New Yorker FR SERIES Operating Instructions Manual Download | Manualshive

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Summary of Contents for FR SERIES

Page 1: ...irs 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 FR Heating Contractor Phone Number Address 8147202R5 7 07 RESIDENTIAL HEATING BOILERS Price 3 00 ...

Page 2: ...assembly and operations of controls and safety devices 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 situation which if not avoided will result in death serious injury or substantial property damage Indicates a potentially hazardous situat...

Page 3: ...oists is considered combustible flooring Do not install boiler on carpeting When boiler is installed on concrete which is over a material that is subject to melting PVC PEX radiant tubing etc a combustible floor shield must be used A concrete pad is not sufficient to protect combustible flooring Do not operate on masonry floors which may contain moisture Do not tamper with or alter the boiler or c...

Page 4: ... an unapproved vent system This boiler needs fresh air for safe operation and must be installed so there are provisions for adequate combustion and ventilation air The interior of the venting and air intake systems must be inspected and cleaned before the start of the heating season and should be inspected periodically throughout the heating season for any obstructions Clean and unobstructed venti...

Page 5: ...ER MODEL A B C E F G FR HGS 31 7 8 19 7 8 18 3 8 31 3 8 3 1 8 5 7 8 FR HGS II 31 7 8 19 7 8 18 3 8 31 3 8 3 1 8 6 7 8 FR 98 122 37 7 8 19 7 8 18 3 8 30 1 2 3 7 8 5 7 8 FR 147 173 46 5 8 21 7 8 21 5 8 35 3 4 5 3 8 6 7 8 FR 205 232 46 5 8 21 7 8 25 7 8 40 3 4 6 1 8 7 7 8 FR 265 305 51 1 8 21 7 8 25 7 8 38 3 4 6 1 8 7 7 8 FR 350 400 58 25 7 8 27 7 8 40 7 8 6 1 8 9 7 8 FR 462 58 25 7 8 33 7 8 46 3 4 6...

Page 6: ...id 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 burner and removal of tankless heater For minilnuln clearances to combustible materials See Figure 2 Do not support boiler by placing blocks at the four 4 corners of the boiler Boiler base must be evenly supporte...

Page 7: ...s crawl or attic freely colmnunicating with the outdoors Locate one opening within 12 inches of top of space Locate remaining opening within 12 inches of bottom of space Minimum dimension of air opening is 3 inches Size each opening per following a Direct communication with outdoors Minimum free area of 1 square inch per 4 000 BTU per hour input of all equipment in space b Vertical ducts Minimum f...

Page 8: ...e jacket panels with the screws provided so that the assembled components make a U shape and can stand alone see Figure 19 Approaching the boiler from the rear place the assembled jacket pieces from Step 1 around the boiler so that the lower rear panel passes below the rear slnokebox Attach the lower front panel upper front panel and upper rear panel Make sure the jacket clearance holes line up pr...

Page 9: ...BURNER MOUNTING W KEYHOLE SLOTS OIL BURNER Figure 3 Burner Mounting ...

Page 10: ...lel with the heating boiler using appropriate valves to prevent the chilled medium from entering the boiler See Figure 4 Also consult I B R Installation and Piping Guides WA T_R i 2 t 3 i it Y HA H iN _ 4 _i rJRN HA N _ R b _ CDF S N II _i AT N6 DH _ _q _ q P T H 8 Cg ill 3Y3 H 8_ C ii NI 3Y8 _ _ Figure 4 Recommended Piping for Combination Heating and Cooling Refrigeration System 10 New Yorker rec...

Page 11: ...allation INSTALL SAFETY RELIEF VALVE See Figures 5 and 6 Safety Relief Valve must be installed with spindle in the vertical position Installation of the relief valve must be consistent with ANSI ASME Boiler and Pressure Vessel Code Section IV Safety relief valve discharge piping must be piped near floor to eliminate potential of severe burns Do not pipe in any area where freezing could occur Do no...

Page 12: ...N IN P P_NG 18_ MIN OF ON_vZ_IONAL I TO _ _ _ __ _ _o _ _ _ S oo0 r0o_ B B SYS TE_UMk F 1 REDUCING VAWE I IFREQU RED L J VNZ COLO WATER _ _ ICIRCULA ORFLoW EXPANSION SUPPPY I CONTROL 4 SUPPLY TANK _ VALVE VALVE r SHUT OFF 4_LVE TO TO NY MATE ZONE 2 WATER N_TER OF USED OR ZONE RETURN VALVE RE_ _W Figure 5 Recommended Water Piping for Circulator Zoned Heating Systems ...

Page 13: ...RUN EACH ZONE PiPE DOWN THEN UP TO ZONE TO PREVENT NR ACCUMULATION IN P_P1NG PRESSURE REDUCING VALVE CHECK VALV_ F REQUIRE O COLD WATER SUPPLY TO ADDmO_ ZONES ZONE VAU_ _ NY MATE WATER HEATER OPUSED OR ZONE 1 TO ZONE 2 REAR _qEW Figure 6 Recommended Water Piping for Zone Valve Zoned Heating Systems ...

Page 14: ...e achieved since the user will not waste as much hot water while seeking a water temperature Higher temperature hot water required by dishwashers and automatic washers is possible by piping the hot water from the heater prior to entering the mixing valve The mixing valve should be trapped by installing it below the cold water inlet to heater to prevent lime formation in the valve Refer to Figure 7...

Page 15: ... boiler probably has a higher efficiency than the boiler being replaced That probably 3 means that the stack temperature from the new boiler will be lower than that from the old boiler and with less room air being drawn up the chimney to dilute the stack gases The combination of a large uninsulated chimney reduced firing rate reduced firing time lower stack temperature and less dilution air can in...

Page 16: ...e wiring diagrams contained in this manual are for reference purposes only Refer to the wiring diagram of any controls used with the boiler Read understand and follow all wiring instructions supplied with the controls A GENERAL 3 Wiring should conform to Figures on pages 17 and 1 18 of this manual 16 2 Install wiring and electrically ground boiler in accordance with requirements of the authority h...

Page 17: ...culator wire leads to the proper locations on the Aquastat control L7224A L7248A See Figure 10 or 11 Connect the thermostat to the T T terminals on the L7224A L7248A control Set thermostat heat anticipator setting to 0 50 amps GR I_EMS SU_PUED BY _NSTALLER L1 L2 SWiTC_ D SCONN_ T OPHO_L PROTOCOl C_RCURRE_ 41 PO _R SUPPLY 2o 6o _ JUMP_ SUPPLieD BY HONEYWELL WIRE CODE _ BLA_K _L BLUE GR _ GRER RO _ ...

Page 18: ... a high efficiency micron filter Garber or equivalent in addition to the conventional filter is highly recommended B SINGLE PIPE OIL LINES 1 Standard burners are provided with single stage 3450 rpm fuel units with the bypass plug removed for single pipe installations 2 The single stage fuel unit may be installed single pipe with gravity feed or lift Maximum allowable lift is 8 feet See Figure 14 A...

Page 19: ... 12 14 16 18 3 8 OD Tubing 93 85 77 69 60 52 44 36 27 1 2 OD Tubing 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 1 single stage and Table 2 two stage show allowable lift and lengths of 3 8 inch and 1 2 inch OD robing for both suction and return lines Refer to Figure 15 OUTSIDE TANK FUEL ...

Page 20: ... valve in boiler supply piping between air scoop and expansion tank 7 Allow water to flow into drain until discharge from hose is bubble free for 30 seconds 8 When zone is completely purged of air close zone valve or balancing valve Open the zone valve for the next zone to be purged Repeat this step until all zones have been purged At completion open all zone valves or valves 10 below room tempera...

Page 21: ...r the system and automatically restarts if the error condition clears See Table S1 d Low Limit Boiler temperature has gone below the low limit setting minus the low limit differential and has not gone above the low limit setting Table Sl Error Code Err1 Err2 Err3 LEd error codes Cause Action Sensor fault check sensor ECOM fault check EnviraCOM TM wiring Hardware fault replace control e The operati...

Page 22: ...a plastic hose to fuel pump vent fitting and provide a container to catch the oil REMOVE GAUGE PORT PLUG from fuel pump 4 and install pressure gauge Firing Rate GPH o 8o 1 oo 1 30 o 85 1 lO 1 25 1 50 1 75 2 oo 2 5o 2 75 3 oo 3 5o 4 00 Nozzle 65 X 60W Delavan 85 X 60B Hago 1 10 X 60W Delavan 75 X 60B Hago 90 X 60B Hago 1 00 X 60B Hago 1 25 X 60B Hago 1 50 X 60B Hago 1 65 X 60B Hago 2 50 X 80B Delav...

Page 23: ...OF HEAD AT 0 POSITION ON ADJUSTING PLATE V VARIABLE HEAD W TNESS MARK PRIMARY ADJUSTING PLATE KNURLED NUT SECONDARY ADJUST NG PLATE ACORN LOCK WASHER 1_ _ HEAD SETTING AT 0 Vi HEAD V HEAD Figure 16 LI VI Head Electrode Positioning and Gun Setting Beckett AFG 0 ...

Page 24: ...t operating condition If the flame appears stringy instead of a solid flame try another nozzle of the same type Flame should 4 be solid and compact After all adjustlnents 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 M FLAME FAILURE The FR boiler controls operate the burner automatically I...

Page 25: ... 2readings 6 DIRT A fuel filter is a good investment Accidental accumulation of dirt in the fuel system can clog the nozzle strainer and produce a poor spray pattern from the nozzle CHECK TEST PROCEDURE A very good test for isolating fuel side problems is to disconnect the fuel system and with a two 2 foot length of tubing fire out of an auxiliary five gallon pail of clean fresh warm 2 oil from an...

Page 26: ...est setting b Observe temperature gauge When temperature is indicated adjust limit to setting below observed temperature Burner should stop c Adjust limit to setting above observed temperature Burner should start d Adjust thermostat to lowest setting Adjust limit to desired setting CHECK LOW WATER CUTOFF if so equipped a Adjust thermostat to highest setting b With boiler operating open drain valve...

Page 27: ...sconnect electric service to burner b To gain access to the firembes remove the front flue box door For boilers equipped with flue box swingdoor remove two 2 nuts at top of flue box door and swing door down For boilers not equipped with swingdoor remove fasteners around the perimeter of flue box frame and remove door c Remove turbulators d Using a firetube brush clean firetubes Use care not to dam...

Page 28: ...NIOSH ap proved 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 washing ma chine after use to avoid contaminating other clothes Discard used RCF components by sealing in an air tight plastic bag First Aid...

Page 29: ...r 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 29 ...

Page 30: ...Figure 19 Jacket Repair Parts 30 ...

Page 31: ...50 400 FR 462 FR HGS HGSII FR 98 122 FR 147 thru FR 305 FR 350 400 462 FR 98 122 FR 147 thru FR 232 FR 265 305 FR 350 400 462 PART NUMBER 60472010 60472011 60472012 60472013 60472014 60472015 60472016 604370372 60472020 60437037 60437046 60437054 60437067 60437071 60437034 60437043 60437060 L RPanels 2 60437039 2 60437047 9 ASME Data Cover Plate FR 147 thru FR 462 Notes 1 Jacket Lower front panels...

Page 32: ... Figure 20 FR Bare Boiler Repair Parts Z u o ...

Page 33: ... 3 8 8 Braided Fiberglass Rope Gasket 3 16 9 Boiler Shell Assembly Contact Sales Office 10 Observation Door 11 Heater Coil Cover Plate Gasket 12 Blank Heater Cover Plate 13 Tankless Heater Coil 14 Hex Head Cap Screw 3 8 16 x 1 1 4 LG 15 Hea W Hex Nut 3 8 16 16 Sheet Metal Screw 12 x 3 4 LG 17 Hex Head Cap Screw 3 8 16 x 3 4 LG 18 Cerafelt Insulation 1 2 x 1 All Models All Models All Less Heater Mo...

Page 34: ...2072001 FR 147 173 62072002 FR 205 232 265 305 62072003 FR 350 400 62072004 FR 462 62072005 Flue Box Insulation Replacement Kits Flue Box Insulation Replacement Kits provide the flue box door insulation flue box frame top bottom insulation pieces and flue box frame side insulation pieces FR Model s Kit Part Number FR HGS 98 122 62072006 FR HGSll 62072007 FR 147 173 205 232 62072008 FR 265 305 6207...

Page 35: ...NER MANUFACTURER R W BECKETT CORE R O BOX 1289 ELYRIA OHIO 44036 1 800 645 2876 NOTE When ordering parts always give the serial and model numbers shown on the boiler and burner Also provide the name of the part s Ordering Information for Quality Replacement Parts SIDE VIEW FRONT VIEW Figure 21 BECKETT AFG MODEL BURNER 35 ...

Page 36: ... Shutter Blower Bulkhead Fitting Bulkhead Fitting Locknut Connector Tube Assembly Coupling Electrode Clamp Electrode Insulator Assembly Spider Spacer Assembly Escutcheon Plate Flange and Air Tube Assembly BECKETT AF and SF MODEL BURNERS 19 Head 20 Housing Assembly w Inlet Bell 21 Motor 22 Nozzle Adapter 23 Nozzle Line Electrode Assembly 25 Pump 27 Static Plate 28 Ignitor 29 Ignitor Hinge Screw 30 ...

Page 37: ...thus providing continuity of the 120 VAC service to the boiler It is recommended to supply power to the probe LWCO with the same line voltage boiler service as shown below _E OLTAOE N 31 18 How to Pipe A tee is co_ranonly used to connect the probe LWCO to the supply or return piping as shown below SYSiN_ SYSI_ _ Si i P Y _E_U RN I I K O_d_ 1_411 _UM E _ A El LiNE LWCO Location Select the appropria...

Page 38: ...DATE SERVICE RECORD SERVICE PERFORMED 38 ...

Page 39: ...DATE SERVICE RECORD SERVICE PERFORMED 39 ...

Page 40: ...r Maintenance These warranties 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 indnstry standards 5 hnproper Operation These walxanties will not be applicable if the boiler has been damaged as a result of b...

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