New Yorker microTEKDV Service manual

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INSTALLATION, OPERATING AND
SERVICE INSTRUCTIONS FOR
microTEKDV DIRECT VENT
OIL FIRED BOILER
8141965R6-2/06 Price - $3.00

2
IMPORTANT INFORMATION - PLEASE READ THIS PAGE CAREFULLY
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.
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3
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4
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5
Figure 1: microTEKDV Packaged Boiler
Table of Contents
I. Pre-Installation .......................................................6
II. Unpack Boiler.........................................................7
III. Water Piping and Trim............................................9
IV. Venting/Air Intake Piping.....................................12
V. Electrical and Sequence of Operations..................18
VI. Oil Piping .............................................................20
VII. System Start-up.....................................................22
VIII. Service and Cleaning.............................................26
IX. Repair Parts ..........................................................29
X. Appendix
Low Water Cut Off................................................35
Water Content: 6.1 Gallons

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 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 in front of final position before removing
crate. See Figure 1. Boiler's approximate shipping
weight is 325 pounds.
1. LOCATE so that vent pipe will be short and direct.
Refer to Section V. A., General Venting Guidelines.
2. BOILER IS SUITABLE FOR INSTALLATION
ON COMBUSTIBLE FLOOR. Boiler cannot be
installed on carpeting.
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.
4. PROVIDE SERVICE CLEARANCE of at least
24” at front of boiler for servicing.
5. For minimum clearances to combustible materials,
see Figure 2.
I. Pre-Installation
C.Provide combustion air supply to accommodate
proper combustion of oil. Local and national codes may
apply and should be referenced.
1. In unconfined spaces (basement) in buildings of
conventional frame, brick, or stone construction,
infiltration normally is adequate to provide air for
combustion. An unconfined space is a space whose
volume is greater than or equal to 50 cubic feet
per 1000 BTUH of the combined input of all air
consuming appliances in the space.
2. In a confined space, combustion air may be ducted
directly from the outdoors to the burner. Refer to
Section IV for installation of air intake duct to the
burner.
D. Ventilation air must be provided to maintain the
ambient temperature at safe limits. Local and national
codes may apply and should be referenced.
1. In unconfined spaces (basement) in buildings of
conventional frame, brick, or stone construction,
infiltration normally is adequate to provide air for
ventilation.
2. In confined spaces (closet, etc.) two permanent
openings, one near the top of the enclosure and one
near the bottom, shall be provided. Each opening
shall have a free area of not less than 1 sq. inch per
1000 BTUH of the total input of all appliances in the
space.
E. Do not install boiler where gasoline or other
flammable vapors or liquids, or sources of
hydrocarbons (i.e. bleaches, cleaners, chemicals, sprays,
paint removers, fabric softeners, etc.) are used or stored.

7
II. Unpack Boiler
NOITUAC
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A.Remove Crate
1. Remove all fasteners at crate skid.
2. Lift outside container and remove all other inside
protective spacers and bracing. Remove vacuum
relief valve and miscellaneous trim bag containing
safety/relief valve, and pipe fittings.
B.Removal of Boiler From Skid
1. Boiler is secured to base with 2 bolts, 1 at left front
and 1 at right rear. Remove both bolts.
2. Tilt boiler, "walk" boiler backward, and set rear
legs down on floor. Tilt boiler backward, pull skid
forward and set front legs down on edge of skid.
Install close nipple, tee, and plug in return coupling.
See Section III and Figure 5. Point tee toward
permanent return location.
3. Tilt boiler backward and remove skid. Be careful not
to damage Burner or Jacket.
C. Determine Proper Hinge Location for Burner Swing
Door. Boiler is shipped with hinges on left side.
Approximately 12 inches are required on the hinge side
for burner clearance. If there will be less than 12 inches
from left side of boiler to wall, move hinges to right
side (refer to Paragraph D).
D. Hinge Location Change (if required) (refer to Figure
3).
1. Pull 2 halves of Burner Swing Door Interlock apart.
Swing Door Interlock is connected to R-W terminals
on R7184P Control. Lift Honeywell R7184P Control
off of Burner Junction Box and disconnect wiring
harness from burner.
2. Remove 8 sheet metal screws from jacket. Remove
rear jacket box and bend both sides of Jacket
Wrapper up, see Figure 20.
3. Remove 2 (two) 5/16" - 18 x 3" long hex head cap
screws and flat washers from right side of door.
Remove 2 hairpin cotter pins and 2 hinge pins
from hinges on left side of door and remove Door
Assembly from boiler. Inspect Front and Rear Door
Insulation Pieces and Combustion Chamber Liner,
see Paragraph G.
4. Remove 4 hex nuts from bolts that attach hinges and
hinge spacers to left side of Tubesheet. Remove 4
hex head cap screws that attach hinges to door.
5. Attach 2 hinge brackets & spacers to Tubesheet and
2 hinge brackets to Door on right side of boiler. 3
Holes in each Hinge Bracket must line up with 3
matching holes in Spacer, Tubesheet or Door. See
Figure 3. Tighten hex nuts, bolts and screws by hand
only.
6. Replace door assembly. Hinge brackets attached to
door must rest on top of hinge brackets attached to
tubesheet. See Figure 3. Slide hinge pins through
hinges from top and install cotter pins. Close door
and install 5/16" - 18 x 3" long hex head cap screws
through flat washers and left side of door and into
tapped holes in tubesheet. Tighten all hex nuts,
bolts and screws. When door is installed properly, it
is parallel to Tubesheet when viewed from top and
sides.
7. Bend sides of Jacket Wrapper down and attach 2
Jacket Straps to 4 slots at bottom of Jacket Wrapper
sides with sheet metal screws. Install Rear Jacket
Box with 4 sheet metal screws. See Figure 20.
8. Connect wiring harness to burner Junction Box
and install Honeywell R7184P Control, see Wiring
Diagram, Figure 15.
Reconnect Swing Door Interlock.
E.Install Boiler Control.
1. Pull bulb and capillary tube out of hole in back of
control. Insert bulb in immersion well on top of
boiler and secure control with set screw in control.
2. Secure flexible conduit to Jacket Wrapper side with
conduit clamp and sheet metal screw. Conduit must
be on same side of boiler as Swing Door hinges.
F.Move boiler to permanent position by sliding or
walking.
G.Inspect Front and Rear Door Insulation and
Combustion Chamber Liner.
1. OPEN BURNER SWING DOOR on front of
boiler. Use flashlight to inspect insulation secured to
front and rear doors. Inspect ceramic fiber blanket
secured to bottom of combustion chamber. Inspect
inner and outer door gaskets. Replace any damaged
pieces.

8
Figure 2: Minimum Clearances to Combustible Materials
Figure 3: Proper Hinge Bracket Installation and Assembly

9
III. Water Piping and Trim
NOITUAC
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A. Design and install boiler and system piping to
prevent oxygen contamination of boiler water.
NOITUAC
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There are many possible causes of oxygen
contamination such as:
1. Addition of excessive make-up water as a result of
system leaks.
2. Absorption through open tanks and fittings.
3. Oxygen permeable materials in the distribution
system.
In order to insure long product life, oxygen sources
should be eliminated. This can be accomplished by
taking the following measures:
1. Repairing system leaks to eliminate the need for
addition of make-up water.
2. Eliminating open tanks from the system.
3. Eliminating and/or repairing fittings which allow
oxygen absorption.
4. Use of non-permeable materials in the distribution
system.
5. Isolating the boiler from the system water by
installing a heat exchanger.
B. Connect system supply and return piping to boiler.
See Figure 5. Also consult I=B=R Installation and
Piping Guides. Maintain minimum ½ inch clearance
from hot water piping to combustible materials.
1. 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 6. Also
consult I=B=R Installation and Piping Guides.
2. 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.
3. If boiler is used with a New Yorker Mate Indirect-
Fired Domestic Water Heater, install the New Yorker
Mate as a separate heating zone. Refer to the New
Yorker Mate Installation, Operating, and Service
Instructions for additional information.
NOITUAC
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4. 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 5 and 7 in
order to regulate water flow for maintenance of
higher boiler water temperature.
Set the by-pass 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 than 120°F return
temperature. Adjust both valves simultaneously.
Closing the boiler return valve while opening
the by-pass valve will raise the boiler return
temperature. Opening the boiler return valve while
closing the by-pass valve will lower the boiler return
temperature.
5. A hot water boiler installed above radiation level
must be provided with a low water cutoff device as
part of the installation.
If a low water cut-off is required, it must be
mounted in the system piping above the boiler.
The minimum safe water level of a hot water boiler
is just above the highest water containing cavity of
the boiler; that is, a hot water boiler must be full of
water to operate safely.
C. Install Safety Relief Valve. See Figures 5 and 7.
Safety Relief Valve must be installed with spindle in
vertical position. Installation of the relief valve must
be consistent with the ANSI/ASME Boiler and Pressure
Vessel Code, Section IV.
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10
Figure 5: Recommended Boiler Piping for Zoning with Valves
D.Install Drain Valve in return piping. See Figure 5.
E. Oil, grease, and other foreign materials which
accumulate in new hot water boilers 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.
F. 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.
G. Fill entire heating system with water and vent air
from system. Use the following procedure on a Series
Loop System equipped with zone valves. (See Figure
5).
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 below
isolation valve in boiler supply piping. (Note
- Terminate hose in five gallon bucket at a suitable
floor drain or outdoor area).
4. Starting with one circuit, open zone valve.
5. Open hose bib.
6. Open fill valve (Make-up water line should be
located directly above isolation valve in boiler
supply piping).
7. Allow water to overflow from bucket until discharge
from hose is bubble free for 30 seconds.
8. Open zone valve to the second zone to be purged,
then close the first. Repeat this step until all zones
have been purged, but always have one zone open.
At completion, open all zone valves.
9. Close hose bib, continue filling the system until
the pressure gauge reads 12 psi. Close fill valve.
(Note - If make-up water line is equipped with
pressure reducing valve, system will automatically
fill to 12 psi.
10.Open isolation valve in boiler supply piping.
11.Remove hose from hose bib.

11
Figure 6: Recommended Piping for Combination Heating & Cooling (Refrigeration) Systems
Figure 7: Recommended Boiler Piping for Zoning with Circulators

12
IV. Venting / Air Intake Piping
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 microTEKDV Series is designed as a Direct
Vent boiler. In this configuration, all air for
combustion is supplied directly to the burner
from outdoors and flue gases are vented directly
outdoors (through wall). See Figures 10 and
11. The microTEKDV may be side-wall vented
with combustion air supplied from indoors. This
configuration may be used in installations where
infiltration provides adequate air for combustion
and ventilation. Flue gases are still vented directly
outdoors (through wall).
3. For minimum clearances to combustible materials
refer to Figure 2.
4. Maximum wall thickness that vent terminal may be
installed through is 12 inches.
GNINRAW
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5. Vent Terminal Location (see Figure 8). Locate vent
terminal so vent pipe is short and direct. The vent
terminal must be located:
a. Not less than 12 inches above grade plus snow
accumulation.
b. Not less than 4 feet below, 4 feet horizontally,
or 1 foot above any door, window, or gravity air
inlet.
c. Not less than 3 feet above any forced air inlet
located within 10 feet.
d. Not less than 2 feet from an adjacent building.
e. Not less than 7 feet above a public walkway.
NOITUAC
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egamadtoosnitluseryamrenrubdetsujda
.esuohfoedisot
Figure 8: Vent Terminal Location

13
6. Intake Terminal Location (Direct Vent only) -
Locate Air Intake Terminal not less than 12 inches
to the left, right, or bottom of the vent terminal. Do
not locate air intake terminal above vent terminal.
Intake terminal must be at least 12 inches above
grade plus snow accumulation. See Figure 9.
7. The microTEKDV must be vented with 4" Z-Flex
Direct Oil™ Vent. 20 feet is the maximum vent
length allowed. The vent pipe is available in 10 and
20 foot lengths. Table 1 lists vent part numbers.
Figure 9: Intake Terminal Location
Table 1: Vent Pipe Part Numbers
8. The vent system must be completed with the Direct
Oil™ Vent Kit, which is shipped with the boiler.
Components of this kit are listed in the Repair Parts
Section of this manual.
REGNAD
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.gnissimrodeyarf,degamad
B. Vent Installation (Direct Vent and Side-Wall Vent)
1. Install Vent Terminal. See Figure 10.
a. After determining the location from previous
Section, cut an opening in the wall for the vent
terminal.
• Combustible wall: 8 inches diameter hole
is required to maintain a 1 inch clearance to
combustible materials.
• Non-combustible wall: 6½ inches diameter
hole is required.
b. Secure 10" square trim plate to outside wall.
c. Insert the vent terminal through the opening until
the stop bead rest against the trim plate.
d. Slide the 10" square inside trim plate assembly
(fitted with gear clamp) onto the terminal pipe.
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14
Figure 10: Vent Installation
Figure 11: Vent Connector, Un-Assembled

15
Figure 13: Air Intake Installation
Figure 12: Vent Connector, Assembled

16
e. Secure the inside trim plate to inside wall.
f. Tighten the gear clamp to the terminal pipe.
g. Seal all external joints with a weatherproof
caulk.
2. Cut vent pipe to length with a hack saw.
3. Install Vent Connector/Appliance Adaptor. See
Figures 11 and 12.
a. Apply a continuous bead of high temperature
adhesive/sealant (supplied with boiler) around
outside of corrugated pipe of vent connector.
b. Twist vent connector into end of vent pipe.
Turn the connector counter-clockwise until it is
engaged approximately 4 inches into the inner
vent pipe and the outer collar of the connector
overlaps the outside of the vent pipe.
c. Tighten the gear clamp on the outer collar of the
connector.
d. Repeat steps a. through c. with the appliance
adapter.
4. Connect vent pipe to boiler.
a. Apply a continuous bead of high temperature
adhesive/sealant (supplied with boiler) to inside
of appliance adapter (approximately ½ inch from
end).
b. Slip appliance adapter over boiler flue collar and
tighten gear clamp.
5. Connect vent pipe to terminal.
a. Carefully slide insulation sleeve over vent
connector and vent pipe until gear clamp on
small end of connector can be accessed.
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b. Apply a continuous bead of high temperature
adhesive/sealant (supplied with boiler) on inside
of cent connector (approximately ½ inch from
end).
c. Clip connector over vent terminal until it is fully
engaged. Then tighten gear clamp.
d. Slide insulation sleeve over terminal connection
so that connector is completely covered.
e. Secure each end of insulation sleeve with the
gear clamps provided.
6. Secure vent pipe in position with pipe straps.
a. All horizontal runs must rise at least ¼ inch per
foot toward vent terminal.
b. Avoid any sags or dips in vent pipe.
C. Air Intake Installation (Direct Vent only)
See Figure 13.
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1. General
a. Use 4 inch diameter single wall metal pipe and
fittings available at most heating distributors.
Maximum allowable air intake length is 40
equivalent feet. Each elbow is equal to 6
equivalent feet.
b. Start at Burner. Work toward air intake terminal.
c. Maintain minimum of ¼ inch per foot slope in
horizontal run to air intake terminal. Slope down
toward air intake terminal.
d. Seal all joints gas-tight, using silicone caulk or
self-adhesive aluminum tape.
2. After determining location, cut a hole in the wall to
accept 4 inch air intake pipe.
3. Remove the black plastic inlet cover from the right
side of the Beckett AFII burner.
4. Mount the vacuum relief valve tee assembly or 90°
elbow into the burner inlet ring. See Figure 13.
a. Secure with at least three (3) sheet metal screws
evenly spaced around the burner inlet ring.
b. Assemble the vacuum relief valve balance
weight onto the gate. Refer to the vacuum relief
valve manufacturer's instructions.
c. Mount the vacuum relief valve assembly into the
tee and fasten with a screw and nut in collar tabs.
To ensure proper operation, the gate must be
level across the pivot point and plumb. Refer to
vacuum relief valve manufacturer's instructions.
5. Install remainder of air intake, securing each joint
with at least three (3) sheet metal screws evenly
spaced.

17
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6. Install air intake terminal. See Figure 13.
7. Seal all external joints with weatherproof caulk.
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D. Air Intake Installation (Indoor Air for Combustion)
1. Remove the black plastic inlet cover from the right
side of the Beckett AFII burner.
2. Attach the Air Intake Terminal directly to the burner
intake collar.
3. Discard the Vacuum Relief Valve Assembly.
Alternate to 1., 2. and 3.:
Keep the black plastic inlet cover in place and
discard the Air Intake Terminal and the Vacuum
Relief Valve.

18
V. Electrical and Sequence of Operations
A. Electrical
1. Install wiring and ground boiler in accordance with
requirements of 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 must be run from
the main electrical service with an over-current
device/disconnect in the circuit. A service switch is
recommended and may be required by some local
jurisdictions.
3. Wiring should conform to Figure 15.
B. Sequence of Operations
1. General.A call for heat by the thermostat energizes
the L8148A limit control which in turn energizes the
R7184P primary control to turn on the burner. The
circulator will operate as long as there is a call for
heat. If the call for heat is not satisfied and the high
limit setting is reached, the circulator will continue
to operate, and the burner will stop until the high
limit circuit is closed by a drop in boiler water
temperature.
2. L8148A Combination Limit control.
The switching action within the L8148A control has
one setting, the high limit. The switching relay is
controlled by the low voltage room thermostat. On
a call for heat, the relay contacts close to complete
the line voltage circulator circuit and also the burner
circuit if the boiler water temperature is below the
high limit setting. The high limit switch shuts off
the burner if boiler water temperature exceeds the
high limit setting. See Figure 14.
3. R7184P Oil Primary Control.
The R7184P operates the oil burner motor, solenoid
oil valve, and the ignition transformer in response to
a call for heat from the L8148A limit control.
a. A call for heat will energize the burner motor and
ignition transformer.
b. After a 15 second pre-purge period, in which
time a draft is established in the flueways, the oil
valve is opened.
c. If the burner ignites within 15 seconds from
the time the oil valve opens and the CAD cell
senses a flame, the ignitor is de-energized and
the burner will operate until the call for heat
is satisfied or the setting of the high limit is
reached.
d. A manual reset button is provided to reset the
safety switch after lockout.
e. When the call for heat ends, or the CAD cell
fails to sense a flame, the oil valve will close.
The combustion blower will continue to operate
for a postpurge period of approximately two (2)
minutes.
4. CAD Cell.
The Beckett AFII burners used on the microTEKDV
Series are supplied with a C554A Cadmium Sulfide
(cad cell) Flame Detector to monitor the burner
flame and shut down the burner on ignition failure
or on flame failure during the run cycle. On either
failure, the manual reset button on the R7184P will
be tripped.
Figure 14: Control Differential

19
Figure 15: Schematic Wiring Diagram

20
VI. Oil Piping
A. General
1. Use flexible oil line(s) so that Swing Door can be
opened without disconnecting oil supply.
2. A supply line fuel oil filter is recommended as a
minimum for all firing rates but a pleated paper fuel
oil filter is recommended for the lowest (.6 GPH)
firing rate application to prevent nozzle fouling.
3. Use Flared fittings only. Do not use compression
fittings.
4. Use of a high efficiency micron oil filter (Garber
or equivalent) in addition to 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 16.
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