Thermo Products OL6RA072DV5B-R, OL6FA072DV5B-R, OL6RA072D48B-R, OL6RX072DV5R, OL6FX072DV5R User Manual

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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 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.

c WARNING: 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, OR SERVICE AGENCY.

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.

PO BOX 217

NORTH JUDSON, IN 46366

PHONE: (574) 896-2133

MO-483

 

ECN 5113-PB 100901

Made IN USA

SECTION

CONTENTS

PAGE

 

I. SAFETY SECTION

1

 

A. CODES AND CLEARANCES

3

 

B. MAKE-UP AIR

4

II. GENERAL INSTRUCTIONS

5

 

A. CHIMNEY

5

 

B. VENTING

10

 

C. DRAFT REGULATORS

10

 

D. DUCT WORK/AIR CONDITIONING

11

 

E.

AIR FILTER(S)

15

 

F.

LIMIT POSITION AND LOCATION

16

 

G.

BURNER INSTALLATION

17

 

H.

BURNER SPECIFICATIONS AND APPLICATIONS

18

 

I.

OILTANK AND PIPING

20

 

J.

OIL FILTER

22

 

K.

ELECTRICAL WIRIING

22

 

L.

BLOWER SETUP

26

 

M. BLOWER CONTROLLER INFORMATION FOR PSC MOTOR

31

 

N. STARTUP PROCEDURES

36

III.

USERS INFORMATION SECTION

44

 

A. OIL SUPPLY

44

 

B. COMBUSTION AIR SUPPLY

44

 

C. INSPECTION AREAS

44

 

D. STARTING THE BURNER

45

 

E. FILTER CLEANING AND LOCATION

45

IV.

INSTALLER'S INSTRUCTIONS TO USER

46

V.

DEALER MAINTENANCE

47

 

A. GENERAL INSPECTION

47

 

B. HEAT EXCHANGER

48

 

C. HEAT EXCHANGER CLEANING INSTRUCTIONS

48

 

D. ELECTRICAL SYSTEM

50

 

E. SUPPLY/RETURN AIR BLOWER

50

 

F.

SUPPLY/RETURN AIR FILTER

50

 

G. EXTENDED APPLIANCE SHUTDOWN

51

VI. HOMEOWNER/USER INFORMATION AND ROUTINE MAINTENANCE

53

VII. TROUBLESHOOTING

55

 

A. DIAGNOSTICS

55

 

B. CAD CELL CHECK-OUT PROCEDURE

56

VIII. SEQUENCE OF OPERATIONS FLOW CHART

57

IX.

TROUBLE SHOOTING FLOW CHART

59

APPENDIX – A

65

 

REPLACEMENT PARTS LIST

APPENDIX – B

69

 

WIRING DIAGRAMS

WARRANTY

72

i

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 = Highboy D = Downflow L= Lowboy

 

L

 

 

 

 

 

 

 

 

 

 

6 = Heat Exchanger Size Identifier

 

 

6

 

 

 

 

 

 

 

 

 

F = Front

 

 

 

F

 

 

 

 

 

 

 

 

R = Rear

 

 

 

R

 

 

 

 

 

 

 

 

A = Single Stage

 

 

 

 

A

 

 

 

 

 

 

 

X = 2-Stage

 

 

 

 

X

 

 

 

 

 

 

 

Heating Capacity MBTUH (000's) with factory installed nozzle

 

 

 

 

 

0

7

2

 

 

 

 

D = Direct Drive

 

 

 

 

 

 

 

 

D

 

 

 

Clg. Airflow: Example = 48MBTUH = 4 tons @ 400cfm/ton

 

 

 

 

 

 

 

 

 

4

8

 

Clg. Airflow Variable Speed (ECM) V5 = 5tons

 

 

 

 

 

 

 

 

 

V

5

 

B = Beckett, R = Riello

 

 

 

 

 

 

 

 

 

 

 

B

ii

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.

cWARNING AND CAUTIONS:

cWARNING: This furnace is not to be used as a construction heater. See Page 3

cWARNING: 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. See Page 16

cWARNING: THE HEAT EXCHANGER MUST BE CLEANED BY A QUALIFIED SERVICE PERSON. See Page 48

cCAUTION: DO NOT ATTEMPT TO MAKE REPAIRS YOURSELF! See Page 44

cWARNING: The area around the furnace should be kept free and clear of combustible liquids and material, especially papers and rags. See Page 3

cWARNING: NEVER burn garbage or refuse in your furnace. Never try to ignite oil by tossing burning papers or other material into your furnace. See Page 44

cWARNING: Thermo Products oil furnaces are designed to burn No. 1 or No. 2 distillate fuel oil. NEVER USE GASOLINE OR A MIXTURE OF OIL AND GASOLINE. See Page 44

cCAUTION: DO NOT ATTEMPT TO START THE BURNER WHEN:

1.Excess oil has accumulated,

2.The furnace is full of vapors

3.The combustion chamber is very hot.

IF ONE OR MORE OF THESE CONDITIONS EXIST, CONTACT A QUALIFIED SERVICE PERSON. See Page 44

cWARNING: DO NOT START BURNER UNLESS BLOWER DOOR IS SECURED IN PLACE.

1

Thermo Products OL6RA072DV5B-R, OL6FA072DV5B-R, OL6RA072D48B-R, OL6RX072DV5R, OL6FX072DV5R User Manual

2

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.Inform the user of all pertinent warnings and precautions concerning this appliance.

cWARNING: This unit is not to be used for temporary heating of buildings, or structures, under construction. Construction dust may enter the appliance or the duct system and cause a fire hazard. Certain chemicals used during construction when burned, form corrosive condensate that can substantially reduce the life of the heating system heat exchanger.

This appliance is shipped completely assembled and internally wired. All electrical wiring has been factory installed and inspected. At the time of installation, the unit will require connection to electric power, fuel oil supply, and supply and return air ductwork. In the event of a shortage of parts or damage, contact Thermo Pride office.

This unit uses a fan-assisted combustion system, consisting of a pressure atomizing, oil burner and combustion air blower, used to push the products of combustion through the heat exchanger system. After installation, the furnace and duct system must be adjusted to obtain a temperature rise of 50°F to 80°F through the unit. (Refer to the rating label located on side panel inside the burner compartment). The installation 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. The installation must also comply with CSA B139 for recommended installation practices where applicable.

A. CODES AND CLEARANCES:

The following items must be considered when choosing the size and location of the unit.

1.All local codes and/or regulations take precedence over the instructions in this manual and should be followed accordingly. In the absence of local codes, installation must conform to these instructions and the guidelines of the National Fire Protection Association (NFPA). Two applicable NFPA installation codes are the National Electrical Code, ANSI/NFPA 70-1999, and Standard for the Installation of Oil-Burning Equipment, NFPA 31-1997. The latest editions of these codes should be consulted.

2.The selection of a heating unit should be based on a rate of heat loss calculation for the residence according to the manuals provided by the Air Conditioning Contractors of America (ACCA) or the American Society of Heating, Refrigeration, and Air Conditioning Engineers (ASHRAE). The heating capacity of the unit proposed for installation should meet or slightly exceed the rate of heat loss for the residence. Over sizing should not exceed 25% of the heat loss calculation.

3.When installed, this unit should be level. If possible, it should be installed in a central location, with respect to outlet registers of the supply air ductwork.

4.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 flame proofed, fire-retardant treated, or plastered.”

3

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.”

: Carefully read and thoroughly understand the following guidelines and warnings before continuing with the installation of this appliance. Failure to follow these guidelines can cause improper and unsafe operation of this appliance. Unsafe operation can result in substantial property damage, severe personal injury, or death.

1.This appliance shall be used with only the type of fuel oil for which it is approved. Refer to the appliance-rating label for the required type of fuel.

2.This appliance is an oil-fired furnace designed for installation on non-combustible materials. This appliance is also approved for attic installation on non-combustible materials.

3.Ensure that adequate combustion and ventilation air is available to the unit.

4.The airflow resistance of the duct system attached to this appliance must fall within the allowable external static pressure range for this unit. Refer to the Airflow Requirements and Sizing of Ductwork section of this manual.

5.Make sure supply and return air ducts are completely sealed to the appliance casing. Refer to the

Airflow Requirements and Sizing of Ductwork section of this manual.

This 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 50ft³/1000 btu (per NFPA 54). However, if the furnace is located in an area of the building that doesn’t meet this requirement, two openings into another room are recommended (each opening having a free area of 1 square inches per 1,000 BTUH input of the total input of all appliances located in the room). If these openings are in a wall, they must be at least 6 inches from the ceiling and floor (Fig. 1A) or they are in a door, they must be at least 6 inches from the top of the door and 6 inches from the bottom of the door (Fig. 1B). THESE OPENINGS MUST BE FREE AND UNOBSTRUCTED.

Fig 1: Properly Positioned Combustion Air Openings In Walls (Fig. 1A) and Doors (Fig. 1B).

B. MAKE-UP AIR: Today's emphasis on home insulation increases the probability of inadequate air supply to the furnace. Heavy insulation cuts off infiltration of outside air, which previously replaced inside air removed by bathroom, kitchen and laundry vent fans, and air escaping up chimneys. This causes a negative pressure differential within the home that reduces the supply of air available to the furnace for combustion and ventilation.

The Thermo Pride Make-Up-Air Control, installs quickly and easily on any warm air heating system, delivers controlled, fresh air automatically during the winter and a constant supply of clean, fresh air for comfortable summer living. It resolves the negative pressure differential problem.

4

II. GENERAL INSTRUCTIONS - READ BEFORE 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 provided by the Air Conditioning Contractors of America (ACCA) or the American Society of Heating, Refrigeration and Air Conditioning Engineers, Inc. (ASHRAE).

2.All local codes and/or regulations take precedence over the instructions in this manual and should be followed accordingly. In the absence of local codes, installation must conform with these instructions and regulations of the National Fire Protection Association, and to the provisions of the National Electrical Code (ANSI/NFPA 70-1999 or latest edition).

3.The installed furnace must be level and positioned in a central location with respect to outlet registers. It should be located near the chimney to minimize any horizontal run of flue pipe, which may be required.

4.A furnace installed in a residential garage must be installed so the burner and ignition source are located higher than 18 inches above the floor. The furnace must also be located or protected to avoid physical damage by vehicles.

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

5. Listed below are definitions of "COMBUSTIBLE 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 resistant or not.

Non-Combustible Material: is material that is not capable of being ignited and burned. Such materials consist entirely of, or a combination of, steel, iron, brick, tile, concrete, slate, or glass.

Table 1: MINIMUM CLEARANCES TO COMBUSTIBLE MATERIALS

TYPE OF

 

FROM

 

TOP &

FROM THE

REAR

MODEL NO.

SIDES OF

FRONT

SIDES OF

UNIT

FLUE/VENT

 

FURNACE

 

PLENUM

 

 

 

 

 

 

 

 

 

 

 

 

 

Lowboy

OL6**072D***

0”

6” ‡

1”

7”

0” ‡

 

 

 

 

 

 

 

The minimum clearances listed in the preceding table are for fire protection. Clearance for servicing the front and rear of the furnace should be at least 24 inches.

NOTE: The OL6 furnace is approved for closet installation. If the furnace is installed in a closet, it requires two openings in the closet door for combustion air, each having a minimum area of 162 sq. inches. This free area intentionally exceeds the recommended minimum free area of 1 square inch per 1000 BTUH of input rate.

A. CHIMNEY:

The furnace must be connected to an adequate chimney or an approved vent in accordance with these instructions. An adequate chimney is one that is sealed and lined with the capability of producing a (-).04" WC flue draft and having the capacity to handle the amount of stack gases that are introduced into it. A chimney with an internal construction of corrosion resistant tile, stainless steel, or some other material that will withstand flue gas temperatures up to 900°F is required.

5

Qualified service personnel must perform all installations and services.

The following are common chimney requirements necessary 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, Vents, and Solid Fuel Burning Appliances (NFPA211-1996 or latest edition).

1. PROPER CHIMNEY SIZE:

The inside area of the chimney liner should equal, at minimum, the area of the vent pipe exiting the furnace.

EXAMPLE: π x r2 = Area of Pipe (sq. in.)

r= radius of pipe

π= 3.1417

Flue Pipe Diameter = 6" [Radius of pipe = ½ diameter of pipe = ½ (6 in.) = 3in.] π x 32 = 28 sq. in.

NOTE: This formula calculates the minimum inside area of the chimney. If more than one appliance vent connector pipe is connected to the chimney, the minimum inside area of the chimney should be equal to the area of the largest vent pipe plus one half the area of any additional vent pipes. If the chimney is too large or condensation has been a problem in the past refer to the NFPA Standard for the Installation of Oil Burning Equipment (NFPA31-1997 or latest edition) Appendix E for proper liner sizing.

2. PREVENTION OF 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 water vapor on the chimney walls if they are chilled below the dew point.

Condensing will always occur on chimney walls whose temperatures are below the dew point, but the condensate may evaporate when the walls warm above the dew point. If the chimney wall temperature does not exceed the dew point during the heating cycle of the furnace, the moisture may accumulate in large enough quantities to cause problems such as corrosion of a metal chimney (especially plain steel or galvanized steel), erosion and break up of a tile liner in a masonry chimney and, in severe cases, corrosion of the heat exchanger. Condensate also could enter the home through cracks or joints in the chimney in a worse case situation.

Condensation most likely will not occur at the bottom of the chimney because the stack gas heats the chimney walls as it rises and the bottom will be heated first. This heating of the walls will cause the stack gas temperature to drop, which in turn may reduce the stack gas temperature below dew point, causing condensation to appear on the upper part of the chimney first. This condensation may then run down inside the chimney and drip back as far as the flue pipe and heat exchanger, where corrosion may occur, if not treated.

To prevent condensation, it is necessary that the internal chimney wall temperature always be kept above the dew point. If the chimney is a masonry type, it may have to be fitted with a flue liner, when the temperature loss is too great for the furnace. If the chimney is a metal type, then an "all fuel" chimney must be used, such as a Class "A" triple wall or insulated metal chimney. A liner will act as an insulator and reduce the stack gas temperature loss. Insulation may be added around the liner for further temperature stability. If the chimney is on the home's exterior or passes through a sizable, unheated area of the building, such as a porch, high ceiling attic, etc., and condensing occurs, the chimney must be insulated around its exterior to help the flue hold its temperature. Also, check to see if the chimney is too large for the furnace and other appliances connected to it. If so, reduce to proper size (see Appendix E of NFPA31) by lining. Be sure to use stainless steel liners, such as stainless types 430, 304, or for the toughest corrosion problems, type 316. If the chimney is the correct size for the unit and condensing still

6

occurs, then insulating the vent connector and/or reducing the efficiency of the furnace may have to be done to raise the chimney temperature.

More 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 point where it passes through the roof of a building and at least 2 feet higher than any portion of a building within a horizontal distance of 10 feet. (See Fig. 2a).

Fig. 2: Proper chimney termination height for pitched roofs

If the chimney penetrates a roof more than 10 feet from a ridge, wall or parapet, a minimum of 3 feet above roof or exit point must be maintained. See Figure 2b.

If the roof is flat rather than the normal residential pitched roof, refer to Figure 3 for proper clearances.

Fig. 3: Proper chimney termination height for flat roofs

4. PROPER VENT CONNECTOR PIPE/CHIMNEY CONNECTION:

The vent connector pipe should extend only to (and not beyond) the inside wall of the chimney (See Fig. 4). A thimble should be used to connect the vent connector pipe to the chimney so that the vent connector pipe may be readily removed in case of inspection or replacement.

Fig. 4: Proper insertion of the vent connector in the chimney.

7

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 the chimney must be tightly sealed. The inside of the chimney should be free of any obstructions, such as loose brick, broken pieces of tile, or corroded metal.

7. TIGHT CLEAN-OUT DOORS AND CONNECTIONS:

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 flues within one chimney, make sure there are no openings in the partition separating the divided or individual flues.

9 FLUE PIPE CLEARANCES, SIZING AND TYPE:

The vent connector pipe must not pass through a combustible wall or partition unless adequate protection is provided at the passageway. An acceptable passageway could be either an approved, ventilated metal thimble which is at least 12 inches larger in diameter than the vent connector pipe, or brick work which is at least 8 inches thick constructed into the wall and surrounding the vent connector pipe. (See Fig. 6)

Fig. 6: Suggested method to accommodate vent connector passage through a wall composed of a combustible material.

8

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 inches, refer to Fig. 7.

Required clearance with no protection from the appliance or

18 inches

9 inches

6 inches

chimney connector is:

 

 

 

 

 

 

 

 

Ceiling

Wall

Ceiling

Wall

Ceiling

Wall

a.

3-1/2" thick masonry wall without ventilation air space….

--

12

--

6

--

5

b. 1/2" insulation board over 1" glass fiber or mineral wool batts…

12

9

6

5

4

3

c. 0.024(24 gauge) sheet metal over 1" glass fiber or mineral

9

6

5

3

3

3

wool batts reinforced with wire on rear face with ventilated air

 

 

 

 

 

 

space…

 

 

 

 

 

 

d.

3- 1/2" thick masonry wall with ventilation air space..

--

6

--

6

--

6

e.

0.024 (24 gauge) sheet metal with ventilated air space.

9

6

5

3

3

2

f. 1/2" thick insulation board with ventilation air space..

9

6

5

3

3

3

g. 0.024 ( 24 gauge) sheet metal with ventilated air space over

9

6

5

3

3

3

0.024 (24 gauge) sheet metal with ventilated air space….

 

 

 

 

 

 

h. 1" glass fiber or mineral wool batts sandwiched between two

9

6

5

3

3

3

sheets 0.024 (24 gauge) sheet metal with ventilated air space

 

 

 

 

 

 

A.Equal the required clearance with no protection.

B.Equals the reduced clearance permitted in accordance with the preceding clearance chart.

C.The protection applied to the construction that covers the combustible material should extend far enough in each direction to make C equal to A.

The vent connector pipe between the furnace and chimney shall be of equal diameter as the flue outlet of the furnace. The vent connector pipe must be made of 24 gauge (or thicker) corrosion-resistant steel. The vent connector pipe should be as short as possible and installed so that it has a continuous rise from the furnace to the chimney. The horizontal length of a connector to a natural draft chimney or vent serving a single appliance shall not be more than 75 percent of the height of the vertical portion of the chimney or vent above the connector. Elbows should be minimized and the pipe should be joined with metal screws and supported by straps. All horizontal runs of vent connector pipe should be pitched upward a minimum of ¼ inch per foot of run. A thimble should be used to connect the vent connector pipe to the chimney so the pipe may be readily removed in case of inspection or replacement. See Fig. 6 on preceding page.

B. VENTING:

9

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 position 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 installation instructions see AOPS2687 kit.

c CAUTION MUST BE TAKEN NOT TO EXCEED 90° ROTATION (OF THE FLUE ELBOW) .

ROTATION OF FRONT FLUE ELBOW:

When an installation requires that the flue exit out the left side casing, remove screw securing the 90 deg. elbow and rotate it 90°. Then, remove knock-out in side casing and extend vent through the opening.

A trim collar may be ordered from Thermo Products to hide the gap around the flue pipe. This trim collar, however, is not required for operation. Trim collar/gasket part numbers(s) 14121 / 330073 for OL6.

The OL6 may be vented through a standard correctly sized chimney.

The OL6 may also be horizontally vented through a sidewall. Thermo Products has available the Field model FDVS-45/FOVP-415 side wall vent kit for such applications. When installing the sidewall vent kit, outside combustion air must also be applied to the burner. The following table identifies application order information.

SIDE WALL VENTING APPLICATION ORDER INFORMATION

 

 

 

 

COMBUSTION AIR INTAKE

 

FIELD VENT TERMINATION

SIDE WALL VENT

 

KIT

ACCESSORIES KIT

HOOD KIT

 

(15’ application MAX)

(BURNER SPECIFIC)

(FOR COMBUSTION AIR

BURNER

APPLICATIONS ONLY)

THERMO PRODUCTS PART

THERMO PRODUCTS

 

THERMO PRODUCTS PART

 

NUMBER

PART NUMBER

NUMBER

 

(OL6)

 

 

Beckett AFG

AOPS8393

AOPS8394

AOPS8397

 

 

 

 

Riello BF3

AOPS8393

AOPS8395

AOPS8416

 

 

 

 

Table 2: Sidewall vent kits

The Field vent kit is set up with 4 inch diameter vent pipe for OL6 with concentric through-the-wall vent termination/inlet air vent hood. The combustion air inlet pipe diameter is also 4 inch diameter. For Riello, the combustion air inlet pipe will be reduced to 3 inch diameter with the Riello sidewall vent kit. For Beckett, the combustion air inlet pipe will be reduced to 3” diameter with the Beckett sidewall vent kit.

The side wall vent may be installed either through the knock-out on the right or left side casing of the unit or vertically out the top opening of the vestibule.

The combustion air inlet can be installed through either the lower left side casing knockout or the lower right side casing knockout.

C. DRAFT REGULATORS:

Note: Do not use with Direct Vent application.

A draft regulator is supplied with the furnace and should be installed according to the regulator manufacturers recommendations. With the burner operating, use a draft gauge to adjust the regulator to the proper setting. (refer to the instructions enclosed with draft regulator to adjust to the proper setting). When the burner air supply and draft are properly adjusted, the over fire draft should be a negative (-).01"

10

to (-).02" WC, as measured at the 5/16" over fire air tap (See Fig. 12). This tap is provided in the upper burner mounting plate. To measure the flue draft, punch a small hole in the vent connector pipe as close to the furnace as possible and always before the draft regulator.

Note: Draft over fire may be positive for high fire applications but not to exceed (+).02" WC.

D. DUCT WORK/AIR CONDITIONING:

If the furnace is used in connection with summer air conditioning (cooling), the furnace should be installed parallel with or on the upstream side of the evaporator coil to avoid condensation in the furnace heat exchanger. If the cooling unit is installed with a parallel flow arrangement, dampers or other 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 either unit, unless the damper is in the full heat or cool position.

The duct system should again follow the current design standard of Air Conditioning Contractors of America (ACCA) or ASHRAE Fundamentals volume. The most common location for the A-shaped coil (A style) is shown in Fig. 8.

Fig 8: Acceptable locations for the air conditioner evaporator coil.

NOTICE: The minimum coil pan clearance for a sectional or drum type heat exchanger is three inches unless specified otherwise by the individual coil manufacturer.

NOTICE: The minimum return air temperature is 55° F.

Airflow Requirements and Sizing of Duct Work:

The duct system must be sized and installed by a qualified installer or service person, following the design standards of the Air Conditioning Contractors of America (ACCA) or the American Society of Heating, Refrigeration, and Air Conditioning Engineers (ASHRAE). This furnace has been designed to operate against a maximum external static pressure of 0.5 in. W.G. This is equivalent to 0.1 in. W.G. supply, and 0.1 in. W.G. return, and 0.3 in. W.G. for evaporator coil.

1.Supply and return air ducts have to be furnished by the installer and run between the appliance, which must be installed outdoors, and the interior of the structure the appliance serves. These ducts must be sealed to the casing of the appliance.

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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 contraction, 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 capacity (CFM) for a given pressure drop. Use a supplier's catalog for proper sizing of outlet and return air registers and grills to ensure that they meet the flow requirements of the run to which they are connected.

4.The duct system shall be sized to provide the maximum airflow rate (CFM) required of the installation. Two common rules for determining minimum airflow in heating and cooling systems follow:

a.For heating, 14 CFM of airflow are required per 1000 BTU/hr of heat output, based on steady state operation and a 50° to 80° temperature rise.

b.For cooling, 400 CFM of airflow are required per ton of air conditioning. (For reference, a ton of A/C = 12,000 BTU/hr removed from the space.)

Refer to Examples 1 & 2, (page 15) for a sample calculation of how to determine the required minimum airflow rate.

5.Duct sizing is based upon both air velocity and pressure drop considerations. When possible, current practice favors designing ductwork for lower air velocities. (For residences, a maximum air velocity of 800 FPM is suggested.) This results in quieter duct systems, systems which require less fan power (reduced operating costs), and less carefully constructed ductwork (lower initial costs).

However, lower air velocities also result in larger duct sizes than necessary at higher velocities. In some cases, space restrictions may limit the ductwork to smaller than optimal sizes.

6.The following method can be used to size ductwork when air velocities 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 sources of heat loss, i.e. windows and doors, around the perimeter of the building. Return grills should be located in central positions as far away from the supply registers as practical.)

b.Find a location for the appliance that minimizes the amount of ducting required to connect the appliance to the supply and return air duct systems. Consider issues of access to the oil supply and electrical service, required service and venting clearances, and operating noise when selecting this location.

c.Plan an efficient layout for the ductwork connecting each of the supply air registers in the supply system to the unit. Plan and layout ductwork connecting each of the return air grills in the return system to the unit. Measure or estimate the length of duct between each register and grill.

d.Select values for the airflow through each register and grill.

e.Select values for the pressure drops of both the supply and return air systems. Each branch of the supply (or the return) air system will have this pressure drop. The total pressure drop of the supply and return air systems added together cannot exceed the maximum external static pressure that can be supplied by the appliance blower.

f.Determine the required flow rate for each branch of the supply and return air systems. The total airflow rate, by adding the airflow rate of each branch of the supply system, must equal the minimum required airflow rate (refer to part 3, above). Likewise, the airflow rate of each of the branches of the return air system must sum to the required minimum flow rate.

g.Using the selected air flow rates for each component of the duct system and manufacturer’s literature, or published literature on duct system pressure drops, the pressure drop for each component in the duct system can be estimated.

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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 (or return grill) should then be summed together to determine the total pressure drop for each branch. This value should be close to the assumed value for the pressure drop of the system. If it is not close, then flow rates for each branch must be adjusted, or the design of the duct system must be altered, to give the proper pressure drops. Usually, the cross-sectional area of the ductwork should be changed in order to adjust the pressure drop to a suitable value. Refer to Example 2, (page 14) for a sample calculation of how to use this method for sizing the supply side ductwork for a residence.

Table 3 shows the air handling capacities of 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 airflow rate and the second is the required diameter for a circular duct. The third column is the required cross-sectional area of the duct and the other columns to the left are rectangular ducts with sufficient cross-sectional area to handle the flow at the specified pressure drop. [For lengths of ductwork less than 100 ft., simply multiply 0.1 in. W.G. by the ratio of the actual duct length (in feet) over 100 ft. for the approximate pressure drop.] Use the supplier’s catalog for proper sizing of outlet air registers and return air grills to insure that they provide the required flow rate at the desired pressure drop.

Table 3: Suggested Duct Sizes for Homes, Quiet Offices, Or Similar Installations (Based on a 0.1 in. W.G. static pressure drop per 100 ft. of duct.)

7.The supply and return air ducts, or flexible joints, should be carefully secured and sealed to the appliance housing to prevent air leakage from, or into, the duct system. For best performance, insulate the outside surfaces of the ducts to reduce heat loss from, or heat gain to, the ducts.

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8.As a final step in the installation, the appliance must be adjusted to deliver a temperature rise within the range of 50° to 80°F. Adjust the blower motor speed to obtain a temperature rise within the acceptable range. The required blower speed will depend on the airflow resistance of a supply and return air duct systems.

Fig. 9: Supply air duct sizing Example

The RETURN AIR DUCT SYSTEM should equal the warm air duct system in airflow capabilities.

NOTE: When a return register is located in the same room as the furnace, the 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 combustion heating and cooling system.

1.HEATING CFM:

HEAT OUTPUT OF FURNACE (BTUH)

1.1 X TR (TEMPERATURE RISE, °F) = HEATING(CFM)

EXAMPLES:

A.110,000 BTUH OUTPUT

1.1X 85°F TR = 1176 CFM FOR HEATING

B.110,000 BTUH OUTPUT

1.1X 70°F TR = 1429 CFM FOR HEATING

2.COOLING CFM: 400 CFM X COOLING TONNAGE (12,000 BTUH PER TON)=AIRFLOW FOR COOLING(CFM)

EXAMPLES:

A. 400 CFM X 3 TON (12,000 BTUH) = 1,200 CFM FOR COOLING 1TON

B. 400 CFM X 2.5 TON (12,000 BTUH) = 1,000 CFM FOR COOLING 1 TON

IMPORTANT: SIZE THE DUCT SYSTEM FOR THE LARGER OF THE TWO AIRFLOW REQUIREMENTS.

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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 desired, refer to Table 4 below for minimum sizing guidelines for selecting filter for the unit.

 

Maximum

Model Number

 

Filter Type

Air Velocity

 

 

(ft/min)

OL6

 

Qty

*Thermo Products

600

280 in²

 

2

Supplied Permanent

 

 

 

 

 

Standard

500

576 in²

 

2

Permanent

 

 

 

 

 

Disposable

300

960 in²

 

2

 

 

 

 

 

Table 4: Minimum Required Filter Area (in square inches)

* The Thermo Products supplied filter can be cut to size to fit other filter retention systems as long as the minimum size requirement is met.

NOTICE: Any internal stiffeners used in the filter must not be removed, although they can be cut to size as needed.

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F. LIMIT POSITION AND LOCATION

cWARNING: 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.

The unit must have the limit control installed at the time of unit installation.

Fig. 11: Limit location for OL6

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G. BURNER INSTALLATION:

NOTICE: Remove all cardboard packing from around chamber before installing burner.

The oil burner will mount on three stud mounting bolts on the lower mounting plate covering the opening in the front of the heat exchanger. The end of the burner tube should be inserted no further than 1/4 inch back from the inside surface of the combustion chamber. A distance further than 1/4 inch back from the inside chamber wall may cause impingement and sooting. This unit is equipped with a chamber retainer (refer to Fig.12). The retainer secures the chamber during shipping and helps to maintain insertion depth.

DO NOT remove this retainer when installing burner.

Fig. 12: Typical location of the over fire air tap and components in burner mounting plate area

Fig. 13: Burner insertion illustration (Top view)

When mounting the burner, the mounting plate (Fig. 12) must be removed to provide access to the area in front of the combustion chamber. A fiber insulating sleeve or amulet is provided on the burner tube of specific Thermo Pride burners.(see Fig. 13). See Thermo Pride burner application chart for type of insulator. Do not allow the burner tube or end cone to physically touch or protrude into the chamber, as excess heat transfer could result in destruction of the tube, end cone or both. The burner tube/end cone is properly positioned, when the end is ¼ inch back from the inside surface of the combustion chamber wall.

DO NOT CHANGE POSITION OF THE CHAMBER!

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H. BURNER SPECIFICATIONS AND APPLICATIONS:

 

THERMO

*

BECKETT

HEAD

STATIC

MAXIMUM

SHIPPED

OIL

 

PRIDE’S

INS

BURNER

 

PLATE

NOZZLE

NOZZLE

PUMP

FURNACE MODEL

BURNER

 

MODEL &

 

 

SIZE**

SIZE

PRESSURE

 

SPEC NO.

 

TUBE

 

 

 

 

(PSIG)

 

 

 

LENGTH

 

 

 

 

 

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 be used with OL6.

 

THERMO

 

RIELLO

HEAD

STATIC

MAXIMUM

SHIPPED

OIL

 

PRIDE’S

INS

BURNER

 

PLATE

NOZZLE

NOZZLE SIZE

PUMP

FURNACE MODEL

BURNER

+

MODEL &

 

 

SIZE**

 

PRESSURE

 

SPEC NO.

 

TUBE

 

 

 

 

(PSIG)

 

 

 

LENGTH

 

 

 

 

 

OL6*A072D**R

C8511325

S

BF3-4.5”

N/A

N/A

0.70X80° H

0.60X80° H

140

 

 

 

 

 

 

 

 

 

Table 6: Beckett & Riello burners specifications

+ INSULATOR S = SLEEVE OR N = NONE

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”.

For more specific burner information, contact:

Thermo Products, LLC. P.O. Box 217, North Judson, IN 46366.

Phone 574-896-2133.

OIL NOZZLE CAPACITY CHART

 

NOZZLE SIZE

EQUIVALENT HEAT

EFFECTIVE HEATING

UNITS

(GPH)

 

INPUT RATE NOTE #1

CAPACITY NOTE #2

Beckett

Riello

(BTU/HR)

(BTU/HR)

 

 

 

 

 

 

 

 

 

OL6*A060D***

.50

.50

70,000

60,000

OL6*A072D***

.60

.60

85,000

73,000

OL6*A090D***

.75

.70

106,250

90,000

Table 7: Oil nozzle capacity

All rates shown achieved with 120 PSIG pump pressure for Beckett and 140 PSIG pump pressure for Riello.

NOTE #1 Based on #2 domestic heating fuel oil having heating value of 140,000 BTU per gallon. NOTE# 2 Based on thermal efficiency of 84%-85%.

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Riello 2-stage burner specifications and applications:

MODEL

OL6 2-STAGE

PART

 

MTG. PLATE PART NO.

11700

 

 

MTG. PLATE GASKET

330212

PART NO.

 

**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 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”.

*Optional equipment not shipped with burner.

**NOTE: The reason the Riello burner nozzle sizes are smaller than the standard Thermo Pride burner nozzles is that pre-set pump pressures are higher, therefore achieving the same firing rate with a smaller nozzle.

For more specific burner information, specifications or service information, reference the training manual enclosed with each Riello burner or contact:

Riello Corporation of America,

5 Pond Park Road Hingham, Massachusetts 02043

Phone: (617) 749-8292

2 STAGE FIRING RATES

CAPACITY

FIRING

NOZZLE SIZE

INPUT RATE*

EFFECTIVE**

 

RATE

Riello

(BTU/HR)

HEATING

 

 

 

 

CAPACITY

HIGH CAPACITY

HIGH FIRE

.70 X 45° W

106,250/170psi

90,000

LOW FIRE

85,000/130psi

74,000

 

 

LOW CAPACITY

HIGH FIRE

.50 X 45° W

85,000/170psi

74,000

LOW FIRE

70,000/130psi

60,000

 

 

Table 9: Riello 2-stage firing rates

*Based on #2 domestic heating fuel oil having heating value of 140,000 BTU per gallon.

**Based on thermal efficiency of 84%-85%.

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MOUNTING THE 2-STAGE RIELLO BURNER:

It is necessary that the insulation gasket be placed between the mounting plate and the burner flange. The insulating gasket has six holes, which, if necessary, 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 installed burner is lightly leaned towards the button. (See figure 14-1) The burner is designed to allow entry of the flexible oil-lines on either side of the burner.

I. OIL TANK AND PIPING:

: All local codes and ordinances take precedence with regard to selection and installation of oil storage tank and oil supply (and return) lines. In the absence of local codes, all tanks and lines must be selected and installed according to the instructions in this manual and the Standard for the Installation of Oil-Burning Equipment, NFPA 31-1997, or the latest edition.

1.The use of black steel pipe and malleable iron fittings is recommended for all fuel oil service lines. Never use galvanized steel piping or fittings for any fuel oil lines.

2.Where practical, provide rigid supports for the piping.

3.If the piping size in a run must be reduced, use reducing couplings only. Avoid the use of reducing bushings.

4.Remove all pipe thread burrs and inspect the pipe for dirt or other foreign material prior to connecting. If present, remove any deposits in the piping and discard any excessively corroded piping.

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