Thermo Pride OD6FA072D48B, Installation And Operation Manual

Page 1: ...STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS AND LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE c WARNING IMPROPER INSTALLATION ADJUSTMENT ALTERATION SERVICE OR MAINTENANCE CAN CAUSE INJUR...

Page 2: ...SECTION 45 A OIL SUPPLY 45 B COMBUSTION AIR SUPPLY 45 C INSPECTION AREAS 45 D STARTING THE BURNER 46 E FILTER CLEANING AND LOCATION 46 IV INSTALLER S INSTRUCTIONS TO USER 47 V DEALER MAINTENANCE 48 A...

Page 3: ...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 2 D V 5 R O D 6 R X 0 7 2 D V 5 R O Oil O H Highboy D Downflow D 6 Heat Exchanger Size Identifier...

Page 4: ...al injury substantial property damage or death See Page 16 cWARNING THE HEAT EXCHANGER MUST BE CLEANED BY A QUALIFIED SERVICE PERSON See Page 49 cCAUTION DO NOT ATTEMPT TO MAKE REPAIRS YOURSELF See Pa...

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Page 6: ...tallation must conform with local codes or in the absence of local codes with the Standard for the Installation of Oil Burning Equipment NFPA 31 1997 or the latest edition and to these instructions A...

Page 7: ...is area in which the furnace is located must have adequate supply of air for combustion and draft control operation The minimum required volume of free air should be 50ft 1000 btu per NFPA 54 However...

Page 8: ...OMBUSTIBLE MATERIAL and NON COMBUSTIBLE MATERIAL Combustible Material is made of or surfaced with wood compressed paper plant fibers plastics or other material that will ignite and burn whether flame...

Page 9: ...CHIMNEY CONDENSING Stack gas may do one of two things as it escapes up the chimney A Remain entirely in a gaseous state if the internal chimney wall temperature is above the dew point B Condense wate...

Page 10: ...ore detailed information may be obtained from the latest edition of the ASHRAE HVAC Systems and Equipment Handbook 3 PROPER CHIMNEY HEIGHT The chimney shall terminate at least 3 feet above the highest...

Page 11: ...ONNECTIONS All chimney clean out doors and flue connections must fit tightly so they will seal to avoid air leaks 8 NO INTERCONNECTED CHIMNEY FLUES If chimney flues are divided or there are multiple f...

Page 12: ...ass fiber or mineral wool batts 12 9 6 5 4 3 c 0 024 24 gauge sheet metal over 1 glass fiber or mineral wool batts reinforced with wire on rear face with ventilated air space 9 6 5 3 3 3 d 3 1 2 thick...

Page 13: ...ay also be removed and the unit can be vented through the front center panel after removing the knock out A trim collar may be ordered from Thermo Products to hide the gap around the flue pipe This tr...

Page 14: ...means used to control flow of air should be provided to prevent chilled air from entering the furnace If such a damper is manually operated it must be equipped with a means to prevent operation of ei...

Page 15: ...es are low to moderate a Using a floor view of the residence determine or layout the locations of the supply registers and the return air grills Generally supply registers should be located close to s...

Page 16: ...100 ft lengths of circular and rectangular ductwork based on a 0 1 in W G static pressure drop The first column to the right is the air flowrate and the second is the required diameter for a circular...

Page 17: ...he register must be at least 20 feet away from the furnace SIZING THE DUCT WORK FOR A COMBINATION HEATING AND COOLING SYSTEM Two formulas must be used in determining the CFM requirements of a combusti...

Page 18: ...t If a method other than Thermo Pride filter racks is selected for retention of the filter and or use of a different filter type is desired refer to Table 4 below for minimum sizing guidelines for sel...

Page 19: ...cation of limit control and auxiliary limit control for OD6 G BURNER INSTALLATION NOTICE Remove all cardboard packing from around chamber before installing burner The oil burner will mount on three st...

Page 20: ...17 Fig 12 1 Typical location of the overfire air tap and components in burner mounting plate area for OD6F 072D counterflow and horizontal installations...

Page 21: ...18 Fig 12 2 Typical location of the overfire air tap and components in burner mounting plate area for OD6R 072D counterflow and horizontal installations...

Page 22: ...ATIONS 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 OD6 072D B TP2...

Page 23: ...W 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 NOTE The reason t...

Page 24: ...value of 140 000 BTU per gallon Based on thermal efficiency of 84 85 MOUNTING THE 2 STAGE RIELLO BURNER It is necessary that the insulation gasket be placed between the mounting plate and the burner...

Page 25: ...only be applied to the male member of a joint The first two threads on the end of the male member of each pipe joint should be clean and free from thread sealant 8 Connection of the oil supply piping...

Page 26: ...h the provisions of the National Electrical Code ANSI NFPA 70 1999 or the latest edition and this instruction manual This appliance requires 120 VAC 60 Hz single phase power Refer to Table 10 for typi...

Page 27: ...ctions may loosen due to vibration while the appliance is in transit Please be certain that all electrical connections remain tight 2 Review wiring diagram for proper routing and connection of all fie...

Page 28: ...a more constant indoor temperature by adjusting the length of the heating cooling cycle to fit the application A vital consideration of this calibration is related to the thermostat heat anticipator T...

Page 29: ...the needle on to the measurement scale of the instrument proceed as follows 1 Wrap 10 loops of single strand insulated thermostat wire around the prongs of an ammeter refer to Figure 17 Set the scale...

Page 30: ...eating mode for proper operation If a digital ammeter is used read the current draw directly from meter Steps 1 through 3 are not required The meter reading is the correct anticipator setting L Blower...

Page 31: ...109 1 25 3 OFF 2 OFF 1 ON 826 66 80 0 5 174 1 92 0 02 123 1 40 3 OFF 2 ON 1 OFF 898 61 74 0 5 203 2 20 0 02 146 1 63 Factory SW1 Switch Settings 3 OFF 2 ON 1 ON 983 56 67 84 0 5 226 2 45 0 02 176 1 9...

Page 32: ...04 109 755 109 3 OFF 2 OFF 1 ON 826 661 83 826 80 661 100 826 100 3 OFF 2 ON 1 OFF 898 718 70 898 74 718 92 898 92 3 OFF 2 ON 1 ON 983 786 64 983 67 786 84 983 84 3 ON 2 OFF 1 OFF 1068 854 59 1068 62...

Page 33: ...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 702 0 5 419 4 40 0 2 462 4 83 Factory SW1 Switch Settings 6 ON 5 OFF 4...

Page 34: ...6 6 04 5 73 5 46 5 17 4 9 High Fire Temperature Rise 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 90 91 91 92 101 108 114 ML 72 72 74 74 77 80 91 MH 58 5...

Page 35: ...iello Connections Thermostat Humidistat connections C Common ground W Thermostat call for heat R 24 VAC to thermostat G Thermostat call for fan Y Thermostat call for cool DEHUM Humidistat call for deh...

Page 36: ...ermostat call for fan G 24 VAC thermostat input A call for fan is recognized when the thermostat connects G to R This input has an indicator LED in that will light when the control receives a call for...

Page 37: ...received from the thermostat If the heat mode is not active or the anti short cycle delay is not in effect the control will energize the CC terminal and after a 10 second power demand conservation de...

Page 38: ...d following the blower on delay for that call The speed taps are interconnected and interlocked only one speed may be powered at any one time When a speed is to be operated the speed select relays are...

Page 39: ...s and are located directly below those inputs They will light to indicate the presence of these signals The red Board Status LED has two functions It will light when the board recognizes a valid input...

Page 40: ...d relatively clean of dirt and debris e Make sure the thermostat is set in the heating mode of operation Operating Instructions i STOP Read the safety information above ii Set the thermostat to the lo...

Page 41: ...ollowing test instruments are required A smoke density measuring and rating device A carbon dioxide CO2 or oxygen O2 analyzer A flue gas temperature measuring device e g thermocouple or thermister pro...

Page 42: ...ment should be made using combustion instrumentation for smoke carbon dioxide CO2 or excess oxygen O2 and flue gas temperature In order to achieve the most efficient combustion the following steps mus...

Page 43: ...turns of the rod a hole 3 at its end facilitates counting the number of turns AIR DAMPER ADJUSTMENT The settings indicated in the schedule refer to the burner with its metal cover fitted and the combu...

Page 44: ...er remains permanently in the 2nd stage Loosen the nut 6 turn the screw 7 until the air shutter 1 reaches the position desired Then lock the nut 6 Pressure regulation this is set at 170 psi at the fac...

Page 45: ...ure rise is equal to the supply air temperature minus return air temperature Under steady state operating conditions the temperature rise across the heating section should be approximately 65 F A high...

Page 46: ...erature Rise To avoid injury from moving parts or electrical shock shut off the power to the appliance before removing supply air blower compartment door and servicing this appliance All OD6 models ar...

Page 47: ...control as follows i Shut off incoming power ii Block return air opening or disconnect blower motor leads iii Restore power to appliance iv In the heating mode set the thermostat above room temperatu...

Page 48: ...erials damage from rust or corrosion soot or carbon build up EXTERIOR OF FURNACE The furnace exterior should be inspected for signs of excessive heat such as discoloration of materials and damage from...

Page 49: ...ANING AND LOCATION cWARNING To avoid injury from moving parts hot surfaces or electrical shock shut off the power to the furnace before removing any furnace access doors to service the air filters The...

Page 50: ...n and Routine Maintenance section of this manual 5 That failure to maintain and operate this appliance in accordance with these instructions could result in hazardous conditions property damage and bo...

Page 51: ...isually check the burner and below the burner for indications of oil leaks Correct any if found Remove the burner and measure the ignition electrode gap It should be set to 5 32 inch Adjust it if nece...

Page 52: ...rner and the burner mounting plates When removing the clean out plugs turn T handle counterclockwise approximately two 2 full turns or just until the plug is able to be pulled from tube Take care not...

Page 53: ...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 devic...

Page 54: ...this manual for electrical specifications on these components 4 Check for correct operation and proper settings if manually adjustable of all controls E SUPPLY RETURN AIR BLOWER Check in the blower c...

Page 55: ...filter inspections during operation to ensure maximum operating efficiency G EXTENDED APPLIANCE SHUTDOWN Should the appliance be shutdown or turned off for an extended period of time several steps can...

Page 56: ...ove room temperature 5 Open all valves in the oil supply line 6 Open the inspection cover on the upper mounting plate 7 Turn on the electrical power to start the burner If the burner does not start im...

Page 57: ...ng it Do not attempt to make repairs yourself Contact your local qualified heating contractor Under normal conditions this appliance will operate in either heating or cooling mode depending upon the m...

Page 58: ...mbling the unit Never operate the appliance without clean air filters in place This appliance requires air for combustion ventilation and cooling Do not block or obstruct air openings in the unit and...

Page 59: ...occurs the LED light on the control will rapidly flash indicating the operational status of the unit In event this control malfunctions the entire control should be replaced It is not field repairabl...

Page 60: ...fferent from above replace the plug in portion of cell Honeywell Part No 130367 5 Carefully reinsert the plug in portion of the cad cell into the receptacle If the cad cell appears to be functioning c...

Page 61: ...58 VIII Sequence of Operations Flow Chart...

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Page 63: ...60 IX Trouble Shooting Flow Chart...

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Page 68: ...LINER FUEL LINE FILTER DRAFT CONTROL COMBUSTION TESTS Operate burner at least 10 minutes before CO2 in stack pipe INITIAL SERVICE SERVICE SERVICE INSTALLATION Draft Over fire Draft in stack pipe Smok...

Page 69: ...66 Appendix A Replacement Parts Replacement Parts for OD6F 072D...

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Page 71: ...68 Replacement Parts for OD6R 072D...

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Page 73: ...70 Appendix B Wiring Diagrams OD6 A072D48 PSC Wiring Diagram...

Page 74: ...71 OD6 A072DV5 ECM Wiring Diagram...

Page 75: ...72 OD6 X072DV5 ECM 2 Stage Wiring Diagram...

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