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Thermo Products THV1M119A960SA Installation And Operation Manual

Oil fired furnace
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INSTALLATION AND OPERATION MANUAL
WITH USERS INFORMATION SECTION
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-523
ECN 5577-MA 190824
OIL FIRED FURNACE
HIGHBOY MODELS:
THV1M119A960SA, THV1M119A9T5SA
Thermo Products, LLC
Manufactured by:
PO Box 237
Denton, NC 27239
Made in USA

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Summary of Contents for Thermo Products THV1M119A960SA

  • Page 1 INSTALLATION AND OPERATION MANUAL WITH USERS INFORMATION SECTION HIGHBOY MODELS: THV1M119A960SA, THV1M119A9T5SA 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.

  • 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 FILTER J.

  • Page 5: Safety Section

    I. SAFETY SECTION This page and the following contain various warnings and cautions found throughout the Oil Furnace Manual. Please read and comply with the statements below. WARNING AND CAUTIONS: WARNING: This furnace is not to be used as a construction heater. See Page 3 WARNING: The predetermined limit locations on all of the THV1M119A* oil-fired furnaces have been tested and approved.

  • Page 7: 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 8: 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 9: 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 10: 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 11 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 12 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 13 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 14: Venting

    B. VENTING: NOTE: On the THV1M119A* it is possible to rotate the flue elbow (which is factory installed for vertical discharge) 90° counter clockwise or clockwise from the vertical position to adapt to various venting systems. Notice: Blocked Vent Switch Installation The blocked vent switch kit must be installed to comply with CAN STD B140.4 where applicable.

  • Page 15: 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 16: Air Filter(S)

    E. Air Filter Mounted External to Furnace: On highboy furnaces, it is necessary to cut the return air opening in the side, rear casing or base, depending upon the needs of the specific installation. The filter rack provided with the furnace, refer to Fig.
  • Page 17 If a method other than supplied filter rack is selected for retention of the filter and/or use of a different filter type is desired, refer to Table 3 below for minimum sizing guidelines for selecting filters for the unit. Maximum Filter Type Air Velocity Model Number...

  • Page 18: Limit Position And Location

    F. LIMIT POSITION AND LOCATION WARNING: The predetermined limit locations on all of the THV1M119A* oil-fired furnaces have been tested and approved. 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 19: Burner Specifications And Applications

    Fig. 12: Burner insertion illustration (Top view) When mounting the burner, the mounting plate (Fig. 11) 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 burners.(see Fig.

  • Page 20: Oiltank And Piping

    75 deg. C. Model No. of Phases Full Load or Inverse Current Copper Power (V/Hz/Ph) Current Time Circuit (Amps) @ 115 Wiring Size (Amps) @ Breaker Size (AWG) 115 VAC (Amps) THV1M119A960SA 120/60/1 19.2 THV1M119A9T5SA 120/60/1 Table 7: Typical Electrical Requirements...
  • Page 21 Wire size selections in Table 7 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.

  • Page 22: Blower Setup

    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. Thermostat models having a scale as shown in Figure 14 on the next page, must be adjusted to each application.
  • Page 23 AS SHIPPED HTG.  High Low Fire Temperature Rise vs. External Static pressure (in. WC.) Speed Tap\ Static Pressure High Figure 15a: Heating speed by input THV1M119A960SA Speed vs. color code for *PSC Motor: Low = Red Med-Low = Blue Med-High = Yellow...
  • Page 24 THV1M119A9T5SA 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 42,000 Med Low AS SHIPPED CLG.  48,000 Med High 60,000 High Furnace Airflow (CFM) vs. External Static pressure (in. WC.) Speed Tap\ Static Pressure 1520 1429...

  • Page 25: Blower Controller Information For Psc And Ctm Motor

    Speed vs. color code for *CTM Motor: Low = Red Med-Low = Purple Medium = Blue Med-High = Yellow High = Black *CTM is an abbreviation for Constant Torque Motor M. BLOWER CONTROLLER INFORMATION FOR PSC AND CTM MOTOR TERMINAL DEFINITIONS & FIELD WIRING Burner Harness Connector P1 Pin 1- Limit switch connector.
  • Page 26 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 27 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 28 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 29 PSC AND CTM 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 30: 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 31 NOTICE: Read the burner operation and service instructions, Model AFG Oil Burner Instruction Manual, before continuing. To initially adjust and successfully service the oil burner in the appliance heating section, the following test instruments are required:  A smoke density measuring and rating device, A carbon-dioxide (CO ) or oxygen (O ) analyzer,...

  • Page 32: 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 33: 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 34: Dealer Maintenance

    IV. 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 35 Figure 17: Heat Exchanger Clean-Outs Vacuum Hose Length THV1M119A* Fig. 18: Recommended method and device for cleaning inside of heat exchanger.

  • Page 36: Sequence Of Operations Flow Chart

    V. Sequence of Operations Flow Chart:...

  • Page 38: Trouble Shooting Flow Chart

    VI. Trouble Shooting Flow Chart:...
  • Page 43 COMBUSTION AND EFFICIENCY TESTING FOR OIL FIRED CENTRAL FURNACES. Complete this form for each furnace installed. Read instruction manual carefully before making tests. Retain this form with furnace. furnace. CUSTOMER NAME ADDRESS CITY, STATE BURNER MODEL NO. BLAST TUBE LGTH. AIR SHUTTER OPENING HEATING INS.
  • Page 44 Appendix – A Replacement Parts for THV1M119A*...
  • Page 46 Appendix – B THV1M119A960SA PSC Wiring Diagram...
  • Page 47 THV1M119A9T5SA CTM Wiring Diagram...

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