NEW YORKER WC-130 (01) PDF Document

The NEW YORKER WC-130 must be installed with specific clearances from combustible surfaces according to NFPA-89A. The unit must also be installed on a non-combustible floor.

No. The manual explicitly states in a warning: “UNDER NO CIRCUMSTANCES SHOULD THIS UNIT BE INSTALLED ON A COMBUSTIBLE FLOOR”. The foundation for the NEW YORKER WC-130 must be non-combustible. A 4″ high, level, concrete pad on top of a non-combustible floor, the size of the boiler plus the clearance dimensions, is required.

The components included in the NEW YORKER WC-130 package are:

1) Shell and Jacket

2) L6006A Operating Control Aquastat

3) L4006B Overheat Control Aquastat

4) Relief Valve

5) Drain

6) Gauge

7) Blower

8) Name Plate

9) Rating Plate

10) Ash Pan

The NEW YORKER WC-130 boiler should be located as close as possible to the chimney inlet while maintaining acceptable clearances from all combustible materials. The location must permit access to both the flue pipe and chimney outlet for periodic cleaning.

The boiler is designed for non-combustible foundations only. A 4-inch high, level, concrete pad on top of a non-combustible floor, sized to the boiler plus its clearance dimensions, is required.

WARNING: DO NOT STORE OR USE FLAMMABLE LIQUIDS, ESPECIALLY GASOLINE, IN THE VICINITY OF THE UNIT.

The chimney for the NEW YORKER WC-130 should be built according to the National Fire Protection Association Code. It should be solid masonry or reinforced concrete with a fire clay flue liner extending from 8 inches below the connection or flue throat.

1) The wall thickness should be a minimum of four inches.

2) The liner thickness should be a minimum of 5/8″.

3) The chimney should terminate three feet above the roof and two feet above any portion of any building within 10 feet.

The recommended chimney size is a masonry with fire clay liner of 8″ x 8″ x 15′ or equivalent.

For the NEW YORKER WC-130, the flue pipe should be 24 gauge minimum thickness. To obtain maximum efficiency, pipes should be as straight as possible. Avoid horizontal runs; if they are necessary, the flue pipe must have a 1/4″ rise per foot. This pitch allows any creosote to return to the unit to be burned. Joints must fit tightly to prevent room air from entering the chimney. The pipe should be screwed or riveted, and furnace cement must be used to ensure a tight and complete seal. The flue pipe should not extend through an unoccupied area of the house where regular inspection cannot be carried out.

A positive stop, solid fuel type barometric control must be installed on the flue pipe within 24 inches of the boiler outlet, in the same room as the boiler. The draft must not be adjusted higher than -.04″ W.C. (Water Column).

WARNING: IF THE -.04″ W.C. DRAFT SETTING IS EXCEEDED, DURING A POWER FAILURE, THE CONDITION COULD CAUSE A SOLID FUEL FIRE TO BURN OUT OF CONTROL.

A minimum of 100 square inches of free air infiltration is necessary for proper operation of the NEW YORKER WC-130, as oxygen is required for the combustion (burning) of wood or coal.

Yes. The use of the NEW YORKER WC-130 wood/coal add-on boiler increases the system water volume by approximately 25 gallons. Therefore, you must make provisions for this expansion by adding a second expansion tank to the system.

Recommended sizes are:

Conventional Expansion Tank Size: 24 Gallons

Diaphragm: #30 Extrol, #110 Fill-trol

While it is recommended that the NEW YORKER WC-130 boiler be connected to a separate chimney, it may be connected to a single chimney or vent with another fuel burning appliance, provided that:

a. Sufficient draft is available for safe combustion in each appliance, and

b. Sufficient draft is available for the removal of all products of combustion safely to the outdoors, and

c. Gas and oil appliances connected to the same chimney are equipped with primary safety controls.

When wiring the NEW YORKER WC-130, please follow these specifications:

Wire for 120V: 12G

Wire for 24V: 18G

Wiring should conform to national and local electrical codes. The equipment is to be grounded according to standard electrical practices. The maximum overcurrent protection is 15 amps.

Note for add-on with zone valves: The L8124A and L6006A must be on the same circuit to prevent a short due to the common use of C1 & C2 terminals.

The valve positions depend on whether the NEW YORKER WC-130 add-on boiler is being used.

When the add-on boiler is in use:

Valve A is open.

Valve B is open.

Valve C is closed.

When the add-on boiler is isolated and not needed for supplemental heat:

Valve A is closed.

Valve B is closed.

Valve C is open.

To prevent an overheat condition during a power failure, a normally open zone valve (2) must be used and connected to the supply end of the largest system zone. Additionally, a manual by-pass valve ‘D’ should be installed in case of a failure of the normally open zone valve (2).

L6006A – 120V Operating Control:

This is the operating control for the add-on boiler, activated by a manual switch when a fire is started. The (RB) combustion air blower switch closes, and the (RW) circulator switch remains open until the boiler water temperature reaches its set point. At the set point, (RB) breaks (turning off the blower) and (RW) makes (turning on circulation) between the add-on and primary boiler. The L6006A should be set at 190°F.

L4006B – 24V High Limit-Overheat Control:

This is the high limit-overheat control. It acts as a 24-volt switch. In an overheat condition, it will open the system zone valve (largest zone) and activate the system circulator to dissipate the excessive heat into the system. The L4006B should be set at 210°F.

When the thermostat calls for heat, it will open the zone valve(s) and start the system circulator. The primary oil or gas burner will not fire as long as the NEW YORKER WC-130 wood/coal boiler is able to maintain the water temperature above the high limit setting on the oil or gas boiler (typically 180°F). If the NEW YORKER WC-130 fails to maintain this temperature, the oil or gas burner will activate.

To assure satisfactory combustion and safe operation of the NEW YORKER WC-130, several conditions must be met:

1) There must be a continuous supply of oxygen.

2) There must be a proper amount of fuel – not enough to cause overheating, but enough to maintain a flue temperature that prevents the accumulation of creosote residues.

Complete combustion is achieved by supplying sufficient air and maintaining a sufficient heat level. Incomplete combustion can result from an insufficient or misapplied air supply, or insufficient heat. Proper operation requires that the entire combustion system (boiler chimney, joints, and flues) be clean and in proper working order.

When wood is burning slowly, the smoke can contain a substance called creosote, which collects on the combustion chamber surfaces, tubes, and flue pipe. The main causes of creosote buildup are:

1) Wet or unseasoned wood.

2) Incomplete combustion.

3) Cool surfaces.

The best method of controlling creosote is to prevent its buildup. This can be done by maintaining a briskly burning fire with dry, well-seasoned wood and by maintaining a flue temperature exceeding 250°F, which will prevent creosote condensation.

Circulators:

C1: This is the primary circulator, powered on a call-for-heat by the oil or gas boiler controller. It is also activated on an overheat condition by the WC-L4006B control.

C2: This is the by-pass circulator between the two boilers. It is powered when the WC-L6006A operating control reaches its set point.

Valves:

Balancing Valve: Used to ensure proper flow to the system zone on a call for heat.

Valve “A”: Open during WC operation. Closed when WC is inactive.

Valve “B”: Open during WC operation. Closed when WC is inactive.

Valve “C”: Open during WC operation. Closed when WC is inactive.

Valve “D”: Close during WC operation. Open when WC is inactive.

Valve “E”: Closed during normal operation. Open when WC is manually operated under power failure conditions.

Z1: A normally open zone valve that will be open under power failure conditions to permit gravity flow to the system.

Z2: A normally open zone valve that will be open under power failure conditions to permit gravity flow from the system.

The combustion air shutter on the side of the blower housing should be fixed at the opening specified in the table below. Do not alter this setting without consulting the factory.

1) The WC air setting should be fixed at the ‘A’ opening (1/2″ to 1″ for the WC-130). Do not alter this setting without factory consultation.

2) Larger air openings will provide excessively high stack temperatures and will burn fuel rapidly and inefficiently.

3) Smaller air openings will smother the fire and create dangerous creosote formation or coal gas.

CAUTION: To prevent a runaway fire, excessive stack temperature, or other hazardous conditions, keep the loading and ash removal doors closed during operation. All seals should be maintained for air tightness.

The over-fuel air shutter on the NEW YORKER WC-130 should be adjusted to an open position to burn coal or wood gases that develop above the fuel bed immediately after a full loading of the unit. You should close the shutter gradually as these gases are burnt off.

Follow these steps to start a wood fire in your NEW YORKER WC-130:

1) Ball up single sheets of newspaper and loosely stack the paper balls and wood kindling inside.

2) Light the paper with a match and close the loading door.

3) Manually switch on the electrical power to the wood boiler operating control. This will activate the combustion air blower.

4) Allow several minutes for the kindling to ignite. Then, turn off the blower, carefully open the loading door, and gradually add split logs to the suggested load level.

5) Switch the blower back on. Open the air shutter over the fuel bed slightly to relieve any accumulated gases.

6) Adjust the barometric regulator to a maximum of -.04″ water column.

CAUTION: Be careful when opening the loading door to prevent possible flash-back of accumulated gases. Prevent this by unlocking and opening the loading door very slowly. Never open the loading door with the manual switch in the open position. The blower should not be operating while the loading door is open.

To start a coal fire in your NEW YORKER WC-130, first establish a wood fire and then proceed with the following steps:

1) Follow the steps outlined to establish an operating wood fire.

2) Allow the wood to burn down to a red-coal condition.

3) Turn off the blower and spread a thin, loose layer of anthracite coal over the wood coals. Close the door and turn the blower on.

4) Allow several minutes for the blower to operate and ignite the coal.

5) Then, turn off the blower and gradually spread layers of coal to eventually reach the suggested bed level. Open the over-fuel bed air shutter slightly to prevent gas accumulation in the combustion chamber.

CAUTION: Be careful when opening the loading door to prevent possible flash-back of accumulated gases. Prevent this by unlocking and opening the loading door very slowly. Never open the loading door with the manual switch in the open position. The blower should not be operating while the loading door is open.

Wood: Stack wood loosely to the middle of the loading door height. This is approximately 80 lbs. for the WC-130.

Coal: The maximum bed height is the lower edge of the loading door. This is approximately 60 lbs. for the WC-130.

CAUTION: Load fuel carefully to avoid damage. Do not burn garbage, gasoline, naphtha, or engine oil.

To operate the NEW YORKER WC-130 during a power failure, follow these steps:

1) Manually open all zone valves and flow check valves to permit gravity circulation through the system.

2) Light a small fire, using approximately 1/4 to 1/2 of the normal load.

3) Adjust the combustion air blower shutter and the over-fuel air shutter to attain proper burning conditions.

Do not expect to maintain maximum comfort conditions during a power failure. CAUTION: Care must be taken to prevent overheating of the boiler.

In the event of a runaway fire in your NEW YORKER WC-130, follow this procedure:

1) Shut off the combustion air blower – close or cover all air shutters.

2) Increase thermostats to their maximum setting. Open all zone valves.

3) Open the barometric damper wide.

CAUTION: “Do not shut off power because circulation is needed to dissipate heat.” “Excessive heat caused by extreme over-firing may cause the relief valve to blow off water.”

It is not necessary or desirable to shake the grates every time you refuel the NEW YORKER WC-130. Shake only when necessary to make room for more coal or to clear the grates of excessive ashes. Use a few short strokes of the shaker handle until the first red glow appears in the ash pit. STOP shaking as soon as you see the red glow. This method ensures some ashes are left on top of the grates, which is important. If a hot fire is allowed to contact the grates for extended periods, they may warp or burn out. Always carry a layer of ashes on the grates.

A shake bar extension can be fabricated from a short length of one-inch pipe with one end capped.

Ashes must be removed from the ash pit on a daily basis. They should never be allowed to accumulate high enough to touch the grates, as this can cut off necessary air circulation and lead to warped or burnt-out grates.

For disposal, store ashes in a non-combustible metal container with a tight-fitting lid. Place the closed container on a non-combustible floor or on the ground, well away from all combustible materials, until final disposal.

Wood:

You should burn dry and well-seasoned hardwood. Wood should be seasoned for at least six months, and preferably for a year to eighteen months. Seasoned wood often shows cracks radiating from the heartwood towards the bark. Wood should be split into quarters and be approximately 18 inches in length.

Coal:

Use stove grade anthracite coal. Chestnut size is preferable; however, pea size coal is also acceptable.

Wood and coal fuel should be stored in a dry location while maintaining the required clearances from combustible materials. The storage area must be located at least 48 inches from the loading door and 18 inches from the rear and sides of the boiler.

If a chimney fire occurs, follow these steps:

1) Call your local fire department immediately.

2) Close all openings, the combustion air blower shutter, and draft controls on the boiler.

3) If the fire is burning vigorously, you can squirt a multipurpose (ABC) dry chemical extinguisher or throw baking soda onto the fire. The chemicals will travel up the chimney and may extinguish the fire. If possible, avoid introducing water into the chimney, as it could damage the brittle heated flue liner.

NOTE: The burning of creosote results in a very intense fire. Any chimney can be weakened or deformed by a chimney fire. The complete chimney should be inspected after a fire, and any necessary repairs must be made before restarting the boiler.

In addition to any extinguishers already in your home, a multipurpose fire extinguisher should be installed near the NEW YORKER WC-130 boiler. For additional protection in case of a fire, you should also equip your home with an early warning fire detection system.

During the operating season, the NEW YORKER WC-130 should be cleaned weekly. Failure to keep surfaces clean of soot, ash, and creosote will markedly reduce the boiler’s efficiency and can provide conditions for flue and chimney fires.

Cleaning Procedure:

1) Turn off the power, make sure the fire is out, and allow the ashes to cool.

2) Vacuum all loose ash from the combustion area.

3) Brush the flue pipe and flue baffle.

4) Clean the walls of the firebox and empty all debris from the ash pan.

5) Reverse the procedure in preparation for firing.

Boiler Sealant: The addition of boiler sealant will damage the boiler and void the warranty.

Blower: The blower motor should be oiled according to the instructions of the blower manufacturer.

Coil Gasket: The coil gasket should be inspected regularly to ensure a proper seal.

Relief Valve: The relief valve should be tested yearly at the beginning of the heating season. Test the valve by operating the hand lever. Observe the valve closely after the test to be sure it is closing tightly and not dripping.

The boiler water legs and tube sheet of the NEW YORKER WC-130 should be flushed yearly to prevent the accumulation of scale or sludge. After flushing, refill the boiler immediately and either boil the water or heat it to at least 180°F to dissolve gases. You may add boiler water treatment chemicals when necessary to prevent internal scaling or corrosion, and maintain a pH higher than 7 but lower than 9.

The smoke pipe for your NEW YORKER WC-130 should be inspected on a regular basis during the heating season. Whenever possible, the smoke pipe should be dismantled and cleaned out. Carefully examine it for defects such as corrosion or seams coming apart. If any defects are noticed, the pipe should be replaced.

Since the NEW YORKER WC-130 is a supplemental heat source, it will be idle during warmer months. To prevent corrosion, a stringent maintenance program must be followed.

Fire Side Care:

1. After the last firing, when the boiler is cool, thoroughly clean the tubes and other heating surfaces, scraping down to clean metal. Clean the smoke box, ash box, and other areas where soot or scale may accumulate. It is necessary to remove all residue at the beginning of the non-operating season.

2. Keep the loading door, ash pit door, and smoke hood open to allow for good air circulation and reduce moisture. The manual flue damper should be in the closed position.

3. Swab the heating surface with neutral mineral oil to protect against rust.

4. If the boiler room is damp, take further precautions. Place a tray of calcium chloride, slaked lime, quicklime, or silica gel in the combustion chamber to absorb moisture. Alternatively, place a light bulb in the chamber to maintain a warm and dry environment.

To test the Low Water Cut Off (LWCO) on the heating system, follow these steps:

1. Shut off the fuel supply.

2. Lower the water level until it is BELOW the LWCO.

3. Generate a boiler demand by turning up the thermostat. The boiler should not attempt to operate.

4. Increase the water level by filling the system.

5. The boiler should attempt to operate once the water level is above the LWCO.