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 [email protected]

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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

___________________________________________________________________________________

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

___________________________________________________________________________________

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

___________________________________________________________________________________

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

___________________________________________________________________________________

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

___________________________________________________________________________________

Firing Rate 0.90 1.00 1.10 1.25 1.35 1.50

___________________________________________________________________________________

Tubes 10 10 10 16 16 16

___________________________________________________________________________________

Baffles

___________________________________________________________________________________

Water Content 30 30 30 28 28 28

___________________________________________________________________________________

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

___________________________________________________________________________________

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

___________________________________________________________________________________

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

___________________________________________________________________________________

Steady State 86.5 86.2 85.5 85.6 85.4 84.9

___________________________________________________________________________________

AFUE - DOE Efficiency 85.1 84.8 84.2 85.0 84.7 84.0

___________________________________________________________________________________

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

___________________________________________________________________________________

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

___________________________________________________________________________________

Weight 458 458 458 485 485 485

___________________________________________________________________________________

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

___________________________________________________________________________________

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

___________________________________________________________________________________

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

___________________________________________________________________________________

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

___________________________________________________________________________________

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

___________________________________________________________________________________

Firing Rate 1.65 1.75 2.00 2.25 2.50 2.75

___________________________________________________________________________________

Tubes 18 18 18 24 24 24

___________________________________________________________________________________

Baffles

___________________________________________________________________________________

Water Content 48 48 48 46 46 46

___________________________________________________________________________________

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

___________________________________________________________________________________

Returns (2) 2" 2" 2" 2” 2" 2"

___________________________________________________________________________________

Coil Capacity

___________________________________________________________________________________

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

___________________________________________________________________________________

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

___________________________________________________________________________________

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

___________________________________________________________________________________

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

___________________________________________________________________________________

Weight 680 680 680 710 710 710

___________________________________________________________________________________

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

5

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.

9

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)

10

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.

11

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

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 burners 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 burner is 90 seconds.

4. 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 control can also be used for multi-zone control by using a separate circula­tor and an R845 relay for each zone. The primary control is factory wired to the aquastat relay.
These controls, working as a system, will prevent the circulator 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.

12

K) SEQUENCE OF OPERATION

Forced Circulation Hot Water 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 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 below the operating control setting (160°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.

L) FUEL SYSTEM

1. Fuel Units
NOTE: Pump pressure 140 PSI for Beckett and Carlin, 175 PSI for Beckett NX, and 150 PSI

for Riello.
a. 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.
b. 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.

2. Tubing

Use continuous heavy walled copper tubing with flare fittings only
locations. If possible, tubing should be installed under the floor. Running tubing against boiler
casings or across ceiling or floor joints should be avoided.

3. 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.

4. 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.

. Locate fittings in accessible

13

M) FLUE SYSTEM - CHIMNEY VENT APPLICATIONS

1. General

NOTE: An oil fired unit shall be connected to a flue having sufficient draft at all times to
assure proper operation.

2. 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.

3. 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 system.

4. 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.

5. Vent Cap

Install a U.L. listed vent cap where the possibility of down drafts exist.

6. Boiler Venting

This boiler must be vented into a properly sized chimney, or into an Underwriters Laboratories
Inc. listed 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 installation requirements are essential for safe and proper operation of the boiler.

Only a trained experienced serviceman should attempt the installation or service of any boil-

er and or venting device.

All venting installations must comply with the recommendations of the venting manufacturer

and with all state and local codes.

N) WIRING

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 for all
field wiring.

1. Field connections should be protected with a 15 amp fuse.

2. 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.

14

3. A separate service box with disconnect switch is provided, wired but not fastened to the jack­et. Connect the service box to the jacket using the hole and screw provided.

O) WARRANTY

NOTE: The limited warranty is not applicable unless these installation instructions are
followed.

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A) START UP

CAUTION: DO NOT START UNLESS CLEAN OUT DOORS ARE IN PLACE.

1. Make sure service switch to boiler is off.

2. Make sure boiler has been filled with enough water until the entire system has been purged

and desired pressure is obtained.

3. Check to make sure the oil storage tank is filled with No. 2 heating oil.

4. Make sure all manual shut off valves in the fuel system are open.

5. Set operating controls at 160°F.

6. Set limit switch at 180°F.

7. Install a pressure gauge in the 1/8" gauge port or nozzle port of the fuel pump. Do not take

readings at the bleed valve port.

NOTE: The pressure should be set per Installer/Serviceman Label.

8. Adjust the burner air band and air shutter in accordance with Installer/serviceman Label.

9. 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.

10. With the burner running, bleed the fuel unit again until all air is eliminated from lines.

Close and tighten the bleed port.

11. Check all lines and plugs for oil leaks and eliminate.

B) START UP ADJUSTMENTS

1. Equipment Required

a. CO2 analyzer
b. Draft gauge.
c Fuel pressure gauge.
d. Stack thermometer.
e. Smoke tester.

15

2. Burner Adjustments

Allow the burner to operate steadily for at least 15 minutes. Check the burner settings according
to the installer/serviceman labels for Series I and II boilers at the end of this manual, and make
the following adjustments:
a. Sampling Hole - punch 1/4" hole in the flue between the flue box and the draft regulator. All
test readings should be taken from this point.
b. 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.
c. 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 Series I and II
boilers starting on page 30. Reinstall the draft port plug after all readings have been taken.
d. Pump Pressure - Adjust the pump discharge pressure per value on serviceman label.
e. 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.
f. Stack Temperatures - Check to see that the stack temperature is according to the installer/ser-
viceman labels for Series I and II boilers starting on page 30.

3. Instructing the Homeowner

The care and operation of the boiler should be explained to the homeowner, including care of the
burner, 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.

C) BURNER SERVICING

1. 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).

2. 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.

3. Electrode Settings

The electrode setting is critical for proper ignition of the fuel. Check to be sure electrode settings
comply with the specifications.

4. Fan and Blower Housing

The fan and blower housing should be kept clean from lint and dirt. If the boiler is located near
an unvented dryer, special care must be taken so that lint does not block air passages in the burn­er and proper combustion air is provided.

16

!#'##("!!'!# #!!##")

A) VENT SYSTEM

DANGER: ESCAPING GASES ARE DANGEROUS. THE ENTIRE FLUE AND VENTING
SYSTEM SHOULD BE INSPECTED AT LEAST ONCE A YEAR BY A QUALIFIED SER­VICEMAN.

B) OIL FILTER

The oil filter cartridge should be replaced annually.

C) CLEANING

The heat exchanger and combustion chamber should be examined annually for scale and soot
accumulation. The heat exchanger examination and cleaning is to be performed through the front
clean out panel located above the burner.

1. To clean the unit, Remove the 3/8" brass nuts, clean out cover, and front refractory board.

2. Remove baffles from front. Brush all of the tubes using a 2" soft flue brush.

3. Remove the flue pipe and check for any residue through the flue collector opening. A boiler
vacuum can be used to collect any soot and scale. It is not normally necessary to remove the flue
box for cleaning.

4. Remove the oil burner to inspect the burner head. Any soot or scale can be removed from the
chamber through the burner opening.

NOTICE: DO NOT REMOVE THE REAR COVER AND REAR REFRACTORY FOR
NORMAL MAINTENANCE. SOOT OR SCALE MUST BE REMOVED FROM THE
FRONT BURNER OPENING ONLY.

D) OIL BURNER

1. Thoroughly brush clean the burner fan blades. Only with clean fan blades is proper combus­tion air delivery possible.

2. Clean nozzle assembly and all air handling parts.

3. Check spacing and condition of the ignition electrodes.

4. Nozzles should be inspected every year for plugged distributor slots or plugged orifices. If it
is necessary to replace the nozzle, use only the specified nozzle to be sure that the replacement
meets the spray pattern specifications of the burner.

E) GASKETS

Tighten the nuts on the water coil annually to prevent any gasket leaks. Deterioration due to coil
gasket leaks shall void the warranty.

F) WIRING

Check the electrical wiring for damage or frayed insulation.

17

%$("& $$'!#(!("!!'!# #!!##")

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 Push reset button.
Overloads switch. (If equipped) overload.

Check primary control safety Primary 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
Control 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.

Burner 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.

Pump 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

TROUBLE: BURNER STARTS BUT DOES NOT ESTABLISH FLAME

SOURCE PROCEDURE CAUSES REMEDY

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 Line Open pump bleed port and start
and 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. Pressure should be
according to the installer/service­man labels for Series I & II
boilers.

Ignition Connect transformer leads to line
Transformer voltage. Listen for spark. Check

that transformer terminals are not
arcing with buss bars. Check that
transformer is properly grounded.

Empty tank.

Water in oil tank.

Fuel supply valve closed.

Air leak in fuel system.

Oil filter plugged.

Plugged pump strainer.

Restriction in oil line.

Pump worn - low pressure.
Motor overloads.

Coupling worn or broken.

Pump discharge pressure set
too low.

No spark or weak spark.

Line voltage below 102V.

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 for
Series I & II boilers.

Replace transformer.

Call utility company.

Ignition Remove and inspect drawer
Electrodes assembly.

Carboned and shorted
electrodes.

Eroded electrode tips.

Incorrect electrode settings.

Cracked porcelain insulators.

Nozzle Check for faulty nozzle.

Plugged orifice or distributor.

Plugged nozzle strainer.

Poor spray pattern.

Inspect nozzle for correct size

Incorrect nozzle installed.

and specifications.

Combustion See “Burner Adjustment
Air Instructions” in this manual.

Air shutter open too far.

Air band open too far.

Adjustments

When checking burner adjustments always use instruments.

Clean electrodes.

Replace and reset
electrodes.

Replace and reset electrodes.

Replace nozzle with nozzle
according to the installer/
serviceman labels for Series I & II
boilers.

Install correct nozzle.

Decrease air shutter setting.

Decrease air band opening.

19

TROUBLE: BURNER FIRES, BUT THEN FAILS ON SAFETY

SOURCE PROCEDURE CAUSES REMEDY

Cad Cell Check cad cell with ohmmeter. If

more than 2000 ohms, cad cell is
defective or dirty.

Primary After burner fires, open cad cell
Control circuit if flame looks OK. If

burner continues to operate, fault
is in primary control.

Heat Inspect heat exchanger.
Exchanger
Restriction

Burner Burner motor trips on overload.
Motor Turn off power and rotate blower

by hand to check for excessive
drag.

TROUBLE: TOO MUCH HEAT

Faulty or dirty cad cell

Faulty primary control

Plugged heat exchanger.

Line voltage below 102V

Faulty motor.

Pump or blower overloading
motor.

Clean or replace cad cell.

Replace primary control.

Clean out heat exchanger.

Call utility company.

Replace motor.

Replace blower or pump.

SOURCE PROCEDURE CAUSES REMEDY

Circulator Check to see if operating control

is working properly.

Thermostat Check thermostat settings and

calibration.

Flow Valve Check to see if flow valve is

operating properly.

When checking burner adjustments always use instruments.

Circulator does not stop
running.

Thermostat set too high.

Thermostat defective

Thermostat out of calibration.

Flow valve dirty and stuck.

Flow valve defective.

Repair operating control.

Reset thermostat.

Replace thermostat.

Recalibrate. Check level.

Clean flow valve.

Replace flow valve.

20

TROUBLE: BURNER FIRES, BUT THEN LOSES FLAME

SOURCE PROCEDURE CAUSES REMEDY

Poor Fire Inspect flame for stability.

Oil Supply If burner loses flame prior to the

primary control locking out, fault
is in fuel system.

Combustion Reduce combustion air supply.
Air

Pump Install pressure gauge in gauge

port of fuel pump. Pressure
should be according to installer/
serviceman labels for Series I & II
boilers .

Unbalanced fire.

Excessive draft.

Insufficient draft.

Insufficient combustion air sources.

Air leak in fuel system.

Water in oil tank.

Fuel supply valve closed.

Restriction in oil line.

Plugged fuel filter.

Plugged pump strainer.

Cold oil.

Too much combustion air.

Pump discharge pressure
incorrectly set.

Coupling worn or broken.

Replace nozzle with specified
nozzle.

Reduce draft setting.

Increase draft.

Increase combustion air sources.

Repair leak - use only flare
fittings.

Strip tank of water exceeding
2" in depth.

Open valve.

Clear oil line restriction.

Replace filter cartridge.

Clean Strainer.

Use #1 heating oil.

Close air band and air to raise
CO2. Check with instruments.

Set pressure according to
installer/serviceman labels for
Series I & II boiler.

Replace coupling.

Pump worn - low pressure
motor overloads.

Excessive Take a draft reading. Draft should

Incorrect draft setting.

Draft be according to installer/service-

man labels for Series I & II boilers
starting.

Poor Flue Insert CO2 probe into heat

Leak in flue system.

Gas Sample exchanger tube. If reading is

greater by 1/2% or more, sample
was being diluted near flue box.

Testing Using a chemical absorption type

Weak fluid.

Method device, let instrument set after a

test before venting. If CO2
reading increases 1/2% fluid is
weak.

Nozzle Check for faulty nozzle.

Plugged orifice or distributor.

Plugged nozzle strainer.

Poor spray pattern.

When checking burner adjustments always use instruments.

Replace pump.

Reduce setting. Install second
draft regulator if necessary.

Sample CO2 in heat exchanger.

Seal flue system leak.

Replace fluid in testing device.

Replace nozzle with specified
nozzle.

21

TROUBLE: BURNER FIRES, BUT PULSATES

SOURCE PROCEDURE CAUSES REMEDY

Draft Take a draft reading. Draft should

be according to installer/service­man labels for Series I & II boiler.

Draft Inspect draft regulator for correct
Regulator location on flue system.

Combustion Inspect installation for
Air combustion air provisions.

See Table 1.

Open air band wide and take
CO2 reading.

Oil Supply Bleed pump; inspect for air leaks

or water contamination.

Pump Install pressure gauge in gauge
Pressure port of fuel pump. Pressure

should be according to installer/
serviceman labels for Series I & II
boiler.

Down drafts.

Insufficient draft.

Excessive draft.

Improper installation.

Improper installation.

Improper adjustment.

Air leak in fuel system.
Compression fittings.

Water in oil tank.

Pump discharge pressure
incorrectly set.

Coupling worn or broken.

Install vent cap.

Increase draft setting.

Reduce draft settings, install
second draft regulator if
necessary.

Move draft regulator to
correct location.

Provide sufficient sources of air
for combustion.

Adjust CO2 level - start with air
band wide open. Use instrument.

Repair leak - use only flare
joints.

Strip tank of water exceed 2"
in depth.

Set pressure according to
installer/serviceman labels for
Series I & II boiler.

Replace coupling.

Pump worn - low pressure
motor overloads.

Nozzle Check for faulty nozzle.

Plugged orifice or distributor.

Plugged nozzle strainer.

Poor spray pattern.

Heat Inspect heat exchanger.

Plugged heat exchanger.

Exchanger
Restrictions

When checking burner adjustments always use instruments.

Replace pump.

Replace nozzle with nozzle
specified on burner housing.

Clean out heat exchanger.

22

TROUBLE: INSUFFICIENT HEAT

SOURCE PROCEDURE CAUSES REMEDY

Circulator Check if circulator is operational.

Check if circulator is correct
size.

Check if circulator is up to
speed; check if voltage to
circulator is sufficient.

Thermostat Check thermostat settings.

Check thermostat location.

Check thermostat calibration.

Flow Valve Check flow valve for sticking in

partially closed position.

Radiation Check for air in radiators.

Coupling worn or broken.

Pump binding.

Circulator motor burned out.

Wiring from operating control
defective.

Operating control defective.

Circulator too small.

Circulator defective.

Insufficient voltage.

Settings too low.

Bad location due to heat build
up.

Out of calibration.

Flow valve not opening fully.

Radiators airbound.

Replace coupling.

Replace pump.

Replace circulator motor.

Repair wiring.

Repair or replace operating
control.

Replace with proper circulator.

Repair circulator.

Call utility company.

Increase setting.

Move thermostat to a better
location.

Recalibrate. Level thermostat.

Clean or replace flow valve.

Bleed radiators.

Check to see if radiators are
sized properly.

Boiler Determine structure heat load.

Piping Check to see if piping is sized

properly.

Heat Check heat exchanger for soot or
Exchanger scale accumulation.

Burner Check pump pressure with

pressure gauge.

Nozzle Check nozzle for size and spray

angle.

Check for faulty nozzle.

Radiators inadequate.

Boiler too small.

Piping inadequate.

Insufficient heat transfer.

Insufficient pump pressure.

Wrong nozzle installed.

Nozzle underfiring due to
defective nozzle.

Install adequate radiation.

Additional heating capacity.

Install adequate piping.

Clean heat exchanger.

Increase pressure according to
installer/serviceman labels for
Series I & II boilers.

Install specified nozzle.

Replace nozzle.

23

TROUBLE: HIGH NET STACK TEMPERATURES

SOURCE PROCEDURE CAUSES REMEDY

Nozzle Check pump pressure with pump Nozzle overfiring due to high Reduce pump pressure according

gauge. pump pressure. to installer/serviceman labels for

Series I & II boilers starting on
page 30.

Heat Check heat exchanger surfaces Heat exchanger fouled. Clean heat exchanger.
Exchanger for soot or scale fouling.

Baffles Check baffles installed. Baffles not installed. Install baffles.

TROUBLE: INSUFFICIENT DOMESTIC HOT WATER

SOURCE PROCEDURE CAUSES REMEDY

Tankless Analyze capacity vs. usage. Insufficient coil capacity. Install larger coil.
Coil

Operating Check operating control. Setting too low. Set operating control to 180°F.
Control Raise differential set point.

Heat Inspect coils for fouled surfaces Flow restriction. Remove restriction.
Exchanger and/or flow restrictions.

Fouled surfaces on heat exchanger. Clean heat exchanger surfaces.

24

ITEM DESCRIPTION

01 WETBASE HEAT EXCHANGER

02 FLUE BOX

03 REAR REFRACTORY-MOLDED

04 REAR COVER

05 COIL PLATE

06 FRONT COVER

07 FRONT REFRACTORY BOARD

08 TURBULATOR

09 RIGHT SIDE JACKET

10 LEFT SIDE JACKET

11 FRONT UPPER JACKET

12 FRONT LOWER JACKET

13 TOP JACKET

14 REAR JACKET

15 COIL GASKET

16 3/8-16 CARRIAGE BOLT

19 3/8 WASHER

17 3/8-16 CARRIAGE BOLT

18 3/8-16 BRASS HEX NUT

22 3/8-16 XHVHEX NUT

20 3/8 SPACER

23 CHAMBER LINER

21 3/8 X 3/4 SPACER

Figure No. 10 - Exploded Parts View

25



For Models 90/100/110 & 125/135/150

(Designate boiler and burner model numbers on all orders).

Item No. Description Part No.

1a 90/100/110 Heat Exchanger 241800

1b 125/135/150 Heat Exchanger 241810

2a HT 6" Flue Box (Chimney Vent) 241128

2b HT 5" Flue Box (Direct Vent) 241129

3 Rear Refractory - Molded, Target Wall Only 337910

4 Rear Cover with Molded Refractory Assembly 241120

5a Coil Plate - Blank 229151

5b Coil - 5 GPM cartoned with Gasket 530245

6 Front Cover 241124

7 Front Refractory Board 1" 337921

8 Turbulator (10 for 90-110, 16 for 125-150) 241150

9 Right Side Jacket 501104

10 Left Side Jacket 501103

11 Front Upper Jacket 501105

12 Front Lower Jacket 501101

13 Top Jacket 501106

14 Rear Jacket 501107

15 Coil Gasket 481005

16 3/8" - 16 x 4" Carriage Bolt (Qty. 4) 311113

17 3/8" - 16 x 2" Carriage bolt (Qty. 12) 311110

18 3/8" - 16 Brass Hex Nut (Qty. 20) 312011

19 3/8" Washer (Qty. 24) 313002

20 3/8" x 3/8" Spacer (Qty. 12) 319917

21 3/8" x 3/4" Spacer (Qty. 4) 319916

22 3/8" - 16 Heavy Brass Hex Nut (Qty. 8) 312002

23 Chamber Liner 337410

26



For Models 165/175/200 & 225/250/275

(Designate boiler and burner model numbers on all orders).

Item No. Description Part No.

1a 165/175/200 Heat Exchanger 241820

1b 225/250/275 Heat Exchanger 241825

2 Flue Box 241366

3 Rear Refractory - Molded, Target Wall Only 337416

4 Rear Cover with Molded Refractory Assembly 241360

5a Coil Plate - Blank 229151

5b Coil - 5 GPM cartoned with Gasket 530245

5c Coil - 7 GPM Cartoned with Gasket 530246

6 Front Cover 241350

7 Front Refractory Board 1" 337415

8 Turbulator (0 for 165/200, 12 for 225-275) 241155

9 Right Side Jacket

10 Left Side Jacket

11 Front Upper Jacket

12 Front Lower Jacket

13 Top Jacket

14 Rear Jacket

15 Coil Gasket 481005

16 3/8" - 16 x 7" Carriage Bolt (Qty. 4) 311103

17 3/8" - 16 x 2" Carriage bolt (Qty. 12) 311110

*KD Jacket Assembly purchased as a set, not individual pieces.

165/275 Jacket Assembly* 501225

}

27



INSTALLER/SERVICEMAN

Model Number HT-90 HT-100 HT-110

Burner Type Beckett Beckett Beckett

Burner Model AFG AFG AFG

Nozzle Type .75 80°B .85 80°B .90 80°B

Pump Pressure PSI 140 140 140

Head/Pin Position F-3 F-3 F-3

Air Band CLOSED 23

Air Shutter 10 10 10

Draft Over Fire +.085" +.085" +.085"

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

CO2Reading 10-11.5 10-11.5 10-11.5

Smoke Reading ZERO ZERO ZERO

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.

________________________

________________________
________________________
________________________
________________________
________________________
________________________
________________________
________________________
________________________

NOTICE

INSTALLER/SERVICEMAN

Model Number HT-90 HT-100 HT-110

Burner Type Beckett Beckett Beckett

Burner Model AFII AFII AFII

Nozzle Type .75 60B .85 60B .90 60B

Pump Pressure PSI 140 140 140

Head/Pin Position 333

Air Band 344.5

Air Shutter N/A N/A N/A

Draft Over Fire +.085" +.085" +.085"

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

CO2Reading 10-11.5 10-11.5 10-11.5

Smoke Reading ZERO ZERO ZERO

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.

________________________

________________________
________________________
________________________
________________________
________________________
________________________
________________________
________________________
________________________

NOTICE

INSTALLER/SERVICEMAN

Model Number HT-90 HT-100 HT-110

Burner Type Carlin Carlin Carlin

Burner Model EZ-1 EZ-1 EZ-1

Nozzle Type .75 60A .85 60A .90 60A

Pump Pressure PSI 140 140 140

Head/Pin Position .85-1.00 .85-1.00 1.10-1.25

Air Band 100 100 125

Air Shutter N/A N/A N/A

Draft Over Fire +.085" +.085" +.085"

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

CO2Reading 10-11.5 10-11.5 10-11.5

Smoke Reading ZERO ZERO ZERO

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.

________________________

________________________
________________________
________________________
________________________
________________________
________________________
________________________
________________________
________________________

NOTICE

INSTALLER/SERVICEMAN

Model Number HT-90 HT-100 HT-110

Burner Type Riello Riello Riello

Burner Model F5 F5 F5

Nozzle Type .75 60B .85 60B .90 60B

Pump Pressure PSI 150 150 150

Head/Pin Position 1.5 2.0 2.5

Air Band N/A N/A N/A

Air Shutter 2.0 2.5 2.75

Draft Over Fire +.04" +.06" +.08"

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

CO2Reading 10-11.5 10-11.5 10-11.5

Smoke Reading ZERO ZERO ZERO

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.

________________________

________________________
________________________
________________________
________________________
________________________
________________________
________________________
________________________
________________________

NOTICE

28

INSTALLER/SERVICEMAN

Model Number HT-90DV HT-100DV HT-110DV

Burner Type Beckett Beckett Beckett

Burner Model AFII AFII AFII

Nozzle Type .75 60B .85 60B .90 60B

Pump Pressure PSI 140 140 140

Head/Pin Position 333

Air Band 344.5

Air Shutter N/A N/A N/A

Draft Over Fire +.085" +.085" +.085"

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

CO2Reading 10-11.5 10-11.5 10-11.5

Smoke Reading ZERO ZERO ZERO

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.

________________________

________________________
________________________
________________________
________________________
________________________
________________________
________________________
________________________
________________________

NOTICE

INSTALLER/SERVICEMAN

Model Number HT-90DV HT-100DV HT-110DV

Burner Type Carlin* Carlin* Carlin*

Burner Model EZ-1 EZ-1 EZ-1

Nozzle Type .75 60A .85 60A .90 60A

Pump Pressure PSI 140 140 140

Head/Pin Position .85-1.00 .85-1.00 1.10-1.25

Air Band 100 100 125

Air Shutter N/A N/A N/A

Draft Over Fire +.085" +.085" +.085"

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

CO2Reading 10-11.5 10-11.5 10-11.5

Smoke Reading ZERO ZERO ZERO

*Requires Carlin Air Intake Adapter

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.

________________________

________________________
________________________
________________________
________________________
________________________
________________________
________________________
________________________
________________________

NOTICE

INSTALLER/SERVICEMAN

Model Number HT-90DV HT-100DV HT-110DV

Burner Type Riello Riello Riello

Burner Model BF5 BF5 BF5

Nozzle Type .75 60B .85 60B .90 60B

Pump Pressure PSI 150 150 150

Head/Pin Position 1.5 2.0 2.5

Air Band N/A N/A N/A

Air Shutter 3.5 4.0 4.5

Draft Over Fire 0 TO .10" 0 TO .10" 0 TO .10"

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

CO2Reading 10-11.5 10-11.5 10-11.5

Smoke Reading ZERO ZERO ZERO

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.

________________________

________________________
________________________
________________________
________________________
________________________
________________________
________________________
________________________
________________________

NOTICE

INSTALLER/SERVICEMAN

Model Number HT-90DV HT-100DV HT-110DV

Burner Type Beckett Beckett Beckett

Burner Model NX NX NX

Nozzle Type 0.70 60°B 0.75 60°B 0.85 60°B

Pump Pressure PSI 175 175 175

Head/Pin Position 2.0 2.5 3.75

Air Band N/A N/A N/A

Air Shutter N/A N/A N/A

Draft Over Fire +0.040" +0.090" +0.160"

Draft In Stack +0.000" +0.050" +0.060"

CO2Reading 10-11.5% 10-11.5% 10-11.5%

Smoke Reading ZERO ZERO ZERO

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.

________________________

________________________
________________________
________________________
________________________
________________________
________________________
________________________
________________________
________________________

NOTICE

29

INSTALLER/SERVICEMAN

INSTALLER/SERVICEMAN

Model Number HT-90 HT-100 HT-110

Burner Type Beckett Beckett Beckett

Burner Model NX NX NX

Nozzle Type 0.70 60°B 0.75 60°B 0.85 60°B

Pump Pressure PSI 175 175 175

Head/Pin Position 2.0 2.25 3.75

Air Band N/A N/A N/A

Air Shutter N/A N/A N/A

Draft Over Fire +0.040" +0.050" +0.110"

Draft In Stack -0.020" -0.020" -0.020"

CO2Reading 10-11.5% 10-11.5% 10-11.5%

Smoke Reading ZERO ZERO ZERO

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.

________________________

________________________
________________________
________________________
________________________
________________________
________________________
________________________
________________________
________________________

NOTICE

odel Number HT-125 HT-135 HT-150

M

Burner Type Beckett Beckett Beckett

Burner Model AFG AFG AFG

Nozzle Type 1.00 80°B 1.10 80°B 1.25 80°B

Pump Pressure PSI 140 140 140

Head/Pin Position F-6 F-6 F-6

Air Band 2 4.5 6

Air Shutter 10 10 10

Draft Over Fire +.085" +.085" +.085"

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

CO2Reading 10-11.5 10-11.5 10-11.5

Smoke Reading ZERO ZERO ZERO

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.

________________________

________________________
________________________
________________________
________________________
________________________
________________________
________________________
________________________
________________________

NOTICE

INSTALLER/SERVICEMAN

Model Number HT-125 HT-135 HT-150

Burner Type Beckett Beckett Beckett

Burner Model AFII AFII AFII

Nozzle Type 1.00 60B 1.10 60B 1.25 60B

Pump Pressure PSI 140 140 140

Head/Pin Position 778

Air Band 348

Air Shutter N/A N/A N/A

Draft Over Fire +.085" +.085" +.085"

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

CO2Reading 10-11.5 10-11.5 10-11.5

Smoke Reading ZERO ZERO ZERO

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.

________________________

________________________
________________________
________________________
________________________
________________________
________________________
________________________
________________________
________________________

NOTICE

INSTALLER/SERVICEMAN

Model Number HT-125 HT-135 HT-150

Burner Type Carlin Carlin Carlin

Burner Model EZ-1 EZ-1 EZ-1

Nozzle Type 1.00 60A 1.10 60A 1.25 60A

Pump Pressure PSI 140 140 140

Head/Pin Position 1.1-1.25 1.35-1.5 1.35-1.5

Air Band 125 150 150

Air Shutter N/A N/A N/A

Draft Over Fire +.085" +.085" +.085"

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

CO2Reading 10-11.5 10-11.5 10-11.5

Smoke Reading ZERO ZERO ZERO

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.

________________________

________________________
________________________
________________________
________________________
________________________
________________________
________________________
________________________
________________________

NOTICE

30

INSTALLER/SERVICEMAN

INSTALLER/SERVICEMAN

Model Number HT-125 HT-135 HT-150

Burner Type Riello Riello Riello

urner Model F5 F5 F5

B

Nozzle Type 1.00 60B 1.10 60B 1.25 60B

Pump Pressure PSI 150 150 150

Head/Pin Position 2.5 3.5 4.0

Air Band N/A N/A N/A

Air Shutter 3.0 3.5 4.5

Draft Over Fire +.03" +.05" +.07"

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

CO2Reading 10-11.5 10-11.5 10-11.5

Smoke Reading ZERO ZERO ZERO

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.

________________________

________________________
________________________
________________________
________________________
________________________
________________________
________________________
________________________
________________________

NOTICE

Model Number HT DV-125 HT DV-125 HT DV-125

Burner Type Beckett Carlin* Riello

Burner Model AFII EZ-1 BF5

Nozzle Type 1.00 60°B 1.00 60°B 1.00 60°B

Pump Pressure PSI 140 140 150

Head/Pin Position 7.0 0.85-1.00 2.0

Air Band N/A N/A N/A

Air Shutter 6.0 6.0 6.0

Draft Over Fire +.0.16 +.0.14 +0.13

Draft In Stack -0.08 -0.07 -0.07

CO2Reading 10-11.5% 10-11.5% 10-11.5%

Smoke Reading ZERO ZERO ZERO

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.

________________________

________________________
________________________
________________________
________________________
________________________
________________________
________________________
________________________
________________________

*Requires Carlin Air Intake Adapter

NOTICE

INSTALLER/SERVICEMAN

Model Number HT-165 HT-175 HT-200

Burner Type Beckett Beckett Beckett

Burner Model AFG AFG AFG

Nozzle Type 1.50 60B 1.65 60B 1.75 60B

Pump Pressure PSI 140 140 140

Head/Pin Position M-2 M-3 M-3

Air Band 557

Air Shutter OPEN OPEN OPEN

Draft Over Fire +.06" +.08" +0.10"

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

CO2Reading 10-11.5 10-11.5 10-11.5

Smoke Reading ZERO ZERO ZERO

NOTE: Pressure over fire will vary according to CO2setting.

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.

________________________

________________________
________________________
________________________
________________________
________________________
________________________
________________________
________________________
________________________

NOTICE

INSTALLER/SERVICEMAN

Model Number HT-225 HT-250 HT-275

Burner Type Beckett Beckett Beckett

Burner Model CF-375 CF-375 CF-375

Nozzle Type 2.00 60B 2.25 60B 2.50 60B

Pump Pressure PSI 140 140 140

Head/Pin Position 334

Air Band 366

Air Shutter OPEN OPEN OPEN

Draft Over Fire +.06" +.09" +0.11"

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

CO2Reading 10-11.5 10-11.5 10-11.5

Smoke Reading ZERO ZERO ZERO

NOTE: Pressure over fire will vary according to CO2setting.

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.

________________________

________________________
________________________
________________________
________________________
________________________
________________________
________________________
________________________
________________________

NOTICE

31

INSTALLER/SERVICEMAN

INSTALLER/SERVICEMAN

Model Number HT-90 HT-100 HT-110

Burner Type Beckett Beckett Beckett

Burner Model NX NX NX

Nozzle Type 0.70 60°B 0.75 60°B 0.85 60°B

Pump Pressure PSI 175 175 175

Head/Pin Position 2.0 2025 3.75

Air Band N/A N/A N/A

Air Shutter N/A N/A N/A

Draft Over Fire +0.040" +0.050" +0.110"

Draft In Stack -0.020" -0.020" -0.020"

CO2Reading 10-11.5% 10-11.5% 10-11.5%

Smoke Reading ZERO ZERO ZERO

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.

________________________

________________________
________________________
________________________
________________________
________________________
________________________
________________________
________________________
________________________

NOTICE

Model Number HT-90DV HT-100DV HT-110DV

urner Type Beckett Beckett Beckett

B

Burner Model NX NX NX

Nozzle Type 0.70 60°B 0.75 60°B 0.85 60°B

Pump Pressure PSI 175 175 175

Head/Pin Position 2.0 2.5 3.75

Air Band N/A N/A N/A

Air Shutter N/A N/A N/A

Draft Over Fire +.0.040 +.0.090 +0.160

Draft In Stack +0.000 +0.050 +0.060

CO2Reading 10-11.5% 10-11.5% 10-11.5%

Smoke Reading ZERO ZERO ZERO

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.

________________________

________________________
________________________
________________________
________________________
________________________
________________________
________________________
________________________
________________________

*Requires Carlin Air Intake Adapter

NOTICE

32

ELECTRICAL DIAGRAM FOR HT SERIES BOILERS

TO CONNECT BURNER TO AQUASTAT

(APPLIES TO BECKETT CHIMNEY VENT BURNERS)

33

ELECTRICAL DIAGRAM FOR HT SERIES BOILERS

TO CONNECT BURNER TO AQUASTAT

(APPLIES TO BECKETT DIRECT VENT BURNERS)

34

ELECTRICAL DIAGRAM FOR HT SERIES BOILERS

TO CONNECT BURNER TO AQUASTAT

APPLIES TO CARLIN CHIMNEY VENT AND CARLIN DIRECT VENT BURNERS)

(

35

ELECTRICAL DIAGRAM FOR HT SERIES BOILERS

TO CONNECT BURNER TO AQUASTAT

APPLIES TO RIELLO CHIMNEY VENT BURNERS)

(

36

ELECTRICAL DIAGRAM FOR HT SERIES BOILERS

TO CONNECT BURNER TO AQUASTAT

APPLIES TO RIELLO DIRECT VENT BURNERS)

(

37

Thermo-Dynamics Boiler Company

Route 61 - P.O. Box 325, Schuylkill Haven, PA 17972
[phone] • Fax [phone] • [email protected]

Limited Lifetime Warranty for Residential Steel Water Boilers

Effective July 1, 2000

This Warranty gives you specific legal rights, and you may also have other rights which vary from state to state.

FIRST YEAR, LIMITED WARRANTY, RESIDENTIAL WATER BOILERS

Thermo-Dynamics Boiler Company (“Thermo”) warrants to the origi­nal consumer purchaser (“purchaser”) that its residential water boiler is free
from defects in material and workmanship under normal usage for one year
from the date of original installation. If any parts are found to be defective
in manufacture during this one year period, Thermo will, at its option,
repair or replace the defective part.

SECOND THROUGH FIFTEENTH YEARS, LIMITED
WARRANTY, RESIDENTIAL BOILERS

Thermo warrants to purchaser that the pressure vessel of its residential
steel boilers are free from defects in material and workmanship. If such pres­sure vessel proves to be defective under normal usage within fifteen (15) years
of the date of installation, Thermo shall, at its option, furnish a replace­ment or repair such pressure vessel. Purchaser’s remedy shall be limited to
such repair or replacement.

SIXTEENTH THROUGH TWENTY-FIFTH YEARS AND BEYOND

In the event that a pressure vessel is found to be defective sixteen (16)
years or more following installation, Thermo will repair or replace the pres­sure vessel and the purchaser will pay a proportionate charge for the time the
pressure vessel has been in service based upon a percentage of the list price of
such vessel at the time Thermo is notified of the defect, as listed in the table
below.

EXCEPTIONS AND EXCLUSIONS

1. Component parts, coil, fire chamber, burner, jackets, controls, and
other equipment furnished by Thermo but manufactured by others shall be
limited to the manufacturer’s warranty, if any.

2. This warranty is applicable only to models of residential steel water
boilers installed in one or two family residential dwellings in accordance
with the basic BOCA Building Code and local statutes or ordinances,
whichever shall be more restrictive.

3. This warranty does not cover expenses for removal or reinstallation.
The purchaser will be responsible for the cost of removing and reinstalling
the defective part or its replacement and all labor and material connected
therewith. The purchaser will be responsible for returning the defective pres­sure vessel prepaid. Replacement pressure vessels or components will be
invoiced by Thermo in the usual manner and will be subject to adjustment
upon proof of defect.

4. This limited warranty is applicable only to defects in material and
workmanship and shall not cover failure of the pressure vessel or other com­ponents due to any other reason including, but not limited to (a) lack of
water, (b) freezing, (c) floods, (d) fire, (e) acts of God, (f) negligent or
improper operation or installation, (g) corrosion of tubes or plates (such as

Years

In Service 1-15 16 17 18 19 20 21 22 23 24

Service Charge

as % of No

Retail Price Charge 30 35 40 45 50 55 60 65 70 75

Note: Lifetime Limited Warranty applies only to Boiler Pressure Vessel.

oxygen attack), (h) leaky gaskets, (i) improper water conditioning, (k)
improper maintenance of external and fireside surfaces.

5. This limited warranty will not be applicable if the boiler is used or
operated over its rated capacity, or installed for uses other than home heat­ing, or is not maintained in accordance with Thermo’s recommendation or
accepted good practice as determined by industry standards.

6. This limited warranty in no way can be considered as a guarantee of
workmanship of an installer connected with the installation of the Thermo
water boiler or as imposing on Thermo’s liability of any nature for unsatis­factory performance as a result of faulty workmanship in the installation,
which liability is expressly disclaimed.

7. This warranty applies only to boilers installed within the United
States of America.

8. This warranty is in lieu of all others, and any and all expressed or
implied warranties (including, without limitation, any implied warranties
of merchantability or fitness for a particular purpose) are expressly limited
in duration to the period of the warranty as previously stated herein. Some
states do not allow the exclusion or limitations of incidental or consequen­tial damages, or limitations on how long an implied warranty lasts, so the
above limitation may not apply to you.

IMPLIED WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE
AND MERCHANTABILITY SHALL BE LIMITED TO THE DURATION
OF THE EXPRESSED WARRANTY. THERMO SHALL NOT BE LIABLE
FOR ANY CONSEQUENTIAL DAMAGES RESULTING FROM BREACH
OF THIS OR ANY OTHER WARRANTY, EXPRESSED OR IMPLIED.

This warranty does not apply to swimming pool and out-

door boilers. See the specific warranty for those products.

WARRANTY SERVICE

1. Proof of purchase is required to validate warranty. This limited war­ranty does not extend to anyone except the first purchaser at retail and only
when the boiler is in the original installation site.

2. For prompt warranty service, notify the installer who will notify the
Thermo distributor from where the boiler was purchased. If this action does
not result in warranty service, write to Thermo at the address listed above or
contact us on our website. Alleged defective parts must be handled through
trade channels and using Thermo’s returned goods procedure. Thermo will
furnish replacement or repaired parts to the Thermo Distributor who will
furnish them to the contractor who installed the boiler.

If you have any questions concerning the coverage of the warranty, con-

tact Thermo at the address listed above or at our website.

25

and

above

38



1. Date

2. Model Number

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

nitial Set Up

I

12345

11. Clean Pump Filter Yes/No

12. Inspect Coil Gasket

13. Check for Leaks @ plugs/fittings

14. Brush Clean Flue Tube Passages

15. Vacuum Chamber/Flue Tubes

16. Clean Blower Wheel

17. Check/Set Electrodes

*See pump pressure according to the installer/serviceman labels for Series I and II boilers.

MET-3985 12/09-500