New Yorker Boiler CL Installation Manual
INSTALLATION, OPERATING
Br
Be
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).
®
9700609
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Price - $5.00
IMPORTANT INFORMATION - READ CAREFULLY
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.
B. Current Edition of American National Standard ANSI/NFPA 211, “Chimneys, Fireplaces,
Vents, and Solid Fuel 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.
D. All wiring on boilers installed in the USA shall be made in accordance with the National
Electrical Code and/or Local Regulations.
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.
Indicates a potentially hazardous situation which,
if not avoided, may result in moderate or minor
injury or property damage.
Indicates special instructions on installation,
operation, or maintenance which are important
but not related to personal injury hazards.
CAUTION
NOTICE
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.
Surface rust on cast iron sections may be attributed to the manufacturing process as well as condensation
during storage. Surface rust is normal and does not affect the performance or longevity of a boiler.
2
DANGER
DO NOT store or use gasoline or other ammable vapors or liquids in the vicinity of this or any other boiler.
WARNING
Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal
injury or loss of life. Failure to follow all instructions in the proper order can cause personal injury or
death. Read and understand all instructions, including all those contained in component manufacturers
manuals which are provided with the boiler before installing, starting-up, operating, maintaining or servicing
this boiler. Keep this manual and literature in legible condition and posted near boiler for reference by
owner and service technician.
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.
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.
Installation is not complete unless a pressure relief valve is installed into the tapping located on top left
corner of front section- Refer to Figures 1A thru 1D and Section III "Installation Instructions" for additional
details.
It is the responsibility of the installing contractor to see that all controls are correctly installed and are
operating properly when installation is complete including verifying that the limit sensor is fully installed
(seated in bottom of Well).
Failure to properly install Limit Sensor may result in property damage, personal injury or loss of life due
to elevated operating temperatures and/or pressures.
This boiler is suitable for installation on combustible ooring. DO NOT install boiler on carpeting.
DO NOT tamper with or alter the boiler or controls.
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.
Oil Burner and Controls must be checked at least once a year or as may be necessitated.
DO NOT operate boiler with jumpered or absent controls or safety devices.
DO NOT operate boiler if any control, switch, component, or device has been subject to water.
Boiler 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 boiler.
3
WARNING
This boiler contains very hot water under 12 - 15 PSI pressure. DO NOT unscrew any pipe ttings nor
attempt to disconnect any components of this boiler without positively assuring the water is cool and has
no pressure. Always wear protective clothing and equipment when installing, starting up or servicing this
boiler to prevent scald injuries. DO NOT rely on the pressure and temperature gauges to determine the
temperature and pressure of the boiler. This boiler contains components which become very hot when
the boiler is operating. DO NOT touch any components unless they are cool.
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. Refer to Section III "Installation Instructions" for additional details.
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 or vent system in good condition. Serious
property damage could result if the boiler is connected to a dirty or inadequate chimney or vent system.
The interior of the chimney 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.
DO NOT operate boiler with the absence of an approved vent system.
This boiler is supplied with controls which may cause the boiler to shut down and not re-start 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.
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.
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.
TABLE OF CONTENTS
I. General Information ................................... 5
II. Pre-Installation .........................................10
III. Installation Instructions ........................... 12
IV. Electrical ................................................... 24
V. System Start-Up ....................................... 30
VI. Operating .................................................. 37
VII. Maintenance & Service Instructions. .... 42
4
VIII. Boiler Cleaning ........................................ 45
IX. Trouble Shooting .....................................48
X. Repair Parts .............................................51
XI. Burner Specications .............................58
Appendix A - Low Water Cut-Off ..........60
I: GENERAL INFORMATION
'B'
'C'
DIA.
Figure 1A: CL3 Thru CL5 Water Boiler without Tankless Heater, All Burner Options
Figure 1B: CL3 Thru CL5 Water Boiler With Tankless Heater, All Burner Options
5
I: GENERAL INFORMATION (continued)
'A'
'B'
'C'
DIA.
Figure 1C: CL3 Thru CL5 Steam Boiler with or without Tankless Heater,
McDonnell & Miller PS-801, Beckett Burner
Figure 1D: CL3 thru CL5 Steam Boiler with or without Tankless Heater,
McDonnell & Miller PS-801, Riello Burner
6
I: GENERAL INFORMATION (continued)
TABLE 1: DIMENSIONAL DATA / GENERAL INFORMATION (SEE FIGURES 1A THRU 1D)
Boiler Model
CL3 17-3/8" 8-1/4" 5-7/8" 16 14.33
CL4 22-3/8" 10-7/8" 6-7/8" 20 20.90
CL5 27-3/8" 13-3/8" 7-7/8" 24 27.46
Maximum Working Pressure: Steam: 15 PSI; Water: 30 PSI Shipped Standard from Factory, 50 PSI Optional
"A" "B" "C"
Dimensions
Approx. Water Content
- Gallons
Heat Transfer Surface
Area - Sq. Ft.
TABLE 2: RATING DATA
Burner
Boiler Model
Capacity
No. *
GPH MBH
CL3-091(W) 0.65 91 80 --- 70 --- --- 6 8 x 8 15 86.1 ---
CL3-091(S) 0.65 91 --- 78 --- 56 233 6 8 x 8 15 --- 84.1
CL3-105(W) 0.75 105 91 --- 79 --- --- 6 8 x 8 15 86.0 ---
CL3-105(S) 0.75 105 --- 90 --- 68 283 6 8 x 8 15 --- 83.8
CL3-140(W) 1.00 140 120 --- 104 --- --- 6 8 x 8 15 84.3 ---
CL3-140(S) 1.00 140 --- 119 --- 89 370 6 8 x 8 15 --- 82.7
CL4-126(W) 0.90 126 111 --- 97 --- --- 7 8 x 8 15 86.0 ---
CL4-126(S) 0.90 126 --- 108 --- 81 338 7 8 x 8 15 --- 84.1
CL4-175(W) 1.25 175 152 --- 132 --- --- 7 8 x 8 15 85.1 ---
CL4-175(S) 1.25 175 --- 149 --- 112 467 7 8 x 8 15 --- 83.5
CL4-210(W) 1.50 210 179 --- 156 --- --- 7 8 x 8 15 84.0 ---
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 85.9 ---
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 85.1 ---
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 84.7 ---
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
AHRI NET Ratings
Water
MBH
Steam
MBH
Steam
Sq. Ft.
Minimum Chimney
Requirements
Round
In. Dia.
Rectangle
In. x In.
Height
Ft.
AFUE %
Water Steam
7
I: GENERAL INFORMATION (continued)
TABLE 3A: PURPOSE OF TAPPINGS (WATER)
Tapping
Location
A 1½” Return
B ½” Limit Well Plug
C ¼”
D 1½” Supply
E 1½” Optional Return
F ¾” Relief Valve
G ¾” N/A DHW Outlet
H ¾” N/A Limit Well
I ¾” N/A DHW Inlet
Size,
NPT
Less Heater With Heater
Purpose
Temperature/Pressure
Gauge
Figure 2A: Purpose of Tappings (Water)
8
I: GENERAL INFORMATION (continued)
TABLE 3B: PURPOSE OF TAPPINGS (STEAM)
Tapping
Location
A 1½” Return
B ½” Pressure Limit
C ¼” Pressure Gauge
D 3” Supply
E 1½” Optional Return
F ¾” Relief Valve
G ¾” N/A DHW Outlet
H ¾” N/A Limit Well
J ¾” Drain
K ¾” LWCO
L ½” Water Gauge Glass
M ½” Water Gauge Glass
N 1” Indirect Water Heater Supply
O ½” Indirect Water Heater Limit
P 1½” Surface Blowoff
Size,
NPT
Less Heater With Heater
I ¾” N/A DHW Inlet
Purpose
Figure 2B: Purpose of Tappings (Steam)
9
II: PRE-INSTALLATION
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 near nal position before removing
crate. See Figures 1A thru 1D. Using hand truck or
pipe rollers under skid, move boiler into position along
side installation site.
1. LOCATE so that vent pipe connection to chimney
will be short and direct.
2. BOILER IS SUITABLE FOR INSTALLATION
ON COMBUSTIBLE FLOOR. Boiler cannot be
installed on carpeting.
3. FOR BASEMENT INSTALLATION, provide
a solid elevated base, such as concrete, if oor is
not level, or if water may be encountered on oor
around boiler.
4. PROVIDE SERVICE CLEARANCE of at least
24” clearance from front jacket panel for servicing
and removal of front tankless heater. If boiler is
equipped with a rear tankless heater, provide at
least 24" service clearance on the right side of the
boiler. Boiler ueways may be cleaned either from
the top or from the right side. Provide at least 24"
clearance from either the right side of the boiler or
the top of the boiler for cleaning ueways.
5. For minimum clearances to combustible materials.
See Figure 3.
NOTICE
Clearance to venting is for single wall vent
pipe. If Type L vent is used, clearance may be
reduced to the minimum required by the vent pipe
manufacturer.
C. PROVIDE COMBUSTION AND VENTILATION
AIR. Local and National Codes may apply and should
be referenced.
Figure 3: 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
10
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.
II: PRE-INSTALLATION (continued)
WARNING
Adequate combustion and ventilation air must
be provided to assure proper combustion and
to maintain safe ambient air temperatures.
DO NOT install boiler where gasoline or other
ammable vapors or liquids, or sources of
hydrocarbons (i.e. bleaches, fabric softeners,
etc.) are used or stored.
1. Determine volume of space (boiler room). Rooms
communicating directly with the space in which
the appliances are installed, through openings not
furnished with doors, are considered a part of the
space.
3
Volume(ft
2. Determine total input of all appliances in the space.
Add inputs of all appliances in the space and round
the result to the nearest 1000 BTU per hour.
3. Determine type of space. Divide Volume by total
input of all appliances in space. If the result is
greater than or equal to 50 ft3/1000 BTU per hour,
then it is considered an unconned space. If the
result is less than 50 ft3/1000 BTU per hour then the
space is considered a conned space.
4. For boiler located in an unconned space of a
conventionally constructed building, the fresh
air inltration through cracks around windows
and doors normally provides adequate air for
combustion and ventilation.
5. For boiler located in a conned space or an
unconned space in a building of unusually tight
construction, provide outdoor air.
Outdoor air may be provided with the use of two
permanent openings which communicate directly or
by duct with the outdoors or spaces (crawl or attic)
freely communicating with the outdoors. Locate one
opening within 12 inches of top of space.
) = Length(ft) x Width(ft) x Height(ft)
Locate remaining opening within 12 inches of
bottom of space. Minimum dimension of air opening
is 3 inches. Size each opening per following:
a. Direct communication with outdoors.
Minimum free area of 1 square inch per 4,000
BTU per hour input of all equipment in space.
b. Vertical ducts. Minimum free area of 1 square
inch per 4,000 BTU per hour input of all
equipment in space. Duct cross-sectional area
shall be same as opening free area.
c. Horizontal ducts. Minimum free area of 1
square inch per 2,000 BTU per hour input of all
equipment in space. Duct cross-sectional area
shall be same as opening free area.
Alternate method for boiler located within
conned space. Use indoor air if two permanent
openings communicate directly with additional
space(s) of sufcient volume such that combined
volume of all spaces meet criteria for unconned
space. Size each opening for minimum free area
of 1 square inch per 1,000 BTU per hour input
of all equipment in spaces, but not less than 100
square inches.
6. Louvers and Grilles of Ventilation Ducts
a. All outside openings should be screened and
louvered. Screens used should not be smaller
than 1/4 inch mesh. Louvers will prevent the
entrance of rain and snow.
b. Free area requirements need to consider the
blocking effect of louvers, grilles, or screens
protecting the openings. If the free area of the
louver or grille is not known, assume wood
louvers have 20-25 percent free area and metal
louvers and grilles have 60-75 percent free area.
c. Louvers and grilles must be xed in the open
position, or interlocked with the equipment to
open automatically during equipment operation.
11
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