Instruction/ maintenance manual of the product OH6FA072D48B Thermo Products
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MO - 437 ECN 5338 - MA 14 030 1 Made IN USA OIL FIRED FURNACE INST ALL ATION AND OPERATION M ANUAL WITH USERS INFO RM ATION SECTION MODEL: OH6FA 072D48B OH6FA 072DV4B OH8FA 119D60B OH8FA 119DV5B OH6FA.
i CONTENT S SECTI ON PAG E I. SAFET Y SEC TION 1 A. CODES AND CLEARANCES 3 B. MA KE - UP AI R 4 II. GENERAL INSTRUCT IONS 5 A. CHIMNE Y 6 B. VENT ING 10 C. DRAFT REGULAT ORS 11 D. DUCT W ORK/AIR CO NDITIONING 11 E. AIR F ILTER (S ) 15 F. LIMIT POSITIO N AND LO CATION 17 G.
ii Model Number D ig it 1 2 3 4 5 6 7 8 9 10 11 12 Fuel Configura tion Heat Exchan ger Identifie r Flue Feature Capacity Capacity Capacity Blower Typ e Clg Airfl ow Cap.
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.
2.
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.
4 b. Non - combust ibl e mater i al: “...m aterial that is not capa ble of bei ng ignited a nd burned; s uch as m ater ial consistin g entire ly of, or a c om bination of, stee l, iron, brick , concr ete, slate, asbestos, glass, an d plaste r.
5 II. GENERA L INSTRUCTION S - READ BEFORE S TART OF INSTALLATION 1. The he ating outp ut capa city of the f urnace pro posed f or installat ion sho uld be based on a heat loss calculati on made ac co.
6 A. CHIMNEY : The f urnace mus t be conne cted to an adequate c himne y or an appro ved vent i n accor dance wi th these instructio ns. An a dequate c himne y i s one that is s ealed an d lined with t he capab ility of producing a ( - ).
7 2. PROPER CHI MNEY HEIGHT: The chim ney shall term inate at least 3 feet above the highes t point where it passes through th e roof of a building a nd at least 2 feet high er than an y portion of a buil ding withi n a horizontal dis tance of 10 f eet.
8 4. PROPER CHIM NEY BOTTOM LEV EL: In cases where th e chimney ext ends to t he basem ent f loor, the draf t can usu ally be im proved b y filling the base of the chim ney with sand t o with in 12 inches of the vent conn ector pipe after reloc ating the c lean - out door.
9 Fig. 7: Alternate construction s that allow reduced clearan ces to com busti ble materials. REDUCTION OF CLE A R ANCES WITH SP ECIFIED FORMS OF PROTE CTION: T y pe of protecti on applie d to and cov.
10 B. VENTING: NOT E: On the OH 6 & OH8 it is possib le to rotat e the fl ue elbow ( which is f actory i nstalled for vertical discharge) 90° co unter c lock wise from t he vertical pos ition to adapt to v arious ve nting s ystems . The OH 8 flue elbo w can als o be rotat ed 90° clockwise.
11 C. DRAFT REGUL ATORS: Note: Do not use with Direct Vent a pplication. A draft regul ator is sup plied with t he furnace an d should be i nstalled ac cording to th e regulator manuf acturers r ecommendations . W ith the burner o perating , use a draft gau ge to adjust the r egulator to the proper s etting.
12 1. Suppl y and return a ir ducts have to be f urnished by the insta ller an d run betw een the a ppliance, which m ust be inst alled out doors, an d the inter ior of th e structur e the appl iance serves . These d ucts must be s ealed to t he casin g of the appliance.
13 g. Using the s electe d air flo w rates f or each com ponent o f the duct s ystem and manuf acturer’s literature, or publ ished liter ature on d uct s ystem press ure drops, the press ure drop f or each component in the duc t s y stem can be estim ated.
14 Table 3: Suggested Duct Sizes for Homes, Quiet Offices, Or Si milar In s t a l latio ns (Based on a 0.1 in. W.G. static pressure drop per 100 ft. of duct.) 7. The s upply and ret urn air d ucts, or f lexible joi nts, shoul d be careful ly secur ed and sealed to t he applianc e housing t o preve nt air leak age from , or into, the d uct s ystem.
15 SIZING THE DUCT W ORK FOR A COM BINA TION H EA TING AND COOLING SY STEM: Two form ulas m ust be used in determ ining the CF M requir ements of a com bustion heating and coo ling s ys t e m . 1. HEATING CFM : H E AT OUTPUT OF FURNACE (BTUH) 1.1 X T R (T EMPER ATURE R ISE, °F ) = HE ATING(CFM) EXAMPL ES: A.
16 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. 10a & 10 b). Fig. 10a: A typical filter rack and dimensions for the OH6 furnace.
17 Filter Ty pe Maxim um Air Velocit y (ft/min) Model Number OH6 OH8 *Therm o Products Supplied Pe rmanent 600 384 in² 480 in² Standard Perm anent 500 461 in² 576 in² Disposab le 300 768 in² 960 .
18 G. BURNER INS T ALLATION: NOTICE: Rem ove all card boar d pac king f rom around cham ber before instal ling b urner. The oil bur ner wi ll mount on thr ee stud m ounting bolts on t he lower m ounting pl ate cov ering the op ening in the fr ont of the he at exch anger.
19 Fig. 13: Bur ner insertion ill ustration (T op view) W hen mounting the b urner, the mounti ng plate (F ig. 12 ) must be r emoved to provide acc ess to t he area in front of the com bustion c hamber . A fiber ins ulating s leeve or am ulet is provided on the bur ner tube of specif ic Therm o Pride burn ers.
20 Table 7: Oil nozzle capacit y All rates s hown ac hieved w ith 120 PSIG pump pr essure f or Beck ett and 140 P SIG pum p pres sure for Riello . * Based o n #2 dom estic heatin g fuel oi l having he ating va lue of 140, 000 BTU per gallon . ** Based on therm al eff iciency of 84% - 8 5%.
21 For m ore specif ic burner inf ormation, s pecificati ons or s ervice infor mation, r eferenc e the train ing manual enclosed with each R iello b urner or cont act: Riello Cor poration of Am erica,.
22 Verif y that the insta lled bur ner is lig htly leaned toward s the butto n. (See f igure 14 - 1) T he burner is designed to allo w entry of the f lexible oil - lines o n eithe r side of the burner.
23 the pump. Pitching the line upward tow ard the tank will help prevent th e formation of air pock ets in the line. NOTIC E: A n oil safet y valve or a d elay ed - ac ti on, s olenoid valve should be in stalled in t he oil su pply line of all grav it y - fed sy stems.
24 T y pic all y, control wir ing between the app liance and the indoor th erm ostat, and if used, electr onic air cleaner or humidif ier, will be requir ed.
25 in conju nction with a hum idistat to co ntrol a hum idifier. Thes e terminals are energi zed whene ver the blowe r is act ive. Figure 15: The Fan 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.
26 Figure 16: Heat Anticipator Adjustment S cale In man y cases, th is setting can be fou nd in the t hermostat ins tallat ion instruct ions. If this inform ation is not availab le, or if the c orrect.
27 This f ormula can be us ed to c alculate t he correc t setting f or the adjus table hea t antici pator: Amm eter reading = Anticipator Settin g. No. of wire loops Or in this case, _ 2.5 A. = 0.25 A. ( Anticipator Settin g) 10 4. Adjus t the posi tion of th e anticipator indicator to matc h the calcu lated amm eter set ting.
28 Heating Speed Set - ups OH6F A 072D V4 Furnace Motor Current Draw ( Amps/ / Watt s) vs. External Static Pr essure ( in W.C.) Low Fire Med Fi re Hi gh F ir e Static Pressure (Amps/Watts) BTUH 60,000 7 2,000 90,000 Fan Control SW 1 Sw it ch Setting s Heatin g CFM Aprox.
29 Heating Speed Set - ups OH8F A 119D V5 Furnace Motor Curr e nt Draw ( Amps / Watt s) vs. External Static Pr essure ( in W.C) Low Fire Med Fi re Hi gh F ir e BTUH 101, 000 119, 000 132, 000 Fan Control SW 1 Sw it ch Setting s Heatin g CFM Aprox. Ris e (F 0 ) Aprox.
30 Heating Sp eed Set - ups ( 2 – Stage ) OH6FX072D V4 HEATING AIR FLOW / TEMPERATURE RISE L OW C AP ACI T Y HIG H C AP ACI T Y F AN CONTROL SW 1 SWIT CH SETT INGS BTUH LOW FIRE 60,000 HI FIRE 72,000 LOW FIRE 72,000 HI FIRE 90,000 HEATING CFM APPR OX.
31 Cooling Sp e ed Set - ups OH6F*072D V4 Furnace Motor Curre nt Draw ( Amps / Watt s) vs. External S t atic Pressu re (in W.C) Air F low Static Pressure (Amps/Watts) Fan Control SW 1 Sw it ch Setting s Clg. To n age Cool Continuous 0.2 0.5 6- OFF 5- OFF 4- OFF 2 799 5 00 1.
32 Cooling Sp e ed Set - ups OH8F A 119D V5 Furnace Motor Current Draw ( Amps/Watts) v s. External Static Pr essure ( in W.C.) Air F low Fan Con trol SW 1 Sw it ch Setting s Clg . Tonn age Cool Continuous Dehum .02 .05 6- OFF 5- OFF 4- OFF 2 8 00 500 557 1.
33 For PSC s ystems, th e ½ hp m otor is equip ped with 4 speeds . The unit is set f or m id - fire tem p rise @ 66 ºF. See ta ble for proper blo wer m otor set up: OH6F A 072D 48 ALTERATIONS RE Q.
34 OH8F A 119D 60 ALTERATIONS RE Q’D FOR A/C @ DESIGN EXTERN A L S TATIC PRESS URE COOL ING UNIT HTG Speed by Input Low Mi d High Fire F ire Fire Recommended CLG Speed 36,000 L/ML ML/MH MH/H Low (L).
35 M. BLOWE R CO NTROLLER INFORMATION FOR P SC MO TOR (Note: for E CM blower controll er informati on see: ECM Operation Manual d ocument # Mo- 440) TERMIN A L DEFINITIONS & FIELD WIRING Burner Har ness Co nnector P1 Pin 1 - Limit s witch connec tor.
36 A . Inputs Pow er suppl ie s Line volt age is app lied bet ween the “ S1” and “N1” qui ck connec t terminals . 24 V AC Class II Transf ormer s econdary voltage s upplie d to X and C Lim it switc h The 120 VAC optical ly isola ted lim it switch inp ut is con nected on pin P2 - 1 & 9.
37 EAC (electr onic air cleaner) The cont rol prov ides a 12 0 VAC o utp ut f or an electr on i c air cleaner . T his output is ener g i zed whene ver the fan m otor is energi zed ( eith er lo w, heat or cool s pe ed). C onn ec tion is m ade via m ale quick connect term inal labeled “ EAC”.
38 He at Mode W hen a call for he at (“W ” ) is received f rom the therm ostat , if the “Co ol” m ode is n ot alr ead y active, th e “T - T” term inal is energ ized and the blower o n delay i s started. T he on - off pattern of DIP s witch SW 2 (positions 1 and 2) select o ne of four blower on de lay values (s ee Table 11).
39 ECM & PSC TROUBLE SHOOTING 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.
40 N. STARTUP PROCEDURE S: A. Heatin g System 1. Initial S ta rtup: : Turn off po w er to furnace. Before th e oil pipi ng system i s placed in to service, i t must have been l eak tested by a quali fied heating c o n tr a ctor.
41 To Turn Off Oil to Applianc e: i. Set the t herm ostat to the l owest s etting and se t the op erating m ode switch t o “OFF”. ii. If s ervice is to be perform ed, turn of f the electr ical po wer to the a ppliance. iii. Tur n the manual o il shutoff valve to the “OFF” position.
42 Figure 19: Preliminary Adjustment of B urner A ir Band and A ir Shutter i. W hen ignition is establis hed, m ake a prel iminar y burner air a djustm ent to attain a clean combus tion flam e.
43 The set ting of the f an outpu t accordin g to the ins tallat ion should be done onl y through the air dam per. Shoul d you want to a djust the se tting of the com bustion he ad, with the burner ru.
44 Figure 22 1 st STA GE ADJUSTMEN T: A djustment of air shutter: place the s mall plug ( 9) of the econom izer (10) into the pos ition I ( Item A). In this way the bur ner will r em ain permanentl y in the 1 st stage. Loosen the nut (2), turn the s crew (3) u ntil the air shutter ( 1) reaches th e positi on desired.
45 ii. C A RBON DIO XIDE (CO 2 ) OR OXYGEN (O 2 ): Take a CO 2 s ample f rom 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 better to have a sli ghtly lower CO 2 (or higher O 2 ) re ading with zero sm oke m easured.
46 a. W ith the oil sh ut off, r emove the 1/8 in. NPT thr eaded pi pe plug loc ated on th e lower r ear side of the oil pump, r efer to Figur e 22. At tach a pres sure gage, c apable of meas uring press ure in pounds per squar e inch gage , PSIG, in this op ening, on t he dischar ge sid e, of the oi l pum p.
47 5. Checkout Procedure: Before an y system of oil pipin g is finall y put int o service, it s hall be c areful ly tested to assure that it is “gas - tight”, as indica ted in t he Heating System Initial Startup section of this m anual.
48 III. USERS INF ORMATION SECT ION A . OIL SUPPLY: Do not allow the f uel tank to run c om pletely empt y. During th e summ er, keep the tank f ull to prevent c ondens ation of m oisture on t he insi de surf ace of the ta nk. If the fuel tank runs complete ly dry, it m ay be nec essar y to purge the lines of trapped air.
49 D. STARTING THE B URNER: 1. Turn the m ain ser vice s witch to "OFF " positio n. 2. Set ther mos tat substantiall y above r oom tem perature. 3. Open s hut - off val ves in o il suppl y line to bur ner. 4. Turn s ervice s witch to f urnace "ON".
50 IV. INS T A L LE R'S INSTRUCTI O NS TO USER: After completing the instal lation, the installer shall inform and/or demonstra te to the homeowner the follo wing i te ms: 1. The locat ion of t hese inst ructions. T he instruc tions m ust be kept a long w ith instr uctions for any access ories in the plastic p ouch with t he appli ance.
51 V. DE A LER M A INTENANCE: SAFETY DURING SER VICING A ND INSPECTION : Personal injury or property da mage could resul t from repair or service of this applianc e by anyone other than a qualified heatin g c ontractor . The user may only perfor m the activitie s described i n th e Home owner/User Rou ti ne Maintenance secti on of this manua l.
52 B. HEAT EXCH ANGER: WARNING: A qualified heat ing co ntract or must clean the he at exchanger. At least o nce a year, inspe ct the heat exchanger for evidence of cor rosion, pitt ing, war page, det erioratio n, and carb on (soot) build - up.
53 Figure 24: Heat Exchanger Clean - Outs Vacuum Hose Length OH6 8FT OH8 8FT Fig. 25: Recommended method and device for cleaning inside of heat exchanger.
54 4. Opera tional Ch eck: CAUTION: Before trouble shooting, familiariz e y ours elf with the start up a nd check out procedur es NOTIC E: A fter reasse mbling the app liance , check for fuel oi l leakage fr om the supply piping. a. Check proper oper ation of t he ignition s ystem and for pr oper com bustion.
55 Figure 26: Locatio n of Su pply/R eturn A ir Fi lter Filter r eplace ment: To ensur e an adequat e replacem ent filter is s elected, s hould the filter require re placing, ref er to Table 4 , in Air Filters section of this manual, f or the m inimum filter areas required f or diff erent types of available filter s.
56 ON STARTUP: 1. Have s ystem inspec ted and s tarted b y a qualifie d heating contractor. 2. Check oil level in tank. If the tank has not been f illed w ith fresh oi l, inspec t the rem aining oi l for signs of contam ination with water, alg ae, dirt or other i mpurities .
57 : Do not use this appliance if any part has been un der wat er. Immediately call a qu alified s ervice techn ician t o inspe ct the furnace an d to rep lace any part of the control s y s tem and an y oil control that has be en under water.
58 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.
59 2. Make s ure therm ostat is cal ling for bur ner oper ation. 3. Check oil suppl y and mak e sure all valves are open. A. DIAGNOSTICS : To ass ist in troubles hootin g this app liance, it is equip ped with an integr ated saf ety and ignit ion contro l with diagn ostics.
60 3. Check the res istance across the cad cel l pins with the cel l covere d (protec ted from exposur e to ambient l ight). T he resistan ce should b e greater th an 2 0,000 ohm s. 4. If cell r esis tances are differ ent from above, r eplace the pl ug - in port ion of cell, (H oneywell Par t No.
61 VIII. Seq uen ce of Op eration s Flo w Chart :.
62.
63 IX. Trouble Shooting Flow Cha rt:.
64.
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66.
67.
68 COM B US T I ON AN D EFF I C I EN CY T ES T I NG F OR T H ERM O PRI DE OI L FI R ED CENT RAL FUR NACES . Com pl e t e t hi s f or m f or e a ch T he r m o P r i de f ur na ce i ns t a l l e d. Re a d i ns t r uct i on CUS T OM ER NA M E A DDR E S S C I TY , S TA TE H EAT I NG SY ST E M BUR NE R M O DE L NO .
69 A ppendi x – A Replace ment Part s: Replacem ent Parts f or OH6FA0 72D**.
70 Replacem ent Parts f or OH8FA1 19D**.
71 A ppendi x – B Wiring Diagram s OH6FA072D 48 PSC W i ring Diagram.
72 OH6FA072D V4 ECM W iring Diagr am.
73 OH6FX072D V4 ECM 2 - Stage W iring Diagram.
74 OH8FA1119D 60 PSC W iring D iagram.
75 OH8FA1119D V5 EC M W iring Diagram.
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However, one of the most important roles played by the user manual is to help in solving problems with Thermo Products OH6FA072D48B. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Thermo Products OH6FA072D48B along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
