INSTALLATION, OPERATINGAND SERVICE INSTRUCTIONS
AP-U "rMSERIES
STEEL OIL-FIRED BOILER
For service or repairs to boiler, call your heating contractor. When seeking information onboiler, provide Boiler Model Number and Serial Number as shown on Rating Label.
Boiler Model Number Boiler Serial Number Installation Date
AP U
Heating Contractor Phone Number
Address
8147101 R7-1/10
®
RESIDENTIAL HEATING BOILERS
Price - $3.00
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 installationsare made.
In all cases, reference should be made to the following Standards:
All wiring on boilers shall be made in accordance with the National Electrical Code and/or Local
Regulations.
A. Current Edition of American National Standard ANSI/NFPA 31, "Installation of Oil Burning
Equipment", for recommended installation practices.
B. Current Edition of American National Standard ANSI/NFPA 211, "Chimneys, Fireplaces, Vents,
and Solid Fuel Burning Appliances", For Venting requirements.
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 safetydevices.
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.
Indicates an imminently hazardous situationwhich, if not avoided, will result in death, seriousinjury or substantial property damage,
Indicates a potentially hazardous situation which,if not avoided, may result in moderate or minorinjury or property damage,
Indicates a potentially hazardous situation which,if not avoided, could result in death, serious injuryor substantial property damage,
Indicates special instructions on installation,operation, or maintenance which are importantbut not related to personal injury hazards,
This boiler has a limited warranty, a copy of which is printed on the back of this manual.
It is the responsibility of the installing contractor to see that all controls are correctly installed and areoperating properly when the installation is complete. The warranty for this boiler is valid only if the boiler hasbeen installed, maintained and operated in accordance with these instructions.
2
DO NOT store or use gasoline or other flammable vapors or liquids in the vicinity of this or any otherappliance.
Improper installation, adjustment, alteration, service or maintenance can cause property damage, personalinjury or loss of life. Failure to follow all instructions in the proper order can cause personal injury ordeath. Read and understand all instructions, including all those contained in component manufacturersmanuals which are provided with the appliance before installing, starting-up, operating, maintaining orservicing this appliance. Keep this manual and literature in legible condition and posted near appliancefor reference by owner and service technician.
This boiler requires regular maintenance and service to operate safely. Follow the instructions containedin this manual. Installation, maintenance, and service must be performed only by an experienced, skilledand knowledgeable installer or service agency. All heating systems should be designed by competentcontractors and only persons knowledgeable in the layout and installation of hydronic heating systemsshould attempt installation of any boiler. It is the responsibility of the installing contractor to see that allcontrols are correctly installed and are operating properly when the installation is completed. Installationis not complete unless a pressure relief valve is installed into the tapping located on top of appliance- See Section III of this manual for details.
This boiler is not suitable for installation on combustible flooring, unless installed with a combustiblefloor shield (available at extra cost).
Do not install boiler on carpeting.
When boiler is installed on concrete which is over a material that is subject to melting (PVC, PEX radianttubing, etc.) the combustible floor shield must be used.
A concrete pad is not sufficient to protect combustible flooring.
Do not tamper with or alter the boiler or controls. Retain your contractor or a competent serviceman toassure that the unit is properly adjusted and maintained.
Have Firetubes cleaned at least once a year - preferably at the start of the heating season to remove sootand scale. The inside of combustion chamber should also be cleaned and inspected at the same time.
Have Oil Burner and Controls checked at least once a year or as may be necessitated.
Do not operate unit with jumpered or absent controls or safety devices.
Do not operate unit if any control, switch, component, or device has been subject to water.
Appliance materials of construction, products of combustion and the fuel contain alumina, silica, heavymetals, carbon monoxide, nitrogen oxides, aldehydes and/or other toxic or harmful substances whichcan cause death or serious injury and which are known to the state of California to cause cancer, birthdefects and other reproductive harm. Always use proper safety clothing, respirators and equipment whenservicing or working nearby the boiler.
This boiler is designed to burn No. 2 fuel oil only. Do not use gasoline, crankcase drainings, or any oilcontaining gasoline. Never burn garbage or paper in this boiler. Do not convert to any solid fuel (i.e.wood, coal). Do not convert to any gaseous fuel (i.e. natural gas, LP). All flammable debris, rags, paper,wood scraps, etc., should be kept clear of the boiler at all times.
Keep the boiler area clean and free of fire hazards.
Thisboilercontainsvery hotwaterunderhighpressure. Donot unscrewanypipefittings nor attemptto disconnect any components of this boiler without positively assuring the water is cool and has nopressure. Always wear protective clothing and equipment when installing, starting up or servicing thisboiler to prevent scald injuries. Do not rely on the pressure and temperature gauges to determine thetemperature and pressure of the boiler. This boiler contains components which become very hot whenthe boiler is operating. Do not touch any components unless they are cool.
This appliance must be properly vented and connected to an approved vent system in good condition.Serious property damage could result if the boiler is connected to an approved vent system.
This boiler needs fresh air for safe operation and must be installed so there are provisions for adequatecombustion and ventilation air.
The interior of the venting and air intake systems must be inspected and cleaned before the start of theheating season and should be inspected periodically throughout the heating season for any obstructions.Clean and unobstructed venting and air intake systems are necessary to allow noxious fumes that couldcause injury or loss of life to vent safely and will contribute toward maintaining the boiler's efficiency.
This boiler is supplied with controls which may cause the boiler to shut down and not re-start withoutservice. If damage due to frozen pipes is a possibility, the heating system should not be left unattended incold weather; or appropriate safeguards and alarms should be installed on the heating system to preventdamage if the boiler is inoperative.
Do not operate boiler on combustible floor without a factory supplied floor shield. Concrete overwood joistsis considered combustible flooring. Do not operate on masonry floors, which may contain moisture.
Table of Contents
I. Pre-Installation ............................... 6
II. Knockdown Boiler Assembly .......... 9
III. Water Piping and Trim ................. 12
1M. Venting ......................................... 17
V. Electrical ....................................... 19
VI. Oil Piping ..................................... 22
VII. System Start-Up ............................ 24
VIII.
IX.
X.
Service and Cleaning .................... 33
Repair Parts .................................. 35
Beckett AFG Burner Parts for
AP-U TM Series Boilers .................... 38
XI. Riello Burner Parts for
_-U TM Series Boilers .................... 40
XII. AppendixLowWater Cut Off ....................... 41
4
_" MPTSAFE_
RELIEF VALVECONNECTION
TOP VIEW
I #" MPTSUPPLYCONNECTION
CB!UNG
fo
wz
TANKLESS H_.TER
( _" NPT CONNECTIONS)
TEMPERATURE/PRESSURE GAU@E
RETURN
CONNECTION
FRONT VIEW
¢° FPDRNN VALVECONNECTION
AQUASTATCONTROL
BURNER
FLOOR
LiNE
RIGHT SIDE VIEW
Boiler ModelNumber
AP-490U
AP-590U
AP-690U
AP-790U
Dimension
,A _
34-9/16
41"
Minimum RecommendedChimney Sizes
Rectangular Round
8" x 8" x 15'6" x 15'
7" x 15'
Water
Capacity
(gallons)
10.7
10.1
16.3
15.4
Approx.Shipping Weight (lb.)
290
300
340
355
Figure 1: AP-U Series Boiler Dimensional Data
I. Pre-lnstallation
A.
B°
INSPECT SHIPMENT carefully for any signs ofdamage.
1. ALL EQUIPMENT is carefully manufactured,inspected and packed. Our responsibility ceasesupon delivery of the crated boiler to the carrier ingood condition.
2. ANY CLAIMS for damage or shortage of shipmentmust filed immediately against the carrier by theconsignee. No claims for variances from, or
shortage in orders, will be allowed by themanufacturer unless presented within sixty (60) daysafter receipt of goods.
LOCATE BOILER in front of final position beforeremoving crate.
1. LOCATE so that smoke pipe connection to chimneywill be short and direct. BOILER IS NOT SUIT-ABLE FOR INSTALLATION ON COMBUSTIBLE
FLOOR unless combustible floor shield, supplied byNew Yorker(R)Boiler Co. Inc., is used.
2.
3.
DO NOT install on carpeting. See Figure 3 for floorshield part number and installation instructions.
FOR BASEMENT INSTALLATION, provide asolid base, such as concrete, if floor is not level, or if
water may be encountered on floor around boiler.
PROVIDE SERVICE CLEARANCE of at least 48"
from the front of the jacket for servicing of burnerand removal of tankless heater.
For minilnuln clearances to combustible materials. See
Figure 2.
Do not support boiler by placing blocks at thefour (4) corners of the boiler.Boiler base must be evenly supported underentire base.
Do not operate boiler on combustible floorwithout a factory supplied floor shield.Concrete over wood joists is consideredcombustible flooring. Do not operateon masonry floors, which may containmoisture.
NOTE:
Figure 2:
FLOOR
UNE
RIGHT SIDE _W
Minimum Clearances to Combustible Materials
1.
2.
3.
6
Listed clearances comply with American National Standard ANSI/NFPA 3l, Installation of Oil Burning Equipment.
AP-U TM boilers can be installed in rooms with clearances from combustible material as listed above. Listed clearances cannot be reduced for alcove or closet installations.
For reduced clearances to combustible material, protection must be provided as described in the above ANSI/NFPA 31standard.
Co
Do
REMOVAL OF BOILER
1. Move boiler (in carton) to installation site as close
as practical.
2. Remove the carton sleeve.
4.
Remove four (4) hex head lag screws, attachingboiler base plate to shipping skid.
Carefully, walk boiler to the edge of the skid. Tiltthe boiler back, allowing boiler base edge to rest onthe floor, then, remove the skid.
PROVIDE COMBUSTION AND VENTILATION
AIR. Local code provisions may apply and should bereferenced.
Adequate combustion and ventilation air mustbe provided to assure proper combustion andto maintain safe ambient air temperatures.
Do not install boiler where gasoline or otherflammable vapors or liquids, or sources ofhydrocarbons (i.e. bleaches, fabric softeners,etc.) are used or stored.
1. Determine volume of space (boiler room). Roomscolnlnunicating directly with the space in which theappliances are installed, through openings notfurnished with doors, are considered a part of the
space.
Volulne(ft 3)= Length(ft) x Width(ft) x Height(ft)
2. Determine total input of all appliances in the space.
Add inputs of all appliances in the space and roundthe result to the nearest 1000 BTU per hour.
3. Determine type of space. Divide Volume by totalinput of all appliances in space. If the result isgreater than or equal to 50 ft3/1000 BTU per hour,then it is considered an uncol_ned space. If theresult is less than 50 ft3/1000 BTU per hour then thespace is considered a co17finedspace.
4. For boiler located in an uncolTfined space of aconventionally constructed building, the fresh airinfiltration through cracks around windows anddoors normally provides adequate air forcombustion and ventilation.
5. For boiler located in a confined space or anunconfined space in a building of unusually tightconstruction, provide outdoor air with the use of twopermanent openings which colnlnunicate directly orby duct with the outdoors or spaces (crawl or attic)freely colmnunicating with the outdoors. Locate oneopening within 12 inches of top of space. Locateremaining opening within 12 inches of bottom ofspace. Minimum dimension of air opening is 3inches. Size each opening per following:
a. Direct communication with outdoors.
Minimum free area of 1 square inch per 4,000BTU per hour input of all equipment in space.
b. Vertical ducts. Minimum free area of 1 squareinch per 4,000 BTU per hour input of allequipment in space. Duct cross-sectional areashall be same as opening free area.
c. Horizontal ducts. Minimum free area of 1
square inch per 2,000 BTU per hour input of allequipment in space. Duct cross-sectional areashall be same as opening free area.
Alternate method for boiler located withincol_ned space. Use indoor air if two permanentopenings colnlnunicate directly with additionalspace(s) of sufficient volume such that combinedvolume of all spaces meet criteria for unconfinedspace. Size each opening for minilnuln free areaof 1 square inch per 1,000 BTU per hour input ofall equipment in spaces, but not less than 100square inches.
6. Louvers and Grilles of Ventilation Ducts
All outside openings should be screened andlouvered. Screens used should not be smaller
than 1/4 inch mesh. Louvers will prevent theentrance of rain and snow.
b. Free area requirements need to consider theblocking effect of louvers, grilles, or screensprotecting the openings. If the free area of thelouver or grille is not known, assume woodlouvers have 20-25 percent free area and metallouvers and grilles have 60-75 percent free area.
c. Louvers and grilles must be fixed in the openposition, or interlocked with the equipment toopen automatically during equipment operation.
INSTALLATION INSTRUCTIONS FOR OPTIONAL SHIELD REQUIREDFOR 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" TO BOILER HEIGHT
1)
2)
3)
Place shield on combustible floor with "TOP" surface
upward and "FRONT" surface directly below theexpected position of the oil burner.
Locate shield such that clearances to combustible walls
are as indicated in Figure 3. These dimensions willassure that the boiler jacket will be at least 18" fromthe side and rear walls and 48" from the front wall, as
required by ANSI/NFPA 31.
Fasten shield to combustible floor to keep shield fromshifting position during setting of boiler.
4) Set boiler squarely on top of shield such that base plateof boiler rests flat on top surface of shield and does notover-hang shield on any side. Confirm clearance tocombustible walls. Refer to Figure 2.
5) Do not enclose boiler (including shield) on all foursides. Boiler may be enclosed on any three sides whilemaintaining lninilnuln clearances shown in Figure 2 foreach of those three sides.
COMBUSTIBLE
Figure 3: Floor Shield
I1. Knockdown Boiler Assembly
Knockdown AP-U Series boilers are shipped as two B. INSTALLING THE JACKET
separate items: 1.
Bare Boiler Assembly (mounted on skid)
Jacket Carton Assembly 2.
Inspect shipment carefully for any signs of damage.
A. REMOVAL OF BOILER
1. Remove and discard four boiler-to-skid hold down
fasteners. Refer to Figure 4.
2. Carefully walk boiler to the skid edge. Tilt the boilerback, allowing the base edge to rest on the floor, andremove the skid.
3. Remove the adhesive backed label-containingenvelope from boiler and set aside.
4. Remove Misc. Parts Bag and bagged Telnperamreand Pressure Gauge (both tucked inside canopy
assembly flue collar) and set aside.
3.
Remove jacket parts and jacket hardware bag fromJacket Carton Assembly shipping carton.
Install the Wrap-Around jacket panel first. BendWrap-Around panel as shown in Figure 5. Attachthe bent panel to base using three #10-1/2" slottedhex washer head screws supplied. Engage all screwsbut do not tighten yet.
Remove 5/16-18 hex nut, 5/16 flat washer,
observation cover spring and Observation PortCover and set aside.
4.
5.
6.
Attach Lower Front Jacket panel to installed Wrap-Around panel with four # 10-1/2" slotted hex washerhead screws supplied. See Figure 5.
Attach Upper Front Jacket panel to installed Wrap-Around panel with four # 10-1/2" slotted hex washerhead screws supplied. See Figure 5.
Lastly, install Top Jacket panel and secure toinstalled Wrap-Around panel with two remaining#10-1/2" slotted hex washer head screws. See Figure5.
7. Once installed, center Top Jacket panel opening overcanopy assembly flue collar and tighten up all threescrews securing Wrap-Around panel to base.
Figure 4: Bare Boiler on Skid
Figure 5: Jacket Installation
8.
9.
Attach provided New Yorker logo plate to installedTop Jacket panel with two #8 x */4sheet metalscrews. See Figure 6.
Remove labels from the adhesive backed label-
containing envelope and attach them to jacketpanels. See Figure 6 for approximate labelpositioning.
C. INSTALLATION OF BOILER CONTROLS
1.
2.
Install provided Temperature and Pressure gaugeand aquastat well into appropriate tappings; tightensecurely to prevent water leaks.
Install provided 1-1/4 x 3/4 reducing hex bushingand drain valve into lower right hand 1-1/4 forgedcoupling 'drain' taping.
3.
4.
5.
6.
Install provided 1-1/4 x 3" black nipple into lowerleft hand 1-1/4 forged coupling 'return' taping.
Mount installer-supplied aquastat onto theilmnersion well. Wire the control per Figure 15 orFigure 16, Section IV 'Electrical" of the Installationand Operating Instructions,for AP- U Series Oil-Fired Boiler, as applicable.
Install provided safety relief valve (for details seeFigure 9.
Re-install Observation Port Cover and related
hardware in reverse order to removal. See Figure 7.
Figure 6: Label Locations
10
D. BURNER INSTALLATION
1. Insure burner gasket proper fit/positioning on burnerair robe, relative to burner mounting flange, prior toburner mounting. See Figure 7.
Do not install burner without gasket.
2.
3.
Mount installer-supplied burner onto base frontpanel studs and secure with provided 5/16 flatwashers and brass 5/16-18 hex nuts. Refer to
Figure 7.
Wire the burner per instructions, provided with theburner, and, Figure 15, 15A, 16 or 16A, asapplicable.
OBSERVATION PORTCOVER
OBSERVATION COVER:SPRING
5/i6" FLAT WASRER
5/16"-18 HX NUT(H_,W HX)
BURNER MOUNTING FLANGE
W/ KEYHOLE SLOTS
@L BURNER
Figure 7: Burner Mounting
11
III. Water Piping and Trim
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, andcan lead to boiler failure. New Yorker's Standard Warranty does not cover problems caused by oxygencontamination of boiler water or scale (lime) build-up caused by frequent addition of water.
A. DESIGN A PIPING SYSTEM and install boiler which
will prevent oxygen contamination of boiler water andfrequent water additions.
1. There are many possible causes of oxygencontamination such as:
a. Addition of excessive make-up water as a resultof system leaks.
b. Absorption through open tanks and fittings.
c. Oxygen permeable materials in the distributionsystem.
2. In order to insure long product life, oxygen sourcesshould be eliminated. This can be accomplished bytaking the following measures:
a. Repairing system leaks to eliminate the need foraddition of make-up water.
b. Eliminating open tanks from the system.
c. Eliminating and/or repairing fittings which allowoxygen absorption.
d. Use ofnon-perlneable materials in thedistribution system.
e. Isolating the boiler from the system water byinstalling a heat exchanger.
System supply and return piping must beconnected to correct boiler pipe.
New Yorker recommends sizing the systemcirculator to supply sufficient flow (GPM) toallow a 20°F temperature differential in thesystem. When sizing the system circulator,the pressure drop of all radiators, baseboardand radiant tubing and all connecting pipingmust be considered.
3. Connect System supply and return piping to boiler.See Figures 9 and 10. Also, consult I=B=RInstallation and Piping Guides. Maintain minilnuln1/2inch clearance from hot water piping tocombustible materials.
12
a. If this boiler is used in connection with
refrigeration systems, the boiler must be installedso that the chilled medium is piped in parallelwith the heating boiler using appropriate valvesto prevent the chilled medium from entering theboiler. See Figure 8. Also, consult I=B=RInstallation and Piping Guides.
SUPPLY lqA_N TF/ __U_N NAIN _R_['}Y
S C(:]SLIN6 SYS]_LH S C08LINC SYSi[:_,"
Figure 8: Recommended Piping for CombinationHeating and Cooling (Refrigeration) System
b. If this boiler is connected to heating coils locatedin air handling units where they may be exposedto refrigerated air, the boiler piping must beequipped with flow control valves to preventgravity circulation of boiler water during theoperation of the cooling system.
c. If boiler is used with an Indirect-Fired Domestic
Water Heater, install the Indirect-Fired DomesticWater Heater as a separate heating zone. Referto the Indirect-Fired Domestic Water Heater
Installation, Operating, and Service Instructionsfor additional information.
d. Use a system bypass if the boiler is to beoperated in a system which has a large volume orexcessive radiation where low boiler water
temperatures may be encountered (i.e. convertedgravity circulation system, etc.) The bypassshould be the same size as the supply and returnlines with valves located in the bypass and return
B°
e.
line as illustrated in Figures 10 and 11 in order toregulate water flow for maintenance of higherboiler water temperature. Set the bypass andreturn valves to a half throttle position to start.Operate boiler until the system water temperaturereaches its normal operating range. Adjust thevalves to maintain 180°F to 200°F boiler water
temperature and greater the 120°F returntemperature. Adjust both valves simultaneously.Closing the boiler return valve while opening thebypass valve will raise the boiler returntemperature. Opening the boiler return valvewhile closing the by-pass valve will lower theboiler return temperature.
A water boiler installed above radiation level
must be provided with a low water cutoff deviceas part of the installation.
INSTALL SAFETY RELIEF VALVE. See Figures 9,10 and 11. Safety Relief Valve must be installed withspindle in the vertical position. Installation of the reliefvalve must be consistent with ANSI/ASME Boiler and
Pressure Vessel Code, Section IV.
Safety (relief) valve discharge piping must bepiped near floor to eliminate potential of severeburns. Do not pipe in any area where freezingcould occur. Do not install any shut-off valves,plugs or caps.
Co AIR VENT. An air vent or purge must be incorporatedin the system to easily remove air from the boiler whenthe system is filled. The boiler has a built in dip tubewhich works with the air vent to clear the boiler of air.
Improper application of the air vent will cause steamingin the boiler. See Figure 9.
D. INSTALL DRAIN VALVE in return piping. See
Figures l0 and ll.
E.
17.
G.
OIL, GREASE, AND OTHER FOREIGNMATERIALS which accumulate in new hot water
and a new or reworked system should be boiledout, and then thoroughly flushed. A qualified watertreatment chemical specialist should be consulted forrecommendations regarding appropriate chemicalcompounds and concentrations which are compatiblewith local environmental regulations.
Figure 9: Air Vent and Safety Relief ValveInstallation Detail
AFTER THE BOILER AND SYSTEM HAVE BEEN
CLEANED and flushed, and before refilling the entiresystem add appropriate water treatment chemicals, ifnecessary, to bring the pH between 7 and 11.
CONNECT TANKLES S HEATER PIP1NG ASSHOWN IN FIGURE 12. See Table 1 for Tankless
Heater Rating.
Install automatic mixing valve at tankless heateroutlet to avoid risk of burns or scalding due toexcessively hot water at fixtures. Adjust andmaintain the mixing valve in accordance withthe manufacturer's instructions. Do not operatetankless heater without mixing valve.
13
A_R VENT
LOW WATERCUT_O_
(O_T_ON/¢)
MR VENT
PRESSUREREUEFVAL_
%_ FROM ADO}TIONAL ZONES
FROM ZONE 2
F_M N_TE WATER NEAT_
OR ZONE 1
SHUT-OFFV#£VES
NOES_RUN EACH ZONE PIPE _WN THEN UP TO ZONETO PRD_ENT MR AC:CUMU_T_ON iN PiPiNG,
SHUTOFFVALVE
TONY_MATE
WATER H_T_
_: usED:)ZONE !
C_RCULa,TOR
TOZONE 2
TO/_DO_T/ONAL
ZONES
6" OF PLOOR FRONT VIEW
Figure 10: Recommended Boiler Piping for Circulator Zoned Heating Systems
mR VE_
_-x, _ FROM ADDRIONAiL ZONES
iLOW'WATER
CUT_OFF(OP ION )
NR _NT
P_SSUREREUEFVALVE
i
_" "q_'Ir--_74 _ FROM NY-#ATE WATERHEAT_OR ZONE I
SHUT-O£FVAEVES
BYPASS tb,tNEVE_DI_ONAL
_TEM UMiT
i iF REQU RED)
Lt SUPPLYVALVE
_S_MSUPPLY
EXPANSIONT_NK
NOTES;:RUN EACH ZONE PiPE DOWN THEN UP TO ZONETO PR_NT AiR ACCUMULATION iN PIP!NG_
PRESSUREREDU@NG
V_VE
_!®!l
SHUT-OWVALVE
C:O_ WATERSUPPLY
TO,
_ _NO_ AL
i i'
TO TONY_MATE ZONE :2
HDATER
USED)OR ZONE !
6" OF _OOR FRONT VI_
Figure 11: Boiler Piping for Zone Valve Zoned Heating Systems
THE FOLLOWING GUIDELINES SHOULD BE
FOLLOWED WHEN PIPING THE TANKLESS HEATER:
1. FLOW REGULATION -- If flow through the heateris greater than its rating, the supply of adequate hotwater may not be able to keep up with the demand.For this reason a flow regulator matching the heaterrating should be installed in the cold water line tothe heater. The flow regulator should preferably belocated below the inlet to the heater and a lninilnuln
of 3' away from the inlet so that the regulator is notsubjected to excess temperatures that may occurduring "off' periods when it is possible for heat tobe conducted back through the supply line. The flowregulator also limits the flow of supply waterregardless of inlet pressure variations in the range of20 to 125 psi.
2. TEMPERING OF HOT WATER -- Installation of
an automatic mixing valve will lengthen the deliveryof the available hot water by mixing some coldwater with the hot. This prevents the possibility ofscalding hot water at the fixtures. In addition,savings of hot water will be achieved since the userwill not waste as much hot water while seeking awater telnperamre. Higher telnperamre hot water
3.
4.
required by dishwashers and automatic washers ispossible by piping the hot water from the heaterprior to entering the mixing valve. The mixing valveshould be "trapped" by installing it below the coldwater inlet to heater to prevent lime formation in thevalve. Refer to Figure 12.
FLUSHING OF HEATER -- All water containssome sediment which settles on the inside of the
coil. Consequently, the heater should be periodicallybackwashed. This is accomplished by installing hosebibs as illustrated and allowing water at citypressure to run into hose bib A, through the heater,and out hose bib B until the discharge is clear. Thetees in which the hose bibs are located should be thesame size as heater connections to minilnize
pressure drop.
HARD WATER -- A water analysis is necessary todetermine the hardness of your potable water. Thisis applicable to some city water and particularly towell water. An appropriate water softener should beinstalled based on the analysis and dealer'srecolranendation. This is not only beneficial to thetankless heater but to piping and fixtures plus themany other benefits derived from soft water.
Figure 12: Schematic Tankless Heater Piping
Table 1: Tankless Heater Ratings
Boiler Model
AP-490U
AP-590U
AP-690U
AP-790U
Tankless Heater Model
S-4 S-5
GPM PSID GPM PSID
3 12 3½ 15
3¼ 16
3½ 1933A 25
16
IV. Venting
A. GENERAL GUIDELINES.
1.
2.
Vent system installation must be in accordance withthese instructions and applicable provisions of localbuilding codes. Contact local building or fireofficials about restrictions and installation inspectionin your area.
The AP-U Series is designed to be vented into afireclay tile-lined masonry chimney or chimneyconstructed from type-L vent or a factory builtchimney that complies with the type HTrequirements of UL103. The chimney or vent pipeshall have a sufficient draft at all times, to assuresafe proper operation of the boiler. See Figure 13 forrecommended installation.
a.
b.
Install a draft regulator (supplied by installer)following the instructions furnished with theregulator. See Figure 14 for alternate regulatorlocations.
With any new or replacement installation thechimney has to be considered. Chimneys thathave a high heat loss become less suitable as theheat loss of the home goes down and theefficiency of the boiler goes up. Most homeshave a chimney appropriate for the fuel and theera in which the home was built. That may havebeen a coal fired or an inefficient oil fired boilerbuilt into a home without insulation or storm
windows. With increasing fuel prices that homeprobably has been insulated and fitted with stormwindows so that the heat loss of the home has
been reduced. This requires less fuel to beburned and sends less heat up the chimney.A new boiler probably has a higher efficiencythan the boiler being replaced. That probably
3.
means that the stack temperature from the newboiler will be lower than that from the old boiler
and with less room air being drawn up thechimney to dilute the stack gases. Thecombination of a large uninsulated chimney,reduced firing rate, reduced firing time, lowerstack temperature and less dilution air can, insome cases, contribute to the condensing ofsmall amounts of water vapor in the chimney.Such condensation, when it occurs, can causechimney deterioration. In extreme cases, thechimney may have to be lined to insulate thechimney and thus prevent the condensation. Theaddition of dilution air into the chimney mayassist in drying the chimney interior surfaces.A massive chimney on a cold, or exposed outsidewall may have produced adequate draft when itwas fired with a higher input and greater volumesof heated gases. With reduced input and volume,the draft may be severely affected. In oneinstance our research showed a new chimney ofadequate sizing produced only -.035" W.C. after
30 minutes of continuous firing at 13.0% CO 2.Outside wall chimneys take longer to heat up andcan have .00" W.C. draft at burner start-up. Youmay have to consider a special alloy chimneyflue liner with insulation around it and stabilizingdraft cap or even a draft inducing fan in severecases.
c. For the same reasons as in (2.) above, heatextractors mounted into the breeching are notrecommended.
For minilnuln clearances to combustible materials
refer to Figure 2.
17
F_RECLAY TILELINED
THIMBLE
GA, MINo X FUDL S_ZEOF CANOPY OUTLET COLOR (DO NOT REDUCE)NOTE: ALL HOR!ZONTAL SNOKEP!PE SHOULD SLOPEUPWARD NOT LESS T_N ONE INCH _N FOUR FEF
AiR GAPREGU_TOR
DILUTION NR
CL_NOUT
O_L BURNER
FLOORUNE
VIEWFigure 13: Recommended Smokepipe Arrangement and Chimney Requirements
18
PROPER LOCATIONS UNACCEPTABLE LOCATIONS
_,A- ;L; 1
ACCEPTABLE LOCATION
_EER
0
I BOILER
5
0
BOILER
_[LER
I
IFigure 14: Draft Regulator Locations
V. Electrical
Positively assure all electrical connections are unpowered before attempting installation or service ofelectrical components or connections of the boiler or building. Lock out all electrical boxes with padlockonce power is turned off.
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 anyelectrical work.
Each boiler must be protected with a properly sized fused disconnect.
Never jump out or make inoperative any safety or operating controls.
The wiring diagrams contained in this manual are for reference purposes only. Refer to the wiring diagramof any controls used with the boiler. Read, understand and follow all wiring instructions supplied withthe controls.
A. GENERAL 2.
2.
Install wiring and electrically ground boiler inaccordance with requirements of the authorityhaving jurisdiction, or in absence of suchrequirements the National Electrical Code, ANSI/NFPA 70, and/or the CSA C22.1 Electric Code.
A separate electrical circuit must be run from themain electrical service with an over-current device/disconnect in the circuit. A service switch is
recommended and may be required by some localjurisdictions.
3. Wiring should conform to Figure 15 and/or 16.
B. SYSTEM CONTROLS AND WIRING
1. Refer to National Electric Code or Local Electric
Codes for proper size and type of wire required.Follow Code.
3.
4.
5.
Use anti-short bushings on all wiring passing
through boiler jacket, junction boxes and/or controlboxes.
Use armored cable (BX) over all exposed linevoltage wiring.
If an indirect water heater is used, use priorityzoning. Do not use priority zoning for Hydro-AirSystems.
Single Zone System - Refer to Figure 15 or 16 forthe electrical diagram for this type of system.Connect the system circulator wire leads to theproper locations on the Aquastat control, L7224A/L7248A. See Figure 15Aor 16A. Connect thethermostat to the 'T-T' terminals on the L7224A/
L7248A control. Set thermostat heat anticipatorsettings to 0.60 amps.
19
24V _HZRM_,_
iB:_B: @IJRPU !'Ii_
M2JASffAT CQN'_BOZRElY
_RCLILATOR
SC|IEMATIe DIAGRAM _GEND
UNE VBLTAOE BIB 14 A_G
lINE BBITA_)Z B4_Z IB g_¢
WPE _ OR TW/BW_ !_RE
_iRZNUT
_ Q@I!K (X_N_4_C_ R_BiP_AB_Z
JM_ZR SLI_HZ_IBY bONE_LL
_BBf_OR
BURNER
........_ ........
..........................................................................................................:_.!_.........
wH
WR W_
..............................................................................................................................................NZ 5_ _-._
BURNER
J-BOX
i, _4Y UP H_ C_!01_AL _I_Z AS SU_LU,I _*_f/,_ I:H _ LL@4CE _US BZ
RE_B_, _T _ _ REPhraSED WF#H _RE AS _BWN OR _S EQU@A_£N1",
BECKEE R184B _R_M#_Y OON'_ROL
................i_ 1ONCOR
................ _ VALVE
÷÷.............. _h L2 I I
i i..............................._;_ I i
¥_I IYE
r<OJ'tJ
W_EECODE_ BLACK
-- BLUE
GR * GRHN
OR - O_NCE
RB - REi}
YE YEIOB
BL,£@_ BLUE Wi _(TE TRACE
.........ZNV@_EJOM_TERMINN_S
x_._ 1-oT TERMINAtS
Figure 15: AP-U Boiler Wiring Less Tankless, Single Circulator w/Beckett Burner
B[LLO BURNER W/PRIMA_Y CONTROL
SCHEMATIC D]AQRAM LEGEND
...... tO_@ VOLTA_Z SIZE 18/2 AWG POWER
L,/M!T_D CIRCLIT C_I: '25 i05'C
LINE 'VOL]:ABE SIZE 14 AWO
T'f_E TW OR ?D4_'/AWM WIRE
UNZ VOLJAGE SiZE 18 AWGTYPE I'#OR TE_JA'#M WiRE
NC)TES:
I, I_ ANY OF ?RE ORIGINAL WIRE AS BUPPDZB _iTH BE _PLIANCZ MUST B£
BEPIACEB _ M*JS_BE REPLACFJ9 WITH _IR _B BBC:WN OR _TS EQU:BALEN_
#I_E CODE
BL _ BLUEOR _ QRZZ_
RD _ RED
WB _ _4_F
Figure 15A: AP-U Boiler Wiring Less Tankless, Single Circulator w/Riello Burner
20
gaV _H_RM_ ¸
_)IE_,TId D_)SRAM _GEND
NOTE_
F_ ":Z:_ _ _ +!
; L _
@'+ffOR
,..,÷URNR
WH
_UNNER&:BOX
B_:_CK_f['TR7_848 PR+_RY CONIROL
.........................+° ++
Y_
W]_ dODE
O@ "- Off_ANOE
+ YfiLu_
cD--t
I
.... =+=--__:+ ?+t _++ MiNAbS
\_::, J+#+¢'ER
Figure 16: AP-U Boiler Wiring with Tankless, Single Circulator w/Beckett Burner
ZR
®
I'_'E_SSURPU+:9 BY II@S'f_LL_R
+
++ ii:::;:i--Z +.1w+++
; +: +
S+:RVffC+ FUSED DISCON+¢EC+S_TTO S+#ffOH
SCHEMATIC DIAGP,AM _GEND
..... LG!W VO TA_E SIZE 18/2 A'_G POWER
UM[TED CtRCU_ CABLE 75 IOB+C
UNE COLLAGE SiZE 14 A_#G
tYPE !# OR _EW/AW_ @tR_
SUPPgY
R+_U_O BURNER W/PR_ARY COtITROL
(2@/ ¢ONSTA+_T POWER::
"SIRE dODE
_L - BLUE
RD - R_
+@14 - WHITE
UN8 VOLTAGE SIZE 8 A'#G
NOTES:
I, ++" ANY O_ THE ORIG _'_L W;RE AS SUPPU_D WITH TH_ *+PPU_k_CE MUST 8_
R_LAI.';FD+ IT M_ST _£ R_PLACFO WIT+'_WIR A% S>4OWN OR RS EQUIVR_FNT.
Figure 16A: AP-U Boiler Wiring with Tankless, Single Circulator w/Riello Burner
21
Vl. Oil Piping
A. GENERAL.
1. Use flexible oil line(s) so that burner can be
removed without disconnecting the oil supply.
2. A supply line fuel oil filter is recommended as aminilnuln for all firing rates but a pleated paper fueloil filter is recolmnended for the lowest firing rateapplication to prevent nozzle fouling.
3. Use Flared fittings only. Do not use compressionfittings.
4. Use of a high efficiency micron filter (Garber orequivalent) in addition to conventional filter ishighly recommended.
B. SINGLE-PIPE OIL LINES.
1. Standard burners are provided with single-stage3450 rpm fuel units with the bypass plug removedfor single-pipe installations.
2. The single-stage fuel unit may be installed single-pipe with gravity feed or lift. Maximum allowablelift is 8 feet. See Figure 17.
Oil piping must be absolutely airtight or leaks orloss of prime may result. Bleed line and fuel unitcompletely.
AIRVEN
FILLPIPE
OILTANK
FU EL
FLEXIBLE OIL PIPING RECOMMENDEDNEAR BURNER SWING DOOR
PUMP
SHUT-OFFVALVE
IN
MAIN FILTER
RECOMMENDEDFILTER (GA RBEROR EQUIVALENT)
MAXIMUM
ONE PiPE
Figure 17: Single-Pipe Installation
22
Table 2: Single Stage Units (3450 RPM)Two Pipe Systems
Lift "H"(See Figure)
0 I
1'
2'
3'
4'
5'
6'
7'
8'
9'
10'
11'
12'
13'
14'
Maximum Length of Tubing"H" + "R" (See Figure)
3/8" OD Tubing(3 GPH)
84'
78'
73'
68'
63'
57'
52'
47'
42'
36'
31'
26'
21'
1/2" OD Tubing
(3 GPH)
100'
100'
100'
100'
100'
100'
100'
100'
100'
100'
100'
100'
83'
62'
41'
Table 3: Two-Stage Units (3450 RPM)Two Pipe Systems
Lift "H"(See Figure)
0 I
2'
4'
6'
8'
10'
12'
14'
16'
18'
Maximum Length of Tubing"H" + "R" (See Figure)
3/8" OD Tubing(3 GPH)
93'
85'
77'
69'
60'
52'
44'
36'
27'
1/2" OD Tubing
(3 GPH)
100'
100'
100'
100'
100'
100'
100'
100'
100'
76'
C. TWO-PIPE OIL LINES
1. For two-piped systems, where more lift is required,the two-stage fuel unit is recommended. Table 2(single-stage) and Table 3 (two-stage) showallowable lift and lengths of 3/8 inch and 1/2 inchOD robing for both suction and return lines. Referto Figure 18.
OUTSIDE TANK FUEL PUMP ABOVE
BOSOM OF TANK
FILLPIPE
AiRVENT
FUEL
RETURNLINE
FLEXIBLENEAR
RETURNLINE
OIL PIPING RECOMMENDEDBURNER SWING DOOR
RECOMMENDEDFILTER (GARBEROR EQUIVALENT)
INLET l
'H'
Figure 18: Two-Pipe Installation23
VII. System Start-Up
A°
B°
VERIFY that the venting, water piping, oil piping,and electrical system are installed properly. Refer toinstallation instructions contained in this manual.
CONFIRM all electrical, water and oil supplies areturned off at the source and that the vent is clear fromobstructions.
Completely read, understand and follow allinstructions in this manual before attemptingstart up.
C°
24
FILL ENTIRE HEATING SYSTEM WITH WATER
and vent air from system. Use the following procedureon a Series Loop or multi-zoned system installed as perFigure 10 or 11.
1. Close isolation valve in boiler supply piping.
2. Isolate all circuits by closing zone valves orbalancing valves.
3. Attach a hose to hose bib located just belowisolation valve in boiler supply piping. (Note -Terminate hose at a suitable floor drain or outdoor
area).
4. Starting with one circuit at a time, open zone valveor valve.
5. Open hose bib.
6. Open fill valve (Make-up water line should belocated directly after isolation valve in boiler supplypiping between air scoop and expansion tank).
7. Allow water to flow into drain until discharge fromhose is bubble free for 30 seconds.
8. When zone is completely purged of air, close zonevalve or balancing valve. Open the zone valve forthe next zone to be purged. Repeat this step until allzones have been purged. At completion, open allzone valves or valves.
The maximum operating pressure of this boiler is30 psig. Never exceed this pressure. Do not plugor change pressure relief valve.
9. Close hose bib, continue filling the system until thepressure gauge reads 12 psig. Close fill valve.(Note - If make-up water line is equipped withpressure reducing valve, system will automaticallyfill to 12 psig.
10. Open isolation valve in boiler supply piping.
11. Remove hose from hose bib.
Do
E°
F.
Go
CONFIRM that the boiler and system have no waterleaks.
CHECK CONTROLS, WIRING AND BURNER tobe sure that all connections are tight and burner isrigid. Verify that all electrical connections have beencompleted, fuses installed, that the oil tank is filled andoil lines have been tested.
LUBRICATION. Follow instruction on burner and
circulator label to lubricate, ifoil lubricated. Most
motors currently used on residential type burnersemploy permanently lubricated bearings and thus donot require any field lubrication. Water lubricatedcirculators do not need field lubrication.
ADJUST CONTROLS SETTINGS with burner serviceswitch turned "ON".
1.
2.
SET ROOM THERMOSTAT about 10°F below
room temperature.
PRESS RED RESET BUTTON on front of
burner cover (Beckett, Riello burners) hold buttonfor one (1) second and release to reset primarycontrol.
3. On WATER BOILERS WITHOUT TANKLESS
HEATERS equipped with L7248 electronic aquastatcontroller, set High Limit (HL) at 180°F. Thistemperature can be varied to suit installationrequirements. L7248 controller has the High Limitadjustlnent range from 180°F to 240°F (82°C to116°C). High Limit Differential is fixed at 15°F(soc).
4. On WATER BOILERS WITH TANKLESS
HEATERS equipped with L7224 electronic aquastatcontroller, set operating control (low limit [LL]) at190°F and high limit (HL) at 210°F. Operatingcontrol (low limit) setting must be a lninilnuln of20°F below high limit setting.
L7224 controller has the High Limit adjustlnentrange from 130°F to 240°F (55°C to 116°C), and theLow Limit adjustlnent range from 110°F to 220°F(43°C to 104°C). High Limit Differential is fixed at10°F (6°C), and Low Limit Differential hasadjustlnent range from 10°F (6°C) to 25°F (14°C).
5. ADJUSTING AQUASTAT CONTROLLERSETTINGS. To discourage unauthorized changingof Aquastat settings, a procedure to enter theADJUSTMENT mode is required. To enter theADJUSTMENT mode, press the UP, DOWN, andI buttons (refer to Figure 19) simultaneously forthree seconds. Press the I button until the feature
requiring adjustlnent is displayed:
CAPAC TOR
tRANSFORMER
FUSE
THERMOSTAiT ------TERM NALS
-- RELAYS
SENSOR CONNEC'[OR '--- FFLD T_"_RMINALS
L_ SENSOR HO(_':
(HORIZONTAL MOUNT)
Figure 19:1_7248/1_7224 Circuit Board Layout-Horizontal Mount
6.
• HL_-- High Limit.• LL -- Low Limit.• Ldf-- Low Limit Differential.• °F-- °C.
Then, press the UP and/or DOWN buttons to movethe set point to the desired value. After 60 secondswithout any button inputs, the control willautomatically return to the RUN mode.
Note that L7224 Aquastat Controller will display allfour (4) above-listed adjustlnent features, but L7248Aquastat Controller will not display Low Limit andLow Limit Differential adjustlnent features.
DISPLAY READOUT
In the RUN mode, the Aquastat will flash "bt"(boiler telnp) followed by the telnperamre (i.e.,220), followed by °F or °C.
To read boiler settings, press the I key to read theparameter of interest. For example, press I HighLimit (ILL) is displayed, followed by a three-digitnumber, i.e., 220, followed by °F or °C. Pressingthe I button again (on L7224 models) will displaythe Low Limit iLL) followed by a three-digitnumber and the corresponding degree designator.See Display Readout, Figure 20.
Text Desc ription Shows
bt Boiler Temperature
HL High Limit _k
LL Low Limit L t.
Ldf Low Limit Differential k dF
tt Local Thermostat Status _
tie Enviracom Thermostat Status
en Error Code
f Degrees Fahrenheit QF
C Degrees Celsius O_"
Figure 20: Display Readout Definitions
7.
Table 4:
After approximately 60 seconds without any keypresses, the display will enter a dim display mode.To return to the bright display mode, simply pressany key.
OPERATION
The L7224 model can be in any of four operationalstates - Nounal, High Limit, Low Limit and Error.The controller moves back and forth from HighLimit to Nounal to Low Limit state as part ofnounal operation.
The L7248 model is restricted to three operationalstates - Nounal, High Limit and Error. Thecontroller moves back and forth from High Limit toNounal state as part of nounal operation.
For both models, the controller will enter the Errorstate when there is an abnormal condition. The
operating states are:
a. Nounal: Boiler telnperamre went below theHigh Limit setting (minus the Differential) andhas not exceeded the High Limit setting; or theboiler telnperamre went above the Low Limitsetting and has not gone below the Low Limitsetting (minus the Differential).
b. High Limit: Boiler telnperamre went above theHigh Limit setting and has not dropped belowthe High Limit setting (minus the Differential).
c. Low Limit: Boiler telnperamre went below theLow Limit setting (minus the Low LimitDifferential) and has not gone above the LowLimit setting.
d. Error: The controller has detected an error
condition (e.g., open sensor) and has shut downthe burner output. The ZC output is energized.The controller continues to monitor the systemand automatically restarts if the error conditionclears. Refer to Table 4.
The operating sequence for the L7224/L7248 isshown in Table 5.
LED Error Codes
ErrorCause / Action
Code
Errl Sensor fault; check sensor.
Err2 ECOM fault; check EnviraCOM TM wiring.
Err3 Hardware fault; replace control.
Err4 B 1 fault; check B 1 wiring/voltage.
Err5 Low Line; check L1-L2, 110 Vac.
Err6 Fuse; check ECOM wires, replace fuse.
Err7 EEPROM, HL, LL, HdL Ldf; reset to defaultvalues. Restore desired settings.
Err8 Repeated B 1 fault (voltage present at B 1 whenoutput is turned off); check B 1 wiring/voltage.
25
Table 5:Se(L7224 / L7248 Controller Operating
uence
Action
Thermostatcalls for heat.
Boiler exceeds
the High Limit.
Thermostat issatisfied.
Errorcondition 1-5.
Error
condition 6.
Errorcondition 7.
Error
condition 8.
System Response
Circulator starts when water temperature
is above Low Limit setting (if applicable).
Boiler temperature is checked. Burner starts
when water temperature is below High Limit
setting.
Burner is turned off. Burner restarts when the
water temperature drops below the High Limit
setting minus the Differential.
Circulator and burner turn off.
If an error condition is detected, all outputs
except ZC are shut down. Burner is off.
Control continues to function and restarts
when error is corrected.
During the error check sequence, the systemchecks tbr drift in the sensor and corrosion in
the connections.
EnviraCOM communication is not available.
The control has reset the High Limit, LowLimit and Differential setting to a defaultsetting and will continue to run at thosesettings.Performance of the system will be degraded.
If the error condition is detected, all outputsexcept ZC are shut down. Burner is off.Control continues to function and restarts
when all three user keys have been pressedlonger than 60 seconds.
26
8. HIGH LIMIT CONTROLLER
The High Limit opens and turns off the burner whenthe water temperature reaches the setpoint. TheHigh Limit automatically resets after the watertemperature drops past the setpoint and through theDifferential. The L7248 models have High LimitDifferential presets of 15°F (8°C). The L7224models have High Limit Differential presets of 10°F(6°C).
9. LOW LIMIT AND CIRCULATOR CONTROLLER
On a temperature rise, with the adjustableDifferential at the default setting of 10°F (6°C), theburner circuit breaks and the circulator circuit makes
(assuming no call for heat is present) at the LowLimit setpoint. On a temperature drop of 10°F(6°C) below the Low Limit setpoint, the burnercircuit makes and the circulator circuit breaks. See
Figure 21.
10. CHECKOUT
Put the system into operation and observe at leastone complete cycle to make sure that the controlleroperates properly. See Step 11, TROUBLESHOOTING to use LED to assist in determiningsystem operation.
i : (4:5
Figure 21 : Setpoints and Differentials
11. TROUBLE SHOOTING
When attempting to diagnose system performance,reference to the LED display can help to identifyspecific areas not working properly. The LEDdisplay will scroll Err, followed by a digit (1-8).Refer to Table 4 for a description of each error andsuggested actions.
For Beckett Burner
H. REMOVE GUN ASSEMBLY
1. Check nozzle size, head size, gun setting, andpositioning of electrodes. This information is shownin Figure 22, and Table 6.
2. Reinstall gun assembly.
I° VERIFY OIL BURNER SETTINGS BEFORESTARTING
1. BURNER AIR BAND AND AIR SHUTTER
SETTINGS, see Table 6.
2. OPEN ALL OIL LINE VALVES.
3. Attach a plastic hose to fuel pump vent fitting andprovide a container to catch the oil.
4. REMOVE GAUGE PORT PLUG from fuel pumpand install pressure gauge.
£LECTROOIE
_/11 AIOV ZLE
ELECTRODE ADJUSTMENTS
Figure 22: Electrode / Head Setting
Table6: BeckettAFGBurners
BoilerModel
*AP-490U
AP-590U
AP-690U
AP-790U
Firing Rate(GPH)
0.75
1.00
1.10
1.35
Nozzle
0.65 - 80°ABDanfoss
0.85 - 80°BHAGO
0.90 - 80°BHAGO
1.10 - 80°BHAGO
Shutter
7
4
6
8
Band
0
0
0
0
Head (stop screw)
N/A
N/A
N/A
N/A
Air Settings
Pump Pressure
140
140
140
140
* Equipped with low firing rate baffle
J. START OIL BURNER
1. Open vent fitting on fuel pump.
2. TURN 'ON' BURNER service switch and allow
burner to run until oil flows from vent fitting in aSOLID stream without air bubbles for
approximately 10 seconds.
3. Close vent fitting and burner flame should start
immediately.
4. If the burner does not start immediately, check themanual overload switch on the motor, if so
equipped, and the safety switch on the burner
primary control.
K. ADJUST OIL PRESSURE
1. Locate oil pressure adjusting screw and turn screw
until Pressure Gauge reads the correct pump
pressure required for the specific boiler. Refer toTable 6.
2. DO NOT REMOVE PRESSURE GAUGE untillater.
L. OTHER ADJUSTMENTS
1. ADJUST THE AIR BAND AND/OR AIR
SHUTTER.
2.
3.
Beckett Burners:
a. Adjust air supply by loosening lock screws andmoving the air shutter and if necessary the airband. Refer to Table 6 preliminary settings.
ADJUST DRAFT REGULATOR for a draft of
-.02" (water gauge) over the fire after chimney hasreached operating telnperature and while burner isrunning.
READJUST AIR BANDS on burner for a lightorange colored flame while draft over the fire is-.02" w.c. Use a smoke test and adjust air forminilnuln smoke (not to exceed #1) with aminilnuln of excess air. Make final check using
suitable instrumentation to obtain a CO 2of 11.5 to12.5% with draft of-.02" w.c. in fire box. These
settings will assure a safe and efficient operating
®
4.
condition. If the flame appears stringy instead of a
solid flame, try another nozzle of the same type.
Flame should be solid and compact. After all
adjustments have been made, recheck for a draft of-.02" w.c. over the fire.
TURN "OFF" BURNER and remove pressure
gauge. Install gauge port plug and tighten. Start
burner again.
For Riello Burner
M. INSPECT NOZZLE_ ELECTRODES ANDTURBULATOR SETTING
1. Loosen Burner Cover Screws and remove BurnerCover.
2. Installation/Removal of Drawer Assembly, Refer toFigure 23.
Figure 23: Installation/Removal of Drawer Assembly
a. Removal:
• Disconnect oil delivery tube nut from pump.
• Loosen SCREW (3), and then unplug
PRIMARY CONTROL (1) by carefully
pulling it back and then up.
• Remove the AIR TUBE COVER
PLATE (5) by loosening the retaining
27
3.
SCREW (4) (Two SCREWS-Model F5).
• Loosen SCREW (2), and then slide the
complete drawer assembly out of thecombustion head as shown.
b. Installation:
To insert drawer assembly, reverse theprocedure in Step 2a.
Nozzle Replacement, Refer to Figure 24
4.
% •
Figure 24: Nozzle Replacement
a. Remove the NOZZLE ADAPTER (2) from theDRAWER ASSEMBLY by loosening theSCREW (1).
b. Remove existing nozzle from nozzle adapter.
c. Insert the proper NOZZLE into NOZZLEADAPTER and tighten securely (Do not overtighten).
d. Replace adapter, with nozzle installed, intodrawer assembly and secure with screw (1).
Inspect and measure burner electrodes. Refer toFigure 25 for the proper electrode settings.
IMPORTANT: THESE DIMENSIONS MUST BE OBSERVED AND VERIFIED.
..................@r5/_4" :'_/64" 0r 2 to2.smm_
Figure 25: Electrode Setting
5. Re-install Drawer Assembly into CombustionHead per Step 2a.
6. Turbulator Setting, Refer to Figure 26
'4 0
Figure 26: Turbulator Setting
7.
a. Confirm the turbulator setting is correct forstandard higher (lnaxilnuln) input oil nozzleinstalled in the burner. If the lower (lninilnuln)input is desired, readjust turbulator setting toindex mark specified in Table 7.
b. Loosen NUT (1), and then turn SCREW (2) untilthe INDEX MARKER (3) is aligned with thecorrect index number in the Burner Setup chart(Table 7).
c. Retighten the RETAINING NUT (1).
MODEL F3 NOTE: Zero and three are scale
indicators only. From left to right the first line is3 and the last line 0.
Pump Connections and Port Identification, Referto Figure 27.
This burner is shipped with the oil pump set tooperate on a single line system. To operate on atwo-fine system the bypass plug must be installed.
WARNING: Do not operate a single line systemwith the by-pass plug installed. Operating a singleline system with the by-pass plug installed willresult in damage to the pump shaft seal.
NOTE: Pump pressure was factory pre-set but mustbe checked at time of burner start-up. A pressuregauge is attached to the PRESSURE/BLEEDERPORT (7) for pressure readings. Two PIPE
Table 7: Riello Burner Specifications
BoilerModel
AP-490U
AP-590U
AP-690U
AP-790U
FiringRate
(GPH)
0.75
1.00
1.10
1.35
BurnerModel
40F3
40F5
Nozzle
(Delavan)
0.65 - 60W
0.85 - 80B
0.90 - 80B
1.10 - 80B
Air Gate
Setting
2.75
3
3.5
Turbulator
Setting
1
0
2
PumpPressure
(PSIG)
145
Combus-tion Head
VSBT
Insertion
Depth
1%
28
PUMP LEGEND
t. PUMP COVER2. PUMP COVER O-RING3. BSPP TO NPT ADAPTERS
4, SUPPLY AND RETURN OiL LINES5. RETURN PORT BY PASS SCREW
6, NOZZLE PORT - PUMP OULET TO NOZZLE7, PUMP PRESSURE PORT AND BLEEDER PORT8, PUMP SUPPLY PORT9. PUMP RETURN PORT
10. PUMP PRESSURE REGULATING SCREWtt, VACUUM PORTI2. PUMP VALVE STEM
Figure 27: Pump Connections and Port Identification
8.
CONNECTORS (4) are supplied with the burnerfor connection to either a single or two-line system.Also supplied are two ADAPTORS (3), two female¼" NPT to adapt oil lines to burner pipe connectors.All pump port threads are British Parallel Threaddesign. Direct connection of NPT threads to thepump will damage the pump body.
Riello manometers and vacuum gauges do notrequire any adapters, and can be safely connected tothe pump ports. An NPT x metric adapter must beused when connecting other gauge models.
Replace Burner Cover and Tighten Burner CoverScrews.
N. VERIFY OIL BURNER SETT1NGS BEFORESTARTING
1. Check burner AIR DAMPER (GATE) and
TURBULATOR settings per Table 7, readjust if
necessary.
2. OPEN ALL OIL LINE VALVES.
3. Provide a pan to catch oil.
4. Remove pressure port/bleeder plug from fuel pumpand install Riello Combination Pressure Gauge andBleeder "CalveAssembly.
5. OPEN FLAME OBSERVATION PORT COVER on
burner swing door.
O° START OIL BURNER
1. Open bleeder valve (vent fitting) on RielloCombination Pressure Gauge and Bleeder "CalveAssembly.
2. TURN 'ON' BURNER service switch and allow
burner to run until oil flows from vent fitting in aSOLID stream without air bubbles for
approximately 10 seconds.
3. Close vent fitting and burner flame should startilnlnediately.
P. ADJUST OIL PRESSURE
1. Locate oil pressure adjusting screw and turn screwto obtain proper pump pressure, refer to Table 7.
Qo ADJUST OIL BURNER WHILE OPERATING (flame
present)1. ADJUST DRAFT REGULATOR for a draft of-
0.02" (water gauge) over the fire after chilnney hasreached operating temperature and while burner isrunning.
2. READJUST THE AIR DAMPER SETTING on the
burner for a light orange colored flame while thedraft over the fire is -0.02". Use a smoke tester and
adjust air for lninilnuln smoke (not to exceed #1)with a lninilnuln of excess air. Make final check
using suitable instrumentation to obtain a CO 2of11.5 to 12.5% with draft of-0.02" (water gauge) infire box. These settings will assure a safe andefficient operating condition. If the flame appearsstringy instead of a solid fire, try another nozzle ofthe same type. Flame should be solid and compact.After all adjustlnents are made recheck for a draft of-0.02" over the fire.
3. READJUST THE TURBULATOR SETTING onlyif necessary.
a. AP-490U throughAP-790U
Move the turbulator setting forward or back one
position at a time to optimize the smoke and CO2readings.
4. Turn "OFF" burner and remove Riello Combination
Pressure Gauge and Bleeder "CalveAssembly.Install pressure port/bleeder plug and tighten. Startburner again.
R. FLAME FAILURE
Do not attempt to start the burner when excess oilhas accumulated, when the unit is full of vapor, orwhen the combustion chamber is very hot.
The AP-U boiler controls operate the burnerautomatically. If for unknown reasons the burnerceases to fire and the rest button on the primary controlhas tripped, the burner has experienced ignition failure.
29
So
To
30
Before pressing the rest button, call your servicemanimmediately.
CHECK FOR CLEAN CUT OFF OF BURNER
1. AIR IN THE OIL LINE between fuel unit and
nozzle will compress when burner is on and willexpand when burner stops, causing oil to squirt fromnozzle at low pressure as burner slows down andcausing nozzle to drip after burner stops. Usuallycycling the burner operation about 5 to 10 times willrid oil line of this air.
2. IF NOZZLE CONTINUES TO DRIR repeat stepN. 1. If this does not stop the dripping, remove cutoff valve and seat, and wipe both with a clean clothuntil clean. Then replace and readjust oil pressure.If dripping or after burn persist replace fuel pump.
HINTS ON COMBUSTION
1. NOZZLES-- Although the nozzle is a relativelyinexpensive device, its function is critical to thesuccessful operation of the oil burner. The selectionof the nozzle supplied with the AP-U boiler is theresult of extensive testing to obtain the best flameshape and efficient combustion. Other brands of thesame spray angle and spray pattern may be used but
may not perform at the expected level of CO2 andsmoke. Nozzles are delicate and should protectedfrom dirt and abuse. Nozzles are mass produced andcan vary from sample to sample. For all of thosereasons a spare nozzle is a desirable item for aserviceman to carry.
2. FLAME SHAPE -- Looking into the combustionchamber through the flame plug hole, the flameshould appear straight with no sparklers rolling uptoward the top of the chamber. If the flame drags tothe right or left, sends sparklers upward or makeswet spots on the combustion chamber, the nozzleshould be replaced. If the condition persists look forfuel leaks, air leaks, water or dirt in the fuel as
described in following steps.
3. FUEL LEAKS--Any fuel leak between the pumpand the nozzle will be detrimental to goodcombustion results. Look for wet surfaces in the air
tube, under the ignitor, and around the air inlet. Anysuch leaks should be repaired as they may causeerratic burning of the fuel and in the extreme casemay become a fire hazard.
4. AIR LEAKS-- Any such leaks should be repaired,as they may cause erratic burning of the fuel and inextreme cases may become a fire hazard.
There may be many possible causes of leaks in oil linessuch as:
a. Fitting leaks due to misflared tubing or damagedfitting.
b. Fuel line leak due to crushed or bent tubing.
c. Filter connection leaks.
d. Tank connection leaks.
The following actions can eliminate air leaks:
a. Bleed pump as detailed in System Start-UpSection of this manual.
b. Replace flare fittings.
c. Replace oil supply line.
d. Repair oil filter leaks
e. Replace or repair tank fittings.
5. GASKET LEAKS-- If 11.5% to 12.5% CO2 with a#1 smoke cannot be obtained in stack, look for airleaks around the canopy seal. Such air leaks will
cause a lower CO 2 reading in the stack. The smallerthe firing rate the greater effect an air leak can have
on CO 2readings.
6. DIRT-- A fuel filter is a good investment.Accidental accumulation of dirt in the fuel systemcan clog the nozzle strainer and produce a poorspray pattern from the nozzle.
7. WATER-- Water in the fuel, in large amounts, willstall the fuel pump. Water in the fuel pump, insmaller amounts, will cause excessive wear on the
pump, but more importantly water does not burn. Itchills the flame, causes smoke, and allows unburned
fuel to pass through the combustion chamber andclog the flueways of the boiler.
CHECK TEST PROCEDURE. A very good test forisolating fuel side problems is to disconnect thefuel system and with a 24" length of tubing, fireout of an auxiliary five gallon pail of clean, fresh,warm #2 oil from another source. If the burner runssuccessfully when drawing out of the auxiliarypail then the problem is isolated to the fuel or fuellines being used on the jobsite.
8. COLD OIL-- If the oil temperature approaching thefuel pump is 40°F or lower, poor combustion ordelayed ignition may result. Cold oil is harder toatomize at the nozzle. Thus, the spray droplets getlarger and the flame shape gets longer. An outsidefuel tank that is above grade or has fuel lines buriedin the ground above the frost line is a good candi-date for cold oil. The best solution is to place thetank and oil lines in the ground below the frost line.
9. HIGH ALTITUDE INSTALLATIONS
10.
Typically, the rule to use for high altitudes is toincrease the air supply by 4% per each 1000 ft.above 2000 ft. altitude from sea level. This means
that the air setting will have to be higher than thecalibration marks in proportion to the altitude. Use
instruments and set for 11.5 to 12.5% CO2.
START-UP NOISE -- Late ignition is the cause ofstart-up noises. If it occurs recheck for electrodesettings, flame shape, air or water in the fuel lines.
11. SHUT DOWN NOISE -- If the flame runs out of
air before it runs out of fuel, an after burn with
noise may occur. That may be the result of a faultycut-offvalve in the fuel pump, or it may be airtrapped in the nozzle line. It may take several firingcycles for that air to be fully vented through thenozzle. Water in the fuel or poor flame shape canalso cause shut down noises.
U. TEST CONTROLS
Before installation of the boiler is consideredcomplete, the operation of all boiler controls mustbe checked, particularly the primary control andhigh limit control.
2.
CHECK THERMOSTAT OPERATION. Raise and
lower thermostat setting as required to start and stopburner.
VERIFY PRIMARY CONTROL SAFETY
FEATURES using procedures outlined inInstructions furnished with control (See back ofControl Cover) or Instructions as follows:
Service of this boiler should be undertaken onlyby trained and skilled personnel from a qualifiedservice agency.
a. Simulate flame failure:
• Follow the starting procedure to turn on theburner.
b.
• Close the hand valve in the oil supply line.
• Control enters recycle mode and tries torestart burner after approximately 60seconds.
Safety switch should lock out in approximately15 seconds. Ignition and motor should stop andoil valve should open to stop oil flow.
• Indicator light will flash 1/2second on,1/2second off.
• Push red reset button to reset safety switch.
Simulate ignition failure:
• Follow the starting procedure to turn on theburner, but do not open the oil supply handvalve.
Safety switch should lock out in approximately15 seconds. Ignition and motor should stop andoil valve should open to stop oil flow.
3.
go Boiler
• Indicator light will flash 1/2second on,1/2second off.
• Push red reset button to reset safety switch.
c. Simulate power failure:
• Follow the starting procedure to turn on theburner.
• With the burner running, turn off the powerto the system by tripping the circuit breakeror removing the fuse.
• Burner should stop.
• Restore power. Burner should start.
* The CleanCut Oil Pump's Solenoid "Calveis abypass valve, not a blocking valve.
VERIFY HIGH LIMIT OPERATION.
a. Adjust thermostat to highest setting.
b. Observe temperature gauge. When telnperamreis indicated, adjust limit to setting belowobserved temperature. Burner should stop.
c. Adjust limit to setting above observedtemperature. Burner should start.
d. Adjust thermostat to lowest setting. Adjust limitto desired setting.
is now ready to be put into service.
IF, DURING NORMAL OPERATION, IT ISNECESSARY TO ADD WATER MORE FREQUENTLYTHAN ONCE A MONTH, CONSULT A QUALIFIEDSERVICE TECHNICIAN TO CHECK YOURSYSTEM FOR LEAKS.
A leaky system will increase the volume of make-upwater supplied to the boiler which can significantlyshorten the life of the boiler. Entrained in make-upwater are dissolved minerals and oxygen. When thefresh, cool make-up water is heated in the boiler theminerals fall out as sediment and the oxygen escapesas a gas. Both can result in reduced boiler life. Theaccumulation of sediment can eventually isolate thewater from contacting the steel. When this happensthe steel in that area gets extremely hot and eventuallycracks. The presence of free oxygen in the boiler createsa corrosive atmosphere which, if the concentrationbecomes high enough, can corrode the steel throughfrom the inside. Since neither of these failure types arethe result of a manufacturing defect the warranty doesnot apply. Clearly it is in everyone's best interest toprevent this type of failure. The maintenance of systemintegrity is the best method to achieve this.
31
Advances in the new Series 5 Beckett R7184B 1032 Oil Primary Controls found on New Yorker AP-U boilers are bringing new
features to Oil-Fired AP-U's.
New Beckett Series 5 Control Features Include:
• EnviraCOM TM connnunication terminals and logic have been added for furore HVAC system networking.
• Quick connect terminals on the control allow quick component change out and reduce the number ofleads in the wiring box.
See below for location of Beckett R7184B 1032 Series 5 Control features:
_ESE _ BUWON
NOTE:
T TER_,AiNAL$
Figure 28: Beckett R7184B1032, Series 5 Control
The use of EnviraCOM TM terminals is not required for control operation.
32
VIII. Service and Cleaning
BURNER SHUTDOWN: Open Service Switchto turn off burner.
Manual Oil Supply Valve should be closed andElectric Service to boiler turned off if boiler
will not be operated for an extended periodof time.
A. GENERAL. Inspection service and cleaning should
be conducted annually. Turn off electric power andclose oil supply valve while conducting service ormaintenance.
B. FIRETUBES AND COMBUSTION CHAMBER. (See
Figure 29)
1. CLEAN THE FIRETUBES
a. Disconnect electric to burner and remove stack.
b. For access to the firembes, pull top jacket paneloff. Remove brass nuts, that hold canopy down.Without taking off carriage bolts, pull canopyoff.
c. Remove turbulators.
d. Using a firetube brush clean firetubes. DO NOTextend brush past the end of the bottomtubesheet.
e. Assemble the boiler in reverse order.
Units should be cleaned at least once a year, preferablyat the end of each heating season.
It is not necessary to remove burner to clean boiler.
Brush, scrape, or vacuum from top.
NOTE: UNITS SHOULD BE C_NED ATLF_AST ONCE A YE/_R, PREFER_LYAT THE END OF EACH HEATING
SEASON.
iS NOT NECESSARY TO REMOVE
BURNER TO CLEAN BOILER.
BRUSH, SCRAPE OR VACUUMCLEAN FLUE TUBES CAREFULLYFROM TOP WITHOUT EXTENDINGCLONING TOOLS BEYONDBOTTOM OF FLUE TUBE TOPREVENT DAMAGE TO COMBUSTIONCHAMBER,
COMBUSTION C_B_
tS A LIGHTWEIGHT CERAMIC TYPE,
EXTEND CLEANINGTOOK BEYOND BOTTOM OFFLUE TUBES TO PRINTDAMAGE TO COMBUSTIONCH_BER.
BOILER MODEL_-490U & _-590U
AP-BgOU & AP-790U
II
STEP 1
DISCONNECT _DTRICAL POWER
TO O{L BURN_
STEP 2
REMOVE STACK
STEP 3
REMOVE J_K_ TOP PANEL
STEP 4-
REMOVE BRA_ HEX NUTS
ND WASHERS
STEP 5REMOVECANOPY
s_P 6REMO'v_ TURBULATORS
STEP 7
R_RBE PR_EDURE
TO ASSEMBLE
EXTEND _UE
BRUSH BEYOND THIS
POINT
COMBUSTION CHAMB_
CLEANING INSTRUCTIONS
Figure 29: Cleaning of AP-U Boiler33
Warninq:
The Repair Parts list designates parts that contain refractory ceramic fibers(RCF). RCF has been classified as a possible human carcinogen. Whenexposed to temperatures about 1805°F, such as during direct flame contact,RCF changes into crystalline silica, a known carcinogen. When disturbed as aresult of servicing or repair, these substances become airborne and, if inhaled,may be hazardous to your health.
AVOID Breathinq Fiber Particulates and Dust
Precautionary Measures:
Do not remove or replace RCF parts or attempt any service or repair workinvolving RCF without wearing the following protective gear:
1. A National Institute for Occupational Safety and Health (NIOSH)approved respirator
2. Long sleeved, loose fitting clothing
3. Gloves
4. Eye Protection
• Take steps to assure adequate ventilation.
• Wash all exposed body areas gently with soap and water after contact.
• Wash work clothes separately from other laundry and rinse washingmachine after use to avoid contaminating other clothes.
• Discard used RCF components by sealing in an airtight plastic bag. RCFand crystalline silica are not classified as hazardous wastes in the UnitedStates and Canada.
First Aid Procedures:
• If contact with eyes: Flush with water for at least 15 minutes. Seekimmediate medical attention if irritation persists.
• If contact with skin: Wash affected area gently with soap and water.Seek immediate medical attention if irritation persists.
• If breathing difficulty develops: Leave the area and move to a locationwith clean fresh air. Seek immediate medical attention if breathingdifficulties persist.
• Ingestion: Do not induce vomiting. Drink plenty of water. Seekimmediate medical attention.
34
IX. Repair Parts
All AP-U TM 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.
AP-U Series Boiler Repair Parts
ITEM DESCRIPTION
1 Jacket Top Panel Assembly
2 Jacket Lower Front Panel Assembly
3 Jacket Upper Front Panel Assembly - 490U / 590U
Jacket Upper Front Panel Assembly - 690U / 790U
4 Jacket WAR Panel Assembly - 490U / 590U
Jacket WAR Panel Assembly - 690U / 790U
5 Temperature / Pressure Gauge
6 Honeywell L7248A1000 Aquastat
Honeywell L7224A1008 Aquastat
7 Observation Port Cover
Observation Cover Spring V1
Flat Washer, SAE, 5/16"
Hex Nut, 5/16 -18, Heavy
8 Burner Primary Control, R7184B
PART NUMBER QTY.
6047104 1
60471042 1
60471041 1
60471061 1
60471043 1
60417063 1
100282-01 1
100879-01 1
100862-01 1
7026001 1
8026015 1
80860647 1
80860402 1
80160847 1
Figure 30: AP-U Boiler Jacket Parts and Controls35
NOTE: When ordering parts always give the serial number and model number shown on the boiler. Also provide the name ofthe part(s) shown below:
36
Figure 31: AP-490U thru 790U Bare Boiler Repair Parts
AP-USeries Boiler Repair Parts (continued)
ITEMDESCRIPTION QTY.
NO.
9 2
10 10
11 2
12 2
13 1
14 1
15 1
16 _A _
Hex Nut, 1/4 - 20, Brass
Flat Washer, SAE 1/4
C-bolt, 1/4 - 20 x 3
1/4" Threaded Stud Push Retainer
Canopy Assembly
Fiberglass Tape Gasket 1/8 x 1 x 12-3/8"
Fiberglass Tape Gasket 1/8 x 1 x 13-3/8"
Turbulator, Short
Turbulator, Long
Shell Assembly
Hex Lock Nut 1/4 - 20
Machine Screw 1/4 - 20 x 1-1/4"
Base Assembly
Combustion Chamber
Base Front Insulation
Cerafelt, 1/2" Thick x 2" x 18-1/2"
Cerafelt, 1/2" Thick x 2" x 13-3/4"
S-4 Heater Coil Assembly
S-5 Heater Coil Assembly
Blanket Heater Cover Plate
Gasket, Blanket Heater Cover Plate
SA-307B 3/8 x 1-1/4" Hex Head Bolt
Heavy Hex Nut, 3/8 - 16
Flat Washer USS, 3/8"
PART NO.
80860119
80860424
80860847
80861725
6113509
9206032
9206032
7116037
7116038
See Table Below
80860456
80860810
61835062
8203006
8203512
9206003
9206003
6037201
6037202
7033715
8206036
80861360
80860400
80860645
17 'B'18 4
19 4
2O 1
21 1
22 1
23 1
24 1
125
1
26 1
27 1
28 10
29 10
30 10
BOILER MODEL
AP-490U
AP-590U
AP-690U
AP-790U
'A'12
16
12
16
_B _
63071100
63071101
63071102
63071103
37
X. Beckett AFG Burner Parts for AP-U Series Boilers
NOTE:
FOR REPLACEMENT OIL BURNER PARTS, CONTACT YOUR WHOLESALER OR THE BURNERMANUFACTURER:
R. W. BECKETT CORE
R O. BOX 1289
ELYRIA, OHIO 440361-800-645-2876
When ordering parts always give the serial and model numbers shown on the boiler and burner. Also, provide thename of the part(s) and part(s) number as listed below.
Boiler Model AP-490U AP-590U AP-690U AP-790U
Burner Model AFG AFG AFG AFG
Air Tube Combination AF40WR AF40BZ AF40WB AF40BZ
Spec. No. NY2101 NY2103 NY2105 NY2108
AFG Housing 5874BK 5874BK 5874BK 5874BK
Air Band 3492BKA 3492BKA 3492BKA 3492BKA
Air Band Nut 4150 4150 4150 4150
Air Band Screw 4198 4198 4198 4198
Air Shutter 3709 3709 3709 3709
Air Shutter Screw 4198 4198 4198 4198
Blower Wheel 2999U 2999U 2999U 2999U
Bulkhead Fitting 571801 571801 571801 571801
Bulkhead Fitting Locknut 3666 3666 3666 3666
Connector Tube Assembly 5636 5636 5636 5636
Coupling 2454 2454 2454 2454
Electrode Clamp 149 149 149 149
Electrode Clam p Screw 4219 4219 4219 4219
Electrode Insulator Assembly 5780 5780 5780 5780
Spider Spacer Assembly 5653 5653 5653 5653
Escutcheon Plate 3493 3493 3493 3493
Flange and Air Tube Assembly 3146806 3146806 3146806 3146806
Gasket 3811 3811 3811 3811
Head 360003 360004 360004 360004
Head Screws 4221 4221 4221 4221
Hole Plug 2139 2139 2139 2139
Housing Assembly w!lnlet Bell 5877 5877 5877 5877
Motor 21805U 21805U 21805U 21805U
Nozzle Adapter 213U 213U 213U 213U
Nozzle Line Electrode Assembly NL40WR NL40BZ NL40WB NL40BZ
Pu mp 21844 21844 21844 21844
Static Plate 3898 31646 3898 31646
Ignitor 51771U 51771U 51771U 51771U
Ignitor Hinge Screw 4217 4217 4217 4217
Ignitor Holding Screw 4198 4198 4198 4198
Ignitor Gasket Kit 51304 51304 51304 51304
Wire Guard 3345 3345 3345 3345
Junction box 5770 5770 5770 5770
Flame Detector 7006Q 7006Q 7006Q 7006Q
Baffle 5880 .........
38
Ordering Information for Quality Replacement Parts
_LY
TU_
SIDE
FOR R_ N_
VIEWFRONT VIEW
4X4_
NOZZLE DETAIL
Figure 32: BECKETT AFG MODEL BURNER
39
XI. Riello 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 viewof the burner and a list of spare parts.
For replacement Riello oil burner parts, contact your wholesaler or the burner manufacturer:
Riello Corporation of Alnerica35 Pond Park Road
Hingham, Massachusetts 02043Telephone: (617) 749-8292Facsimile: (617) 740-2069
Toll Free: (outside Massachusetts)(800) 992-7637
Riello Canada Inc.
2165 Meadowpine Blvd.Mississauga, Ontario L5N 6H6
Telephone: (905) 542-0303
Facsimile: (905) 542-1525
Toll Free: (800) 387-3898
40
XII. Low Water Cut Off (LWCO) on Hot Water Boilers
When
A low water cutoff is required to protect a hot waterboiler when any connected heat distributor (radiation)is installed below the top of the hot water boiler (i.e.baseboard on the same floor level as the boiler). Inaddition, some jurisdictions require the use of a LWCOwith a hot water boiler.
Where
The universal location for a LWCO on both gas and oilhot water boilers is above the boiler, in either the supplyor return piping. The lninilnuln safe water level of awater boiler is at the uppermost top of the boiler; that is,it must be full of water to operate safely.
What Kind
Typically, in residential applications, a probe typeLWCO is used instead of a float type, due to theirrelative costs and the simplicity of piping for a probeLWCO.
How to Pipe
A "tee" is commonly used to connect the probe LWCOto the supply or return piping, as shown below.
EYS_EM SU#_[ g
gg IJRN I
LWCO Location
Select the appropriate size tee using the LWCOmanufacturer's instructions. Often, the branch
connection must have a minimum diameter to
prevent bridging between the probe and the tee. Also,the run of the tee must have a lninilnuln diameter to
prevent the end of the probe from touching or beinglocated too close to the inside wall of the run of the tee.
Ideally, manual shutoff valves should be locatedabove the LWCO and the boiler to allow for servicing.This will allow probe removal for inspection without
draining the heating system. Many probe LWCOmanufacturers reco_ranend an annual inspection of theprobe.
How to Wire
LWCO's are available in either 120 VAC or 24 VAC
configurations. The 120 VAC configuration can beuniversally applied to both gas and oil boilers by wiringit in the line voltage service to the boiler (after theservice switch, if so equipped).The presence of water in a properly installed LWCOwill cause the normally open contact of the LWCO toclose, thus providing continuity of the 120 VAC serviceto the boiler.
It is recommended to supply power to the probe LWCOwith the same line voltage boiler service as shown
below. 'r,:_r<E
EiR 87
5V_ _CP
(}SI>T 0 _& )
2{/60
I:._ (: N::)
TO 80£(?A}
Wiring of Typical LWCO
A 24 VAC LWCO is used primarily for gasfiredboilers where a 24 volt control circuit exists within the
boiler. However, a 24 VAC LWCO can only be usedif the boiler manufacturer has provided piping andwiring connections and instructions to allow for thisapplication.
How to Test
Shut off fuel supply. Lower water level until waterlevel is BELOW the LWCO. Generate a boiler demand
by turning up thermostat. Boiler should not attempt tooperate. Increase the water level by filling the system.The boiler should attempt to operate once the waterlevel is above the LWCO.
41
DATE
SERVICE RECORDSERVICE PERFORMED
42
DATE
SERVICE RECORDSERVICE PERFORMED
43
NEW YORKER BOILER CO., INC.
imite arrantiesFor Residential Cast hon mad Steel Water Boilers
By this Warranty Statement New" Yorker Boiler Co., Inc. ("New Yorker"),
issues limited warranties subject to the terms and conditions stated below.
These limited warranties apply to residential cast iron and steel water boilers
labeled with the New Yorker ® brand which are sold on or after March 1,2004.
ONE YE_,JI LIMITED WARRANTY
One Yeas Limited Warranty for Residential Water Boilers New" Yorker
warrants to the original consumer purchaser at the original installation addressthat its residential cast iron and steel water boilers will be free fi'om defects in
material and workmanship under normal usage for a period of one year fromthe date of original installation. In the event that any defect in material or
workmanship is found during the one year period lbllowing the date of
installmion, New" Yorker will, at its option, repair the defective part or provide
a replacement free of chm'ge, F.O.B. its factory.FIVE "tEAR LIMITED WARRANTY
Five Yea-Pressure Vessel Limited Warranty for WC TM Residential Water
Boilers New Yorker warrants to the original consumer purchaser at the
original installation address that the pressure vessel of the boiler will be free
of defects in material and workmanship under noruml usage for a period of
five years following the date of installation. In the event that any defect in
material or workmanship is found during the five year period following thedine of installation, New Yorker will, at its option, repair the defective
pressure vessel or provide a replacement free of charge, F.O.B. its factor),.LIFE TIME LBIITED WARRANTY
Lifetime Pressure Vessel Limited Warranty for AP-UTM_ FIR.TM, S-AP TM,
microTEK3 TM, microTEKDV TM, CLW TM, CG-A TM and PVCG TM Residential
Water Boilers New" Yorker warrants to the original consumer purchaser at the
original installation address that the pressure vessel component of the boiler
will be fl'ee of defects in material mid workmanship under normal usage for
the lifetime of the original consumer purchaser. In the event th_ any defect inmaterial or workmanship is found during the ten year period following the
date of installation, New Yorker will, at its option, repair the defective
pressure vessel or provide areplacement free of charge, F.O.B. its factory. In
the event that any defect in material or workmanship is found after the tenth
y ear following the date of installation, New Yorker will provide a rep lacem ent
pressure vessel upon payment by the original consumer purchaser of anamount equal to a percentage of the then current retail price of the model
boiler involved (or, in the event that such model is not then in production, the
most comparable model then in production), as follows:Ye_'s In
Service llth 12th 13fl_ 14th 15th 16th 17th 18thConsmner
Purshaser Pays 5% 1_:_ 15% 2_/o 25% 30% 35% 40%
Years In [ 19th [ 20th ] 21st [ 22nd [ 23rd ] 24th [ 25th I
Se<ceI , I0,. I , I Oy° I I0,0I beyond ioIConsumer o o o o o o o
Purchaser I I I I I I IPays
EXCEPTIONS AND EXCLUSIONS
1. Components Manufactured by Others Following the expiration of the
foregoing one year limited warranty, all component parts of a boiler which are
manufactured by others (such as burners, burner controls, circulato5 tanklesswater heater, and New Yorker Link) shall be subject only to the
mamfacturer's win'realty, if any.
2. Removal and Raplacement Costs These wm'ranties do not cover expenses
of removal or reinstallation. Tile consumer purchaser will be responsible for
the cost of removing and replacing any defective part and all labor and related
materials connected therewith. Raplacenlent pasts will be invoiced to the
distributor in the usual manner mid will be subject to adjustment upon proof ofdefect.
3. Proper Installation These warranties are conditioned upon the installation
of the boiler in strict compliance with New Yorker's Installmion, Operating
and Service Instructions. New" Yorker specifically disclaims any liability of
any kind which arises from or relates to improper installation.
4. Improper Use or Maintenance These w_rranties will not be applicable if
the boiler is used or operated over its rated capacity, is installed for uses other
than home heating, or is not maintained in accordance with New Yorker's
Installation, Operating and Service Instructions and hydronics industrystandards.
5. Improper Operation These warranties _ill not be applicable if the boiler
has been damaged as aresult of being improperly serviced or operated,
including but not limited to the following: operated with insufficient water,allowed to fi'eeze; subjected to flood conditions; or operated with water
conditions and/or fuels or additives which cause unusual deposits or con'osion
in or on the pressure vessel or associated controls.
6. Geographic Limitations These wmranties apply only to boilers installed
within the 48 contiguous United States.
7. In_allation Requirements In order for these warranties to be effective:
a, The boiler must be installed in a single or _,o-family residential
dwelling. Tiffs wan-anty does not apply to boilers installed in apartments or
for commercial or industrial applications.
b. The boiler must be installed in strict compliance with New Yorker's
Installation, Operating and Service Instructions by an installer regularlyengaged in boiler inNallations.
¢. Boiler sections must not have been damaged during shipment orinstallation,
d. The boiler must be vented in accordance with chimney
recommendations set forth in New Yorker's Installation, Operating andService Instructions.
8. Exclusive Remedy New Yorker's obligation in the event of any breach of
these warranties is expressly limited to the repair or replacement of any partfound to be defective under conditions of normal use.
9. Limitation of Damages Under no circumstances will New Yorker be liable
for incidental indirect, special or consequential damages of any kind under
these warranties, including, without limitation injury or damage to persons or
property and damages for loss of use inconvenience or loss of time. New
Yorker's liability under these warranties shall under no circumstances exceed
the purchase price paid for the boiler involved. Some states do not allow theexclusion or limitation of incidental or consequential damages, so the above
limitation or exclusion may not apply to you.
1 0. Limitation of Wmranty These limited warranties are given in lieu of allother express _arranties and set fo_h the entire obligation of New Yorker
with respect to any defect in aresidential water boiler. New Yorker shall haveno express obligations, responsibilities or liabilities of any kind, other thanthose set forth herein,
ALL APPLICABLE IMPLIED WARRANTIES, IF ANY, INCLUDINGANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A
PARTICUL,_aR PURPOSE, ,_E EXPRESSLY LIMITED IN
DURATION TO A PERIOD OF ONE YEAR, EXCEPT THAT
IMPLIED WARRANTIES, IF ANY, APPLICABLE TO THEPRESSURE VESSEL OF A RESIDENTIAL WATER BOILER
SHALL BE LIMITED IN DURATION TO THE LESSER OF THE
DURATION OF SUCH IMPLIED WARRANTY OR A PERIOD
EQUAL TO THE TERM OF THE APPLICABLE EXPRESSWARRANTY. Some states do not allow limitations on how long an
implied walranty lasts, so the above limitation may not apply to you.PROCEDURE FOR OBTAINING WARRANTY SERVICE
Upon discove W of a condition believed to be related to a defect in material
or workmanship covered by these warranties, the original consumer purchaser
should notify the installer, who will in turn notify the distributor, ffthis action
is not possible or does not produce a prompt response, the original consmner
purchaser should wTite to New Yorker Boiler Co., Inc, at P.O. Box 10,
Hatfield, PA 19440-0010, giving full particulars in support of the claim.The original consumer purchaser is required to make available for
inspection by New Yorker or its represent_ive the parts claimed to be
defective and, if requested by New Yorker, to ship those parts prepaid to New
Yorker at the above address for inspection or repair. In addition, the originalconsumer purchaser agrees to make all reasonable efforts to settle any
disagreement arising in connection with any warranty claim before resortingto legal remedies in the courts.THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU
MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO
STATE.
RESIDEN_D_& HEATING BOI_RS
02/04
