INSTALLATION, OPERATING AND SERVICE INSTRUCTIONS PVCG-B™ SERIES GAS BOILER 9700609 BEFORE INSTALLATION: READ THIS MANUAL SAVE THESE INSTRUCTIONS Installing contractor and homeowner should read and be informed as to the proper installation and operation of this boiler. The manufacturer will not be responsible for improper installation or operation. This manual and all associated instruction material should be conspicuously posted near the boiler.
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.
Special Installation Requirements for Massachusetts A. For all side wall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in whole or in part for residential purposes and where the side wall exhaust vent termination is less than seven (7) feet above grade, the following requirements shall be satisfied: 1.
WARNING 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. Installation and service must be performed only by an experienced, skilled, and knowledgeable installer or service agency.
Table of Contents I. Pre-Installation................................ 7 VIII. System Start-up............................. 35 II. Unpack Boiler................................. 8 IX. Operation...................................... 39 III. Venting............................................ 9 X. Troubleshooting............................ 43 IV. Water Piping and Trim.................. 19 XI. Service........................................... 48 V. Gas Piping.....................................
Supply 1¼ NPT Model PVCG30B PVCG40B PVCG50B PVCG60B PVCG70B PVCG80B PVCG90B 1¼ NPT Return 4 3 Vent ¾ NPT Relief Valve PVCG-B CONNECTION SIZES(DIMENSIONS IN INCHES) Figure 2: Dimensions ‘A’ 11.65 14.72 17.78 20.84 23.90 26.97 30.
I. Pre-Installation WARNING If you do not follow these instructions exactly, a fire or explosion may result causing property damage or personal injury. DANGER Do not install boiler where gasoline or other flammable vapors or liquids, or sources of hydrocarbons (i.e. bleaches, cleaners, chemicals, sprays, paint removers, fabric softeners, etc.) are used or stored.
I. Pre-Installation (continued) volume of all spaces meet criteria for unconfined space. Size each opening for minimum free area of one (1) square inch per 1,000 Btu per hour input of all equipment in spaces, but not less than 100 square inches. 7. Combustion Air/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.
III. Venting WARNING Do not use this boiler with galvanized, Type 304 or Type 316 stainless steel, non metallic or any other non AL29-4C® based vent systems. Do not use a barometric damper or draft hood with this appliance. Do not use vent dampers with this boiler. Moisture and ice may form on surfaces around termination. To prevent deterioration, surfaces should be in good repair (sealed, painted, etc.).
III. Venting (continued) A. Vent Guidelines Due to Removal of an Existing Table 3: Vent System Components Boiler Vent System Component Part Number 3” Dia. Pipe x 1 Ft 8116296U 4” Dia. Pipe x 1 Ft 100176-01 3” Dia. Pipe x 3 Ft 8116298U 4” Dia. Pipe x 3 Ft 100177-01 Equivalent Feet of Pipe 1 3 3” Dia. Pipe x 5 Ft 8116300U 4” Dia. Pipe x 5 Ft 100178-01 3” Dia. Pipe x Adjustable 4” Dia. Pipe x Adjustable Equal to Installed Length 100179-01 (1.06 TO 1.64) 3” Dia. 90° Elbow 8116294U 4” Dia.
III. Venting (continued) B. General Guidelines 1. Vent system installation must be in accordance with National Fuel Gas Code, ANSI Z223.1/ NFPA 54 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. a. The product is designed to use New Yorker Boiler supplied AL29-4C® Stainless Steel vent system components.
III. Venting (continued) 10. Plan venting system to avoid possible contact with plumbing or electrical wires. Start at vent connector on top of boiler and work towards vent terminal. 11. If a non-standard length pipe is required: Gasketed Vent System: The use of the adjustable length pipe (P/N 8116319U) is recommended to complete a non-standard pipe length. This pipe requires a minimum installed length of 12¾ inch and can adjust across a 7 inch gap up to a maximum of 19¾ inch long.
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III. Venting (continued) Figure 5: Horizontal – Vent Terminal Configuration (3” or 4” Vent) E. Separate Vertical Venting System - See Figures 6, 7, 8 and 9 NOTICE Roof penetrations require the use of roof flashing and storm collar - not supplied with boiler. Vertical Venting – 1. See Figure 28 for Blower Vent Connector Assembly. Do not exceed maximum vent lengths. Refer to Table 4. 2. Installation of a vertical vent drain tee 8116304U is required on all vertical vent applications. See Figures 6 and 7.
Figure 6: Vertical Vent Installation III.
Figure 8: Vertical Vent Termination Extend Vent Piping to maintain minimum vertical (“X”) and minimum horizontal (“Y”) distance of twelve (12) inches from roof surface. Allow additional vertical (“X”) distance for expected snow accumulation. III.
III. Venting (continued) F. Optional Exterior Separate Horizontal Vent Terminal Mounting – See Figure 9. 1. See Figure 28 for Blower Vent Connector Assembly. Do not exceed maximum vent lengths. Refer to Table 4. 2. This installation will allow a maximum of seven (7) feet vertical exterior run of the vent piping to be installed . NOTICE Exterior run to be included in equivalent vent lengths. 3. Install vent piping. a. Install vent piping for desired venting system.
IV. Water Piping and Trim WARNING Failure to properly pipe boiler may result in improper operation and damage to boiler or structure. Oxygen contamination of 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. B. Optional Probe LWCO Installation A.
IV. Water Piping and Trim (continued) 5. When constructing a piping tree to install LWCO select fittings (tees, elbows etc) and nipples to have the same size (NPT) as boiler supply connection. At minimum, 1-1/4” tee with ¾” branch outlet is required to connect the probe LWCO to the supply piping. See Figure 10. DO NOT REDUCE THE SIZE OF NEAR BOILER SUPPLY FITTINGS AND NIPPLES. 2. The recommended location for an Auxiliary Limit on gas hot water boilers is in the supply piping.
IV. Water Piping and Trim (continued) NOTICE New Yorker recommends sizing the system circulator to supply sufficient flow (GPM) to allow a 20°F temperature differential in the system. When sizing the system circulator, the pressure drop of all radiators, baseboard and radiant tubing and all connecting piping must be considered. E. Install circulator with flanges, gaskets and bolts provided. Circulator harness allows circulator to be mounted on supply or return.
IV. Water Piping and Trim (continued) K. After the boiler and system have been cleaned and flushed, and before refilling the entire system add appropriate water treatment chemicals, if necessary, to bring the pH between 7 and 11. L. If it is required to perform a long term pressure test of the hydronic system, the boiler should first be isolated to avoid a pressure loss due to the escape of air trapped in the boiler.
Figure 14: Recommended Boiler Piping For Circulator Zoned Heating Systems IV.
Figure 15: Recommended Water Piping for Zone Valve Zoned Heating Systems IV.
V. Gas Piping 3. Length of piping and number of fittings. Refer to Table 7 for maximum capacity of Schedule 40 pipe. Table 8 lists equivalent pipe length for standard fittings. WARNING Failure to properly pipe gas supply to boiler may result in improper operation and damage to the boiler or structure. Always assure gas piping is absolutely leak free and of the proper size and type for the connected load. An additional gas pressure regulator may be needed. Consult gas supplier. 4.
V. Gas Piping (continued) Table 7: Maximum Capacity of Schedule 40 Pipe in CFH* For Natural Gas Pressures of 0.5 psig or Less 0.3 inch w.c. Pressure Drop Length [Feet] ½ 10 132 20 92 30 73 40 50 ¾ 0.5 inch w.c.
V. Gas Piping (continued) C. Pressure test. The boiler and its gas connection must be leak tested before placing boiler in operation. 1. Protect boiler gas control valve. For all testing over ½ psig, boiler and its individual shutoff valve must be disconnected from gas supply piping. For testing at ½ psig (3.5kPa) or less, isolate boiler from gas supply piping by closing boiler’s individual manual shutoff valve. 2.
VI. Electrical DANGER 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 Failure to properly wire electrical connections to the boiler may result in serious physical harm. Electrical power may be from more than one source. Make sure all power is off before attempting any electrical work.
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VI. Electrical (continued) NOTICE All wire, wire nuts, controls etc. are installer supplied unless otherwise noted. If an additional system limit is used, install in series with the auxiliary limit jumper shown in the drawing below.
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VII. Modular Installation A. General Guidelines 1. Read and follow all venting, combustion air, water piping, gas piping and electrical instructions contained in this manual unless otherwise instructed in this section. 2. Consult Local Building Codes or National Fuel Gas Code, NFPA 54/ANSI Z222.3 for restrictions and instructions on modular boiler installations. B. Module Sizing New Yorker recommends sizing each boiler in a modular system to provide 20 % of the combined heating load where ever possible.
Figure 21: Modular Boiler Piping VII.
VIII. System Start-up A. Verify that the venting, water piping, gas piping and electrical system are installed properly. Refer to installation instructions contained in this manual. B. Confirm all electrical, water and gas supplies are turned off at the source and that vent is clear of obstructions. C. Confirm that all manual shut-off gas valves between the boiler and gas source are closed. WARNING Completely read, understand and follow all instructions in this manual before attempting start up. D.
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VIII. System Start-up (continued) H. Check pilot burner flame. See Figure 24. Flame should be steady, medium hard blue enveloping 3/8 to ½ inch of sensing probe. I. Check main burner flame. See Figure 23. Flame should have clearly defined inner cone with no yellow tipping. Orange-yellow streaks should not be confused with true yellow tipping. 3. Main burners and pilot burner will extinguish and blower will stop when water level drops below low water cutoff probe.
VIII. System Start-up (continued) WARNING Failure to properly adjust gas input rate will result in over firing or under firing of the appliance. Improper and unsafe boiler operation may result. 4. Determine Input Rate. Multiply gas flow rate by gas heating value. 5. Compare measured input rate to input rate stated on rating plate. a. Boiler must not be over fired. Reduce input rate by decreasing manifold pressure. Do not reduce more than 0.3 inch w.c.
IX. operation A. Boiler Sequence of Operation NORMAL OPERATION 1. The PVCG-B Boilers are equipped with a Boiler Control (control). This control replaces the traditional separate ignition control, high limit switch, blower relay and circulator relay and adds energy saving thermal purge features. Energy is saved by starting the circulator and delaying the burner start when there is residual heat available in the boiler.
IX. operation (continued) The STA (status) display code has the below listed values. This list is also available on the control cover. Status Code Displayed in STA Mode Figure 26: Boiler Display The control display, along with Up ñ, Down ò, and “I” keys may be used to view boiler operating status (Figure 26). D. Viewing the Operating Mode Options In operating mode the user may view (but not change) boiler operating status, settings and troubleshooting information. To view control display information: 1.
IX. operation (continued) E. Changing the Adjustable Parameters To adjust parameters such as High Limit Setpoint and High Limit Differential: 1. Access the adjustment mode by pressing and holding the Up , Down , and “I” keys simultaneously for three (3) seconds. This procedure is intended to discourage unauthorized changes or accidental changes to limit settings. 140-180°F Start Temperature On or off Priority time 4.
IX. operation (continued) 7. Domestic Hot Water (DHW) Terminal Function () The control allows configuration of the DHW Circulator output functionality to help the PVCG-B integrate into each installation more effectively. The DHW Circulator output can be connected to a domestic hot water circulator or a second heating zone circulator. These applications are selected as follows: a.
X. troubleshooting check the wiring on the boiler against the wiring diagram in Figures 17 and 18. Ensure that incoming 120 Vac power polarity is correct and that the boiler is properly grounded. Further, ensure that the control power supply is 24 VAC (minimum 18 VAC to maximum 30 VAC) and polarity is correct. A. Before troubleshooting The following pages contain trouble shooting tables for use in diagnosing control problems. When using these tables the following should be kept in mind: 1.
X. troubleshooting (continued) Use Control Display (error) Number To Direct TroubleShooting Efforts If the control detects an error it will flash “” (error) followed by a number. Use this number to identify the boiler problem and corrective action in the table below.
X. troubleshooting (continued) Use STA (status) Number To guide TroubleShooting The control will flash “” followed by a number. Use this number to identify the boiler problem in the table below: 1. Boiler and Circulator Off Recommended Corrective Action Display / Status The boiler has not detected a call for heat (tt = off and dh = off).
X. troubleshooting (continued) 5. Circulator is On, Blower is On but Boiler Fails to Start Display / Status Retry / Recycle Delay StA 11 Pressure Switch Failed to Open STA 12 Pressure Switch Failed to Close Soft Lockout Hard Lockout Flame Out of Sequence 46 Description The Boiler is in “Retry Delay”: - The burner failed to light (no flame signal). After a 5 minute delay, control will attempt to light the burner again. There is no limit to the number of retries.
X. troubleshooting (continued) 6. Circulator is On, Blower is On but Boiler Fails to Start (continued) Display / Status Recommended Corrective Action 1. No Spark a. Can you hear sparking while is displayed? - If there is no spark noise replace the control. b.
XI. Service DANGER 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.
XI. Service (continued) WARNING This boiler must only be serviced and repaired by skilled and experienced service technicians. If any controls are replaced, they must be replaced with identical models. Read, understand and follow all the instructions and warnings contained in all the sections of this manual. Never jump out or bypass any safety or operating control or component of this boiler. Read, understand and follow all the instructions and warnings contained in ALL of the component instruction manuals.
XI. Service (continued) 9. Inspect heating surface in combustion chamber. Clean with straight handle wire brush. 10. Install Flue Gas Baffles. 11. Replace Canopy Assembly and seal. 12. Connect Silicone Tubing between Pressure Fittings on Canopy Assembly and Pressure Switch. Route through bushings in Vestibule Panel . See Figure 27. 13. Install Jacket Top Rear Panel. 14. Connect vent system. See Figure 28. 15. Connect Blower Motor Wiring Harness E. Main Burners and Firebox. 1. Vacuum firebox.
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XI. Service (continued) Table 16: Pilot Burner Location Model Main Burner with Pilot Bracket Pilot Burner Located Between Main Burners * PVCG30B 2 2&3 PVCG40B 3 3&4 PVCG50B 4 4&5 PVCG60B 5 5&6 PVCG70B 6 6&7 PVCG80B 7 7&8 PVCG90B 8 8&9 * Main burners numbered left to right as viewed from front of boiler. Figure 30: Differential Pressure Measurement Table 17: Differential Pressure Switch Settings Minimum Differential Pressure 52 Model Sea Level to 4,999 Ft.
XII. Repair Parts All PVCG-B™ Repair Parts may be obtained through your local New Yorker 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 Customer Service at (215) 855-8055 or Fax (215) 855-8229.
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XII. Repair Parts (continued) Key No. [Quantity] Part Number Description PVCG30B PVCG40B PVCG50B PVCG60B PVCG70B PVCG80B PVCG90B 61707031 61707041 61707051 61707061 61707071 61707081 61707091 [6] 71707003 [6] 71707003 [7] 71707003 1.
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XII. Repair Parts (continued) [Quantity] Part Number Key No. Description PVCG30B PVCG40B PVCG50B PVCG60B PVCG70B PVCG80B PVCG90B 2.
XII. Repair Parts (continued) Key No. [Quantity] Part Number Description PVCG30B PVCG40B PVCG50B PVCG60B PVCG70B PVCG80B PVCG90B 3.
XII. Repair Parts (continued) [Quantity] Part Number Key No. Description PVCG30B PVCG40B PVCG50B PVCG60B PVCG70B PVCG80B PVCG90B 4.
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XII. Repair Parts (continued) Key No. [Quantity] Part Number Description PVCG30B PVCG40B PVCG50B PVCG60B PVCG70B PVCG80B PVCG90B 5.
XII. Repair Parts (continued) Key No. [Quantity] Part Number Description PVCG30B PVCG40B PVCG50B PVCG60B PVCG70B PVCG80B PVCG90B 6.
XII. Repair Parts (continued) Key No. Description [Quantity] Part Number PVCG30B PVCG40B PVCG50B PVCG60B PVCG70B PVCG80B PVCG90B 7.
XII. Repair Parts (continued) Key No. Description [Quantity] Part Number PVCG30B PVCG40B PVCG50B PVCG60B PVCG70B PVCG80B PVCG90B 8.
SERVICE RECORD DATE SERVICE PERFORMED 65
SERVICE RECORD DATE SERVICE PERFORMED 66
SERVICE RECORD DATE SERVICE PERFORMED 67
