Thermo Pride OH6FA072D48B Installation And Operation Manual
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Thermo Pride OH6FA072D48B Installation And Operation Manual

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INSTALLATION AND OPERATION MANUAL
OH6FA072D48B
OH6FA072D48R
OH6FA072D48N
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 5142-MA 100625
OIL FIRED FURNACE
WITH USERS INFORMATION SECTION
MODEL:
OH6FA072DV4B
OH6FA072DV4R
OH6FA072DV4N
OH6FX072DV4R
THERMO PRODUCTS, LLC.
PO BOX 217
NORTH JUDSON, IN 46366
PHONE: (574) 896-2133
OH8FA119D60B
OH8FA119D60R
OH8FA119DV5B
OH8FA119DV5R
Made IN USA

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Summary of Contents for Thermo Pride OH6FA072D48B

  • Page 1 OIL FIRED FURNACE INSTALLATION AND OPERATION MANUAL WITH USERS INFORMATION SECTION MODEL: OH6FA072D48B OH6FA072DV4B OH8FA119D60B OH8FA119DV5B OH6FA072D48R OH6FA072DV4R OH8FA119D60R OH8FA119DV5R OH6FA072D48N OH6FA072DV4N 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 2: 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 3 Model Number Digit 9 10 11 12 Oil Furnace Model Nomenclature Example Model Numbers 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 D = Direct Drive Clg.

  • Page 4: 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 6: 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 7: Make-Up Air

    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...

  • 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

    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 10 must be used, such as a Class "A" triple wall or insulated metal chimney. A liner will act as an insulator and reduce the stack gas temperature loss. Insulation may be added around the liner for further temperature stability. If 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 vent connector pipe between the furnace and chimney shall be of equal diameter as the flue outlet of the furnace. The vent connector pipe must be made of 24 gauge (or thicker) corrosion-resistant steel. The vent connector pipe should be as short as possible and installed so that it has a continuous rise from the furnace to the chimney.

  • Page 14: Draft Regulators

    diameter with the Riello sidewall vent kit. For Beckett, the combustion air inlet pipe will be reduced to 3” diameter with the Beckett sidewall vent kit. The side wall vent may be installed either through the knock-out on the right or left side casing of the unit or vertically out the top opening of the vestibule.
  • Page 15 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.
  • Page 16 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.
  • Page 17 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 18: 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 19 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 20: 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 21: 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 22: 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 23 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 24 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 25: 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 26: 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 27 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 28 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 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. = 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 31 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 Control SW 1 Switch Heating Aprox. Rise Aprox. Rise Aprox. Rise Settings 3-OFF 0.9/75 1.4/123 1.7/156...
  • Page 32 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 3-OFF 1202...
  • Page 33 Heating Speed Set-ups ( 2 – Stage ) OH6FX072DV4 Figure 18-2: ECM 2-stage blower motor speed chart...
  • Page 34 Cooling Speed Set-ups OH6F*072DV4 Furnace Motor Current Draw (Amps / Watts) vs. External Static Pressure (in W.C) Air Flow Control SW 1 Switch Clg. Settings Tonnage Cool Continuous 6-OFF 5-OFF 4-OFF 0.9/79 1.5/128 1.9/170 6-OFF 5-OFF 4-ON 1017 1.3/112 1.9/171 2.6/238 6-OFF 5-ON...
  • Page 35 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 0.8/69 1.0/88 1.3/112 1.5/132 1.7/147 1.9/169 2.2/194 5-OFF 4-OFF 6-OFF 1018 1.1/92 1.4/123 1.7/148 1.9/170...
  • Page 36 For PSC systems, the ½ hp motor is equipped with 4 speeds. The unit is set for mid-fire temp rise @ 65ºF. 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 37 OH8FA119D60 ALTERATIONS REQ’D FOR A/C @ DESIGN EXTERNAL STATIC PRESSURE COOLING UNIT Recommended CLG Speed HTG Speed by Input High Fire Fire Fire L/ML ML/MH MH/H Low (L) 36,000 L/ML ML/MH MH/H Med Low (ML) 42,000 L/ML ML/MH MH/H Med High (MH) 48,000 L/ML ML/MH...

  • Page 38: 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 39 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 40 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 41 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 42 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 43: 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 44 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 45 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 46 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 47 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 48 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 49 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 50 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 51: 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 52: 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 53: 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 54: 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 55: 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 56 Figure 24: Heat Exchanger Clean-Outs Vacuum Hose Length Fig. 25: Recommended method and device for cleaning inside of heat exchanger.

  • Page 57: 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 58: 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 59: 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 60 : 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 61: Troubleshooting

    Beckett Burner Riello Burner 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.

  • Page 62: Diagnostics

    1. Check for 115VAC line supply voltage to the furnace. If there is no supply voltage, check fuses and service switch. cCAUTION: When testing electrical equipment, always follow standard electrical procedures. 2. Make sure thermostat is calling for burner operation. 3.
  • Page 63 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. If cell resistances are different from above, replace the plug-in portion of cell, (Honeywell Part No. 130367).

  • Page 64: Sequence Of Operations Flow Chart

    VIII. Sequence of Operations Flow Chart:...

  • Page 66: Trouble Shooting Flow Chart

    IX. Trouble Shooting Flow Chart:...
  • Page 71 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.

  • Page 72: Replacement Parts List

    Appendix – A Replacement Parts: Replacement Parts for OH6FA072D**...
  • Page 73 Replacement Parts for OH8FA119D**...

  • Page 74: Wiring Diagrams

    Appendix – B Wiring Diagrams OH6FA072D48 PSC Wiring Diagram...
  • Page 75 OH6FA072DV4 ECM Wiring Diagram...
  • Page 76 OH6FX072DV4 ECM 2-Stage Wiring Diagram...
  • Page 77 OH8FA1119D60 PSC Wiring Diagram...
  • Page 78 OH8FA1119DV5 ECM Wiring Diagram...

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