Energy Tech Laboratories 40 Series manual

INSTALLATION, OPERATING AND SERVICE INSTRUCTIONS CL™ SERIES CAST IRON OIL-FIRED BOILER 100825-01R5-10/08 Price - $3.00 n o n o i t a m r o f n i g n i k e e s n e h W . r o t c a r t n o c g n i t a e h r u o y l l a c , r e l i o b o t s r i a p e r r o e c i v r e s r o F . l e b a L g n i t a R n o n w o h s s a r e b m u N l a i r e S d n a r[...]

2 IMPORT ANT INFORMA TION - PLEASE READ THIS P AGE CAREFULL Y 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 pos[...]

3 W ARNING 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 T rim Sections of this manual for details. This boiler is designed to burn No. 2 fuel [...]

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.[...]

5 Figure 1A: CL3 Thru CL5 W ater Boiler Less T ankless Heater Figure 1B: CL3 Thru CL5 W ater Boiler With T ankless Heater[...]

6 Figure 1C: CL3 Thru CL5 Steam Boiler with or without T ankless Heater T ABLE 1: DIMENSIONAL DA T A (SEE FIGURES 1A THRU 1C) Boiler Model Dimensions Minimum Chimney Size Approx. W ater Content - Gallons Heat T ransfer Surface Area - Sq. Ft. "A" "B" "C" Rectangular Round CL3 17-3/8" 8-1/4" 5-7/8" 8"[...]

7 Figure 2: Minimum Installation Clearances T o Combustible Materials (Inches) T ABLE 2: RA TING DA T A NOTE 1: Listed clearances comply with American National Standard NFP A 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. Li[...]

8 II. Installation Instructions A. REMOVE CRA TE 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. REMOV AL OF BOILER F[...]

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. T ighten 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 t[...]

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: Ele[...]

1 1 NOTE: V ertical 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. V alve spindle must be in vertical position. T ighten with wrench. Pipe discharge as shown in F[...]

12 in left rear corner on top of boiler as shown in Figure 1C. T ighten with wrench. Pipe dischar ge as shown in Figure 1 1. Installation of the relief valve must be consistent with ANSI/ASME Boiler and Pressure V essel Code, Section IV . Figure 10: Recommended Piping for Combination Heating & Cooling (Refrigeration) Systems Figure 1 1: Recomme[...]

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[...]

14 I. CONNECT T ANKLESS HEA TER PIPING AS SHOWN IN Figure 12. See T able 3 for T ankless 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 h[...]

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 t[...]

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 syst[...]

17 Figure 17: Wiring Diagram for W ater Boilers With Beckett AFG Burner and Split Controls Less T ankless Heater SEQUENCE OF OPERA TION 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 a[...]

18 Figure 17A: Wiring Diagram for W ater Boilers With Carlin EZ-HP Burner and Split Controls Less T ankless Heater Figure 17B: Wiring Diagram, W ater without T ankless Heater , Riello Burner[...]

19 Figure 18: Wiring Diagram for W ater Boilers with Beckett AFG Burner and Split Controls with T ankless Heater SEQUENCE OF OPERA TION 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 a[...]

20 Figure 18A: Wiring Diagram for W ater Boilers with Carlin EZ-PH Burner and Split Controls with T ankless Heater Figure 18B: Wiring Diagram, W ater with Rear T ankless Heater , Riello Burner[...]

21 SEQUENCE OF OPERA TION 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 d[...]

22 Figure 19A: Wiring Diagram, Steam Boilers With or W ithout T ankless Heater , McDonnell & Miller PS-801 Probe L WCO, Carlin EZ-HP Burner Figure 19B: Wiring Diagram, Steam with or without T ankless Heater , Optional McDonnell & Miller PS-801 Probe L WCO, Riello Burner[...]

23 III. Indirect W ater Heater Piping A. CONNECT Alliance™ or other Indirect W ater Heater Piping as shown in Figures 15 and 16. Refer to Alliance™ or other Indirect W ater Heater Instruction Manual for additional installation information. Figure 20: Indirect W ater Heater Piping on CL Series W ater Boiler 1. CL SERIES W A TER BOILER - Figure 2[...]

24 IV . Operating and Service Instructions 3. On WA TE R BOILERS WITH T ANKLESS HEA TERS 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 [...]

25 Figure 23: Display Readout Denitions T ABLE 7: L7248/L7224 C O NT RO L LE R OPERATING SEQUENCE T ABLE 6: L ED 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, 1 10 V ac. E[...]

26 Figure 24: Setpoints and Differentials System Condition Diagnostic Condition Check Action Boiler is cold, house is cold. Display is OFF . 120 V ac System power . T urn system power on. Display is ON. 24 V ac T -T No 24 V ; replace control. 24 V present; disconnect thermostat, short T -T . Boiler starts, check wiring and thermostat. 120 V ac at B[...]

27 Figure 26: Adjusting Fuel Pump Pressure Figure 25A: Electrode Settings (Carlin EZ-HP) G. ADJUST OIL BURNER BEFORE ST AR TING. 1. SET BURNER AIR BAND AND AIR SHUTTER, see T able 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 nece[...]

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 T able 9A[...]

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.[...]

30 V . Maintenance and Service Instructions A . MAINTENANCE OF LOW WATER CUT- O FF DEVICES W ARNING 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 [...]

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 . T urn off oil burner . Drain boiler . Open all radiator valves. Reinstall all supply main air valves. Open gate valve in Hartford Loop. v . When b[...]

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 valv[...]

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 elimina[...]

34 VI. Boiler Cleaning Figure 28: Cleaning of Boiler Flueways A. CLEAN THE FLUEW A YS (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[...]

35 Important Produc t Safety Information Refractory Ceram ic 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 know[...]

36 TROUBLE SHOOTING CARLIN 40200 OIL PRIMAR y CONTROL CARLIN 40200 OIL PRIMAR y 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. C[...]

37 All CL™ Series repair parts may be ordered through New Y orker Boiler Co., Inc., or its authorized distributors. Should you require assistance in locating a New Y orker Distributor in your area, or have questions regarding the availability of New Y orker products or repair parts, please contact: New Y orker Boiler Co., Inc., P .O. Box 10, Hat?[...]

38 Bare Boiler Assembly (Exploded View)[...]

39 Item No. Description Boiler Size / Quantity Part No. CL3 CL4 CL5 Bare Boiler Assembly 1 Front Section (Non-Htr .), Machined W ater ---(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 W ater ---(OR)--- Rear Section (Non-Htr .), Machined Steam 1 1 1 71720[...]

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 3 Jacket Reversible Side Panel Assembly Non-Heater Build 2 --- --- 100821-03 --- 2 -[...]

41 CL3 Thru CL5 W ater Boilers - T rim and Controls Item No. Description Boiler Size / Quantity Part No. CL3 CL4 CL5 CL3 Thru CL5 W ater Boilers - T rim and Controls 1 Beckett R7184B Oil Primary Control 1 1 1 100136-01 2 Honeywell L7248C1014 Hi Limit, Circ. Relay --- (OR)--- L7224C1004 Hi & Lo Limit, Circ. Relay 111 100059-01 100862-01 3 ¾&quo[...]

42 Item No. Description Boiler Size / Quantity Part No. CL3 CL4 CL5 CL3 Thru CL5 Steam Boilers - T rim and Controls 1 Beckett R7184B Oil Primary Control 1 1 1 100136-01 2 McDonnell & Miller PS801 L WCO With Probe 1 1 1 80160723 3 Honeywell P A404A1009 Pressuretrol 1 1 1 80160300 3A ¼" x 90° Syphon, 2½" Equal Leg 1 1 1 806603006 3B [...]

43 BECKETT OIL BURNER P ARTS LIST MODEL AFG --- 60-Hz, 3450 RPM FOR REPLACEMENT OIL BURNER P ARTS, CONT ACT YOUR WHOLESALER OR THE BURNER MANUF ACTURER: R. W . BECKETT CORP . P .O. BOX 1289 EL YRIA, OHIO 44036 1-800-645-2876 Beckett AFG Burner[...]

44 BECKETT OIL BURNER P ART 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 T ube Combination AFG70MBAS AFG70MBAS AFG70MDAS[...]

45 VIII. Low W ater Cut Off (L WCO) A 24 V AC L WCO is used primarily for gas red boilers where a 24 volt control circuit exists within the boiler . However, a 24 V AC L WCO can only be used if the boiler manufacturer has provided piping and wiring connections and instructions to allow for this application. How to T est Shut off fuel supply . Lo[...]

46 T ABLE 9: BURNER SPECIFICA TIONS Beckett AFG Boiler Model Firing Rate GPH Settings Nozzle 3 Pump Pressure Head (Setting) Air Shutter Air Band GPH x Angle T ype 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[...]

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.[...]

48 SER VICE RECORD DA TE SERVICE PERFORMED[...]

49 SER VICE RECORD DA TE SERVICE PERFORMED[...]

50 SER VICE RECORD DA TE SERVICE PERFORMED[...]

51[...]

52 NEW YORKER BOILER CO., INC. Limited Warranties For Residential Cast Iron Steam Boilers By this Warranty Statement New Yo rker 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® bra[...]