New Yorker FR-HGS Series Service manual

111079-01 - 12/20
Installation, Operating and Service Instructions for
FRTM
Models:
•FRHGSL
•FRHGS
•FR122E
•FR147
•FR173E
• Residential
•Natural Draft
• Oil-Fired
•Water Boiler
TO THE INSTALLER:
Affix these instructions adjacent to boiler.
TO THE CONSUMER:
Retain these instructions for future reference.
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.
Manual Contents Page
1. General Information ......................5
2. Pre-Installation ..........................7
3. Knockdown Boiler Assembly...............9
4. Water Piping and Trim ...................12
5. Venting................................17
6. Electrical ..............................19
7. Oil Piping ..............................21
8. System Start-Up ........................23
9. Operating ..............................29
10. Maintenance & Service Instructions ........33
11. Boiler Cleaning .........................35
11. Troubleshooting ........................38
12. Service Parts...........................43
13. Burner Specifications ....................47
Appendix: Aftermath Low Water Cut-off ........48
•FR205
•FR232E
•FR122E-T
•FR173E-T
•FR232E-T

2111079-01 - 12/20
FR Installation & Service Manual
All boilers must be installed in accordance with National, State and Local Plumbing,All boilers must be installed in accordance with National, State and Local Plumbing,
Heating and Electrical Codes and the regulations of the serving utilities. TheseHeating and Electrical Codes and the regulations of the serving utilities. These
Codes and Regulations may differ from this instruction manual. Authorities havingCodes and Regulations may differ from this instruction manual. Authorities having
jurisdiction should be consulted before installations are made.jurisdiction should be consulted before installations are made.
In all cases, reference should be made to the following Standards:In all cases, reference should be made to the following Standards:
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.
USA BOILERSUSA BOILERS
A. Current Edition of American National Standard ANSI/NFPA 31, “Installation of OilA. Current Edition of American National Standard ANSI/NFPA 31, “Installation of Oil
Burning Equipment”, for recommended installation practices.Burning Equipment”, for recommended installation practices.
B. Current Edition of American National Standard ANSI/NFPA 211, “Chimneys, FireB. Current Edition of American National Standard ANSI/NFPA 211, “Chimneys, Fire
places, Vents, and Solid Fuel Burning Appliances”, For Venting requirements.places, Vents, and Solid Fuel Burning Appliances”, For Venting requirements.
C. Current Edition of American Society of Mechanical Engineers ASME CSD-1,C. Current Edition of American Society of Mechanical Engineers ASME CSD-1,
“Controls and Safety Devices for Automatically Fired Boilers”, for assembly and“Controls and Safety Devices for Automatically Fired Boilers”, for assembly and
operations of controls and safety devices.operations of controls and safety devices.
D. All wiring on boilers installed in the USA shall be made in accordance with theD. All wiring on boilers installed in the USA shall be made in accordance with the
National Electrical Code and/or Local Regulations.National Electrical Code and/or Local Regulations.
IMPORTANT
This boiler is equipped with a feature that saves energy by reducing the boiler water temperature as the heating
load decreases. This feature is equipped with an override which is provided primarily to prevent the use of external
energy management system that serves the same function. THIS OVERRIDE MUST NOT BE USED UNLESS AT
LEAST ONE OF THE FOLLOWING CONDITIONS IS TRUE:
• An external energy management system is installed that reduces the boiler water temperature as the heating load
decreases.
•This boiler is not used for any space heating.
•This boiler is part of a modular or multiple boiler system having a total input of 300,000 BTU/HR or greater.
•This boiler is equipped with a tankless coil.
NOTICE This boiler has a limited warranty, a copy of which is included with this boiler. The warranty for this boiler
is valid only if the boiler has been installed, maintained and operated in accordance with these instructions.
Surface rust on cast iron sections may be attributed to the manufacturing process as well as condensation
during storage. Surface rust is normal and does not affect the performance or longevity of a boiler.
NOTICE: Indicates special instructions on
installation, operation, or maintenance which
are important but not related to personal injury
hazards.
DANGER
Indicates an imminently hazardous situation
which, if not avoided, will result in death, serious
injury or substantial property damage.
CAUTION
Indicates a potentially hazardous situation
which, if not avoided, may result in moderate or
minor injury or property damage.
WARNING
Indicates a potentially hazardous situation
which, if not avoided, may result in moderate or
minor injury or property damage.
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IMPORTANT INFORMATION - READ CAREFULLY

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DANGER
DO NOT store or use gasoline or other flammable vapors or liquids in the vicinity of this or any other
appliance.
!
WARNING
Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal
injury or loss of life. Failure to follow all instructions in the proper order can cause personal injury or death.
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 in the front left corner - See Water Piping and Trim Section of this manual for additional 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 flooring. DO NOT operate boiler on combustible
flooring without factory supplied floor shield (available option at extra cost). A concrete pad is NOT sufficient
to protect combustible flooring. Concrete over wood joists 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.
• DO NOT operate on masonry floors, 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.
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WARNING
This boiler contains very hot water under 12 - 15 PSI pressure. DO NOT unscrew any pipe fittings nor attempt
to disconnect any components of this boiler without positively assuring the water is cool and has no pressure.
Always wear protective clothing and equipment when installing, starting up or servicing this boiler to prevent
scald injuries. 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 flow 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 flue must be inspected and cleaned before the start of the heating season for any obstructions.
A clean and unobstructed chimney flue 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 efficiency. 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 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.
• 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 firing of burner outside the combustion chamber. Be sure to tighten swing door fastener
completely when service is completed.
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Figure 1A: FR-HGS Water Boiler (Heat Only), Beckett Burner
Figure 1B: FR-122E Thru FR-232 Water Boiler With or Without Tankless Heater, Beckett Burner
1General Information

6111079-01 - 12/20
FR Installation & Service Manual
Boiler SeriesBoiler Series
Dimensions - InchesDimensions - Inches Approx. WaterApprox. Water
Content - GallonsContent - Gallons
AABBCCDDEEFFGG
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-122FR-122 37-7/837-7/8 19-7/819-7/8 18-3/818-3/8 25-1/425-1/4 30-1/230-1/2 3-7/83-7/8 5-7/85-7/8 20.020.0
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-205/232FR-205/232 51-1/851-1/8 21-7/821-7/8 25-7/825-7/8 29-3/429-3/4 40-3/440-3/4 6-1/86-1/8 7-7/87-7/8 46.046.0
Table 1-1: Dimensional Data (see Figures 1A and 1B)
Table 1-2: Rating Data
Boiler
Series Boiler Model
Burner
Capacity Heating
Capacity
MBH (2)
Net Ratings
Water, MBH
(3)
AFUE
%
Minimum Chimney
Requirement
GPH MBH
(1)
Round
In. Dia.
Rectangle
In. x In.
Height
Ft.
FR-HGS * FRHGSL 0.80 112 100 87 87.8 6 8 x 8 15
FRHGS 1.00 140 122 106 86.3 6 8 x 8 15
FR-122 FR-122E 1.00 140 121 105 86.0 6 8 x 8 15
FR-122ET
FR-147 FR147 1.25 175 154 134 86.7 7 8 x 8 15
FR-173 *FR-173E 1.50 210 182 158 86.0 7 8 x 8 15
*FR-173ET
FR-205 FR205 1.75 245 215 187 86.0 8 8 x 8 15
FR-232 *FR-232E 1.90 266 231 201 86.0 8 8 x 8 15
*FR-232ET
* Field Converted
Maximum Allowable Working Pressure = 30 PSI
(1) MBH refers to thousands of BTU per hour
(2) Based on Standard Test prescribed by the United States Department of Energy at Combustion
conditions of 13.0% CO2
(3) Net AHRI ratings based on a piping and pickup allowance of 1.15.
1General Information (continued)

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3. FOR BASEMENT INSTALLATION, provide a
solid elevated base, such as concrete, if floor
is not level, or if water may be encountered on
floor 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
floors, 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 2-1.
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.
C. PROVIDE COMBUSTION AND VENTILATION
AIR. Local and National Codes may apply and
should be referenced.
Figure 2-1: Minimum Installation Clearances to Combustible Materials (Inches)
C
A
Above
B
Front
Chimney
Connector
D
Rear
E
Sides
6 24 18 6 6
NOTE 1: Listed clearances comply with American National
Standard NFPA 31, Standard for the Installation of Oil
Burning Equipment.
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.
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 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.
B. LOCATE BOILER near final position before
removing crate. See Figures 1A and 1B. 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 floor.
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.
2Pre-Installation
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FR Installation & Service Manual
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
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 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(ft3) = 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
unconfined space. If the result is less than
50 ft3/1000 BTU per hour then the space is
considered a confined space.
4. For boiler located in an unconfined 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.
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.
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
confined space. Use indoor air if two
permanent openings communicate directly
with additional space(s) of sufficient volume
such that combined volume of all spaces
meet criteria for unconfined 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 fixed in the
open position, or interlocked with the
equipment to open automatically during
equipment operation.
2Pre-Installation (continued)
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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 Figure 3-2 and Table 3-3 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 and 1B.
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 and 1B. 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 3-1.
3. Mount burner to front fire door and wire
according to instructions provided with the
burner. Refer to Figure 3-4.
A. REMOVAL OF BOILER from skid.
1. Remove all boiler-to-skid hold down fasteners.
2. Carefully walk boiler to the edge of skid. Tilt
the boiler back, allowing an edge to rest on the
floor, and remove the 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 flue 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.
Figure 3-1: Limit Sensor Insertion
3Knock-Down Boiler Assembly
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Figure 3-2: Marking Locations
ITEM DESCRIPTION PART NUMBER
1 New Yorker Logo Plate
2 Rating Label
3Combo Warning / Safety Label,
Combustible Floor 103026-04
4Burner Spec. Label, Beckett Burners 106235-03
Burner Spec. Label, Riello Burners 111083-01
5 Energy Guide Label
6 Limit Sensor Insertion Depth Warning Label 103106-03
7 ASME Cover Plate Label 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.
Table 3-3: Labels
3Knock-Down Boiler Assembly (continued)

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Figure 3-4: Burner Mounting
3Knock-Down Boiler Assembly (continued)

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FR Installation & Service Manual
Figure 4-1: Recommended Piping for Combination
Heating and Cooling (Refrigeration) System
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 of non-permeable materials in the
distribution system.
e. Isolating the boiler from the system water by
installing a heat exchanger.
3. Connect System supply and return piping
to boiler. See Figures 4-2 and 4-3. Also,
consult I=B=R “Residential Hydronic Heating
Installation and Design Guide”. Maintain
minimum ½ inch clearance from hot water
piping to combustible materials.
NOTICE: 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.
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
4-1. Also, consult I=B=R “Residential
Hydronic Heating Installation and Design
Guide”.
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 Hot Water Heater, install the
Indirect-Fired Domestic Hot Water Heater
as a separate heating zone. Refer to
the Indirect-Fired Domestic Hot 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 line as illustrated in
Figures 4-2 and 4-3 in order to regulate
4Water Piping and Trim
WARNING
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.
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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.
e. A water boiler installed above radiation level
must be provided with a low water cutoff
device as part of the installation.
B. INSTALL SAFETY RELIEF VALVE. See Figures
4-2 and 4-3. 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
I V.
WARNING
Installation is NOT complete unless a safety
relief valve is installed as shown in Figure 6A
or 6B. 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.
C. INSTALL DRAIN VALVE IN RETURN PIPING.
See Figures 4-2 and 4-3.
D. 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.
E. 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.
4Water Piping and Trim (continued)
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Figure 4-2: Recommended Water Piping for Circulator Zoned Heating Systems
4Water Piping and Trim (continued)

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Figure 4-3: Recommended Water Piping for Zone Valve Zoned Heating Systems
4Water Piping and Trim (continued)

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Figure 4-4: Schematic Tankless Heater Piping
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 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 8.
3. FLUSHING OF HEATER — All water
contains some sediment which settles on the
inside of the coil. Consequently, the heater
should be periodically back washed. 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
minimize pressure drop.
4. 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
recommendation. This is not only beneficial to
the tankless heater but to piping and fixtures
plus the many other benefits derived from soft
water.
F. CONNECT TANKLESS HEATER PIPING AS
SHOWN IN FIGURE 4-4.
4Water Piping and Trim (continued)
WARNING
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.
!
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 minimum 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

17
111079-01 - 12/20
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Figure 5-1: Recommended Smoke Pipe Arrangement and Chimney Requirements
A. GENERAL GUIDELINES
1. 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.
2. The FR™ 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 5-1 for recommended
installation.
a. Install a draft regulator (supplied by
installer) following the instructions furnished
with the regulator. See Figure 5-2 for
alternate regulator locations.
b. 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
5Venting
less heat up the chimney.
A new boiler probably has a higher
efficiency than the boiler being replaced.
That probably 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.

18 111079-01 - 12/20
FR Installation & Service Manual
Figure 5-2: Draft Regulator Locations
5Venting (continued)
c. For the same reasons as in (2.) above, heat
extractors mounted into the breeching are
not recommended.
3. For minimum clearances to combustible
materials refer to Figure 2-1.

19
111079-01 - 12/20
FR Installation & Service Manual
A. GENERAL
1. 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.
2. Refer to National Electric Code or Local
Electric Codes for proper size and type of wire
required. Follow Code.
3. A separate electrical circuit must be run from
the main electrical service with an over-current
device/disconnect in the circuit. A 15 amp
circuit breaker is recommended. A service
switch is recommended and may be required
by some local jurisdictions.
4. Wiring should conform to Figure 6-1.
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.
2. Use anti-short bushings on all wiring passing
through boiler jacket, junction boxes and/or
control boxes.
3. Use armored cable (BX) over all exposed line
voltage wiring.
4. If an Indirect-Fired Domestic Hot Water Heater
is used, use priority zoning. Do not use priority
zoning for Hydro-Air Systems.
5. Single or Multiple Zone Water System – Refer
to Figure 6-1 for electrical diagram. Connect
the system circulator wire leads to the proper
locations on the HydroStat. See Figure 6-1.
C. INSTALL A ROOM THERMOSTAT on an
inside wall about four feet above floor. Never
install thermostat on an outside wall or where
it will be influenced by drafts, hot or cold water
pipes, lighting fixtures, television, rays of the sun
or near a fireplace. Keep large furniture away from
thermostat so there will be free movement of room
air around this control.
Connect the thermostat to the ‘T-T’ terminals on
the control.
WARNING
The maximum allowable current for each
circulator is 5 amps at 120V AC. For circulators
with higher amp ratings, you must install a
circulator relay or starter coil to provide line
voltage to the circulator and connect only the
relay or starter coil to boiler terminals. The
combined boiler and circulator amperage must
not exceed 15 amps.
Install over-current protection in accordance with
authority having jurisdiction or, in the absence
of such requirements, follow the National Electric
Code, NFPA 70, and/or CSA C22.1 Electrical
Code. Do not provide over-current protection
greater than 15 amperes.
6Electrical
DANGER
Positively assure all electrical connections are unpowered before attempting installation or service of electrical
components or connections of the boiler or building. Lock out all electrical boxes with padlock once power is
turned off.
WARNING
Failure to properly wire electrical connections to the boiler may result in serious physical harm.
Electrical power may be from more than one source. 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.
!
!
!

20 111079-01 - 12/20
FR Installation & Service Manual
Figure 6-1: Schematic Wiring Diagram, without Tankless Heater, Cold Start Control (Beckett Burner)
6Electrical (continued)