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New Yorker AP-590U - User Manual

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INSTALLATION, OPERATING
AND SERVICE INSTRUCTIONS
AP-U™ SERIES
STEEL OIL-FIRED BOILER
104338-03 - 12/13
Price - $5.00
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
Boiler Serial Number Installation Date
Heating Contractor Phone Number
Address

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Summary

Installation, Operating and Service Instructions

Important Information

USA BOILERS Standards

Lists relevant US standards for boiler installation and operation.

Hazard Severity Levels

Defines hazard severity levels used throughout the manual.

Safety Warnings and Precautions

Flammable Liquid Storage

Warning against storing flammable liquids near the boiler.

Installation and Maintenance Warnings

General warnings about improper installation, service, and maintenance.

Boiler Placement and Flooring

Guidelines on suitable flooring and clearances for boiler installation.

System Safety and Operation Warnings

Hot Water, Pressure, and Ventilation Safety

Safety warnings regarding hot water, pressure, and ventilation.

I: GENERAL INFORMATION

Boiler Dimensional Data

Illustrates boiler dimensions and connection points.

Boiler Rating Data Overview

Provides physical dimensions and capacity for different boiler models.

I: GENERAL INFORMATION (continued)

Boiler Rating Data Details

Details burner capacity, heating capacity, chimney requirements, and AFUE.

II: PRE-INSTALLATION

Shipment Inspection

Instructions for inspecting the boiler shipment for damage.

Boiler Location and Clearances

Guidance on positioning the boiler and required clearances.

II: PRE-INSTALLATION (continued)

Crate and Skid Removal

Steps for removing the boiler from its shipping crate and skid.

Combustion and Ventilation Air

Guidelines for ensuring adequate air supply for combustion and ventilation.

II: PRE-INSTALLATION (continued)

Combustible Floor Shield Installation

Details for installing the optional floor shield.

III: WATER PIPING AND TRIM

Preventing Oxygen Contamination

Steps to design a piping system preventing oxygen contamination.

Combination Heating;Cooling System Piping

Diagram for integrating with a cooling system.

III: WATER PIPING AND TRIM (continued)

Safety Relief Valve Installation

Instructions for installing the safety relief valve.

Air Vent System

Importance and function of the air vent system.

III: WATER PIPING AND TRIM (continued)

Zoned Heating System Piping Diagram

Diagram for zoned heating systems with a supply circulator.

III: WATER PIPING AND TRIM (continued)

Zone Valve Zoned Heating System Piping

Diagram for zoned heating systems with zone valves.

III: WATER PIPING AND TRIM (continued)

Tankless Heater Piping Guidelines

Recommendations for tankless heater piping.

IV: VENTING

General Venting Guidelines

General rules for vent system installation and chimney requirements.

Chimney Suitability and Deterioration

Discusses chimney suitability, heat loss, and condensation issues.

IV: VENTING (continued)

Recommended Smokepipe Arrangement

Illustrates proper smokepipe setup and chimney needs.

Draft Regulator Location Guide

Shows acceptable and unacceptable draft regulator positions.

V: ELECTRICAL

Electrical Installation Warnings

Electrical installation and grounding requirements.

System Controls Wiring

Guidance on system wiring and controls, including priority zoning.

Thermostat Installation

Instructions for thermostat installation and adjustment.

V: ELECTRICAL (continued)

Cold Start Wiring Diagram

Wiring diagram for cold start control without tankless heater.

V: ELECTRICAL (continued)

Warm Start Wiring Diagram

Wiring diagram for warm start control with tankless heater.

V: ELECTRICAL (continued)

Burner Control Wiring Diagrams

Wiring diagrams for different burner primary controls.

VI: OIL PIPING

General Oil Piping Guidelines

Guidelines for oil supply lines and filters.

Single-Pipe Oil Line System

Information on single-pipe oil line installations.

VI: OIL PIPING (continued)

Two-Pipe Oil Line Systems

Details on two-pipe oil line systems.

VII: SYSTEM START-UP

Pre-Start Installation Inspection

Checklist before initiating burner start-up.

Filling and Venting the Heating System

Procedure for filling and venting the heating system.

VII: SYSTEM START-UP (continued)

Oil Burner Pre-Start Checks

Pre-start checks for the oil burner.

Beckett AFG Burner Specifications

Specifications for Beckett AFG burners.

Riello Burner Specifications

Specifications for Riello 40 Series burners.

VII: SYSTEM START-UP (continued)

Burner Electrode Adjustment

Details on setting burner electrode positions.

Riello Burner Assembly and Nozzle Replacement

Instructions for Riello burner assembly and nozzle replacement.

VII: SYSTEM START-UP (continued)

Riello Burner Setting Diagrams

Diagrams for Riello electrode, turbulator, and pump settings.

VII: SYSTEM START-UP (continued)

Starting and Adjusting the Oil Burner

Steps for starting and adjusting burner settings during operation.

VII: SYSTEM START-UP (continued)

Cad Cell Service and Burner Cut-Off Checks

Information on servicing the cad cell and checking burner cut-off.

Testing Boiler Controls

How to test thermostat and oil primary control operations.

VII: SYSTEM START-UP (continued)

Oil Primary Control Safety Checks

Detailed safety checks for the oil primary control.

VII: SYSTEM START-UP (continued)

High Limit Control Verification

Procedure to verify the high limit control operation.

Operating Control Check (Tankless Heaters)

Verifying operation of controls on boilers with tankless heaters.

VIII: OPERATING

Cold Start Boiler Operation Sequence

Operation sequence for boilers without tankless heaters.

Boiler Control Status Codes

Displays status codes and descriptions for boiler control.

Warm Start Boiler Operation Sequence

Operation sequence for boilers with tankless heaters.

VIII: OPERATING (continued)

Using the Boiler Control Interface

Location and basic use of the boiler control.

Viewing Operating Modes and Settings

How to view boiler status and settings.

Adjusting Boiler Control Parameters

Procedure for adjusting boiler control parameters.

VIII: OPERATING (continued)

Cold Start Boiler Control Adjustment Options

Lists adjustable parameters for cold start controls.

Warm Start Boiler Control Adjustment Options

Lists adjustable parameters for warm start controls.

Detailed Parameter Explanations

Detailed explanations of adjustable parameters.

VIII: OPERATING (continued)

Circulator Pre-Purge Time Example

Example of circulator pre-purge time settings.

Domestic Hot Water Demand Influence

Table showing DHW demand influence on system.

ZC and ZR Terminal Functionality

How ZC/ZR terminals integrate AP-U with other systems.

VIII: OPERATING (continued)

Zone Request Parameter Settings

Table for zone request inputs and circulator status.

External Low Limit Parameter Settings

Table for external low limit control status.

External Low Limit Control Function

How external low limit affects boiler control.

IX: MAINTENANCE & SERVICE INSTRUCTIONS

Water Boiler Filling and Cleaning

Maintenance steps for water boilers.

Boiler System Filling Procedure

Procedure for filling the boiler and system with water.

Boiling Out Boiler and System

Steps for cleaning a new boiler with boil-out compound.

pH and Alkalinity Testing

How to perform pH and alkalinity tests on boiler water.

IX: MAINTENANCE & SERVICE INSTRUCTIONS (continued)

Boiler Storage and Freeze Protection

Warning about unattended boilers and freeze damage.

X: BOILER CLEANING

Firetube and Combustion Chamber Cleaning

Steps for cleaning firetubes and combustion chamber.

Product Safety Information

Refractory Ceramic Fiber Product Safety

Safety information and precautions for RCF products.

Breathing Fiber Particulates and Dust Avoidance

Measures to prevent inhalation of fiber dust.

First Aid Procedures for RCF Contact

First aid steps for contact with RCF materials.

XI: TROUBLESHOOTING

Combustion Issues

Troubleshooting common combustion issues.

Fuel System Issues

Troubleshooting fuel leaks, dirt, water, and cold oil problems.

Flame and Noise Issues

Diagnosing issues based on flame appearance and noises.

XI: TROUBLESHOOTING (continued)

Oil Primary Control Troubleshooting

Troubleshooting burner not coming on or shutting down.

Intelligent Boiler Control Diagnostics

Using the boiler control for diagnostics.

Troubleshooting Guide Table

Guide for diagnosing system conditions and actions.

XI: TROUBLESHOOTING (continued)

Boiler Control Error Code Reference

Lists boiler control error codes and corrective actions.

Service Record

XII: REPAIR PARTS

Obtaining Replacement Parts

How to obtain replacement parts and contact customer service.

Boiler Jacket Parts Diagram

Diagram identifying jacket parts and controls.

XII: REPAIR PARTS (continued)

AP-U Series Boiler Repair Parts List

List of AP-U series boiler repair parts with numbers.

XII: REPAIR PARTS (continued)

Bare Boiler Repair Parts Diagram

Exploded view of bare boiler parts.

XII: REPAIR PARTS (continued)

AP-U Series Boiler Repair Parts List (continued)

Continued list of AP-U series boiler repair parts.

XIII: BECKETT AFG BURNER PARTS

Beckett Burner Parts Contact Information

Contact details for R.W. Beckett Corp. for parts.

Beckett AFG Burner Model Part Cross-Reference

Lists Beckett AFG burner parts for specific boiler models.

XIII: BECKETT AFG BURNER PARTS (continued)

Beckett AFG Burner Diagram

Diagram of Beckett AFG model burner with parts labeled.

XIV: RIELLO 40 SERIES BURNER PARTS

Riello Burner Parts Contact Information

Contact details for Riello for burner parts.

APPENDIX A: LOW WATER CUT OFF (LWCO)

LWCO Installation Safety Warning

Safety warning regarding LWCO installation.

LWCO Installation Location and Type

Recommended locations and types for LWCO installation.

LWCO Piping and Wiring Instructions

Instructions for piping and wiring a LWCO.

APPENDIX A: LOW WATER CUT OFF (LWCO) (continued)

LWCO Testing Procedure

Procedure for testing the LWCO functionality.

Service Record

Service Record

Service Record

Limited Warranties

One Year Limited Warranty

Covers defects for one year from installation.

Five Year Pressure Vessel Limited Warranty

Covers pressure vessel defects for five years.

Lifetime Limited Warranty (Heat Exchanger)

Covers heat exchanger defects for the lifetime of the purchaser.

Warranty Exceptions and Exclusions

Lists conditions voiding the warranty.

Obtaining Warranty Service

Steps to follow when seeking warranty service.

New Yorker AP-590U Specifications

General IconGeneral
BrandNew Yorker
ModelAP-590U
CategoryBoiler
LanguageEnglish

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