New Yorker CL3-105, Installation, Operating And Service Instructions

Page 1: ...u N l a i r e S d n a r e b m u N l e d o M r e l i o B e d i v o r p r e l i o b r e b m u N l e d o M r e l i o B r e b m u N l a i r e S r e l i o B e t a D n o i t a l l a t s n I L C r o t c a r t n o C g n i t a e H r e b m u N e n o h P s s e r d d A As an ENERGY STAR Partner New Yorker Boiler Co Inc has determined that the CL3 091 CL3 105 CL4 126 and CL5 168 water boilers meet the ENERGY S...

Page 2: ...ntion to the presence of hazards of various risk levels or to important information concerning product life All boilers must be installed in accordance with National State and Local Plumbing Heating and Electrical Codes and the regulations of the serving utilities These Codes and Regulations may differ from this instruction manual Authorities having jurisdiction should be consulted before installa...

Page 3: ...talling contractor to see that all controls are correctly installed and are operating properly when installation is complete including verifying that the limit sensor is fully installed seated in bottom of Well Failure to properly install Limit Sensor may result in property damage personal injury or loss of life due to elevated operating temperatures and or pressures This boiler is suitable for in...

Page 4: ...d condition Serious property damage could result if the boiler is connected to a dirty or inadequate chimney or vent system The interior of the chimney flue must be inspected and cleaned before the start of the heating season for any obstructions A clean and unobstructed chimney flue is necessary to allow noxious fumes that could cause injury or loss of life to vent safely and will contribute towa...

Page 5: ...5 Figure 1A CL3 Thru CL5 Water Boiler without Tankless Heater All Burner Options Figure 1B CL3 Thru CL5 Water Boiler With Tankless Heater All Burner Options I GENERAL INFORMATION B C DIA ...

Page 6: ...eam Boiler with or without Tankless Heater McDonnell Miller PS 801 Beckett Burner Figure 1D CL3 thru CL5 Steam Boiler with or without Tankless Heater McDonnell Miller PS 801 Riello Burner I GENERAL INFORMATION continued A B C DIA ...

Page 7: ...3 091 W 0 65 91 80 70 6 8 x 8 15 86 1 CL3 091 S 0 65 91 78 56 233 6 8 x 8 15 84 1 CL3 105 W 0 75 105 91 79 6 8 x 8 15 86 0 CL3 105 S 0 75 105 90 68 283 6 8 x 8 15 83 8 CL3 140 W 1 00 140 120 104 6 8 x 8 15 84 3 CL3 140 S 1 00 140 119 89 370 6 8 x 8 15 82 7 CL4 126 W 0 90 126 111 97 7 8 x 8 15 86 0 CL4 126 S 0 90 126 108 81 338 7 8 x 8 15 84 1 CL4 175 W 1 25 175 152 132 7 8 x 8 15 85 1 CL4 175 S 1 ...

Page 8: ...er A 1 Return B Limit Well Plug C Temperature Pressure Gauge D 1 Supply E 1 Optional Return F Relief Valve G N A DHW Outlet H N A Limit Well I N A DHW Inlet Table 3A Purpose of Tappings Water I GENERAL INFORMATION continued Figure 2A Purpose of Tappings Water ...

Page 9: ...ith Heater A 1 Return B Pressure Limit C Pressure Gauge D 3 Supply E 1 Optional Return F Relief Valve G N A DHW Outlet H N A Limit Well I N A DHW Inlet J Drain K LWCO L Water Gauge Glass M Water Gauge Glass N 1 Indirect Water Heater Supply O Indirect Water Heater Limit P 1 Surface Blowoff I GENERAL INFORMATION continued ...

Page 10: ...See Figure 3 NOTICE Clearance to venting is for single wall vent pipe If Type L vent is used clearance may be reduced to the minimum required by the vent pipe manufacturer C PROVIDE COMBUSTION AND VENTILATION AIR Local and National Codes may apply and should be referenced A INSPECT SHIPMENT carefully for any signs of damage 1 All equipment is carefully manufactured inspected and packed Our respons...

Page 11: ...freely communicating with the outdoors Locate one opening within 12 inches of top of space Locate remaining opening within 12 inches of bottom of space Minimum dimension of air opening is 3 inches Size each opening per following a Direct communication with outdoors Minimum free area of 1 square inch per 4 000 BTU per hour input of all equipment in space b Vertical ducts Minimum free area of 1 squa...

Page 12: ...lower input is desired remove the nozzle that was factory installed f Remove Beckett MB L1 or MD V1 head g Locate the desired nozzle Refer to Table 14A at rear of this manual for proper nozzle The nozzle must be securely installed to assure leak free joints between the nozzle and adapter When installing the nozzle be careful not to bump or move the burner electrodes Note On the CL3 091 0 65 GPH bu...

Page 13: ...MB L1 or the blue line MD V1 are aligned readjust if necessary Refer to Figure 26 m Tighten knurled nut n Swing igniter closed rotate tabs and tighten two 2 igniter screws 3 On the Riello 40 Series Oil Burner use the following procedure to complete the inspection check the settings and to change the nozzle to a lower firing rate Refer also to Model F3 F5 Installation Manual Riello 40 Series Reside...

Page 14: ... Teflon or Sealant to all joints prior to assembly Thread 1 NPT x 5 Lg return nipple into 1 NPT tapping located in lower left corner of front section Thread 1 x x 1 NPT tee onto 5 nipple Thread drain valve into NPT connection on tee Tighten all joints with wrench Figure 9 Riello Pump Connections and Port Identification until water tight and 1 NPT return connection on tee is facing away from boiler...

Page 15: ...Do not remove T T jumper unless wiring diagram indicates a direct connection from III Installation Instructions continued thermostat and or tankless heater aquastat control to the oil burner primary control s T T terminal Refer to Figures 22 and 23 H CONNECT SUPPLY AND RETURN PIPING TO HEATING SYSTEM 1 CLEARANCES Steam and hot water pipes shall have clearances of at least from all combustible cons...

Page 16: ...16 Figure 11A Recommended Water Piping for Circulator Zoned Heating System Supply Side Circulator III Installation Instructions continued ...

Page 17: ...17 Figure 11B Recommended Water Piping for Zone Valve Zoned Heating System Supply Side Circulator III Installation Instructions continued ...

Page 18: ...18 III Installation Instructions continued Figure 12 Recommended Boiler Piping for Gravity Return Steam Boiler ...

Page 19: ...leaks ii Absorption through open tanks and fittings iii Oxygen permeable materials in the distribution system b In order to insure long product life oxygen sources should be eliminated This can be accomplished by taking the following measures i Repairing system leaks to eliminate the need for addition of make up water ii Eliminating open tanks from the system iii Eliminating and or repairing fitti...

Page 20: ... hot water by mixing some cold water with the hot This prevents excessive and possibly scalding hot water at the fixtures In addition savings of hot water will be achieved since the user will not waste as much hot water while seeking water temperature to his liking Higher temperature hot water required by dishwashers and automatic washers is possible by piping the hot water from the heater prior t...

Page 21: ...cient draft at all times to assure safe proper operation of the boiler See Figure 16 for recommended installation 1 Install a draft regulator supplied by installer following the instructions furnished with the regulator See Figure 17 for draft regulator locations 2 Consider the chimney overall Chimneys that have a high heat loss may become less suitable as the heat loss of the home goes down and t...

Page 22: ...er volumes of heated gases With reduced input and volume the draft may be severely affected In one instance research showed a new chimney of adequate sizing produced only 035 W C after 30 minutes of continuous firing at 13 0 CO2 Outside wall chimneys take longer to heat up and can have 00 W C draft at burner startup You may have to consider a special alloy chimney flue liner with insulation around...

Page 23: ...gle stage 3450 rpm fuel units with the by pass plug removed for single pipe installations The single stage fuel unit may be installed single pipe with gravity feed or lift Maximum allowable lift is 8 feet See Figure 18 TWO PIPE OIL LINES For two pipe systems where more lift is required the two stage fuel unit is recommended Table 5 single stage and Table 6 two stage show allowable lift and lengths...

Page 24: ...fireplace Keep large furniture away from thermostat so there will be free movement of room air around this control Heat Anticipator in Thermostat should be set to match the requirements of the control to which it is connected See Figures 20 thru 24 for desired system and heat anticipator setting If system tends to overheat above the thermostat s temperature setting reduce heat anticipator setting ...

Page 25: ...hematic Wiring Diagram without Tankless Heater Cold Start Control Beckett and Riello Burners IV Electrical continued Refer to Figure 24 for Schematic wiring diagram of appropriate burner and oil primary control option ...

Page 26: ...chematic Wiring Diagram with Tankless Heater Warm Start Control Beckett and Riello Burners IV Electrical continued Refer to Figure 24 for Schematic wiring diagram of appropriate burner and oil primary control option ...

Page 27: ...robe LWCO Beckett AFG Burner IV Electrical continued McDonnell Miller PS 801 Terminals May Be Lettered or Numbered as Follows Wire Color Numbered Terminals Lettered Terminals RD 5 B BK 1 H WH 2 N Jumper 1 3 H C Refer to Figure 24 for Schematic wiring diagram of appropriate burner and oil primary control option ...

Page 28: ... Diagram Steam Boilers with or without Tankless Heater McDonnell Miller PS 801 Probe LWCO Riello 40 Burner IV Electrical continued Refer to Figure 24 for Schematic wiring diagram of appropriate burner and oil primary control option ...

Page 29: ...rner Options w Various Oil Primary Controls NOTE APPLY THIS BURNER SCHEMATIC TO APPROPRIATE STEAM OR WATER BOILER CONTROL SCHEMATIC REFER TO FIGURES 20 THRU 23 NOTE APPLY THIS BURNER SCHEMATIC TO APPROPRIATE STEAM OR WATER BOILER CONTROL SCHEMATIC REFER TO FIGURES 20 THRU 23 ...

Page 30: ...e a potential hazard which can cause severe property damage personal injury or loss of life if ignored Before opening swing door turn off service switch to boiler to prevent accidental firing of burner outside the combustion chamber Be sure to tighten swing door fastener completely when service is completed V system start up e Open purge valve f Open shut off valve in cold water supply piping loca...

Page 31: ...Figure 26 and Table 14A at the rear of this manual b Check burner air band and air shutter settings Readjust if necessary see Burner Specifications Table 14A at the rear of this manual V system start up continued c OPEN ALL OIL LINE VALVES d Attach a plastic hose to fuel pump vent fitting and provide a pan to catch the oil e OPEN FLAME OBSERVATION PORT COVER on burner swing door 3 Riello Burners a...

Page 32: ...afe and efficient operating condition If the flame appears stringy instead of a solid fire try another nozzle of the same type Flame should be solid and compact After all adjustments are made recheck for a draft of 0 02 over the fire 7 ONLY READJUST THE HEAD TURBULATOR SETTING if necessary a CL3 through CL5 All Models Move the setting forward or back one position at a time to optimize the smoke an...

Page 33: ...33 Figure 26 L1 and V1 Head Electrode Positioning and Gun Setting Beckett AFG V system start up continued ...

Page 34: ...icroprocessor based control The indicator light provides diagnostic information for lockout recycling and cad cell status There is a manual reset button to exit the Lockout Mode ii Pump Priming Cycle To facilitate purging air from the oil lines and filters the 7505 can be placed in a purge routine by After the burner starts press and hold the reset button for 15 seconds until the yellow light turn...

Page 35: ...s on to the controls Make sure limit control is closed V system start up continued Check contacts between ignitor and the electrodes Check the oil pump pressure Check the piping to the oil tank Check the oil nozzle oil supply and oil filter b Check Safety Features Safe Start Place a jumper across cad cell terminals Follow procedure to turn on burner Burner must not start indicator light turns on a...

Page 36: ...erate Open boiler drain to allow water level to drop to bottom of sight glass until burner operation is shut down by low water cut off Close boiler drain and refill to normal water line Burner should automatically restart during fill Lower thermostat setting b Water Boiler Refer to Appendix A at the rear of this manual 6 Check operating control on boiler applications equipped with tankless heater ...

Page 37: ...thin approximately 15 seconds primary control will shut down the burner and enter into a lockout mode A lockout is reset by pressing the reset button located on the primary control If the flame is lost while the burner is firing the primary control shuts down the burner enters a 60 second recycle delay and repeats the ignition sequence If after three 3 trials for ignition flame is not detected pri...

Page 38: ...to view boiler operating status Figure 30 4 Viewing the Operating Mode Options In operating mode the user may view but not change boiler operating status settings and troubleshooting information To view Boiler Control display information Press and release the I key on the Boiler Control to change from one parameter to the next Each setting will alternately flash between the relevant display code a...

Page 39: ...ature the boiler turns on and the ZC terminal and System Circulator outputs are de energized when the boiler temperature is less than the Low Limit Setpoint less the differential On a rising temperature when the boiler temperature is above the Low Limit Setpoint the boiler turns off the ZC terminal output is energized and the System circulator is enabled to respond to a call for heat The Low Limit...

Page 40: ...culator pre purge time delay control logic is bypassed to allow the boiler to fire without delay When DHW demand ends the System Circulator force off is removed the circulator can respond normally and the DHW Circulator is de energized The DHW call for heat is detected by a voltage on to the ZR terminal When a Priority Time parameter is set to off the System Circulator is not forced off for a DHW ...

Page 41: ...t C1 Output ZC Output off off off off on off on off on on on on off on off on Table 10 zone request parameter zc_ zr B STEAM BOILERS SEQUENCE OF OPERATION Upon a thermostat call for heat when provided the R8239A Control Center Relay or the Oil Primary Control is energized when the steam pressure is below the L404F Pressure Limit and water level is above the Low Water Cut Off When energized the Oil...

Page 42: ...e pipe threads of the probe to remove old hardened pipe dope and other foreign matter i Apply a moderate amount of good quality pipe dope to the pipe threads on the probe leaving the two end threads bare Do not use PTFE Teflon tape j Screw the probe into the boiler tapping k Mount the low water cut off control on the probe l Reconnect the control to probe wiring m Fill the boiler to its normal wat...

Page 43: ...hot and will rise slowly VII Maintenance and Service Instructions continued into supply main and back through return main flowing from drain hose at about 180 F Continue until water runs clear from drain hose for at least 30 minutes iv Stop feeding water to boiler but continue operating oil burner until excess water in boiler flows out through supply main and water lowers by steaming until it reac...

Page 44: ...c readings A color chart on the side of the small hydrion dispenser gives the reading pH VII Maintenance and Service Instructions continued Hydrion paper is inexpensive and obtainable from any chemical supply house or through your local druggist The pH should be higher than 7 but lower than 11 Add some of the washout chemical caustic soda if necessary to bring the PH within the specified range e B...

Page 45: ...protective cloth with debris and vacuum as necessary but be careful not to damage blanket Inspect target wall combustion chamber blanket and burner mounting plate insulation for signs of damage If damaged replace as needed E REASSEMBLE BOILER CAUTION Do not start the burner unless canopy smokepipe and burner swing door are secured in place 1 Install the canopy taking care to align the gaskets with...

Page 46: ...46 Figure 31 Cleaning of Boiler Flueways VIII Boiler Cleaning continued ...

Page 47: ... Long sleeved loose fitting clothing 3 Gloves 4 Eye Protection Take steps to assure adequate ventilation Wash all exposed body areas gently with soap and water after contact Wash work clothes separately from other laundry and rinse washing machine after use to avoid contaminating other clothes Discard used RCF components by sealing in an airtight plastic bag RCF and crystalline silica are not clas...

Page 48: ... pattern from the nozzle The smaller the firing rate the smaller the slots become in the nozzle and the more prone to plugging it becomes with the same amount of dirt 6 WATER Water in the fuel in large amounts will stall the fuel pump Water in the fuel in smaller amounts will cause excessive wear on the pump but more importantly water doesn t burn It chills the flame and causes smoke and unburned ...

Page 49: ...the oil primary control Hard Lockout will occur if the Oil Primary Control locks out three 3 times during a call for heat This is indicated by red light reset button solid on C INTELLIGENT OIL BOILER CONTROL Cold Start Boiler Control is used on Boilers without Tankless Heaters Warm Start Boiler Control is used on Boilers with Tankless Heaters 1 When a problem occurs with the boiler operation the B...

Page 50: ...ring safety output relay check sequence or un powered during running or powered in idle in combination with water temperature above 264 F limit Cycle power to the control Replace control if problem persists Err 5 Line Voltage Fault 80 Vac AC voltage out of specification high or low check L1 L2 110 VAC Err 6 Fuse missing Internal fuse is blown or missing The fuse protects the Aquastat from miswirin...

Page 51: ...rs 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 P O Box 10 Hatfield PA 19440 0010 Phone 215 855 8055 Attn Customer Service Department X Repair Parts ...

Page 52: ...52 X Repair Parts continued Bare Boiler Assembly Exploded View ...

Page 53: ...20051 11 BSD Hinge Loop Bracket 2 2 2 100795 02 12 5 16 Flat Washer Plated 4 4 4 80860611 13 5 16 18 x 1 Lg Cap Screw Plated 2 2 2 80861341 14 5 16 18 x 1 1 2 Lg Cap Screw Plated 2 2 2 80861349 15 Burner Swing Door only Machined Painted 1 1 1 100793 01 16 Burner Swing Door Insulation 1 1 1 82020001 17 Observation Port Cover Machined Painted 1 1 1 71728004 18 5 16 18 x 3 4 Lg Cap Screw Plated 1 1 1...

Page 54: ...el Assembly 1 1 1 100820 01 3 Jacket Reversible Side Panel Assembly Non Heater Build 2 100821 03 2 100821 04 2 100821 05 With Heater Build 1 100821 03 1 100821 04 1 100821 05 4 Jacket Left Side Heater Panel Assembly WT R ST R Heater Builds 1 100824 03 1 100824 04 1 100824 05 5 Jacket Split Front Top Panel Assembly 1 1 1 100823 01 6 Jacket Split Rear Top Panel Assembly 1 100822 03 1 100822 04 1 100...

Page 55: ...452 4 Temperature Pressure Gauge NPT x 2 1 2 Dia x 1 1 2 Lg Shank 1 1 1 100282 01 5 3 4 NPT x 7 1 4 Lg Nipple SCH 80 Black 1 1 1 100839 01 6 Relief Valve 3 4 F x 3 4 F 30 PSI 10 408 05 1 1 1 81660319 7 1 1 2 NPT x 5 Lg Nipple Black 1 1 1 806600060 8 1 1 2 x 3 4 x 1 1 2 NPT Tee Black 1 1 1 806601003 9 3 4 NPT Ball Drain Valve Conbraco 35 302 03 1 1 1 806603061 10 Circulator w Gaskets Taco 007 1 1 1...

Page 56: ...eel 1 1 1 806600524 4 Honeywell L4006A2015 Aquastat 1 1 1 80160400 5 3 4 NPT x 3 Immersion Well Honeywell 123871A 1 1 1 80160452 6 Steam Gauge 1 4 NPT x 2 1 2 Dia x 7 8 Shank 1 1 1 100325 01 7 10 Gauge Glass Set Conbraco 22 171 10 1 1 1 100854 01 7A 1 2 Male x Female NPT Brass Extension Piece 1 1 1 100853 01 7B 1 2 NPT Brass Street Elbow 1 1 1 100852 01 8 3 4 NPT x 7 Lg Nipple SCH 80 Black 1 1 1 1...

Page 57: ...57 Beckett AFG Burner X Repair Parts continued ...

Page 58: ...e Clamp Screw 4219 4219 4219 4219 4219 Electrode Insulator Assembly 5780 5780 5780 5780 5780 Spider Spacer Assembly 5653 5653 5653 5653 5653 Escutcheon Plate 3493 3493 Adjusting Plate Assembly 5941 5941 5941 Head 5912 5912 5913 5913 5913 Head Screws 4221 4221 4221 4221 4221 Flange Gasket 3416 3416 3416 3416 3416 AFG Housing 5874BK 5874BK 5874BK 5874BK 5874BK Motor 21805 21805 21805 21805 21805 Noz...

Page 59: ...4 210 1 50 V1 3 10 2 1 10 x 45B Hago Installed 175 CL5 168 1 20 V1 3 10 0 0 90 x 45B Hago Installed 175 CL5 245 1 75 V1 3 7 3 1 35 x 45B Hago Installed 175 CL5 280 2 00 V1 4 10 3 1 50 x 45B Hago Installed 175 1 Beckett low firing rate baffle required on CL3 091 0 65 GPH application only shipped loose with nozzle 2 Nozzle s for alternate boiler model firing rate s are shipped loose in bag attached ...

Page 60: ...el firing rate s are shipped loose in bag attached to the burner designated by corresponding symbol i e p CL3 105 3 Single stage fuel pump is standard two stage fuel pump is optional Burner manufacturer has preset single stage fuel pump to settings shown in table above NOTE When ordering parts always give the serial and model numbers shown on the boiler and burner Refer to Models F3 F5 Installatio...

Page 61: ...upply or return piping as shown below Select the appropriate size tee using the LWCO manufacturer s instructions Often the branch connection must have a minimum diameter to prevent bridging between the probe and the tee Also the run of the tee must have a minimum diameter to prevent the end of the probe from touching or being located too close to the inside wall of the run of the tee Ideally manua...

Page 62: ...O probe It may be necessary to open relief valve seat to allow air into system for the water to drain close drain valve and relief valve once completed Generate a boiler demand by turning up thermostat Boiler should not attempt to operate Open fill valve to increase the water level by filling the system It may be necessary to open relief valve to allow air to escape during filling process The boil...

Page 63: ...63 SERVICE RECORD DATE SERVICE PERFORMED ...

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