Temp-O-Matic TMP-105 User Manual

Temp-O-Matic Oil Furnace
TMP Multi-Position (Counterflow / Horizontal)
KEEP THESE INSTRUCTIONS WITH FURNACE FOR FUTURE REFERENCE.
Hazards that will cause severe personal injury, death or substantial property damage.
Hazards that can cause severe personal injury, death or substantial property damage.
INSTALLER – Read all instructions before installing. Read page 2 first. Follow all instructions in proper order to prevent personal injury or death.
Consider ducting, fuel supply, venting and installation when determining furnace location.
Any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee.
Do not store or use gasoline or other flammable liquids or vapors near this furnace or any other appliance.
Ventilate house while operating furnace for the first time. Odors may be emitted for a brief period.
Do not alter this furnace in any way. The manufacturer will not be liable for any damage resulting from changes made in the field to the furnace or its components or from improper installation. Failure to comply could result in severe personal injury, death or substantial property damage.
Hazard definitions
Furnace Manual
Contents Page
Read this first!............................................................................ 2
1. Check furnace location..............................................................3
2. Prepare furnace and place in position.......................................6
3. Connect supply and return ducts............................................... 8
4. Venting..................................................................................... 11
5. Connect fuel oil piping ............................................................. 12
6. Wire furnace and burner.......................................................... 14
7. Start-up.................................................................................... 17
8. Checkout procedure ................................................................ 18
9. Troubleshooting....................................................................... 19
10. Service and maintenance ........................................................ 20
11. Components and replacement parts........................................ 23
12. Dimensions and ratings ........................................................... 25
13. Owner’s information .................................................................27
Hazards that will or can cause minor personal injury or property damage.
Special instructions on installation, operation or maintenance that are important but not related to personal injury or property damage.
USER – Please read the following. Failure to comply could result in severe personal injury, death or substantial property damage.
This manual is for use only by your qualified
heating installer / service technician.
Please see the Owner’s information only, on back page of this manual.
Have the furnace serviced by a qualified service technician, at least annually.
This manual must only be used by a qualified heating installer / service technician. Furnace and burner must be installed and serviced only by a qualified heating installer / service technician. Failure to comply could result in severe personal injury, death or substantial property damage.
When calling or writing about the furnace – Please indicate furnace model number and serial number from rating label. You may list the serial number and model number in the space provided on the “Installation and service certificate” found on page 18.
Printed on 100% recycled paper 670-000-004/1010
READ THIS FIRST!
Service and maintenance –
1. To avoid electric shock, disconnect electrical supply before performing maintenance.
2. To avoid severe burns, allow furnace to cool before performing maintenance.
3. Perform service and maintenance as described in this manual and the burner manual.
4. Do not attempt to make adjustments to the blower or motor while the furnace is in operation. Disconnect power to the furnace and be sure all parts have stopped moving before attempting adjustments or maintenance.
5. The burner must be set up and adjusted using combustion test instruments. Visual examination of the flame alone cannot determine combustion performance.
Operation -
6. Do not use the furnace as a construction heater.
7. Do not operate any furnace if the heat exchanger is damaged,
corroded or pitted. Toxic flue products could enter the air stream.
8. Do not jumper, attempt to by-pass or override any limit control.
9. Do not block flow of combustion or ventilation air to furnace. Do
not block or obstruct the air openings in the furnace casing.
10. Do not store or use combustible materials, gasoline, or other flammable liquids or vapors in the furnace area.
11. Do not operate the furnace if the furnace area will be exposed to air contaminants as described on page 5.
12. Should overheating occur, do not turn off or disconnect electrical supply to furnace. Instead, shut off the oil supply at a location external to the appliance, if possible.
13. Do not use this furnace if any part has been under water. Call a qualified service technician immediately, to inspect the furnace and to replace any part of the furnace, control system or burner that was submerged in water.
14. Do not operate furnace if temperature rise through heat exchanger exceeds 85
Installation –
1. Be sure to level the furnace, using a spirit level at the front and one side. If the furnace is not level, oil can drip into the combustion chamber after burner cycling, contaminating the heat exchanger and the burner head.
2. Avoid locating return grills in rooms that may contain undesirable odors.
3. Never locate a return air grill closer than approximately 20 feet from the furnace.
Failure to adhere to the guidelines below can result in severe personal injury, death or substantial property damage.
o
F.
Apply the following suggestions to prevent unsatisfactory operation of the furnace.
15. Inspect, clean and replace (if necessary) return air filter regularly.
16. Do not obstruct return air grills or supply air outlets.
17. Supply only #2 fuel oil to the burner. Never attempt to use
gasoline, a mixture of gasoline and oil, waste fuel, refuse or any other substance in the burner of furnace.
Installation -
18. Do not block flow of combustion or ventilation air to furnace. Do not block or obstruct the air openings in the furnace casing.
19. Connect furnace only to a functional vent system in good condition. Place the furnace to allow proper venting, with the shortest possible venting and minimum number or elbows.
20. Always connect and seal a return air duct to the furnace unless the furnace is located in a large space, such as an unpartitioned basement. Route the return air duct to an adjacent room if no return air manifold is used.
21. Install furnace maintaining minimum clearances for service and separation from combustible surfaces described in this manual. If furnace is installed on a combustible floor, you must use the combustible floor base or provide the minimum clearance from the furnace to the floor as given in this manual.
22. Install, start-up, service and maintain burner per instructions in this manual and the burner manual.
23. Verify burner is properly inserted through the combustion chamber opening.
24. Furnace must be installed so that burner and control system components are protected from dripping, spraying water or rain during operation or service.
25. If installing an air conditioning evaporator coil, install the coil downstream of, or in parallel with, the furnace to prevent condensation on the furnace heat exchanger. If the coil is in parallel, provide means to prevent flow of chilled air into the furnace, including an interlock to prevent simultaneous operation of heating and air conditioning.
4. Locate the furnac e near the center of the supply and return duct systems.
5. Always check the size of the ducts on a replacement installation, particularly if adding air conditioning.
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1 Check furnace location
Pre-installation checklist
Verify code compliance
Local, state, provincial, and national codes, laws, regulations
and ordinances
NFPA-31, Installation of Oil-Burning Equipment National Electrical Code All local codes and/or regulations take precedence over the
instructions in this manual and should be followed accordingly.
TMP furnaces, their burners and controls met safe lighting and other performance criteria when furnace underwent tests specified in Underwriters Laboratories Standard UL727.
Check location and furnace specifications
Use the table below to verify:
Furnace heating capacity Space is large enough to provide required clearances
Verify the installation will meet the requirements of this manual:
Clearances (page 3) Combustion/ventilation air openings (pages 4) Supply air duct (page 8) Vent system (page 11) Fuel oil piping (page 12 plus burner manual) Electrical connection (page 14)
Clearances
Minimum clearance to combustible materials
1. Install the furnace, ductwork and vent such that no combustible surface is closer than listed in Table 1.
Flue pipe clearances must take precedence over jacket clearances (listed below).
Service accessibility clearances
1. Provide no less than the minimum clearances given in Table 1 to ensure the furnace can be properly operated, serviced and maintained.
Table 1 Minimum clearances
2. Always apply whichever clearance is LARGER – combustible construction or service accessibility.
Flooring and foundation
Flooring
TMP furnaces are approved for installation on non-combustible floor. If a combustible floor is used, follow these instructions:
Horizontal installation on combustible floor
Always keep the minimum installation clearances of 1 inch between the combustible floor and the furnace sides. Use appropriate leveling legs or optional kit #HFB-1-W.
Counterflow installation on combustible floor
Always keep the minimum installation clearances of 1 inch between the combustible floor and the furnace bottom or air supply plenum. Use appropriate leveling base and spacers or optional kit #CFB­1-W.
Do not install furnace on carpeting even if foundation is used. Fire can result, causing severe personal injury, death or substantial property damage.
Foundation
1. Provide a solid brick or minimum 2-inch thick concrete foundation pad if any of the following is true:
the floor can become flooded.
the furnace mounting area is not level.
Residential garage installations
Take the following special precautions when installing the furnace in a residential garage. If the furnace is located in a residential garage:
Mount the furnace a minimum of 18 inches above the floor
of the garage.
Locate or protect the furnace so it cannot be damaged by a
moving vehicle.
Minimum installation clearances from combustible materials ( Chimney installation)
Location Application Counterflow Horizontal
Sides Back Furnace 1 " 1 "
Top Furnace casing or plenum 1 " 1 " Bottom Furnace – combustible f l oor 1 " 1 " Front Furnace 24 " 24 " Flue pipe 18 " 18 "
* Use appropriate leveling legs or optional ki t #HFB-1-W; ** Use appropriat e l eveling base and spacers or optional kit #CFB -1 -W.
670-000-004/1010 3
Supply plenum, warm air duct wit hin 6ft of furnace 1 " 1 "
Furnace 1 " 1 "
***
TMP Oil FurnacesFurnace Manual
1 Check furnace location (continued)
Air for combustion and ventilation
Adequate combustion and ventilation air ensures proper combustion and reduces risk of severe personal injury or death from possible flue gas leakage and carbon monoxide emissions.
Do not install exhaust fan in furnace room.
Consider building construction
Older buildings with single-pane windows, minimal weather-stripping and no vapor barrier often provide enough natural infiltration and ventilation without dedicated openings.
New construction or remodeled buildings are most often built tighter. Windows and doors are weather-stripped, vapor barriers are used and openings in walls are caulked. As a result, such tight construction is unlikely to allow proper natural air infiltration and ventilation.
For buildings with tight construction, provide openings directly to outside or to a ventilated crawl space or attic. Size the openings to the same specifications as for the furnace location per the following paragraphs.
Follow state, provincial or local codes when sizing adequate combustion and ventilation air openings. In absence of codes, use the following guidelines when furnace is in a confined room (defined by NFPA 31 as less than 7200 cubic feet per 1 GPH input of all appliances in area. A room 8 ft. high x 30.0 ft. x 30.0 ft. is 7200 cu. ft.).
Provide two permanent openings
Openings locations
One within 12 inches of ceiling, one within 12 inches of floor. Minimum height or length dimension of each rectangular opening should be at least 3 inches.
When inside air is used:
Each opening must freely connect with areas having adequate infiltration from outside. Each opening should be at least 140 sq. in. per 1 GPH input (1 sq. in. per 1000 BTU input) of all fuel-burning appliances plus requirements for any equipment that can pull air from room (including clothes dryer and fireplace).
When outside air is used:
Connect each opening directly, by ducts to the outdoors, or to crawl or attic space that freely connects with outdoors. Size per below:
Through outside wall or vertical ducts – at least 35 sq. in. per 1 GPH input (1 sq. in. per 4000 BTU input) of all fuel burning appliances plus requirements for any equipment that can pull air from room (including clothes dryer and fireplace).
Through horizontal ducts – at least 70 sq. in. per 1 GPH furnace input (1 sq. in. per 2000 BTU input) of all fuel-burning appliances plus requirements for any equipment that can pull air from room (including clothes dryer and fireplace).
Where ducts are used, they should have the same cross­sectional area as free area of openings to which they connect. Compensate for louver, grille or screen blockage when calculating free air openings. Refer to the manufacturers’ instructions for details. If unknown, use:
Wood louvers, which provide 20-25% free air.
Metal louvers or grilles, which provide 60-75% free air.
Lock louvers in open position or interlock with equipment to prove open before furnace operation.
Basement installations
When the furnace is located in an unconfined space, such as an unpartitioned basement, adequate air should normally be available without additional openings. An unconfined space is defined as one having no less than 50 cubic feet room volume per 1,000 BTU/h input of all appliances in the space.
If the house is of tight construction, provide air openings to the basement directly from outside or from a ventilated attic. Size the openings as described above under “When outside air is used”.
Closet installations – special NOTICE
Openings in closet doors
Provide TWO openings – one within 6 inches of top of closet door, the other within 6 inches of the bottom of closet door.
EACH opening must be at least 24 inches wide by 12 inches high.
Advise homeowner that the openings to the closet must never be obstructed or blocked in any way. Failure to provide adequate air for combustion and ventilation could result in severe personal injury, death or substantial property damage.
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1 Check furnace location (continued)
Air contamination
Please review the following information on potential combustion air contamination problems.
See Table 2 for products and areas which may cause contaminated combustion air.
To prevent the potential of severe personal injury or death, check for products or areas listed below before installing the furnace. If any of these contaminants are found:
Remove contaminants permanently.
-OR-
Isolate furnace and provide outside combustion air. See national, provincial or local codes for further information.
Table 2 Corrosive contaminants and likely locations
Products to avoid
Spray cans containing chloro/fluorocarbons Permanent wave solutions Chlorinated waxes/cleaners Chlorine-based swimming pool chemicals Calcium chloride used for thaw ing Sodium chloride used for water softening Refrigerant leaks Paint varnish removers Hydrochloric acid/muriatic acid Cements and glues Anti static fabric softeners used in clothes dryers Chlorine-type bleaches, detergents, and cleaning solvents found in
household laundry rooms Adhesives used to fasten building products and other similar
products
Areas likely to have contaminants
Dry cleaning/laundry areas and establishments Swimming pools Metal fabrication plants Beauty shops Refrigeration repair shops Photo processing plants Auto body sho ps Plastic manufacturing plants Furniture refinishing areas and esta blishme nts New building construction Remodeling areas Garages with workshops
670-000-004/1010 5
TMP Oil FurnacesFurnace Manual
2 Prepare furnace and place in position
Inspect & prepare furnace
Remove furnace from carton
Remove the furnace from its shipping carton and inspect thoroughly. Remove access panels to inspect the furnace interior.
Immediately file a claim with the transportation company if you discover concealed damage.
Do not install or attempt to operate the furnace if the heat exchanger, burner or controls have been damaged. Immediately contact your furnace supplier. Operating a damaged furnace could result in severe personal injury, death or substantial property damage.
Prepare burner
Remove the burner from its shipping carton and inspect thoroughly. Read the burner manual and follow instructions for preparing and installing the burner.
Install the correct nozzle for the required firing rate, using the burner manual shipped with the burner. Follow the burner manual instructions for nozzle installation. Verify the correct setting of electrodes after nozzle and burner oil tube assembly are in place.
Openings in walls, floor & ceiling
General
Ensure that the finished door opening to the furnace room is large enough to install and remove the furnace, water heater or any other appliances in the room.
Before placing furnace in a closet or small room, cut all openings required in floor, ceiling or walls for ducts and vent. This will simplify the work and prevent construction dust from entering the furnace heat exchanger.
Verify that all clearances to combustible construction and for service accessibility will be met. The vent must be no closer than 18 inches to any combustible surface unless a type “L” double-wall vent pipe is used or the vent is constructed per the requirements of the NFPA 31. Provide a ventilated thimble per all applicable codes where vent pipe passes through wall or ceiling. Failure to comply could result in severe personal injury, death or substantial property
Duct locations and sizing
Verify that the size of the supply and return duct system is sufficient for the application. The pressure drop through the duct system must not exceed 0.2” water column. The total drop through the duct system and air conditioning condensing coil (if used) must not exceed 0.5” water column.
See suggested duct sizing in this manual. For more detailed sizing information, refer to ACCA Manual D.
damage.
Openings …
Supply and return ducts
You must install a return air duct, sealed to the furnace, even if no return manifold is used. Cut the required opening for the supply air duct in the floor of the room before placing the furnace.
(continued)
Verify that the filter will be easily accessible for removal after the furnace is in place.
Install furnace and burner
Place furnace
Place the furnace in the desired location. Measure clearances and verify per page 3 or table 1 of this manual.
Level the furnace using a spirit level on the front and one side.
Inspect combustion chamber
Inspect the combustion chamber. Verify that it is in good condition and correctly positioned inside the heat exchanger. The burner opening in the chamber must align with the burner heat exchanger opening.
The combustion chamber is constructed of ceramic fiber materials. See the WARNING information on page 21 of this manual. Comply with these instructions when handling any ceramic fiber or fiberglass materials. Failure to adhere to these guidelines could result in severe personal injury or
Insert burner
Following the burner manual instructions, install the burner and its gasket in the burner opening. Make sure the burner passes through the opening in the combustion chamber and does not protrude more than ¼ inch into the chamber.
Secure the burner in place with the four nuts and washers provided. Wire and pipe fuel to the burner as per the burner manual and this manual.
Burner orientation
For a horizontal installation, you must turn the burner 90o, to the normal orientation. Always keep the motor shaft in horizontal position.
death.
6 670-000-004/1010
TMP Oil FurnacesFurnace Manual
2 Prepare furnace and place in position (continued)
Blocked Vent Shut-Off (BVSO) for chimney venting (OPTIONAL)
It is imperative that this device be installed by a qualified agency.
This device is designed to detect the insufficient evacuation of combustion gases in the event of a vent blockage. In such a case the thermal switch will shut down the oil burner. The device will then need to be re-armed MANUALLY.
In the event that the BVSO repetitively shuts down the oil burner, a qualified technician needs to evaluate the cause of this shut down.
Refer to the figures 3 to 5 at section 6, Wiring Diagrams and detailed instructions supplied with the BVSO for the installation and wiring procedures. It is also essential that the BVSO be maintained annually. For more details refer to the instructions supplied with the device itself, as well as the Maintenance Section.
Figure 1
Installation : Upflow with Vertical exhaust
Blocked Vent Shutt-Off device wiring
(Optional)
Figure 2
Blocked Vent Shutt-Off device wiring
Installation : Horizontal flow with vertical exhaust
(Optional)
670-000-004/1010 7
TMP Oil FurnacesFurnace Manual
3 Connect supply and return ducts
Duct sizing
Determine airflow CFM
The temperature rise through the furnace must not exceed 85oF and should be at least 55 assume a temperature rise of 70
The noticeable temperature change for cooling would be approximately 27-30 approximately 18-21
To calculate the noticeable heat temperature change (ΔT), you can use the formula:
ΔT = BTU/h/(1.1 x CFM) Eq. 3-1
To calculate airflow when you know temperature change (ΔT), you can use:
CFM = BTU/h/(1.1 x ΔT) Eq. 3-2
You can estimate airflow using the following rules of thumb:
Heating: 14 CFM per 1,000 BTU/h output Eq. 3-3 Cooling: 400 CFM per ton air conditioning Eq. 3-4
Determine the required airflow based on whichever is larger – heating mode or air conditioning mode.
Examples:
1. What would the temperature rise be for a 100,000 BTU/h output furnace with an airflow rate of 1200 CFM?
Use Equation 3-1 since you know CFM and BTU/h:
ΔT = 100,000/(1.1 x 1200) = 76
The temperature rise would be 76
If the air enters the furnace at 70
furnace at 70
2. What would the airflow be to obtain a 70 120,000 BTU/h output furnace?
Use equation 3-2 since you know ΔT and BTU/h: CFM = 120,000/(1.1 x 70) = 1,558 CFM
The airflow would have to be 1,558 CFM to obtain a
temperature rise of 70
3. Estimate the required airflow for a 75,000 BTU/h output furnace installed with a 2-ton air conditioning evaporator coil.
Heating mode airflow (use Equation 3-3): CFM = 75 x 14 = 1,050 CFM Cooling mode airflow (use Equation 3-4): CFM = 2 x 400 = 800 CFM
The larger number is 1,050 CFM (heating), so the duct
system should be sized for 1,050 CFM.
The supply duct would need to be 16” round or a rectangular
equivalent such as 8” x 25” or 12” x 16”, using Table 4, page 8.
4. Estimate the required airflow for the same furnace installed with a 4-ton air conditioning evaporator coil.
Heating mode airflow is still 1,050 CFM. Cooling mode airflow (use Equation 3-4): CFM = 4 x 400 = 1,600 CFM
The larger number is 1,600 CFM (cooling), so the duct
system should be sized for 1,600 CFM.
The supply duct would need to be 18” round or a rectangular
equivalent such as 8” x 36” or 12” x 21”, using Table 4, page 9.
o
F for comfort. When calculating airflow,
o
F.
o
F. Actual temperature change will be
o
F due to humidity of the air.
o
F
o
F.
o
o
F + 76o F = 146o F.
o
F.
F, it would leave the
o
F rise through a
Always check the size of existing ducts, particularly if you are adding air conditioning. The air pressure loss through the cooling evaporator coil reduces available airflow. If the ducts are too small as well, the system may not work satisfactorily on either heating or cooling.
Determine duct dimensions
Table 4, page 9, and Table 5, page 10, provide typical round and rectangular duct sizes for rectangular and flat oval galvanized ducts. Do not apply these tables to size ductwork if the total equivalent length of the duct exceeds approximately 100 feet. For longer systems or for ductboard, fiberglass-lined or flexible duct sizing, use the ACCA Manual D or the ACCA duct sizing slide rule. These tables are based on pressure loss of approximately 0.10” water column per 100 feet equivalent length of duct.
Use Table 3 below to size or check sizing of take-offs to supply registers or return grills.
Verify the size and type of registers, diffusers and grills from the manufacturer’s ratings. Do not exceed the recommended flow rate. The pressure drop allowance for each should not exceed approximately 0.05” water column.
Install a return air filter, sized per specifications in Section 12. Use only a return air filter mounted to the furnace. Do not add
additional filters unless the duct system is carefully sized to allow for the additional pressure drop.
Table 3 Suggested maximum flow to runouts
TAKE-OFF SIZE
(Inches)
Sheet metal or ductboard
5 Round 60 45 6 Round 100 75 7 Round 140 110 8 Round 210 160
3 ¼ x 8 Stack 70 55 3 ¼ x 10 Stack 100 75 3 ¼ x 14 Stack 140 110 2 ¼ x 12 Stack 70 55 2 ¼ x 14 Stack 90 70
Flexible duct (keep bends to minimum)
6 Round 55 40
8 Round 120 90 10 Round 200 160 12 Round 320 250 14 Round 480 375 16 Round 660 530 18 Round 880 680 20 Round 1200 900
SUPPLY RETURN
CFM
8 670-000-004/1010
TMP Oil FurnacesFurnace Manual
3 Connect supply and return ducts (continued)
Duct sizing (continued)
Table 4 Typical duct sizing for systems not over 100 feet equivalent length – round or rectangular galvanized
(For approx imately 0.10 i nc h w.c. in a typic al residential instal lation of galvaniz ed metal duc t)
Round
CFM
duct
diameter4567891012141618202224262830
(inches)xxxxxxxxxxxxxxxxx
45
65 100 150 200 250 300 400 500 600 700 800 900
1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2200 2400 2600 2800 3000 3500 4000
Rectangular duct equival ent sizes Mini mum widt h
4 5 6 7 8 9
9 10 12 12 12 14 14 16 16 16 16 18 18 18 18 18 20 20 20 22 22 22 22 24 26
444-------------­6544- ------------
865544- - - -------­1297655544- ------­141198766544------­181310987665544- - - - ­20151210987665544- - - ­2619151311109876655544­322318151312119876665555 3828221815131210987766655 46322520171514111098777666 523628231917151311109887766 58 41 31 25 21 19 17 14 12 11 10 9 8 8 7 7 7 64 45 34 28 23 20 18 15 13 11 10 9 9 8 8 7 7 72 49 38 30 25 22 19 16 14 12 11 10 9 9 8 8 7
- 544133272421171513121110 9 9 8 8
- 58443529252218161412111010 9 9 8
- 6347383127241916141312111010 9 9
- 685140342925201715141212111010 9
- 725443363027211816141312111110 9
- - 58 45 38 32 28 23 19 17 15 14 13 12 11 10 10
- - 61 48 40 34 29 24 20 17 16 14 13 12 11 11 10
- - 64 51 42 35 31 25 21 18 16 15 14 13 12 11 11
- - 68 53 44 37 32 26 22 19 17 15 14 13 12 12 11
- - - 59 48 41 35 28 23 20 18 16 15 14 13 12 12
- - - 64 52 44 38 30 25 22 19 17 16 15 14 13 12
- - - 69 56 47 41 32 27 23 21 19 17 16 15 14 13
----61514434292522201817151514
----65544737302623211917161514
-----635442342926232119181716
-----726147393329262321201918
Do not apply this table for duct systems over approximately 100 equivalent feet in length. For longer systems or systems using other duct materials, refer to ACCA Manual D. Incorrectly sizing duct systems can result in unsafe or uncomfortable operation.
(inches)
Typical duct sizing
for duct heights
(inches)
of :
670-000-004/1010 9
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