Thermo Products MO-425 User Manual

OIL FURNACE

GENERAL SERVICE AND MAINTENANCE MANUAL

FOR USE WITH THERMO PRIDE OIL FURNACES

THERMO PRODUCTS, LLC.
PO BOX 217
NORTH JUDSON, IN 46366
PHONE: [phone]

MO-425

ECN 4392-MA

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

TABLE OF CONTENTS

SECTION BEGINNING PAGE

I. GENERAL INSTRUCTIONS 1
II. INSTALLATION 2
A. CHIMNEY 2

1. PROPER CHIMNEY SIZE 2

2. PREVENTION OF CHIMNEY CONDENSING 3

3. PROPER CHIMNEY HEIGHT 4

4. PROPER VENT CONNECTOR PIPE/CHIMNEY CONNECTION 4

5. PROPER CHIMNEY BOTTOM LEVEL 5

6. TIGHT JOINTS 5

7. TIGHT CLEAN-OUT DOORS AND CONNECTIONS 5

8. NO INTERCONNECTED CHIMNEY FLUES 5
B. FLUE PIPE CLEARANCES, SIZING AND TYPE 5
C. DUCT WORK 7
D. OIL TANK AND PIPING 9
E. OIL FILTER 9
F. WIRING 9
G. INITIAL BURNER OPERATION 11
III. DEALER MAINTENANCE 12
A. TROUBLE SHOOTING 12
B. CAD CELL CHECKOUT PROCEDURE 17
C. CLEANING OR REPLACING FLUE PIPES 17
D. EXTENDED SHUT DOWN AND RESTART 17

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

I. 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

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, unless the required combustion air is taken from the exterior of the garage. Also, the furnace must be
located or protected to avoid physical damage by vehicles.

(ANSI/NFPA 70-1999, or latest edition).

????WARNING: 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:
Material 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:

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.

6. The area in which the furnace is located must have as adequate supply of air for combustion and draft control operation.
Open, non-partitioned basements, below grade utility rooms without storm windows, or rooms with loose access doors will
generally permit adequate air infiltration. However, if the furnace is located in an area of the building with tightly fitting doors
and windows, 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 if 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.

EXAMPLE: 100,000 BTUH input furnace requires "two" openings of 100 square inches each.

(Fig. 1A) (Fig. 1B)

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

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

If the "entire" building is unusually tightly constructed and/or has an exhaust fan installed, a low pressure zone could be created
within the structure. Air for combustion and draft control operation must be supplied from the outdoors or from spaces freely
communicating with the outdoors. Under these conditions, a permanent opening or openings having total free area of not less
than 1 square inch per 5,000 BTUH of the total input rating of all the appliances located in the same proximity of the furnace
should be provided. These openings must remain free and unobstructed.

Example: 100,000 BTUH input furnace plus a 40,000 BTUH input water heater require an opening or openings totaling 28
square inches of free area.

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.

II. INSTALLATION

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

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
Fireplaces, Vents, and Solid Fuel Burning Appliances (NFPA211-1996 or latest edition).

1. PROPER CHIMNEY SIZE:

The inside area of the chimney liner

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

r = radius of pipe
F = 3.1417
Flue Pipe Diameter = 6" [Radius of pipe = ½ diameter of pipe = ½ (6 in.) = 3in.]
F x 32 = 28 sq. in.

NOTE: This formula calculates the minimum
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
sizing.

should equal, at minimum, the area of the vent pipe exiting the furnace-

inside area of the chimney. If more than one appliance vent connector pipe is

comply with local codes and NFPA Standard for Chimneys,

(NFPA31-1997 or latest edition) Appendix E for proper liner

°F is required.

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

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, or
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 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

Should the previous recommendations and the information obtained from the ASHRAE Handbook fail to resolve a
condensation problem, another alternative to consider is power side wall venting. For more information, contact your Thermo
Pride representative or contact Thermo Products, LLC. at the address or phone number shown on the cover of this manual.

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

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.

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