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New Yorker CGS-A 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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104460-01 - 11/12
CGS-A™ 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 CGS-A™ 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 The New York City Department of Buildings has approved the Series boiler: Approval No. MEA 165-94-E. Classic CGS-A™ 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 Series boiler.

  • Page 3: Table Of Contents

    Table of Contents I. Pre-Installation ....... 3 VI. Electrical ........13 II. Unpack Boiler ........ 5 VII. System Start-up ......16 III. Steam Piping and Trim ....5 VIII. Service ......... 21 IV. Gas Piping ........8 IX. Repair Parts ........27 V.

  • Page 4: I. Pre-Installation

    I. Pre-Installation (continued) Recommended service clearance is 24 inches from 5. For boiler located in an unconfined space in a left side, right side and front. Service clearances may building of other than unusually tight construction, be reduced to minimum clearances to combustible adequate combustion and ventilation air is normally materials.

  • Page 5: Unpack Boiler

    II. Unpack Boiler 1. Place base on floor with insulated surface facing CAUTION upward and part number facing forward. Do not drop boiler. Do not bump boiler jacket 2. Position base to provide minimum clearances to against floor. combustible walls. See Figure 3. Secure in place. 3.

  • Page 6: Iii. Steam Piping And Trim

    III. Steam Piping and Trim (continued) Table 3: Purpose of Tappings WARNING Tapping Size Purpose Safety valve discharge piping must be piped near floor to eliminate potential of severe burns. Do 30 - 70: Plugged, Optional Second Supply 2" not pipe in any area where freezing could occur. 80: Second Supply Do not install any shut-off valves.
  • Page 7 III. Steam Piping and Trim (continued) Figure 6: Recommended Boiler Piping for Gravity Return...

  • Page 8: Gas Piping

    IV. Gas Piping For materials or conditions other than those listed Size gas piping. Design system to provide adequate gas above, refer to National Fuel Gas Code, NFPA supply to boiler. Consider these factors: 54/ANSI Z223.1, or size system using standard 1.

  • Page 9: Iv. Gas Piping

    IV. Gas Piping (continued) Table 6: Fitting Equivalent Lengths Table 7: Specific Gravity Correction Factors for Natural Gas Nominal Pipe Size Fitting Specific Correction Specific Correction ½ ¾ 1¼ Gravity Factor Gravity Factor 45° Ell 0.50 1.10 1.30 1.07 0.55 1.04 1.40 1.04...

  • Page 10: Venting

    National Fuel Gas Code, ANSI Z223.1/NFPA 54, Part 7, Venting of Equipment. Install any of the following for this Classic CGS-A Series Category I, draft hood equipped appliance: 1. Type B or Type L gas vent. Install in accordance with listing and manufacturer's instructions.

  • Page 11: V. Venting

    V. Venting (continued) Vent damper assembly includes pre-wired WARNING connection harness with polarized plug for use on all EI control systems. Failure to properly install and use this Blocked 3. Mount vent damper assembly on draft hood without Vent Switch may result in property damage, modification to either.
  • Page 12 V. Venting (continued) venting system are located and other spaces of the Install Vent Connector from vent damper to chimney building. Turn on clothes dryers and any appliance or gas vent. See Figure 10. not connected to the common venting system. 1.

  • Page 13: Electrical

    VI. Electrical General. Install wiring and ground boiler in accordance Table 8: Wiring Diagrams with requirements of authority having jurisdiction, or in absence of such requirements the National Electrical Ignition System Low Water Figure No. Code, ANSI/NFPA 70. Cutoff Intermittent (EI) Connect Vent Damper.

  • Page 14: Vi. Electrical

    VI. Electrical (continued) Figure 12: Wiring Diagram, Intermittent Ignition (EI) and Hydrolevel Model 400 or McDonnell & Miller PS-802-24 Low Water Cutoff do not attempt to place boiler in operation. The Sequence of Operation with Intermittent Ignition source of blockage must be corrected by trained and (EI).
  • Page 15 VI. Electrical (continued) Figure 13: Wiring Diagram, Intermittent Ignition (EI) and McDonnell & Miller 67 Low Water Cutoff Sequence of Operation with Intermittent Ignition of blockage must be corrected by trained and skilled (EI). personnel from a qualified service agency before resetting switch.

  • Page 16: System Start-Up

    VII. System Start-up Safe operation and other performance criteria were met with gas manifold and control assembly provided on boiler when boiler underwent tests specified in American National Standard for Gas-Fired Low- Pressure Steam and Hot Water Boilers, ANSI Z21.13. Check main burners.

  • Page 17: Vii. System Start-Up

    Boiler must not be overfired. Reduce input rate by decreasing manifold pressure. Do not reduce more than 0.3 inch w.c. If boiler is still overfired, contact New Yorker Boiler Company for replacement Gas Orifices. b. Increase input rate if less than 98% of rating label input.
  • Page 18 VII. System Start-up (continued) Figure 16: Operating Instructions 9. Return other gas-fired appliances to previous Remove Main Burners per procedure in Section VIII. Service. conditions of use. ii. Remove gas orifices. Drill one (1) drill size Adjust gas input rate to boiler (LP/Propane). larger (drill size is stamped on orifice, or see 1.
  • Page 19 VII. System Start-up (continued) 4. Follow instructions to TURN OFF GAS TO Open boiler fill valve sufficiently to permit a steady APPLIANCE. See Figure 16 for intermittent trickle of water from the pipe. Continue this slow ignition (EI). Remove manometer. boiling and trickle of overflow for several hours until the water coming from the overflow is clear.
  • Page 20 VII. System Start-up (continued) 11. Drain boiler. Open all radiator valves. Reinstall Add Boiler Water Treatment. all supply main air valves. Open shut off valve in 1. Low pressure steam boilers such as this CGS-A Hartford Loop. Series should be maintained with appropriate water 12.
  • Page 21 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. Do not place any obstructions in boiler room that will hinder flow of combustion and ventilation air.

  • Page 22: Viii. Service

    VIII. Service (continued) Table 10: Ignition Module Terminal Cross- 5. For reliable operation the flame current should be Reference 2 μAmp or greater. 6. To ensure adequate flame current: Ignition Module Wiring Ladder Diagram Terminal Designation Terminal Number a. Turn off boiler power at circuit breaker or fuse box.
  • Page 23 VIII. Service (continued) e. Check the pilot flame. It must be blue, steady and Float Low Water Cutoff. McDonnell & Miller 67 envelop the flame sensing rod 3/8” to ½”. Only. f. If needed, adjust pilot flame by turning the 1.
  • Page 24 VIII. Service (continued) Figure 18: Jacket Front Panel and Vestibule Panel Removal 7. Install canopy a. Verify that sealing surfaces between canopy and heat exchanger are clean. b. Secure canopy to heat exchanger with carriage bolts, nuts, and washers. c. Seal gap between canopy and heat exchanger with high temperature boiler cement or Dow Corning Silastic 732 RTV, Dow Corning Silastic 736 RTV, Polybac #500 RTV, or Sil-bond RTV...
  • Page 25 VIII. Service (continued) Table 12: Pilot Burner Location Check operation. Follow steps D through P from Section VII: System Start-up. Boiler Main Burner with Pilot Burner Located Lubrication. There are no parts requiring lubrication Model Pilot Bracket * Between Main Burners * by service technician or owner.
  • Page 26 VIII. Service (continued) "CALL FOR HEAT." POWER TO CHECK LINE VOLTAGE POWER, LOW VOLTAGE TRANSFORMER, LIMIT CONTROLLER, THERMOSTAT (CONTROLLER), AND WIRING. ALSO, MODULE? (24 V CHECK AIR PROVING SWITCH ON COMBUSTION AIR BLOWER SYSTEM (IF USED) AND THAT THE VENT DAMPER END SWITCH (IF USED) NOMINAL) IS MADE.
  • Page 27 All CGS-A™ Series repair parts may be obtained through your local New Yorker Boiler Co., Inc. authorized 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's main office: New Yorker Boiler Co., Inc.

  • Page 28: Ix. Repair Parts

    IX. Repair Parts (continued) Quantity Description Part No. Main Burner Orifice, #45 (Pink) (Natural Gas) 822711 Main Burner Orifice, #48 (Natural Gas) 822726 Main Burner Orifice, #49 (Yellow) (Natural Gas) 822709 Main Burner Orifice, 1.25 mm (Purple) (LP) 822705 Main Burner Orifice, #55 (Green) (LP) 822708 Main Burner Orifice, #56 (LP) 822707...
  • Page 29 IX. Repair Parts (continued) Quantity Description Part No. Safety Valve, 15 psi, 3/4 NPT, Conbraco 13-511-08 81660530 Gauge Glass Set, Conbraco 20-104-10 (with 9" Gauge Glass) 8056020 Limit, Honeywell PA404A1009 80160300 Syphon 806603006 Pressure Gauge 100325-01 Drain Valve, Conbraco 35-302-03 806603061 Transformer, 40VA, Honeywell AT140D1012 80160039...
  • Page 30 Important Product Safety Information Refractory Ceramic Fiber Product Warning: The Repair Parts list designates parts that contain refractory ceramic fibers (RCF). RCF has been classified as a possible human carcinogen. When exposed to temperatures about 1805°F, such as during direct flame contact, RCF changes into crystalline silica, a known carcinogen.

  • Page 31: Service Record

    SERVICE RECORD DATE SERVICE PERFORMED...

  • Page 32: Warranty

    New Yorker’s liability under these warranties shall under following the date of installation, New Yorker will, at its option, repair the no circumstances exceed the purchase price paid for the boiler defective part or provide a replacement free of charge, F.O.B.

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