New Yorker PVCG-B Series Installation, Operating And Service Instructions
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New Yorker PVCG-B 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.
Part Number
Heating Contractor
Address
103759-04 - 10/13
AND
PVCG-B™ 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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Summary of Contents for New Yorker PVCG-B Series

  • Page 1 INSTALLATION, OPERATING SERVICE INSTRUCTIONS PVCG-B™ 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 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.
  • Page 3 Special Installation Requirements for Massachusetts A. For all side wall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in whole or in part for residential purposes and where the side wall exhaust vent termination is less than seven (7) feet above grade, the following requirements shall be satisfied: 1.
  • Page 4 WARNING 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.

  • Page 5: Table Of Contents

    Table of ConTenTs I. Pre-Installation ....... 7 VIII. System Start-up ......35 II. Unpack Boiler ........ 8 IX. Operation ........39 III. Venting ........... 9 X. Troubleshooting ......43 IV. Water Piping and Trim ....19 XI. Service .......... 48 V.

  • Page 7: Pre-Installation

    2. Determine Total Input of all appliances in space. system load will result in excessive boiler cycling Round result to nearest 1,000 Btu per hour (Btuh). and accelerated component failure. New Yorker 3. Determine type of space. Divide Volume by Total DOES NOT warrant failures caused by mis-sized Input.

  • Page 8: Unpack Boiler

    I. PRE-INSTALLATION (continued) volume of all spaces meet criteria for unconfined Locate remaining opening within twelve (12) inches of bottom of space. Minimum dimension of air space. Size each opening for minimum free area opening is three (3) inches. Size each opening per of one (1) square inch per 1,000 Btu per hour following: input of all equipment in spaces, but not less than...

  • Page 9: Venting

    III. VENTING WARNING 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 draft hood with this appliance. Do not use vent dampers with this boiler.
  • Page 10 III. VENTING (continued) Vent Guidelines Due to Removal of an Existing Table 3: Vent System Components Boiler Part Equivalent IF AN EXISTING BOILER IS REMOVED - Vent System Component Number Feet of Pipe When an existing boiler is removed from a common 3”...
  • Page 11 (4) inches 2. This appliance requires a Special Gas Vent. (102 mm) when vent is installed in a fully enclosed a. The product is designed to use New Yorker (chase) application or three (3) inches (76 mm) ®...
  • Page 12 5. For noncombustible wall application when thimble Install Vent Pipe, Gasketed Vent System. is not used, size opening such that bell with locking 1. Procedure for Joining New Yorker Gasketed Vent band attached cannot pass through. Pipe and Fittings. See Figure 3.
  • Page 13 III. VENTING (continued) Figure 3: New Yorker Gasketed Vent Joint Detail...
  • Page 15 III. VENTING (continued) Figure 5: Horizontal – Vent Terminal Configuration (3” or 4” Vent) E. Separate Vertical Venting System - See Figures 6, 7, 8 and 9 NOTICE Roof penetrations require the use of roof flashing and storm collar - not supplied with boiler. Vertical Venting 5.
  • Page 18 III. VENTING (continued) Optional Exterior Separate Horizontal Vent Terminal Mounting – See Figure 9. 3. Install vent piping. 1. See Figure 28 for Blower Vent Connector Assembly. a. Install vent piping for desired venting system. Do not exceed maximum vent lengths. Refer to Refer to specific section for details for vent pipe Table 4.

  • Page 19: Water Piping And Trim

    Oxygen contamination of boiler water will cause corrosion of iron and steel boiler components, and can lead to boiler failure. New Yorker’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.
  • Page 20 IV. WATER PIPING AND TRIM (continued) 5. When constructing a piping tree to install LWCO 2. The recommended location for an Auxiliary Limit select fittings (tees, elbows etc) and nipples to have on gas hot water boilers is in the supply piping. See the same size (NPT) as boiler supply connection.
  • Page 21 IV. WATER PIPING AND TRIM (continued) NOTICE New Yorker recommends sizing the system circulator to supply sufficient flow (GPM) to allow a 20°F temperature differential in the system. When sizing the system circulator, the pressure drop of all radiators, baseboard and radiant tubing and all connecting piping must be considered.
  • Page 22 IV. WATER PIPING AND TRIM (continued) After the boiler and system have been cleaned and To perform a long term pressure test including the flushed, and before refilling the entire system add boiler, ALL trapped air must first be removed from the boiler.

  • Page 25: Gas Piping

    V. Gas PiPinG 3. Length of piping and number of fittings. Refer to WaRninG Table 7 for maximum capacity of Schedule 40 pipe. Table 8 lists equivalent pipe length for standard Failure to properly pipe gas supply to boiler may fittings. result in improper operation and damage to the 4. Corrections for the specific gravity of natural gas boiler or structure.
  • Page 26 V. GAS PIPING (continued) Table 7: Maximum Capacity of Schedule 40 Pipe in CFH* For Natural Gas Pressures of 0.5 psig or Less 0.3 inch w.c. Pressure Drop 0.5 inch w.c. Pressure Drop Length [Feet] ½ ¾ 1¼ ½ ¾ 1¼...
  • Page 27 V. GAS PIPING (continued) 2. Locate leaks using approved combustible gas Pressure test. The boiler and its gas connection must detector, soap and water, or similar nonflammable be leak tested before placing boiler in operation. solution. 1. Protect boiler gas control valve. For all testing over ½...

  • Page 28: Electrical

    VI. ELECTRICAL DANGER Positively assure all electrical connections are unpowered before attempting installation or service of electrical components or connections of the boiler or building. Lock out all electrical boxes with padlock once power is turned off. WARNING Failure to properly wire electrical connections to the boiler may result in serious physical harm. Electrical power may be from more than one source.
  • Page 29 VI. ELECTRICAL (continued) Figure 17: Wiring Connection Diagram...
  • Page 30 VI. ELECTRICAL (continued) NOTICE All wire, wire nuts, controls etc. are installer supplied unless otherwise noted. If an additional system limit is used, install in series with the auxiliary limit jumper shown in the drawing below. Figure 18: Wiring Ladder Diagram...

  • Page 33: Modular Installation

    Size (NPT) < 166 1¼” Module Sizing < 260 1½” New Yorker recommends sizing each boiler in a modular system to provide 20 % of the combined < 550 2” heating load where ever possible. < 900 2½”...

  • Page 35: System Start-Up

    VIII. SYSTEM START-UP 6. Open fill valve (Make-up water line should be Verify that the venting, water piping, gas piping and electrical system are installed properly. Refer to located directly after full port ball valve in system installation instructions contained in this manual. supply piping between air scoop and expansion tank).
  • Page 36 VIII. SYSTEM START-UP (continued) Figure 22: Operating Instructions...
  • Page 37 VIII. SYSTEM START-UP (continued) Check pilot burner flame. See Figure 24. Flame 3. Main burners and pilot burner will extinguish and blower will stop when water level drops below low should be steady, medium hard blue enveloping 3/8 to water cutoff probe. Verify limit, thermostat or other ½...
  • Page 38 Do not reduce more than 0.3 inch w.c. If boiler is still overfired, 7. Return other gas-fired appliances to previous contact your New Yorker distributor or Regional conditions of use. Office for replacement Gas Orifice. Review User’s Information Manual and system...

  • Page 39: Operation

    IX. OPERATION Table 11: Sequence of Operation Boiler Sequence of Operation Status Codes displayed in STA Mode NORMAL OPERATION Status Description 1. The PVCG-B Boilers are equipped with a Boiler Control (control). This control replaces the Standby traditional separate ignition control, high limit switch, (Burner off No call for heat detected Circulator off)
  • Page 40 IX. OPERATION (continued) The STA (status) display code has the below listed values. This list is also available on the control cover. Status Code Displayed in STA Mode Standby Waiting for Pressure Switch to Open Waiting for Pressure Switch to Close Prepurge Spark Flame Proving...
  • Page 41 IX. OPERATION (continued) panel settings allow water flow to the priority zone CHANGING THE ADJUSTABLE PARAMETERS after the call for heat ends. The Circulator Overrun To adjust parameters such as High Limit Setpoint and Time is adjustable between 0 through 10 minutes. High Limit Differential: 4.
  • Page 42 IX. OPERATION (continued) Table 14: DHW Terminal Function (dh_) 7. Domestic Hot Water (DHW) Terminal Function (dh_) The control allows configuration of the DHW Selection = Domestic Hot Water Demand, (Parameter dh_ = dh) Circulator output functionality to help the PVCG-B integrate into each installation more effectively.

  • Page 43: Troubleshooting

    X. TROUBLESHOOTING check the wiring on the boiler against the wiring Before troubleshooting diagram in Figures 17 and 18. Ensure that incoming The following pages contain trouble shooting tables for 120 Vac power polarity is correct and that the boiler use in diagnosing control problems.
  • Page 44 X. TROUBLESHOOTING (continued) Use Control Display ERR (error) Number To Direct TroubleShooting Efforts If the control detects an error it will flash “Err” (error) followed by a number. Use this number to identify the boiler problem and corrective action in the table below. If there is no Err display proceed to next Section: IQ Boiler Control Error Codes (when "Err"...
  • Page 45 X. TROUBLESHOOTING (continued) Use STA (status) Number To guide TroubleShooting The control will flash “STA” followed by a number. Use this number to identify the boiler problem in the table below: 1. Boiler and Circulator Off Display / Recommended Corrective Action Status The boiler has not detected a call for heat (tt = off and dh = off).
  • Page 46 X. TROUBLESHOOTING (continued) 5. Circulator is On, Blower is On but Boiler Fails to Start Display / Status Description The Boiler is in “Retry Delay”: - The burner failed to light (no flame signal). After a 5 minute delay, control will attempt to light the burner STA 10 again.
  • Page 47 X. TROUBLESHOOTING (continued) 6. Circulator is On, Blower is On but Boiler Fails to Start (continued) Display / Status Recommended Corrective Action 1. No Spark a. Can you hear sparking while STA 6 is displayed? - If there is no spark noise replace the control. b.

  • Page 48: Service

    XI. SERVICE DANGER This boiler uses flammable gas, high voltage electricity, moving parts, and very hot water under high pressure. Assure that all gas and electric power supplies are off and that the water temperature is cool before attempting any disassembly or service. Do not attempt any service work if gas is present in the air in the vicinity of the boiler.
  • Page 49 XI. SERVICE (continued) WARNING This boiler must only be serviced and repaired by skilled and experienced service technicians. If any controls are replaced, they must be replaced with identical models. Read, understand and follow all the instructions and warnings contained in all the sections of this manual.
  • Page 50 NOTE: If switch drops-out before boiler reaches temperature or if pressure differential readings are below minimums shown in Table 17, check for cracks in hose or contact your nearest New Yorker representative. 4. Stop boiler, remove manometer and reconnect hoses to differential pressure switch.
  • Page 52 XI. SERVICE (continued) Table 16: Pilot Burner Location Model Main Burner with Pilot Bracket Pilot Burner Located Between Main Burners * PVCG30B 2 & 3 PVCG40B 3 & 4 PVCG50B 4 & 5 PVCG60B 5 & 6 PVCG70B 6 & 7 PVCG80B 7 &...

  • Page 53: Repair Parts

    All PVCG-B™ Repair Parts may be obtained through your local New Yorker Wholesale distributor. 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 Customer...
  • Page 54 XII. REPAIR PARTS (continued)
  • Page 55 XII. REPAIR PARTS (continued) [Quantity] Part Number Description PVCG30B PVCG40B PVCG50B PVCG60B PVCG70B PVCG80B PVCG90B 1. CASTING ASSEMBLY Section Assembly 61707031 61707041 61707051 61707061 61707071 61707081 61707091 Left End Section 71707001 Center Section 71707003 71707003 71707003 71707003 71707003 71707003 71707003 Right End Section 71707002 [10]...
  • Page 56 XII. REPAIR PARTS (continued)
  • Page 57 XII. REPAIR PARTS (continued) [Quantity] Part Number Description PVCG30B PVCG40B PVCG50B PVCG60B PVCG70B PVCG80B PVCG90B 2. BASE ASSEMBLY Base Wrapper 71807031 71807041 71807051 71807061 71807071 71807081 71807091 Base Tray 71807032 71807042 71807052 71807062 71807072 71807082 71807092 Burner Tray Assembly 61807031 61807041 61807051 61807061 61807071 61807081 61807091 Base Front Panel 102705-03 102705-04 102705-05 102705-06 102705-07 102705-08 102705-09 Burner Access Panel...
  • Page 58 XII. REPAIR PARTS (continued) [Quantity] Part Number Description PVCG30B PVCG40B PVCG50B PVCG60B PVCG70B PVCG80B PVCG90B 3. BASE ASSEMBLY Burner Cover (Natural Gas Only) 102033-03 102033-04 102033-05 102033-06 102033-07 102033-08 102033-09 Manifold Support Bracket 718070001 Sheet Metal Screw, #8 x 1/2” [2] 80860000 Self Tapping Screw, 10-32 x 3/8”...
  • Page 59 XII. REPAIR PARTS (continued) [Quantity] Part Number Description PVCG30B PVCG40B PVCG50B PVCG60B PVCG70B PVCG80B PVCG90B 4. FAN/CANOPY ASSEMBLY Canopy Assembly - Sea Level 61107031 61107041 61107051 61107061 61107071 61107081 61107091 Canopy Assembly - High Altitude 61107032 61107042 61107052 61107062 61107072 61107082 61107092 Cerafelt...
  • Page 61 XII. REPAIR PARTS (continued) [Quantity] Part Number Description PVCG30B PVCG40B PVCG50B PVCG60B PVCG70B PVCG80B PVCG90B 5. BURNER ASSEMBLY Gas Valve (Natural Gas), 81660282 Honeywell VR8204P1171 Gas Valve (Natural Gas), 81660283 Honeywell VR8304P4496 Gas Valve (LP Gas), 81660146 Honeywell VR8204C3015 Gas Valve (LP Gas), 81660181 Honeywell VR8304P4280 ½”...
  • Page 62 XII. REPAIR PARTS (continued) [Quantity] Part Number Description PVCG30B PVCG40B PVCG50B PVCG60B PVCG70B PVCG80B PVCG90B 6. CONTROL PANEL ASSEMBLY Limit Rated Temperature Sensor, 103195-01 12”, Honeywell 50001464-001 Transformer, Honeywell 102516-01 AT140B1297 Boiler Control, Induced Draft, 103661-01 Honeywell S9361A2075 Control Panel 103727-01 Temperature Sensor Clip 102422-01...
  • Page 63 XII. REPAIR PARTS (continued) [Quantity] Part Number Description PVCG30B PVCG40B PVCG50B PVCG60B PVCG70B PVCG80B PVCG90B 7. JACkET PARTS Left Side Panel 60407002 Right Side Panel 60407001 Rear Panel 60407033 60407043 60407053 60407063 60407073 60407083 60407093 Vestibule Panel 60407034 60407044 60407054 60407064 60407074 60407084...
  • Page 64 XII. REPAIR PARTS (continued) [Quantity] Part Number Description PVCG30B PVCG40B PVCG50B PVCG60B PVCG70B PVCG80B PVCG90B 8. MISCELLANEOUS PARTS CARTON Water Manifold 80607001 Temperature/Pressure Gauge 100282-01 Circulator Wiring Harness 6130701 Safety Relief Valve 81660363 Boiler Drain Valve 806603061 Vent Terminal 8110701 Vent Connector 8110703 8110704...
  • Page 65 SERVICE RECORD DATE SERVICE PERFORMED...
  • Page 66 SERVICE RECORD DATE SERVICE PERFORMED...
  • Page 67 SERVICE RECORD DATE SERVICE PERFORMED...

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