OIL FIRED FURNACE INSTALLATION AND OPERATION MANUAL WITH USERS INFORMATION SECTION MODEL: OHCFA072DV4R 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. WARNING: IMPROPER INSTALLATION, ADJUSTMENT, ALTERATION, SERVICE, OR MAINTENANCE CAN CAUSE INJURY OR PROPERTY DAMAGE.
CONTENTS SECTION PAGE I. SAFETY SECTION A. CODES AND CLEARANCES 1 3 II. GENERAL INSTRUCTIONS A. VENTING B. INSTALLATION OF VENTOR C. CONDENSATE DRAIN LINE CONNECTION D. DUCT WORK/AIR CONDITIONING E. AIR FILTER MOUNTED EXTERNAL TO FURNACE F. LIMIT POSITION AND LOCATION G. BURNER INSTALLATION H. BURNER SPECIFICATIONS AND APPLICATIONS I. OILTANK AND PIPING J. ELECTRICAL WIRIING L. BLOWER MOTOR SPEED SELECTION M. BLOWER CONTROLLER INFORMATION FOR ECM MOTOR N.
ii 0 7 2 0 7 2 Burner A 9 10 11 12 Clg Airflow Cap. 8 Clg Airflow Cap. 7 Blower Type 6 Capacity F 5 Capacity C 4 Flue Heat Exchanger Identifier Configuration O H 3 Capacity O = Oil H = Highboy D = Downflow C = Heat Exchanger Identifier F = Front R = Rear A = Single Stage Heating Capacity MBTUH (000's) with factory installed nozzle D = Direct Drive Clg. Airflow: Example = 48MBTUH = 4 tons @ 400cfm/ton Clg.
I. SAFETY SECTION This page and the following contains 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 Thermo Pride oil fired furnaces have been tested and approved by Thermo Products, LLC.
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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. 2. Inform the user of the hazards of flammable liquids and vapors and to remove such liquids and vapors from the vicinity of the appliance. 3.
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. Such materials shall be considered combustible even though flame proofed, fire-retardant treated, or plastered.” 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.
II. GENERAL INSTRUCTIONS A. VENTING: The OHC furnace venting system must be installed by a qualified service person in accordance with local installation codes and these instructions. In the absence of applicable local codes, conform to the National Fuel Gas Code, NFPA 54/ANSI Z223.1 or latest edition. Installation shall, at least, conform to the following requirements. 1. The exhaust vent/combustion air intake termination specified by Thermo Products, in this manual, shall be used. 2.
Care should be taken to design the shortest possible intake and exhaust systems. Each system should contain as few elbows as possible to insure the satisfactory operation of the furnace. However, system length should never be less than 8 ft of pipe with two (2), 90 deg. elbows. For best overall operation of the combustion system, we recommend the actual equivalent lengths for both the constructed intake and the exhaust systems have approximately the same value. 9.
fiberglass insulation, or equivalent, to prevent freezing of condensate within the pipe. 13. No clearance is required from the outer surface of the thermoplastic piping to combustible materials for fire hazard prevention. No clearance is required from the outer surface of the ventor assembly either. 14. When attaching the 3” PVC to the burner combustion air inlet collar, first apply a bead of RTV sealant to the burner inlet collar only to ensure an airtight seal.
NOTICE: Ventor assembly must be installed so that it is level. If unit is not level, condensate will leak in to ventor box thru inducer and potentially freeze. 1. The OHC must be installed with the side-wall ventor/ blower assembly. Do Not attempt to operate the OHC without the ventor assembly as this could result in damage to the appliance or home. 2. No clearance is required from the outer surface of the ventor assembly to combustible materials for fire hazard prevention. 3.
A. The exit termination of the draft system shall not be less than 7’ above grade when located adjacent to public walkways. B. The venting system shall terminate at least 3’ above any forced air inlet located within 10’ horizontally. C. The venting system shall terminate at least 4’ horizontally from, or 1’ above any door, window or gravity air inlet into the building. D. The vent termination shall be located at least 12” from any opening through which vented gases could enter the building. E.
C. Condensate Drain Line Connections: Fig-4 1. The trap/blocked drain switch assembly comes pre-mounted to the underside of blower pan just below the secondary drain port on the right side of the furnace. Prior to installing the drain, the PVC elbow must be sealed to the plastic trap with silicone and then the spring clamp applied. This 0 positioning of the elbow can be turned to right for exiting the right side casing or rotated 180 and exit the left side of the furnace.
4. A condensate pump may be required when: • • • a suitable drain is not present, the drain is above the trap outlet level on the furnace, or the drain line cannot be sloped downward its full length to the drain. If gravity drainage of the condensate from the furnace to a drain is impractical for any of these reasons, a condensate pump (part #350225) is available from Thermo Products. Follow the pump manufacturer’s instructions for proper installation. 5.
blower and blower motor have been selected to work successfully against the following range of duct system resistance. Recommended range of duct system resistance for all models: 0.2 to 0.5 in. W. G. external static pressure. Due to the need to maintain an adequate supply of combustion and ventilation air, the furnace shall not be installed in small room without return air duct system. A duct the full size of the furnace return aid opening shall extend to a location outside the furnace room.
Now the filter rack can be anchored to the furnace with screws or pop-rivets through the securing flange of the filter rack. Connect the return air plenum to the filter rack and slide the filter into place. Dimensions for adapting the return air plenum to the filter rack are provided (See Fig. 6). Note: Filter rack and condensate drain must be on separate sides of the furnace. Fig-6 A typical filter rack and dimensions for the OHC furnace.
F. LIMIT POSITION AND LOCATION: WARNING: 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. G. BURNER INSTALLATION: NOTICE: This furnace comes with a Riello BF3 burner preinstalled from the factory.
THE NOZZLE SIZE GIVES THE NOMINAL FLOWRATE, IN GPH, FOLLOWED BY THE SPRAY ANGLE, IN DEGREE’S, AND THE SPRAY PATTERN, EITHER “H” FOR HOLLOW CONE OR “S” FOR SOLID CONE. FOR EXAMPLE, A NOZZLE RATED AT 0.65 GPH @ 100 PSIG THAT PROVIDES AN 80° SPRAY ANGLE AND A HOLLOW SPRAY PATTERN WOULD BE ABBREVIATED IN THE TABLE AS “0.65 X 80°H”.
If available, the use of ultra-low or low sulfur (less than 0.0015% S and 0.05% S, by weight, respectively), no. 2 fuel oil is highly recommended. Low sulfur fuel oil can help to significantly reduce instances of blockage and corrosion of the oil burner fuel delivery system (especially the nozzle), the furnace heat exchanger, and the flue gas venting system. Air pollutants emitted by the furnace and the typical malodorous smell of oil combustion will be reduced. 1.
the pump. Pitching the line upward toward the tank will help prevent the formation of air pockets in the line. J. ELECTRICAL WIRING: : This appliance must be grounded in accordance with local codes, or in the absence of local codes, with the National Electrical Code, ANSI/NFPA 70-1999, or the latest edition. Electrical Connections NOTICE: All field wiring must conform to local, state, and national installation codes. A disconnection switch equipped with overcurrent protection rated at 15 A. (e.g.
Model Voltage/Frequency No. of Phases (V/Hz/Ph) OHCFA072DV4 120/60/1 Maximum Time Delay Minimum Oil Burner Supply/Return Type Fuse Recommende Assembly OHC Full Load Air Blower Full or Inverse d 75 deg. C. Full Load Current (Amps) @ Load Current Time Current Copper 120 VAC Circuit (Amps) @ 120 (Amps) @ Power Wiring Breaker VAC 120 VAC Size (AWG) Size (Amps) 11.45 7.15 ECM 2.
Fig-8: 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 provide the proper control and supply voltage for the accessory being installed. Refer to the manufacturer’s instructions for the humidifier or EAC for additional information.
OHCFA072DV4 ALTERATIONS REQ’D FOR A/C @ DESIGN EXTERNAL STATIC PRESSURE Recommended CLG Speed COOLING UNIT Recommended HTG 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 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.
M. BLOWER CONTROLLER INFORMATION FOR ECM MOTOR TERMINAL DEFINITIONS & FIELD WIRING Burner Harness Connector P1 Pin 1- Limit switch connector. Pin 2- 120 VAC Line connection. Pin 3- Burner pilot contact. Pin 4&5120 VAC Neutral connections. Pin 6- Burner pilot contact. Pin 7&8From oil primary control. Pin 9- Limit Switch Input (LSI).
Thermostat call for cool, “Y” 24 VAC thermostat input. A call for cooling is recognized when the thermostat connects “Y” to “R”. This input has an indicator LED that will light when the control receives a call for cooling. Refer to the Cool Mode section for the control operation. Thermostat call for dehumidification “DEHUM” 24 VAC thermostat input. A call for dehumidification is recognized when the humidistat connects “DEHUM” to “R”.
Thermostat Input LEDs Four green LEDs are placed beneath their respective thermostat connections (W, Y, G and DEHUM) and operate whenever a call is present. See Diagnostic Features for a function description of operation. Operating Modes Standby Mode All outputs are off and the control is waiting for a thermostat demand. The thermostat inputs, and limit switch are continuously monitored. The control initiates action when a thermostat call is received or limit switch opens.
Motor Blower Speed Three interconnected blower speed outputs are provided. A “G” call for fan will provide power to the LOW speed tap only. A “W” heat call will provide power to the Heat speed tap only. A “Y” cooling call will provide power to the Cool speed tap only. In the case of thermostat calls for “Y” and “W” together, blower speed selection will be determined by the input that was first initiated.
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. They will light to indicate the presence of these signals.
Operating Instructions: i. STOP! Read the safety information above. ii. Set the thermostat to the lowest setting. iii. Turn off all electric power to the appliance. iv. This appliance is equipped with an ignition system that automatically lights the burner. Do not try to light the burner by hand. iv. Rotate the manual oil shutoff valve to the “ON” position. vi. Turn on the electric power to the appliance. vii. Set the thermostat to the desired setting. viii.
1. Call for heat TSTAT closes sending 24 volts to “W”. 2. The 24 volt relay closes sending 115v to the inducer in the ventor assembly. 3. The inducer comes up to speed and provides flow and pressure which closes the pressure switch. 4. Upon this pressure switch closing, T & T are closed to bring on the burner. To initially fire the oil burner, proceed in the following manner: a. Turn the disconnecting switch, which provides power to the appliance, to the "OFF" position. b.
k. CARBON DIOXIDE (CO2) OR OXYGEN (O2): Take a CO2 sample from flue passageway. It is possible to achieve readings of up to 14% CO2 (or 2% O2), but it is recommended to have a lower CO2 (or higher O2) reading with zero smoke measured. To achieve a lower CO2 reading, open the air plate on the burner until zero smoke is measured. A CO2 of 11-1/2% is recommended. For example, if a 13% CO2 (or 3.5% O2) is recorded at a trace of smoke, open the air shutter until zero smoke is measured with a 11-1/2% CO2 (or 4.
Fig-9 NOTICE: To achieve proper combustion and the efficiencies listed in sales brochures, instruments must be used to secure CO2 or O2 readings. 3. Adjustment Of Heat Input Rate: This appliance was shipped from the factory with one, fixed, main burner nozzle sized to produce the input rate using no. 2 fuel oil at 145 psi. The input rate cannot be increased.
Temperature rise = supply air temperature - return air temperature. After 15 to 20 minutes of continuous operation, the temperature rise through the furnace must fall within a range of 55° to 85° F. If the outlet or supply duct temperature is too high, check to make sure the return air filter is clean, the return air registers are free from obstruction, the outlet registers are properly adjusted and clear, and the supply and return air ducts are open.
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. Contact a qualified technician to bleed the lines and restart the burner. OIL SUPPLY VALVE: Turn the oil supply valve off if the burner is shut down for an extended period of time. B.
The air filters should be inspected each month and cleaned when dirty. Cleaning the air filters frequently may reduce airborne contaminants from entering the furnace and depositing in the furnace, duct system and home. Fig-10 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.
8. Inform the user to maintain adequate clearances around air openings into the appliance housing and not to block or restrict the entrance of air into the condenser coil or the burner compartment air opening. 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.
• Visually inspect the 4 heat exchanger tubes for excessive carbon (soot) build-up. Refer to heat exchanger section of the manual. 5. Oil Filter – Replace the supply line oil filter cartridge with a new filter of the same type and rating. Clean the body of, or mounting plate for, the oil filter. 6. Labels and Markings - Clean all appliance labels, markings, and instruction plates, as necessary, and verify that all are still legible. Any illegible or missing markings must be replaced.
6. Reassemble the secondary to its original state. Replace heat exchanger, coil block-offs, and separator. Reassemble furnace to its original construction. Remount the burner combustion air inlet. Reconfirm combustion settings. Replace any damaged or corroded components. All gaskets and insulation must be inspected, and replaced, if they show any signs of damage.
Fig-12 Fig-13 36
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 strange or abnormal in character, look for a component or components that were not reassembled correctly.
Fig-14 Filter replacement: To ensure an adequate replacement filter is selected, should the filter require replacing, refer to Table 2, 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 importance of monthly filter inspections during operation to ensure maximum operating efficiency. G.
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 season, an oil stabilizer should be added to the oil tank. Consult your oil supplier for recommendations. ON STARTUP: 1. Have system inspected and started by a qualified heating contractor. 2. Check oil level in tank.
VI. HOMEOWNER/USER INFORMATION AND ROUTINE MAINTENANCE: WARNING: Never burn garbage or refuse in this appliance. Never try to ignite oil by tossing burning papers or other material into the combustion chamber. WARNING: Oil-fired appliances produced by Thermo Products are designed for burning No. 2 distillate (domestic heating) fuel oil. Never use gasoline or a mixture of oil and gasoline. : Do not use this appliance if any part has been under water.
Fig-16 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.
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. 1.
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COMBUSTION AND EFFICIENCY TESTING FOR THERMO PRIDE OIL FIRED CENTRAL FURNACES. Compl e te thi s form for e a ch The rmo Pri de furna ce i ns ta l l e d. Re a d i ns tructi on ma nua l ca re ful l y be fore ma ki ng te s ts . Re ta i n thi s form wi th furna ce . CUSTOMER NAME ADDRESS CITY, STATE HEATING BURNER MODEL NO. BLAST TUBE LENGTH AIR SHUTTER OPENING % OF MAX.
Appendix – A Replacement Parts: 49
OHC BF3 RIELLO BURNER (380790) ITEM 1 2 3 4 5 6 7 8 9 10 11 12 DESCRIPTION AIR TUBE COMPLETE BLAST TUBE ONLY ELECTRODE ASSEMBLY PUMP MOTOR BLOWER WHEEL PRIMARY CONTROL PHOTO CELL INSULATING AMULET NOZZLE, .
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Appendix – B Wiring Diagram OHCFA072DV4R 52