New Yorker Boiler CG-E Installation Manual
INSTALLATION, OPERATING
AND
SERVICE INSTRUCTIONS
CG-E™ SERIES
GAS BOILER
9700609
BEFORE INSTALLATION: READ THIS MANUAL
SAVE THESE INSTRUCTIONS
Installing contractor and homeowner should read and be informed as to the proper installation and operation of this boiler.
The manufacturer will not be responsible for improper installation or operation. This manual and all associated instruction
material should be conspicuously posted near the boiler.
For service or repairs to boiler, call your heating contractor. When seeking information on boiler,
provide Boiler Model Number and Serial Number as shown on Rating Label.
Boiler Model Number
CG _ _ E
Heating Contractor Phone Number
Address
Boiler Serial Number Installation Date
106213-01- 11/15
Price - $5.00
The City of New York requires a Licensed Master Plumber supervise the installation of this product.
The Massachusetts Board of Plumbers and Gas Fitters has approved the CG-E™ Series Boiler. See the Massachusetts Board of
Plumbers and Gas Fitters website, http://license.reg.state.ma.us/pubLic/pl_products/pb_pre_form.asp for the latest Approval
Code or ask your local Sales Representative.
The Commonwealth of Massachusetts requires this product to be installed by a licensed Plumber or Gas tter.
The following terms are used throughout this manual to bring attention to the presence of hazards of various
risk levels, or to important information concerning product life.
DANGER
Indicates an imminently hazardous situation
which, if not avoided, will result in death, serious
injury or substantial property damage.
WARNING
Indicates a potentially hazardous situation which,
if not avoided, could result in death, serious injury
or substantial property damage.
Table of Contents
CAUTION
Indicates a potentially hazardous situation which,
if not avoided, may result in moderate or minor
injury or property damage.
NOTICE
Indicates special instructions on installation,
operation, or maintenance which are important
but not related to personal injury hazards.
I. Pre-Installation ....................................5
II. Unpack Boiler .....................................5
III. Water Piping and Trim ........................6
IV. Venting .............................................. 10
V. Gas Piping .........................................12
VI. Electrical ............................................13
2
VII. System Start-up and Checkout ..................... 17
VIII. Operation ..........................................20
IX. Service and Maintenance ...................22
X. Troubleshooting ................................24
XI. Repair Parts .......................................29
Warranty .............................Back Cover
Table 1A: Dimensions and Connections
Boiler
Model
CG30E 32 14 40 1¼ 1¼ 4 ½ ¾ ¾
CG40E 32 16 40 1¼ 1¼ 5 ½ ¾ ¾
CG50E 32 19 40 1¼ 1¼ 6 ½ ¾ ¾
CG60E 32 22 40 1¼ 1¼ 6 ½ ¾ ¾
CG70E 32 25 40 1¼ 1¼ 7 ¾ ¾ ¾
CG80E 32 28 40 1¼ 1¼ 7 ¾ ¾ ¾
CG90E 32 31 40 1¼ 1¼ 8 ¾ ¾ ¾
Depth Width Height
Supply NPT
(inch)
Return NPT
(inch)
Vent
(inch)
Gas NPT
(inch)
Relief Valve
NPT (inch)
Drain
NPT (inch)
Table 1B: Inputs, Weights and Volumes
Boiler
Model
CG30E 70 254 180 2
CG40E 105 304 231 3
CG50E 140 357 284 4
CG60E 175 405 332 5
CG70E 210 462 382 6
CG80E 245 518 438 7
CG90E 280 564 484 8
(1)
Input ratings can be used for elevations up to 2000 ft. Refer to System Start-up and Checkout Sections for elevations 2000 ft.
or higher.
Input (MBH)
(1)
Shipping Weight
(lbs)
Empty Weight
(lbs)
Water Content
(gal)
Electrical Requirements: 120VAC, 60 Hz, 1-ph, Less than 12A
Maximum Allowable Working Pressure - 50 psi. Boiler shipped from factory with a 30 psi relief valve.
3
Figure 1: Minimum Clearance to Combustible Materials and Alcove Dimensions
4
I. Pre-Installation
WARNING
Carefully read all instructions before installing
boiler. Failure to follow all instructions in proper
order can cause personal injury or death.
A. Inspect shipment carefully for any signs of damage.
All equipment is carefully manufactured, inspected
and packed. Our responsibility ceases upon delivery
of boiler to carrier in good condition. Any claim
for damage or shortage in shipment must be led
immediately against carrier by consignee. No claims
for variances or shortages will be allowed by Boiler
Manufacturer, unless presented within sixty (60) days
after receipt of equipment.
B. Installation must conform to the requirements of the
authority having jurisdiction. In the absence of such
requirements, installation must conform to National
Fuel Gas Code, ANSI Z223.1/NFPA 54.
C. Appliance is design certied for installation on
combustible ooring. The boiler must not be installed
on carpeting.
D. Provide clearance between boiler jacket and
combustible material in accordance with local re
ordinance. Refer to Figure 1 for minimum clearance
from combustible material for alcove installation.
Provide 1/2" clearance from water piping to
combustible materials.
F. Install on level oor. For basement installation provide
concrete base if oor is not level or if water may be
encountered on oor around boiler.
CAUTION
ASSURE THAT THE FRONT AIR DAM is in place
and undamaged. A damaged front air dam will
negatively affect the performance of this boiler,
which can cause serious property damage,
personal injury or death.
G. Protect gas ignition system components from water
(dripping, spraying, rain, etc.) during boiler operation
and service (circulator replacement, condensate trap,
control replacement, etc.).
H. Provide combustion and ventilation air in accordance
with the section "Air for Combustion and Ventilation,"
of the National Fuel Gas Code, ANSI Z223.1/NFPA 54,
or applicable provisions of local building codes.
WARNING
Adequate combustion and ventilation air must be
provided to assure proper combustion.
I. Do not install boiler where gasoline or other
ammable vapors or liquids, or sources of
hydrocarbons (i.e. bleaches, cleaners, chemicals, sprays,
paint removers, fabric softeners, etc.) are used or stored.
E. Provide practical service clearances. A minimum
of 24" from the left side and front jacket panels is
recommended for servicing but may be reduced to
minimums shown in Figure 1.
II. Unpack Boiler
CAUTION
Do not drop boiler. Do not bump boiler jacket
against oor.
A. Move boiler to approximate installed position.
B. Remove all crate fasteners.
C. Lift outside container and remove with all other
inside protective spacers and bracing. Save two of the
wooden slats from the container sleeve for use in Steps
E and F.
D. Remove all boiler hold-down fasteners.
E. Tilt the boiler to one side and slide a wooden slat under
the two raised feet.
F. Tilt the boiler to the other side and slide another
wooden slat under the two raised feet.
G. Slide the boiler forward or backward off the skid using
the two wooden slats as runners.
H. Move boiler to its permanent location.
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