New Yorker FR SERIES User manual

INSTALLATION, OPERATING
AND SERVICE INSTRUCTIONS
FR"rMSERIES
HORIZONTAL TUBE BOILER
For service or repairs to boiler, call your heating contractor. When seeking information on
boiler, provide Boiler Model Number and Serial Number as shown on Rating Label.
Boiler Model Number Boiler Serial Number Installation Date
FR
Heating Contractor Phone Number
Address
8147202R5-7/07
®
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:
A. All wiring on boilers shall be made in accordance with the National Electrical
Code and/or Local Regulations.
B. Current Edition of American National Standard ANSI/NFPA 31, "Installation of Oil
Burning Equipment", for recommended installation practices.
C. Current Edition of American National Standard ANSI/NFPA211, "Chimneys,
Fireplaces, Vents, and Solid Fuel Burning Appliances", For Venting requirements.
D. 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.
lndicates 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. Itistheresponsibilityoftheinstallingcontractortoseethatall
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 constructed in accordance with NFPA 31. 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.
A concrete pad is not sufficient to protect combustible flooring.
Do not operate on masonry floors, which may contain moisture.
Do not tamper with or alter the boiler or 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.

This boiler containsvery hot water under highpressures. Do not unscrewany pipe fittings nor
attemptto disconnect anycomponentsof this boilerwithout positivelyassuring the wateris cool
and hasno pressure. Alwayswearprotectiveclothing andequipment 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 unapproved vent
system.
This boiler needs fresh air for safe operation and must be installed so there are provisions for
adequate combustion and ventilation air.
The interior of the venting and air intake systems must be inspected and cleaned before the start
of the heating season and should be inspected periodically throughout the heating season for any
obstructions. Clean and unobstructed 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 unatttended in cold weather; or appropriate safeguards and alarms should be installed
on the heating system to prevent damage if the boiler is inoperative.
4

Table of Contents
I. Pre-Installation ............................... 6
II. Knockdown Boiler Assembly .......... 8
III. Water Piping and Trim ................. 10
IV. Venting ......................................... 15
V. Electrical ....................................... 16
VI°
VII.
VIII.
VIX.
X.
Oil Piping ..................................... 18
System Start-Up ............................ 20
Service and Cleaning .................... 27
Repair Parts .................................. 29
Appendix
LowWater Cut Off ....................... 37
Figure 1: FR Packaged Boiler
BOILER
MODEL A B C E F G
FR-HGS 31-7/8 19-7/8 18-3/8 31-3/8 3-1/8 5-7/8
FR-HGS II 31-7/8 19-7/8 18-3/8 31-3/8 3-1/8 6-7/8
FR-98/122 37-7/8 19-7/8 18-3/8 30-1/2 3-7/8 5-7/8
FR-147/173 46-5/8 21-7/8 21-5/8 35-3/4 5-3/8 6-7/8
FR-205/232 46-5/8 21-7/8 25-7/8 40-3/4 6-1/8 7-7/8
FR-265/305 51-1/8 21-7/8 25-7/8 38-3/4 6-1/8 7-7/8
FR-350/400 58 25-7/8 27-7/8 40-7/8 6-1/8 9-7/8
FR-462 58 25-7/8 33-7/8 46-3/4 6-1/8 9-7/8
Dimensions -Inches
D
25-3/4
26-1/2
25-1/4
30-1/4
29-3/4
34
35-3/4
35-3/4

I. Pre-lnstallation
A.
B°
INSPECT SHIPMENT carefully for any signs of
damage.
1. ALL EQUIPMENT is carefully lnanu_actured,
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
lnanufacturer unless presented within sixty (60) days
after receipt of goods.
LOCATE BOILER in front of final position before
removing crate.
Do not drop boiler. Do not bump boiler jacket
against floor.
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.
2.
3.
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.
Concrete over wood joists is considered
combustible flooring. Do not operate on
masonry floors, which may contain
moisture.
1.
2.
3.
FLOOR FLOOR
UNE LINE
Figure 2: Minimum Clearances to Combustible Materials
Listed clearances comply with American National Standard ANSI/NFPA 3l, Installation of Oil Burning Equipment.
FRTM 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.
For reduced clearances to combustible material, protection must be provided as described in the above ANSI/NFPA 31
standard.

Co 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 uncol?fined 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.

II. Knock-Down Boiler Assembly
A. REMOVAL OF BOILER.
1.
B.
2.
C. INSTALLING THE JACKET
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 floor, and remove the skid.
FR-265 thru FR-462: A mechanical lifting device
may be required to safely remove boiler from skid.
TEST HEAT EXCHANGER FOR LEAKS before
proceeding with jacket assembly.
2.
Install pressure relief valve supplied, a hose to the
city water and a valve in the supply tapping. Plug
remainder of tappings.
Fill boiler with water and apply a pressure of at least
10 psig but no more than 30 psig.
If front flue box or rear smoke box fasteners
are removed, tighten them to 26 ft/Ibs when
replacing them.
3.
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).
Approaching the boiler from the rear, place the
assembled jacket pieces from Step 1 around the
boiler so that the lower rear panel passes below the
rear slnokebox.
Attach the lower front panel, upper front panel, and
upper rear panel. Make sure the jacket clearance
holes line up properly with the appropriate boiler
extensions and tappings.
4. Attach the top panel assembly (left and right pieces).
D. INSTALLATION OF BOILER CONTROLS
1.
2.
3.
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.
Mount the limit control. Thread the provided
immersion well into the 3/4"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.
Mount burner to front fire door and wire according
to instructions provided with the burner. Refer to
Figure 3.

BURNER MOUNTING
W!KEYHOLE SLOTS
OIL, BURNER
Figure 3: Burner Mounting

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 of non-permeable 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.
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.
@, WA T_R
/*i 2 ;t,
3}i}it.Y HA H iN _.4!_irJRN HA N _ R@b _
CDF!S N!II? _i:AT/N6 {DH}_ _q(_} !q£P:!T H@
8, Cg@ ill@ 3Y3 @H 8_ C@ii!! NI;: 3Y8 _'_
Figure 4: Recommended Piping for Combination
Heating and Cooling (Refrigeration) System
10
New Yorker 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 5 and 6. Also, consult
I=B=R Installation and Piping Guides. Maintain
minilnuln */2inch 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 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

B°
e.
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 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 telnperamre 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 telnperamre.
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
5 and 6. Safety Relief Valve must be installed with
spindle in the vertical position. Installation of the relief
valve must be consistent with ANSI/ASME Boiler and
Pressure Vessel Code, Section IV.
Safety (relief) valve discharge piping must be
piped near floor to eliminate potential of
severe burns. Do not pipe in any area where
freezing could occur. Do not install any shut-
off valves, plugs or caps.
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 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.
11

FROM _DITIONAL ZONES
FROM ZONE 2
FROM NY-MATE WATER HEATER
OR ZONE I
SHUT-OFF
VAL_S
BYPASS
VALVE
NOTES:
RUN _CH ZONE PiPE _N THEN UP TO ZONE
TO PRIDCENTAJR ACCUMULA_ON IN P|P_NG.
18_ MIN
OF ¢ON_vZ_IONAL I
TO
' _ _--_ __ ....................................................................._" _o_ _,_ S ,,oo0-r0o_
B!B SYS'TE_UMk F 1 REDUCING VAWE !
I (IFREQU!RED) L JVNZ,% COLOWATER" ° ' _] _] ICIRCULA,ORFLoW
EXPANSION SUPPPY I CONTROL
4 SUPPLY TANK _ VALVE:
VALVE
r SHUT-OFF
\4_LVE
TO TO
NY- MATE ZONE 2
WATER N_TER
OF USED)
OR ZONE !
RETURN VALVE RE_ _W
Figure 5: Recommended Water Piping for Circulator Zoned Heating Systems

NR _N3"
PRESSURE
REUEF
v_&v_ i
PIPE W_R_tN
6" OF R_00R
LFROM ADDITION_ ZONES
ROM ZONE 2
NOSE
NOTES:
RUN EACH ZONE PiPE DOWN THEN UP TO ZONE
TO PREVENT NR ACCUMULATION IN P_P1NG,
PRESSURE
REDUCING
VALVE
CHECK VALV_
(!F REQUIRE!O)
COLD WATER
SUPPLY
TO
ADDmO_
ZONES
ZONE
VAU_,_
NY- MATE
WATER HEATER
OPUSED)
OR ZONE 1
TO
ZONE 2
REAR _qEW
Figure 6: Recommended Water Piping for Zone Valve Zoned Heating Systems

F. CONNECT TANKLESS HEATER PIPING AS
SHOWN IN FIGURE 7.
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 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 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 beneficial to the
tankless heater but to piping and fixtures plus the
many other benefits derived from soft water.
HOSE BtB
SAFETY RELIEF
GLOBE VALVE
OR SO. HD COCK
COLD WATER
SUPPLY
FLOW REGULATOR iN
COLD WATER LiNE
AT LEAST 3 FE_
AHEAD OF TANKLESS HEATER
AUTOMATIC
MIXING
VALVE HEATER
14
H_GH TEMP WATER
FOR AUTOMATIC
WASHERS, ETC,
Schematic Tankless Heater Piping
®
HOSE BiB IN HOT
WATER UNE FOR PERIODIC
FLUSHING OF SEDIME_

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 FRTM 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 8 for
recommended installation.
a.
b.
Install a draft regulator (supplied by installer)
following the instructions furnished with the
regulator. See Figure 9 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% CO 2.
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
reco_mnended.
For minimum clearances to combustible materials
refer to Figure 2.
Figure 8:
,,EF! SIDE VIEW
Recommended Smoke Pipe Arrangement and Chimney Requirements 15

PROPER LOCATIONS
ACCRUABLE LOCATION
_LEN
UNACCEPTABLE LOCATIONS
Figure 9: 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 3. Wiring should conform to Figures on pages 17 and
1. 18 of this manual.
16
2.
Install wiring and electrically ground boiler in
accordance with requirements of the authority
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 should be run from
the main electrical service with a fused disconnect
switch in the circuit.
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. Usearmoredcable(BX)overallexposedline
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
24V THE PhJO STAT
(_ OTHERS?
SCHEMATIC DIAGRAM LEGEND
.... LOW VOLTAGE $1ZZ 1S/2 AW3 POWER
LJM{YED CIR_JfT C_LS 7B- lOB°
-- _NE VOLYAG£ SIZ£ 14 ANG
WP£ rW OR _WiAW_ W_RE
UN£ VOtfAf;E S_Z_!; I_ A_'#3
TYPE 'PN OR TEW/K¢CM W_R£
A WiR['Nt# f
_ QUCK CONNECT R£C£PTACL£
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.
GR
I_EMS SU_PUED BY _NSTALLER
L1
L2
SWiTC_ D!SCONN_(:T
(OPHO_L} PROTOCOl/
C_RCURRE_'41
PO'_R SUPPLY
2o/6o/
_ JUMP_ SUPPLieD
BY HONEYWELL
WIRE CODE
_ BLA_K
_L - BLUE
GR _ GRER
RO _ R£OB£CKEFf R7184B PRtMARY CON?ROL
YE _ YELLOW
-_ BURNER [ [ Bt:"_ _,U_ W/ _HITE TR#_C:_
MOTOR
I VALVE
, ' L2 @_-.4 _ ENV_RACOM"
CAD CELL _'_)
NOTES:
L F ARY OP
REPLACED_
THE ORIGINAL WR£ _ SUPPLIED WffH TN_ _PL#NC£ _UST _£
_" MUg'[ t3£ R£_L_CED Wm'_ WIRE _ SNO_R OR _TS [QUVAtENL
Figure 10: FR Water Boiler Wiring, Less Tankless, Single Circulator
17

Vl. Oil Piping
A. GENERAL
1. Use flexible 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 filter is recommended as a
lninilnuln for all firing rates but a pleated paper fuel
oil filter is recommended for the lowest firing rate
applications to prevent nozzle fouling.
3. Use Flared fittings only. Do not use compression
fittings.
4. Use of a high efficiency micron filter (Garber or
equivalent) in addition to the conventional filter is
highly recommended.
B. SINGLE-PIPE OIL LINES
1. Standard burners are provided with single-stage
3450 rpm fuel units with the bypass plug removed
for single-pipe installations.
2. The single-stage fuel unit may be installed single-
pipe with gravity feed or lift. Maximum allowable
lift is 8 feet. See Figure 14.
AIR
VEN
FILL
PIPE
OIL
TANK
FU EL
FLEXIBLE OIL PIPING RECOMMENDED
NEAR BURNER SWING DOOR
PUMP
SHUT-OFF
VALVE IN
MAIN FILTER
RECOMMENDED
FILTER (GARBER
OR EQUIVALENT)
MAXIMUM
ONE PiPE
Figure 14: Single-Pipe Installation
18

TABLE 1:
Lift "H"
(See Figure)
SINGLE STAGE UNITS (3450 RPM)
TWO PIPE SYSTEMS
Maximum Length of Tubing
"H" +"R" (See Figure)
el
1'
2'
3'
4'
5'
6'
7'
8'
9'
10'
11'
12'
13'
14' ---
3/8" OD
Tubing (3 GPH)
84'
78'
73'
68'
63'
57'
52'
47'
42'
36'
31'
26'
21'
1/2" OD
Tubing (3 GPH)
100'
100'
100'
100'
100'
100'
100'
100'
100'
100'
100'
100'
83'
62'
41'
TABLE 2:
Lift "H"
(See Figure)
TWO-STAGE UNITS (3450 RPM)
TWO-PIPE SYSTEMS
Maximum Length of Tubing
"H" + "R" (See Figure)
el
2'
4'
6'
8'
10'
12'
14'
16'
18' ---
3/8" OD
Tubing
93'
85'
77'
69'
60'
52'
44'
36'
27'
1/2" OD
Tubing
100'
100'
100'
100'
100'
100'
100'
100'
100'
76'
C. TWO-PIPE OIL LINES
1. For two-piped systems, where more lift is required,
the two-stage fuel unit is recommended. Table
1 (single-stage) and Table 2 (two-stage) show
allowable lift and lengths of 3/8 inch and 1/2 inch
OD robing for both suction and return lines. Refer
to Figure 15.
OUTSIDE TANK FUEL PUMP ABOVE
BOSOM OF TANK
AIR
VENT
FLEXIBLE
NEAR
FUEL PUMP
RETURN
LINE
OIL PIPING RECOMMENDED
BURNER SWING DOOR
RECOMMENDED
FILTER (GARBER
OR EQUIVALENT)
INLET l
RETUR:N
LINE
Figure 15: Two-Pipe Installation 19

VII. System Start-Up
E
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.
Completely read, understand and follow all
instructions in this manual before attempting
start up.
C. FILL ENTIRE HEAT1NG SYSTEM WITH WATER
O.
2O
F.
G°
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 filled and
oil lines have been tested.
LUBRICATION. Follow instruction on burner and
circulator label to lubricate, ifoil lubricated. Most
motors currently used on residential type burners
employ permanently lubricated bearings and thus do
not require any field lubrication. Water lubricated
circulators do not need field lubrication.
ADJUST CONTROL SETTINGS with burner
service switch turned "ON" and room thermostat set
and vent air from system.
steps below:
1.
See Figures 5 & 6 and follow
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 floor
drain or outdoor area).
4. Starting with one circuit at a time, open zone valve
or valve.
5. Open hose bib.
6. Open fill 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 flow into drain until discharge from
hose is bubble free for 30 seconds.
8. When zone is completely purged of air, close zone
valve or balancing valve. Open the zone valve for
the next zone to be purged. Repeat this step until
all zones have been purged. At completion, open all
zone valves or valves.
10°below room 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 fixed
at 15°F.
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 I buttons (see Figure S1) simultaneously
for three (3) seconds. Press the T button
until the feature requiring adjustment is
displayed (press the 'T' button again and
will display LL (Low Limit on L7224):
•High Limit
• °F -- °C (Toggle)
The maximum operating pressure of this
boiler is 30 psig. Never exceed this pressure.
Do not plug or change pressure relief valve.
9. Close hose bib, continue filling the system until the
pressure gauge reads 12 psig. Close fill valve.
(Note - If make-up water line is equipped with
pressure reducing valve, system will automatically
fill to 12 psig.
10. Open isolation valve in boiler supply piping.
11. Remove hose from hose bib.
CONFIRM that the boiler and system have no water
leaks.
RELAYS
>NSORCON,_CrO
Fiqure S1 :
f°ELD _ERMNALS
SENSOR _{OLE
(HOPJZON_AL MOUN1)
L7248 Circuit Board Lagout -
Horizontal Mount