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INSTALLATION, OPERATING
AND SERVICE INSTRUCTIONS
PACKAGED HEATING UNIT
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M24500R5-7/07
FOR microTEK3™
OIL FIRED BOILER
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Price - $3.00
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Summary of Contents for New Yorker M
- Page 1 INSTALLATION, OPERATING AND SERVICE INSTRUCTIONS FOR microTEK3™ OIL FIRED BOILER PACKAGED HEATING UNIT M24500R5-7/07 Price - $3.00...
- Page 2 IMPORTANT INFORMATION - PLEASE READ THIS PAGE CAREFULLY THIS BOILER HAS LIMITED WARRANTIES, COPIES OF WHICH ARE PRINTED ON THE BACK COVER OF THIS MANU- 2. THIS BOILER IS SUITABLE FOR INSTALLATION ON COMBUSTIBLE FLOORING. BOILER CAN NOT BE IN- STALLED ON CARPETING. 3. ALL BOILERS MUST BE INSTALLED IN ACCORDANCE WITH NATIONAL, STATE AND LOCAL PLUMBING, HEATING AND ELECTRICAL CODES AND THE REGULATIONS OF THE SERVING UTILITIES WHICH MAY DIF- FER FROM THIS MANUAL. AUTHORITIES HAVING JURISDICTION SHOULD BE CONSULTED BEFORE INSTAL- LATIONS ARE MADE. IN ALL CASES, REFERENCE SHOULD BE MADE TO THE FOLLOWING STANDARDS: A. Current Edition of American National Standard ANSI/NFPA 31, “Installation of Oil Burning Equipment”, for clearances between boiler, vent connector and combustible material. B. Current Edition of American National Standard ANSI/NFPA 211, “Chimneys, Fireplaces, Vents, and Solid Fuel Burning Appliances”, For Chimney require- ments, type of venting material and clearances between vent connector pipe and combustible materials. C. Current Edition of American Society of Mechanical Engineers ASME CSD-1, “Controls and Safety Devices for Automatically Fired Boilers”, for assembly and operations of controls and safety devices. 4. ALL HEATING SYSTEMS SHOULD BE DESIGNED BY COMPETENT CONTRACTORS AND ONLY PERSONS KNOWL- EDGEABLE IN THE LAYOUT AND INSTALLATION OF HYDRONIC HEATING SYSTEMS SHOULD ATTEMPT INSTALLA- TION OF ANY BOILER. 5. THE BOILER MUST BE CONNECTED TO AN APPROVED CHIMNEY IN GOOD CONDITION. SERIOUS PROPERTY DAMAGE COULD RESULT IF THE BOILER IS CONNECTED TO A DIRTY OR INADEQUATE CHIMNEY. THE INTERIOR OF THE CHIMNEY FLUE MUST BE INSPECTED AND CLEANED BEFORE THE START OF THE HEATING SEASON AND SHOULD BE INSPECTED PERIODICALLY THROUGHOUT THE HEATING SEASON FOR ANY OBSTRUCTIONS. A CLEAN AND UNOBSTRUCTED CHIMNEY FLUE IS NECESSARY TO ALLOW NOXIOUS FUMES THAT COULD CAUSE INJURY OR LOSS OF LIFE TO VENT SAFELY AND WILL CONTRIBUTE TOWARD MAINTAINING THE BOILER’S EF- FICIENCY. 6. READ THE LITERATURE ENCLOSED BY THE MANUFACTURER WITH THE VARIOUS ACCESSORY DEVICES. THESE ACCESSORY DEVICES MUST BE INSTALLED AND USED ACCORDING TO THE RECOMMENDATIONS OF THE MANU- FACTURER.
- Page 3 table of contentS I. General Information ....... 3 IV. Boiler Cleaning ........19 II. Installation Instructions ......4 V. Repair Parts ........... 20 III. Operating & Service Instructions ..11 VI. Appendix Low Water Cut Off ........ 25 Section i: General information Water content: 6.1 Gallons Figure 1: microTEK3 Packaged Boiler INSPECT SHIPMENT carefully for any signs of LOCATE BOILER in front of final position before damage.
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Page 4: Combustible Materials
D. For boiler located in an unconfined space of a conventionally constructed building, the fresh air infiltration through cracks around windows and doors normally provides adequate air for combustion and ventilation. E. For boiler located in a confined space or an unconfined space in a building of unusually tight construction, provide outdoor air with the use of two permanent openings which communicate directly or by duct with the outdoors or spaces (crawl or attic) freely communicating with the outdoors. Locate one opening within 12 inches of top of space. Locate remaining opening within 12 inches of bottom of space. Minimum dimension of air opening is 3 Figure 2: Minimum Installation Clearances To inches. Size each opening per following: Combustible Materials 1. Direct communication with outdoors. Minimum free area of 1 square inch per 4,000 l l a BTU per hour input of all equipment in space. 2. Vertical ducts. Minimum free area of 1 square e l i e l l inch per 4,000 BTU per hour input of all s i l... - Page 5 B. Tilt boiler backward and remove skid. Be careful not G. Replace door assembly. Hinge brackets attached to to damage Burner and Jacket. door must rest on top of hinge brackets attached to tubesheet. See Figure 3. Slide hinge pins through CHANGE HINGE POSITION if necessary. hinges from top and install cotter pins. Close door A. Look at the area where boiler will be installed. If and install 5/16" - 18 x 3" long hex head cap screws left side of boiler will be less than 12 inches from through flatwashers and left side of door and into a wall, move hinges to right side of boiler. See B tapped holes in tubesheet. Tighten all hex nuts, through J below. bolts and screws. When door is installed properly, it is parallel to Tubesheet when viewed from top and B. Pull 2 halves of Burner Swing Door Interlock apart. sides. Swing Door Interlock is connected to T-T terminals on R7184A Control. Lift Honeywell R7184A H. Bend sides of Jacket Wrapper down and attach 2 Control off of Burner Junction Box, open Burner Jacket Straps to 4 slots at bottom of Jacket Wrapper Ignition Transformer and disconnect wiring harness sides with sheet metal screws. Install Rear Jacket from left side of burner. Find round plastic cover Box with 4 sheet metal screws. See Figure 18. inside Junction Box and install in hole in left side of I. Connect wiring harness to a knockout on right side burner. of Junction Box and install Honeywell R7184A C. Remove 8 sheet metal screws from jacket. Remove Control, see Wiring Diagram, Figure 11. rear jacket box and bend both sides of Jacket Reconnect Swing Door Interlock.
- Page 6 Figure 4: Recommended Boiler Piping for Zoning with Valves Figure 5: Recommended Boiler Piping for Zoning with Circulators...
- Page 7 E. A hot water boiler installed above radiation level CONNECT SUPPLY AND RETURN PIPING TO must be provided with a low water cutoff device as HEATING SYSTEM part of the installation. A. Hot water pipes shall have clearances of at least ½” If a low water cut-off is required, it must be from all combustible construction. mounted in the system piping above the boiler. B. Use a system by-pass if the boiler is to be operated The minimum safe water level of a hot water boiler in a system which has a large volume or excessive is just above the highest water containing cavity of radiation where low boiler water temperatures may the boiler; that is, a hot water boiler must be full of be encountered (i.e. converted gravity circulation water to operate safely. system, etc.). F. There are many possible causes of oxygen Valves should be located in the by-pass and return contamination such as: line as illustrated in Figures 4 and 5 in order to 1. Addition of excessive make-up water as a result regulate water flow for maintenance of higher boiler of system leaks. water temperature. 2. Absorption through open tanks and fittings. Set the by-pass and return valves to a half throttle 3. Oxygen permeable materials in the distribution position to start. Operate boiler until the system system. water temperature reaches its normal operating range. In order to insure long product life, oxygen sources should be eliminated. This can be accomplished by Adjust the valves to maintain 180°F to 200°F boiler...
- Page 8 small amounts of water vapor in the chimney. Such condensation, when it occurs, can cause chimney deterioration. In extreme cases, condensed water may be visible on the outside of the breeching or chimney. In those extreme cases, the chimney may have to be lined to insulate the chimney and thus prevent the condensation. The addition of dilution air into the chimney may assist in drying the chimney interior surfaces. C. Heat extractors mounted into the breeching are not recommended. INSTALL ELECTRIC WIRING in accordance with National Electrical Code and local regulations. A separate ELECTRICAL CIRCUIT must be run from the main electrical service with an over-current device/disconnect in the circuit. A service switch is recommended and may be required by some local jurisdictions. Wiring should conform to Figures 11A and 11B. FUEL UNITS AND OIL LINES Figure 7 Use flexible oil line(s) so that Swing Door can be opened without disconnecting oil supply. A supply line fuel oil filter is recommended as a minimum for all firing rates but a pleated paper fuel oil filter is recommended for the lowest (.6 GPH) firing rate application to prevent nozzle fouling. 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 9. Figure coal fired or an inefficient oil fired boiler built into a home without insulation or storm windows. With increasing fuel prices that home probably has been insulated and fitted with storm windows so that the heat loss of the home has been reduced. This requires less fuel to be burned and sends less heat up...
- Page 9 TWO-PIPE OIL LINES - For two-pipe systems where more lift is required, the two-stage fuel unit is recommended. Tables 2 (single-stage) and 3 (two-stage) show allowable lift and lengths of 3/8-inch and ½-inch OD tubing for both suction and return lines. Refer to " " " " t f i " " Figure 10. " " Be sure that all oil line connections are absolutely airtight. Check all connections and joints. Flared fittings are recommended. Do not use compression fittings. Open the air-bleed valve and start the burner. For clean bleed, slip a 3/16” ID hose over the end of the bleed valve and bleed into a container. Continue to bleed for 15 seconds after oil is free of air bubbles. Stop burner and close valve. " " " " t f i " " - - - " " Figure 10 - - - - - -...
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Page 10: Sequence Of Operation
Figure 11A: Wiring Diagram for microTEK3 Boilers with Beckett AFG Burner and Split Controls SeQUence of oPeration A call for heat by the thermostat energizes the L7248C control which in turn energizes the R7184B primary control. The burner will initiate ignition after completing a 10 second pre-purge cycle. If burner ignites within approximately 45 seconds and the cad cell sees flame, the burner will continue to operate until the call for heat is satisfied or the setting of the high limit is reached. - Page 11 Section iii: oPeratinG anD SerVice inStrUctionS r i f that all electrical connections have been completed and ALWAYS INSPECT INSTALLATION BEFORE fuses installed, and that oil tank is filled and oil lines STARTING BURNER. have been tested. FILL HEATING SYSTEM WITH WATER. LUBRICATION — Follow instruction on burner NOTE: It is important to properly remove the oil and and circulator label to lubricate, if oil lubricated. Most dirt from the system. motors currently used on residential type burners employ permanently lubricated bearings and thus do CLEAN HEATING SYSTEM If boiler water is dirty, not require any field lubrication. Water lubricated refer to step 13 for proper cleaning instructions. circulators do not need field lubrication. A. Fill entire Heating System with water and vent air Do not over-lubricate. This can cause as much trouble as no from system. Use the following procedure on a lubrication at all. Series Loop or Multi-Zoned System installed as per Figures 4 and 5, to remove air from system when ADJUST CONTROL SETTINGS with burner service filling: switch turned “ON” and room thermostat set 10° (1) Close isolation valve in boiler supply piping. below room temperature. (2) Isolate all circuits by closing zone valves or A. adjustment and display modes of the L7248/ balancing valves.
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Page 12: Operating Sequence
(2) High-Limit: Boiler temperature has gone above the high limit setting and has not dropped below the high limit setting (minus the differential). (3) Error: The controller has detected an error condition (e.g., open sensor) and has shut down the burner output. The controller continues to monitor the system and automatically restarts if the error condition clears. See Table 4. (4) Low-Limit: Boiler temperature has gone below the low limit setting (minus the low limit differential) and has not gone above the low limit setting. TABLE 4: LED ERROR CODES Figure 12: L724 Circuit Board Layout - Horizontal Mount ii. Display: ; t l In the RUN mode, the Aquastat will ; t l ™ flash “bt” (boiler temp.) followed by the temperature (i.e., 220), followed by °F or ;... - Page 13 as long as the thermostat is calling for heat. The prevents burner flame until 10 seconds has elapsed high limit automatically resets after the water after initial power is applied to burner. During temperature drops past the setpoint and through pre-purge, the motor and ignitor will operate but the the differential. oil valve will remain closed. Refer to Oil Primary Control Instructions for more details. ADJUST OIL PRESSURE A. Locate oil pressure adjusting screw and turn screw to obtain the oil pressure indicated in Table 4. B. DO NOT REMOVE PRESSURE GAUGE until later. OTHER ADJUSTMENTS A. ADJUST THE AIR BAND AND/OR AIR SHUTTER Beckett Burners: Adjust air supply by loosening lock screws and moving the air shutter and if necessary the air band. Refer to Table 6 for preliminary settings. B. ADJUST DRAFT REGULATOR for a draft of 0 to maximum of -.03" (water gauge) in the breeching after chimney has reached operating temperature and while burner is running. Burner will operate Figure 14: L724/L7224 Setpoint and Differential with a positive draft over fire and zero draft in Switching Action the breeching. Adjust Draft Regulator such that maximum draft of -.03" is reached in coldest REMOVE GUN ASSEMBLY weather.
- Page 14 Warning: This product contains refractory ceramic fibers (RCF). RCF has been classified 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.
- Page 15 Figure 15: "L1 and "V1 Head Electrode Positioning and Gun Setting (Beckett AFG) TABLE : BECKETT AFG BURNER ° 0 ° 0 ° 5 f i r r i f r i f r i f...
- Page 16 1. Safe Start a. Jumper the yellow cad cell leads. b. Follow procedure to turn on burner. Burner must not start, indictor light turns on and control remains in Idle Mode. 2. Simulate Flame Failure. a. Follow procedure to turn on burner. b. Close hand valve in oil supply line. c. Device enters recycle mode. d. Device tries to restart system after approximately 60 seconds. e. Safety switch locks out approximately in Figure 1 safety switch timing indicated on label. Indicator light flashes at 1 Hz rate. Ignition and motor stop and oil valve closes. 3. Simulate Ignition Failure. a. Follow procedure to turn on burner, but do not open oil supply hand valve. b. Observe that safety switch locks out approximately within safety switch timing as indicated on the label. Indicator light flashes at 1 Hz rate. Ignition and motor stop CHECK FOR CLEAN CUT OFF OF BURNER and oil valve closes. A. AIR IN THE OIL LINE between fuel unit and 4. The indicator light on the oil primary control nozzle will compress when burner is on and will provides lockout, recycle and cad cell indications...
- Page 17 1. Remove Safety Relief Valve using extreme care water are dissolved minerals and oxygen. When the to avoid damaging it. fresh, cool make-up water is heated in the boiler the minerals fall out as sediment and the oxygen escapes 2. Partially fill boiler and add caustic soda or as a gas. Both can result in reduced boiler life. The trisodium phosphate. Add an appropriate amount accumulation of sediment can eventually isolate of recommended boil out compound. the water from contacting the steel. When this 3. Replace Safety Relief Valve. happens the steel in that area gets extremely hot and 4. Fill the entire system with water. eventually cracks. The presence of free oxygen in 5. Start firing the boiler. the boiler creates a corrosive atmosphere which, if 6. Circulate the water through the entire system. the concentration becomes high enough, can corrode the steel through from the inside. Since neither of 7. Vent the system, including the radiation. these failure types are the result of a manufacturing 8. Allow boiler water to reach operating defect the warranty does not apply. Clearly it is temperature, if possible. in everyone’s best interest to prevent this type of 9. Continue to Circulate the water for a few hours. failure. The maintenance of system integrity is the 10. Stop firing the boiler. best method to achieve this.
- Page 18 3. Filter connection leaks. J. START-UP NOISE — Late ignition is the cause of start-up noises. If it occurs recheck for electrode 4. Tank connection leaks. settings, flame shape, air or water in the fuel lines. There are various test kits available to trace air K. SHUT DOWN NOISE — If the flame runs out of leaks, such as electronic sight glasses. Follow the air before it runs out of fuel, an after burn with noise manufacturers' instructions to find air leaks. may occur. That may be the result of a faulty cut-off The following actions can eliminate air leaks: valve in the fuel pump, or it may be air trapped in 1. Bleed pump as detailed previously. the nozzle line. It may take several firing cycles for 2. Replace flare fittings. that air to be fully vented through the nozzle. Water 3. Replace oil supply line. in the fuel or poor flame shape can also cause shut down noises. 4. Repair oil filter leaks. 5. Replace or repair tank fittings. E. GASKET LEAKS — If 11.5 to 12.5% CO with a #1 smoke or less cannot be obtained in the breeching, look for air leaks around the flue collar. Such air leaks will cause a lower CO reading in the breeching. The smaller the firing rate the greater effect an air leak can have on CO readings. F. DIRT — A fuel filter is a good investment.
- Page 19 Section iV: boiler cleaninG . f f r i f CLEAN THE FIRETUBES CLOSE BOILER A. For access to fireside of boiler, pull two halves of CAUTION: Do not start burner unless burner swing door is Burner Swing Door Interlock wiring harness apart, securely closed. Close door, install hex nuts, and tighten remove hex nuts holding door closed and open securely. Door should be parallel to tubesheet when swing door. viewed from top and sides. Reconnect two halves of Swing Door Interlock. B. Prior to cleaning boiler, lay a protective cloth or plastic over combustion chamber liner. C. Using a 1 1/2" diameter wire brush (30" handle), clean firetubes. Measure 15" from end of brush opposite handle, and mark handle. DO NOT allow this mark to go past front end of firetube during cleaning, or brush will hit rear door insulation peice. CLEAN THE COMBUSTION CHAMBER Using wire or fiber bristle brush, clean inside of combustion chamber. DO NOT let brush hit rear door insulation piece or combustion chamber liner. AFTER CLEANING Vacuum debris inside bottom of rear door, remove protective cloth, and vacuum remaining fireside of boiler as necessary. BE CAREFUL not to damage liner or rear door insulation piece. Inspect front and rear door insulation pieces, front door gaskets and combustion l l i chamber liner for damage. Replace any damaged...
- Page 20 V: rePair PartS All microTEK3™ Repair Parts can be ordered through New Yorker Boiler Co., Inc. or its authorized dis- tributors. Please contact New Yorker's main office for closest local source and/or any additional information regarding repair parts. New Yorker Boiler Co., Inc. P. O. Box 10 Hatfield, Pennsylvania 19440-0010 Phone: (215) 855-8055 Attn: Customer Service Department Figure 17: microTEK3 Boiler Trim & Controls Item Description Qty. Part Number Honeywell L7248C1014 High Limit & Circulator Relay 100059-01 --OR-- Honeywell L4080B1261 High Limit 80160402 Honeywell 123871A, 3/4 NPT x 3 80160452 Conbraco 10-408-05, 3/4 FPT, 30 PSI Relief Valve 81660319...
- Page 21 Figure 1: microTEK3 Boiler Jacket & Insulation...
- Page 25 Vi: loW Water cUt off (lWco) on Hot Water boilerS f i t . f f When draining the heating system. Many probe LWCO manufacturers recommend an annual inspection of the A low water cutoff is required to protect a hot water probe. boiler when any connected heat distributor (radiation) is installed below the top of the hot water boiler (i.e. How to Wire baseboard on the same floor level as the boiler). In LWCO’s are available in either 120 VAC or 24 VAC addition, some jurisdictions require the use of a LWCO configurations. The 120 VAC configuration can be with a hot water boiler. universally applied to both gas and oil boilers by wiring Where it in the line voltage service to the boiler (after the service switch, if so equipped). The universal location for a LWCO on both gas and oil The presence of water in a properly installed LWCO hot water boilers is above the boiler, in either the supply will cause the normally open contact of the LWCO to or return piping. The minimum safe water level of a close, thus providing continuity of the 120 VAC service water boiler is at the uppermost top of the boiler; that is, to the boiler.
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Page 26: Service Record
SERVICE RECORD DATE SERVICE PERFORMED... - Page 27 SERVICE RECORD DATE SERVICE PERFORMED...
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