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Model GPA Instruction and Service Manual

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1. 75 installations and services must be performed by qualified service personnel APPENDIX D SEQUENCE OF OPERATIONS OPA 1of 2 A SEQUENCE OF OPERATIONS FOR THE HEATING SYSTEM Mode of Operation Control System Action Standby At any time the oil Continous safe operation check If valve is not energized flame simulation condition present system shuts off oil valve ignitor and burner motor activates fast flashing LED Start Thermostat calls for heat contacts close Ignition electrodes spark Burner motor energized Oil valve energized after On power interruption system 15 second time dela shuts off restarts when power is restored Start trial for ignition If flame is not detected the Flame must bo detected oil valve is de energized fter 45 seconds gt the ignitor is turned off and 4 the ignition control module goes into the retry sequence The retry sequence provides a 60 second wait before ignition is attempted again 76 installations and services must be performed by qualified service personnel 20f2 Mode of Operation Control System Action After 45 second delay the ignition electrodes are de energized The circulating air fan is energized at heating ee Burner speed The optional electronic peration air cleaner amp h
2. The larger of the two airflow figures should be selected i e 1600 CFM cooling requirement If only 3 tons 36 000 BTU hr was installed the required cooling airflow is 3 tons x 400 CFM ton 1200 Then the duct system should be sized for the 1400 CFM heating requirement Example 2 Problem A plan view of a residence with 1600 sq ft living area is shown in Figure 15 The supply registers and the GPA unit have been positioned Ductwork interconnecting the registers is also shown What is the required air flowrate at each register What is the required duct size for each segment of the duct system 64 installations and services must be performed by qualified service personnel Ps ae a 1 nd 7 0 1 m Figure 15 Plan View of Typical Residence Solution If certain flowrates are desired for heating or cooling reasons or are required by local codes those guidelines should be followed In lieu of other requirements room floor area can be used to select flowrates for each room For instance the floor area of the living room is 400 sq ft Using the result of our previous example the required minimum air flowrate for the residence is 1400 CFM The air flowrate for the living room will be the total flowrate multiplied by the ratio of the living room area to the total floor area or 400 sq ft 1600 sq ft CFM 1400 350 Living Rm 65 in
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4. 67 installations and services must be performed by qualified service personnel However there are two 90 degree turns in the branch that will cause a large pressure drop not accounted for in our calculations To compensate for this drop we should increase the effective length of the branch For a 90 degree mitered elbow the equivalent straight duct length is given by the following formula Ly PN EIS 65 Dn For a 6 inch diameter 90 degree elbow the equivalent straight duct length is L 65 9 325 fi 90 elbow 12 So the total equivalent straight duct length is Le 71 ft 2 32 5 ft 136 ft Now the required duct diameter should be recalculated 0 1 6 67 in 7 in Thus for section A the required duct diameter is 7 inches Now it is necessary to determine the allowable pressure drops for all other segments in the branch The equation for duct diameter can be rearranged to give the pressure drop for any flowrate providing the duct length the flowrate and the duct diameter are known The equation looks like this 1 82 AP in WG 0 00123174 Le f V CFM For section B if the flowrate is 120 CFM the length is 11 ft and the duct diameter 7 in the pressure drop will be 1 82 AP _ 0 00123174 11 120 B 4 86 7 0 00644 in W G 68 installations and services must be performed by qualified service personnel For section C including a 7 i
5. No ADJUST AIR TO A TRACE OF SMOKE THEN TAKE CO2 OR O2 READING NEXT SUBTRACT 196 FROM THE CO2 OR ADD 1 TO O2 THEN ADJUST AIR TO OBTAIN NEW CO2 OR O2 VALUES IS COMBUSTION AIR Yes TRY TO RAISE ROOM amp OIL IF THIS CANNOT BE DONE DO THE FOLLOWING DECREASE NOZZLE SIZE AND INCREASE PUMP PRESSURE CHOOSE SMALLER NOZZLE SIZE AND PUMP PRESSURE FROM EFFECTS OF PRESSURE ON NOZZLE FLOW RATES AT THE END OF THE TROUBLE SHOOTING SECTION installations and services must be performed by qualified service personnel DOES FURNACE OPERATE WITHOUT CONDENSING No IS STACK TEMPERATURE IS BURNER SET AS INDICATED No ADJUST BURNER COMBUSTION IN ABOVE SECTION TO PRODUCE ZERO SMOKE Yes ER ae No SLOW THE BLOWER SPEED TO RAISE TEMPERATURE Yes DIFFERENCE BETWEEN SUPPLY RISE Yes Yes INCREASE LENGTH OF BURNER ON CYCLE BY RESETTING BURNER PRIMARY CONTROL DIP SWITCHES FOR A LONGER OFF DELAY Y TROUBLE SHOOTING ENDS REPEAT PROCEDURE UNTIL TROUBLE FREE OPERATION IS OBTAINED EFFECTS OF PRESSURE ON NOZZLE FLOW RATE NOZZLE NOZZLE FLOW RATES IN NOZZLE NOZZLE FLOW RATES IN RATING GALLONS PER HOUR Approx RATING GALLONS PER HOUR Approx AT AT 100 PSI 80PSI 120PSI 140PSI 100 PSI 80PSI 120PSI 140PSI 50 0 45 0 55 0 59 1 35 1 21 1 48 1 60 1 50 1 34 1 64 1 78 65 0 58 0 71 0 77 1 65 1 48 1 81 1 95 75 0 67 0 82 0 8
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7. ile The location of these instructions in the appliance These instructions must be kept along with instructions for any accessories in the plastic pouch on the inside of the appliance The location and use of the manual oil shutoff valve and appliance electrical disconnecting device The end user must be instructed to always shut off the electric power to the appliance before shutting off the oil supply The sequence of operation of the appliance The correct operation and maintenance of the appliance as outlined in the Homeowner User Information and Routine Maintenance section of this manual That failure to maintain and operate this appliance in accordance with these instructions could result in hazardous conditions property damage and bodily injury It may also void the limited warranty on the appliance Review with and encourage the user to read the label reproductions and all warnings and instructions outlined on the front cover and in Sections 1 and of this manual Recommend the user have a qualified heating contractor inspect the entire appliance at least once a year Inform the user of the frequency of inspection required for each item in the Dealer Maintenance section of this manual Inform the user to maintain adequate clearances around air openings into the appliance housing and not to block or restrict the entrance of air into the condenser coil or the burner compartment air openings
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9. and less carefully constructed ductwork lower initial costs However lower air velocities also result in larger duct sizes than necessary at higher velocities In some cases space restrictions may limit the ductwork to smaller than optimal sizes 19 installations and services must be performed by qualified service personnel 6 The following method can be used to size ductwork when air velocities are low to moderate a Using a floor view of the residence determine or layout the locations of the supply registers and the return air grills Generally supply registers should be located close to sources of heat loss i e windows and doors around the perimeter of the building Return grills should be located in central positions as far away from the supply registers as practical Find a location for the appliance outside the building that minimizes the amount of ducting required to connect the appliance to the supply and return air duct systems Consider issues of access to the oil supply and electrical service required service and venting clearances exposure to sunlight and operating noise when selecting this location Plan an efficient layout for the ductwork connecting each of the supply air registers in the supply system to the unit Plan and layout ductwork connecting each of the return air grills in the return system to the unit Measure or estimate the length of duct between each register and grill Select valu
10. recommended sizes for over current and short circuit devices and minimum recommended field wiring sizes Electrical service must be brought to the unit from a circuit breaker or fused disconnect switch in accordance with local codes The disconnecting switch must be located reasonably close to and within sight of the unit Three wire service two hot leads L1 and L2 and a neutral N plus a ground conductor is required Connect power to the appliance control system at the junction box in the burner compartment A knockout fitting is provided on the exterior of the burner compartment for this purpose A ground wire must be connected to the grounding lug or screw marked Equipment Ground in the junction box Field wiring of power circuits to the appliance should consist of copper conductors rated for at least 240 VAC with an insulation temperature rating of at least 75 temperature rise Depending upon code requirements rigid or flexible conduit is recommended and may be required Connect the electric power supply as shown in the wiring diagram located on the inside of the burner compartment cover or in this manual The cooling system operates on 208 240 VAC electric power from supply wires L1 and L2 The heating system operates on 120 VAC electric power from supply wires L1 and N 24 installations and services must be performed by qualified service personnel Typically control wiring between the outdoor appliance a
11. 46 installations and services must be performed by qualified service personnel VI DEALER MAINTENANCE SAFETY DURING SERVICING AND INSPECTION ANWARNING Personal injury or property damage could result from repair or service of this appliance by anyone other than a qualified heating contractor The user may only perform the activities described in the Homeowner User Routine Maintenance section of this manual ANWARNING To avoid injury from moving parts or electrical shock shut off the power to the appliance before removing blower compartment door and servicing this appliance ACAUTION When servicing controls label all wires prior to disconnecting Reconnect any removed wires correctly Wiring errors can cause improper and dangerous operation Dangerous operation can result in injury or damage IMPORTANT Verify the proper operation of this appliance after any servicing is performed A qualified heating contractor should perform the following maintenance procedures at the beginning of each heating season Correct any deficiencies at once A General Inspection AWARNING Shut off oil and disconnect power before continuing w this inspection 1 Vent terminal Visually inspect the terminal for restrictions loose or missing fasteners external damage and carbon build up Clean the vent terminal and the screen s covering any opening in the terminal Repair any minor damage necessary replace a severely damaged or
12. Definition of Superheat eee neon ge cue one endende 42 3 EVaporator Superlieat 4 43 4 Definition of Subcooling 4223222410224 oc ton lod et is esed 44 5 Condenser Suboooling 44 6 Recommendations for Operation at Low Temperatures 45 V INSTALLER S INSTRUCTIONS TO USER 46 installations and services must be performed by qualified service personnel Contents SECTION PAGE VI DEALER MAINTENANCE eite eee ee eld te 47 General ge E P 47 B Heat Exchanger 48 1 Disassembly to Access Heat Exchanger 48 2 Reusssembly of Unit edel eee nre dee e ee eiae 50 Bs eousque DET 51 C Electrical System iode Meine a 51 D Supply Return Air Blower 52 E Supply Return Air 52 1 Filtet Malfiteriarit 6 5 3 9 6 9 Do D actas Mast 52 2 Filter Replacement icio iav E ce ab Ee Eze deu 52 F Extended Appliance Shutdown 53 VII HOMEOWNER USER INFORMATION AND ROUTINE MAINTENANCE 55 Vill TROUBLESHOOTING 59 A Heating Syster oce cH enira Rao e EE Ur Ee ee cad d 59 B Cooling SYSteMm oie ea ea ie e i ie ai dai ee
13. This compartment must be closed except when servicing Turn power off before removing panel Turn power off before removing panel 390458 FOR INSTALLATION COMBUSTIBLE FLOORING WITH CLEARANCES TO COMBUSTIBLE MATERIAL NOT LESS THAN SIDE _ _REAR FRONT BOITOM VENT HOOD INCHES NM 3 o 3 NO MATERIALS OR CONSTRUCTION SHALL BE PLACED ABOVE TOP OF THE UNIT REFER TO THE INSTRUCTION MANUAL FOR OPERATIONAL AND SERVICE CLEARANCES SUPPLY VOLTAGE 203 230 PHASE 1 HERTZ 60 MAX FUSE YD OR CIRCUIT BAFAKER PER OVERCURRENT PROTECTION 50 AMPS MINIMUM CIRCUIT AMPACITY 36 1 HEATING MAXIMUM TDTAL INPUT AMPS 15 0 CONDENSER HLOWER BURNER INDUCER COMPRESSOR FAN MOTOR MOTOR VOLTS 208 230 208 230 115 115 PHASE 1 1 1 1 HERTZ 60 60 50 60 1 4 34 TH 2 1 34 0 5 8 LRA 95 6 18 4 FACTORY CHARGE HCFC 22 BY WEIGHT 74 07 MAXIMUM DESIGN PRESSURE HIGH SIDE 400 5 1 0 MINIMUM DESIGN TEST PRESSURE 150 P S 1 8 All installations and services must be performed by qualified service personnel YOUR SAFETY READ BEFORE OPERATING WARNING if you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life This appliance is equipped with an ignition device which automatically lights the burner Do not try to light the burner by
14. When servicing controls label all wires prior to disconnecting Reconnect any wires removed correctly Wiring errors can cause improper and dangerous operation Dangerous operation can result in injury or damage A WARNING Disconnect electrical power before servicing this unit installations and services must be performed by qualified service personnel ACAUTION Waterproof type connectors must be used when connecting electrical power and control wiring to the unit to prevent moisture from being drawn into the unit during operation AWARNING Refrigerant is under pressure Guard against refrigerant spraying into the face or on skin Always wear protective equipment i e safety glasses or goggles and gloves when working with refrigerant ACAUTION Do not under any circumstances heat the refrigerant cylinder with a torch or by any other means other than warm water Excessive pressures generated in this manner may weaken the refrigerant container and result in an explosion A WARNING To avoid injury from moving parts or electrical shock shut off the power to the appliance before removing blower compartment door and servicing this appliance ACAUTION When servicing controls label all wires prior to disconnecting Reconnect any removed wires correctly Wiring errors can cause improper and dangerous operation Dangerous operation can result in injury or damage ACAUTION Do not use this appliance if any part has been under water Im
15. Burner Operation section c RSS RS A 2 A wee S Figure 10 View of OPA Heat Exchanger Replace any damaged or corroded components All gaskets and insulation must be inspected and replaced if they show any signs of damage 50 installations and services must be performed by qualified service personnel 3 Operational Check ACAUTION Before troubleshooting familiarize yourself with the start up and check out procedures NOTICE After reassembling the appliance check for fuel oil leakage from the supply piping a Check proper operation of the ignition system and for proper combustion b Observe the main burner flame If the flame appears strange or abnormal in character look for a component or components that were not reassembled correctly If the components have been reassembled correctly check for a blocked vent malfunctioning combustion air blower or fuel pump and partially blocked burner nozzle C Electrical System ANWARNING When servicing controls label all wires prior to disconnecting Correctly reconnect any wires removed during servicing Wiring errors can cause improper and dangerous operation Dangerous operation can result in injury or damage 1 Check all wiring for loose connections and any signs of damage or unusual wear Replace any damaged or frayed wiring and tighten any loose connections Use a voltmeter or a multimeter to check for adequate voltage at the f
16. EET es Appliance Gross Flue Gas Temp deg F Ambient Air Temp deg et Flue Gas Temp deg F hermal Efficiency 96 s Control Operation Any Oil Leaks Refrigeration Tests Service uction Line Pressure PSIG uction Line Temp deg F at Temp Evap deg vaporator Superheat deg F Cooling System iquid Line Pressure PSIG at Temp Cond deg iquid Line Temp deg F Condenser Subcooling deg F Any Refrigerant Leaks ests Performed By Date Technician Notes ame Installer Address hone No Operate system for at least 10 minutes before taking measurements U z o o 3 5 2 A 89 diz 5 AUD ON elas ON sse1ppy 5 JO ajeg suouMo diz 5 ARO t 12 968 F 9 Hd 5 99c9p tuospnf SH3H10 AAAO WIA SIH YASVHONNd IHL A8 ASNSIW 3SN SLI 40 39N3003SNOO 3HL ALMA TIV SIWNSSV LNaMWdinos 30 IHL ONIN ANY 40 ADVINVG LNanoasNoo ALMAVI ON SSHINSSY OTT SLONGONd HSNNVIA ANY NI SIHL JO SWHAL AJOON MALI OL SVH ON DTI 51 OWYAHL 3O SNOLLVOTTHO ANV S3LLNVHSHVM H3HLO TTV 520
17. THE T STAT SUBBASE AND SET HEAT ANTICIPATOR ACCORDINGLY Yes IF PROBLEM PERSISTS CONTINUE TO NEXT SECTION BLOWER RUNS NORMAL CYCLE No IS TEMPERATURE RISE No ves CHECK FAN ON amp OFF DIP SWITCH SETTINGS ON FAN CONTROL 79 CHECK BLOWER SPEED AND RETURN AIR TEMPERATURE installations and services must be performed by qualified service personnel PROPER COMBUSTION ACHIEVED No IS THE PROBLEM DELAYED IS THE AIR TUBE INSERTION 0 1 4 BACK FROM INSIDE OF REFRACTORY Yes IGNITION Yes Yes PROPERLY ALIGNED Yes IS PUMP PRESSURE SET No ACCORDING TO BURNER APPLICATION CHART Yes No ARE THE ELECTRODES No No SX ARE VENT TERMINAL AND HEAT EXCHANGER CLEAN IS BURNER TO PRODUCE A TRACE OF SMOKE AND THEN DETUNED IS THE NOZZLE PLUGGING IS WATER DIRT OR SLUDGE PRESENT IN THE OIL SYSTEM Yes REPAIR OR REPLACE TANK TO PREVENT FUTURE PROBLEMS MIX IN PROPER ADDITIVES TO REMOVE WATER AND SLUDGE 80 No CORRECT INSERTION OR AIR TUBE BURNOFF MAY OCCUR ALIGN ELECTRODES PER BURNER INSTRUCTION MANUAL SPECIFICATIONS ADJUST TO 100 120 PSI UNLESS COMBUSTION AIR OR OIL BELOW 50 deg F 15 PRESENT THIS IS CONSIDERED BELOW
18. a branch to a register is included in the 0 1 in W G pressure drop of the register Now the size of the ducting for each segment of the duct system can begin For the branch of the duct system which includes segments B F and the pressure drop cannot exceed 0 1 in W G This branch of the duct system has two 90 degree turns The total length of this branch is the sum of the lengths of each segment L La Lg TL LL 11 6 ft 11 ft 6 fi 22 ft 12 1 3 fi 71 ft Using the flowrate total length of the duct and the pressure drop the required size of the duct can be determined using the following equation 1 82 0 2058 D in 0 00123174 Le ft V CFM W G See page 75 for a copy of the ASHRAE chart This equation is applicable to standard air between 50 to 90 degrees F flowing through clean round galvanized ductwork with approximately 40 joints per 100 feet Using duct lengths in feet flowrate in CFM and pressure drop in inches W G the equation will calculate the required circular duct diameter in inches If it is desired to substitute rectangular duct for circular duct refer to Table 7 for equivalent sizes Returning to the example for a total length of 71 ft a flowrate of 120 CFM from the farthest register on segment and a pressure drop of 0 1 in W G the required duct diameter is 5 182 0 2058 p pese meee 5 85 in 2 6 in
19. and cooling Do not block or obstruct air openings in the unit and the air space around the perimeter of the unit 1 At least every three months under normal usage conditions check and clean all air filters in the appliance and if present in the duct system If excessively dirty air filters are not cleaned or changed poor system performance will result due to reduced airflow Low airflow places unnecessary strain on the compressor possibly causing the system to shutdown on the refrigerant high pressure switch Refer to Figure 16 for a sketch of the filter location 2 Keep the outside condenser coil clean by carefully spraying the finned area with plain water from the inside of the coil outward 3 Carefully remove any leaves twigs debris trash and insect or small animal nests homes from in and around any openings in the appliance housing 4 Visually inspect the vent terminal for restrictions and blockages With the heating system in operation the vent terminal will be hot Shut off the unit and allow the vent terminal to cool before removing any foreign materials from within the vent terminal 5 Inspect the exterior of the appliance for signs of excessive heat such as discoloration of materials damage from rust or corrosion or evidence of oil leakage Pay special attention to the mounting base the appliance is resting upon If the base is severely damaged deteriorated or unstable shutdown the unit and call a qualified hea
20. approximately 2 seconds 2 seconds off while the burner is operating If either control has sensed a flame failure which was uncorrected by initiating another trial for ignition the control will cease ignition trials and shutdown the burner or lockout The LED will continuously flash at a high rate approximately 1 4 second 1 4 second off for the model R7184P or approximately 1 2 second on 1 2 second for the model R7997P during the lockout mode To initiate another trial for ignition it is necessary to manually depress the reset button on the control module IACAUTION If the appliance fails to relight after resetting the primary control twice contact a qualified service company DO NOT continue to reset primary control 59 installations and services must be performed by qualified service personnel The operational condition of the flame sensor or cad cell can be checked by depressing the reset button on the control module while the burner is operating Count the number of flashes of the LED and compare them to the table below Number of flashes Cad Cell Resistance in ohms Model R7184P Model R7997D d RN uoti Less than 625 Less than 300 Zulu n MA 625 to 1250 300 to 600 sam 1250 to 2500 600 to 1200 d ssepe 2500 to 5000 1200 to 5000 If itis necessary to troubleshoot the flame sensor independently of the burner primary the following procedure
21. cause property damage personal injury or loss of life Refer to the user s information manual provided with this appliance Installation and service must be performed by a qualified installer service agency or the gas supplier For safe operation it is the responsibility of the owner and or user that the burner vent terminal heat exchanger and controls should be inspected every year by a qualified heating contractor The owner and or user should also conduct periodic visual inspections Refer to the users information manual provided with this appliance for details Any deficiencies noled must be corrected at once by a qualified heating contractor Do not attempt to make repairs yourself For assistance or additional information consult a qualified installer service agency the gas supplier s For your safety do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance Operating instructions are located behind this panel near burner assembly aa 7 installations and services must be performed by qualified service personnel The following warnings and cautions are found throughout the Thermo Pride Model Installation and Service Manual Please read and comply with the statements below AWARNING IF YOU DO NOT FOLLOW THESE INSTRUCTIONS EXACTLY A FIRE OR EXPLOSION MAY RESULT CAUSING PROPERTY DAMAGE PERSONAL INJURY OR LOSS OF LIFE A
22. cause damage or unintended problems The pressure temperature chart on the wiring diagram is to serve only as a guide Pressures shown are realistic averages which will vary somewhat with changes in air temperatures air flowrate across the evaporator and condenser coils and humidity both inside and outside If a charge must be added to the system connect to the suction service port of the service valve and add a vapor charge only while the system is operating Addition of liquid refrigerant at the suction port may damage the compressor 2 Definition of Superheat Superheat is extra heat added to refrigerant above the vaporization pressure temperature of the refrigerant A small amount of refrigerant superheat is usually beneficial and needed to help assure the best operation of the cooling system Superheat cannot be measured with a pressure gauge alone Both pressure and temperature readings of the suction line are required to evaluate the amount of refrigerant superheating The degree of superheating gives an indication of two important system operating parameters Superheat at the suction line outlet of the evaporator indicates the efficiency of the evaporator coil Superheated vapor at the suction line inlet to the compressor insures that liquid refrigerant is not being pumped into the compressor Highly superheated vapor is also detrimental to system operation The highly superheated refrigerant may overheat the compressor resul
23. continuing with the installation of this appliance Failure to follow these guidelines can cause improper and unsafe operation of this appliance Unsafe operation can result in substantial property damage severe personal injury or death 1 This appliance shall be used with only the type of fuel oil for which it is approved Refer to the appliance rating label for the required type of fuel 2 This appliance is a single packaged oil fired furnace with air conditioner designed for outdoor installation on either combustible or non combustible materials This appliance is also approved for rooftop installation on combustible or non combustible roofing materials 3 Ensure that adequate combustion and ventilation air is available to the unit 4 The airflow resistance of the duct system attached to this appliance must fall within the allowable external static pressure range for this unit Refer to the Airflow Requirements and Sizing of Ductwork section of this manual 5 Make sure supply and return air ducts are completely sealed to the appliance casing Refer to the Airflow Requirements and Sizing of Ductwork section of this manual installations and services must be performed by qualified service personnel GENERAL INSTRUCTIONS The entire text of these instructions must be read and understood before installing the appliance It is the installer s responsibility to do the following 1 Inform and demonstrate to the user the cor
24. gt PRIMARYLOCKED _ POWER IF 115 VAC PRESENT CHECK OUT FAN CONTROL MODULE amp PRIMARY MODULE ACCORDING TO MANUFACTURER S INSTRUCTIONS Yes Yes Yes PUSH IN PRIMARY RESET BUTTON Y ISBURNER MOTORRESET No ACA Vt REPLACE BURNER BUTTON POPPED OUT UP MOTOR Yes Yes REPLACE OIL PUMP PUSH IN MOTOR RESET BUTTON Y 78 installations and services must be performed by qualified service personnel Yes Y IS IGNITION ESTABLISHED No ARE THE ELECTRODES ARCING Yes Yes Y IS IGNITION TRANSFORMER CAPABLE OF PRODUCING A 3 4 ARC 10 000 VAC No REPLACE IGNITION TRANSFORMER Yes DETERMINE IF THE ELECTRODES ARE ALIGNED CONTACT SPRINGS TOUCHING ELECTRODE RODS amp PORCELAIN INSULATORS CLEAN AND UNCRACKED ADJUST OR REPLACE AS NECESSARY IS THE OIL PUMP OPERATING IS THE COUPLING BETWEEN THE BURNER MOTOR AND THE PUMP STRIPPED No No REPLACE PUMP Yes REPLACE COUPLER IS OIL AVAILABLE TO THE BURNER No VERIFY ALL OIL VALVE S ARE OPEN OIL TANK IS SUFFICIENTLY FULL Y FURNACE OPERATES FOR COMPLETE CYCLE No BURNER RUN NORMAL CYCLE AND OIL LINE CONTAINS OIL IS HEAT ANTICAPATOR SET TO MILLIAMP SETTING MEASURED ON SUBBASE Yes MEASURE MILLIAMPS BETWEEN W amp R ON
25. hand BEFORE OPERATING inspect around the appliance area for oil leaks WHAT TO DO IF YOU HAVE AN OIL LEAK Do not try to light any appliance immediately call your oil supplier If you cannot reach your oil supplier call the fire department Do not use this appliance if any part has been under water Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any oil control which has been under water IEEE OPERATING INSTRUCTIONS BN STOP Read the safety information above on this label Set the thermostat to lowest setting Turn off all electric power to the appliance This appliance equipped with an ignition device which automatically lights the burner Do not try to light the burner by hand Turn oil valve on Turn on all electric power to the unit Set thermostat to desired setting If appliance will not operate follow the instructions supplied with burner controls and call your service technician or oil supplier NENNEN APPLIANCE EE 1 Set thermostat to lowest setting 2 If service is to be performed turn off all electric power to the appliance and close the oil valve 390465 4 p COS TAN DARE WHEN TH SYSTEM WITH ARI Turn power off Keep flammable vapors before servicing and liquids away SPECIAL HOMEOWNERS INSTRUCTIONS Improper installation adjustment alteration service or maintenance can
26. housing Remove the access panel Slide the dirty air filter out of the filter rack Clean the filter by either vacuuming rinsing with tap water hosing or dipping in an ordinary detergent solution After cleaning and drying the filter replace the completely dry filter in the rack If the filter has a supporting mesh the mesh side of the filter must be placed towards the furnace Figure 12 Location of the OPA Supply Return Air Filter 2 Filter replacement To ensure an adequate replacement filter is selected should the filter require replacing refer to Table 4 in Air Filters section of this manual for the minimum filter areas required for different types of available filters 52 installations and services must be performed by qualified service personnel NOTICE Remind the homeowner of the importance of monthly filter inspections during operation to ensure maximum operating efficiency F Extended Appliance Shutdown ACAUTION Do not attempt to start burner when Primary reset has been engaged more than two times Excess oil has accumulated in the combustion chamber or beneath the burner assembly The combustion chamber or the heat exchanger is full of fuel vapor The combustion chamber is very hot Should the appliance be shutdown or turned off for an extended period of time several steps can be taken to help insure a smooth and reliable restart of the heating system ON SHUTDOWN 1 Close oil supp
27. local codes follow the Standard for Installation of Oil Burning Equip ment NFPA 31 If disassembly of this unit is required all parts and components must be reinstalled in their original as manufactured positions sac This compartment must be closed except when servicing 17 US CONTROL NO 2000980 WODEL Qeaa2 80 SERIAL NO 000000000000000 0 OIL FORCED AIR FURNACE WITH COOLING UNIT INSTALLATION ONLY CONFORMS TO UL STD 1995 amp UL STD 727 PRODUCT DESIGNED TO OPERATE WITH DUCTS CONNECTED DESIGNED MAXIMUM OUTLET AIR TEMPERATURE 200 F AIR TEMPERATURE RISE 50 TQ MAXIMUM EXTERNAL STATIC PRESSURE 0 4 IN W C MIN AMBIENT AIR TEMP 20 F OIL NOT HEAVIER THAN NO 2 OIL BURNER MODEL 1 7501 AIR TUBE COMBINATION AFS3BNSS INPUT NOZZLE G P H TYPE PUMP P S I G B8TUH INPUT OUTPUT HiGH FIRE 0 75 BO DEG H 130 105 000 85 000 LOW FIRE 0 60 80 DEG H 120 B5 000 68 000 FACTORY EQUIPPED WITH 0 75 GPR 80 DEG H NOZZLE FOR MAXIMUM EFFICIENCY AFUE SET BURNFR COMBUSTION FOR 12 CARBON DIOXIDE MINIMUM THERMO PRODUCTS LLC P 0 BOX 217 JUDSON IN 46366 ness durae To clean or replace the air filter remove the filter from the filter rack a Wash the filter in water and allow it to dry b Replace the filter with an identical new filter Position the air filter in the filter rack Reinstall and secure this panel
28. of the refrigerant at the evaporator suction line connection With the estimated refrigerant pressure and measured temperature at the same point tabulated data on R22 from the refrigerant manufacturer or ASHRAE can be used to evaluate the degree of superheat 68 PSIG Suction pressure measured at condenser 0 PSIG Added for pressure drop of suction line 68 PSIG Estimated pressure of refrigerant at evaporator exit From the R22 pressure temperature chart Figure 16 at 68 PSIG 82 7 PSIA the saturation temperature is approximately 40 F Temperature deg F 160 140 120 100 80 60 40 20 Figure 16 Saturation Temperature vs Pressure for Refrigerant 22 R22 0 0 50 0 100 0 150 0 200 0 250 0 300 0 350 0 Pressure PSIG 72 installations and services must be performed by qualified service personnel Now the degree of superheat can be calculated 48 F Suction line temperature at outlet of evaporator 40 F Saturation temperature for R22 at 68 PSIG 8 F Degree of evaporator superheat Example 4 Problem Additional refrigerant measurements are made on the cooling system of our typical GPA installation The liquid line pressure measured at the condenser unit liquid line charging port is 210 PSIG The temperature of the refrigerant R22 at the evaporator liquid li
29. or use of a different filter type is desired refer to Table 4 for minimum sizing guidelines for selecting filter for the unit Table 4 Minimum Required Filter Area in square inches Filter Type Air Velocity Model Number ft min Thermo Products Supplied Permanent 240 288 336 192 Standard 500 230 288 346 403 Permanent Disposable The Thermo Products supplied filter can be cut to size to fit other filter retention systems as long as the minimum size requirement is met NOTICE Any internal stiffeners used in the filter must not be removed although they can be cut to size as needed 23 installations and services must be performed by qualified service personnel J Electrical Wiring AWARNING This appliance must be grounded in accordance with local codes or in the absence of local codes with the National Electrical Code ANSI NFPA 70 1999 or the latest edition ACAUTION Waterproof type connectors must be used when connecting electrical power and control wiring to the unit to prevent moisture from being drawn into the unit during operation All wiring must conform to the provisions of local codes or in the absence of local codes with the provisions of the National Electrical Code ANSI NFPA 70 1999 or the latest edition and this instruction manual This appliance requires 208 240 VAC 60 Hz single phase power Refer to Table 5 for typical electrical current draws of the individual appliance motors
30. the saturation pressure temperature of the refrigerant A small amount of refrigerant subcooling is usually beneficial and needed to help assure the best operation of the cooling system Subcooling takes place in the condenser It is a function of the amount of airflow into the condenser the outside ambient air temperature the refrigerant pressure into the condenser and pressure drop through the condenser Refrigerant with low subcooling or saturated refrigerant may partially change back into vapor or flash to gas while flowing to the evaporator The resulting gas bubbles can block or interrupt flow through refrigerant controls causing the evaporator to starve for liquid refrigerant consequences are poor evaporator efficiency high superheat and generally poor cooling of the conditioned space Unless very well insulated long liquid lines from the condenser to the evaporator specifically liquid lines exposed to high ambient temperatures are prone to reduce refrigerant subcooling To insure sub cooled liquid refrigerant reaches the evaporator under all conditions it is usually advisable to take subcooling measurements during the warmest part of the day Test measurements taken during this time would provide results typical of the most adverse conditions under which the cooling system would operate Installing a liquid line sight glass at the inlet to the evaporator is a simple but effective way to prove liquid is feeding the eva
31. this calibration is related to the thermostat heat anticipator The proper thermostat heat anticipator setting is 0 1 ampere To increase the length of the cycle increase the setting of the heat scale to decrease the length of the cycle decrease the setting of the heat scale Anticipators for the cooling operation are generally pre set by the thermostat manufacturer and require no adjustment Anticipators for the heating operation are of two types pre set and adjustable Those that are pre set will not have an adjustment scale and are generally marked accordingly Thermostat models having a scale as shown in Figure 5 must be adjusted to each application HOLE SUITABLE FOR PENCIL POINT TO MOVE INDICATOR HEATER C INDICATOR lt SCALE Figure 5 Heat Anticipator Adjustment Scale In many cases this setting can be found in the thermostat installation instructions If this information is not available or if the correct setting is questioned the following procedures should be followed 28 installations and services must be performed by qualified service personnel Preferred method of adjustment Using an analog ammeter on the lowest scale such as an Amp Check connect the meter across terminals R and W on the sub base RH amp W on an isolating thermostat sub base If the reading is too low to move the needle on to the measurement scale of the instrument proceed as follows i Wrap 10 loops of sin
32. 2 6 8 6 8 IO 2000L Hli XY ACC AOV ooo X OY DA CAPUA NN m RADAR UT A 800 VA LL A A mare iN A A OA NAAT 7 KA AAA 4 V LZ AM A VOCARE SIS F LL LM m FIT L Set E E er m CU FT OF AIR PER MINUTE PX DEN ANA SATA ATMA SERE ZTN CANNA b XA TE VA ANN ACA M OA WE LAS M d n VA VE M ATY AH PA 02 03 A 06 08 1 2 34 6 BI 2 4 6 810 FRICTION LOSS IN INCHES OF WATER PER 100 FT Based on Standard Air of 0 075 Ib per cu ft density flowing through average clean round galvanized metal ducts having approximately 40 joints per 100 ft Caution Do not extrapolate below chart Friction of air in straight ducts for volumns of 10 to 2000 efm 74 installations and services must be performed by qualified service personnel XII APPENDIX C ELECTRICAL SCHEMATIC AND CONNECTION DIAGRAM ee ee os lt lt m 5 ua 260 zu 2 252 59 ous 2 2 5 1 PSP 55 2507 m eset e 6 Hi E 3 1 lt lt lt 1 lt lt
33. 2 e aq jou 99 suogoanasutr pue 2711 51 Jo pue syuawasinbas je21 29 o pue VJS pue e20 uy ui pue dn jas 5 aq jsnui yun ay Suonepuaululo29M uonipe juanma enue Jo 51002 PBuruonipuo WOOW YPMA ur 5 Jonp e ejelado gun eu peubisep sem u3IuA 404 ay ug pue uo payeolpul se yoedeo pazei sy Jsnw jun 99 mo a OTI syonpoJd OULISY IVA o s ep 06 Ajeuru uii avo NOLLVHISIOSM 343 pue JauMo 99 say ALNVYYVM 30 SNOLLIINOO SHL 1 predaJd Aq jsnui Jea YYY eu Jaye 104 saumo 991 5 s jeuMo ou HIM ead YYY 291 Jaye JojgJodeAo JO dy Jo 5 51502 uonejiodsuei 10 uy e sanes
34. 3533415 A 15S34dX3 ALNVMHHVM SIHL 031517 34 TIY GIOA TIIM SNOLLIINOO 3AO8V 30 A IdiNO 2 OL ul9js S OY 0j sa2uejsulnoJlo JO Jo sjoe abewep 10j 31915404532 aq jou 27171 SJonposg owy sssuppe uonejejsul sy yewa jsnur gun ayy goueuajulew 5 pue aq jsnul roo pue pun 99 H uUogeanBijuoo ubisep sy Teuueur Ul 10 pue aq jou jsnur pun 5 pessed q aq jou jes aJd pue eui 5 5 5 4 enge jeau jojeuunn so2ejins Jouur BY JO pide esneo e jo gase uonsnquioo au uaym yaya eu Aue Jo auo s 1 02102 y uoneogdde zy T1 ouueu say 2 5 Jo sloped 5 5 5 Ap aq se yons 5351 0 100
35. 5 48 75 392 0 2058 0 0614 Dp 9 50 in 10 in or an increase in duct size of about 1 inch in diameter The pressure drops for the remaining branches of the system must be set This includes segment G segments I and J and segments L and M balance the system the pressure drop for each branch must be approximately equal to the pressure drops of the other branches For example segment G must equal segments D E and F combined Thus AP AP AP AP Likewise for the other branches AP AP 0 1 in W G AP AP AP 0 1in WG Using the previous technique duct sizes can be found for all the remaining segments The duct sizes adequate for the entire supply system are summarized in Table 7 below Table 7 Required Duct Sizes for the Residence in Example 2 Equivalent Rectangular Duct Dim s Air Velocity in Circular Duct FPM N A Not Applicable 71 installations and services must be performed by qualified service personnel Example 3 Problem Refrigerant measurements are made on the cooling system of a typical GPA installation The suction line pressure measured at the condenser unit suction line charging port is 68 PSIG The temperature of the refrigerant R22 at the evaporator suction line connection is measured as 48 F What is the degree of superheat for this system Solution Calculate the pressure
36. 60 DR REFERENCES UP oL tr b yao AUN LUN Tof M Ud 62 X APPENDIX A SOURCES FOR REFERENCED STANDARDS 63 XI APPENDIX B CALCULATIONS 64 XII APPENDIX C ELECTRICAL SCHEMATIC AND CONNECTION XIII APPENDIX D SEQUENCE OF OPERATIONS 76 XIV APPENDIX E TROUBLESHOOTING FLOWCHARTS 78 XV APPENDIX F SPECIFICATION SHEETS 86 XVI APPENDIX REPLACEMENT PARTS 87 XVII APPENDIX OPA HEATING AND COOLING TEST FORM 89 WARRANTY RENI aes 90 All installations and services must be performed by qualified service personnel SAFETY INFORMATION This page and the following page contain reproductions of the various instructions and warning labels placed on the Thermo Pride gas fired appliances Please read and comply with the contents of these labels This compartment must be closed except when servicing MAKE FIELD WIRING CONNECTIONS INSIDE JUNCTION BOX USE INSULATED COPPER CONDUCTOR SUPPLY WIRES IF REQUIRED REPLACE THE CONTROL CIRCUIT FUSE WITH A TIME DELAY TYPE CLASS CC 15A 600 FUSE ONLY CAUTION Instalkthis appliance outdoors only This appliance must be installed in accordance with the manufacturer s instructions and local codes In the absence of
37. 66 6 36 1 50 Directly driven DWDI FC centrifugal 12 in O D 1300 1200 1030 860 Permanent split capacitor air over 48Y 3 4 11 4 1130 Clockwise 5 59 6 25 0 5 3 75 Permanent 1 20x25 35 47 47 20 x 12 20 x 12 610 All installations and services must be performed by qualified service personnel APPENDIX G REPLACEMENT PARTS LIST BURNER ENCLOSURE SHT SIDE 87 All installations and services must be performed by qualified service personnel 88 installations and services must be performed by qualified service personnel XVI APPENDIX OPA HEATING AND COOLING SYSTEMS TEST FORM Complete this form for each Thermo Pride appliance installed Read the instruction manual carefully i Retain this form with appliance ame Customer Address ity State amp Zip Code Model No No 1501 Mfgr amp Model of Fuel Oil Filter ombustion Tests Service Combustion Chamber Condition lp Ste ozzle Size amp Type O O Oil Pump Pressure PSIG CO2 eo E moke No ee rr d C Heating System Air Shutter Opening _ d 3 of max __________
38. 9 1 75 1 57 1 92 2 07 85 0 76 0 93 1 00 2 00 1 79 2 19 2 37 90 0 81 0 99 1 07 2 25 2 01 2 47 2 66 1 00 0 89 1 10 1 18 2 50 2 21 2 74 2 96 1 10 0 99 1 21 1 30 2 75 2 44 3 00 3 24 1 20 1 07 1 31 1 41 3 00 2 69 3 29 3 55 1 25 1 12 1 37 1 48 3 81 installations and services must be performed by qualified service personnel puo 1240 uo Jo 1 eaea 5 5 pmbr JO Sn 00 our seBed y uo ay udej6ejed ay ees y 3noqe uogeuuojul 104 3JON uo 81 paiso sks Tore WAS S ut sopqesuopuoo UOU 10 38124512 0 IAP siodweq Jodo1du opis Joyoedeo porougso1 oAnoggoq 001511521 apts YIH 3910810091 10 paro1ysas 8 pun sag peo 25007 uo 10 5 8 qarg 211155244 peau
39. Do not under any circumstances heat the refrigerant cylinder with a torch or by any other means other than warm water Excessive pressures generated in this manner may weaken the refrigerant container and result in an explosion ACAUTION Do not attempt to operate the cooling section on a day when outdoor temperatures are 45 F or cooler On cool days 65 F or lower attempts to operate the cooling section and take gauged pressure readings may be unsuccessful as unusually low pressure will be observed on the suction line This type of operation may give the impression of an undercharged unit This is not necessarily the case A low refrigerant pressure reading may occur due to the combined action of the large condenser surface area and cold ambient air removing a large amount of heat from the refrigerant As a result subcooling of the refrigerant occurs and very low refrigerant pressures can be measured Adding refrigerant in cold weather will result in overcharged unit During warm or hot weather high ambient temperatures will greatly increase the refrigerant pressure which may then cause the high limit pressure switch to shutdown the unit Due to the high probability of taking a false reading suction line pressure should not be taken for test purposes when the outdoor temperature is below 70 F When the outdoor air temperature is cooler than the indoor air temperature refrigerant vapor will condense in the compressor If the compressor
40. T 1996 Marks Standard Handbook for Mechanical Engineers 10th Ed McGraw Hill New York pp 12 88 amp 12 89 62 installations and services must be performed by qualified service personnel X APPENDIX A SOURCES FOR REFERENCED STANDARDS 1 Air Conditioning Contractors of America 1712 New Hampshire Avenue NW Washington D C 20009 202 483 9370 2 American National Standards Institute Inc Attn Customer Service 11 West 42 Street New York New York 10036 212 642 4900 3 American Society of Heating Refrigeration and Air Conditioning Engineers Inc 1791 Tullie Circle N E Atlanta Georgia 30329 404 636 8400 4 National Fire Protection Association 1 Batterymarch Park Quincy Massachusetts 02269 800 344 3555 63 installations and services must be performed by qualified service personnel XI APPENDIX B CALCULATIONS Example 1 Problem It is desired to install a warm air furnace w an air conditioning evaporator coil at a residence The net output of the furnace is 100 000 BTU hr and the evaporator will provide 4 tons of cooling to the space Estimate the minimum required airflow for the system to operate satisfactorily Solution From the heat output of furnace the heating airflow requirements can be estimated 100 000 BTU hr x 14 CFM 1000 BTU hr 1400 From the required cooling performance the cooling airflow requirements can be estimated 4 tons x 400 1600
41. TION Do not attempt to make repairs yourself Contact your local qualified heating contractor Under normal conditions this appliance will operate in either heating or cooling mode depending upon the mode of operation set at the thermostat The unit will cycle on and off automatically as required to maintain the air temperature within the residence as closely as possible to the thermostat setting However in rare cases the unit may shutdown automatically during a normal cycle or may not operate under seemingly normal conditions If the unit will not operate in the heating mode it may be possible to reactivate the unit by resetting one of the burner controls To attempt resetting of the burner controls follow this procedure 1 Turn the thermostat temperature setting down and set the operating mode to OFF or COOLING 2 Remove the burner compartment cover 3 Check to see if the LED on the burner primary ignition control module is flashing at a rapid rate If so the control may have locked out To recycle the control system depress the reset button Refer to Figure 14 55 installations and services must be performed by qualified service personnel 4 Check to see if the high temperature limit switch reset button on the burner motor has popped out If so the control has activated To reactivate the control depress the reset button 5 Replace and secure the burner compartment cover 6 Set the operatin
42. Thermo Pride OUTDOOR COMBINATION OIL FIRED FURNACE AND AIR CONDITIONING UNIT MODEL OPA INSTALLATION AND SERVICE MANUAL AWARNING If the information in this manual is not followed exactly a fire or explosion may result causing property damage personal injury or loss of life Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance WHAT TO DO IF YOU FIND AN OIL LEAK e Do not try to light any appliance e Immediately call your oil supplier f you cannot reach your oil supplier call the fire department Installation and service must be performed by a qualified installer service agency or the oil supplier These entities are referred to in these instructions as a qualified heating contractor Please read these instructions prior to installation initial firing and before performing any service or maintenance These instructions must be retained by the homeowner for future reference by qualified heating contractor WWTERTE Thermo Products LLC 3 PO Box 217 US MO 424 North Judson IN 46366 4650 574 896 2133 Made In USA installations and services must be performed by qualified service personnel Contents SECTION PAGE l SAFETY INFORMA TION discit dcdit au ved og eta re o osea ceo ei uod GENERAL INSTRUCTIONS GENERALINSTALLA MON totis totis hot
43. WARNING Carefully read and thoroughly understand the following guidelines and warnings before continuing with the installation of this unit Failure to follow these guidelines can cause improper and unsafe operation of this appliance Unsafe operation can result in substantial property damage severe personal injury or death A WARNING This unit is not to be used for temporary heating of buildings or structures under construction ANWARNING Maximum gross stack temperature must not exceed 550 F 288 C under any circumstances ACAUTION Failure to comply with minimum filter installation requirements may effect the performance and or void the warranty on this unit ANWARNING This appliance must be grounded in accordance with local codes in the absence of local codes with the National Electrical Code 70 1999 or the latest edition A WARNING Turn off the electrical power to the appliance before attempting to change supply air blower speed wiring A WARNING Personal injury or property damage could result from repair or service of this appliance by anyone other than a qualified heating contractor The end user may only perform the service described under the Homeowner User Routine Maintenance section of this manual A WARNING To avoid injury from moving parts or electrical shock shut off the power to the appliance before removing supply air blower compartment door and servicing this appliance A WARNING
44. alance the system the pressure drop for segments D and E combined must be approximately equal to the pressure drops of segments A B and combined Thus AP AP AP AP Using the previous pressure drop equation the pressure drop through segment is 0 0321 in W G Then the pressure drop for the D and E branch is AP 0 0321 in W G 0 0644 in 0 0257 in W G 0 0643 in W G The duct diameter required to pass 196 0 0643 in W G pressure drop is 5 73 in 6 in Dac 0 00123174 17 196 0 2058 0 0643 Including a 6 in 90 degree elbow in segment E the required diameter would be gt e 182 0 2058 D uM 7 14 in x 7 in or approximately 1 inch larger than without the elbow The pressure drop through segment D should be calculated for a 5 ft straight section with a 7 in 90 degree elbow From our previous equation the pressure drop is about _ 0 00123174 5 37 9 196 4 86 7 0 0614 in W G The flowrate through section D is 392 CFM 196 196 With the required pressure drop the duct diameter is D 0 00123174 5 37 9 392 0 2058 A 9 07 in 9 in 0 0614 Recalculating the duct size considering the effective length of a 9 in 90 degree elbow 70 installations and services must be performed by qualified service personnel _ 0 00123174
45. block the discharge of flue products If these conditions occur the performance of the heating system will be adversely affected Choose an installation location where the vent terminal does not discharge over sidewalks walkways and patios These areas may become slippery when wetted by water vapor in the flue products Combustion products must not be allowed to accumulate within a confined space and recirculate back into the combustion system Recirculation of combustion products promotes poor combustion In severe cases it may lead to sooting of the combustion chamber and heat exchanger or to nuisance shutdowns of the heating system 13 installations and services must be performed by qualified service personnel In addition long term exposure of building materials to combustion products may cause discoloration of material surfaces and corrosion or degradation of materials The preferred installation location will allow combustion products to freely escape the immediate area of the appliance and rapidly disperse into the atmosphere without being drawn back into the appliance or a nearby structure To prevent combustion products from entering a structure the vent terminal must expel combustion products away from any point of entry The minimum acceptable distances from the vent terminal to points of entry to a building are 4 feet horizontally from and 1 foot above or at least 4 feet below any window door or gravity air inlet
46. ce after installation it may be necessary to purge the air out of the oil line A qualified heating contractor should do this AWARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life ACAUTION Do not run the oil pump dry for more than five minutes as irreparable damage may result ACAUTION Before troubleshooting familiarize yourself with the start up and check out procedures AWARNING Never burn garbage or refuse in this appliance Never try to ignite oil by tossing burning papers or other material into the combustion chamber AWARNING Oil fired appliances produced by Thermo Products are designed for burning No 2 distillate domestic heating fuel oil Never use gasoline or a mixture of oil and gasoline IACAUTION Do not attempt to make repairs yourself Contact your local qualified heating contractor ACAUTION This appliance is designed to directly vent combustion products into the atmosphere through and using only the supplied vent terminal Do not attempt to attach a vent connector or a vent system to or in place of the supplied vent terminal ACAUTION Do not attempt to operate the cooling section on a day when outdoor temperatures are 45 F or cooler installations and services must be performed by qualified service personnel AWARNING Carefully read and thoroughly understand the following guidelines and warnings before
47. ched If equipped have the disconnect switch fuses blown or has the circuit breaker tripped If an electrical fault has occurred more than once call your qualified service person to diagnose the cause and perform the required repair s Is the sub base of the thermostat switched to the COOL position Is the temperature setting on the thermostat low enough to bring the cooling system on Has the unit stopped cooling making it necessary to wait several hours before the unit will restart The fan motor or compressor may have shutdown on thermal overload due to overheating If this event frequently occurs call your qualified heating contractor 61 installations and services must be performed by qualified service personnel IX REFERENCES 1 International Approval Services U S Inc and the National Fire Protection Association 1996 National Fuel Gas Code ANSI Z223 1 1996 NFPA 54 1996 6th Ed pp 10 amp 13 2 Earley M W Sheehan J V Caloggero J M 1999 National Electrical Code Handbook 8th Ed National Fire Protection Assoc Inc pp 142 143 256 amp 502 510 3 American Society of Heating Refrigerating and Air Conditioning Engineers Inc 1997 ASHRAE Handbook Fundamentals pp 19 9 32 1 32 50 4 Lindeberg M R 1984 Mechanical Engineering Review Manual 7th Ed Professional Engineering Registration Program San Carlos CA pp 5 8 amp 5 9 5 Avallone E A Baumeister Ill
48. degraded vent terminal 2 Burner Visually check the burner and below the burner for indications of oil leaks Correct any if found Remove the burner and measure the ignition electrode gap It should be set to 5 32 inch Adjust it if necessary Clean any accumulation of dust dirt or debris from the air shutter or air band openings If necessary clean housing and blower wheel with a damp cloth Use a vacuum to remove any lint or dust from motor assembly Add a few drops of non detergent oil to each of the motor lubrication holes 3 Combustion Chamber Inspect the liner for deterioration oil and carbon build up If the accumulation of oil or carbon is significant this is a strong indicator that the burner is out of adjustment Inspect the burner nozzle for partial blockage and 47 installations and services must be performed by qualified service personnel excessive wear Replace it if required Check and adjust oil pump pressure if needed Refer to Initial Heating System Adjustments section of this manual Heat Exchanger Visually inspect the heat exchanger for excessive carbon soot build up Refer to the Heat Exchanger section of the manual Oil Filter Replace the supply line oil filter cartridge with a new filter of the same type and rating Clean the body of or mounting plate for the oil filter Evaporator and Condenser Coils Inspect both the evaporator and the condenser coils for dust dirt debri
49. e can be changed to the high fire by switching to the larger burner nozzle and increasing the pump pressure The main burner oil nozzles for this unit were selected based upon the following assumed characteristic values of the fuel oil suitable for use with this appliance design e For no 2 distillate fuel domestic heating oil having a higher heating value of 140 000 BTU per gallon and a specific gravity of 0 88 60 deg F gravity of 30 deg 60 deg It is possible to make minor adjustments to the heat input rate by adjusting the pump pressure Sizeable changes in input rate especially reductions should be made by replacing the burner nozzle To adjust the pump pressure to the main burner a With the oil shut off remove the 1 8 in NPT threaded pipe plug located on the lower rear side of the oil pump refer to Figure 13 Attach a pressure gage capable of measuring pressure in pounds per square inch gage PSIG in this opening on the discharge side of the oil pump NOTICE It may be necessary to remove the oil pump to attach the plumbing required to connect a pressure gage to the pump 37 installations and services must be performed by qualified service personnel b Turn on the fuel oil and cause the appliance to activate the heating section by answering a call for heat NOTICE It may be necessary to bleed air from the oil line before the burner can be fired c Allow the heating section
50. e following should be checked a With heating system in normal heating operation check to make certain blower will start and stop automatically under control of the indoor thermostat b Check safety limit control as follows i Shut off incoming power ii Block return air opening or disconnect blower motor leads iii Restore power to appliance iv In the heating mode set the thermostat above room temperature producing call for heat v When high air temperatures are reached within the heating section the high limit control should act to shutdown the burner vi Shut off the electrical power IMPORTANT Remove blockage or reconnect blower motor and restore power 39 installations and services must be performed by qualified service personnel c Make certain the thermostat will automatically start and stop the appliance NOTICE Heat exchanger oil will burn off on initial firing creating an unpleasant odor To prevent this odor from occurring more than once it is suggested the heating section be allowed to run for 30 minutes or until odor has dissipated 40 installations and services must be performed by qualified service personnel B Cooling Section 1 Initial Startup AWARNING Refrigerant is under pressure Guard against refrigerant spraying into the face or on skin Always wear protective equipment i e safety glasses or goggles and gloves when working with refrigerant ACAUTION
51. e summed together to determine the total pressure drop for each branch This value should be close to the assumed value for the pressure drop of the system If it is not close then flowrates for each branch must be adjusted or the design of the duct system must be altered to give the proper pressure drops Usually the cross sectional area of the ductwork should be changed in order to adjust the pressure drop to a suitable value Refer to Example 2 in Appendix B Calculations of this manual for a sample calculation of how to use this method for sizing the supply side ductwork for a residence Table 3 shows the air handling capacities of 100 ft lengths of circular and rectangular ductwork based on a 0 1 in W G static pressure drop The first column to the right is the air flowrate and the second is the required diameter for a circular duct The third column is the required cross sectional area of the duct and the other columns to the left are rectangular ducts with sufficient cross sectional area to handle the flow at the specified pressure drop For lengths of ductwork less than 100 ft simply multiply 0 1 in W G by the ratio of the actual duct length in feet over 100 ft for the approximate pressure drop Use the suppliers catalog for proper sizing of outlet air registers and return air grills to insure that they provide the required flowrate at the desired pressure drop 21 installations and services must be performed by qua
52. eadings of up to 14 or 2 but it is better to have a slightly lower CO or higher O2 reading with zero smoke measured To achieve a lower CO reading open the air band or shutter on the burner until zero smoke is measured For example if a 13 CO or 3 5 O is recorded at a trace of smoke open the air shutter until zero smoke is measured with a 12 CO or 4 596 O Adjustment of the burner to achieve a slightly lower CO reading is recommended although it slightly reduces combustion efficiency to keep the heating system within normal operating conditions though external conditions may vary Some out of spec conditions which may adversely affect burner performance are low oil supply temperature dirty contaminated oil low heating content BTU gal oil cold heat exchanger surfaces and downdraft conditions By adjusting the burner in this manner an operational tolerance is established allowing the burner to function well even under less than ideal conditions This results in less service and maintenance during a heating season FLUE GAS TEMPERATURE The flue gas temperature will vary to some extent depending on the heat input rate duct design and the amount of air flow across the heat exchanger The suggested minimum net flue gas temperature 15 3509 F and the maximum gross flue gas temperature is 550 F The lower the flue gas temperature the higher the heating efficiency However stack temperatures und
53. ents Remove the clean out covers Also remove the burner compartment cover the burner and the burner mounting plate When removing the clean out covers special care must be taken not to damage the gaskets Should any of the gaskets separate show evidence of cracks or breaks or otherwise be unable to provide the necessary seal the gasket must be replaced before reattaching the clean out covers refer to Figure 10 49 installations and services must be performed by qualified service personnel With access to the inside of the heat exchanger through the burner area cleanout openings and vent terminal connection it is now possible to use a long flexible wire brush and an industrial type vacuum cleaner to remove any soot build up NOTICE A one inch outside diameter vacuum cleaner hose will fit into the radiator To vacuum and brush the horizontal drum of the heat exchanger enter the drum through the clean out openings in both directions 2 Heat Exchanger Reassembly After the heat exchanger has been cleaned install the heat exchanger and reassemble the components to their factory produced state in reverse order of disassembly and removal refer to figures 9 and 10 Remount the burner being certain that the air tube is properly inserted into the chamber opening If heavy soot deposits were found in the heat exchanger this indicates that the burner may be out of adjustment Reset the burner as indicated under the Initial
54. er 5 Measures should be taken to prevent the entry of corrosive chemicals or vapors to the combustion and ventilation air supply Such chemicals include but are not limited to chlorinated and or fluorinated hydrocarbons These substances are found in refrigerants aerosol propellants dry cleaning fluids degreasers and removers Other harmful compounds may come from acids salts bleaches air fresheners cements and glues Do not store or use these chemicals for long periods of time in close proximity to this appliance Vapors from such products can form corrosive compounds when burned in a flame These compounds promote rapid corrosion of the burner combustion chamber heat exchanger and the vent terminal Rapid or excessive corrosion will significantly reduce the useful life of the appliance 6 Refer to the following section Venting of Combustion Products for additional installation location restrictions C Venting of Combustion Products ACAUTION This appliance is designed to directly vent combustion products into the atmosphere through and using only the supplied vent terminal Do not attempt to attach a vent connector or a vent system to or in place of the supplied vent terminal The appliance should be instaled in a location such that heavy snow accumulation will not excessively restrict the flow of flue combustion products from the unit The vent terminal should not be located in a position where ice buildup could
55. er 3509 F may result in condensation of water vapor in the flue gases which in turn promotes corrosion of the heat exchanger TEMPERATURE RISE Temperature rise is equal to the supply air temperature minus return air temperature Under steady state operating conditions the temperature rise across the heating section should be approximately 650 A higher temperature rise will slightly lower the heating efficiency A lower temperature rise will slightly raise efficiency but may cause condensation 36 installations and services must be performed by qualified service personnel The supply air temperature should be measured in the supply air trunkline approximately 12 inches downstream of the supply air outlet of the appliance NOTICE Minimum temperature rise is 50 F maximum temperature rise is 800 l After final adjustments are completed tighten all screws to fix the positions of the burner air band m Check for the presence of oil leaks Correct any oil leaks found n Reassemble the burner compartment cover o Start and stop the unit several times while checking for proper ignition of the burner The flame should ignite and stabilize without any significant rumbles or pulsations 3 Adjustment Of Heat Input Rate This appliance was shipped from the factory with one fixed main burner nozzle sized to produce the low fire input rate using no 2 fuel oil at the pump pressure shown on the rating label The input rat
56. erate with a subcooling of between 5 and 15 F 6 Recommendations for Operation at Low Temperatures If the cooling system will be operated with outdoor ambient air temperatures below 65 F Thermo Pride strongly recommends the following modifications be made to the system to aid in promoting the longevity and durability of the compressor 1 To help evaporate any liquid refrigerant that accumulates in the compressor a crankcase heater should be installed in the compressor 2 A low temperature 45 F minimum ambient control contact should be added to the 24 volt leg of the control circuit to the contactor coil This contact should act to shutdown the cooling system in the event that outdoor temperatures drop below 45 F 3 To assist the system in temporarily storing unneeded refrigerant charge a suction line accumulator should be installed in the system 4 Test and confirm the compressor is receiving superheated vapor under the coldest of expected operating conditions Adjust the superheat if required These items will assist in preventing liquid floodback flooded starts and refrigerant migration to the compressor during off cycle These situations are detrimental to the service life of the compressor 45 installations and services must be performed by qualified service personnel V INSTALLER S INSTRUCTIONS TO USER After completing the installation the installer shall inform and or demonstrate to the homeowner
57. es Celsius contained in raceway at 30 degrees Celsius For other wire insulation temperature ratings and ambient conditions refer to the National Electrical Code for the minimum wire sizing requirements NOTICE Before the unit is started the installer and or electrician must check the following items 1 Check every electrical connection of push on or screw on type terminals to ensure that all wires and wire connectors are firmly secured A loose terminal can cause poor flow of electrical power to motors and to the refrigeration compressor This may result in very high current draws by these components If great enough high current draw will cause blown fuses burned wires and contactor points and pre mature motor or compressor failure Each electrical connection has been factory checked however connections may loosen due to vibration while the appliance is in transit Please be certain that all electrical connections remain tight 2 Review wiring diagram for proper routing and connection of all field wiring 25 installations and services must be performed by qualified service personnel 3 All wiring sizes must comply with local codes or the National Electrical Code To minimize voltage drop to the appliance the next larger size wire should be used when long wiring runs in excess of 100 ft are employed Refer to the wiring diagrams when wiring or servicing NOTICE Proper operation of the heating section of this uni
58. es for the airflow through each register and grill Select values for the pressure drops of both the supply and return air systems Each branch of the supply or the return air system will have this pressure drop The total pressure drop of the supply and return air systems added together cannot exceed the maximum external static pressure that can be supplied by the appliance blower Determine the required flowrate for each branch of the supply and return air systems The total air flowrate by adding the air flowrate of each branch of the supply system must equal the minimum required air flowrate refer to part 3 above Likewise the air flowrate of each of the branches of the return air system must sum to the required minimum flowrate Using the selected air flowrates for each component of the duct system and manufacturer s literature or published literature on duct system pressure drops the pressure drop for each component in the duct system can be estimated Chapter 32 of the ASHRAE Handbook Fundamentals is an excellent source of duct system design principles and pressure drop data Conversely for a specified type of fitting it is also possible to determine the required size or diameter of the component for a specified pressure drop and flowrate 20 installations and services must be performed by qualified service personnel h The resistance of the take off and the outlet register or return grill should then b
59. esirable Since most residential cooling systems including Thermo Pride evaporators do not provide a test port sometimes referred to as a Schraeder port at the evaporator the suction pressure must be read at the suction inlet to the compressor Typically it would be necessary to compensate for the pressure drop through the line connecting the evaporator and the compressor However due to the close proximity of these components the pressure drop will be small and can be neglected A good resistive type thermometer or thermocouple based sensor should be used to measure the suction line temperature exiting the evaporator On evaporators using thermal expansion valves read the temperature directly under the expansion bulb located on the side of the suction line exiting the evaporator Measure refrigerant temperature at the 2 00 or 10 00 positions on the outer surface of the evaporator suction tube Wrap the thermometer or thermocouple with a rag or insulation to insure system airflow does not influence the temperature readings 43 installations and services must be performed by qualified service personnel Refer to Example 3 in Appendix B Calculations of this manual for a sample calculation of how to figure the degree of superheat for the evaporator In general Thermo Pride recommends an operating evaporator superheat of between 5 and 12 F 4 Definition of Subcooling Subcooling is extra heat removed from refrigerant below
60. fuel oil heating value Also fouling of the heat exchanger surfaces will reduce temperature rise In general a lower temperature rise through the heating section will result in higher heating efficiency Temperature rise supply air temperature return air temperature 38 installations and services must be performed by qualified service personnel After 15 to 20 minutes of continuous operation the temperature rise through the furnace must fall within a range of 50 to 80 F If the outlet or supply duct temperature is too high check to make sure the return air filter is clean the return air registers are free from obstruction the outlet registers are properly adjusted and clear and the supply and return air ducts are open The circulating air blower is not moving enough air if the supply air temperature is still too high Before proceeding further turn off the power supply to the appliance and remove the blower access door The speed of the blower must be increased by changing from a lower motor speed tap to a higher speed tap refer to Figure 10 5 Checkout Procedure Before any system of oil piping is finally put into service it shall be carefully tested to assure that it is gas tight as indicated in the Heating System Initial Startup section of this manual NOTICE controls on the unit should be checked for proper functioning prior to the qualified service personnel leaving the job site Specifically th
61. g mode on the thermostat to HEATING and turn the thermostat temperature setting up Figure 14 Location of Reset Buttons on the Burner Primary Control and the Burner Motor If this action does not reactivate the unit contact a qualified service agency for assistance In general if the thermostat is set in the heating mode the heating system functions entirely automatically However under certain circumstances the appliance may not be able to fire the burner For instance if the manual oil shutoff valve has been closed or the oil tank is out of fuel the oil line may have air trapped in it It will be necessary to purge the air by bleeding the supply line from the tank to the burner again for the heating system to operate Refer to the instructions under the Extended Appliance Shutdown section of this manual NOTICE Thermo Products recommends that the user homeowner contact a qualified service agency for assistance in bleeding the fuel line s and lighting off the heating section 56 installations and services must be performed by qualified service personnel The following maintenance points should be reviewed periodically to assure the heating and cooling systems continue to function properly ANWARNING Shut off unit and disconnect the power source before disassembling the unit ANARNING Never operate the appliance without clean air filters in place ACAUTION This appliance requires air for combustion ventilation
62. gle strand insulated thermostat wire around the prongs of an ammeter refer to Figure 6 Set the scale to the 1 to 5 or 1 to 6 amp scale TYPICAL SUB BASE RorRH W 10 LOOPS PASSING THROUGH CENTER OF AMP METER PRONGS Figure 6 Analog Ammeter w Wire Loops to Boost Reading Connect the bare ends of this wire jumper across terminals and W on the sub base RH and W on an isolating thermostat sub base This test must be performed without the thermostat attached to the sub base iii Let the heating system operate in this position for about one minute Read the amp meter scale Regardless of the value of the meter reading divide the value by 10 for 10 loops of wire This formula can be used to calculate the correct setting for the adjustable heat anticipator Ammeter reading Anticipator Setting No of wire loops 29 installations and services must be performed by qualified service personnel Or in this case 25A 0 25A Anticipator Setting 10 iv Adjust the position of the anticipator indicator to match the calculated ammeter setting If a slightly longer cycle is desired the pointer should be moved to a higher setting Slightly shorter cycles can be achieved by moving to a lower setting v Remove the meter jumper wire and reconnect the thermostat Check the thermostat in the heating mode for proper operation If a digital ammeter is used read the current draw directly f
63. h or above the burner thus permitting gravity flow of oil to the burner If the tank is above the burner and gravity oil feed to the burner is permitted a single line system may be used The line should have a gradual slope downward of approximately 1 2 inch per foot or more from the tank to a point directly below where it is connected to the pump Pitching the line upward toward the tank will help prevent the formation of air pockets in the line NOTICE An oil safety valve or a delayed action solenoid valve should be installed in the oil supply line of all gravity fed systems When the oil tank is located below the level of the burner it is necessary to lift the oil to the burner A return line should be connected between the fuel pump 16 installations and services must be performed by qualified service personnel and tank This requires insertion of the by pass plug into the fuel pump If the lift vertical distance between the supply line inlet and the burner exceeds approximately 10 feet a two stage pump should be installed with a return line When a return line is used with either single or two stage pumps in line air is automatically returned to the tank making the oil pump and lines self purging Underground tanks should be located outside the building Installation of above ground tanks is permitted inside buildings under certain conditions as well as outside Consult the Standard for Installation of Oil Burning Eq
64. he heating capacity of the unit proposed for installation should meet or slightly exceed the rate of heat loss for the residence Oversizing should not exceed 125 of the heat loss calculation When installed this unit should be level If possible it should be installed in a central location with respect to outlet registers of the supply air ductwork Definitions of combustible and non combustible materials as presented in the 1996 version of the National Fuel Gas Code ANSI Z223 1 1996 NFPA 70 1996 are as follows a Combustible material materials made of surfaced with wood compressed paper plant fibers or other materials that are capable of being ignited and burned Such materials shall be considered combustible even though flameproofed fire retardant treated or plastered b Non combustible material material that is not capable of being ignited and burned such as material consisting entirely of or a combination of steel iron brick concrete slate asbestos glass and plaster 10 installations and services must be performed by qualified service personnel 5 Table 1 lists the required minimum clearances to combustible surfaces from the outer surfaces of the appliance Table 1 Minimum Clearances to Combustible Materials Model Top Side Rear Front Bottom Vent Terminal No in in in in in in 3 The minimum clearances listed
65. id and suction line pressures 2 105 0 If the suction pressure is low add charge to see if the pressure comes up to the specified value on the appliance rating label 2 106 0 Check line voltage to the compressor to see if it is excessively high or low 2 107 0 A defective run capacitor can also cause the compressor to overheat Check out the run capacitor 2 108 0 The compressor may be drawing excessive current due to an internal defect such as severely worn or damaged bearings 2 109 0 Possible causes of a high superheat 15 deg F or higher could be a faulty expansion valve or an extremely low charge 3 101 0 A low suction pressure that could indicate the system is low on refrigerant charge However first review the following items 84 installations and services must be performed by qualified service personnel 3 101 1 Dirty air filters may restrict the airflow across the evaporator coil resulting in frost on the coil 3 101 2 Are the duct system and air blower setup to move enough air to have an 18 20 degree F drop across the coil 3 101 3 Are there any registers or dampers closed restricting the airflow of the duct system 3 101 4 If the evaporator coil frosts this indicates a low charge or insufficient air movement 3 101 5 The coil may not frost up but still not cool properly Is the system slightly low on refrigerant Check for an 18 F temperature drop across the coil 3 101 6 Make sure the liquid line has
66. ield connections when the appliance operating Use an ammeter or a multimeter to check the current draws of the blower motor burner assembly and air conditioning compressor to assure they are not exceeding rating label current specifications for each component Also refer to Table 5 for electrical specifications on these components Check for correct operation and proper settings if manually adjustable of all controls 51 installations and services must be performed by qualified service personnel D Supply Return Air Blower Check in the blower compartment for dust dirt debris and for the presence of insects Remove any foreign material Clean the blower wheel housing and compartment of dust and lint with a vacuum The blower motor has sealed bearings that are permanently lubricated The blower motor bearings do not require oil or any type of additional lubrication E Supply Return Air Filter A permanent type air filter is provided in the return section of this unit This filter should be inspected regularly When the filter is dirty it should be cleaned or replaced to assure proper heating cooling system operation Follow the cleaning removal and replacement procedure below 1 Filter maintenance procedure The filter rack is located behind an access panel on the left hand side of the unit refer to Figure 12 Shut off the electrical power to the unit Remove the screws retaining the access panel to the
67. ime the pump to remove air in the oil supply line When ignition is established make preliminary burner air adjustment to attain a clean combustion flame Generally the burner bulk air band should be about 3 16 inch open and the opening of the burner air shutter set in the range of 2 to 7 refer to Figure 8 Figure 8 Preliminary Adjustment of Burner Air Band and Air Shutter Replace the inspection cover above the burner After the appliance is warmed up to a steady state condition about 15 minutes the final burner adjustment should be made using combustion instrumentation for smoke carbon dioxide CO or excess oxygen and flue gas temperature In order to achieve the most efficient combustion the following steps must be taken SMOKE A smoke sample should be drawn from the heat exchanger flue passageway which is covered by the vent terminal Remove a large machine screw from the front face of the vent terminal for direct access to the flue through the opening If the first smoke reading is zero 0 close the air band or shutter on the burner until a trace smoke reading is measured 35 installations and services must be performed by qualified service personnel NOTICE To achieve proper combustion and the efficiencies listed in sales brochures instruments must be used to secure CO O readings CARBON DIOXIDE CO OR OXYGEN 0 Take CO sample from flue passageway It is possible to achieve r
68. in Table 1 are for fire protection purposes only Adequate operational and service clearances must be maintained under all circumstances minimum of 36 inches clearance around the condenser coil should be maintained for adequate airflow to the unit Any overhanging material or construction must not block from above the condenser fan and the vent terminal The suggested minimum clearances for servicing the front of the unit and to all points requiring access are at least 24 inches Notice Access panels for the return air filter and the blower motor are located on the rear left hand and right hand sides of the unit respectively 6 Install this unit outdoors only 7T This appliance is approved for use as a forced air furnace with cooling unit 8 This appliance has been designed for use with no 2 distillate fuel domestic heating oil B Selection of Installation Location 1 The unit should not be placed in a position where it is directly exposed to sunlight during the majority of the day Inside corners on the southeast and southwest sides of the structure should be avoided Heat build up due to solar radiation in such corners would place an increased cooling load on the unit Shaded areas on the north side of the structure are preferred 2 The unit must be located on a level dry surface in an area which is free and protected from excessive drafts or wind Mount the unit on a sturdy base at least one inch above the ground or roof s
69. ingly on all male pipe threads Always consult and conform to the requirements of local plumbing codes E Oil Tank and Piping A WARNING All local codes and ordinances take precedence with regard to selection and installation of oil storage tank and oil supply and return lines In the absence of local codes all tanks and lines must be selected and installed according to the instructions in this manual and the Standard for the Installation of Oil Burning Equipment NFPA 31 1997 or the latest edition 1 The use of black steel pipe and malleable iron fittings is recommended for all fuel oil service lines Never use galvanized steel piping or fittings for any fuel oil lines Where practical provide rigid supports for the piping If the piping size in a run must be reduced use reducing couplings only Avoid the use of reducing bushings Remove all pipe thread burrs and inspect the pipe for dirt or other foreign material prior to connecting If present remove any deposits in the piping and discard any excessively corroded piping 15 installations and services must be performed by qualified service personnel 5 10 11 A readily accessible design certified manual oil shutoff valve with non displaceable rotor member shall be installed in the fuel oil supply piping within 6 feet of the appliance A pipe union or flanged connection shall be provided downstream from the manual oil shutoff valve to permi
70. into the building And 3 feet or more above any forced air inlet to the building located within 10 feet of the terminal Once the unit is installed in a suitable location the installer must mount the vent terminal to the appliance Two sheet metal screws are installed in the unit for this purpose Refer to Figure 2 for a sketch of the correctly assembled vent terminal FIGURE 2 Vent Terminal Mounting Position D Condensate Drain This appliance is equipped with a inch female NPT coupling for connection of a condensate line to the evaporator drain pan A condensate removal line should be fabricated and attached to the coupling refer to Figure 3 The condensate drain line must be pitched downward to drain properly The drain line can also be trapped and the condensate pumped to a suitable drain If the drain line clogs when the air conditioner is operating the condensate tray under the evaporator coil will fill with water As a result water may enter the appliance housing and the supply air ductwork to the structure 14 installations and services must be performed by qualified service personnel PUT Figure 3 Installation of a Condensate Drainage Line on the Evaporator Coil Condensate from the evaporator is non corrosive and may be disposed of in any appropriate manner The drain connection should be sealed at the appliance housing to prevent air leakage from the supply air system Pipe sealant should be used spar
71. is started when it contains liquid refrigerant the lubricating oil in the crankcase will be diluted Bearing damage may result under these conditions In addition if the compressor attempts to squeeze the liquid refrigerant serious and permanent mechanical damage to the compressor can result The appliance is equipped with gauge ports to connect both liquid and suction line pressure gauges These ports are located near the base of the unit inside the burner compartment Refrigerant hoses must be the types that incorporate a finger to depress the valve core Connections may be made to these ports at any time even while unit is in operation Follow EPA guidelines in connecting service equipment to refrigerant lines For example using quick connects and short service hoses is recommended to minimize refrigerant losses Line pressures on an operating air conditioning unit will vary with outdoor temperatures As outdoor temperatures rise pressures will also rise Refer to a 41 installations and services must be performed by qualified service personnel pressure temperature chart on the unit for approximate system line pressures at various temperatures The suction pressure is the most significant pressure reading If a unit is suspected of having a low refrigerant charge the unit should be recharged using the suction pressure as a guide The unit is fully charged when proper suction pressure is obtained Any additional refrigerant may
72. lified service personnel Table 3 Suggested Duct Sizes for Homes Quiet Offices Or Similar Installations Based on a 0 1 in W G static pressure drop per 100 ft of duct 7 The supply and return air ducts or flexible joints should be carefully secured and sealed to the appliance housing to prevent air leakage from or into the duct system For best performance insulate the outside surfaces of the ducts to reduce heat loss from or heat gain to the ducts The insulation system should be carefully selected and installed to minimize water and moisture absorption by the insulation 22 installations and services must be performed by qualified service personnel 8 As a final step in the installation the appliance must be adjusted to deliver a temperature rise within the range of 50 to 80 F Adjust the blower motor speed to obtain a temperature rise within the acceptable range The required blower speed will depend on the airflow resistance of a supply and return air duct systems 1 Filters 1 Filter Installation This OPA unit has been factory supplied with a high quality re usable filter rated for air velocities up to 600 ft min 2 Use of non Thermo Pride Filters or Retention Means ACAUTION Failure to comply with minimum filter installation requirements may affect the performance and or void the warranty on this unit If a method other than Thermo Pride filter racks is selected for retention of the filter and
73. ly or manual shutoff valve 2 Disconnect all electrical power to the unit 3 Fill the oil tank to reduce water condensation in the tank 4 f the shutdown period will exceed one heating season an oil stabilizer should be added to the oil tank Consult your oil supplier for recommendations ON STARTUP 1 Have system inspected and started by a qualified heating contractor 2 Check oil level in tank If the tank has not been filled with fresh oil inspect the remaining oil for signs of contamination with water algae dirt or other impurities If excessive consult your oil supplier for recommendations 3 Change the oil filter cartridge and clean the canister 4 Set the room thermostat above room temperature 5 Open all valves in the oil supply line 53 installations and services must be performed by qualified service personnel 6 Open the inspection cover on the upper mounting plate 7 Turn on the electrical power to start the burner If the burner does not start immediately reset the manual overload switch on the motor if so equipped and the safety switch of the burner primary control Bleed air from the fuel oil line as soon as the burner motor starts rotating To bleed the fuel pump attach a clear plastic hose over the vent plug refer to Figure 13 Loosen the plug and catch the expelled oil in an empty container Tighten the plug when all the trapped air appears to be purged If the burner stops during bleedi
74. may be used CAD CELL CHECKOUT PROCEDURE 1 Stop burner and shutoff electrical power to the appliance 2 Open burner junction box on top of the burner blower and remove the plug in portion of the cad cell by pulling it forward from and clear of the receptacle Connect an ohmmeter across cad cell pins With the cell exposed to direct room light the measured resistance should be less than 2500 ohms in fact it may be less than 200 ohms 3 Check the resistance across the cad cell pins with the cell covered protected from exposure to ambient light The resistance should be greater than 20 000 ohms 4 If cell resistances are different from above replace the plug in portion of cell Honeywell Part No 130367 5 Carefully reinsert the plug in portion of the cad cell into the receptacle If the cad cell appears to be functioning correctly troubleshoot the fan control module and the safety and ignition control primary control module according to the Honeywell instructions covering the devices B Cooling System NOTICE Before troubleshooting familiarize yourself with the Initial Startup and the Cooling System Troubleshooting Flowchart If the air conditioning system will not operate check the following points before calling a qualified heating contractor 60 installations and services must be performed by qualified service personnel 1 Is the disconnect switch or the circuit breaker serving the appliance swit
75. mediately call a qualified service technician to inspect the furnace and to replace any part of the control system and any gas control that has been under water ACAUTION The area around the appliance including the top of the unit must be kept clear and free of combustible materials gasoline and other flammable vapors and liquids ACAUTION The appliance vent terminal may be hot If the terminal is hot allow it to cool before touching it ANWARNING Shut off unit and disconnect the power source before disassembling the unit A WARNING Never operate the appliance without clean air filters in place ACAUTION This appliance requires air for combustion ventilation and cooling Do not block or obstruct air openings in the unit and the air space around the perimeter of the unit A WARNING All local codes and ordinances take precedence with regard to selection and installation of oil storage tank and oil supply and return lines In the absence of local codes all tanks and lines must be selected and installed according to the instructions in this manual and the Standard for the Installation of Oil Burning Equipment NFPA 31 1997 or the latest edition ANWARNING Turn off power to furnace Before the oil piping system is placed into service it must have been leak tested by a qualified heating contractor installations and services must be performed by qualified service personnel AWARNING For initial start up of the applian
76. mp Oil Flowrate Heat Input Heat Output Burner Modell Air Tube Nezsig Mode Pressure Nozzle Rate PSIG GPH BTUH Number Combination Type High Fire 105 000 85 000 Simplex 80 AFG TP1501 AF35 BOSS deg hollow Based on Z2 fuel domestic heating oil having higher heating value of 140 000 BTU per gallon Based on an assumed steady state thermal efficiency of 80 For more specific burner information consult the Model AFG Oil Burner Instruction Manual or contact Thermo Products LLC P O Box 217 North Judson IN 46366 Phone no 574 896 2133 18 installations and services must be performed by qualified service personnel H Airflow Requirements and Sizing of Duct Work The duct system must be sized and installed by a qualified installer or service person following the design standards of the Air Conditioning Contractors of America ACCA or the American Society of Heating Refrigeration and Air Conditioning Engineers ASHRAE This furnace has been designed to operate against a maximum external static pressure of 0 4 in W G This is equivalent to 2 in W G supply and 2 in W G return pressure drops 1 Supply and return air ducts have to be furnished by the installer and run between the appliance which must be installed outdoors and the interior of the structure the appliance serves These ducts must be sealed to the casing of the appliance To reduce the transmission of vibration and
77. nch 90 degree elbow the pressure drop is _ 0 00123174 6 37 9 120 4 86 7 0 0257 in W G AF Likewise the pressure drops for the two remaining segments in this branch can be calculated in the same manner They are AP 0 0129 in W G and 0 00702 in W G Referring to section f and g of the method it is now necessary to resize each of these duct segments for the actual required flowrate while maintaining the pressure drops calculated above For instance to maintain the pressure drop through segment B at the design flowrate of 120 CFM 115 CFM 235 CFM the required duct diameter is 182 0 2058 For segment C the design flowrate is 235 115 350 while the pressure drop is 0 0257 in W G then required duct diameter is pt 350 D 10 2058 11 lin 11in 0 00257 Including an 11 in 90 degree elbow in segment the required diameter would be 11 4 D 0 00123174 6 59 6 350 0 2058 0 00257 or approximately the same as without the elbow For the segments F and at 742 and 798 respectively the required duct diameters are D 13 9 in 14 in and 2143 in 14 in 69 installations and services must be performed by qualified service personnel Next the branch of the system which includes segments D and E can be evaluated To b
78. nd the indoor thermostat and if used electronic air cleaner or humidifier will be required Field wiring of control circuits should consist of copper conductors rated for at least 240 VAC with an insulation temperature rating conforming to Type T wire 35 C temperature rise Depending upon code requirements rigid or flexible conduit is recommended and may be required Make connections between the thermostat and electronic air cleaner or humidifier if used and the fan control module inside the burner compartment Consult the wiring diagram for the appropriate connection points on the thermostat and the fan control module Table 5 Typical Electrical Requirements for Various OPA Models Maximum Compressor Compressor Condenser Oil Burner Recommended Minimum Supply Return Time Dela Running Locked Fan Full Assembly y Potential Frequency Air Blower Full Type Fuse Load Rotor Load Full Load Type Fuse or 75 deg No of Phases Load Current or Inverse V Hz Ph Current Current Current Amps Q 115 Current Time Circuit Inverse Time Copper Power Amps Amps Amps Amps Circuit Breaker Wiring Size Amps Amps Amps VAC Amps Breaker Size 9 200 VAC 200VAC 200 VAC 115 VAC Anos Size Amps 93 OPA3D OPA36 208 240 60 1 m mm Wire size selections in Table 5 are based upon Table 310 16 of the National Electrical Code for three copper conductors with insulation rated for 75 degre
79. ne connection is measured as 95 F What is the degree of subcooling for this system Solution Calculate the pressure of the refrigerant at the evaporator liquid line connection With the estimated refrigerant pressure and measured temperature at the same point tabulated data on R22 from the refrigerant manufacturer or ASHRAE can be used to evaluate the degree of subcooling 210 PSIG Liquid line pressure measured at condenser 0 PSIG Added for pressure drop of liquid line 210 PSIG Estimated pressure of refrigerant at evaporator inlet From the R22 pressure temperature chart at 210 PSIG 224 7 PSIA the saturation temperature is approximately 105 F Now the degree of subcooling can be calculated 105 F Saturation temperature for R22 at 210 PSIG 95 F Suction line temperature at outlet of evaporator 10 F Degree of evaporator subcooling 73 installations and services must be performed by qualified service personnel Reprinted by permission from ASHRAE Guide and Data Book 1967 500 A V DCN ACE NN e AC M ANAL vr FOR AAA AA NX NUUAM ANA A DK FAC OX BN WAN LX LIN VAT NEN QUON oh ini MW AT AWOL TA NACA AN Tu Ol 02 03 04 06
80. ng wait three to five minutes for the control safety switch to cool Then manually reset the switch Continue bleeding the line until the air is completely removed gt QA NAN Figure 13 Location of Oil Pump Vent Plug 8 Follow the previous Initial Burner Operation procedures 54 installations and services must be performed by qualified service personnel HOMEOWNER USER INFORMATION AND ROUTINE MAINTENANCE AWARNING Never burn garbage or refuse in this appliance Never try to ignite oil by tossing burning papers or other material into the combustion chamber AWARNING Oil fired appliances produced by Thermo Products are designed for burning No 2 distillate domestic heating fuel oil Never use gasoline or a mixture of oil and gasoline ACAUTION Do not use this appliance if any part has been under water Immediately call a qualified service technician to inspect the furnace and to replace any part of the control system and any oil control that has been under water ACAUTION Should overheating occur or the oil supply fail to shut off shut off the electrical power to the appliance before shutting off the manual oil valve ACAUTION The area around the appliance including the top of the unit must be kept clear and free of combustible materials gasoline and other flammable vapors and liquids IACAUTION The appliance vent terminal may be hot If the terminal is hot allow it to cool before touching it IACAU
81. noise to the duct system and to reduce flexure of the duct system due to thermal expansion and contraction it is recommended that flexible joints be installed at the supply and return duct connections to the unit The return air duct system must equal the supply air duct system in the flow capacity CFM for a given pressure drop Use a supplier s catalog for proper sizing of outlet and return air registers and grills to ensure that they meet the flow requirements of the run to which they are connected The duct system shall be sized to provide the maximum air flowrate CFM required of the installation Two common rules for determining minimum airflow in heating and cooling systems follow a For heating 14 CFM of airflow are required per 1000 BTU hr of heat output based on steady state operation and a 50 to 80 temperature rise b For cooling 400 CFM of airflow are required per ton of air conditioning For reference ton of A C 12 000 BTU hr removed from the space Refer to Example 1 in Appendix B Calculations of this manual for a sample calculation of how to determine the required minimum air flowrate Duct sizing is based upon both air velocity and pressure drop considerations When possible current practice favors designing ductwork for lower air velocities For residences a maximum air velocity of 800 FPM is suggested This results in quieter duct systems systems which require less fan power reduced operating costs
82. not kinked or collapsed slightly causing a restriction 3 101 7 Hold bulb in hand to see if the pressure changes this action should increase the suction pressure 3 101 8 Check out the supply return air blower to make sure it is functioning properly and not shutting down on thermal overload due to high motor temperatures 3 201 0 Check the following items for high suction pressure and low liquid pressure Allow at least 5 minutes off time for valve to close when pressures have equalized if compressor has internal pressure relief valve 3 201 1 There may be a restriction in the condenser coil This could be caused by water or other contaminants in the system A restriction in the coil is a very rare problem 3 201 2 Check the expansion valve for restriction of the metering orifice 3 301 0 For high suction pressure and low superheat temperatures review the following items 3 301 1 If the system is overcharged with refrigerant the system will become flooded Consequently the evaporator coil will not effectively absorb heat from the airflow The temperature drop across the evaporator coil will be low 3 301 2 Check for a properly sized expansion valve 85 installations and services must be performed by qualified service personnel XV APPENDIX F SPECIFICATION SHEETS Model Heating Performance using 2 fuel oil Input rate BTUH Maximum Minimum Heating capacity BTUH Maximum Minimum Design temp ri
83. o the control transformer Check control fuse for 115 VAC supply Check to see if the thermostat is closing to complete the 24 VAC circuit Remove thermostat and jump terminals R Y and R G If jumping the sub base works replace thermostat If the contactor is reading 24 VAC on the coil but is not pulling in the contactor replace the contactor Check the entire 24 VAC circuit between the thermostat fan control and contactor for loose connections and wires pulled away from terminations or terminals These conditions can cause an open circuit Check for 24 VAC across the refrigerant high pressure switch If 24 VAC is present reset the red button on the switch and recheck for 24 VAC If the contactor is closed and line voltage is measured across lines L1 and L2 but the unit does not run proceed with the following checks Check 240 volt wire leads to the capacitors and the compressor Make sure the terminals on the compressor and capacitors are not touching or loose Check for continuity across the three terminals of the compressor If continuity is not measured the compressor windings are opened Check for grounded compressor windings by checking continuity to ground The compressor may be tapped with a rubber mallet or piece of wood to jar the compressor loose Allow the compressor to cool below 130 F Check for continuity between terminals S and C on the compressor If you do not have continuity the thermal protector may re
84. porator If the sight glass shows all liquid flow without bubbles this is a good indication that the amount of subcooling is adequate 5 Condenser Subcooling Before taking subcooling measurements allow the system to stabilize through continuous operation for at least 15 minutes To determine subcooling measure the refrigerant pressure at the liquid line as it leaves the condenser is preferable to measure pressure of the liquid line at the evaporator but most manufacturers including Thermo Pride do not include test ports or Schraeder valves at the evaporator Typically it would be necessary to compensate for the pressure drop through the line connecting the condenser and the expansion valve However due to the close proximity of these components the pressure drop will be small and can be neglected 44 installations and services must be performed by qualified service personnel Once the liquid line pressure is known the refrigerant temperature must be taken on the liquid line as it enters the evaporator Use a good resistive thermometer or thermocouple protected with a rag or insulation Subtract the measured temperature from the saturation temperature of the refrigerant The result is the degree of refrigerant subcooling Refer to Example 4 in Appendix B Calculations of this manual for a sample calculation of how to figure the degree of subcooling for the condenser In general Thermo Pride recommends the evaporator op
85. quire more time to cool down Check capacitance of the run capacitor 83 installations and services must be performed by qualified service personnel 2 101 0 Check to see if the condenser fan motor is excessively hot as to cause the thermal overload to function Possible causes for outdoor fan motor to kick off on overload are 1 Loose wire connections 2 Excessive current amp draw possibly due to low operating voltage 3 Bad motor bearings 4 Excessively dirty coil causing restricted airflow 5 Excessively hot air being pulled into unit 6 Stalled fan due to blockage of rotation 2 101 1 Make sure wire leads to the motor are making good connections loose connection can cause an excessive current draw and overheat the motor 2 101 2 Check for defective fan run capacitor Use an ohmmeter on highest resistance scale i e R X 100 000 scale or continuity Full needle deflection or no audible sound indicates the capacitor is open Replace the capacitor 2 101 3 Check for continuity of the motor windings as the motor itself may be damaged 2 102 0 Make sure the discharged hot air is not recirculating back through the coil fins 2 103 0 A slight restriction in the outdoor coil might cause an excessive head pressure that over time may cause the compressor to function on thermal overload Note Water in the system may cause restriction after a period of time 2 104 0 Check for refrigerant overcharge by excessive liqu
86. rect operation and maintenance of the appliance as explained in the Homeowner User Information and Routine Maintenance section of this manual 2 Inform the user of the hazards of flammable liquids and vapors and to remove such liquids and vapors from the vicinity of the appliance 3 Inform the user of all pertinent warnings and precautions concerning this appliance Ill GENERAL INSTALLATION AWARNING This unit is not to be used for temporary heating of buildings or structures under construction Construction dust may enter the appliance or the duct system and cause a fire hazard Certain chemicals used during construction when burned form corrosive condensate that can substantially reduce the life of the heating system heat exchanger With exception of the vent terminal this appliance is shipped completely assembled and internally wired All fuel oil and refrigerant piping refrigerant charge and electrical wiring have been factory installed and inspected At the time of installation the unit will require connection to electric power fuel oil supply condensate drain and supply and return air ductwork In addition the vent termination kit will need assembly In the event of a shortage of parts or damage refer to the Dealer Receiving and Freight Claim Procedure section of the Price Guide This unit uses a fan assisted combustion system consisting of a pressure atomizing oil burner and combustion air blower used to push the prod
87. rom meter Steps 1 through 3 are not required The meter reading is the correct anticipator setting 3 Blower Motor Speed Selection AWARNING Turn off the electrical power to the unit before attempting to change supply air blower speed wiring In order to obtain the required supply air flowrates in both the heating and cooling modes of operation it may be necessary to reset the blower motor speeds The blower motor is located behind an access panel along the right hand rear side of the unit To adjust fan speeds it is necessary to remove this panel and physically change the wiring connections at a terminal block mounted on the blower housing There are four blower speeds available high medium high medium low and low The terminal blocks will be marked with the symbols H ML L respectively to indicate these speeds refer to Figure 7 In addition the left most terminal block will be marked with the symbol for common A white wire should always be connected to terminal block marked C The black wire controls the blower speed during the cooling cycle The blue wire controls the blower speed during the heating cycle The black and blue wires may be connected to any of the four terminals Change the position of the wires on the terminal blocks to set the desired blower speed for each mode of operation Typically two of the blower speeds will not be used 30 installations and service
88. s and insects lodged between the fins Remove any foreign materials found using a vacuum cleaner with a brush attachment or a water spray from a garden hose Carefully straighten any bent fins with a thin piece of wood or a fin comb Labels and Markings Clean all appliance labels markings and instruction plates as necessary and verify that all are still legible Any illegible or missing markings must be replaced Replacements can be obtained by contacting Thermo Products B Heat Exchanger AWARNING A qualified heating contractor must clean the heat exchanger At least once a year inspect the heat exchanger for evidence of corrosion pitting warpage deterioration and carbon soot build up A layer of soot on the inside of the heat exchanger will act as an insulator and reduce heat transfer resulting in less heating efficiency Also look for loose or deteriorated gaskets and insulation around the flue pipe the burner and accessible areas of the heat exchanger If this inspection indicates heat exchanger cleaning is necessary follow the heat exchanger cleaning instructions below 1 Disassembly to Access Heat Exchanger To clean the heat exchanger first turn off all electrical power to the unit Next remove the cleanout access panel inside the burner compartment to gain entry to the cleanout covers refer to Figure 9 48 Figure 9 Heat Exchanger Clean out Ports and Related Compon
89. s must be performed by qualified service personnel Figure 7 Blower Motor Terminal Blocks amp Wiring 31 installations and services must be performed by qualified service personnel IV STARTUP PROCEDURES A Heating System 1 Initial Startup A WARNING Turn off power to furnace Before the oil piping system is placed into service it must have been leak tested by a qualified heating contractor A WARNING For initial start up of the appliance after installation it may be necessary to purge the air out of the oil line A qualified heating contractor should do this Review the following items before the initial startup It may be helpful to review the Sequence of Operations in Appendix D of this manual also a Check all wiring for loose connections and proper hook up Refer to the connection diagram b Leak test all field oil piping connections Generally this will involve pressurizing the oil piping with air while being careful to isolate the oil tank at high test pressures A qualified heating contractor should perform this service c Check to see that the vent terminal is correctly installed and the terminal openings are clear and free from blockage d Make sure the air filter is in place and relatively clean of dirt and debris e Make sure the thermostat is set in the heating mode of operation 32 installations and services must be performed by qualified service personnel For Your Safet
90. se deg F on LOW fan speed Burner nozzle amp oil pressure for max input rate Burner nozzle amp oil pressure for min input rate Cooling Performance Cooling capacity tons Fan speed SEER Refrigerant Factory refrigerant charge by weight in ounces Nominal Electrical Power Requirements 208 240V 60 Hz 1 Ph current Amps Min fuse or circuit breaker rating Amps Circulating Fan Motor amp Air Filter Blower wheel design and size Airflow 0 4 in W G external static pressure High speed SCFM Medium high speed SCFM Medium low speed SCFM Low speed SCFM Blower motor type amp frame Nominal blower motor output HP Blower motor full load current Amps Number of blower speeds Rotation speed on HIGH RPM Direction of rotation from shaft end Motor housing diameter in Motor housing length in Shaft diameter in Shaft length in Filter type Number and size of air filters in Dimensions amp Weight Height of housing in Width of housing in Depth of housing in Supply air outlet width in x height in Return air inlet width in x height in Approx shipping weight including packaging Ibs 86 OPA24 80 OPA30 80 OPA36 80 OPA42 80 105 000 85 000 85 000 68 000 65 0 75 GPH 130 PSIG 80 deg hollow cone type 0 60 GPH 120 PSIG 80 deg hollow cone type 3 5 Medium high High 12 HCFC 22 R 22 6
91. stallations and services must be performed by qualified service personnel This procedure can be repeated to determine the airflow for each room in the residence The results of these calculations are given in Table 6 below Table 6 Required Room Air Flowrates Based on Floor Area for Example 2 Flowrate per Register CFM Number of Registers 14 36 22 22 6 Master peat ee eee ee 1400 We will assume the airflow is approximately equally split between all registers in a particular room This completes steps a through d of the duct sizing method 4 0 4 4 4 4 For step e static pressure drops for each system branch and component must be selected Since the appliance circulating blower can only tolerate a maximum pressure of 0 4 in W G the combined resistance of the supply and return air systems cannot exceed this amount 66 installations and services must be performed by qualified service personnel Therefore choose a supply system static pressure drop of 0 2 in W G Then the return air system will also have a static pressure drop of 0 2 in W G Furthermore we will assume that the static pressure drops for all registers in the supply system will be 0 1 in W G This leaves a static pressure drop of only 0 1 in W G for all the ducting between the outlet flange of the appliance to each of the registers We will assume that the pressure drop through any short piece of ductwork connecting
92. t depends upon correctly connecting the electrical power source The hot leg L1 of the supply circuit must be connected to the black line lead and the neutral leg N to the white line lead in the burner compartment junction box All ungrounded circuit conductors must be broken by the disconnecting switch to prevent the hazard of electrical shock when servicing this appliance In the event a circuit breaker trips or a fuse blows as a result of the operation of this appliance investigate the appliance electrical system to determine the cause Correct any electrical faults and abnormal conditions before putting the unit back into operation Do not put in a larger fuse and do not exceed maximum fuse size listed on the rating label in order to temporarily fix the problem The rating label is located on the inside of the burner compartment cover The appliance control system contains a 15 amp time delay type fuse to protect the heating system control circuitry The control fuse is located within the junction box which is located in the burner compartment In the event the fuse blows replace the fuse with one of equivalent type and rating 1 Electronic Air Cleaner EAC and Humidifier Installation The standard control system for the appliance does not have the ability to directly control the operation of an electronic air cleaner or a humidifier If these devices are used a means to initiate and discontinue their operation must be provided ex
93. t removal of the appliance oil pump Pipe unions must be the ground joint type or flanged jointed using a gasket resistant to the corrosive action of fuel oils Pipe dope or thread sealant design certified to be resistant to the action of fuel oils should be used on all threaded joints Thread sealant should only be applied to the male member of a joint The first two threads on the end of the male member of each pipe joint should be clean and free from thread sealant Connection of the oil supply piping to the appliance should be made from the left hand side of the burner facing the burner compartment cover When tubing is to be used for fuel oil supply lines use of continuous runs of heavy wall copper tubing is recommended Avoid running tubing against any type of heating unit and across ceiling or floor joists If possible install the tubing under the floor Where tubing is used for fuel oil supply lines insure the tubing contains no kinks sharp bends or collapsed regions where the inside cross sectional area of the tube is greatly reduced These will excessively reduce the flow of oil Flared fittings should be used at all tube joints when tubing is used for fuel supply lines Do not use compression fittings Avoid the use of tube fittings in inaccessible locations Burners are equipped with a single stage fuel pump This type of fuel pump when connected with a supply line only is satisfactory where the fuel supply is level wit
94. ternal to the accessory if such means is not provided internally Typically an airflow sensing control is installed in the duct system to determine operation of the furnace and automatically activate and also deactivate the EAC or humidifier If the control system contains the Honeywell brand model ST7997 electronic fan timer this unit has designated terminals to control the operation of an electronic air cleaner and or humidifier These terminals provide line voltage for the control of these accessories refer to Figure 4 26 installations and services must be performed by qualified service personnel 8 Figure 4 The Fan Control Module NOTICE t is important to confirm that the operating voltage of the humidifier or EAC being installed matches the output of this control If not a field supplied relay or transformer may be necessary to provide the proper control and supply voltage for the accessory being installed Refer to the manufacturer s instructions for the humidifier or EAC for additional information 27 installations and services must be performed by qualified service personnel 2 Thermostat Anticipator Setting Proper control of the indoor air temperature can only be achieved if the thermostat is calibrated to the heating and or cooling cycle Calibration will help to produce a more constant indoor temperature by adjusting the length of the heating cooling cycle to fit the application A vital consideration of
95. tete teo GOdES Clearances D 10 B Selection of Installation Location 11 C Venting Of Combustion Products 13 D Condensate Drain DER o PUER dug s 14 E Tank and Piping reete ieee see 15 uas NIE cR 17 Burner Specifications and Performance 17 H Airflow Requirements and Sizing of Ductwork 19 RE dlc 23 1 Filter Installation ean 23 2 Use of non Thermo Pride Filters or Retention Means 23 2 24 1 Electronic Air Cleaner EAC and Humidifier Installation 26 2 Thermostat Anticipator 28 3 Blower Motor Speed Selection 30 I STARTUP PROCEDURES voee bia tds ttem m ste t MED 32 A HEATING SYSTEM JB lo uS 32 2 Adjustment of Burner Combustion 34 3 Adjustment of Heat Input Rate 37 4 Setting Supply Air Temperature Rise 38 5 Checkout so opea adi 39 B COOLING SYSTEM timtal Di ta Ro Fou Deas au Peg Ces ow 41 2
96. ting contractor for recommendations on repair or replacement of the base 6 Do not allow the fuel oil tank to run completely empty During the summer keep the tank full to reduce condensation of moisture on the inside surface of the tank If the fuel tank runs completely dry it may be necessary to bleed air from the fuel lines Contact a qualified heating contractor to bleed the lines and restart the burner 7 Check the supply and return air connections to the appliance to insure the seals between the duct and appliance and the appliance and home are intact Check the 57 installations and services must be performed by qualified service personnel ducts for any signs of collapse holes or excessive corrosion Repair or replace components as required 8 It is advisable to wax the outer surface of the appliance housing yearly to provide the surface finish protection from excessive degradation by sunlight and inclement weather A good grade of automotive wax should be used to protect the finish 58 installations and services must be performed by qualified service personnel Vill TROUBLESHOOTING A WARNING Power must be disconnected before servicing Refer to the appendices of this manual for an electrical schematic a connection diagram flowcharts to assist in troubleshooting product specifications and a replacement parts list follow for this appliance A Heating System Qualified HVAC and cooling contractors m
97. ting in premature failure and or intermittent thermal cutout of the compressor High superheat at the evaporator also indicates the evaporator is operating very inefficiently by vaporizing the refrigerant too quickly in the evaporator coil High superheat at the evaporator results in some loss of the evaporator heat removal capacity 42 installations and services must be performed by qualified service personnel Startup of a new cooling system and checkout of an existing system should always include superheat measurements Before measuring superheat allow the system to operate under a load for approximately 15 minutes A conditioned space load will usually provide enough heat for the evaporator to remove for at least this period of time Operating the cooling system for 15 minutes allows the refrigeration system to stabilize providing good operating pressures and temperatures NOTICE Do not attempt a superheat measurement when the ambient temperature is less than 60 F Low loading on the cooling system will result in low or erroneous superheat measurements NOTICE When adding or removing charge to fine tune the cooling system performance allow 15 to 20 minutes of system operating time after each adjustment of the charge After 15 to minutes of operation a reliable superheat reading may be taken 3 Evaporator Superheat To measure superheat at the evaporator a suction pressure reading at the outlet of the evaporator would be d
98. to operate for 10 to 15 minutes d Note the oil pressure at the pump e To adjust the pressure use a common screwdriver to turn in the pressure adjustment screw located on the upper front of the oil pump f Allow the fuel flow rate to stabilize for a moment Recheck the oil pressure g If required repeat the oil pressure adjustment again h When the input rate adjustment has been completed shut off the fuel oil to the appliance Remove the pressure gage Reinstall the pipe plug using a thread compound resistant to the action of LP gases and fuel oil NOTICE It may be necessary to bleed air from the oil line before the burner can be fired To insure the combustion air supply is adequate it is now necessary to repeat the steps in the previous Initial Burner Adjustment section of this manual 4 Setting Supply Air Temperature Rise ANWARNING To avoid injury from moving parts or electrical shock shut off the power to the appliance before removing supply air blower compartment door and servicing this appliance All OPA models are designed and wired at the factory for a blower speed during heating that should result in an approximate temperature rise of 65 F The temperature rise through the heating section for any given blower speed may vary depending on a number of factors A few of these factors are variations in the actual resistance of the duct system to airflow at any time the return air temperatures and the
99. ucts of combustion through the heat exchanger system After installation the furnace and duct system must be adjusted to obtain a temperature rise of 50 F to 80 F through the unit Refer to the rating label located on side panel inside the burner compartment The installation must conform with local codes or in the absence of local codes with the Standard for the Installation of Oil Burning Equipment NFPA 31 1997 or the latest edition and to these instructions installations and services must be performed by qualified service personnel Codes and Clearances The following items must be considered when choosing the size and location of the unit 1 local codes and or regulations take precedence over the instructions in this manual and should be followed accordingly In the absence of local codes installation must conform to these instructions and the guidelines of the National Fire Protection Association Two applicable installation codes are the National Electrical Code ANSI NFPA 70 1999 and Standard for the Installation of Oil Burning Equipment NFPA 31 1997 The latest editions of these codes should be consulted The selection of a heating unit should be based on a rate of heat loss calculation for the residence according to the manuals provided by the Air Conditioning Contractors of America ACCA or the American Society of Heating Refrigeration and Air Conditioning Engineers ASHRAE T
100. uipment for restrictions If permitted connect the burner oil supply line near the base of the tank opposite of the fill end Connection at this point tends to flush older oil through and out of the tank This helps to prevent the accumulation of rainwater and condensed water vapor in the tank which can cause the tank to corrode If the oil supplier does not already use oil additives it is recommended that additives be used to emulsify any water accumulation in the oil F OilFilter It is strongly recommended that an oil filter assembly be installed in the oil supply line to the unit Use an oil filter with the capacity to trap a 40 50 micron particle for all installations Install the filter between the oil manual shutoff valve and the burner The filter cartridge should be replaced at least once a year The filter body should be thoroughly cleaned before installing a new cartridge G Burner Specifications And Performance The appliance is supplied with two oil burner nozzles one for the high fire and one for the low fire heat input rate The model OPA has the low fire oil nozzle already installed in the burner by the factory Table 2 gives the burner specifications and the estimated performance of the appliance operating under high and low fire conditions 17 installations and services must be performed by qualified service personnel Table 2 Burner Specifications and High and Low Fire Heating Performance Heating Oil Pu
101. umidifier are energized Y Y If ignition attempt is unsuccessful the ignition control module goes into Repeat Ignition system lockout Trial When thermostat is satisfied contacts open and the oil valve is de energized After Y a 2 minute burner off delay Call for Heat burner motor is de energized Satisfied The 2 minute delay to fan off period begins If system is in lockout check if LED Y is flashing fast try to recycle the system by depressing the RESET button System Lockout on the ignition control module Y After the delay to fan off Y period ends the circulating air fan and optional End of Cycle electronic air cleaner are de energized 77 installations and services must be performed by qualified service personnel XIV APPENDIX E TROUBLESHOOTING FLOWCHARTS TURN THERMOSTAT TO CALL FOR HEAT DOES THERMOSTAT MAKE CONTACT No No No RECON TENPERATUR IS ROOM TEMPERATURE TURN STAT gt BELOW THERMOSTAT SETTING TEMBER ATURE Yes Yes Yes Y ALLOW THE ROOM AIR TO COOL CHECK IN PUT POWER DISCONNECTING SWITCH AND FUSE S IF EQUIPPED Y DOES BURNER MOTOR START No CHECK FOR LINE VOLTAGE FAN CONTROL MODULE IF NOT 115 VAC CHECK FOR No IS THE BURNER No BLOWN FUSE OR TURN ON IS VOLTAGE PRESENT
102. urface A poured concrete slab or equivalent is ideal If concrete blocks or bricks are used be sure to use well tamped gravel fill beneath the blocks or bricks to prevent settling The unit is manufactured with runner supports that raise the unit about 1 25 inches above the mounting base allowing air circulation beneath the metal 11 installations and services must be performed by qualified service personnel surfaces This clearance helps to promote air circulation under the base that allows the unit to be mounted on combustible materials This clearance also helps to reduce metal corrosion caused by a buildup of moisture under the appliance 3 The cooling system condenser must have an unrestricted supply of air for efficient cooling 4 The cooling system fan discharges air upward through the top grill For this reason this appliance should not be located under an overhang or any other obstruction to airflow that would redirect the heated discharge air back into the condenser The appliance should be located as illustrated in Figure 1 below Figure 1 Selection of Appliance Installation Location For proper and safe operation of this appliance ensure that adequate clearances around air openings into the burner compartment and the 12 installations and services must be performed by qualified service personnel condenser coil area are maintained These openings are not to be blocked or restricted in any mann
103. ust perform all service NOTICE Before troubleshooting familiarize yourself with the Initial Startup Checkout Procedure and Heating System Troubleshooting Flowchart To assist in troubleshooting the heating section of this appliance it is equipped with an integrated safety and ignition control with diagnostics These diagnostics include an indicator light that relays the operational status of the control and can help in diagnosing the condition of the flame sensor Diagnostic Features The Honeywell brand model R7184P or alternate R7997D safety and ignition control module used on this unit continuously monitors the operation of the heating system If an abnormal condition occurs the LED light on the control will rapidly flash indicating the operational status of the unit In event this control malfunctions the entire control should be replaced It is not field repairable In the event of an operational failure of the burner system the rate of flashes if any of the ignition control module LED should be noted before turning off power to the unit Otherwise power to the heating section will be interrupted and the control LED will not furnish the diagnostic flashing It may be necessary to restart the furnace and have the failure occur again For the model R7184P under normal operating conditions the LED will be continuously lit while the burner is operating For the model R7997D the LED will be continuously flash at a low rate
104. ve to the OFF position 2 Adjustment of Burner Combustion ANWARNING Maximum gross stack temperature must not exceed 550 F 288 C under any circumstances ACAUTION Do not run the oil pump dry for more than five minutes as irreparable damage may result NOTICE Read the burner operation and service instructions Model AFG Oil Burner Instruction Manual before continuing To initially adjust and successfully service the oil burner in the appliance heating section the following test instruments are required A smoke density measuring and rating device e Acarbon dioxide CO2 or oxygen 02 analyzer e A flue gas temperature measuring device e g thermocouple or thermister probe with readout device An analog or digital multimeter and e An oil pressure gauge capable of reading 0 150 PSIG To initially fire the oil burner proceed in the following manner a the disconnecting switch which provides power to the appliance to the OFF position b Setthe room thermostat above room temperature c Verify the oil tank is filled with sufficient fuel oil to operate the appliance d Open all valves in the oil supply line to the burner e Remove the burner compartment cover from the appliance 34 installations and services must be performed by qualified service personnel f Open the inspection cover on the upper mounting plate above the burner Turn the disconnecting switch to ON Pr
105. y Read Before Operating A WARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life This appliance does not have a pilot light It is equipped with an ignition system that automatically lights the burner Do not attempt to light the burner by hand Do not use this appliance if any part has been under water Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any oil control that has been under water Operating Instructions VI TT viii STOP Read the safety information above Set the thermostat to the lowest setting Turn off all electric power to the appliance This appliance is equipped with an ignition system that automatically lights the burner Do not try to light the burner by hand Rotate the manual oil shutoff valve to the ON position Turn on the electric power to the appliance Set the thermostat to the desired setting If the appliance will not operate call your qualified service technician or oil supplier To Turn Off Oil to Appliance Set the thermostat to the lowest setting and set the operating mode switch to OFF 33 installations and services must be performed by qualified service personnel ii If service is to be performed turn off the electrical power to the appliance iii Turn the manual oil shutoff val

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