New Yorker FR SERIES Service manual

INSTALLATION, OPERATING
AND SERVICE INSTRUCTIONS
FR™ SERIES
HORIZONTAL TUBE BOILER
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8147202R5-7/07 Price - $3.00

2
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.
REGNAD
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NOITUAC
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ECITON
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erahcihwecnanetniamro,noitarepo
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IMPORTANT INFORMATION - READ CAREFULLY
ECITON
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3
REGNAD
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GNINRAW
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tpmettadluohssmetsysgnitaehcinordyhfonoitallatsnidnatuoyalehtnielbaegdelwonk
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4
GNINRAW
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.metsys
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dellatsniebdluohssmraladnasdraugefasetairporpparo;rehtaewdlocnidednetttanutfelebton
.evitareponisireliobehtfiegamadtneverpotmetsysgnitaehehtno

5
Table of Contents
I. Pre-Installation...............................6
II. Knockdown Boiler Assembly..........8
III. Water Piping and Trim .................10
IV. Venting.........................................15
V. Electrical.......................................16
Figure 1: FR Packaged Boiler
VI. Oil Piping.....................................18
VII. System Start-Up............................20
VIII. Service and Cleaning ....................27
VIX. Repair Parts..................................29
X. Appendix
Low Water Cut Off .......................37
RELIOB
LEDOM
sehcnI-snoisnemiD
A B C D E F G
SGH-RF 8/7-13 8/7-91 8/3-81 4/3-52 8/3-13 8/1-3 8/7-5
IISGH-RF 8/7-13 8/7-91 8/3-81 2/1-62 8/3-13 8/1-3 8/7-6
221/89-RF 8/7-73 8/7-91 8/3-81 4/1-52 2/1-03 8/7-3 8/7-5
371/741-RF 8/5-64 8/7-12 8/5-12 4/1-03 4/3-53 8/3-5 8/7-6
232/502-RF 8/5-64 8/7-12 8/7-52 4/3-92 4/3-04 8/1-6 8/7-7
503/562-RF 8/1-15 8/7-12 8/7-52 43 4/3-83 8/1-6 8/7-7
004/053-RF 85 8/7-52 8/7-72 4/3-53 8/7-04 8/1-6 8/7-9
264-RF 85 8/7-52 8/7-33 4/3-53 4/3-64 8/1-6 8/7-9

6
A. 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 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 in front of nal position before
removing crate.
NOITUAC
tekcajreliobpmubtonoD.reliobpordtonoD
.roolftsniaga
1. LOCATE so that smoke pipe connection to
chimney will be short and direct. BOILER IS
NOT SUITABLE FOR INSTALLATION ON
COMBUSTIBLE FLOOR. DO NOT install on
carpeting.
I. Pre-Installation
2. FOR BASEMENT INSTALLATION, provide a
solid base, such as concrete, if oor is not level, or if
water may be encountered on oor around boiler.
3. PROVIDE SERVICE CLEARANCE of at least 48”
from the front of the jacket for servicing of burner
and removal of tankless heater.
For minimum clearances to combustible materials. See
Figure 2.
Figure 2: Minimum Clearances to Combustible Materials

1. Listed clearances comply with American National Standard ANSI/NFPA 31, Installation of Oil Burning Equipment.
2. FR™ boilers may be installed in rooms with clearances from combustible material as listed above. Listed clearances may not
be reduced for alcove or closet installations.
3. For reduced clearances to combustible material, protection must be provided as described in the above ANSI/NFPA 31
standard.
GNINRAW
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niatnocyamhcihw,sroolfyrnosam
.erutsiom

7
C. PROVIDE COMBUSTION AND VENTILATION
AIR. Local code provisions may apply and should be
referenced.
GNINRAW
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.derots
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 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 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
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.

8
II. Knock-Down Boiler Assembly
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 19).
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).
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.
2. Mount the limit control. Thread the provided
immersion well into the ¾” NPT tapping located on
the front or top of boiler. Place the aquastat control
with sensing bulb on well so that bulb is inserted
fully into well.
3. Mount burner to front re door and wire according
to instructions provided with the burner. Refer to
Figure 3.
A. REMOVAL OF BOILER.
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 and 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 30 psig.
GNINRAW
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NOITUAC
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9
Figure 3: Burner Mounting

10
Figure 4: Recommended Piping for Combination
Heating and Cooling (Refrigeration) System
III. Water Piping and Trim
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 ttings.
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 ttings 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.
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. Also, consult I=B=R
Installation and Piping Guides.
3. Connect System supply and return piping to
boiler. See Figures 5 and 6. Also, consult
I=B=R Installation and Piping Guides. Maintain
minimum ½ inch clearance from hot water piping to
combustible materials.
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 ow 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
GNINRAW
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.deredisnoc

11
should be the same size as the supply and
return lines with valves located in the bypass
and return line as illustrated in Figures 5 and 6
in order to regulate water ow 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
5 and 6. Safety Relief Valve must be installed with
spindle in the vertical position. Installation of the relief
valve must be consistent with ANSI/ASME Boiler and
Pressure Vessel Code, Section IV.
GNINRAW
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C. INSTALL DRAIN VALVE IN RETURN PIPING.
See Figures 5 and 6.
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 ushed. A qualied 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
relling the entire system add appropriate water
treatment chemicals, if necessary, to bring the pH
between 7 and 11.
GNINRAW
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12
Figure 5: Recommended Water Piping for Circulator Zoned Heating Systems

13
Figure 6: Recommended Water Piping for Zone Valve Zoned Heating Systems

14
Figure 7: Schematic Tankless Heater Piping
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 xtures. 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 7.
3. 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 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 benecial to the
tankless heater but to piping and xtures plus the
many other benets derived from soft water.
THE FOLLOWING GUIDELINES SHOULD BE
FOLLOWED WHEN PIPING THE TANKLESS
HEATER:
1. FLOW REGULATION — If ow 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 ow regulator
matching the heater rating should be installed in
the cold water line to the heater. The ow 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 ow regulator also
limits the ow of supply water regardless of inlet
pressure variations in the range of 20 to 125 psi.
F. CONNECT TANKLESS HEATER PIPING AS
SHOWN IN FIGURE 7.
GNINRAW
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rosnrubfoksirdiovaotteltuoretaeh
taretawtohylevissecxeoteudgnidlacs
evlavgniximehtniatniamdnatsujdA.serutxif
s'rerutcafunamehthtiwecnadroccani
retaehsselknatetarepotonoD.snoitcurtsni
.evlavgniximtuohtiw

15
IV. Venting
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 re
ofcials about restrictions and installation inspection
in your area.
2. The FR™ Series is designed to be vented into a
reclay 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 sufcient draft at all times, to assure
safe proper operation of the boiler. See Figure 8 for
recommended installation.
a. Install a draft regulator (supplied by installer)
following the instructions furnished with the
regulator. See Figure 9 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
efciency 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 red or an inefcient oil red
boiler built into a home without insulation or
storm windows. With increasing fuel prices that
home probably has been insulated and tted 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 efciency
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 ring rate, reduced ring 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 red 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 ring 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
ue 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.
3. For minimum clearances to combustible materials
refer to Figure 2.
Figure 8: Recommended Smoke Pipe Arrangement and Chimney Requirements

16
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. A separate electrical circuit should be run from
the main electrical service with a fused disconnect
switch in the circuit.
V. Electrical
REGNAD
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htiwsexoblacirtcelellatuokcoL.gnidliubroreliobehtfosnoitcennocrostnenopmoclacirtcelefo
.ffodenrutsirewopecnokcoldap
Figure 9: Draft Regulator Locations
3. Wiring should conform to Figures on pages 17 and
18 of this manual.
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.
GNINRAW
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erofebffosirewopllaerusekaM.ecruosenonahterommorfebyamrewoplacirtcelE
.krowlacirtceleynagnitpmetta
.tcennocsiddesufdezisylreporpahtiwdetcetorpebtsumreliobhcaE
.slortnocgnitareporoytefasynaevitareponiekamrotuopmujreveN
ehtotrefeR.ylnosesoprupecnereferroferalaunamsihtnideniatnocsmargaidgniriwehT
gniriwllawollofdnadnatsrednu,daeR.reliobehthtiwdesuslortnocynafomargaidgniriw
.slortnocehthtiwdeilppussnoitcurtsni

17
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 Zone Water System – Refer to Figures 10
and 11 for electrical diagram. Connect the system
circulator wire leads to the proper locations on the
Aquastat control, L7224A/L7248A. See Figure 10
or 11. Connect the thermostat to the ‘T-T’ terminals
on the L7224A/L7248A control. Set thermostat heat
anticipator setting to 0.50 amps.
Figure 10: FR Water Boiler Wiring, Less Tankless, Single Circulator
Figure 11: FR Water Boiler Wiring, With Tankless, Single Circulator

18
A. GENERAL
1. Use exible oil line(s) so that burner door can
be opened, or burner can be removed, without
disconnecting the oil supply.
2. A supply line fuel oil lter is recommended as a
minimum for all ring rates but a pleated paper fuel
oil lter is recommended for the lowest ring rate
applications to prevent nozzle fouling.
3. Use Flared ttings only. Do not use compression
ttings.
4. Use of a high efciency micron lter (Garber or
equivalent) in addition to the conventional lter is
highly recommended.
VI. Oil Piping
Figure 14: Single-Pipe Installation
ECITON
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B. SINGLE-PIPE OIL LINES
1. Standard burners are provided with single-stage
3450 rpm fuel units with the bypass plug removed
for single-pipe installations.
2. The single-stage fuel unit may be installed single-
pipe with gravity feed or lift. Maximum allowable
lift is 8 feet. See Figure 14.

19
C. TWO-PIPE OIL LINES
1. For two-piped systems, where more lift is required,
the two-stage fuel unit is recommended. Table
1 (single-stage) and Table 2 (two-stage) show
allowable lift and lengths of 3/8 inch and 1/2 inch
OD tubing for both suction and return lines. Refer
to Figure 15.
Figure 15: Two-Pipe Installation
ELBAT 1 )MPR0543(STINUEGATSELGNIS:
SMETSYSEPIPOWT
"H"tfiL
)erugiFeeS(
gnibuTfohtgneLmumixaM
)erugiFeeS("R"+"H"
DO"8/3
)HPG3(gnibuT
DO"2/1
)HPG3(gnibuT
'0 '48 '001
'1 '87 '001
'2 '37 '001
'3 '86 '001
'4 '36 '001
'5 '75 '001
'6 '25 '001
'7 '74 '001
'8 '24 '001
'9 '63 '001
'01 '13 '001
'11 '62 '001
'21 '12 '38
'31 --- '26
'41 --- '14
ELBAT 2 )MPR0543(STINUEGATS-OWT:
SMETSYSEPIP-OWT
"H"tfiL
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DO"8/3
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'0 '39 '001
'2 '58 '001
'4 '77 '001
'6 '96 '001
'8 '06 '001
'01 '25 '001
'21 '44 '001
'41 '63 '001
'61 '72 '001
'81 --- '67

20
VII. System Start-Up
A. VERIFY that the venting, water piping, oil piping,
and electrical system are installed properly. Refer to
installation instructions contained in this manual.
B. CONFIRM all electrical, water and oil supplies are
turned off at the source and that the vent is clear from
obstructions.
GNINRAW
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gnitpmettaerofeblaunamsihtnisnoitcurtsni
.putrats
C. FILL ENTIRE HEATING SYSTEM WITH WATER
and vent air from system. See Figures 5 & 6 and follow
steps below:
1. Close isolation valve in boiler supply piping.
2. Isolate all circuits by closing zone valves or
balancing valves.
3. Attach a hose to hose bib located just before
isolation valve in boiler supply piping. See Figures
5 and 6. (Note - Terminate hose at a suitable oor
drain or outdoor area).
4. Starting with one circuit at a time, open zone valve
or valve.
5. Open hose bib.
6. Open ll valve (Make-up water line should be
located directly after isolation valve in boiler supply
piping between air scoop and expansion tank).
7. Allow water to ow into drain until discharge from
hose is bubble free for 30 seconds.
8. When zone is completely purged of air, close zone
valve or balancing valve. Open the zone valve for
the next zone to be purged. Repeat this step until
all zones have been purged. At completion, open all
zone valves or valves.
GNINRAW
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.erusserpsihtdeecxereveN.gisp03sireliob
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9. Close hose bib, continue lling the system until the
pressure gauge reads 12 psig. Close ll valve.
(Note - If make-up water line is equipped with
pressure reducing valve, system will automatically
ll to 12 psig.
10. Open isolation valve in boiler supply piping.
11. Remove hose from hose bib.
D. CONFIRM that the boiler and system have no water
leaks.
E. CHECK CONTROLS, WIRING AND BURNER
to be sure that all connections are tight and burner is
rigid. Verify that all electrical connections have been
completed, fuses installed, that the oil tank is lled and
oil lines have been tested.
F. LUBRICATION. Follow instruction on burner and
circulator label to lubricate, if oil lubricated. Most
motors currently used on residential type burners
employ permanently lubricated bearings and thus do
not require any eld lubrication. Water lubricated
circulators do not need eld lubrication.
G. ADJUST CONTROL SETTINGS with burner
service switch turned “ON” and room thermostat set
10° below room temperature.
1. Adjustment and display modes of the L7248/
L7224 Oil Electronic Aquastat Controller.
a. On the L7248/L7224, the overall range of the
High Limit is from 180°F to 240°F (82°C to
116°C).
b. Set the High Limit (designated HL) on the
L7248/L7224 Aquastat Control at 180°F. This
temperature setting may be varied to suit
requirements of installation. Differential is xed
at 15°F.
i. Adjusting Settings:
To discourage unauthorized changing of
Aquastat settings, a procedure to enter the
adjustment mode is required. To enter the
adjustment mode, press the UP, DOWN,
and Ibuttons (see Figure S1) simultaneously
for three (3) seconds. Press the ‘I’ button
until the feature requiring adjustment is
displayed (press the “I” button again and
will display LL (Low Limit on L7224):
· High Limit
·°F -- °C (Toggle)
Figure S1: L7248 Circuit Board Layout -
Horizontal Mount