Energy Tech Laboratories New Yorker Cl Series Users Manual

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INSTALLATION, OPERATING

AND SERVICE INSTRUCTIONS

CL™ SERIES

CAST IRON OIL-FIRED BOILER

100825-01R5-10/08 Price - $3.00

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As an

ENERGY

STAR® Partner,

New Yorker Boiler Co., Inc.

has determined that the

CL3-091, CL3-105, CL4-126

and CL5-168 water boilers

meet the ENERGY STAR®

guidelines for Energy

efciency established by the

United States Environmental

Protection Agency (EPA).

2

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 ammable vapors or liquids in the vicinity of this or any other

appliance.

3

WARNING

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

Installation is not complete unless a pressure relief valve is installed into the tapping located on top left

corner of rear section - See Piping and Trim Sections of this manual for details.

This boiler is designed to burn No. 2 fuel oil only. Do not use gasoline, crankcase drainings, or any oil

containing gasoline. Never burn garbage or paper in this boiler. Do not convert to any solid fuel (i.e.

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

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

re hazards.

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

combustion and ventilation air.

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

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

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

unobstructed chimney ue is necessary to allow noxious fumes that could cause injury or loss of life to

vent safely and will contribute toward maintaining the boiler's efciency.

Inspect ueways at least once a year - preferably at the start of the heating season. The inside of

the combustion chamber, the vent system and boiler ueways should be cleaned if soot or scale has

accumulated.

When cleaning this boiler, do not damage combustion chamber liner and/or rear target wall. If damaged,

combustion chamber insulation must be replaced immediately.

This boiler requires regular maintenance and service to operate safely. Follow the instructions contained

in this manual. Installation, maintenance, and service must be performed only by an experienced, skilled

and knowledgeable installer or service agency.

It is the responsibility of the installing contractor to see that all controls are correctly installed and

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

controls.

Do not operate unit if any control, switch, component, or device has been subject to water. When cleaning

this boiler, do not damage combustion chamber liner and/or rear target wall. If damaged, combustion

chamber insulation must be replaced immediately.

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

All boilers equipped with burner swing door have a potential hazard which if ignored can cause severe

property damage, personal injury or loss of life. Before opening swing door, turn off service switch to

boiler to prevent accidental ring of burner outside the combustion chamber. Be sure to tighten swing

door fastener completely when service is completed.

Appliance materials of construction, products of combustion and the fuel contain alumina, silica, heavy

metals, carbon monoxide, nitrogen oxides, aldehydes and/or other toxic or harmful substances which

can cause death or serious injury and which are known to the state of California to cause cancer, birth

defects and other reproductive harm. Always use proper safety clothing, respirators and equipment when

servicing or working nearby the appliance.

High water temperatures increase the risk of scalding injury. If this boiler is equipped with a tankless

heater for domestic water supply, a ow regulator and automatic mixing valve must be installed properly

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

4

I. General Information

A. INSPECT SHIPMENT carefully for any signs of

damage.

1. ALL EQUIPMENT is carefully manufactured,

inspected and packed. Our responsibility ceases

upon delivery of crated boiler to the carrier in good

condition.

2. ANY CLAIMS for damage or shortage in shipment

must be led immediately against the carrier by

the consignee. No claims for variances from,

or shortage in orders, will be allowed by the

manufacturer unless presented within sixty (60)

days after receipt of goods.

B. LOCATE BOILER in front of nal position before

removing crate. See Figures 1A thru 1D.

1. LOCATE so that smoke pipe connection

to chimney will be short and direct. BOILER

IS SUITABLE FOR INSTALLATION ON

COMBUSTIBLE FLOOR. Boiler cannot be

installed on carpeting.

2. FOR BASEMENT INSTALLATION, provide a

solid base, such as a concrete pad, if oor is not

level, or if water may be encountered on oor

around boiler.

3. PROVIDE SERVICE CLEARANCE of at least 24”

on top of boiler for cleaning ueways. Provide at

least 24" on right side of boiler for removal of rear

tankless heater. Provide at least 24” clearance from

front jacket panel for servicing.

4. For minimum clearances to combustible materials.

See Figure 2.

C. PROVIDE AIR SUPPLY AND VENTILATION to

accommodate proper combustion. If natural ventilation

is inadequate, provide a screened opening or duct from

the boiler room to the outside. The opening or duct

must be sized so the boiler input will not exceed 4,000

BTUH/Sq. In. of free area. If other air consuming

appliances are near the boiler, the air inlet should be

larger. Consult respective manufacturers.

Table of Contents

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

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

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

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

V. Maintenance and Service Instructions. ...30

VI. Boiler Cleaning ..........................................34

Trouble Shooting

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

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

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

VIII. Appendix

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

Burner Specications ............................46

5

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

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

6

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

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

Boiler

Model

Dimensions Minimum Chimney Size Approx. Water

Content - Gallons Heat Transfer Surface

Area - Sq. Ft.

"A" "B" "C" Rectangular Round

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

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

7

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

TABLE 2: RATING DATA

NOTE 1: Listed clearances comply with American National

Standard NFPA 31, Standard for the Installation of Oil Burn-

ing 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 installa-

tions.

NOTE 3: For reduced clearances to combustible material,

protection must be provided as described in the ANSI/NFPA

31 standard.

C

A

Above B

Front Chimney

Connector D

Rear E

Sides

6 24 18 6 6

Boiler Model

No. *

Burner

Capacity DOE Heating

Capacity I=B=R NET Ratings Minimum Chimney

Requirements AFUE %

GPH MBH Water

MBH Steam

MBH Water

MBH Steam

MBH Steam

Sq. Ft. Round

In. Dia. Rectangle

In. x In. Height

Ft. Water Steam

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

CL3-091(S) 0.65 91 --- 78 --- 56 233 6 8 x 8 15 --- 84.1

CL3-105(W) 0.75 105 91 --- 79 --- --- 6 8 x 8 15 85.1 ---

CL3-105(S) 0.75 105 --- 90 --- 68 283 6 8 x 8 15 --- 83.8

CL3-140(W) 1.00 140 120 --- 104 --- --- 6 8 x 8 15 83.6 ---

CL3-140(S) 1.00 140 --- 119 --- 89 370 6 8 x 8 15 --- 82.7

CL4-126(W) 0.90 126 111 --- 97 --- --- 7 8 x 8 15 85.8 ---

CL4-126(S) 0.90 126 --- 108 --- 81 338 7 8 x 8 15 --- 84.1

CL4-175(W) 1.25 175 152 --- 132 --- --- 7 8 x 8 15 84.2 ---

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

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

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

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

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

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

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

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

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

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

8

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 ring rates are shipped

loose for the CL3 through CL5 models, attached

to the burner. Select the proper oil nozzle for the

installation. The lower input nozzle will provide

greater boiler efciency. However, boiler output

will be reduced. Refer to Table 2 for ring rates.

If the higher rate is desired, inspect the installed

nozzle and assure that the nozzle is the correct size

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

manual.

If a lower input is desired, remove the nozzle

which was factory installed. Locate the lower ring

rate nozzle that is supplied loose. Conrm the

nozzle is the proper size and type for the lower ring

rate as specied in Tables 9 and 9A of this manual.

Install the proper nozzle in the burner nozzle

adaptor.

2. On the Beckett AFG Burner, use the following

procedure to complete the inspection, check the settings

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

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

tabs and swing open igniter about hinge.

b. Loosen knurled nut and disconnect copper

connector tube.

c. Remove nozzle line electrode assembly.

d. If high ring rate is desired, conrm the nozzle

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

proceed to Item i. below.

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 ring rate bafe is required.

Bafe is shipped loose with nozzles. Install

bafe per Beckett Instruction included with

bafe.

h. Reinstall Beckett MD(V1) or MB(L1) Head.

i. Inspect and measure burner electrodes. Refer

to Figure 25 for the proper electrode setting.

Readjust electrode setting to the proper

dimensions if necessary. Refer to Figure 25.

j. Reinstall nozzle line electrode assembly.

k. Connect copper connector tube.

2. Tilt boiler to right and to rear. Using right rear leg

as pivot, rotate boiler 90° in a clockwise direction,

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

and remove crate skid. Care should be exercised to

prevent damage to jacket or burner.

C. MOVE BOILER TO PERMANENT POSITION by

sliding or walking.

D. INSPECT COMBUSTION TARGET WALL AND

COMBUSTION CHAMBER LINER

1. OPEN FLAME OBSERVATION DOOR AND/

OR BURNER SWING DOOR on front of boiler.

Use ashlight to inspect target wall secured to

rear section with silastic sealant. Inspect ceramic

ber blanket secured to oor of boiler with water

glass adhesive. If either is damaged they must be

replaced.

E. INSPECT NOZZLE, ELECTRODES INSERTION

DEPTH AND TURBULATOR SETTING/CHANGE

FIRING RATE: Refer also to Model F3 & F5

Installation Manual, Riello 40 Series Residential Oil

Burners (C6501010) or Model F10 Installation Manual,

Riello 40 Series Residential Oil Burners (2902554).

Figure 3: Removal of Boiler From Skid

9

l. Inspect Beckett head setting on left side of

burner by insuring the blue line MD(V1) or the

line on the label MB(L1) are aligned, readjust if

necessary.

m. Tighten knurled nut.

n. Swing igniter closed, rotate tabs and tighten two

(2) igniter screws.

o. Replace burner cover and tighten burner cover

knobs.

3. On the Carlin EZ-PH Burner, use the following

procedure to complete the inspection, check the

settings and to change the nozzle to a lower ring

rate:

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

tabs and swing open igniter about hinge.

b. Loosen knurled nut and disconnect copper

connector tube.

c. Remove nozzle line electrode assembly from

burner.

d. If high ring rate is desired, conrm the nozzle

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

proceed to Item i. below.

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

retention head and then remove the nozzle that

was factory installed.

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 ring rate, refer to Table 9, and

tighten retaining nut.

i. Readjust air band to preliminary setting that

corresponds to the lower ring rate nozzle

installed, refer to Table 9.

j. Inspect and measure burner electrodes. Refer

to Figure 25A for proper electrode setting.

Readjust electrode setting to the proper

dimensions if necessary.

k. Reinstall nozzle line electrode assembly.

l. Reconnect copper connector tube.

m. Tighten knurled nut.

n. Close igniter, rotate and tighten two (2) igniter

latching screws.

4. On the Riello 40 Series Oil Burner, use the

following procedure to complete the inspection,

check the settings and to change the nozzle to a

lower ring rate:

a. Installation/Removal of Drawer Assembly,

refer to Figure 4.

Figure 4: Installation/Removal of Drawer Assembly

i. Removal:

• Disconnect oil delivery tube nut from

pump.

• Loosen SCREW (3), and then unplug

PRIMARY CONTROL (1) by carefully

pulling it back and then up.

• Remove the AIR TUBE COVER

PLATE (5) by loosening the retaining

SCREW (4) (Two SCREWS-Model F5).

• Loosen SCREW (2), and then slide the

complete drawer assembly out of the

combustion head as shown.

ii. Installation:

To insert drawer assembly, reverse the

procedure in Step i above.

b. Nozzle Replacement, refer to Figure 5.

Figure 5: Nozzle Replacement

i. Remove the NOZZLE ADAPTER (2) from

the DRAWER ASSEMBLY by loosening the

SCREW (1).

10

ii. Remove existing nozzle from nozzle adapter.

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

specied in Table 9A.

f. Turbulator Setting, refer to Figure 7.

Figure 7: Turbulator Setting

g. Pump Connections and Port Identication,

refer to Figure 8.

Figure 8: Pump Connections and Port Identication

This burner is shipped with the oil pump set

to operate on a single line system. To operate

on a two-line system the bypass plug must be

installed.

WARNING: Do not operate a single line

system with the by-pass plug installed.

Operating a single line system with the by-pass

plug installed will result in damage to the pump

shaft seal.

NOTE: Pump pressure was factory pre-set but

must be checked at time of burner start-up. A

pressure gauge is attached to the PRESSURE/

BLEEDER PORT (7) for pressure readings.

Two PIPE CONNECTORS (4) are supplied

with the burner for connection to either a single

or two-line system. Also supplied are two

ADAPTORS (3), two female ¼” NPT to adapt

oil lines to burner pipe connectors. All pump

port threads are British Parallel Thread design.

Direct connection of NPT threads to the pump

will damage the pump body.

Riello manometers and vacuum gauges do not

require any adapters, and can be safely connected

to the pump ports. An NPT x metric adapter

must be used when connecting other gauge

models.

h. Replace Burner Cover and Tighten Burner

Cover Screws.

F. INSTALL WATER BOILER TRIM AND CONTROLS,

(see Figures 1A and 1B)

1. Install return piping supplied with boiler. Apply

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

Thread 1½" NPT x 5" Lg. return nipple into 1½"

NPT tapping located in lower left corner of front

section. Thread 1½" x ¾" x 1½" NPT tee onto

5" nipple. Thread ¾" drain valve into ¾" NPT

connection on tee. Tighten all joints with wrench

until water tight and 1½" NPT return connection on

tee is facing away from boiler horizontally to allow

for proper burner swing door clearance, see Figures

1A, 1B and Figure 9.

11

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

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

control conduit to jacket right side panel with 5/8"

cable clamp provided, refer to Figure 1B.

4. CONNECT FIELD WIRING

a. Water boilers without tankless heater and with

front tankless heater. Connect the eld wiring

from the circulator to the aquastat control and

from the control to the burner. Make the wiring

connections as shown on Figures 16B.

b. Water boilers with rear tankless heater. Connect

the eld wiring from a standard junction box to

the circulator, aquastat control and burner. Make

the wiring connections as shown on Figure 17B.

G. INSTALL STEAM BOILER TRIM AND CONTROLS,

(see Figures 1C and 1D).

1. Thread ¾" MPT safety valve and ¾" NPT coupling

onto factory installed ¾" NPT x 7¼" nipple located

12

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.

Figure 10: Recommended Piping for Combination

Heating & Cooling (Refrigeration) Systems

Figure 11: Recommended Boiler Piping For Gravity Return Steam Boiler

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

in Figure 11.

3. On boilers with rear tankless heater, factory wired

L4006A Aquastat Heater Control was not installed

in heater. Locate ¾" NPT Immersion Well, apply

sealant and thread into ¾" NPT tapping on heater.

Apply heat transfer paste (not furnished) to control

bulb and insert bulb into immersion well. Tighten

clamping screws to secure control to immersion

well. Secure 18/2 Control Cable Wire to jacket right

side panel with 5/16" cable clamp provided, refer to

Figure 1C.

4. CONNECT FIELD WIRING

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

the R8239C Control Center, the LWCO and

the burner primary control. If equipped with

tankless heater, connect eld wiring from the

aquastat control to the R8239C Control Center's

"R-G" terminals. Make the wiring connections

as shown in Figure 19B.

H. CONNECT SUPPLY AND RETURN PIPING TO

HEATING SYSTEM.

1. CLEARANCES — Steam and hot water pipes shall

have clearances of at least ½” from all combustible

construction.

13

i. Assure that all system radiators, piping and

vents are absolutely leak tight.

• When a steam boiler is installed in an

existing system, ALL air vents should be

replaced at the same time. This assures

that the new boiler will not be

compromised by existing system leaks.

• If the system contains hidden supply or

return piping (hidden behind walls, buried

in concrete, etc.) pressure test this piping

to assure there are no leaks.

ii. Repair any leaks in the system.

iii. Install accurate water meter on the fresh

water supply to the boiler.

NOTICE

Do not use softened water in steam boilers.

Accelerated boiler corrosion will result. Tie in

fresh water supply to the boiler upstream of a

water softener.

4. OXYGEN CONTAMINATION:

a. There are many possible causes of oxygen

contamination such as:

i. Addition of excessive make-up water as a

result of system leaks.

ii. Absorption through open tanks and ttings.

iii. Oxygen permeable materials in the

distribution system.

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 ttings which

allow oxygen absorption.

iv. Use of non-permeable materials in the

distribution system.

v. Isolating the boiler from the system water by

installing a heat exchanger.

See Section V, Paragraph B, Step 3 for additional

details.

CAUTION

Oxygen contamination of the boiler water

will cause corrosion of iron and steel boiler

components, and can lead to boiler failure. New

Yorker's Standard Warranty does not cover

problems caused by oxygen contamination of

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

frequent addition of water.

2. WATER BOILER

a. For Forced Circulation HOT WATER HEATING.

See Figure 9. Consult I=B=R Installation and

Piping Guide No. 200.

b. Use a boiler water bypass if the boiler is to be

operated in a system which has a large volume

or excessive radiation where low boiler water

temperature may be encountered (i.e. converted

gravity circulation system, etc.).

Install a pipe tee between the circulator and

boiler return along with a second tee in the

supply piping as shown in Figure 9. The bypass

should be the same size as the supply and return

lines. Locate valves in the bypass and supply

outlet as illustrated in Figure 9 for regulation

of water ow to maintain higher boiler water

temperature.

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

throttle position to start. Operate boiler until the

system water temperature is a normal operating

range.

Adjust the valves to provide 180° to 200°F

supply water temperature. Opening the boiler

supply valves will raise the system temperature,

while opening the bypass valve will lower the

system supply temperature.

c. If this boiler is connected to heating coils located

in air handling units where they may be exposed

to refrigerated air the boiler piping must be

equipped with ow control valves to prevent

gravity circulation of boiler water during the

operation of the cooling system.

d. If this boiler is used in connection with

refrigeration systems, the boiler must be installed

so that the chilled medium is piped in parallel

with the heating boiler using appropriate valves

to prevent the chilled medium from entering

the boiler, see Figure 10. Also consult I=B=R

Installation and Piping Guides.

e. A hot water boiler installed above radiation level

must be provided with a low water cutoff device

as part of the installation. See Section VIII, Low

Water Cut-Off for additional details.

3. STEAM BOILER

a. For Recommended STEAM BOILER PIPING

refer to Figure 11. Also, consult I=B=R

Installation and Piping Guides.

b. Evaluate the Existing Steam System.

The single most important factor in determining

the expected life cycle of a steam boiler, is

the amount of fresh water added to the boiler

during operation. Fresh water brings minerals

and oxygen into the boiler. These contaminants

greatly accelerate corrosion of the cast iron

boiler sections.

14

I. CONNECT TANKLESS HEATER PIPING AS

SHOWN IN Figure 12. See Table 3 for Tankless

Heater Ratings.

addition, savings of hot water will be achieved since

the user will not waste as much hot water while

seeking water temperature to his liking. Higher

temperature hot water required by dishwashers and

automatic washers is possible by piping the hot

water from the heater prior to entering the mixing

valve. The mixing valve should be “trapped” by

installing it below the cold water inlet to heater to

prevent lime formation in the valve.

WARNING

Install automatic mixing valve at tankless heater

outlet to avoid risk of burns or scalding due to

excessively hot water at xtures. Adjust and

maintain the mixing valve in accordance with the

manufacturer's instructions.

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 benecial to the

tankless heater but to piping and xtures plus the

many other benets derived from soft water.

J. INSTALL SMOKEPIPE — The CL Series boiler

should be vented into a reclay tile-lined masonry

chimney or chimney constructed from type L vent or

a factory built chimney that complies with the type

HT requirements of UL103. The chimney and vent

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

safe proper operation of the boiler. See Figure 13 for

recommended installation.

1. Install a draft regulator (supplied by installer)

following the instructions furnished with the

regulator. See Figure 14 for draft regulator locations.

2. Consider the chimney overall. Chimneys that have

a high heat loss may become less suitable as the

heat loss of the home goes down and the efciency

of the boiler installed goes up. Most homes have

a chimney appropriate for the fuel and the era in

which the home was built. That may have been a

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

a home without insulation or storm windows. With

increasing fuel prices that home probably has been

insulated and tted with storm windows so that

Figure 12: Schematic Tankless Heater Piping

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

TABLE 3: TANKLESS HEATER DATA

THE FOLLOWING GUIDELINES SHOULD BE FOL-

LOWED WHEN PIPING THE TANKLESS HEATER:

1. FLOW REGULATION — If ow 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 ow regulator matching the heater

rating should be installed in the cold water line to

the heater. The ow regulator should preferably be

located below the inlet to the heater and a minimum

of 3’ away from the inlet so that the regulator is not

subjected to excess temperatures that may occur

during “off” periods when it is possible for heat

to be conducted back through the supply line. The

ow regulator also limits the ow of supply water

regardless of inlet pressure variations in the range of

20 to 125 psi.

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 xtures. In

15

Figure 13 Recommended Smokepipe Arrangement

and Chimney Requirements

Figure 14: Proper and Improper Locations of Draft Regulator

the heat loss of the home has been reduced. This

requires less fuel to be burned and sends less heat up

the chimney.

A new boiler probably has a higher efciency than

the boiler being replaced. That probably means that

the stack temperature from the new boiler will be

lower than that from the old boiler and with less

room air being drawn up the chimney to dilute the

stack gases. The combination of a large uninsulated

chimney, reduced ring rate, reduced ring time,

lower stack temperature and less dilution air can,

in some cases, contribute to the condensing of

small amounts of water vapor in the chimney. Such

condensation, when it occurs, can cause chimney

deterioration. In extreme cases, condensed water

may be visible on the outside of the breeching or

chimney. In those extreme cases, the chimney may

have to be lined to insulate the chimney and thus

prevent the condensation. The addition of dilution

air into the chimney may assist in drying the

chimney interior surfaces.

A massive chimney on a cold, or exposed outside

wall may have produced adequate draft when it

was red with a higher input and greater volumes

of heated gases. With reduced input and volume,

the draft may be severely affected. In one instance

research showed a new chimney of adequate

sizing produced only .035" W.C. after 30 minutes

of continuous ring at 13.0% CO2. Outside wall

chimneys take longer to heat up and can have .00"

W.C. draft at burner startup. You may have to

consider a special alloy chimney ue liner with

insulation around it and a stabilizing draft cap or

even a draft inducing fan in severe cases.

3. For the same reasons as in 2. above, heat extractors

mounted into the breeching are not recommended.

IMPORTANT

Single-pipe installations must be absolutely

airtight or leaks or loss of prime may result. Bleed

line and fuel unit completely.

16

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 (two-

stage) show allowable lift and lengths of 3/8-inch and

1/2-inch OD tubing for both suction and return lines.

Refer to Figure 16.

Be sure that all oil line connections are absolutely

airtight. Check all connections and joints. Flared

ttings are recommended. Do not use compression

ttings.

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

bleed, slip a 3/16" ID hose over the end of the bleed

valve and bleed into a container. Continue to bleed for

15 seconds after oil is free of air bubbles. Stop burner

and close valve.

Figure 15

Figure 16

Lift "H"

(See Figure)

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'

5' 57' 100'

6' 52' 100'

7' 47' 100'

8' 42' 100'

9' 36' 100'

10' 31' 100'

11' 26' 100'

12' 21' 83'

13' --- 62'

14' --- 41'

TABLE 4: SINGLE 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)

0' 93' 100'

2' 85' 100'

4' 77' 100'

6' 69' 100'

8' 60' 100'

10' 52' 100'

12' 44' 100'

14' 36' 100'

16' 27' 100'

18' --- 76'

TABLE 5: TWO-STAGE UNITS (3450 RPM)

TWO-PIPE SYSTEMS

17

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

Split Controls Less Tankless Heater

SEQUENCE OF OPERATION

A call for heat by the thermostat energizes the L7248C control which in turn energizes the primary control. The burner

will initiate ignition after completing a 15 second pre-purge cycle. If burner ignites within approximately 45 seconds

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

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

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

is closed by a drop in boiler water temperature.

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.

18

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

19

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

Split Controls with Tankless Heater

SEQUENCE OF OPERATION

A call for heat by the thermostat energizes the L7224C control which in turn energizes the primary control. The burner

will initiate ignition after completing a 15 second pre-purge cycle. If burner ignites within approximately 45 seconds

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

operate when the thermostat calls for heat if the boiler water temperature is up to the setting of the low limit in the

L7224C control. If boiler water temperature is below the low limit setting the burner will operate but the circulator will

not, giving preference to the domestic hot water demand.

On call for heat by the thermostat the burner will continue to operate until the thermostat is satised or the setting of

the high limit is reached. If the thermostat is not satised when the high limit is reached the burner will stop but the

circulator will continue to operate until the thermostat is satised.

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

maintain domestic water temperature.

20

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

21

SEQUENCE OF OPERATION

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

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

high limit is reached. When the high limit control restores the circuit on a drop in pressure, the burner will start if the

thermostat is still calling for heat. The low water cut off will shut down the burner if the water level in the boiler drops

too low. The control resets and restarts the burner with a call for heat a few seconds after the water is returned to its

normal level.

The McDonnell Miller low water cut off incorporates a 10 second delay to prevent nuisance burner cut-off due to rapid

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

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

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

safety and must be reset before burner can be restarted.

When there is no demand for heat, the operating control will maintain the boiler water temperature at the selected set-

ting for proper operation of the domestic water heater, if equipped with optional tankless heater.

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

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

22

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

23

III. Indirect Water Heater Piping

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

Indirect Water Heater Instruction Manual for additional installation information.

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

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

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

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

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

additional details.

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

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.

24

IV. Operating and Service Instructions

3. On WATER BOILERS WITH TANKLESS

HEATERS equipped with L7224 electronic aquastat

controller, set operating control (low limit [LL])

at 190°F and high limit (HL) at 210°F. Operating

control (low limit) setting must be a minimum of

20°F below high limit setting.

L7224 controller has the High Limit adjustment

range from 130°F to 240°F (55°C to 116°C), and

the Low Limit adjustment range from 110°F to

220°F (43°C to 104°C). High Limit Differential is

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

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

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:

• HL_  High Limit.

• LL_  Low Limit.

• Ldf  Low Limit Differential.

• °F  °C.

Then, press the UP and/or DOWN buttons to

move the set point to the desired value. After 60

seconds without any button inputs, the control will

automatically return to the RUN mode.

Note that L7224 Aquastat Controller will display all

four (4) above-listed adjustment features, but L7248

Aquastat Controller will not display Low Limit and

Low Limit Differential adjustment features.

5. DISPLAY READOUT

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

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

220), followed by °F or °C.

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 ll valve.

d. Close purge valve.

e. Open relief valve on boiler.

f. Allow water to run out of drain valve until zone

has been purged of air and lled with water.

g. Open zone valve to the second zone to be

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

all zones have been purged but always have one

zone open. At completion open all zone valves.

h. Close drain valve.

i. When water discharges from relief valve, release

the lever on the top of the relief valve, allowing

it to close.

j. Continue lling the system until the pressure

gauge reads 12 psi. Close ll valve.

C. CHECK CONTROLS, WIRING AND BURNER to be

sure that all connections are tight and burner is rigid,

that all electrical connections have been completed and

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

have been tested.

D. LUBRICATION

1. Follow instruction on burner and circulator

label to lubricate, if oil lubricated. Most motors

currently used on residential type burners employ

permanently lubricated bearings and thus do not

require any eld lubrication. Water lubricated

circulators do not need eld lubrication.

2. Do not over-lubricate. This can cause as much

trouble as no lubrication at all.

E. ADJUST CONTROL SETTINGS with burner

service switch turned “ON”.

1. SET ROOM THERMOSTAT about 10°F below

room temperature.

2. On WATER BOILERS WITHOUT TANKLESS

HEATERS equipped with L7248 electronic

aquastat controller, set High Limit (HL) at 180°F.

This temperature can be varied to suit installation

requirements. L7248 controller has the High Limit

adjustment range from 180°F to 240°F (82°C to

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

(8°C).

Figure 22: L7248/L7224 Circuit Board Layout -

Horizontal Mount

25

Figure 23: Display Readout Denitions

TABLE 7: L7248/L7224 CONTROLLER

OPERATING SEQUENCE

TABLE 6: LED ERROR CODES

Error

Code Cause / Action

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.

6. OPERATION

The L7224 model can be in any of four operational

states - Normal, High Limit, Low Limit and Error.

The controller moves back and forth from High

Limit to Normal to Low Limit state as part of

normal operation.

The L7248 model is restricted to three operational

states - Normal, High Limit and Error. The

controller moves back and forth from High Limit to

Normal state as part of normal operation.

For both models, the controller will enter the Error

state when there is an abnormal condition. The

operating states are:

a. Normal: Boiler temperature went below the

High Limit setting (minus the Differential) and

has not exceeded the High Limit setting; or the

boiler temperature went above the Low Limit

setting and has not gone below the Low Limit

setting (minus the Differential).

b. High Limit: Boiler temperature went above the

High Limit setting and has not dropped below

the High Limit setting (minus the Differential).

c. Low Limit: Boiler temperature went below

the Low Limit setting (minus the Low Limit

Differential) and has not gone above the Low

Limit setting.

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.

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

satised. 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.

The operating sequence for the L7224/L7248 is

shown in Table 7.

26 Figure 24: Setpoints and Differentials

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.

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

• If yes, check burner and wiring.

Refer to Err on display. -----

Boiler is hot, house is

cold. Display is ON. 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

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.

TABLE 8: TROUBLE SHOOTING GUIDE

7. HIGH LIMIT CONTROLLER

The High Limit opens and turns off the burner

when the water temperature reaches the setpoint.

The High Limit automatically resets after the water

temperature drops past the setpoint and through the

Differential. The L7248 models have High Limit

Differential presets of 15°F (8°C). The L7224

models have High Limit Differential presets of 10°F

(6°C).

8. LOW LIMIT AND CIRCULATOR CONTROLLER

On a temperature rise, with the adjustable

Differential at the default setting of 10°F (6°C),

the burner circuit breaks and the circulator circuit

makes (assuming no call for heat is present) at the

Low Limit setpoint. On a temperature drop of 10°F

(6°C) below the Low Limit setpoint, the burner

circuit makes and the circulator circuit breaks. See

Figure 24.

F. REMOVE GUN ASSEMBLY

1. CL Series boilers are equipped with Beckett AFG

burners. Items to be checked are nozzle size, head

size, gun setting, and positioning of electrodes. This

information is shown in Figure 25 and Table 9 at

rear of manual.

2. CL Series boilers are equipped with Carlin EZ-HP

burners. Items to be checked are nozzle size, head

bar size, gun setting, and positioning of electrodes.

This information is shown in Figure 25A and Table

9 at rear of manual.

3. Reinstall gun assembly.

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

Positioning and Gun Setting (Beckett AFG)

27

Figure 26: Adjusting Fuel Pump Pressure

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

G. ADJUST OIL BURNER BEFORE STARTING.

1. SET BURNER AIR BAND AND AIR SHUTTER,

see Table 9 at rear of manual.

2. Inspect Beckett head setting on left side of burner

by insuring the blue line MD(V1) or the line on the

label MB(L1) are aligned, readjust if necessary.

Refer to Figure 25.

3. Inspect Carlin head setting on left side of burner to

ensure that the proper head positioning bar matches

the nozzle that is installed in drawer assembly.

Replace bar if necessary.

Carlin burners for boiler models CL3-140 and

CL4-210 have the higher ring rate nozzle installed

and two (2) loose nozzles with a head positioning

bar kit attached to the nozzle line. Refer to Table

9 for proper nozzle size, air settings and fuel pump

pressure setting based on desired ring rate.

If the desired ring rate is the lower GPH:

a. replace the factory installed high ring rate

nozzle with one of the loose lower ring rate

nozzles.

b. replace the factory installed head positioning bar

with the corresponding head bar that matches the

lower GPH nozzle installed, see Table 9.

c. change the factory air settings according to Table

9 and,

d. check the oil pump pressure and adjust if

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

to Paragraph H, Step 5 for details.

4. INSPECT RIELLO BURNER AIR DAMPER

AND TURBULATOR SETTING, readjust if

necessary, see Table 9a.

a. Remove pressure port/bleeder plug from fuel

pump and install Riello Combination Pressure

Gauge and Bleeder Valve Assembly.

5. OPEN ALL OIL LINE VALVES.

6. ATTACH A PLASTIC HOSE TO FUEL PUMP

VENT FITTING and provide a pan to catch the oil.

7. OPEN FLAME OBSERVATION DOOR on front of

boiler.

H. START OIL BURNER.

1. Open vent tting on fuel pump.

2. TURN ‘ON’ BURNER service switch and allow

burner to run until oil ows from vent tting

in a SOLID stream without air bubbles for

approximately 10 seconds.

3. Close vent tting and burner ame should start

immediately after pre-purge is complete. Pre-purge

prevents burner ame until 15 seconds has elapsed

after initial power is applied to burner. During

pre-purge, the motor and ignitor will operate but the

oil valve will remain closed. Refer to Oil Primary

Control Instructions for more details.

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.

28

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.

6. VERIFY/ADJUST OIL PRESSURE for Riello 40

burner.

Adjust oil pressure. Locate oil pressure adjusting

screw and turn screw to obtain proper pump

pressure, refer to Figure 8 and Table 9A.

I. ADJUST OIL BURNER WHILE OPERATING.

(ame present)

1. ADJUST DRAFT REGULATOR for a draft of

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

reached operating temperature and while burner is

running.

2. READJUST THE AIR DAMPER SETTING on the

burner for a light orange colored ame while the

draft over the re is -0.02”. Use a smoke tester and

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

with a minimum of excess air. Make nal check

using suitable instrumentation to obtain a CO2 of

11.5 to 12.5% with draft of -0.02” (water gauge)

in re box. These settings will assure a safe and

efcient operating condition. If the ame appears

stringy instead of a solid re, try another nozzle of

the same type. Flame should be solid and compact.

After all adjustments are made recheck for a draft of

-0.02” over the re.

3. READJUST THE TURBULATOR SETTING only

if necessary.

a. CL3 through CL5

Move the turbulator setting forward or back one

position at a time to optimize the smoke and CO2

readings.

4. Turn “OFF” burner and remove Riello Combination

Pressure Gauge and Bleeder Valve Assembly.

Install pressure port/bleeder plug and tighten. Start

burner again.

5. FLAME FAILURE

The CL Series boiler controls operate the burner

automatically. If for unknown reasons the burner

ceases to re and the reset button on the primary

control has tripped, the burner has experienced

ignition failure. Before pressing the reset button call

your heating contractor immediately.

WARNING

Do not attempt to start the burner when excess oil

has accumulated, when the unit is full of vapor, or

when the combustion chamber is very hot.

7. CAD CELL LOCATION AND SERVICE

The burner is supplied with a cadmium sulde ame

detector mounted at the factory, mounted on the

bottom of the electronic ignitor. See Figure 27. To

service cad cell or to replace the plug in portion,

swing open the ignitor. After service is complete, be

sure to fasten down the ignitor.

Figure 26A: Adjusting Fuel Pump Pressure

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

29

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

not, install new relay.

CAD CELL TEST (see Figure 27)

g. Open line switch. Clean cell face and see that

cell is securely in socket. Reconnect leads. Reset

safety switch.

h. Close line switch. If burner starts and runs

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

If not, install new cell.

3. WARNING — Check High Limit Control

— Jumper Thermostat Terminals. Allow burner to

operate until shut-down by limit. Installation is not

considered complete until this check has been made.

REMOVE JUMPER.

4. Check low water cut off control with water level at

normal water line (see Figures 1C and 1D). Raise

thermostat setting to allow burner to operate. Open

boiler drain to allow water level to drop to bottom

of sight glass until burner operation is shut-down by

low water cut-off.

Close boiler drain and rell to normal water line.

Burner should automatically restart during ll.

Lower thermostat setting.

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.

and readjust oil pressure. If dripping or after burn

persist replace fuel pump.

K. TEST CONTROLS.

WARNING

Before installation of the boiler is considered

complete, the operation of all boiler controls must

be checked, particularly the primary control and

high limit control.

1. CHECK THERMOSTAT OPERATION. Raise and

lower thermostat setting as required to start and stop

burner.

2. VERIFY PRIMARY CONTROL SAFETY

FEATURES using procedures outlined in

Instructions furnished with control or instructions as

follows:

CHECKOUT PROCEDURE

a. Check wiring connections. Close line switch.

Check power at control.

PRIMARY RELAY TEST

b. Disconnect cad cell leads from quick connects

on underside at primary control. Reset safety

switch.

c. Set controller to call for heat. Burner should

start.

d. Jumper the quick connect terminals within 15 to

30 seconds. Burner should run.

e. Remove the quick connect terminals jumper.

Burner shuts down in approximately 15 to 60

seconds.

30

V. Maintenance and Service Instructions

A. MAINTENANCE OF LOW WATER CUT-

OFF DEVICES

WARNING

Probe and oat type low water cut-off devices

require annual inspection and maintenance.

1. Although these devices are solid state in their

operation, the probe is exposed to possible

contamination in the boiler water and subject to

fouling.

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.

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 (Teon)

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.

31

iv. Stop feeding water to boiler but continue

operating oil burner until excess water in

boiler ows out through supply main and

water lowers (by steaming) until it reaches

normal level in boiler. Turn off oil burner.

Drain boiler. Open all radiator valves.

Reinstall all supply main air valves. Open

gate valve in Hartford Loop.

v. When boiler has cooled down sufciently

(crown sheet of sections are not too hot to

touch), close the drain valves at boiler and

in return main and feed water slowly up to

normal level in boiler. Turn on oil burner

and allow boiler to steam for 10 minutes,

then turn off burner. Draw off one quart of

water from bottom gauge glass tting and

discard. Draw off another quart sample and

if this sample is not clear, repeat the cycle

of draining the boiler and return main and

relling the boiler until sample is clear.

vi. If the boiler water becomes dirty again

at a later date due to additional sediment

loosened up in the piping, close gate valve

in Hartford Loop, open drain valve in

return main, turn on oil burner and allow

Condensate to ow to drain until it has run

clear for at least 30 minutes while feeding

water to boiler so as to maintain normal

water level. Turn off oil burner, drain boiler,

open gate valve in Hartford Loop, then

repeat the full "Boiler and System Cleaning"

procedure outlined in Paragraph B starting

on Page 30.

e. Make pH or Alkalinity Test.

After boiler and system have been cleaned and

relled as previously described, test the pH of

the water in the system. This can easily be done

by drawing a small sample of boiler water and

testing with hydrion paper which is used in the

same manner as litmus paper, except it gives

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

small hydrion dispenser gives the reading in pH.

Hydrion paper is inexpensive and obtainable

from any chemical supply house or through your

local druggist. The pH should be higher than

7, but lower than 11. Add some of the washout

chemical (caustic soda), if necessary, to bring the

pH within the specied range.

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

2. WATER BOILERS:

a. Filling of boiler and system.

GENERAL — In a hot water heating system,

the boiler and entire system (other than the

expansion tank) must be full of water for

satisfactory operation. Water should be added

to the system until the boiler pressure gauge

registers 12 psi. To insure that the system is full,

NOTICE

Check with local authorities or consult local

water treatment services for acceptable chemical

cleaning compounds.

iii. Start burner and operate sufciently to boil

the water without producing steam pressure.

Boil for about 5 hours. Open boiler feed

pipe sufciently to permit a steady trickle

of water from the surface blow-off pipe.

Continue this slow boiling and trickle of

overow for several hours until the water

coming from the overow is clear.

iv. Stop burner and drain boiler in a manner

and to a location that hot water can be

discharged with safety.

v. Rell 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

qualied water treatment company.

c. Remove temporary surface blow-off piping, plug

tapping and reinstall safety valve. Boil or bring

water temperature to 180°F promptly in order to

drive off the dissolved gases in the fresh water.

d. If unsteady water line, foaming or priming

persist, install gate valve in Hartford Loop and

drain valves in return main and at boiler as

shown in Figure 9 and proceed as follows:

i Connect hoses from drain valves to oor

drain. Close gate valve in Hartford Loop and

open drain valve in return main. Fill boiler

to normal water level, turn on oil burner and

operate boiler at this water level for at least

30 minutes after the condensate begins to

run hot, then turn off burner.

Close all radiator valves. Remove all supply

main air valves and plug the openings in

supply main.

ii. Draw about 5 gallons of hot water from

boiler into a container and dissolve into it

the appropriate amount of a recommended

boilout compound. Remove safety valve

from boiler and pour this solution into

boiler, then reinstall safety valve.

iii. Turn on oil burner and keep operating while

feeding water to boiler slowly. This will

raise water level in boiler slowly so that

water will be boiling hot and will rise slowly

into supply main and back through return

main, owing from drain hose at about

180°F. Continue until water runs clear from

drain hose for at least 30 minutes.

32

water should come out of all air vents when

opened.

b. BOILING OUT OF BOILER AND SYSTEM.

The oil and grease which accumulate in a

new hot water boiler can be washed out in the

following manner:

i. Remove relief valve using extreme care to

avoid damaging it.

ii. Add an appropriate amount of recommended

boil out compound.

iii. Replace relief valve.

iv. Fill the entire system with water.

v. Start ring the boiler.

vi. Circulate the water through the entire

system.

vii. Vent the system, including the radiation.

viii. Allow boiler water to reach operating

temperature, if possible.

ix. Continue to circulate the water for a few

hours.

x. Stop ring the boiler.

xi. Drain the system in a manner and to a

location that hot water can be discharged

with safety.

xii. Remove plugs from all available returns

and wash the water side of the boiler as

thoroughly as possible, using a high-

pressure water stream.

xiii. Rell the system with fresh water.

c. Add appropriate boiler water treatment

compounds as recommended by your qualied

water treatment company.

d. Make pH or Alkalinity Test.

After boiler and system have been cleaned and

relled as previously described, test the pH of

the water in the system. This can easily be done

by drawing a small sample of boiler water and

testing with hydrion paper which is used in the

same manner as litmus paper, except it gives

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

small hydrion dispenser gives the reading pH.

Hydrion paper is inexpensive and obtainable

from any chemical supply house or through your

local druggist. The pH should be higher than

7 but lower than 11. Add some of the washout

chemical (caustic soda), if necessary, to bring the

PH within the specied range.

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

3. EXCESSIVE MAKE-UP WATER

A leaky system will increase the volume of make-up

water supplied to the boiler, which can signicantly

shorten the life of the boiler. Entrained in make-

up 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

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 make-

up 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. HINTS ON COMBUSTION

1. NOZZLES — Although the nozzle is a relatively

inexpensive device, its function is critical to the

successful operation of the oil burner. The selection

of the nozzle supplied with the CL boiler is the

result of extensive testing to obtain the best ame

shape and efcient combustion. Other brands of the

same spray angle and spray pattern may be used but

may not perform at the expected level of CO2 and

smoke. Nozzles are delicate and should be protected

from dirt and abuse. Nozzles are mass-produced

and can vary from sample to sample. For all of

those reasons a spare nozzle is a desirable item for a

serviceman to have.

2. FUEL LEAKS — Any fuel leak between the

pump and the nozzle will be detrimental to good

combustion results. Look for wet surfaces in the air

tube, under the ignitor, and around the air inlet. Any

such leaks should be repaired as they may cause

erratic burning of the fuel and in the extreme case

may become a re hazard.

3. AIR LEAKS — Any such leaks should be repaired,

as they may cause erratic burning of the fuel and in

extreme cases may become a re hazard.

SUCTION LINE LEAKS -

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

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

IMPORTANT

IF, DURING NORMAL OPERATION, IT IS

NECESSARY TO ADD MORE WATER THAN

INDICATED BELOW, CONSULT A QUALIFIED

SERVICE TECHNICIAN TO CHECK YOUR

SYSTEM FOR LEAKS.

Model No. Gallons Per

Month Gallons Per

Year

CL3 0.3 4

CL4 0.4 5

CL5 0.5 6

33

bleeding the pump through a clear tube. There must be

no froth visible. There are various test kits available to

enable you to look at the oil through clear tube. There

must be no froth visible. There are various test kits

available to enable you to look at the oil through clear

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

Air eliminators are on the market that have potential.

Also, electronic sight glasses are being used with good

success. At times, new tubing must be run to the tank

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

out before you leave.

Any air leaks in the fuel line will cause an unstable

ame and may cause delayed ignition noises. Use only

are ttings in the fuel lines.

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

#1 smoke cannot be obtained in the breeching, look

for air leaks around the burner mounting gasket,

observation door, and canopy gasket. Such air leaks

will cause a lower CO2 reading in the breeching. The

smaller the ring rate the greater effect an air leak

can have on CO2 readings.

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

Accidental accumulation of dirt in the fuel system

can clog the nozzle or nozzle strainer and produce a

poor spray pattern from the nozzle. The smaller the

ring rate, the smaller the slots become in the nozzle

and the more prone to plugging it becomes with the

same amount of dirt.

6. WATER — Water in the fuel in large amounts will

stall the fuel pump. Water in the fuel in smaller

amounts will cause excessive wear on the pump,

but more importantly water doesn’t burn. It chills

the ame and causes smoke and unburned fuel to

pass out of the combustion chamber and clog the

ueways of the boiler.

7. COLD OIL — If the oil temperature approaching

the fuel pump is 40°F or lower poor combustion or

delayed ignition may result. Cold oil is harder to

atomize at the nozzle. Thus, the spray droplets get

larger and the ame shape gets longer. An outside

fuel tank that is above grade or has fuel lines in a

shallow bury is a good candidate for cold oil. The

best solution is to bury the tank and lines deep

enough to keep the oil above 40°F.

8. FLAME SHAPE — Looking into the combustion

chamber through the observation door, the ame

should appear straight with no sparklers rolling up

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

to the right or left, sends sparklers upward or makes

wet spots on the target wall, the nozzle should be

replaced. If the condition persists look for fuel leaks,

air leaks, water or dirt in the fuel as described above.

9. HIGH ALTITUDE INSTALLATIONS

Air settings must be increased at high altitudes. Use

instruments and set for 11.5 to 12.5% CO2.

10. START-UP NOISE — Late ignition is the cause of

start-up noises. If it occurs recheck for electrode

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

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

before it runs out of fuel, an after burn with

noise may occur. That may be the result of a faulty

cut-off valve in the fuel pump, or it may be air

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

cycles for that air to be fully vented through the

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

cause shut down noises.

NOTICE

CHECK TEST PROCEDURE. A very good test for

isolating fuel side problems is to disconnect the

fuel system and with a short length of tubing,

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

fresh, warm #2 oil from another source. If the

burner runs successfully when drawing out of the

auxiliary pail then the problem is isolated to the

fuel or fuel lines being used on the jobsite.

D. ATTENTION TO BOILER WHILE NOT IN

OPERATION

1. IMPORTANT

IF BOILER IS NOT USED DURING WINTER

TIME, IT MUST BE FULLY DRAINED TO

PREVENT FREEZE DAMAGE.

2. Spray inside surfaces with light lubricating or

crankcase oil using gun with extended stem so as to

reach all corners.

3. With steam boilers, at end of season add sufcient

water to ll boiler to top of water column and leave

it that way until fall when water should be drained

again to proper level. If, at this time, boiler water

is dirty, drain water, ush out boiler, and rell with

clean water to prescribed water level.

4. Always keep the manual fuel supply valve shut off

if the burner is shut down for an extended period of

time.

5. To recondition the heating system in the fall season

after a prolonged shut down, follow the instructions

outlined in Section IV, Paragraphs A through K.

WARNING

This boiler contains controls which may cause the

boiler to shut down and not restart without service.

If damage due to frozen pipes is a possibility, the

heating system should not be left unattended

in cold weather; or appropriate safeguards and

alarms should be installed on the heating system

to prevent damage if the boiler is inoperative.

34

VI. Boiler Cleaning

Figure 28: Cleaning of Boiler Flueways

A. CLEAN THE FLUEWAYS (See Figure 28).

1. Disconnect oil line(s) and remove burner and burner

mounting plate. See Figures 1A thru 1D.

2. Lay protective cloth or plastic over combustion

chamber blanket.

3. Remove the smokepipe as necessary to gain access

to the boiler canopy.

4. Remove the jacket top panels.

5. Remove the canopy being careful not to damage the

cerafelt gasket.

6. Usinga1¼”diameterwireorbrebristlebrush

(30”handle)cleantheueways.Brushfromthetop

using diagonal strokes for best results. DO NOT

allow brush to strike the target wall or liner in the

chamber.

B. CLEANTOPOFBOILERSECTIONS.

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

C. CLEANTHEFIREBOX.

1. Usingwireorbrebristlebrush,cleancrown

of boiler and inside of water legs. DO NOT

allow brush to strike target wall or blanket in the

combustion chamber.

D. AFTERCLEANING,removeprotectiveclothwith

debrisandvacuumasnecessary,butbecarefulnot

todamageblanket.Inspecttargetwall,combustion

chamber blanket and burner mounting plate insulation

forsignsofdamage.Ifdamaged,replaceasneeded.

E. REASSEMBLEBOILER.

CAUTION: Donotstarttheburnerunlesscanopy,

smokepipe and burner swing door are secured in place.

1. Installthecanopytakingcaretoalignthegaskets

withoutblockingtheueways.Ifgasketisdamaged,

replace as needed.

2. Close and secure burner swing door to front section

with fasteners.

3. Reconnect oil line(s).

4. Reinstall Top Panels and secure with sheet metal

screws.

5. Reinstall smokepipe on canopy and secure to collar

with sheet metal screws.

WARNING

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

WARNING

The boiler must be connected to an approved

chimney in good condition. Serious property

damage could result if the boiler is connected

to a dirty or inadequate chimney. The interior of

the chimney ue must be inspected and cleaned

before the start of the heating season and

should be inspected periodically throughout the

heating season for any obstructions. A clean and

unobstructed chimney ue is necessary to allow

noxious fumes that could cause injury or loss

of life to vent safely and will contribute toward

maintaining the boiler's efciency.

35

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.

36

TROUBLE SHOOTING CARLIN 40200 OIL PRIMARY CONTROL

CARLIN 40200 OIL PRIMARY CONTROL

Also refer to Model EZ-1/2/3 Oil Burner - Instruction

Manual (Form #MNEZ123) for additional information.

1. Burner (control) will not come on.

a. No power to control.

b. Control is in lockout. Press reset button for one

(1) second.

c. CAD cell seeing light.

d. CAD assembly defective.

e. Control motor relay is stuck closed (see note

below).

2. Burner (control) will light, then shut down after a

short time, then restart after one (1) minute.

a. CAD cell is defective.

b. Air leaking into oil line causing ame out.

c. Defective nozzle causing ame to be erratic.

d. Excessive airow or draft causing ame to be

erratic.

e. Excessive back pressure causing ame to be

erratic.

3. Control locks out after Trial For Ignition (TFI).

a. No oil to burner.

b. Shorted electrodes.

c. Nozzle clogged.

d. Airow too high.

e. Ignitor module defective.

f. CAD cell defective.

g. Oil valve stuck open or closed.

Note: The Safety Monitoring Circuit (SMC) is

designed to provide lockout in the event of a

stuck or welded motor relay.

NOTICE

If ame is not established within 15 seconds

of oil valve actuation (known as Trial For

Ignition [TFI]) lockout will occur. Lockout is

indicated by a red LED solid-on located on

the oil primary control.

Latch-up will occur if the control locks-out

three (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

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.

37

All CL™ Series repair parts may be ordered through New Yorker Boiler Co., Inc., or its authorized distributors.

Should you require assistance in locating a New Yorker Distributor in your area, or have questions regarding the availability of

New Yorker products or repair parts, please contact: New Yorker Boiler Co., Inc., P.O. Box 10, Hateld, PA 19440-0010, Phone:

(215) 855-8055 Attn: Customer Service Department

VII. Repair Parts

38

Bare Boiler Assembly (Exploded View)

39

Item

No. Description Boiler Size / Quantity Part No.

CL3 CL4 CL5

Bare Boiler Assembly

1Front Section (Non-Htr.), Machined Water

---(OR)---

Front Section (Non-Htr.), Machined Steam 1 1 1 71720103

71720104

2 Center Section 1 2 3 71720301

3

Rear Section (Non-Htr.), Machined Water

---(OR)---

Rear Section (Non-Htr.), Machined Steam 1 1 1

71720201

71720202

Rear Heater Section, Machined Water

---(OR)---

Rear Heater Section, Machined Steam

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

7

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

10

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

19 Canopy Sealing Strip (1/2" x 1 x 10') 1 1 1 6206001

20

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

40

Jacket Assembly (Exploded View)

Item

No. Description Boiler Size / Quantity Part No.

CL3 CL4 CL5

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

1 Jacket Front Panel Assembly 1 1 1 100819-01

2 Jacket Rear Panel Assembly 1 1 1 100820-01

3Jacket Reversible Side

Panel Assembly

Non-Heater Build

2 --- --- 100821-03

--- 2 --- 100821-04

--- --- 2 100821-05

With Heater Build

1 --- --- 100821-03

--- 1 --- 100821-04

--- --- 1 100821-05

4Jacket Left Side Heater Panel Assembly

(with Heater Build)

1 --- --- 100824-03

--- 1 --- 100824-04

--- --- 1 100824-05

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

6 Jacket Split Rear Top Panel Assembly

1 --- --- 100822-03

--- 1 --- 100822-04

--- --- 1 100822-05

41

CL3 Thru CL5 Water Boilers - Trim and Controls

Item

No. Description Boiler Size / Quantity Part No.

CL3 CL4 CL5

CL3 Thru CL5 Water Boilers - Trim and Controls

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

2Honeywell L7248C1014 Hi Limit, Circ. Relay

--- (OR)---

L7224C1004 Hi & Lo Limit, Circ. Relay 111100059-01

100862-01

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

42

Item

No. Description Boiler Size / Quantity Part No.

CL3 CL4 CL5

CL3 Thru CL5 Steam Boilers - Trim and Controls

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

2 McDonnell & Miller PS801 LWCO With Probe 1 1 1 80160723

3 Honeywell PA404A1009 Pressuretrol 1 1 1 80160300

3A ¼" x 90° Syphon, 2½" Equal Leg 1 1 1 806603006

3B ¾" x ¼" NPT Bushing, Black 1 1 1 806600508

4 Honeywell L4006A2015 Aquastat 1 1 1 80160400

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

6 2½" Dia. Steam Gauge 1 1 1 8056010

7 10¼" Gauge Glass Set, Conbraco #22-171-10 1 1 1 100854-01

7A ½" Male x ½" Female NPT Brass Extension Piece 1 1 1 100853-01

7B ½" NPT Brass Street Elbow 1 1 1 100852-01

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

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

10 ¾" NPT Coupling 1 1 1 806602561

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

CL3 Thru CL5 Steam Boilers - Trim and Controls

43

BECKETT OIL BURNER PARTS LIST

MODEL AFG --- 60-Hz, 3450 RPM

FOR REPLACEMENT OIL BURNER PARTS, CONTACT

YOUR WHOLESALER OR THE BURNER MANUFACTURER:

R. W. BECKETT CORP.

P.O. BOX 1289

ELYRIA, OHIO 44036

1-800-645-2876

Beckett AFG Burner

44

BECKETT OIL BURNER PART NOS. FOR CL SERIES BOILERS

NOTE: When ordering parts always give the serial and model numbers shown on the boiler and burner. Also

provide the name of the part(s) and part number as listed below.

Boiler Model CL3-091, 105, 140 CL4-126 CL4-175, 210 CL5-168, 245 CL5-280

Air Tube Combination AFG70MBAS AFG70MBAS AFG70MDAS AFG70MDAS AFG70MLAS

Beckett's Spec No. NY2701 NY2702 NY2703 NY2704 NY2705

Air Band 3492A 3492A 3492A 3492A 3492A

Air Band Nut 4150 4150 4150 4150 4150

Air Band Screw 4198 4198 4198 4198 4198

Air Shutter 3709 3709 3709 3709 3709

Air Shutter Screw 4198 4198 4198 4198 4198

Blower Wheel 2999 2999 2999 2999 2999

Coupling 2454 2454 2454 2454 2454

Low Firing Rate Bafe 5880[1] ---- ---- ---- ----

Bulkhead Knurled Locknut 3-666 3-666 3-666 3-666 3-666

Connector Tube Assembly 5636 5636 5636 5636 5636

Electrode Clamp 1-49 1-49 1-49 1-49 1-49

Electrode Clamp Screw 4219 4219 4219 4219 4219

Electrode Insulator Assembly 5780 5780 5780 5780 5780

Spider Spacer Assembly 5653 5653 5653 5653 5653

Escutcheon Plate 3493 3493 ---- ---- ----

Adjusting Plate Assembly ---- ---- 5941 5941 5941

Head 5912 5912 5913 5913 5913

Head Screws 4221 4221 4221 4221 4221

Flange Gasket 3416 3416 3416 3416 3416

AFG Housing 5874BK 5874BK 5874BK 5874BK 5874BK

Motor 21805 21805 21805 21805 21805

Nozzle Adapter 2-13 2-13 2-13 2-13 2-13

Nozzle Line Electrode Assembly NL70MB NL70MB NL70MD NL70MD NL70ML

Oil Pump, Clean Cut (Single Stage) 2184404U 2184404U 2184404U 2184404U 2184404U

Oil Pump, Clean Cut (Two Stage) 21941U 21941U 21941U 21941U 21941U

Static Plate 3384 3384 3384 3384 Less

Ignitor 51771U 51771U 51771U 51771U 51771U

Ignitor Hinge Screw 4217 4217 4217 4217 4217

Ignitor Holding Screw 4292 4292 4292 4292 4292

Ignitor Gasket Kit 51304 51304 51304 51304 51304

Junction Box 5770 5770 5770 5770 5770

Flame Detector 7006 7006 7006 7006 7006

Oil Solenoid Valve Coil 21755 21755 21755 21755 21755

Oil Solenoid Valve Cord 21807 21807 21807 21807 21807

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

45

VIII. Low Water Cut Off (LWCO)

A 24 VAC LWCO is used primarily for gas red

boilers where a 24 volt control circuit exists within the

boiler. However, a 24 VAC LWCO can only be used

if the boiler manufacturer has provided piping and

wiring connections and instructions to allow for this

application.

How to Test

Shut off fuel supply. Lower water level until water

level is BELOW the LWCO. Generate a boiler demand

by turning up thermostat. Boiler should not attempt to

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

The boiler should attempt to operate once the water

level is above the LWCO.

Wiring of Typical LWCO

When

A low water cutoff is required to protect a hot water

boiler when any connected heat distributor (radiation)

is installed below the top of the hot water boiler (i.e.

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

addition, some jurisdictions require the use of a LWCO

with a hot water boiler.

Where

The universal location for a LWCO on both gas and oil

hot water boilers is above the boiler, in either the supply

or return piping. The minimum safe water level of a

water boiler is at the uppermost top of the boiler; that is,

it must be full of water to operate safely.

What Kind

Typically, in residential applications, a probe type

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

relative costs and the simplicity of piping for a probe

LWCO.

How to Pipe

A “tee” is commonly used to connect the probe LWCO

to the supply or return piping, as shown below.

LWCO Location

manufacturers recommend an annual inspection of the

probe.

How to Wire

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

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

universally applied to both gas and oil boilers by wiring

it in the line voltage service to the boiler (after the

service switch, if so equipped).

The presence of water in a properly installed LWCO

will cause the normally open contact of the LWCO to

close, thus providing continuity of the 120 VAC service

to the boiler.

It is recommended to supply power to the probe LWCO

with the same line voltage boiler service as shown

below.

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

WARNING

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

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

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

46

TABLE 9: BURNER SPECIFICATIONS

Beckett AFG

Boiler Model Firing Rate

GPH

Settings Nozzle 3 Pump

Pressure

Head

(Setting) Air

Shutter Air

Band GPH x Angle Type 2 Shipped

1 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

p 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) l Loose 175

l 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

Carlin Burner

Boiler Model Firing Rate

GPH Burner

Model

Settings Nozzle 3 Pump

Pressure

Head

Bar Air

Band GPH x Angle Type 2 Shipped

CL3-091 0.65

EZ-1HP

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

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

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

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

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

3 Single stage fuel pump is standard, two stage fuel pump is optional. Burner manufacturer has preset

single stage fuel pump to settings shown in table above.

47

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.

RIELLO OIL BURNER PART NUMBERS FOR CL SERIES BOILERS

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

Riello Corporation of America

35 Pond Park Road

Hingham, Massachusetts 02043

Telephone: (617) 749-8292

Facsimile: (617) 740-2069

Toll Free: (outside Massachusetts)

(800) 992-7637

Riello Canada Inc.

2165 Meadowpine Blvd.

Mississauga, Ontario L5N 6H6

Telephone: (905) 542-0303

Facsimile: (905) 542-1525

Toll Free: (800) 387-3898

TABLE 9A: RIELLO BURNER SPECIFICATIONS

Boiler

Model

Firing

Rate

GPM

Burner

Model

Settings Nozzle Pump

Pressure Combustion

Head Insertion

Depth

Air Shutter Turbulator GPH x Angle

Type Shipped

CL3-105 0.75

40F5

2.60 0 0.60 x 60A

(Delavan) Loose

150

SBT 6.0” 2-3/8”

CL3-140 1.00 2.85 2 0.85 x 60W

(Delavan) Installed

CL4-175 1.25 40F5 4 4 1.00 x 60A

(Delavan) Installed SBT 6.0” 2-3/8”

CL4-210 1.50 40F10 3 1 1.25 x 60B

(Delavan) Installed SBT 5.0” 2-1/2”

CL5-245 1.75

40F10

3 1.5 1.35 x 45B

(Delavan) Loose

SBT 5.0” 2-1/2”

CL5-280 2.00 3.8 2 1.65 x 45B

(Delavan) Installed

48

SERVICE RECORD

DATE SERVICE PERFORMED

49

SERVICE RECORD

DATE SERVICE PERFORMED

50

SERVICE RECORD

DATE SERVICE PERFORMED

51

52

NEW YORKER BOILER CO., INC.

Limited Warranties

For Residential Cast Iron Steam Boilers

By this Warranty Statement New Yorker Boiler Co., Inc. ("New Yorker")

issues limited warranties subject to the terms and conditions stated below.

These limited warranties apply to residential cast iron steam boilers labeled

with the New Yorker® brand which are sold on or after March 1, 2004

ONE YEAR LIMITED WARRANTY

One Year Limited Warranty for Residential Cast Iron Steam Boilers New

Yorker warrants to the original consumer purchaser at the original installation

address that its residential cast iron steam boilers will be free of defects in

material and workmanship under normal usage for a period of one year from

the date of original installation. In the event that any defect in material or

workmanship is found during the one-year period following the date of

installation, New Yorker will, at its option, repair the defective part or provide

a replacement free of charge, F.O.B. its factory.

TEN YEAR LIMITED WARRANTY

Ten Year Pressure Vessel Limited Warranty for Residential Cast Iron Steam

Boilers New Yorker warrants to the original consumer purchaser at the

original installation address that the pressure vessel of its residential cast iron

steam boilers will be free of defects in material and workmanship under

normal usage for a period of 10 years from the date of original installation. In

the event that any defect in material or workmanship is found during the ten

year period following the date of installation, New Yorker will, at its option,

repair the defective pressure vessel or provide a replacement free of charge,

F.O.B. its factory. EXCEPTIONS AND EXCLUSIONS

1.Components Manufactured by Others Following the expiration of the

foregoing one year limited warranty, all component parts of a boiler which are

manufactured by others (such as burners, burner controls, circulator, tankless

water heater, and New Yorker Link) shall be subject only to the

manufacturer's warranty, if any.

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

of removal or reinstallation. The consumer purchaser will be responsible for

the cost of removing and replacing any defective part and all labor and related

materials connected therewith. Replacement parts will be invoiced to the

distributor in the usual manner and will be subject to adjustment upon proof of

defect.

3.Proper Installation These warranties are conditioned upon the installation

of the boiler in strict compliance with New Yorker's Installation, Operating

and Service Instructions. New Yorker specifically disclaims any liability of

any kind which arises from or relates to improper installation.

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

the boiler is used or operated over its rated capacity, is installed for uses other

than home heating, or is not maintained in accordance with New Yorker

Installation ’s

, Operating and Service Instructions and hydronics industry

standards.

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

has been damaged as a result of being improperly serviced or operated,

including but not limited to the following: operated with insufficient wat

allowed to freeze; subjected to flood conditions; or operated with water

conditions and/or fuels or additives which cause un

ler

er;

usual deposits or corrosion

in or on the pressure vessel or associated controls.

6.Geographic Limitations These warranties apply only to boilers installed

within the 48 contiguous United States.

7.Installation Requirements In order for these warranties to be effective:

a)The boiler must be installed in a single or two-family residential dw

This warranty does not apply to boilers installed in apart elling.

ments or for

commercial or industrial applications.

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

Installation, Operating and Service Instructions, including the installation of a

low water cut-off, by an installer regularly engaged in boiler installations.

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

installation.

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

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

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

these warranties is expressly limited to the repair or replacement of any part

found to be defective under conditions of normal use.

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

for incidental, indirect, special or consequential damages of any kind under

these warranties, including, without limitation, injury or damage to persons or

property and damages for loss of use, inconvenience or loss of time. New

Yorker's liability under these warranties shall under no circumstances exceed

the purchase price paid for the boiler involved. Some states do not allow the

exclusion or limitation of incidental or consequential damages, so the above

limitation or exclusion may not apply to you.

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

other express warranties and set forth the entire obligation of New Yorker

with respect to any defect in a residential cast iron steam boiler. New Yorke

shall have no express obligations, r

other

A

n

er

.

SO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO

STATE.

responsibilities or liabilities of any kind,

than those set forth herein.

ALL APPLICABLE IMPLIED WARRANTIES, IF ANY, INCLUDING

ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR

PARTICULAR PURPOSE, ARE EXPRESSLY LIMITED IN

DURATION TO A PERIOD OF ONE YEAR, EXCEPT THAT

IMPLIED WARRANTIES, IF ANY, APPLICABLE TO THE

PRESSER VESSEL OF A RESIDENTIAL CAST IRON STEAM

BOILER SHALL BE LIMITED IN DURATION TO THE LESSER OF

THE DURATION OF SUCH IMPLIED WARRANTY OR A PERIOD

OF TEN YEARS. Some states do not allow limitations on how long a

i u.

PROCEDURE FOR OBTAINING WARRANTY SERVICE

Upon discovery of a condition believed to be related to a defect in material

or workmanship covered by these warranties, the original consumer purchaser

should notify the installer, who will in turn notify the distributor. If this action

is not possible or does not produce a prompt response, the original consum

purchaser should write to New Yorker Boiler Co., Inc. at P.O. Box 10,

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

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

The original consumer purchaser is required to make available for

inspection by New Yorker or its representative the parts claimed to be

defective and, if requested by New Yorker, to ship those parts prepaid to New

Yorker at the above address for inspection or repair. In addition, the original

consumer purchaser agrees to make all reasonable efforts to settle any

disagreement arising in connection with any warranty claim before resorting

to legal remedies in the courts.

THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU

MAY AL

02/04