thermotron - Columbia Heating
THERMOTRON
Thermo-Dynamics
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www.thermodynamicsboiler.com
Operation
Maintenance
and
Installation
Instructions
Models OTF / ITF
Contents
General Information ......................................................................................................1
Service Policy ................................................................................................................1
Installation Instructions .................................................................................................2
Filling Instructions .........................................................................................................2
Winterizing .....................................................................................................................3
Start-Up and Operation ................................................................................................3
Piping/Connection Diagrams .......................................................................................4
Assembly Diagrams ......................................................................................................5
Trouble Shooting ..........................................................................................................6
Care and Maintenance .................................................................................................6
Pool Coil Diagram .........................................................................................................7
Wiring Diagrams ...........................................................................................................8
Parts List ........................................................................................................................9
Specifications ..........................................................................................................10
Home Owner Information .......................................................................................11
Set-Up and Service Records ..................................................................................12
Warranty Information ..............................................................................................12
G e n e r a l I nf o r m a t i o n
1) Please read all instructions and review all diagrams prior to proceeding with installation.
2) Instructions and diagrams are intended only as guidelines.
3) Installations must conform with all applicable national, state and local codes.
4) Additional guidelines are available from National Fire Protection Association (NFPA), American
society of Mechanical Engineers (ASME) and Building Officials and Code Administrators
(BOCA).
Service Policy
Congratulations on the purchase of your new pool heater. Here 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 pool heater, it is recommended that the unit be winterized at the end of the season and that the burner/boiler be serviced annually. 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 pool heater 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 pool heater, 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, ThermoDynamics 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 heater up and running as quickly as possible.
Thank you for purchasing the Thermo-Dynamics pool heater. 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.
1
Section I. Installation Instructions
component to obtaining optimum
performance (see piping diagram on
page 4). In order to properly adjust
the flowrate through the system,
please adhere to the following steps:
By-Pass Set-Up
a) Use piping and full-size valve
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of the pool coil.
b) With the bypass valve wide
open take a pressure reading at the
gauge on the pool filter.
c) Pressure reading with bypass
valve full open is the baseline pressure.
d) Slowly close the bypass valve
so that the pressure increases.
e) Stop when pressure reaches 2
to 4 psi above the baseline at the filter.
Alternatively, flowrate may be set
by comparing the temperature differe
n
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streams of the pool coil.
a) Use full size piping and valve
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of the pool coil.
b) Allow the boiler to fire continuously for a period of ten (10) to fif(2) Connections:
Do not run any piping along the teen (15) minutes.
c) With the bypass valve wide
front access panel of heater as they
may interfere with servicing. The tap- open take temperature readings for
pings for connecting the unit to the the coil.
d) Note: surface temperature
pool circulation lines are at the back of
readings
taken on a cold day will vary
the heater. These connections are 11/2" NPT. Connections should be significantly from test data.
e) Slowly close the bypass valve
made as per the piping illustration on
page 4. Install unions at the heat and continue to take temperature
exchanger so it can be readily readings.
f) Stop when the temperature
removed for service. If plastic pipe is
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used, make connection to the unit with d
streams
reaches
forty-five
(45)
to
fifty
metal piping and run metal piping to
the floor line before joining to plastic (50) degrees Fahrenheit.
g) Flowrate should correspond to
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reduce possible damage to the plastic six (6) gallons per minute. (See chart
pipes from overheating. Install posi- page 7).
tive check valve on inlet side. Install a
Tee joint at the coil where the PIPING (3) Flue Connections:
FROM the pool filter/pump ENTERS (A) OTF Series (Outdoor Units)
the coil. Install the copper well providThe OTF heaters are provided with
ed into the piping Tee and insert the an outdoor vent cap to be installed
remote sensing bulb from the L-4031 directly on top of the cabinet at the flue
pool thermostat.
outlet. This vent cap provides for a
An adjustable by-pass around the waterproof unit as well as proper conheat-exchanger is required. The bypass is an important and necessary
(1) Locating The Heater:
Before uncrating the unit prepare
the location. It should be placed upon
a good level concrete floor or pad.
Care should be taken to locate the
unit for easy accessibility. Please
maintain the following clearances to
combustible materials:
OTF
(Outdoor Pool Heaters)
Front 24 inches
Back 24 inches
Sides 12 inches
ITF
(Indoor Pool Heaters)
Front 24 inches
Back 12 inches
Sides 12 inches
In addition, the air openings in the
cabinet shall have adequate clearance
to allow for sufficient air intake to the
burner. Uncrate the unit as close to
its permanent location as possible to
prevent handling damage.
2
Control of combustion draft.
(B) ITF Series (Indoor Units)
(a) General:
Oil fired units must be connected
to a flue having sufficient draft at all
times to assure proper operation.
(b) Draft:
A draft regulator should be
installed in accordance with the manu
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over the fire.
(c) Roof Clearances:
The flue gas exit of the venting
system should be at least three (3)
feet above the outside point where it
passes through the roof and at least
two (2) feet higher than any portion of
a building within ten (10) feet of the
venting system.
(d) Chimney Connections:
The horizontal length of a chimney connector should not exceed ten
(10) feet unless a draft booster is
used. The connector should be
pitched upward at least one-quarter
(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 connections should be positioned to
effect the shortest possible run of
smoke pipe to the chimney.
(e) Vent Cap:
Install a UL listed vent cap where
the possibility of down draft exists.
Section II
Filling
Instructions
The Thermotron Pool Heater is
an indirect heater using primary water
in the boiler shell to act as a heat
transfer medium to the pool water
flowing through the separate all
copper/bronze heat exchanger coil.
Therefore the pool heater, or boiler
section, MUST be filled with fresh city
water. DO NOT FILL WITH CHLORINATED OR WATER FROM THE
SWIMMING POOL.
(1) Do not turn on electrical
power to heater until boiler is properly
filled with water.
(2) * Connect the male end of a
garden hose to the hose adapter of
the heater drain valve.
(3) Open the vent at the top of
the boiler section location as shown
on page 4.
(4) Turn on water and open drain
valve, allow water to flow into boiler
section.
(5) When water flows out of
boiler vent, close vent and leave
heater drain valve open until pressure
gauge reads approximately 10 PSI.
(6) Close drain valve and disconnect hose.
(7) Pool temperature control
should be set at desired temperature.
(8) Burner can now be operated
as per specified instructions.
*You may choose to install permanent piping...filling instructions would be the same.
IMPORTANT NOTICE
Winterizing The Heater:
If the pool heater is installed in an
area known to have a freezing climate
it is necessary to COMPLETELY drain
both the primary boiler and indirect
heat exchanger (pool coil).
Connect a hose to the boiler drain
at the bottom of the boiler section.
Open the vent at the top of the boiler,
as well as the drain valve and drain
the boiler section completely.
Disconnect the unions and the piping
at the pool coil heat exchanger.
Remove the 1/8" pipe plugs in the bottom of the pool coil heat exchanger
header (to be completely certain that
all water is out of the indirect heat
exchanger, it may be advisable to
remove the pool coil completely or
force an anti-freeze solution into the
pool coil.)
Section III
Start Up and
Operation
A Start Up:
(1) Make sure the electrical
power is turned off.
(2) Check the Oil Burner ignition
electrodes carefully and adjust if necessary.
B Equipment Adjustments:
Equipment Required:
(1) CO2 Analyzer (absorption
type)
(2) Draft Gauge
(3) Fuel Pressure
Gauge/Vacuum Gauge
(4) Stack Thermometer
(5) Smoke Tester (Bacharach
Type)
Allow the burner to operate continuously for at least 15 minutes and
then make adjustments:
(a) Combustion Samples:
Should be taken through the
observation port above the burner,
directly over the fire.
(b) Draft:
Take a draft reading over the fire
(OTF outdoor equipment will range
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.
(ITF
indoor
equipment
should
be
(3) Check to be certain oil tank is
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full.
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.
)
(4) Be certain unit is filled with
(c) Pump Pressure:
water as per filling instructions.
Adjust the pump discharge pres(5) Turn on pool filter pump.
sure
to 100 PSI. Vacuum must not
(6) Set limit control at 180°.
exceed 6" on one pipe and 10" on a
(7) Install pressure gauge in the
two-pipe system.
nozzle port of the fuel pump. Do not
(d) Combustion Settings/CO2
take reading at the bleed port. The
Reduce the air supply by closing
pressure gauge should have a minithe
air
band to allow just sufficient air
mum range of 100 PSI. Consult Fuel
for
clean
combustion. This is accomPump specification sheet (shipped
plished
by
loosening the lock screws
with Oil Burner).
on
the
air
shutter
and closing the air
(8) Turn on burner power switch.
shutter until a TRACE of smoke is
(9) Push the safety reset button
recorded. Take a CO2 sample, which
on the primary control and release.
should be approximately 12%. Open
(10)Bleed the fuel unit on onethe air shutter and lower CO2 reading
pipe systems as soon as the burner
approximately by 1-1/2 to 2% from the
motor starts. To bleed, attach a piece
a
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e
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mo
k
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a
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ing
of 1/4" OD clear plastic tubing to the
should result with a CO2 reading of
end of the bleed port. Loosen same
approximately 10%.
and purge oil of air for at least 15 sec(e) Stack Temperature: (ITF
onds after oil appears to be clear. If oil
only)
stream does not become clear and
Check to see that the stack temfree of air bubbles or foam, check all
perature
is approximately 500° above
fittings, filter and valve connections.
the
ambient
temperature.
Foam can also be caused by kinks in
(f)
Turn
LIMIT CONTROL to the
the oil line, causing an oil vacuum
lowest
setting;
burner should shut
condition. High vacuum readings can
down.
Turn
back
to the desired seta
l
s
ob
ec
a
u
s
e
db
yt
o
oh
i
g
ha“
l
i
f
t
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r
ting,
(normally
180°)
burner should
too small diameter tubing. Consult
operate.
Fuel Pump specification sheet.
(g) Turn POOL TEMPERATURE
CONTROL down to lowest setting;
3
burner should shut down. Turn con(b) Dirty fan/air handling parts.
trol to highest setting; burner should
(c) Improper burner adjustment
operate. Reset to desired temperarefer to B Equipment
ture, approximately 80°.
Adjustment.
(h) Allow burner to operate until
pool is at desired temperature. Adjust
p
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e
mp
e
r
a
t
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ec
o
n
t
r
o
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“
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o
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r
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i
l (5) Cycling On/Off:
(a) Differential between pool
burner shuts down. This is the setting
setting and high limit too
that will be maintained by the heater.
close.
C Trouble Shooting
(b) High limit setting too low.
(1) Motor Does Not Run:
(c) Remote pool sensing bulb in
(a) Check fuses and power to
outlet water piping instead of
heater.
inlet water piping.
(b) Set pool temperature control
and boiler temperature limit
to highest setting.
Section IV
(c) Reset primary control (push
red button). Reset button
Care and
should only be pushed one
time!
Maintenance
(d) Reset thermal overload
button on motor.
(1) Heat Exchanger:
(e) Check for defective temperaThe tubular portions of the heat
ture controls by jumping the exchanger should be cleaned annualcontrols one side at a time.
ly or at start-up each heating season.
(f) Check for power to motor. Motor
(a) Remove the cabinet top.
may be defective.
(b) Remove the flue collector
(g) Ensure that boiler is pressurtop.
ized with water. The low
(c)
Remove all baffles from fire
water cutoff disrupts the
tubes.
electrical circuit for the burn(d) Brush clean the flue ways
er.
with a 2" soft brush and vac(2) Motor Runs - No Fire:
uum the unit carefully.
Reverse the above steps.
(a) No oil in tank.
(b) Bad or plugged burner
nozzle.
(2) Oil Filter:
(c) Blocked oil line.
The oil filter cartridge should be
(d) Loose transformer connecreplaced annually.
tions/defective ignition
transformer.
(3) Oil Burner:
(e) Inspect electrode settings
(a) Thoroughly brush clean the
and insulators.
burner fan blades. Proper
(f) Check fuel pump pressure.
combustion air delivery is
only possible when fan
(3) Burner Fired--Shuts Down
blades are clean.
On Cad Cell Safety:
(b) Clean nozzle assembly and
(a) Defective C-554 Cad Cell.
all other air handling parts.
(b) Dirty Cad Cell.
(c) Check spacing and condition
(c) Defective R-7184A primary
of electrodes. Adjust or
control.
replace as necessary.
(4) Smoke Coming Out of Flue:
(d) Nozzles should be inspected
(a) Clogged nozzle.
for malfunctions. If nozzle
does not perform according
6
to the prescribed conditions
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ra
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s
t
me
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,
”
replace it with only the specified type.
(4) Lubrication:
For unsealed motor bearings
only, lubricate the motor annually with
two (2) drops of SAE-10 nondetergent
oil.
(5) Gaskets:
Carefully tighten nuts on the pool
heat exchanger flange to prevent gasket leaks. DETERIORATION DUE TO
GASKET LEAKS SHALL VOID THE
WARRANTY.
7
P arts L ist
OTF/ITF 510/1600 Beckett AF Burner Parts List - #540500
(Designate heater and burner model numbers on all orders.)
Item No.
1
2
3
4
5
6
6
6
7
8
9
9
10
11
11
Cad Cell C-554-A
Primary Control R7184B
Pool Controller L4031A
Temperature and Altitude Gauge
1/4 - 2-1/2" Round
Relief Valve - 3/4"
Nozzle 1.00 x 80° Hollow
Nozzle 1.50 x 80° Hollow
Nozzle 2.00 x 80° Hollow
Description
Motor 1/7 HP 3450 RPM - PSC
Fan 4-1/2 Dia. x 3-7/16
Flexible Coupling
Beckett Single Stage Clean-Cut Fuel Pump
France Electronic Igniter
Head F-3 (510/560)
Head F-12 (640-801)
Head F-22 (901-1600)
Electrode Assembly
Gun Assembly (Nozzle Line/Electrode Assy.)
Air Tube Combination Pkg. (510/801)
Air Tube Combination Pkg. (901/1600)
Burner Flange Gasket
Blank Air Band (510/801)
8 Hole Air Band (901/1600)
553024
553010
552035
Part
Number
675141
675130
675160
675315
675981
675400
675420
675430
675500
675630
675620
675640
675170
675110
675120
Nozzle 2.50 x 80° Hollow
Coil Gasket
SC-150 Coil (510-801)
SC-200 Coil (901-1600)
Ceraform Sleeve
#15 Expansion Tank (510 thru 801)
#30 Expansion Tank (901 thru 1600)
McDonnell Miller Low Water Cutoff
559560
575020
680146
680196
680226
9
680246
481000
530060
530070
352000
972000
972010
553101
Specifications
Model - OTF - ITF
Gross Input
Gross Output - BTU/Hr.
Flue Pipe Dia.
Firing Rate - GPH
Width OTF-ITF
Length OTF-ITF
Height OTF-ITF
510
140,000
109,200
6"
1.00
22"
31"
38-1/2"
801
210,000
163,800
6"
1.50
22"
31"
38-1/2"
1010
280,000
218,400
8"
2.00
26-1/4"
34"
45"
1600
350,000
273,000
8
”
2.50
26-1/4"
34"
45"
STANDARD EQUIPMENT
OTF— Al
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I
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dEn
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Fi
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h
Boiler body with combustion chamber installed, theraltimeter, completely assembled and packaged with oil burner,
cadcell relay, pool & limit control, low water cutoff (OTF only), relief valve, indirect pool heating coil SC-150 (510/801)
SC-200 (1010/1600) with 1-1/2" I.P.S. tappings.
Selection of the right size OTF/ITF Heater
There are many factors related to proper sizing of Pool Heaters. We recommend you contact your installing dealer for
help in determining the correct size for your particular application.
POOL HEATER SIZING CHART - HEAT LOSS FROM POOL SURFACE - BTUs PER HOUR
Surface Area of Pool
Sq. Ft.
Desired
Pool Temperature
(°F)
80°
85°
90°
500
137,000 Btu.
155,000 Btu.
200,000 Btu.
600
166,000 Btu.
185,000 Btu.
240,000 Btu.
700
200,000 Btu.
218,000 Btu.
280,000 Btu.
800
220,000 Btu.
250,000 Btu.
320,000 Btu.
900
248,000 Btu.
280,000 Btu.
360,000 Btu.
1000
275,000 Btu.
310,000 Btu.
400,000 Btu.
1200
330,000 Btu.
370,000 Btu.
480,000 Btu.
1400
384,000 Btu.
435,000 Btu.
560,000 Btu.
1600 or Larger: Refer inquiry to Thermo-Dynamics, Schuylkill Haven, PA 17972
Approximate
Gallons
20,000
24,000
28,000
32,000
36,000
40,000
48,000
56,000
NOTES: 1. These heat losses are based on an assumed wind velocity at the water surface of 5 m.p.h. and an ambient
temperature of 60°F.
2. Where surface area and gallons do not coincide, surface area must take precedence.
10
H o m e Ow n e r I n f o r m a t i o n :
The Service Company:
Name
Address
Phone No.
SERVICE INFORMATION:
To avoid unnecessary expense and inconvenience your pool heater should be cleaned and serviced at least annually by a qualified service man. If difficulty occurs, the following should be observed before calling a service man:
(a) Check to be sure there is fuel in tank.
(b) Make sure power switch is turned on.
(c) Check to see if the desired pool setting is greater than the temperature of the pool.
WARNING
EVEN THOUGH THE VENT CAP AREA IS APPROXIMATELY 40 INCHES ABOVE GROUND, KEEP SMALL CHILDREN AWAY
FROM YOUR POOL HEATER.
11
OTF/ITF Pool Heater
Beckett AF Burner
Service Set Up Records
Initial Set Up
1
2
3
4
1. Date
2. Model Number
3. Firing Rate
4. Pump Pressure
5. CO2
6
.
“
0
”
Smo
k
e
7. Gross Stack
8. Draft Over Fire
9. Replaced Filter Yes/No
10. Replaced Nozzle Yes/No
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
Swimming Pool Heater Warranty
( 5- Y ear Li m it ed)
Swimming Pool Heaters (boiler wet section) are guaranteed for 5 years against defective material and workmanship from the date of installation. The indirect heat exchanger (copper pool coil) are guaranteed for 1 year
against defective material and workmanship from the date of installation. Controls and accessories made by
others and attached to or furnished with the Swimming Pool Heaters are guaranteed (only) to the extent of the
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12
Part Number 595821
250 - 6/03
MIP-6426
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