New Yorker CG20D Installation, Operating And Service Instructions
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New Yorker CG20D Installation, Operating And Service Instructions

New yorker cg-d series gas boilers
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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
D
Heating Contractor
Address
103710-03 - 10/12
AND
CG-D™ SERIES
GAS BOILER
BEFORE INSTALLATION: READ THIS MANUAL
SAVE THESE INSTRUCTIONS
Boiler Serial Number
9700609
Installation Date
Phone Number
Price - $3.00

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  • Page 1: Service Instructions

    INSTALLATION, OPERATING SERVICE INSTRUCTIONS CG-D™ 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 7-1/4 8" Dia. [1] CG20D only. Dimension 'G' includes allowance for 4" x 3" reducer furnished with boiler. See Figure 10. [2] Refer to the National Fuel Gas Code for equivalent areas of circular and rectangular flue linings. Maximum Allowable Working Pressure, Water - 50 PSI...

  • Page 3: Table Of Contents

    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-D™ 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 4 5. For boiler located in an unconfined space in a Provide practical service clearances. A minimum building of other than unusually tight construction, of 24" from the left side and front jacket panels is adequate combustion and ventilation air is normally recommended for servicing but may be reduced to provided by fresh air infiltration through cracks minimums shown in Figure 2.

  • Page 5: Unpack Boiler

    Space heating and domestic water heating with the WARNING New Yorker Link SL™ indirect water heater. Install the New Yorker Link SL™ indirect water heater as a Failure to properly pipe boiler may result in separate heating zone. Refer to the New Yorker Link improper operation and damage to boiler or SL™...
  • Page 8 Adjust valves to provide 180° to 200°F supply water 2. The recommended location for a LWCO on gas temperature. Opening the boiler supply valve will raise hot water boilers is above the boiler, in the supply system temperature, while opening by-pass valve will piping.

  • Page 9: Gas Piping

    IV. Gas Piping Table 2: Rated Input Size gas piping. Design system to provide adequate gas supply to boiler. Consider these factors: Input Rate Boiler 1. Allowable pressure drop from point of delivery to [cubic feet per hour] Model Connection boiler.
  • Page 10 . Connect boiler gas valve to gas supply system. Pressure test. The boiler and its gas connection must be leak tested before placing boiler in operation. 1. Use methods and materials in accordance with local plumbing codes and requirements of gas supplier. In 1.

  • Page 11: Venting

    V. Venting 3. Slide mounting bracket tight against lower edge of Install vent system in accordance with local building Draft Hood skirt. Position #10 sheet metal screw codes; or local authority having jurisdiction; or above skirt's stiffening rib. National Fuel Gas Code, ANSI Z223.1/NFPA 54. Install any of the following for this CG-D Series 4.
  • Page 12 Draft Hood supplied with the boiler (see Install Vent Connector Figure 1). Unpack the damper carefully - DO NOT 1. Model CG20D only - Install provided 4" x 3" vent FORCE IT CLOSED! Forcing the damper may reducer into vent damper outlet, then, install vent damage the gear train and void the warranty.
  • Page 13 4. Do not connect into same leg of chimney serving an WARNING open fireplace. 5. Inspect chimney for obstructions or restrictions and remove. Clean chimney if necessary. If an Existing Boiler is Removed: When an existing boiler is removed from a common 6.

  • Page 14: Electrical

    0.1 or 0.2 amps. heating system to prevent damage if the boiler is inoperative. New Yorker Link SL™ indirect water heater (if used). See Figures 11 and 12. Also refer to the New Yorker Link SL™ Indirect Water Heater Installation,...
  • Page 15 Figure 11: Wiring Schematic, Boiler Control...
  • Page 16 Figure 12: Wiring Schematic, Boiler Control...
  • Page 17 Figure 13: Wiring Schematic, Zone Valves Figure 14: Wiring Schematic, Zone Circulators...

  • Page 18: System Start-Up And Checkout

    VII. System Start-up and Checkout 4. Turn "OFF" the electric switch serving boiler. . Main Burner Check - Check main burners to see that they were not dislodged during shipment. Rear 5. Open valve on main gas line at meter. of burners should be in the vertical slots in the rear of 6.
  • Page 19 Figure 16: Operating Instructions...
  • Page 20 first two items in order to utilize the formula Check Gas Input to Boiler below. The gas meter should then be clocked for three (3) minutes with stop watch and NOTICE substituting the appropriate values in the formula below, determine what the gas flow should be in CG-D Series boilers built for installation at altitudes this 3 minute period to give the input shown on greater than 2,000 feet above sea level have been...
  • Page 21 Check Pilot Burner Flame. 1. See Figure 19. The pilot burner should be lit only if thermostat is calling for heat. The pilot burner produces three (3) flames. The center flame should be steady, medium hard blue enveloping 3/8 to 1/2 inch of thermocouple.

  • Page 22: Operation

    VIII. Operation BOILER SEQUENCE OF OPERATION Table 4: Sequence of Operation NORMAL OPERATION Status Codes displayed in STA Mode 1. The CG-D Series Boilers are equipped with a Status Description Boiler Control (control). This control replaces Standby the traditional separate ignition control, high limit (Burner off No call for heat detected switch and circulator relay and adds energy saving...
  • Page 23 For example, when the “I” key is pressed on the control until “bt” is displayed, it will then flash a three digit number (such as “180”) followed by either “F” (or “C”). This indicates that the boiler water temperature is 180°F. Other operating parameters display the information in a similar fashion.
  • Page 24 2. Differential (df_) heat is over. When Priority Time parameter is set to “Off” the DHW call for heat does not force “off” the The control is factory programmed with a system circulator. The Priority Time has a factory Differential of 15°F. The Differential is the number setting of “On”...
  • Page 25 Table 7: DHW Terminal Function (dh_) Table 8: DHW Terminal Function (dh_) Selection = Domestic Hot Water Demand, Selection = Second Heating Zone, (Parameter dh_ = dh) (Parameter dh_ = tt2) Call for Heat Circulator Status Call for Heat Circulator Status Priority System System...

  • Page 26: Service And Maintenance

    IX. Service and Maintenance 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 27 7. Connect pilot gas supply, igniter/sensor wire, and ground wire at Boiler Control. 8. Install Burner Access Panel. Connect Flame Rollout Switch wires. Check Operation. Follow steps C through J from Section VII: System Start-up. Removal or replacement of pilot assembly or pilot assembly parts.

  • Page 28: Troubleshooting

    X. Troubleshooting BEFORE TROUBLESHOOTING diagram in Figures 13 and 14. Ensure that incoming 120 Vac power polarity is correct and that the boiler The following pages contain trouble shooting tables for is properly grounded. Further, ensure that the control use in diagnosing control problems. When using these power supply is 24 VAC (minimum 18 VAC to tables the following should be kept in mind: maximum 30 VAC) and polarity is correct.
  • Page 29 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 Paragraph C: Display Status Recommended Corrective Action...
  • Page 30 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 / Status Recommended Corrective Action The boiler has not detected a call for heat (tt = off and dh = off. Check that the thermostat: STA1 - When a thermostat call for heat is detected control display “tt”...
  • Page 31 5. Circulator is On But Damper is Not Open Display / 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: - During status “STA18"...
  • Page 32 6. Circulator is On, Damper is Open But Boiler Fails to Start (continued) Recommended Corrective Action Display / Status 1. No Spark a. Can you hear sparking while STA 6 is displayed? - If there is no spark noise replace the control. b.

  • Page 33: Repair Parts

    All CG-D™ 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 34 CG-D MODEL Part Description Number 6171702 6171703 6171704 6171705 Cast Iron Section Assembly (Complete) 6171706 6171707 6171708 6171709 6171710 Flue Baffle 71106001 (CG30DH Thru CG60DH Models Only) 61117022 611170302 611170402 1[a] 100310-01 1[b] 611170502 611170602 1[a] 100310-02 1[b] 6111706010 1[c] 611170702 Canopy Assembly 611170802...
  • Page 35 Section Assembly and Canopy Group...
  • Page 36 CG-D MODEL Part Description Number 718600291 718600391 718600491 718600591 Base Tray 718600691 718600791 718600891 718600991 718601091 718600211 718600311 718600411 718600511 Base Wrapper 718600611 718600711 718600811 718600911 718601011 Base End Insulation 720601 72060025 72060035 72060045 72060055 Base Rear Insulation 72060065 72060075 72060085 72060095 72060105...
  • Page 37 CG-D MODEL Part Description Number 718600261 718600361 718600461 718600561 Burner Access Panel 718600661 718600761 718600861 718600961 718601061 Self-Tapping Screw ¼ - 20 x ½ 80860700 Self-Tapping Screw 5/16 - 18 x 1¼ 80860717 Flat Washer 5/16", USS 80860601 Hex Lock Nut 5/16 - 18 80860464 Cerafelt Sealing Strip ½"...
  • Page 38 CG-D MODEL Part Description Number Burner Tray, Main Burners and Manifold (1 Inch Main Burners Only) 718600205 100307-01 718600405 718600505 Burner Tray/Burner Tray Assembly 718600605 100307-02 100307-03 718600905 100307-04 Main Burner w/Slotted Orifice Bracket 8236119 Main Burner w/60° Pilot Bracket - 8236118 EI, Natural &...

  • Page 39: Manifold And Main Burners 1 Inch Main Burners

    Manifold and Main Burners (1 Inch Main Burners)
  • Page 40 CG-D MODEL Description Part Number Burner Tray, Main Burners and Manifold (40mm Main Burners Only) 100308-01 7186047 7186057 7186067 Burner Tray/Burner Tray Assembly 7186077 100308-02 718600906 100308-03 Main Burner 8236135 Main Burner w/41° Pilot Bracket 8236136 82219032 82219042 82219052 82219062 Manifold 82219072 82219082...

  • Page 41: 40Mm Main Burners

    Manifold and Main Burners (40mm Main Burners)

  • Page 42: Pilot Burner And Gas Valve

    CG-D MODEL Part Key No. Description Number 90 100 Pilot Burner and Gas Valve, Natural & LP Gas Pilot Burner, Honeywell Q3481B1206 (Nat. Gas) 103704-01 Pilot Burner, Honeywell Q3481B1420 (LP) 103705-01 Pilot Orifice, Honeywell NE22 (Nat. Gas) Included with Pilot Burner Pilot Orifice, Honeywell KR14 (LP) Included w/ Compression Fitting, 7/16"...

  • Page 43: Jacket Assembly, Complete

    CG-D MODEL Description Part Number Jacket Assembly, Complete 100292-01 100294-02 100294-03 100294-04 Jacket Assembly, Complete 100294-05 100294-06 100294-07 100294-08 100294-09...

  • Page 44: Controls And Trim

    CG-D MODEL Part Description Number Controls and Trim Temperature / Pressure Gauge 100282-01 Drain Valve, Conbraco 35-302-03 806603061 Safety Relief Valve, 30 psi, 3/4 NPT Conbraco 10- 81660319 408-05 Flame Rollout Switch 80160044 Flame Rollout Switch Mounting Bracket 7186018 Blocked Vent Switch Replacement Assembly 6016066 Limit Rated Temperature Sensor, 48"...

  • Page 46: Service Record

    SERVICE RECORD DATE SERVICE PERFORMED...
  • Page 47 SERVICE RECORD DATE SERVICE PERFORMED...

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