INSTALLATION, OPERATING AND SERVICE INSTRUCTIONS AP-U™ SERIES STEEL OIL-FIRED BOILER For service or repairs to boiler, call your heating contractor. When seeking information on boiler, provide Boiler Model Number and Serial Number as shown on Rating Label. Boiler Model Number AP- U Heating Contractor Boiler Serial Number Installation Date Phone Number Address 104338-03 - 12/13 Price - $5.
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: USA BOILERS A.
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.
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.
I: general information Figure 1: AP-U Series Boiler Dimensional Data table 1: dimensional data (See Figure 1) Boiler Model Number AP-490U AP-590U AP-690U AP-790U Dimension ‘A’ Water Capacity (gallons) Approx. Shipping Weight (lb.) 10.7 290 10.1 300 16.3 340 15.4 355 34-9/16 41” Note: Maximum Working Pressure: Water 30 PSI shipped standard.
I: general information (continued) Table 2: Rating Data Boiler Model No. Burner Capacity DOE Heating Capacity MBH GPH MBH Minimum Chimney Requirements Round In. Dia. Rectangle In. x In. Height Ft. AFUE % AP-490U 0.75 105 88 77 6 8x8 15 84 AP-590U 1.00 140 119 103 6 8x8 15 84 AP-690U 1.10 154 131 114 6 8x8 15 84 AP-790U 1.
II: Pre-Installation 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.
II: Pre-Installation (continued) C. REMOVE CRATE 1. Remove all fasteners at crate skid. 2. Lift outside container and remove all other inside protective spacers and bracing. Remove accessory parts carton. D. REMOVE BOILER FROM SKID 1. Remove four (4) hex head lag screws, attaching boiler base plate to shipping skid. 2. Carefully, walk boiler to the edge of the skid. Tilt the boiler back, allowing boiler base edge to rest on the floor, then, remove the skid. 3. Position boiler for final installation. E.
Ii: Pre-Installation (continued) INSTALLATION INSTRUCTIONS FOR OPTIONAL SHIELD REQUIRED FOR COMBUSTIBLE FLOOR This shield for combustible floors is intended for use only with the following New Yorker oil-fired boilers: Use Part Number 6183504 for the following models: AP-490U AP-590U AP-690U AP-790U ADDS 4-3/16” TO BOILER HEIGHT 1) Place shield on combustible floor with “TOP” surface upward and “FRONT” surface directly below the expected position of the oil burner.
III: Water 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. A.
III: Water Piping and Trim (continued) line as illustrated in Figures 6A and 6B in order to regulate water flow for maintenance of higher boiler water temperature. Set the bypass and return valves to a half throttle position to start. Operate boiler until the system water temperature reaches its normal operating range. Adjust the valves to maintain 180°F to 200°F boiler water temperature and greater the 120°F return temperature. Adjust both valves simultaneously.
Figure 6A: Recommended Boiler Piping for Circulator Zoned Heating Systems, Supply Side Circulator III: Water Piping and Trim (continued)
Figure 6B: Boiler Piping for Zone Valve Zoned Heating Systems, Supply Side Circulator III: Water Piping and Trim (continued)
iII: Water Piping and Trim (continued) THE FOLLOWING GUIDELINES SHOULD BE FOLLOWED WHEN PIPING THE TANKLESS HEATER: 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. 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.
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 fire officials about restrictions and installation inspection in your area. 2. The AP-U Series is designed to be vented into a fireclay tile-lined masonry chimney or chimney constructed from type-L vent or a factory built chimney that complies with the type HT requirements of UL103.
IV: Venting (continued) Figure 8: Recommended Smokepipe Arrangement and Chimney Requirements 16 Figure 9: Draft Regulator Locations
V: Electrical 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.
Refer to Figure 12 for Schematic wiring diagram of appropriate burner and oil primary control option Figure 10: Schematic Wiring Diagram, without Tankless Heater, Cold Start Control (Beckett and Riello Burners) V: Electrical (continued)
Refer to Figure 12 for Schematic wiring diagram of appropriate burner and oil primary control option Figure 11: Schematic Wiring Diagram, with Tankless Heater, Warm Start Control (Beckett and Riello Burners) V: Electrical (continued)
V: Electrical (continued) NOTE: APPLY THIS BURNER SCHEMATIC TO APPROPRIATE STEAM OR WATER BOILER CONTROL SCHEMATIC, REFER TO FIGURES 10 AND 11 NOTE: APPLY THIS BURNER SCHEMATIC TO APPROPRIATE STEAM OR WATER BOILER CONTROL SCHEMATIC, REFER TO FIGURES 10 AND 11 Figure 12: Schematic Wiring Diagrams For All Burner Options w/Various Oil Primary Controls 20
VI: Oil Piping A. General. B. Single-pipe Oil Lines. 1. Use flexible oil line(s) so that burner can be removed without disconnecting the 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 firing rate application to prevent nozzle fouling. 1. Standard burners are provided with single-stage 3450 rpm fuel units with the bypass plug removed for single-pipe installations. 2.
VI: Oil Piping (continued) Table 4: Single Stage Units (3450 RPM) Two Pipe Systems Lift "H" (See Figure) Maximum Length of Tubing "H" + "R" (See Figure) 3/8" OD Tubing (3 GPH) 1/2" OD Tubing (3 GPH) 0' 84' 100' 1' 78' Table 5: Two-Stage Units (3450 RPM) Two Pipe Systems Lift "H" (See Figure) 3/8" OD Tubing (3 GPH) 1/2" OD Tubing (3 GPH) 0' 93' 100' 100' 2' 85' 100' 2' 73' 100' 4' 77' 100' 3' 68' 100' 6' 69' 100' 4' 63' 100' 8' 60' 100' 5' 57' 100' 10' 52' 100' 6' 5
VII: System Start-Up A. ALWAYS INSPECT INSTALLATION BEFORE STARTING BURNER. 1. Verify that the venting, water piping, oil piping, and electrical system are installed properly. Refer to Installation Instructions contained in this manual. 2. Confirm all electrical, water and oil supplies are turned off at the source and that the vent is clear from obstructions. WARNING Completely read, understand and follow all instructions in this manual before attempting start up. B. FILL HEATING SYSTEM WITH WATER.
VII: System Start-Up (continued) 4. WATER BOILERS WITH TANKLESS HEATERS are equipped with a Warm Start Intelligent Oil Boiler Control (Warm Start Boiler Control). The Warm Start Boiler Control is factory programmed with a High Limit setpoint of 180°F. The High Limit setpoint is adjustable between 140°F and 240°F. High Limit Differential is factory programmed at 10°F. Additionally, the Warm Start Boiler Control is factory programmed with a Low Limit setpoint of 110°F.
VII: System Start-Up (continued) Figure 15: Electrode / Head Setting • Remove the AIR TUBE COVER PLATE (5) by loosening the retaining SCREW (4) (Two SCREWS-Model F5). • Loosen SCREW (2), and then slide the complete drawer assembly out of the combustion head as shown. ii. Installation: To insert drawer assembly, reverse the procedure in Step i above. b. Nozzle Replacement, refer to Figure 17. i. Remove the NOZZLE ADAPTER (2) from the DRAWER ASSEMBLY by loosening the SCREW (1). ii.
VII: System Start-Up (continued) WARNING: Do not operate a single line system with the by-pass plug installed. Operating a single line system with the by-pass plug installed will result in damage to the pump shaft seal. Note: Pump pressure was factory pre-set but must be checked at time of burner start-up. A pressure gauge is attached to the PRESSURE/ BLEEDER PORT (7) for pressure readings. Two PIPE CONNECTORS (4) are supplied with the burner for connection to either a single or two-line system.
VII: System Start-Up (continued) G. START OIL BURNER. H. ADJUST OIL BURNER WHILE OPERATING. 1. Open vent fitting on fuel pump. (flame present) 2. TURN ‘ON’ BURNER service switch and allow burner to run until oil flows from vent fitting in a SOLID stream without air bubbles for approximately 10 seconds. 1. SET ROOM THERMOSTAT about 10°F below room temperature. 2. PRESS RED RESET BUTTON on Oil Primary Control and release. 3.
VII: System Start-Up (continued) 7. CAD CELL LOCATION AND SERVICE The burner is supplied with a cadmium sulfide flame detector mounted at the factory, mounted on the bottom of the electronic ignitor. See Figure 22. To service cad cell or to replace the plug in portion, swing open the ignitor. After service is complete, be sure to fasten down the ignitor. I. CHECK FOR CLEAN CUT OFF OF BURNER. 1.
VII: System Start-Up (continued) successfully satisfy a call for heat, the 7505 locks out. iv. Limited Reset (Restricted Mode): In order to limit the accumulation of unburned oil in the combustion area, the control can only be reset three times. The reset count returns to zero each time a call for heat is successfully completed. v. T-T Jumper: Select models have preinstalled T-T jumper. Do not remove jumper.
VII: System Start-Up (continued) WARNING Cad Cell Jumper must be removed after this check. 4. CHECK HIGH LIMIT a. Adjust system thermostat(s) to highest setting. K. IF CONTROLS MEET REQUIREMENT outlined in Paragraph I. 1. Allow boiler to operate for approximately 30 minute, confirm the boiler and system have no leaks. b. Allow burner to run until boiler water temperature exceeds high limit setting. The burner should shut down and circulators continue running. L. IF CONTROLS DO NOT MEET c.
VIII: operating A. WATER BOILERS SEQUENCE OF OPERATION 1. Water Boilers Without Tankless Heaters (Cold Start), Sequence Of Operation: a. The AP-U Boiler is equipped with an Intelligent Oil Boiler Control (Cold Start Boiler Control). The boiler control replaces the traditional electronic aquastat and circulator relays and adds energy saving thermal purge features. Energy is saved by starting the circulator and delaying the burner start when there is residual heat available in the boiler. b.
VIII: operating (continued) d. If the thermostat is not satisfied and the Operating Setpoint (SP) is reached the system circulator will continue to operate and the burner will stop. When the boiler water temperature drops below the setpoint less the differential setting the burner will restart. Press and release the “I” key on the Boiler Control to change from one parameter to the next. Each setting will alternately flash between the relevant display code and its corresponding value.
VIII: operating (continued) Cold Start Boiler Control Adjustment Mode Options HL_ HdF ZC_ Or_ PP_ St_ Pt_ f-C bac 140-240°F 10-30°F dh, ZR or ELL 0-10 minutes 2-20 minutes 140 - 180°F On or Off F or C Adjust High Limit Setting Adjust High Limit Differential ZC and ZR Terminal Function Pump Overrun Time Pump Pre-purge Time Start Temperature Priority Time Select degrees F or C Mode Back to Operating Mode Warm Start Boiler Control Adjustment Mode Options HL_ LL_ 140-240°F 110-220°F Ldf 10-25°F ZC_ Or_
VIII: operating (continued) Table 9: circulator pre-purge time example, parameter pp_= 2 minutes Call for Heat TT= on ZC and ZR Terminal Boiler Function Temp. (ZC_) -- Boiler Status, (B1 Output) < 140 Start with no delay TT = on -- >140 Start after 2 minute delay ZR = on ZC_ = ZR <140 Start with no delay ZR = on ZC_ = ZR >140 Start after 2 minute delay ZR = on ZC_ = DH <140 Start with no delay ZR = on ZC_ = DH >140 Start with no delay g.
VIII: operating (continued) Table 11: zone request, parameter zc_= zr Call for Heat T-T ZR Input Input off on on off off off on on Circulator Status C1 ZC Output Output off on on off off off on on ii. When is set equal to Zone Request () When there is no IWH the Cold Start Boiler Control “ZC” output may be configured to control a second heating zone. This is particularly helpful when the home uses only two heating zones. The boiler control replaces the need for a two circulator zone panel.
IX: maintenance & service Instructions A. WATER BOILERS: 1. Filling of boiler and system. General — In a hot water heating system, the boiler and entire system (other than the expansion tank) must be full of water for satisfactory operation. Water should be added to the system until the boiler pressure gauge registers 12 psi. To insure that the system is full, water should come out of all air vents when opened. 2. Boiling Out of Boiler and System.
IX: maintenance & service Instructions (continued) 4. Always keep the manual fuel supply valve shut off if the burner is shut down for an extended period of time. 5. To recondition the heating system in the fall season after a prolonged shut down, follow the instructions outlined in Section VII, System Start-Up, Paragraphs A through M. WARNING This boiler contains controls which may cause the boiler to shut down and not restart without service.
X: boiler Cleaning NOTICE BURNER SHUTDOWN: Open Service Switch to turn off burner. Manual Oil Supply Valve should be closed and Electric Service to boiler turned off if boiler will not be operated for an extended period of time. A. General. Inspection service and cleaning should be conducted annually. Turn off electric power and close oil supply valve while conducting service or maintenance. B. Firetubes and Combustion Chamber. (See Figure 26) 38 1. CLEAN THE FIRETUBES a.
Important Product Safety Information Refractory Ceramic Fiber Product Warning: The Repair Parts list designates parts that contain refractory ceramic fibers (RCF). RCF has been classified as a possible human carcinogen. When exposed to temperatures about 1805°F, such as during direct flame contact, RCF changes into crystalline silica, a known carcinogen. When disturbed as a result of servicing or repair, these substances become airborne and, if inhaled, may be hazardous to your health.
XI: TROUBLESHOOTING A. COMBUSTION 1. NOZZLES — Although the nozzle is a relatively inexpensive device, its function is critical to the successful operation of the oil burner. The selection of the nozzle supplied with the AP-U boiler is the result of extensive testing to obtain the best flame shape and efficient combustion. Other brands of the same spray angle and spray pattern may be used but may not perform at the expected level of CO2 and smoke.
Xi: TROUBLESHOOTING (continued) B. OIL PRIMARY CONTROL (Oil Primary) f. CAD cell defective. 1. Burner (Oil Primary) will not come on. a. No power to Oil Primary. b. Oil Primary is in lockout or restricted mode. Press reset button for one (1) second to exit lockout. If control has recycled three times within the same call for heat, it will enter into restricted mode. To reset from restricted mode, refer to Section VII, Paragraph I, Step 2 for details. c. CAD cell seeing light. d. CAD assembly defective. e.
Xi: TROUBLESHOOTING (continued) b. If the Boiler Control detects an error it will flash "" (boiler control error) followed by a number. Use this text and number to identify the boiler problem and corrective action in Table 14 below.
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XII: Repair Parts All AP-U™ Series Repair Parts may be obtained through your local New Yorker Wholesale distributor. Should you require assistance in locating a New Yorker distributor in your area, or have questions regarding the availability of New Yorker products or repair parts, please contact: New Yorker Boiler Co., Inc., P.O. Box 10, Hatfield, PA 19440-0010, Phone: (215) 855-8055 or Fax: (215) 855-8229, ATTN: Customer Service Department.
XII: Repair Parts (continued) AP-U Series Boiler Repair Parts ITEM description PART NUMBER QTY.
Figure 28: AP-490U thru 790U Bare Boiler Repair Parts NOTE: When ordering parts always give the serial number and model number shown on the boiler.
XII: Repair Parts (continued) AP-U Series Boiler Repair Parts (continued) ITEM NO. DESCRIPTION PART NO. QTY.
XIII: Beckett AFG Burner Parts for AP-U Series Boilers FOR REPLACEMENT OIL BURNER PARTS, CONTACT YOUR WHOLESALER OR THE BURNER MANUFACTURER: R. W. BECKETT CORP. P. O. BOX 1289 ELYRIA, OHIO 44036 1-800-645-2876 NOTE: When ordering parts always give the serial and model numbers shown on the boiler and burner. Also, provide the name of the part(s) and part(s) number as listed below.
XiII: Beckett AFG Burner Parts for AP-U Series Boilers (continued) Ordering Information for Quality Replacement Parts Figure 29: BECKETT AFG MODEL BURNER (Fixed ‘F’ Head) 49
XIV: Riello 40 series Burner Parts for AP-U Series Boilers NOTE: When ordering parts always give the serial and model numbers shown on the boiler and burner. Refer to Models F3 & F5 Installation Manual, Riello 40 Series Residential Oil Burners (C6501010) for an exploded view of the burner and a list of spare parts.
appendix a: Low Water Cut Off (LWCO) on Hot Water Boilers WARNING DO NOT ATTEMPT to cut factory wires to install an aftermarket Low Water Cut Off (LWCO). Only use connections specifically identified for Low Water Cut Off. In all cases, follow the Low Water Cut Off (LWCO) manufacturer's instructions. When A low water cutoff is required to protect a hot water boiler when any connected heat distributor (radiation) is installed below the top of the hot water boiler (i.e.
appendix a: Low Water Cut Off (LWCO) on Hot Water Boilers (continued) A 24 VAC LWCO is used primarily for gas fired boilers where a 24 volt control circuit exists within the boiler. However, a 24 VAC LWCO can only be used if the boiler manufacturer has provided piping and wiring connections and instructions to allow for this application. 52 How to Test Shut off fuel supply. Lower water level until water level is BELOW the LWCO. Generate a boiler demand by turning up thermostat.
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SERVICE RECORD DATE SERVICE PERFORMED 55