Thermo-Dynamics Boiler S100, Installation, Operation & Maintenance Manual

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

Page 2: ... and maintenance of your boiler will allow you to enjoy the benefits of your new purchase as well as extend its long useful life In the event that your serviceman encounters difficulty with the boiler he she shall contact the distributor from which the product was purchased The distributor shall in turn contact the Thermo Dynamics sales represen tative for your area By adhering to this protocol Th...

Page 3: ...First 2 Specifications 4 Installation 4 Operational Sequence 7 Start Up 8 Appendices Troubleshooting Guide A Dimensions and Jacket Assembly B Specifications C Piping Diagram D Wiring Diagrams E Installer Serviceman Labels F Appendix G ...

Page 4: ...r 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...

Page 5: ...l 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 Indi...

Page 6: ...e hot water system by eliminating air pockets without installa tion of air scoops The supply line tapping in the top of the boiler extends approximately 1 inch below the top of the boiler allowing only air free water to enter the heating system supply Any air trapped in the top of the boiler is purged through the 3 4 vent tapping The 3 4 vent tapping should be connected to an automatic float vent ...

Page 7: ...tal length of a chimney connector should not exceed 10 feet unless a draft booster is used Where the possibility of down drafts exist install a listed vent cap WARNING Installation and venting with improper materials or methods may result in serious injury or death due to asphyxiation from poisonous gases such as carbon monoxide A carbon monoxide detector should be installed per the manufacturer s...

Page 8: ...the burner locating both the filter and the valve close to the burner for ease of servicing CAUTION All oil feed lines to burners must be air tight Use only flare fittings when assembling oil lines since the slightest air leak caused by loose fittings bad gaskets or any other reason can cause a foaming oil stream which will cause any of the following conditions a Intermittent firing causing safety...

Page 9: ...requirements are satisfied thermostat setting is reached or until boiler water temperature reaches the high limit control temperature setting If the high limit control temperature setting is reached the burner shuts off and 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 ...

Page 10: ...w limit is set based on the application If the boiler is used with an indirect hot water heater for domestic hot water the low limit is set at 160 F to support the operation of the indirect hot water heater If the an indirect hot water heater is not used the low limit may be set between 120 F and 140 F to provide protection against condensation in the boiler The settings are nominal and many be ad...

Page 11: ...F THE BURNER MUST BE MADE USING PROPER COMBUS TION TEST EQUIPMENT Combustion test equipment required for proper burner adjustment a CO2 Analyzer b Draft Gauge c Oil Pressure Gauge 0 200 PSI d Stack Thermometer e Smoke Test Gun f Vacuum Gauge 0 30 in of Hg Notice Read the burner manufacturer s instructions supplied with this manual to set combus tion The burner instructions contain special instruct...

Page 12: ...s The nozzle specifications listed in the manual are the result of years of exhaustive engineering testing Use extreme care in handling nozzles to avoid scratches or dirt that could cause leaks or affect the oil spray pattern CAUTION Any nozzle replacement should be of the exact type as listed in the specifications 4 Fan and blower housing should be kept clean of dirt and lint If heating unit is l...

Page 13: ...r enough to slide the base out the front The pipes should flex enough to raise the boiler heat exchanger G Remove the soft chamber and replace Replace the spacer block under the chamber if it is deteriorated H Reinstall the firebox and reassemble the boiler I Check boiler for proper operation Alternate chamber replacement procedure A Turn off power to the boiler and burner and shut off the oil sup...

Page 14: ... cad cell wires Repair or replace wires primary control If the burner starts fault is in Dirty cell face Clean face detector circuit Faulty cad cell Replace cad cell Primary Check for line voltage between Limit control switch open Check limit setting 200 Control the black and white leads No voltage indicates no power to Jump terminals if burner the control starts replace control Open circuit betwe...

Page 15: ...r Transformer line voltage Listen for spark Check that transformer Line voltage below 102V Call utility company terminals are not arcing with buss bars Check that trans former is properly grounded Ignition Remove and inspect draw Carboned and shorted Clean electrodes Electrodes assembly electrodes Eroded electrode tips Dress up tips and reset Incorrect electrode settings electrodes Cracked porcela...

Page 16: ...low pressure Replace pump motor overloads Excessive Take a draft reading Draft Incorrect draft setting Reduce draft setting Install Draft should be 05 06 W C in second draft regulator if stack necessary Poor Flue Insert C02 probe into heat Leak in flue system Sample C02 in heat exchanger Gas Sample exchanger tube If reading is greater by 1 2 or more sample Seal flue system leak was being diluted n...

Page 17: ...lugged orifice or distributor Replace nozzle with nozzle orifice and distributor slots Plugged nozzle strainer specified on burner housing Poor spray pattern Heat Take draft reading at flue box Plugged heat exchanger Clean out heat exchanger Exchange rand read draft over the fire Restrictions Difference should not exceed 03 TROUBLE BURNER FIRES BUT THEN FAILS ON SAFETY SOURCE PROCEDURE CAUSES REME...

Page 18: ...brate Flow Valve Check flow valve for sticking Flow valve not opening fully Clean or replace flow valve in partially closed position Radiation Check for air in radiators Radiators airbound Bleed radiators Check to see if radiators are Radiators inadequate Install adequate radiation sized properly Boiler Determine structure heat load Boiler too small Additional heating capacity required Piping Chec...

Page 19: ...ol is working properly running Thermostat Check thermostat settings and Thermostat set too high Reset thermostat calibration Thermostat defective Replace thermostat Thermostat out of calibration Recalibrate Flow Check to see if flow valve is Flow valve dirty and stuck Clean flow valve Valve operating properly Flow valve defective Replace flow valve ...

Page 20: ...SECTION G F H C E D B A RELIEF VALVE HYDRONIC RETURN BACK S Series Dimensions A Jacket Height 381 2 B Jacket Width 211 4 C Jacket Length 211 4 D Coil Height 311 2 E Hydronic Return Height 22 F Alt Hydronic Return 22 G Hydronic Supply Height 36 H Burner Opening From Floor 83 4 I Flue Pipe Diameter 6 Figure 1 Figure 2 Jacket Assembly ...

Page 21: ...Width 21 1 4 21 1 4 21 1 4 21 1 4 21 1 4 21 1 4 21 1 4 21 1 4 C Coil Supply Height 31 1 2 31 1 2 31 1 2 31 1 2 31 1 2 31 1 2 31 1 2 31 1 2 D Hydronic Return Height 22 22 22 22 22 22 22 22 E Jacket Length 21 1 4 21 1 4 21 1 4 21 1 4 21 1 4 21 1 4 21 1 4 21 1 4 F Alt Hydronic Return 22 22 22 22 22 22 22 22 G Hydronic Supply Height 36 36 36 36 36 36 36 36 H Flue Pipe Diameter 6 6 6 6 6 6 6 6 I Relief...

Page 22: ...QUASTAT RELAY ALTITUDE GAUGE S Series FLO CONTROL VALVE AIR VENT EXPANSION TANK CIRCULATING PUMP DRAIN GATE VALVE RETURN TEMPERING VALVE TANKLESS COIL W T A SUPPLY PRESSURE RED VALVE GATE VALVE CHECK VALVE DOMESTIC HI TEMP WATER WARM WATER DOMESTIC COLD WATER IN Install Relief Valve in top tapping on rear of boiler Relief Valve discharge and drain valve piping should be piped to a safe place of di...

Page 23: ...RAM FOR S SERIES BOILERS TO CONNECT BURNER TO AQUASTAT APPLIES TO BECKETT CHIMNEY VENT BURNERS ELECTRICAL DIAGRAM FOR S SERIES BOILERS TO CONNECT BURNER TO AQUASTAT APPLIES TO CARLIN CHIMNEY VENT AND RIELLO CHIMNEY VENT BURNERS ...

Page 24: ... 5 Smoke Reading ZERO ZERO NOTICE Above settings are approximate Final adjustments to be made with proper test equipment Be sure all oil lines are air free and the use of flare fittings is recommended See installation service manual for detailed information ________________________ ________________________ ________________________ ________________________ ________________________ _________________...

Page 25: ...e Reading ZERO ZERO ZERO With AFG use low firing rate baffle NOTICE Above settings are approximate Final adjustments to be made with proper test equipment Be sure all oil lines are air free and the use of flare fittings is recommended See installation service manual for detailed information ________________________ ________________________ ________________________ ________________________ ________...

Page 26: ...11 5 10 11 5 10 11 5 Smoke Reading ZERO ZERO ZERO NOTICE Above settings are approximate Final adjustments to be made with proper test equipment Be sure all oil lines are air free and the use of flare fittings is recommended See installation service manual for detailed information ________________________ ________________________ ________________________ ________________________ ___________________...

Page 27: ...11 14 2N1 Sensor 552108 15 Relief Valve 3 4 Male 575020 16 Altitude Gauge 1 4 2 1 2 Round 559560 17 Coil Gasket TDR All 481005 18 Blank Coil Plate with 3 4 Tapping TDR 229151 19 35 Coil TDR w Gasket Cartoned 530243 20 55 Coil TDR w Gasket Cartoned 530247 21 Replacement Soft Chamber Only 337350 22 Chamber Base Assembly Complete with Metal Base 221750 23 Chamber Base Front Only Metal with Studs 2230...

Page 28: ...lly restrict the flow of combustion air to the combustion head When the baffle is placed in the stream of air going from the blower wheel to the head it increases the load on the blower wheel This reduces the CFM and increases the operating pressure At the lower firing rates the combustion head has an easier time controlling the reduced air supply The result is better starts and running characteri...