Thermo Pride OH8FA119D60C Installation And Operation Manual
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Thermo Pride OH8FA119D60C Installation And Operation Manual

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INSTALLATION AND OPERATION MANUAL
OH6FA072D48B
OH6FA072D48R
OH6FA072D48N
OH6FA072D48C
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-437
ECN 5550-MA 180910
OIL FIRED FURNACE
WITH USERS INFORMATION SECTION
MODEL:
OH6FA072DV4B
OH6FA072DV4R
OH6FA072DV4N
OH6FA072DV4C
OH6FX072DV4R
THERMO PRODUCTS, LLC.
PO BOX 217
NORTH JUDSON, IN 46366
PHONE: 800-476-4328
OH8FA119D60B
OH8FA119D60R
OH8FA119D60C
OH8FA119DV5B
OH8FA119DV5R
OH8FA119DV5C
Made IN USA

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Summary of Contents for Thermo Pride OH8FA119D60C

  • Page 1 OH8FA119D60B OH8FA119DV5B OH6FA072D48R OH6FA072DV4R OH8FA119D60R OH8FA119DV5R OH6FA072D48N OH6FA072DV4N OH8FA119D60C OH8FA119DV5C OH6FA072D48C OH6FA072DV4C OH6FX072DV4R 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.

  • Page 3: Table Of Contents

    CONTENTS SECTION PAGE 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 5 Model Number Digit 9 10 11 12 Oil Furnace Model Nomenclature Example Model Numbers 2 D V 9 D V O = Oil 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...

  • Page 6: Safety Section

    This furnace is not to be used as a construction heater. See Page 3 cWARNING: 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...

  • Page 8: Codes And Clearances

    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.

  • Page 9: Make-Up Air

    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, or other materials that are capable of being ignited and burned.

  • Page 10: General Instructions

    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.

  • Page 11: Chimney

    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).
  • Page 12 2. PROPER CHIMNEY HEIGHT: The chimney shall terminate at least 3 feet above the highest point where it passes through the roof of a building and at least 2 feet higher than any portion of a building within a horizontal distance of 10 feet. (See Fig.
  • Page 13 4. PROPER CHIMNEY BOTTOM LEVEL: In cases where the chimney extends to the basement floor, the draft can usually be improved by filling the base of the chimney with sand to within 12 inches of the vent connector pipe after relocating the clean-out door.
  • Page 14 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 15: Venting

    B. VENTING: NOTE: On the OH6 & OH8 it is possible to rotate the flue elbow (which is factory installed for vertical discharge) 90° counter clockwise from the vertical position to adapt to various venting systems. The OH8 flue elbow can also be rotated 90° clockwise. Notice: Blocked Vent Switch Installation The blocked vent switch kit must be installed to comply with CAN STD B140.4 where applicable.

  • Page 16: Draft Regulators

    C. DRAFT REGULATORS: Note: Do not use with Direct Vent application. A draft regulator is supplied with the furnace and should be installed according to the regulator manufacturers recommendations. With the burner operating, use a draft gauge to adjust the regulator to the proper setting.
  • Page 17 1. Supply and return air ducts have to be furnished by the installer and run between the appliance, which must be installed outdoors, and the interior of the structure the appliance serves. These ducts must be sealed to the casing of the appliance. 2.
  • Page 18 g. Using the selected air flow rates for each component of the duct system and manufacturer’s literature, or published literature on duct system pressure drops, the pressure drop for each component in the duct system can be estimated. The ASHRAE Handbook – Fundamentals is an excellent source of duct system design principles and pressure drop data.
  • Page 19 Table 3: Suggested Duct Sizes for Homes, Quiet Offices, Or Similar Installations (Based on a 0.1 in. W.G. static pressure drop per 100 ft. of duct.) 7. The supply and return air ducts, or flexible joints, should be carefully secured and sealed to the appliance housing to prevent air leakage from, or into, the duct system.

  • Page 20: Air Filter(S)

    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.
  • Page 21 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...

  • Page 22: Limit Position And Location

    F. LIMIT POSITION AND LOCATION cWARNING: 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 23: Burner Installation

    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.

  • Page 24: Burner Specifications And Applications

    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.
  • Page 25 AN 80° SPRAY ANGLE AND A HOLLOW SPRAY PATTERN WOULD BE ABBREVIATED IN THE TABLE AS “0.65 X 80H”. ** NOTE: The reason the Riello burner nozzle sizes are smaller than the standard Thermo Pride burner nozzles is that pre-set pump pressures are higher, therefore achieving the same firing rate with a smaller...
  • Page 26 For more specific burner information, specifications or service information, reference the training manual enclosed with each Riello burner or contact: Riello Corporation of America, 5 Pond Park Road Hingham, Massachusetts 02043 Phone: (617) 749-8292 2 STAGE FIRING RATES CAPACITY FIRING NOZZLE SIZE INPUT RATE* EFFECTIVE**...

  • Page 27: Oiltank And Piping

    Verify that the installed burner is lightly leaned towards the button. (See figure 14-1) The burner is designed to allow entry of the flexible oil-lines on either side of the burner. I. OIL TANK AND PIPING: : All local codes and ordinances take precedence with regard to selection and installation of oil storage tank and oil supply (and return) lines.

  • Page 28: Oil Filter

    the pump. Pitching the line upward toward the tank will help prevent the formation of air pockets in the line. NOTICE: An oil safety valve or a delayed-action, solenoid valve should be installed in the oil supply line of all gravity-fed systems. When the oil tank is located below the level of the burner, it is necessary to “lift”...
  • Page 29 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C temperature rise.
  • Page 30 in conjunction with a humidistat to control a humidifier. These terminals are energized whenever the blower is active. 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.
  • Page 31 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 32: 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. = 0.25 A. (Anticipator Setting) 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 33 Heating Speed Set-ups OH6FA072DV4 Furnace Motor Current Draw (Amps/ / Watts) vs. External Static Pressure (in W.C.) Low Fire Med Fire High Fire BTUH 60,000 72,000 90,000 Static Pressure (Amps/Watts) Control SW 1 Switch Heating Aprox. Rise Aprox. Rise Aprox. Rise Settings 3-OFF 1.1/98...
  • Page 34 Heating Speed Set-ups OH8FA119DV5 Furnace Motor Current Draw (Amps / Watts) vs. External Static Pressure (in W.C) Low Fire Med Fire High Fire BTUH 101,000 119,000 132,000 Control SW 1 Switch Heating Aprox. Aprox. Aprox. Settings Rise (F Rise (F Rise (F 1.6/146 2.5/233...
  • Page 35 Heating Speed Set-ups ( 2 – Stage ) OH6FX072DV4 HEATING AIR FLOW / TEMPERATURE RISE LOW CAPACITY HIGH CAPACITY LOW FIRE HI FIRE LOW FIRE HI FIRE BTUH 60,000 72,000 72,000 90,000 CONTROL SW 1 APPROX. APPROX. APPROX. APPROX. HEATING SWITCH CFM/RISE CFM/RISE...
  • Page 36 Cooling Speed Set-ups OH6F*072DV4 Furnace Motor Current Draw (Amps / Watts) vs. External Static Pressure (in W.C) Static Pressure (Amps/Watts) Air Flow Control SW 1 Switch Settings Clg. Tonage Cool Continuous 6-OFF 1.2/109 2.1/186 5-OFF 4-OFF 6-OFF 1017 1.8/160 2.5/230 5-OFF 4-ON 6-OFF...
  • Page 37 Cooling Speed Set-ups OH8FA119DV5 Furnace Motor Current Draw (Amps/Watts) vs. External Static Pressure (in W.C.) Air Flow Control SW 1 Switch Clg. Settings Tonnage Cool Continuous Dehum 6-OFF 1.0/89 1.8/161 5-OFF 4-OFF 6-OFF 1.4/121 2.1/192 1018 5-OFF 4-ON 6-OFF 1.8/159 2.6/231 1212 5-ON...
  • Page 38 For PSC systems, the ½ hp motor is equipped with 4 speeds. The unit is set for mid-fire temp rise @ 66ºF. See table for proper blower motor set up: OH6FA072D48 ALTERATIONS REQ’D FOR A/C @ DESIGN EXTERNAL STATIC PRESSURE COOLING UNIT Recommended CLG Speed HTG Speed by Input...
  • Page 39 OH8FA119D60 ALTERATIONS REQ’D FOR A/C @ DESIGN EXTERNAL STATIC PRESSURE COOLING UNIT Recommended CLG Speed HTG Speed by Input High Fire Fire Fire 36,000 L/ML ML/MH MH/H Low (L) 42,000 L/ML ML/MH MH/H Med Low (ML) 48,000 L/ML ML/MH MH/H Med High (MH) 60,000 L/ML...

  • Page 40: 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 41 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 42 EAC (electronic air cleaner) The control provides a 120 VAC output for an electronic air cleaner. This output is energized whenever the fan motor is energized (either low, heat or cool speed). Connection is made via male quick connect terminal labeled “EAC”. Humidifier The control provides a 120 VAC output for a humidifier.
  • Page 43 Heat Mode When a call for heat (“W”) is received from the thermostat, if the “Cool” mode is not already active, the “T-T” terminal is energized and the blower on delay is started. The on-off pattern of DIP switch SW2 (positions 1 and 2) select one of four blower on delay values (see Table 11).
  • Page 44 ECM & 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 45: 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 46 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 47 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 48 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 49 Figure 22 STAGE ADJUSTMENT: Adjustment of air shutter: place the small plug (9) of the economizer (10) into the position I (Item A). In this way the burner will remain permanently in the 1 stage. Loosen the nut (2), turn the screw (3) until the air shutter (1) reaches the position desired. Then lock the nut (2).
  • Page 50 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 51 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 52 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 53: Users Information Section

    NEVER burn garbage or refuse in your furnace. Never try to ignite oil by tossing burning papers or other material into your furnace. cWARNING: Thermo Pride 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 54: 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 55: 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 56: Dealer Maintenance

    V. DEALER MAINTENANCE: SAFETY DURING SERVICING AND INSPECTION : 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. : 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.

  • Page 57: 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 58 Figure 24: Heat Exchanger Clean-Outs Vacuum Hose Length Fig. 25: Recommended method and device for cleaning inside of heat exchanger.

  • Page 59: 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 60: Extended Appliance Shutdown

    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.

  • Page 61: Homeowner/User Information And Routine Maintenance

    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.
  • Page 62 : 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. : Should overheating occur, or the oil supply fail to shut off, shut off the electrical power to the appliance, before shutting off the manual oil valve.
  • Page 63 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.

  • Page 64: 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 65: Sequence Of Operations Flow Chart

    VIII. Sequence of Operations Flow Chart:...

  • Page 67: Trouble Shooting Flow Chart

    IX. Trouble Shooting Flow Chart:...
  • Page 72 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. NAME CUSTOMER ADDRESS CITY, STATE BURNER MODEL NO.

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