Thermo Products OMC-70, GMC-85 User Manual

0 (0)

GAS-FIRED OR OIL-FIRED FURNACE

DOWN FLOW & DIRECT VENT (SEALED COMBUSTION)

MODELS: OMC-70 AND GMC-85 INSTALLATION AND SERVICE MANUAL

For installation in:

1. Manufactured Homes

2.Modular Homes/Buildings

3.Site Construction—Residential (Single Story Dwellings)

:

FOR YOUR SAFETY

Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.

WHAT TO DO IF YOU SMELL GAS

Do not try to light any appliance.

Do not touch any electrical switch; do not use any phone in your building.

Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions.

If you cannot reach your gas supplier, call the fire department.

: 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.

: Improper installation, adjustment, alteration, service, or maintenance can cause injury or property damage. Refer to this manual. For assistance or additional information consult a qualified installer, service agency, or fuel supplier.

: Do not use this appliance if any part has been underwater. Immediately call a qualified service technician to inspect the appliance and to replace any part of the electrical or control system that has been underwater.

PLEASE READ THESE INSTRUCTIONS PRIOR TO INSTALLATION, INITIAL FIRING, AND BEFORE PERFORMING ANY SERVICE OR MAINTENANCE. THESE INSTRUCTIONS MUST BE LEFT WITH THE USER AND SHOULD BE RETAINED FOR FUTURE REFERENCE BY QUALIFIED SERVICE PERSONNEL.

THERMO PRODUCTS, LLC.

POST OFFICE BOX 217

NORTH JUDSON, IN 46366

PHONE: (574) 896-2133

MO-422

ECN 4528-MA

MADE IN USA

All installations and services must be performed by qualified service personnel.

I. SAFETY SECTION

This page and the following two pages contain various warnings and cautions found throughout this furnace Service and Installation Manual. Please read and comply with the statements on the cover and the statements below.

: All local codes and ordinances must be followed with regard to the oil tank and oil lines. All lines must have shut off valves, use a proper pipe joint compound (specified for use with oil) on all pipe threads, no kinks, no sharp bends, and be properly tested for leaks. Flare fittings are recommended for tubing.

: This furnace is not to be used as a construction heater.

: DO NOT RUN THE OIL PUMP DRY FOR MORE THAN FIVE MINUTES.

: When testing electrical equipment, always follow standard electrical procedures and precautions.

: The heat exchanger must be cleaned by a qualified service person.

: The area around the furnace should be kept free and clear of combustible materials, especially papers and rags.

: NEVER burn garbage or refuse in your furnace. NEVER try to ignite oil or gas by tossing burning papers or other material into your furnace.

: Thermo Pride oil furnaces are designed to burn commercial standards of No. 1 and No. 2 fuel oil. NEVER USE GASOLINE OR A MIXTURE OF OIL AND GASOLINE.

: Do not attempt to start the burner when: 1. Excess oil has accumulated 2. The furnace is full of vapors or 3. The combustion chamber is very hot. If one or more of these conditions exist, contact a qualified service person.

: If the temperature rise exceeds 100°F, the heat exchanger may fail voiding the heat exchanger warranty resulting in property damage, personal injury or loss of life.

: Burner adjustments must be confirmed by instrumentation. Failure to use accurate or calibrated instrumentation to setup the burner may result in reduced efficiency, sooting and/or the production of hazardous carbon monoxide gas.

: Any attempt to relocate safety controls or replace safety controls with a control that is not approved or incompatible, may result in personal injury, substantial property damage or death.

1

All installations and services must be performed by qualified service personnel.

: If you do not follow these instructions exactly, a fire or explosion may result causing personal injury, loss of life or property damage.

: NEVER use gasoline or a mixture of oil and gasoline to start the burner or furnace.

: HAZARD OF ASPHYXIATION: Negative pressure inside the closet with closet door closed and the furnace blower operating shall be no more negative than minus 0.05 inch water column.

: Do not obstruct any return air openings, including the return grille on the furnace. To do so may cause the furnace to activate the high limit and shut down or it may cause asphyxiation.

: Because of the potential of odorant fade, a gas leak may not be detected by smell. If this furnace is installed below grade, contact your gas supplier for a gas detector.

: All gas pipe connections must be leak tested using a strong soap and water solution (with the gas turned on). Any leaks must be repaired immediately after turning off the gas supply. A final test for gas leakage must be made after purging the gas line.

: DO NOT wet electronic components during the leak test. Wetting electronic components may damage circuitry and cause a hazardous situation. Dry moisture from all leads and terminals if wetting occurs. Wait at least 24 hours for the circuit to fully dry before energizing the system.

: The furnace and its gas valve must be disconnected from the gas supply during pressure testing of the gas supply system at pressures in excess of 1/2 PSIG or 13.9 inches W.G. The furnace can be isolated from the gas supply by closing its manual shut off valve at test pressures equal to or less than 1/2 PSIG or 13.9 inches W.G.

: Copper and brass tubing and fittings (except tin lined) shall not be used if the gas contains more than a trace (0.3 grains per 100 cubic ft.) of hydrogen sulfide gas. Check with your gas supplier.

: All local codes and ordinances take precedence with regard to tank and oil lines. All lines must have shutoff valves, a good pipe joint compound approved for use with oil on all pipe threads, no kinks, no sharp bends and be properly tested for leaks. Flare fittings are recommended for tubing.

: Do not use motor oil or any fuel other than No. 1 or No. 2 fuel oil in this furnace.

2

All installations and services must be performed by qualified service personnel.

: If you suspect there is a problem with the furnace, the venting system or any other related problem, immediately contact a qualified service agency. If a service agency is not available contact your fuel supplier.

: Personal injury, or property damage, could result from major repair or service of this furnace by anyone other than a qualified contractor. Only the routine maintenance described in the user section of this manual should be performed by the user.

: The area around the furnace should be kept free and clear of combustible materials, especially papers and rags.

: Never burn garbage or refuse in your furnace. Never try to ignite oil or gas by tossing burning papers or other material into your furnace.

: Do not attempt to start the burner when:

1.Excess oil or gas has accumulated.

2.The furnace is full of vapors.

4.The combustion chamber is very hot.

If one or more of these conditions exist, contact a qualified service person.

: Do not block or obstruct air openings on the furnace or air openings communicating with the area in which the furnace is installed.

: Do not allow the outside air intake to be blocked or obstructed by vegetation, ice, snow or any other materials.

: Do not use this furnace if any part has been underwater. Immediately call a qualified service agency to inspect the furnace and to replace any part of the electrical or control system which has been underwater.

: Should overheating occur or the fuel supply fail to shut off, shut off the manual fuel supply valve to the furnace before shutting off the electrical supply.

3

All installations and services must be performed by qualified service personnel.

This page and the following page contain reproductions of the various warning and instruction labels placed on the Thermo Pride Oil Furnace. Please read and comply with the contents of these labels.

4

Thermo Products OMC-70, GMC-85 User Manual

All installations and services must be performed by qualified service personnel.

POWER SWITCH

5

All installations and services must be performed by qualified service personnel.

 

 

TABLE OF CONTENTS

 

 

SECTION

BEGINNING PAGE

I.

SAFETY SECTION

1

II.

GENERAL INSTRUCTIONS AND CLEARANCES

7

III.

FURNACE SPECIFICATIONS

9

IV.

INSTALLATION

11

 

A. ROOF JACK

11

 

B. STANDARD CHIMNEY

11

 

C. FURNACE LOCATION

11

 

D. BASE INSTALLATION

13

 

1.

Combustible Floor Base Model: 70-BASE

13

 

2.

Cottage Base Model: OMCCOT-BASE

14

 

E. ALCOVE INSTALLATION

16

 

F. CLOSET INSTALLATION

16

 

G. COMBUSTION AIR

17

 

H. FUEL PIPING

20

 

1.

General Gas Piping

20

 

2.

Oil Tank and Piping

21

 

J. ELECTRICAL WIRING

23

 

1.

Electrical Branch Supply Circuit

24

 

2.

Connection of Power Supply Wires

24

 

3.

Connection of Thermostat Wires

24

 

4.

Wiring Diagram

26

 

K. BURNER INSTALLATION

27

 

L. BURNER OPERATION AND ADJUSTMENT

28

 

M. FLUE GAS COMBUSTION ANALYSIS

30

V.

DEALER MAINTENANCE

31

 

A. TROUBLESHOOTING

31

 

B. CAD CELL CHECKOUT PROCEDURE

37

 

C. HEAT EXCHANGER CLEANING INSTRUCTIONS

38

 

D. CLEANING OR REPLACING FLUE PIPES

39

 

E. EXTENDED SHUTDOWN AND RESTART

40

VI.

USERS INFORMATION SECTION

41

 

A. WARNINGS & CAUTIONS

41

 

B. COMPONENT LOCATIONS

42

 

C. INSPECTION AREAS

42

 

D. FILTER LOCATION AND CLEANING

43

APPENDIX A - REPLACEMENT PARTS LIST

44

6

All installations and services must be performed by qualified service personnel.

II. GENERAL INSTRUCTIONS AND CLEARANCES NOTE: READ THIS SECTION BEFORE STARTING INSTALLATION

1.The selection of a furnace heating capacity for a proposed installation should be based on a heat loss calculation made according to the manuals provided by the Air Conditioning Contractors of America (ACCA) or the American Society of Heating, Refrigeration and Air Conditioning Engineers, Inc. (ASHRAE).

2.The installer shall be familiar with and comply with all codes and regulations applicable to the installation of these heating appliances and related equipment. In lieu of local codes, the installation shall be in accordance with the current provisions of one or more of the following standards.

a.Federal Manufactured Home Constructions & Safety Standard (HUD Total 24, Part 280).

b.American National Standard (ANSI-119.2/NFPA-501C), for all recreational vehicle installations.

c.American National Standard (ANSI-Z223.1/NFPA-54), for all gas-fired furnaces.

d.American National Standard (ANSI-Z95.1/NFPA-31), for all oil-fired furnaces.

e.American National Standard Electric Code (ANSI-C1/NFPA-70), for all electrical field wiring.

The oil-fired furnace has been investigated under the UL 307A test standard and the gas-fired furnace under the UL 307B test standard. Both gas and oil fired units are listed by Underwriters Laboratories and described as, “For installation as central furnace special type for single story dwelling.”

: The area around the furnace must be kept free and clear of combustible materials, especially papers and rags.

: This furnace is not to be used as a construction heater.

1.Definitions of "combustible" and "non-combustible" materials as presented in the 1996 version of the National Fuel Gas Code, ANSI Z223.1-1996/NFPA 70-1996, are as follows:

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 flameproofed, fireretardant treated, or plastered.”

7

All installations and services must be performed by qualified service personnel.

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.”

This heating appliance must be installed with clearances to combustible material surfaces of not less than the minimum distances given below. Also, allow ample clearances for servicing the furnace for easy access to the air filter, blower assembly, burner assembly, controls, and vent connections.

MODELS OMC/GMC

CLOSET

ALCOVE

FRONT

6”

18”

BACK

0”

0”

SIDES

0”

0”

ROOF JACK

0”

0”

VENT CONNECTOR

6”

6”

TOP

1”

1”

PLENUM SIDES

1”

1”

TOP AND SIDES OF DUCT

1”

1”

BOTTOM OF DUCT

1”

1”

8

All installations and services must be performed by qualified service personnel.

III. FURNACE SPECIFICATIONS

 

MODEL

 

OMC-70

GMC-85

HEAT INPUT RATE (BTUH)

 

85,000

85,000

HEATING CAPACITY (BTUH)

 

71,000

69,700

BURNER NOZZLE (GPH X

 

 

 

ANGLE, HOLLOW CONE)

 

0.65X80A

-------

BURNER ORIFICE-NAT. GAS

 

---------

#17 DMS

BURNER ORIFICE-PROP. GAS

 

---------

#36 DMS

OIL PUMP PRESSURE (PSIG)

 

100

-------

GAS SUPPLY PRESSURE (IN.W.G.)

 

MINIMUM REQUIRED

 

 

 

PROPANE

 

---------

11

NATURAL

 

---------

4.5

MAXIMUM ALLOWED

 

 

 

PROPANE

 

---------

13.9

NATURAL

 

---------

13.9

GAS MANIFOLD PRESSURE (IN. W.G.)

 

PROPANE

 

---------

10 + 0.3

NATURAL

 

---------

3.5 + 0.3

VENT PIPE SIZE (INCHES)

4

 

4

DESIGN TEMPERATURE RISE (°F) 85

85

SEASONAL EFFICIENCY

 

 

 

(AFUE*, %)

 

84

82

*AFUE - INCLUDES STEADY STATE THERMAL EFFICIENCY AND OFF CYCLE LOSSES.

ELECTRICAL RATINGS AND SETTINGS: ELECTRICAL SUPPLY: 120 VAC / 60HZ / 1 PHASE

MAXIMUM TIME DELAY TYPE FUSE OR HACR BREAKER RATING: 15 AMPS TOTAL RATED CURRENT (AMPS): 11.3 (OMC), 6.81 (GMC)

NOMINAL HEAT ANTICIPATOR SETTING -- 0.2 mA (OMC), 0.8 mA (GMC)

DIMENSIONS & WEIGHTS:

CABINET: WIDTH - 18 IN., DEPTH - 24 IN., HEIGHT - 57 IN.

NO.70 MOBILE HOME BASE: WIDTH - 18 5/16 IN., DEPTH - 24¼ IN., HEIGHT - 4 IN. WARM AIR DUCT: WIDTH – 12 IN., DEPTH – 12 IN., HEIGHT - 14 ¼ IN.

COTTAGE BASE: WIDTH – 18 3/16 IN., DEPTH - 24¼ IN., HEIGHT – 14¾ IN. FILTER QUANTITY & SIZE: (2) @ 17 ¾ IN. x 13 ¾ IN. x 1 IN. EA. APPROXIMATE SHIPPING WEIGHT: 240 LBS.

PRODUCT LISTED UNDER UL FILE NUMBER -- MP3241

9

All installations and services must be performed by qualified service personnel.

 

BURNER DATA

 

 

OMC-70

GMC-85

MANUFACTURER:

R.W. BECKETT CORP.

WAYNE COMBUSTION SYSTEMS

MODEL:

AFG

P265 FEP

AIR TUBE LENGTH (IN.): 3-5/8

3-5/8

HEAD DESIGN:

F-3

--------

REFRACTORY TYPE:

MHC (FIBER)

MHC (FIBER)

OIL PUMP

 

 

PRESSURE (P.S.I.G.)

100

--------

FOR BURNER COMBUSTION INFORMATION, REFER TO SECTION (M) – FLUE GAS COMBUSTION ANALYSIS.

BLOWER DATA

MANUFACTURER: MORRISON PRODUCTS, INC.

BLOWER MODEL:10-7, DIRECT DRIVE

NOMINAL MOTOR POWER OUTPUT (HORSEPOWER): 1/5

NOMINAL MOTOR SHAFT SPEED (RPM): 1075

TYPICAL AIRFLOW ON LOW FAN SPEED

 

@ SPECIFIED EXTERNAL

 

STATIC PRESSURES (SCFM @ .IN.W.G.):

780 @ 0.2, 650 @ 0.5

ALL SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE.

10

All installations and services must be performed by qualified service personnel.

IV. INSTALLATION

A. ROOF JACK

The roof jack assembly and accessories must be listed by a nationally recognized testing agency for the appropriate fuel.

The roof jack assembly must be installed according to the vent manufacturer’s instructions prior to the furnace installation. (Refer to Figure 2 for flue location on furnace.) Adapters for pitched roofs as well as extended barrel length roof jacks are available from other suppliers.

All vent seams and connections must be sealed with high temperature silicone caulk and/or high temperature aluminum tape.

B. STANDARD CHIMNEY

When installed as a central furnace special type for single story dwelling, venting into a metal vent system approved by a nationally recognized testing agency for the appropriate fuel type is permitted. Lined masonry chimneys are acceptable when sized appropriately. The minimum chimney size should equivalent to the inside free area of the 4-inch diameter vent collar exiting the furnace, or 12.5 square inches.

Maximum chimney sizes and acceptable installation practices are referenced in the following publications. In lieu of local codes, when installing the OMC-70 with fuel oil, refer to the latest edition of the installation standard NFPA 31, Installation of Oil Burning Equipment. When installing the GMC-85 with natural or LP gases, refer to Appendix G of the latest edition of the installation standard NFPA 54, National Fuel Gas Code.

C.FURNACE LOCATION

1.For best performance, locate the furnace so that it is centralized with respect to the duct system.

2.This furnace is only intended for installation with free air return through the furnace door louvers. DO NOT connect a ducted return air system directly to the furnace. Improper installation may create a fire hazard and damage internal equipment, as well as void all manufacturer’s warranties.

3.This furnace may be installed on combustible flooring when utilizing either the No. 70 counterflow floor base, for below the floor duct systems, or with the cottage base, for floor level air distribution. See Figures 1 for depictions of the No. 70 and the cottage bases.

4.This furnace is U.L. listed for closet, alcove or freestanding applications. All applications must comply with the requirements of this manual.

11

All installations and services must be performed by qualified service personnel.

Combustible Floor Base

Model: 70-BASE

Figure 1A.

Cottage Base

Model: 01COT-BASE

12

All installations and services must be performed by qualified service personnel.

Figure 1B.

D. BASE INSTALLATION

1. Combustible Floor Base Model: 70-BASE

Referring to Figure 1A, for applications using a combustion air channel and a supply air duct, use the base as a template to mark the floor opening locations. See Figure 2 for cutout locations. Cut a square opening in the floor for the supply air duct. Cut the opening 1-inch larger than the square template opening. Cut the combustion air duct opening. Cut opening 1/8 inch larger than the template opening. See Figure 1A for cutout sizes.

Figure 2.

Place the bottom base panel in position. Mark the square opening location on the distribution duct at the connection point of feeder duct. Remove the bottom panel. Cut an opening in the duct slightly larger than the feeder duct. Cut the feeder duct to length. (Refer to Figure 3 for location of this cut.) Install the feeder duct. Bend over each tab. Insure an airtight seal by using high temperature sealant or tape on the joint. Reinstall the bottom panel over the feeder duct. Insert and secure the combustion air duct. Put the top panel in place.

IMPORTANT: A combustion air duct must be used. If the underside of the mobile home is skirted or enclosed (e.g. enclosed in a crawlspace), the combustion air intake should exit through the skirting, or enclosure, if at all possible. All joints and seams of supply ducts and combustion air ducts must be closed with a sealing method suitable to the application conditions and temperatures ( e.g. high temperature silicone caulk and/or aluminum tape).

13

Loading...
+ 32 hidden pages