Energy Tech Laboratories New Yorker CL, Riello 40, New Yorker F5, New Yorker F3 User Manual
INSTALLATION, OPERATING
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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
efciency 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 efciency.
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 Specications ............................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 Sufx: (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 efciency. 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 specied 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. Conrm the
nozzle is the proper size and type for the lower ring
rate as specied 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, conrm 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 bafe is required.
Bafe is shipped loose with nozzles. Install
bafe per Beckett Instruction included with
bafe.
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, conrm 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
specied 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 Identication,
refer to Figure 8.
F. INSTALL WATER BOILER TRIM AND CONTROLS,
(see Figures 1A and 1B)
1. Install return piping supplied with boiler. Apply
Teon 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 Identication
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 benecial to the
tankless heater but to piping and xtures plus the
many other benets 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 sufcient 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 efciency
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 inefcient 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 efciency 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
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