Thermo-Dynamics Boiler HT 100 Installation, Operation & Maintenance Manual Download Page 1

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Models HT 90/100/110, HT DV 90/100/110, HT 125/135/150

HT DV 125, HT 165/175/200 and HT 225/250/275

Installation

Operation

Maintenance

Manual

Thermo-Dynamics Boiler Company

ROUTE 61 • P.O. BOX 325 • SCHUYLKILL HAVEN, PA 17972

TEL (570) 385-0731 • FAX (570) 385-5304

WEB www.thermodynamicsboiler.com • EMAIL [email protected]

HT Series

Summary of Contents for HT 100

Page 1: ...T 165 175 200 and HT 225 250 275 Installation Operation Maintenance Manual Thermo Dynamics Boiler Company ROUTE 61 P O BOX 325 SCHUYLKILL HAVEN PA 17972 TEL 570 385 0731 FAX 570 385 5304 WEB www thermodynamicsboiler com EMAIL sales thermodynamicsboiler com HT Series ...

Page 2: ...ler Registered with National Board Factory Mounted Wired Burner and Controls Fully Insulated Heat Exchanger with Powder Coated Cabinet Packaged with Standard Five Gallon per Minute Tankless Coil Domestic Hot Water Equipped with Triple Aquastat Circulator and Temperature Altitude Gauge Outfitted with Additional Nozzles to Achieve a Variety of Heat Inputs Provided with a Lifetime Limited Warranty Fi...

Page 3: ...your boiler will allow you to enjoy the benefits of your new pur chase as well as extend its long useful life In the event that your serviceman encounters difficulty with the boiler he she shall contact the distributor from which the product was purchased The distributor shall in turn contact the Thermo Dynamics sales representative for your area By adhering to this protocol Thermo Dynamics wishes...

Page 4: ...area around the boiler must be kept clean and free of any combustible materials particularly oily rags or papers The boiler must be accessible for service D Annual Tune Up The boiler should be serviced once a year ideally just prior to the heating season The tune up is to be done by a qualified technician following procedures listed under Maintenance in this man ual E If Boiler Doesn t Start 1 Che...

Page 5: ...be properly sized Draft requirements are essential for safe and proper operation of the boiler 8 If the boiler is connected to a venting device make sure that it is listed by a recognized testing service Follow the venting device manufacturer s installation instructions Verify that the venting device installation complies with the recommendations of the manufacturer and local and state codes 9 Con...

Page 6: ...______________________________________________________________________ ___________________________________________________________________________________ ___________________________________________________________________________________ ___________________________________________________________________________________ _____________________________________________________________________________...

Page 7: ...OUTLET CHIMNEY VENT 5 FLUE OUTLET DIRECT VENT 37 7 16 37 29 3 16 22 3 4 31 3 4 22 1 16 22 1 2 4 3 4 10 3 4 13 1 8 30 5 8 39 1 4 14 1 8 12 1 2 4 3 4 22 1 16 24 33 42 45 1 8 45 1 2 35 5 16 2 RETURN INLET CIRCULATOR PIPED EITHER SIDE 2 SUPPLY OUTLET 8 FLUE OUTLET AQUASTAT RELAY T A GAUGE FIGURE 3 SERIES II BOILERS MODEL DIMENSIONS ...

Page 8: ...culated heat loss of the structure Over sizing will result in short cycling and inefficient operation D BOILER LOCATION 1 Boiler to be installed in a level position with clearances in accordance with NFPA 31 Table 10 6 1 STANDARD CLEARANCES Front 24 Sides 6 Top 18 Rear 12 Chimney Connector 18 Floor Sizes 90 150 may be installed on combustible flooring 2 Reduced clearance installations shall comply...

Page 9: ...e to provide air for combustion b In buildings of tight construction when the basement windows are weather stripped one open ing to a well ventilated attic or with the outdoors should be provided See part A for opening requirements 3 Special Conditions When a boiler is located in an area where exhaust fans kitchen ventilation systems clothes dry ers or fireplaces may create conditions of unsatisfa...

Page 10: ...ly line or Riser tapping in the top of the boiler extends approximately 1 below the top or waterline of the boiler thus allowing only air free water to enter the supply to the heating system The air trapped in the top of the boiler is then purged through a 3 4 vent tapping to be released with an 1 automatic float vent 2 a manual vent or 3 piped into a conventional type expansion tank All plugs and...

Page 11: ...E REDUCING VALVE AIR VENT EXPANSION TANK RELIEF VALVE HYDRONIC SYSTEM SUPPLY FLOW VALVE RETURN ALTERNATE RETURN LOCATED ON OPPOSITE SIDE OF BOILER CIRCULATOR MAY ALSO MOUNT THE CIRCULATOR ON SUPPLY DRAIN VALVE DRAFT SIGHT PORT AIR VENT EXPANSION TANK RELIEF VALVE SECONDARY HIGH LIMIT HYDRONIC SYSTEM SUPPLY FIGURE 7 PIPING DIAGRAM FOR SERIES II BOILERS PIPING THE SAME EXCEPT THE ADDITION OF A SECON...

Page 12: ...s 2 Oil Primary Control Chimney Vent Non Post Purge Control The oil primary control with the solid state flame sensing circuit provides automatic non recy cling control of oil burners When used with the cadmium sulfide flame detector the control will automatically control the oil heating system The primary control will stop the oil burner within a predetermined number of seconds if the fuel fails ...

Page 13: ...ions require a longer purge cycle The length of post purge on the Carlin burner is not adjustable The post purge timing on the Carlin burner is 90 seconds 4 Aquastat Relay This control is installed in the 3 4 fitting next to the domestic coil These immersion type con trols are used with forced hydronic heating systems which include domestic water service This model provides high and low limits for...

Page 14: ...sfied L FUEL SYSTEM 1 Fuel Units NOTE Pump pressure 140 PSI for Beckett and Carlin 175 PSI for Beckett NX and 150 PSI for Riello a Burners are commonly fitted with a single stage fuel unit A single stage unit may be con nected with a supply line only when the fuel supply is level with or above the burner When the burner is above the oil level a return line should be provided between the fuel unit ...

Page 15: ...nstall a U L listed vent cap where the possibility of down drafts exist 6 Boiler Venting This boiler must be vented into a properly sized chimney or into an Underwriters Laboratories Inc listed venting device which is capable of maintaining the specified draft requirements As indicated in this manual chimney sizes draft requirements and other additional service and installation requirements are es...

Page 16: ...s at 160 F 6 Set limit switch at 180 F 7 Install a pressure gauge in the 1 8 gauge port or nozzle port of the fuel pump Do not take readings at the bleed valve port NOTE The pressure should be set per Installer Serviceman Label 8 Adjust the burner air band and air shutter in accordance with Installer serviceman Label 9 Push the safety reset button on the primary control and release Adjust the ther...

Page 17: ...2 to 2 A zero smoke reading should result If this adjustment cannot be obtained refer to the trou ble shooting section in this manual f Stack Temperatures Check to see that the stack temperature is according to the installer ser viceman labels for Series I and II boilers starting on page 30 3 Instructing the Homeowner The care and operation of the boiler should be explained to the homeowner includ...

Page 18: ...eaning 4 Remove the oil burner to inspect the burner head Any soot or scale can be removed from the chamber through the burner opening NOTICE DO NOT REMOVE THE REAR COVER AND REAR REFRACTORY FOR NORMAL MAINTENANCE SOOT OR SCALE MUST BE REMOVED FROM THE FRONT BURNER OPENING ONLY D OIL BURNER 1 Thoroughly brush clean the burner fan blades Only with clean fan blades is proper combus tion air delivery...

Page 19: ...for line voltage between Control the black and white leads No voltage indicates no power to the control Check for line voltage between orange and white leads No voltage indicates a faulty control Burner Check for voltage at the black and white leads to the burner motor Voltage indicates power to motor and a fault in the burner Open cad cell wires Dirty cell face Faulty cad cell If 400 600 ohms cel...

Page 20: ...mp worn low pressure Motor overloads Coupling worn or broken Pump discharge pressure set too low No spark or weak spark Line voltage below 102V Carboned and shorted electrodes Eroded electrode tips Incorrect electrode settings Cracked porcelain insulators Plugged orifice or distributor Plugged nozzle strainer Poor spray pattern Incorrect nozzle installed Air shutter open too far Air band open too ...

Page 21: ...d cell Replace primary control Clean out heat exchanger Call utility company Replace motor Replace blower or pump SOURCE PROCEDURE CAUSES REMEDY TROUBLE BURNER FIRES BUT THEN FAILS ON SAFETY Circulator Check to see if operating control is working properly Thermostat Check thermostat settings and calibration FlowValve Check to see if flow valve is operating properly Circulator does not stop running...

Page 22: ...upply valve closed Restriction in oil line Plugged fuel filter Plugged pump strainer Cold oil Too much combustion air Pump discharge pressure incorrectly set Coupling worn or broken Pump worn low pressure motor overloads Incorrect draft setting Leak in flue system Weak fluid Plugged orifice or distributor Plugged nozzle strainer Poor spray pattern Replace nozzle with specified nozzle Reduce draft ...

Page 23: ...tment Air leak in fuel system Compression fittings Water in oil tank Pump discharge pressure incorrectly set Coupling worn or broken Pump worn low pressure motor overloads Plugged orifice or distributor Plugged nozzle strainer Poor spray pattern Plugged heat exchanger Install vent cap Increase draft setting Reduce draft settings install second draft regulator if necessary Move draft regulator to c...

Page 24: ...fective Operating control defective Circulator too small Circulator defective Insufficient voltage Settings too low Bad location due to heat build up Out of calibration Flow valve not opening fully Radiators airbound Radiators inadequate Boiler too small Piping inadequate Insufficient heat transfer Insufficient pump pressure Wrong nozzle installed Nozzle underfiring due to defective nozzle Replace...

Page 25: ...es not installed Install baffles SOURCE PROCEDURE CAUSES REMEDY TROUBLE HIGH NET STACK TEMPERATURES Tankless Analyze capacity vs usage Insufficient coil capacity Install larger coil Coil Operating Check operating control Setting too low Set operating control to 180 F Control Raise differential set point Heat Inspect coils for fouled surfaces Flow restriction Remove restriction Exchanger and or flo...

Page 26: ...TE 06 FRONT COVER 07 FRONT REFRACTORY BOARD 08 TURBULATOR 09 RIGHT SIDE JACKET 10 LEFT SIDE JACKET 11 FRONT UPPER JACKET 12 FRONT LOWER JACKET 13 TOP JACKET 14 REAR JACKET 15 COIL GASKET 16 3 8 16 CARRIAGE BOLT 17 3 8 16 CARRIAGE BOLT 18 3 8 16 BRASS HEX NUT 19 3 8 WASHER 20 3 8 SPACER 21 3 8 X 3 4 SPACER 22 3 8 16 XHVHEX NUT 23 CHAMBER LINER ...

Page 27: ...GPM cartoned with Gasket 530245 6 Front Cover 241124 7 Front Refractory Board 1 337921 8 Turbulator 10 for 90 110 16 for 125 150 241150 9 Right Side Jacket 501104 10 Left Side Jacket 501103 11 Front Upper Jacket 501105 12 Front Lower Jacket 501101 13 Top Jacket 501106 14 Rear Jacket 501107 15 Coil Gasket 481005 16 3 8 16 x 4 Carriage Bolt Qty 4 311113 17 3 8 16 x 2 Carriage bolt Qty 12 311110 18 3...

Page 28: ...late Blank 229151 5b Coil 5 GPM cartoned with Gasket 530245 5c Coil 7 GPM Cartoned with Gasket 530246 6 Front Cover 241350 7 Front Refractory Board 1 337415 8 Turbulator 0 for 165 200 12 for 225 275 241155 9 Right Side Jacket 10 Left Side Jacket 11 Front Upper Jacket 12 Front Lower Jacket 13 Top Jacket 14 Rear Jacket 15 Coil Gasket 481005 16 3 8 16 x 7 Carriage Bolt Qty 4 311103 17 3 8 16 x 2 Carr...

Page 29: ..._____ ________________________ ________________________ ________________________ ________________________ INSTALLER SERVICEMAN Model Number HT 90 HT 100 HT 110 Burner Type Riello Riello Riello Burner Model F5 F5 F5 Nozzle Type 75 60B 85 60B 90 60B Pump Pressure PSI 150 150 150 Head Pin Position 1 5 2 0 2 5 Air Band N A N A N A Air Shutter 2 0 2 5 2 75 Draft Over Fire 04 06 08 Draft In Stack 0 02 0...

Page 30: ...____________________ ________________________ ________________________ INSTALLER SERVICEMAN Model Number HT 90DV HT 100DV HT 110DV Burner Type Carlin Carlin Carlin Burner Model EZ 1 EZ 1 EZ 1 Nozzle Type 75 60A 85 60A 90 60A Pump Pressure PSI 140 140 140 Head Pin Position 85 1 00 85 1 00 1 10 1 25 Air Band 100 100 125 Air Shutter N A N A N A Draft Over Fire 085 085 085 Draft In Stack 0 02 0 02 0 0...

Page 31: ...__ ________________________ ________________________ ________________________ ________________________ INSTALLER SERVICEMAN Model Number HT 125 HT 135 HT 150 Burner Type Beckett Beckett Beckett Burner Model AFG AFG AFG Nozzle Type 1 00 80 B 1 10 80 B 1 25 80 B Pump Pressure PSI 140 140 140 Head Pin Position F 6 F 6 F 6 Air Band 2 4 5 6 Air Shutter 10 10 10 Draft Over Fire 085 085 085 Draft In Stac...

Page 32: ...__________ ________________________ ________________________ ________________________ ________________________ ________________________ INSTALLER SERVICEMAN Model Number HT 125 HT 135 HT 150 Burner Type Riello Riello Riello Burner Model F5 F5 F5 Nozzle Type 1 00 60B 1 10 60B 1 25 60B Pump Pressure PSI 150 150 150 Head Pin Position 2 5 3 5 4 0 Air Band N A N A N A Air Shutter 3 0 3 5 4 5 Draft Over...

Page 33: ..._______ ________________________ ________________________ ________________________ INSTALLER SERVICEMAN Model Number HT 90DV HT 100DV HT 110DV Burner Type Beckett Beckett Beckett Burner Model NX NX NX Nozzle Type 0 70 60 B 0 75 60 B 0 85 60 B Pump Pressure PSI 175 175 175 Head Pin Position 2 0 2 5 3 75 Air Band N A N A N A Air Shutter N A N A N A Draft Over Fire 0 040 0 090 0 160 Draft In Stack 0 ...

Page 34: ...33 ELECTRICAL DIAGRAM FOR HT SERIES BOILERS TO CONNECT BURNER TO AQUASTAT APPLIES TO BECKETT CHIMNEY VENT BURNERS ...

Page 35: ...34 ELECTRICAL DIAGRAM FOR HT SERIES BOILERS TO CONNECT BURNER TO AQUASTAT APPLIES TO BECKETT DIRECT VENT BURNERS ...

Page 36: ...35 ELECTRICAL DIAGRAM FOR HT SERIES BOILERS TO CONNECT BURNER TO AQUASTAT APPLIES TO CARLIN CHIMNEY VENT AND CARLIN DIRECT VENT BURNERS ...

Page 37: ...36 ELECTRICAL DIAGRAM FOR HT SERIES BOILERS TO CONNECT BURNER TO AQUASTAT APPLIES TO RIELLO CHIMNEY VENT BURNERS ...

Page 38: ...37 ELECTRICAL DIAGRAM FOR HT SERIES BOILERS TO CONNECT BURNER TO AQUASTAT APPLIES TO RIELLO DIRECT VENT BURNERS ...

Page 39: ...gligent or improper operation or installation g corrosion of tubes or plates such as oxygen attack h leaky gaskets i improper water conditioning k improper maintenance of external and fireside surfaces 5 This limited warranty will not be applicable if the boiler is used or operated over its rated capacity or installed for uses other than home heat ing or is not maintained in accordance with Thermo...

Page 40: ...Replaced Nozzle Yes No 11 Clean Pump Filter Yes No 12 Inspect Coil Gasket 13 Check for Leaks plugs fittings 14 Brush Clean Flue Tube Passages 15 Vacuum Chamber Flue Tubes 16 Clean Blower Wheel 17 Check Set Electrodes See pump pressure according to the installer serviceman labels for Series I and II boilers MET 3985 12 09 500 bURNER SERVICE SET UP RECORDS ...

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