Thermo Products PHCFA072DV4R manual

MO - 490 ECN 5095 - PC 131030 Made IN USA OIL FIRED FURNACE INST ALL ATION AND OPERATION M ANUAL WITH USERS INFO RM ATION SECTION MODEL: OHCF A 072DV4 R  WARNING: IF THE INFORMAT ION IN THESE INST RUCTIONS IS NOT FOLL O W ED EXACTLY, A FIRE OR EXPLO SION MAY R ESULT CAUSI NG PRO PERT Y DAMAG E, P ERSONAL I NJU RY, OR LOSS OF LIFE. DO NO T ST ORE[...]

i CONTENT S SECTI ON PAG E I. SAFET Y SEC TION 1 A. CODES AND CLEARANCES 3 II. GENERAL INST RUCTIONS 5 A. VENT ING 5 B. INST ALLAT ION OF VENT OR 7 C. CONDEN SATE D RAIN LINE CONN ECTION 10 D. DUCT W ORK/AIR CO NDITIONING 11 E. AIR F ILTER MOUNTED EXTERNAL T O FURNACE 12 F. LIMIT POSITIO N AND LO CATION 1 4 G. BURNER INST ALLAT ION 1 4 H. BURNER SP[...]

ii Model Number D igit 1 2 3 4 5 6 7 8 9 10 11 12 Fuel Configura tion Heat Exchan ger Identi fier Flue Feature Capacity Capacity Capacity Blower Typ e Clg Airfl ow Cap. Clg Airfl ow Cap. Burner Oil Furna c e Model Nomenclatur e Example Model Numbe r s O H C F A 0 7 2 D V 4 R O = Oil O H = Highboy D = Downflow H C = Heat Exchanger Id entifier C F = [...]

1 I. SA FETY SECTION This page and the following c onta i ns v arious wa r ni ngs and cautions found throughout the Oil Furnac e Manual. Please read and compl y with the statements be low .  WARNING AND C AUTIONS:  WARNING: This furnace is not to be used as a construc ti on heat er. See Pag e 3  WARNING: The predeter mine d limit l ocati o[...]

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3 The entire text of these instructions must be read and unders tood, before installing the appliance. It is the in staller's respon sibility to do the following: 1. Inform and demons trate to the user, t he correct operati on and m aintenance of the app liance, as explaine d in the Hom eowner/ User Information a nd Routine Maintenance section[...]

4 a . Combustibl e material : “...m aterials m ade of or s urfaced with wood, com pres sed paper, pl ant fibers , or other m aterials that are capabl e of being ignited and bur ned. Such m aterials shall be co nsidered c ombus tible even tho ugh f lame proof ed, fire - retar dant treated, or plaster ed.” b. Non - combust ibl e mater i al: “..[...]

5 II. GENERA L INSTRUCTIONS A . V E NTING: The OH C furnace ve nting s ystem m ust be insta lled by a qu alified ser vice per son in ac cordance with local inst allation c odes and these inst ructions. I n the a bsence of ap plicab le local c odes, confor m to the National F uel Gas C ode, N FPA 54/ANS I Z223.1 or la test ed ition . Installat ion s[...]

6 Care should be taken to design the s hortes t possible intake and exhaust system s. Each s y stem sho uld conta in as few elbows as p ossible t o insure the satisf actory oper ation of the furnac e. Howe ver, system length shoul d never be less than 8 ft of pipe with two (2), 90 de g . elbows. For b est overa ll oper ation of the com bustion syst[...]

7 fiberg lass insul ation, or equivalent, to prev ent free zing of cond ensate within the p ipe. 13 . No cle arance is require d from the outer sur face of the therm oplastic p iping to c ombustible m aterials for f ire hazard preventi on. No cl earance is required f rom the outer surf ace of the ventor ass embl y eit her. 14 . W hen attaching the [...]

8 NOT ICE: Ventor assemb ly must be in stalled so t hat it is level. If unit is not le vel, condens ate will leak in t o ventor box thru in ducer an d potentia lly free ze. 1. The OH C mus t be installed with the s ide - wall vent or/ blower assem bly. Do Not attem pt to oper ate the OHC w ithout the ventor as sembl y as this could result in damage[...]

9 A. The exit term ination of the draft s y stem shall not be less than 7’ a bove grade when located adjacent t o public walkwa ys. B. T he venting s ystem shall term inate at least 3’ above an y forced air in let located within 10 ’ horizontal ly. C . The venting s ystem shall term inate at least 4’ horizontal ly from , or 1’ above an y [...]

10 C. Condensate Drain Line Connec tions: Fig -4 1. The trap/ block ed drain s witch assem bly com es pre - m ounted to the u nders ide of blower pan jus t below th e second ary drain port on the r ight side of the f urnace. Pr ior to ins talling th e drain, the PVC elbow m ust be s ealed to the plast ic trap wit h silicon e and then t he spring c [...]

11 4 . A cond ensate pum p m ay be r equired when: • a suitable dr ain is no t prese nt, • the drain is above t he tra p outl et level on the furnace , or • the drain line canno t be slo ped downwar d its f ull length to t he drain . If gra vity drain age of th e condens ate from the furnac e to a dra in is im practical f or any of th ese rea[...]

12 blower an d blower motor have been se lected to work suc cessfully aga inst the f ollo wing range of duct system resistanc e. Recommend ed rang e of duct s ystem resist ance for all model s: 0.2 to 0. 5 in. W . G. extern al static pressure. Due to th e need to m aintai n an adequa te suppl y of com bustion and ventilat ion air , the furnace s ha[...]

13 Now the f ilter rac k can be a nchored to t he furnac e with s crews or p op - rivets thr ough the s ecuring f lange of the f ilter rack . Connect th e ret urn a ir plen um to the filt er rac k and s li de the f ilter into p lace. D im ensions for ada pting t he return air plenum to the filte r rack ar e provided (S ee Fig. 6 ). Note: Filter rac[...]

14 F . LIMIT PO SITION AN D LOCATION :  WARNING: The pred eterm ined limit locati ons on all of the Ther mo Pride oil fir ed furnaces have been tested and ap proved b y Th erm o Products, LLC. An y attempt to relocate these s afety controls or replace these saf ety controls with a control that is not a pproved, or is i ncompatible, m ay result i[...]

15 THE N OZZL E SIZE GI VES T HE NOM INAL FLO WR ATE, IN GPH, FO LLOW ED BY THE SPR AY ANGL E, IN DEG REE’ S, A ND TH E SPR A Y P A TT ERN, EITHER “H” FOR HOL LOW CONE OR “S” FOR SO LID CO NE. FO R EX AMPLE, A NOZZ LE R ATED A T 0.65 G PH @ 10 0 PSIG TH A T PR OVIDE S AN 80° SPR A Y A NGLE AND A HOLLOW SPR A Y PATT ERN WOULD BE A BBREVIA[...]

16 If availa ble, the use of ultra-low or low sulfur (l ess than 0 .0015% S and 0.05% S, b y weight, respecti vely ), no. 2 fuel o il i s highly recomme nded. Low sulf ur fuel o il can help to signif icantl y reduce instances of block age and corrosion of the oi l burner f uel deliver y system (especiall y the nozzle) , the furnac e heat exchan ger[...]

17 the pump. Pitching the line upward tow ard the tank will help prevent th e formation of air pock ets in the line. J . ELECTR ICAL WIRIN G: : This applian c e must be grounded in a ccordance with local c odes, or in the abs ence of local c odes, with the Nationa l Electr ical Code , ANSI/NFP A 70 - 1999, o r the latest edition. Electri c al Conne[...]

18 Tabl e 5: Ty pical El ectri cal Requirements Post - Purg e T imer: This f urnace is equ ipped wi th a post - pur ge tim er located in the blo wer com partment on t he contro l panel. It is pre - set at the fac tory for a 4 minute post - purg e. This is d esigned to ensure t hat no residual heat or combus tion odors per meate bac k into the hom e[...]

19 Fig -8 : The Fa n Contro l Module NOTICE: It is i mportant to confir m that the operating voltag e of the humidifi er or EAC being install ed matches the output of thi s control. If not, a field s upplied relay or transformer m ay b e necessary to p r ovide the proper control and su p p ly volta ge for the acc essory being i nstalled. Refer to t[...]

20 OHCFA072DV4 ALTERATIONS RE Q’D FOR A/C @ DESIGN EXTERN A L S TATIC PRE SS URE COOLING UNI T Recommended HTG Speed Recommended CLG Speed 24,000 Med Low Low 30,000 Med Low Med Low 36,000 Med Low Med 42,000 Med Low Med High 48,000 Med Low High Low= Red Med Low= Purp le Med= Blue Med Hi= Yellow High= Black Table 6: Blower Motor Speed Setup Speed T[...]

21 M. BLOWE R CONTROLLER INFORM ATION FOR ECM MOTOR TERMIN A L DEFINITIONS & FIELD WIRING Burner Har ness Co nnector P1 Pin 1 - Limit s witch connec tor. Pin 2 - 120 VAC L ine conn ection. Pin 3 - Burner pi lot contact . Pin 4 &5 - 120 VAC N eutral c onnections . Pin 6 - Burner pi lot contact . Pin 7 &8 - From oil prim ar y c ontrol. Pi[...]

22 Therm ostat call f or cool, “Y ” 24 VAC th erm ostat input. A call f or cooling is reco gnized when the t herm ostat connec ts “Y” to “ R”. This input has an ind icator L ED that wi ll light when th e cont rol receives a cal l for coo ling. R efer to the Cool Mode sec tion for the c ontro l operation. Therm ostat call f or dehum idif[...]

23 Therm ostat Input L EDs Four green LEDs are pl aced beneat h their respec tive ther mos tat connections (W , Y, G and DEHU M) and operate whenever a call is present . See Diagnos tic Features for a f unction descripti on of operatio n. Operating Modes Standb y Mode All outputs ar e off and the control is waiting for a therm ostat demand. T he th[...]

24 Motor Blo wer Speed Three inter connecte d blower speed out puts are pro vided. A “G ” call f or fan will provide po wer to the LOW speed tap onl y . A “W ” heat call will provide power to the Heat spee d tap onl y . A “ Y ” cooling ca ll will prov ide power to the Cool s peed tap only. In the case of therm ostat calls for “Y” an[...]

25 TROUBLE SHOO TING DIAGNOSTIC FE A T URES The cont rol board is eq uipp ed with 4 green In put Stat us LEDs and 1 red Boar d Status LED. Thes e are intended to provide a quick view into fur nace perf orm ance without r equiring a voltm eter. The green Input Status L EDs are driven b y the “Y” , “W ”, “G”, and “D EHUM” i nputs an d[...]

26 Operating I nstructions: i. STOP! Read the safety i nformation above. ii. Set t he therm ostat to th e lowest setting. iii. Turn off all electric p ower to the appliance. iv. T his applianc e is eq uipped with an ig nition s ystem that autom atically light s the burner. D o not tr y to lig ht the burn er by hand. iv. Rotat e the m anual oil s hu[...]

27 1 . Call f or heat TST AT c loses sending 2 4 volts t o “W”. 2. The 24 volt rela y closes s ending 115 v to the in ducer in th e ventor as sem bly. 3. The in ducer com es up t o speed and pr ovides f low and pr essure which closes the press ure switc h. 4. Upon t his pressur e swit ch closin g, T & T ar e closed to bring on the burn er. [...]

28 k . CARBON DIOXIDE (CO 2 ) OR OXYGEN (O 2 ): T ak e a CO 2 sam ple fr om flue pass agewa y. It is possible to achiev e reading s of up to 1 4% CO 2 (or 2% O 2 ), but it is recom mended to ha ve a lo wer C O 2 (or hi gher O 2 ) reading w ith zero s moke m easured. To ac hieve a lower CO 2 reading, open the air plate on the bu rner until zero sm o[...]

29 Fig -9 NOTICE: To achieve pr oper combu s tion and the efficie ncies listed i n sales brochures, i nstruments must be u sed to secu re CO 2 or O 2 reading s. 3. A djustment Of He at Input Rate: This appl iance was shipped f rom the f actory with o ne, f ixed, main burner no zzle si zed to produc e the input rate using no. 2 fuel o il at 145 ps i[...]

30 Temp erature rise = suppl y air temper ature - return air temp erature. After 15 t o 20 m inutes of c ontinuous oper ation, t he temper ature rise t hrough th e furnac e mus t fall within a range o f 55° t o 8 5 ° F. If the outlet or sup ply duct tem perature is too high , check to mak e sure the retur n air filter is clean, t he return air re[...]

31 III. USERS INF ORMATION SECT ION A. OIL SUPPLY : Do not allo w the fuel tank to run com pletel y empt y. During the s umm er, keep the tank full to pr event cond ensation of mois ture on the ins ide sur face of the tank. If the fue l tank r uns completel y dry, it m ay be neces sary to purge the lines of tr apped a ir. Contact a qualif ied techn[...]

32 The air f ilters sho uld be ins pected eac h month a nd cle aned when d irty. Clean ing the a ir filters frequentl y may reduce airborne c ontam inants f rom entering t he furnace a nd dep ositing in t he fur nace, duct s ystem and home. Fig - 10 IV. INSTALLER'S INST RUCTIONS TO USER: A fter completing the install a tion, the install er sha[...]

33 8. Inform the user to maint ain adequa te clearances around air openi ngs into t he applianc e housi ng and not t o block or restric t the entrance of air i nto the c ondenser c oil or the b urner c ompartment air opening. V. DE ALER M AINT EN AN C E : SAFETY DURING SER VICING A ND INSPECTION : Personal injury or property d a mage could res u l [...]

34 • Visuall y inspect the 4 heat ex changer tub es for excessive c arbon (s oot) build - up . Ref er to heat exc hanger sec tion of the m anual. 5. Oi l Filte r – Re place the s uppl y line oil fi lter cartr idge with a new filter of the same t ype and rat ing. Clean the bod y of, or m ounting pla te for, t he oil f ilter. 6. Labels and Mar ki[...]

35 6. Reass emble the s econd ary to its or iginal stat e. Re place heat ex changer , coil block - off s, and separator. Reassem ble fur nace to its or iginal c onstruc tion. Rem ount the burner com bustion a ir inlet. Re - confirm combus tion setting s. Replace a ny damaged or cor roded compon ents. A ll gaskets and ins ulation must be ins pected,[...]

36 Fig - 12 Fig - 13[...]

37  CAUTION: Before trouble s hooting, fam i liarize yoursel f with the start up and che ck out procedures NOTICE: Afte r reassembling the app l iance, check for fuel oil lea kage from the supply piping. a. Check proper oper ation of t he ignition s ystem and for pr oper com bustion. b. Observe t he main b urner fl ame. If the flame appe ars st [...]

38 Fig - 14 Filter rep lacement: To ensur e an adequat e replacem ent filter is s elected, s hould the filter require re placing, ref er to Table 2 , in Air Filter s section of this m anual, for the m inimum f ilter areas requir ed for diff erent types of available filter s. NOTICE: Remind th e homeowner of the importa nce of monthly filter inspect[...]

39 2. Disconnect all elec trical p ower to t he unit. 3. Fill th e oil t ank to reduc e water condensat ion in th e tank . 4. If the shutd own peri od will exceed one h eating s eason, an oil stabil izer shou ld be adde d to the oi l tank. Cons ult your o il supp lier for r ecomm endations. ON STARTUP: 1. Have s ystem inspec ted and s tarted b y a [...]

40 VI. HOME OW NE R/USER INFORMATION AND RO UTI NE MAINTEN ANCE:  WARNING: Never burn garba ge or refuse in this appliance. Never tr y to ignite oil by tossing burning papers or other material into the combustion chamber.  WARNING: Oil - fired appliances pr oduced by Thermo Products a re de signe d for burning No. 2 disti llate (domes tic hea[...]

41 Fig - 16 If this ac tion does no t react ivate th e unit, cont act a qual ified serv ice agenc y for ass istance. In genera l, if the th erm ostat is set i n the heat ing mode, the heating system function s entirel y automat ically. Ho wever, un der certai n circum stances , the applia nce m ay not be a ble to fire th e burner. For insta nce, if[...]

42 VII. TROUBLESHOOT ING: THIS SECT I ON IS ONLY TO BE PERFORMED BY TR AINED, QUALIFIED SERV I CE PERSONNE L, AND NOT BY THE FURN ACE OWNER. NOTICE: Before trouble shooting, familiarize y our s elf with the Initia l S tartup, Checkout Procedure , and Troubleshooting Flowchart. Refer to the ap pendices of this m anual for an electric al schem atic, [...]

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48 COM BUS T ION AND E FFICIE NCY T E ST ING FOR TH E R MO P R ID E OI L F I RED C EN TRAL F U RN A C ES . C om pl e t e t hi s f or m f or ea c h T he r mo P r i de f ur na c e i ns t a l l e d. Rea d i ns t r uc t i on m an ual c ar ef ully b ef or e m ak ing t est s. R et ain t h is f or m w it h f ur nac e. C US TO ME R NAM E A DDRESS C I TY, S[...]

49 A ppendi x – A Replace ment Part s:[...]

50 OHC BF3 RIE LLO BURNER (3807 90) I TEM DE SCR IPT ION TP P A RT # 1 A I R TUBE CO MPLETE 380760 2 BLA S T TUBE O N LY 380710 3 ELEC TRO DE A SS EMBLY 380712 4 P UMP 380633 5 M OTOR 380630 6 BLO WER WHEEL 380629 7 P RIM A RY CON TROL 380449 8 PHOT O CEL L 380628 9 INSU LAT ING AM U L ET 380789 10 N O Z Z L E , . 50 60 °W 380387 11 COIL 380719 12[...]

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52 A ppendi x – B Wiring Diagram OH CF A072D V4 R[...]