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Thermo Products OD6RX072DV5R Furnace User Manual

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2. No IS THE COUPLING BETWEEN No gt THE BURNER MOTOR AND gt REPLACE PUMP 5 OPERATING THE PUMP STRIPPED Yes Yes REPLACE COUPLER IS OIL AVAILABLE TO THE BURNER M gt VERIFY ALL OIL VALVE S ARE OPEN OIL TANK IS SUFFICIENTLY FULL Y FURNACE OPERATES FOR COMPLETE CYCLE AND OIL LINE CONTAINS OIL No BURNER RUN NORMAL 10 No IS HEAT ANTICAPATOR SET Ng MEASURE MILLIAMPS BETWEEN amp R CYCLE TO MILLIAMP SETTING ON THE T STAT SUBBASE AND SET HEAT MEASURED ON SUBBASE ANTICIPATOR ACCORDINGLY Y Yes Yes IF PROBLEM PERSISTS CONTINUE TO NEXT SECTION Yes BLOWER RUNS LNo 15 TEMPERATURE RISE No l CHECK BLOWER SPEED NORMAL CYCLE AND RETURN AIR TEMPERATURE CHECK FAN ON amp DIP SWITCH SETTINGS ON FAN CONTROL 62 USTION ACHIEVED No 15 THE PROBLEM DELAYED Yes IS THE AIR TUBE INSERTION No 0 1 4 BACK FROM INSIDE AIR TUBE BURNOFF Yes CORRECT INSERTION OR 2 IGNITION OF REFRACTORY MAY OCCUR Yes THE ELECTRODES ALIGN ELECTRODES PER PROPERLY ALIGNED 7 BURNER INSTRUCTION MANUAL SPECIFICATIONS Yes IS PUMP PRESSURE SET ADJUST TO 100 120 PSI No ACCORDING TO
3. LADDER DIAGRAM 15A LIMIT AUX AUX LIMIT LIMIT d AUX AUX LIMIT LIMIT PR PR CONTROL 1 CONNECTOR 3 10 8 15 16 2 6 5 4 12 7 BL FAN CONTROL viwW2RH 8 ORC 4DEHUMIDISTAT OIL 2 STAGE 5 o BURNER HEATING AIR FLOW TEMPERATURE LOW CAPACITY LOW FIRE HI FIRE 60 000 72 000 BTUH WIRING DIAGRAM OD6 X072DV5 FUSE SETTINGS ELECTRICAL SCHEMATIC EHUMIDISTAT ODUN ER 0000 uy S 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 2 AMPS 4 SINGLE STAGE T STAT CONNECT W T STAT WIRE TO W2 FOR 15 MIN DELAY TO HIGH FIRE SW SEE CHART BELOW BLOWER DELAY SW2 SWITCH SETTINGS N 0N F OFF N DELAY OFF DELAY SEC 30 60 120 240 or 2 F F N N 2 2 CONTROL BL CHOKE 120 NEUTRAL EAC TRANSFORMER TRANSFORMER WARNING DUE TO SHOCK AND FIRE HAZARD CLASS 2 HEATING AND COOLING CIRCUITS MUST REMAIN SEPARATED SW 1 SWITCH SETTINGS HEATING APPROX APPROX CFM CFM RISE F CFM RISE 604 91 755 87 604 109 661 100 755 109 826 100 718 92 898 92 1025 50 1282 52 SETTING RECOMMENDED HEATING SPEED 11
4. Aue pejeiredo Jo pue eq jou pun eu pessed Aq Jo peJege eq JOU jes aJd Huey pue ayj periddns uorum 0009 jur eine ay Ajeyeuunin seoejins ayy jo pide esneo eoeuin e jo uonsnquuoo eui Buusjue uaym uorum y jo Aue 10 euo si v uoneorydde O77 sjonpold Bunoejuoo jeujsnpul 10 suononujsul pue OTT SLOn aod OINHaH L 10 pue sepoo ejejs pue 220 YM eouepioooe ui peurejureui pue dn jas paesu eq Jun eu L S epoo Bunuea Uy eouepioooe ui peuDisep 5 6 e pue suonepueuluiooel uonipe juano enuey Jo Buruonipuo adv yogy uy eouepioooe ulejs s e uj ejeedo jun eu o peuDisep y yojym feni eui ti pue ayy uo payeotpul se Ayoedeo pajen sy uyma pejeredo eq yun eq Ajneeq syewopune Kup eq se uons sjsixe e eudsoule e einjonujs Aue pe ejsui eq jou yun eu Jej
5. The retry sequence provides a 60 second wait before ignition is attempted again TURN THERMOSTAT TO CALL FOR HEAT DOES THERMOSTAT MAKE CONTACT No IS ROOM TEMPERATURE BELOW THERMOSTAT SETTING No IS ROOM TEMPERATURE TURN T STAT SETTING ABOVE ROOM TEMPERATURE 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 Yes Yes ALLOW THE ROOM AIR TO COOL CHECK IN PUT POWER DISCONNECTING SWITCH AND FUSE S IF EQUIPPED DOES BURNER MOTOR START No iS VOLTAGE PRESENT 2 AT BURNER MOTOR OUT ON EAEI Yes Yes Yes PUSH IN PRIMARY RESET BUTTON IS THE OIL PUMP Ng MECHANICALLY 5 LOCKED UP Yes REPLACE OIL PUMP 61 Yes IS IGNITION ESTABLISHED No ARE THE ELECTRODES No TION TRANSFORMER No REPLACE IGNITION ARCING gt CAPABLE OF PRODUCING TRANSFORMER 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 IS THE OIL PUMP
6. REMOVE RIGHT BLOWER ACCESS DOOR TO ACCESS FILTERS AFTER INSPECION AND OR CLEANING OF FILTERS RE INSTALL FILTERS AND ACCESS DOOR Fig 23 Filter Location for OD6 46 IV INSTALLER S INSTRUCTIONS TO USER After completing the installation the installer shall inform and or demonstrate to the homeowner the following items 1 The location of these instructions The instructions 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 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 fr
7. TRANSFORMER 24v 350464 1 350464 1 350464 1 OC INDUCTOR 2 350856 350856 1 OD HARNESS VESTIBULE 350329 350326 350459 1 1 PANEL BLOWER ACCESS RIGHT 8649 18649 8649 1 12 BRACKET LIMIT SPACER 18652 18652 18652 1 12A LIMIT SWITCH 350783 350783 350783 1 3 GASKET 330119 330119 330119 1 4 BAFFLE RIGHT SIDE CASING 8460 18460 8460 1 5 BAFFLE LEFT SIDE CASING 8461 18461 8461 1 6 FILTER RACK 62865 628651 628651 1 7 PLENUM STRIP 18 750 618462 2 618462 2 518462 2 8 PLENUM ANGLE 8653 2 18653 2 8653 2 9 PLENUM ANGLE 8309 2 18309 2 8309 2 20 BLOWER SUB ASSEMBLY 50054158 50054159 50054189 1 340042 340042 340042 20A BLOWER HOUSING 120 9 120 9T 120 9T 1 350337 AOPS7474 AOPS7474 208 MOTOR 1 2 HP 1 ECM 1 1 200 AUXILIARY SWITCH 35089 2 350891 2 350891 2 350073 20D CAPACITOR 10 370 20 HARNESS BLOWER COMPARTMENT 350330 350327 350327 1 21 CLEAN OUT PLUG ASSEMBLY 50054456 4 50054456 4 50054456 4 22 PLATE CLEAN OUT 18555 4 18555 4 18555 4 23 GASKET PLATE 330215 4 330215 4 330215 4 24 DOOR PULL 320157 2 320157 2 320157 2 25 5 ELBOW LOW PROFILE 36050 1 36050 1 36050 1 26 DRAW COLLAR 14121 1 14121 1 14121 1 27 GASKET FLUE COLLAR 330073 1 330073 1 330073 1 28 29 30 COMBUSTION CHAMBER HARD 380685 1 380685 1 380685 31 CHAMBER RETAINER 18557 1 18557 1 18557 1 32 PLATE BURNER MOUNTING 31891 1 31891 1 11700 32A HINGE ASSEMBLY
8. 41 ii CARBON DIOXIDE CO2 OR OXYGEN 02 Take CO sample from flue passageway It is possible to achieve readings of up to 14 CO or 2 O but it is better to have a slightly lower CO or higher O2 reading with zero smoke measured To achieve a lower CO reading open the air band or shutter on the burner until zero smoke is measured For example if a 13 CO or 3 5 is recorded at a trace of smoke open the air shutter until zero smoke is measured with 12 CO or 4 5 Adjustment of the burner to achieve a slightly lower CO reading is recommended although it slightly reduces combustion efficiency to keep the heating system within normal operating conditions though external conditions may vary Some out of spec conditions which may adversely affect burner performance are low oil supply temperature dirty contaminated oil low heating content BTU gal oil cold heat exchanger surfaces and downdraft conditions By adjusting the burner in this manner an operational tolerance is established allowing the burner to function well even under less than ideal conditions This results in less service and maintenance during a heating season iii 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 tempe
9. HAR 35032 350326 550459 11_ PANEL BLOWER ACCESS RIGHT 18649 18649 18649 2 BRACKET LIMIT SPACER 18652 18652 18652 12A LIMIT SWITCH 350783 350783 350783 3 GASKET 330119 330119 330119 4 CHAMBER EXTENSION 380723 380723 380723 5 RACK 628651 62865 628651 16 PLENUM STRIP 18 750 618462 2 618462 2 618462 2 7 PLENUM ANGLE 18653 2 18653 2 18653 2 18 PLENUM ANGLE 18309 2 18309 2 18309 2 19 BLOWER SUB ASSEMBLY 50054163 50054164 1 50054164 1 340042 340042 340042 9A BLOWER HOUSING 120 91 120 97 1 120 9T 1 350337 0 57474 AOPS7474 98 MOTOR 2 HP 1 ECM 1 HP ECM 1 9C AUXILIARY LIMIT SWITCH 9 2 35089 2 350891 2 19D CAPACITOR 3 19E HARNESS BLOWER COMPARTMENT 350330 350327 350327 20 CLEAN OUT PLUG ASSEMBLY soos 4 50 4 50054489 4 21 PLATE CLEAN OUT 18553 4 18553 18553 22 GASKET TRIM PLATE 330215 4 330715 4 330215 4 3 DOOR PULL 320157 2 32015 2 320157 24 DRAW COLLAR 4121 14121 14121 25 GASKET FLUE COLLAR 330073 330073 330073 26 27 28 COMBUSTION CHAMBER HARD 380685 380685 380685 29 CHAMBER RETAINER 18557 18557 18557 30 PLATE BURNER MOUNTING 31891 31891 11700 30A HINGE ASSEMBLY AOPS7219 31 GASKET BURNER MOUNTING PLATE 330212 330212 330212 32 COVER OVER FIRE DRAFT OPENING 1 18556 18556 33 34 35 36 KNOB BRIGHT CHROME 1 2 320145 1 320145 1 320145 1 37 38 39 DRAFT CONTROL 370110 1 370110 1 370110 1 40
10. 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 50 F to 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 A CODES AND CLEARANCES The following items must be considered when choosing the size and location of the unit 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 t
11. WIRING DIAGRAM 006 0720 5 ELECTRICAL SCHEMATIC MIT Fl TTINGS s 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 2 AMPS RECOMMENDED HEATING SPEED SETTING Aux AUX LIMIT LIMIT N ON F OFF gt ON DELAY O PR P3 BL A D UNIT 3X6 HEC 2X5 Ww 210 Ona LOWE PR 7 25 25 1 foe BECKETT rle _____ 120 VAC BURNER c 2020 2 21 NEUTRAL woot al 90817 1 DON GE spe ene kk 355 MIS p 12 T Ww 1 OR v gk MOTOR 14 TRANSFORMER IGNITO l lu ENTIE E TEEN lor 1 ANE i E Xt dcr HUMIDIFIER CAD HUMIDISTAT CELL RIELLO BURNER CONNECT Y Y TO THERMOSTAT W TO W amp R TO BK HEATING SPEED SET UPS LOW FIRE 60 000 MED FIRE 72 000 HI FIRE 90 000 APPROX APPROX RISE RISE SWITCH SETTINGS CFM APPROX RISE COOLING SPEED SET UPS AIR FLOW COOLING TONNAGE COOL CONTINUOUS 2 5 2010 993 WARNING DUE TO SHOCK AND FIRE HAZARD CLASS 2 HEATING AND COOLING CIRCUITS MUST REMAIN SEPARATED FIELD WIRING FACTORY WIRING 71 OD6 X072DV5 2 Stage Wiring Diagram WD 585 4822
12. refer to Fig 7 18 inches 9 inches 6 inches Sides amp Sides amp Sides amp Above Rear Above Rear Rear Required clearance with no protection from the appliance or chimney connector is a 3 1 2 thick masonry wall without ventilation air space 1 2 insulation board over 1 glass fiber or mineral wool batts 0 024 24 gauge sheet metal over 1 glass fiber or mineral wool batts reinforced with wire on rear face with ventilated air space 9 1 2 thick masonry wall with ventilation air space e 0 024 24 gauge sheet metal with ventilated air space qn mom f 1 2 thick insulation board with ventilation air space Se ae 37 9 9 0 024 24 gauge sheet metal with ventilated air space over 0 024 24 gauge sheet metal with ventilated air space h 1 glass fiber 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
13. Block return air opening or disconnect blower motor leads Restore power to appliance In the heating mode set the thermostat above room temperature producing call for 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 44 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 BL
14. NITS GPH INPUT RATE CAPACITY Beckett Riello BTU HR BTU HR OD6F RAO60D 50 50 70 000 60 000 OD6F RA072D 60 60 85 000 73 000 OD6F RAO90D 75 70 106 250 90 000 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 MODEL OD6 2 STAGE PART MTG PLATE PART NO we MTG PLATE GASKET 330212 PART NO NOZZLE SIZE 70 X 45 W NOZZLE 380702 PART NO OIL PUMP AL PRESSURE BURNER G5D BURNER PART NO PONET 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 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 For more specific burner information specifications or service information referen
15. Watts Amps 6 OFF 0 2 102 1 16 5 OFF 2 799 500 4 OFF 0 5 165 1 83 6 OFF 0 2 149 1 68 5 OFF 2 5 1017 508 4 ON 0 5 238 2 60 6 OFF 0 2 213 2 35 5 ON 3 1210 605 4 OFF 0 5 306 3 27 6 OFF 0 2 304 3 32 5 ON 3 5 1404 702 4 0 5 419 4 40 Factory 6 ON 0 2 462 4 83 SW1 Switch 5 4 1622 799 Settings 4 OFF 0 5 584 5 96 6 ON 0 2 813 8 18 5 ON 5 2010 993 4 0 5 1000 10 1 NOTE All information is approximate Results will vary by installation Figure 18 3 Cooling blower motor speed chart 30 For PSC systems the 72 hp motor is equipped with 5 speeds The unit is set for mid fire temp rise 65 F See table for proper blower motor set up Speed Tap Furnace Airflow CFM vs External Static pressure in WC Static Pressure 0 1 0 2 0 3 0 4 0 5 0 6 0 7 Low 930 915 912 910 822 774 730 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 28 3 1 3 02 2 91 2 64 2 49 2 36 ML 4 18 4 02 3 91 3 74 3 59 3 34 2 95 MH 5 44 5 17 4 95 4 72 4 43 4 21 3 95 High 6 61 6 36 6 04 5 73 5 46 5 17 4 9 Speed Tap High Fire Temperature Rise vs External Static pressure in WC Static 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 Tap M
16. 12 000 BTUH 1 200 FOR COOLING 1TON B 400 CFM X 2 5 TON 12 000 BTUH 1 000 FOR COOLING 1 TON IMPORTANT SIZE THE DUCT SYSTEM FOR THE LARGER OF THE TWO AIRFLOW REQUIREMENTS AirFilters Filter Installation The OD6 comes with 2 two 18 3 4 x 12 3 4 reusable filters A W style filter rack is shipped with the furnace for placement of the filters inside the return air plenum Access to the filters is through the removable blower door For horizontal installations it is recommended that return air grill filters be installed for homeowner access 19 125 3 000 Fig 10 A typical filter rack and dimensions for the OD6 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 Filter Type Air Velocity Model Number OD6 Supplied Permanent 2 filters 238in each Permanent 2 filters 288in each Disposable 300 960 in 2 filters 480in each Table 4 Minimum Required Filter Area in square inches The Thermo Products supplied filter can be cut to size to fit other filter retention systems as long as the minimum size requirement is met NOTICE An
17. AOPS7219 33 GASKET BURNER MOUNTING PLATE 330212 1 330212 1 330212 34 COVER OVER FIRE DRAFT OPENING 18556 1 18556 1 18556 35 36 37 38 KNOB BRICHT CHROME 1 2 320145 1 320145 1 320145 39 40 41 DRAFT CONTROL 370110 1 370110 1 370110 1 4 43 44 45 46 FILTER 370041 2 370041 2 370041 2 47 48 49 50 FRONT CENTER PANEL 618715 1 618715 1 618715 1 51 FRONT BOTTOM PANEL 628716 1 628716 1 628716 1 67 Replacement Parts for OD6R 072D 68 in SUB ASSEMBLY 50040917 50040918 50040924 00684072048 006407225 OD6RX072DV5 PARTS DESCRIPTION o qm PART NO PART NO 1 BASE 8648 18648 18648 2 CASING LEFT SIDE 628645 628645 628645 CASING RIGHT SIDE 628646 628646 628646 4 FRONT SEPARATOR 618640 618640 618640 5 ANEL FRONT 628641 628641 628641 6 FRONT TOP PANEL 618714 618714 618714 7 EXCHANGER 38633 38633 38633 8 __ CASING 618643 618643 618643 9 BLOWER PAN 18677 18677 18577 10 CONTROL PANEL SUB ASSEMBLY 50054475 50054476 50054477 10A CONTROL FAN TIMER AOPSB380 AOPS8381 350184 108 TRANSFORMER 24v 350464 350464 350464 10C INDUCTOR z 350856 350856
18. Never operate the appliance without clean air filters in place A CAUTION 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 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 55 Vil TROUBLESHOOTING THIS SECTION IS ONLY TO PERFORMED BY TRAINED QUALIFIED SERVICE PERSONNEL AND NOT BY THE FURNACE OWNER NOTI
19. 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 at 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 40 Item Figure 22 1 STAGE ADJUSTMENT
20. 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 position 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 O2 readings
21. CONNECTIONS All chimney clean out doors and flue connections must fit tightly so they will seal to avoid air leaks 8 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 B 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 Fig 6 Suggested method to accommodate vent connector passage through wall composed of a combustible material CONSTRUCTION USING COMBUSTIBLE MATERIAL PLASTERED UNPLAS TERE D OC APPLIANCE OR CHIMNEY OR VENT CONNECTOR SHEET METAL OR OTHER PROTECTIUN 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
22. Hz Ph Amps 115 Circuit Power Wiring VAC Amps Breaker 115 VAC Size Size AWG Amps oero 75285 17 0067072075 oem Table 10 Typical Electrical Requirements for Various OD6 Models 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 following items 1 Check every electrical connection of push on or screw on type terminals to ensure that all wires and wire connectors are firmly secured A loose terminal can cause poor flow of electrical power to motors 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 d
23. 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 airflow resistance of the duct system attached to this appliance must fall within the allowable external static pressure range for this unit Refer to the Airflow Requirements and Sizing of Ductwork section of this manual 5 Make sure supply and return air ducts are completely sealed to the appliance casing Refer to the Airflow Requirements and Sizing of Ductwork section of this manual 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 5015 1000 btu 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
24. 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 Ec COIL CABINET COUNTERFLOW HORIZONTAL Fig 8 Acceptable locations for 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 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 1 Supply and return air ducts have to be furnished by the installer and run between the appliance
25. drop per 100 ft of duct 7 The supply and return air ducts or flexible joints should be carefully secured and sealed to the appliance housing to prevent air leakage from or into the duct system For best performance insulate the outside surfaces of the ducts to reduce heat loss from or heat gain to the ducts 13 8 As a final step in the installation the appliance must be adjusted to deliver a temperature rise within the range of 50 to 80 F Adjust the blower motor speed to obtain a temperature rise within the acceptable range The required blower speed will depend on the airflow resistance of a supply and return air duct systems 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 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 1176 FOR HEATING 110 000 BTUH OUTPUT 1 1 X 70 F TR 1429 FOR HEATING 2 COOLING CFM 400 CFM X COOLING TONNAGE 12 000 BTUH PER TON AIRFLOW FOR COOLING CFM EXAMPLES 400 CFM X 3 TON
26. 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 33 Humidifier The control provides a 120 VAC output for a humidifier Connections are made to a male quick connect terminal labeled The control does not switch this output it provides a pass through connection from P1 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 demand 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 l
27. 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 ANARNING 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 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 pro
28. horizontal applications the mounting plate and chamber retainer will need be rotated 90 left or right depending on furnace position 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 PSIG LENGTH OD6 072D B TP2501 IN AFG 4 5 3 5 8 0 75X80 H 0 60X80 im The optional BF3 Riello flame retention oil burner can be used with OH6 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 LENGTH OD6 072D R C8511325 EN BF3 4 5 NA 0 70X80 0 60X80 LEM Table 6 Beckett amp Riello burners specifications INSULATOR S SLEEVE OR THE NOZZLE SIZE GIVES THE NOMINAL FLOWRATE IN GPH FOLLOWED BY THE SPRAY ANGLE DEGREE S AND THE SPRAY PATTERN EITHER H FOR HOLLOW OR 5 FOR SOLID CONE FOR EXAMPLE A NOZZLE RATED AT 0 65 GPH 100 PSIG THAT PROVIDES 80 SPRAY ANGLE AND HOLLOW SPRAY PATTERN WOULD 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 OIL NOZZLE CAPACITY CHART NOZZLE SIZE EQUIVALENT HEAT EFFECTIVE HEATING
29. oil by tossing burning papers or other material into your furnace NWARNING Thermo Pride oil furnaces are designed to burn No 1 or 2 distilate fuel oil NEVER USE GASOLINE OR A MIXTURE OF OIL AND GASOLINE 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 45 D STARTING THE BURNER 1 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 ANWARNING 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 PLENUM ON 9 9 NN FILTER ge RIGHT BLOWER 4 ACCESS DOOR
30. part of the control system and any oil control that has been under water Operating Instructions STOP Read the safety information above ii Set the thermostat to the lowest setting iii Turn off all electric power to the appliance iv This appliance is equipped with an ignition system 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 37 To Turn Off Oil to Appliance 1 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 iii Turn the manual oil shutoff valve to the OFF position 2 Adjustment of Burner Combustion A WARNING Maximum gross stack temperature must not exceed 550 F 288 C under 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 smoke density measuring and rating de
31. 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 8 ENS Y Y 8 Fig 1 Properly Positioned Combustion Air Openings In Walls Fig 1 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 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 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
32. 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 physical damage by vehicles ZAWARNING 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
33. 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 Underwriters Laboratories Inc USTED woe sam J OIL FIRED FURNACE CERTIFIED TO UL STD 727 FOR USE ONLY WITH R W BECKETT OIL BURNER MODEL AFG TP 2501 OR RIELLO OIL BURNER MODEL C8511325 390025 BECKETT E IDENTIFIER INPUT BTU HR OUTPUT BTU HR NOZZLE GPH TYPE NOZZLE GPH TYPE Aue 60 70 000 60 000 0 50 80 A 0 50 80 1 1 72 85 000 72 000 0 60 80 0 60 80 11 11 90 106 250 90 000 0 75 807A 0 70 80 125 13 PUMP PRESSURE 120 PSI 140 PSI FACTORY EQUIPPED WITH 0 60 80 A NOZZLE USE 2 DISTILLATE FUEL OIL FOR MAXIMUM EFFICIENCY AFUE SET THE BURNER COMBUSTION AS INDICATED IN THE CHART ABOVE DO EXCEED A TRACE SMOKE SPOT AND 65 F TEMPERATURE RISE ELECTRICAL SPECIFICATIONS 120 VOLTS 60 HZ 1 PHASE TOTAL CURRENT AMPS 8 7 MINIMUM CIRCUIT 10 25 MAXIMUM FUSE SIZE AMPS 15 THERMO PRODUCTS LLC mean gee ve P O BOX 217 NORTH JUDSON IN 46366 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 DIRECT DRIVE BLOWER EXTERNAL STATIC PRESSURE INCHES W C 0 20 TO 0 50 MAXIMUM DESIGNED OUTLET AIR TEMPERATURE 180 F OR LESS FOR INSTALLATION IN A CLOSET ALCOVE OR ATTIC WITH C
34. 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 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 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 Counterflow Operation Counter flow operation will be allowed if JW10 is cut If JW10 is not cut the control will not perform any of the Counter Flow Operation as described below Counter Flow Operation is only valid when a call for Heat is present Counter Flow Operation will bring the blower on at a defined low speed at a defined time between the enabling of the burner and the selected turn on time delay Turn on delay times for the Counter Flow Operation are defined in Ta
35. 39 48 1424 46 72 HUMIDIFIER HUMIDISTAT COOLING SPEED SET UPS AIR FLOW CONTINUOUS FIELD WRING FACTORY WIRING tT ce VW CO p diz ayers ON eues ON JePoIN Sseippy uoneieisu jo seu diz ejeis Aio ic 968 v 8 Hd Sselppv 9959 uospnr uuoN Liz 0 SUN 971 SH3HIO JIAO SIH AHL A8 ASNSIW ASN dO ADNANDASNOD JHL 404 ALTAYA TIY S3INGSSV SIHL dO 3ONY Ld390V YASVHOWNd ONY ANY 30 39 VIAVO LNANDASNOS ON SIWNSSY OTI stondosd OWYSHL HSNNVIA ANY NI ALNVHHYM SIHL 30 SINH31 SHL ASIGOW MO O1 ALIHOHLR V SVH NOS33d ON 211 SLONGOdd 40 ONY S3IENVHSVAA H3HLO 53035 43415 A18838dX3 ALNVYNVAA SIHL 03151 530 ANY THM ANY OL SYN UY 5 pod sjoe anp Aue ejqisuodssJ jou EUS 011 SseJppe sy yun eu eaeuin JO epis eu uo eq dund yeay Buruonipuoo are uoneanDijuoo uBIsep sy oyo
36. 41 42 43 44 FILTER 370041 2 370041 2 370041 2 46 47 48 FRONT CENTER PANEL 618718 1 618718 1 618718 1 49 FRONT BOTTOM PANEI 628716 1 628716 1 628716 1 69 Appendix Wiring Diagrams OD6 A072D48 PSC Wiring Diagram WIRING DIAGRAM WD 565 OD6 A072D48 ECN 4822 PB LADDER DIAGRAM LIMIT AUX AUX LIMIT LIMIT BURNER CONTROL BECKETT OIL BURNER RIELLO BURNER CONNECT Y Y TO THERMOSTAT W TO W amp R TO BK HEATING SPEED BY INPUT ELECTRICAL SCHEMATIC 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 2 AMPS BLOWER DELAY SW2 SWITCH N ON F OFF SETTINGS N OFF DELAY sw2 F ACTORY FACTORY 0 1 N F 30 60 120 240 2 F F N N TRANSFORMER COOLING SPEED 2 ML LOW ML 2 5 ML MH ML 3 ML MID FIRE HI FIRE LOW LOW LOW LOW M MH LOW 70 DA TRANSFORMER HUMIDISTAT WARNING DUE TO SHOCK AND FIRE HAZARD CLASS 2 HEATING AND COOLING CIRCUITS MUST REMAIN SEPARATED LEGEND FIELD WIRING FACTORY WIRING D6 A072DV5 Wiring Diagram 0 584 4822 LADDER DIAGRAM
37. BURNER No UNLESS COMBUSTION APPLICATION CHART AIR OR OIL BELOW 50 deg F IS PRESENT THIS IS CONSIDERED BELOW Yes ARE VENT TERMINAL AND HEAT EXCHANGER CLEAN Y ADJUST AIR TO A TRACE OF SMOKE THEN TAKE CO2 OR No IS BURNER SET TO O2 READING NEXT SUBTRACT IS THE NOZZLE PRODUCE ATRACE ____ 1 FROM THE CO2 OR ADD 1 TO O2 THEN ADJUST AIR TO THEN DETUNED OBTAIN NEW 2 OR O2 VALUES Yes IS WATER DIRT OR No SLUDGE PRESENT IN THE OIL SYSTEM Yes 15 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 63 Yes DOES FURNACE OPERATE WITHOUT CONDENSING IS STACK TEMPERATURE IS BURNER SET AS INDICATED ADJUST BURNER COMBUSTION IN ABOVE SECTION TO PRODUCE ZERO SMOKE Yes SLOW THE BLOWER SPEED IS THE TEMPERATURE TO RAISE TEMPERATURE Yes DIFFERENCE BETWEEN SUPPLY RISE Yes Yes INCREASE LENGTH OF BURNER ON CYCLE 7 9 BY RESETTING BURNER PRIMARY CONTROL DIP SWITCHES FOR A LON
38. CE 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 Checkfor 115VAC line supply voltage to the furnace If there is no supply voltage check fuses and service switch NCAUTION When testing electrical equipment always follow standard electrical procedures 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 of the flame sensor Diagnostic Features The Honeywell brand model R7184B or alternate R7184U 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
39. DLE COUNTER CLOCKWISE TO LOOSEN amp REMOVE PLUG ASSEMBLY HEAT EXCHANGER CLEAN OUT ACCESS TUBE CLEAN OUT PLUG ASSEMBLY T HANDLE PART OF CLEAN OUT PLUG ASSEMBLY Figure 24 Heat Exchanger Clean Outs 2 OUTER RADIATOR ANOUT OPENING CLEANOUT OPENING Fig 25 Recommended method and device for cleaning inside of heat exchanger 50 4 Operational Check NCAUTION 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 NWARNING 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 t
40. FETY 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 ZAWARNING This furnace is not to be used as a construction heater See Page 3 CAUTION MUST BE TAKEN TO EXCEED 90 ROTATION OF THE FLUE ELBOW LEFT OR RIGHT FROM THE VERTICAL POSITION See Page 10 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 16 Z WARNING THE HEAT EXCHANGER MUST BE CLEANED BY A QUALIFIED SERVICE PERSON See Page 49 NCAUTION DO NOT ATTEMPT TO MAKE REPAIRS YOURSELF See Page 45 Z WARNING The area around the furnace should be kept free and clear of combustible liquids and material especially papers and rags See Page 3 ZAWARNING 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 45 ZAWARNING Thermo Products oil furnaces are designed to burn 1 or No 2 distillate fuel oil NEVER USE GASOLINE OR A MIXTURE OF OIL AND GASOLINE See Page 45 DO NOT ATTEMPT TO START THE BURNER WHEN 1 Excess oi
41. Figure 18 1 ECM blower motor speed chart 28 Heating Speed Set ups 2 Stage LOW CAPACITY HIGH CAPACITY FAN CONTROL SW 1 SWITCH SETTINGS BTUH LOW FIRE 60 000 HI FIRE 72 000 LOW FIRE 72 000 HI FIRE 90 000 HEATING CFM APPROX CFM RISE F APPROX CFMIRISE F APPROX CFM RISE F APPROX CFMIRISE F 3 OFF 2 OFF 1 OFF 755 604 91 755 87 604 109 755 109 OFF 2 OFF 1 ON 826 661 83 826 80 661 100 826 100 OFF 2 ON 1 OFF 898 718 70 898 74 718 92 898 92 3 OFF 2 ON 1 ON 983 786 64 983 67 786 84 983 84 3 ON 2 OFF 1 OFF 1068 854 59 1068 62 854 77 1068 77 3 ON 2 OFF 1 ON 1168 934 54 1168 57 934 71 1168 71 Factory SW1 Switch Settings 3 ON 2 ON 1 OFF 1282 1025 50 1282 52 1025 64 1282 64 3 ON 2 ON 1 ON 1424 1139 48 1424 46 1139 58 1424 58 Recommended heating speed setting Figure 18 2 ECM 2 stage blower motor speed chart 29 Cooling Speed Set ups Air Flow Fan Control SW1 Static Switch Clg Pressure Settings Tonage Cool in W C
42. GER OFF DELAY Y TROUBLE SHOOTING ENDS REPEAT PROCEDURE UNTIL TROUBLE FREE OPERATION IS OBTAINED EFFECTS OF PRESSURE ON NOZZLE FLOW RATE NOZZLE RATING AT 100 PSI 50 65 75 85 90 1 00 1 10 1 20 1 25 NOZZLE FLOW RATES IN GALLONS PER HOUR Approx 80PSI 120PSI 0 45 0 58 0 67 0 76 0 81 0 89 0 99 1 07 1 12 0 55 0 71 0 82 0 93 0 99 1 10 1 21 1 31 1 37 140PSI 0 59 0 77 0 89 1 00 1 07 1 18 1 30 1 41 1 48 NOZZLE RATING AT 100 PSI 1 35 1 50 1 65 1 75 2 00 2 25 2 50 2 75 3 00 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 64 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 STATE HEATING BURNER MODEL NO BLAST TUBE LGTH AIR SHUTTER OPENING INS OF MAX EST SYSTEM COMBUSTION CHAMBER CONDITION MATERIAL FURNACE MODEL TYPE OF VENTING SYSTEM L MASONRY L METAL L SIDEWALL L MASONRY CHIMNEY CHIMNEY POWER VENTER CHIMNEY L METAL MASONRY CHIMNEY W INDUCER CHIMNEY W METAL LINER W INDUCER INITIAL commustion att oy
43. IELLO 2 STAGE MTG PLATE HAS OD6R 072D EMBOSSMENT INSTALL 2 STAGE MTG PLATE WI HORIZONTAL RAISED SURFACE TOWARD COMBUSTION CAMBER AND BURNER MTG STUDS TOWARD FRONT OF FURNACE OVERFIRE DRAFT ACCESS PORT BURNER MOUNTING STUD 8 PLACES OVERFIRE DRAFT ACCESS PORT BURNER MOUNTING STUD 3 PLACES RAISED SURFACE OF EMBOSSMENT RIELLO 2 STAGE MTG PLATE Fig 12 2 Typical location of the overfire air tap and components in burner mounting plate area OD6R 072D counterflow and horizontal installations 18 HEAT EXCHANGER DRUM I 1 4 n E N AY Sc uM BURNER MOUNTING PLATE BURNE D gt NSULATING SLEEVE ON E ir OR AMULET IF APPLICABLE WALL 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 inch back from the inside surface of the combustion chamber wall For
44. LEARANCES TO UNPROTECTED COMBUSTIBLE MATERIAL NOT LESS THAN ANY SIDE OF SUPPLY PLENUM TOP SIDES REAR FLUE PIPE INCHES 1 1 0 0 6 7 24 INCHES FOR SERVICE PURPOSES MAY BE INSTALLED ON COMBUSTIBLE FLOORING WITH COMBUSTIBLE FLOOR BASE NO D6 BASE CLOSET INSTALLATION REQUIRES TWO SEPARATE VENTILATION OPENINGS LOCATED 6 INCHES FROM THE TOP AND BOTTOM OF THE CLOSET DOORS OR PANELS MEASURING NO LESS THAN 17 INCHES WIDE 8 1 2 INCHES HIGH THIS UNIT APPROVED FOR COUNTERFLOW AND HORIZONTAL LEFT RIGHT APPLICATIONS 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 appliance NWARNING 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
45. OCK 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 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 NWARNING The area around the furnace should be kept free and clear of combustible liquids and material especially papers and rags ZAWARNING NEVER burn garbage or refuse in your furnace Never try to ignite
46. RD COMBUSTION CAMBER OD6F 072D OF HORIZONTAL OVERFIRE DRAFT ACCESS PORT BURNER MOUNTING STUD 3 PLACES OVERFIRE DRAFT ACCESS PORT BURNER MOUNTING STUD 3 PLACES RAISED SURFACE OF EMBOSSMENT RIELLO 2 STAGE MTG PLATE Fig 12 1 Typical location of the overfire air tap and components in burner mounting plate area for OD6F 072D counterflow and horizontal installations 17 HEAT EXCHANGER CLEAN OUT 4 PLACES BURNER MOUNTING LIMIT PLATE GASKET BURNER MOUNTING PLATE BURNER NUT amp WASHER CHAMBER EXTENSION MOUNTING 4 PLACES REAR FLUE MODELS ONLY STUDS 3 PLACES COMBUSTION CHAMBER OVERFIRE DRAFT ACCESS COVER CHAMBER RETAINER OVERFIRE DRAFT BURNER ACCESS PORT NOTE MOUNTING PLATE FOR BECKETT RIELLO SINGLE STAGE PLATE SHOWN RIELLO 2 STAGE MTG PLATE HAS T EMBOSSMENT INSTALL 2 MTG PLATE W OD6R 072D RAISED SURFACE TOWARD COMBUSTION CAMBER AND BURNER MTG STUDS TOWARD FRONT OF COUNTERFLOW FURNACE COMBUSTION CHAMBER HEAT EXCHANGER CLEAN OUT 4 PLACES BURNER MOUNTING PLATE GASKET LIMIT CHAMBER EXTENSION BURNER MOUNTING PLATE REAR FLUE MODELS ONLY OVERFIRE DRAFT ACCESS COVER NUT amp WASHER 4 PLACES BURNER MOUNTING STUDS 3 PLACES OVERFIRE DRAFT BURNER ACCESS COVER MOUNTING PLATE OVERFIRE DRAFT ACCESS PORT CHAMBER RETAINER NOTE MTG PLATE FOR BECKETT RIELLO SINGLE STAGE SHOWN R
47. SERVICE service SERVICE 2 TESTS Operate burner at least 10 minutes before Smoke number starting tests Gross stack temp Furnace room temp Net stack temp Gross stack minus furnace room temp Efficiency Nozzle size and spray Oil pump pressure Operation of Controls Burner Safety Controls Check for oil leaks Tests taken by Date NOTES INSTALLER NAME amp ADDRESS 65 Appendix Replacement Parts Replacement Parts for OD6F 072D 6 9 6589 9 gt 66 SUB ASSEMBLY 50040915 50040916 50040925 006 072048 OD6FAO72DV5 OD6FX072DV5 ITEM PARTS DESCRIPTION PART NO qm PART NO PART 11 1 18648 1 18648 1 18648 1 2 CASING LEFT SIDE 628645 1 628645 1 628645 1 3 CASING RIGHT SIDE 628646 1 628646 1 628646 1 4 PANEL FRONT SEPARATOR 618639 618639 618639 1 5 PANEL FRONT 628641 628641 628641 1 6 FRONT TOP PANEL 618714 618714 618714 1 7 HEAT EXCHANGER 38626 38626 38626 1 8 CASING BACK 618642 618642 618642 1 9 BLOWER PAN 18647 18647 18647 1 0 CONTROL PANEL SUB ASSEMBLY 50054475 50054476 50054477 1 CONTROL FAN TIMER AOPSB380 AOPS8381 350184 1
48. TION ot reo ee cec tu ca aad B COMBUSTION AIR SUPPLY C D STARTING THE BURNER E FILTER CLEANING AND LOCATION IV INSTALLER S 5 V DEALER MAINTENANCE Qmnmoou m D gt lt VI HOMEOWNER USER INFORMATION AND ROUTINE MAINTENANCE VII TROUBLESHOOTING APPENDIX A REPLACEMENT PARTS LIST APPENDIX B WIRING DIAGRAMS WARRANTY 66 70 73 Model Number Digit 1 2 3 4 5 6 7 8 9 10 11 12 o OFS SSO Gals 5 55 25555255 5 cs s roO al m 2 Lco o 2 gs olol oj 2 ui lt lt Ol d I Oil Furnace Model Nomenclature Example Model Numbers O D 6 07 12 01418 B 6 017 206 5 6 07 2 0 4 8 B 6 01712 5 6 017 2 5 6 01712 5 O Oil D Downflow D 6 Heat Exchanger Size Identifier 6 F Front F Rear R A Single Stage A X 2 Stage X Heating Capacity MBTUH 000 s with factory installed nozzle 01712 D Direct Drive D Clg Airflow Example 48MBTUH 4 tons 400cfm ton 4 8 Clg Airflow Variable Speed V5 5tons 5 Beckett Riello SA
49. TOR 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 Figure 17 Set the scale to the 1 to 5 or 1 to 6 amp scale TYPICAL 508 T EN 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 anti
50. The on off pattern of 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 34 DIP SWITCH 2 SECTION STATE BLOWER DELAY TIMES 1 2 3 4 Counter FOW ON SEC OFF MIN OFF OFF 15 30 ON OFF 24 60 OFF ON 36 120 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 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 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
51. Thermo Pride CHEN OIL FIRED FURNACE INSTALLATION AND OPERATION MANUAL WITH USERS INFORMATION SECTION MODEL Counterflow Horizontal OD6FA072D48B OD6RA072D48B OD6FX072DV5R OD6FA072DV5B OD6RA072DV5B OD6RX072DV5R OD6FA072D48R OD6RA072D48R OD6FA072DV5R OD6RA075DV5R WARNING IF THE INFORMATION IN THESE INSTRUCTIONS IS NOT FOLLOWED EXACTLY 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 Sandals PHONE 574 896 2133 ama LISTED MO 458 ECN 4936 MA Made IN USA CONTENTS SECTION PAGE 1 SAFETY SECTION AIBCEISTER S Ar mee actin roS DA r nae A nene AA LIMIT POSITION AND LOCATION ____________________________________ BURNER INSTALLATION zErmc rommoom USERS INFORMATION SEC
52. ble 11 For PSC control the LOW speed blower tap will be energized once the selected on delay has expired Once the selected Blower On Delay time has been reached the blower operation will change to the operation described in Motor Blower Speed section Blower On and Off Delays Four Heat blower on and four blower off delays are selected by two dip switches for each function Refer to Table 11 for specific delay values 35 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 and 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 36 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 qual
53. ce 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 1 amp 12 2 For horizontal installation rotate retainer and mounting plate 90 degrees The retainer secures the chamber during shipping and helps to maintain insertion depth DO NOT remove this retainer when installing burner 16 CLEAN OUT 8 PLACES BURNER MOUNTING UNIT PLATE GASKET BURNER MOUNTING PLATE BURNER NUT amp WASHER MOUNTING 4 PLACES STUDS OVERFIRE DRAFT 3 PLACES ACCESS COMER OVERFIRE DRAFT COMBUSTION CHAMBER ACCESS COVER CHAMBER RETAINER OVERFIRE DRAFT Skir ACCESS PORT NOTE MOUNTING MTG PLATE FOR BECKETT RIELLO SINGLE STAGE PLATE SHOWN RIELLO 2 STAGE MTG PLATE HAS EMBOSSMENT INSTALL 2 STAGE MTG PLATE OD6F 072D RAISED SURFACE TOWARD COMBUSTION CAMBER AND BURNER MTG STUDS TOWARD FRONT OF COUNTERFLOW FURNACE COMBUSTION CHAMBER LIMIT OVERFIRE DRAFT ACCESS COVER BURNER MOUNTING STUDS 3 PLACES BURNER MOUNTING PLATE HEAT EXCHANGER CLEAN OUT 4 PLACES BURNER MOUNTING PLATE GASKET BURNER MOUNTING PLATE NUT amp WASHER 4 PLACES OVERFIRE DRAFT ACCESS COVER OVERFIRE DRAFT ACCESS PORT CHAMBER RETAINER MTG PLATE FOR BECKETT RIELLO SINGLE STAGE SHOWN RIELLO 2 STAGE MTG PLATE HAS EMBOSSMENT INSTALL 2 STAGE MTG PLATE W RAISED SURFACE TOWA
54. ce 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 20 2 STAGE FIRING RATES CAPACITY FIRING NOZZLE SIZE INPUT RATE EFFECTIVE RATE Riello BTU HR HEATING CAPACITY HIGH CAPACITY HIGH FIRE 70 45 106 250 170psi 90 000 LOW FIRE 85 000 130psi 74 000 LOW CAPACITY HIGH FIRE 50 45 85 000 170psi 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 per gallon Based on thermal efficiency of 84 85 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 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 21 OIL TANK AND PIPING A WARNING All local codes and ordinances take precedence with regard to selection and installation of oil storage tank and oil supply and return lines In the absence of local codes all tanks and lines must be selected and
55. cipator Ammeter reading Anticipator Setting No of wire loops Or in this case 2 5A 0 25 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 ANWARNING Turn off the electrical power to the unit before attempting to change supply air blower speed wiring The OD6 comes from the factory with the proper cooling speed selected and the heat rise set to approximately 65 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 Single Stage Factory SW1 Switch Settings E Recommended Heating Speed Setting
56. d 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 fonward from and clear of the receptacle Connect an ohmmeter across cad cell pins With the cell exposed to direct room light the measured resistance should be less than 2500 ohms in fact it may be less than 200 ohms 3 Check the resistance across the cad cell pins with the cell covered protected from exposure to ambient light The resistance should be greater than 20 000 ohms 4 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 troubleshooting 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 problem and or repair is found After any maintenance or repair the trouble shooting
57. dences 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 the supply registers and the return air grills Generally supply registers should be located close to sources of heat loss i e windows and doors around the perimeter of the building Return grills should be located in central positions as far away from the supply registers as practical b Finda location 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 gril
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60. equency 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 47 V DEALER MAINTENANCE SAFETY DURING SERVICING AND INSPECTION A WARNING Personal injury or property damage could result from repair or service of this appliance by anyone other than a qualified heating contractor The user may only perform the activities described in the Homeowner User Routine Maintenance section of this manual ANWARNING To avoid injury from moving parts or electrical shock shut off the power to the appliance before removing blower compartment door and servicing this appliance 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 ZAWARNING Shut off oil and disconnect power before continuing with this inspection 1 Vent terminal Visually inspect the terminal for re
61. et 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 54 OIL PRIMARY CONTROL RESET BUTTON LE CE Beckett Burner Riello Burner OIL PRIMARY CONTROL RESET BUTTON Figure 28 Location of oil primary control reset button If this action does not reactivate the unit contact a qualified service agency for assistance In general if the thermostat is set in the heating mode the heating system functions entirely automatically However under certain circumstances the appliance may not be able to fire the burner For instance if the manual oil shutoff valve has been closed or the oil tank is out of fuel the oil line may have air trapped in it It will be necessary to purge the air by bleeding the supply line from the tank to the burner again for the heating system to operate Refer to the instructions under the Extended Appliance Shutdown section of this manual NOTICE Thermo Products recommends that the user homeowner contact a qualified service agency for assistance in bleeding the fuel line s and lighting off the heating section The following maintenance points should be reviewed periodically to assure the heating and cooling systems continue to function properly ANWARNING Shut off unit and disconnect the power source before disassembling the unit ANWARNING
62. excess oxygen O 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 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 Regulating rod Blast tube Shutter Figure 20 39 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 Figure 21 In order to reduce the volume of air entering the combustion chamber and thus increasing its pressure The CO improves and the adhesion of the flame to the diffuser tends to reduce
63. ful the ignition control module goes into system lockout period begins 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 y air fan and optional de energized After the delay to fan off period ends the circulating electronic air cleaner are 59 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 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 60 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
64. hamber 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 52 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 Ifthe shutdown period will exceed one heating season an stabilizer should be added to the oil tank Consult your oil supplier for recommendations ON STARTUP 1 Have system inspected and started by a qualified heating contractor 2 Check oil level in tank If the tank has not been filled with fresh oil inspect the remaining oil for signs of contamination with water algae dirt or other impurities If excessive consult your oil supplier for recommendations 3 Change the oil filter cartridge and clean the canister 4 Setthe room thermostat above room temperature 5 Open all valves in the oil supply line 6 Openthe inspection cover on the upper mounting plate 7 Turn on the electrical power to start the burner If the burner does not start immediately reset the manual overload switch on the motor if
65. he 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 The heating capacity of the unit proposed for installation should meet or slightly exceed the rate of heat loss for the residence Oversizing should not exceed 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 compressed paper plant fibers other materials that are capable of being ignited and burned Such materials shall be considered combustible even though flameproofed fire retardant treated or plastered b Non combustible material material that is not capable of being ignited and burned such as material consisting entirely of or a combination of steel iron brick concrete slate asbestos glass and plaster A WARNING Carefully read
66. hread 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 flow 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 the pump Pitching the line upward toward the tank will help prevent the formation of air pockets in the
67. id Fire Temperature Rise vs External Static pressure in WC Static 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 Low Fire Temperature Rise vs External Static pressure in WC Static 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 19 Heating speed by input Speed vs color code for PSC Motor Low Orange M Low Red Med Blue M High Yellow High Black 31 BLOWER CONTROLLER INFORMATION FOR PSC MOTOR Note for blower controller information see Operation Manual document Mo 440 TERMINAL DEFINITIONS amp FIELD WIRING Burner Harness Connector P1 Pin 1 Limit switch connector Pin2 120 VAC Line connection Pin 3 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 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 Common ground Thermostat call for heat 24 to thermostat Thermostat call for fan Thermosta
68. ified heating contractor A WARNING For initial start up of the appliance after installation it may be necessary to purge the air out of the oil line A qualified heating contractor should do this Review the following items before the initial startup It may be helpful to review the Sequence of Operations in 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
69. imney 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 6 and reduce the stack gas temperature loss Insulation may be added around the liner for further temperature stability If 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 3 PROPER CHIMNEY HEIGHT The chimney shall terminate at least 3 feet above the highest point where it passes through
70. 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 the piping and discard any excessively corroded piping 5 A readily 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 e 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 t
71. ion is recognized when the humidistat connects DEHUM to 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 24 VAC thermostat input A call for fan is recognized when the thermostat connects to 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 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 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 EAC
72. iron brick tile concrete slate or glass Table 1 MINIMUM CLEARANCES TO COMBUSTIBLE MATERIALS FROM TOP amp UNT MODEL SIDES OF FRONT SIDES OF REAR FURNACE PLENUM 056210726 0 Note 7 0 Horizontal Counterflow oD6R 072D 0 1 7 13 Horizontal Note OD6 front clearance 6 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 The OD6 furnaces may be installed on combustible flooring with the use of combustible floor base 06 BASE or a cottage base 06 NOTE The OD6 furnace is approved for closet installation If the OD6 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 This free area for the OD6 intentionally exceeds the recommended minimum free area of 1 square inche per 1000 BTUH of input rate The OD6 is also approved for attic installations Provisions should be made for proper combustion air if attic is of tight construction CHIMNEY The furnace must be connected to an adequate chimney an approved vent 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 s
73. l 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 flowrate for each branch of the supply and return air systems The total air flowrate by adding the air flowrate of each branch of the supply system must equal the minimum required air flowrate refer to part 3 above Likewise the air flowrate of each of the branches of the return air system must sum to the required minimum flowrate g Using the selected air flowrates for each component of the duct system and manufacturer s literature or published literature on duct system pressure drops the pressure drop for each component in the duct system can be estimated 12 ASHRAE Handbook Fundamentals is an excellent source of duct system design principles and pressure drop data Conversely for a specified type of fitting it is also possible to determine the required size or diameter of the component for a specified pressure drop and flowrate 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 va
74. l 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 45 ANNUAL SERVICE REQUIRED The following items should be inspected every year by a qualified heating servicer Shut off power before inspecting Correct any deficiencies at once Failure to do so may result in injury property damage or loss of life Heat Exchanger Inspect for corrosion pitting warpage cracks deterioration carbon build up and loose gaskets Burner Check for correct operation proper combustion no fuel leakage and replace burner oil filter Chimney Vent Pipe Inspect for restriction loose joints abnormal carbon build up and condensation Controls Check for correct operation and proper settings if manually adjustable Periodic visual inspections should also be made by the owner during the heating season Call a qualified heating servicer to report suspected deficiencies Do not attempt to make repairs yourself Further owner and heating servicer responsibilities are detailed in the printed information provided with the furnace SPECIAL HOMEOWNERS INSTRUCTIONS Improper installation adjustment alteration service or maintenance can cause injury or property damage Refer to the user s information section in the manual For assistance or additional information consult a qualified installe
75. lace 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 48 ZAWARNING qualified heating contractor must clean the heat exchanger At least once a year inspect the heat exchanger for evidence of corrosion pitting warpage deterioration and carbon soot build up A layer of soot on the inside of the heat exchanger will act as an insulator and reduce heat transfer resulting in less heating efficiency Also look for loose or deteriorated gaskets and insulation around the flue pipe the burner and accessible areas of the heat exchanger If this inspection indicates heat exchanger cleaning is necessary follow the heat exchanger cleaning instructions below C HEAT EXCHANGER CLEANING INSTRUCTIONS NWARNING THE HEAT EXCHANGER MUST 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 tur
76. 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 22 When the oil tank is located below the level of the burner it is necessary to lift the oil to the burner 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 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
77. lue should be close to the assumed value for the pressure drop of the system If it is not close then flowrates for each branch must be adjusted or the design of the duct system must be altered to give the proper pressure drops Usually the cross sectional area of the ductwork should be changed in order to adjust the pressure drop to a suitable value Refer to Example 2 page 14 for a sample calculation of how to use this method for sizing the supply side ductwork for a residence Table 3 shows the air handling capacities of 100 ft lengths of circular and rectangular ductwork based on a 0 1 in W G static pressure drop The first column to the right is the air flowrate and the second is the required diameter for a circular duct The third column is the required cross sectional area of the duct and the other columns to the left are rectangular ducts with sufficient cross sectional area to handle the flow at the specified pressure drop For lengths of ductwork less than 100 ft simply multiply 0 1 in W G by the ratio of the actual duct length in feet over 100 ft for the approximate pressure drop Use the supplier s catalog for proper sizing of outlet air registers and return air grills to insure that they provide the required flowrate at the desired pressure drop 20 514 18 18 Table 3 Suggested Duct Sizes for Homes Quiet Offices Or Similar Installations Based on a 0 1 in W G static pressure
78. 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 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 ch
79. n 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 long 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 49 TURN T HAN
80. ng 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 were selected based upon the following assumed characteristic values of the fuel oil suitable for use with this appliance design 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 0 60 F or gravity of 30 0 609 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 42 a With the shut off remove the 1 8 in 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
81. o 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 electrical 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 A permanent type air filter is provided in the return section of this unit This filter should be inspected regularly When the filter is dirty it should be cleaned or replaced to assure proper heating cooling system operation Follow the cleaning removal and replacement procedure below Filter maintenance procedure Shut off the electrical power to the unit The filter rack is located above the blower refer to Figure 26 on the next page Remove the front door of the furnace Remove the 2 screws retaining the right blower access door to the housing Remo
82. odule 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 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 INDICA
83. 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 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 cell can be checked by depressing the reset button on the control module while the burner is operating Count the number of flashes of the LED and compare them to the table below Number of flashes Cad Cell Resistance in ohms Model R7184B 0 to 400 400 to 800 800 to 1600 1600 s IN 56 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 an
84. ong 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 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 Operation 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 Heat Mode When call for heat W is received from the thermostat if the Cool mode is not already active the terminal is energized and the blower on delay is started
85. 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 stabilize for a moment Recheck the oil pressure g If required repeat the oil pressure adjustment again h When the input rate adjustment has been completed shut off the fuel oil to the appliance Remove the pressure gage Reinstall the pipe plug using a thread compound resistant to the action of LP gases and fuel oil 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 ANARNING 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 OD6 models are designed and wired at the factory for a blower speed during heating that should result in an approximate temperature rise of 65 F The temperature rise through the heating section for any given blower speed may vary depending on a number of factors A few of these factors are variations in the actual resistance of the duct system to airflow at any time the return air temperatures and the 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
86. r service agency or the gas oil supplier REINSTALL ALL PARTS Should this unit be disassembled all components panels block offs collars gaskets and fasteners must be reassembled as originally factory produced Failure to do so may result in property damage injury or loss of life 390056 390055 pre HAZARDOUS VOLTAGE Avoid contact with exposed live voltage terminals Do not bypass or disconnect limit Turn off power prior to service Failure to do so may result in property damage injury or loss of life 390526 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 and in proper position 1o 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
87. r removing the knock out 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 The OD6 may be vented through a standard correctly sized chimney The OD6 may also be horizontally vented through a side wall Thermo Products has available the Field model FDVS 45 FVOP 415 side wall vent kit for such applications When installing the FDVS 45 FVOP 415 side wall vent kit outside combustion air must also be applied to the burner The following table identifies application order information SIDE WALL VENTING APPLICATION ORDER INFORMATION FIELD VENT SIDE WALL VENT COMBUSTION AIR INTAKE TERMINATION KIT ACCESSORIES KIT HOOD KIT 15 application MAX BURNER SPECIFIC FOR COMBUSTION AIR APPLICATIONS ONLY THERMO PRODUCTS THERMO PRODUCTS THERMO PRODUCTS BURNER PART NUMBER PART NUMBER PART NUMBER Beckett AFG AOPS8393 AOPS8394 AOPS8397 Riello BF3 AOPS8393 58395 AOPS7402 Table 2 Side wall vent kits The Field vent kit is set up with 4 inch diameter vent pipe 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 side wall vent kit For Beckett the combustion air inlet pipe will be reduced to 3 diameter
88. rature 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 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 65 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 50 F maximum temperature rise is 80 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 rati
89. rop 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 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 in conjunction with a humidistat to control a humidifier These terminals are energized whenever the blower is active 24 DELAY COOL HEAT i OFF ON 4810 CC COM cc F1 HSCI 1158 83 1 x Figure 15 The Fan Control M
90. sequence should be repeated until normal system operation is achieved 57 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 gnitor 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 58 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 sequence provides a 60 second wait before ignition is attempted again Operation 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 Repeat Ignition Trial Y Call for Heat Satisfied Y System Lockout Y End of Cycle Y Y If ignition attempt is unsuccess
91. 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 a INLET PORT VALVE _ RETURN PORT amp INLET INTERNAL BY PASS Figure 27 Location of Oil Pump Vent Plug 8 Follow the previous Initial Burner Operation procedures 53 VI HOMEOWNER USER INFORMATION AND ROUTINE MAINTENANCE ZAWARNING Never burn garbage or refuse in this appliance Never try to ignite oil by tossing burning papers or other material into the combustion chamber NWARNING Oil fired appliances produced by Thermo Products are designed for burning No 2 distillate domestic heating fuel oil Never use gasoline or a mixture of oil and gasoline ACAUTION Do not use this appliance if any part has been under water Immediately call a qualified service technician to inspect the furnace and to replace any part of the control system and any oil control that has been under water ACAUTION Should overheating occur or the oil supply fail
92. strictions 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 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 OD6R 072D furnaces 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 Rep
93. t call for cool DEHUM Humidistat call for dehumidification TXV systems ONLY Male quick connect terminals S1 3 120 VAC Hot N1 7 120 VAC Neutral EAC Electronic Air Cleaner 120 VAC connection FAN Fan On Signal XC 24 VAC from transformer C 24 VAC common from transformer Compressor Contactor CC COM Compressor Contactor Common LOW Continuous Blower Speed HEAT Blower heat speed tap COOL Blower cool speed tap 32 A Inputs Power supplies Line voltage is applied between the 51 and 1 quick connect terminals 24 VAC Class Il 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 thermostat input A call for heat is recognized when the thermostat connects W to This input has an indicator LED that will light when the control receives a call for heat Refer to the Heat Mode section 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 dehumidificat
94. tack 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 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 PROPER CHIMNEY SIZE The inside area of the chimney liner should equal at minimum the area of the vent pipe exiting the furnace EXAMPLE x 2 Area of Pipe sq in radius of pipe 3 1417 Flue Pipe Diameter 6 Radius of pipe 72 diameter of pipe gt 6 in 3in x3 28 sq in NOTE This formula calculates the minimum inside area of the chimney If more than one appliance vent connector pipe is connected to the chimney the minimum inside area of the chimney should be equal to the area of the largest vent pipe plus one half the area of any additional vent pipes If the chimney is too large or condensation has been a problem in the past refer to the NFPA Standard for the Installation of Oil Burning Equipment NFPA31 1997 or latest edition Appendix E for proper liner sizing 2 PREVENTION OF CHIMNEY CONDENSING Stack gas
95. 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 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 Fig 3 Proper chimney termination height for flat roofs 4 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 Fig 4 Proper insertion of the vent connector the chimney 5 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 Fig 5 Suggested method to improve chimney draft 6 TIGHT JOINTS 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 7 TIGHT CLEAN OUT DOORS AND
96. 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 If the unit will not operate in the heating mode it may be possible to reactivate the unit by resetting one of the burner controls To attempt resetting of the burner controls follow this procedure 1 Turn the thermostat temperature setting down and set the operating mode to OFF or COOLING 2 Remove the 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 res
97. ve 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 Replace the right blower access door and the front door before turning the electrical power back on to the furnace 51 PLENUM zc FILTER FILTER RACK 8 b RIGHT BLOWER A ACCESS DOOR REMOVE RIGHT BLOWER ACCESS DOOR TO ACCESS FILTERS z z AFTER INSPECION AND OR CLEANING OF FILTERS RE INSTALL FILTERS AND ACCESS DOOR Figure 26 Location of Supply Return Air Filter Filter replacement To ensure an adequate replacement filter is selected should the filter require replacing refer to Table 4 in Air Filters section of this manual for the minimum filter areas required for different types of available filters NOTICE Remind the homeowner of the importance of monthly filter inspections during operation to ensure maximum operating efficiency G EXTENDED APPLIANCE SHUTDOWN A CAUTION 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 c
98. 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 OD6 it is possible to rotate the flue elbow which is factory installed for vertical discharge 90 clockwise or counter clockwise from the vertical position to adapt to various venting systems 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 side casing on a front flue unit remove screw securing the 90 deg elbow and rotate it 90 Then remove knock out in side casing and extend vent through the opening The elbow may also be removed and the unit can be vented through the front center panel afte
99. vice Acarbon dioxide or oxygen O2 analyzer Aflue gas temperature measuring device e g thermocouple or thermister probe with readout device e An analog or digital multimeter and Anoil pressure gauge capable of reading 0 150 PSIG To initially fire the oil burner proceed 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 the upper mounting plate above the burner Turn the disconnecting switch to ON Prime the pump to remove air the supply line 38 Figure 19 Preliminary Adjustment of Burner 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 2 or
100. vided 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 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 Typically control wiring between the appliance and the indoor thermostat and if used electronic air cleaner or humidifier will be required Field wiring of control circuits should consist of copper conductors rated for at least 15 amp service with an insulation temperature rating conforming to Type T wire 35 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 23 Maximum Time Dela y Minimum Oil Burner Fuse Assembly Recommende or Inverse Full Load d 75 deg C Supply Return Potential Frequenc Air Blower Full ylNo of Phases Load Current Time Current V
101. 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 air registers and grills to ensure that they meet the flow requirements of the run to which they are connected The duct system shall be sized to provide the maximum air flowrate CFM required of the installation Two common rules for determining minimum airflow in heating and cooling systems follow a For heating 14 CFM of airflow are required per 1000 BTU hr of heat output based on steady state operation and a 50 to 80 temperature rise b For cooling 400 CFM of airflow are required per ton of air conditioning For reference a ton of A C 12 000 BTU hr removed from the space Refer to Example 1 page 14 for a sample calculation of how to determine the required minimum air flowrate Duct sizing is based upon both air velocity and pressure drop considerations When possible current practice favors designing ductwork for lower air velocities For resi
102. will result in higher heating efficiency Temperature rise 7 supply air temperature return air temperature After 15 to 20 minutes of continuous operation the temperature rise through the furnace must fall within a range of 50 to 80 F If the outlet or supply duct temperature is too high check to make sure the return air filter is clean the return air registers are free from obstruction the outlet registers are properly adjusted and clear and the supply and return air ducts are open The circulating air blower is not moving enough air if the supply air temperature is still too high Before proceeding further turn off the power supply to the appliance and remove the vestibule cover The speed of the blower must be increased by changing the switch setting on the control board please refer to Figure 18 43 5 Checkout Procedure Before any system of oil piping is finally put into service it shall be carefully tested to assure that it is gas tight as indicated in the Heating System Initial Startup section of this manual NOTICE controls on the unit should be checked for proper functioning prior to the qualified service personnel leaving the job site Specifically 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 vi Shut off incoming power
103. with the Beckett side wall vent kit The side wall vent may be installed either through the lower knock out on the right and left side casing of the unit or vertically out the top opening of the vestibule 10 The combustion air inlet can be installed through the either the lower left side casing knock out or the lower right side casing knock out C DRAFT REGULATORS 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 instructions enclosed with draft regulator to adjust to the proper setting When the burner air supply and draft are properly adjusted the overfire draft should be a negative 01 to 02 WC as measured at the 5 16 overfire 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 overfire 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
104. y internal stiffeners used in the filter must not be removed although they can be cut to size as needed 15 LIMIT POSITION AND LOCATION 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 The unit listed in the table below must have the limit control installed at the time of unit installation 7 o D o AUX LIMIT CONTROL Q AUX LIMIT CONTROL Q 0 CONTROL OD6 OD6 OD6 LEFT VIEW FRONT VIEW RIGHT VIEW Fig 11 Limit and auxiliary limit locations for OD6 MODEL DIM DIM DIM DIM OD6 4 5 16 15 10 3 7 16 Table 5 Installation location of limit control and auxiliary limit control for OD6 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 distan

Thermo Products OD6RX072DV5R Furnace User Manual

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