Thermo-Dynamics Boiler TDE-10 Manual

Installation and Maintenance Manual
Thermo-Dynamics Boiler Company
ROUTE 61 • P.O. BOX 325 • SCHUYLKILL HAVE , PA 17972
[phone] FAX [phone]
THERMO-DYNAMICS
Electric Boiler
A Compact, Versatile, Easy-to-Use
Heat Source for Forced Hot Water Systems

The Thermo-Dynamics TDE Electric Boiler is compact, clean, quite, and does not require
a storage facility or chimney allowing convenient
installation near the point of use. The TDE electric
boiler provides an energy efficient supply of warm
and comfortable heat, and is built to Thermo-
Dynamics quality standards – the highest in the
heating industry.
This electric boiler is versatile and provides an
easy-to-use heat source for forced hot water
systems in:
• new homes
• replacement systems in existing homes
• back-up units for solar heating systems
• supplemental heating systems for the heat
pump.
CLEAN.
The TDE heating system eliminates the need for
fuel storage facilities and chimneys. There are
never any odors to permeate the home or combus-
tion emissions to pollute our environment.
COMPACT.
The TDE electric boiler is extremely compact and
can be easily wall-mounted almost anywhere in the
home to provide heat for areas that are isolated
from the main heat supply. These areas include
garages, apartments, and utility rooms to name a
few.
QUIET.
uiet operation is maintained because elements are
energized in steps, thus preventing power surge and
start-up vibration. uality electrical componentry,
circulator and cabinet design also contribute to the
whisper-quiet operation of the TDE electric boiler.
ENERGY EFFICIENT.
With Thermo-Dynamic’s unique “flow control”
system, the TDE electric boiler delivers a steady
flow of healthful heat using a minimal amount of
electricity. Low watt density heating elements, low
voltage thermostat and thorough insulation for
minimum heat loss are just a few design features
built in to deliver more comfort for every energy
dollar.
SMALL BOILER.
BIG IDEAS.
When your projects call for the efficiency of hot
water heat and the convenience of electricity,
choose the TDE electric boiler. The TDE is small
enough to install almost anywhere (remember, all
you need is a wall), yet powerful to handle big hot
water heating jobs.
A Word About Supplemental
Heat for the Heat Pump
If you live in the great northeast, or in a region of the country where temperatures regularly
fall below 40°F in the winter, the heat pump will
run almost constantly to heat the home. When
the temperatures fall below 32°F, most heat
pumps literally shut down and the resistance heat
comes on to provide back-up.
To extend the life of the very expensive heat
pump unit, the electric boiler provides supple-
mental heat allowing the heat pump to “rest.”
When heat is called for when the temperature
drops below 32°F, the air in the heat pump sys-
tem is below body temperature and therefore
feels cool. The electric boiler can provide a heat
source that is warm and comfortable to the touch.
Thermo-Dynamics TDE Electric Boiler

Desi ned for
Reliable Home
Heatin Comfort
A Summary of Practical Applications
•Solar Heating S stems. Every active solar heating
system needs a reliable back-up heating unit that can
perform through long periods of adverse weather.
The TDE is UL listed as a central heating boiler, thus
providing the power needed for total solar security.
•Recreational Pools. Because the TDE heats water
fast and efficiently, it is an ideal way to warm
swimming pool water. Ideal for home, hotel, club
and spa pools, and popular with the hot tubs, too. Its
powerful circulator maintains steady flow to keep
water at uniform temperature.
•Therapeutic Pools. Sports and institutional
facilities need a precisely regulated hot water supply
for their hydrotherapy facilities. Of course, the TDE
is the safe choice, offering a high limit switch feature
that instantly de-energizes heating elements at a set
temperature while the circulator continues operation.
•Condominiums, Co-ops, Apartments. When each
living unit needs individual hot water heat, the TDE is
the cost-efficient answer. It features staged start-up
for quiet operation; can be easily piped into existing
hydronic systems; is great for new construction; and a
necessity for conversion projects.
A Summary of Product Features
• Five models: 10 kw to 30 kw.
• One-piece steel boiler shell.
• Easily accessible controls.
• Low voltage thermostat.
• Heats single or multi-zone systems.
• Heat process water used in a manufacturing
process.
• Boiler Cabinet easily removes before or after
piping unit to system.
• UL Listed as central heating boiler.
• Circulator piped and wired at factory.
• 10 Year, plus 10 years pro-rated at 5% per year,
limited warranty on boiler shell; full year limited
warranty on all other components.
• One-piece steel boiler shell, ASME-constructed.
• Built-in dip tube air elimination system.
• Low voltage thermostat.
• Uniform water temperature.
• Factory tested.
• Low voltage fuse protected control circuit.
A Summary of Product Benefits
The Thermo-Dynamic TDE electric boiler features low watt density heating elements installed through the
sides of the boiler with ample access for service. The elements are energized in steps to prevent power
surge, prolonging heater element life and assuring quiet operation.
Standard controls are factory-wired on the control panel. All controls are easily accessible through the
removable cover.
Every TDE boiler is insulated with fiberglass insulation for minimum heat loss and housed in a rugged steel
cabinet finished in azure blue powder coat for extra durability.
Clean, compact, quiet, energy efficient, versatile, affordable, and backed by Thermo-Dynamics.

Thermo-Dynamics
Energy efficiency is an important consideration when buying any heating system. But there are other fac-
tors you must consider too. Like manufacturer experience, reputation and service. The simple fact is, any
heating system is only as good as the company behind it.
Only the finest materials and craftsmanship is used to manufacture our products.
Operation
On call for heat the circulator comes on immediately, and the elements are energized in steps — two elements
per step spaced at approximately 60 second intervals. When the thermostat is satisfied, all elements and circu-
lator are de-energized at once. A high limit condition will instantly de-energize all elements and the circulator
will continue to run.
Ratin s
ELECTRICAL CHARACTERISTICS — 120/240 VOLTS A.C. 3 WIRE SINGLE PHASE 60 HZ
*Net ratings are based on installed radiation of sufficient quantity to serve the requirements of the building and nothing need be added for normal
piping and pick up. Net rating is based on a piping and pick up allowance of 13%.
Dimensions Equipment
Steel boiler, jacket, insulation, controls and
circulator
Factor Installed – ASME relief valve,
temperature and pressure gauge, elements,
circulator, drain cock, completely wired.
Included but not installed Air vent, thermostat.
Boiler
Size
TDE-10
TDE-15
TDE-20
TDE-25
TDE-30
KW
Rating
10
15
20
25
30
Input
34,000
51,000
68,000
85,000
102,000
Gross
Output
34,000
51,000
68,000
85,000
102,000
*Net
Output
30,000
44,000
59,000
74,000
89,000
1
43
43
43
43
43
2
–
21
42
42
42
3
–
–
–
21
42
Total
43
64
85
106
127
No. of 5KW
Heater
Elements
2
3
4
5
6
Watts
at
240V
10,000
15,000
20,000
25,000
30,000
Approx.
Shipping
Wgt. Lbs.
120
125
125
141
150
BT /Hour Amps
Circuit

1
CAUTION: READ ME FIRST
Check the unit for shipping damage. If there is any evidence of damage,
including damage to the exterior jacket, you should contact your freight
company immediately and file a claim. Do not install the oiler.
Proper selection of the right size TDE, or any heating device, requires an
accurate heat alance performed y a qualified heating professional.
Consult the supplier of the indirect hot water heater or Thermo-Dynamics
for detailed instructions related to indirect hot water heater applications.
Follow the indirect hot water heater installation and piping instructions to
ensure proper performance.
These instructions include options for installation, including system com-
ponents. Components are not provided, unless specifically noted other-
wise. Suggested installation schemes are for the rand names specified. If
another rand is used, see the manufacturer’s instructions for installation.
Installation of the Thermo-Dynamics TDE electric oiler requires an expe-
rienced and trained service person. The TDE is similar to an oil or gas fired
oiler in many ways. The differences are important. Follow the installation
instructions carefully to avoid pro lems. Contact Thermo-Dynamics if you
have any questions or concerns.
Wiring, piping and construction must meet all local, state and federal
codes that may apply. In the event that no local electrical codes apply, the
National Electrical Code should e followed.
See the outline and dimension drawing on page 6 for location of all elec-
trical and hydronic connections.
Before you start. You will need the following:
Four 3/16" lag screws or toggle bolts for mounting.
A low voltage, remote mounting thermostat.
Expansion tank: Check manufacturer’s instructions for sizing criteria.
Isolation valves, piping and zone devices as described in the installation diagrams.

2
INSTALLATION
1. Carefully remove unit from shipping
carton. Remove the boiler jacket by
removing the jacket assembly screws
around the perimeter of the jacket.
(The jacket can be reinstalled after
wiring and piping. The following
accessories are included and are
loose inside boiler jacket:
• Air Vent - mount in 1/8" pipe tap
hole at boiler top.
2. The Boiler must be wall mounted
only. The air vent provided must be
at the top of the boiler. The TDE is
provided with wall mounting
flanges integrally attached to the
boiler back sheet. There are two
holes 3/8" diameter on 16 inch cen-
ters in each flange. Securely mount
the boiler to the wall with 3/16" lag
screws or 3/16" toggle bolts. Be
sure the boiler is level before com-
pleting the boiler attachment to the
wall.
3. Allow 20" clearance in front of the
unit for removal of the jacket, for
making electrical connections and
servicing. The required side and top
clearance is 12". The required bot-
tom and rear clearance is 0".
4. The only piping connections
required are the boiler water supply
and return, expansion tank, water
supply and drain line from the relief
valve. The circulator is factory
mounted. Flow should be UP,
toward the boiler vessel. An arrow
cast into the body of the circulator
indicates water flow direction.
5. An Expansion Tank (Not Provided)
must be matched to the system and
installed in accordance with the
manufacturer’s recommendations.
A conventional expansion type of
tank may be connected to the 1/2"
NPT fitting in the boiler top. If a
pressure type tank is used the 1/2"
opening must be plugged. See the
manufacturer’s instructions for siz-
ing the expansion tank.
Do not under-size the expansion tank.
6. The home inlet water system shall
not exceed 60 psi. A pressure
reducer will be required if the sys-
tem exceeds this pressure. An auto-
matic feed valve (Not Provided)
should be installed in the water
inlet line to keep the entire system
(boiler and radiation) from falling
below the pressure setting of the
valve (12 psi).
7. The water supply and return lines
of the system must be connected
with shut off valves and purging
valves. Purging the system of air
prior to operation is critical to sat-
isfactory operation. All connections
must be air tight and leak proof.
8. Required electrical power input is
three wire, 120/240 volt, single
phase, 60 hz. (The TDE-15 and TDE-
30 units may be wired using three
phase power, two or three branch
circuits. See wiring diagram.)
Caution
Wire the circuits as shown on the
diagram. The separate 120 volt circuit
for the circulator and control power
circuits is required to allow operation of
the circulator during the start-up
procedure, without energizing the
heater elements.

3
9. Circuit breaker size is 60 amps per
heater circuit and 15 amps for the
circulator pump and control circuit.
The 24 volt control circuit is pro-
tected with a 2 amp ferrule fuse.
10. An opening is provided in the cabi-
net lower right hand corner of the
boiler for input wiring. All wiring
must be in accordance with local
electric code, or the National
Electric Code in the absence of a
local code.
Warning: DISCONNECT ALL
WIRING AT THE MAIN SWITCH
BEFORE WIRING UNIT
11. Connect power to terminals marked
L1 and L2 and the neutral leg of the
three wire service to the terminal
marked N (neutral).
12. Connect a ground wire to the case
ground connection and connect the
ground wire to a ground that meets
local electrical codes. Improper
grounds may result in unsafe con-
ditions and interfere with other
electronic devices.
13. Replace boiler jacket and re-install
assembly screws. Remove the door
holding screw to allow the door to
be opened.
Re-install the door holding screw when
the system is operating to avoid acci-
dental or unintentional opening of the
door.
14. Install the thermostat (not included)
in accordance with the instructions
provided by the manufacturer.
Caution: The Thermostat, ground wire
and power wires are the only connec-
tions that should e made to the TDE.
Do not supply power to any other sys-
tem components from the TDE.
OPERATION
Caution: Follow the start-up procedure
carefully and completely. Failure to fol-
low the start-up procedure may cause
damage to components including the
heater elements.
START-UP
1. Verify that the supply breaker at the
main circuit breaker panel to the
TDE and all of the TDE electrical
breakers are in the off position.
NEVER PUT ELECTRICAL POWER TO
BOILER UNLESS BOILER AND
HYDRONIC SYSTEM ARE
FULL OF WATER.
2. Fill the hydronic system and the
boiler. Purge all air from the system
at the purge valve. If it is a multi-
zone system, air purge each system.
3. Turn the supply breaker in the Main
Circuit panel for 120 volt power to
the TDE to on. Turn the 15 amp
breaker in the TDE to on. D N T
ENERGIZE THE HEATER CIRCUITS.
The 15 amp breaker provides power
to the circulator and the controls.
Turn the thermostat up until it turns
the circulator on. If multiple zone
circulators are installed, turn the
zone circulators on. Continue to
vent the system with the circulators
running, until all air is purged.
4. The pressure gauge should read 12
psi if an automatic feed valve is

4
used. If equipped with manual feed,
close the system water supply
valve when a pressure reading of
12 psi is obtained. The purge valve
may have to be bled to reduce
pressure to 12 psi.
Check the system for leaks y shutting
the water supply valve and o serving
the pressure gauge. Any decrease in
system pressure indicates a leak that
must e repaired prior to operation.
5. Set the thermostat at the lowest
setting. Turn the supply breaker for
the TDE at the main circuit breaker
panel to on. Turn all TDE breakers
to on.
6. Raise the thermostat to above room
temperature. The unit should oper-
ate. The pump and heater element
relays will cycle on and off accord-
ing to demand of the thermostat
and timing sequence. See the
Sequence of peration section in
this manual for time delay descrip-
tion.
7. The pressure of the system will rise
when heated. The normal pressure
gauge reading should be between
20 and 22 psi. If pressure rises
above 22 psi, additional expansion
tank capacity may be necessary.
See the manufacturer’s manual for
information on sizing the expansion
tank.
Note:
The pressure relief valve is a safety
device set to open at 30 psi.
8. Set the heat anticipator in the ther-
mostat in accordance with the man-
ufacturers directions, if so
equipped.
Wh n installation is compl t and
th syst m is op rating satisfac-
torily, clos th cabin t door and
r -install th door holding scr w
to pr v nt accid ntal or unint n-
tional op ning of th door.
SEQUENCE OF OPERATION
The thermostat closes on a call for heat
and energizes the circulator relay and
the first heater relay which pulls in the
circulator and two heating elements.
The remaining elements are energized
on at one minute intervals (two ele-
ments at one time). When the thermo-
stat is satisfied, all the elements de-
energize at once and the circulator
stops.
Operating temperatures on the
temperature gauge of the TDE
may e 110 - 140° F, or lower.
This is normal for the TDE.
This unit is furnished with a dual hot
water control aquastat with a High Limit
Safety Setting (labeled “Hi”) and an
perating Control Limit Setting (labeled
“Lo”). The High Limit Safety is factory
set at 200°F. The perating Control
Limit is set at 170°. If the boiler water
reaches 170° the perating Control
Limit will open the heater relay circuit
causing heater elements to de-energize,
even though the thermostat may be
calling for heat. The circulator will con-
tinue to run, as long as the thermostat
is calling for heat. When boiler water
temperature drops to 160° the
perating Control Limit will close and
bring the heating elements back on,
provided that the thermostat is calling
for heat.

5
If the water temperature reached 200°,
due to a failure of the perating Control
Limit, for example, the High Limit safety
will shut off all elements at once.
The High Limit Safety is set at 200°
Do not attempt to change the High
Limit setting. Do not set the Operating
Control Limit a ove 180°. Remem er,
this is not a low temperature set point
like on an oil or gas fired oiler. There
is no low set point and, if there is a call
for heat, the circulator will run and the
elements will e energized as long as
the thermostat calls for heat and the
Operating Control Limit and High
Safety limit are not reached.
Refer to the instruction sheet for the
control when making adjustments.
MAINTENANCE
A trained and experienced service per-
son should check the system prior to
each heating season. The supply break-
er to the electric boiler should be off
prior to performing any service.
If a component is changed in the sys-
tem, follow the start-up procedure in
this manual prior to operating the unit.
Check for leaks after every mainte-
nance, once per year and if there is any
visual evidence of a leak. To check for
leaks, shut the water supply valve and
observe the pressure gauge. Any loss of
pressure indicates a leak in the system
that must be repaired.
Frequent heater element failures or
short heater element life is an indication
that there is air in the system. Follow
the start-up procedure to make sure
that all air is eliminated from the sys-
tem and verify that the system is leak-
free to prevent introduction of air dur-
ing operation.
Staging
The TDE-15, 20, 25 and 30 can be
“staged” using a second thermostat or
a dual thermostat. Staging may be a
valuable feature if the user’s electric bill
is based on peak demand. Staging pre-
vents the timed elements from energiz-
ing unless the temperature set point of
a second or third thermostat is reached.
A careful heat balance is required to set
the TDE for effective staged operation.
The staging terminals shown in the
wiring diagrams have a factory installed
jumper when delivered. When the ther-
mostat closes on a call for heat, the first
two heater elements are energized
immediately. The remaining elements
are energized, two at a time at one
minute intervals. To stage the TDE,
remove the factory installed jumper and
install a thermostat or outdoor stat (Not
provided) wired to the same terminals
where the jumper was removed. The
thermostat may be located outdoors, or
in a zoned space and set or selected so
that if the temperature is above the
thermostat set point, heater elements
that are time delayed will not turn on. If
the outside temperature or a separate
zone temperature is below the second
thermostat set point, the time delayed
heater elements will be energized after
the appropriate time delay. The TDE-25
and 30 have two staging terminal sets.
The second factory installed jumper can
be used so that the first two heaters are
energized by a call for heat from the
interior thermostat and the remaining
heater elements are energized only if
the second thermostat set points are
reached. Both sets of staging terminals
can be connected to thermostats to

6
allow two of the heater elements to
come on after time delay if one set
point is reached and the remaining
heaters will be energized if the other set
point is reached.
When using outside temperature to
stage, start by setting the first staged
thermostat at 40°F. Set a second ther-
mostat at 20°F if a second stage is used.
If required, adjust the thermostats to
maintain desired level of comfort.
3/4" PT FOR RELIEF VALVE
(FACTORY I SALLED)
3/4" DRAI VALVE
(FACTORY I SALLED)
1-1/4" PT FOR
SYSTEM SUPPLY PRESSURE &
TEMPERATURE GAUGE
THERMOSTAT
WIRI G ACCESS
AMEPLATE /
RATI G PLATE
3/8" DIA.
MOU TI G HOLES (4)
ELECTRICAL
WIRI G ACCESS
1-1/4" PT FOR
WATER SUPPLY/
COLD WATER RETUR
1/8" PT FOR AIR VE T
(FIELD I STALLED)
1/2" PT FOR FIELD
CO ECTIO TO CO VE TIO AL
EXPA SIO TA K ( OTE 1)
11 3/4
2
3/4
4 7/8
2
21
5/8 TYP.
19 5/8
20 1/4
4 7/8
2 3/8
9 1/8
4 3/4
3
11 3/4
26 3/8
7
16
OTES:
1. SEE I STRUCTIO S FOR
DETAILED I FORMATIO .
2. ALL DIME SIO S ARE
FOR REFERE CE O LY.
11
Thermo-Dynamics
DWG NO. TDE-011

7

8

9

10

11

12

13
PIPING DIAGRAM, DIAPHRAGM TYPE EXPANSION TANK
PIPING DIAGRAM, CONVENTIONAL EXPANSION TANK
TDE
TDE

14

15
Thermo-Dynamics Electric Boiler
Pow r Supply Wir Siz s
Split Pow r Supply
Wire Sizes AWG Copper
Model 10 15 20 25 30
N 14 14 14 14 14
Circuit 1 L1 66666
L2 66666
L1 8666
Circuit 2 L2 8666
L1 86
Circuit 3 L2 86
Equipment GRD. 66666
Model 10 15 20 25 30
Wire Size 642100
Single Power Supply

TDE ELECTRIC BOILER WARRANTY
A. Full Three Year Warranty. Thermo-Dynamics warrants the TDE boiler units are free from
defects in material and workmanship for 3 years from date of installation. If any parts are found
to be defective in manufacture, Thermo-Dynamics will repair or replace them at Thermo-
Dynamics’ option.
B. Limited Lifetime Warranty: Thermo-Dynamics warrants that the steel boiler of it’s TDE
boiler is free from defects in material and workmanship. Any boiler found to be defective will
be repaired or replaced at Thermo-Dynamics’ option.
This warranty does not cover:
1. Boilers located out of doors.
2. Components of the heating system not supplied by Thermo-Dynamics.
3. Workmanship of the installer. This warranty does not assume any liability of any nature for
unsatisfactory performance caused by improper installation.
4. Failures due to shipping damage. Any evidence of shipping damage must be reported to the
shipping company immediately and a claim filed. Do not install the boiler.
5. Improper adjustments, control settings, care, maintenance or failure to follow installation
instructions provided with the boiler.
6. Defects resulting from freezing, excessive pressure, temperature or leaks at water connec-
tions or any similar cause.
7. Any installation that has been modified, neglected, altered, tampered with, vandalized,
misused subjected to accident, fire, flood or other casualty.
8. Installations for which a heat balance provided by an experienced heating professional
indicates that the boiler is inadequate for the application.
This warranty does not extend to anyone except for the first purchaser at retail, and only when
the boiler is in the original installation site, which must be within the continental limits of the
United Sates.
Implied warranties of fitness for a particular purpose and merchantability shall be limited to the
duration of the express warranty. Thermo-Dynamics expressly disclaims and excludes any lia-
bility for consequential or incidental damages for breach of any express or implied warranty,
except as otherwise provided by state law.
For prompt service, notify the installer, who in turn will notify the distributor who supplied the
boiler. Alleged defective parts must be returned in accordance with the Thermo-Dynamics pro-
cedure currently in force. Thermo-Dynamics will provide the new parts to the installing dealer
or distributor.
This warranty gives you specified legal rights. You may have other rights that vary from state to
state.
MET-6709