Thermo Dynamics CWL Instruction manual

Installation
Operation
Maintenance
Manual
Thermo-Dynamics Boiler Company
ROU E 61 • P.O. BOX 325 • SCHUYLKILL HAVEN, PA 17972
EL [phone] • FAX [phone]
WEB www.thermodynamicsboiler.com • EMAIL [e-mail]
CWL Series - LE Edition
www.thermodynamicsboiler.com
Models CWL, NCWL, CWLDV

Contents
Service Policy 2
Homeowner Information 3
Read This First 4
Model S ecifications 5
Installation 6
O eration 13
Maintenance 16
Trouble Shooting 17
Parts List 24
Preliminary Settings 25
Wiring Diagrams 27
Burner Service Records Inside Back Cover
Product Features
• 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 allon per Minute Tankless Coil
(Domestic Hot Water)
• NCWL Model Available Without Tankless Coil
• Equipped with Triple Aquastat, Circulator, and Temperature /
Altitude auge
• Provided With Additional Nozzles to Achieve a Variety of Heat Inputs
• Provided with a Lifetime Limited Warranty
• Available as Direct Vent and Rear Vent Models
C L-LE
NC L C L-DV

Service Policy
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,
in turn, will contact the Thermo-Dynamics sales representative for your area. By
adhering to this protocol, Thermo-Dynamics will 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 heater up and running as quickly as possi-
ble.
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.
2

3
HOMEO NER INFORMATION
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 pre-
vent 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 erratic, noisy combustion will result. Under these conditions fuel odors may occur. The instal-
lation 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 manual
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.

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. Refer to local codes for oil burning equipment, for recommended installation practice. You will
need to be familiar with NFPA International 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.
ARNING: 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.
4

5
HEATING CAPACITY 101,000 118,000 127,000
IBR NET RATING 88,000 103,000 110,000
INPUT 119,000 140,000 154,000
FIRING RATE .85 1.00 1.10
CHIMNEY SIZE 8 x 8 x 15 8 x 8 x 15 8 x 8 x 15
OVER FIRE PRESSURE W.C. 0-+.05 0-+.08 0-+.10
WATER CONTENT 15 GAL. 15 GAL. 15 GAL.
COIL CAPACITY 5 GAL. 5 GAL. 5 GAL.
A. JAC ET HEIGHT* 29-1/2 29-1/2 29-1/2
B. JAC ET WIDTH 21 21 21
C. COIL SUPPLY HEIGHT 22 22 22
D. SUPPLY HEIGHT (HYDRONIC) 27-1/2 27-1/2 27-1/2
E. BURNER HEIGHT 7-7/8 7-7/8 7-7/8
F. HYDRONIC RETURN HEIGHT 15-1/2 15-1/2 15-1/2
G. FLUE PIPE DIA. 5 5 5
H. WASHOUT (ALT. RETURN HEIGHT) 3-1/2 3-1/2 3-1/2
I. JAC ET DEPTH (INCL. FLANGE) 22 22 22
DEPTH FRONT TO REAR W/BURNER 30-3/4 30-3/4 30-3/4
HYDRONIC SUPPLY 1-1/4 1-1/4 1-1/4
HYDRONIC RETURN SIZE 1-1/4 1-1/4 1-1/4
WASHOUT (ALT. RETURN) 1-1/4 (2) 1-1/4 (2) 1-1/4 (2)
AFUE RATING - W/DAMPER 86.0 84.9 84.1
AFUE RATING - W/O DAMPER 84.3 83.2 82.1
*Specifications apply to CWL-LE, NCWL and CWL-DV except when using REAR FLUE IT, jacket height increases by
4-1/4 inches
Model Specifications CWL 85 CWL 100 CWL 110
“0” Clearance Sides and Back
A roved for combustible Floors
Fi ure 1 - Model Dimensions

6
Installation
I GENERAL
This hot water steel boiler is a high quality oil fired heating units. The installation of the boiler shall be
in accordance with state and local regulations. Refer to local Installation Codes for Oil Burning
Equipment, for recommended installation practice.
II FREIGHT CLAIMS
All units must be inspected for damage upon arrival. Concealed damage claims should be filed immedi-
ately against the carrier by the consignor. The carrier is responsible for taking prompt action on all claims.
III SIZING
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 cal-
culation of the structure is necessary to choose the proper size unit to install. The boiler 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.
IV BOILER LOCATION
A) Boiler to be installed in a level position with clearances in accordance with NFPA 31 Table
10.6.1.
STANDARD CLEARANCES
Front 0" (leave 12" to access burner/control)
Sides 0"
Rear 0"
Chimney Connector 18"
Top 0" (leave 18" for cleaning)
Floor: Approved for installation on combustible flooring
B) Reduced clearance installations shall comply with NFPA 31 Table 10.6.2.
C) To move the unit, push against the flue box or skids. Pushing or pulling the jacket or burner
will result in damage.
D) Be sure to level the unit by inserting shims under the elevated base.
E) CWL Series - LE rear flue kit with built-in draft regulator.

7
V. AIR FOR COMBUSTION AND VENTILATION - CHIMNEY VENT APPLICATIONS
The unit must be installed where provisions exist for combustion and ventilation air. Ordinarily, provi-
sions may be furnished by the following methods.
A) Utility Room or Closet
In buildings of tight construction, including most modern homes, you should provide an opening, con-
necting 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 enclo-
sure 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.
B. Basement
1. When a boiler is installed in a full basement, infiltration is normally adequate to provide air
for combustion.
2. 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. The opening should have a mini-
mum free area of 1 square inch per 1,000 Btu per hour of total input for all appliances in the enclosure.
C. 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 provisions
should be made for additional air for combustion, as specified by local authority.
VI. AIR FOR COMBUSTION AND VENTILATION - DIRECT VENT APPLICATIONS
A) VENTING SYSTEM
CAUTION: EXTERNAL VENT SURFACES ARE HOT.
NOTE: USE ONLY THE ETL LISTED VENTIN SYSTEM COMPONENTS SUPPLIED WITH
THE TV-175 DIRECT VENT KIT.
SURFACE DISCOLORATION OF THE BUILDIN MAY OCCUR DUE TO IMPROPER BOIL-
ER/BURNER ADJUSTMENT. THERMO DYNAMICS BOILER COMPANY WILL NOT ACCEPT
ANY LIABILITY FOR SUCH DISCOLORATION.
Install TV-175 Direct Vent Kit in accordance with installation instructions provided with the kit.

8
VII JACKET AND TRIM ASSEMBLY
A. Knock Down Boiler
1. Jacket Assembly - Unpack the jacket parts being careful not to damage the finish. Piping and acces-
sories are installed after the jacket is in place. Assemble the jacket as shown in Figure 5.
2. Trim Assembly
a. 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.
b. Install the limit control in the 3/4" fitting provided in the tankless coil plate.
c. Install the altitude/temperature gauge in the 1/4" fitting provided in the coil plate.
B. Packaged Boiler
Controls and burner are installed and prewired at the factory. Install Relief Valve as noted in Section 2a
(Trim Assembly).
VIII BOILER PIPING
This style of boiler is equipped with a built in “Air Scoop System -
Figure 2.” This feature allows quiet air free operation of your hot water
system by assuring the removal of noisy air pockets. 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.
Relief valve discharges and drain valve piping should be piped to a safe
place of discharge. All plugs and water connections should be checked
for leaks upon installation and annually.
FIGURE 2
BUILT-IN AIR SCOO

9
IX TANKLESS ATER HEATING PIPING
The tankless heater may be connected as shown in Figure 3. A mixing valve (not supplied) may be used
to reduce the water temperature at kitchen or bathroom taps. High temperature water for a dishwasher
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 gasket leaks shall
void warranty.
* Venting - Refer to Section VI BOILER PIPING
** Relief Valve discharge and drain valve piping
should be piped to a safe place of discharge.
CWL Boiler Pipin
Figure 3

10
X BURNER AND CONTROLS
A) 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.
1. Remove the burner parts and instructions from the carton.
2. Referring to specifications at the back of the manual, check to see that the burner model and size match
the boiler model.
3. Make sure the correct nozzle is in place and is tightly sealed.
4. Check the electrode position and set the air intake as indicated in the burner manual.
5. 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.
6. Make the electrical connections as shown in the wiring diagram in this manual and in the control man-
ufacturers installation manual. All wiring must be done in accordance with the local electrical code.
7. For units installed in Maine, New Jersey and New York, a low-water cutoff is required on all hot water
boilers. See the low water cutoff manufacturers installation manual for wiring instructions.
B) Oil Primary Control - Chimney Vent (Non Post Purge Control)
The oil primary control with the solid state flame sensing circuit provides automatic, non-recycling con-
trol 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. THE RESET MUST NEVER BE PRESSED MORE THAN ONCE DUR-
ING A SINGLE FLAME FAILURE.
C) 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 control 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. THE RESET MUST NEVER BE PRESSED MORE THAN ONCE DUR-
ING A SINGLE FLAME FAILURE.
Post-purge is provided to ensure that the boiler fires at maximum efficiency and dependability through-
out the heating season.
Post-purge of the oil burner is controlled through the electronic circuitry supplied. Post-purge timing is
variable. The factory set post-purge timing is at approximately one minute. It is recommended 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

11
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 burn-
ers 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 burn-
er is 90 seconds.
D) Aquastat Relay
This control is installed in the 3/4" fitting next to the domestic coil. These immersion type controls 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 circulator controls. This con-
trol can also be used for multi-zone control by using a separate circulator and an R845 relay for each
zone. See the control manufacturers installation manual for proper wiring of this unit. The primary con-
trol is factory wired to the aquastat relay. These controls, working as a system, will prevent the circula-
tor operation if the water temperature is below a predetermined low level. Likewise, if the water level
reaches a predetermined high limit, the burner will automatically shut off.
CAUTION: The aquasat relay high limit set point is factory set at 180°F. Do not raise the high limit set
point over 200°F.
XI SEQUENCE OF OPERATION
Forced Circulation Hot ater System with Tankless Heater
When room temperature falls below thermostat setting, the thermostat calls for heat starting the
circulating pump. The burner and pump continue to operate until room heating requirements 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 burner shuts off, the circulating pump
continues to operate until the room heating requirements are satisfied. 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 180°F around the tankless coil by the
operating control so that an abundance of hot water is available. If the boiler water temperature should
fall below the operating control setting (180°F), the oil burner will be started again by that control (and
the circulating pump will be prevented from operating) until the operating control setting is satisfied.
A cadmium sulfide flame scanner (cad cell) is provided with the oil burner. The cad cell will stop
the oil burner within a predetermined number of seconds if the fuel fails to ignite or if the flame extin-
guishes during operation. The oil burner will remain off until the red reset button on the relay has been
pushed. (Reset must never be pressed more than once during a single flame failure.)
XII FUEL SYSTEM
A) Fuel Units
NOTE: Pump pressure 140 PSI for Beckett and Carlin, and 150 PSI for Riello.
1. Burners are commonly fitted with a single stage fuel unit. A single stage unit may be connected 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.

12
2. 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.
B) Tubing
Use continuous heavy walled copper tubing with flare fittings only. Locate fittings in accessible loca-
tions. If possible, tubing should be installed under the floor. Running tubing against boiler casings or
across ceiling or floor joints should be avoided.
C) 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.
D) 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.
XIII FLUE SYSTEM - CHIMNEY VENT APPLICATIONS
A) General
AN OIL FIRED UNIT SHALL BE CONNECTED TO A FLUE HAVIN SUFFICIENT DRAFT AT
ALL TIMES TO ASSURE PROPER OPERATION.
B) 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.
C) 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 sys-
tem.
D) 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.
E) Vent Cap
Install a U.L. listed vent cap where the possibility of down drafts exist.
F) Boiler Venting
This boiler must be vented into a properly sized chimney, or into an Underwriters Laboratories Inc. list-
ed 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 instal-
lation requirements are essential for safe and proper operation of the boiler.
Only a trained experienced serviceman should attempt the installation or service of any boiler and or
venting device.

13
All venting installations must comply with the recommendations of the venting manufacturer and
with all state and local codes.
XIV IRING
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 in the burner manu-
facturer’s installation manual and the control manufacturers installation manual for all field wiring.
A) Field connections should be protected with a 15 amp fuse.
B) 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 circulator control.
XV ARRANTY
The limited warranty is not applicable unless these installation instructions are followed.
Operation
I START UP
A. Make sure service switch to boiler is off.
B. Make sure boiler has been filled with enough water until the entire system has been purged and
desired pressure is obtained.
C. Check to make sure the oil storage tank is filled with No. 2 heating oil.
D. Make sure all manual shut off valves in the fuel system are open.
E. Set operating controls at 180°F.
F. Set limit switch at 200°F.
. Install a pressure gauge in the 1/8" gauge port or nozzle port of the fuel pump. Do not take read-
ings at the bleed valve port. The pressure should be set per Installer/Serviceman Label.
H. Adjust the burner air band and air shutter in accordance with Installer/serviceman Label.
I. 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.
J. With the burner running, bleed the fuel unit again until all air is eliminated from lines. Close and
tighten the bleed port.
K. Check all lines and plugs for oil leaks and eliminate.
II START UP ADJUSTMENTS
A) Equipment Required
1. CO2 analyzer 4. Stack thermometer.
2. Draft gauge. 5. Smoke tester.
3. Fuel pressure gauge.

14
B) Burner Adjustments
Allow the burner to operate steadily for at least 15 minutes. Check the burner settings according to the
installer/serviceman labels starting on page 24, and make the following adjustments:
When servicing this appliance or any forced draft unit, it is important to properly seal the gasketed
areas around the flue collector and burner mounting flange. Check to be sure that the sampling port
above the burner has had the port plug installed after servicing.
NOTE: A Draft regulator is an integral part of the flue collector located behind the front jacket panel.
Units shipped from the factory without the draft regulator installed, but shipped with a blank plate will
have the draft regulator packed in the miscellaneous parts box.
The CWL-Series is a forced draft boiler and requires a positive pressure over the fire. If chim-
ney draft causes the overfire draft to become negative, the draft regulator must be installed. The over-
fire draft must not be less than +.005 (positive).
Combustion Analysis of Boiler with Rear Vent Kit
When a rear flue unit with a draft regulator is used, flue gas sampling must either be taken by
inserting the CO2 probe or the smoke tester probe down into a fire tube. You can also take flue gas
sampling from the sight fitting/sampling port above the burner. If using the sampling port, do not insert
the probe into the combustion area too far. Insert probe approximately 1/2” to 1”. Excessive insertion
may cause false readings.
Combustion readings should not be taken through the draft regulator or through a sampling hole
in the breaching on Rear Flue units. The gases become diluted as a result of room air being brought in
through the built-in draft regulator and are inaccurate.
Figure 4 - Test Location for Boiler with Rear Vent Kit
1. Sampling Hole - punch 1/4" hole in the flue between the flue box and the draft regulator. All test read-
ings should be taken from this point.
2. In The Stack Draft - Take a draft reading from the flue pipe sampling hole. Adjust the barometric 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.
3. 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 starting on page 24. Reinstall the
draft port plug after all readings have been taken.
1 NOTE: INTEGRAL PART OF FLUE COL LEC TOR LOCATED
BEHIND JAC ET PANEL.
Sample Location

15
4. Pump Pressure - Adjust the pump discharge pressure per value on serviceman label.
5. 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 trouble shooting section
in this manual.
C) Instructing the Homeowner
The care and operation of the boiler should be explained to the homeowner, including care of the burn-
er, 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.
III BURNER SERVICING
A) Burner Components
If a replacement part is necessary, use only the part specified on the burner parts list in this manual.
Specify the part number and description when ordering. (See included burner literature).
B) Nozzles
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.
C) Electrode Settings
The electrode setting is critical for proper ignition of the fuel. Check to be sure electrode settings com-
ply with the specifications.
D) Fan and Blower Housing
The fan and blower housing should be kept clean from lint and dirt. If the boiler is located near an unvent-
ed dryer, special care must be taken so that lint does not block air passages in the burner and proper com-
bustion air is provided.

16
Maintenance
I VENT SYSTEM
ESCAPIN ASES ARE DAN EROUS. THE ENTIRE FLUE AND VENTIN SYSTEM SHOULD
BE INSPECTED AT LEAST ONCE A YEAR BY A QUALIFIED SERVICEMAN.
II OIL FILTER
The oil filter cartridge should be replaced annually.
III CLEANING
The tubular portions of the heat exchanger should be examined annually for scale and soot accumu-
lation.
Remove scale and soot with a flexible, 2 inch, soft, round brush and a boiler vacuum cleaner. Be care-
ful not to damage internal refractory insulation of the chamber floor.
Remove the oil burner to inspect the burner head. Any soot or scale can be removed from the cham-
ber through the burner opening.
IV OIL BURNER
A) Thoroughly brush clean the burner fan blades. Only with clean fan blades is proper combustion air
delivery possible.
B) Clean nozzle assembly and all air handling parts.
C) Check spacing and condition of the ignition electrodes.
D) Nozzles should be inspected every year for plugged distributor slots or plugged orifices. If it is nec-
essary to replace the nozzle, use only the specified nozzle to be sure that the replacement meets the spray
pattern specifications of the burner.
V GASKETS
Tighten the nuts on the water coil annually to prevent any gasket leaks. Deterioration due to coil gasket
leaks shall void the warranty.
VI IRING
Check the electrical wiring for damage or frayed insulation..

17
Troubleshooting Guide
TROUBLE: BURNER DOES NOT 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 ush reset button.
Overloads switch. (If equipped) overload.
Check primary control safety rimary 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.
If 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.
ump seized.
Blower wheel binding.
Burner motor defective.
Repair or replace wire.
Clean or replace face.
Replace cad cell.
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 always use instruments.

18
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 Install pressure gauge in port of
fuel pump. ressure should be
according to the installer/service-
man labels starting on page 24.
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.
Inspect nozzle for correct size
and specifications.
Combustio See “Burner Adjustment
Air Instructions” in this manual.
Adjustme ts
Empty tank.
Water in oil tank.
Fuel supply valve closed.
Air leak in fuel system.
Oil filter plugged.
lugged pump strainer.
Restriction in oil line.
ump worn - low pressure.
Motor overloads.
Coupling worn or broken.
ump discharge pressure set
too low.
No spark or weak spark.
Line voltage below 120V.
Carboned and shorted
electrodes.
Eroded electrode tips.
Incorrect electrode settings.
Cracked porcelain insulators.
lugged orifice or distributor.
lugged nozzle strainer.
oor spray pattern.
Incorrect 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
starting on page 24.
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 starting on
page 24.
Install correct nozzle.
Decrease air shutter setting.
Decrease air band opening.
SOURCE PROCEDURE CAUSES REMEDY
TROUBLE: BURNER STARTS BUT DOES NOT ESTABLISH FLAME
When checking burner adjustments always use instruments.