipe line from the appropriate amount of a recommended boilout surface blowoff connection to an open drain or compound. Remove safety valve from boiler and some other location where hot water may be pour this solution into boiler, then reinstall safety discharged safely. Do not install valve in this valve. line. c. Turn on oil burner and keep operating while b. Drain about 5 gallons of hot water from feeding water to boiler slowly. This will raise boiler into a container and dissolve into it water level in boiler slowly so that water will an appropriate amount of recommended boil be boiling hot and will rise slowly into supply out compound. Remove safety valve and add main and back through return main, flowing solution to boiler water thru exposed tapping from drain hose at about 180°F. Continue until using a funnel. water runs clear from drain hose for at least 30 minutes. NOTICE d. Stop feeding water to boiler but continue Check with local authorities or consult local operating oil burner until excess water in boiler water treatment services for acceptable chemical flows out through supply main and water lowers...
- Page 16 6. Boiler is now ready to be put into service. IMPORTANT IMPORTANT SUCTION LINE LEAKS - WHATEVER IT TAKES, THE OIL MUST BE FREE OF AIR. This can be IF, DURING NORMAL OPERATION, IT IS a tough problem, but it must be resolved. Try NECESSARY TO ADD MORE WATER PER bleeding the pump through a clear tube.
- Page 17 shallow bury is a good candidate for cold oil. The 1. IMPORTANT best solution is to bury the tank and lines deep IF BOILER IS NOT USED DURING WINTER enough to keep the oil above 40°F. TIME, IT MUST BE FULLY DRAINED TO 9. HIGH ALTITUDE INSTALLATIONS PREVENT FREEZE DAMAGE. Air settings must be increased at high altitudes. Use 2. Spray inside surfaces with light lubricating or instruments and set for 11.5 to 12.5% CO crankcase oil using gun with extended stem so as to reach all corners. 10. START-UP NOISE — Late ignition is the cause of start-up noises. If it occurs recheck for electrode 3. With steam boilers, at end of season add sufficient settings, flame shape, air or water in the fuel lines. water to fill boiler to top of water column and leave it that way until fall when water should be drained 11. SHUT DOWN NOISE — If the flame runs out of again to proper level. If at this time boiler water is air before it runs out of fuel, an after burn with dirty, drain water, flush out boiler, and refill with noise may occur. That may be the result of a faulty clean water to prescribed water level. cut-off valve in the fuel pump, or it may be air trapped in the nozzle line. It may take several firing 4. Always keep the manual fuel supply valve shut off cycles for that air to be fully vented through the if the burner is shut down for an extended period of nozzle. Water in the fuel or poor flame shape can time. also cause shut down noises. 5. To recondition the heating system in the fall season after a prolonged shut down, follow the instructions NOTICE outlined in Section III, Items A through M.
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Page 18: Boiler Cleaning
IV. Boiler Cleaning WARNING All boiler cleaning must be completed with burner service switch turned off. A. CLEAN THE FLUEWAYS (See Figure 13). 1. Install the canopy taking care to align the gaskets without blocking the flueways. If gasket is damaged, 1. Prior to cleaning boiler, lay a protective cloth or replace as needed. plastic over combustion chamber blanket to collect debris falling from flueways. 2. Reinstall flue plates, making sure gasket on each plate is in place and forms gas tight seal. If damaged 2. For access to firebox, remove burner and burner replace as needed. mounting plate. 3. Reinstall split top panel and secure with sheet metal NOTICE screws. Replace jacket upper right side access panel. 4. Reinstall smokepipe on canopy and secure to collar Boiler flueways may be cleaned from the top or with sheet metal screws. - Page 19 DATE SERVICE PERFORMED...
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Page 20: Repair Parts
V. Repair parts All CLS Series repair parts may be ordered through New Yorker Boiler Co., Inc. or its authorized distributors. Should you require assistance in locating a New Yorker Distributor in your area, or have questions regarding the availability of New Yorker products or repair parts, please contact: New Yorker Boiler Co., Inc., P.O. Box 10, Hatfield, PA 19440-0010, Phone: (215) 855-8055 Attn: Customer Service Department... - Page 21 Bare Boiler Assembly CLS Boiler Size / Quantity Item Description Part No. Front Section 71727018 Center Section 71727021 Rear Section 71727036 5" Cast Iron Slip Nipple 7066003 2-1/2" Cast Iron Slip Nipple 7066001 Combustion Chamber Insulation Rear Target Wall Insulation 8202701 Combustion Chamber Liner 1/2"...
- Page 23 CLS Boiler Size / Quantity Item Description Part No. Jacket Components - Items 1 thru 6 Include Insulation As Part of Assembly Jacket Front Panel Assembly 604730375 Jacket Rear Panel Assembly 604730376 604730372 604730472 604730572 Jacket Left Side/Top Panel Assembly 604730672 604730772 604730872...
- Page 24 New Yorker with respect to any defect in a residential cast iron steam workmanship under normal usage for a period of 10 years from the boiler.
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