Thermo Products OL6RA072DV5(B/R) manual

MO-483 ECN 5113-PB 100901 Made IN USA OIL FIRED FURNACE INSTALLATION AND OPERATION MANUAL WITH USERS INFORMATION SECTION MODEL: OL6RA072D48(B/R) OL6FA072D48(B/R) OL6RA072DV5(B/R) OL6FA072DV5(B/R) OL6RX072DV5(R) OL6FX072DV5(R) c WARNING: IF THE INFORMATION IN THESE INSTRUCT IONS IS NOT FOLLOWED EXACTLY, A FIRE OR EXPLOSION MAY RESULT CAUSING PROPERT[...]

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 5 B . V E N T I N G 10 C. DRAFT REGULATORS 10 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 17 H. BURNER SPECIFICATIONS AND APPLICATIONS 18 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 L 6 F A 0 7 2 D 4 8 B O L 6 F A 0 7 2 D V 5 B O L 6 F X 0 7 2 D V 5 R O L 6 R A 0 7 2 D 4 8 R O = Oil O H = [...]

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 WARNING: The predetermined limit locations on a ll of the Thermo P[...]

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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 Qualified service personnel must perform all installations and services. The following are common chimney requirements nec essary 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, Vent s, and Solid Fuel Burning Appliances (NFPA2[...]

7 occurs, then insulating the vent connector and/or reduc ing the efficiency of the furnace may have to be done to raise the chimney temperature. More detailed information may be obtained from t he latest edition of the ASHRAE HVAC Systems and Equipment Handbook . 3. PROPER CHIMNEY HEIGHT: The chimney shall terminate at least 3 feet above t he high[...]

8 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 method to improve chimney draft. 6. TIGHT JOINTS: All joints of[...]

9 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 inc[...]

10 NOTE: On the OL6 it is possible to rotate the flue elbow (which is factory installed for vertical discharge) 90° counter clockwise from the vertical positi on 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. For installati[...]

11 to (-).02" WC, as measured at the 5/16" over fire ai r tap (See Fig. 12). This tap is provided in the upper burner mounting plate. To measure the flue draft, punc h a small hole in the vent connector pipe as close to the furnace as possible and al ways before the draft regulator. Note: Draft over fire may be positive for high fire appl[...]

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 flow rate. h. The resistance of the take-off and the outlet register (o[...]

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 Mounted Internal to Furnace: Fig. 10: Internal filter rack. : Failure to comply with minimum filter installation requirements may affect the performance and/or void the warranty on this unit. If a method other than internal Thermo Pride filter rack is selected for retention of the filters and/or use of a different filter type is d[...]

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 G. BURNER INSTALLATION: NOTICE: Remove all cardboard packing from around chamber before installing burner. The oil burner will mount on three stud mounting bol ts on the lower mounting plate covering the opening in the front of the heat exchanger. The end of the bur ner tube should be inserted no further than 1/4 inch back from the inside surfac[...]

18 H. BURNER SPECIFICATIONS AND APPLICATIONS: FURNACE MODEL THERMO PRIDE’S BURNER SPEC NO. * INS BECKETT BURNER MODEL & TUBE LENGTH HEAD STATIC PLATE MAXIMUM NOZZLE SIZE** SHIPPED NOZZLE SIZE OIL PUMP PRESSURE (PSIG) OL6*A072D**B TP2501 N AFG-4.5” F3 3-5/8 0.75X80 ° H 0.60X80 ° H 120 The optional BF3 Riello flame retention oil burner can [...]

19 Riello 2-stage burner specifications and applications: MODEL PART OL6 2-STAGE MTG. PLATE PART NO. 11700 MTG. PLATE GASKET PART NO. 330212 **NOZZLE SIZE .70x45 ° W / .50x45 ° W* NOZZLE PART NO. 380702 / 380724* OIL PUMP PRESSURE 130 LOW 170 HIGH BURNER G5D BURNER PART NO. 380529 Table 8: Riello burner application THE NOZZLE SIZE GIVES THE NOMIN[...]

20 MOUNTING THE 2-STAGE RIELLO BURNER: It is necessary that the insulation gasket be plac ed between the mounting plate and the burner flange. The insulating gasket has six holes, which, if nece ssary, can be modified as shown. (see figure 14-1) Figure 14-1: Burner gasket and mounting Figure 14-2: Burner fixing and hinge assembly Verify that the in[...]

21 5. A readily accessible, design-certified, manual oil shutoff valve, with a non-displaceable rotor member, shall be installed in the fuel oil s upply piping within 6 feet of the appliance. 6. A pipe union, or flanged connection, shall be pr ovided downstream from the manual oil shutoff valve to permit removal of the appliance oil pum p. Pipe uni[...]

22 J. OIL FILTER: It is strongly recommended that an oil filter assembly be installed in the oil supply line to the unit. This filter should have the capacity to trap a 40-50 micron particle. The filter cartridge should be replaced at least onc e a year. The filter body should be thoroughly cleaned before installing a new cartridge. K. ELECTRICAL W[...]

23 Wire size selections in Table 10 are based upon Table 310-16 of the National Electrical Code for three copper conductors, with insulation rated for 75 degr ees Celsius, contained in raceway at 30 degrees Celsius. For other wire insulation temperature ra tings and ambient conditions, refer to the National Electrical Code for the minimum wire sizi[...]

24 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[...]

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

26 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[...]

27 Heating Speed Set-ups OL6*A072DV5 Furnace Motor Current Draw (Amps/ / Watts) v s. External Static Pressure (in W.C.) Low Fire Med Fire High Fire BTUH 60,000 72,000 90,000 Fan Control SW 1 Switch Settings Heating CFM Ap rox. Rise (F 0 ) A prox. Rise (F 0 ) A prox. Rise (F 0 ) 0.2 0.4 0.6 3-OFF 2-OFF 1-OFF 755 73 o 1.2/107 1.6/151 2.1/208 3-OFF 2-[...]

28 Heating Speed Set-ups ( 2 – Stage ) OL6*X072DV5 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 A PPROX. CFM/RISE (ºF) A MPS/WATTS A PPROX. CFM/RISE (ºF) A MPS/WATTS A PPROX. CFM/RISE (ºF) A MPS/WATTS A PPROX. CFM/RISE (ºF) A MPS/WATTS 3 – OFF 2 ?[...]

29 Cooling Speed Set-ups OL6**072DV5 Furnace Motor Current Draw (Amps / Watts) v s. External Static Pressure (in W.C) NOTE: All information is approximate. Results w ill v ary by installation. Figure 18-3: Cooling blower motor speed chart Fan Control SW 1 Switch Setting s Clg. Tonnage Coo l Continuous 0.2 0.5 6-OFF 5-OFF 4-OFF 2 799 500 1.3/ 115 2.[...]

30 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: OL6*A072D48 ALTERA TIONS REQ’D FOR A/C @ DESIGN EXTERNA L STATIC PRESSURE HTG Speed by Input COOLING UNIT Low fire Mid Fire High Fire Recommended CLG Speed 24,000 ML MED MH Med Low 30,000 ML MED [...]

31 Speed vs. color code for PSC Motor: Low = Orange Med-Low = Red Med= Blue Med-High = Yellow High = Black 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 P2 Pin 1- Limit switch connector. Pin[...]

32 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[...]

33 EAC (electronic air cleaner) The control provides a 120 VAC output for an electr onic 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 hum idifier. Connections are[...]

34 Heat Mode When a call for heat (“W”) is received from the thermost at, 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 del ay values (see Table 11). When the delay time has elapsed, the ?[...]

35 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[...]

36 N. STARTUP PROCEDURES: A. Heating System 1. Initial Startup: : Turn off pow er 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. A qualified heating [...]

37 To Turn Off Oil to Appliance: i. Set the thermostat to the lowest setting and set the operating mode switch to “OFF”. ii. If servic e 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[...]

38 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[...]

39 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[...]

40 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[...]

41 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[...]

42 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[...]

43 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[...]

44 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[...]

45 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[...]

46 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[...]

47 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 [...]

48 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 [...]

49 Figure 24: Heat Exchanger Clean-Outs Vacuum Hose Length OL6 8FT Fig. 25: Recommended method and device for cleaning inside of heat exchanger.[...]

50 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[...]

51 Figure 26: Location of Supply/Return A ir Filters 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 [...]

52 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 system inspected and start ed by a qualified heating contractor. 2. Check oil level in tank. If the tank ha[...]

53 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[...]

54 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[...]

55 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[...]

56 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[...]

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

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

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64 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[...]

65 Appendix – A Replacement Parts: Replacement Parts for OL6F*072D**[...]

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67 Replacement Parts for OL6R*072D**[...]

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69 Appendix – B Wiring Diagrams OL6*A072D48 PSC Wiring Diagram[...]

70 OL6*A072DV5 ECM Wiring Diagram[...]

71 OL6*X072DV5 ECM 2-Stage Wiring Diagram[...]

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