New Yorker Boiler FR-HGS Installation Manual

INSTALLATION, OPERATING

AND SERVICE INSTRUCTIONS

FR™ SERIES

HORIZONTAL TUBE BOILER

For service or repairs to boiler, call your heating contractor. When seeking information on boiler, provide Boiler Model Number and Serial Number as shown on Rating Label.

Boiler Model Number

Heating Contractor Phone Number

Address

104183-06 - 9/16

Boiler Serial Number Installation Date

Price - $5.00

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 installations are made. In all cases, reference should be made to the following Standards:

USA BOILERS 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 safety devices. D. All wiring on boilers installed in the USA shall be made in accordance with the National Electrical Code and/or Local Regulations.

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.

DANGER

Indicates an imminently hazardous situation which, if not avoided, will result in death, serious injury or substantial property damage.

WARNING

Indicates a potentially hazardous situation which, if not avoided, could result in death, serious injury or substantial property damage.

Indicates a potentially hazardous situation which, if not avoided, may result in moderate or minor injury or property damage.

Indicates special instructions on installation, operation, or maintenance which are important but not related to personal injury hazards.

CAUTION

NOTICE

This boiler has a limited warranty, a copy of which is printed on the back of this manual. The warranty for this boiler is valid only if the boiler has been installed, maintained and operated in

accordance with these instructions.

DANGER

DO NOT store or use gasoline or other ammable vapors or liquids in the vicinity of this boiler or any other

appliance.

WARNING

Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury or loss of life. Failure to follow all instructions in the proper order can cause personal injury or death. Read and understand all instructions, including all those contained in component manufacturers manuals which are provided with the boiler before installing, starting-up, operating, maintaining or servicing this boiler. Keep this manual and literature in legible condition and posted near boiler for reference by owner and service technician.

This boiler requires regular maintenance and service to operate safely. Follow the instructions contained in this manual.

Installation, maintenance, and service must be performed only by an experienced, skilled and knowledgeable installer or service agency.

All heating systems should be designed by competent contractors and only persons knowledgeable in the layout and installation of hydronic heating systems should attempt installation of any boiler.

Installation is NOT complete unless a pressure relief valve is installed into the tapping located on top of Shell Assembly near rear of boiler - See Piping and Trim Sections of this manual for details.

It is the responsibility of the installing contractor to see that all controls are correctly installed and are operating properly when installation is complete including verifying that the limit sensor is fully installed (seated in bottom of Well).

Failure to properly install Limit Sensor may result in property damage, personal injury or loss of life due to elevated operating temperatures and/or pressures.

This boiler is NOT suitable for installation on combustible ooring, unless installed with a combustible oor shield constructed in accordance with NFPA 31. A concrete pad is not sufcient to protect combustible ooring. Concrete over wood joists is considered combustible ooring.

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 oor shield must be used.

DO NOT operate on masonry oors, which may contain moisture.

DO NOT tamper with or alter the boiler or controls.

Retain your contractor or a competent serviceman to assure 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 soot and scale. The inside of combustion chamber should also be cleaned and inspected at the same time.

When cleaning this boiler, DO NOT damage combustion chamber. If damaged, combustion chamber must be replaced immediately.

Oil Burner and Controls must be checked at least once a year or as may be necessitated.

DO NOT operate boiler with jumpered or absent controls or safety devices.

DO NOT operate boiler if any control, switch, component, or device has been subject to water.

Boiler materials of construction, products of combustion and the fuel contain alumina, silica, heavy metals, carbon monoxide, nitrogen oxides, aldehydes and/or other toxic or harmful substances which can cause death or serious injury and which are known to the state of California to cause cancer, birth

defects and other reproductive harm. Always use proper safety clothing, respirators and equipment

when servicing or working nearby the boiler.

WARNING

This boiler contains very hot water under 12 - 15 PSI pressure. DO NOT unscrew any pipe ttings nor attempt to disconnect any components of this boiler without positively assuring the water is cool and has

no pressure. Always wear protective clothing and equipment when installing, starting up or servicing this

boiler to prevent scald injuries. DO NOT rely on the pressure and temperature gauges to determine the temperature and pressure of the boiler. This boiler contains components which become very hot when the boiler is operating. DO NOT touch any components unless they are cool.

High water temperatures increase the risk of scalding injury. If this boiler is equipped with a tankless heater for domestic water supply, a ow regulator and automatic mixing valve must be installed properly

in tankless heater piping. See Piping and Trim Sections of this manual for details.

This boiler needs fresh air for safe operation and must be installed so there are provisions for adequate

combustion and ventilation air.

This boiler must be connected to an approved chimney or vent system in good condition. Serious

property damage could result if the boiler is connected to a dirty or inadequate chimney or vent system. The interior of the chimney ue must be inspected and cleaned before the start of the heating season for any obstructions. A clean and unobstructed chimney ue is necessary to allow noxious fumes that could cause injury or loss of life to vent safely and will contribute toward maintaining the boiler's efciency.

DO NOT operate boiler with the absence of an approved vent system.

This boiler is supplied with controls which may cause the boiler to shut down and not re-start without service. If damage due to frozen pipes is a possibility, the heating system should not be left unattended in cold weather; or appropriate safeguards and alarms should be installed on the heating system to prevent damage if the boiler is inoperative.

This boiler is designed to burn No. 2 fuel oil only. DO NOT use gasoline, crankcase drainings, or any oil containing 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 ammable debris, rags, paper, wood scraps, etc., should be kept clear of the boiler at all times. Keep the boiler area clean and

free of re hazards.

All boilers equipped with burner swing door have a potential hazard which if ignored can cause severe

property damage, personal injury or loss of life. Before opening swing door, turn off service switch to

boiler to prevent accidental ring of burner outside the combustion chamber. Be sure to tighten swing

door fastener completely when service is completed.

TABLE OF CONTENTS

I. General Information ..............................5

II. Pre-Installation ......................................8

III. Knockdown Boiler Assembly .............10

IV. Water Piping and Trim ........................14

V. Venting .................................................19

VI. Electrical ..............................................21

VII. Oil Piping .............................................25

VIII. System Start-Up ..................................27

IX. Operating .............................................33

X. Maintenance & Service Instructions .38

XI. Boiler Cleaning .................................... 40

XII. Troubleshooting ..................................43

XIII. Repair Parts ......................................... 46

XIV. Burner Specications ......................... 53

Appendix A - Aftermarket Low Water

Cut-Off................................................. 54

I: GENERAL INFORMATION

Figure 1A: FR-HGS and FR-HGSII Water Boiler (Heat Only), Beckett Burner

Figure 1B: FR-98 Thru FR-232 Water Boiler With or Without Tankless Heater, Beckett Burner

I: General Information (continued)

Figure 1C: FR-265 Thru FR-462 Water Boiler With or Without Tankless Heater, Beckett Burner

TABLE 1: DIMENSIONAL DATA (SEE FIGURES 1A THRU 1C)

Dimensions - Inches

Boiler Series

A B C D E F G

FR-HGS 31-7/8 19-7/8 18-3/8 25-3/4 31-3/8 3-1/8 5-7/8 9.5

FR-HGSII 31-7/8 19-7/8 18-3/8 26-1/2 31-3/8 3-1/8 6-7/8 9.0

FR-98/122 37-7/8 19-7/8 18-3/8 25-1/4 30-1/2 3-7/8 5-7/8 20.0

FR-147/173 46-5/8 21-7/8 21-5/8 30-1/4 35-3/4 5-3/8 6-7/8 40.0

FR-205/232 51-1/8 21-7/8 25-7/8 29-3/4 40-3/4 6-1/8 7-7/8 46.0

FR-265/305 51-1/8 21-7/8 25-7/8 34 38-3/4 6-1/8 7-7/8 52.0

FR-350/400 58 25-7/8 27-7/8 35-3/4 40-7/8 6-1/8 9-7/8 70.0

FR-462 58 25-7/8 33-7/8 35-3/4 46-3/4 6-1/8 9-7/8 80.0

Content - Gallons

Approx. Water

I: General Information (continued)

TABLE 2: RATING DATA

Burner

Boiler

Series

FR-HGS

FR-HGSII FRHGSII 1.30 182 158 137 85.0 7 8 x 8 15

FR-98 FR98 0.85 119 104 90 86.4 6 8 x 8 15

FR-122 FR122 1.10 154 132 115 85.1 6 8 x 8 15

FR-147 FR147 1.25 175 154 134 86.7 7 8 x 8 15

FR-173 FR173 1.50 210 184 160 85.9 7 8 x 8 15

FR-205 FR205 1.75 245 215 187 86.0 8 8 x 8 15

FR-232 FR232 2.00 280 242 210 85.1 8 8 x 8 15

FR-265 FR265W 2.35 329 265 230 82.2 10 8 x 12 15

FR-305 FR305W 2.60 364 305 265 83.4 10 8 x 12 18

FR-350 FR350W 3.00 420 350 304 83.1 10 8 x 12 20

FR-400 FR400W 3.50 490 402 350 82.0 10 8 x 12 20

FR-462 FR462W 4.00 560 462 402 82.7 10 12 x 12 20

* Field Converted from Boiler Model FRHGS

Boiler Model

* FRHGSL 0.80 11 2 100 87 87.8 6 8 x 8 15

FRHGS 1.00 140 122 106 86.3 6 8 x 8 15

Capacity

GPH MBH

** Output

MBH

Net Ratings Water, MBH

AFUE

Thermal

Efciency

Minimum Chimney

Requirements

Round

In. Dia.

Rectangle

In. x In.

Height

** “Output” is “Heating Capacity” for units with inputs < 300 MBH and “Gross Output” for units > 300 MBH Maximum Allowable Working Pressure = 30 PSI

Ft.

II: PRE-INSTALLATION

A. INSPECT SHIPMENT carefully for any signs of

damage.

1. All equipment is carefully manufactured, inspected and packed. Our responsibility ceases upon delivery of crated boiler to the carrier in good condition.

2. Any claims for damage or shortage in shipment

must be led immediately against the carrier by the

consignee. No claims for variances from, or shortage in orders, will be allowed by the manufacturer unless presented within sixty (60) days after receipt of goods.

B. LOCATE BOILER near nal position before removing

crate. See Figures 1A thru 1C. Using hand truck or pipe rollers under skid, move boiler into position along side installation site.

CAUTION

DO NOT drop boiler. DO NOT bump boiler jacket

against oor.

1. LOCATE so that vent pipe connection to chimney will be short and direct.

2. BOILER IS NOT SUITABLE FOR INSTALLATION ON COMBUSTIBLE FLOOR unless installed with a Combustible Floor Shield constructed in accordance with NFPA31.. Boiler cannot be installed on carpeting.

3. FOR BASEMENT INSTALLATION, provide

a solid elevated base, such as concrete, if oor is not level, or if water may be encountered on oor

around boiler.

WARNING

Do not support boiler by placing blocks at the four (4) corners of the boiler. Boiler base must be evenly supported under entire base.

Concrete over wood joists is considered combustible flooring. Do not operate on

masonry oors, which may contain moisture.

4. PROVIDE SERVICE CLEARANCE of at least 48” clearance from front jacket panel for servicing and removal of front tankless heater.

5. For minimum clearances to combustible materials. See Figure 2.

NOTICE

Clearance to venting is for single wall vent pipe. If Type L vent is used, clearance may be

reduced to the minimum required by the vent pipe

manufacturer.

Figure 2: Minimum Installation Clearances to Combustible Materials (Inches)

Above

6 24 18 6 6

NOTE 1: Listed clearances comply with American National Standard NFPA 31, Standard for the Installation of Oil Burning Equipment.

Front

Chimney

Connector

Rear

Sides

NOTE 2: FR™ Series boilers can be installed in rooms with clearances from combustible material as listed above. Listed clearances cannot be reduced for alcove or closet installations.

NOTE 3: For reduced clearances to combustible material, protection must be provided as described in the ANSI/NFPA 31 standard.

II: Pre-Installation (continued)

C. PROVIDE COMBUSTION AND VENTILATION

AIR. Local and National Codes may apply and should be referenced.

WARNING

Adequate combustion and ventilation air must

be provided to assure proper combustion and to maintain safe ambient air temperatures.

DO NOT install boiler where gasoline or other

ammable vapors or liquids, or sources of

hydrocarbons (i.e. bleaches, fabric softeners, etc.) are used or stored.

1. Determine volume of space (boiler room). Rooms communicating directly with the space in which the appliances are installed, through openings not furnished with doors, are considered a part of the space.

Volume(ft

2. Determine total input of all appliances in the space.

Add inputs of all appliances in the space and round

the result to the nearest 1000 BTU per hour.

3. Determine type of space. Divide Volume by total input of all appliances in space. If the result is greater than or equal to 50 ft3/1000 BTU per hour, then it is considered an unconned space. If the result is less than 50 ft3/1000 BTU per hour then the space is considered a conned space.

4. For boiler located in an unconned space of a conventionally constructed building, the fresh

air inltration through cracks around windows

and doors normally provides adequate air for combustion and ventilation.

5. For boiler located in a conned space or an unconned space in a building of unusually tight

construction, provide outdoor air.

Outdoor air may be provided with the use of two

permanent openings which communicate directly or by duct with the outdoors or spaces (crawl or attic) freely communicating with the outdoors. Locate one opening within 12 inches of top of space.

) = Length(ft) x Width(ft) x Height(ft)

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 free area of 1 square

inch per 4,000 BTU per hour input of all equipment in space. Duct cross-sectional area shall be same as opening free area.

c. Horizontal ducts. Minimum free area of 1

square inch per 2,000 BTU per hour input of all equipment in space. Duct cross-sectional area shall be same as opening free area.

Alternate method for boiler located within

conned space. Use indoor air if two permanent

openings communicate directly with additional

space(s) of sufcient volume such that combined volume of all spaces meet criteria for unconned

space. Size each opening for minimum free area of 1 square inch per 1,000 BTU per hour input of all equipment in spaces, but not less than 100 square inches.

6. Louvers and Grilles of Ventilation Ducts

a. All outside openings should be screened and

louvered. Screens used should not be smaller than 1/4 inch mesh. Louvers will prevent the entrance of rain and snow.

b. Free area requirements need to consider the

blocking effect of louvers, grilles, or screens protecting the openings. If the free area of the louver or grille is not known, assume wood louvers have 20-25 percent free area and metal louvers and grilles have 60-75 percent free area.

c. Louvers and grilles must be xed in the open

position, or interlocked with the equipment to open automatically during equipment operation.

III: KNOCK-DOWN BOILER ASSEMBLY

A. REMOVAL OF BOILER from skid.

1. Remove all boiler-to-skid hold down fasteners.

2. FR-HGS thru FR-232: Carefully walk boiler to the edge of skid. Tilt the boiler back, allowing an edge

to rest on the oor, and remove the skid.

FR-265 thru FR-462: A mechanical lifting device

may be required to safely remove boiler from skid.

B. TEST HEAT EXCHANGER FOR LEAKS before

proceeding with jacket assembly.

1. Install pressure relief valve supplied, a hose to the city water to a valve in the supply tapping. Plug remainder of tappings.

2. Fill boiler with water and apply a pressure of at least 10 psig but no more than 25 psig, to prevent weeping from seat of relief valve.

WARNING

Do not apply more than 30 psig to boiler.

CAUTION

If front ue box or rear smoke box fasteners are

removed, tighten them to 26 ft/lbs when replacing them.

C. INSTALLING THE JACKET

1. Attach lower rear jacket panel to left side and right side jacket panels with the screws provided so that the assembled components make a “U” shape and can stand alone (see Figure 23).

2. 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 smokebox.

3. Attach the lower front panel, upper front panel, and upper rear panel. Make sure the jacket clearance holes line up properly with the appropriate boiler extensions and tappings.

4. Attach the top panel assembly (left and right pieces).

5. See Figures 4A thru 4C and Table 3 for label placement.

D. INSTALLATION OF BOILER CONTROLS

1. Install provided pressure/temperature gauge into ¼” NPT coupling located on front or top of the boiler. Tighten so not to have any water leaks. See Figures 1A thru 1C.

2. Mount the limit control. Thread the provided immersion well into the 3/4” NPT tapping located on the front or top of boiler, see Figures 1A thru 1C. Place the Boiler Control on immersion well and tighten clamp screws to secure control to immersion well. Apply heat transfer paste (not furnished) to limit sensor and fully insert limit sensor into immersion well such that the tip on the limit sensor touches the bottom of the immersion well. See Figure 3.

Figure 3: Limit Sensor Insertion

III: Knock-Down Boiler Assembly (continued)

Figure 4A: Marking Locations for FR-HGS thru FR-122-W Knockdown Boilers (Model FR-122-W Shown)

TABLE 3: LABELS

ITEM DESCRIPTION APPLICATION PART NUMBER

1 New Yorker Logo Plate All Builds 8143705

3 Rating Label All Builds 81460234

Combo Warning / Safety Label,

Combustible Floor

Burner Spec. Label, Beckett Burners

Burner Spec. Label, Riello Burners L23765

6 Energy Guide Label FR-HGS thru FR-232 101988-01

7 Limit Sensor Insertion Depth Warning Label All Builds 103106-03

Cold Start Boiler Control Interface Label Water Boiler Without Tankless Heater 103971-01

Warm Start Boiler Control Interface Label Water Boiler With Tankless Heater 103972-01

9 ASME Cover Plate Label All Builds 81460041

Notes:

1. Installation is Not complete unless all labels furnish with this boiler are attached in appropriate location as shown.

2. It is the responsibility of the installing contractor to see that all labels are applied correctly as depicted.

All Builds 103026-04

All Builds

L23760

III: Knock-Down Boiler Assembly (continued)

Figure 4B: Marking Locations for FR-147-W thru FR-305-W Knockdown Boilers

Figure 4C: Marking Locations for FR-350-W thru FR-462-W Knockdown Boilers

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New Yorker Boiler FR-HGS Installation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual