Thermo Pride OD6FA072D48R Installation And Operation Manual

Thermo Pride OD6FA072D48R Installation And Operation Manual

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INSTALLATION AND OPERATION MANUAL
OD6FA072D48B
OD6FA072DV5B
OD6FA072D48R
OD6FA072DV5R
c WARNING: IF THE INFORMATION IN THESE INSTRUCTIONS IS NOT FOLLOWED EXACTLY, A
FIRE OR EXPLOSION MAY RESULT CAUSING PROPERTY DAMAGE, PERSONAL INJURY, OR
LOSS OF LIFE.
DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS AND LIQUIDS IN THE
VICINITY OF THIS OR ANY OTHER APPLIANCE.
c 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.
MO-458
ECN 4936-MA
OIL FIRED FURNACE
WITH USERS INFORMATION SECTION
MODEL: Counterflow / Horizontal
OD6RA072D48B
OD6RA072DV5B
OD6RA072D48R
OD6RA075DV5R
THERMO PRODUCTS, LLC.
PO BOX 217
NORTH JUDSON, IN 46366
PHONE: (574) 896-2133
OD6FX072DV5R
OD6RX072DV5R
Made IN USA

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Summary of Contents for Thermo Pride OD6FA072D48R

  • Page 1 THE USER AND SHOULD BE RETAINED FOR FUTURE REFERENCE BY QUALIFIED SERVICE PERSONNEL. MO-458 ECN 4936-MA OIL FIRED FURNACE OD6RA072D48B OD6FX072DV5R OD6RA072DV5B OD6RX072DV5R OD6RA072D48R OD6RA075DV5R THERMO PRODUCTS, LLC. PO BOX 217 NORTH JUDSON, IN 46366 PHONE: (574) 896-2133 Made IN USA...
  • Page 2: Table Of Contents

    SECTION I. SAFETY SECTION A. CODES AND CLEARANCES B. MAKE-UP AIR II. GENERAL INSTRUCTIONS A. CHIMNEY B. VENTING C. DRAFT REGULATORS D. DUCT WORK/AIR CONDITIONING E. AIR FILTER(S) F. LIMIT POSITION AND LOCATION G. BURNER INSTALLATION H. BURNER SPECIFICATIONS AND APPLICATIONS OILTANK AND PIPING J.
  • Page 3 Model Number Digit Oil Furnace Model Nomenclature Example Model Numbers H = Highboy D = Downflow 6 = Heat Exchanger Size Identifier F = Front R = Rear A = Single Stage X = 2-Stage Heating Capacity MBTUH (000's) with factory installed nozzle D = Direct Drive Clg.
  • Page 4: Safety Section

    See Page 45 cWARNING: Thermo Products oil furnaces are designed to burn No. 1 or No. 2 distillate fuel oil. NEVER USE GASOLINE OR A MIXTURE OF OIL AND GASOLINE.
  • Page 6: Codes And Clearances

    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.
  • Page 7: Make-Up Air

    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.” : Carefully read and thoroughly understand the following guidelines and warnings before continuing with the installation of this appliance.
  • Page 8: General Instructions

    II. GENERAL INSTRUCTIONS - READ BEFORE START OF INSTALLATION 1. The heating output capacity of the furnace proposed for installation should be based on a heat loss calculation made according to the manuals provided by the Air Conditioning Contractors of America (ACCA) or the American Society of Heating, Refrigeration and Air Conditioning Engineers, Inc.
  • Page 9: Chimney

    A. CHIMNEY: The furnace must be connected to an adequate chimney or an approved vent in accordance with these instructions. An adequate chimney is one that is sealed and lined with the capability of producing a (-).04" WC flue draft and having the capacity to handle the amount of stack gases that are introduced into it. A chimney with an internal construction of corrosion resistant tile, stainless steel, or some other material that will withstand flue gas temperatures up to 900°F is required.
  • Page 10 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.
  • Page 11 Fig. 4: Proper insertion of the vent connector in 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.
  • Page 12 Fig. 6: Suggested method to accommodate vent connector passage through a wall composed of a combustible material. Fig. 7: Alternate constructions that allow reduced clearances to combustible materials. REDUCTION OF CLEARANCES WITH SPECIFIED FORMS OF PROTECTION: Type of protection applied to and covering all surfaces of combustible material within the distance specified as the required clearance with no protection unless otherwise noted, all dimensions in inches, refer to Fig.
  • Page 13: Venting

    The elbow may also be removed and the unit can be vented through the front center panel after 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.
  • Page 14: Draft Regulators

    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.
  • Page 15 2. 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. 3.
  • Page 16 The ASHRAE Handbook – Fundamentals is an excellent source of duct system design principles and pressure drop data. Conversely, for a specified type of fitting, it is also possible to determine the required size or diameter of the component for a specified pressure drop and flowrate. h.
  • Page 17 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.
  • Page 18: Air Filters

    Disposable 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: Any internal stiffeners used in the filter must not be removed, although they can be cut to size as needed.
  • Page 19: Limit Position And Location

    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.
  • Page 20 Fig. 12-1: Typical location of the overfire air tap and components in burner mounting plate area for OD6F*072D*** counterflow and horizontal installations...
  • Page 21 Fig. 12-2: Typical location of the overfire air tap and components in burner mounting plate area for OD6R*072D*** counterflow and horizontal installations...
  • Page 22: Burner Specifications And Applications

    FOR SOLID CONE. FOR EXAMPLE, A NOZZLE RATED AT 0.65 GPH @ 100 PSIG THAT PROVIDES AN 80° SPRAY ANGLE AND A HOLLOW SPRAY PATTERN WOULD BE ABBREVIATED IN THE TABLE AS “0.65 X 80°H”. Thermo Products, LLC. P.O. Box 217, North Judson, IN 46366. Fig. 13: Burner insertion illustration (Top view) BECKETT...
  • Page 23 NOZZLE SIZE (GPH) UNITS Beckett OD6F/RA060D*** OD6F/RA072D*** OD6F/RA090D*** 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%.
  • Page 24 CAPACITY FIRING RATE HIGH FIRE HIGH CAPACITY LOW FIRE HIGH FIRE LOW CAPACITY LOW FIRE * Based on #2 domestic heating fuel oil having heating value of 140,000 BTU 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.
  • Page 25: Oiltank And Piping

    I. OIL TANK AND PIPING: : All local codes and ordinances take precedence with regard to selection and installation of oil storage tank and oil supply (and return) lines. In the absence of local codes, all tanks and lines must be selected and installed according to the instructions in this manual and the Standard for the Installation of Oil-Burning Equipment, NFPA 31-1997, or the latest edition.
  • Page 26: Oil Filter

    When the oil tank is located below the level of the burner, it is necessary to “lift” the oil to the burner. A return line should be connected between the fuel pump and tank. This requires insertion of the "by-pass" plug into the fuel pump.
  • Page 27 Potential/Frequenc Model y/No. of Phases (V/Hz/Ph) OD6**072D48 120/60/1 OD6**072DV5 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.
  • Page 28 Figure 15: The Fan Control Module 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.
  • Page 29 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”...
  • Page 30: Blower Setup

    This formula can be used to calculate the correct setting for the adjustable heat anticipator: Ammeter reading = Anticipator Setting. No. of wire loops Or in this case, _2.5 A. 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.
  • Page 31 Heating Speed Set-ups (Single Stage) Control SW 1 Switch Settings 3-OFF 2-OFF 1-OFF 3-OFF 2-OFF 1-ON 3-OFF 2-ON 1-OFF Factory 3-OFF SW1 Switch 2-ON Settings 1-ON 3-ON 2-OFF 1-OFF 3-ON 2-OFF 1-ON 3-ON 2-ON 1-OFF 3-ON 2-ON 1-ON Low Fire Med Fire High Fire BTUH 60,000 72,000...
  • Page 32 Heating Speed Set-ups ( 2 – Stage ) CONTROL SW 1 SWITCH SETTINGS 3 – OFF 2 – OFF 1 – OFF 3 – OFF 2 – OFF 1 – ON 3 – OFF 2 – ON 1 – OFF 3 –...
  • Page 33 Cooling Speed Set-ups Control SW1 Switch Settings 6-OFF 5-OFF 4-OFF 6-OFF 5-OFF 4-ON 6-OFF 5-ON 4-OFF 6-OFF 5-ON 4-ON Factory 6-ON SW1 Switch 5-OFF Settings 4-OFF 6-ON 5-ON 4-OFF NOTE: All information is approximate. Results will vary by installation. Air Flow Clg.
  • Page 34 For PSC systems, the ½ hp motor is equipped with 5 speeds. The unit is set for mid-fire temp rise @ 65ºF. See table for proper blower motor set up: Furnace Airflow (CFM) vs. External Static pressure (in. WC.) Speed Tap\ Static Pressure 1155 1442...
  • Page 35: Blower Controller Information For Psc Motor

    M. BLOWER CONTROLLER INFORMATION FOR PSC MOTOR (Note: for ECM blower controller information see: ECM Operation Manual document # Mo-440) TERMINAL DEFINITIONS & FIELD WIRING Burner Harness Connector P1 Pin 1- Limit switch connector. Pin 2- 120 VAC Line connection. Pin 3- Burner pilot contact.
  • Page 36 A. Inputs Power supplies Line voltage is applied between the “S1” and “N1” quick connect terminals. 24 VAC Class II Transformer secondary voltage supplied to X and C Limit switch The 120 VAC optically isolated limit switch input is connected on pin P2-1 & 9. Refer to the Heat Mode section for the control operation.
  • Page 37 Humidifier The control provides a 120 VAC output for a humidifier. Connections are made to a male quick connect terminal labeled “FAN”. The control does not switch this output, it provides a pass-through connection from 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.
  • Page 38 DIP SWITCH 2 SECTION STATE 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.
  • Page 39 PSC TROUBLE SHOOTING DIAGNOSTIC FEATURES The control board is equipped with 4 green Input Status LEDs and 1 red Board Status LED. These are intended to provide a quick view into furnace performance without requiring a voltmeter. The green Input Status LEDs are driven by the “Y”, “W”, “G”, and “DEHUM” inputs and are located directly below those inputs.
  • Page 40: Startup Procedures

    N. STARTUP PROCEDURES: A. Heating System 1. Initial Startup: : Turn off power to furnace. Before the oil piping system is placed into service, it must have been leak tested by a qualified heating contractor. : For initial start-up of the appliance after installation, it may be necessary to purge the air out of the oil line.
  • Page 41: Adjustment Of Burner Combustion

    To Turn Off Oil to Appliance: Set the thermostat to the lowest setting and set the operating mode switch to “OFF”. 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.
  • Page 42 Figure 19: Preliminary Adjustment of Burner Air Band and Air Shutter 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”...
  • Page 43 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...
  • Page 44 STAGE ADJUSTMENT: Adjustment of air shutter: place the small plug (9) of the economizer (10) into the position I (Item A). In this way the burner will remain permanently in the 1 Loosen the nut (2), turn the screw (3) until the air shutter (1) reaches the position desired. Then lock the nut (2).
  • Page 45: Adjustment Of Heat Input Rate

    CARBON DIOXIDE (CO 2 ) OR OXYGEN (O 2 ): Take a CO 2 sample from flue passageway. It is possible to achieve readings of up to 14% CO 2 (or 2% O 2 ), but it is better to have a slightly lower CO 2 (or higher O ) reading with zero smoke measured.
  • Page 46: Setting Supply Air Temperature Rise

    a. With the oil shut off, remove the 1/8 in. NPT threaded pipe plug located on the lower rear side of the oil pump, refer to Figure 22. Attach a pressure gage, capable of measuring pressure in pounds per square inch gage, PSIG, in this opening, on the discharge side, of the oil pump.
  • Page 47: Checkout Procedure

    5. Checkout Procedure: Before any system of oil piping is finally put into service, it shall be carefully tested to assure that it is “gas-tight”, as indicated in the Heating System Initial Startup section of this manual. NOTICE: All controls on the unit should be checked for proper functioning prior to the qualified service personnel leaving the job site.
  • Page 48: Users Information Section

    III. 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.
  • Page 49: Starting The Burner

    D. STARTING THE BURNER: 1. Turn the main service switch to "OFF" position. 2. Set thermostat substantially above room temperature. 3. Open shut-off valves in oil supply line to burner. 4. Turn service switch to furnace "ON". If burner starts and runs, but stops again on lockout, it may be necessary to bleed the lines or make burner combustion air adjustments.
  • Page 50: Installer's Instructions To User

    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.
  • Page 51: Dealer Maintenance

    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.
  • Page 52: Heat Exchanger

    B. HEAT EXCHANGER: cWARNING: A qualified heating contractor must clean the heat exchanger. At least once a year, inspect the heat exchanger for evidence of corrosion, pitting, warpage, deterioration, and carbon (soot) build-up. A layer of soot on the inside of the heat exchanger will act as an insulator and reduce heat transfer, resulting in less heating efficiency.
  • Page 53 TURN T-HANDLE COUNTER-CLOCKWISE TO LOOSEN & REMOVE PLUG ASSEMBLY Figure 24: Heat Exchanger Clean-Outs Fig. 25: Recommended method and device for cleaning inside of heat exchanger. HEAT EXCHANGER CLEAN-OUT ACCESS (TUBE) CLEAN-OUT PLUG ASSEMBLY T-HANDLE (PART OF CLEAN-OUT PLUG ASSEMBLY)
  • Page 54: Electrical System

    4. Operational Check: cCAUTION: 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.
  • Page 55: Extended Appliance Shutdown

    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.
  • Page 56 ON SHUTDOWN: 1. Close oil supply (or manual shutoff) valve. 2. Disconnect all electrical power to the unit. 3. Fill the oil tank to reduce water condensation in the tank. 4. If the shutdown period will exceed one heating season, an oil stabilizer should be added to the oil tank.
  • Page 57: Homeowner/User Information And Routine Maintenance

    Never burn garbage or refuse in this appliance. Never try to ignite oil by tossing burning papers or other material into the combustion chamber. cWARNING: 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.
  • Page 58 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.
  • Page 59: Troubleshooting

    VII. TROUBLESHOOTING: THIS SECTION IS ONLY TO BE PERFORMED BY TRAINED, QUALIFIED SERVICE PERSONNEL, AND NOT BY THE FURNACE OWNER. NOTICE: Before troubleshooting, familiarize yourself with the Initial Startup, Checkout Procedure, and Troubleshooting Flowchart. Refer to the appendices of this manual for an electrical schematic, a connection diagram, flowcharts to assist in troubleshooting, product specifications, and a replacement parts list follow for this appliance.
  • Page 60: Cad Cell Checkout Procedure

    If it is necessary to troubleshoot the flame sensor independently of the burner primary, the following procedure may be used. B. CAD CELL CHECKOUT PROCEDURE: 1. Stop burner and shutoff electrical power to the appliance. 2. Open burner junction box (on top of the burner blower) and remove the plug-in portion of the cad cell by pulling it forward from and clear of the receptacle.
  • Page 61: Sequence Of Operations Flow Chart

    VIII. Sequence of Operations Flow Chart:...
  • Page 63: Trouble Shooting Flow Chart

    IX. Trouble Shooting Flow Chart:...
  • Page 68 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 BURNER MODEL NO. HEATING SYSTEM COMBUSTION CHAMBER...
  • Page 69: Replacement Parts List

    Appendix – A Replacement Parts: Replacement Parts for OD6F*072D**...
  • Page 71 Replacement Parts for OD6R*072D**...
  • Page 73: Wiring Diagrams

    Appendix – B Wiring Diagrams OD6*A072D48 PSC Wiring Diagram...
  • Page 74 OD6*A072DV5 ECM Wiring Diagram...
  • Page 75 OD6*X072DV5 ECM 2-Stage Wiring Diagram...

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