New Yorker CG-C Series Installation & Operating Manual
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New Yorker CG-C Series Installation & Operating Manual

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See also: Installation, Operating and Service Instructions
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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100291-01R7-1/09
CG-C™ SERIES
GAS BOILER
BEFORE INSTALLATION: READ THIS MANUAL
SAVE THESE INSTRUCTIONS
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Price - $3.00

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Summary of Contents for New Yorker CG-C Series

  • Page 1: Service Instructions

    INSTALLATION, OPERATING SERVICE INSTRUCTIONS CG-C™ 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 following terms are used throughout this manual to bring attention to the presence of hazards of various risk levels, or to important information concerning product life. CAUTION DANGER Indicates a potentially hazardous situation which, Indicates an imminently hazardous situation if not avoided, may result in moderate or minor which, if not avoided, will result in death, serious injury or property damage.

  • 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-C 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 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

    II. Unpack Boiler . Remove all boiler hold-down fasteners. CAUTION Tilt the boiler to one side and slide a wooden slat under Do not drop boiler. Do not bump boiler jacket the two raised feet. against floor. Tilt the boiler to the other side and slide another wooden slat under the two raised feet.

  • Page 6: Gas Piping

    New Yorker Link SL™ indirect water heater. Install supply piping as shown in Figure 3. Bypass should be the New Yorker Link SL™ indirect water heater as a same size as the supply and return lines with valves separate heating zone. Refer to the New Yorker Link located in bypass and supply outlet as illustrated in SL™...
  • Page 7 Table : Maximum Capacity of Schedule 0 Pipe in CFH for Natural Gas Pressures of 0. 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 1,050 1,400 Table 5: Specific Gravity Correction Factors for Table : Fitting Equivalent Lengths Natural Gas Nominal Pipe Size...

  • Page 8: Venting

    National Fuel Gas Code, ANSI Z223.1/NFPA 54. Inspect existing chimney before installing boiler. Install any of the following for this Classic CG-C Series Failure to clean or replace perforated pipe or tile Category I, draft hood equipped appliance: lining will cause severe injury or death.
  • Page 9 3. Slide mounting bracket tight against lower edge of WARNING Draft Hood skirt. Position #10 sheet metal screw above skirt's stiffening rib. Failure to properly install and use this Blocked 4. Secure bracket in position by tightening #10 sheet Vent Switch may result in property damage, metal screw against outer surface of Draft Hood personal injury or loss of life.
  • Page 10 to be too large for proper venting of the appliances NOTICE remaining connected to it. At the time of removal of an existing boiler, the Provide adequate clearance for servicing. following steps shall be followed with each appliance remaining connected to the common venting system placed in operation, while the other appliances WARNING remaining connected to the common venting system are...

  • Page 11: Electrical

    See Figure 12 for continuous ignition (standing Plug the factory wired Vent Damper Harness into pilot) or Figure 13 for intermittent ignition (EI). Also refer to the New Yorker Link SL™ Indirect Water polarized receptacle. Heater Installation, Operating and Service Instructions.
  • Page 12 3. Vent Damper reaches fully open position. Power is Vent Damper Sequence of Operation. See Figure 11. sent back to Limit through Terminal 2. 1. Vent Damper continuously powered at Terminal 1. 4. Call for heat ends. Vent Damper closes. 2.
  • Page 13 Figure 12: Wiring Diagram, Continuous Ignition (Standing Pilot) Sequence of Operation, Continuous Ignition to operate and Vent Damper remains open with (Standing Pilot). call for heat. If blocked vent switch is activated 1. Normal Operation do not attempt to place boiler in operation. The source of blockage must be corrected by trained a.
  • Page 14 Figure 1: Wiring Diagram, Electronic Intermittent Ignition (EI) and skilled personnel from a qualified service Sequence of Operation, Electronic Intermittent agency before resetting switch. Ignition (EI). c. Flame Roll-out Switch. Automatically interrupts 1. Normal Operation boiler operation when flames or excessive heat a.

  • Page 15: System Start-Up

    VII. System Start-up Safe lighting and other performance criteria were met with the gas manifold and control assembly provided on the boiler when the boiler underwent tests specified in American National Standard for Gas-Fired Low-Pressure Steam and Hot Water Boilers, ANSI Z21.13.
  • Page 16 Table : Ignition Module Terminal Cross-Reference Instructions to Put the Boiler in Operation. 1. Electronic Ignition Modules with LED indicators. Wiring Ladder Diagram Ignition Module Table 6 cross-references the ignition module Terminal Number Terminal Designation terminal designations to the ignition terminal numbers in the wiring ladder diagrams.
  • Page 17 Table : 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- burner, spark and flame sense wir-...
  • Page 18 Figure 1: Operating Instructions...
  • Page 19 Figure 17: Lighting 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-C boilers built for installation at altitudes greater this 3 minute period to give the input shown on than 2,000 feet above sea level have been specially...
  • Page 21 Check Pilot Burner Flame. 1. Continuous Ignition (Standing Pilot, Natural Gas), Models 20 through 70 and Model 20 (Standing Pilot, LP). See Figure 19. Pilot burner produces a single flame. The flame should be steady, medium hard blue enveloping 3/8 to 1/2 inch of thermocouple.

  • Page 22: Ei Trouble Shooting Guide

    Honeywell Electronic Ignition Trouble Shooting Guide...

  • Page 23: Service

    VIII. Service 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 flame roll-out switch wires, pilot gas supply, thermocouple lead or pilot lead. 7. For Continuous Ignition (Standing Pilot) connect thermocouple at gas valve. For Intermittent Ignition (EI) connect pilot gas supply, igniter/sensor wire, and ground wire at Ignition Module. 8. Install Burner Access Panel. Connect Flame Rollout Switch wires.

  • Page 25: Repair Parts

    IX. Repair Parts All Classic CG-C™ 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 26 CG-C MODEL Part Description Number 6171702 6171703 6171704 6171705 Cast Iron Section Assembly 6171706 (Complete) 6171707 6171708 6171709 6171710 71106001 1[d] 2[a,b] 3[a,b] 4[a,b] 5[a,b] 6[b] 7[c] 8[c] 9[c] Footnote to Flue Baffle: [a] - CG-CH Models only Flue Baffle [b] - Standing Pilot, LP, 1"...
  • Page 27 Section Assembly and Canopy Group...
  • Page 28 CG-C MODEL Part Description Number 718600291 718600391 718600491 718600591 Base Tray 718600691 718600791 718600891 718600991 718601091 718600211 718600311 718600411 718600511 718600611 Base Wrapper 718600711 718600811 718600911 718601011 Base End Insulation 720601 72060025 72060035 72060045 72060055 Base Rear Insulation 72060065 72060075 72060085 72060095 72060105...
  • Page 29 CG-C 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 30 CG-C 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/70° Pilot Bracket & Offset Lancings - Q350 Standing Pilot, 8236117 Natural Gas...

  • Page 31: Manifold And Main Burners 1 Inch Main Burners

    Manifold and Main Burners (1 Inch Main Burners)
  • Page 32 CG-C MODEL Description Part Number Burner Tray, Main Burners and Manifold (0mm Main Burners Only) 100308-01 7186047 7186057 7186067 Burner Tray/Burner Tray Assembly 7186077 100308-02 718600906 100308-03 Main Burner 8236135 Intermittent Ignition (EI) Only Main Burner w/41° Pilot Bracket 8236136 2V Continuous Ignition (Standing Pilot) Natural Gas Only Main Burner w/48°...

  • Page 33: 40Mm Main Burners

    Manifold and Main Burners (0mm Main Burners)

  • Page 34: Pilot Burner And Gas Valve

    CG-C MODEL Part Description Number 70 80 90 100 Continuous Ignition (2V Standing Pilot) - 1 Inch and 0mm Main Burners - Pilot Burner and Gas Valve, Natural & LP Gas Pilot Burner, Honeywell Q350A1321 (Nat. Gas) 8236065 Pilot Burner, Honeywell Q327A1006 (Nat. Gas) 8236022 Pilot Burner, Honeywell Q350A1339 (LP) 8236066...

  • Page 36: Jacket Assembly, Complete

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

  • Page 38: Controls And Trim

    CG-C 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 81660319 10-408-05 Flame Rollout Switch 80160044 7186018 Flame Rollout Switch Mounting Bracket Footnote to Flame Rollout Switch Mounting Bracket: *1 - 40mm Burner Only Blocked Vent Switch Replacement Assembly 6016066...

  • Page 40: Service Record

    SERVICE RECORD DATE SERVICE PERFORMED...
  • Page 41 SERVICE RECORD DATE SERVICE PERFORMED...
  • Page 42 SERVICE RECORD DATE SERVICE PERFORMED...

  • Page 43: 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.

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