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INSTALLATION, OPERATING
AND SERVICE INSTRUCTIONS
CL™ SERIES
CAST IRON OIL-FIRED BOILER
As an
ENERGY
®
STAR Partner,
New Yorker Boiler Co., Inc.
has determined that the
CL3-091, CL3-105, CL4-126
and CL5-168 water boilers
®
meet the ENERGY STAR
guidelines for Energy
efficiency established by the
United States Environmental
Protection Agency (EPA).
For service or repairs to boiler, call your heating contractor. When seeking information on
boiler, provide
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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 kno
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WARNING This boiler is suitable for installation on combustible flooring. Do not install boiler on carpeting. Installation is not complete unless a pressure relief valve is installed into the tapping located on top left corner of rear section - See Piping and Trim Sections of this manual for details. This boiler is designed to burn No. 2 fuel oil only. Do not use gasoline, crankcase drainings, or any oil containing gasoline. Never burn garbage or paper in this boiler. Do not convert to any
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Table of Contents I. General Information .................................... Trouble Shooting Carlin 0200 .............................................6 II. Installation Instructions .............................. 8 Riello 0 Series ....................................... 6 III. Indirect Water Heater Piping .................... 2 VII. Repair Parts .............................................7 IV. Operating & Service Instructions ............ 2 VIII. Appendix V. Maintenanc
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Figure 1A: CL Thru CL5 Water Boiler Less Tankless Heater Figure 1B: CL Thru CL5 Water Boiler With Tankless Heater 5
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Figure 1C: CL Thru CL5 Steam Boiler with or without Tankless Heater Figure 1D: CL thru CL5 Steam Boiler with McDonnell & Miller PS-801 Low Water Cut-Off, Riello Burner TABLE 1: DIMENSIONAL DATA (SEE FIGURES 1A THRU 1C) Dimensions Minimum Chimney Size Boiler Approx. Water Heat Transfer Surface Model Content - Gallons 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
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TABLE 2: RATING DATA Burner DOE Heating Minimum Chimney I=B=R NET Ratings AFUE % Capacity Capacity Requirements Boiler Model No. * Water Steam Water Steam Steam Round Rectangle Height GPH MBH Water Steam MBH MBH MBH MBH Sq. Ft. In. Dia. In. x In. Ft. 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) 1.0
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II. Installation Instructions 1. PACKAGED CL™ Series boilers are shipped with A. REMOVE CRATE the highest input oil nozzle installed in the burner. 1. Remove all fasteners at crate skid. Oil nozzles for lower firing rates are shipped 2. Lift outside container and remove all other loose for the CL3 through CL5 models, attached inside protective spacers and bracing. Remove to the burner. Select the proper oil nozzle for the miscellaneous steam or water trim carton. installation. The low
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check the settings and to change the nozzle to a l. Inspect Beckett head setting on left side of lower firing rate: burner by insuring the blue line MD(V1) or the line on the label MB(L1) are aligned, readjust if a. Installation/Removal of Drawer Assembly, necessary. refer to Figure 4. m. Tighten knurled nut. n. Swing igniter closed, rotate tabs and tighten two (2) igniter screws. o. Replace burner cover and tighten burner cover knobs. 3. On the Carlin EZ-PH Burner, use the following pro
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ii. Remove existing nozzle from nozzle adapter. This burner is shipped with the oil pump set to operate on a single line system. To operate iii. Insert the proper NOZZLE into NOZZLE on a two-line system the bypass plug must be ADAPTER and tighten securely (Do not installed. cover tighten). WARNING: Do not operate a single line iv. Replace adapter, with nozzle installed, into system with the by-pass plug installed. drawer assembly and secure with screw (1). Operating a single line
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Figure : Recommended Boiler Piping for Series Loop Hot Water System NOTE: Vertical piping will prevent door from opening control conduit to jacket right side panel with 5/8" fully for service and cleaning of boiler. cable clamp provided, refer to Figure 1B. 2. Thread relief valve onto factory installed ¾" NPT 4. CONNECT FIELD WIRING x 7¼" nipple located in left rear corner on top a. Water boilers without tankless heater and with of boiler as shown in Figures 1A and 1B. Valve front tank
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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 wi
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2. WATER BOILER i. Assure that all system radiators, piping and vents are absolutely leak tight. a. For Forced Circulation HOT WATER HEATING. • When a steam boiler is installed in an See Figure 9. Consult I=B=R Installation and existing system, ALL air vents should be Piping Guide No. 200. replaced at the same time. This assures b. Use a boiler water bypass if the boiler is to be that the new boiler will not be operated in a system which has a large volume compromised by e
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addition, savings of hot water will be achieved since I. CONNECT TANKLESS HEATER PIPING AS the user will not waste as much hot water while SHOWN IN Figure 12. See Table 3 for Tankless seeking water temperature to his liking. Higher Heater Ratings. 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 he
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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
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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 lif
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in the circuit. A service switch is recommended and L. INSTALL ELECTRIC WIRING in accordance with may be required by some local jurisdictions. Wiring National Electrical Code and local regulations. A should conform to Figures 17 thru 19B. separate electrical circuit must be run from the main electrical service with an over-current device/disconnect Figure 17: Wiring Diagram for Water Boilers With Beckett AFG Burner and Split Controls Less Tankless Heater SEQUENCE OF OPERATION A call f
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Figure 17A: Wiring Diagram for Water Boilers With Carlin EZ-HP Burner and Split Controls Less Tankless Heater Figure 17B: Wiring Diagram, Water without Tankless Heater, Riello Burner 18
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Figure 18: Wiring Diagram for Water Boilers with Beckett AFG Burner and Split Controls with Tankless Heater SEQUENCE OF OPERATION A call for heat by the thermostat energizes the L7224C control which in turn energizes the primary control. The burner will initiate ignition after completing a 15 second pre-purge cycle. If burner ignites within approximately 45 seconds and the cad cell sees flame the burner will continue to operate until the call for heat is satisfied. The circulator will also
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Figure 18A: Wiring Diagram for Water Boilers with Carlin EZ-PH Burner and Split Controls with Tankless Heater Figure 18B: Wiring Diagram, Water with Rear Tankless Heater, Riello Burner 20
