Thermo-Dynamics Boiler HT 200, HT 225, HT 250, HT 275, HT 90 Installation, Operation & Maintenance Manual

HT Series

Models HT 90/100/110, HT DV 90/100/110, HT 125/135/150

HT DV 125, HT 165/175/200 and HT 225/250/275

Installation

Operation

Maintenance

Manual

Thermo-Dynamics Boiler Company

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

TEL [phone] • FAX [phone]

WEB www.thermodynamicsboiler.com • EMAIL [e-mail]

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• ASME Coded Boiler Registered with National Board

• Factory Mounted/Wired Burner and Controls

• Fully Insulated Heat Exchanger with Powder-Coated Cabinet

• Packaged with Standard Five Gallon per Minute Tankless Coil (Domestic Hot Water)

• Equipped with Triple Aquastat, Circulator, and Temperature / Altitude Gauge

• Outfitted with Additional Nozzles to Achieve a Variety of Heat Inputs

• Provided with a Lifetime Limited Warranty

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

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Service Policy 2

Homeower Information 3

Read This First 4

Model Specifications 5

Installation 7

Operation 15

Maintenance 17

Trouble Shooting 18

Parts List 26, 27

Preliminary Settings 28

Wiring Diagrams 33

Warranty 38

Burner Service Set-Up Records Back Cover

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Congratulations on the purchase of your boiler. At Thermo-Dynamics Boiler
Company we pride ourselves on the design and construction of our product. Our
intent is to furnish you with a high quality appliance that will provide you and your
family with years of trouble free service.

In order to maintain peak performance of your boiler, it is recommended that
the burner/boiler be serviced annually, preferably prior to the onset of the winter
heating season. Servicing of your appliance must be performed by a qualified heat­ing 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 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 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.

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Heating Contractor:

Address:

Phone No.:

A) General

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

Never burn garbage or refuse in your boiler or leave combustible material around it. Do not allow
the fuel tank to run out of oil. The fuel tank should be kept full during the summer, or periods of
non-use, to prevent condensation of moisture on the inside of the tank.

B) Combustion Air Supply

The burner requires an ample amount of clean combustion air to burn efficiently. If ample supply
is not available, noisy and erratic combustion will result. Under these conditions fuel odors may
occur. The installation and use of venting fans (anywhere in the house) or a vented dryer will
greatly increase the need for outside air.

C) Area Around Boiler

The area around the boiler must be kept clean and free of any combustible materials, particularly
oily rags or papers. The boiler must be accessible for service.

D) Annual Tune-Up

The boiler should be serviced once a year, ideally just prior to the heating season. The tune-up is
to be done by a qualified technician following procedures listed under Maintenance in this 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. Working with a burner and setting-up the combustion process
requires specific technical knowledge, skills and instruments. In addition, your boiler is only part
of your overall home heating system. Other controls (etc.) may require adjustment or replacement.

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

technician.

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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 Standard 31, “Standard for the Installation of Oil
Burning Equipment”.

5. A complete heat loss calculation is necessary to choose the proper size unit to install. The
boiler should be sized to within 25% of the actual heat loss of the structure. Over sizing
will result in short cycling and inefficient operation.

6. When moving the boiler, do not push against the jacket or burner. Damage will result.

7. If the boiler is vented to a chimney, be certain the chimney is clean and free of
obstructions. The chimney must be masonry with tile lining or metal insulated with a
stainless steel surface. The chimney must be properly sized. Draft requirements are
essential for safe and proper operation of the boiler.

8. If the boiler is connected to a venting device, make sure that it is listed by a recognized
testing service. Follow the venting device manufacturer’s installation instructions. Verify
that the venting device installation complies with the recommendations of the
manufacturer and local and state codes.

9. Conduct a thorough checkout when installation is complete. Check for indications of
leaks and make sure that no material is left adjacent to the boiler.

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

11. Modification, substitution or elimination of factory equipped, supplied or specified
components may result in property damage, personal injury or the loss of life.

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

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

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

CAUTION: Indicates a hazardous situation which if not avoided, may result in a minor injury.
It may also warn against unsafe practices that may result in minor injury or damage to
equipment.

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

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Table 1 - Series I Boilers

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

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

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

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

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Firing Rate 0.90 1.00 1.10 1.25 1.35 1.50

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Tubes 10 10 10 16 16 16

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Baffles

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Water Content 30 30 30 28 28 28

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

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

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

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Steady State 86.5 86.2 85.5 85.6 85.4 84.9

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AFUE - DOE Efficiency 85.1 84.8 84.2 85.0 84.7 84.0

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

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

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Weight 458 458 458 485 485 485

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Burner Model

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

Fully Baffled Fully Baffled Fully Baffled Fully Baffled Fully Baffled Fully Baffled

Beckett AFG, Beckett AFG, Beckett AFG, Beckett AFG Beckett AFG Beckett AFG
AFII and NX AFII and NX AFII and NX Beckett AFII Beckett AFII Beckett AFII

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

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

Riello BF5 Riello BF5 Riello BF5 Riello BF5

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

Table 2 - Series II Boilers

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

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

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

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

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Firing Rate 1.65 1.75 2.00 2.25 2.50 2.75

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Tubes 18 18 18 24 24 24

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Baffles

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Water Content 48 48 48 46 46 46

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

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Returns (2) 2" 2" 2" 2” 2" 2"

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Coil Capacity

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

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

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

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

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Weight 680 680 680 710 710 710

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Burner Model

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

5 (7 GPM opt.) 5 (7 GPM opt.) 5 (7 GPM opt.) 5 (7 GPM opt.) 5 (7 GPM opt.) 5 (7 GPM opt.)

Beckett AFG “M” Beckett AFG “M” Beckett AFG “M” Beckett CF375 Beckett CF375 Beckett CF375

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

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AQUASTAT RELAY

T

/A GAUGE

1

-1/4" RETURN INLET/CIRCULATOR

PIPED EITHER SIDE

1-1/4" SUPPLY OUTLET

6" FLUE OUTLET (CHIMNEY VENT)
5" FLUE OUTLET (DIRECT VENT)

37 7/16

37

29 3/16

22 3/4

31 3/4

22 1/16

22 1/2

4 3/4

10 3/4

13 1/8

30 5/8

39 1/4

14 1/8

12 1/2

4 3/4

22 1/16

24

33

42

45 1/8
45 1/2

35 5/16

2" RETURN INLET/CIRCULATOR

PIPED EITHER SIDE

2" SUPPLY OUTLET

8" FLUE OUTLET

AQUASTAT RELAY

T/A GAUGE

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FIGURE 2 - SERIES I BOILERS

FIGURE 3 - SERIES II BOILERS

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A) GENERAL

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

B) FREIGHT CLAIMS

All units should be inspected for damage upon arrival. Concealed damage claims should be filed
immediately against the carrier by the consignor. The carrier is responsible for taking prompt
action on all claims.

C) 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 calculation 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.

D) BOILER LOCATION

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

10.6.1.

STANDARD CLEARANCES

Front 24"

Sides 6"

Top 18"

Rear 12"

Chimney Connector 18"

Floor: Sizes 90-150 may be installed on combustible flooring

2. Reduced clearance installations shall comply with NFPA 31 Table 10.6.2.

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

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

E) AIR FOR COMBUSTION AND VENTILATION - CHIMNEY VENT APPLICATIONS

The unit must be installed where provisions exist for combustion and ventilation air. Ordinarily,
provisions may be furnished by the following methods.

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1. Utility Room or Closet

In buildings of tight construction, including most modern homes, you should provide an opening,
connecting to a well ventilated attic, crawl space or directly with the outdoors. The opening should
have a minimum free area of 1 square inch per 1,000 Btu per hour of total input for all appliances
in the enclosure and should terminate below the burner level. Boilers installed in confined areas
or closets must have two ventilation openings in the closet door. Each opening should have a free
area of not less than 1 square inch per 1000 Btu (140 square inch per US gph) of the total input
for all appliances in the enclosure. One opening located near the top of enclosure and one near
the bottom.

2. Basement

a. When a boiler is installed in a full basement, infiltration is normally adequate to provide air
for combustion.
b. In buildings of tight construction when the basement windows are weather stripped, one open­ing to a well ventilated attic or with the outdoors should be provided. (See part A for opening
requirements)

3. Special Conditions

When a boiler is located in an area where exhaust fans, kitchen ventilation systems, clothes dry­ers, 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.

F) AIR FOR COMBUSTION AND VENTILATION - DIRECT VENT APPLICATIONS

CAUTION: External vent surfaces are hot..

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

Surface discoloration of the building may occur due to improper boiler/burner adjustment.
Thermo Dynamics Boiler Company will not accept any liability for such discoloration.

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

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G) JACKET AND TRIM ASSEMBLY

1. Knock Down Boiler

a. Jacket Assembly - Unpack the jacket parts being careful not to damage the finish. Piping and
accessories are installed after the jacket is in place.
b. Trim Assembly
Install the safety relief valve in the 3/4" tapping in the top of the boiler. The relief valve should
be piped to a safe place of discharge.
Install the limit control in the 3/4" fitting provided in the boiler plate.
Install the altitude/temperature gauge in the 1/4" fitting provided in the coil plate.
Install plugs provided in the parts box in all openings that are not used.

2. Packaged Boiler

Controls and burner are installed and prewired at the factory. Install Relief Valve as noted in
Figures 6 and 7.

H) BOILER PIPING

This style of boiler is equipped with a built in “Air Scoop
System.” This feature allows quiet air free operation of your
hot water system by assuring the removal of noisy air 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. All plugs and water connec­tions should be checked for leaks upon installation and annual­ly.

BUILT-IN AIR SCOOP

FIGURE 5

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

I) TANKLESS WATER HEATING PIPING

The tankless heater may be connected as shown in Figure 6. 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.

WARNING: An anti-scald/mixing valve (not supplied) must be used to reduce the water
temperature at kitchen or bathroom taps.

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FIGURE 6 - PIPING DIAGRAM FOR SERIES I BOILERS

WATER SUPPLY

STOP VALVE

DOMESTIC
COLD WATER
IN

ANTI-SCALD/MIXING
VA LVE

TEMPERED

WATE R

(SHOWERS AND

F

AUCETS)

HOT WATER

(DISHWASHER)

BALL VALVE

B

ACK FLOW PREVENTER

PRESSURE REDUCING VALVE

AIR VENT

EXPANSION TANK

RELIEF VALVE

HYDRONIC SYSTEM
S

UPPLY

FLOW VALVE

RETURN

ALTERNATE RETURN LOCATED
ON OPPOSITE SIDE OF BOILER

CIRCULATOR

MAY ALSO MOUNT THE
CIRCULATOR ON SUPPLY

DRAIN

VA LVE

DRAFT / SIGHT

PORT

AI R V EN T

EXPANSION TANK

RE LI EF VALVE

SECONDARY
HIGH LIMIT

HYDRONIC SYSTEM
SUPPLY

FIGURE 7 - PIPING DIAGRAM FOR SERIES II BOILERS
(PIPING THE SAME EXCEPT THE ADDITION OF A SECONDARY HIGH LIMIT)

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J) BURNER AND CONTROLS

1. Burner Installations

Packaged boilers are shipped with the burner installed and prewired. Boilers that are shipped
knocked-down must be field assembled. Follow the procedures listed below to install and connect
the burner.
a. Remove the burner parts and instructions from the carton.
b. Referring to specifications at the back of the manual, check to see that the burner model and
size match the boiler model.
c. Make sure the correct nozzle is in place and is tightly sealed.
d. Check the electrode position and set the air intake as indicated in the burner manual.
e. The burner is installed with a mounting flange. The end of the burner air tube should be 1/4"
from the inside surface of the front wall of the combustion chamber.
f. Make the electrical connections as illustrated in the wiring schematics. All wiring must be done
in accordance with the local electrical code. A service box is provided with disconnect switch so
power can be shut off to the boiler, but power for a utility lamp is still available.
g. For units installed in Maine, New Jersey and New York, a low-water cutoff is required on all
hot water boilers.

2. Oil Primary Control - Chimney Vent (Non Post Purge Control)

The oil primary control with the solid state flame sensing circuit provides automatic, non-recy­cling control of oil burners. When used with the cadmium sulfide flame detector, the control will
automatically control the oil heating system.

The primary control will stop the oil burner within a predetermined number of seconds if the fuel
fails to ignite or if the flame goes out during operation. The oil burner will remain off until the
reset button on the relay has been pushed.

WARNING: The reset must never be pressed more than once during a single flame fail­ure.

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

The oil primary control with the solid state flame sensing circuit provides interrupted ignition.
Used in conjunction with a cadmium sulfide flame detector, the control will automatically 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.

WARNING: The reset must never be pressed more than once during a single flame fail­ure.

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

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