Energy Tech Laboratories New Yorker Cl Series Users Manual
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2015-02-06
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INSTALLATION, OPERATING
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
efficiency established by the
United States Environmental
Protection Agency (EPA).
F o r s e rvi c e o r re p a i rs to b o i le r, c a ll yo ur he a ti ng c o ntra c to r. W he n s e e k i ng i nfo rma ti o n o n
b o i le r, p r o vi d e B o i le r Mo d e l Num b e r a nd S e ri a l Numb e r a s s ho wn o n Ra ti ng L a b e l.
B o i le r Mo d e l Numb e r
B o i le r S e ri a l Numb e r
Ins ta lla ti o n D a te
CL
He a ti ng C o ntr a c to r
P ho ne Numb e r
A d d re s s
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.
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.
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 flammable vapors or liquids in the vicinity of this or any other
appliance.
WARNING
This boiler is suitable for installation on combustible flooring. 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 flammable debris, rags, paper,
wood scraps, etc., should be kept clear of the boiler at all times. Keep the boiler area clean and free of
fire 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 flue
must be inspected and cleaned before the start of the heating season for any obstructions. A clean and
unobstructed chimney flue is necessary to allow noxious fumes that could cause injury or loss of life to
vent safely and will contribute toward maintaining the boiler's efficiency.
Inspect flueways at least once a year - preferably at the start of the heating season. The inside of
the combustion chamber, the vent system and boiler flueways 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 firing 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 flow regulator and automatic mixing valve must be installed properly
in tankless heater piping. See Piping and Trim Sections of the manual for details.
Table of Contents
I. General Information..................................... 4
III. Indirect Water Heater Piping..................... 23
Trouble Shooting
Carlin 40200.............................................. 36
Riello 40 Series........................................ 36
IV. Operating & Service Instructions............. 24
VII. Repair Parts..............................................37
V. Maintenance and Service Instructions..... 30
III. Appendix
V
Low Water Cut Off...................................45
II. Installation Instructions............................... 8
VI. Boiler Cleaning........................................... 34
Burner Specifications.............................46
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 filed 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 final 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.
2. FOR BASEMENT INSTALLATION, provide a
solid base, such as a concrete pad, if floor is not
level, or if water may be encountered on floor
around boiler.
3. PROVIDE SERVICE CLEARANCE of at least 24”
on top of boiler for cleaning flueways. 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.
Figure 1A: CL3 Thru CL5 Water Boiler Less Tankless Heater
Figure 1B: CL3 Thru CL5 Water Boiler With Tankless Heater
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
Dimensions
"A"
"B"
"C"
Minimum Chimney Size
Rectangular
Round
Approx. Water
Content - Gallons
Heat Transfer Surface
Area - Sq. Ft.
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
table 2: rating data
Burner
Capacity
Boiler Model
No. *
DOE Heating
Capacity
GPH MBH
CL3-091(W)
0.65
91
Minimum Chimney
Requirements
I=B=R NET Ratings
AFUE %
Water
MBH
Steam
MBH
Water
MBH
Steam
MBH
Steam
Sq. Ft.
Round
In. Dia.
Rectangle
In. x In.
Height
Ft.
80
---
70
---
---
6
8x8
15
Water Steam
86.0
---
CL3-091(S)
0.65
91
---
78
---
56
233
6
8x8
15
---
84.1
CL3-105(W)
0.75
105
91
---
79
---
---
6
8x8
15
85.1
---
CL3-105(S)
0.75
105
---
90
---
68
283
6
8x8
15
---
83.8
CL3-140(W)
1.00
140
120
---
104
---
---
6
8x8
15
83.6
---
CL3-140(S)
1.00
140
---
119
---
89
370
6
8x8
15
---
82.7
CL4-126(W)
0.90
126
111
---
97
---
---
7
8x8
15
85.8
---
CL4-126(S)
0.90
126
---
108
---
81
338
7
8x8
15
---
84.1
CL4-175(W)
1.25
175
152
---
132
---
---
7
8x8
15
84.2
---
CL4-175(S)
1.25
175
---
149
---
112
467
7
8x8
15
---
83.5
CL4-210(W)
1.50
210
179
---
156
---
---
7
8x8
15
83.1
---
CL4-210(S)
1.50
210
---
177
---
133
554
7
8x8
15
---
82.6
CL5-168(W)
1.20
168
147
---
128
---
---
8
8x8
15
85.7
---
CL5-168(S)
1.20
168
---
144
---
108
450
8
8x8
15
---
83.7
CL5-245(W)
1.75
245
210
---
183
---
---
8
8x8
15
83.0
---
CL5-245(S)
1.75
245
---
207
---
155
646
8
8x8
15
---
82.5
CL5-280(W)
2.00
280
238
---
207
---
---
8
8x8
15
82.5
---
CL5-280(S)
2.00
280
---
235
---
176
733
8
8x8
15
---
82.3
* Boiler Model Suffix: (W) = Water, (S) = Steam
Figure 2: Minimum Installation Clearances To Combustible Materials (Inches)
C
A
Above
B
Front
Chimney
Connector
D
Rear
E
Sides
6
24
18
6
6
NOTE 1: Listed clearances comply with American National
Standard NFPA 31, Standard for the Installation of Oil Burning Equipment.
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. 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.
3. Using hand truck or pipe rollers under skid, move
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.
1. PACKAGED CL™ Series boilers are shipped with
the highest input oil nozzle installed in the burner.
Oil nozzles for lower firing 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 efficiency. However, boiler output
will be reduced. Refer to Table 2 for firing rates.
If the higher rate is desired, inspect the installed
nozzle and assure that the nozzle is the correct size
and type as specified in Tables 9 and 9A of this
manual.
If a lower input is desired, remove the nozzle
which was factory installed. Locate the lower firing
rate nozzle that is supplied loose. Confirm the
nozzle is the proper size and type for the lower firing
rate as specified 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 firing 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.
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 floor. 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 flashlight to inspect target wall secured to
rear section with silastic sealant. Inspect ceramic
fiber blanket secured to floor 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).
d. If high firing rate is desired, confirm 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 nozzle
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 firing rate baffle is required.
Baffle is shipped loose with nozzles. Install
baffle per Beckett Instruction included with
baffle.
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.
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.
check the settings and to change the nozzle to a
lower firing rate:
a. Installation/Removal of Drawer Assembly,
refer to Figure 4.
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 firing
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 firing rate is desired, confirm 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 flame
retention head and then remove the nozzle that
was factory installed.
f. 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.
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 firing rate, refer to Table 9, and
tighten retaining nut.
i. Readjust air band to preliminary setting that
corresponds to the lower firing 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.
4. On the Riello 40 Series Oil Burner, use the
following procedure to complete the inspection,
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).
ii. Remove existing nozzle from nozzle adapter.
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.
iii. Insert the proper NOZZLE into NOZZLE
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 Assembly into Combustion
Head per Step 4a above.
e. Insertion Depth, verify the distance between
the tip of the end cone is equal to the distance
specified in Table 9A.
f. Turbulator Setting, refer to Figure 7.
h. Replace Burner Cover and Tighten Burner
Cover Screws.
F. INSTALL WATER BOILER TRIM AND CONTROLS,
(see Figures 1A and 1B)
Figure 7: Turbulator Setting
g. Pump Connections and Port Identification,
refer to Figure 8.
1. Install return piping supplied with boiler. Apply
Teflon 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.
Figure 8: Pump Connections and Port Identification
10
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 field 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 field 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
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
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.
a. Connect the field wiring to the pressure limit,
the R8239C Control Center, the LWCO and
the burner primary control. If equipped with
tankless heater, connect field 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.
Figure 11: Recommended Boiler Piping For Gravity Return Steam Boiler
12
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 flow 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.
i.
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 fittings.
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 flow control valves to prevent
gravity circulation of boiler water during the
operation of the cooling system.
iii. Oxygen permeable materials in the
distribution system.
b. In order to insure long product life, oxygen
sources should be eliminated. This can be
accomplished by taking the following measures:
i. Repairing system leaks to eliminate the need
for addition of make-up water.
ii. Eliminating open tanks from the system.
iii. Eliminating and/or repairing fittings 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.
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.
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.
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 fixtures. 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
Rating (Gal/Min)
Pressure Drop
(PSI)
Steam
Water
Steam
Water
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
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.
4. HARD WATER — A water analysis is necessary to
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 beneficial to the
tankless heater but to piping and fixtures plus the
many other benefits derived from soft water.
J. INSTALL SMOKEPIPE — The CL Series boiler
THE FOLLOWING GUIDELINES SHOULD BE FOLLOWED WHEN PIPING THE TANKLESS HEATER:
1. FLOW REGULATION — If flow through the heater
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 flow regulator matching the heater
rating should be installed in the cold water line to
the heater. The flow 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
flow regulator also limits the flow of supply water
regardless of inlet pressure variations in the range of
20 to 125 psi.
2. TEMPERING OF HOT WATER — Installation
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 fixtures. In
14
should be vented into a fireclay 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 sufficient 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 efficiency
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 fired or an inefficient oil fired boiler built into
a home without insulation or storm windows. With
increasing fuel prices that home probably has been
insulated and fitted 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 efficiency 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 firing rate, reduced firing 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 fired 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 firing at 13.0% CO2. Outside wall
chimneys take longer to heat up and can have .00"
W.C. draft at burner startup. You may have to
consider a special alloy chimney flue liner with
insulation around 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
fittings are recommended. Do not use compression
fittings.
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
Lift "H"
(See Figure)
16
Maximum Length of Tubing
"H" + "R" (See Figure)
3/8" OD
Tubing (3 GPH)
1/2" OD
Tubing (3 GPH)
0'
84'
100'
1'
78'
100'
2'
73'
100'
3'
68'
100'
4'
63'
100'
Figure 16
table 5: two-stage units (3450 rpm)
two-pipe systems
Lift "H"
(See Figure)
Maximum Length of Tubing
"H" + "R" (See Figure)
3/8" OD
Tubing (3 GPH)
1/2" OD
Tubing (3 GPH)
5'
57'
100'
0'
93'
100'
6'
52'
100'
2'
85'
100'
7'
47'
100'
4'
77'
100'
8'
42'
100'
6'
69'
100'
9'
36'
100'
8'
60'
100'
10'
31'
100'
10'
52'
100'
11'
26'
100'
12'
44'
100'
12'
21'
83'
14'
36'
100'
13'
---
62'
16'
27'
100'
14'
---
41'
18'
---
76'
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 flame, the burner will continue to operate until the call for heat is satisfied 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
satisfied 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
Figure 17B: Wiring Diagram, Water without Tankless Heater, Riello Burner
18
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 flame the burner will continue to operate until the call for heat is satisfied. 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 satisfied or the setting of
the high limit is reached. If the thermostat is not satisfied when the high limit is reached the burner will stop but the
circulator will continue to operate until the thermostat is satisfied.
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
Figure 18B: Wiring Diagram, Water with Rear Tankless Heater, Riello Burner
20
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 completing 15 second pre-purge cycle. The burner will operate until the thermostat is satisfied 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 fluctuations. The LWCO also has a time delay of 15 seconds which allows additional fill time after water
touches the probe. Red LED indicates a low water condition.
On burner start, if the cad cell does not see flame 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
Figure 19B: Wiring Diagram, Steam with or without Tankless Heater,
Optional McDonnell & Miller PS-801 Probe LWCO, Riello Burner
22
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 flow 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
2. CL SERIES STEAM BOILER - All CL Series steam boilers are equipped with tappings to permit the connect of an
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:
a. Close all but one zone valve.
b. Open drain valve on boiler.
c. Open fill 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 filled with water.
g. Open zone valve to the second zone to be
purged, then close the first. 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 filling the system until the pressure
gauge reads 12 psi. Close fill valve.
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
fixed at 10°F (6°C), and Low Limit Differential has
adjustment range from 10°F (6°C) to 25°F (14°C).
4. ADJUSTING AQUASTAT CONTROLLER
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:
•
•
•
•
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.
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 filled 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 field lubrication. Water lubricated
circulators do not need field lubrication.
HL_ High Limit.
LL_ Low Limit.
Ldf Low Limit Differential.
°F °C.
5. DISPLAY READOUT
In the RUN mode, the Aquastat will flash "bt"
(boiler temp) followed by the temperature (i.e.,
220), followed by °F or °C.
2. Do not over-lubricate. This can cause as much
trouble as no lubrication at all.
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 fixed 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
EEPROM, HL, LL, Hdf, Ldf; reset to default
values. Restore desired settings.
Err8
Repeated B1 fault (voltage present at B1 when
output is turned off); check B1 wiring/voltage.
Figure 23: Display Readout Definitions
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).
Cause / Action
The operating sequence for the L7224/L7248 is
shown in Table 7.
Table 7: L7248/L7224 Controller
Operating Sequence
Action
System Response
Thermostat
calls for heat.
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.
Boiler
exceeds the
High Limit.
Burner is turned off. Burner restarts when
the water temperature drops below the
High Limit setting minus the Differential.
Thermostat is
satisfied.
Circulator and burner turn off.
Error
condition 1-5.
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.
Error
condition 6.
EnviraCOM communication is not
available.
Error
condition 7.
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.
Error
condition 8.
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.
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.
25
table 8: trouble shooting guide
System Condition
Diagnostic Condition
Check
Action
Boiler is cold, 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.
Boiler starts, check wiring and thermostat.
Boiler is hot, house is
cold.
120 Vac at B1-B2
• If no, replace control.
• If yes, check burner and wiring.
Refer to Err on display.
-----
120 Vac at C1-C2
• 120 Vac at C1-C2, check 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
Display is ON.
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.
• 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.
26
Figure 24: Setpoints and Differentials
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.
Figure 25: "L1" and "V1" Head Electrode
Positioning and Gun Setting (Beckett AFG)
H. START OIL BURNER.
1. Open vent fitting on fuel pump.
2. TURN ‘ON’ BURNER service switch and allow
burner to run until oil flows from vent fitting
in a SOLID stream without air bubbles for
approximately 10 seconds.
Figure 25A: Electrode Settings (Carlin EZ-HP)
G. ADJUST OIL BURNER BEFORE STARTING.
3. Close vent fitting and burner flame should start
immediately after pre-purge is complete. Pre-purge
prevents burner flame 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.
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 firing 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 firing rate.
If the desired firing rate is the lower GPH:
a. replace the factory installed high firing rate
nozzle with one of the loose lower firing 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 specified 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.
Figure 26: Adjusting Fuel Pump Pressure
4. ADJUST OIL PRESSURE for Beckett AFG burners
(shut the burner off).
a. When checking a fuel unit's operating pressure, 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
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 fire 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.
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.
7. CAD CELL LOCATION AND SERVICE
The burner is supplied with a cadmium sulfide flame
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.
(flame present)
1. ADJUST DRAFT REGULATOR for a draft of
-0.02” (water gauge) over the fire 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 flame while the
draft over the fire is -0.02”. Use a smoke tester and
adjust air for minimum smoke (not to exceed #1)
with a minimum of excess air. Make final check
using suitable instrumentation to obtain a CO2 of
11.5 to 12.5% with draft of -0.02” (water gauge)
in fire box. These settings will assure a safe and
efficient operating condition. If the flame appears
stringy instead of a solid fire, try another nozzle of
the same type. Flame should be solid and compact.
After all adjustments are made recheck for a draft of
-0.02” over the fire.
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
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.
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.
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.
1. CHECK THERMOSTAT OPERATION. Raise and
lower thermostat setting as required to start and stop
burner.
2. VERIFY PRIMARY CONTROL SAFETY
FEATURES using procedures outlined in
Instructions furnished with control or instructions as
follows:
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 refill to normal water line.
Burner should automatically restart during fill.
Lower thermostat setting.
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.
REMOVE JUMPER.
5. CHECK OPERATING CONTROL on boiler
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 CUTOFF DEVICES
WARNING
Probe and float 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.
2. It is important to physically remove the probe from
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.
30
h. Clean the pipe threads of the probe to remove
old, hardened pipe dope and other foreign matter.
i. Apply a moderate amount of good quality pipe
dope to the pipe threads on the probe, leaving the
two end threads bare. Do not use PTFE (Teflon)
tape.
j. Screw the probe into the boiler tapping.
k. Mount the low water cut-off control on the
probe.
l. Reconnect the control to probe wiring.
m. Fill the boiler to its normal 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.
NOTICE
Check with local authorities or consult local
water treatment services for acceptable chemical
cleaning compounds.
iii. Start burner and operate sufficiently to boil
the water without producing steam pressure.
Boil for about 5 hours. Open boiler feed
pipe sufficiently to permit a steady trickle
of water from the surface blow-off pipe.
Continue this slow boiling and trickle of
overflow for several hours until the water
coming from the overflow is clear.
iv. Stop burner and drain boiler in a manner
and to a location that hot water can be
discharged with safety.
v. Refill boiler to normal water line. If water
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
qualified 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 floor
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, flowing from drain hose at about
180°F. Continue until water runs clear from
drain hose for at least 30 minutes.
iv. Stop feeding water to boiler but continue
operating oil burner until excess water in
boiler flows out through supply main and
water lowers (by steaming) until it 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 sufficiently
(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 fitting 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
refilling 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 flow 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
refilled 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
specific 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 specified 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 firing 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 firing 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. Refill the system with fresh water.
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.
CL3
0.3
4
CL4
0.4
5
CL5
0.5
6
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 flame
shape and efficient 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 fire hazard.
3. EXCESSIVE MAKE-UP WATER
32
Gallons Per
Year
C. HINTS ON COMBUSTION
d. Make pH or Alkalinity Test.
After boiler and system have been cleaned and
refilled 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
specific 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 specified range.
e. Boiler is now ready to be put into service.
A leaky system will increase the volume of make-up
water supplied to the boiler, which can significantly
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
Gallons Per
Month
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.
c. Add appropriate boiler water treatment
compounds as recommended by your qualified
water treatment company.
Model No.
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 fire 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
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 fitting.
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 fittings put on. Just make sure you get the air
out before you leave.
Any air leaks in the fuel line will cause an unstable
flame and may cause delayed ignition noises. Use only
flare fittings in the fuel lines.
10. START-UP NOISE — Late ignition is the cause of
start-up noises. If it occurs recheck for electrode
settings, flame shape, air or water 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 firing rate the greater effect an air leak
can have on CO2 readings.
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,
fire out of an auxiliary five 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.
5. DIRT — A fuel filter 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
firing rate, the smaller the slots become in the nozzle
and the more prone to plugging it becomes with the
same amount of dirt.
6. WATER — Water in the fuel in large amounts will
stall the fuel pump. Water in the fuel in smaller
amounts will cause excessive wear on the pump,
but more importantly water doesn’t burn. It chills
the flame and causes smoke and unburned fuel to
pass out of the combustion chamber and clog the
flueways 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 flame 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 flame
should appear straight with no sparklers rolling up
toward the crown of the chamber. If the flame 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.
11. SHUT DOWN NOISE — If the flame 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 firing
cycles for that air to be fully vented through the
nozzle. Water in the fuel or poor flame shape can also
cause shut down noises.
NOTICE
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 sufficient
water to fill 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, flush out boiler, and refill 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 fibre bristle brush
(30” handle) clean the flueways. 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 fibre 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.
34
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 flueways. 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 flue 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 flue 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 efficiency.
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
3. Control locks out after Trial For Ignition (TFI).
Also refer to Model EZ-1/2/3 Oil Burner - Instruction
Manual (Form #MNEZ123) for additional information.
a. No oil to burner.
1. Burner (control) will not come on.
c. Nozzle clogged.
b. Shorted electrodes.
a. No power to control.
d. Airflow too high.
b. Control is in lockout. Press reset button for one
(1) second.
e. Ignitor module defective.
c. CAD cell seeing light.
f. CAD cell defective.
g. Oil valve stuck open or closed.
d. CAD assembly defective.
Note: The Safety Monitoring Circuit (SMC) is
designed to provide lockout in the event of a
stuck or welded motor relay.
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.
a. CAD cell is defective.
NOTICE
If flame 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.
b. Air leaking into oil line causing flame out.
c. Defective nozzle causing flame to be erratic.
d. Excessive airflow or draft causing flame to be
erratic.
e. Excessive back pressure causing flame to be
erratic.
Latch-up will occur if the control locks-out
three (3) times during a call for heat. This is
indicated by red and amber LED's solid-on.
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: (413) 525-7700
Facsimile: (413) 525-8306
TROUBLE SHOOTING RIELLO 40 SERIES
36
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.
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, Hatfield, PA 19440-0010, Phone:
(215) 855-8055 Attn: Customer Service Department
37
38
Bare Boiler Assembly (Exploded View)
Item
Description
No.
Boiler Size / Quantity
Part No.
CL3
CL4
CL5
Front Section (Non-Htr.), Machined Water
---(OR)--Front Section (Non-Htr.), Machined Steam
1
1
1
Center Section
1
Bare Boiler Assembly
1
2
3
Rear Section (Non-Htr.), Machined Water
---(OR)--Rear Section (Non-Htr.), Machined Steam
Rear Heater Section, Machined Water
---(OR)--Rear Heater Section, Machined Steam
71720103
71720104
2
3
71720301
71720201
71720202
1
1
1
71720203
71720204
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
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
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
7
10
19
Canopy Sealing Strip (1/2" x 1 x 10')
1
1
1
6206001
Canopy Assembly - 3 Section
1
---
---
100827-03
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
28
3/8"-16 x 7/8" Lg. Cap Screw, Plated, ASME Grade
SA307B
8
8
8
80861337
20
39
Jacket Assembly (Exploded View)
Item
No.
Boiler Size / Quantity
Description
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
---
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
1
1
100823-01
1
---
---
100822-03
---
1
---
100822-04
---
---
1
100822-05
Non-Heater Build
3
Jacket Reversible Side
Panel Assembly
With Heater Build
4
Jacket Left Side Heater Panel Assembly
(with Heater Build)
5
Jacket Split Front Top Panel Assembly
6
40
Jacket Split Rear Top Panel Assembly
CL3 Thru CL5 Water Boilers - Trim and Controls
Item
No.
Description
Boiler Size / Quantity
CL3
CL4
CL5
Part No.
CL3 Thru CL5 Water Boilers - Trim and Controls
1
Beckett R7184B Oil Primary Control
1
1
1
100136-01
2
Honeywell L7248C1014 Hi Limit, Circ. Relay
--- (OR)--L7224C1004 Hi & Lo Limit, Circ. Relay
1
1
1
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
100059-01
100862-01
41
CL3 Thru CL5 Steam Boilers - Trim and Controls
Item
Description
No.
Boiler Size / Quantity
CL3
CL4
CL5
Part No.
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
42
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
Beckett AFG Burner
R. W. BECKETT CORP.
P.O. BOX 1289
ELYRIA, OHIO 44036
1-800-645-2876
FOR REPLACEMENT OIL BURNER PARTS, CONTACT
YOUR WHOLESALER OR THE BURNER MANUFACTURER:
BECKETT OIL BURNER PARTS LIST
MODEL AFG --- 60-Hz, 3450 RPM
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
Air Tube Combination
CL3-091, 105, 140
AFG70MBAS
Beckett's Spec No.
Air Band
CL4-126
CL4-175, 210
CL5-168, 245
CL5-280
AFG70MBAS AFG70MDAS
AFG70MDAS
AFG70MLAS
NY2701
NY2702
NY2703
NY2704
NY2705
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 Baffle
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
----
----
----
----
----
5941
5941
5941
Head
Adjusting Plate Assembly
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
21805
21805
21805
21805
21805
Motor
Nozzle Adapter
Nozzle Line Electrode Assembly
Oil Pump, Clean Cut (Single Stage)
Oil Pump, Clean Cut (Two Stage)
Static Plate
Ignitor
2-13
2-13
2-13
2-13
2-13
NL70MB
NL70MB
NL70MD
NL70MD
NL70ML
2184404U
2184404U
2184404U
2184404U
2184404U
21941U
21941U
21941U
21941U
21941U
3384
3384
3384
3384
Less
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 firing 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 specifically identified 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 floor level as the boiler). In
addition, some jurisdictions require the use of a LWCO
with a hot water boiler.
manufacturers recommend an annual inspection of the
probe.
How to Wire
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 float type, due to their
relative costs and the simplicity of piping for a probe
LWCO.
LWCO’s are available in either 120 VAC or 24 VAC
configurations. The 120 VAC configuration 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.
How to Pipe
A “tee” is commonly used to connect the probe LWCO
to the supply or return piping, as shown below.
Wiring of Typical LWCO
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
A 24 VAC LWCO is used primarily for gas fired
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 filling the system.
The boiler should attempt to operate once the water
level is above the LWCO.
45
Table 9: Burner Specifications
Beckett AFG
Firing Rate
Boiler Model
GPH
1
p
l
Settings
Head
Air
(Setting) Shutter
Nozzle
Air
Band
GPH x Angle Type
3
2
Shipped
Pump
Pressure
CL3-091
0.65
L1
8
0
0.55 x 70B (Delavan)
p
Loose
140
CL3-105
0.75
L1
6
0
0.65 x 45B (Hago)
p
Loose
140
CL3-140
1.00
L1
10
1
0.85 x 45B (Hago)
Installed
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)
Loose
175
CL4-210
1.50
V1(0)
10
2
1.10 x 45B (Hago)
Installed
175
CL5-168
1.20
V1(2)
10
0
0.90 x 45B (Hago)
Loose
175
CL5-245
1.75
V1(3)
7
3
1.35 x 45B (Hago)
Installed
175
CL5-280
2.00
V1(4)
10
3
1.50 x 45B (Hago)
Installed
175
l
Carlin Burner
Firing Rate
Boiler Model
GPH
p
Burner
Model
Settings
Nozzle
3
Head
Bar
Air
Band
GPH x Angle Type
2
Shipped
Pump
Pressure
CL3-091
0.65
0.50
0.55
0.55 x 70B (Delavan)
p
Loose
150
CL3-105
0.75
0.60/0.65
0.60
0.60 x 60ES (Hago)
p
Loose
150
CL3-140
1.00
0.85/1.00
0.75
0.85 x 60B (Hago)
Installed
150
CL4-126
0.90
0.75
0.75
0.75 x 60A (Delavan)
Loose
150
CL4-175
1.25
0.85/1.00 1.00-1.10
1.00 x 60A (Delavan)
Loose
150
CL4-210
1.50
1.10/1.25 1.25-1.35
1.25 x 60B (Hago)
Installed
150
CL5-168
1.20
0.85/1.00
0.90
1.00 x 60B (Hago)
Installed
150
CL5-245
1.75
1.50
1.75
1.50 x 60A (Delavan)
Installed
150
EZ-1HP
EZ-2HP
1
Beckett low firing rate baffle required on CL3-091 (0.65 GPH) application only; shipped loose with nozzle.
2
Nozzle(s) for alternate boiler model firing rate(s) are shipped loose in bag attached 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.
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 Canada Inc.
2165 Meadowpine Blvd.
Mississauga, Ontario L5N 6H6
Telephone: (905) 542-0303
Facsimile: (905) 542-1525
Toll Free: (800) 387-3898
Riello Corporation of America
35 Pond Park Road
Hingham, Massachusetts 02043
Telephone: (617) 749-8292
Facsimile: (617) 740-2069
Toll Free: (outside Massachusetts)
(800) 992-7637
Table 9A: Riello Burner Specifications
Boiler
Model
Firing
Rate
GPM
CL3-105
0.75
Settings
Burner
Model Air Shutter Turbulator
1.00
CL4-175
1.25
CL4-210
1.50
CL5-245
1.75
40F5
40F10
2.00
Shipped
0
0.60 x 60A
(Delavan)
Loose
2.85
2
0.85 x 60W
(Delavan)
Installed
4
4
1.00 x 60A
(Delavan)
Installed
Pump
Pressure
Combustion
Head
Insertion
Depth
SBT 6.0”
2-3/8”
SBT 6.0”
2-3/8”
SBT 5.0”
2-1/2”
SBT 5.0”
2-1/2”
150
3
1
1.25 x 60B
(Delavan)
Installed
3
1.5
1.35 x 45B
(Delavan)
Loose
3.8
2
1.65 x 45B
(Delavan)
Installed
40F10
CL5-280
GPH x Angle
Type
2.60
40F5
CL3-140
Nozzle
47
SERVICE RECORD
DATE
48
SERVICE PERFORMED
SERVICE RECORD
DATE
SERVICE PERFORMED
49
SERVICE RECORD
DATE
50
SERVICE PERFORMED
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’s
Installation, Operating and Service Instructions and hydronics industry
standards.
5. Improper Operation These warranties will not be applicable if the boiler
has been damaged as a result of being improperly serviced or operated,
including but not limited to the following: operated with insufficient water;
allowed to freeze; subjected to flood conditions; or operated with water
conditions and/or fuels or additives which cause unusual 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 dwelling.
This warranty does not apply to boilers installed in apartments 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 Yorker
shall have no express obligations, responsibilities or liabilities of any kind,
other than those set forth herein.
ALL APPLICABLE IMPLIED WARRANTIES, IF ANY, INCLUDING
ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A
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 an
implied warranty lasts, so the above limitation may not apply to you.
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 consumer
purchaser should write to New Yorker Boiler Co., Inc. at P.O. Box 10,
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 ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO
STATE.
02/04
52
Source Exif Data:
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