Thermo Products OD6FX072DV5R manual

MO-458 ECN 4936-MA Made IN USA OIL FIRED FURNACE INSTALLATION AND OPERATION MANUAL WITH USERS INFORMATION SECTION MODEL: Counterflow / Horizontal OD6FA072D48B OD6RA072D48B OD6FX072DV5R OD6FA072DV5B OD6RA072DV5B OD6RX072DV5R OD6FA072D48R OD6RA072D48R OD6FA072DV5R OD6RA075DV5R c WARNING: IF THE INFORMATION IN THESE INSTRUCT IONS IS NOT FOLLOWED EXACT[...]

i CONTENTS SECTION PAGE I. SAFETY SECTION 1 A. CODES AND CLEARANCES 3 B. MAKE-UP AIR 4 II. GENERAL INSTRUCTIONS 5 A . C H I M N E Y 6 B . V E N T I N G 10 C. DRAFT REGULATORS 11 D. DUCT WORK/AIR CONDITIONING 11 E . A I R F I L T E R ( S ) 15 F. LIMIT POSITION AND LOCATION 16 G. BURNER INSTALLATION 16 H. BURNER SPECIFICATIONS AND APPLICATIONS 19 I. [...]

ii Model Number Digit 1 2 3 4 5 6 7 8 9 10 11 12 Fuel Configuration Heat Exchanger Identifier Flue Feature Capacity Capacity Capacity Blower Type Clg Airflow Cap. Clg Airflow Cap. Burner Oil Furnace Model Nomenclature Example Model Numbers O D 6 F A 0 7 2 D 4 8 B O D 6 F A 0 7 2 D V 5 R O D 6 R A 0 7 2 D 4 8 B O D 6 R A 0 7 2 D V 5 R O D 6 F X 0 7 [...]

1 I. SAFETY SECTION This page and the following contains various w arnings and cautions found throughout the Oil Furnace Manual. Please read and comply with the statements below. c WARNING AND CAUTIONS: c WARNING: This furnace is not to be used as a construction heater. See Page 3 c CAUTION MUST BE TAKEN NOT TO EXCEED 90° ROTATION (OF THE FLUE ELB[...]

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3 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 Homeow ner/User Information and Routine Maintenance section of this ma[...]

4 b. Non-combustible material: “...material that is not capable of bei ng ignited and burned; such as material consisting entirely of, or a combination o f, steel, iron, brick, concrete, slate, asbestos, glass, and plaster.” : Carefully read and thoroughly understand the following guidelines and w arnings before continuing w ith the installatio[...]

5 II. GENERAL INSTRUCTIONS - READ BE FORE 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 provi ded by the Air Conditioning Contractors of America (ACCA) or the American Society of Heating, Refrigeration and Air Conditioning Engine[...]

6 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 s ealed 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 i[...]

7 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 atti c, etc., and condensing occurs, the chimney must be insulated around its exterior to hel[...]

8 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. (See Fig. 5). Fig. 5: Suggested[...]

9 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[...]

10 The vent connector pipe between the furnace and chimney s hall 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 inst alled so that it has a continuous rise from the furnace to the chimney. The[...]

11 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. With the burner operat ing, use a draft gauge to adjust t[...]

12 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 c ontraction, it is recommended that flexible joints be installed at the supply and return duct connections to the unit. 3. The return air duct system must equal the supply air duct system in the flow capa[...]

13 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. The resistance of the take-off and the outlet register (or[...]

14 8. As a final step in the installation, the appliance mu st be adjusted to deliver a temperature rise within the range of 50° to 80°F. Adjust the blower moto r speed to obtain a temperature rise within the acceptable range. The required blower speed w ill depend on the airflow resistance of a supply and return air duct systems. Fig. 9: Supply [...]

15 E. Air Filters Filter Installation The OD6 comes with (2) two 18-3/4” x 12-3/4” reusable filters. A “W” style filter rack is shipped with the furnace for placement of the filters inside the retu rn air plenum. Access to the filters is through the removable blower door. For horizontal installations, it is recommended that return air grill[...]

16 F. LIMIT POSITION AND LOCATION c WARNING: The predetermined limit locations on all of t he Thermo Pride oil fired furnaces have been tested and approved by Thermo Products, LLC. Any attempt to relocate thes e safety controls or replace these safety controls with a control that is not approved, or is incompat ible, may result in personal injury, [...]

17 Fig. 12-1: Typical location of the ov erfire air tap and components in burner mounting plate area for OD6F*072D*** counterflow and horizontal installations[...]

18 Fig. 12-2: Typical location of the ov erfire air tap and components in burner mounting plate area for OD6R*072D*** counterflow and horiz ontal installations[...]

19 Fig. 13: Burner insertion illustration (Top view) When mounting the burner, the mounting plate (Fig. 12) must be removed to provide access to the area in front of the combustion chamber. A fiber insulati ng sleeve or amulet is pr ovided on the burner tube of specific Thermo Pride burners.(s ee Fig. 13). See Thermo Pride bur ner application chart[...]

20 Table 7: Oil nozzle capacity 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 havi ng heating value of 140,000 BTU per gallon. ** Based on thermal efficiency of 84%-85%. Riello 2-stage burner specifications and applications: MODEL PART OD6 2-STAGE MTG.[...]

21 2 STAGE FIRING RATES CAPACITY FIRING RATE NOZZLE SIZE Riello INPUT RATE* (BTU/HR) EFFECTIVE** HEATING CAPACITY HIGH FIRE 106,250/170psi 90,000 HIGH CAPACITY LOW FIRE .70 X 45 ° W 85,000/130psi 74,000 HIGH FIRE 85,000/170psi 74,000 LOW CAPACITY LOW FIRE .50 X 45 ° W 70,000/130psi 60,000 Table 9: Riello 2-stage firing rates * Based on #2 domesti[...]

22 I. OIL TANK AND PIPING: : All local codes and ordinances take precedence w ith 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 acco rding to the instructions in this manual and the Standard for the Installation of Oil-Bur[...]

23 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. If the lift (vertical dist ance between the supply line inlet and the burner) exceeds appro[...]

24 M odel P ote ntia l/Fr e q u en c y /No. of Phases (V /H z/P h ) Suppl y / Retur n A ir B lo w er Fu ll Load Curr ent (A mps) @ 115 VA C O il B u rne r A ssemb ly Ful l Load C urre n t (A m ps ) @ 115 VA C Ma xi mu m T im e D ela y Ty pe Fuse o r Inv e rs e Ti m e Ci r cu i t Breaker Si z e (A m ps) Mi n i mu m Reco m mend e d 75 deg. C. Copper [...]

25 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 prov ide the proper control and supply v oltage for the accessory being installed. Refer to the manufacturer[...]

26 Figure 16: Heat Anticipator A djustment 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 questi oned, the following procedures should be followed: Preferred method of adjustment: Using an analog ammeter on the lowest scale, such as an Am[...]

27 This formula can be used to calculate the corre ct 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) 10 4. Adjust the position of the anticipator i ndicator to match the calculated ammeter setting. If a slightly longer cycle is desired, t[...]

28 Heating Speed Set-ups (Single Stage) Low Fire Med Fire High Fire BTUH 60,000 72,000 90,000 Fan Control SW 1 Switch Settings Heating CFM Approx. Rise (F 0 ) Approx. Rise (F 0 ) Approx. Rise (F 0 ) Static Pressure in W.C. Watts Amps 0.2” 93 1.07 3-OFF 2-OFF 1-OFF 755 73 0.5” 162 1.80 0.02” 109 1.25 3-OFF 2-OFF 1-ON 826 66 80 0.5” 174 1.92 [...]

29 Heating Speed Set-ups ( 2 – Stage ) LOW CAPACITY HIGH CAPACITY BTUH LOW FIRE 60,000 HI FIRE 72,000 LOW FIRE 72,000 HI FIRE 90,000 FAN CONTROL SW 1 SWITCH SETTINGS HEATING CFM APPRO X. CFM/RISE (ºF) APPRO X. CFM/RISE (ºF) APPRO X. CFM/RISE (ºF) APPRO X. CFM/RISE (ºF) 3 – OFF 2 – OFF 1 – OFF 755 604 / 91º 755 / 87º 604 / 109º 755 / [...]

30 Cooling Speed Set-ups Air Flow Fan Control SW1 Switch Settings Clg. Tonage Cool Continous Static Pressure in W.C. Watts Amps 0.2” 102 1.16 6-OFF 5-OFF 4-OFF 2 799 500 0.5” 165 1.83 0.2” 149 1.68 6-OFF 5-OFF 4-ON 2.5 1017 508 0.5” 238 2.60 0.2” 213 2.35 6-OFF 5-ON 4-OFF 3 1210 605 0.5” 306 3.27 0.2” 304 3.32 6-OFF 5-ON 4-ON 3.5 1404[...]

31 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 0.1 0.2 0.3 0.4 0.5 0.6 0.7 Low 930 915 912 910 822 774 730 ML 1155 1152 1130 1126 1085 1042 920 MH 1442 1432[...]

32 M. BLOWER CONTROLLER IN FORMATION FOR PSC MOTOR (Note: for ECM blow er controller informati on see: ECM Operation Manual document # Mo-440) TERMINAL DEFINITION S & FIELD WIRING Burner Harness Connector P1 Pin 1- Limit switch connector. Pin 2- 120 VAC Line connection. Pin 3- Burner pilot contact. Pin 4&5- 120 VAC Neutral connections. Pin [...]

33 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. Thermostat call fo[...]

34 Humidifier The control provides a 120 VAC output for a hum idifier. 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 i[...]

35 DIP SWITCH 2 SECTION STATE BLOWER DELAY TIMES 1 2 3 4 Counter Flow ON - SEC ON - SEC OFF - MIN OFF OFF 15 30 ON OFF 24 60 OFF ON 36 120 ON ON 48 240 OFF OFF 2 ON OFF 4 OFF ON 6 ON ON 8 Table 11: ON and OFF Blower Delay Time Sw itch Settings Motor Blower Speed Three interconnected blower speed outputs are provi ded. A “G” call for fan will pr[...]

36 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 direct[...]

37 N. STARTUP PROCEDURES: A. Heating System 1. Initial Startup: : Turn off pow er to furnace. Before the oil piping system is placed into servi ce, 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. A qualified heating[...]

38 To Turn Off Oil to Appliance: i. Set the thermostat to the lowest setting and set the operating mode switch to “OFF”. ii. If s ervice is to be performed, turn off t he electrical power to the appliance. iii. Turn the manual oil shutoff valve to the “OFF” position. 2. Adjustment of Burner Combustion: : Maximum gross stack temperature must[...]

39 Figure 19: Preliminary A djustment of Burner Air Band and A ir Shutter i. When ignition is established, make a prelim inary burner air adjustment to attain a clean combustion flame. Generally, the burner bul k air band should be about 3/16 inch open and the opening of the burner air shutter set in the range of “2” to “7”, refer to Figure[...]

40 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 combustion chamber and t[...]

41 Figure 22 1 st 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 st stage. Loosen the nut (2), turn the screw (3) until the air s hutter (1) reaches the position desired. Then lock the nut (2). Pressure regulation: thi[...]

42 ii. 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 2 ) reading with zero smoke measured. To achieve a lower CO 2 reading, open the air band, or shutter, on the burner until zero smoke i[...]

43 a. With the oil shut off, remove the 1/8 in. NPT threaded pipe pl ug 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 t he discharge side, of the oil pump. NOTICE: It may be necessary to remove the oil pump to attach[...]

44 5. Checkout Procedure: Before any system of oil piping is finally put into serv ice, 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 leavi[...]

45 III. USERS INFORMATION SECTION A. OIL SUPPLY: Do not allow the fuel tank to run comp letely 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 li nes of trapped air. Contact a qualified technician to bleed the l[...]

46 D. STARTING THE BURNER: 1. Turn the main service switch to "OFF" position. 2. Set thermostat substantia lly 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[...]

47 IV. INSTALLER'S INSTRUCTIONS TO USER: After completing the installation, the installer shall inform and/or demonstrate to the homeowner the follow ing items: 1. The location of these instructions. The instruct ions must be kept along with instructions for any accessories in the plastic pouch with the appliance. 2. The location and use of th[...]

48 V. DEALER MAINTENANCE: SAFETY DURING SERVICING AND INSPECTION : Personal injury or property damage could result from repair or service of this appliance by any one 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 [...]

49 B. HEAT EXCHANGER: c WARNING: A qualified heating contractor must clean the heat exchanger. At least once a year, inspect the heat exchanger for evidence of corrosi on, pitting, warpage, deterioration, and carbon (soot) build-up. A layer of soot on the in side of the heat exchanger will act as an insulator and reduce heat transfer, resulting in [...]

50 HEAT EXCHANGER CLEAN-OUT ACCESS (TUBE) CLEAN-OUT PLUG ASSEMBLY T-HANDLE (PART OF CLEAN-OUT PLUG ASSEMBLY) 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.[...]

51 4. Operational Check: c CAUTION: 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. Observe the main burner flame. If the flame appears st[...]

52 Figure 26: Location of Supply/Return A ir Filter Filter replacement: To ensure an adequate replacement filter is selected, shoul d 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 impor tance o[...]

53 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 s eason, an oil stabilizer should be added to the oil tank. Consult your oil supplier for recommendations. ON STARTUP: 1. Have[...]

54 VI. HOMEOWNER/USER INFORM ATION AND ROUTINE MAINTENANCE: c WARNING: Never burn garbage or refuse in th is appliance. Never try to ignite oil by tossing burning papers or other material into the combustion chamber. c WARNING: Oil-fired appliances produced by Thermo Products are designed for burning No. 2 distillate (domestic heating) fuel oil. Ne[...]

55 Beckett Burner R i e l l o B u r n e r Figure 28: Location of oil primary control reset button If this action does not reactivate the unit, c ontact a qualified service agency for assistance. In general, if the thermostat is set in the heat ing mode, the heating system functions entirely automatically. However, under certain circumstances, the a[...]

56 VII. TROUBLESHOOTING: THIS SECTION IS ONLY TO BE PERFORM ED BY TRAINED, QUALIFIED SERVICE PERSONNEL, AND NOT BY THE FURNACE OWNER. NOTICE: Before troubleshooting, familiarize y ourself with the Initial Startup, Checkout Procedure, and Troubleshooting Flowchart. Refer to the appendices of this manual for an electrical schematic, a connection diag[...]

57 If it is necessary to troubleshoot the flame sens or independently of the burner primary, the following procedure may be used. B. CAD CELL CHECKOUT PROCEDURE: 1. Stop burner and shutoff electr ical power to the appliance. 2. Open burner junction box (on top of the burner bl ower) and remove the plug-in portion of the cad cell by pulling it forwa[...]

58 VIII. Sequence of Operations Flow Chart:[...]

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60 IX. Trouble Shooting Flow Chart:[...]

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65 COMBUSTION AND EFFICIENCY TESTING FOR THERMO PRIDE OIL FIRED CENTRAL FURNACES. Complete this form for each Thermo Pride furnace installed. Read instruction CUSTOMER NAME ADDRESS CITY, STATE HEATING SYSTEM BURNER MODEL NO. AIR SHUTTER OPENING INS. % OF MAX. (EST) FURNACE MODEL TYPE OF VENTING SYSTEM MASONRY CHIMNEY METAL CHIMNEY SIDEWALL POWER VE[...]

66 Appendix – A Replacement Parts: Replacement Parts for OD6F*072D**[...]

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68 Replacement Parts for OD6R*072D**[...]

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70 Appendix – B Wiring Diagrams OD6*A072D48 PSC Wiring Diagram[...]

71 OD6*A072DV5 ECM Wiring Diagram[...]

72 OD6*X072DV5 ECM 2-Stage Wiring Diagram[...]

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