Thermo Dynamics TDX-90, TDX-100, TDX-110, TDX-125 Installation And Operating Manual

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TDX Series

Installation

Operation

Maintenance

Manual

Thermo-Dynamics Boiler Company

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

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

www.thermodynamicsboiler.com

Service Policy

Congratulations on the purchase of your boiler. Here at Thermo-Dynamics Boiler Com-

pany 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 burn-

er/boiler be serviced annually, preferably prior to the onset of the winter heating season.

Servicing of your appliance must be performed by a qualified heating technician. You should

utilize a qualified heating technician familiar with your installation to manage your boiler and

perform periodic maintenance. Proper care and maintenance of your boiler will allow you to

enjoy the benefits of your new purchase as well as extend its long useful life.

In the event that your serviceman encounters difficulty with the boiler, he/she shall con-

tact the distributor from which the product was purchased. The distributor shall, in turn, contact

the Thermo-Dynamics sales representative for your area. By adhering to this protocol, 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 possible.

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 family for many years to

come. Please consider Thermo-Dynamics Boiler Company in the future for all of your home

heating needs.

TDX Series

Boiler Installation and Operating Manual

Contents

Subject Page

Read This First 2

Specifications 4

Installation 4

Operational Sequence 7

Start-Up 8

Appendices

Troubleshooting Guide A 14

Dimensions B 16

Piping Diagrams C 17

Wiring Diagrams D 18

Installer/Serviceman Labels E 20

Burner Service Set Up Records 22

Installation and Service Check List Back Cover

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 a claim must be filed with the freight carrier who transported the boiler from the factory to the distributor where it was purchased. Do not install the boiler. Contact your 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. 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 njury or damage to equipment.

NOTICE: Indicates that special attention to information is required. Not related to personal injury or property damage.

12. Modifications, substitutions or removal of equipment supplied or specified may result in property damage, personal injury or loss of life.

Specifications

___________________________________________________________________________________

Model TDX-90 TDX-100 TDX-110 TDX-125

___________________________________________________________________________________

Input BTU/HR 126,000 140,000 154,000 175,000

___________________________________________________________________________________

Heat Capacity BTU/HR 110,000 121,000 132,000 148,000

___________________________________________________________________________________

Net Output BTU/HR 95,000 105,000 115,000 129,000

___________________________________________________________________________________

Firing Rate GPH 0.90 1.00 1.10 1.25

___________________________________________________________________________________

Supply 1 1/4” 1 1/4” 1 1/4” 1 1/4”

___________________________________________________________________________________

Return 1 1/4” 1 1/4” 1 1/4” 1 1/4”

___________________________________________________________________________________

Coil Capacity (WC Model) 5 GPM 5 GPM 5 GPM 5 GPM

___________________________________________________________________________________

Steady State 87.0 86.5 86.0 85.5

___________________________________________________________________________________

AFUE 87.0 86.5 86.0 85.5

___________________________________________________________________________________

Burner Model Carlin EZ-1 PRO Carlin EZ-1 PRO Carlin EZ-1 PRO Carlin EZ-1 PRO

___________________________________________________________________________________

Burner Model Beckett NX Beckett NX Beckett NX Beckett NX

A. Installation Instructions

1) Place the boiler on a level floor, preferably raised and as close to the chimney as possible. Refer to the installers label to determine if the boiler may be installed on combustible flooring or if non-combustible flooring is required. The minimum clearances for installation are shown below. Reduced clearance installations must follow NFPA-31 guidelines. If the boiler is a Knock Down (not packaged for ease of installation), install the jacket in accordance with the directions provided in the jacket package, prior to piping.

Standard Clearances

Front 24”

Sides 6”

Rear 12”

Top 18”

Chimney Connector 18”

Floor Non-Combustible

2) Install the boiler piping. For location of piping refer to the Installation Drawing.

DANGER: Boilers with tankless coils must be piped in accordance with the piping diagram including installation of a tempering or mixing valve. Domestic hot water temperatures exceeding 125°F will cause severe burns instantly or death by scalding.

WARNING: Relief valve discharges and drain valve piping must be piped to a safe place of discharge.

NOTICE: TDX Series Boilers are provided with a built-in air scoop feature. This feature allows quiet, air free operation of the hot water system by eliminating air pockets without installation of air scoops. The supply line tapping in the top of the boiler extends approximately 1 inch 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, a manual vent or piped to a conventional expansion tank.

3) Packaged boilers are shipped with the burner, aquastat and circulator installed and wired at the factory. See the Basic Wiring Diagram for wiring schematic. See component manufacturer’s manual for wiring instructions.

4) An expansion tank, not provided, must be matched to the system and installed in accordance with the manufacturer’s instructions. Do not undersize the expansion tank. An automatic feed and pressure reducing valve, not provided, should be installed in the water inlet line to keep the entire system from falling below the pressure setting of the valve ( about 12 psi) See the feed valve suppliers instructions for maximum allowed water supply pressure and requirements for pressure reducers. For piping and wiring of other system components see the manufacturer’s installation manuals.

5 The tank-less water heater may be piped as shown in the Installation Drawing. A mixing

valve (tempering valve), not supplied, must 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 in the Installation Drawing. The nuts that secure the tank-less coil flange should be tightened before the boiler is filled with water, after initial firing and once a year during the annual maintenance.

CAUTION: Deterioration due to coil gasket leaks will void the warranty.

6) a. Chimney Vent Aplications. Connect boiler flue outlet to chimney using galvanized smoke pipe. The flue pipe should be pitched upward at least 1/4” per foot of run. Refer to the boiler specifications for proper size flue pipe for your model boiler. Use only elbows and straight sections. Tees may be used in a straight section in conjunction with a barometric draft regulator however they must not be used for a 90° turn. Each joint should be securely fastened with sheet metal screws. The flue pipe must not be inserted beyond the inside wall of the chimney. Install barometric draft regulator in the horizontal or vertical section of the flue pipe. The draft regulator should be installed in accordance with the manufacturer’s instructions. Set the draft to in the stack as specified in the boiler specifications and on the Installer/Serviceman Label on the boiler jacket. The flue gas exit of the venting system should be at designed with clearances in accordance with NFPA

31. A chimney must 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 within 10 feet of the venting system. The horizontal 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.

b. Direct Vent Applications. Follow the instructions provided with the Double Wall Direct Vent Kit for installation, operation and maintenance.

CAUTION: External vent surfaces are hot.

NOTICE: Use only the venting system components supplied with the kit.

NOTICE: Surface discoloration of the building may occur due to improper burner/boiler

adjustmet. Thermo-Dynamics will not accept any liability for such discoloration.

7) The boiler room must be well ventilated to allow sufficient make-up air to support combustion. Lack of adequate combustion air may result in erratic operation of the burner, noisy combustion or fuel odors. Remember your need for outside air will be greatly

increased if you have a vented dryer in the basement or other venting fans in the home. Boilers located in confined spaces shall be provided with two permanent openings, one near the top and one near the bottom of the enclosure. Each opening shall have a free area of not less than one square inch per 1000 BTU per hour input rating of the boiler, freely communicating with interior areas having adequate infiltration from the outside.

8) Fill boiler and system with water. Be sure entire system has been purged of air and the desired pressure is obtained. Leak-check the boiler and piping system by turning off the make-up water supply and observing the boiler pressure gage. A loss of pressure indicates a system leak that must be repaired prior to operating the boiler.

9) Remove the nozzle line assembly and check that the correct nozzle is installed for the desired firing rate. Check that burner settings are correct for the nozzle that is installed. See the Installer/Serviceman Label.

10) Connect burner to fuel supply. Refer to fuel unit manufacturer literature for piping, connections, lift and tank installation. If such information is unavailable use the following guide lines.

FUEL UNITS/FUEL LINES

Fuel supply “level with” or “above” burner: A single stage fuel unit connected to the fuel supply with a single supply line is the most common type of installation for these conditions. Manual venting of the fuel unit is usually required on initial start-up. Failure to vent air could result in an air lock/oil starvation condition. (One pipe)

Fuel supply below the level of burner:

Use a single stage fuel unit in lift conditions of up to 10 ft., and a two stage fuel unit when the lift exceeds 10 ft. Both conditions require the use of a return line which purges the fuel unit of air returning it to the fuel tank. The “by-pass” plug must be inserted into the fuel unit when installing a return line. (Two pipe)

Fuel line installation:

Continuous lengths of heavy wall copper tubing are recommended and should be installed under the floor when possible. Always use flare fittings. Always install fittings in accessible locations. Never use teflon tape on any fuel fitting. Use of teflon will void any warranty. Fuel lines should not run against the appliance or the ceiling joists.

Fuel line valve and filter:

Install two high quality shutoff valves in accessible locations on the oil supply line. Locate one close to the tank and the other close to the burner ahead of the filter. Some filters come with built-in shutoff valves. Install a generous capacity filter inside the building between the fuel tank shutoff valve and 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 shutdown b) Poor starts c) Smokey starts d) Continual sooting of boiler and burner parts including the cad cell e) Reduced firing rate, inefficient operation and erratic fire pattern f) A dangerous combustion condition, allowing the firebox to fill with a lean mixture (too

much air in the oil stream) which could cause a delay in ignition of the fuel mixture until the danger point has been reached.

Suction Vacuum Test. A fuel pump suction vacuum test should be performed. See the fuel pump manufacturers literature for details. The suction vacuum must be limited to ensure that there is adequate pump lift. This problem becomes proportionately larger with underground tanks. If the following procedures are followed, burner related problems will be minimized:

a) Connect vacuum gauge to fuel pump. Suction vacuum must not exceed 10 inches of mer-

cury for single stage pumps and 15 inches for two stage pumps. It is preferable to stay below these limitations.

b) When the suction line is tight and properly installed the pump will hold its vacuum for a

minimum of 60 minutes after shutdown.

c) Installation of a check valve in the suction line of a two pipe system is advisable under all

circumstances. Be sure the check valve fittings are airtight.

11) Connect the electric supply to the boiler as indicated on the wiring diagram. The wiring

must be instal

led in accordance with the National Electrical Code and any other state and

local codes and the following requirements.

a) Internal wiring is completed at the factory on packaged boilers. External wiring must

conform with the National Electric Code and local codes. b) Field connections should be protected with a 15 amp fuse. c) A separate, fused disconnect switch should be installed and located near the unit so

that power can be shut-off for servicing, unless already equipped. d) Install the room thermostat (not provided) on an inside wall away from cold drafts,

windows or heat from fireplaces, appliances or sunlight. Set the heat anticipator in

accordance with the manufacturer’s instructions. Connect the thermostat leads to the

“TT” terminals on the circulator control.

C. Operational Sequence

1) TDX-WC equipped with tankless coil are equipped with a combination aquastat control which has high and low limits to be set at 180° F and 160° F respectively by the installer. These settings are nominal and may be adjusted for the particular installation conditions. A 20° F difference between high and low limit is recommended. The control prioritizes domestic hot water heating as explained below.

a) When room temperature falls below thermostat setting, thermostat calls for heat start

ing the burner and 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 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 dropped to approximately 10 degrees below the temperature setting of the high limit control, the oil burner will start again and the circulating pump will continue to run.

b. The boiler water temperature 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 temperature should fall approximately 10 °F below the operating control low

limit setting, the oil burner will be started again by the control (and the circulating pump will be prevented from operating) until the operating control setting is satisfied. The operating control has an adjustable low limit differential setting. The low limit differential setting determines how high the boiler temperature must rise before the burner turns off and or the circulator comes on if the thermostat calls for heat. The differential is measured from 10°F below the low limit. See control manufacturer’s literature included in the data package for detailed wiring, operating and safety instructions.

c) Adjusting the low limit differential to higher values will provide priority to heating

domestic hot water over a greater range of boiler temperature. (Maximum of approximately 25°F differential measured from 10°F below the low limit setting.)

2) TDX boilers that do not have a tankless coil

and are equipped with a high limit aquastat must be used with bypass control which should be set at 180°F by the installer. This setting is nominal and may be adjusted for the particular installation conditions.

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

ing the burner and 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 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 dropped to approximately 15 degrees below the temperature setting of the high limit control, the oil burner will start again and the circulating pump will continue to run.

b) The boiler water temperature need not be maintained at a160°F low limit setting since

there is no domestic hot water load to protect. See control manufacturers literature included in the data package for detailed wiring, operating and safety instructions.

c) Boilers without Tankless Coils may be equipped with a combination aquastat that has

a high and low limit setting. The high limit control is set at 180°F and the low 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 indi rect 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 adjusted for the particular installation conditions.

3) A cadmium sulfide flame scanner (cad cell) and relay are 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 goes out 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.

D. Start-Up and Check-Out Procedure

CAUTION : Only a trained, experienced serviceman should attempt the checkout procedure outlined below. You should read to the burner manual provided with this manual for specific instructions and set points.

1) Confirm that electrical power to the boiler is off. The fuel tank must be filled with No. 2 heating oil. Low Sulfur fuel is preferred.

2) Check electrode settings, nozzle size and air setting. Electrode settings are shown in the burner manual provided along with this manual. Burner settings are listed on the Service Man’s Label attached to the boiler and on the Specifications provided along with this manual.

3) Set thermostats substantially above room temperature.

4) Open all shut-off valves in the fuel supply line to the burner.

5) Install pressure gauge in the port provided on the fuel pump. Attach a length of 1/4” O.D. clear plastic tubing to the end of the bleed plug.

6) Turn on power to the boiler. If burner does not start immediately reset manual overload switches and control. See control manual for reset instructions.

7) On one pipe systems bleed the fuel pump as soon as burner motor starts. To bleed the pump, loosen plug while holding an empty container under the tubing installed in step 6 to catch all of the expelled fuel. Bleed for at least 15 seconds after the fuel stream is free of all air. If air is still evident in the bleed line you must check the oil lines, all fittings, filters and any other connections for tightness. Kinks in the fuel lines will create undue high vacuum therefore they must be eliminated. When you are sure all air has been eliminated then close the bleed valve. Ignition should be instantaneous following the closing of this valve. If it is not, proceed to the trouble shooting guide to determine why the fuel did not ignite.

8) Be sure the fuel pump discharge pressure is adjusted to the pressure listed on the Installer/ Service Man Label. If it is not, refer to the burner manufacturer’s instruction sheet for pressure adjustment procedure.

FINAL ADJUSTMENTS OF THE BURNER MUST BE MADE USING PROPER COMBUS TION TEST EQUIPMENT. Combustion test equipment required for proper burner adjustment:

a) CO

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 combustion. The burner instructions contain special instructions that may apply to the model supplied with your boiler including how special features may affect the set-up procedure.

9) Burner Adjustments. Allow the burner to operate steadily for 5 to15 minutes. Check burner settings shown on the Installer/Service Man Label and make the following adjustments.

a) Punch or drill a 1/4” hole in the flue pipe between the boiler and the barometric draft

regulator. All test readings should be taken from this point.

b) Take a draft reading from the flue pipe sampling hole. Adjust the draft in the stack,

using the barometric draft regulator, to the value shown on the Installer/Serviceman Label. In tall chimneys a second draft regulator may be required in the flue pipe to regulate draft under high draft conditions.

c) Remove the draft port plug over the fire and take a draft reading from the draft port.

Compare the readings with those on the INSTALLER/SERVICEMAN label. Refer to the trouble shooting procedure if the draft over the fire reading is not correct. Reinstall the draft port plug after all readings have been taken.

d) Follow the burner manufacturer’s instructions to adjust the air supply until a trace of

smoke is recorded. At the trace of smoke level, measure the CO

. This is the refer-

ence point for all further adjustments.

e) Increase the air supply to reduce the CO

about 1-1/2% to 2% from the reference

point. A zero smoke reading should result. If this adjustment can not be obtained, refer to the Trouble Shooting section of this manual.

f.) When combustion is set, follow the burner manufacturer’s instructions to lock or

tighten adjustment mechanisms as required.

10) Check operation of the cad cell relay by removing one cad cell wire from external terminal during the flame cycle. The relay should cut the burner off in approximately 15 sec.

11) Direct Vent Applications. The burner control for direct vent applications is provided with a post-purge feature to keep the burner fan operating after the flame is off. The post purge cycle time is 120 seconds. See the burner manufacturer’s operating instructions for more information on the post purge settings.

E. Servicing the Boiler/Burner Unit:

1) Burner Components: If replacement of burner parts is necessary, always use parts recommended by the manufacturer. Specify part number and description when ordering.

2) Electrode settings are important for reliable ignition of the fuel. Check to be sure the settings are in accordance with the instructions provided in the burner manual.

3) Nozzles: 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 fuel 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 located near an unvented dryer, special care must be taken so that lint does not clog the burner air inlets.

5) Replace the fuel filter cartridge annually.

6) Check all water connections and plugs for evidence of leaks. Check for leaks by shutting the make-up water supply valve. If boiler pressure decreases, it is evidence of a leak which must be repaired.

7) Cleaning the Boiler: Cleaning should be done only by a trained, experienced serviceman.

DANGER: Before cleaning turn off all power to the boiler. Failure to turn off power could result in firing the boiler when it is open.

a) Remove the burner cover by lifting up to disengage the fasteners and out to remove

the cover. Remove the boiler front cover and rear cover by lifting up and out.

b) Disconnect the control wires from the aquastat control to the burner.

c) Remove the brass nuts that secure the hinged burner door and carefully open the

door.

d) Remove the rear cover on the flue box.

e) Remove baffles from the units and clean them. Brush all tubes and the furnace tube

with a #2 soft flue brush. Use a boiler vacuum to collect any residue.

f) Inspect the burner head. Remove any accumulation on the burner. Inspect and

follow burner manufacturer’s recommendations for cleaning and maintenance.

g) Check all refractory and gaskets for resilience and continuity. Replace damaged

parts prior to re-assembling the unit.

h) Reassemble the boiler.

F. Changing the Burner Door Hinge Location.

The side that the hinge is located on may be changed as follows.

1) Turn power off to the burner.

DANGER: Failure to turn off power to the burner during maintenance may result in serious injury or death.

2) Remove the burner cover by lifting it up, out and away from the burner. Remove the front boiler cover by lifting up, out and away from the burner.

3) Disconnect the burner power cord.

4) Disconnect the fuel supply line to the burner.

5) Remove the burner from the burner flange and set the burner to the side.

6) Remove two brass nuts that hold the door bracket to the boiler. Remove two brass nuts that hold the door bracket to the door. Remove the two brass nuts that hold the hinge the door. Set the door to the side.

7) Remove the two brass nuts that hold the hinge to the boiler, move the hinge to the other side and attach it to the boiler using two brass nuts. Do not tighten the nuts fully. The thick side of the hinge is attached to the boiler. The hinge pin is on the outside.

8) Attach the door bracket to the door using two brass nuts. Swing the door to make sure that it is free and that the door bracket fits over the boiler studs on the other side. Make final adjustments and tighten all nuts.

9) Close the door and attach the bracket to the boiler using two brass nuts. Do not tighten completely.

10) Install the burner. Remove the two nuts that hold the door flange to the boiler. Check that the door swings free. Adjust as required. Install and tighten door flange nuts.

11. Attach fuel supply line and burner cord to burner.

Follow start-up procedure in this manual. Check for combustion gas leaks around the door gasket and repair prior to operation.

Appendix C

Low Water Cutoff if required, install low water cutoff(s) in the piping anywhere above the top of the boiler. Install in accordance with the manufacturer's instructions.

Supply to heating circuits

Bypass Piping

Burner

TDX-LC

Return from heating circuits

TDX-WC

Burner

Supply to heating c

ircuits

Domestic Hot Water Coil

Hot Water Out Dishwasher

Tempered Hot Water

Cold Water In

Legend

1. Circulator

2. Relief Valve

3. Expansion Tank Pressurized

4. Vent

5. Flow Check

6. Shut off valve

7. Auto Refill/Pressure reducing valve

8. Drain

9. Tempering Valve

10. Manual Bypass Valve

11. Optional Danfoss Bypass Valve

Piping Diagram

ELECTRICAL DIAGRAM FOR TDX SERIES

BOILERS TO CONNECT BURNER TO AQUASTAT

(APPLIES TO CARLIN CHIMNEY VENT AND CARLIN DIRECT VENT BURNERS)

ELECTRICAL DIAGRAM FOR TDX SERIES

BOILERS TO CONNECT BURNER TO AQUASTAT

(APPLIES TO BECKETT CHIMNEY VENT AND DIRECT VENT BURNERS)

ELECTRICAL DIAGRAM FOR TDX SERIES

BOILERS TO CONNECT BURNER TO AQUASTAT

(APPLIES TO RIELLO CHIMNEY VENT BURNERS)

ELECTRICAL DIAGRAM FOR TDX SERIES

BOILERS TO CONNECT BURNER TO AQUASTAT

(APPLIES TO RIELLO DIRECT VENT BURNERS)

Installer/Serviceman Labels

Appendix E

INSTALLER/SERVICEMAN

Model Number TDX-WC 90 TDX-WC 100 TDX-WC 110 TDX-WC 125

Burner Type Beckett Beckett Beckett

Burner Model NX NX NX

Nozzle Type 0.70 60°B 0.75 60°B 0.85 60°B N/A

Pump Pressure PSI 175 175 175 N/A

Head/Pin Position 2.5 3.00 4.5 N/A

Air Band N/A N/A N/A N/A

Air Shutter N/A N/A N/A N/A

Draft Over Fire +0.06" +0.08" +0.10" N/A

Draft In Stack -0.02" -0.02" -0.02" N/A

CO2Reading 10-12% 10-12% 10-12% N/A

Smoke Reading ZERO ZERO ZERO N/A

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.

_____________________________

N/A

_____________________________ _____________________________ _____________________________ _____________________________ _____________________________ _____________________________ _____________________________ _____________________________ _____________________________

NOTICE

INSTALLER/SERVICEMAN

Model Number TDX-WC 90 TDX-WC 100 TDX-WC 110 TDX-WC 125

Burner Type Beckett* Beckett* Beckett* Burner Model NX NX NX

Nozzle Type 0.70 60°B 0.75 60°B 0.85 60°B N/A

Pump Pressure PSI 175 175 175 N/A

Head/Pin Position 2.75 3.25 4.00 N/A

Air Band N/A N/A N/A N/A

Air Shutter N/A N/A N/A N/A

Draft Over Fire +0.080" +0.115" +0.125" N/A

Draft In Stack +0.040" +0.055" +0.065" N/A

CO2Reading 10-12% 10-12% 10-12% N/A

Smoke Reading ZERO ZERO ZERO N/A

DV DV DV DV

_____________________________

N/A

_____________________________ _____________________________

*Beckett Air Boot Adaptor

NOTICE

See the label attached to your boiler for data specific to your boiler.

INSTALLER/SERVICEMAN

Model Number TDX-WC 90 TDX-WC 100 TDX-WC 110 TDX-WC 125

Burner Type Carlin Carlin Carlin Carlin

Burner Model EZ-1 PRO EZ-1 PRO EZ-1 PRO EX-1 PRO

Nozzle Type 0.75 60°B 0.85 60°B 0.90 60°B 1.00 60°B

Pump Pressure PSI 150 150 150 150

Head/Pin Position 0.75 0.85-1.00 0.85-1.00 0.85-1.00

Air Band 0.75 0.85 0.90 1.00

Air Shutter N/A N/A N/A N/A

Draft Over Fire +0.04" +0.07" +0.09" +0.12"

Draft In Stack -0.02" -0.02" -0.02" -0.02"

CO2Reading 10-12% 10-12% 10-12% 10-12%

Smoke Reading ZERO ZERO ZERO ZERO

_____________________________

NOTICE

INSTALLER/SERVICEMAN

Model Number TDX-WC 90 TDX-WC 100 TDX-WC 110 TDX-WC 125

Burner Type Carlin* Carlin* Carlin* Carlin*

Burner Model EZ-1 PRO EZ-1 PRO EZ-1 PRO EX-1 PRO

Nozzle Type 0.75 60°B 0.85 60°B 0.90 60°B 1.00 60°B

Pump Pressure PSI 150 150 150 150

Head/Pin Position 0.75 0.85-1.00 0.85-1.00 0.85-1.00

Air Band 45 40 65 180

Air Shutter N/A N/A N/A N/A

Draft Over Fire +0.080" +0.115" +0.125" +0.140"

Draft In Stack +0.040" +0.055" +0.065" +0.075"

CO2Reading 10-12% 10-12% 10-12% 10-12%

Smoke Reading ZERO ZERO ZERO ZERO

DV DV DV DV

_____________________________

_____________________________ _____________________________

*Field Control Air Boot Adaptor

NOTICE

INSTALLER/SERVICEMAN

Model Number TDX-WC 90 TDX-WC 100 TDX-WC 110 TDX-WC 125

Burner Type Carlin* Carlin* Carlin* Carlin*

Burner Model EZ-1 PRO EZ-1 PRO EZ-1 PRO EX-1 PRO

Nozzle Type 0.75 60°B 0.85 60°B 0.90 60°B 1.00 60°B

Pump Pressure PSI 150 150 150 150

Head/Pin Position 0.75 0.85-1.00 0.85-1.00 0.85-1.00

Air Band 0.65 0.75 1.00 1.10

Air Shutter N/A N/A N/A N/A

Draft Over Fire +0.080" +0.115" +0.125" +0.140"

Draft In Stack +0.040" +0.055" +0.065" +0.075"

CO2Reading 10-12% 10-12% 10-12% 10-12%

Smoke Reading ZERO ZERO ZERO ZERO

DV DV DV DV

_____________________________

_____________________________ _____________________________

*Carlin Air Boot Adaptor

NOTICE

See the label attached to your boiler for data specific to your boiler.

BURNER SERVICE SET-UP RECORDS

1. Date

2. Model

3. Firing Rate

4. Pump Pressure

5. CO2

6. “0” Smoke

7. Gross Stack °F

8. Draft Over Fire

9. Replaced Filter Yes/No

10. Replaced Nozzle Yes/No

Initial Set Up

12345

11. Clean Pump Filter Yes/No

12. Inspect Coil Gasket Yes/No

13. Check for Leaks

14. Brush Clean Flue Tube Passages

15. Vacuum Chamber/Flue Tubes

16. Clean Blower Wheel

17. Check Electrodes

Installation and Service Check List

Boiler Model: ______________________________ Serial No.: ____________________________

Installation Date: ___________________________

Installer Name: _____________________________ Phone No.: ____________________________

Boiler Installation

q Boiler level and in solid contact with floor? q Boiler and burner wired per wiring diagram and National Electric Code? 120VAC wiring

Type_______ Size_______ AWG

q Burner sealed to boiler? Mounting nuts tight? q Space is large enough to provide required clearances? q NFPA 31 Installation of Oil Burning Equipment followed? q Local, state and national codes, laws, regulations and ordinances followed?

Vent System

q Existing chimney and vent system inspected to NFPA 211 and in good condition? q New vent pipe installed and properly sealed? q Vent size checked against furnace manual and codes?

Burner Operation

q Burner Model: ____________________ Nozzle: _____ GPH _____ Deg. _____ Type _____ q Burner Pump Pressure: _________________ q Fuel Filer and fuel lines installed and inspected as per burner manual? q Air bled from oil piping? Piping checked for leaks? q Burner started, adjusted and tested per burner manual?

Boiler Operation

q Thermostat heat anticipator set per burner manual instructions? q Limit control tested for proper operation? q Boiler observed going through several operational cycles for proper operation?

Post Installation

q Reviewed owners’ information in this manual with owner or maintenance personnel

and instructed to keep for future reference?

q Inserted burner manual instructions with boiler manual for future use

MET-3381

1/08-250

Thermo Dynamics TDX-90, TDX-100, TDX-110, TDX-125 Installation And Operating Manual

Specifications and Main Features

Frequently Asked Questions

User Manual