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New Yorker AP-790U - 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

Pre-Installation

Inspect Shipment

Check for shipping damage and file claims promptly with the carrier.

Locate Boiler

Position the boiler near its installation site, considering vent pipe connections and clearances.

Provide Combustion and Ventilation Air

Ensure adequate air supply for combustion and ventilation based on room volume and appliance input.

Combustible Floor Installation Instructions

Install optional floor shield for combustible floors following specific guidelines and clearances.

Water Piping and Trim

Design a Piping System

Design system to prevent oxygen contamination and frequent water additions.

Install Safety Relief Valve

Install safety relief valve vertically as per code and ensure discharge piping is safe.

Connect Tankless Heater Piping

Connect tankless heater piping as shown in Figure 7, with a mixing valve.

Flow Regulation Guidelines

Install flow regulator in cold water line to match heater rating and limit pressure variations.

Tempering of Hot Water

Install automatic mixing valve to prevent scalding and save hot water.

Venting

General Venting Guidelines

Install vent system according to instructions and local codes, ensuring proper draft.

AP-U Series Venting Requirements

Vent AP-U series into approved chimney, considering heat loss and chimney deterioration.

Electrical

General Electrical Installation

Install wiring and ground boiler according to codes, using a separate circuit and disconnect.

System Controls and Wiring

Follow NEC/local codes for wire size, use anti-short bushings, armored cable, and check priority zoning.

Install Room Thermostat

Install thermostat on an inside wall, connect it correctly, and set heat anticipator.

Oil Piping

General Oil Piping Practices

Use flexible oil lines, install fuel filters, use flared fittings, and consider micron filters.

Single-Pipe Oil Lines

Standard burners use single-stage fuel units; ensure piping is airtight and bleed lines.

Two-Pipe Oil Lines

For more lift, use two-stage fuel units and refer to tables for allowable lift and tubing lengths.

System Start-Up

Inspect Installation

Verify venting, water piping, oil piping, and electrical system are installed properly.

Fill Heating System with Water

Fill the system, vent air, and ensure it's full to the correct pressure.

Check Control, Wiring, and Burner

Ensure all connections are tight, burner is rigid, fuses are installed, and oil tank is full.

Check Oil Burner Before Starting

Check and readjust burner settings, nozzle, air band, and shutter.

Start Oil Burner

Open vent fitting, start burner, and purge air from the fuel pump.

Adjust Oil Burner While Operating

Readjust air damper, draft regulator, and turbulator for optimal flame and CO2.

Test Controls

Test thermostat, oil primary control features, safety features, and high limit controls.

Check High Limit

Verify high limit control operation by checking burner shutdown and restart.

Operating

Water Boilers Sequence of Operation

Describes sequence for cold start boilers without tankless heaters, controlled by Intelligent Oil Boiler Control.

Using Boiler Control

Locate and use the Boiler Control display to view status and settings.

Changing Adjustable Parameters

Access adjustment mode to change parameters like High Limit Setpoint and Differential.

Maintenance & Service Instructions

Water Boilers Maintenance

Instructions for filling boiler, boiling out, adding treatment compounds, and testing pH.

Excessive Make-Up Water

Prevent damage from leaky systems by keeping make-up water below 2% monthly.

Boiler Attention While Not in Operation

Drain boiler for winter use, spray inside surfaces, and handle steam boilers appropriately.

Boiler Cleaning

General Cleaning Procedures

Conduct annual inspection, service, and cleaning, turning off power and closing oil supply.

Firetubes and Combustion Chamber Cleaning

Clean firetubes and combustion chamber annually using a firetube brush.

Troubleshooting

Combustion Issues

Addresses issues with nozzles, fuel leaks, suction line leaks, dirt, water, cold oil, and flame shape.

Oil Primary Control Problems

Covers issues with the burner not coming on, shutting down early, or locking out after TFI.

Intelligent Oil Boiler Control Errors

Details how the boiler control provides information and error codes for troubleshooting.

Appendix A: Low Water Cut Off (LWCO) on Hot Water Boilers

When LWCO is Required

Explains when a low water cutoff is required for hot water boilers based on installation.

LWCO Installation Location

Describes the universal location for LWCO installation above the boiler.

LWCO Piping Instructions

Instructions on piping the probe LWCO using a tee and ensuring proper clearance.

LWCO Wiring Instructions

Wiring LWCOs using line voltage service, explaining how water presence closes the contact.

LWCO Testing Procedure

Procedure to test LWCO by lowering water level and generating a boiler demand.

New Yorker AP-790U Specifications

General IconGeneral
BrandNew Yorker
ModelAP-790U
CategoryBoiler
LanguageEnglish

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