Thermo-dynamics boiler Ht 250 Instruction manual

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

aintenance

anual

Thermo-Dynamics Boiler Company

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

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

WEB www.thermodynamicsboiler.com • EMAIL sales@thermodynamicsboiler.com

HT Series

Service Policy 2

Homeower Information 3

Read This First 4

Model Specifications 5

Installation 7

Operation 15

Maintenance 17

Trouble Shooting 18

Parts List 26, 27

Preliminary Settings 28

Wiring Diagrams 33

Warranty 38

Burner Service Set-Up Records Back Cover

• ASME Coded Boiler 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

Figure 1 Thermo Dynamics HT 90/100/110 DV Series

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Congratulations on the purchase of your boiler. At Thermo-Dynamics Boiler

Company we pride ourselves on the design and construction of our product. Our

intent is to furnish you with a high quality appliance that will provide you and your

family with years of trouble free service.

In order to maintain peak performance of your boiler, it is recommended that

the burner/boiler be serviced annually, preferably prior to the onset of the winter

heating season. Servicing of your appliance must be performed by a qualified heat-

ing technician. You should utilize a qualified heating technician familiar with your

installation to manage your heater and perform periodic maintenance. Proper care

and maintenance of 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 to provide you with responsive

and unparalleled service. We realize the importance that our product means to you

and your family and our goal is to get your boiler up and running as quickly as pos-

sible.

Thank you for purchasing the Thermo-Dynamics boiler. Again, it is our intent

to provide you with a high quality trouble free product that will be part of your fam-

ily for many years to come. Please consider Thermo-Dynamics Boiler Company in

the future for all of your home heating needs.

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Heating Contractor:

Address:

Phone No.:

A) General

Installation and service is to be done only by a certified and qualified technician.

Never burn garbage or refuse in your boiler or leave combustible material around it. Do not allow

the fuel tank to run out of oil. The fuel tank should be kept full during the summer, or periods of

non-use, to prevent condensation of moisture on the inside of the tank.

B) Combustion Air Supply

The burner requires an ample amount of clean combustion air to burn efficiently. If ample supply

is not available, noisy and erratic combustion will result. Under these conditions fuel odors may

occur. The installation and use of venting fans (anywhere in the house) or a vented dryer will

greatly increase the need for outside air.

C) Area Around Boiler

The 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) Check if there is fuel in the tank.

2) Is thermostat setting above room temperature.

3) Is service switch in the “on” position.

Should there be a problem with operation of the boiler, call a qualified service technician. Do not

tamper with the unit or controls. Working with a burner and setting-up the combustion process

requires specific technical knowledge, skills and instruments. In addition, your boiler is only part

of your overall home heating system. Other controls (etc.) may require adjustment or replacement.

F) Keep this manual in a safe place near your boiler as reference for your service

technician.

Read This First

1. Installer must be a trained, experienced technician and should read all instructions before

installation.

2. Inspect the boiler, jacket and all components to be sure damage has not occurred

in shipment. If damage is evident, do not install the boiler. Contact your distributor

immediately. A claim must be filed with the freight carrier that transported the boiler

from the factory to the distributor.

3. Disconnect power supply before connecting wiring.

4. efer to local codes for oil burning equipment, for recommended installation practice. You

will need to be familiar with NFPA Standard 31, “Standard for the Installation of Oil

Burning Equipment”.

5. A complete heat loss calculation is necessary to choose the proper size unit to install. The

boiler should be sized to within 25% of the actual heat loss of the structure. 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 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. Conduct a thorough checkout when installation is complete. Check for indications of

leaks and make sure that no material is left adjacent to the boiler.

10. The use of low sulfur No. 2 heating oil is highly recommended.

11. Modification, substitution or elimination of factory equipped, supplied or specified

components may result in property damage, personal injury or the loss of life.

12. The following definitions apply to potential hazards noted in this manual.

DANGER: Indicates a hazardous situation which if not avoided will result in death or serious

injury.

WARNING: Indicates a hazardous situation which if not avoided could result in death or

serious injury.

CAUTION: Indicates a hazardous situation which if not avoided, may result in a minor injury.

It may also warn against unsafe practices that may result in minor injury or damage to

equipment.

NOTICE: Indicates that special attention to information is required. Not related to personal

injury or property damage.

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Table 1 - Series I Boilers

Model 90/100/110* Model 125/135/150*

nput 126,000 140,000 154,000 175,000 189,000 210,000

Heat Capacity 109,000 121,000 132,000 150,000 161,000 178,000

Gross Output N/A N/A N/A N/A N/A N/A

Net Out 95,000 105,000 115,000 130,000 140,000 155,000

Firing Rate 0.90 1.00 1.10 1.25 1.35 1.50

Tubes 10 10 10 16 16 16

Baffles Fully Baffled Fully Baffled Fully Baffled Fully Baffled Fully Baffled Fully Baffled

Water Content 30 30 30 28 28 28

Supply 1-1/4" 1-1/4" 1-1/4" 1-1/4" 1-1/4" 1-1/4"

Returns (2) 1-1/4" 1-1/4" 1-1/4" 1-1/4” 1-1/4" 1-1/4"

Coil Capacity 5 GPM 5 GPM 5 GPM 5 GPM 5 GPM 5 GPM

Steady State 86.5 86.2 85.5 85.6 85.4 84.9

AFUE - DOE Efficiency 85.1 84.8 84.2 85.0 84.7 84.0

Combustion Efficiency N/A N/A N/A N/A N/A N/A

Overall Efficiency N/A N/A N/A N/A N/A N/A

Weight 458 458 458 485 485 485

Burner Model Beckett AFG, Beckett AFG, Beckett AFG, Beckett AFG Beckett AFG Beckett AFG

AF and NX AF and NX AF and NX Beckett AF Beckett AF Beckett AF

Carlin EZ-1 Carlin EZ-1 Carlin EZ-1 Carlin EZ-1 Carlin EZ-1 Carlin EZ-1

Riello F5 Riello F5 Riello F5 Riello F5 Riello F5 Riello F5

Riello BF5 Riello BF5 Riello BF5 Riello BF5

*Model 90/100/110 and 125 available in choice of chimney or direct vent. With AF , NX EZ1 and BF5 burners only.

Table 2 - Series II Boilers

Model 165/175/200 Model 225/250/275

nput 231,000 245,000 280,000 315,000 350,000 385,000

Heat Capacity 200,000 212,000 242,000 N/A N/A N/A

Gross Output N/A N/A N/A 264,000 291,000 319,000

Net Out 174,000 184,000 210,000 230,000 253,000 277,000

Firing Rate 1.65 1.75 2.00 2.25 2.50 2.75

Tubes 18 18 18 24 24 24

Baffles Not Baffled Not Baffled Not Baffled Top Pass Baffled Top Pass Baffled Top Pass Baffled

Water Content 48 48 48 46 46 46

Supply 2" 2" 2" 2" 2" 2"

Returns (2) 2" 2" 2" 2” 2" 2"

Coil Capacity 5 (7 GPM opt.) 5 (7 GPM opt.) 5 (7 GPM opt.) 5 (7 GPM opt.) 5 (7 GPM opt.) 5 (7 GPM opt.)

Steady State 86.7 86.5 85.4 N/A N/A N/A

AFUE - DOE Efficiency 86.0 85.6 84.6 N/A N/A N/A

Combustion Efficiency N/A N/A N/A 85.5 85.2 84.9

Overall Efficiency N/A N/A N/A 83.7 83.3 82.9

Weight 680 680 680 710 710 710

Burner Model Beckett AFG “M” Beckett AFG “M” Beckett AFG “M” Beckett CF375 Beckett CF375 Beckett CF375

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FIGURE 2 - SERIES I BOILERS

AQUASTAT RELAY

T/A GAUGE

1-1/4" RETURN INLET/CIRCULATOR

PIPED EITHER SIDE 1-1/4" SUPPLY OUTLET

6" FLUE OUTLET (CHIMNEY VENT)

5" FLUE OUTLET (DIRECT VENT)

37 7/16

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

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

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A) GE ERAL

The installation of the unit shall be in accordance with state and local regulations.

B) FREIGHT CLAIMS

All units should be inspected for damage upon arrival. Concealed damage claims should be filed

immediately against the carrier by the consignor. The carrier is responsible for taking prompt

action on all claims.

C) SIZI G

Replacement boilers should not be sized from the firing rate of the old boiler; a DOE sponsored

study indicated 65% of the heating units in U.S. homes are substantially oversized. A complete

heat loss calculation of the structure is necessary to choose the proper size unit to install. The boil-

er should be sized to within 25% of the actual calculated heat loss of the structure. Over sizing

will result in short cycling and inefficient operation.

D) BOILER LOCATIO

1. Boiler to be installed in a level position with clearances in accordance with NFPA 31 Table

10.6.1.

STA DARD CLEARA CES

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 with NFPA 31 Table 10.6.2.

3. To move the unit, push against the flue box or skids. Pushing or pulling the jacket or burner

will result in damage.

4. Be sure to level the unit by inserting shims under the elevated base.

E) AIR FOR COMBUSTIO A D VE TILATIO - CHIM EY VE T APPLICATIO S

The unit must be installed where provisions exist for combustion and ventilation air. Ordinarily,

provisions may be furnished by the following methods.

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1. Utility Room or Closet

In buildings of tight construction, including most modern homes, you should provide an opening,

connecting to a well ventilated attic, crawl space or directly with the outdoors. The opening should

have a minimum free area of 1 square inch per 1,000 Btu per hour of total input for all appliances

in the enclosure and should terminate below the burner level. Boilers installed in confined areas

or closets must have two ventilation openings in the closet door. Each opening should have a free

area of not less than 1 square inch per 1000 Btu (140 square inch per US gph) of the total input

for all appliances in the enclosure. One opening located near the top of enclosure and one near

the bottom.

2. Basement

a. When a boiler is installed in a full basement, infiltration is normally adequate 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 unsatisfactory combustion or venting, special provi-

sions should be made for additional air for combustion, as specified by local authority.

F) AIR FOR COMBUSTIO A D VE TILATIO - DIRECT VE T APPLICATIO S

CAUTION: External vent surfaces are hot..

NOTICE: Use only the ETL listed venting system components supplied with the TV-175 Direct

Vent Kit.

Surface discoloration of the building may occur due to improper boiler/burner adjustment.

Thermo Dynamics Boiler Company will not accept any liability for such discoloration.

Follow the instructions provided with the TV175 Direct Vent Kit for locating and installing the

vent kit.

G) JACKET A D TRIM ASSEMBLY

1. Knock Down Boiler

a. Jacket Assembly - Unpack the jacket parts being careful not to damage the finish. Piping and

accessories are installed after the jacket is in place.

b. Trim Assembly

Install the safety relief valve in the 3/4" tapping in the top of the boiler. The relief valve should

be piped to a safe place of discharge.

Install the limit control in the 3/4" fitting provided in the boiler plate.

Install the altitude/temperature gauge in the 1/4" fitting provided in the coil plate.

Install plugs provided in the parts box in all openings that are not used.

2. Packaged Boiler

Controls and burner are installed and prewired at the factory. Install Relief Valve as noted in

Figures 6 and 7.

H) BOILER PIPI G

This style of boiler is equipped with a built in “Air Scoop

System.” This feature allows quiet air free operation of your

hot water system by assuring the removal of noisy air pock-

ets. The supply 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 water connec-

tions should be checked for leaks upon installation and annual-

ly.

WARNING: elief valve discharges and drain valve piping must be piped to a safe place

of discharge.

I) TA KLESS WATER HEATI G PIPI G

The tankless heater may be connected as shown in Figure 6. High temperature water for a dish-

washer may be obtained by piping as shown.

The nuts that secure the tankless coil flange should be tightened before the boiler is filled with

water, after initial firing and every year during annual maintenance. Deterioration due to coil gas-

ket leaks shall void warranty.

WARNING: An anti-scald/mixing valve (not supplied) must be used to reduce the water

temperature at kitchen or bathroom taps.

FIGURE 5

BUILT-IN AIR SCOOP

FIGURE 6 - PIPING DIAGRA FOR SERIES I BOILERS

WATER SUPPLY

STOP VALVE

DOMESTIC

COLD WATER

ANTI-SCALD/MIXING

VALVE

TEMPERED

WATER

(SHOWERS AND

FAUCETS)

HOT WATER

(DISHWASHER)

BALL VALVE

BACK FLOW PREVENTER

PRESSURE 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 DIAGRA FOR SERIES II BOILERS

(PIPING THE SA E EXCEPT THE ADDITION OF A SECONDARY HIGH LI IT)

J) BUR ER A D CO TROLS

1. Burner Installations

Packaged boilers are shipped with the burner installed and prewired. Boilers that are shipped

knocked-down must be field assembled. Follow the procedures listed below to install and connect

the burner.

a. Remove the burner parts and instructions from the carton.

b. Referring to specifications at the back of the manual, check to see that the burner model and

size match the boiler model.

c. Make sure the correct nozzle is in place and is tightly sealed.

d. Check the electrode position and set the air intake as indicated in the burner manual.

e. The burner is installed with a mounting flange. The end of the burner air tube should be 1/4"

from the inside surface of the front wall of the combustion chamber.

f. Make the electrical connections as illustrated in the wiring schematics. All wiring must be done

in accordance with the local electrical code. A service box is provided with disconnect switch so

power can be shut off to the boiler, but power for a utility lamp is still available.

g. For units installed in Maine, New ersey and New York, a low-water cutoff is required on all

hot water boilers.

2. Oil Primary Control - Chimney Vent ( on 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 to ignite or if the flame goes out during operation. The oil burner will remain off until the

reset button on the relay has been pushed.

WARNING: The reset must never be pressed more than once during a single flame fail-

ure.

3. Oil Primary Control - Direct Vent (Post Purge Control)

The oil primary control with the solid state flame sensing circuit provides interrupted ignition.

Used in conjunction with a cadmium sulfide flame detector, the control will automatically con-

trol the oil burner.

The primary control will stop the oil burner within a predetermined number of seconds if the fuel

fails to ignite or if the flame goes out during operation. The oil burner will remain off until the

reset button on the relay has been pushed.

WARNING: The reset must never be pressed more than once during a single flame fail-

ure.

Post-purge is provided to ensure that the boiler fires at maximum efficiency and dependability

throughout the heating season.

Post-purge of the oil burner is controlled through the electronic circuitry supplied. Post-purge tim-

ing is variable. The factory set post-purge timing is at approximately one minute. It is recom-

mended that it be left at this setting. In no case should the post purge timing be reduced to less

than 1 minute.

Length of Vent Kit Minimum Post Purge Time

0 - 10 Feet 1 Minute

10.1 - 15 Feet 1 Minute

15.1 - 20 Feet 2 Minutes

Times are approximate and should be considered minimum settings for the length of intake pipe

installed.

The length of post-purge may be increased on those units using the Beckett AFII or Riello BF-5

oil burners to any value up to its maximum setting if field conditions 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 maintaining minimum boiler water temperature and cir-

culator controls. This control can also be used for multi-zone control by using a separate circula-

tor and an R845 relay for each zone. The primary control is factory wired to the aquastat relay.

These controls, working as a system, will prevent the circulator operation if the water tempera-

ture is below a predetermined low level. Likewise, if the water level reaches a predetermined high

limit, the burner will automatically shut off.

K) SEQUE CE OF OPERATIO

Forced Circulation Hot Water System with Tankless Heater

When room temperature falls below thermostat setting, the thermostat calls for heat start-

ing the circulating pump. The burner and pump continue to operate until room heating require-

ments are satisfied (thermostat setting is reached), or until boiler water temperature reaches high

limit control temperature setting. If the high limit control temperature setting is reached, the burn-

er shuts off, the circulating pump continues to operate until the room heating requirements are sat-

isfied. If the thermostat continues to call for heat after the boiler water temperature has dropped

below the temperature setting of the high limit control the oil burner will start again, while the

circulating pump will continue to run.

The boiler water temperature is normally maintained at 160°F around the tankless coil by

the operating control so that an abundance of hot water is available. If the boiler water tempera-

ture should fall below the operating control setting (160°F), the oil burner will be started again by

that control (and the circulating pump will be prevented from operating) until the operating con-

trol setting is satisfied.

L) FUEL SYSTEM

1. Fuel Units

OTE: 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 and the tank.

A “by-pass” plug in the fuel unit is then required. The return line automatically purges air from

fuel units and returns it to the tank.

b. Two stage fuel unit. If the height difference between the burner and the fuel supply level

exceeds 10 ft., a two stage unit should be used, and a return line should be installed.

2. Tubing

Use continuous heavy walled copper tubing with flare fittings only. Locate fittings in accessible

locations. If possible, tubing should be installed under the floor. Running tubing against boiler

casings or across ceiling or floor joints should be avoided.

3. In-Line Oil Filter

The oil filter should be of a generous capacity. It should be located inside the building between

the tank shut off valve and the burner. A shut off valve and the oil filter should be located as close

to the burner as possible for ease of servicing.

4. Oil Shut Off Valve

Install manual oil shut off valves at the burner and near the tank on the supply line. Both valves

should be easily accessible.

M) FLUE SYSTEM - CHIM EY VE T APPLICATIO S

1. General

NOTE: An oil fired unit shall be connected to a flue having sufficient draft at all times to

assure proper operation.

2. Draft

The draft regulator should be installed in accordance with the manufacturers instructions. Set the

draft to negative .02 to .04 inches W.C. in the stack.

3. Roof Clearances

The flue gas exit of the venting system should be at least 3 feet above the highest point where it

passes through the roof and at least 2 feet higher than any portion of a building with 10 feet of the

venting system.

4. Chimney Connectors

The horizontal length of a chimney connector should not exceed 10 feet unless a draft booster is

used. The connector should be pitched upward at least 1/4 inch to the foot. Use only high quality

lock seam smoke pipe. Each joint should be securely fastened with sheet metal screws. Chimney

connectors should be positioned to the shortest possible run of smoke pipe to the chimney.

5. Vent Cap

Install 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 essential for safe and proper operation of the boiler.

Only a trained experienced serviceman should attempt the installation or service of any boil-

er and or venting device.

All venting installations must comply with the recommendations of the venting manufacturer

and with all state and local codes.

) WIRI G

All internal electrical wiring is completed at the factory on packaged boilers. All external wiring

must conform with the National Electric Code and local codes. Refer to wiring diagrams for all

field wiring.

1. Field connections should be protected with a 15 amp fuse.

2. Install the room thermostat on an inside wall away from cold drafts, windows, or heat from

fireplaces, appliances, or sunlight. Connect the thermostat leads to the “TT” terminals on the cir-

culator control.

3. A separate service box with disconnect switch is provided, wired but not fastened to the jack-

et. Connect the service box to the jacket using the hole and screw provided.

O) WARRA TY

NOTE: The limited warranty is not applicable unless these installation instructions are

followed.

A) START UP

CAUTION: DO NOT STA T UNLESS CLEAN OUT DOO S A E IN PLACE.

1. Make sure service switch to boiler is off.

2. Make sure boiler has been filled with enough water until the entire system has been purged

and desired pressure is obtained.

3. Check to make sure the oil storage tank is filled with No. 2 heating oil.

4. Make sure all manual shut off valves in the fuel system are open.

5. Set operating controls 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 thermostat to

call for heat. Turn the service switch to the on position. Bleed the fuel unit. If burner fails to start,

refer to the trouble shooting guide in this manual.

10. With the burner running, bleed the fuel unit again until all air is eliminated from lines.

Close and tighten the bleed port.

11. Check all lines and plugs for oil leaks and eliminate.

B) START UP ADJUSTME TS

1. Equipment Required

a. CO2 analyzer

b. Draft gauge.

c Fuel pressure gauge.

d. Stack thermometer.

e. Smoke tester.

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2. Burner Adjustments

Allow the burner to operate steadily for at least 15 minutes. Check the burner settings according

to the installer/serviceman labels for Series I and II boilers at the end of this manual, and make

the following adjustments:

a. Sampling Hole - punch 1/4" hole in the flue between the flue box and the draft regulator. All

test readings should be taken from this point.

b. In The Stack Draft - Take a draft reading from the flue pipe sampling hole. Adjust the baro-

metric draft regulator to -.02" in the stack. In tall chimneys a second draft regulator may be

required in the flue pipe to regulate draft under high draft conditions.

c. Overfire Draft - Take a draft reading from the draft port located to the left of the burner.

Compare the readings with those according to the installer/serviceman labels for Series I and II

boilers starting on page 30. Reinstall the draft port plug after all readings have been taken.

d. Pump Pressure - Adjust the pump discharge pressure per value on serviceman label.

e. Combustion Air - Reduce the air supply to allow just sufficient air for clean combustion. This

is accomplished by loosening the lock screws on the air shutter, and closing the air shutter until a

trace of smoke is recorded. Take a CO2 sample. Open the air shutter lowering CO2 about 1-1/2%

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, including care of the

burner, how to adjust the thermostat, necessity of air supply to the burner, and the simple checks

to make before calling the serviceman if the burner fails to operate automatically.

C) BUR ER SERVICI G

1. Burner Components

If a replacement part is necessary, use only the part specified on the burner parts list in this man-

ual. Specify the part number and description when ordering. (See included burner literature).

2. ozzles

Use only the correct nozzle specified on the “Installer/Serviceman” decal located on front boiler

jacket. Be extremely careful not to touch the nozzle orifice to avoid scratches or dirt which may

cause leaks or effect the oil spray pattern.

3. Electrode Settings

The electrode setting is critical for proper ignition of the fuel. Check to be sure electrode settings

comply with the specifications.

4. Fan and Blower Housing

The fan and blower housing should be kept clean from lint and dirt. If the boiler is located near

an unvented dryer, special care must be taken so that lint does not block air passages in the burn-

er and proper combustion air is provided.

A) VE T SYSTEM

DANGER: ESCAPI G GASES ARE DA GEROUS. THE E TIRE FLUE A D VE TI G

SYSTEM SHOULD BE I SPECTED AT LEAST O CE A YEAR BY A QUALIFIED SER-

VICEMA .

B) OIL FILTER

The oil filter cartridge should be replaced annually.

C) CLEA I G

The heat exchanger and combustion chamber should be examined annually for scale and soot

accumulation. The heat exchanger examination and cleaning is to be performed through the front

clean out panel located above the burner.

1. To clean the unit, Remove the 3/8" brass nuts, clean out cover, and front refractory board.

2. Remove baffles from front. Brush all of the tubes using a 2" soft flue brush.

3. Remove the flue pipe and check for any residue through the flue collector opening. A boiler

vacuum can be used to collect any soot and scale. It is not normally necessary to remove the flue

box for cleaning.

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 OT REMOVE THE REAR COVER A D REAR REFRACTORY FOR

ORMAL MAI TE A CE. SOOT OR SCALE MUST BE REMOVED FROM THE

FRO T BUR ER OPE I G O LY.

D) OIL BUR ER

1. Thoroughly brush clean the burner fan blades. Only with clean fan blades is proper combus-

tion air delivery possible.

2. Clean nozzle assembly and all air handling parts.

3. Check spacing and condition of the ignition electrodes.

4. Nozzles should be inspected every year for plugged distributor slots or plugged orifices. If it

is necessary to replace the nozzle, use only the specified nozzle to be sure that the replacement

meets the spray pattern specifications of the burner.

E) GASKETS

Tighten the nuts on the water coil annually to prevent any gasket leaks. Deterioration due to coil

gasket leaks shall void the warranty.

F) WIRI G

Check the electrical wiring for damage or frayed insulation.

!#'##("!!'!# #!!##")

TROUBLE: BUR ER DOES OT START

SOURCE PROCEDURE CAUSES REMEDY

Thermostat Check Thermostat Thermostat set too low. Turn thermostat up.

Thermostat on “off ” or “cool.” Switch to heat.

Open thermostat wires. Repair or replace wires.

Loose thermostat connectors. Tighten connection.

Faulty thermostat. Replace thermostat.

Thermostat not level. Level thermostat.

Circuit Check burner motor overload Burner motor tripped on Push reset button.

Overloads switch. ( f equipped) overload.

Check primary control safety Primary tripped on safety. Reset safety switch.

switch.

Power Check boiler disconnect switch Switch open. Close switch.

and main disconnect switch. Tripped breaker or blown fuse. Reset breaker or replace fuse.

Cad Cell Jump the FF terminals on

primary control, if the burner

starts, fault is in detector circuit.

Check resistance across cad cell.

Primary Check for line voltage between

Co trol 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.

Bur er 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.

f 400-600 ohms cell is bad.

Limit control switch open

Open circuit between limit

control and disconnect switch.

Low line voltage or power

failure

Defective control.

Pump seized.

Blower wheel binding.

Burner motor defective.

Repair or replace wire.

Clean or replace face.

Replace cad cell.

Check limit setting.

Jump terminals - if burner

starts replace control.

Repair circuit.

Call utility company.

Replace control.

Turn off power to burner.

Rotate blower by hand, check

for excessive drag. Replace

fuel unit or blower wheel.

Replace burner motor.

When checking burner adjustments alwa s use instruments.

%$("& $$'!#(!("!!'!# #!!##")

Oil Supply Check tank for oil.

Check for water in oil tank using

a dip stick coated with litmus

paste.

Listen for pump whine.

Oil Li e Open pump bleed port and start

a d Filter burner. Milky oil or no oil

indicates loss of prime.

Listen for pump whine.

Oil Pump nstall pressure gauge in port of

fuel pump. Pressure should be

according to the installer/service-

man labels for Series &

boilers.

Ig itio Connect transformer leads to line

Tra sformer voltage. Listen for spark. Check

that transformer terminals are not

arcing with buss bars. Check that

transformer is properly grounded.

Ig itio Remove and inspect drawer

Electrodes assembly.

Nozzle Check for faulty nozzle.

nspect nozzle for correct size

and specifications.

Combustio See “Burner Adjustment

Air nstructions” in this manual.

Adjustme ts

Empty tank.

Water in oil tank.

Fuel supply valve closed.

Air leak in fuel system.

Oil filter plugged.

Plugged pump strainer.

Restriction in oil line.

Pump 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.

ncorrect electrode settings.

Cracked porcelain insulators.

Plugged orifice or distributor.

Plugged nozzle strainer.

Poor spray pattern.

ncorrect nozzle installed.

Air shutter open too far.

Air band open too far.

Fill tank.

Strip tank of water exceeding

2" in depth.

Open valve.

Repair leak, using only flared

fittings. Do not use Teflon

tape on oil fittings.

Replace filter cartridge.

Clean Strainer.

Repair oil line.

Replace pump.

Replace coupling.

Set pressure according to the

installer/serviceman labels for

Series & boilers.

Replace transformer.

Call utility company.

Clean electrodes.

Replace and reset

electrodes.

Replace and reset electrodes.

Replace nozzle with nozzle

according to the installer/

serviceman labels for Series &

boilers.

nstall correct nozzle.

Decrease air shutter setting.

Decrease air band opening.

SOURCE PROCEDURE CAUSES REMEDY

TROUBLE: BUR ER STARTS BUT DOES OT ESTABLISH FLAME

When checking burner adjustments alwa s use instruments.

This manual suits for next models

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