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Thermo Dynamics TDX-100, Installation And Operating Manual, Page: 3 / 24

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TDX Series

Boiler Installation and Operating Manual

Contents

Subject

Page

Read This First

2

Specifications

4

Installation

4

Operational Sequence

7

Start-Up

8

Appendices

Troubleshooting Guide

A

14

Dimensions

B

16

Piping Diagrams

C

17

Wiring Diagrams

D

18

Installer/Serviceman Labels

E

20

Burner Service Set Up Records

22

Installation and Service Check List

Back Cover

Summary of Contents for TDX-100

Page 1: ...Installation Operation Maintenance Manual TDX Series Thermo Dynamics Boiler Company ROUTE 61 P O BOX 325 SCHUYLKILL HAVEN PA 17972 570 385 0731 FAX 570 385 5304 www thermodynamicsboiler com ...

Page 2: ... and maintenance of your boiler will allow you to enjoy the benefits of your new purchase as well as extend its long useful life In the event that your serviceman encounters difficulty with the boiler he she shall con tact 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 Th...

Page 3: ...s First 2 Specifications 4 Installation 4 Operational Sequence 7 Start Up 8 Appendices Troubleshooting Guide A 14 Dimensions B 16 Piping Diagrams C 17 Wiring Diagrams D 18 Installer Serviceman Labels E 20 Burner Service Set Up Records 22 Installation and Service Check List Back Cover ...

Page 4: ...re Over sizing will result in short cycling and inefficient operation 6 When moving the boiler do not push against the jacket or burner Damage will result 7 If the boiler is vented to a chimney be certain the chimney is clean and free of obstructions The chimney must be masonry with tile lining or metal insulated with a stainless steel surface The Chimney must be properly sized Draft requirements ...

Page 5: ... hazardous situation which if not avoided may result in a minor injury It may also warn against unsafe practices that may result in minor njury or damage to equipment NOTICE Indicates that special attention to information is required Not related to personal injury or property damage 12 Modifications substitutions or removal of equipment supplied or specified may result in property damage personal ...

Page 6: ...ath by scalding WARNING Relief valve discharges and drain valve piping must be piped to a safe place of discharge NOTICE TDX Series Boilers are provided with a built in air scoop feature This feature allows quiet air free operation of the hot water system by eliminating air pockets without installation of air scoops The supply line tapping in the top of the boiler extends approximately 1 inch belo...

Page 7: ...your model boiler Use only elbows and straight sections Tees may be used in a straight section in conjunction with a barometric draft regulator however they must not be used for a 90 turn Each joint should be securely fastened with sheet metal screws The flue pipe must not be inserted beyond the inside wall of the chimney Install barometric draft regulator in the horizontal or vertical section of ...

Page 8: ... unit in lift conditions of up to 10 ft and a two stage fuel unit when the lift exceeds 10 ft Both conditions require the use of a return line which purges the fuel unit of air returning it to the fuel tank The by pass plug must be inserted into the fuel unit when installing a return line Two pipe Fuel line installation Continuous lengths of heavy wall copper tubing are recommended and should be i...

Page 9: ...inside wall away from cold drafts windows or heat from fireplaces appliances or sunlight Set the heat anticipator in accordance with the manufacturer s instructions Connect the thermostat leads to the TT terminals on the circulator control C Operational Sequence 1 TDX WC equipped with tankless coil are equipped with a combination aquastat control which has high and low limits to be set at 180 F an...

Page 10: ...uirements are satisfied If the thermo stat continues to call for heat after the boiler water temperature has dropped to approximately 15 degrees below the temperature setting of the high limit control the oil burner will start again and the circulating pump will continue to run b The boiler water temperature need not be maintained at a160 F low limit setting since there is no domestic hot water lo...

Page 11: ...nds after the fuel stream is free of all air If air is still evident in the bleed line you must check the oil lines all fittings fil ters and any other connections for tightness Kinks in the fuel lines will create undue high vacuum therefore they must be eliminated When you are sure all air has been eliminated then close the bleed valve Ignition should be instantaneous following the closing of thi...

Page 12: ...zero smoke reading should result If this adjustment can not be obtained refer to the Trouble Shooting section of this manual f When combustion is set follow the burner manufacturer s instructions to lock or tighten adjustment mechanisms as required 10 Check operation of the cad cell relay by removing one cad cell wire from external termi nal during the flame cycle The relay should cut the burner o...

Page 13: ...l wires from the aquastat control to the burner c Remove the brass nuts that secure the hinged burner door and carefully open the door d Remove the rear cover on the flue box e Remove baffles from the units and clean them Brush all tubes and the furnace tube with a 2 soft flue brush Use a boiler vacuum to collect any residue f Inspect the burner head Remove any accumulation on the burner Inspect a...

Page 14: ...inge is attached to the boiler The hinge pin is on the outside 8 Attach the door bracket to the door using two brass nuts Swing the door to make sure that it is free and that the door bracket fits over the boiler studs on the other side Make final adjustments and tighten all nuts 9 Close the door and attach the bracket to the boiler using two brass nuts Do not tighten completely 10 Install the bur...

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Page 18: ... LC 6 7 8 8 Return from heating circuits 8 6 7 1 2 4 3 Return from heating circuits TDX WC 8 Burner 5 Supply to heating circuits Domestic Hot Water Coil Hot Water Out Dishwasher Tempered Hot Water Cold Water In 9 Legend 1 Circulator 2 Relief Valve 3 Expansion Tank Pressurized 4 Vent 5 Flow Check 6 Shut off valve 7 Auto Refill Pressure reducing valve 8 Drain 9 Tempering Valve 10 Manual Bypass Valve...

Page 19: ...ERIES BOILERS TO CONNECT BURNER TO AQUASTAT APPLIES TO CARLIN CHIMNEY VENT AND CARLIN DIRECT VENT BURNERS ELECTRICAL DIAGRAM FOR TDX SERIES BOILERS TO CONNECT BURNER TO AQUASTAT APPLIES TO BECKETT CHIMNEY VENT AND DIRECT VENT BURNERS ...

Page 20: ...AL DIAGRAM FOR TDX SERIES BOILERS TO CONNECT BURNER TO AQUASTAT APPLIES TO RIELLO CHIMNEY VENT BURNERS ELECTRICAL DIAGRAM FOR TDX SERIES BOILERS TO CONNECT BURNER TO AQUASTAT APPLIES TO RIELLO DIRECT VENT BURNERS ...

Page 21: ...__________________ _____________________________ INSTALLER SERVICEMAN Model Number TDX WC 90 TDX WC 100 TDX WC 110 TDX WC 125 DV DV DV DV Burner Type Beckett Beckett Beckett Burner Model NX NX NX Nozzle Type 0 70 60 B 0 75 60 B 0 85 60 B N A Pump Pressure PSI 175 175 175 N A Head Pin Position 2 75 3 25 4 00 N A Air Band N A N A N A N A Air Shutter N A N A N A N A Draft Over Fire 0 080 0 115 0 125 ...

Page 22: ... Reading ZERO ZERO ZERO ZERO Carlin Air Boot Adaptor NOTICE Above settings are approximate Final adjustments to be made with proper test equipment Be sure all oil lines are air free and the use of flare fittings is recommended See installation ser vice manual for detailed information _____________________________ _____________________________ _____________________________ _________________________...

Page 23: ...s Stack F 8 Draft Over Fire 9 Replaced Filter Yes No 10 Replaced Nozzle Yes No 11 Clean Pump Filter Yes No 12 Inspect Coil Gasket Yes No 13 Check for Leaks 14 Brush Clean Flue Tube Passages 15 Vacuum Chamber Flue Tubes 16 Clean Blower Wheel 17 Check Electrodes BURNER SERVICE SET UP RECORDS 22 ...

Page 24: ...stem inspected to NFPA 211 and in good condition q New vent pipe installed and properly sealed q Vent size checked against furnace manual and codes Burner Operation q Burner Model ____________________ Nozzle _____ GPH _____ Deg _____ Type _____ q Burner Pump Pressure _________________ q Fuel Filer and fuel lines installed and inspected as per burner manual q Air bled from oil piping Piping checked...

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