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New Yorker Classic CGS-A Series Installation, Operating And Service Instructions

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INSTALLATION, OPERATING
SERVICE INSTRUCTIONS
CLASSIC CGS-A SERIES
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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GAS BOILER
BEFORE INSTALLATION: READ THIS MANUAL
SAVE THESE INSTRUCTIONS
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  • Page 1 INSTALLATION, OPERATING SERVICE INSTRUCTIONS CLASSIC CGS-A 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 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 ......18 III. Steam Piping and Trim ....5 VIII. Service ......... 23 IV. Gas Piping ........8 IX. Repair Parts ........28 V. Venting ......... 10 Warranty ......Back Cover I. Pre-Installation Table 2: Special Base for Installation on Combustible Flooring .
  • Page 4 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 Move boiler to permanent location. When using special base for installation on combustible floor: 1. Place base on floor with insulated surface facing upward and part number facing forward. 2. Position base to provide minimum clearances to combustible walls.
  • Page 6 Table 3: Purpose of Tappings " 2 ¾ " ¼ ½ " " 2 Install Drain Valve in Tapping 'F'. See Figure 4. ¾ " " 2 " 2 ¾ " ¾ " l l e & l l i Connect system supply and return piping to boiler.
  • Page 7 Figure 7: Recommended Boiler Piping for Gravity Return...

  • Page 8: Gas Piping

    IV. Gas Piping Size gas piping. Design system to provide adequate gas Table 4: Rated Input supply to boiler. Consider these factors: 1. Allowable pressure drop from point of delivery to boiler. Maximum allowable system pressure is ½ psig. Actual point of delivery pressure may be less; contact gas supplier for additional information.
  • Page 9 Table 5: Maximum Capacity of Schedule 40 Pipe in CFH For Natural Gas Pressures of 0.5 psig or Less ½ ¾ ¼ ½ ¾ ¼ Table : Fitting Equivalent Lengths Table 7: Specific Gravity Correction Factors for Natural Gas t t i ½...

  • 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 Vent damper assembly includes pre-wired connection harness with polarized plug for use on all 24V standing pilot or EI control systems. 3. Mount vent damper assembly on draft hood without modification to either. Refer to instructions packed f i l with vent damper for specific instructions.
  • Page 12 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 12. not connected to the common venting system. 1. Do not connect into same leg of chimney serving an Turn on any exhaust fans, such as range-hoods and open fireplace.

  • Page 13: Electrical

    VI. Electrical Table 8: Wiring Diagrams General. Install wiring and ground boiler in accordance with requirements of authority having jurisdiction, or in absence of such requirements the National Electrical Code, ANSI/NFPA 70. t n I Connect Vent Damper. See Figure 11. o l i 1.
  • Page 14 Figure 14: Wiring Diagram, Continuous Ignition (Standing Pilot) and Hydrolevel Model 400 or McDonnell & Miller PS-802-24 Cutoff Sequence of Operation, Continuous Ignition c. Blocked Vent Switch. Automatically interrupts (Standing Pilot). main burner operation when excessive vent 1. Normal Operation system blockage occurs.
  • Page 15 Figure 15: Wiring Diagram, Intermittent Ignition (EI) and Hydrolevel Model 400 or McDonnell & Miller PS-802-24 Low Water Cutoff Sequence of Operation with Intermittent Ignition operation. The source of blockage must be (EI). corrected by trained and skilled personnel from a qualified service agency before resetting switch.
  • Page 16 Figure 1: Wiring Diagram, Continuous Ignition (Standing Pilot) and McDonnell & Miller 7 Low Water Cutoff Sequence of Operation, Continuous Ignition c. Blocked Vent Switch. Automatically interrupts (Standing Pilot). main burner operation when excessive vent system blockage occurs. Vent Damper remains 1.
  • Page 17 Figure 17: Wiring Diagram, Intermittent Ignition (EI) and McDonnell & Miller 7 Low Water Cutoff Sequence of Operation with Intermittent Ignition operation. The source of blockage must be (EI). corrected by trained and skilled personnel from a qualified service agency before resetting switch. 1.

  • Page 18: System Start-Up

    VII. System Start-up Safe operation and other performance criteria were Check pilot burner flame. met with gas manifold and control assembly provided 1. Continuous Ignition (standing pilot). See Figure on boiler when boiler underwent tests specified in 18. Pilot produces a single flame. Flame should be American National Standard for Gas-Fired Low- steady, medium hard blue enveloping 3/8 to ½...
  • Page 19 i t l f i r i t l f i t . t f Figure 20: Main Burner Flame . t f Table 9: Gas Flow Rate in Cubic Feet per Hour 3. Main burners and pilot burner will extinguish when water level falls below low water cutoff (water should still be visible in gauge glass).
  • Page 20 Do not reduce more than 0.3 inch w.c. If boiler is still 7. Follow instructions to TURN OFF GAS TO overfired, contact New Yorker Boiler Company APPLIANCE. See Figure 21 for continuous for replacement Gas Orifices.
  • Page 21 Figure 22: Operating Instructions 9. Return other gas-fired appliances to previous 5. Follow Lighting or Operating Instructions to place conditions of use. boiler in operation. See Figure 21 for continuous ignition (standing pilot) or Figure 22 for intermittent Adjust gas input rate to boiler (LP/Propane). ignition (EI).
  • Page 22 ignition (standing pilot) or Figure 22 for intermittent Boil-out boiler. ignition (EI). 1. Follow instructions TO TURN OFF GAS TO 3. Operate boiler at this water level for at least 30 APPLIANCE. See Figure 21 for continuous minutes after the condensate begins to run hot. ignition (standing pilot) or Figure 22 for intermittent ignition (EI).

  • Page 23: Service

    If the boiler water becomes dirty again at a later date due to 3. Make pH or Alkalinity Test. additional sediment loosened up in the piping: After boiler and system have been cleaned and 1. Follow instruction to TURN OFF GAS TO refilled as previously described, test the pH of the APPLIANCE.
  • Page 24 24 Volt Probe Low Water Cutoff. Hydrolevel Model 400 and McDonnell & Miller PS-802-24 Only. 1. Drain boiler to point below Tapping 'K'. 2. Disconnect wire(s) connecting control and probe. 3. Remove control from probe. 4. Unscrew probe from Tapping 'K'. Inspect for scale and sediment buildup.
  • Page 25 2. Remove soot accumulations with wire brush and Table 10: Pilot Burner Location vacuum. 3. Repair or replace deteriorated vent pipe and vent accessories. 4. Provide proper support. Repair sags, particularly in horizontal sections. & 5. Repair leaking joints. & Inspect Boiler Flue Passages for blockage or soot &...
  • Page 26 ELECTRONIC IGNITION TROUBLE SHOOTING GUIDE...

  • Page 28: Repair Parts

    IX. Repair Parts All Classic 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 29 f i r - - - - - - - - - - - - f i r - - - - - - - - - f i r o l l - - - - - - - - - - - - f i r - - -...
  • Page 30 ¾ " 9 , t i o l l , f f , f f & l l i & l l I - - - - - - - - - - - - - - - - - - - - - - - - - - -...
  • Page 31 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 32: Warranty

    These limited warranties apply to residential cast iron steam boilers labeled low water cut-off, by an installer regularly engaged in boiler installations. with the New Yorker® brand which are sold on or after March 1, 2004 Boiler sections must not have been damaged during shipment or ONE YEAR LIMITED WARRANTY installation.

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