Thermo Products OMC-70, GMC-85 User Manual

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: [phone]

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.

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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

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

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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.”

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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
FRONT
BACK
SIDES
ROOF JACK
VENT CONNECTOR
TOP
PLENUM SIDES
TOP AND SIDES OF DUCT
BOTTOM OF DUCT

CLOSET ALCOVE

6”
0”
0”
0”
6”
1”
1”
1”
1”

18”

0”
0”
0”
6”
1”
1”
1”
1”

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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

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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.

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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.

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

Combustible Floor Base
Model: 70-BASE

Figure 1A.

Cottage Base
Model: 01COT-BASE

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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).

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