Thermo-Dynamics Boiler THERMOTRON OTF Operation, Maintenance, And Installation Instructions

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THERMOTRON

Thermo-Dynamics

ROUTE

•

BOX

325

•

SCHUYLKI

HAVEN,

17972

•

(

570)

385-

0731

•

FAX

(

570)

385-

5304

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 n f 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).

S e r v i c e P o l i c y

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 win-
terized 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 heat-
ing technician familiar with your installation to manage your heater and perform periodic mainte-
nance. 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, Thermo-
Dynamics wishes to provide you with responsive and unparalleled service. We realize the impor-
tance that our product means to you and your family and our goal is to get your heater up and run-
ning 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.

Section I. Installation Instructions

Control of combustion draft.

(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) Connections:

Do not run any piping along the

front access panel of heater as they

may interfere with servicing. The tap-

pings for connecting the unit to the

pool circulation lines are at the back of

the heater. These connections are 1-

1/2" NPT. Connections should be

made as per the piping illustration on

page 4. Install unions at the heat

exchanger so it can be readily

removed for service. If plastic pipe is

used, make connection to the unit with

metal piping and run metal piping to

the floor line before joining to plastic

pe.

Thi

“

heat

ap”

and

reduce possible damage to the plastic

pipes from overheating. Install posi-

tive check valve on inlet side. Install a

Tee joint at the coil where the PIPING

FROM the pool filter/pump ENTERS

the coil. Install the copper well provid-

ed into the piping Tee and insert the

remote sensing bulb from the L-4031

pool thermostat.

An adjustable by-pass around the

heat-exchanger is required. The by-

pass is an important and necessary

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

onnec

“

n”

and

“

Out

”

eams

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 differ-

enc

e bet

ween t

he “

n”

and “

Out

”

streams of the pool coil.

a) Use full size piping and valve

onnec

“

n”

and

“

Out

”

eams

of the pool coil.

b) Allow the boiler to fire contin-

uously for a period of ten (10) to fif-

teen (15) minutes.

c) With the bypass valve wide

open take temperature readings for

the coil.

d) Note: surface temperature

readings taken on a cold day will vary

significantly from test data.

e) Slowly close the bypass valve

and continue to take temperature

readings.

f) Stop when the temperature

enc

bet

ween

“

n”

and

“

Out

”

streams reaches forty-five (45) to fifty

(50) degrees Fahrenheit.

g) Flowrate should correspond to

six (6) gallons per minute. (See chart

page 7).

(3) Flue Connections:

(A) OTF Series (Outdoor Units)

The OTF heaters are provided with

an outdoor vent cap to be installed

directly on top of the cabinet at the flue

outlet. This vent cap provides for a

waterproof unit as well as proper con-

(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 man-

’

ons

Set

negat

–.

max

over the fire.

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 chim-

ney 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 con-

nections 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 CHLO-

RINATED 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 dis-

connect 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 pip-

ing...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 bot-

tom 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.)

S e c t i o n I I I
S t a r t U p a n d
O p e r a t i o n

A Start Up:

(1) Make sure the electrical

power is turned off.

(2) Check the Oil Burner ignition

electrodes carefully and adjust if nec-

essary.

(3) Check to be certain oil tank is

full.

(4) Be certain unit is filled with

water as per filling instructions.

(5) Turn on pool filter pump.
(6) Set limit control at 180°.

(7) Install pressure gauge in the

nozzle port of the fuel pump. Do not

take reading at the bleed port. The

pressure gauge should have a mini-

mum range of 100 PSI. Consult Fuel

Pump specification sheet (shipped

with Oil Burner).

(8) Turn on burner power switch.

(9) Push the safety reset button

on the primary control and release.

(10)Bleed the fuel unit on one-

pipe systems as soon as the burner

motor starts. To bleed, attach a piece

of 1/4" OD clear plastic tubing to the

end of the bleed port. Loosen same

and purge oil of air for at least 15 sec-

onds after oil appears to be clear. If oil

stream does not become clear and

free of air bubbles or foam, check all

fittings, filter and valve connections.

Foam can also be caused by kinks in

the oil line, causing an oil vacuum

condition. High vacuum readings can

aus

“

”

too small diameter tubing. Consult

Fuel Pump specification sheet.

B Equipment Adjustments:

Equipment Required:
(1) CO

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 continu-

ously 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

“

0”

–.

negat

mum)

(ITF indoor equipment should be

adj

–.

mum

–.

max

)

Adjust the pump discharge pres-

sure to 100 PSI. Vacuum must not

exceed 6" on one pipe and 10" on a

two-pipe system.

(d) Combustion Settings/CO

Reduce the air supply by closing

the air band to allow just sufficient air

for clean combustion. This is accom-

plished by loosening the lock screws

on the air shutter and closing the air

shutter until a TRACE of smoke is

recorded. Take a CO

sample, which

should be approximately 12%. Open

the air shutter and lower CO

reading

approximately by 1-1/2 to 2% from the

abov

eadi

ng.

“

0”

mok

ead

ing

should result with a CO

reading of

approximately 10%.

(e) Stack

Temperature:

(ITF

only)

Check to see that the stack tem-

perature is approximately 500° above

the ambient temperature.

(f) Turn LIMIT CONTROL to the

lowest setting; burner should shut

down. Turn back to the desired set-

ting, (normally 180°) burner should

operate.

(g) Turn POOL TEMPERATURE

CONTROL down to lowest setting;

burner should shut down. Turn con-

trol to highest setting; burner should

operate. Reset to desired tempera-

ture, approximately 80°.

(h) Allow burner to operate until

pool is at desired temperature. Adjust

pool

emper

ont

“

ool

”

unt

burner shuts down. This is the setting

that will be maintained by the heater.

C Trouble Shooting

(1) Motor Does Not Run:

(a) Check fuses and power to

heater.

(b) Set pool temperature control

and boiler temperature limit

to highest setting.

red button). Reset button

should only be pushed one

time!

(d) Reset thermal overload

button on motor.

(e) Check for defective tempera-

ture controls by jumping the

controls one side at a time.

(f) Check for power to motor. Motor

may be defective.

(g) Ensure that boiler is pressur-

ized with water. The low

water cutoff disrupts the

electrical circuit for the burn-

er.

(2) Motor Runs - No Fire:

(a) No oil in tank.

(b) Bad or plugged burner

nozzle.

(d) Loose transformer connec-

tions/defective ignition

transformer.

(e) Inspect electrode settings

and insulators.

(f) Check fuel pump pressure.

(3) Burner Fired--Shuts Down

On Cad Cell Safety:

(a) Defective C-554 Cad Cell.
(b) Dirty Cad Cell.

control.

(4) Smoke Coming Out of Flue:

(a) Clogged nozzle.

(b) Dirty fan/air handling parts.
(c) Improper burner adjustment

refer to B Equipment

Adjustment.

(5) Cycling On/Off:

(a) Differential between pool

setting and high limit too

close.

(b) High limit setting too low.
(c) Remote pool sensing bulb in

outlet water piping instead of
inlet water piping.

S e c t i o n I V
C a r e a n d
M a in te n an c e

(1) Heat Exchanger:

The tubular portions of the heat

exchanger should be cleaned annual-
ly or at start-up each heating season.

(a) Remove the cabinet top.
(b) Remove the flue collector

top.

tubes.

(d) Brush clean the flue ways

with a 2" soft brush and vac-
uum the unit carefully.
Reverse the above steps.

(3) Oil Burner:

(a) Thoroughly brush clean the

burner fan blades. Proper

combustion air delivery is

only possible when fan

blades are clean.

(b) Clean nozzle assembly and

all other air handling parts.

of electrodes. Adjust or
replace as necessary.

(d) Nozzles should be inspected

for malfunctions. If nozzle
does not perform according

to the prescribed conditions

under

“

bur

ner

adj

ment

”

replace it with only the spec-
ified 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 gas-

ket leaks. DETERIORATION DUE TO

GASKET LEAKS SHALL VOID THE

WARRANTY.

(2) Oil Filter:

The oil filter cartridge should be

replaced annually.

P a r t s L i s t

Item No.

OTF/ITF 510/1600 Beckett AF Burner Parts List - #540500

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

Description

Part

Number

Motor 1/7 HP 3450 RPM - PSC

675141

Fan 4-1/2 Dia. x 3-7/16

675130

Flexible Coupling

675160

Beckett Single Stage Clean-Cut Fuel Pump

675315

France Electronic Igniter

675981

Head F-3 (510/560)

675400

Head F-12 (640-801)

675420

Head F-22 (901-1600)

675430

Electrode Assembly

675500

Gun Assembly (Nozzle Line/Electrode Assy.)

675630

Air Tube Combination Pkg. (510/801)

675620

Air Tube Combination Pkg. (901/1600)

675640

Burner Flange Gasket

675170

Blank Air Band (510/801)

675110

8 Hole Air Band (901/1600)

675120

Cad Cell C-554-A

553024

Nozzle 2.50 x 80° Hollow

680246

Primary Control R7184B

553010

Coil Gasket

481000

Pool Controller L4031A

552035

SC-150 Coil (510-801)

530060

Temperature and Altitude Gauge

SC-200 Coil (901-1600)

530070

1/4 - 2-1/2" Round

559560

Ceraform Sleeve

352000

Relief Valve - 3/4"

575020

#15 Expansion Tank (510 thru 801)

972000

Nozzle 1.00 x 80° Hollow

680146

#30 Expansion Tank (901 thru 1600)

972010

Nozzle 1.50 x 80° Hollow

680196

McDonnell Miller Low Water Cutoff

553101

Nozzle 2.00 x 80° Hollow

680226

Specifications

Model - OTF - ITF

510

801

1010

1600

Gross Input

140,000

210,000

280,000

350,000

Gross Output - BTU/Hr.

109,200

163,800

218,400

273,000

Flue Pipe Dia.

8”

Firing Rate - GPH

1.00

1.50

2.00

2.50

Width OTF-ITF

22"

26-1/4"

Length OTF-ITF

31"

34"

Height OTF-ITF

38-1/2"

45"

STANDARD EQUIPMENT

OTF

—

umi

num

ent

Bak

Enamel

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

Desired

PoolTemperature
(°F)

Surface Area of Pool

Sq. Ft.

80°

85°

90°

Approximate

Gallons

500

137,000 Btu.

155,000 Btu.

200,000 Btu.

20,000

600

166,000 Btu.

185,000 Btu.

240,000 Btu.

24,000

700

200,000 Btu.

218,000 Btu.

280,000 Btu.

28,000

800

220,000 Btu.

250,000 Btu.

320,000 Btu.

32,000

900

248,000 Btu.

280,000 Btu.

360,000 Btu.

36,000

1000

275,000 Btu.

310,000 Btu.

400,000 Btu.

40,000

1200

330,000 Btu.

370,000 Btu.

480,000 Btu.

48,000

1400

384,000 Btu.

435,000 Btu.

560,000 Btu.

56,000

1600 or Larger: Refer inquiry to Thermo-Dynamics, Schuylkill Haven, PA 17972

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.

H o m e O w 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 annu-
ally 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.

OTF/ITF Pool Heater

Beckett AF Burner

Service Set Up Records

nitial Set Up

1. Date
2. Model Number
3. Firing Rate
4. Pump Pressure
5. CO

“

0”

Smok

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 e ar L i m i t e d )

Swimming Pool Heaters (boiler wet section) are guaranteed for 5 years against defective material and work-
manship 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

manuf

’

guar

ant

eed.

Thi

war

ant

epar

Ther

mo-

nami

’

dent

war

ant

Part Number 595821
250 - 6/03

MIP-6426

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