INSTALLATION, OPERATING AND SERVICE INSTRUCTIONS FOR GHE™ SERIES CONDENSING HIGH EFFICIENCY DIRECT VENT GAS-FIRED HOT WATER BOILER As an ENERGY STAR® Partner, New Yorker Boiler Co. Inc. has determined that the GHE Series meets the ENERGY STAR® guidelines for energy efficiency established by the United States Environmental Protection Agency (EPA). 9700609 For service or repairs to boiler, call your heating contractor.
IMPORTANT INFORMATION - READ CAREFULLY The following terms are used throughout this manual to bring attention to the presence of hazards of various risk levels, or to important information concerning product life. DANGER CAUTION Indicates an imminently hazardous situation which, if not avoided, will result in death, serious injury or substantial property damage. Indicates a potentially hazardous situation which, if not avoided, may result in moderate or minor injury or property damage.
DANGER Explosion Hazard. DO NOT store or use gasoline or other flammable vapors or liquids in the vicinity of this or any other appliance. If you smell gas vapors, DO NOT try to operate any appliance - DO NOT touch any electrical switch or use any phone in the building. Immediately, call the gas supplier from a remotely located phone. Follow the gas supplier’s instructions or if the supplier is unavailable, contact the fire department. WARNING • Asphyxiation Hazard.
Table of Contents I. Product Description 4 II. Specifications 4 III. Before Installing 5 IV. Locating The Boiler 6 V. Mounting The Boiler 7 VI. Air For Ventilation 8 VII. Venting 11 A. General Vent System Design 11 B. Design Requirements Unique to Horizontal Twin Pipe Venting Systems 17 C. Design Requirements Unique to Vertical Venting Systems 22 D. Design Requirements Unique to Split Vent Systems 25 E.
I Product Description This boiler is a stainless steel gas fired condensing boiler designed for use in forced hot water heating systems requiring supply water temperatures of 180°F or less. It is designed for installation on a wall. This boiler may be vented vertically or horizontally with combustion air supplied from outdoors. It is not designed for use in systems containing significant amounts of dissolved oxygen. II Specifications FIGURE 2.
Table 2.2: Specifications GHE Series AHRI Ratings Other Specifications SUPPLY & APPROX. MAXIMUM MINIMUM HEATING NET AHRI WATER VENT GAS AFUE RETURN NET MODEL* INPUT INPUT CAPACITY RATING* VOLUME COLLAR CONNECTION (%) CONNECTION WEIGHT (MBH) (MBH) (MBH) (MBH) (Gal.) DIA. SIZE (NPT) SIZE (NPT) (lb) GHE80 80 16 74 64 94.0 0.36 2” 1” 1/2” 81 GHE100 100 20 92 80 93.3 0.44 2” 1” 1/2” 83 GHE120 120 24 112 97 94.0 0.53 3” 1” 1/2” 86 GHE150 150 30 142 123 95.0 0.
4) All boilers are shipped from the factory configured for use with natural gas. They may be converted for use with LP gas (“propane”) using a combustion analyzer in accordance with the instructions in Appendix A. DANGER • • • Do not attempt to operate this boiler on LP gas without converting it in accordance with the instructions shown in Appendix A. Do not attempt to convert this boiler to LP gas without the use of a combustion analyzer.
Figure 4.1: Minimum Clearances To Combustible Construction V Mounting The Boiler CAUTION This boiler weighs as much as 111 pounds: • Two people are required to safely lift this boiler onto the wall mounting hook. • Make sure that wall mounting hook is anchored to a structure capable of supporting the weight of the boiler and attached piping when filled with water. Jurisdictions in areas subject to earthquakes may have special requirements for supporting this boiler.
1) If the boiler is installed on a framed wall, minimum acceptable framing is 2 x 4 studs on 16” centers. The boiler mounting holes are on 16” centers for installation between two studs at the standard spacing. In cases where the boiler cannot be centered between the studs, or where the studs are spaced closer than 16” apart, the boiler may be anchored to ¾” plywood or horizontal 2 x 4s anchored to the studs. 2) 5/16” x 2” lag screws and washers are provided for mounting this boiler.
Figure 5.
Figure 5.
VII Venting WARNING • Asphyxiation Hazard. Failure to vent this boiler in accordance with these instructions could cause products of combustion to enter the building resulting in severe property damage, personal injury or death. • Do not interchange vent systems or materials unless otherwise specified. • The use of thermal insulation covering vent pipe and fittings is prohibited. • Do not use a barometric damper, draft hood or vent damper with this boiler.
FIGURE 7.0 BASIC VENT OPTIONS FIGURE 7.0a: HORIZONTAL TWIN PIPE FIGURE 7.0b: VERTICAL TWIN PIPE FIGURE 7.0c: SPLIT VENTING All of these systems are considered “direct vent” because the air for combustion is drawn directly from the outdoors into the boiler. One of the vent option columns in Tables 7.5, 7.11 or 7.15 must match the planned vent and air intake system exactly. Design details applying to all vent systems are shown in this section.
2.
TABLE 7.1: VENT/ AIR INTAKE FITTING EQUIVALENT LENGTH CPVC/PVC FITTING EQUIVALENT LENGTH (ft) 2” 90 ELBOW (“SANITARY BEND”) 2.6 3” 90 ELBOW (“SANITARY BEND”) 4.0 2” 90 ELBOW (“SHORT BEND” ) 6.0 3” 90 ELBOW (“SHORT BEND”) 10.0 2” 45 ELBOW 1.5 3” 45 ELBOW 2.0 2” COUPLING 0.0 3” COUPLING 0.0 FIGURE 7.2: CPVC AND PVC ELBOWS 4. Minimum Vent and Air Intake Lengths - Observe the minimum vent lengths shown in Tables 7.5, 7.11 and 7.15. 5.
9. Running PVC Vent Pipe Inside Enclosures and Through Walls - PVC vent pipe must be installed in a manner that permits adequate air circulation around the outside of the pipe: • • Do not enclose PVC venting - Use CPVC in enclosed spaces, even if PVC is installed upstream. PVC venting may not be used to penetrate combustible or non-combustible walls unless all of the following conditions are met: a. The wall penetration is at least 66 inches from the boiler as measured along the vent. b.
FIGURE 7.
B. Design Requirements Unique to Horizontal Twin Pipe Venting Systems Table 7.5 summarizes all horizontal twin pipe vent options. Illustrations of horizontal twin pipe vent systems are shown in Figures 7.7 – 7.9. In addition to the requirements in Part VII-A, observe the following design requirements: 1. Permitted Terminals for Horizontal Venting: Terminal Option A: Fittings – Vent terminates in a plain end. Intake terminates in a PVC 90 sweep elbow pointing down.
Table 7.5: Summary of Horizontal Twin Pipe Venting Options Vent Option Illustrated in Figure Pipe Vent Penetration through Intake Structure 1 2 7.7, 7.8, 7.9 7.7, 7.8, 7.
• • • Under certain conditions, water in the flue gas may condense, and possibly freeze, on objects around the vent terminal including on the structure itself. If these objects are subject to damage by flue gas condensate, they should be moved or protected. Install the vent and air intake terminals on a wall away from the prevailing wind. Reliable operation of this boiler cannot be guaranteed if these terminals are subjected to winds in excess of 40 mph.
FIGURE 7. 8: HORIZONTAL CPVC/PVC VENTING WITH LOW PROFILE TERMINAL, (VENT OPTIONS #1 & 2, TERMINAL OPTIONS B & C) FIGURE 7.
21 FIGURE 7.10: LOCATION OF VENT TERMINAL RELATIVE TO WINDOWS, DOORS, GRADES, OVERHANGS, METERS AND FORCED AIR INLETS TWO PIPE SYSTEM VENT TERMINAL (SHOWN) TWO-PIPE SYSTEM AIR INTAKE TERMINAL (NOT SHOWN) Note: Air intake termination not shown.
C. Design Requirements Unique to Vertical Venting Systems Table 7.11 summarizes all vertical twin pipe vent options. In addition to the requirements in Part VII-A, observe the following design requirements: 1. Permitted Terminals for Vertical Venting Terminal Option H: Fittings – Vent terminates in a plain end (coupling for PVC. Intake terminates in a PVC 180 elbow pointing down (two sweep 90’s may be substituted). Observe the clearances from the roof, and normal snow line on the roof, shown in Figures 7.
Table 7.11: Summary of Vertical Twin Pipe Venting Options Option Illustrated in Figure Pipe Vent Penetration through Intake Structure Material Vent Intake Vent Nominal Diameter Intake Min Equivalent Vent Length: 080 100 120 Models 150 10 11 7.12, 713 7.12, 7.
FIGURE 7.12: VERTICAL CPVC/PVC VENTING, (VENT OPTIONS 10 & 11, TERMINAL OPTION H) FIGURE 7.
D. Design Requirements Unique to Split Vent Systems Table 7.15 summarizes all split vent options. Illustrations of split vent systems are shown in Figure 7.14. In addition to the requirements in Part VII-A, observe the following design requirements: 1. Permitted Terminals for Split Venting: Rigid Vent Systems (Vent Options 25-26) – Vent terminates in a plain end (coupling for PVC). Intake terminates in a PVC 90 sweep elbow pointing down.
Table 7.15: Summary of Split Vent System Options Option # Illustrated in Figure Pipe Penetration Through Structure Vent Intake Vent Material Intake Vent Nominal Diameter Intake Min Equivalent Vent Length: 080 100 120 Models 150 25 26 7.14 Roof Wall CPVC/PVC (Note 2) PVC 2” 2” or 3” 7.
E. Assembly of CPVC/PVC Vent Systems WARNING • • • • • • 1. Asphyxiation Hazard. Failure to follow these instructions could cause products of combustion to enter the building, resulting in severe property damage, personal injury, or death. A CPVC elbow and a 30” straight section of CPVC (not supplied) must be installed at the boiler end of the vent system before transitioning to Schedule 40 PVC pipe (ASTM 2665) components for remainder of vent system.
FIGURE 7.17: VENT CONNECTIONS AND FLUE GAS SAMPLE CAP LOCATION b. c. 4. If desired, the terminals can be attached to the end of the vent and/or intake pipes with field supplied stainless steel screws so that they can be later removed for cleaning and inspection. If this is done, drill a clearance hole in the coupling or elbow and a tap hole in the end of the vent/intake pipes to accept these screws. If these terminals are installed on snorkels, assemble the snorkels as shown in Figure 7.6.
RODENT SCREENS ARE SUPPLIED BY INSTALLER FIGURE 7.18: INSTALLATION OF STANDARD HORIZONTAL TERMINALS RODENT SCREENS ARE SUPPLIED BY INSTALLER FIGURE 7.
b. c. d. 7. e. f. g. h. i. Drill two 3-1/8 holes through the wall for the vent and intake pipes. Drill four 3/16 holes for the mounting screws. Install the vent and intake pipe sections passing through the wall. Cut the pipes so that they protrude the following distances from the surface on which the vent plate will be mounted: • Vent: Between 1-3/4 and 2-1/4” • Intake: Between ¼ and 1” Seal pipe penetrations in wall with RTV (silicone sealant).
FIGURE 7.20: INSTALLATION OF IPEX LOW PROFILE TERMINAL THROUGH SIDEWALL FIGURE 7.
FIGURE 7.22: CUTTING IPEX AND DIVERSITECH CONCENTRIC VENT TERMINALS FIGURE 7.
FIGURE 7.
F. Condensate Trap and Drain Line All condensate which forms in the boiler or vent system passes through the heat exchanger and out of a bottom drain port which is connected to the condensate trap with a hose. This trap allows condensate to drain from the heat exchanger while retaining flue gases in the boiler. This trap is an integral part of the boiler but must be connected to a drain pipe as shown in Figure 7.25.
G. Removing an Existing Boiler From a Common Chimney This section only applies if this boiler is replacing an existing boiler that is being removed from a common chimney. In some cases, when an existing boiler is removed from a common chimney, the common venting system may be too large for the remaining appliances.
VIII Gas Piping WARNING Explosion Hazard. Failure to properly pipe gas supply to boiler may result in improper operation or leaks of flammable gas. • • • • • Gas supply to boiler and system must be absolutely shut off prior to installing or servicing boiler gas piping. Always assure gas piping is absolutely leak free and of the proper size and type for the connected load. Use a thread compound compatible with liquefied petroleum gas.
CAUTION • • • Support the weight of the gas line piping independently from the boiler gas connection fitting located on the bottom of the boiler. If an additional regulator is used to reduce boiler inlet pressure below 1/2 psig (3.4 kPa) it must be at least 6 to 10 feet upstream of the boiler. It is very important that the gas line is properly purged by the gas supplier or utility company. FIGURE 8.1: GAS CONNECTION TO BOILER NOTICE Install 1/2” ground joint union (nut side down) as shown in Figure 8.1.
IX System Piping A. General System Piping Precautions WARNING • Failure to properly pipe boiler may result in improper operation and damage to boiler or structure. Install boiler so that the gas ignition system components are protected from water (dripping, spraying, rain, etc.) during boiler operation and service (circulator replacement, etc.). Oxygen contamination of boiler water will cause corrosion of iron and steel boiler components and can lead to boiler failure.
B. Near Boiler Piping Design Proper operation of this boiler requires that the water flow rate through it remain within the limits shown in Table 9.1 any time the boiler is firing. At flow rates below the minimum shown, the boiler’s flow switch and/or temperature rise limit function may prevent the boiler from firing. Flow rates through the boiler in excess of the maximum shown in Table 9.
40 FIGURE 9.
41 FIGURE 9.
42 FIGURE 9.
Example – A 120MBH model is to be connected to a heating system as shown in Figure 9.2. A total of 20 ft of straight pipe will be installed between the boiler and the system loop. Count all fittings in the boiler loop (shaded in Figure 9.2): 4 90 Elbows 2 Turn in Tee (under boiler- primary-secondary tees not counted) 2 Isolation Valves 1 Y Strainer having a Cv of 30. Note: Unions, Secondary Connection Tees, and factory supplied fittings are ignored. Calculate total equivalent length from Table 9.
C: Standard Piping Installation Requirements Observe the following requirements when installing the boiler piping: 1) Relief Valve (Required) – The relief valve is shipped loose and must be installed in the location shown in Figure 9.6, using the side outlet Tee and other fittings provided. ASME Section IV currently requires that this relief valve be installed above the heat exchanger as shown.
11) Low Water Cut-off (may be required by local jurisdiction) – Protection of this boiler against low water and/or inadequate flow is provided by the UL353 certified flow switch built into the boiler. This is a water tube boiler and this flow switch is therefore the only effective way to provide such protection. Section HG614(c ) of the 2015 ASME boiler and Pressure Vessel Code recognizes the use of a listed flow switch in lieu of a low water cut-off on water tube boilers.
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X Wiring DANGER Electrical Shock Hazard. Positively assure all electrical connections are unpowered before attempting installation or service of electrical components or connections of the boiler or building. Lock out all electrical boxes with padlock once power is turned off. WARNING All wiring and grounding must be done in accordance with the authority having jurisdiction or, in the absence of such requirements, with the National Electrical Code /NFPA 70).
The use of the pump outputs are as follows: a) Boiler pump - Pumps water through the boiler. It is on whenever there is a call for CH or DHW. b) DHW Pump (“IWH Circulator”) - Pumps water directly through the indirect water heater. c) System Pump - Pumps water through the radiation. This pump is hydraulically separated from the boiler pump, either by closely spaced tees, or by a hydraulic separator. The system pump is always on when the system is responding to a call for CH.
FIGURE 10.2: LINE VOLTAGE FIELD CONNECTIONS FIGURE 10.
b) Outdoor Sensor - Use only the Tasseron TSA00AA outdoor sensor supplied with the boiler. When this sensor is connected and enabled, the boiler will adjust the target supply water temperature downwards as the outdoor air temperature increases. This sensor should be located on the outside of the structure in an area where it will sense the average air temperature around the house. Avoid placing this sensor in areas where it may be covered with ice or snow.
FIGURE 10.4a: 120V LWCO FIELD WIRING FIGURE 10.
L Gnd N 120VAC/60Hz/1Ph R7910B Boiler Control J4‐2 J4‐3 P1‐4 Ground screw in boiler J‐box P1‐2 DHW Pump J4‐4 J4‐5 P1‐3 P1‐1 Boiler Pump J4‐6 J4‐7 P1‐5 System Pump Combustion Fan (120V Conn.
FIGURE 10.
54
XI Start-up and Checkout WARNING Completely read, understand and follow all instructions in this manual before attempting start-up. NOTICE Safe lighting and other performance criteria were met with the gas train assembly provided on the boiler when the boiler underwent the test specified in Z21.13. Use the following procedure for initial start-up of the boiler: 1) Verify that the venting, water piping, gas piping and electrical system are installed properly.
DANGER Asphyxiation Hazard. Failure to properly convert this boiler for use on lp gas can cause unreliable operation at elevated carbon monoxide (CO) levels, resulting in personal injury or death.
MANUAL AIR VENT ATTACH 1/4" ID CLEAR TUBING TO HOSE BARB AND ROUTE TO SAFE PLACE AWAY FROM CONTROLS BEFORE OPENING VENT. FIGURE 11.1: LOCATION OF MANUAL AIR VENT 10) If the boiler is to be converted to propane (LP gas), start-up and adjust throttle as described in Appendix A. 11) Start the boiler using the lighting instructions on page 61. With the boiler powered up, and with no call for heat, the display will “boot up” as shown in Figure 11.2a for a period of 1-2 minutes.
Power Up Present for approx. 2s Software ver. flashes for approx. 80s Home Screen with no demand FIGURE 11.2a: HOME SCREEN AT POWER-UP (No Call for Heat) Alternate Flash Outlet (Supply) Temp. Demand Codes: CH = Heat dH = Domestic Hot Water FP = Frost Protection Demand Code FIGURE 11.2b: HOME SCREEN ON HEAT DEMAND For a list of Hold and Lockout Codes, see Section XIV Alternate Flash Outlet (Supply) Temp Alternate Flash Hold Code Outlet (Supply) Temp Hold Lockout Code Lockout FIGURE 11.
WARNING Asphyxiation Hazard. Each boiler is tested at the factory and adjustments to the air-fuel mixture are normally not necessary when operating on natural gas at sea level. Consult the factory before attempting to make any such adjustments. Improper gas valve or mixture adjustments could result in property damage, personal injury or loss of life due to carbon monoxide (CO) poisoning. WARNING Asphyxiation Hazard.
16) Perform a combustion test. Boilers are equipped with a screw cap in the vent adapter. Be sure to replace this cap when combustion testing is complete. Check CO2 (or O2) and CO at both high and low fire. The boiler may be temporarily locked into high or low fire as follows: a) From the home screen, press and hold both the LH and RH buttons for 3s. The screen will change to into Diagnostic mode and show the flame signal (Figure 12.7).
Lighting and Operating Instructions 61
XII Operation A. General Information This boiler uses the microprocessor based Honeywell R7910B (“boiler control”) to manage all boiler functions including flame supervision and modulation. Two set point or “target” boiler supply temperatures are stored in the control’s memory; one for space heating (CH) and one for domestic hot water (DHW) production.
UP DWN LH (”Done”/”Reset”) RH (“Next”) Default Mode = User Mode To Reach Set‐up Mode: Press and hold both UP and DWN for 3s To reach Diagnostic Mode: Press and Hold LH and RH for 3s. FIGURE 12.0: CONTROL PANEL When Odr is on, and when the boiler is responding to a call for space heat, the target water temperature will adjust downward (within certain limits) as the outdoor temperature increases. The graph in Figure 12.3 shows how the target water temperature changes with outdoor temperature.
WARNING Burn Hazard. Water temperatures over 125°F can cause personal injury or death due to scalding. Children, Disabled, and Elderly are at most risk of being scalded. This boiler is not designed to directly control domestic water temperature. • Use only the thermostat recommended by the indirect water heater manufacture to control the DHW temperature. • Adjust the thermostat set point in accordance with the indirect water heater manufacturer’s instructions.
S1 S2 Alternate Flash Alternate Flash From User Mode S0 S3 S5 S4 S6 Outdoor Reset (Odr) On Outdoor Reset (Odr) Off Alternate Flash S7 See Table 12.4 and text for a description of settings Set‐up Mode Button Usage: LH (Done) – Save & return to User Mode RH (Next) – Save & move to next screen UP/DWN – Change setting FIGURE 12.
FIGURE 12.3: OUTDOOR RESET CURVE (DEFAULT SETTINGS SHOWN) TABLE 12.4: Default Settings and Ranges Scr. # S0 Description on Screen “F” or “C” S1 “CH” S2 S3 S4 S5 “Odr” “LBT” “HOD” “LOD” S6 “dH” S7 ASC Description Temperature Units Heating set point (max temperature set-point upon a call for space heat) Outdoor Reset Enable Low boiler temp (Fig 12.3) High outdoor temp (Fig 12.3) Low outdoor temp (Fig 12.
C. Pump Control and DHW Priority Pump operation in response to different demands is shown in Table 12.5. This behavior cannot be changed. Like all boilers, this one is capable of regulating only one target boiler water temperature at any given time. This means that priority must be given to either the CH or DHW target temperature. For this reason, the boiler gives priority to the DHW demand for the first 60 minutes during which both calls for CH and DHW continuously exist.
E. Diagnostic Mode Enter Diagnostic Mode by pressing and holding both the LH and RH buttons for at least 3s. The RH (“Next”) button navigates between screens. The LH (“Done”) button returns to User Mode. All Diagnostic Mode screens are shown in Figure 12.7. A description of each is below. For more information on troubleshooting, see Section XIV. uA – Flame signal in micro-Amps. This is shown as “---“ when the burner is off. Alert – Not used (screen will always read zero).
XIII. Service and Maintenance WARNING • Asphyxiation Hazard. Fire Hazard. Explosion Hazard. This boiler requires regular maintenance and service to operate safely. Follow the instructions contained in this manual. • Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury or loss of life. Read and understand the entire manual before attempting installation, start-up operation, or service.
NOTICE Warranty does not cover boiler damage or malfunction if the following steps are not performed at the intervals specified. 1) Continuously: a. Keep the area around the boiler free from combustible materials, gasoline and other flammable vapors and liquids. b. Keep the area around the combustion air inlet terminal free from contaminates. c. Keep the boiler room ventilation openings open and unobstructed. 2) Monthly Inspections: a.
BURNER DOOR MOUNTING NUT (FOUR PLACES) FLAME ROD IGNITION ELECTRODE FIGURE 13.1: FLAME IONIZATION ELECTRODE AND IGNITION ELECTRODE LOCATION FIGURE 13.2: IGNITION ELECTRODE GAP j. k. l. m. n. Unplug the ignition, ground, and flame rod wires from the ignition electrode and the flame rod (Figure 13.1). Use a 10mm wrench to remove the four nuts securing the fire door to the heat exchanger (Figure 13.1).
o. p. Inspect the ignition electrode and flame rod for deposits. Clean any found with steel wool. Do not use sand paper or Emory cloth for this cleaning. Inspect the ceramic portion of both of these parts for cracks and replace if any are found. Verify that the ignition electrode gap is within the range shown in Figure 13.2 Inspect the blower gas valve assembly, looking for dust, lint, or other debris that may have been drawn into this assembly. Excessive deposits may be vacuumed out.
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 above 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.
FIGURE 13.3: CONDENSATE TRAP EXPLODED PARTS VIEW t. Replace any wiring which has been disconnected. u. Inspect the hydronic system. Look for leaks and repair any found. If system contains antifreeze, or other additives, test and/or maintain them as directed by the additive manufacturer. See Part XI (Start-up and Checkout) for important information on boiler water and the use of boiler water additives. v. Test the flow switch. To do this: • Start with the boiler in standby.
XIV. Troubleshooting DANGER • Explosion Hazard. Electrical Shock Hazard. Burn Hazard. This boiler uses flammable gas, high voltage electricity, moving parts, and very hot water under high pressure. Assure that all gas and electric power supplies are off and that the water temperature is cool before attempting any disassembly or service. • Do not attempt any service work if gas is present in the air in the vicinity of the boiler. Never modify, remove or tamper with any control device.
B. Troubleshooting when the Display is Blank Use the flow chart in Figure 14.5 to locate the problem when the display is blank or is not readable. C. Operation and Troubleshooting of Boiler Limits, Switches and Sensors For the location of the controls described below, see Figure 14.6. Thermal Fuse – The thermal fuse is designed to prevent boiler operation in the event that the heat exchanger is damaged by excessive flue gas temperatures. It is set to open at 358F and is a one shot non-replaceable device.
“Hold” Illuminated FIGURE 14.0: HOLD SCREEN Alternate Flash Outlet (Supply) Temp Hold Code FIGURE 14.1: SUSTAINED HOLD Alternate Flash Outlet (Supply) Temp Lockout Code FIGURE 14.2:Lockout LOCKOUT SCREEN Supply Sensor – The boiler control infers the supply temperature based on the resistance measured at the supply sensor. Table 14.8a shows this resistance as a function of water temperature.
LH (”Reset”) Figure 14.3: RESET BUTTON Condensate Trap – The condensate trap allows condensate to leave the boiler while containing flue gasses. In the event that this trap becomes blocked, condensate will start to back up in the trap. To prevent a rising condensate level from backing up into the heat exchanger, both a ground wire and the flame rod wire are bonded to this trap in such a way that an abnormally high condensate level will conduct flame current directly to ground (Figure 10.5).
FIGURE 14.4: LOCKOUT/HOLD CODES Code Meaning Possible Causes/Remedies 0 No hold or lockout present 47 Flame rod to ground leakage • • • Damaged flame rod Blocked condensate drain Shorted or mis-wired flame rod wiring 49 Voltage supplied to control is outside of acceptable range. • • • Line voltage supply to boiler is outside acceptable range. Defective transformer Bad connection between transformer and control. 50 Control modulation parameters are incorrectly set.
START N Is display completely dark? See Figures 10.5 and 10.6 for the location of connectors referenced here Y Verify that display is not still in power‐up ” process (Figure 11.
FIGURE 14.6: CONTROLS LOCATION FIGURE 14.
Table 14.8b: Outdoor Air Temperature Sensor Temperature versus Resistance Table 14.8a: Supply, Return and Flue Temperature Sensor Temperature versus Resistance Temperature °F 32 50 68 77 86 104 122 140 158 176 194 212 230 248 °C 0 10 20 25 30 40 50 60 70 80 90 100 110 120 Outdoor Temperature °F °C -20 -28.9 -10 -23.3 0 -17.8 10 -12.2 20 -6.7 30 -1.1 40 4.4 50 10.0 60 15.6 70 21.1 76 24.4 78 25.6 80 26.7 90 32.2 100 37.8 110 43.3 120 48.
XV Parts All GHE Series Repair Parts may be obtained through your local New Yorker Boiler Wholesale distributor. Should you require assistance in locating a New Yorker Distributor in your area, or have questions regarding the availability of New Yorker products or repair parts, please contact: New Yorker Boiler Co., Inc., P.O. Box 10, Hatfield, PA 19440-001, ATTN: Customer Service Department.
KEY # DESCRIPTION QTY.
Blower/Gas Valve Assembly for 80, 100, 120 KEY # 27, 28, 29, 36 DESCRIPTION BLOWER REPAIR KIT (includes blower, hardware and gasket) QTY.
Blower/Gas Valve Assembly for 150, 180 86
KEY # DESCRIPTION 51, 52, 53, 54, 57, 59, 60, 61 CONDENSATE TRAP REPAIR KIT (includes trap, trap ball, bracket, tubing, gasket, trap wires and hardware) QTY.
KEY # DESCRIPTION 63, 64, 66, 131 JUNCTION BOX ASSY (includes j-box, j-box mounting bracket, line voltage field connection harness and hardware) QTY.
89
DESCRIPTION 63, 64, 66, 131 JUNCTION BOX ASSY (includes j-box, j-box mounting bracket, line voltage field connection harness and hardware) 107154-01 65 CONTROL BOX 106723-01 1 EA 1 EA 1 EA 1 EA 1 EA 77 bottom panel 1 EA 106726-01 106726-02 106726-03 106829-01 106829-01 78 REAR PANEL ASSEMBLY 1 EA 106733-01 106733-01 106733-01 106836-01 106836-01 79 TOP PANEL REPAIR KIT 1 EA 107158-01 107158-01 107158-02 107158-03 107158-03 80 JACKET DRIP SHIELD, 80-180 106724-01 1 EA
KEY # 115 DESCRIPTION 1”NPT x 2” NIPPLE QTY.
130 131 132 133 134 KEY # DESCRIPTION QTY.
Appendix A: Instructions for Conversion of This Boiler for Use with LP Gas DANGER These instructions include a procedure for adjusting the air-fuel mixture on this boiler. This procedure requires a combustion analyzer to measure the CO2 and Carbon Monoxide (CO) levels in flue gas. Adjusting the air-fuel mixture without a proper combustion analyzer could result in unreliable boiler operation, personal injury, or death due to carbon monoxide poisoning.
WARNING • The throttle adjustments shown in Table A.2 are approximate. The final throttle setting must be found using a combustion analyzer. Leaving the boiler in operation with a CO level in excess of 200PPM air-free could result in injury or death from carbon monoxide poisoning. Leaving the boiler in operation with a CO2 level outside of the range shown in Table A.
FIGURE A.1a: GAS VALVE DETAIL (80MBH THRU 120MBH) FIGURE A.1b: GAS VALVE DETAIL (150MBH, 180MBH) TABLE A.
TABLE A.3: ACCEPTABLE COMBUSTION READINGS Model Allowable CO2 Readings (%) Fuel Sea Level - 2000 ft 80 100 120 150 180 Nat. Gas LP Nat. Gas LP Nat. Gas LP 2001 - 4500 ft 4501 - 7800 ft 7801 - 10200 ft Max CO (PPM Air-Free) 8.7 - 9.3 200 10.1 - 10.3 200 8.5 - 9.3 200 10.1 - 10.3 200 8.8 - 9.3 10.1 - 10.3 NOT PERMITTED 200 200 Nat. Gas 8.6 - 9.3 LP 9.7 - 10.3 200 Nat. Gas 8.5 - 9.1 200 LP 9.9 - 10.3 200 TABLE A.4: ACCEPTABLE GAS INLET PRESSURE RANGE Fuel Inlet Pressure (in w.
Appendix B: Special Requirements For Side-Wall Vented Appliances In The Commonwealth of Massachusetts IMPORTANT The Commonwealth of Massachusetts requires compliance with regulation 248 CMR 4.00 and 5.
1. Detailed instructions for the installation of the venting system design or the venting system components; and 2. A complete parts list for the venting system design or venting system. (d) MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED.
Appendix C: Control Set-up Using PIM This boiler’s control is equipped with a Program Module (PIM). This device is essentially a special “memory stick” containing a copy of the software parameters that were programmed into the control by the factory. This PIM has two uses: 1) If the control must be replaced, the data on this PIM may be transferred to a “universal” replacement control, so that it is correctly programmed with the parameters unique to the boiler at the installation.
FIGURE C1: REMOVAL OF PIM UP DWN LH (”Done”/”Reset”) RH (“Next”) FIGURE C2: HOME SCREEN 100 Press and hold both RH and DWN for approx.
From Home Screen Press RH (“Confirm”) to start uploading process “rES” flashes during upload process Upload successful? Confirm No Yes “rES” stops Flashing if upload successful Error code appears if upload fails. See Table C.4 for a list of codes To Home Screen FIGURE C3: UPLOADING PIM DATA TO CONTROL FIGURE C.4: PIM ERROR CODES Code Meaning Possible Causes/Remedies E81 Password not recognized.
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New Yorker Boiler Co. Inc. P.O. Box 10 Hatfield, PA 19440-0010 www.newyorkerboiler.
