New Yorker AP-U SERIES Manual

INSTALLATION, OPERATING
AND SERVICE INSTRUCTIONS
AP-U "rMSERIES
STEEL OIL-FIRED BOILER
For service or repairs to boiler, call your heating contractor. When seeking information on
boiler, provide Boiler Model Number and Serial Number as shown on Rating Label.
Boiler Model Number Boiler Serial Number Installation Date
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 installations
are 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 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 situation which,
if not avoided, may result in moderate or minor
injury or property damage,
Indicates a potentially hazardous situation which,
if not avoided, could result in death, serious injury
or substantial property damage,
Indicates special instructions on installation,
operation, or maintenance which are important
but 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 are
operating properly when the installation is complete. The warranty for this boiler is valid only if the boiler has
been 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 other
appliance.
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 appliance before installing, starting-up, operating, maintaining or
servicing this appliance. Keep this manual and literature in legible condition and posted near appliance
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. It is the responsibility of the installing contractor to see that all
controls are correctly installed and are operating properly when the installation is completed. Installation
is 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 combustible
floor 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 radiant
tubing, 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 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.
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, 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.
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 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.

Thisboilercontainsveryhotwaterunderhighpressure.Donotunscrewanypipefittings 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.
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 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 venting and air intake systems are necessary to allow noxious fumes that could
cause 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 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.
Do not operate boiler on combustible floor without afactory supplied floor shield. Concrete overwood joists
is 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. Appendix
LowWater Cut Off ....................... 41
4

_" MPT
SAFE_
RELIEF VALVE
CONNECTION
TOP VIEW
I #" MPT
SUPPLY
CONNECTION
CB!UNG
fo
wz
TANKLESS H_.TER
(_" NPT CONNECTIONS)
TEMPERATURE/
PRESSURE GAU@E
RETURN
CONNECTION
FRONT VIEW
¢° FP
DRNN VALVE
CONNECTION
AQUASTAT
CONTROL
BURNER
FLOOR
LiNE
RIGHT SIDE VIEW
Boiler Model
Number
AP-490U
AP-590U
AP-690U
AP-790U
Dimension
,A _
34-9/16
41"
Minimum Recommended
Chimney 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 of
damage.
1. ALL EQUIPMENT is carefully manufactured,
inspected and packed. Our responsibility ceases
upon delivery of the crated boiler to the carrier in
good condition.
2. ANY CLAIMS for damage or shortage of shipment
must filed 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.
LOCATE BOILER in front of final position before
removing crate.
1. LOCATE so that smoke pipe connection to chimney
will be short and direct. BOILER IS NOT SUIT-
ABLE FOR INSTALLATION ON COMBUSTIBLE
FLOOR unless combustible floor shield, supplied by
New Yorker(R)Boiler Co. Inc., is used.
2.
3.
DO NOT install on carpeting. See Figure 3 for floor
shield part number and installation instructions.
FOR BASEMENT INSTALLATION, provide a
solid 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 supported under
entire base.
Do not operate boiler on combustible floor
without a factory supplied floor shield.
Concrete over wood joists is considered
combustible flooring. Do not operate
on masonry floors, which may contain
moisture.
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 can
not be reduced for alcove or closet installations.
For reduced clearances to combustible material, protection must be provided as described in the above ANSI/NFPA 31
standard.

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, attaching
boiler base plate to shipping skid.
Carefully, walk boiler to the edge of the skid. Tilt
the boiler back, allowing boiler base edge to rest on
the floor, then, remove the skid.
PROVIDE COMBUSTION AND VENTILATION
AIR. Local code provisions may apply and should be
referenced.
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
flammable 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
colnlnunicating directly with the space in which the
appliances are installed, through openings not
furnished 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 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 uncol_ned space. If the
result is less than 50 ft3/1000 BTU per hour then the
space is considered a co17finedspace.
4. For boiler located in an uncolTfined space of a
conventionally constructed building, the fresh air
infiltration through cracks around windows and
doors normally provides adequate air for
combustion and ventilation.
5. For boiler located in a confined space or an
unconfined space in a building of unusually tight
construction, provide outdoor air with the use of two
permanent openings which colnlnunicate directly or
by duct with the outdoors or spaces (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 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
col_ned space. Use indoor air if two permanent
openings colnlnunicate directly with additional
space(s) of sufficient volume such that combined
volume of all spaces meet criteria for unconfined
space. Size each opening for minilnuln free area
of 1square 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
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 fixed in the open
position, or interlocked with the equipment to
open automatically during equipment operation.

INSTALLATION INSTRUCTIONS FOR OPTIONAL SHIELD REQUIRED
FOR COMBUSTIBLE FLOOR
This shield for combustible floors is intended for use only with the following New Yorker oil-fired boilers:
Use Part Number 6183504 for the following models:
AP-490U AP-590U AP-690U AP-790U
ADDS 4-3/16" TO BOILER HEIGHT
1)
2)
3)
Place shield on combustible floor with "TOP" surface
upward and "FRONT" surface directly below the
expected position of the oil burner.
Locate shield such that clearances to combustible walls
are as indicated in Figure 3. These dimensions will
assure that the boiler jacket will be at least 18" from
the side and rear walls and 48" from the front wall, as
required by ANSI/NFPA 31.
Fasten shield to combustible floor to keep shield from
shifting position during setting of boiler.
4) Set boiler squarely on top of shield such that base plate
of boiler rests flat on top surface of shield and does not
over-hang shield on any side. Confirm clearance to
combustible walls. Refer to Figure 2.
5) Do not enclose boiler (including shield) on all four
sides. Boiler may be enclosed on any three sides while
maintaining lninilnuln clearances shown in Figure 2 for
each 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 boiler
back, allowing the base edge to rest on the floor, and
remove the skid.
3. Remove the adhesive backed label-containing
envelope from boiler and set aside.
4. Remove Misc. Parts Bag and bagged Telnperamre
and Pressure Gauge (both tucked inside canopy
assembly flue collar) and set aside.
3.
Remove jacket parts and jacket hardware bag from
Jacket Carton Assembly shipping carton.
Install the Wrap-Around jacket panel first. Bend
Wrap-Around panel as shown in Figure 5. Attach
the bent panel to base using three #10-1/2" slotted
hex washer head screws supplied. Engage all screws
but do not tighten yet.
Remove 5/16-18 hex nut, 5/16 flat washer,
observation cover spring and Observation Port
Cover and set aside.
4.
5.
6.
Attach Lower Front Jacket panel to installed Wrap-
Around panel with four # 10-1/2" slotted hex washer
head screws supplied. See Figure 5.
Attach Upper Front Jacket panel to installed Wrap-
Around panel with four # 10-1/2" slotted hex washer
head screws supplied. See Figure 5.
Lastly, install Top Jacket panel and secure to
installed Wrap-Around panel with two remaining
#10-1/2" slotted hex washer head screws. See Figure
5.
7. Once installed, center Top Jacket panel opening over
canopy assembly flue collar and tighten up all three
screws 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 installed
Top Jacket panel with two #8 x */4sheet metal
screws. See Figure 6.
Remove labels from the adhesive backed label-
containing envelope and attach them to jacket
panels. See Figure 6 for approximate label
positioning.
C. INSTALLATION OF BOILER CONTROLS
1.
2.
Install provided Temperature and Pressure gauge
and aquastat well into appropriate tappings; tighten
securely to prevent water leaks.
Install provided 1-1/4 x 3/4 reducing hex bushing
and drain valve into lower right hand 1-1/4 forged
coupling 'drain' taping.
3.
4.
5.
6.
Install provided 1-1/4 x 3" black nipple into lower
left hand 1-1/4 forged coupling 'return' taping.
Mount installer-supplied aquastat onto the
ilmnersion well. Wire the control per Figure 15 or
Figure 16, Section IV 'Electrical" of the Installation
and Operating Instructions,for AP- U Series Oil-
Fired Boiler, as applicable.
Install provided safety relief valve (for details see
Figure 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 burner
air robe, relative to burner mounting flange, prior to
burner mounting. See Figure 7.
Do not install burner without gasket.
2.
3.
Mount installer-supplied burner onto base front
panel studs and secure with provided 5/16 flat
washers and brass 5/16-18 hex nuts. Refer to
Figure 7.
Wire the burner per instructions, provided with the
burner, and, Figure 15, 15A, 16 or 16A, as
applicable.
OBSERVATION PORT
COVER
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, and
can lead to boiler failure. New Yorker's Standard Warranty does not cover problems caused by oxygen
contamination of boiler water or scale (lime) build-up caused by frequent addition of water.
A. DESIGN A PIPING SYSTEM and install boiler which
will prevent oxygen contamination of boiler water and
frequent water additions.
1. There are many possible causes of oxygen
contamination such as:
a. Addition of excessive make-up water as a result
of system leaks.
b. Absorption through open tanks and fittings.
c. Oxygen permeable materials in the distribution
system.
2. In order to insure long product life, oxygen sources
should be eliminated. This can be accomplished by
taking the following measures:
a. Repairing system leaks to eliminate the need for
addition of make-up water.
b. Eliminating open tanks from the system.
c. Eliminating and/or repairing fittings which allow
oxygen absorption.
d. Use ofnon-perlneable materials in the
distribution system.
e. Isolating the boiler from the system water by
installing a heat exchanger.
System supply and return piping must be
connected to correct boiler pipe.
New Yorker recommends sizing the system
circulator to supply sufficient flow (GPM) to
allow a 20°F temperature differential in the
system. When sizing the system circulator,
the pressure drop of all radiators, baseboard
and radiant tubing and all connecting piping
must be considered.
3. Connect System supply and return piping to boiler.
See Figures 9 and 10. Also, consult I=B=R
Installation and Piping Guides. Maintain minilnuln
1/2inch clearance from hot water piping to
combustible materials.
12
a. If this boiler is used in connection with
refrigeration systems, the boiler must be installed
so that the chilled medium is piped in parallel
with the heating boiler using appropriate valves
to prevent the chilled medium from entering the
boiler. See Figure 8. Also, consult I=B=R
Installation 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 Combination
Heating and Cooling (Refrigeration) System
b. If this boiler is connected to heating coils located
in air handling units where they may be exposed
to refrigerated air, the boiler piping must be
equipped with flow control valves to prevent
gravity circulation of boiler water during the
operation of the cooling system.
c. If boiler is used with an Indirect-Fired Domestic
Water Heater, install the Indirect-Fired Domestic
Water Heater as a separate heating zone. Refer
to the Indirect-Fired Domestic Water Heater
Installation, Operating, and Service Instructions
for additional information.
d. Use a system bypass if the boiler is to be
operated in a system which has a large volume or
excessive radiation where low boiler water
temperatures may be encountered (i.e. converted
gravity circulation system, etc.) The bypass
should be the same size as the supply and return
lines with valves located in the bypass and return

B°
e.
line as illustrated in Figures 10 and 11 in order to
regulate water flow for maintenance of higher
boiler water temperature. Set the bypass and
return valves to a half throttle position to start.
Operate boiler until the system water temperature
reaches its normal operating range. Adjust the
valves to maintain 180°F to 200°F boiler water
temperature and greater the 120°F return
temperature. Adjust both valves simultaneously.
Closing the boiler return valve while opening the
bypass valve will raise the boiler return
temperature. Opening the boiler return valve
while closing the by-pass valve will lower the
boiler return temperature.
A water boiler installed above radiation level
must be provided with a low water cutoff device
as part of the installation.
INSTALL SAFETY RELIEF VALVE. See Figures 9,
10 and 11. 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 not install any shut-off valves,
plugs or caps.
Co AIR VENT. An air vent or purge must be incorporated
in the system to easily remove air from the boiler when
the system is filled. The boiler has a built in dip tube
which works with the air vent to clear the boiler of air.
Improper application of the air vent will cause steaming
in the boiler. See Figure 9.
D. INSTALL DRAIN VALVE in return piping. See
Figures l0 and ll.
E.
17.
G.
OIL, GREASE, AND OTHER FOREIGN
MATERIALS which accumulate in new hot water
and a new or reworked system should be boiled
out, and then thoroughly flushed. A qualified water
treatment chemical specialist should be consulted for
recommendations regarding appropriate chemical
compounds and concentrations which are compatible
with local environmental regulations.
Figure 9: Air Vent and Safety Relief Valve
Installation Detail
AFTER THE BOILER AND SYSTEM HAVE BEEN
CLEANED and flushed, and before refilling the entire
system add appropriate water treatment chemicals, if
necessary, to bring the pH between 7 and 11.
CONNECT TANKLES S HEATER PIP1NGAS
SHOWN IN FIGURE 12. See Table 1 for Tankless
Heater Rating.
Install automatic mixing valve at tankless heater
outlet to avoid risk of burns or scalding due to
excessively hot water at fixtures. Adjust and
maintain the mixing valve in accordance with
the manufacturer's instructions. Do not operate
tankless heater without mixing valve.
13

A_R VENT
LOW WATER
CUT_O_
(O_T_ON/¢)
MR VENT
PRESSURE
REUEF
VAL_
%_ FROM ADO}TIONAL ZONES
FROM ZONE 2
F_M N_TE WATER NEAT_
OR ZONE 1
SHUT-OFF
V#£VES
NOES_
RUN EACH ZONE PIPE _WN THEN UP TO ZONE
TO PRD_ENT MR AC:CUMU_T_ON iN PiPiNG,
SHUTOFF
VALVE
TO
NY_MATE
WATER H_T_
_: usED:)
ZONE !
C_RCULa,TOR
TO
ZONE 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
i
LOW'WATER
CUT_OFF
(OP ION )
NR _NT
P_SSURE
REUEF
VALVE i
_" "q_'Ir--_74 _ FROM NY-#ATE WATERHEAT_
OR ZONE I
SHUT-O£F
VAEVES
BYPASS t
b,tNEVE _DI_ONAL
_TEM UMiT
iiF REQU RED)
Lt SUPPLY
VALVE
_S_M
SUPPLY
EXPANSION
T_NK
NOTES;:
RUN EACH ZONE PiPE DOWN THEN UP TO ZONE
TO PR_NT AiR ACCUMULATION iN PIP!NG_
PRESSURE
REDU@NG
V_VE
_!®!l
SHUT-OW
VALVE
C:O_ WATER
SUPPLY
TO,
_ _NO_ AL
i i'
TO TO
NY_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 heater
is greater than its rating, the supply of adequate hot
water may not be able to keep up with the demand.
For this reason a flow regulator matching the heater
rating should be installed in the cold water line to
the heater. The flow regulator should preferably be
located below the inlet to the heater and a lninilnuln
of 3' away from the inlet so that the regulator is not
subjected to excess temperatures that may occur
during "off' periods when it is possible for heat to
be conducted back through the supply line. The flow
regulator also limits the flow of supply water
regardless of inlet pressure variations in the range of
20 to 125 psi.
2. TEMPERING OF HOT WATER -- Installation of
an automatic mixing valve will lengthen the delivery
of the available hot water by mixing some cold
water with the hot. This prevents the possibility of
scalding hot water at the fixtures. In addition,
savings of hot water will be achieved since the user
will not waste as much hot water while seeking a
water telnperamre. Higher telnperamre hot water
3.
4.
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 12.
FLUSHING OF HEATER -- All water contains
some sediment which settles on the inside of the
coil. Consequently, the heater should be periodically
backwashed. This is accomplished by installing hose
bibs as illustrated and allowing water at city
pressure to run into hose bib A, through the heater,
and out hose bib B until the discharge is clear. The
tees in which the hose bibs are located should be the
same size as heater connections to minilnize
pressure drop.
HARD WATER -- A water analysis is necessary to
determine the hardness of your potable water. This
is applicable to some city water and particularly to
well water. An appropriate water softener should be
installed based on the analysis and dealer's
recolranendation. This is not only beneficial to the
tankless heater but to piping and fixtures plus the
many 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 19 33A 25
16

IV. Venting
A. GENERAL GUIDELINES.
1.
2.
Vent system installation must be in accordance with
these instructions and applicable provisions of local
building codes. Contact local building or fire
officials about restrictions and installation inspection
in your area.
The AP-U Series is designed to be vented into a
fireclay tile-lined masonry chimney or chimney
constructed from type-L vent or a factory built
chimney that complies with the type HT
requirements of UL103. The chimney or vent pipe
shall have a sufficient draft at all times, to assure
safe proper operation of the boiler. See Figure 13 for
recommended installation.
a.
b.
Install a draft regulator (supplied by installer)
following the instructions furnished with the
regulator. See Figure 14 for alternate regulator
locations.
With any new or replacement installation the
chimney has to be considered. Chimneys that
have a high heat loss become less suitable as the
heat loss of the home goes down and the
efficiency of the boiler goes up. Most homes
have a chimney appropriate for the fuel and the
era in which the home was built. That may have
been a coal fired or an inefficient oil fired boiler
built into a home without insulation or storm
windows. With increasing fuel prices that home
probably has been insulated and fitted with storm
windows so that the heat loss of the home has
been reduced. This requires less fuel to be
burned and sends less heat up the chimney.
A new 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
some cases, contribute to the condensing of
small amounts of water vapor in the chimney.
Such condensation, when it occurs, can cause
chimney deterioration. In extreme cases, the
chimney may have to be lined to insulate the
chimney and thus prevent the condensation. The
addition of dilution air into the chimney may
assist in drying the chimney interior surfaces.
A massive chimney on a cold, or exposed outside
wall may have produced adequate draft when it
was fired with a higher input and greater volumes
of heated gases. With reduced input and volume,
the draft may be severely affected. In one
instance our research showed a new chimney of
adequate sizing produced only -.035" W.C. after
30 minutes of continuous firing at 13.0% CO2.
Outside wall chimneys take longer to heat up and
can have .00" W.C. draft at burner start-up. You
may have to consider a special alloy chimney
flue liner with insulation around it and stabilizing
draft cap or even a draft inducing fan in severe
cases.
c. For the same reasons as in (2.) above, heat
extractors mounted into the breeching are not
recommended.
For minilnuln clearances to combustible materials
refer to Figure 2.
17

F_RECLAY TILE
LINED THIMBLE
GA, MINo X FUDL S_ZE
OF CANOPY OUTLET COLOR (DO NOT REDUCE)
NOTE: ALL HOR!ZONTAL SNOKEP!PE SHOULD SLOPE
UPWARD NOT LESS T_N ONE INCH _N FOUR FEF
AiR GAP REGU_TOR
DILUTION NR
CL_NOUT
O_L BURNER
FLOOR
UNE
VIEW
Figure 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
I
Figure 14: Draft Regulator Locations

V. Electrical
Positively assure all electrical connections are unpowered before attempting installation or service of
electrical components or connections of the boiler or building. Lock out all electrical boxes with padlock
once power is turned off.
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 any
electrical 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 diagram
of any controls used with the boiler. Read, understand and follow all wiring instructions supplied with
the controls.
A. GENERAL 2.
2.
Install wiring and electrically ground boiler in
accordance with requirements of the authority
having jurisdiction, or in absence of such
requirements the National Electrical Code, ANSI/
NFPA 70, and/or the CSA C22.1 Electric Code.
A separate electrical circuit must be run from the
main electrical service with an over-current device/
disconnect in the circuit. A service switch is
recommended and may be required by some local
jurisdictions.
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 control
boxes.
Use armored cable (BX) over all exposed line
voltage wiring.
If an indirect water heater is used, use priority
zoning. Do not use priority zoning for Hydro-Air
Systems.
Single Zone System - Refer to Figure 15 or 16 for
the electrical diagram for this type of system.
Connect the system circulator wire leads to the
proper locations on the Aquastat control, L7224A/
L7248A. See Figure 15Aor 16A. Connect the
thermostat to the 'T-T' terminals on the L7224A/
L7248A control. Set thermostat heat anticipator
settings to 0.60 amps.
19

24V _HZRM_,_
iB:_B: @IJRPU !'Ii_
M2JASffAT CQN'_BOZ
RElY
_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_I
BY 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't
J
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 AWG
TYPE 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 _ BLUE
OR _ QRZZ_
RD _ RED
WB _ _4_F
Figure 15A: AP-U Boiler Wiring Less Tankless, Single Circulator w/Riello Burner
20