New Yorker FR SERIES Installation, Operating And Service Instructions
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New Yorker FR SERIES Installation, Operating And Service Instructions

Fr series horizontal tube boiler
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INSTALLATION, OPERATING
AND SERVICE INSTRUCTIONS
HORIZONTAL TUBE BOILER
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Price - $3.00

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  • Page 1 INSTALLATION, OPERATING AND SERVICE INSTRUCTIONS FR™ SERIES HORIZONTAL TUBE BOILER 8147202R5-7/07 Price - $3.00...
  • Page 2 IMPORTANT INFORMATION - READ CAREFULLY t i l f f i t i r “ ” t “ , ” " , " 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.
  • Page 3 f i l i l i I I I . i ( . ) l . i (...
  • Page 4 t t i l i t . r i l l i t i l...

  • Page 5: Table Of Contents

    Table of Contents I. Pre-Installation ....... 6 VI. Oil Piping ........18 II. Knockdown Boiler Assembly ..8 VII. System Start-Up ......20 III. Water Piping and Trim ....10 VIII. Service and Cleaning ....27 IV. Venting ......... 15 VIX. Repair Parts ........29 V. Electrical ........16 X. Appendix Low Water Cut Off .......

  • Page 6: Pre-Installation

    I. Pre-Installation . INSPECT SHIPMENT carefully for any signs of 2. FOR BASEMENT INSTALLATION, provide a damage. solid base, such as concrete, if floor is not level, or if water may be encountered on floor around boiler. 1. ALL EQUIPMENT is carefully manufactured, inspected and packed. Our responsibility ceases 3. PROVIDE SERVICE CLEARANCE of at least 48” upon delivery of the crated boiler to the carrier in from the front of the jacket for servicing of burner good condition. and removal of tankless heater. 2. ANY CLAIMS for damage or shortage of shipment For minimum clearances to combustible materials. See must filed immediately against the carrier by Figure 2.
  • Page 7 by duct with the outdoors or spaces (crawl or attic) PROVIDE COMBUSTION AND VENTILATION freely communicating with the outdoors. Locate one AIR. Local code provisions may apply and should be opening within 12 inches of top of space. Locate referenced. remaining opening within 12 inches of bottom of space. Minimum dimension of air opening is 3 inches. Size each opening per following: a. Direct communication with outdoors. l i t Minimum free area of 1 square inch per 4,000 BTU per hour input of all equipment in space. b. Vertical ducts. Minimum free area of 1 square inch per 4,000 BTU per hour input of all equipment in space. Duct cross-sectional area shall be same as opening free area. . i ( c. Horizontal ducts. Minimum free area of 1 square inch per 2,000 BTU per hour input of all equipment in space. Duct cross-sectional area 1. Determine volume of space (boiler room). Rooms shall be same as opening free area. communicating directly with the space in which Alternate method for boiler located within the appliances are installed, through openings not confined space. Use indoor air if two permanent furnished with doors, are considered a part of the...

  • Page 8: Knockdown Boiler Assembly

    II. Knock-Down Boiler Assembly INSTALLING THE JACKET . REMOVAL OF BOILER. 1. Remove all boiler-to-skid hold down fasteners. 1. Attach lower rear jacket panel to left side and right side jacket panels with the screws provided so that 2. FR-HGS thru FR-232: Carefully walk boiler to the the assembled components make a “U” shape and edge of skid. Tilt the boiler back, allowing an edge can stand alone (see Figure 19). to rest on the floor, and remove the skid. 2. Approaching the boiler from the rear, place the FR-265 thru FR-462: A mechanical lifting device assembled jacket pieces from Step 1 around the may be required to safely remove boiler from skid. boiler so that the lower rear panel passes below the rear smokebox. . TEST HEAT EXCHANGER FOR LEAKS before proceeding with jacket assembly. 3. Attach the lower front panel, upper front panel, and upper rear panel. Make sure the jacket clearance 1. Install pressure relief valve supplied, a hose to the holes line up properly with the appropriate boiler city water and a valve in the supply tapping. Plug extensions and tappings.
  • Page 9 Figure : Burner Mounting...

  • Page 10: Water Piping And Trim

    III. Water Piping and Trim l l i i l ( DESIGN A PIPING SYSTEM and install boiler which a. If this boiler is used in connection with will prevent oxygen contamination of boiler water and refrigeration systems, the boiler must be installed frequent water additions. so that the chilled medium is piped in parallel with the heating boiler using appropriate valves 1. There are many possible causes of oxygen to prevent the chilled medium from entering contamination such as: the boiler. See Figure 4. Also, consult I=B=R a. Addition of excessive make-up water as a result Installation and Piping Guides. of system leaks. b. Absorption through open tanks and fittings. c. Oxygen permeable materials in the distribution system. 2. In order to insure long product life, oxygen sources should be eliminated. This can be accomplished by taking the following measures: a. Repairing system leaks to eliminate the need for addition of make-up water.
  • Page 11 should be the same size as the supply and return lines with valves located in the bypass and return line as illustrated in Figures 5 and 6 in order to regulate water flow for maintenance of higher boiler water temperature. Set the bypass and return valves to a half throttle position to start. Operate boiler until the system water temperature reaches its normal operating range. Adjust the valves to maintain 180°F to INSTALL DRAIN VALVE IN RETURN PIPING. 200°F boiler water temperature and greater the See Figures 5 and 6. 120°F return temperature. Adjust both valves simultaneously. Closing the boiler return valve . OIL, GREASE, AND OTHER FOREIGN while opening the bypass valve will raise the MATERIALS which accumulate in new hot water boiler return temperature. Opening the boiler and a new or reworked system should be boiled return valve while closing the by-pass valve will out, and then thoroughly flushed. A qualified water lower the boiler return temperature. treatment chemical specialist should be consulted for e. A water boiler installed above radiation level recommendations regarding appropriate chemical must be provided with a low water cutoff device compounds and concentrations which are compatible...
  • Page 14 . CONNECT TANKLESS HEATER PIPING AS 2. TEMPERING OF HOT WATER — Installation of SHOWN IN FIGURE 7. an automatic mixing valve will lengthen the delivery of the available hot water by mixing some cold water with the hot. This prevents the possibility of scalding hot water at the fixtures. In addition, savings of hot water will be achieved since the user will not waste as much hot water while seeking a water temperature. Higher 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 heater to prevent lime formation in the valve. Refer to Figure 7. 3. FLUSHING OF HEATER — All water contains THE FOLLOWING GUIDELINES SHOULD BE some sediment which settles on the inside of the FOLLOWED WHEN PIPING THE TANKLESS coil. Consequently, the heater should be periodically HEATER: backwashed. This is accomplished by installing 1. FLOW REGULATION — If flow through the hose bibs as illustrated and allowing water at city heater is greater than its rating, the supply of pressure to run into hose bib A, through the heater,...

  • Page 15: Venting

    IV. Venting . GENERAL GUIDELINES means that the stack temperature from the 1. Vent system installation must be in accordance new boiler will be lower than that from the with these instructions and applicable provisions of old boiler and with less room air being drawn local building codes. Contact local building or fire up the chimney to dilute the stack gases. The officials about restrictions and installation inspection combination of a large uninsulated chimney, in your area. reduced firing rate, reduced firing time, lower stack temperature and less dilution air can, in 2. The FR™ Series is designed to be vented into a some cases, contribute to the condensing of small fireclay tile-lined masonry chimney or chimney amounts of water vapor in the chimney. Such constructed from type-L vent or a factory condensation, when it occurs, can cause chimney...

  • Page 16: Electrical

    Figure : Draft Regulator Locations V. Electrical . f f . GENERAL 3. Wiring should conform to Figures on pages 17 and 1. Install wiring and electrically ground boiler in 18 of this manual. accordance with requirements of the authority . SYSTEM CONTROLS AND WIRING having jurisdiction, or in absence of such 1. Refer to National Electric Code or Local Electric requirements the National Electrical Code, ANSI/ Codes for proper size and type of wire required. NFPA 70, and/or the CSA C22.1 Electric Code. Follow Code. 2. A separate electrical circuit should be run from 2. Use anti-short bushings on all wiring passing the main electrical service with a fused disconnect through boiler jacket, junction boxes and/or control switch in the circuit. boxes.
  • Page 17 3. Use armored cable (BX) over all exposed line and 11 for electrical diagram. Connect the system voltage wiring. circulator wire leads to the proper locations on the Aquastat control, L7224A/L7248A. See Figure 10 4. If an Indirect-Fired Domestic Hot Water Heater or 11. Connect the thermostat to the ‘T-T’ terminals is used, use priority zoning. Do not use priority on the L7224A/L7248A control. Set thermostat heat zoning for Hydro-Air Systems. anticipator setting to 0.50 amps. 5. Single Zone Water System – Refer to Figures 10 Figure 10: FR Water Boiler Wiring, Less Tankless, Single Circulator Figure 11: FR Water Boiler Wiring, With Tankless, Single Circulator...

  • Page 18: Oil Piping

    VI. Oil Piping . GENERAL . SINGLE-PIPE OIL LINES 1. Use flexible oil line(s) so that burner door can 1. Standard burners are provided with single-stage be opened, or burner can be removed, without 3450 rpm fuel units with the bypass plug removed disconnecting the oil supply. for single-pipe installations. 2. A supply line fuel oil filter is recommended as a 2. The single-stage fuel unit may be installed single- minimum for all firing rates but a pleated paper fuel pipe with gravity feed or lift. Maximum allowable oil filter is recommended for the lowest firing rate lift is 8 feet. See Figure 14.
  • Page 19 " t " " " " " " " " + " " t " " 8 " 2 " 8 " 2 - - - . TWO-PIPE OIL LINES 1. For two-piped systems, where more lift is required, the two-stage fuel unit is recommended. Table 1 (single-stage) and Table 2 (two-stage) show allowable lift and lengths of 3/8 inch and 1/2 inch OD tubing for both suction and return lines. Refer to Figure 15. Figure 15: Two-Pipe Installation...

  • Page 20: System Start-Up

    VII. System Start-Up . CHECK CONTROLS, WIRING AND BURNER . VERIFY that the venting, water piping, oil piping, to be sure that all connections are tight and burner is and electrical system are installed properly. Refer to rigid. Verify that all electrical connections have been installation instructions contained in this manual. completed, fuses installed, that the oil tank is filled and oil lines have been tested. . CONFIRM all electrical, water and oil supplies are turned off at the source and that the vent is clear from . LUBRICATION. Follow instruction on burner and obstructions. circulator label to lubricate, if oil lubricated. Most motors currently used on residential type burners employ permanently lubricated bearings and thus do not require any field lubrication. Water lubricated circulators do not need field lubrication. G. ADjUsT CONTROL sETTINGs with burner service switch turned “ON” and room thermostat set . FILL ENTIRE HEATING SYSTEM WITH WATER...

  • Page 21: Operating Sequence

    Then press the UP and/or DOWN buttons Table S1: LEd error codes to move the set point to the desired value. After 60 seconds without any button inputs, the control will automatically return to the READ mode. ; t l ii. Display: ; t l ™ In the RUN mode, the Aquastat will flash “bt” (boiler temp.) followed by the ; t l temperature (i.e., 220), followed by °F or °C. To read boiler settings, press the ‘I’ key to e. The operating sequence for L7248/L7224 is read the parameter of interest. For example, described below and shown in Table S2. press I (HL) High Limit is displayed, followed by a three-digit number, i.e., 220, followed by °F or °C. Table S2: L7248/L7224 Controller See Figure S2 for Display Readout Operating Sequence...
  • Page 22 REMOVE GUN ASSEMBLY 1. Check nozzle size, head size, gun setting, and positioning of electrodes. This information is shown in Figures 16 & 17 and Table 3. 2. Reinstall gun assembly. VERIFY OIL BURNER SETTINGS BEFORE STARTING 1. BURNER AIR BAND AND AIR SHUTTER SETTINGS, see Table 3. 2. OPEN ALL OIL LINE VALVES. 3. Attach a plastic hose to fuel pump vent fitting and provide a container to catch the oil. 4. REMOVE GAUGE PORT PLUG from fuel pump and install pressure gauge. Figure S: L7248/L7224 Setpoint and Differential START OIL BURNER Switching Action 1. Open vent fitting on fuel pump. Table : Beckett AFG &...
  • Page 24 Figure 17: Electrode / Head Setting (“F” Head) 2. TURN ‘ON’ BURNER service switch and be solid and compact. After all adjustments have allow burner to run until oil flows from vent been made, recheck for a draft of -.02” w.c. over the fitting in a SOLID stream without air bubbles for fire. approximately 10 seconds. 4. TURN “OFF” BURNER and remove pressure 3. Close vent fitting and burner flame should start gauge. Install gauge port plug and tighten. Start immediately.
  • Page 25 result of extensive testing to obtain the best flame 6. DIRT— A fuel filter is a good investment. shape and efficient combustion. Other brands of Accidental accumulation of dirt in the fuel system the same spray angle and spray pattern may be can clog the nozzle strainer and produce a poor used but may not perform at the expected level of spray pattern from the nozzle. and smoke. Nozzles are delicate and should be protected from dirt and abuse. Nozzles are mass produced and can vary from sample to sample. For all of those reasons a spare nozzle is a desirable item for a serviceman to carry. 2. FLAME SHAPE — Looking into the combustion chamber through the flame plug hole, the flame should appear straight with no sparklers rolling up toward the top of the chamber.
  • Page 26 • . TEST CONTROLS Burner should stop. • Restore power. Burner should start. 3. VERIFY HIGH LIMIT OPERATION. a. Adjust thermostat to highest setting. b. Observe temperature gauge. When temperature is indicated, adjust limit to setting below observed temperature. Burner should stop. c. Adjust limit to setting above observed temperature. Burner should start. 1. CHECK THERMOSTAT OPERATION. Raise and lower thermostat setting as required to start and d. Adjust thermostat to lowest setting. Adjust limit stop burner. to desired setting. 2. VERIFY PRIMARY CONTROL SAFETY 4. CHECK LOW WATER CUTOFF (if so FEATURES using procedures outlined in equipped). Instructions furnished with control (See back of a. Adjust thermostat to highest setting. Control Cover) or Instructions as follows: b. With boiler operating, open drain valve and slowly drain boiler. c. Burner should stop when water level drops below low water cutoff probe. Verify limit, thermostat or other controls have not shut off boiler.

  • Page 27: Service And Cleaning

    VIII. Service and Cleaning 1. CLEAN THE FIRETUBES a. Disconnect electric service to burner. b. To gain access to the firetubes, remove the front flue box door. For boilers equipped with flue box swingdoor, remove two (2) nuts at top of flue box door and swing door down. For boilers not equipped with swingdoor, remove fasteners l l i around the perimeter of flue box frame and remove door.
  • Page 28 Warning: This product contains refractory ceramic fibers (RCF). RCF has been classi- fied as a possible human carcinogen. After this product is fired, RCF may, when exposed to extremely high temperature (>1800F), change into a known human carcinogen. When disturbed as a result of servicing or repair, RCF becomes airborne and, if inhaled, may be hazardous to your health. AVOID Breathing Fiber Particulates and Dust Precautionary Measures: Do not remove or replace previously fired RCF (combustion chamber insulation, target walls, canopy gasket, flue cover gasket, etc.) or attempt any service or repair work involving RCF without wearing the following protective gear: 1. A National Institute for Occupational Safety and Health (NIOSH) ap-...

  • Page 29: Vix. Repair Parts

    IX. Repair Parts All FR™ Repair Parts may be obtained through your local New Yorker Wholesale distribu- tor. 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. Customer Service at (215) 855-8055 or Fax (215) 855-8229.
  • Page 30 Figure 1: Jacket Repair Parts...
  • Page 31 JACKET ASSEMBLY & s i l...
  • Page 32 NOTE: When ordering parts always give the serial number and model number shown on the boiler. Also provide the name of the part(s) shown below:...

  • Page 33: Bare Boiler Assembly

    BARE BOILER ASSEMBLY " 6 " 8 " 6 l l e " 2 " 1 s i l d l i...
  • Page 34 INSULATION REPLACEMENT KITS Combustion Chamber Insulation Replacement Kits Combustion Chamber Insulation Replacement Kits provide the floor insulation and the burner door insulation. Flue Box Insulation Replacement Kits Flue Box Insulation Replacement Kits provide the flue box door insulation, flue box frame top/bottom insulation pieces and flue box frame side insulation pieces.
  • Page 35 BECKETT BURNER PARTs LIsT FOR FR sERIEs sTEEL BOILERs FOR REPLACEMENT OIL BURNER PARTS, CONTACT YOUR WHOLESALER OR THE BURNER MANUFACTURER: R. W. BECKETT CORP. P. O. BOX 1289 ELYRIA, OHIO 44036 1-800-645-2876 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). Ordering Information for Quality Replacement Parts Figure 21: BECKETT AFG MODEL BURNER...
  • Page 36 BECKETT BURNER PARTs LIsT FOR FR sERIEs sTEEL BOILERs FOR REPLACEMENT OIL BURNER PARTS, CONTACT YOUR WHOLESALER OR THE BURNER MANUFACTURER: R. W. BECKETT CORP. P. O. BOX 1289 ELYRIA, OHIO 44036 1-800-645-2876 Figure 22: BECKETT AF and SF MODEL BURNERS l n I t t i t t i...

  • Page 37: Low Water Cut Off

    X. Low Water Cut Off (LWCO) f i t . f f When manufacturers recommend an annual inspection of the probe. A low water cutoff is required to protect a hot water boiler when any connected heat distributor (radiation) How to Wire is installed below the top of the hot water boiler (i.e. LWCO’s are available in either 120 VAC or 24 VAC baseboard on the same floor level as the boiler). In configurations. The 120 VAC configuration can be addition, some jurisdictions require the use of a LWCO universally applied to both gas and oil boilers by wiring with a hot water boiler.

  • Page 38: Service Record

    SERVICE RECORD DATE SERVICE PERFORMED...
  • Page 39 SERVICE RECORD DATE SERVICE PERFORMED...
  • Page 40 Upon discovery of a condition believed to be related to a defect in ma terial Components Manufactured by Others Following the expiration of the or workmanship covered by these warranties, the original consumer purch aser foregoing one year limited warranty, all component parts of a boiler which are ould notify the installer, who will in turn notify the distributor. If thi s action manufactured by others (such as burners, burner controls, circulator, tankless is not possible or does not produce a prompt response, the original cons umer water heater, and New Yorker Link) shall be subject only to the purchaser should write to New Yorker Boiler Co., Inc. at P.O. Box 10, manufacturer's warranty, if any. Hatfield, PA 19440-0010, giving full particulars in support of the claim. Removal and Replacement Costs These warranties do not cover expenses The original consumer purchaser is required to make available for of removal or reinstallation. The consumer purchaser will be responsible for inspection by New Yorker or its representative the parts claimed to be the cost of removing and replacing any defective part and all labor and related defective and, if requested by N ew Yorker, to ship those parts prepaid to New materials connected therewith. Replacement parts will be invoiced to the Yorker at the above address for inspection or repair. In addition, the original distributor in the usual manner and will be subject to adjustment upon proof of consumer purchaser agrees to make all reasonable efforts to settle any defect.

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