New Yorker AP-490U Installation, Operating And Service Instructions
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New Yorker AP-490U Installation, Operating And Service Instructions

Ap-u series steel oil-fired boiler
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See also: Installation, Operation and Service Instructions
INSTALLATION, OPERATING
AND SERVICE INSTRUCTIONS
STEEL OIL-FIRED BOILER
For service or repairs to boiler, call your heating contractor. When seeking information on boiler,
provide Boiler Model Number and Serial Number as shown on Rating Label.
Boiler Model Number
AP-
U
Heating Contractor
Address
104338-03 - 12/13
AP-U™ SERIES
Boiler Serial Number
Installation Date
Phone Number
Price - $5.00

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Summary of Contents for New Yorker AP-490U

  • Page 1 INSTALLATION, OPERATING AND SERVICE INSTRUCTIONS AP-U™ SERIES STEEL OIL-FIRED BOILER For service or repairs to boiler, call your heating contractor. When seeking information on boiler, provide Boiler Model Number and Serial Number as shown on Rating Label. Boiler Model Number Boiler Serial Number Installation Date Heating Contractor...
  • Page 2 IMPORTANT INFORMATION - READ CAREFULLY All boilers must be installed in accordance with National, State and Local Plumbing, Heating and Electrical Codes and the regulations of the serving utilities. These Codes and Regulations may differ from this instruction manual. Authorities having jurisdiction should be consulted before installations are made.
  • Page 3 DANGER DO NOT store or use gasoline or other flammable vapors or liquids in the vicinity of this or any other appliance. WARNING Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury or loss of life. Failure to follow all instructions in the proper order can cause personal injury or death.

  • Page 4: Table Of Contents

    WARNING This boiler contains very hot water under 12 - 15 PSI pressure. DO NOT unscrew any pipe fittings nor attempt to disconnect any components of this boiler without positively assuring the water is cool and has no pressure. Always wear protective clothing and equipment when installing, starting up or servicing this boiler to prevent scald injuries.

  • Page 5: General Information

    I: GENERAL INFORmATION Figure 1: AP-U Series Boiler Dimensional Data TABLE 1: DImENSIONAL DATA (See Figure 1) Dimension Water Capacity Approx. Boiler Model Number ‘A’ (gallons) Shipping Weight (lb.) AP-490U 10.7 34-9/16 AP-590U 10.1 AP-690U 16.3 41” AP-790U 15.4 Note: Maximum Working Pressure: Water 30 PSI shipped standard.
  • Page 6 Minimum Chimney Requirements AHRI NET Boiler Model AFUE % Capacity - Ratings - Round In. Rectangle Height Ft. Dia. In. x In. AP-490U 0.75 8 x 8 AP-590U 1.00 8 x 8 AP-690U 1.10 8 x 8 AP-790U 1.35 8 x 8...

  • Page 7: Pre-Installation

    II: PRE-INSTALLATION constructed in accordance with NFPA 31. DO NOT INSPECT SHIPMENT carefully for any signs of install boiler on carpeting. damage. 3. FOR BASEMENT INSTALLATION, provide a 1. All equipment is carefully manufactured, inspected solid elevated base, such as concrete, if floor is not and packed.
  • Page 8 II: PRE-INSTALLATION (continued) REMOVE CRATE 5. For boiler located in a confined space or an unconfined space in a building of unusually tight 1. Remove all fasteners at crate skid. construction, provide outdoor air with the use of two 2. Lift outside container and remove all other inside permanent openings which communicate directly or protective spacers and bracing.
  • Page 9 II: PRE-INSTALLATION (continued) INSTALLATION INSTRUCTIONS FOR OPTIONAL SHIELD REQUIRED FOR COmBUSTIBLE FLOOR This shield for combustible floors is intended for use only with the following New Yorker oil-fired boilers: Use Part Number 6183504 for the following models: AP-490U AP-590U AP-690U AP-790U ADDS 4-3/16”...

  • Page 10: Water Piping And Trim

    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.
  • Page 11 III: WATER PIPING AND TRIm (continued) line as illustrated in Figures 6A and 6B in order . OIL, GREASE, AND OTHER FOREIGN to regulate water flow for maintenance of higher MATERIALS which accumulate in new hot water boiler water temperature. Set the bypass and and a new or reworked system should be boiled return valves to a half throttle position to start.
  • Page 14 Higher temperature hot water required by dishwashers and automatic washers is Figure 7: Schematic Tankless Heater Piping TABLE 3: TANKLESS HEATER RATINGS Tankless Heater Model Boiler Model S-5A PSID AP-490U 3½ AP-590U AP-690U 3¾ AP-790U...

  • Page 15: Venting

    IV: VENTING means that the stack temperature from the new . GENERAL GUIDELINES. boiler will be lower than that from the old boiler 1. Vent system installation must be in accordance with and with less room air being drawn up the these instructions and applicable provisions of local chimney to dilute the stack gases.
  • Page 16 IV: VENTING (continued) Figure 8: Recommended Smokepipe Arrangement and Chimney Requirements Figure 9: Draft Regulator Locations...

  • Page 17: Electrical

    V: 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.
  • Page 20 V: ELECTRICAL (continued) NOTE: APPLy THIS BURNER SCHEMATIC TO APPROPRIATE STEAM OR WATER BOILER CONTROL SCHEMATIC, REFER TO FIGURES 10 AND 11 NOTE: APPLy THIS BURNER SCHEMATIC TO APPROPRIATE STEAM OR WATER BOILER CONTROL SCHEMATIC, REFER TO FIGURES 10 AND 11 Figure 12: Schematic Wiring Diagrams For All Burner Options w/Various Oil Primary Controls...

  • Page 21: Oil Piping

    VI: OIL PIPING . GENERAL. . SINGLE-PIPE OIL LINES. 1. Use flexible oil line(s) so that burner can be 1. Standard burners are provided with single-stage removed without disconnecting the oil supply. 3450 rpm fuel units with the bypass plug removed for single-pipe installations.
  • Page 22 VI: OIL PIPING (continued) TABLE 4: SINGLE STAGE UNITS (3450 RPm) TABLE 5: TWO-STAGE UNITS (3450 RPm) Two Pipe Systems Two Pipe Systems Maximum Length of Tubing Maximum Length of Tubing "H" + "R" (See Figure) "H" + "R" (See Figure) Lift "H"...

  • Page 23: System Start-Up

    VII: SYSTEm START-UP ALWAyS INSPECT INSTALLATION BEFORE Note - If make-up water line is equipped with pressure STARTING BURNER. reducing valve, system will automatically fill to 12 psig. 1. Verify that the venting, water piping, oil piping, and electrical system are installed properly. Refer to NOTICE Installation Instructions contained in this manual.
  • Page 24 TABLE 6: BECKETT AFG BURNERS Settings Firing Rate Boiler model Nozzle (GPH) Shutter Band Head (stop screw) Pump Pressure 0.65 - 80°AB *AP-490U 0.75 DANFOSS 0.85 - 80°B AP-590U 1.00 HAGO 0.90 - 80°B AP-690U 1.10 HAGO 1.10 - 80°B AP-790U 1.35...
  • Page 25 VII: SYSTEm START-UP (continued) Figure 15: Electrode / Head Setting • Remove the AIR TUBE COVER iv. Replace adapter, with nozzle installed, into PLATE (5) by loosening the retaining drawer assembly and secure with screw (1). SCREW (4) (Two SCREWS-Model F5). c.
  • Page 26 VII: SYSTEm START-UP (continued) WARNING: DO NOT operate a single line ADAPTORS (3), two female ¼” NPT to adapt system with the by-pass plug installed. oil lines to burner pipe connectors. All pump Operating a single line system with the by-pass port threads are British Parallel Thread design.
  • Page 27 Shut the burner off. The to Table 7. pressure should drop and hold. a. AP-490U through AP-790U (All Models) d. Remove the gauge and install bleeder port and/or Move the setting forward or back one position at reconnect the nozzle port line.
  • Page 28 VII: SYSTEm START-UP (continued) 7. CAD CELL LOCATION AND SERVICE The burner is supplied with a cadmium sulfide flame detector mounted at the factory, mounted on the bottom of the electronic ignitor. See Figure 22. To service cad cell or to replace the plug in portion, swing open the ignitor.
  • Page 29 VII: SYSTEm START-UP (continued) successfully satisfy a call for heat, the 7505 a. Preliminary Steps locks out. • Check wiring connections and power supply. iv. Limited Reset (Restricted Mode): In order • Make sure power is on to the controls. to limit the accumulation of unburned oil in •...
  • Page 30 VII: SYSTEm START-UP (continued) 5. CHECK OPERATING CONTROL on boiler WARNING applications equipped with tankless heater(s). With burner off, draw hot water until burner starts, then Cad Cell Jumper must be removed after this turn off hot water and check burner shut-down. check.

  • Page 31: Operating

    VIII: OPERATING WATER BOILERS SEQUENCE OF OPERATION 1. Water Boilers Without Tankless Heaters (Cold Start), Sequence Of Operation: a. The AP-U Boiler is equipped with an Intelligent Oil Boiler Control (Cold Start Boiler Control). The boiler control replaces the traditional electronic aquastat and circulator relays and adds energy saving thermal purge features.
  • Page 32 VIII: OPERATING (continued) d. If the thermostat is not satisfied and the “I” Press and release the key on the Boiler Control Operating Setpoint (SP) is reached the system to change from one parameter to the next. Each circulator will continue to operate and the burner setting will alternately flash between the relevant will stop.
  • Page 33 VIII: OPERATING (continued) c. Low Limit (LL_) Cold Start Boiler Control The Warm Start Boiler Control is factory Adjustment mode Options programmed with a Low Limit Setpoint of 140-240°F Adjust High Limit Setting 110°F. On falling temperature the boiler turns 10-30°F Adjust High Limit Differential “on”...
  • Page 34 VIII: OPERATING (continued) TABLE 9: CIRCULATOR PRE-PURGE TImE EXAmPLE, TABLE 10: DOmESTIC HOT WATER DEmAND, PARAmETER PP_= 2 mINUTES (PARAmETER ZC_= DH) Call for Heat Circulator Status ZC and ZR Call for Terminal Boiler Boiler Status, Priority System Heat Function Temp.
  • Page 35 VIII: OPERATING (continued) TABLE 11: ZONE REQUEST, PARAmETER ZC_= ZR TABLE 12: EXTERNAL LOW LImIT, PARAmETER ZC_= ELL Call for Heat Circulator Status Call for Heat Circulator Status Input Input Output Output Input Input Output Output ii. When ZC_ is set equal to Zone Request (ZR) The Warm Start Boiler Control with ZC_ set When there is no IWH the Cold Start Boiler equal to Zone Request (ZR) energizes the...

  • Page 36: Maintenance & Service Instructions

    No. l. Remove plugs from all available returns and month Year wash the water side of the boiler as thoroughly as AP-490U possible, using a high-pressure water stream. AP-590U m. Refill the system with fresh water. AP-690U 3. Add appropriate boiler water treatment compounds...
  • Page 37 IX: mAINTENANCE & SERVICE INSTRUCTIONS (continued) 4. Always keep the manual fuel supply valve shut off WARNING if the burner is shut down for an extended period of time. This boiler contains controls which may cause 5. To recondition the heating system in the fall season the boiler to shut down and not restart without after a prolonged shut down, follow the instructions service.

  • Page 38: Boiler Cleaning

    X: BOILER CLEANING 1. CLEAN THE FIRETUBES NOTICE a. Disconnect electric to burner and remove stack. BURNER SHUTDOWN: Open Service Switch b. For access to the firetubes, pull top jacket panel to turn off burner. off. Remove brass nuts, that hold canopy down. manual Oil Supply Valve should be closed and Without taking off carriage bolts, pull canopy Electric Service to boiler turned off if boiler will...
  • Page 39 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 about 1805°F, such as during direct flame contact, RCF changes into crystalline silica, a known carcinogen.

  • Page 40: Troubleshooting

    XI: TROUBLESHOOTING COMBUSTION 6. WATER — Water in the fuel in large amounts will 1. NOZZLES — Although the nozzle is a relatively stall the fuel pump. Water in the fuel in smaller inexpensive device, its function is critical to the amounts will cause excessive wear on the pump, but successful operation of the oil burner.
  • Page 41 XI: TROUBLESHOOTING (continued) f. CAD cell defective. OIL PRIMARy CONTROL (Oil Primary) 1. Burner (Oil Primary) will not come on. g. Oil valve stuck open or closed. a. No power to Oil Primary. Note: The Safety Monitoring Circuit (SMC) is b.
  • Page 42 XI: TROUBLESHOOTING (continued) b. If the Boiler Control detects an error it will flash "Err" (boiler control error) followed by a number. Use this text and number to identify the boiler problem and corrective action in Table 14 below. TABLE 14: BOILER CONTROL ERROR NUmBERS Display Status Recommended Corrective Actions...

  • Page 43: Service Record

    SERVICE RECORD DATE SERVICE PERFORMED...

  • Page 44: Repair Parts

    All AP-U™ Series 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 Boiler Co., Inc., P.O.
  • Page 45 XII: REPAIR PARTS (continued) AP-U SERIES BOILER REPAIR PARTS ITEm DESCRIPTION PART NUmBER QTY. Jacket Top Panel Assembly 6047104 Jacket Lower Front Panel Assembly 60471042 Jacket Upper Front Panel Assembly - 490U / 590U 60471041 Jacket Upper Front Panel Assembly - 690U / 790U 60471061 Jacket Wrap-a-Round Panel Assembly - 490U / 590U 60471043...
  • Page 47 Gasket, Blanket Heater Cover Plate 8206036 SA-307B 3/8 x 1-1/4” Hex Head Bolt 80861360 Heavy Hex Nut, 3/8 - 16 80860400 Flat Washer USS, 3/8” 80860645 PART NO. BOILER mODEL ‘A’ ‘B’ ‘C’ AP-490U 63071100 AP-590U 63071101 AP-690U 63071102 AP-790U 63071103...

  • Page 48: Beckett Afg Burner Parts For Ap-U™ Series Boilers

    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) and part(s) number as listed below. Boiler Model AP-490U AP-590U AP-690U AP-790U Burner Model...
  • Page 49 XIII: BECKETT AFG BURNER PARTS FOR AP-U SERIES BOILERS (continued) Ordering Information for Quality Replacement Parts Figure 29: BECKETT AFG mODEL BURNER (Fixed ‘F’ Head)

  • Page 50: Ap-U™ Series Boilers

    XIV: RIELLO 40 SERIES BURNER PARTS FOR AP-U SERIES BOILERS NOTE: When ordering parts always give the serial and model numbers shown on the boiler and burner. Refer to Models F3 & F5 Installation Manual, Riello 40 Series Residential Oil Burners (C6501010) for an exploded view of the burner and a list of spare parts.

  • Page 51: Appendix A - Low Water Cut Off

    APPENDIX A: LOW WATER CUT OFF (LWCO) ON HOT WATER BOILERS WARNING DO NOT ATTEmPT to cut factory wires to install an aftermarket Low Water Cut Off (LWCO). Only use connections specifically identified for Low Water Cut Off. In all cases, follow the Low Water Cut Off (LWCO) manufacturer's instructions. When minimum connection must have a...
  • Page 52 APPENDIX A: LOW WATER CUT OFF (LWCO) ON HOT WATER BOILERS (continued) How to Test A 24 VAC LWCO is used primarily for gas fired boilers where a 24 volt control circuit exists within the Shut off fuel supply. Lower water level until water boiler.
  • Page 53 SERVICE RECORD DATE SERVICE PERFORMED...
  • Page 54 SERVICE RECORD DATE SERVICE PERFORMED...
  • Page 55 SERVICE RECORD DATE SERVICE PERFORMED...

This manual is also suitable for:

Ap-590uAp-690uAp-790u

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