New Yorker M Manuel de service

INSTALLATION, OPERATING

AND SERVICE INSTRUCTIONS

FOR microTEK3™

OIL FIRED BOILER

PACKAGED HEATING UNIT

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M24500R5-7/07 Price - $3.00

IMPORTANT INFORMATION - PLEASE READ THIS PAGE CAREFULLY

1. THIS BOILER HAS LIMITED WARRANTIES, COPIES OF WHICH ARE PRINTED ON THE BACK COVER OF THIS MANU-

AL.

2. THIS BOILER IS SUITABLE FOR INSTALLATION ON COMBUSTIBLE FLOORING. BOILER CAN NOT BE IN-

STALLED ON CARPETING.

3. ALL BOILERS MUST BE INSTALLED IN ACCORDANCE WITH NATIONAL, STATE AND LOCAL PLUMBING,

HEATING AND ELECTRICAL CODES AND THE REGULATIONS OF THE SERVING UTILITIES WHICH MAY DIF-

FER FROM THIS MANUAL. AUTHORITIES HAVING JURISDICTION SHOULD BE CONSULTED BEFORE INSTAL-

LATIONS ARE MADE.

IN ALL CASES, REFERENCE SHOULD BE MADE TO THE FOLLOWING STANDARDS:

A. Current Edition of American National Standard ANSI/NFPA 31, “Installation of Oil Burning Equipment”, for clearances between boiler, vent connector and

combustible material.

B. Current Edition of American National Standard ANSI/NFPA 211, “Chimneys, Fireplaces, Vents, and Solid Fuel Burning Appliances”, For Chimney require-

ments, type of venting material and clearances between vent connector pipe and combustible materials.

C. Current Edition of American Society of Mechanical Engineers ASME CSD-1, “Controls and Safety Devices for Automatically Fired Boilers”, for assembly

and operations of controls and safety devices.

4. ALL HEATING SYSTEMS SHOULD BE DESIGNED BY COMPETENT CONTRACTORS AND ONLY PERSONS KNOWL-

EDGEABLE IN THE LAYOUT AND INSTALLATION OF HYDRONIC HEATING SYSTEMS SHOULD ATTEMPT INSTALLA-

TION OF ANY BOILER.

5. THE BOILER MUST BE CONNECTED TO AN APPROVED CHIMNEY IN GOOD CONDITION. SERIOUS PROPERTY

DAMAGE COULD RESULT IF THE BOILER IS CONNECTED TO A DIRTY OR INADEQUATE CHIMNEY. THE INTERIOR

OF THE CHIMNEY FLUE MUST BE INSPECTED AND CLEANED BEFORE THE START OF THE HEATING SEASON

AND SHOULD BE INSPECTED PERIODICALLY THROUGHOUT THE HEATING SEASON FOR ANY OBSTRUCTIONS. A

CLEAN AND UNOBSTRUCTED CHIMNEY FLUE IS NECESSARY TO ALLOW NOXIOUS FUMES THAT COULD CAUSE

INJURY OR LOSS OF LIFE TO VENT SAFELYAND WILL CONTRIBUTE TOWARD MAINTAINING THE BOILER’S EF-

FICIENCY.

6. READ THE LITERATURE ENCLOSED BY THE MANUFACTURER WITH THE VARIOUS ACCESSORY DEVICES. THESE

ACCESSORY DEVICES MUST BE INSTALLED AND USED ACCORDING TO THE RECOMMENDATIONS OF THE MANU-

FACTURER.

7. IT IS THE RESPONSIBILITY OF THE INSTALLING CONTRACTOR TO SEE THAT ALL CONTROLS ARE CORRECTLY

INSTALLED AND ARE OPERATING PROPERLY WHEN THE INSTALLATION IS COMPLETED.

8. FOR OPTIMUM PERFORMANCE AND SERVICEABILITY FROM THIS UNIT ADHERE TO THE FOLLOWING RECOM-

MENDATIONS:

A. DO NOT TAMPER WITH THE UNIT OR CONTROLS. Retain your contractor or a competent serviceman to assure that the unit is properly adjusted and

maintained.

B. Clean Firetubes at least once a year - preferably at the end of the heating season to remove soot and scale. Inside of Combustion Chamber should also be

cleaned at the same time.

GNINRAW

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SECTION I: GENERAL INFORMATION

Figure 1: microTEK3 Packaged Boiler

2. LOCATEBOILERinfrontofnalpositionbefore

removing crate. See Figure 1.

A. LOCATE so that smoke pipe connection to chimney

will be short and direct. BOILER IS SUITABLE

FOR INSTALLATION ON COMBUSTIBLE

FLOOR. Boiler can not be installed on carpeting.

B. FOR BASEMENT INSTALLATION, provide a

solidbase,suchasconcrete,ifoorisnotlevelorif

watermaybeencounteredonooraroundBoiler.

C. PROVIDE SERVICE CLEARANCE of at least 24”

clearance in front for servicing.

D. For minimum clearances to combustible materials

See Figure 2.

1. INSPECT SHIPMENT carefully for any signs of

damage.

A. ALL EQUIPMENT is carefully manufactured,

inspected and packed. Our responsibility ceases

upon delivery of crated Boiler to the carrier in good

condition.

B. ANY CLAIMS for damage or shortage in shipment

mustbeled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.

Approximate shipping weight: 325 pounds

Water content: 6.1 gallons

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Water Content: 6.1 Gallons

I. General Information ...............................3

II. Installation Instructions..........................4

III. Operating & Service Instructions..........11

TABLE OF CONTENTS

IV. Boiler Cleaning .....................................19

V. Repair Parts...........................................20

VI. Appendix

Low Water Cut Oﬀ................................25

SECTION II: INSTALLATION INSTRUCTIONS

2. REMOVAL OF BOILER FROM SKID

A. Tilt boiler, "walk" boiler backward, and set rear

legsdownonoor.Tiltboilerbackward,pull

skid forward and set front legs down on edge of

skid. Install close coupling, tee, and plug in return

coupling, see Step 7 and Figure 4. Point tee toward

permanent return location.

1. REMOVE CRATE

A. Remove all fasteners at crate skid.

B. Lift outside container and remove all other inside

protective spacers and bracing. Remove container

containing Safety Relief Valve and Pipe Fittings.

3. PROVIDE COMBUSTION AND VENTILATION

AIR. Local code provisions may apply and should be

referenced.

D.Forboilerlocatedinanunconnedspaceofa

conventionally constructed building, the fresh

airinltrationthroughcracksaroundwindows

and doors normally provides adequate air for

combustion and ventilation.

E. Forboilerlocatedinaconnedspaceoran

unconnedspaceinabuildingofunusuallytight

construction, provide outdoor air with the use of two

permanent openings which communicate directly or

by duct with the outdoors or spaces (crawl or attic)

freely communicating with the outdoors. Locate one

opening within 12 inches of top of space. Locate

remaining opening within 12 inches of bottom of

space. Minimum dimension of air opening is 3

inches. Size each opening per following:

1. Direct communication with outdoors.

Minimum free area of 1 square inch per 4,000

BTU per hour input of all equipment in space.

2. Vertical ducts. Minimum free area of 1 square

inch per 4,000 BTU per hour input of all

equipment in space. Duct cross-sectional area

shall be same as opening free area.

3. Horizontal ducts. Minimum free area of 1

square inch per 2,000 BTU per hour input of all

equipment in space. Duct cross-sectional area

shall be same as opening free area.

Alternate method for boiler located within

conned space. Use indoor air if two permanent

openings communicate directly with additional

space(s)ofsufcientvolumesuchthatcombined

volumeofallspacesmeetcriteriaforunconned

space. Size each opening for minimum free area

of 1 square inch per 1,000 BTU per hour input

of all equipment in spaces, but not less than 100

square inches.

F. Louvers and Grilles of Ventilation Ducts

1. All outside openings should be screened and

louvered. Screens used should not be smaller

than 1/4 inch mesh. Louvers will prevent the

entrance of rain and snow.

2. Free area requirements need to consider the

blocking effect of louvers, grilles, or screens

protecting the openings. If the free area of the

louver or grille is not known, assume wood

louvers have 20-25 percent free area and metal

louvers and grilles have 60-75 percent free area.

3. Louversandgrillesmustbexedintheopen

position, or interlocked with the equipment to

open automatically during equipment operation.

A. Determine volume of space (boiler room). Rooms

communicating directly with the space in which

the appliances are installed, through openings not

furnished with doors, are considered a part of the

space.

Volume(ft3) = Length(ft) x Width(ft) x Height(ft)

B. Determine total input of all appliances in the space.

Add inputs of all appliances in the space and round

the result to the nearest 1000 BTU per hour.

C. Determine type of space. Divide Volume by total

input of all appliances in space. If the result is

greater than or equal to 50 ft3/1000 BTU per hour,

thenitisconsideredanunconnedspace.Ifthe

result is less than 50 ft3/1000 BTU per hour then the

spaceisconsideredaconnedspace.

Figure 2: Minimum Installation Clearances To

Combustible Materials

GNINRAW

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B. Tilt boiler backward and remove skid. Be careful not

to damage Burner and Jacket.

3. CHANGE HINGE POSITION if necessary.

A. Look at the area where boiler will be installed. If

left side of boiler will be less than 12 inches from

a wall, move hinges to right side of boiler. See B

through J below.

B. Pull 2 halves of Burner Swing Door Interlock apart.

Swing Door Interlock is connected to T-T terminals

on R7184A Control. Lift Honeywell R7184A

Control off of Burner Junction Box, open Burner

Ignition Transformer and disconnect wiring harness

from left side of burner. Find round plastic cover

inside Junction Box and install in hole in left side of

burner.

C. Remove 8 sheet metal screws from jacket. Remove

rear jacket box and bend both sides of Jacket

Wrapper up, see Figure 18.

D. Remove 2 (two) 5/16" - 18 x 3" long hex head cap

screwsandatwashers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 step 6.

E. 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.

F. 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.

Figure 3: Hinge Installation & Assembly, microTEK3 Boiler

G. 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atwashers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.

H. 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 18.

I. Connect wiring harness to a knockout on right side

of Junction Box and install Honeywell R7184A

Control, see Wiring Diagram, Figure 11.

Reconnect Swing Door Interlock.

4. INSTALL BOILER CONTROL.

A. 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.

B. SecureexibleconduittoJacketWrappersidewith

conduit clamp and sheet metal screw. Conduit must

be on same side of boiler as Swing Door hinges.

5. MOVE BOILER TO PERMANENT POSITION by

sliding or walking.

6. INSPECT FRONTAND REAR DOOR INSULATION

PIECES AND COMBUSTION CHAMBER LINER

A. OPEN SWING DOOR on front of boiler. Use

ashlighttoinspectinsulationpiecessecuredto

front and rear doors. Inspect Ceramic Fiber Blanket

secured to bottom of combustion chamber with

water glass adhesive. Replace any damaged pieces.

Figure 4: Recommended Boiler Piping for Zoning with Valves

Figure 5: Recommended Boiler Piping for Zoning with Circulators

E. 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.

F. 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ttings.

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ttings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.

7. CONNECT SUPPLY AND RETURN PIPING TO

HEATING SYSTEM

A. Hot water pipes shall have clearances of at least ½”

from all combustible construction.

B. Use a system by-pass 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.).

Valves should be located in the by-pass and return

line as illustrated in Figures 4 and 5 in order to

regulatewaterow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.

C. 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.

D. 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owcontrolvalvestopreventgravity

circulation of boiler water during the operation of

the cooling system.

Figure 6: Recommended Piping for Combination

Heating & Cooling

(Refrigeration) Systems

NOITUAC

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8. INSTALL SMOKEPIPE — The microTEK3™ should

beventedintoareclaytile-linedmasonrychimney

or a chimney constructed from Type L Vent or a

factory built chimney that complies with the Type

HT requirement, of UL103. The chimney and vent

pipeshallhaveasufcientdraftatalltimes,toassure

safe proper operation of the boiler. See Figure 7 for

recommended installation.

A. Install the draft regulator following the instructions

furnished with the regulator. See Figure 8 for

alternate draft regulator locations.

B. Consider the chimney overall. Chimneys that have

a high heat loss may become less suitable as the

heatlossofthehomegoesdownandtheefciency

of the boiler installed goes up. Most homes have

a chimney appropriate for the fuel and the era in

which the home was built. That may have been a

Figure 9

coalredoraninefcientoilredboilerbuiltinto

a home without insulation or storm windows. With

increasing fuel prices that home probably has been

insulatedandttedwithstormwindowssothat

the heat loss of the home has been reduced. This

requires less fuel to be burned and sends less heat up

the chimney.

 Anewboilerprobablyhasahigherefciencythan

the boiler being replaced. That probably means that

the stack temperature from the new boiler will be

lower than that from the old boiler and with less

room air being drawn up the chimney to dilute the

stack gases. The combination of a large uninsulated

chimney,reducedringrate,reducedringtime,

lower stack temperature and less dilution air can,

in some cases, contribute to the condensing of

Figure 8

Figure 7

small amounts of water vapor in the chimney. Such

condensation, when it occurs, can cause chimney

deterioration. In extreme cases, condensed water

may be visible on the outside of the breeching or

chimney. In those extreme cases, the chimney may

have to be lined to insulate the chimney and thus

prevent the condensation. The addition of dilution

air into the chimney may assist in drying the

chimney interior surfaces.

C. Heat extractors mounted into the breeching are not

recommended.

9. INSTALL ELECTRIC WIRING in accordance with

National Electrical Code and local regulations. 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. Wiring should conform to Figures 11A

and 11B.

10. FUEL UNITS AND OIL LINES

 Useexibleoilline(s)sothatSwingDoorcanbe

opened without disconnecting oil supply.

 Asupplylinefueloillterisrecommendedasa

minimumforallringratesbutapleatedpaperfueloil

lterisrecommendedforthelowest(.6GPH)ring

rate application to prevent nozzle fouling.

SINGLE-PIPE OIL LINES — Standard burners are

provided with single-stage 3450 rpm fuel units with the

by-pass plug removed for single-pipe installations.

The single-stage fuel unit may be installed single-pipe

with gravity feed or lift. Maximum allowable lift is 8

feet. See Figure 9.

TNATROPMI

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Figure 10

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TWO-PIPE OIL LINES - For two-pipe systems

where more lift is required, the two-stage fuel unit is

recommended. Tables 2 (single-stage) and 3 (two-stage)

show allowable lift and lengths of 3/8-inch and ½-inch

OD tubing for both suction and return lines. Refer to

Figure 10.

Be sure that all oil line connections are absolutely

airtight.

 Checkallconnectionsandjoints.Flaredttingsare

recommended.Donotusecompressionttings.

Open the air-bleed valve and start the burner. For clean

bleed, slip a 3/16” ID hose over the end of the bleed

valve and bleed into a container. Continue to bleed for

15 seconds after oil is free of air bubbles. Stop burner

and close valve.

Figure 11B: Wiring Diagram for microTEK3 Boilers with Beckett AFG Burner,

Smart Control, and Honeywell L4080B High Limit

SEQUENCE OF OPERATION

Refer to Smart Manual for wiring and operation details.

Figure 11A: Wiring Diagram for microTEK3 Boilers with Beckett AFG Burner and Split Controls

SEQUENCE OF OPERATION

A call for heat by the thermostat energizes the L7248C control which in turn energizes the R7184B primary control.

The burner will initiate ignition after completing a 10 second pre-purge cycle. If burner ignites within approximately 45

seconds and the cad cell sees ame, the burner will continue to operate until the call for heat is satised or the setting

of the high limit is reached. The circulator will operate as long as the thermostat is calling for heat. If the thermostat is

not satised and the high limit is reached, the circulator will continue to operate, and the burner will stop until the high

limit is closed by a drop in boiler water temperature.

Ce manuel convient aux modèles suivants

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