New Yorker PVCG SERIES Installation, Operating And Service Instructions
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New Yorker PVCG 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.
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8141975R14-11/09
PVCG™ SERIES
GAS BOILER
BEFORE INSTALLATION: READ THIS MANUAL
SAVE THESE INSTRUCTIONS
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Price - $3.00

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  • Page 1: Service Instructions

    INSTALLATION, OPERATING SERVICE INSTRUCTIONS PVCG™ SERIES 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.
  • 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 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.
  • Page 3 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 4: Table Of Contents

    Table of Contents I. Pre-Installation ........5 VI. Electrical ......... 20 II. Unpack Boiler ........7 VII. System Start-up ....... 22 III. Venting ..........8 VIII. Service ..........29 IV. Water Piping and Trim ....14 IX. Repair Parts ........36 V. Gas Piping ........18 X. Appendix Low Water Cut Off .

  • Page 5: Pre-Installation

    I. Pre-Installation WARNING NOTICE Carefully read all instructions before installing Due to the low water content of the boiler, mis- boiler. Failure to follow all instructions in proper sizing of the boiler with regard to the heating order can cause personal injury or death. system load will result in excessive boiler cycling and accelerated component failure.
  • Page 6 immediately against carrier by consignee. No claims 1. Determine volume of space (boiler room). Rooms for variances or shortages will be allowed by Boiler communicating directly with space (through Manufacturer, unless presented within sixty (60) days openings not furnished with doors) are considered after receipt of equipment.

  • Page 7: Unpack Boiler

    Alternate method for boiler located within confined of insects and rodents. Louvers and grilles must be space. Use indoor air if two permanent openings fixed in open position or interlocked with equipment communicate directly with additional space(s) of to open automatically before burner operation. sufficient volume such that combined volume of all Screens must not be smaller than ¼...

  • Page 8: Venting

    III. Venting WARNING Do not use this boiler with galvanized, Type 04 or Type 1 stainless steel, non metallic or any other non AL9-4C 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.
  • Page 9 Table : Vent System Components 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”...
  • Page 10 6. After it has been determined that each appliance 3. Provide and maintain vent pipe minimum clearance remaining connected to the common venting system to combustible materials. Vent pipe minimum properly vents when tested as outlined above, return clearance to combustible material is five (5) doors, windows, exhaust fans, fireplace dampers and inches when vent is installed in a fully enclosed any other gas burning appliance to their previous...
  • Page 11 bond RTV 4500 (Acetoxy) and Sil-bond RTV 6500. Do not use other adhesives or sealants. Install Vent Pipe, Gasket-Less Vent System. 1. Procedure for Joining Gasket-Less Vent Pipe and Fittings. See Figure 4A. Figure 4B: Gasketed Vent Joint Detail c. Tighten locking band by HAND with a 5/16" nut driver until snug plus ¼...
  • Page 12 f. Once the installation is complete, operate Horizontal (Through Wall) Vent Installation. appliance and inspect all joints to ensure that flue 1. Maintain minimum ¼ inch per foot slope in gases and/or liquid condensate will not escape. horizontal runs. Slope pipe down toward vent 2.

  • Page 14: Water Piping And Trim

    This can be accomplished by New Yorker Link SL™ indirect water heater. Install taking the following measures: New Yorker Link SL™ indirect water heater as a separate heating zone. Refer to New Yorker Link SL™ a. Repairing system leaks to eliminate the need for Installation, Operating and Service Instructions for addition of make-up water.
  • Page 17 If a low water cut-off is required, it must be mounted in If boiler is connected to heating coils located in the system piping above the boiler. air handling units where they may be exposed to refrigerated air, boiler piping must be equipped with The minimum safe water level of a hot water boiler is flow control valves to prevent gravity circulation of just above the highest water containing cavity of the...

  • Page 18: Gas Piping

    V. Gas Piping Connect boiler gas valve to gas supply system. WARNING WARNING Failure to properly pipe gas supply to boiler may result in improper operation and damage to the Failure to use proper thread compounds on all boiler or structure. Always assure gas piping is gas connectors may result in leaks of flammable absolutely leak free and of the proper size and gas.
  • Page 19 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 20: Electrical

    New Yorker Link SL™ indirect water heater (if General. Install wiring and ground boiler in accordance used). See Figure 11. Also refer to New Yorker Link with requirements of authority having jurisdiction, or in SL™ Installation, Operating and Service Instructions.

  • Page 22: System Start-Up

    VII. System Start-Up Safe operation and other performance criteria were Repeat this step until all zones have been purged. At met with gas manifold and control assembly provided completion, open all zone valves or shut-off valves. on boiler when boiler underwent tests specified in 9.
  • Page 23 Figure 1: Operating Instructions...
  • Page 24 numbers in the wiring ladder diagrams. The yellow Operating Instructions LED indicates the status of the flame, see Table 8. 1. See Figure 13 to place boiler in operation. The green LED indicates the status of the system, 2. Electronic Ignition Modules with LED indicators. see Table 9.
  • Page 25 Table 9: Green LED Status Codes Green LED Flash Code Indicates Next System Action Recommended Service Action (X + Y) No “Call for Heat” None Startup - Flame sense Flash Fast None calibration Heartbeat Normal operation None If system fails to light on next trial for ignition check gas supply, pilot 5 minute Retry Delay- Initiate new trial for ignition after retry...
  • Page 26 Honeywell Electronic Ignition Troubleshooting Guide Figure 15: Troubleshooting Guide...
  • Page 27 Sequence of Operation. See Figure 16. If boiler fails to operate properly, see Troubleshooting Guides in Service Section. Check pilot burner flame. See Figure 17. Flame should be steady, medium hard blue enveloping 3/8 to 1/2 inch of sensing probe. Figure 17: Pilot Burner Flame Check main burner flame.
  • Page 28 5. Compare measured input rate to input rate stated on rating plate. a. Boiler must not be over fired. Reduce input rate by decreasing manifold pressure. Do not reduce more than 0.3 inch w.c. If boiler is still over- fired, contact your New Yorker distributor for replacement Gas Orifice.

  • Page 29: Service

    VIII. 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. Assure that all gas valves and electrical disconnect switches are off before attempting any disassembly or service.
  • Page 30 Reinstall Burner Access Panel. as illustrated in Figure 20. Replace canopy Reconnect Flame Rollout Switch wires. and seal using kit available from New Yorker Distributors, Part No. 6111716. Check operation. Follow Steps G through P from System Start-up Section.
  • Page 31 b. Spark gap should be 1/8 inch for optimum performance. 3. To replace complete pilot assembly. a. Remove two machine screws holding pilot burner to pilot bracket. b. Disconnect pilot tubing. c. Disconnect all other leads to pilot. d. Select pilot assembly with identical model number, reconnect leads and pilot tubing.
  • Page 32 NOTE: If switch drops-out before boiler reaches temperature or if inlet pressure reading is below minimum shown in Table 12, check for cracks in hose or contact your nearest New Yorker representative. 4. Stop boiler, remove manometer and reconnect hose to pressure switch.
  • Page 33 THIS PAGE LEFT INTENTIONALLY BLANK...
  • Page 34 Troubleshooting Guide...
  • Page 35 Troubleshooting Guide...

  • Page 36: Repair Parts

    IX. Repair Parts All PVCG™ 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.
  • Page 37 [Quantity] Part Number Description PVCG0 PVCG40 PVCG50 PVCG0 Pilot Assembly, Natural Gas, Honeywell Q348A1002 8236072 Pilot Assembly, LP Gas, Honeywell Q348A1010 8236081 Pilot Tubing, 1/4" OD x 40" 8236123 Gas Valve, 1/2 x 1/2, Natural Gas, Honeywell VR8204C3007 81660145 Gas Valve, 1/2 x 1/2, LP/Propane, Honeywell VR8204C3015 81660146 Igniter/Sensor Cable, 36", Honeywell 394803-2 8236121...

  • Page 38: Low Water Cut Off

    X. Low Water Cut Off (LWCO) on Hot Water Boilers WARNING DO NOT ATTEMPT to cut factory wires to install an aftermarket Low Water Cut Off (LWCO). Only use connections specifically identified for Low Water Cut Off. In all cases, follow the Low Water Cut Off (LWCO) manufacturer's instructions. When draining the heating system.

  • Page 39: Service Record

    SERVICE RECORD DATE SERVICE PERFORMED...
  • Page 40 These limited warranties apply to residential cast iron and steel water boilers including but not limited to the following: operated with insufficient water; labeled with the New Yorker ® brand which are sold on or after March 1, allowed to freeze; subjected to flood conditions; or operated with water conditions and/or fuels or additives which cause unusual deposits or corrosio 2004.

This manual is also suitable for:

Pvcg30Pvcg50Pvcg40Pvcg60

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