New Yorker PVCG SERIES Installation, Operating And Service Instructions
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New Yorker PVCG SERIES, 24 H. Operating Instructions 1. See Figure 13 to place boiler in operation. 2. Electronic Ignition Modules with LED indicators. Table 7 cross-references the ignition module terminal designations to the ignition terminal Figure 14: LED Locations Ignition Module Terminal Designation Wiring Ladder Diagram Terminal Number MV 1 MV/PV 2 PV 3 GND 4 24V (GND) 5 24V 6 SPARK 9 Table 7: Ignition Module Terminal Cross-Reference Yellow LED Flash Code a Indicates Recommended Service Action Heartbeat Normal Flame Signal N/A 2 Weak Flame Signal - System will operate reliably but ame signal is less than desired. Note: This indication may ash tempor
New Yorker PVCG SERIES, 32 Table 12: Minimum Fan Inlet Pressure Figure 21: Procedure for Measuring Fan Inlet Pressure I. Lubrication. There are no parts requiring lubrication by service technician or owner. Circulator bearings are water lubricated. Blower motor bearings are factory sealed. J. Procedure for measuring fan inlet pressure. See Figure 21. 1. With boiler off, remove hoses at pressure switch. 2. With tee connect water manometer as shown with additional tubing. 3. Start boiler and read Pressure on Manometer when boiler water temperature reaches operating temper
New Yorker PVCG SERIES, 30 2. Terminal and wall thimble (if used) must be weathertight. 3. Pipe must be full round shape, and show no damage from impact or excessive temperature. 4. Pipe must be supported at minimum five (5) foot intervals and must not sag. 5. All vent joints must be secure and watertight. 6. If pipe must be disassembled for removal of obstructions or resealing of joint, see Venting Section. E. Inspect Boiler Flue Passages for blockage or soot accumulation. See Figure 20. 1. Disconnect vent connector from blower discharge flange. 2. Remove sheet metal sc
New Yorker PVCG SERIES, 8 NOTICE The gasketed vent system components pictured below in Figure A are being phased in and each vent component is interchangeable with the previously supplied gasket-less venting components. The newer vent components are generally quicker and easier to join, as they do not require the sealant application and their clamp bands are attached. In the event a gasketed vent component and a gasket-less vent component must be intercon- nected, follow the instructions associated wit
27 I. Sequence of Operation. See Figure 16. If boiler fails to operate properly, see Troubleshooting Guides in Service Section. J. Check pilot burner flame. See Figure 17. Flame should be steady, medium hard blue enveloping 3/8 to 1/2 inch of sensing probe. Figure 16: Sequence of Operation Figure 17: Pilot Burner Flame Figure 18: Main Burner Flame K. Check main burne
New Yorker PVCG SERIES, 5 I. Pre-Installation NOTICE Due to the low water content of the boiler, mis- sizing of the boiler with regard to the heating system load will result in excessive boiler cycling and accelerated component failure. Manufacturer DOES NOT warrant failures caused by mis-sized boiler applications. DO NOT oversize the boiler to the system. A. Inspect shipment carefully for any signs of damage. All equipment is carefully manufactured, inspected and packed. Manufacturer's responsibility ceases upon delivery of boiler to carrier in good condition. Any claim for damage or shortage in shipment must be filed WARNING Carefu
New Yorker PVCG SERIES, 40 NEW YORKER BOILER CO., INC. Limited Warranties For Residential Cast Iron and Steel Water 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 and steel water 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 Water Boilers New Yorker warrants to the original consumer purchaser at the original installation address that its
New Yorker PVCG SERIES, 28 Table 10: Gas Flow Rate in Cubic Feet per Hour 3. Main burners and pilot burner will extinguish and blower stop when water level drops below low water cut-off probe. Verify limit, thermostat or other controls have not shut off boiler. 4. Adjust thermostat to lowest setting. Refill boiler. O. Check limit (Combination Control). 1. Adjust thermostat to highest setting. 2. Observe temperature gauge. When temperature is indicated, adjust limit to setting below observed temperature. Main burners and pilot burner should extinguish, an
New Yorker PVCG SERIES, 29 VIII. Service A. General. Inspection and service should be conducted annually. Turn off electrical power and gas supply while conducting service or maintenance. Follow instructions TO TURN OFF GAS TO APPLIANCE. See Figure 13. B. Inspect Housekeeping. Boiler area must be clear and free from combustible materials, gasoline and other flammable vapors and liquids. Remove obstructions to the flow of combustion and ventilation air. C. Low water cut-off (if so equipped). 1. Float Type a. Monthly Blowoff. During the heating season, if an external float type low water cut-off is on the boiler, the blo
New Yorker PVCG SERIES, 20 A. General. Install wiring and ground boiler in accordance with requirements of authority having jurisdiction, or in absence of such requirements, the National Electrical Code, ANSI/NFPA 70. B. Install thermostat. Locate on inside wall approximately 4 feet above floor. Do not install on outside wall, near fireplace, or where influenced by drafts or restricted air flow, hot or cold water pipes, lighting fixtures, television, or sunlight. Allow free air movement by avoiding placement of furniture near thermostat. C. Wire thermostat. Provide Class II circuit between thermostat and boiler. Run wires through grommet in L8148E Combination Control
New Yorker PVCG SERIES, 7 Alternate method for boiler located within confined space. Use indoor air if two permanent openings communicate directly with additional space(s) of sufficient volume such that combined volume of all spaces meet criteria for unconfined space. Size each opening for minimum free area of 1 square inch per 1,000 Btu per hour input of all equipment in spaces, but not less than 100 square inches. 7. Ventilation Duct Louvers and Grilles. Equip outside openings with louvers to prevent entrance of rain and snow, and screens to prevent entrance of insects and rodents. Louvers and grilles must be fixed in open position or interlocked with equipment to open automatically b
New Yorker PVCG SERIES, 31 Figure 19: Spark Gap Setting Figure 20: Flueway Cleaning b. Spark gap should be 1/8 inch for optimum performance. 3. To replace complete pilot assembly. a. Remove two machine screws holding pilot burner to pilot bracket. b. Disconnect pilot tubing. c. Disconnect all other leads to pilot. d. Select pilot assembly with identical model number, reconnect leads and pilot tubing. Resecure to pilot bracket. 4. Reinstall main burner following procedure described in Paragraph F.1.
New Yorker PVCG SERIES, 18 V. Gas Piping A. Size gas piping. Design system to provide adequate gas supply to boiler. Consider these factors: 1. Allowable pressure drop from point of delivery to boiler. Maximum allowable system pressure is ½ psig. Actual point of delivery pressure may be less; contact gas supplier for additional information. Minimum gas valve inlet pressure is listed on rating label on front of boiler. 2. Maximum gas demand. Table 3 lists boiler input rate. Also consider existing and expected future gas utilization equipment (i.e. wate
New Yorker PVCG SERIES, 2 IMPORTANT INFORMATION - READ CAREFULLY NOTE: The equipment shall be installed in accordance with those installation regulations enforced in the area where the installation is to be made. These regulations shall be carefully followed in all cases. Authorities having jurisdiction shall be consulted before installations are made. All wiring on boilers installed in the USA shall be made in accordance with the National Electrical Code and/or local regulations. The New York City Department of Buildings has approved the PVCG™ Series boiler: Approval No. MEA 318-99-E. The City of Ne
New Yorker PVCG SERIES, 9 Table 2: Vent System Components A. General Guidelines. 1. Vent system installation must be in accordance with National Fuel Gas Code, NFPA 54/ANSI Z221.3, Venting of Equipment or applicable provisions of local building codes. Contact local building or fire officials about restrictions and installation inspection in your area. 2. This appliance requires a Special Gas Vent. Use Vent Connector and Vent Terminal in Vent Accessory Carton provided with boiler (See Repair Parts). The product is designed to use factory supplied
New Yorker PVCG SERIES, 4 I. Pre-Installation .................................. 5 II. Unpack Boiler ................................... 7 III. Venting ............................................. 8 IV. Water Piping and Trim .................... 14 V. Gas Piping ....................................... 18 VI. Electrical ......................................... 20 VII. System Start-up ............................... 22 VIII. Service ............................................. 29 IX. Repair Parts ..................................... 36 X. Appendix Low Water Cut Off ....................... 38 Table of Contents Figure 1: Dimensional Draw
New Yorker PVCG SERIES, 12 f. Once the installation is complete, operate appliance and inspect all joints to ensure that flue gases and/or liquid condensate will not escape. 2. Procedure for joining the female end of Gasket- Less Vent with the male end of Gasketed Vent. See Figure 4D. a. Clean joints of pipe or fittings using an alcohol pad to remove any dirt and grease. b. Slip a locking band over female (bell) end of pipe/fitting. c. Apply a continuous ¼ inch bead of sealant around male end of joint no more than 1/8 inch from end. d. Align weld seams in pipes and use a slight twisting moti
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