Energy Tech Laboratories New Yorker CL, Riello 40, New Yorker F5, New Yorker F3 User Manual

INSTALLATION, OPERATING

nonoitamrofnignikeesnehW.rotcartnocgnitaehruoyllac,reliobotsriaperroecivresroF

.lebaLgnitaRnonwohssarebmuNlaireSdnarebmuNledoMrelioBedivorp,reliob

rebmuNledoMrelioB rebmuNlaireSrelioB etaDnoitallatsnI

LC

rotcartnoCgnitaeH rebmuNenohP

sserddA

AND SERVICE INSTRUCTIONS

CL™ SERIES

CAST IRON OIL-FIRED BOILER

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 STAR
guidelines for Energy

efciency established by the

United States Environmental
Protection Agency (EPA).

®

100825-01R5-10/08

Price - $3.00

IMPORTANT INFORMATION - PLEASE READ THIS PAGE CAREFULLY

1. Read and understand all instructions, including all those contained in component manufacturers manuals which are
provided with the appliance before installing, starting-up, operating, maintaining or servicing this appliance. Keep this
manual and literature in legible condition and posted near appliance for reference by owner and service technician.

2. All heating systems should be designed by competent contractors and only persons knowledgeable in the layout and
installation of hydronic heating systems should attempt installation of any boiler.

3. 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 installations are made.

In all cases, reference should be made to the following Standards:

USA BOILERS

A. Current Edition of American National Standard ANSI/NFPA 31, “Installation of Oil Burning Equipment”, for

recommended installation practices.

Current Edition of American National Standard ANSI/NFPA 211, “Chimneys, Fireplaces, Vents, and Solid Fuel

B.

Burning Appliances”, For Venting requirements.

C.

Current Edition of American Society of Mechanical Engineers ASME CSD-1, “Controls and Safety Devices for

Automatically Fired Boilers”, for assembly and operations of controls and safety devices.

All wiring on boilers installed in the USA shall be made in accordance with the National Electrical Code and/or

D.

Local Regulations.

CANADIAN BOILERS

A.

Current Edition of Canadian Standards Association CSA B139, “Installation Code for Oil Burning Equipment”,

for recommended Installation Practices.

B. All wiring on boilers installed in Canada shall be made in accordance with the Canadian Electrical Code and/or

Local Regulations.

NOTICE

This boiler has a limited warranty, a copy of which is printed on the back of this manual.
The warranty for this boiler is valid only if the boiler has been installed, maintained and operated in accordance

with these instructions.

DANGER

DO NOT store or use gasoline or other ammable vapors or liquids in the vicinity of this or any other

appliance.

2

WARNING

This boiler is suitable for installation on combustible ooring. Do not install boiler on carpeting.

Installation is not complete unless a pressure relief valve is installed into the tapping located on top left
corner of rear section - See Piping and Trim Sections of this manual for details.

This boiler is designed to burn No. 2 fuel oil only. Do not use gasoline, crankcase drainings, or any oil
containing gasoline. Never burn garbage or paper in this boiler. Do not convert to any solid fuel (i.e.

wood, coal). Do not convert to any gaseous fuel (i.e. natural gas, LP). All ammable debris, rags, paper,

wood scraps, etc., should be kept clear of the boiler at all times. Keep the boiler area clean and free of

re hazards.
This boiler needs fresh air for safe operation and must be installed so there are provisions for adequate

combustion and ventilation air.
This boiler must be connected to an approved chimney in good condition. Serious property damage

could result if the boiler is connected to a dirty or inadequate chimney. The interior of the chimney ue

must be inspected and cleaned before the start of the heating season for any obstructions. A clean and

unobstructed chimney ue is necessary to allow noxious fumes that could cause injury or loss of life to
vent safely and will contribute toward maintaining the boiler's efciency.

Inspect ueways at least once a year - preferably at the start of the heating season. The inside of
the combustion chamber, the vent system and boiler ueways should be cleaned if soot or scale has

accumulated.
When cleaning this boiler, do not damage combustion chamber liner and/or rear target wall. If damaged,
combustion chamber insulation must be replaced immediately.

This boiler requires regular maintenance and service to operate safely. Follow the instructions contained
in this manual. Installation, maintenance, and service must be performed only by an experienced, skilled

and knowledgeable installer or service agency.
It is the responsibility of the installing contractor to see that all controls are correctly installed and

are operating properly when the installation is completed. Do not tamper with or alter the boiler or
controls.

Do not operate unit if any control, switch, component, or device has been subject to water. When cleaning
this boiler, do not damage combustion chamber liner and/or rear target wall. If damaged, combustion
chamber insulation must be replaced immediately.

Oil Burner and Controls must be checked at least once a year or as may be necessitated.

All boilers equipped with burner swing door have a potential hazard which if ignored can cause severe
property damage, personal injury or loss of life. Before opening swing door, turn off service switch to
boiler to prevent accidental ring of burner outside the combustion chamber. Be sure to tighten swing

door fastener completely when service is completed.
Appliance materials of construction, products of combustion and the fuel contain alumina, silica, heavy

metals, carbon monoxide, nitrogen oxides, aldehydes and/or other toxic or harmful substances which
can cause death or serious injury and which are known to the state of California to cause cancer, birth
defects and other reproductive harm. Always use proper safety clothing, respirators and equipment when

servicing or working nearby the appliance.

High water temperatures increase the risk of scalding injury. If this boiler is equipped with a tankless
heater for domestic water supply, a ow regulator and automatic mixing valve must be installed properly

in tankless heater piping. See Piping and Trim Sections of the manual for details.

3

Table of Contents

I. General Information ....................................4

II. Installation Instructions ..............................8

III.

Indirect Water Heater Piping ....................23

IV. Operating & Service Instructions ............24

V. Maintenance and Service Instructions. ...30

VI. Boiler Cleaning ..........................................

34

I. General Information

A. INSPECT SHIPMENT carefully for any signs of

damage.

1. ALL EQUIPMENT is carefully manufactured,
inspected and packed. Our responsibility ceases
upon delivery of crated boiler to the carrier in good
condition.

2. ANY CLAIMS for damage or shortage in shipment

must be led immediately against the carrier by

the consignee. No claims for variances from,
or shortage in orders, will be allowed by the
manufacturer unless presented within sixty (60)
days after receipt of goods.

B. LOCATE BOILER in front of nal position before

removing crate. See Figures 1A thru 1D.

1. LOCATE so that smoke pipe connection
to chimney will be short and direct. BOILER
IS SUITABLE FOR INSTALLATION ON
COMBUSTIBLE FLOOR. Boiler cannot be
installed on carpeting.

Trouble Shooting

Carlin 40200 .............................................36

Riello 40 Series .......................................36

VII. Repair Parts .............................................37

VIII. Appendix

Low Water Cut Off ..................................45

Burner Specications ............................46

2. FOR BASEMENT INSTALLATION, provide a

solid base, such as a concrete pad, if oor is not
level, or if water may be encountered on oor

around boiler.

PROVIDE SERVICE CLEARANCE of at least 24”

3.

on top of boiler for cleaning ueways. Provide at

least 24" on right side of boiler for removal of rear
tankless heater. Provide at least 24” clearance from
front jacket panel for servicing.

4. For minimum clearances to combustible materials.
See Figure 2.

C. PROVIDE AIR SUPPLY AND VENTILATION to

accommodate proper combustion. If natural ventilation
is inadequate, provide a screened opening or duct from
the boiler room to the outside. The opening or duct
must be sized so the boiler input will not exceed 4,000
BTUH/Sq. In. of free area. If other air consuming
appliances are near the boiler, the air inlet should be
larger. Consult respective manufacturers.

4

Figure 1A: CL3 Thru CL5 Water Boiler Less Tankless Heater

Figure 1B: CL3 Thru CL5 Water Boiler With Tankless Heater

5

Figure 1C: CL3 Thru CL5 Steam Boiler with or without Tankless Heater

Figure 1D: CL3 thru CL5 Steam Boiler with McDonnell & Miller PS-801 Low Water Cut-Off, Riello Burner

TABLE 1: DIMENSIONAL DATA (SEE FIGURES 1A THRU 1C)

Boiler

Model

CL3 17-3/8" 8-1/4" 5-7/8" 8" x 8" x 15' 6" x 15' 16 14.33
CL4 22-3/8" 10-7/8" 6-7/8" 8" x 8" x 15' 7" x 15' 20 20.90
CL5 27-3/8" 13-3/8" 7-7/8" 8" x 8" x 15' 8" x 15' 24 27.46

Maximum Working Pressure: Steam: 15 PSI; Water: 30 PSI Shipped Standard from Factory, 50 PSI Optional

Dimensions Minimum Chimney Size

"A" "B" "C" Rectangular Round

Approx. Water

Content - Gallons

Heat Transfer Surface

Area - Sq. Ft.

6

TABLE 2: RATING DATA

Burner

Boiler Model

Capacity

No. *

GPH MBH

CL3-091(W) 0.65 91 80 --- 70 --- --- 6 8 x 8 15 86.0 ---

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 85.1 ---

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 83.6 ---

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 85.8 ---

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 84.2 ---

CL4-175(S) 1.25 175 --- 149 --- 112 467 7 8 x 8 15 --- 83.5

CL4-210(W) 1.50 210 179 --- 156 --- --- 7 8 x 8 15 83.1 ---

CL4-210(S) 1.50 210 --- 177 --- 133 554 7 8 x 8 15 --- 82.6

CL5-168(W) 1.20 168 147 --- 128 --- --- 8 8 x 8 15 85.7 ---

CL5-168(S) 1.20 168 --- 144 --- 108 450 8 8 x 8 15 --- 83.7

CL5-245(W) 1.75 245 210 --- 183 --- --- 8 8 x 8 15 83.0 ---

CL5-245(S) 1.75 245 --- 207 --- 155 646 8 8 x 8 15 --- 82.5

CL5-280(W) 2.00 280 238 --- 207 --- --- 8 8 x 8 15 82.5 ---

CL5-280(S) 2.00 280 --- 235 --- 176 733 8 8 x 8 15 --- 82.3

* Boiler Model Sufx: (W) = Water, (S) = Steam

DOE Heating

Capacity

Water

MBH

Steam

MBH

I=B=R NET Ratings

Water

MBH

Steam

MBH

Steam
Sq. Ft.

Minimum Chimney

Requirements

Round

In. Dia.

Rectangle

In. x In.

Height

Ft.

AFUE %

Water Steam

Figure 2: Minimum Installation Clearances To Combustible Materials (Inches)

C

A

Above

6 24 18 6 6

NOTE 1: Listed clearances comply with American National
Standard NFPA 31, Standard for the Installation of Oil Burn­ing Equipment.

B

Front

Chimney

Connector

D

Rear

E

Sides

NOTE 2: CL Series boilers can be installed in rooms with
clearances from combustible material as listed above. Listed
clearances cannot be reduced for alcove or closet installa­tions.

NOTE 3: For reduced clearances to combustible material,
protection must be provided as described in the ANSI/NFPA
31 standard.

7

II. Installation Instructions

A. REMOVE CRATE

1. Remove all fasteners at crate skid.

2. Lift outside container and remove all other
inside protective spacers and bracing. Remove
miscellaneous steam or water trim carton.

Using hand truck or pipe rollers under skid, move

3.
boiler into position along side installation site.

B. REMOVAL OF BOILER FROM SKID

1. Boiler is secured to base with 4 carriage bolts, 2 on
left side and 2 on right side. See Figure 3. Remove
all bolts.

Figure 3: Removal of Boiler From Skid

2. Tilt boiler to right and to rear. Using right rear leg
as pivot, rotate boiler 90° in a clockwise direction,

and lower left side of boiler to oor. Tilt boiler

and remove crate skid. Care should be exercised to
prevent damage to jacket or burner.

C. MOVE BOILER TO PERMANENT POSITION by

sliding or walking.

D. INSPECT COMBUSTION TARGET WALL AND

COMBUSTION CHAMBER LINER

1. OPEN FLAME OBSERVATION DOOR AND/
OR BURNER SWING DOOR on front of boiler.

Use ashlight to inspect target wall secured to

rear section with silastic sealant. Inspect ceramic

ber blanket secured to oor of boiler with water

glass adhesive. If either is damaged they must be
replaced.

E. INSPECT NOZZLE, ELECTRODES INSERTION

DEPTH AND TURBULATOR SETTING/CHANGE
FIRING RATE: Refer also to Model F3 & F5

Installation Manual, Riello 40 Series Residential Oil
Burners (C6501010) or Model F10 Installation Manual,
Riello 40 Series Residential Oil Burners (2902554).

1. PACKAGED CL™ Series boilers are shipped with
the highest input oil nozzle installed in the burner.

Oil nozzles for lower ring rates are shipped

loose for the CL3 through CL5 models, attached
to the burner. Select the proper oil nozzle for the
installation. The lower input nozzle will provide

greater boiler efciency. However, boiler output
will be reduced. Refer to Table 2 for ring rates.

If the higher rate is desired, inspect the installed
nozzle and assure that the nozzle is the correct size

and type as specied in Tables 9 and 9A of this

manual.

If a lower input is desired, remove the nozzle

which was factory installed. Locate the lower ring
rate nozzle that is supplied loose. Conrm the
nozzle is the proper size and type for the lower ring
rate as specied in Tables 9 and 9A of this manual.

Install the proper nozzle in the burner nozzle
adaptor.

2.

On the Beckett AFG Burner, use the following

procedure to complete the inspection, check the settings

and to change the nozzle to a lower ring rate:

a. Loosen two (2) igniter latching screws, rotate

tabs and swing open igniter about hinge.

b.

Loosen knurled nut and disconnect copper

connector tube.
c. Remove nozzle line electrode assembly.
d. If high ring rate is desired, conrm the nozzle

is the proper size and type, refer to Table 9, then

proceed to Item i. below.

If a lower input is desired, remove the nozzle

e.

that was factory installed.
f. Remove Beckett MD(V1) or MB(L1) head.
g. Locate the desired nozzle. Refer to Table 9 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) burner

application, a low ring rate bafe is required.

Bafe is shipped loose with nozzles. Install

bafe per Beckett Instruction included with

bafe.

h. Reinstall Beckett MD(V1) or MB(L1) Head.
i. Inspect and measure burner electrodes. Refer

to Figure 25 for the proper electrode setting.

Readjust electrode setting to the proper

dimensions if necessary. Refer to Figure 25.
j. Reinstall nozzle line electrode assembly.
k. Connect copper connector tube.

8

l. Inspect Beckett head setting on left side of

burner by insuring the blue line MD(V1) or the
line on the label MB(L1) are aligned, readjust if

necessary.
m. Tighten knurled nut.
n. Swing igniter closed, rotate tabs and tighten two

(2) igniter screws.
o. Replace burner cover and tighten burner cover

knobs.

3. On the Carlin EZ-PH Burner, use the following
procedure to complete the inspection, check the

settings and to change the nozzle to a lower ring

rate:
a. Loosen two (2) igniter latching screws, rotate

tabs and swing open igniter about hinge.

b. Loosen knurled nut and disconnect copper

connector tube.

c. Remove nozzle line electrode assembly from

burner.

d.

If high ring rate is desired, conrm the nozzle

is the proper size and type, refer to Table 9, then
proceed to Item i. below.

e. If a lower input is desired, remove the ame

retention head and then remove the nozzle that
was factory installed.

Locate the desired nozzle, refer to Table 9 for

f.

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.

g.

Reinstall Flame Retention Head on Nozzle Line

Electrode Assembly. Make sure the clamp is
fully sated against the shoulder on the nozzle
adapter before securing.

h. Loosen and remove the retaining nut and factory

installed head bar from side of burner housing.
Install the proper head bar that corresponds

to the desired ring rate, refer to Table 9, and

tighten retaining nut.

i. Readjust air band to preliminary setting that

corresponds to the lower ring rate nozzle

installed, refer to Table 9.

j. Inspect and measure burner electrodes. Refer

to Figure 25A for proper electrode setting.
Readjust electrode setting to the proper

dimensions if necessary.
k. Reinstall nozzle line electrode assembly.
l. Reconnect copper connector tube.
m. Tighten knurled nut.
n. Close igniter, rotate and tighten two (2) igniter

latching screws.

On the Riello 40 Series Oil Burner, use the

4.
following procedure to complete the inspection,

check the settings and to change the nozzle to a

lower ring rate:

a. Installation/Removal of Drawer Assembly,

refer to Figure 4.

Figure 4: Installation/Removal of Drawer Assembly

i. Removal:

• Disconnect oil delivery tube nut from
pump.

• Loosen SCREW (3), and then unplug
PRIMARY CONTROL (1) by carefully
pulling it back and then up.

• Remove the AIR TUBE COVER
PLATE (5) by loosening the retaining
SCREW (4) (Two SCREWS-Model F5).

• Loosen SCREW (2), and then slide the
complete drawer assembly out of the
combustion head as shown.

ii. Installation:

To insert drawer assembly, reverse the

procedure in Step i above.

b. Nozzle Replacement, refer to Figure 5.

Figure 5: Nozzle Replacement

i. Remove the NOZZLE ADAPTER (2) from

the DRAWER ASSEMBLY by loosening the
SCREW (1).

9

ii. Remove existing nozzle from nozzle adapter.

Insert the proper NOZZLE into NOZZLE

iii.

ADAPTER and tighten securely (Do not
cover tighten).

iv. Replace adapter, with nozzle installed, into

drawer assembly and secure with screw (1).

c.

Inspect and measure burner electrodes. Refer

to Figure 6 for the proper electrode settings.

Figure 6: Electrode Setting

d. Re-install Drawer

Head per Step 4a above.

e. Insertion Depth, verify the distance between

the tip of the end cone is equal to the distance

specied in Table 9A.

f. Turbulator Setting, refer to Figure 7.

Assembly into Combustion

This burner is shipped with the oil pump set

to operate on a single line system. To operate
on a two-line system the bypass plug must be
installed.

WARNING: Do not operate a single line

system with the by-pass plug installed.
Operating a single line system with the by-pass
plug installed will result in damage to the pump
shaft seal.

NOTE: Pump pressure was factory pre-set but

must be checked at time of burner start-up. A
pressure gauge is attached to the PRESSURE/
BLEEDER PORT (7) for pressure readings.
Two PIPE CONNECTORS (4) are supplied
with the burner for connection to either a single
or two-line system. Also supplied are two
ADAPTORS (3), two female ¼” NPT to adapt
oil lines to burner pipe connectors. All pump
port threads are British Parallel Thread design.
Direct connection of NPT threads to the pump
will damage the pump body.

Riello manometers and vacuum gauges do not

require any adapters, and can be safely connected
to the pump ports. An NPT x metric adapter
must be used when connecting other gauge
models.

h. Replace Burner Cover and Tighten Burner

Cover Screws.

Figure 7: Turbulator Setting

g. Pump Connections and Port Identication,

refer to Figure 8.

F. INSTALL WATER BOILER TRIM AND CONTROLS,

(see Figures 1A and 1B)

1. Install return piping supplied with boiler. Apply

Teon or Sealant to all joints prior to assembly.

Thread 1½" NPT x 5" Lg. return nipple into 1½"
NPT tapping located in lower left corner of front
section. Thread 1½" x ¾" x 1½" NPT tee onto
5" nipple. Thread ¾" drain valve into ¾" NPT
connection on tee. Tighten all joints with wrench
until water tight and 1½" NPT return connection on
tee is facing away from boiler horizontally to allow
for proper burner swing door clearance, see Figures
1A, 1B and Figure 9.

10

Figure 8: Pump Connections and Port Identication

Figure 9: Recommended Boiler Piping for Series Loop Hot Water System

NOTE: Vertical piping will prevent door from opening

fully for service and cleaning of boiler.

2. Thread relief valve onto factory installed ¾" NPT
x 7¼" nipple located in left rear corner on top
of boiler as shown in Figures 1A and 1B. Valve
spindle must be in vertical position. Tighten with
wrench. Pipe discharge as shown in Figure 9.
Installation of the relief valve must be consistent
with ANSI/ASME Boiler and Pressure Vessel Code,
Section IV.

3. On boilers with rear tankless heater, factory wired
L7224C Control Relay was not installed in heater.
Locate ¾" NPT Immersion Well, apply sealant and
thread into ¾" NPT tapping on heater. Apply heat
transfer paste (not furnished) to control bulb and
insert bulb into immersion well. Tighten clamp
screws to secure control to immersion well. Secure

control conduit to jacket right side panel with 5/8"
cable clamp provided, refer to Figure 1B.

4.

CONNECT FIELD WIRING

a. Water boilers without tankless heater and with

front tankless heater. Connect the eld wiring

from the circulator to the aquastat control and
from the control to the burner. Make the wiring
connections as shown on Figures 16B.

b. Water boilers with rear tankless heater. Connect

the eld wiring from a standard junction box to

the circulator, aquastat control and burner. Make
the wiring connections as shown on Figure 17B.

G. INSTALL STEAM BOILER TRIM AND CONTROLS,

(see Figures 1C and 1D).

1. Thread ¾" MPT safety valve and ¾" NPT coupling
onto factory installed ¾" NPT x 7¼" nipple located

11

Figure 10: Recommended Piping for Combination

Heating & Cooling (Refrigeration) Systems

in left rear corner on top of boiler as shown in
Figure 1C. Tighten with wrench. Pipe discharge as
shown in Figure 11. Installation of the relief valve
must be consistent with ANSI/ASME Boiler and
Pressure Vessel Code, Section IV.

2. Install ¾" drain valve in wet return piping as shown
in Figure 11.

3.

On boilers with rear tankless heater, factory wired

L4006A Aquastat Heater Control was not installed
in heater. Locate ¾" NPT Immersion Well, apply
sealant and thread into ¾" NPT tapping on heater.
Apply heat transfer paste (not furnished) to control
bulb and insert bulb into immersion well. Tighten
clamping screws to secure control to immersion
well. Secure 18/2 Control Cable Wire to jacket right
side panel with 5/16" cable clamp provided, refer to
Figure 1C.

4. CONNECT FIELD WIRING

a. Connect the eld wiring to the pressure limit,

the R8239C Control Center, the LWCO and
the burner primary control. If equipped with

tankless heater, connect eld wiring from the

aquastat control to the R8239C Control Center's
"R-G" terminals. Make the wiring connections
as shown in Figure 19B.

H. CONNECT SUPPLY AND RETURN PIPING TO

HEATING SYSTEM.

1. CLEARANCES — Steam and hot water pipes shall
have clearances of at least ½” from all combustible
construction.

12

Figure 11: Recommended Boiler Piping For Gravity Return Steam Boiler

2. WATER BOILER
a. For Forced Circulation HOT WATER HEATING.

See Figure 9. Consult I=B=R Installation and
Piping Guide No. 200.

b.

Use a boiler water bypass if the boiler is to be

operated in a system which has a large volume
or excessive radiation where low boiler water
temperature may be encountered (i.e. converted
gravity circulation system, etc.).

Install a pipe tee between the circulator and

boiler return along with a second tee in the
supply piping as shown in Figure 9. The bypass
should be the same size as the supply and return
lines. Locate valves in the bypass and supply
outlet as illustrated in Figure 9 for regulation

of water ow to maintain higher boiler water

temperature.

Set the by-pass and boiler supply valves to a half

throttle position to start. Operate boiler until the
system water temperature is a normal operating
range.

Adjust the valves to provide 180° to 200°F

supply water temperature. Opening the boiler
supply valves will raise the system temperature,
while opening the bypass valve will lower the
system supply temperature.

c. If this boiler is connected to heating coils located

in air handling units where they may be exposed
to refrigerated air the boiler piping must be

equipped with ow control valves to prevent

gravity circulation of boiler water during the
operation of the cooling system.

d. If this boiler is used in connection with

refrigeration systems, the boiler must be installed
so that the chilled medium is piped in parallel
with the heating boiler using appropriate valves
to prevent the chilled medium from entering
the boiler, see Figure 10. Also consult I=B=R
Installation and Piping Guides.

e. A hot water boiler installed above radiation level

must be provided with a low water cutoff device
as part of the installation. See Section VIII, Low
Water Cut-Off for additional details.

3. STEAM BOILER
a. For Recommended STEAM BOILER PIPING

refer to Figure 11. Also, consult I=B=R
Installation and Piping Guides.

b. Evaluate the Existing Steam System.
The single most important factor in determining

the expected life cycle of a steam boiler, is
the amount of fresh water added to the boiler
during operation. Fresh water brings minerals
and oxygen into the boiler. These contaminants
greatly accelerate corrosion of the cast iron
boiler sections.

i. Assure that all system radiators, piping and

vents are absolutely leak tight.

• When a steam boiler is installed in an
existing system, ALL air vents should be
replaced at the same time. This assures
that the new boiler will not be
compromised by existing system leaks.

• If the system contains hidden supply or
return piping (hidden behind walls, buried
in concrete, etc.) pressure test this piping
to assure there are no leaks.

ii. Repair any leaks in the system.
iii. Install accurate water meter on the fresh

water supply to the boiler.

NOTICE

Do not use softened water in steam boilers.
Accelerated boiler corrosion will result. Tie in
fresh water supply to the boiler upstream of a
water softener.

4. OXYGEN CONTAMINATION:
a. There are many possible causes of oxygen

contamination such as:
i. Addition of excessive make-up water as a

result of system leaks.

ii. Absorption through open tanks and ttings.
iii. Oxygen permeable materials in the

distribution system.

In order to insure long product life, oxygen

b.

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 ttings which

allow oxygen absorption.

iv. Use of non-permeable materials in the

distribution system.

v. Isolating the boiler from the system water by

installing a heat exchanger.

See Section V, Paragraph B, Step 3 for additional

details.

CAUTION

Oxygen contamination of the boiler water

will cause corrosion of iron and steel boiler
components, and can lead to boiler failure. New
Yorker's Standard Warranty does not cover

problems caused by oxygen contamination of

boiler water or scale (lime) build-up caused by

frequent addition of water.

13

I. CONNECT TANKLESS HEATER PIPING AS

SHOWN IN Figure 12. See Table 3 for Tankless
Heater Ratings.

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 to entering the mixing
valve. The mixing valve should be “trapped” by
installing it below the cold water inlet to heater to
prevent lime formation in the valve.

WARNING

Install automatic mixing valve at tankless heater

outlet to avoid risk of burns or scalding due to

excessively hot water at xtures. Adjust and
maintain the mixing valve in accordance with the

manufacturer's instructions.

Figure 12: Schematic Tankless Heater Piping

TABLE 3: TANKLESS HEATER DATA

Boiler

Model

CL3-091 2.25 2.75 2.3 3.9
CL3-105 2.25 3.00 2.3 4.7
CL3-140 2.50 3.25 3.1 5.6
CL4-126 2.50 3.25 3.1 5.6
CL4-175 2.75 3.75 3.9 7.2
CL4-210 3.00 4.00 4.7 8.0
CL5-168 2.75 3.50 3.9 6.4
CL5-245 3.25 4.25 5.6 8.8
CL5-280 3.50 4.75 6.4 9.6

THE FOLLOWING GUIDELINES SHOULD BE FOL­LOWED WHEN PIPING THE TANKLESS HEATER:

1.

FLOW REGULATION — If ow through the heater

2. TEMPERING OF HOT WATER — Installation

Rating (Gal/Min)

Steam Water Steam Water

is greater than its rating, the supply of adequate hot
water may not be able to keep up with the demand.

For this reason a ow regulator matching the heater

rating should be installed in the cold water line to

the heater. The ow regulator should preferably be

located below the inlet to the heater and a minimum
of 3’ away from the inlet so that the regulator is not
subjected to excess temperatures that may occur
during “off” periods when it is possible for heat
to be conducted back through the supply line. The

ow regulator also limits the ow of supply water

regardless of inlet pressure variations in the range of
20 to 125 psi.

of an automatic mixing valve will lengthen the
delivery of the available hot water by mixing some
cold water with the hot. This prevents excessive

and possibly scalding hot water at the xtures. In

Pressure Drop

(PSI)

14

3. FLUSHING OF HEATER — All water contains
some sediment which settles on the inside of the
coil. Consequently, the heater should be periodically
backwashed. This is accomplished by installing
hose bibs as illustrated and allowing water at city
pressure to run into hose bib A, through the heater,
and out hose bib B until the discharge is clear. The
tees in which the hose bibs are located should be
the same size as heater connections to minimize
pressure drop.

HARD WATER — A water analysis is necessary to

4.
determine the hardness of your potable water. This
is applicable to some city water and particularly to
well water. An appropriate water softener should
be installed based on the analysis and dealer’s

recommendation. This is not only benecial to the
tankless heater but to piping and xtures plus the
many other benets derived from soft water.

J. INSTALL SMOKEPIPE — The CL Series boiler

should be vented into a reclay tile-lined masonry

chimney or chimney constructed from type L vent or
a factory built chimney that complies with the type
HT requirements of UL103. The chimney and vent

pipe shall have a sufcient draft at all times, to assure

safe proper operation of the boiler. See Figure 13 for
recommended installation.

1. Install a draft regulator (supplied by installer)
following the instructions furnished with the
regulator. See Figure 14 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 the efciency

of the boiler installed goes up. Most homes have
a chimney appropriate for the fuel and the era in
which the home was built. That may have been a

coal red or an inefcient oil red boiler built into

a home without insulation or storm windows. With
increasing fuel prices that home probably has been

insulated and tted with storm windows so that

Figure 13 Recommended Smokepipe Arrangement

and Chimney Requirements

the heat loss of the home has been reduced. This
requires less fuel to be burned and sends less heat up
the chimney.

A new boiler probably has a higher efciency than

the boiler being replaced. That probably means that
the stack temperature from the new boiler will be
lower than that from the old boiler and with less
room air being drawn up the chimney to dilute the
stack gases. The combination of a large uninsulated

chimney, reduced ring rate, reduced ring time,

lower stack temperature and less dilution air can,

in some cases, contribute to the condensing of
small amounts of water vapor in the chimney. Such
condensation, when it occurs, can cause chimney
deterioration. In extreme cases, condensed water
may be visible on the outside of the breeching or
chimney. In those extreme cases, the chimney may
have to be lined to insulate the chimney and thus
prevent the condensation. The addition of dilution
air into the chimney may assist in drying the
chimney interior surfaces.

A massive chimney on a cold, or exposed outside

wall may have produced adequate draft when it

was red with a higher input and greater 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 ring 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 ue liner with

insulation around it and a stabilizing draft cap or
even a draft inducing fan in severe cases.

3. For the same reasons as in 2. above, heat extractors
mounted into the breeching are not recommended.

IMPORTANT

Single-pipe installations must be absolutely
airtight or leaks or loss of prime may result. Bleed
line and fuel unit completely.

Figure 14: Proper and Improper Locations of Draft Regulator

15

K. FUEL UNITS AND OIL LINES

SINGLE-PIPE OIL LINES Standard burners are

provided with single-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 15.

TWO-PIPE OIL LINES For two-pipe systems

where more lift is required, the two-stage fuel unit is
recommended. Table 4 (single-stage) and Table 5 (two­stage) show allowable lift and lengths of 3/8-inch and
1/2-inch OD tubing for both suction and return lines.
Refer to Figure 16.

Be sure that all oil line connections are absolutely

airtight. Check all connections and joints. Flared

ttings are recommended. Do not use compression
ttings.

Open the air-bleed valve and start the burner. For clean

bleed, slip a 3/16" ID hose over the end of the bleed
valve and bleed into a container. Continue to bleed for
15 seconds after oil is free of air bubbles. Stop burner
and close valve.

Figure 15

TABLE 4: SINGLE STAGE UNITS (3450 RPM)
TWO PIPE SYSTEMS

Maximum Length of Tubing

Lift "H"

(See Figure)

0' 84' 100'
1' 78' 100'
2' 73' 100'
3' 68' 100'
4' 63' 100'
5' 57' 100'
6' 52' 100'
7' 47' 100'
8' 42' 100'

9' 36' 100'
10' 31' 100'
11' 26' 100'
12' 21' 83'
13' --- 62'
14' --- 41'

"H" + "R" (See Figure)

3/8" OD

Tubing (3 GPH)

1/2" OD

Tubing (3 GPH)

Figure 16

TABLE 5: TWO-STAGE UNITS (3450 RPM)
TWO-PIPE SYSTEMS

Maximum Length of Tubing

Lift "H"

(See Figure)

0' 93' 100'
2' 85' 100'
4' 77' 100'
6' 69' 100'

8' 60' 100'
10' 52' 100'
12' 44' 100'
14' 36' 100'
16' 27' 100'
18' --- 76'

"H" + "R" (See Figure)

3/8" OD

Tubing (3 GPH)

1/2" OD

Tubing (3 GPH)

16

L. INSTALL ELECTRIC WIRING in accordance with

National Electrical Code and local regulations. A
separate electrical circuit must be run from the main
electrical service with an over-current device/disconnect

in the circuit. A service switch is recommended and
may be required by some local jurisdictions. Wiring
should conform to Figures 17 thru 19B.

Figure 17: Wiring Diagram for Water Boilers With Beckett AFG Burner and

Split Controls Less Tankless Heater

SEQUENCE OF OPERATION

A call for heat by the thermostat energizes the L7248C control which in turn energizes the primary control. The burner
will initiate ignition after completing a 15 second pre-purge cycle. If burner ignites within approximately 45 seconds

and the cad cell sees ame, the burner will continue to operate until the call for heat is satised or the setting of the

high limit is reached. The circulator will operate as long as the thermostat is calling for heat. If the thermostat is not

satised and the high limit is reached, the circulator will continue to operate, and the burner will stop until the high limit

is closed by a drop in boiler water temperature.

17

Figure 17A: Wiring Diagram for Water Boilers With Carlin EZ-HP Burner and

Split Controls Less Tankless Heater

18

Figure 17B: Wiring Diagram, Water without Tankless Heater, Riello Burner

Figure 18: Wiring Diagram for Water Boilers with Beckett AFG Burner and

Split Controls with Tankless Heater

SEQUENCE OF OPERATION

A call for heat by the thermostat energizes the L7224C control which in turn energizes the primary control. The burner
will initiate ignition after completing a 15 second pre-purge cycle. If burner ignites within approximately 45 seconds

and the cad cell sees ame the burner will continue to operate until the call for heat is satised. The circulator will also

operate when the thermostat calls for heat if the boiler water temperature is up to the setting of the low limit in the
L7224C control. If boiler water temperature is below the low limit setting the burner will operate but the circulator will
not, giving preference to the domestic hot water demand.

On call for heat by the thermostat the burner will continue to operate until the thermostat is satised or the setting of
the high limit is reached. If the thermostat is not satised when the high limit is reached the burner will stop but the
circulator will continue to operate until the thermostat is satised.

Any time the boiler water temperature drops below the setting of the low limit the burner will be energized in order to
maintain domestic water temperature.

19

Figure 18A: Wiring Diagram for Water Boilers with Carlin EZ-PH Burner and

Split Controls with Tankless Heater

20

Figure 18B: Wiring Diagram, Water with Rear Tankless Heater, Riello Burner

Figure 19: Wiring Diagram, Steam Boilers With or Without Tankless Heater,

McDonnell & Miller PS-801 Probe LWCO, Beckett AFG Burner

SEQUENCE OF OPERATION

When the thermostat calls for heat, it energizes the cad cell primary control. The burner will initiate ignition after com-

pleting 15 second pre-purge cycle. The burner will operate until the thermostat is satised or the limit setting on the

high limit is reached. When the high limit control restores the circuit on a drop in pressure, the burner will start if the
thermostat is still calling for heat. The low water cut off will shut down the burner if the water level in the boiler drops
too low. The control resets and restarts the burner with a call for heat a few seconds after the water is returned to its
normal level.
The McDonnell Miller low water cut off incorporates a 10 second delay to prevent nuisance burner cut-off due to rapid

water level uctuations. The LWCO also has a time delay of 15 seconds which allows additional ll time after water

touches the probe. Red LED indicates a low water condition.

On burner start, if the cad cell does not see ame within approximately 45 seconds, primary control will lock out on

safety and must be reset before burner can be restarted.
When there is no demand for heat, the operating control will maintain the boiler water temperature at the selected set­ting for proper operation of the domestic water heater, if equipped with optional tankless heater.

21

Figure 19A: Wiring Diagram, Steam Boilers With or Without Tankless Heater,

McDonnell & Miller PS-801 Probe LWCO, Carlin EZ-HP Burner

22

Figure 19B: Wiring Diagram, Steam with or without Tankless Heater,

Optional McDonnell & Miller PS-801 Probe LWCO, Riello Burner

III. Indirect Water Heater Piping

A. CONNECT Alliance™ or other Indirect Water Heater Piping as shown in Figures 15 and 16. Refer to Alliance™ or other

Indirect Water Heater Instruction Manual for additional installation information.

Figure 20: Indirect Water Heater Piping on CL Series Water Boiler

1.

CL SERIES WATER BOILER - Figure 20 shows indirect water heater piping on typical hot water heating system. Boiler

piping is the same as for any two-zone system. Figure 20 shows circulator zoning, which is usually preferred for indirect

water heaters. Size the circulator and indirect water heater piping to obtain the boiler water ow through the indirect

water heater called for by the indirect water heater manufacturer. Refer to the indirect water heater instruction manual for
additional details.

Figure 21: Indirect Water Heater Piping on CL Series Steam Boiler

CL SERIES STEAM BOILER - All CL Series steam boilers are equipped with tappings to permit the connect of an

2.
Alliance™ or other indirect water heater. In this type of system, hot boiler water is drawn from below the water line and
passed through the heat exchanger in the indirect water heater. This section describes boiler-side piping only. Refer to the
indirect water heater instruction manual for additional details.

23

IV. Operating and Service Instructions

A. ALWAYS INSPECT INSTALLATION BEFORE

STARTING BURNER.

B. FILL HEATING SYSTEM WITH WATER.

1. Hot Water Boilers: Fill entire Heating System with
water and vent air from system. Use the following
procedure on a Series Loop System installed as per
Figure 9:

Close all but one zone valve.

a.
b. Open drain valve on boiler.

c. Open ll valve.

d. Close purge valve.
e. Open relief valve on boiler.
f. Allow water to run out of drain valve until zone

has been purged of air and lled with water.

g.

Open zone valve to the second zone to be

purged, then close the rst. Repeat this step until

all zones have been purged but always have one

zone open. At completion open all zone valves.
h. Close drain valve.
i. When water discharges from relief valve, release

the lever on the top of the relief valve, allowing

it to close.

j. Continue lling the system until the pressure

gauge reads 12 psi. Close ll valve.

C. CHECK CONTROLS, WIRING AND BURNER to be

sure that all connections are tight and burner is rigid,
that all electrical connections have been completed and

fuses installed, and that oil tank is lled and oil lines

have been tested.

D. LUBRICATION

1. Follow instruction on burner and circulator
label to lubricate, if oil lubricated. Most motors
currently used on residential type burners employ
permanently lubricated bearings and thus do not

require any eld lubrication. Water lubricated
circulators do not need eld lubrication.

2. Do not over-lubricate. This can cause as much
trouble as no lubrication at all.

3. On WATER BOILERS WITH TANKLESS

HEATERS equipped with L7224 electronic aquastat
controller, set operating control (low limit [LL])
at 190°F and high limit (HL) at 210°F. Operating
control (low limit) setting must be a minimum of
20°F below high limit setting.

L7224 controller has the High Limit adjustment

range from 130°F to 240°F (55°C to 116°C), and
the Low Limit adjustment range from 110°F to
220°F (43°C to 104°C). High Limit Differential is

xed at 10°F (6°C), and Low Limit Differential has

adjustment range from 10°F (6°C) to 25°F (14°C).

ADJUSTING AQUASTAT CONTROLLER

4.
SETTINGS. To discourage unauthorized changing
of Aquastat settings, a procedure to enter the

ADJUSTMENT mode is required. To enter the
ADJUSTMENT mode, press the UP, DOWN, and
I buttons (refer to Figure 22) simultaneously for

three seconds. Press the I button until the feature
requiring adjustment is displayed:

• HL_  High Limit.

• LL_  Low Limit.

• Ldf  Low Limit Differential.

• °F  °C.

Then, press the UP and/or DOWN buttons to

move the set point to the desired value. After 60
seconds without any button inputs, the control will
automatically return to the RUN mode.

Note that L7224 Aquastat Controller will display all

four (4) above-listed adjustment features, but L7248
Aquastat Controller will not display Low Limit and
Low Limit Differential adjustment features.

5. DISPLAY READOUT

In the RUN mode, the Aquastat will ash "bt"

(boiler temp) followed by the temperature (i.e.,

220), followed by °F or °C.

E. ADJUST CONTROL SETTINGS with burner

service switch turned “ON”.

1. SET ROOM THERMOSTAT about 10°F below
room temperature.

2. On WATER BOILERS WITHOUT TANKLESS
HEATERS equipped with L7248 electronic
aquastat controller, set High Limit (HL) at 180°F.
This temperature can be varied to suit installation
requirements. L7248 controller has the High Limit
adjustment range from 180°F to 240°F (82°C to

116°C). High Limit Differential is xed at 15°F

(8°C).

24

Figure 22: L7248/L7224 Circuit Board Layout -

Horizontal Mount

To read boiler settings, press the I key to read the

parameter of interest. For example, press I High
Limit (HL) is displayed, followed by a three-digit
number, i.e., 220, followed by °F or °C. Pressing
the I button again (on L7224 models) will display
the Low Limit (LL) followed by a three-digit
number and the corresponding degree designator.
See Display Readout, Figure 23.

After approximately 60 seconds without any key

presses, the display will enter a dim display mode.
To return to the bright display mode, simply press
any key.

d. Error: The controller has detected an error

condition (e.g., open sensor) and has shut down
the burner output. The ZC output is energized.
The controller continues to monitor the system
and automatically restarts if the error condition
clears. Refer to Table 6. Refer to Table 8 for
Trouble Shooting Guide.

TABLE 6: LED ERROR CODES

Error

Code

Err1 Sensor fault; check sensor.
Err2 ECOM fault; check EnviraCOM™ wiring.
Err3 Hardware fault; replace control.
Err4 B1 fault; check B1 wiring/voltage.
Err5 Low Line; check L1-L2, 110 Vac.
Err6 Fuse; check ECOM wires, replace fuse.

Err7

Err8

EEPROM, HL, LL, Hdf, Ldf; reset to default

values. Restore desired settings.

Repeated B1 fault (voltage present at B1 when

output is turned off); check B1 wiring/voltage.

Cause / Action

The operating sequence for the L7224/L7248 is

shown in Table 7.

Figure 23: Display Readout Denitions

6. OPERATION
The L7224 model can be in any of four operational

states - Normal, High Limit, Low Limit and Error.
The controller moves back and forth from High
Limit to Normal to Low Limit state as part of
normal operation.

The L7248 model is restricted to three operational

states - Normal, High Limit and Error. The
controller moves back and forth from High Limit to
Normal state as part of normal operation.

For both models, the controller will enter the Error

state when there is an abnormal condition. The
operating states are:

a. Normal: Boiler temperature went below the

High Limit setting (minus the Differential) and
has not exceeded the High Limit setting; or the
boiler temperature went above the Low Limit
setting and has not gone below the Low Limit
setting (minus the Differential).

b. High Limit: Boiler temperature went above the

High Limit setting and has not dropped below
the High Limit setting (minus the Differential).

c. Low Limit: Boiler temperature went below

the Low Limit setting (minus the Low Limit
Differential) and has not gone above the Low
Limit setting.

TABLE 7: L7248/L7224 CONTROLLER

OPERATING SEQUENCE

Action System Response

Thermostat

calls for heat.

Boiler

exceeds the

High Limit.

Thermostat is

satised.

Error

condition 1-5.

Error

condition 6.

Error

condition 7.

Error

condition 8.

Circulator starts when water temperature
is above Low Limit setting (if applicable).

Boiler temperature is checked. Burner

starts when water temperature is below

High Limit setting.

Burner is turned off. Burner restarts when

the water temperature drops below the

High Limit setting minus the Differential.

Circulator and burner turn off.

If an error condition is detected, all outputs

except ZC are shut down. Burner is off.

Control continues to function and restarts

when error is corrected.

During the error check sequence, the

system checks for drift in the sensor and

corrosion in the connections.

EnviraCOM communication is not

available.

The control has reset the High Limit, Low

Limit and Differential setting to a default

setting and will continue to run at those

settings.

Performance of the system will be

degraded.

If the error condition is detected, all

outputs except ZC are shut down. Burner

is off. Control continues to function and

restarts when all three user keys have

been pressed longer than 60 seconds.

25

TABLE 8: TROUBLE SHOOTING GUIDE

System Condition Diagnostic Condition Check Action

Boiler is cold, house is

cold.

Boiler is hot, house is

cold.

Display is OFF. 120 Vac System power. Turn system power on.

Display is ON. 24 Vac T-T No 24 V; replace control.

24 V present; disconnect

thermostat, short T-T.

120 Vac at B1-B2 • If no, replace control.

Refer to Err on display. -----

Display is ON. 120 Vac at C1-C2 • 120 Vac at C1-C2, check wiring

Boiler below the Low Limit

temperature, wait for boiler to go

above Low Limit temperature.

Boiler above LL? If yes, check

for 120 Vac between ZC and L2.

Boiler starts, check wiring and thermostat.

• If yes, check burner and wiring.

to pump.

• Wiring OK, is pump running?

• If not, replace the pump.

• If pump is running, check for

trapped air or closed zone valves

• If no 120 Vac , replace control.

• If yes, check zone relays, circulators
and wiring.

-----

7. HIGH LIMIT CONTROLLER
The High Limit opens and turns off the burner

when the water temperature reaches the setpoint.
The High Limit automatically resets after the water
temperature drops past the setpoint and through the
Differential. The L7248 models have High Limit
Differential presets of 15°F (8°C). The L7224
models have High Limit Differential presets of 10°F
(6°C).

8.

LOW LIMIT AND CIRCULATOR CONTROLLER

On a temperature rise, with the adjustable

Differential at the default setting of 10°F (6°C),
the burner circuit breaks and the circulator circuit
makes (assuming no call for heat is present) at the
Low Limit setpoint. On a temperature drop of 10°F
(6°C) below the Low Limit setpoint, the burner
circuit makes and the circulator circuit breaks. See
Figure 24.

F. REMOVE GUN ASSEMBLY

1. CL Series boilers are equipped with Beckett AFG
burners. Items to be checked are nozzle size, head
size, gun setting, and positioning of electrodes. This
information is shown in Figure 25 and Table 9 at
rear of manual.

2. CL Series boilers are equipped with Carlin EZ-HP
burners. Items to be checked are nozzle size, head
bar size, gun setting, and positioning of electrodes.
This information is shown in Figure 25A and Table
9 at rear of manual.

3. Reinstall gun assembly.

26

Figure 24: Setpoints and Differentials

Figure 25: "L1" and "V1" Head Electrode

Positioning and Gun Setting (Beckett AFG)

Figure 25A: Electrode Settings (Carlin EZ-HP)

G. ADJUST OIL BURNER BEFORE STARTING.

1. SET BURNER AIR BAND AND AIR SHUTTER,
see Table 9 at rear of manual.

2. Inspect Beckett head setting on left side of burner
by insuring the blue line MD(V1) or the line on the
label MB(L1) are aligned, readjust if necessary.
Refer to Figure 25.

3. Inspect Carlin head setting on left side of burner to
ensure that the proper head positioning bar matches
the nozzle that is installed in drawer assembly.

Replace bar if necessary.
Carlin burners for boiler models CL3-140 and

CL4-210 have the higher ring rate nozzle installed

and two (2) loose nozzles with a head positioning
bar kit attached to the nozzle line. Refer to Table
9 for proper nozzle size, air settings and fuel pump

pressure setting based on desired ring rate.

If the desired ring rate is the lower GPH:

a. replace the factory installed high ring rate

nozzle with one of the loose lower ring rate

nozzles.

b. replace the factory installed head positioning bar

with the corresponding head bar that matches the
lower GPH nozzle installed, see Table 9.

c. change the factory air settings according to Table

9 and,

d. check the oil pump pressure and adjust if

necessary to the setting specied in Table 9, refer

to Paragraph H, Step 5 for details.

4. INSPECT RIELLO BURNER AIR DAMPER
AND TURBULATOR SETTING, readjust if
necessary, see Table 9a.

a. Remove pressure port/bleeder plug from fuel

pump and install Riello Combination Pressure
Gauge and Bleeder Valve Assembly.

5. OPEN ALL OIL LINE VALVES.

6. ATTACH A PLASTIC HOSE TO FUEL PUMP
VENT FITTING and provide a pan to catch the oil.

7. OPEN FLAME OBSERVATION DOOR on front of
boiler.

H. START OIL BURNER.

1. Open vent tting on fuel pump.

2. TURN ‘ON’ BURNER service switch and allow

burner to run until oil ows from vent tting

in a SOLID stream without air bubbles for
approximately 10 seconds.

3. Close vent tting and burner ame should start

immediately after pre-purge is complete. Pre-purge

prevents burner ame until 15 seconds has elapsed

after initial power is applied to burner. During
pre-purge, the motor and ignitor will operate but the
oil valve will remain closed. Refer to Oil Primary
Control Instructions for more details.

Figure 26: Adjusting Fuel Pump Pressure

ADJUST OIL PRESSURE for Beckett AFG burners

4.
(shut the burner off).

When checking a fuel unit's operating pressure, a

a.

reliable pressure gauge may be installed in either
the bleeder port or the nozzle port. See Figure

26.

b. Locate oil pressure adjusting screw and turn

screw for appropriate pump pressure, refer to
Table 9 at rear of manual.

c. To check the cutoff pressure, deadhead a reliable

pressure gauge onto the copper connector tube
attached to the nozzle port. Run the burner for
a short period of time. Shut the burner off. The
pressure should drop and hold.

d. Remove the gauge and install bleeder port and/or

reconnect the nozzle port line.

5. VERIFY/ADJUST FUEL PUMP PRESSURE for
Carlin EZ-HP burners.

a. Turn “off” burner service switch.

27

Figure 26A: Adjusting Fuel Pump Pressure

b. When checking a fuel pump’s operating pressure,

a reliable pressure gauge may be installed in
either the gauge port or the bleeder port. See
Figure 26A.

a. CL3 through CL5
Move the turbulator setting forward or back one

position at a time to optimize the smoke and CO2
readings.

4. Turn “OFF” burner and remove Riello Combination
Pressure Gauge and Bleeder Valve Assembly.
Install pressure port/bleeder plug and tighten. Start
burner again.

5. FLAME FAILURE

The CL Series boiler controls operate the burner

automatically. If for unknown reasons the burner

ceases to re and the reset button on the primary

control has tripped, the burner has experienced
ignition failure. Before pressing the reset button call
your heating contractor immediately.

WARNING

Do not attempt to start the burner when excess oil

has accumulated, when the unit is full of vapor, or
when the combustion chamber is very hot.

7. CAD CELL LOCATION AND SERVICE

The burner is supplied with a cadmium sulde ame

detector mounted at the factory, mounted on the
bottom of the electronic ignitor. See Figure 27. To
service cad cell or to replace the plug in portion,
swing open the ignitor. After service is complete, be
sure to fasten down the ignitor.

6. VERIFY/ADJUST OIL PRESSURE for Riello 40
burner.

Adjust oil pressure. Locate oil pressure adjusting

screw and turn screw to obtain proper pump
pressure, refer to Figure 8 and Table 9A.

I. ADJUST OIL BURNER WHILE OPERATING.

(ame present)

1. ADJUST DRAFT REGULATOR for a draft of

-0.02” (water gauge) over the re after chimney has

reached operating temperature and while burner is
running.

2. READJUST THE AIR DAMPER SETTING on the

burner for a light orange colored ame while the
draft over the re is -0.02”. Use a smoke tester and

adjust air for minimum smoke (not to exceed #1)

with a minimum of excess air. Make nal check

using suitable instrumentation to obtain a CO2 of

11.5 to 12.5% with draft of -0.02” (water gauge)
in re box. These settings will assure a safe and
efcient operating condition. If the ame appears
stringy instead of a solid re, 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 re.

3. READJUST THE TURBULATOR SETTING only
if necessary.

28

Figure 27: Cad Cell Location

J. CHECK FOR CLEAN CUT OFF OF BURNER.

1. AIR IN THE OIL LINE between fuel unit and
nozzle will compress when burner is on and will
expand when burner stops, causing oil to squirt from
nozzle at low pressure as burner slows down and
causing nozzle to drip after burner stops. Usually
cycling the burner operation about 5 to 10 times will
rid oil line of this air.

2. IF NOZZLE CONTINUES TO DRIP, repeat
Paragraph J, Step 1. If this does not stop the
dripping, remove cutoff valve and seat, and wipe
both with a clean cloth until clean, then replace

and readjust oil pressure. If dripping or after burn
persist replace fuel pump.

K. TEST CONTROLS.

WARNING

Before installation of the boiler is considered
complete, the operation of all boiler controls must
be checked, particularly the primary control and
high limit control.

1. CHECK THERMOSTAT OPERATION. Raise and
lower thermostat setting as required to start and stop
burner.

VERIFY PRIMARY CONTROL SAFETY

2.
FEATURES using procedures outlined in
Instructions furnished with control or instructions as
follows:

CHECKOUT PROCEDURE

a. Check wiring connections. Close line switch.

Check power at control.
PRIMARY RELAY TEST
b. Disconnect cad cell leads from quick connects

on underside at primary control. Reset safety

switch.
c.

Set controller to call for heat. Burner should

start.
d. Jumper the quick connect terminals within 15 to

30 seconds. Burner should run.
e. Remove the quick connect terminals jumper.

Burner shuts down in approximately 15 to 60

seconds.

f. If burner operates as described, relay is good. If

not, install new relay.
CAD CELL TEST (see Figure 27)
g. Open line switch. Clean cell face and see that

cell is securely in socket. Reconnect leads. Reset

safety switch.
h. Close line switch. If burner starts and runs

beyond safety switch cut-out time, cell is good.

If not, install new cell.

3. WARNING — Check High Limit Control
— Jumper Thermostat Terminals. Allow burner to
operate until shut-down by limit. Installation is not
considered complete until this check has been made.

REMOVE JUMPER.

4. Check low water cut off control with water level at
normal water line (see Figures 1C and 1D). Raise
thermostat setting to allow burner to operate. 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 rell to normal water line.

Burner should automatically restart during ll.

Lower thermostat setting.

CHECK OPERATING CONTROL on boiler

5.
equipped with tankless heaters. With burner off,
draw hot water until burner starts, then turn off hot
water and check burner shut-down.

IF CONTROLS DO NOT MEET REQUIREMENTS

AS OUTLINED ABOVE, REPLACE CONTROL AND
REPEAT CHECK-OUT PROCEDURES.

29

V. Maintenance and Service Instructions

A. MAINTENANCE OF LOW WATER CUT-

OFF DEVICES

WARNING

Probe and oat type low water cut-off devices
require annual inspection and maintenance.

1. Although these devices are solid state in their
operation, the probe is exposed to possible
contamination in the boiler water and subject to
fouling.

It is important to physically remove the probe from

2.
the boiler tapping annually and inspect that probe
for accumulation of scale or sediment.

3. Follow these steps to inspect, clean and/or replace
the probe:
a. Turn off electric service to the boiler.

b. Drain boiler water to a level below the tapping

for the probe.

DANGER

Assure that the boiler is at zero pressure before

removing the LWCO probe. Do not rely on the
pressure gauge to indicate that the boiler is at

zero pressure. Open the safety valve to relieve

all internal pressure prior to proceeding. Safety
valve discharge piping must be piped such that
the potential for burns is eliminated.

c. Disconnect wiring connections between the low

water cut-off control and the probe.

d.

Remove the low water cut-off control from the

probe.

e. Unscrew the probe from the boiler tapping.
f. Inspect that portion of the probe that is exposed

to the boiler water for a scale or sediment
buildup.

g. Light deposits may be removed by wiping the

probe with a damp cloth. Wiping the probe with
a cloth soaked in vinegar will remove more
tenacious lime deposits. The most stubborn
deposits may be removed from the probe by
using a diluted amount, 3 parts of water to 1 part
of phosphoric acid (H2PO4).

CAUTION

Exercise caution when handling phosphoric acid

and follow the instruction label on its container.

h. Clean the pipe threads of the probe to remove

old, hardened pipe dope and other foreign matter.

Apply a moderate amount of good quality pipe

i.

dope to the pipe threads on the probe, leaving the

two end threads bare. Do not use PTFE (Teon)

tape.
j. Screw the probe into the boiler tapping.
k. Mount the low water cut-off control on the

probe.

Reconnect the control to probe wiring.

l.
m. Fill the boiler to its normal waterline.
n. Add boiler water treatment compound as needed

(refer to Paragraph B.).
o. Restore electric service to the boiler.
p. Fire burner to bring the water in the boiler to a

boil to drive off free oxygen.
q.

WARNING — BEFORE RETURNING

BOILER TO SERVICE: Follow the low water

cut-off check out procedure in Section IV.

Operating & Service Instructions.

B. BOILER AND SYSTEM CLEANING

INSTRUCTIONS FOR TROUBLE FREE
OPERATION.

1. STEAM BOILERS:
a. Oil, greases & sediments which accumulate in a

new boiler and piping must be removed from the
system in order to prevent an unsteady water line
and carry over of the water into the supply main
above boiler.

Operate the boiler with steam in the entire

system for a few days allowing the condensate
to return to the boiler. If the condensate can
temporarily be wasted, operate boiler only for
the length of time it takes for condensate to run
clear. If the latter cannot be achieved or if the
condensate is returned to the boiler, boil out
the boiler using the SURFACE BLOW-OFF
connection.

i. Drain boiler until 1” of water is visible in

gauge glass. Run temporary 1½” NPT pipe
line from the surface blow-off connection to
an open drain or some other location where
hot water may be discharged safely. Do not
install valve in this line.

ii.

Drain about 5 gallons of hot water from

boiler into a container and dissolve into it
an appropriate amount of recommended boil
out compound. Remove safety valve & add
solution to boiler water thru exposed tapping
using a funnel.

30

NOTICE

Check with local authorities or consult local
water treatment services for acceptable chemical
cleaning compounds.

Start burner and operate sufciently to boil

iii.

the water without producing steam pressure.
Boil for about 5 hours. Open boiler feed

pipe sufciently to permit a steady trickle

of water from the surface blow-off pipe.
Continue this slow boiling and trickle of

overow for several hours until the water
coming from the overow is clear.

iv.

Stop burner and drain boiler in a manner

and to a location that hot water can be
discharged with safety.

Rell boiler to normal water line. If water

v.

in gauge glass does not appear to be clear,
repeat steps (i. thru iii.) and boil out the
boiler for a longer time.

b. Low pressure steam boilers such as the CL

Series should be maintained with appropriate
water treatment compounds. Add suitable water
treatment compounds as recommended by your

qualied water treatment company.

c. Remove temporary surface blow-off piping, plug

tapping and reinstall safety valve. Boil or bring
water temperature to 180°F promptly in order to
drive off the dissolved gases in the fresh water.

d. If unsteady water line, foaming or priming

persist, install gate valve in Hartford Loop and
drain valves in return main and at boiler as
shown in Figure 9 and proceed as follows:

i Connect hoses from drain valves to oor

drain. Close gate valve in Hartford Loop and
open drain valve in return main. Fill boiler
to normal water level, turn on oil burner and
operate boiler at this water level for at least
30 minutes after the condensate begins to
run hot, then turn off burner.

Close all radiator valves. Remove all supply

main air valves and plug the openings in
supply main.

ii. Draw about 5 gallons of hot water from

boiler into a container and dissolve into it
the appropriate amount of a recommended
boilout compound. Remove safety valve
from boiler and pour this solution into
boiler, then reinstall safety valve.

iii. Turn on oil burner and keep operating while

feeding water to boiler slowly. This will
raise water level in boiler slowly so that
water will be boiling hot and will rise slowly
into supply main and back through return

main, owing 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 ows out through supply main and

water lowers (by steaming) until it reaches
normal level in boiler. Turn off oil burner.
Drain boiler. Open all radiator valves.
Reinstall all supply main air valves. Open
gate valve in Hartford Loop.

v. When boiler has cooled down sufciently

(crown sheet of sections are not too hot to
touch), close the drain valves at boiler and
in return main and feed water slowly up to
normal level in boiler. Turn on oil burner
and allow boiler to steam for 10 minutes,
then turn off burner. Draw off one quart of

water from bottom gauge glass tting and

discard. Draw off another quart sample and
if this sample is not clear, repeat the cycle
of draining the boiler and return main and

relling the boiler until sample is clear.

vi. If the boiler water becomes dirty again

at a later date due to additional sediment
loosened up in the piping, close gate valve
in Hartford Loop, open drain valve in
return main, turn on oil burner and allow

Condensate to ow to drain until it has run

clear for at least 30 minutes while feeding
water to boiler so as to maintain normal
water level. Turn off oil burner, drain boiler,
open gate valve in Hartford Loop, then
repeat the full "Boiler and System Cleaning"
procedure outlined in Paragraph B starting

on Page 30.
e. Make pH or Alkalinity Test.
After boiler and system have been cleaned and

relled as previously described, test the pH of

the water in the system. This can easily be done
by drawing a small sample of boiler water and
testing with hydrion paper which is used in the
same manner as litmus paper, except it gives

specic readings. A color chart on the side of the

small hydrion dispenser gives the reading in pH.
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 specied range.

f. Boiler is now ready to be put into service.

2. WATER BOILERS:
a. Filling of boiler and system.
GENERAL — In a hot water heating system,

the boiler and entire system (other than the
expansion tank) must be full of water for
satisfactory operation. Water should be added
to the system until the boiler pressure gauge
registers 12 psi. To insure that the system is full,

31

water should come out of all air vents when
opened.

b. BOILING OUT OF BOILER AND SYSTEM.

The oil and grease which accumulate in a
new hot water boiler can be washed out in the
following manner:

i. Remove relief valve using extreme care to

avoid damaging it.

ii. Add an appropriate amount of recommended

boil out compound.

iii. Replace relief valve.
iv. Fill the entire system with water.
v. Start ring the boiler.
vi. Circulate the water through the entire

system.

vii. Vent the system, including the radiation.
viii. Allow boiler water to reach operating

temperature, if possible.

ix. Continue to circulate the water for a few

hours.

x. Stop ring the boiler.
xi. Drain the system in a manner and to a

location that hot water can be discharged
with safety.

xii. Remove plugs from all available returns

and wash the water side of the boiler as
thoroughly as possible, using a high­pressure water stream.

xiii. Rell the system with fresh water.

c. Add appropriate boiler water treatment

compounds as recommended by your qualied

water treatment company.

d. Make pH or Alkalinity Test.
After boiler and system have been cleaned and

relled as previously described, test the pH of

the water in the system. This can easily be done
by drawing a small sample of boiler water and
testing with hydrion paper which is used in the
same manner as litmus paper, except it gives

specic readings. A color chart on the side of the

small hydrion dispenser gives the reading pH.
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 specied range.

e. Boiler is now ready to be put into service.

3. EXCESSIVE MAKE-UP WATER
A leaky system will increase the volume of make-up

water supplied to the boiler, which can signicantly

shorten the life of the boiler. Entrained in make­up water are dissolved minerals, salts and oxygen.
When the fresh, cool make-up water is heated in the
boiler, the minerals fall out as sediment, the salts

32

IMPORTANT

IF, DURING NORMAL OPERATION, IT IS
NECESSARY TO ADD MORE WATER THAN
INDICATED BELOW, CONSULT A QUALIFIED
SERVICE TECHNICIAN TO CHECK YOUR
SYSTEM FOR LEAKS.

Model No.

CL3 0.3 4

4 0.4 5

CL
CL5 0.5 6

coat the inside of the boiler, and the oxygen escapes
as a gas. The accumulation of sediment eventually
isolates the water from contacting the cast iron.
When this happens the cast iron in that area gets
extremely hot and eventually cracks. The presence
of free oxygen or chloride salts in the boiler
corrodes the cast iron from the inside. More make­up water and higher concentrations of contaminants
damage the boiler sooner. Our warranty does not
cover corrosion and sediment-related damage.
Clearly it is in everyone’s best interest to prevent
this type of failure. You can do your part by ensuring
that your system is leak-free, keeping leakage to less
than 2 percent of the total water volume each month.

Gallons Per

Month

C. HINTS ON COMBUSTION

1. NOZZLES — Although the nozzle is a relatively
inexpensive device, its function is critical to the
successful operation of the oil burner. The selection
of the nozzle supplied with the CL boiler is the

result of extensive testing to obtain the best ame
shape and efcient combustion. Other brands of the

same spray angle and spray pattern may be used but
may not perform at the expected level of CO2 and
smoke. Nozzles are delicate and should be protected
from dirt and abuse. Nozzles are mass-produced
and can vary from sample to sample. For all of
those reasons a spare nozzle is a desirable item for a
serviceman to have.

2. FUEL LEAKS — Any fuel leak between the
pump and the nozzle will be detrimental to good
combustion results. Look for wet surfaces in the air
tube, under the ignitor, and around the air inlet. Any
such leaks should be repaired as they may cause
erratic burning of the fuel and in the extreme case

may become a re hazard.

3. AIR LEAKS — Any such leaks should be repaired,
as they may cause erratic burning of the fuel and in

extreme cases may become a re hazard.

SUCTION LINE LEAKS ­ Whatever it takes, The Oil Must Be Free of Air. This

can be a tough problem , but it must be resolved. Try

Gallons Per

Year

bleeding the pump through a clear tube. There must be
no froth visible. There are various test kits available to
enable you to look at the oil through clear tube. There
must be no froth visible. There are various test kits
available to enable you to look at the oil through clear

tubing adapted to the supply line at the pump tting.

Air eliminators are on the market that have potential.
Also, electronic sight glasses are being used with good
success. At times, new tubing must be run to the tank

or new ttings put on. Just make sure you get the air

out before you leave.

Any air leaks in the fuel line will cause an unstable

ame and may cause delayed ignition noises. Use only
are ttings in the fuel lines.

4. GASKET LEAKS — If 11.5 to 12.5% CO2 with a

#1 smoke cannot be obtained in the breeching, look
for air leaks around the burner mounting gasket,
observation door, and canopy gasket. Such air leaks
will cause a lower CO2 reading in the breeching. The

smaller the ring rate the greater effect an air leak

can have on CO2 readings.

5. DIRT — A fuel lter is a good investment.

Accidental accumulation of dirt in the fuel system
can clog the nozzle or nozzle strainer and produce a
poor spray pattern from the nozzle. The smaller the

ring 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 ame and causes smoke and unburned fuel to

pass out of the combustion chamber and clog the

ueways of the boiler.

7. COLD OIL — If the oil temperature approaching
the fuel pump is 40°F or lower poor combustion or
delayed ignition may result. Cold oil is harder to
atomize at the nozzle. Thus, the spray droplets get

larger and the ame shape gets longer. An outside

fuel tank that is above grade or has fuel lines in a
shallow bury is a good candidate for cold oil. The
best solution is to bury the tank and lines deep
enough to keep the oil above 40°F.

8. FLAME SHAPE — Looking into the combustion

chamber through the observation door, the ame

should appear straight with no sparklers rolling up

toward the crown of the chamber. If the ame drags

to the right or left, sends sparklers upward or makes
wet spots on the target wall, the nozzle should be
replaced. If the condition persists look for fuel leaks,
air leaks, water or dirt in the fuel as described above.

9. HIGH ALTITUDE INSTALLATIONS

Air settings must be increased at high altitudes. Use

instruments and set for 11.5 to 12.5% CO2.

10. START-UP NOISE — Late ignition is the cause of
start-up noises. If it occurs recheck for electrode

settings, ame shape, air or water in the fuel lines.

11. SHUT DOWN NOISE — If the ame runs out of air

before it runs out of fuel, an after burn with
noise may occur. That may be the result of a faulty
cut-off valve in the fuel pump, or it may be air

trapped in the nozzle line. It may take several ring

cycles for that air to be fully vented through the

nozzle. Water in the fuel or poor ame shape can also

cause shut down noises.

NOTICE

CHECK TEST PROCEDURE. A very good test for
isolating fuel side problems is to disconnect the
fuel system and with a short length of tubing,

re out of an auxiliary ve gallon pail of clean,

fresh, warm #2 oil from another source. If the
burner runs successfully when drawing out of the

auxiliary pail then the problem is isolated to the
fuel or fuel lines being used on the jobsite.

D. ATTENTION TO BOILER WHILE NOT IN

OPERATION

1. IMPORTANT
IF BOILER IS NOT USED DURING WINTER

TIME, IT MUST BE FULLY DRAINED TO
PREVENT FREEZE DAMAGE.

2. Spray inside surfaces with light lubricating or
crankcase oil using gun with extended stem so as to
reach all corners.

3. With steam boilers, at end of season add sufcient
water to ll boiler to top of water column and leave

it that way until fall when water should be drained
again to proper level. If, at this time, boiler water

is dirty, drain water, ush out boiler, and rell with

clean water to prescribed water level.

4. Always keep the manual fuel supply valve shut off
if the burner is shut down for an extended period of
time.

5. To recondition the heating system in the fall season
after a prolonged shut down, follow the instructions
outlined in Section IV, Paragraphs A through K.

WARNING

This boiler contains controls which may cause the
boiler to shut down and not restart without service.

If damage due to frozen pipes is a possibility, the

heating system should not be left unattended
in cold weather; or appropriate safeguards and
alarms should be installed on the heating system
to prevent damage if the boiler is inoperative.

33

VI. Boiler Cleaning

WARNING

All boiler cleaning must be completed with burner service switch turned off.

A. CLEAN THE FLUEWAYS (See Figure 28).

1. Disconnect oil line(s) and remove burner and burner
mounting plate. See Figures 1A thru 1D.

2. Lay protective cloth or plastic over combustion
chamber blanket.

3. Remove the smokepipe as necessary to gain access
to the boiler canopy.

4. Remove the jacket top panels.

5. Remove the canopy being careful not to damage the
cerafelt gasket.

6. Usinga1¼”diameterwireorbrebristlebrush
(30”handle)cleantheueways.Brushfromthetop

using diagonal strokes for best results. DO NOT
allow brush to strike the target wall or liner in the
chamber.

B. CLEANTOPOFBOILERSECTIONS.

1. Brushandvacuumthetopsoftheboilersections.

C. CLEANTHEFIREBOX.

1. Usingwireorbrebristlebrush,cleancrown

of boiler and inside of water legs. DO NOT
allow brush to strike target wall or blanket in the
combustion chamber.

D. AFTERCLEANING,remove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
withoutblockingtheueways.Ifgasketisdamaged,

replace as needed.

2. Close and secure burner swing door to front section
with fasteners.

3. Reconnect oil line(s).

4. Reinstall Top Panels and secure with sheet metal
screws.

5. Reinstall smokepipe on canopy and secure to collar
with sheet metal screws.

Figure 28: Cleaning of Boiler Flueways

WARNING

The boiler must be connected to an approved
chimney in good condition. Serious property
damage could result if the boiler is connected
to a dirty or inadequate chimney. The interior of

the chimney ue must be inspected and cleaned

before the start of the heating season and
should be inspected periodically throughout the
heating season for any obstructions. A clean and

unobstructed chimney ue is necessary to allow

noxious fumes that could cause injury or loss
of life to vent safely and will contribute toward

maintaining the boiler's efciency.

34

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. When disturbed as a
result of servicing or repair, these substances become airborne and, if inhaled,
may be hazardous to your health.

AVOID Breathing Fiber Particulates and Dust

Precautionary Measures:
Do not remove or replace RCF parts or attempt any service or repair work

involving RCF without wearing the following protective gear:

1. A National Institute for Occupational Safety and Health (NIOSH)
approved respirator

2. 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 classified as hazardous wastes in the United
States and Canada.

First Aid Procedures:

• If contact with eyes: Flush with water for at least 15 minutes. Seek

immediate medical attention if irritation persists.

• If contact with skin: Wash affected area gently with soap and water.

Seek immediate medical attention if irritation persists.

• If breathing difficulty develops: Leave the area and move to a location

with clean fresh air. Seek immediate medical attention if breathing
difficulties persist.

• Ingestion: Do not induce vomiting. Drink plenty of water. Seek

immediate medical attention.

35

TROUBLE SHOOTING CARLIN 40200 OIL PRIMARy CONTROL

CARLIN 40200 OIL PRIMARy CONTROL
Also refer to Model EZ-1/2/3 Oil Burner - Instruction

Manual (Form #MNEZ123) for additional information.

1. Burner (control) will not come on.
a. No power to control.
b. Control is in lockout. Press reset button for one

(1) second.

c.

CAD cell seeing light.
d. CAD assembly defective.
e. Control motor relay is stuck closed (see note

below).

2. Burner (control) will light, then shut down after a
short time, then restart after one (1) minute.

CAD cell is defective.

a.

b. Air leaking into oil line causing ame out.
c. Defective nozzle causing ame to be erratic.
d. Excessive airow or draft causing ame to be

erratic.

e.

Excessive back pressure causing ame to be

erratic.

Control locks out after Trial For Ignition (TFI).

3.
a. No oil to burner.
b. Shorted electrodes.
c. Nozzle clogged.

d. Airow too high.

e. Ignitor module defective.
f. CAD cell defective.
g. Oil valve stuck open or closed.
Note: The Safety Monitoring Circuit (SMC) is

designed to provide lockout in the event of a
stuck or welded motor relay.

NOTICE

If ame is not established within 15 seconds

of oil valve actuation (known as Trial For
Ignition [TFI]) lockout will occur. Lockout is
indicated by a red LED solid-on located on
the oil primary control.

Latch-up will occur if the control locks-out
three (
indicated by red and amber LED's solid-on.

3) times during a call for heat. This is

CARLIN OIL BURNER PART NUMBERS FOR CL SERIES BOILERS

NOTE: When ordering parts always give the serial and model numbers shown on the boiler and burner.
Refer to Carlin Model EZ-1/2/3 Oil Burner-Instruction Manual (Form #MNEZ123) for an exploded view of the burner and a

list of spare parts.

For replacement Carlin oil burner parts, contact your wholesaler or the burner manufacturer:

CCT, Carlin Combustion Technology, Inc.

70 Maple Street

East Longmeadow, MA 01028

Telephone: [phone]
Facsimile: [phone]

TROUBLE SHOOTING RIELLO 40 SERIES

Not Applicable to Riello 40 Series Burner, refer

to Models F3 and F5 Installation Manual, Riello 40

Series Residential Oil Burners (C6501010 or Model

F10 Installation Manual, Riello 40 Series Residential
Oil Burners (2902554) or contact burner manufacturer.

36

VII. Repair Parts

All CL™ 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., P.O. Box 10, Hateld, PA 19440-0010, Phone:

[phone] Attn: Customer Service Department

37

38

Bare Boiler Assembly (Exploded View)

Item

No.

Description

Boiler Size / Quantity

Part No.

CL3 CL4 CL5

Bare Boiler Assembly

Front Section (Non-Htr.), Machined Water

1

---(OR)--­Front Section (Non-Htr.), Machined Steam

2 Center Section 1 2 3 71720301

Rear Section (Non-Htr.), Machined Water

---(OR)--­Rear Section (Non-Htr.), Machined Steam

3

Rear Heater Section, Machined Water

---(OR)---

Rear Heater Section, Machined Steam
4 5" Cast Iron Slip Nipple 2 3 4 7066003
5 Slip Nipple, 22-B Steel 2 3 4 806600375
6 Rear Target Wall Insulation 1 1 1 82020002

Tie Rod, 3/8"-16 x 12-1/2" Lg. 2 --- --- 80861010
7

Tie Rod, 3/8"-16 x 17-3/4" Lg. --- 2 --- 80861032

Tie Rod, 3/8"-16 x 23" Lg. --- --- 2 80861049
8 3/8" Flat Washer 4 4 4 80860600
9 3/8"-16 Heavy Hex Nut 4 4 4 80860423

Combustion Chamber Liner, 1/2" x 19-1/2" x 9-3/4" 1 --- --- 82020031

10

Combustion Chamber Liner, 1/2" x 19-1/2" x 14-3/4" --- 1 --- 82020041

Combustion Chamber Liner, 1/2" x 19-1/2" x 19-3/4" --- --- 1 82020051

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) 1 1 1 100793-01
16 Burner Swing Door Insulation 1 1 1 82020001
17 Observation Port Cover 1 1 1 71728004
18 5/16-18 x 3/4" Lg. Cap Screw, Plated 1 1 1 80861340
19 Canopy Sealing Strip (1/2" x 1 x 10') 1 1 1 6206001

Canopy Assembly - 3 Section 1 --- --- 100827-03

20

Canopy Assembly - 4 Section --- 1 --- 100827-04

Canopy Assembly - 5 Section --- --- 1 100827-05

21 1/4"-20 x 3" Lg. Carriage Bolt, Plated 2 2 2 80860119
22 1/4"-20 x 3-1/2" Lg. Carriage Bolt, Plated 2 2 2 100838-01
23 1/4" Flat Washer - Plated 4 4 4 80860603
24 1/4"-20 Wing Nut - Plated 4 4 4 80860910
25 Heater Cover Plate Gasket - Rear Heater 1 1 1 8036058
26 V1-2 Heater Carton (WR[T] & SR[T]) Rear Heater 1 1 1 6036031
27 5/16" Flat Washer - Plated 8 8 8 80860611

3/8"-16 x 7/8" Lg. Cap Screw, Plated, ASME Grade

28

SA307B

1 1 1

1 1 1

8 8 8 80861337

71720103
71720104

71720201
71720202
71720203
71720204

39

Jacket Assembly (Exploded View)

Item

No.

Description

Boiler Size / Quantity

Part No.

CL3 CL4 CL5

Jacket Components -- Items 1 thru 6 Include Insulation as Part of Assembly

1 Jacket Front Panel Assembly 1 1 1 100819-01
2 Jacket Rear Panel Assembly 1 1 1 100820-01

2 --- --- 100821-03

Non-Heater Build

Jacket Reversible Side

3

Panel Assembly

With Heater Build

Jacket Left Side Heater Panel Assembly

4

(with Heater Build)

5 Jacket Split Front Top Panel Assembly 1 1 1 100823-01

6 Jacket Split Rear Top Panel Assembly

--- 2 --- 100821-04

--- --- 2 100821-05
1 --- --- 100821-03

--- 1 --- 100821-04

--- --- 1 100821-05
1 --- --- 100824-03

--- 1 --- 100824-04

--- --- 1 100824-05

1 --- --- 100822-03

--- 1 --- 100822-04

--- --- 1 100822-05

40

CL3 Thru CL5 Water Boilers - Trim and Controls

Item

No.

Description

Boiler Size / Quantity

Part No.

CL3 CL4 CL5

CL3 Thru CL5 Water Boilers - Trim and Controls

1 Beckett R7184B Oil Primary Control 1 1 1 100136-01

Honeywell L7248C1014 Hi Limit, Circ. Relay

2

--- (OR)---

L7224C1004 Hi & Lo Limit, Circ. Relay
3 ¾" NPT x 1½" Immersion Well, Honeywell 123870A 1 1 1 80160426
4 2½" Temperature / Pressure Gauge 1 1 1 8056169
5 ¾" NPT x 7¼" Lg. Nipple, SCH 80, Black 1 1 1 100839-01
6 Relief Valve, #10-407-05 1 1 1 81660319
7 1½" NPT x 5" Lg. Nipple, Black 1 1 1 806600060
8 1½" x ¾" x 1½" NPT Tee, Black 1 1 1 806601003
9 ¾" Drain Valve 1 1 1 806603061

10 Taco 007 Circulator 1 1 1 8056007
11 1½" Circulator Flange 2 2 2 806602014
12 Taco Flange Gasket 2 2 2 806602006

1 1 1

100059-01
100862-01

41

CL3 Thru CL5 Steam Boilers - Trim and Controls

Item

No.

Description

Boiler Size / Quantity

Part No.

CL3 CL4 CL5

CL3 Thru CL5 Steam Boilers - Trim and Controls

1 Beckett R7184B Oil Primary Control 1 1 1 100136-01
2 McDonnell & Miller PS801 LWCO With Probe 1 1 1 80160723

3 Honeywell PA404A1009 Pressuretrol 1 1 1 80160300
3A ¼" x 90° Syphon, 2½" Equal Leg 1 1 1 806603006
3B ¾" x ¼" NPT Bushing, Black 1 1 1 806600508

4 Honeywell L4006A2015 Aquastat 1 1 1 80160400

5 #123871A Immersion Well ¾" NPT 1 1 1 80160426

6 2½" Dia. Steam Gauge 1 1 1 8056010

7 10¼" Gauge Glass Set, Conbraco #22-171-10 1 1 1 100854-01
7A ½" Male x ½" Female NPT Brass Extension Piece 1 1 1 100853-01
7B ½" NPT Brass Street Elbow 1 1 1 100852-01

8 ¾" NPT x 7¼" Lg. Nipple, SCH 80, Black 1 1 1 100839-01

9 ¾" NPT, M/F, 15 PSI Safety Valve Conbraco #13-511-08 1 1 1 81660530
10 ¾" NPT Coupling 1 1 1 806602561

11 ¾" NPT Drain Valve, Conbraco #35-302-03 1 1 1 806603061

42

BECKETT OIL BURNER PARTS LIST

MODEL AFG --- 60-Hz, 3450 RPM

P.O. BOX 1289

1-800-645-2876

ELYRIA, OHIO 44036

R. W. BECKETT CORP.

FOR REPLACEMENT OIL BURNER PARTS, CONTACT

YOUR WHOLESALER OR THE BURNER MANUFACTURER:

Beckett AFG Burner

43

BECKETT OIL BURNER PART NOS. FOR CL SERIES BOILERS

NOTE: When ordering parts always give the serial and model numbers shown on the boiler and burner. Also
provide the name of the part(s) and part number as listed below.

Boiler Model CL3-091, 105, 140 CL4-126 CL4-175, 210 CL5-168, 245 CL5-280
Air Tube Combination AFG70MBAS AFG70MBAS AFG70MDAS AFG70MDAS AFG70MLAS
Beckett's Spec No. NY2701 NY2702 NY2703 NY2704 NY2705

Air Band 3492A 3492A 3492A 3492A 3492A
Air Band Nut 4150 4150 4150 4150 4150
Air Band Screw 4198 4198 4198 4198 4198
Air Shutter 3709 3709 3709 3709 3709
Air Shutter Screw 4198 4198 4198 4198 4198
Blower Wheel 2999 2999 2999 2999 2999
Coupling 2454 2454 2454 2454 2454
Low Firing Rate Bafe 5880[1] ---- ---- ---- ---­Bulkhead Knurled Locknut 3-666 3-666 3-666 3-666 3-666
Connector Tube Assembly 5636 5636 5636 5636 5636
Electrode Clamp 1-49 1-49 1-49 1-49 1-49
Electrode 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
Nozzle Adapter 2-13 2-13 2-13 2-13 2-13
Nozzle Line Electrode Assembly NL70MB NL70MB NL70MD NL70MD NL70ML
Oil Pump, Clean Cut (Single Stage) 2184404U 2184404U 2184404U 2184404U 2184404U
Oil Pump, Clean Cut (Two Stage) 21941U 21941U 21941U 21941U 21941U
Static Plate 3384 3384 3384 3384 Less
Ignitor 51771U 51771U 51771U 51771U 51771U
Ignitor Hinge Screw 4217 4217 4217 4217 4217
Ignitor Holding Screw 4292 4292 4292 4292 4292
Ignitor Gasket Kit 51304 51304 51304 51304 51304
Junction Box 5770 5770 5770 5770 5770
Flame Detector 7006 7006 7006 7006 7006
Oil Solenoid Valve Coil 21755 21755 21755 21755 21755
Oil Solenoid Valve Cord 21807 21807 21807 21807 21807

[1] 5880 used on CL3-091 ring rate only

44

VIII. Low Water Cut Off (LWCO)

WARNING

DO NOT ATTEMPT to cut factory wires to install an aftermarket Low Water Cut Off (LWCO). Only use

connections specically identied for Low Water Cut Off.

In all cases, follow the Low Water Cut Off (LWCO) manufacturer's instructions.

When

A low water cutoff is required to protect a hot water

boiler when any connected heat distributor (radiation)
is installed below the top of the hot water boiler (i.e.

baseboard on the same oor level as the boiler). In

addition, some jurisdictions require the use of a LWCO
with a hot water boiler.

Where

The universal location for a LWCO on both gas and oil

hot water boilers is above the boiler, in either the supply
or return piping. The minimum safe water level of a
water boiler is at the uppermost top of the boiler; that is,
it must be full of water to operate safely.

What Kind

Typically, in residential applications, a probe type

LWCO is used instead of a oat type, due to their

relative costs and the simplicity of piping for a probe
LWCO.

How to Pipe

A “tee” is commonly used to connect the probe LWCO
to the supply or return piping, as shown below.

manufacturers recommend an annual inspection of the
probe.

How to Wire

LWCO’s are available in either 120 VAC or 24 VAC

congurations. The 120 VAC conguration can be

universally applied to both gas and oil boilers by wiring
it in the line voltage service to the boiler (after the
service switch, if so equipped).

The presence of water in a properly installed LWCO

will cause the normally open contact of the LWCO to
close, thus providing continuity of the 120 VAC service
to the boiler.

It is recommended to supply power to the probe LWCO

with the same line voltage boiler service as shown
below.

LWCO Location

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, manual shutoff valves should be located

above the LWCO and the boiler to allow for servicing.
This will allow probe removal for inspection without
draining the heating system. Many probe LWCO

Wiring of Typical LWCO

A 24 VAC LWCO is used primarily for gas red

boilers where a 24 volt control circuit exists within the
boiler. However, a 24 VAC LWCO can only be used
if the boiler manufacturer has provided piping and
wiring connections and instructions to allow for this
application.

How to Test

Shut off fuel supply. Lower water level until water
level is BELOW the LWCO. Generate a boiler demand
by turning up thermostat. Boiler should not attempt to

operate. Increase the water level by lling the system.

The boiler should attempt to operate once the water
level is above the LWCO.

45

TABLE 9: BURNER SPECIFICATIONS

Beckett AFG

Boiler Model

1

CL3-091

CL3-105 0.75 L1 6 0 0.65 x 45B (Hago)

p CL3-140

CL4-126 0.90 L1 7 0 0.75 x 45B (Delavan) Installed 140

CL4-175 1.25 V1(0) 10 1 1.00 x 45B (Hago)

 CL4-210

CL5-168 1.20 V1(2) 10 0 0.90 x 45B (Hago)

l CL5-245

CL5-280 2.00 V1(4) 10 3 1.50 x 45B (Hago) Installed 175

Firing Rate

GPH

Head

(Setting)

0.65 L1 8 0 0.55 x 70B (Delavan)

1.00 L1 10 1 0.85 x 45B (Hago) Installed 140

1.50 V1(0) 10 2 1.10 x 45B (Hago) Installed 175

1.75 V1(3) 7 3 1.35 x 45B (Hago) Installed 175

Air

Shutter

Air

Band

GPH x Angle Type

2

Shipped

p Loose

p Loose

 Loose

l Loose

Settings Nozzle

3

Pump

Pressure

140

140

175

175

Carlin Burner

Boiler Model

CL3-091 0.65
CL3-105 0.75 0.60/0.65 0.60 0.60 x 60ES (Hago)

p CL3-140

CL4-126 0.90 0.75 0.75 0.75 x 60A (Delavan)

CL4-175 1.25 0.85/1.00 1.00-1.10 1.00 x 60A (Delavan)

 CL4-210

CL5-168 1.20 0.85/1.00 0.90 1.00 x 60B (Hago) Installed 150

CL5-245 1.75 EZ-2HP 1.50 1.75 1.50 x 60A (Delavan) Installed 150

1

Beckett low ring rate bafe required on CL3-091 (0.65 GPH) application only; shipped loose with nozzle.

2

Nozzle(s) for alternate boiler model ring rate(s) are shipped loose in bag attached to the

burner designated by corresponding symbol, i.e. (p) = CL3-140.

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.

Firing Rate

GPH

1.00 0.85/1.00 0.75 0.85 x 60B (Hago) Installed 150

1.50 1.10/1.25 1.25-1.35 1.25 x 60B (Hago) Installed 150

Burner

Model

EZ-1HP

Head

Bar

0.50 0.55 0.55 x 70B (Delavan)

Air

Band

GPH x Angle Type

2

Shipped

p Loose
p Loose

 Loose

 Loose

Settings Nozzle

3

Pump

Pressure

150
150

150

150

46

RIELLO OIL BURNER PART NUMBERS FOR CL SERIES BOILERS

NOTE: When ordering parts always give the serial and model numbers shown on the boiler and burner.
Refer to Models F3 & F5 Installation Manual, Riello 40 Series Residential Oil Burners (C6501010) or Model F10

Installation Manual, Riello 40 Series Residential Oil Burners (2902554) for an exploded view of the burner and a list of spare
parts.

For replacement Riello oil burner parts, contact your wholesaler or the burner manufacturer:

Riello Corporation of America

35 Pond Park Road

Hingham, Massachusetts 02043

Telephone: [phone]

Facsimile: [phone]

Toll Free: (outside Massachusetts)

[phone]

TABLE 9A: RIELLO BURNER SPECIFICATIONS

Boiler

Model

CL3-105 0.75

CL3-140 1.00 2.85 2

CL4-175 1.25 40F5 4 4

CL4-210 1.50 40F10 3 1

CL5-245 1.75

CL5-280 2.00 3.8 2

Firing

Rate

GPM

Burner

Model

40F5

40F10

Air Shutter Turbulator

Settings Nozzle

2.60 0

3 1.5

GPH x Angle

Type

0.60 x 60A
(Delavan)

0.85 x 60W
(Delavan)

1.00 x 60A
(Delavan)

1.25 x 60B
(Delavan)

1.35 x 45B
(Delavan)

1.65 x 45B
(Delavan)

Riello Canada Inc.

2165 Meadowpine Blvd.

Mississauga, Ontario L5N 6H6

Telephone: [phone]

Facsimile: [phone]

Toll Free: [phone]

Pump

Shipped

Loose

Installed

Installed SBT 6.0” 2-3/8”

Installed SBT 5.0” 2-1/2”

Loose

Installed

Pressure

150

Combustion

Insertion

Head

SBT 6.0” 2-3/8”

SBT 5.0” 2-1/2”

Depth

47

SERVICE RECORD

DATE SERVICE PERFORMED

48

SERVICE RECORD

DATE SERVICE PERFORMED

49

SERVICE RECORD

DATE SERVICE PERFORMED

50

51

NEW YORKER BOILER CO., INC.

Limited Warranties

For Residential Cast Iron Steam Boilers

By this Warranty Statement New Yorker Boiler Co., Inc. ("New Yorker")
issues limited warranties subject to the terms and conditions stated below.
These limited warranties apply to residential cast iron steam boilers labeled
with the New Yorker® brand which are sold on or after March 1, 2004

ONE yEAR LIMITED WARRANTy

One Year Limited Warranty for Residential Cast Iron Steam Boilers

New
Yorker warrants to the original consumer purchaser at the original installation
address that its residential cast iron steam boilers will be free of defects in
material and workmanship under normal usage for a period of one year from
the date of original installation. In the event that any defect in material or
workmanship is found during the one-year period following the date of
installation, New Yorker will, at its option, repair the defective part or provide
a replacement free of charge, F.O.B. its factory.

TEN yEAR LIMITED WARRANTy

Ten Year Pressure Vessel Limited Warranty for Residential Cast Iron Steam
Boilers New Yorker warrants to the original consumer purchaser at the
original installation address that the pressure vessel of its residential cast iron
steam boilers will be free of defects in material and workmanship under
normal usage for a period of 10 years from the date of original installation. In
the event that any defect in material or workmanship is found during the ten
year period following the date of installation, New Yorker will, at its option,
repair the defective pressure vessel or provide a replacement free of charge,
F.O.B. its factory.

EXCEPTIONS AND EXCLUSIONS

1.Components Manufactured by Others Following the expiration of the

foregoing one year limited warranty, all component parts of a boiler which are
manufactured by others (such as burners, burner controls, circulator, tankless
water heater, and New Yorker Link) shall be subject only to the
manufacturer's warranty, if any.

2.Removal and Replacement Costs These warranties do not cover expenses

of removal or reinstallation. The consumer purchaser will be responsible for
the cost of removing and replacing any defective part and all labor and related
materials connected therewith. Replacement parts will be invoiced to the
distributor in the usual manner and will be subject to adjustment upon proof of
defect.

3.Proper Installation These warranties are conditioned upon the installation

of the boiler in strict compliance with New Yorker's Installation, Operating
and Service Instructions. New Yorker specifically disclaims any liability of
any kind which arises from or relates to improper installation.

4.Improper Use or Maintenance These warranties will not be applicable if

the boiler is used or operated over its rated capacity, is installed for uses other
than home heating, or is not maintained in accordance with New Yorker
Installation’s, Operating and Service Instructions and hydronics industry
standards.

5.Improper Operation These warranties will not be applicable if the boi

has been damaged as a result of being improperly serviced or operated,
including but not limited to the following: operated with insufficient wat
allowed to freeze; subjected to flood conditions; or operated with water
conditions and/or fuels or additives which cause un

ler

er;

usual deposits or corrosion

in or on the pressure vessel or associated controls.

6.Geographic Limitations These warranties apply only to boilers installed

within the 48 contiguous United States.

7.Installation Requirements In order for these warranties to be effective:
a)The boiler must be installed in a single or two-family residential dw

This warranty does not apply to boilers installed in apart

elling.

ments or for

commercial or industrial applications.

b)The boiler must be installed in strict compliance with New Yorker's

Installation, Operating and Service Instructions, including the installation of a
low water cut-off, by an installer regularly engaged in boiler installations.

c)Boiler sections must not have been damaged during shipment or

installation.

d)The boiler must be vented in accordance with chimney recommendations

set forth in New Yorker's Installation, Operating and Service Instructions.

8.Exclusive Remedy New Yorker's obligation in the event of any breach of

these warranties is expressly limited to the repair or replacement of any part
found to be defective under conditions of normal use.

9.Limitation of Damages Under no circumstances will New Yorker be liable

for incidental, indirect, special or consequential damages of any kind under
these warranties, including, without limitation, injury or damage to persons or
property and damages for loss of use, inconvenience or loss of time. New
Yorker's liability under these warranties shall under no circumstances exceed
the purchase price paid for the boiler involved. Some states do not allow the
exclusion or limitation of incidental or consequential damages, so the above
limitation or exclusion may not apply to you.

10.Limitation of Warranty These limited warranties are given in lieu of all

other express warranties and set forth the entire obligation of New Yorker
with respect to any defect in a residential cast iron steam boiler. New Yorke
shall have no express obligations,

r

other

A

n

er

.

SO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO

STATE.

responsibilities or liabilities of any kind,

than those set forth herein.

ALL APPLICABLE IMPLIED WARRANTIES, IF ANY, INCLUDING
ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR
PARTICULAR PURPOSE, ARE EXPRESSLY LIMITED IN
DURATION TO A PERIOD OF ONE YEAR, EXCEPT THAT
IMPLIED WARRANTIES, IF ANY, APPLICABLE TO THE
PRESSER VESSEL OF A RESIDENTIAL CAST IRON STEAM
BOILER SHALL BE LIMITED IN DURATION TO THE LESSER OF
THE DURATION OF SUCH IMPLIED WARRANTY OR A PERIOD
OF TEN YEARS. Some states do not allow limitations on how long a
i u.

PROCEDURE FOR OBTAINING WARRANTy SERVICE

Upon discovery of a condition believed to be related to a defect in material
or workmanship covered by these warranties, the original consumer purchaser
should notify the installer, who will in turn notify the distributor. If this action
is not possible or does not produce a prompt response, the original consum
purchaser should write to New Yorker Boiler Co., Inc. at P.O. Box 10,

mplied warranty lasts, so the above limitation may not apply to yo

Hatfield, PA 19440-0010, giving full particulars in support of the claim

The original consumer purchaser is required to make available for
inspection by New Yorker or its representative the parts claimed to be
defective and, if requested by New Yorker, to ship those parts prepaid to New
Yorker at the above address for inspection or repair. In addition, the original
consumer purchaser agrees to make all reasonable efforts to settle any
disagreement arising in connection with any warranty claim before resorting
to legal remedies in the courts.
THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU
MAY AL

02/04

52