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New Yorker FR-147 - User Manual

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INSTALLATION, OPERATING
AND SERVICE INSTRUCTIONS
FR™ SERIES
HORIZONTAL TUBE BOILER
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104183-02 - 7/12
Price - $5.00
As an ENERGY STAR
®
Partner,
New Yorker Boiler Co., Inc.
has determined that the
FR-HGS, FR-HGSII, FR-98,
FR-122, FR-147, FR-173, FR-205
and FR-232 water boilers
meet the ENERGY STAR
®
guidelines for Energy
efciency established by the
United States Environmental
Protection Agency (EPA).
Question and Answer IconNeed help?

Do you have a question about the New Yorker FR-147 and is the answer not in the manual?

Summary

Important Information and Safety Precautions

USA Boiler Installation Standards

Lists applicable standards for boiler installation in the USA.

Hazard and Warning Terminology

Defines terms like DANGER, WARNING, CAUTION, and NOTICE used in the manual.

General Safety Warnings and Precautions

Flammable Materials and Storage Warning

Warning against storing flammable materials near the boiler.

Installation Surface and Placement Warnings

Warns against installing on combustible flooring, carpeting, or wet masonry.

Maintenance and Service Safety Advisories

Advises on firetube cleaning, burner checks, and general maintenance safety.

Water Damage and Toxic Substance Precautions

Warns about water damage to controls and exposure to toxic substances.

Operational Safety Warnings and Requirements

Hot Water, Pressure, and Component Safety

Warns about hot water, pressure, and touching hot components.

Combustion and Ventilation Air Needs

Emphasizes the need for adequate combustion and ventilation air.

Chimney and Vent System Integrity

Stresses the importance of a safe and clean chimney/vent system.

Fuel Type and Handling Restrictions

Specifies fuel type and prohibits unauthorized fuels or materials.

Burner Door Safety Procedures

Outlines safety steps before opening the burner swing door.

General Boiler Information and Diagrams

FR-HGS;HGSII Boiler Diagrams

Front and side views of FR-HGS and FR-HGSII boilers with Beckett burner.

FR-98-W to FR-232-W Boiler Diagrams

Front and side views of FR-98-W to FR-232-W boilers.

General Boiler Information and Dimensional Data

FR-265-W to FR-462-W Boiler Diagrams

Front and side views of FR-265-W to FR-462-W boilers.

Boiler Dimensional Specifications

Table detailing dimensional specifications for various FR boiler models.

General Boiler Information and Rating Data

Boiler Rating Data and Chimney Requirements

Provides rating data including capacity, output, and chimney requirements.

Pre-Installation Procedures

Shipment Inspection and Claims Process

Instructions for inspecting shipment and filing damage/shortage claims.

Boiler Placement and Positioning Guidelines

Guidelines for locating and positioning the boiler before installation.

Service Clearance Requirements

Specifies required clearance for servicing and removal of components.

Clearances to Combustible Materials

Details minimum clearances from the boiler to combustible materials.

Pre-Installation: Combustion and Ventilation Air

Providing Combustion and Ventilation Air

Details how to provide adequate air for combustion and ventilation.

Ventilation Louver and Grille Specifications

Specifies requirements for ventilation louvers and grilles.

Boiler Assembly Procedures

Boiler Removal from Skid Instructions

Instructions for safely removing the boiler from its shipping skid.

Heat Exchanger Leak Testing Procedure

Procedure for testing the heat exchanger for leaks before jacket assembly.

Jacket Assembly and Installation Steps

Steps for assembling and installing the boiler jacket panels.

Boiler Control Component Installation

Guidance on installing the pressure/temperature gauge and limit control.

Boiler Assembly: Burner Mounting Details

Burner Mounting Illustration and Procedure

Illustrates and describes the process of mounting the oil burner.

Water Piping and Trim Installation

Designing the System for Water Flow

Guidelines for designing a system to prevent oxygen contamination and ensure proper flow.

Combination Heating;Cooling Piping Schematic

Diagram showing recommended piping for systems with heating and cooling.

Water Piping and Trim: Safety and Flushing

Safety Relief Valve Installation Guidelines

Instructions for installing the safety relief valve correctly.

Drain Valve Installation in Return Piping

Guidance on installing the drain valve in the return piping.

System Cleaning, Flushing, and Treatment

Procedures for cleaning and flushing the system, and chemical treatment.

Water Piping and Trim: Zoned Systems

Circulator Zoned Heating Piping Diagram

Illustrates recommended water piping for zoned heating systems with circulators.

Water Piping and Trim: Zone Valve Systems

Zone Valve Zoned Heating Piping Diagram

Illustrates recommended water piping for zoned heating systems with zone valves.

Water Piping and Trim: Tankless Heater

Tankless Heater Piping Installation Procedures

Instructions for connecting piping to the tankless heater, including safety.

Tankless Heater Piping Schematic Diagram

Schematic diagram for tankless heater piping, including safety features.

Venting System Installation Guidelines

General Venting System Requirements

General guidelines for vent system installation, codes, and chimney types.

Smoke Pipe and Chimney Arrangement Recommendations

Illustrates recommended smoke pipe arrangement and chimney requirements.

Venting: Draft Regulator Locations

Proper and Unacceptable Draft Regulator Placement

Diagrams showing proper and unacceptable locations for draft regulators.

Electrical Connections and Wiring

General Electrical Installation Requirements

General requirements for wiring, grounding, and electrical circuits.

System Controls and Wiring Procedures

Details on wiring system controls, including indirect water heaters and zone systems.

Room Thermostat Installation and Adjustment

Instructions for installing and adjusting a room thermostat for optimal performance.

Electrical: Wiring Diagrams (No Tankless Heater)

Cold Start Wiring Diagram (No Tankless Heater)

Schematic wiring diagram for cold start control without a tankless heater.

Electrical: Wiring Diagrams (With Tankless Heater)

Warm Start Wiring Diagram (With Tankless Heater)

Schematic wiring diagram for warm start control with a tankless heater.

Electrical: Burner Control Wiring

Beckett Burner Control Wiring Diagram

Wiring diagram for Beckett burners with Genisys Oil Primary Control.

Oil Piping Installation Procedures

General Oil Piping Guidelines and Filters

General recommendations for oil piping, including flexible lines and filters.

Single-Pipe Oil Line Installation Details

Details on installing single-pipe oil lines for burners.

Oil Piping: System Configurations

Oil Piping Length and Lift Specifications

Tables showing maximum tubing lengths for different lift and pipe sizes.

Two-Pipe Oil Line Installation Guidance

Guidance for installing two-pipe oil systems, recommending two-stage fuel units.

System Start-Up Procedures

Pre-Start-Up Installation Inspection Checklist

Final inspection steps before starting the burner and confirming supplies are off.

Filling the Heating System with Water and Purging Air

Step-by-step instructions for filling the system with water and purging air.

Control, Wiring, and Burner Integrity Checks

Verifying connections, wiring, and burner integrity before operation.

Initial Control Settings Adjustment

Adjusting thermostat and primary control settings for initial operation.

System Start-Up: Boiler and Burner Adjustments

Boiler Control Setpoint Configuration

Details on setting high limit and differentials for different boiler types.

Pre-Start Oil Burner Adjustment Procedures

Adjusting burner head, air settings, and oil lines before initial firing.

Initiating Oil Burner Operation Sequence

Steps for starting the oil burner and verifying fuel flow.

On-Operation Oil Burner Adjustment Techniques

Adjusting burner settings while operating to optimize flame and performance.

System Start-Up: Final Checks and Adjustments

Draft, Air Damper, and Head;Turbulator Adjustments

Procedures for adjusting draft, air damper, and head/turbulator settings.

Flame Failure Troubleshooting and Detection

Explains burner automatic operation and what to do if flame fails.

Cad Cell Location and Service Procedures

Information on the cad cell's location and servicing procedures.

Burner Cut-Off and Dripping Checks

Checks for clean cut-off of the burner, addressing oil dripping.

Boiler Control System Testing Protocols

Procedures for testing thermostat, primary control, and high limit operations.

System Start-Up: Beckett Burner Head Adjustment

Beckett AFG Head Electrode Positioning Guide

Detailed guide on positioning heads and electrodes for Beckett AFG burners.

System Start-Up: Genisys 7505 Control Features

Cad Cell Location Overview

Illustrates the location of the Cad Cell on the burner assembly.

Genisys 7505 Control Interface and Functions

Details the Genisys 7505 control terminals, LEDs, and reset button functions.

System Start-Up: Control Verification and Checks

Oil Primary Control Safety Checks

Safety checks for the oil primary control, including wiring and features.

High Limit Control Operational Verification

Procedure to check the high limit control's operation and shutdown function.

Final System Operation and Leak Verification

Verifying control operation and system leaks after adjustments.

Boiler Operating Procedures

Cold Start Boiler Sequence of Operation

Describes the sequence of operation for water boilers without tankless heaters.

Boiler Status Codes Explained

Explains the status codes displayed by the boiler control.

Intelligent Oil Boiler Control Overview

Diagram and explanation of the intelligent oil boiler control unit.

Boiler Operating: Warm Start and Control Settings

Warm Start Boiler Sequence of Operation

Describes the sequence of operation for boilers with tankless heaters.

Viewing Boiler Operating Mode Options

How to view boiler status, settings, and troubleshooting information.

Adjusting Boiler Control Parameters

Procedure for accessing and changing adjustable parameters like High Limit.

Boiler Operating: Adjustable Parameter Details

Cold Start Control Adjustment Mode Options

Lists adjustable parameters and their ranges for cold start controls.

Warm Start Control Adjustment Mode Options

Lists adjustable parameters and their ranges for warm start controls.

High Limit Setting Explanation and Range

Explains the High Limit setting and its adjustment range.

Low Limit Setting Explanation and Range

Explains the Low Limit setting and its adjustment range for warm start.

Boiler Operating: Temperature and Priority Settings

Circulator Pre-Purge Time Setting Examples

Example settings for circulator pre-purge time based on boiler status.

Priority Time Functionality for DHW Demand

Explains how Priority Time affects circulator operation for DHW demand.

ZC;ZR Terminal Function Configuration Options

How to configure ZC/ZR terminals for zone control or DHW.

Boiler Operating: Zone and Low Limit Functions

Zone Request Terminal Settings Table

Table showing circulator status based on zone request inputs.

External Low Limit Functionality Description

How the External Low Limit function works with the boiler control.

Steam Boiler Sequence of Operation

Describes the sequence of operation for steam boilers.

Maintenance and Service Instructions

Water Boiler Maintenance Procedures

Steps for filling, boiling out, and treating water boilers.

Preventing Excessive Make-Up Water Issues

Explains the dangers of excessive make-up water and how to prevent it.

Maintenance and Boiler Cleaning Procedures

Seasonal Shutdown and System Reconditioning

Instructions for shutting down and preparing the system for seasonal changes.

General Boiler Cleaning Requirements

General guidance on annual inspection and cleaning procedures.

Firetube and Combustion Chamber Cleaning

Detailed steps for cleaning firetubes and the combustion chamber.

Boiler Cleaning: Component Diagrams

FR Boiler Cleaning Illustration Guide

Illustration showing the parts involved in cleaning the FR boiler.

Refractory Ceramic Fiber Product Safety Information

Refractory Ceramic Fiber Health Hazard Warning

Warns about potential health hazards from refractory ceramic fibers.

Protective Measures for RCF Handling and Use

Lists necessary protective gear and measures when working with RCF parts.

First Aid Procedures for RCF Exposure

Provides first aid steps for eye, skin contact, or inhalation of RCF.

Troubleshooting Common Operational Issues

Combustion Related Troubleshooting Guide

Addresses issues related to nozzles, fuel leaks, air, water, cold oil, and flame shape.

Installation and Operation Noise Troubleshooting

Troubleshoots issues related to high altitude, start-up noise, and shut down noise.

Troubleshooting Control System Issues

Oil Primary Control Troubleshooting Steps

Diagnoses and resolves issues with the oil primary control.

Intelligent Boiler Control Troubleshooting Guide

Helps resolve problems using the intelligent boiler control display and error codes.

Boiler Troubleshooting Guide Correlation Table

A guide correlating system conditions and diagnostic codes with actions.

Troubleshooting: Boiler Control Error Code Reference

Boiler Control Error Number and Correction Table

Lists boiler control error codes and recommended corrective actions.

Obtaining Replacement Parts Information

Contacting New Yorker for Parts and Support

Provides contact details for ordering New Yorker boiler repair parts.

Repair Parts: Jacket Assembly Diagrams

Jacket Repair Parts Exploded View Illustration

Exploded view illustration of jacket repair parts.

Repair Parts: Jacket Assembly Part Numbers

Jacket Assembly Parts List with Part Numbers

Detailed list of jacket assembly parts and their corresponding part numbers.

Repair Parts: Bare Boiler Assembly Diagrams

Bare Boiler Repair Parts Exploded View Illustration

Exploded view illustration of bare boiler repair parts.

Repair Parts: Bare Boiler Assembly Part Numbers

Bare Boiler Assembly Parts List with Part Numbers

Detailed list of bare boiler assembly parts and their part numbers.

Repair Parts: Insulation Replacement Kits

Combustion Chamber Insulation Kit Part Numbers

Lists part numbers for combustion chamber insulation replacement kits.

Flue Box Insulation Kit Part Numbers

Lists part numbers for flue box insulation replacement kits.

Repair Parts: Beckett Burner Component Details

Beckett AFG Burner Component Illustrations

Diagrams showing details of Beckett AFG burner components like nozzle and electrodes.

Repair Parts: Beckett Burner Parts List

Beckett Burner Parts for FR Series Boilers

A detailed list of Beckett burner parts for FR Series boilers.

Burner Specifications

Beckett AFG and SF Burner Specifications Table

Specifications for Beckett AFG and SF burners, including firing rate, nozzle, and settings.

Appendix A: Low Water Cut Off (LWCO) Installation

LWCO Installation Warning and Safety

Warning against cutting factory wires and emphasizes using specified connections.

LWCO Application, Type, and Location

Explains when LWCO is required, its placement, and typical types.

LWCO Piping Connection Instructions

Details on how to pipe the LWCO probe using a tee connection.

LWCO Wiring Configurations and Guidelines

Instructions for wiring LWCO controls using 120 VAC or 24 VAC configurations.

Appendix A: LWCO Testing and 24 VAC Application

24 VAC LWCO Application in Gas Boilers

Discusses the use of 24 VAC LWCO in gas-fired boilers.

LWCO Testing Procedure and Verification

Step-by-step guide to test the functionality of the LWCO.

Service Record Log

Service Record Log (Continued)

Limited Warranties and Service Procedures

One Year Limited Warranty Coverage

Covers defects in material and workmanship for one year from installation.

Five Year Pressure Vessel Limited Warranty

Limited warranty for the pressure vessel of WCT™ Residential Water Boilers.

Lifetime Pressure Vessel Limited Warranty

Covers pressure vessel defects for the lifetime of the original purchaser.

Warranty Exceptions and Exclusions List

Lists conditions and issues not covered by the limited warranties.

Warranty Service Claim Procedure

Steps to follow for obtaining warranty service and making claims.

New Yorker FR-147 Specifications

General IconGeneral
BrandNew Yorker
ModelFR-147
CategoryBoiler
LanguageEnglish

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