Home

Thermo Products OH6FA072D48R Furnace User Manual

1. WD 611 WIRING DIAGRAM NOTES 1 REPLACEMENT WIRE MUST BE ECN 4888 PC OHBFATI9DV5 TYPE 105 C OR EQUIVALENT Li LADDER DIAGRAM 12 s LS yn TO DS ELECTRICAL SCHEMATIC 3 SET HEAT ANTICIPATOR AT 2 AMPS DEHUMI DISTAT BLOCKED VENT KIT wMO 1 E go REQ D FOR CAN CSA STD B140 4 BLOWER DELAY SW2 SWITCH SETTINGS N ON F OFF MAX LIMIT FUSE SETTINGS sw ewe IM 20A 170 E FF 30 FIF 2 BURNER S FACTORY F N 6o N 4 2 e p2 4 1 N F 120 N F 6 16 N N 240 N JN 8 S TRANS Y 7 SEC SW juo BR a 19 Gi 71966 BL By UNIT A C a en L UNIT HCC ONG BDO bo SY F 1X4 1 BLOWER BURNER d CONTROL P3 2 8 BL 1 BL x PSCQ 1 BLowzR BL 98 3 CONTROL CONNECTOR 1 8 OOO 16 5 2
2. Yes IS IGNITION ESTABLISHED No ARE THE ELECTRODES No SIGNITION TRANSFORMER No REPLACE IGNITION ERST CAPABLE OF PRODUCING A TPANSESENER 3 4 ARC 10 000 VAC Yes DETERMINE IF THE ELECTRODES ARE Yes ALIGNED CONTACT SPRINGS TOUCHING ELECTRODE RODS amp PORCELAIN INSULATORS CLEAN AND UNCRACKED ADJUST OR REPLACE AS NECESSARY Yes No IS THE COUPLING BETWEEN No O gt THE BURNER MOTOR 2 1 REPLACE PUMP THE PUMP STRIPPED Yes Yes REPLACE COUPLER IS OIL AVAILABLE TO THE BURNER N VERIFY ALL OIL VALVE S ARE OPEN OIL TANK IS SUFFICIENTLY FULL Y AND OIL LINE CONTAINS OIL FURNACE OPERATES FOR No COMPLETE CYCLE No ISHEATANTICAPATOR SET Nq MEASURE MILLIAMPS BETWEEN W R 2 gt TOMILLIAMPSETTING 3 ON THE T STAT SUBBASE AND SET HEAT i MEASURED ON SUBBASE ANTICIPATOR ACCORDINGLY Yes Vas IF PROBLEM PERSISTS CONTINUE TO NEXT SECTION Yes BLOWERRUNS No IS TEMPERATURERISE No CHECK BLOWER SPEED NORMAL CYCLE AND RETURN AIR TEMPERATURE je CHECK FAN ON amp OFF DIP SWITCH Y SETTINGS ON FAN CONTROL 65 PROPER COMB USTION ACHIEVED No IS THE PROBLEM DELAYED IGNITION Yes IS THE AIR TUBE INSERTION No
3. L1 L2 51 BLOCKED VENT KIT REQ D FOR 82 BLOWER WE 2 CAN CSA STD 8140 4 nue EUM nie BLOWER DELAY SW2 SWITCH SETTINGS P2 WWO 1 LIMIT s NTON EZOM y BL 204 170 ON DELAY OFF DELAY Sw2 2 1 SEC 4 3 MIN F F 30 rF r 2 BL FACTORY F N 60 FAcTORY F N 4 ES N F 120 N F B R DAANEN w bs N N 240 N N 8 2 1 2 4 i zc TRANS Y SEC H amp Bu A C CC UNIT COM HCC UNIT p2 3 C1r il BURNER T y CONTROL BL ML BL Y MH BL 06 m BECKETT W E NM OIL TEN NEN BURNER wl rf BK I I zal mee l cl aj r iE 1 He 120 VAC on oly aylan NEUTRAL i do RRR e eaae eRT EOS I L1 TO EAC T STAT 2 amu d Y W I D MOTOR E Y 1 BK W GNITOR TRANSFORMER M p vALvE BK VIOLET VALVE ms HOMER TRANSFORMER 5 CELL HUMIDISTAT A RIELLO BURNER CONNECT Y Y TO THERMOSTAT W TO W amp R TO BK WARNING DUE TO SHOCK HEATING SPEED BY INPUT GROUNDS TONS OF LOW FIRE MID FIRE HI FIRE COOLING SPEED CIRCUITS MUST REMAIN SEPARATED 3 LOW ML L MH MH H LOW LEEND 3 5 LOW ML L MH MH H ML FIELD WIRING 4 LOW ML L MH MH H MH FACTORY WIRING 5 LOW ML L MH MH H H 74 H8FA1119DV5 ECM Wiring Diagram
4. WITHOUT CONDENSING No IS STACK TEMPERATURE IS BURNER SET AS INDICATED No ADJUST BURNER COMBUSTION IN ABOVE SECTION TO PRODUCE ZERO SMOKE Yes No SLOW THE BLOWER SPEED IS THE TEMPERATURE DO TO RAISE TEMPERATURE Yes DIFFERENCE BETWEEN SUPPLY RISE Yes Yes INCREASE LENGTH OF BURNER ON CYCLE BY RESETTING BURNER PRIMARY CONTROL DIP SWITCHES FOR ALONGER 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 RATING GALLONS PER HOUR Approx RATING AT AT 100 PSI 80PSI 120PSI 140PSI 100 PSI 50 0 45 0 55 0 59 ide 65 0 58 0 71 0 77 165 5 0 67 0 82 0 89 175 85 0 76 0 93 1 00 200 90 0 81 0 99 1 07 225 1 00 0 89 1 10 1 18 2 50 1 10 0 99 1 21 1 30 275 1 20 1 07 1 31 1 41 3 00 1 25 1 12 1 37 1 48 NOZZLE FLOW RATES IN GALLONS PER HOUR Approx 80 PSI 120 PSI 140 PSI 1 21 1 48 1 60 1 34 1 64 1 78 1 48 1 81 1 95 1 57 1 92 2 07 1 79 2 19 2 37 2 01 2 47 2 66 2 21 2 74 2 96 2 44 3 00 3 24 2 69 3 29 3 55 67 COMBUSTION AND EFFICIENCY TESTING FOR THERMO PRIDE OIL FIRED CENTRAL FURNACES Complete this form for each Thermo Pride furnace installed Read instruction manual carefully before making tests Retain this form with furnace CUSTOMER NAME ADDRESS CITY STA
5. Fig 2 Proper chimney termination height for pitched roofs If the chimney penetrates a roof more than 10 feet from a ridge wall or parapet a minimum of 3 feet above roof or exit point must be maintained See Figure 2b If the roof is flat rather than the normal residential pitched roof refer to Figure 3 for proper clearances FIGURE 3 LESS THAN 10 2 MIN 2 MIN CHIMNEY 3 MIN i WALL OR PARAPET CHIMNEY OR VENT TERMINATION LESS THAN 10 FT FROM RIDGE WALL OR PARAPET Fig 3 Proper chimney termination height for flat roofs 3 PROPER VENT CONNECTOR PIPE CHIMNEY CONNECTION The vent connector pipe should extend only to and not beyond the inside wall of the chimney See Fig 4 A thimble should be used to connect the vent connector pipe to the chimney so that the vent connector pipe may be readily removed in case of inspection or replacement E WALL OF CHI Ei Fig 4 Proper insertion of the vent connector in the chimney 4 PROPER CHIMNEY BOTTOM LEVEL In cases where the chimney extends to the basement floor the draft can usually be improved by filling the base of the chimney with sand to within 12 inches of the vent connector pipe after relocating the clean out door See Fig 5 VENT PIPE CHIMNEY E H INSID
6. 1600 I 1500 VX SZ X OZ M gc 15991 1598 1 WJSNWHO 06 5909 08 7590 W3ENVHO NOILSNANOI 68819 269819 NOLO3S 401 cc 89991 89781 HOLYT 3000 IDOYA 091009 291026 JOvNOWd TIINYH 3000 I 2 95775005 2 955005 5 OMd LNO NYITO O z essal z sal 3ivid WR 6 z 610097 siose 3ivid WML 335vO gz 99581 9681 NIN3dO 13 0 344 YAOI Lz SNILNDON Y3NINE 3LYTd 9c l gare genes divid ONWNNOW s3NN4 IB L3NSvO Gc 9010 9010 TOMLNOD 14940 z 996829 990829 ASSY 3000 HILT Z 296879 296829 ASSY MALT 3199829 189829 SS300v 000 12 L 999929 989829 1NO3j NOOG QC 3689819 589819 MOlVHvd3s INONJ 6l 509 29097 mosTa 8l 26066 LTBOSE Y3M078 SS3NHVH IM LL 90606 96059 3InBLLS3A SSINAYH 91 ei mvaa GL 900085 900089 109 3013 13159 1 TOMLNG SSINYYH fel E M3MOd SSINYVH Ei E s E 920059 1008 NOIVTDSNI Hel 5 LLOOGE sel L 998069 E yo onan 51606 226052 TOULNOD 3OVN30J O 0 por0se YANYOISNVHL 0 9 Sd0v L 0 9 Sd0N ATBNGSSV 1309 YOLON oci L G6z06 9 553 E i LOGLSAOV lt Q3ANVHDOHd X9 1981 L 992062 E SOLON Fol ELK VD 1D INGMGOY dU Gi
7. By 2 OIL BK BURNER M Bi ieee worn R I i I 120 VAC BK Y Dz JR 1 NEUTRAL l T STAT w L2 ToX EAC eer Aan 4 I oX MOTOR E E 1 BL BL GNITOR Y w VALVE JBK VIOLET VALVE Y j BK N E AD TRANSFORMER E CELL IL l A HUMIDIFIER T RIELLO BURNER CONNECT HUMIDISTAT T Y Y TO THERMOSTAT W TO W amp R TO BK WARNING DUE TO SHOCK p AND FIRE HAZARD CLASS 2 HEATING SPEED SET UPS COOLING SPEED SET UPS HEATING AND COOLING LOW FIRE MED FIRE HI FIRE CIRCUITS MUST REMAIN BIUH 101 000 119 000 132 000 ATEM SEPARATED FAN FAN LEGEND CONTROL CONTROL FIELD WRING SW 1 SW 1 FACTORY WIRING SWITCH HEATING APPROX APPROX APPROX SWITCH COOLING SETTINGS CFM RISE F RISE RISE CF SETTINGS TONNAGE COOL CONTINUOUS 3 OFF 6 OFF 2 OFF 1202 787 5 OFF 2 800 500 1 0FF 4 OFF 3 OFF 6 OFF 2 OFF 1315 AF 5 0FF 2 5 1018 509 1 ON 4 0N 3 OFF 6 OFF 2 ON 1429 657 7TF 5 ON 3 1212 606 1 0FF 4 OFF 3 OFF 6 OFF 2 ON 1565 607 70 F 7B F 5 ON 35 1406 703 1 0 4 0 FACTORY 3 FACTORY Em 3 0N eae 6 ON ewitcH 2 OFF 1701 55 65 72F switcH 5 OFF 4 1624 800 SETTINGS 1 OFF SETTINGS 4 OFF 3 ON 6 ON 2 OFF 1860 59 F 86 5 OFF 4 5 1818 897 1 ON 4 ON 3 0N 6 ON 2 ON 2041 60 F 5 ON 5 2012 994 1 0FF 4 OFF 3 ON 6 ON 2 ON 2223 5 0 55 2230 1115 RECOMMENDED 1 ON 4 ON HEATING SPEED
8. 2 5 1018 509 4 ON 6 OFF 848 1 8 159 2 6 231 5 ON 3 1212 606 4 OFF 6 OFF 994 2 3 203 3 1 290 5 ON 3 5 1406 703 4 ON Factory SW1 6 ON 1139 3 0 278 4 0 378 Switch 5 4 Ice 800 Settings 4 OFF 6 ON 1285 3 8 353 50 475 5 OFF 45 1818 897 4 ON 6 ON 1406 4 8 456 6 0 582 5 5 2012 994 4 OFF 6 ON 1551 6 1 593 7 4 729 5 55 2230 1115 4 ON NOTE All information is approximate Results will vary by installation Figure 18 3A Cooling blower motor speed chart 32 For PSC systems the 1 2 hp motor is equipped with 4 speeds The unit is set for mid fire temp rise 66 F See table for proper blower motor set up OH6FA072D48 ALTERATIONS REQ D FOR A C DESIGN EXTERNAL STATIC PRESSURE Recommended CLG Speed MH MH MH MH MH Speed Tap Static Furnace Airflow CFM vs External Static pressure in WC Pressure 0 1 0 2 0 3 0 4 0 5 0 6 0 7 Low 930 915 912 910 822 774 730 ML 1155 1152 1130 1126 1085 1042 920 MH 1442 1432 1418 1382 1334 1293 1230 High 1802 1762 1705 1635 1569 1493 1428 Furnace Motor Current Draw Amps vs External Static pressure in WC Low 3 3 3 1 3 0 2 9 2 6 2 5 2 4 ML 4 2 4 0 3 9 3 7 3 6 3 3 3 0 MH 5 4 5 2 5 0 4 7 4 4 4 2 4 0 High 6 6 6 4 6 0 5 7 5 5 5 2 5 0 Speed Tap Static Hig
9. CONSTRUCTION USING COMBUSTIBLE MATERIAL PLASTERED OR UNPLAST ERED APPLIANCE OR CHIMNEY OR VENT CONNECTOR SHEET METAL OR OTHER C PROTECTION Fig 7 Alternate constructions that allow reduced clearances to combustible materials REDUCTION OF CLEARANCES WITH SPECIFIED FORMS OF PROTECTION Type of protection applied to and covering all surfaces of combustible material within the distance specified as the required clearance with no protection unless otherwise noted all dimensions in inches refer to Fig 7 18 9 6 Required clearance with no protection from the appliance or chimney connector is Sides amp Sides amp Sides amp Rear Above Rear a 3 1 2 thick masonry wall without ventilation air space 1 2 insulation board over 1 glass fiber or mineral wool batts 2 2 8 c 0 024 24 gauge sheet metal over 1 glass fiber or mineral wool batts reinforced with wire on rear face with ventilated air 9 1 2 thick masonry wall with ventilation air space ce T e e 0 024 24 gauge sheet metal with ventilated air space f 1 2 thick insulation board with ventilation air space eee g 0 024 24 gauge sheet metal with ventilated air space over 0 024 24 gauge sheet metal with ventilated air space h 1 glass fi
10. 774 86 968 86 1 ON 3 ON 2 OFF 1054 843 66 1054 63 843 79 1054 79 1 OFF 3 ON 2 OFF 1153 922 60 1153 58 922 72 1153 72 1 ON FACTORY SW1 3 ON o o o o SWITCH 2_ ON 1267 1013 55 1267 53 1013 66 1267 66 SETTINGS 1 OFF 3 ON 2 ON 1424 1139 49 1424 47 1139 59 1424 59 1 ON Recommended heating speed setting Figure 18 2 ECM 2 stage blower motor speed chart 30 Cooling Speed Set ups OH6F 072DV4 Furnace Motor Current Draw Amps Watts vs External Static Pressure in W C Air Flow Static Pressure Amps Watts Fan Control SW 1 Switch Settings Clg Tonage Cool Continuous 0 2 0 5 OR 2 799 500 1 2 109 2 1 186 4 OFF 6 OFF 5 OFF 2 5 1017 508 1 8 160 2 5 230 4 ON 6 OFF 5 ON 3 1210 605 2 4 220 3 3 308 4 OFF 6 OFF 5 ON 3 5 1404 702 3 2 305 4 2 409 4 ON actory aem COD 4 1622 799 4 6 443 5 7 560 Settings 4 OFF NOTE All information is approximate Results will vary by installation Figure 18 3 Cooling blower motor speed chart 31 Cooling Speed Set ups OH8FA119DV5 Furnace Motor Current Draw Amps Watts vs External Static Pressure in W C Air Flow Fan Control SW 1 Switch Clg 02 05 Settings Tonnage Cool Continuous Dehum j gt 6 OFF 1 0 89 1 8 161 5 2 800 500 557 4 OFF 6 OFF 703 1 4 121 2 1 192 5
11. LENGTH OH8FA119D R C8512317 BF5 4 5 1 00X80 H 0 85X80 H Table 6 Beckett amp Riello burners specifications INSULATOR S SLEEVE OR N NONE THE NOZZLE SIZE GIVES THE NOMINAL FLOWRATE IN GPH FOLLOWED BY THE SPRAY ANGLE IN DEGREE S AND THE SPRAY PATTERN EITHER H FOR HOLLOW CONE OR S FOR SOLID CONE FOR EXAMPLE A NOZZLE RATED AT 0 65 GPH 100 PSIG THAT PROVIDES AN 80 SPRAY ANGLE AND A HOLLOW SPRAY PATTERN WOULD BE ABBREVIATED IN THE TABLE AS 0 65 X 80 H For more specific burner information contact Thermo Products LLC P O Box 217 North Judson IN 46366 Phone 574 896 2133 19 OIL NOZZLE CAPACITY CHART NOZZLE SIZE EQUIVALENT HEAT EFFECTIVE HEATING UNITS GPH INPUT RATE CAPACITY Beckett Riello Brum OHG6FA060D 50 50 70 000 60 000 OHG6FA072D 60 60 85 000 73 000 OH6FA090D 75 70 106 250 90 000 OH8FA101D 85 75 119 000 101 000 OH8FA119D 1 00 85 140 000 119 000 OH8FA132D __ 1 10 1 00 156 250 132 000 Table 7 Oil nozzle capacity All rates shown achieved with 120 PSIG pump pressure for Beckett and 140 PSIG pump pressure for Riello Based on 2 domestic heating fuel oil having heating value of 140 000 BTU per gallon Based on thermal efficiency of 84 85 Riello 2 stage burner specifications and applications OH6 ONLY MODEL OH6 2 STAGE PART MTG PLATE PART NO Ip
12. gt 0 1 4 BACK FROM INSIDE m AIR TUBE BURNOFF OF REFRACTORY Yes No Y Yes PROPERLY ALIGNED Yes IS PUMP PRESSURE SET ACCORDING TO BURNER No Yes ARE VENT TERMINAL AND HEAT EXCHANGER CLEAN ARE THE ELECTRODES No APPLICATION CHART 9 AIR OR OIL BELOW 50 CORRECT INSERTION OR MAY OCCUR ALIGN ELECTRODES PER BURNER INSTRUCTION MANUAL SPECIFICATIONS ADJUST TO 100 120 PSI UNLESS COMBUSTION deg F IS PRESENT THIS IS CONSIDERED BELOW IS THE NOZZLE PLUGGING No IS BURNER SET TO No PRODUCE A TRACE OF SMOKE AND THEN DETUNED 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 Yes IS WATER DIRT OR No SLUDGE PRESENT IN THE OIL SYSTEM Yes L gt IS COMBUSTION AIR Yes REPAIR OR REPLACE TANK TO PREVENT FUTURE PROBLEMS MIX IN PROPER ADDITIVES TO REMOVE WATER AND SLUDGE 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 66 Yes DOES FURNACE OPERATE
13. 3819 1NOX3 s000 ze T i ze J i zgLoze JOvOVd TIGNVH 4000 9 2 z osrrsoos z osrrsoos scrrsoos Alg GssY IMd 1 0 219 se n ecegio 295819 795819 wal see z se z 91202 13599 se 9558 9998 1 DNIN340 Lavad 813400 ze i 1 M3A02 0010 13SV5 1 os Stross mE AYTA 91097 JL see i 22609 JOMINOO gz 1 tose i popace M3NIOJSNVML ZZ eose 1 109 i 201082 HOLWS 92 a AYOHO M300d YOLINONI SZ L egzose 1 esos vX9L SS3NNNH orz S0G Sd0V sog saov GINNYNDONd X08 91 9 esce 1 egzose vez Pumas i uw a MOLDNdVO ez ES cceoce mE SS3NNvH IAM zz 1 0092 O038N02 soror SSINAYH JAM iz 197092 12605 1 1260 INWLMOWO awqa SS3NMVH aam 09082 1 ceo 1 92008 NAUSIA SSINYVH IAM 6l 39y 819 9y 819 NOLVYWGIS INOMJ 3NVd 81 osose 1 oso 1 09097 mog LL Hm VT el eee T i eoe i Qce 3014 LDISV9 NMOHS rAG 0 49H0 vi eewsoos 1 osirsoos i svirsoos AlgW3ssv ens mous won was L 1 eresia i 677819 1NO3J 1 oseazg 308 1431 onisvo aseo ft aiscaza 1 iseazg 30 1H98 01
14. Based on thermal efficiency of 84926 8596 MOUNTING THE 2 STAGE RIELLO BURNER It is necessary that the insulation gasket be placed between the mounting plate and the burner flange The insulating gasket has six holes which if necessary can be modified as shown see figure 14 1 Figure 14 1 Burner gasket and mounting Figure 14 2 Burner fixing and hinge assembly 21 Verify that the installed burner is lightly leaned towards the button See figure 14 1 The burner is designed to allow entry of the flexible oil lines on either side of the burner I OIL TANK AND PIPING AWARNING 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 2 Where practical provide rigid supports for the piping 3 Ifthe piping size in a run must be reduced use reducing couplings only Avoid the use of reducing bushings 4 Remove all pipe thread burrs and inspect the pipe for dirt or other foreign material prior to connecting If present remove any deposits in t
15. MTG PLATE GASKET 330212 PART NO NOZZLE SIZE 70 X 45 W NOZZLE errr PART NO OIL PUMP 130 LOW PRESSURE ico Ed BURNER G5D BURNER PART NO Ed Table 8 Riello burner application THE NOZZLE SIZE GIVES THE NOMINAL FLOWRATE IN GPH FOLLOWED BY THE SPRAY ANGLE IN DEGREE S AND THE SPRAY PATTERN EITHER H FOR HOLLOW CONE OR S FOR SOLID CONE FOR EXAMPLE A NOZZLE RATED AT 0 65 GPH 100 PSIG THAT PROVIDES AN 80 SPRAY ANGLE AND A HOLLOW SPRAY PATTERN WOULD BE ABBREVIATED IN THE TABLE AS 0 65 X 80 H NOTE The reason the Riello burner nozzle sizes are smaller than the standard Thermo Pride burner nozzles is that pre set pump pressures are higher therefore achieving the same firing rate with a smaller nozzle 20 For more specific burner information specifications or service information reference the training manual enclosed with each Riello burner or contact Riello Corporation of America 5 Pond Park Road Hingham Massachusetts 02043 Phone 617 749 8292 2 STAGE FIRING RATES CAPACITY FIRING NOZZLE SIZE INPUT RATE EFFECTIVE RATE Riello BTU HR HEATING CAPACITY HIGH CAPACITY HIGH FIRE 70 X 45 W 106 250 1 70psi 90 000 LOW FIRE 85 000 130psi 74 000 LOW CAPACITY HIGH FIRE 50 X 45 W 85 000 1 70psi 74 000 LOW FIRE 70 000 130psi 60 000 Table 9 Riello 2 stage firing rates Based on 2 domestic heating fuel oil having heating value of 140 000 BTU per gallon
16. heat When high air temperatures are reached within the heating section the high limit control should act to shutdown the burner Shut off the electrical power IMPORTANT Remove blockage or reconnect blower motor and restore power 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 47 II USERS INFORMATION SECTION A OIL SUPPLY Do not allow the fuel tank to run completely empty During the summer keep the tank full to prevent condensation of moisture on the inside surface of the tank If the fuel tank runs completely dry it may be necessary to purge the lines of trapped air Contact a qualified technician to bleed the lines and restart the burner OIL SUPPLY VALVE Turn the oil supply valve off if the burner is shut down for an extended period of time B COMBUSTION AIR SUPPLY The burner requires a generous amount of clean combustion air to operate safely Lack of adequate combustion air can result in erratic operation of the burner noisy combustion or fuel odors in the air NEVER BLOCK THE FURNACE FROM THE SUPPLY OF COMBUSTION AIR If there is an exhaust fan dryer or return air grill in the furnace room there should be increased concern and additional efforts
17. 1017 508 E m 2 0N 883 706 79 883 75 706 94 883 94 zd 5 ON 3 1210 605 T a 2 ON 986 774 727 968 69 774 86 968 86 6 OFF Y 5 0N 35 1404 702 T 2 1054 843 667 1054 63 843 79 1054 79 FACTORY 6 D Swi 5 OFF 4 1622 799 SWITCH 2 0FF 1153 922 60 1153 58 922 72 11153 72 SETTINGS 4 OFF nee WARNING DUE TO SHOCK FACTORY 3 ON AND FIRE HAZARD CLASS 2 Swi t HEATING AND COOLING SwitcH 2 1267 1013 55 1267 53 1013 66 1267 66 CIRCUITS MUST REMAIN SETTINGS 1 OFF SEPARATED 3 0N RECOMMENDED LEGEND 2 1424 1139 49 1424 47 1139 59 1424 59 HEATING SPEED FIELD WIRING 10 SETTING FACTORY WIRING 73 OH8FA1119D60 PSC Wiring Diagram WD 610 4888 LADDER DIAGRAM WIRING DIAGRAM OH8F A119D60 NOTES 1 REPLACEMENT WIRE MUST BE ELECTRICAL SCHEMATIC TYPE 105 C OR EQUIVALENT 2 CONNECT HOT TO 1 AND COMMON TO 2 3 SET HEAT ANTICIPATOR AT 2 AMPS
18. 2 6 T 7 5 BL a Pad 1 BLOWER BL w 3 J CONTROL 2 CONNECTOR 1 8 5 1 15 00 Ure 5 2 BECKETT 8 12 OIL it BURNER w CHOKE I m 7 I l 120 VAC ee ic 32241 NEUTRAL DYA B L2 7 Y HOOO P4 EAC po dea E 9 PR MOTOR lenitor BL _BL_licniToR Y w VALVE JBK VIOLET VALVE ats BK b C 2 Y CAD TRANSFORMER iL L CELL Hv THUMIDIFIER RIELLO BURNER CONNECT TRANSFORMER i iDISTAT T Y Y TO THERMOSTAT W TO W amp R TO BK HEATING SPEED SET UPS COOLING SPEED DETUR LOW FIRE MED FIRE HI FIRE 60 000 72 000 90 000 FAN FAN CONTROL CONTROL SW 1 SW 1 SWITCH HEATING APPROX APPROX APPROX SWITCH COOLING SETTINGS CFM RISE TF RISE CF RISE CF SETTINGS TONNAGE COOL CONTINUOUS 3 OFF 6 OFF 2 OFF 740 75 F 80 F 5 OFF 2 799 500 1 OFF 4 OFF 3 OFF 6 OFF 2 OFF 812 68 82 F 5 2 5 1017 508 1 4 3 OFF 6 2 0N 883 63 F 76 F 84 F 5 ON 3 1210 605 1 OFF 4 3 OFF 6 OFF awtcH 2 968 57TF 69 86F 5 ON 35 1404 702 SETTINGS 1 ON 4 ON 3 0N Uer 6 0N 2 OFF 1054 6 79 F ewitcH 5 0FF 4 1622 799 1 OFF SETTINGS 4 0FF 3 0N 2 OFF 1153 587 72F 1 ON 3 0N UN 1267 WARNING DUE TO SHOCK 1 AND FIRE HAZARD CLASS 2 3 0N HEATING AND COOLING CIRCUITS MUST REMAIN 2 0 1424 58 F SEPARATED RECOMMENDED 1 ON LEGEND FIELD WIRING FACTORY WIRI
19. 400 CFM X 3 TON 12 000 BTUH 1 200 CFM FOR COOLING 1TON B 400 CFM X 2 5 TON 12 000 BTUH 1 000 CFM FOR COOLING 1 TON IMPORTANT SIZE THE DUCT SYSTEM FOR THE LARGER OF THE TWO AIRFLOW REQUIREMENTS E Air Filter Mounted External to Furnace On highboy furnaces it is necessary to cut the return air opening in the side rear casing or base depending upon the needs of the specific installation The filter rack provided with the furnace refer to Fig 10a amp 10b will serve as a template to scribe a mark for the return air opening on the casing Place the filter rack on a side casing approximately one inch up from the bottom of the furnace and centered from side to side Place the securing flange against the casing when locating the return air opening For your convenience 4 locator knockouts have been placed at the proper locations on both the left and right side casings PLEASE NOTE While scribing the return air opening the filter rack can be held in position by tape or similar temporary means Position the open end of the filter rack so as to provide access for filter replacement Once the filter rack is positioned correctly scribe a line along the inside of the securing flange on three of the sides To scribe a line on the fourth side the open end use the open end support as a guide Remove the filter rack and cut the return air opening in the casing Now the filter rack can be anchored to the furnace with screws or pop r
20. Air Cleaner EAC and Humidifier Installation The fan timer on 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 15 on the next page Connection between EAC and N6 provides a switched 115 vac to power an electronic fan cleaner The same switched 115 vac is available between EAC and N7 and may be used 24 in conjunction with a humidistat to control a humidifier These terminals are energized whenever the blower is active ee amoe 8 Caco DUE Figure 15 The Fan Control Module E Jwio NOTICE It 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 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 this calibration is
21. BU d Be T OPENING 4 Operational Check ANCAUTION 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 D ELECTRICAL SYSTEM ZAWARNING 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 2 Use a voltmeter or a multimeter to check for adequate voltage at the field connections when the appliance operating 3 Use an ammeter or a multimeter to check the current draws of the blower motor and burner assembly to assure they are not exceeding rating label current specifications for each component Also refer to Table 10 in the electrical wiring section of this manual for e
22. OR A MIXTURE OF OIL AND GASOLINE ANCAUTION DO NOT ATTEMPT TO START THE BURNER WHEN 1 Excess oil has accumulated 2 The furnace is full of vapors 3 The combustion chamber is very hot IF ONE OR MORE OF THESE CONDITIONS EXIST CONTACT A QUALIFIED SERVICE PERSON 48 D STARTING THE BURNER 1 Turn the main service switch to OFF position 2 Set thermostat substantially above room temperature 3 Open shut off valves in oil supply line to burner 4 Turn service switch to furnace ON If burner starts and runs but stops again on lockout it may be necessary to bleed the lines or make burner combustion air adjustments Contact a qualified service person to adjust and start burner E FILTER CLEANING AND LOCATION ZAWARNING To avoid injury from moving parts hot surfaces or electrical shock shut off the power to the furnace before removing any furnace access doors to service the air filters The air filters should be inspected each month and cleaned when dirty Cleaning the air filters frequently may reduce airborne contaminants from entering the furnace and depositing in the furnace duct system and home BLOWER COMPARTMENT DOOR FILTER Fig 23 Filter Location for Typical Highboy Furnace 49 IV INSTALLER S INSTRUCTIONS TO USER After completing the installation the installer shall inform and or demonstrate to the homeowner the followinq items 1 The location of these instructions The instructions
23. SETTING 75
24. and in proper position to ensure complete seal prior to operation Failure to do so may result in property or equipment damage 390528 ROTATING FAN BLADE To avoid injury from hot or moving parts shut off the furnace and allow to cool before removing this door When it becomes necessary to replace or wash filter remove the dirty filter from the racks provided and wash or replace with identical new filters The blower motor located behind this door may or may not require lubrication If lubrication instructions are not shown on the motor nameplate the motor should not be lubricated If the nameplate indicates that the motor requires lubrication lubricate the motor as directed or use 30 drops of SAE 20 weight oil or equivalent twice a year Do not use a light household grade oil FOR INSTALLATION IN A CLOSET OR ALCOVE ON COMBUSTIBLE FLOORING NODE 2048 A 00000000 A MEM WITH CLEARANCES TO UNPROTECTED COMBUSTIBLE MATERIAL NOT LESS TMAN OIL FIRED FURNACE ANY SIDE OF SUPPLYPLENUM SIDES REAR FRONT FLUE PIPE CERTIFIED TO UL STO 727 CAN CSA STD 8140 4 INCHES 1 1 LI FOR USE ONLY WITH R W BECKETT OIL BURNER MODELS AFG TP 250 AND NX TP260 OR 24 INCHES FOR SERVICE PURPOSES RIELLO OIL BURNER MODEL BFI C8511325 CLOSET INSTALLATION REQUIRES TWO SEPARATE VENTILATION OPENINGS LOCATED 6 INCHES 390025 DIRECT DRIVE BLOWER EXTERNAL STATIC PRESSURE INCHES W C 0 20 TO 0 50 MAXIMUM
25. combustion and ventilation The Thermo Pride Make Up Air Control installs quickly and easily on any warm air heating system delivers controlled fresh air automatically during the winter and a constant supply of clean fresh air for comfortable summer living It resolves the negative pressure differential problem Il GENERAL INSTRUCTIONS READ BEFORE START OF INSTALLATION 1 The heating output capacity of the furnace proposed for installation should be based on a heat loss calculation made according to the manuals provided by the Air Conditioning Contractors of America ACCA or the American Society of Heating Refrigeration and Air Conditioning Engineers Inc ASHRAE 2 All 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 with these instructions and regulations of the National Fire Protection Association and to the provisions of the National Electrical Code ANSI NFPA 70 1999 or latest edition 3 The installed furnace must be level and positioned in a central location with respect to outlet registers It should be located near the chimney to minimize any horizontal run of flue pipe which may be required 4 A furnace installed in a residential garage must be installed so the burner and ignition source are located higher than 18 inches above the floor The furnace must also be located or protected to avoid p
26. 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 R7184B 0 to 400 400 to 800 800 to 1600 1600 lt AJU N If it is necessary to troubleshoot the flame sensor independently of the burner primary the following procedure may be used B 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 59 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 f 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 The troublesho
27. discharge 90 counter clockwise from the vertical position to adapt to various venting systems The OH8 flue elbow can also be rotated 90 clockwise Notice Blocked Vent Switch Installation The blocked vent switch kit must be installed to comply with CAN STD B140 4 where applicable For installation instructions see AOPS2687 kit CAUTION MUST BE TAKEN NOT TO EXCEED 90 ROTATION OF THE FLUE ELBOW ROTATION OF FRONT FLUE ELBOW When an installation requires that the flue exit out the left or right OH8 only side casing remove screw securing the 90 deg elbow and rotate it 90 Then remove knock out in side casing and extend vent through the opening A trim collar may be ordered from Thermo Products to hide the gap around the flue pipe This trim collar however is not required for operation Trim collar gasket part numbers s 14121 330073 for OH6 and 14132 330006 for OH8 The OH6 amp OH8 may be vented through a standard correctly sized chimney The OH6 amp OH8 may also be horizontally vented through a sidewall Thermo Products has available the Field model FDVS 45 FOVP 415 and FDVS 67 FOVP 615 side wall vent kits for such applications When installing the sidewall vent kits outside combustion air must also be applied to the burner The following table identifies application order information l SIDE WALL VENTING APPLICATION ORDER INFORMATION WALL VENTING APPLICATION ORDER INFORMATION COMBUSTION AIR INTAKE ACCESSO
28. distance further than 1 4 inch back from the inside chamber wall may cause impingement and sooting This unit is equipped with a chamber retainer refer to Fig 12 The retainer secures the chamber during shipping and helps to maintain insertion depth DO NOT remove this retainer when installing burner OVERFIRE DRAFT ACCESS COVER BURNER MOUNTING PLATI BURNER MOUNTING PLATE E GASKET BURNER NAY MOUNTING NUT amp WASHER 3 BURNER STUDS 4 PLACES MOUNTING 3 PLACES IN PLATE ON COMBUSTION CHAMBER OVERFIRE DRAFT ACCESS COVER w GASKET OVERFIRE DRAFT ACCESS PORT CHAMBER RETAINER MTG PLATE FOR SINGLE STAGE BURNER SHOWN 2 STAGE BURNER MTG PLATE HAS EMBOSSMENT INSTALL 2 STAGE MTG PLATE W RAISED SURFACE TOWARD COMBUSTION CHAMBER AND BURNER MTG STUDS TOWARD FRONT OF FURNACE OVERFIRE DRAFT ACCESS PORT BURNER MOUNTING STUD 2 PLACES RAISED SURFACE OF EMBOSSMENT RIELLO 2 STAGE MTG PLATE OH6 ONLY Fig 12 Typical location of the over fire air tap and components in burner mounting plate area 18 HEAT EXCHANGER DRUM BURNER SAME r AIR TUBE N C_N INSIDE OF BURNER MOUNTING PLATE CHAMBER _ BURNER Wd L a m E BURNER END CONE IS 4j 1 4 BACK FROM INSIDE N U CHAMBER WALL CHAMBER NOTE RIELLO INSULATING INSULATING SLEEVE SLEEVE
29. from the fuel lines Contact a qualified heating contractor to bleed the lines and restart the burner 3 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 ducts for any signs of collapse holes or excessive corrosion Repair or replace components as required VII TROUBLESHOOTING THIS SECTION IS ONLY TO BE PERFORMED BY TRAINED QUALIFIED SERVICE PERSONNEL AND NOT BY THE FURNACE OWNER NOTICE Before troubleshooting familiarize yourself with the Initial Startup Checkout Procedure and Troubleshooting Flowchart 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 1 Check for 115VAC line supply voltage to the furnace If there is no supply voltage check fuses and service switch A CAUTION When testing electrical equipment always follow standard electrical procedures 58 2 Make sure thermostat is calling for burner operation 3 Check oil supply and make sure all valves are open A DIAGNOSTICS To assist in troubleshooting 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
30. may be required to provide adequate combustion oil to the furnace at all times C INSPECTION AREAS VESTIBULE The furnace vestibule area or burner compartment should be inspected by removing the front door of the furnace and looking for signs of excessive heat such as discoloration of components materials damage from rust or corrosion soot or carbon build up EXTERIOR OF FURNACE The furnace exterior should be inspected for signs of excessive heat such as discoloration of materials and damage from rust or corrosion FLUE PIPE VENT PIPE OR CONNECTOR The furnace vent pipe should be inspected for signs of rust corrosion pitting or holes in pipe and leakage around seams in pipe indicated by soot or condensate streaks CHIMNEY OR VENTING SYSTEM The furnace venting system should be inspected for signs of rust corrosion pitting or holes and signs of condensation or moisture leakage from the venting system If any of the above symptoms are evident call a qualified heating contractor for assistance CAUTION DO NOT ATTEMPT TO MAKE REPAIRS YOURSELF ZAWARNING The area around the furnace should be kept free and clear of combustible liquids and material especially papers and rags ANWARNING NEVER burn garbage or refuse in your furnace Never try to ignite oil by tossing burning papers or other material into your furnace ZAWARNING Thermo Pride oil furnaces are designed to burn No 1 or No 2 distillate fuel oil NEVER USE GASOLINE
31. must be kept along with instructions for any accessories in the plastic pouch with the appliance 2 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 3 The sequence of operation of the appliance 4 The correct operation and maintenance of the appliance as outlined in the Homeowner User Information and Routine Maintenance section of this manual 5 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 6 Review with and encourage the user to read the label reproductions and all warnings and instructions outlined on the front cover and in Sections Il and Ill of this manual 7 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 8 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 50 V DEALER MAINTENANCE A WARNING Personal injury or property damage could result from
32. or the latest edition and this instruction manual This appliance requires 120 VAC 60 Hz single phase power Refer to Table 10 for typical electrical current draws of the individual appliance motors 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 Care must be taken to ensure correct polarity when wiring the furnace Two wire service one hot lead L1 and a common L2 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 wire in the junction box Field wiring of power circuits to the appliance should consist of copper conductors rated for at least 15 amp service with an insulation temperature rating of at least 75 C 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 front door 23 Typically control wiring between the appliance and the indoor thermostat and if used electronic air cleaner or
33. 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 16 on the next page must be adjusted to each application 25 HOLE SUITABLE FOR PENCIL POINT TO MOVE INDICATOR HEATER INDICATOR SCALE Figure 16 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 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 1 Wrap 10 loops of single strand insulated thermostat wire around the prongs of an ammeter refer to
34. removed It depends on the output of the burner and is carried out by rotating the regulating rod till the terminal plane of the blast tube is level with the set point as indicated in the schedule Terminal plane of the blast tube In figure 20 the combustion head is set for an output of 0 75 GPH at 130 psi while the shutter is level with set point 2 5 as required by the above schedule 3 Regulating rod Blast tube Shutter Figure 20 42 The setting of the fan output according to the installation should be done only through the air damper Should you want to adjust the setting of the combustion head with the burner running turn the rod 1 with a 6mm wrench 2 as follows TURN TO THE RIGHT SIGN In order to increase the volume of air entering the combustion chamber and thus diminishing its pressure There is a reduction of CO and the adhesion of the flame to the air diffuser disc improves Setting advisable for ignitions at low temperatures TURN TO THE LEFT SIGN In order to reduce the volume of air entering the combustion chamber and thus increasing its pressure The improves and the adhesion of the flame to the diffuser tends to reduce This setting is not advisable for ignitions at low temperatures In any case do not bring the combustion head setting more than one point away from that indicated in the schedule One set point corresponds to 3 turns of the rod a hole 3 a
35. the unit before attempting to change supply air blower speed wiring The furnace comes from the factory with the proper cooling speed selected and the heat rise set to approximately 66 F on mid fire The heat rise is determined by the nozzle size and the switch selection on the control board located in the vestibule compartment For ECM systems switches 1 2 amp 3 of switch block SW1 the six switch red block are used to select the proper blower speed Please refer to figure 15 and table 18 27 Heating Speed Set ups OH6FA072DV4 Furnace Motor Current Draw Amps Watts vs External Static Pressure in W C Low Fire Med Fire High Fire BTUH 60 000 72 000 90 000 Static Pressure Amps Watts Fan Control SW1 Switch Heating Aprox Rise Aprox Rise Aprox Rise Settings CFM F F F 0 2 0 5 3 OFF 2 OFF 1 OFF 740 75 1 1 98 1 8 173 3 OFF o 2 OFF 812 68 82 1 3 114 2 1 193 1 ON 3 OFF o 2 ON 883 63 76 1 5 129 2 4 218 1 OFF Factory 3 SW1 Switch ow 968 57 69 86 1 7 148 2 4 223 Settings 1 ON 3 ON p OFF 1054 63 79 1 9 173 2 7 246 1 OFF 3 ON d 1153 58 72 2 3 207 3 0 283 1 ON 3 ON o 2 ON 1267 66 2 7 247 3 5 332 1 OFF 3 ON o 2 ON 1424 58 3 4 315 4 3 409 1 ON Recommended Heating Speed Setting Figure 18 1 ECM blower motor speed chart 28 Heating Speed Set ups OH
36. through the furnace must fall within a range of 51 to 81 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 vestibule cover The speed of the blower must be increased by changing the switch setting on the control board please refer to Figure 18 46 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 All controls on the unit should be checked for proper functioning prior to the qualified service personnel leaving the job site Specifically the 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 iv Vi Shut off incoming power Block return air opening or disconnect blower motor leads Restore power to appliance In the heating mode set the thermostat above room temperature producing a call for
37. 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 Equipment 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 J OIL FILTER It is strongly recommended that an oil filter assembly be installed in the oil supply line to the unit This filter should have the capacity to trap a 40 50 micron particle The filter cartridge should be replaced at least once a year The filter body should be thoroughly cleaned before installing a new cartridge K ELECTRICAL WIRIING 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 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
38. vi Weg 1 39819 292819 anisva 6 oor 1 T 16811 9NILNDON Hanana yd 8 ui aee i ze i zizoce hivta omuwnow yanana Laysva 7 oss i i 09781 ONISYO 3015 LHOW TlNB 9 19791 1331 Tiiva S ccs 1 vals i 1 010 6 savaa er i os vza 1 0G 29 was 1568 1991 6 19981 avv ado ze sae 1 sse 1 1881 W39NvHOXG LYH z ieresdov 1 teresdov 1 16 54 N3NVHO NOUSNEWOD bp 181 1 asya ON Lava PALO ON Lava CALO ON Lava Noldwasaa sixva au 10 oN dava 0 Lava ON Lawd NOUdwOSIO WALI PAOZLOXIGHO PAGZLOVSSHO grazZov49HO PAOZZO ISHO eraziov4euo Angitassv ans A gitassv 9 5 Replacement Parts for OH6FA072D Appendix A Replacement Parts for OH8FA119D PEL gel 39V30Vd JIONYH 3000 TOYLNOO 13740 NMOHS LON SWALI 3A08V NMOHS kan a E l 9t MOTSE NMOHS 090611 v 38HO 3A08V NMOHS ATBNGSSY 0906 17 38
39. will provide power to the Heat speed tap only A Y cooling call will provide power to the Cool speed tap only In the case of thermostat calls for Y and W together blower speed selection will be determined by the input that was first initiated In the case where the control is in a cooling mode with both Y and W inputs energized and then the Y input is removed the cooling blower off time will be executed prior to the control switching into a heating mode In the case where the control is in a heating mode with both Y and W inputs energized and then the W input is removed the heating blower off time will be executed prior to the control switching into a cooling mode In the case where a call for fan G already exists and either a W or a Y call is initiated the blower speed will switch to the respective W or a Y speed following the blower on delay for that call The speed taps are interconnected and interlocked only one speed may be powered at any one time When a Speed is to be operated the speed select relays are operated to select the path to the motor tap and then the enable relay is operated to switch the operating power to the selected motor speed tap If the speed of the running motor is to be changed first the enable relay removes power from the motor the new speed is selected and then power is restored to the motor Blower On and Off Delays Four Heat blower on
40. zero smoke measured To achieve a lower reading open the air band or shutter on the burner until zero smoke is measured For example if a 13 or 3 5 is recorded at a trace of smoke open the air shutter until zero smoke is measured with a 12 CO or 4 5 O9 Adjustment of the burner to achieve a slightly lower 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 ii 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 is 350 F and the maximum gross flue gas temperature is 500 F The lower the flue gas temperature the higher the heating efficiency However stack temperatures under 350 F may result in condensation of water vapor in the flue gases which in turn promotes corrosion of
41. 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 excessive wear Replace it if required Check and adjust oil pump pressure if needed Refer to Initial Heating System Adjustments section of this manual Note Care must be given to ensure no damage occurs to the chamber insert Refer to Figure 12 4 Heat Exchanger Visually inspect the heat exchanger for excessive carbon soot build up Refer to the Heat Exchanger section of the manual 5 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 6 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 51 B HEAT EXCHANGER ANWARNING qualified heating contracto
42. 72 7 2 739 7 1 730 6 8 704 6 6 683 6 3 661 6 1 641 MH 9 0 908 9 0 905 8 7 888 8 5 871 8 3 842 8 0 818 7 7 796 High 12 5 1270 11 7 1200 11 2 1150 10 7 1110 10 2 1060 9 7 1020 9 2 969 Speed Tap Static High Fire Temperature Rise vs External Static pressure in WC Pressure 0 1 0 2 0 3 0 4 0 5 0 6 0 7 Low 98 98 98 99 101 103 109 ML 83 84 84 86 87 89 93 MH wl 71 72 72 73 74 76 High 53 55 55 57 59 60 70 Speed Tap Static Mid Fire Temperature Rise vs External Static pressure in WC Pressure 0 1 0 2 0 3 0 4 0 5 0 6 0 7 Low 88 88 88 89 90 93 98 ML 75 75 75 77 78 80 83 MH 64 64 64 65 65 66 68 High 48 49 50 51 52 54 63 Speed Tap Static Low Fire Temperature Rise vs External Static pressure in WC Pressure 0 1 0 2 0 3 0 4 0 5 0 6 0 7 Low 75 75 75 713 77 79 83 ML 64 64 64 65 66 68 70 MH 54 54 55 55 56 56 58 High 41 42 42 43 45 46 53 Figure 19B Heating speed by input Speed vs color code for PSC Motor Low Red Med Low Blue Med High Yellow High Black 34 M BLOWER CONTROLLER INFORMATION FOR PSC MOTOR Note for ECM blower controller information see ECM Operation Manual document Mo 440 TERMINAL DEFINITIONS amp FIELD WIRING Burner Harness Connector P1 Pin1 Limit switch connector Pin2 120 VAC Line connection Pin3 Burner pilot contact Pin 4 amp 5 120 VAC Neutral connections Pin 6 Burner pilot contact Pin 7 amp 8 From oil primary control Pin 9 Limit Switch Input LSI Field Wiring
43. 8FA119DV5 Furnace Motor Current Draw Amps Watts vs External Static Pressure in W C Low Fire Med Fire High Fire BTUH 101 000 119 000 132 000 Fan Control SW 1 Switch Heating Aprox Aprox Aprox Settings CFM Rise F Rise F Rise F 02 05 3 OFF 2 OFF 1 OFF 1202 78 1 6 146 2 5 233 3 OFF 19 174 2 7 252 2 0FF 1315 71 84 1 ON 3 OFF o o 2 3 206 3 2 294 2 ON 1429 65 77 1 OFF 3 OFF o 2 6 242 3 6 337 2 0N 1565 60 70 78 1 ON i 3 ON Switch 20 1701 55 65 34292 41 399 1 OFF 3 ON 3 7 354 4 8 466 SOFE 1860 59 66 1 ON 3 ON 3 4 7452 5 71567 ON 2041 60 1 OFF 3 ON o 89 587 72 719 ON 2223 55 1 ON m Figure 18 1A ECM blower motor speed chart 29 Heating Speed Set ups 2 Stage OH6FX072DV4 HEATING AIR FLOW TEMPERATURE RISE LOW CAPACITY HIGH CAPACITY FAN BTUH LOW FIRE HI FIRE LOW FIRE HI FIRE CONTROL 60 000 72 000 72 000 90 000 SW 1 HEATING APPROX APPROX APPROX APPROX SWITCH CFM CFM RISE CFM RISE CFM RISE CFM RISE SETTINGS F 3 OFF 2 OFF 740 592 94 740 90 592 113 740 113 1 OFF 3 OFF 2 OFF 812 650 85 812 82 650 103 812 103 1 ON 3 OFF 2 ON 883 706 79 883 75 706 94 883 94 1 OFF 3 OFF 2 ON 968 744 72 968 69
44. 9002 900 TaGHM N 5 H3MOT8 wel 1115005 5115005 A8W3SSv gnS YIMOTA 3299819 289819 1NOHi dOL dl 3189829 189829 3015 1431 ONISYD 3299929 789979 3015 1 9 NISY OL 3089819 089819 6 9coose 9 o0s 1008 YOLYINSN 8 961059 96106 HOLIMS 0981 5NISV2 3015 IHOIH 3148 9 19781 ONISV 30S 1391 314N8 S YNO L4vHd WHAO 13159 t zggie zagie N3ONVHOX3 LYH 19691 19681 IIHS Lv3H z 61981 6 98 asva ON 1499 ON 159 NOlLdIMOS30 SLY d WLI SAQ6LL 48HO 09061L 48HO Angiassv ans 70 Appendix B Wiring Diagrams OH6FA072D48 PSC Wiring Diagram WIRING DIAGRAM WD 561 NOTES 1 REPLACEMENT WIRE MUST BE 5001 MA OHGFAO072D48 TYPE 105 C OR EQUIVALENT 2 CONNECT HOT TO 1 AND COMMON TO 2 LA
45. DDER DIAGRAM ELECTRICAL SCHEMATIC 3 SET HEAT ANTICIPATOR AT 2 AMPS L1 L2 DEHUMI DISTAT 57 aX 1 BLOCKED VENT 0 1 o REQ D FOR T4 S3 LOWER 88 62 CAN CSA STD B140 4 ul 4 p dide neto oy S3 LBK TRANS H 3 E i 1 or a l RIMARY VAK CEMT eg Lot ol BLOWER DELAY SW2 SWITCH SETTINGS 2 WMO 1 LIMIT CEM SONS ESORE BL 15A 130 E E ON DELAY OFF DELAY F sw2 2 1 SEC 4 3 MIN F F 30 FF 2 n BL FACTORY F N 60 FACTORY F N 4 BURNER B s N 240 MINI R BK We Wo 4 qo sw TRANS Da SEC HEE A C UNIT re HIcc UNIT CC H 4 BURNER y CONTROL BK H T BL BL ML BL R LOW BECKETT W OIL BURNER W z S 120 VAC RAL u oL X 9X8X7 L2 Y PU Y w n oe MOTOR E Y BK 1 it Wicnitor BL BL GNITOR TRANSFORMER M W vALvE VALVE I ia ENR E a L DU VET AV lt HUMIDIFIER CAD TRANSFORMER S CELL HUMIDISTAT 3 A RIELLO BURNER CONNECT Y Y TO THERMOSTAT T W TO W amp R TO BK WARNING DUE TO SHOCK HEATING SPEED BY INPUT AND FIRE HAZARD CLASS 2 HEATING AND COOLING TONS OF LOW FIRE MID FIRE HI FIRE COOLING SPEED CIRCUITS MUST REMAIN SEPARATED 2 LOW ML MH LOW LEGEND EAT LOW ML MH ML FIELD WIRING 3 LOW ML MH MH FACTORY WIRING 5 9 LOW ML MH MH 4 LOW ML MH H 71 H6FA072DV4 ECM Wirin
46. DESIGNED OUTLET AIR TEMPERATURE 180 OF LESS INPUT QUTPUT 8 BECKETT AFG N BECKETT NX A AIELLO 002 FOR MAX FROM THE TOP BOTTOM OF THE CLOSET 00085 OR PANELS MEASURING NO LESS THAN 10 TU HR BTU HA NOZ GPH TYPE NOZ GPM TYPE NOZ GPH TYPE AFUE 19 INCHES WIDE BY 9 1 2 INCHES HIGH 72 85 000 72 000 6 30 0 50 70 0 60 80 A so nm 90 106 250 90 000 0 75 30 A 0 60 70 A 0 70 80 A 12A 13 PUMP PRESS 120 PSI 150 PSI 140 PSI FACTORY EQUIPPED NOZZLE USE NO 2 DISTILLATE FUEL OIL FOR MAXIMUM EFFICIENCY AFUE SET THE BURNER COMBUSTION AS INDICATED IN THE CHART ABOVE 00 EXCEED A TRACE SMOKE SPOT AND A 66 F TEMPERATURE RISE ELECTRICAL SPECIFICATIONS 120 VOLTS 60 HZ 1 PHASE TOTAL CURRENT AMPS 8 7 MINIMUM CIRCUIT AMPACITY 10 25 MAXIMUM FUSE SIZE AMPS 15 impe sia ds THERMO PRODUCTS LLC WWE P O BOX 217 NORTH JUDSON IN 46366 gt 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 correct 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 applian
47. E OF CHIMNE Piae d INCHF H H NOTE MOVE CLEAN OUT imm LOCATION UP ABOVE SANI H i LEVEL E T PROPOSED CLEAN OUT LOCATION H H E Ht EXISTING CLEAN OUT LOCATION i BASEMENT FLOOI Fig 5 Suggested method to improve chimney draft 5 TIGHT JOINTS All joints of the chimney must be tightly sealed The inside of the chimney should be free of any obstructions such as loose brick broken pieces of tile or corroded metal 6 TIGHT CLEAN OUT DOORS AND CONNECTIONS All chimney clean out doors and flue connections must fit tightly so they will seal to avoid air leaks 7 NO INTERCONNECTED CHIMNEY FLUES If chimney flues are divided or there are multiple flues within one chimney make sure there are no openings in the partition separating the divided or individual flues 8 FLUE PIPE CLEARANCES SIZING AND TYPE The vent connector pipe must not pass through a combustible wall or partition unless adequate protection is provided at the passageway An acceptable passageway could be either an approved ventilated metal thimble which is at least 12 inches larger in diameter than the vent connector pipe or brick work which is at least 8 inches thick constructed into the wall and surrounding the vent connector pipe See Fig 6 on the next page H TIRE EE F L ENTILATEL PASSAGE THIMELE Fig 6 Suggested method to accommodate vent connector passage through a wall composed of a combustible material
48. F Sw sw 2 1 4 3 MN a F F 30 F r 2 poo y Y FAGTORY F N 60 FACTORY F N 4 xt 11 120 NJF 6 N N 240 N N 8 Y SEC 1 x TRANS swz es Us BR a TE HES o PE 3X6 EE A C UNIT 5 g H pice 2X8 2 ti BLOWER BX RELAY P2 6 M PR NAR WESS L 4 5 w BL HT BL TURNER Y PR de 75 an w 2ND STAGE BK a L Ta 1 CHOKE BK BK BLOWER eet 120 VAC CONTROL fad e NEUTRAL eal 1 CONNECTOR E ODP N N 10 EL 2 3 wJBL O O W R Y w E L5 H be Jed 5 2 d die a 12 8 DE 3 DD TRANSFORMER NR VD i RM 120 Wi 24 V9 e _ HUMIDIFIER boa A TRANSFORMER HUMIDISTAT DEHUMDISTAT mao 2 STAGE T STAT o SJ6J31 71181 11212 MENT J 3 8 JIP E EL MEA lt mi E BJ fe E HEATING AIR FLOW TEMPERATURE RISE OIL s BURNER LOW CAPACITY HIGH CAPACITY COOLING SPEED SET UPS FAN s BTUH LOW FIRE HI FIRE LOW FIRE HI FIRE AIR FLOW en 60 000 72 000 72 000 90 000 EN SWITCH HEATNG APPROX APPROX APPROX APPROX CONTROL SETTINGS CFM CFM RISE F CFM RSF F CFW RISE F CFM RISE T SW 1 SWITCH COOLING 25082 4 SETTINGS TONNAGE COOL CONTINUOUS 2 OFF 740 592 94 740 90 592 113 740 113 T 5 2 799 500 2 12 650 85 812 82 650 103 812 103 x EM 5 OFF 2 5
49. Figure 17 Set the scale to the 1 to 5 or 1 to 6 amp scale TYPICAL SUB BASE 10 LOOPS PASSING THROUGH CENTER OF AMP METER PRONGS Figure 17 Analog Ammeter w Wire Loops to Boost Reading 2 Connect the bare ends of this wire jumper across terminals R 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 3 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 26 This formula can be used to calculate the correct setting for the adjustable heat anticipator Ammeter reading Anticipator Setting No of wire loops Or in this case _2 5 0 25 A Anticipator Setting 10 4 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 5 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 from meter Steps 1 through 3 are not required The meter reading is the correct anticipator setting L Blower Motor Speed Selection AWARNING Turn off the electrical power to
50. NG 72 H6FX072DV4 2 Stage Wiring Diagram WD 588 ECN 5218 MA F LADDER DIAGRAM L2 WIRING DIAGRAM NOTES 1 REPLACEMENT WIRE MUST BE TYPE 105 C OR EQUIVALENT 2 CONNECT HOT TO 1 AND COMMON TO 2 3 SET HEAT ANTICIPATOR AT 7 OH6FX072DV4 2 AMPS 4 SINGLE STAGE T STAT CONNECT W T STAT WIRE ELECTRICAL SCHEMATIC TO WS On E DEI Y KR TO HIGH FIRE BLOCKED VENT KIT fifo D STAT ____ E REQ D FOR t4 Swi coy CAN CSA STD B140 4 a MORS BEEN SDEHUMIDISTAT T D NE I MEN BLOWER DELAY SW2 SWITCH SETTINGS LIMIT sS 7 N ON F OFF MAX LIMIT od l ON DELAY OFF DELAY a oes E OO
51. Oil Furnace Model Nomenclature Example Model Numbers O H 6 01 171 2 D14181B 6 01712 ID V 4 R OI H 8 F IA 111 19 0 6 OI H 8 F IA 111 191 ID V 5 O Oil Highboy D Downflow H 6 Heat Exchanger Size Identifier 6 F Front F R Rear R A Single Stage A X 2 Stage X Heating Capacity MBTUH 000 s with factory installed nozzle 0 7 2 D Direct Drive D Clg Airflow Example 48MBTUH 4 tons 400cfm ton 4 18 Clg Airflow Variable Speed ECM V5 5tons 5 B Beckett R Riello N Beckett NX B I SAFETY SECTION This page and the following contains various warnings and cautions found throughout the Oil Furnace Manual Please read and comply with the statements below ZAWARNING AND CAUTIONS ZA WARNING This furnace is not to be used as a construction heater See Page 3 ZAWARNING The predetermined limit locations on all of the Thermo Pride oil fired furnaces have been tested and approved by Thermo Products LLC Any attempt to relocate these safety controls or replace these safety controls with a control that is not approved or is incompatible may result in personal injury substantial property damage or death See Page 17 ANWARNING THE HEAT EXCHANGER MUST BE CLEANED BY A QUALIFIED SERVICE PERSON See Page 52 A CAUTION DO NOT ATTEMPT TO MAKE REPAIRS YOURSELF See Page 48 ANWARNING The area around the furnace should be kept free and clear of combustible liquids and material espe
52. Operations in Section VIII 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 For Your Safety 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 i STOP Read the safety information above ii Set the thermostat to the lowest setting ili Turn off all electric power to the appliance iv This appliance is equipped with an ignition sys
53. RIES KIT 2 KIT FOR COMBUSTION AIR BURNER 15 application MAX BURNER SPECIFIC APPLICATIONS ONLY THERMO PRODUCTS PART THERMO PRODUCTS THERMO PRODUCTS PART NUMBER PART NUMBER NUMBER OH6 OH8 Beckett AFG AOPS8393 58414 AOPS8394 AOPS8397 Riello BF3 AOPS8393 AOPS8414 AOPS8395 AOPS8416 oon A aeo Aopsssss 58412 AOPS8413 Table 2 Sidewall vent kits The Field vent kit is set up with 4 inch diameter vent pipe for OH6 and 6 inch diameter vent pipe for the OH8 with concentric through the wall vent termination inlet air vent hood The combustion air inlet pipe diameter is also 4 inch diameter For Riello the combustion air inlet pipe will be reduced to 3 inch diameter with the Riello sidewall vent kit For Beckett the combustion air inlet pipe will be reduced to 3 diameter with the Beckett sidewall vent kit The side wall vent may be installed either through the knock out on the right or left side casing of the unit or vertically out the top opening of the vestibule The combustion air inlet can be installed through the either the lower left side casing knockout or the lower right side casing knockout 10 C DRAFT REGULATORS Note Do not use with Direct Vent application A draft regulator is supplied with the furnace and should be installed according to the regulator manufacturers recommendations With the burner operating use a draft gauge to adjust the regulator to the proper setting refer to the
54. S I ee ee 15 F LIMIT POSITION AND LOCATION LLL 17 G BURNER INSTALLATION 18 H BURNER SPECIFICATIONS AND APPLICATIONS 19 OILTANK AND PIPING 22 J OILFILTER EEE EEE 23 K ELECTRICALWIRIING Te 23 L BLOWER SETUP o LLLI 27 M BLOWER CONTROLLER INFORMATION FOR PSC MOTOR 35 N STARTUP PROCEDURES 40 Ill USERS INFORMATION SECTION 48 A OLSUPPLY wince s 48 B COMBUSTION AIR SUPPLY U LLL 48 INSPECTION AREAS 48 D STARTING THE BURNER 49 E FILTER CLEANING AND LOCATION LLL 49 IV INSTALLER S INSTRUCTIONS TO USER 50 V DEALER MAINTENANCE 51 A GENERAL INSPECTION O 51 HEAT ___ 52 C HEAT EXCHANGER CLEANING INSTRUCTIONS 52 D ELECTRICAL SYSTEM LLL 54 E SUPPLY RETURN AIR BLOWER LLL 54 F SUPPLY RETURN AIRFILTER LLL 54 G EXTENDED APPLIANCE SHUTDOWN 55 Vl HOMEOWNER USER INFORMATION AND ROUTINE MAINTENANCE 56 VII TROUBLESHOOTING 58 A DIAGNOSTICS O 59 B CAD CELL CHECK OUT PROCEDURE 59 VIII SEQUENCE OF OPERATIONS FLOW CHART oe aaa 61 IX TROUBLE SHOOTING FLOW 63 APPENDIX A REPLACEMENT PARTS LIST 69 APPENDIX WIRING DIAGRAMS 71 Model Number Digit 1 2 3 4 5 6 7 8 91011 12 uU S Bo O O 5 5 5 S z z a zs O O o z 2 2 o 5 gt IEE
55. T T input of an oil primary control Rating shall be class 2 24 VAC pilot duty 24 VAC lt 200 Power The switched 120 VAC power from the LIMIT switch passes through the board between Pins 1 amp 2 of connector P1 Compressor contactor The control provides switched 24VAC to operate a compressor contactor Rating shall be class 2 24 VAC pilot duty 24 VAC lt 200 36 EAC electronic air cleaner The control provides a 120 VAC output for an electronic air cleaner This output is energized whenever the fan motor is energized either low heat or cool speed Connection is made via male quick connect terminal labeled EAC Humidifier The control provides a 120 VAC output for a humidifier Connections are made to a male quick connect terminal labeled FAN The control does not switch this output it provides a pass through connection from P 1 7 from the switched primary voltage of the Burner Module Status LED A red LED is provided to indicate any thermostat input has been recognized by the microprocessor on the control See Diagnostic Features for a function description of operation Thermostat Input LEDs Four green LEDs are placed beneath their respective thermostat connections W Y G and DEHUM and operate whenever a call is present See Diagnostic Features for a function description of operation C Operating Modes Standby Mode All outputs are off and the control is waiting for a thermostat dem
56. TE BURNER MODEL NO BLAST TUBELGTH AIR SHUTTER AC SYSTEM COMBUSTION CHAMBER CONDITION MATERIAL FURNACE MODEL TYPE OF VENTING SYSTEM MASONRY L METAL L SIDEWALL L MASONRY CHIMNEY CHIMNEY POWER VENTER CHIMNEY L METAL MASONRY CHIMNEY W INDUCER CHIMNEY W METAL LINER W INDUCER COMBUSTION INE SERVICE SERVICE SERVICE INSTALLATION i k I I si TESTS OR ERU nd CO2 in stack pipe Draft Over fire at least 10 inute base Draft in stack pipe Pe EM 111 Gross stack minus furnace room temp j ime R oed Gmds messa INSTALLER NAME amp ADDRESS 68 69 Replacement Parts c zevaig z 299819 dis WANJA Ob GONG Hood 1 9891 HOLY 3000 LbOVNg e 1 xem 1 09979 SS300v yoo g JOULNOO 1441 rg
57. Thermo Pride OIL FIRED FURNACE INSTALLATION AND OPERATION MANUAL WITH USERS INFORMATION SECTION MODEL OH6FA072D48B OH6FA072DV4B OH8FA119D60B OH8FA119DV5B OH6FA072D48R OH6FA072DV4R OH8FA119D60R OH8FA119DV5R OH6FA072D48N OH6FA072DV4N OH6FX072DV4R WARNING IF THE INFORMATION IN THESE INSTRUCTIONS 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 WARNING IMPROPER INSTALLATION ADJUSTMENT ALTERATION SERVICE OR MAINTENANCE CAN CAUSE INJURY OR PROPERTY DAMAGE REFER TO THIS MANUAL FOR ASSISTANCE OR ADDITIONAL INFORMATION CONSULT A QUALIFIED INSTALLER OR SERVICE AGENCY PLEASE READ THESE INSTRUCTIONS PRIOR TO INSTALLATION INITIAL FIRING AND BEFORE PERFORMING ANY SERVICE OR MAINTENANCE THESE INSTRUCTIONS MUST BE LEFT WITH THE USER AND SHOULD BE RETAINED FOR FUTURE REFERENCE BY QUALIFIED SERVICE PERSONNEL THERMO PRODUCTS LLC PO BOX 217 NORTH JUDSON IN 46366 PHONE 574 896 2133 A LIDI CERTIFIED G UL US LISTED MO 437 ECN 5338 MA 140301 Made IN USA CONTENTS SECTION PAGE SAFETY SECTION 1 A CODES AND CLEARANCES O O 3 B MAKE UPAIR 4 Il GENERAL INSTRUCTIONS d 5 A 6 VENTING _ Lee 10 C DRAFT REGULATORS LLL 11 D DUCT WORK AIR CONDITIONING 11 E AIRFILTER
58. WILL BE FLUSH WITH OR AMULET IF APPLICABLE MPs OUTER SURFACE OF CHAMBER SEE BURNER APPLICATION CHART Fig 13 Burner insertion illustration Top view When mounting the burner the mounting plate Fig 12 must be removed to provide access to the area in front of the combustion chamber A fiber insulating sleeve or amulet is provided on the burner tube of specific Thermo Pride burners see Fig 13 See Thermo Pride burner application chart for type of insulator Do not allow the burner tube or end cone to physically touch or protrude into the chamber as excess heat transfer could result in destruction of the tube end cone or both The burner tube end cone is properly positioned when the end is 1 4 inch back from the inside surface of the combustion chamber wall DO NOT CHANGE POSITION OF THE CHAMBER H BURNER SPECIFICATIONS AND APPLICATIONS THERMO BECKETT HEAD STATIC MAXIMUM SHIPPED OIL PRIDE S BURNER PLATE NOZZLE NOZZLE SIZE PUMP FURNACE MODEL BURNER MODEL amp SIZE PRESSURE SPEC NO TUBE LENGTH OH6FA072D B TP2501 AFG 4 5 3 5 8 0 75X80 H 0 60X80 H OH6FA072D N TP2601 NX 4 5 FIXED 0 60X70 H 0 50X70 OH8FA119D B TP2502 AFG 4 5 2 3 4U 1 10X80 H 1 00X80 H The optional BF3 or BF5 Riello flame retention oil burner can be used with OH6 and OH8 THERMO RIELLO HEAD STATIC MAXIMUM SHIPPED OIL PRIDE S BURNER PLATE NOZZLE NOZZLE SIZE PUMP FURNACE MODEL BURNER MODEL amp SIZE PRESSURE SPEC NO TUBE PSIG
59. acement 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 NOTICE Remind the homeowner of the importance of monthly filter inspections during operation to ensure maximum operating efficiency G EXTENDED APPLIANCE SHUTDOWN ACAUTION Do not attempt to start burner when e Primary reset has been engaged more than two times e Excess oil has accumulated in the combustion chamber or beneath the burner assembly e The combustion chamber or the heat exchanger is full of fuel vapor e 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 supply 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 If the shutdown period will exceed one heating season an oil stabilizer should be added to the oil tank Consult your oil supplier for recommendations 55 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 yo
60. and The thermostat inputs and limit switch are continuously monitored The control initiates action when a thermostat call is received or limit switch opens Fan Mode A call for fan G is received from the thermostat If no other mode is calling for blower operation the control will operate the fan relay K4 and power the Low blower speed terminal The fan mode will be operated as long as the G input is calling and neither the Heat mode nor the Cool mode is calling for blower operation When the Heat and Cool modes call for blower operation their respective outputs will take precedence after their respective turn on time delays have expired Cooling Mode A call for cool Y is received from the thermostat If the heat mode is not active or the anti short cycle delay is not in effect the control will energize the CC terminal and after a 10 second power demand conservation delay energizes the COOL speed blower terminal When the call for cool is satisfied the CC terminal is de energized and the cooling off delay of 45 seconds is started Forty five seconds later the COOL speed blower terminal is de energized and the control reverts to Standby Mode Dehumidification Operation If a call for dehumidification is received while the Cool Mode is active blower speeds will be reduced The PSC COOL blower speed terminal 1158 100 model only will be de energized and Low blower speed will be energized Anti Short Cycle Operat
61. and four blower off delays are selected by two dip switches for each function Refer to Table 11 for specific delay values 38 ECM amp PSC TROUBLE SHOOTING DIAGNOSTIC FEATURES The control board is equipped with 4 green Input Status LEDs and 1 red Board Status LED These are intended to provide a quick view into furnace performance without requiring a voltmeter The green Input Status LEDs are driven by the Y W G and DEHUM inputs and are located directly below those inputs They will light to indicate the presence of these signals The red Board Status LED has two functions It will light when the board recognizes a valid input signal and will stay lit until all valid signals are removed This is intended to show that the board is functioning and able to respond to input signals It will flash rapidly while 120VAC is missing from the LIMIT switch This is intended to give a quick visual indication of the High Limit switch 39 N 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 AWARNING 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
62. ber or mineral wool batts sandwiched between two sheets 0 024 24 gauge sheet metal with ventilated air space A Equal the required clearance with no protection B Equals the reduced clearance permitted in accordance with the preceding clearance chart C The protection applied to the construction that covers the combustible material should extend far enough in each direction to make C equal to A The vent connector pipe between the furnace and chimney shall be of equal diameter as the flue outlet of the furnace The vent connector pipe must be made of 24 gauge or thicker corrosion resistant steel The vent connector pipe should be as short as possible and installed so that it has a continuous rise from the furnace to the chimney The horizontal length of a connector to a natural draft chimney or vent serving a single appliance shall not be more than 75 percent of the height of the vertical portion of the chimney or vent above the connector Elbows should be minimized and the pipe should be joined with metal screws and supported by straps All horizontal runs of vent connector pipe should be pitched upward a minimum of inch per foot of run A thimble should be used to connect the vent connector pipe to the chimney so the pipe may be readily removed in case of inspection or replacement See Fig 6 on preceding page B VENTING NOTE On the OH6 amp 8 it is possible to rotate the flue elbow which is factory installed for vertical
63. ble REINSTALL ALL PARTS Should this unit be disassembled all components panels block offs collars gaskets and Heat Exchanger Inspect for Periodic visual inspections should fasteners must be reassembled as originally factory produced corrosion pitting warpage also be made by the owner during Failure to do so may result in property damage injury or loss of life 390056 cracks deterioration carbon build the heating season Call a up and loose gaskets qualified heating servicer to report suspected deficiencies Do not Burner Check for correct attempt to make repairs yourself operation proper combustion no fuel leakage and replace burner Further owner and heating oil filter servicer responsibilities are HAZARDOUS VOLTAGE Avoid contact with exposed live voltage terminals Do not detailed in the printed information 084 bypass or disconnect limit Turn off power prior to service provided with the furnace Failure to do so may result in properly damage injury or loss of life 390526 PROFESSIONAL INSTALLATION AND SERVICE REQUIRED This unit must be installed and serviced by a qualified servicer Failure to do so may result in property damage injury or loss of life 390057 RESEAL HEAT EXCHANGER ACCESS PORTS Clean outs accessible by qualified service personnel only Access to clean out may require removal of panel Be certain clean out covers and or gaskets are intact
64. ce ANWARNING 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 This appliance is shipped completely assembled and internally wired All electrical wiring has been factory installed and inspected At the time of installation the unit will require connection to electric power fuel oil supply and supply and return air ductwork In the event of a shortage of parts or damage contact Thermo Pride office This unit uses a fan assisted combustion system consisting of a pressure atomizing oil burner and combustion air blower used to push the products of combustion through the heat exchanger system After installation the furnace and duct system must be adjusted to obtain a temperature rise of 51 F to 81 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 The installation must also comply with CSA B139 for recommended installation practices where applicable A CODES AND CLEARANCES The following items m
65. cially papers and rags See Page 3 ANWARNING NEVER burn garbage or refuse in your furnace Never try to ignite oil by tossing burning papers or other material into your furnace See Page 48 ANWARNING Thermo Products oil furnaces are designed to burn No 1 or No 2 distillate fuel oil NEVER USE GASOLINE OR A MIXTURE OF OIL AND GASOLINE See Page 48 NCAUTION DO NOT ATTEMPT TO START THE BURNER WHEN 1 Excess oil has accumulated 2 The furnace is full of vapors 3 The combustion chamber is very hot IF ONE OR MORE OF THESE CONDITIONS EXIST CONTACT A QUALIFIED SERVICE PERSON See Page 48 ANWARNING DO NOT START BURNER UNLESS BLOWER DOOR IS SECURED IN PLACE SPECIAL HOMEOWNERS INSTRUCTIONS Improper installation adjustment alteration service or maintenance can cause injury or property ANNUAL SERVICE REQUIRED The following items should be inspected every year by a qualified heating servicer Shut off power before inspecting Chimney Vent Pipe Inspect for restriction loose joints abnormal carbon build up and condensation consult a qualified installer service agency or the gas oil supplier damage Refer to the user s information section in the manual For assistance or additional information 390055 Correct any deficiencies at once Failure to do so may result in injury property damage or loss of life Controls Check for correct operation and proper settings if manually adjusta
66. d paper plant fibers or other materials that are capable of being ignited and burned Such materials shall be considered combustible even though flame proofed 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 A WARNING Carefully read and thoroughly understand the following guidelines and warnings before 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 an oil fired furnace designed for installation on non combustible materials This appliance is also approved for attic installation on non combustible 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 compl
67. ductwork based on a 0 1 in W G static pressure drop The first column to the right is the airflow rate 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 supplier s catalog for proper sizing of outlet air registers and return air grills to insure that they provide the required flow rate at the desired pressure drop 13 CFM DIA SQ RECTANGULAR DUCT DIMENSIONS INCHES 12 113 14 ike 2x12 14 154 4x12 1 201 5x12 24x8 201 Z 6 201 201 e 25 5 255 8 8 255 22 744 314 18 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 fro
68. e 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 b Findalocation for the appliance 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 and operating noise when selecting this location c 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 d Select values for the airflow through each register and grill e 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 f Determine the required flow rate for each branch of the supply and return air systems The total airflow rate by adding the airflow rate of each branch of the supply sy
69. eed in the following manner Turn the disconnecting switch which provides power to the appliance to the OFF position Set the room thermostat above room temperature Verify the oil tank is filled with sufficient fuel oil to operate the appliance Open all valves in the oil supply line to the burner Remove the burner compartment cover from the appliance Open the inspection cover on the upper mounting plate above the burner Turn the disconnecting switch to ON 7 Prime the pump to remove air in the oil supply line 41 ADJUSTABLE AIR BAND AIR ADJUSTMENT SHUTTER Figure 19 Preliminary Adjustment of Burner Air Band and Air Shutter i When ignition is established make a 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 19 Replace the inspection cover above the burner j 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 CO9 or excess oxygen Oo and flue gas temperature In order to achieve the most efficient combustion the following steps must be taken COMBUSTION HEAD SETTING FOR 2 STAGE RIELLO BURNER This is done when fitting the nozzle with the blast tube
70. er material into the combustion chamber ANWARNING 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 56 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 ACAUTION The appliance vent terminal may be hot If the terminal is hot allow it to cool before touching it ACAUTION 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 I
71. etely sealed to the appliance casing Refer to the Airflow Requirements and Sizing of Ductwork section of this manual This area in which the furnace is located must have adequate supply of air for combustion and draft control operation The minimum required volume of free air should be 50ft3 1000 btu per NFPA 54 However if the furnace is located in an area of the building that doesn t meet this requirement two openings into another room are recommended each opening having a free area of 1 square inches per 1 000 BTUH input of the total input of all appliances located in the room If these openings are in a wall they must be at least 6 inches from the ceiling and floor Fig 1A or they are in a door they must be at least 6 inches from the top of the door and 6 inches from the bottom of the door Fig 1B THESE OPENINGS MUST BE FREE AND UNOBSTRUCTED 1 ALL b Fig 1 Properly Positioned Combustion Air Openings In Walls Fig 1A and Doors Fig 1B B MAKE UP AIR Today s emphasis on home insulation increases the probability of inadequate air supply to the furnace Heavy insulation cuts off infiltration of outside air which previously replaced inside air removed by bathroom kitchen and laundry vent fans and air escaping up chimneys This causes a negative pressure differential within the home that reduces the supply of air available to the furnace for
72. f 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 furnace front door 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 28 4 Replace and secure the furnace front door 5 Set the operating mode on the thermostat to HEATING and turn the thermostat temperature setting up OIL PRIMARY CONTROL RESET BUTTON t EC Gam Beckett Burner Riello Burner OIL PRIMARY CONTROL RESET BUTTON Figure 28 Location of oil primary control reset button 57 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 heati
73. g Diagram HEATING SPEED SETTING enne ea AE NOTES 1 REPLACEMENT WIRE MUST BE ECN 5001 MA OHBF A072D V4 TYPE 105 C OR EQUIVALENT 2 CONNECT HOT TO 1 L1 LADDER DIAGRAM L2 SND COMMON TO 2 ELECTRICAL SCHEMATIC 3 SET HEAT ANTICIPATOR AT 5 2 AMPS DEHUMI 52 T DISTAT BE WoE lt WH Tn i BASS N3 CAN CSA STD 140 4 3 1 BLOWER DELAY SW2 SWITCH SETTINGS mM LIMIT N ON F 0FF A l l ON DELAY OFF DELAY FUSE SETTINGS Ei Sw sw2 2 1 sec 3 15 130 ES F IF 30 FiF 2 MES l FACTORY F N 60 FACTORY F N 4 SEDES ils N F 120 N F 6 N N 240 N JN 8 1L2 1 SW2 BK L 3 BR 2d 9 BL a H AC COM z UNIT YE 125 HCC gt w DG S BLOWER J BURNER HE 7 y CONTROL S
74. h Fire Temperature Rise vs External Static pressure in WC Pressure 0 1 0 2 0 3 0 4 0 5 0 6 0 7 Low 90 91 91 92 101 108 114 ML 72 72 74 74 77 80 91 MH 58 58 59 60 62 64 68 High 46 47 49 51 53 56 58 Speed Static Mid Fire Temperature Rise vs External Static pressure in WC Pressure 0 1 0 2 0 3 0 4 0 5 0 6 0 7 Low 72 73 73 73 81 86 91 ML 58 58 59 59 61 64 72 MH 46 47 47 48 50 52 54 High 37 38 39 41 42 45 47 Speed Tap Static Low Fire Temperature Rise vs External Static pressure in WC Pressure 0 1 0 2 0 3 0 4 0 5 0 6 0 7 Low 60 61 61 61 68 72 76 ML 48 48 49 49 51 53 60 MH 39 39 39 40 42 43 45 High 31 32 33 34 35 37 39 Figure 19A Heating speed by input 33 OH8FA119D60 Low Fire HTG Speed by Input Mid Fire High Fire ALTERATIONS REQ D FOR A C DESIGN EXTERNAL STATIC PRESSURE COOLING UNIT Recommended CLG Speed Furnace Airflow CFM vs External Static pressure in WC Speed Tap Static Pressure 0 1 0 2 0 3 0 4 0 5 0 6 0 7 Low 1254 1254 1251 1246 1221 1189 1126 ML 1473 1464 1460 1437 1415 1377 1329 MH 1733 1731 1718 1705 1686 1660 1627 High 2300 2243 2224 2166 2099 2048 1754 Furnace Motor Current Draw Amps Watts vs External Static pressure in WC Low 6 6 648 6 6 648 6 4 639 6 2 630 6 0 612 5 8 592 5 4 565 ML 7 6 7
75. he piping and discard any excessively corroded piping 5 Areadily accessible design certified manual oil shutoff valve with a non displaceable rotor member shall be installed in the fuel oil supply piping within 6 feet of the appliance 6 A pipe union or flanged connection shall be provided downstream from the manual oil shutoff valve to permit 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 7 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 8 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 9 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 10 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 f
76. humidifier will be required Field wiring of control circuits should consist of copper conductors rated for at least 15 amp service with an insulation temperature rating conforming to Type T wire 35 G 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 vestibule Consult the wiring diagram for the appropriate connection points on the thermostat and the fan control module Maximum Time Delay Supply Return Type Fuse ppy Assembly yp Recommende Potential Frequenc Air Blower Full Full Load or Inverse y No of Phases Load Current Curent Time d PE ee Amps Pawan Wiring oe 115 VAC pate Size AWG Amps Oil Burner Minimum OH6FA072DV5 10 1 EOM SHEEATISDVET 420 60 1 EON 2PSC DE 120 60 1 7 PSC OH8FA119DV5 191ECM Table 10 Typical Electrical Requirements Wire size selections in Table 10 are based upon Table 310 16 of the National Electrical Code for three copper conductors with insulation rated for 75 degrees 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 followi
77. hysical damage by vehicles ANWARNING This furnace is not to be used as a construction heater 5 Listed below are definitions of COMBUSTIBLE MATERIAL and NON COMBUSTIBLE MATERIAL Combustible Material is made of or surfaced with wood compressed paper plant fibers plastics or other material that will ignite and burn whether flame resistant or not Non Combustible Material is material that is not capable of being ignited and burned Such materials consist entirely of or a combination of steel iron brick tile concrete slate or glass Table 1 MINIMUM CLEARANCES TO COMBUSTIBLE MATERIALS FROM TOP amp IE OF MODEL NO SIDESOF FRONT SIDES OF SEVEN REAR FURNACE PLENUM Highboy OH6FA072D 0 Note 1 7 0 Highboy OH8FA119D 0 Note 1 8 0 Note OH6 front clearance 6 for Closet 24 for Alcove 2 OH8 front clearance 8 for Closet 24 for Alcove The minimum clearances listed in the preceding table are for fire protection Clearance for servicing the front of the furnace should be at least 24 inches NOTE The OH6 amp OH8 furnaces are approved for closet installation If the OH6 is installed in a closet it requires two openings in the closet door for combustion air each having a minimum area of 162 sq inches The OH8 requires two openings in the closet door each having a minimum area of 181 sq inches This free area intentionally exceeds the recommended min
78. imum free area of 1 square inch per 1000 BTUH of input rate A CHIMNEY The furnace must be connected to an adequate chimney or an approved vent in accordance with these instructions An adequate chimney is one that is sealed and lined with the capability of producing a 04 WC flue draft and having the capacity to handle the amount of stack gases that are introduced into it A chimney with an internal construction of corrosion resistant tile stainless steel or some other material that will withstand flue gas temperatures up to 900 F is required Qualified service personnel must perform all installations and services The following are common chimney requirements necessary for the furnace to operate correctly A masonry chimney serving a Thermo Pride oil fired furnace must comply with local codes and NFPA Standard for Chimneys Fireplaces Vents and Solid Fuel Burning Appliances NFPA211 1996 or latest edition 1 PREVENTION OF CHIMNEY CONDENSING Stack gas may do one of two things as it escapes up the chimney A Remain entirely in a gaseous state if the internal chimney wall temperature is above the dew point B Condense water vapor on the chimney walls if they are chilled below the dew point Condensing will always occur on chimney walls whose temperatures are below the dew point but the condensate may evaporate when the walls warm above the dew point If the chimney wall temperature does not exceed the dew point during
79. instructions enclosed with draft regulator to adjust to the proper setting When the burner air supply and draft are properly adjusted the over fire draft should be a negative 01 to 02 WC as measured at the 5 16 over fire air tap See Fig 12 This tap is provided in the upper burner mounting plate To measure the flue draft punch a small hole in the vent connector pipe as close to the furnace as possible and always before the draft regulator Note Draft over fire may be positive for high fire applications but not to exceed 02 WC D DUCT WORK AIR CONDITIONING If the furnace is used in connection with summer air conditioning cooling the furnace should be installed parallel with or on the upstream side of the evaporator coil to avoid condensation in the furnace heat exchanger If the cooling unit is installed with a parallel flow arrangement dampers or other means used to control flow of air should be provided to prevent chilled air from entering the furnace If such a damper is manually operated it must be equipped with a means to prevent operation of either unit unless the damper is in the full heat or cool position The duct system should again follow the current design standard of Air Conditioning Contractors of America ACCA or ASHRAE Fundamentals volume The most common location for the A shaped coil A style is shown in Fig 8 COIL CABINET NNN HIGHBOY FURNACE Fig 8 Acceptable locations f
80. ion To prevent compressor short cycling a call for cooling will be ignored for four minutes after the termination of any cooling call The anti short cycle delay is also in effect at power up 37 Heat Mode When a call for heat W is received from the thermostat if the Cool mode is not already active the T T terminal is energized and the blower on delay is started The on off pattern of DIP switch SW2 positions 1 and 2 select one of four blower on delay values see Table 11 When the delay time has elapsed the HEAT blower speed is energized The control remains in steady heat mode until the thermostat is satisfied When the call for heat signal is removed the T T terminal is de energized and the blower off delay is started The on off pattern of DIP switch SW2 positions 3 and 4 select one of four blower off delay values see Table 11 When the delay time has elapsed the HEAT blower speed terminal is de energized DIP SWITCH 2 SECTION STATE BLOWER DELAY TIMES 1 2 3 4 EO ON SEC OFF MIN OFF OFF 15 30 ON OFF 24 60 OFF ON 36 120 ON ON 48 240 OFF OFF 2 ON OFF 4 OFF ON 6 ON ON 8 Table 11 ON and OFF Blower Delay Time Switch Settings Motor Blower Speed Three interconnected blower speed outputs are provided A G call for fan will provide power to the LOW speed tap only A W heat call
81. ir 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 airflow rate 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 51 to 81 temperature rise b For cooling 400 CFM of airflow are required per ton of air conditioning For reference a ton of A C 12 000 BTU hr removed from the space Refer to Examples 1 amp 2 page 15 for a sample calculation of how to determine the required minimum airflow rate 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 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 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 th
82. ivets through the securing flange of the filter rack 15 Connect the return air plenum to the filter rack and slide the filter into place Dimensions for adapting the return air plenum to the filter rack are provided See Fig 10a amp 10b 2 1 8 aN ars 95 E lt 15 FLANGE ui FOR RETURN AIR DUCTWORK CONNECTION gt 24 1 2 FLANGE c d FOR RETURN AIR DUCTWORK CONNECTION FILTER DOOR Fig 10a A typical filter rack and dimensions for the OH6 furnace FILTER RACK WRAP o 6 1 8 ASSEMBLY SHEET METAL SCREWS 4 REQUIRED 19 FLANGE 20 FOR RETURN AIR DUCTWORK CONNECTION 23 3 4 FLANGE FOR RETURN AIR DUCTWORK CONNECTION FILTER RACK DOOR oN FILTER DOOR ASSEMBLY 20x25x6 FILTER RACK ASSEMBLY Fig 10b A typical filter rack and dimensions for the OH8 furnace A CAUTION 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 or use of a different filter type is desired refer to Table 4 below for minimum sizing guidelines for selecting filter for the unit 16 Maximum Filter Type Air Velocity Model Number OHG OH8 ft min Thermo Products T Permanent Table 4 Minimum Required Filter Area in square inches The Thermo Products supplied filter can be cu
83. lectrical specifications on these components 4 Check for correct operation and proper settings if manually adjustable of all controls E 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 F SUPPLY RETURN AIR FILTER The filter rack will be located between the return air plenum and the return air opening on the side of the furnace 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 Filter maintenance procedure Shut off the electrical power to the unit Open the access door Slide the 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 54 BLOWER COMPARTMENT DOOR FILTER Figure 26 Location of Supply Return Air Filter Filter replacement To ensure an adequate repl
84. lectrodes spark Burner motor energized On power interruption system shuts off restarts when power is restored Oil valve energized after 15 second time delay Y Start trial for ignition Y If flame is not detected the oil valve is de energized the ignitor is turned off and the ignition control module goes into the retry sequence Flame must be detected after 45 seconds The retry sequence provides a 60 second wait before ignition is attempted again 63 TURN THERMOSTAT TO CALL FOR HEAT DOES THERMOSTAT MAKE CONTACT No No i IS ROOM TEMPERATURE IS ROOM TEMPERATURE TURN T STAT SETTING BELOW THERMOSTAT SETTING ABOVE ROOM TEMPERATURE Yes ALLOW THE ROOM AIR TO COOL CHECK IN PUT POWER DISCONNECTING SWITCH AND FUSE S IF EQUIPPED DOES BURNER MOTOR START CHECK FOR LINE VOLTAGE FAN CONTROL MODULE IF NOT 115 VAC CHECK FOR BLOWN FUSE OR TURN ON POWER IF 115 VAC PRESENT CHECK OUT FAN CONTROL MODULE amp PRIMARY MODULE ACCORDING TO MANUFACTURER S INSTRUCTIONS IS THE BURNER PRIMARY LOCKED OUT ON SAFETY 15 VOLTAGE PRESENT No AT BURNER MOTOR Yes PUSH IN PRIMARY RESET BUTTON IS THE OILPUMP No MECHANICALLY LOCKED UP REPLACE BURNER MOTOR Yes REPLACE OIL PUMP 64
85. low of oil 11 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 with 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 22 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 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 8 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
86. m or heat gain to the ducts 8 As a final step in the installation the appliance must be adjusted to deliver a temperature rise within the range of 51 to 81 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 MAIN TRUNK TAKE OFF S 8x12 400 CFM 10x6 200CFM 8x12 400 S 10x6 200 800 CFM 10X6 200 10x6 to 6 100 6 100 800CFM MAIN TRUNK WARM MAIN TRUNK LINE AIR LINE gt lt 10x6 8x12 PLENUM 8x12 10x68 lt Fig 9 Supply air duct sizing Example The RETURN AIR DUCT SYSTEM should equal the warm air duct system in airflow capabilities NOTE When a return register is located in the same room as the furnace the register must be at least 20 feet away from the furnace 14 SIZING THE DUCT WORK FOR A COMBINATION HEATING AND COOLING SYSTEM Two formulas must be used in determining the CFM requirements of a combustion heating and cooling system 1 HEATING CFM HEAT OUTPUT OF FURNACE BTUH 1 1 X TR TEMPERATURE RISE F HEATING CFM EXAMPLES A 110 000 BTUH OUTPUT 1 1 X 85 F TR 1176 CFM FOR HEATING B 110 000 BTUH OUTPUT 1 1 X 70 F TR 2 1429 CFM FOR HEATING 2 COOLING CFM 400 CFM X COOLING TONNAGE 12 000 BTUH PER TON AIRFLOW FOR COOLING CFM EXAMPLES A
87. n for the control operation Thermostat call for cool Y 24 VAC thermostat input A call for cooling is recognized when the thermostat connects Y to R This input has an indicator LED that will light when the control receives a call for cooling Refer to the Cool Mode section for the control operation Thermostat call for dehumidification DEHUM 24 VAC thermostat input A call for dehumidification is recognized when the humidistat connects DEHUM to R This input has an indicator that will light when the control receives a call for dehumidification Refer to the Cool Mode section for the control operation Thermostat call for fan G 24 VAC thermostat input A call for fan is recognized when the thermostat connects G to R This input has an indicator LED in that will light when the control receives a call for fan Refer to the Fan Mode section for the control operation B Outputs PSC Control The control shall control a five speed indoor blower motor Rating shall be 10 FLA 30 LRA 120 VAC Connections are made via 0 250 x 0 032 male quick connect terminals labeled HEAT COOL and LOW HEAT is energized when the heat speed blower is to run COOL is energized when the Cool speed blower is to run LOW is energized during a call for fan is received or a call for dehumidification is received Oil Burner Control The control provides dedicated contacts to operate the
88. ng 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 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 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 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 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 Electronic
89. ng 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 The following maintenance points should be reviewed periodically to assure the heating and cooling systems continue to function properly A WARNING 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 1 Atleast 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 23 for a sketch of the filter location 2 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
90. of the flame sensor Diagnostic Features The Beckett Genisys 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 R7184B under normal operating conditions the LED will be continuously lit 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 2 second on 1 2 second off for the model R7184B A CAUTION If the appliance fails to relight after resetting the primary control twice contact a qualified service company DO NOT continue to reset primary control The operational condition of the flame sensor or cad cell can be checked by
91. ong flexible wire brush and an industrial type vacuum cleaner to remove any soot build up NOTE A one inch outside diameter vacuum cleaner hose will fit into the radiator To vacuum and brush the outer radiator of the heat exchanger go through the clean out openings in both directions as shown in figure 25 on the next page 3 Reassemble the furnace to its original construction 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 may indicate the burner is out of adjustment When returning clean out plugs to their original position insert plug and turn T handle clockwise 2 3 turns or until plug cannot be pulled from the clean out access tube This is sufficient for sealing the access tube Replace any damaged or corroded components All gaskets and insulation must be inspected and replaced if they show any signs of damage 52 CLEANOUT OPENI HEAT EXCHANGER CLEAN OUT ACCESS TUBE CLEAN OUT P PART OF CLEAN OUT PLUG ASS EMBLY 2 TURN on T HANDLE lt COUNT Figure 24 Heat Exchanger Clean Outs Vacuum Hose Length OH6 8FT OH8 8FT LUG ASSEMBLY T HANDLE ER CLOCKWISE 0 LOOSEN amp REMOVE PLUG ASSEMBLY Fig 25 Recommended method and device for cleaning inside of heat exchanger 53 cM HE NC 2
92. or the air conditioner evaporator coil NOTICE The minimum coil pan clearance for a sectional or drum type heat exchanger is three inches unless specified otherwise by the individual coil manufacturer NOTICE The minimum return air temperature is 55 F 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 5 in W G This is equivalent to 0 1 in W G supply and 0 1 in W G return and 0 3 in W G for evaporator coil 11 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 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 a
93. osition desired Then lock the nut 2 Pressure regulation this is set at 130 psi at the factory Should such pressure be reset or changed just turn the screw 4 The pressure gauge must be mounted in place of cap 5 2 STAGE ADJUSTMENT Adjustment of air shutter place the small plug 9 of the economizer 10 into the position II Item B In this way the burner remains permanently in the 2 stage Loosen the nut 6 turn the screw 7 until the air shutter 1 reaches the position desired Then lock the nut 6 Pressure regulation this is set at 170 psi at the factory Should such pressure be reset or changed just turn the screw 8 The pressure gauge must be mounted in place of cap 5 i 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 NOTICE To achieve proper combustion and the efficiencies listed in sales brochures instruments must be used to secure CO or readings 44 i CARBON DIOXIDE CO2 OR OXYGEN Take a sample from flue passageway It is possible to achieve readings of up to 14 or 2 but it is better to have a slightly lower or higher O gt reading with
94. oting chart beginning on the following page should help identify the type of malfunction or deviation from normal operation To use this diagram just follow the instructions in the boxes If the answer is yes or the condition is true go down to the next box If the answer is no or the condition is false go to the box on the right Continue checking and answering questions and conditions in each box until a problem and or repair is found After any maintenance or repair the trouble shooting sequence should be repeated until normal system operation is achieved 60 VIII Sequence of Operations Flow Chart Mode of Operation Standby At any time the oil valve is not energized Start Y Start trial for ignition Control System Action Continous safe operation check If flame simulation condition present system shuts off oil valve ignitor and burner motor activates fast flashing LED Thermostat calls for heat contacts close Ignition electrodes spark Burner motor energized Oil valve energized after 15 second time delay Y Flame must be detected after 45 seconds 61 On power interruption system shuts off restarts when power is restored If flame is not detected the oil valve is de energized the ignitor is turned off and the ignition control module goes into the retry sequence The retry se
95. quence provides a 60 second wait before ignition is attempted again Main Burner Operation Y Call for Heat Satisfied Y Y Repeat Ignition Trial Y System Lockout End of Cycle After 45 second delay the ignition electrodes are de energized The circulating air fan is energized at heating speed The optional electronic air cleaner amp humidifier are energized Y Y If ignition attempt is unsuccessful the ignition control module goes into system lockout When thermostat is satisfied contacts open and the oil valve is de energized After a 2 minute burner off delay burner motor is de energized The 2 minute delay to fan off period begins Y After the delay to fan off period ends the circulating air fan and optional electronic air cleaner are de energized 62 Y If system is in lockout check if LED is flashing fast try to recycle the system by depressing the RESET button on the ignition control module IX Trouble Shooting Flow Chart 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 r contacts close Ignition e
96. r 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 C HEAT EXCHANGER CLEANING INSTRUCTIONS ANWARNING THE HEAT EXCHANGER MUST BE CLEANED BY A QUALIFIED SERVICE PERSON It is important to inspect and clean the heat exchanger once a year or as necessary to remove any build up of soot A layer of soot on the inside of the heat exchanger will act as an insulator and reduce heat transfer resulting in less efficiency 1 To clean the heat exchanger first turn off all power to the unit Remove clean out plugs the vent connector pipe to the chimney the burner and the burner mounting plates When removing the clean out plugs turn T handle counterclockwise approximately two 2 full turns or just until the plug is able to be pulled from tube Take care not to remove T handle from assembly 2 With access to the inside of the heat exchanger through the burner area clean out openings and vent pipe connection it is possible to use a l
97. re selected based upon the following assumed characteristic values of the fuel oil suitable for use with this appliance design e Forno 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 F or gravity of 30 60 F 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 45 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 22 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 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 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 body f Allow the fuel flow rate to stabili
98. 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 AWARNING 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 A CAUTION 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 ANWARNING Shut off oil and disconnect power before continuing with 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 If necessary replace a severely damaged or 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
99. stem must equal the minimum required airflow rate refer to part 3 above Likewise the airflow rate of each of the branches of the return air system must sum to the required minimum flow rate 12 g Using the selected air flow rates 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 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 flow rate h The resistance of the take off and the outlet register or return grill should then be 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 flow rates 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 page 14 fora 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
100. t its end facilitates counting the number of turns AIR DAMPER ADJUSTMENT The settings indicated in the schedule refer to the burner with its metal cover fitted and the combustion chamber with zero depression These regulations are purely indicative Each installation however has its own unpredictable working conditions actual nozzle output positive or negative pressure in the combustion chamber the need of excess air etc All these conditions may require a different air damper setting It is important to take account of the fact that the air output of the fan differs according to whether the burner has its metal cover fitted or not Therefore we recommended to proceed as follows e adjust the air damper as indicated in the schedule 3 e mount the cover simply by means of the upper screw e check smoke number e should it become necessary to modify the air output remove the cover by loosening the screw adjust the air damper remount the cover and finally recheck the smoke number The burner is provided with a hydraulic device controlled by the economizer which reduces the max output of oil and air by approximately 7096 43 Item A Hem B Figure 22 1 STAGE ADJUSTMENT Adjustment of air shutter place the small plug 9 of the economizer 10 into the position I Item A In this way the burner will remain permanently in the 1 stage Loosen the nut 2 turn the screw 3 until the air shutter 1 reaches the p
101. t to size to fit other filter retention systems as long as the maximum air velocity is not exceeded NOTICE Any internal stiffeners used in the filter must not be removed although they can be cut to size as needed F LIMIT POSITION AND LOCATION ANWARNING The predetermined limit locations on all of the Thermo Pride oil fired furnaces have been tested and approved by Thermo Products LLC Any attempt to relocate these safety controls or replace these safety controls with a control that is not approved or is incompatible may result in personal injury substantial property damage or death The unit listed in the table below must have the limit control installed at the time of unit installation I WARM AIR PLENUM TABLE 5 Installation location of A j the fan and limit control for each N D furnace DIM A MODEL OH6FA072D 3 1 2 1 3 8 OH8FA119D 3 1 2 1 5 8 FURNACE Fig 11 Limit location for OH6 amp OH8 17 G BURNER INSTALLATION NOTICE Remove all cardboard packing from around chamber before installing burner The oil burner will mount on three stud mounting bolts on the lower mounting plate covering the opening in the front of the heat exchanger The end of the burner tube should be inserted no further than 1 4 inch back from the inside surface of the combustion chamber A
102. tem that automatically lights the burner Do not try to light the burner by hand V Rotate the manual oil shutoff valve to the ON position vi Turn on the electric power to the appliance vii Set the thermostat to the desired setting viii If the appliance will not operate call your qualified service technician or oil supplier 40 To Turn Off Oil to Appliance i Set the thermostat to the lowest setting and set the operating mode switch to OFF ii If service is to be performed turn off the electrical power to the appliance ili Turn the manual oil shutoff valve to the OFF position 2 Adjustment of Burner Combustion AWARNING Maximum gross stack temperature must not exceed 550 F 288 C under any circumstances A CAUTION 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 e Asmoke density measuring and rating device e Acarbon dioxide CO or oxygen O gt analyzer e Aflue gas temperature measuring device e g thermocouple or thermister probe with readout device e Ananalog or digital multimeter and e Anoil pressure gauge capable of reading 0 150 PSIG To initially fire the oil burner proc
103. the chimney is on the home s exterior or passes through a sizable unheated area of the building such as a porch high ceiling attic etc and condensing occurs the chimney must be insulated around its exterior to help the flue hold its temperature Also check to see if the chimney is too large for the furnace and other appliances connected to it If so reduce to proper size see Appendix E of NFPA31 by lining Be sure to use stainless steel liners such as stainless types 430 304 or for the toughest corrosion problems type 316 If the chimney is the correct size for the unit and condensing still occurs then insulating the vent connector and or reducing the efficiency of the furnace may have to be done to raise the chimney temperature More detailed information may be obtained from the latest edition of the ASHRAE HVAC Systems and Equipment Handbook 2 PROPER CHIMNEY HEIGHT The chimney shall terminate at least 3 feet above the highest point where it passes through the roof of a building and at least 2 feet higher than any portion of a building within a horizontal distance of 10 feet See Fig 2a FIGURE 2 FIGURE 2b LESS THAN 10 19 HEIGHT ABOVE ANY ROOF SURFACE WITHIN L 10 HORIZONTALLY 2 MIN RIDGE I CHIMNEY 3 MIN MORE THAN 10 CHIMNEY 3 MIN TERMINATION LESS THAN 10 FT FROM RIDGE WALL OR PARAPET TERMINATION MORE THAN 10 FT FROM RIDGE WALL OR PARAPET A
104. the heat exchanger iv 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 66 F A higher temperature rise will slightly lower the heating efficiency A lower temperature rise will slightly raise efficiency but may cause condensation 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 51 F maximum temperature rise is 81 F Notice Minimum return air temperature is 55 F k After final adjustments are completed tighten all screws to fix the positions of the burner air band Check for the presence of oil leaks Correct any oil leaks found m Reassemble the burner compartment cover n 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 rate 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 we
105. the heating cycle of the furnace the moisture may accumulate in large enough quantities to cause problems such as corrosion of a metal chimney especially plain steel or galvanized steel erosion and break up of a tile liner in a masonry chimney and in severe cases corrosion of the heat exchanger Condensate also could enter the home through cracks or joints in the chimney in a worse case situation Condensation most likely will not occur at the bottom of the chimney because the stack gas heats the chimney walls as it rises and the bottom will be heated first This heating of the walls will cause the stack gas temperature to drop which in turn may reduce the stack gas temperature below dew point causing condensation to appear on the upper part of the chimney first This condensation may then run down inside the chimney and drip back as far as the flue pipe and heat exchanger where corrosion may occur if not treated To prevent condensation it is necessary that the internal chimney wall temperature always be kept above the dew point If the chimney is a masonry type it may have to be fitted with a flue liner when the temperature loss is too great for the furnace If the chimney is a metal type then an all fuel chimney must be used such as a Class A triple wall or insulated metal chimney A liner will act as an insulator and reduce the stack gas temperature loss Insulation may be added around the liner for further temperature stability If
106. to Burner Pilot Tstat Neutral Line Harness Wires Yellow Wires White Red Beckett Connections T T terminals White Black Riello Connections T stat terminals White Black Thermostat Humidistat connections ground Thermostat call for heat R 24 VAC to thermostat G Thermostat call for fan Y Thermostat call for cool DEHUM Humidistat call for dehumidification TXV systems ONLY Male quick connect terminals 51 3 120 Hot 1 7 120 VAC Neutral EAC Electronic Air Cleaner 120 VAC connection FAN Fan On Signal x 24 VAC from transformer C 24 VAC common from transformer CC Compressor Contactor CC_COM Compressor Contactor Common LOW Continuous Blower Speed HEAT Blower heat speed tap COOL Blower cool speed tap 35 A Inputs Power supplies Line voltage is applied between the S1 and N1 quick connect terminals 24 VAC Class II Transformer secondary voltage supplied to X and C Limit switch The 120 VAC optically isolated limit switch input is connected on pin P2 1 amp 9 Refer to the Heat Mode section for the control operation Thermostat_call for heat W 24 VAC thermostat input A call for heat is recognized when the thermostat connects W to R This input has an indicator LED that will light when the control receives a call for heat Refer to the Heat Mode sectio
107. ur oil supplier for recommendations Change the oil filter cartridge and clean the canister Set the room thermostat above room temperature Open all valves in the oil supply line Open the inspection cover on the upper mounting plate OD 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 27 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 bleeding 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 NOZZLE PORT PORT AIR BLEED VALVE EE 2 RETURN PORT amp INLET INTERNAL BY PASS Figure 27 Location of Oil Pump Vent Plug 8 Follow the previous Initial Burner Operation procedures VI HOMEOWNER USER INFORMATION AND ROUTINE MAINTENANCE ANWARNING Never burn garbage or refuse in this appliance Never try to ignite oil by tossing burning papers or oth
108. ust be considered when choosing the size and location of the unit k All 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 NFPA Two applicable NFPA 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 2 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 The heating capacity of the unit proposed for installation should meet or slightly exceed the rate of heat loss for the residence Over sizing should not exceed 25 of the heat loss calculation 3 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 4 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 or surfaced with wood compresse
109. ze 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 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 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 All OH6 amp OH8 models are designed and wired at the factory for a blower speed during heating that should result in an approximate temperature rise of 66 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 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 After 15 to 20 minutes of continuous operation the temperature rise

Thermo Products OH6FA072D48R Furnace User Manual

Contents

Download Pdf Manuals

Related Search

Related Contents