Thermo Products OPB 24, 30, 36- 80 User Manual
OUTDOOR COMBINATION OIL-FIRED
FURNACE AND AIR CONDITIONING UNIT
MODEL OPB (24,30,36)- 80
INSTALLATION AND SERVICE MANUAL
− Do not store or use gasoline or other flammable vapors and liquids in the
− WHAT TO DO IF YOU FIND AN OIL LEAK:
− Installation and service must be performed by a qualified installer, service
Please read these instructions prior to installation, initial firing, and before
performing any service or maintenance.
These instructions must be retained by the homeowner for future reference by
qualified heating contractor.
MO-455 North Judson, IN 46366
ECN 4979-MA Phone: (574) 896-2133 Made In USA
fire or explosion may result causing property damage, personal
injury, or loss of life.
vicinity of this or any other appliance.
• Do not try to light any appliance.
• Immediately call your oil supplier.
• If you cannot reach your oil supplier, call the fire department.
agency or the oil supplier. (These entities are referred to in these instructions
as a qualified heating contractor).
: If the information in this manual is not followed exactly, a
Thermo Products, LLC
PO Box 217
All installations and services must be performed by qualified service personnel.
Contents
SECTION PAGE
I. SAFETY INFORMATION .............................…………………………………….3
II. GENERAL INSTRUCTIONS ...........................................………………….…..9
III. GENERAL INSTALLATION .....................................................………………. 9
A. Codes and Clearances .......................................................……………. 10
B. Selection of Installation Location .........................................…………… 11
C. Venting Of Combustion Products ............................................………….13
D. Condensate Drain ....................................................................…………14
E. Oil Tank and Piping ..................................................................... ……... 15
F. Oil Filter .......................................................................................……… 17
G. Burner Specifications and Performance .......................................…….. 17
H. Airflow Requirements and Sizing of Ductwork ..............................…….. 19
I. Air Filters ......................................................................................…….. 23
1. Filter Installation ......................................................................…….. 23
2. Use of non-Thermo Pride Filters or Retention Means ..............……. 23
J. Electrical Wiring .............................................................................……. 24
1. Electronic Air Cleaner (EAC) and Humidifier Installation ..........…… 26
2. Thermostat Anticipator Setting.................................................…….. 28
3. Blower Motor Speed Selection .................................................……. 30
IV. STARTUP PROCEDURES.........................................................................……...31
A. HEATING SYSTEM
1. Initial Startup .............................................................................…….31
2. Adjustment of Burner Combustion .............................................…… 33
3. Adjustment of Heat Input Rate ...................................................…… 36
4. Setting Supply Air Temperature Rise .....................................……... 37
5. Checkout Procedure ................................................................…….. 38
B. COOLING SYSTEM
1. Initial Startup ......................................................................….……... 40
2. Definition of Subcooling.......................................................... ……... 41
3. Condenser Subcooling...........................................................………. 42
4. Definition of Superheat ..........................................................…….. 42
5. Evaporater Superheat ...........................................................…….. 43
V. INSTALLER'S INSTRUCTIONS TO USER ..........................................….. 44
1
All installations and services must be performed by qualified service personnel.
Contents
SECTION PAGE
VI. DEALER MAINTENANCE ................................................................ ……... 45
A. General Inspection ...................................................................... ……... 45
B. Heat Exchanger ........................................................................………. 46
1. Disassembly to Access Heat Exchanger ...............................……… 46
2. Heat Exchanger Reassembly................................................……… 48
3. Operational Check ..................................................................…….. 49
C. Electrical System ...........................................................................……. 49
D. Supply/Return Air Blower .............................................................……... 50
E. Supply/Return Air Filter ................................................................…….. 50
1. Filter Maintenance ...................................................................…….. 50
2. Filter Replacement ...................................................................……. 50
F. Extended Appliance Shutdown ....................................................……... 51
VII. HOMEOWNER/USER INFORMATION AND ROUTINE MAINTENANCE ..53
VIII. TROUBLESHOOTING .........................................................................…… 57
A. Heating System ................................................................................….. 57
B. Cooling System .................................................................................…. 58
IX. REFERENCES .......................................................................................…. 60
X. APPENDIX A: SOURCES FOR REFERENCED STANDARDS .............…. 61
XI. APPENDIX B: CALCULATIONS ...........................................................….. 62
XII. APPENDIX C: ELECTRICAL SCHEMATIC AND CONNECTION DIAGRAM
.................................................................................................................…. 74
XIII. APPENDIX D: SEQUENCE OF OPERATIONS ....................................….. 75
XIV. APPENDIX E: TROUBLESHOOTING FLOWCHARTS .........................….. 77
XV. APPENDIX F: SPECIFICATION SHEETS .............................................…. 86
XVI. APPENDIX G: REPLACEMENT PARTS ...............................................….. 87
XVII. APPENDIX H: OPB HEATING AND COOLING TEST FORM ...............…. 89
WARRANTY …………………………………………………………………….. 90
2
All installations and services must be performed by qualified service personnel.
I. SAFETY INFORMATION
This page and the following page contain reproductions of the various
instructions and warning labels placed on the Thermo Pride oil-fired appliances.
Please read and comply with the contents of these labels.
3
All installations and services must be performed by qualified service personnel.
4
All installations and services must be performed by qualified service personnel.
The following warnings and cautions are found throughout the Thermo Pride
Model OPB Installation and Service Manual. Please read and comply with the
statements below.
: IF YOU DO NOT FOLLOW THESE INSTRUCTIONS EXACTLY, A FIRE OR
EXPLOSION MAY RESULT CAUSING PROPERTY DAMAGE, PERSONAL INJURY,
OR LOSS OF LIFE.
: Carefully read and thoroughly understand the following guidelines and
warnings before continuing with the installation of this unit. 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.
: This unit is not to be used for temporary heating of buildings, or structures,
under construction.
: Maximum gross stack temperature must not exceed 550°F (288°C) under
any circumstances.
: Failure to comply with minimum filter installation requirements may effect the
performance and/or void the warranty on this unit.
: This appliance must be grounded in accordance with local codes or in the
absence of local codes with the National Electrical Code, ANSI/NFPA 70 –1999, or the
latest edition.
: Turn off the electrical power to the appliance before attempting to change
supply air blower speed wiring.
: Personal injury or property damage could result from repair, or service, of
this appliance by anyone other than a qualified heating contractor. The end user may
only perform the service described under the Homeowner/User Routine Maintenance
section of this manual.
: To avoid injury from moving parts or electrical shock, shut off the power to
the appliance before removing supply air blower compartment door and servicing this
appliance.
: When servicing controls, label all wires prior to disconnecting. Reconnect
any wires removed correctly. Wiring errors can cause improper and dangerous
operation. Dangerous operation can result in injury or damage.
: Disconnect electrical power before servicing this unit.
5
All installations and services must be performed by qualified service personnel.
: Waterproof type connectors must be used when connecting electrical power
and control wiring to the unit to prevent moisture from being drawn into the unit during
operation.
: Refrigerant is under pressure. Guard against refrigerant spraying into the
face or on skin. Always wear protective equipment, i.e. safety glasses or goggles and
gloves when working with refrigerant.
: Do not under any circumstances heat the refrigerant cylinder with a torch or
by any other means other than warm water. Excessive pressures generated in this
manner may weaken the refrigerant container and result in an explosion!
: To avoid injury from moving parts, or electrical shock, shut off the power to
the appliance before removing blower compartment door and servicing this appliance.
: When servicing controls, label all wires prior to disconnecting. Reconnect any
removed wires correctly. Wiring errors can cause improper and dangerous operation.
Dangerous operation can result in injury or damage.
: Do not use this appliance if any part has been under water. Immediately call
a qualified service technician to inspect the furnace and to replace any part of the
control system and any gas control that has been under water.
: The area around the appliance, including the top of the unit, must be kept
clear and free of combustible materials, gasoline, and other flammable vapors and
liquids.
: The appliance vent terminal may be hot. If the terminal is hot, allow it to cool
before touching it.
: Shut off unit and disconnect the power source before disassembling the unit.
: Never operate the appliance without clean air filters in place.
: This appliance requires air for combustion, ventilation, and cooling. Do not
block or obstruct air openings in the unit and the air space around the perimeter of the
unit.
: 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
1997, or the latest edition.
: Turn off power to furnace. Before the oil piping system is placed into
service, it must have been leak tested by a qualified heating contractor.
, NFPA 31-
6
All installations and services must be performed by qualified service personnel.
: For initial start-up of the appliance after installation, it may be necessary to
purge the air out of the oil line. A qualified heating contractor should do this.
: If you do not follow these instructions exactly, a fire or explosion may
result causing property damage, personal injury or loss of life.
damage may result.
procedures.
tossing burning papers or other material into the combustion chamber.
No. 2 distillate (domestic heating) fuel oil. Never use gasoline or a mixture of oil and
gasoline.
I : Do not attempt to make repairs yourself. Contact your local qualified heating
contractor.
the atmosphere through, and using only, the supplied vent terminal. Do not
attempt to attach a vent connector or a vent system to, or in place of, the supplied
vent terminal.
temperatures are 45°F or cooler.
: Do not run the oil pump dry for more than five minutes, as irreparable
: Before troubleshooting, familiarize yourself with the start up and check out
: Never burn garbage or refuse in this appliance. Never try to ignite oil by
: Oil-fired appliances produced by Thermo Products are designed for burning
: This appliance is designed to directly vent combustion products into
: Do not attempt to operate the cooling section on a day when outdoor
7
All installations and services must be performed by qualified service personnel.
: 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 a single, packaged, oil-fired furnace with air conditioner designed
for outdoor installation on either combustible or non-combustible materials. This
appliance is also approved for rooftop installation on combustible or non-combustible
roofing 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.
8
All installations and services must be performed by qualified service personnel.
II. GENERAL INSTRUCTIONS
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.
III. GENERAL INSTALLATION
: 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.
With exception of the vent terminal, this appliance is shipped completely assembled and
internally wired. All fuel oil and refrigerant piping, refrigerant charge, and electrical wiring
have been factory installed and inspected. At the time of installation, the unit will require
connection to electric power, fuel oil supply, condensate drain, and supply and return air
ductwork. In addition, the vent termination kit will need assembly. In the event of a
shortage of parts or damage, refer to the Dealer Receiving and Freight Claim
Procedure section of the Price Guide.
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.
9
All installations and services must be performed by qualified service personnel.
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. Oversizing should not exceed
125% 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 701996, 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, fire-retardant treated, or plastered.”
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.”
10
All installations and services must be performed by qualified service personnel.
5. Table 1 lists the required minimum clearances to combustible surfaces from
the outer surfaces of the appliance.
Table 1: Minimum Clearances to Combustible Materials
Model
No.
OPB - 3 3 3 0 3
The minimum clearances listed in Table 1 are for fire protection purposes
only. Adequate operational and service clearances must be maintained under
all circumstances. A minimum of 36 inches clearance around the
condenser coil should be maintained for adequate airflow to the unit. Any
overhanging material or construction must not block from above the
condenser fan and the vent terminal. The suggested minimum clearances
for servicing the front of the unit and to all points requiring access are at
least 24 inches.
Notice: Access panels for the return air filter and the blower motor are
located on the rear left-hand and right-hand sides of the unit,
respectively.
6. Install this unit outdoors only.
7. This appliance is approved for use as a forced air furnace with cooling unit.
8. This appliance has been designed for use with no. 2 distillate fuel (domestic
heating) oil.
B. Selection of Installation Location
1. The unit should not be placed in a position where it is directly exposed to
sunlight during the majority of the day. Inside corners on the southeast and
southwest sides of the structure should be avoided. Heat build-up due to
solar radiation in such corners would place an increased cooling load on the
unit. Shaded areas on the north side of the structure are preferred.
2. The unit must be located on a level, dry surface in an area, which is free and
protected from excessive drafts or wind. Mount the unit on a sturdy base at
least one inch above the ground or roof surface. A poured concrete slab, or
equivalent, is ideal. If concrete blocks or bricks are used, be sure to use welltamped gravel fill beneath the blocks or bricks to prevent settling.
Notice: Do not install the unit on any type of combustible base.
Top
(in.)
Side
(in.)
Rear
(in.)
Front
(in.)
Bottom
(in.)
Vent Terminal
(in.)
11
All installations and services must be performed by qualified service personnel.
The unit is manufactured with runner supports that raise the unit, about 1.25
inches above the mounting base, allowing air circulation beneath the metal
surfaces. This clearance helps to promote air circulation under the base that
allows the unit to be mounted on combustible materials. This clearance also
helps to reduce metal corrosion caused by a buildup of moisture under the
appliance.
3. The cooling system condenser must have an unrestricted supply of air for
efficient cooling.
4. The cooling system fan discharges air, upward through the top grill. For this
reason, this appliance should not be located under an overhang or any other
obstruction to airflow that would redirect the heated discharge air back into
the condenser. The appliance should be located as illustrated in Figure 1,
below.
Figure 1: Selection of Appliance Installation Location
12
All installations and services must be performed by qualified service personnel.
For proper and safe operation of this appliance, ensure that adequate
clearances around air openings into the burner compartment and the
condenser coil area are maintained. These openings are not to be blocked, or
restricted, in any manner.
5. Measures should be taken to prevent the entry of corrosive chemicals
or vapors to the combustion and ventilation air supply. Such chemicals
include, but are not limited to, chlorinated and/or fluorinated hydrocarbons.
These substances are found in refrigerants, aerosol propellants, dry cleaning
fluids, degreasers, and removers. Other harmful compounds may come from
acids, salts, bleaches, air fresheners, cements, and glues. Do not store or
use these chemicals for long periods of time in close proximity to this
appliance.
Vapors from such products can form corrosive compounds when burned in a
flame. These compounds promote rapid corrosion of the burner, combustion
chamber, heat exchanger, and the vent terminal. Rapid or excessive
corrosion will significantly reduce the useful life of the appliance.
6. Refer to the following section, Venting of Combustion Products, for
additional installation location restrictions.
C. Venting of Combustion Products
: This appliance is designed to directly vent combustion products
into the atmosphere through, and using only, the supplied vent terminal.
Do not attempt to attach a vent connector or a vent system to, or in place
of, the supplied vent terminal.
The appliance should be installed in a location such that heavy snow
accumulation will not excessively restrict the flow of flue (combustion) products
from the unit. The vent terminal should not be located in a position where ice
buildup could block the discharge of flue products. If these conditions occur, the
performance of the heating system will be adversely affected.
Choose an installation location where the vent terminal does not discharge over
sidewalks, walkways, and patios. These areas may become slippery when
wetted by water vapor in the flue products.
Combustion products must not be allowed to accumulate within a confined space
and recirculate back into the combustion system. Recirculation of combustion
products promotes poor combustion. In severe cases, it may lead to sooting of
the combustion chamber and heat exchanger, or to nuisance shutdowns of the
heating system.
13
All installations and services must be performed by qualified service personnel.
In addition, long term exposure of building materials to combustion products may
cause discoloration of material surfaces and corrosion or degradation of
materials. The preferred installation location will allow combustion products to
freely escape the immediate area of the appliance and rapidly disperse into the
atmosphere, without being drawn back into the appliance or a nearby structure.
To prevent combustion products from entering a structure, the vent terminal must
expel combustion products away from any point of entry. The minimum
acceptable distances from the vent terminal to points of entry to a building are 4
feet horizontally from, and 1 foot above, or at least 4 feet below, any window,
door, or gravity air inlet into the building. And, 3 feet or more above any forced
air inlet to the building located within 10 feet of the terminal.
Once the unit is installed in a suitable location, the installer must mount the vent
terminal to the appliance. Two sheet metal screws are installed in the unit for this
purpose. Refer to Figure 2 for a sketch of the correctly assembled vent terminal.
D. Condensate Drain
This appliance is equipped with a ¾ inch PVC stubbed drain extension for
connection of a condensate line to the evaporator drain pan. A condensate
removal line should be fabricated and attached to the PVC drain extension, refer
to Figure 3. The condensate drain line must be pitched downward to drain
properly. The drain line can also be trapped and the condensate pumped to a
suitable drain. If the drain line clogs, when the air conditioner is operating, the
condensate tray under the evaporator coil will fill with water. As a result, water
may enter the appliance housing and the supply air ductwork to the structure.
FIGURE 2: Vent Terminal Mounting Position
14
All installations and services must be performed by qualified service personnel.
Figure 3: Installation of a Condensate Drainage Line on the Evaporator Coil
Condensate from the evaporator is non-corrosive and may be disposed of in any
appropriate manner. The drain connection should be sealed at the appliance
housing to prevent air leakage from the supply air system. Pipe sealant should
be used sparingly on all male pipe threads. Always consult and conform to the
requirements of local plumbing codes.
E. 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.
15
All installations and services must be performed by qualified service personnel.
5. A readily accessible, design-certified, manual oil shutoff valve, with a nondisplaceable rotor member, shall be installed in the fuel oil supply piping
within 6 feet of the appliance.
6. A pipe union, or flanged connection, shall be provided downstream from
the manual oil shutoff valve to permit removal of the appliance oil pump.
Pipe unions must be the ground joint type or flanged-jointed using a
gasket resistant to the corrosive action of fuel oils.
7. Pipe dope or thread sealant design-certified to be resistant to the action of
fuel oils should be used on all threaded joints. Thread sealant should only
be applied to the male member of a joint. The first two threads on the end
of the male member of each pipe joint should be clean and free from
thread sealant.
8. Connection of the oil supply piping to the appliance should be made from
the left-hand side of the burner, facing the burner compartment cover.
9. When tubing is to be used for fuel oil supply lines, use of continuous runs
of heavy wall copper tubing is recommended. Avoid running tubing
against any type of heating unit and across ceiling or floor joists. If
possible, install the tubing under the floor.
10. Where tubing is used for fuel oil supply lines, insure the tubing contains no
kinks, sharp bends, or collapsed regions where the inside cross-sectional
area of the tube is greatly reduced. These will excessively reduce the flow
of oil.
11. Flared fittings should be used at all tube joints, when tubing is used for
fuel supply lines. Do not use compression fittings. Avoid the use of
tube fittings in inaccessible locations.
Burners are equipped with a single-stage, fuel pump. This type of fuel pump,
when connected with a supply line only, is satisfactory where the fuel supply is
level with, or above the burner thus permitting gravity flow of oil to the burner. If
the tank is above the burner, and gravity oil feed to the burner is permitted, a
single line system may be used. The line should have a gradual slope downward
of approximately 1/2 inch per foot, or more, from the tank to a point directly below
where it is connected to the pump. Pitching the line upward toward the tank will
help prevent the formation of air pockets in the line.
NOTICE: An oil safety valve or a delayed-action, solenoid valve should be
installed in the oil supply line of all gravity-fed systems.
16
All installations and services must be performed by qualified service personnel.
When the oil tank is located below the level of the burner, it is necessary to “lift”
the oil to the burner. A return line should be connected between the fuel pump
and tank. This requires insertion of the "by-pass" plug into the fuel pump. If the lift
(vertical distance between the supply line inlet and the burner) exceeds
approximately 10 feet, a two-stage pump should be installed with a return line.
When a return line is used with either single or two-stage pumps, in-line air is
automatically returned to the tank, making the oil pump and lines self-purging.
Underground tanks should be located outside the building. Installation of above
ground tanks is permitted inside buildings, under certain conditions, as well as
outside. Consult the Standard for Installation of Oil-Burning Equipment for
restrictions. If permitted, connect the burner oil supply line near the base of the
tank, opposite of the fill end. Connection at this point tends to flush older oil
through and out of the tank. This helps to prevent the accumulation of rainwater
and condensed water vapor in the tank, which can cause the tank to corrode.
If the oil supplier does not already use oil additives, it is recommended that
additives be used to emulsify any water accumulation in the oil.
F. Oil Filter
It is strongly recommended that an oil filter assembly be installed in the oil supply
line to the unit. The OPB has been shipped with a pre-mounted oil filter. Should
the filter need to be changed, replace with a similar or better filter with the
capacity to trap a 40-50 micron particle.
The filter cartridge should be replaced at least once a year. The filter body should
be thoroughly cleaned before installing a new cartridge.
G. Burner Specifications And Performance
The model OPB has been factory equipped with the Beckett AFG oil burner. A
.60 gal. X 80° A nozzle has been factory installed to provide low-fire operation.
Table 2 gives the burner specifications, estimated input/output performance and
the required nozzle size for high-fire operation.
Note: High-fire nozzle is not included with OPB.
17
All installations and services must be performed by qualified service personnel.
Table 2: Burner Specifications and High and Low Fire Heating Performance
Heating
Mode
Oil Pump
Pressure
(PSIG)
High Fire 130
Low Fire 120
* Based on #2 fuel (domestic heating) oil having higher heating value of 140,000
** Based on an assumed steady state, thermal efficiency of 80%.
For more specific burner information, consult the Model AFG Oil Burner
Instruction Manual or contact Thermo Products, LLC. P.O. Box 217, North
Judson, IN 46366. Phone no. 574-896-2133.
Oil
Flowrate @
Nozzle
(GPH)
2
0.75
1
0.6
BTU per gallon.
1
Factory installed.
2
Provided by installer.
Heat Input
Rate*
(BTUH)
Heat
Output
Rate**
(BTUH)
105,000 85,000
85,000 67,000
Burner Model
Number
Air Tube
Combination
AFG-TP1502 AF42 BNHSSS
Nozzle
Type
Simplex, 80
deg., hollow
cone
18
All installations and services must be performed by qualified service personnel.
H. 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 0.4 in. W.G. This is
equivalent to .2 in. W.G. supply and .2 in. W.G. return pressure drops.
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.
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 air flowrate (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 Example 1, in Appendix B: Calculations of this manual, for a
sample calculation of how to determine the required minimum air flowrate.
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.
19
All installations and services must be performed by qualified service personnel.
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 outside the building 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, exposure to
sunlight, 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 flowrate for each branch of the supply and return
air systems. The total air flowrate, by adding the air flowrate of each
branch of the supply system, must equal the minimum required air
flowrate (refer to part 3, above). Likewise, the air flowrate of each of the
branches of the return air system must sum to the required minimum
flowrate.
g. Using the selected air flowrates 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.
(Chapter 32 of the ASHRAE Handbook – Fundamentals
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 flowrate.
is an excellent
20
All installations and services must be performed by qualified service personnel.
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 flowrates 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, in Appendix B: Calculations of this manual, 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 air flowrate 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 flowrate at the desired
pressure drop.
21
All installations and services must be performed by qualified service personnel.
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. The insulation system
should be carefully selected and installed to minimize water and moisture
absorption by the insulation.
22
All installations and services must be performed by qualified service personnel.
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.
I. Air Filters
1. Filter Installation
This OPB unit has been factory supplied with a high quality, re-usable filter
rated for air velocities up to 600 ft/min.
2. Use of non-Thermo Pride Filters or Retention Means
: 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 Thermo Pride filter racks is selected for retention of the
filter and/or use of a different filter type is desired, refer to Table 4 for
minimum sizing guidelines for selecting filter for the unit.
Table 4: Minimum Required Filter Area (in square inches)
Filter Type
*Thermo Products
Supplied
Permanent
Standard
Permanent
Disposable 300 384 480 576
∗ 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.
Maximum
Air Velocity
(ft/min)
600
500 230 288 346
OPB24 OPB30 OPB36
Model Number
192
240
288
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All installations and services must be performed by qualified service personnel.
J. Electrical Wiring
: This appliance must be grounded in accordance with local
codes, or in the absence of local codes, with the National Electrical Code,
ANSI/NFPA 70-1999, or the latest edition.
: Waterproof type connectors must be used when connecting
electrical power and control wiring to the unit to prevent moisture from
being drawn into the unit during operation.
All wiring must conform to the provisions of local codes or, in the absence of local
codes, with the provisions of the National Electrical Code, ANSI/NFPA 70-1999,
or the latest edition, and this instruction manual.
This appliance requires 208-240 VAC, 60 Hz, single-phase power. Refer to Table
5 for typical electrical current draws of the individual appliance motors,
recommended sizes for over-current and short circuit devices, and minimum
recommended field wiring sizes. Electrical service must be brought to the unit
from a circuit breaker, or fused disconnect switch, in accordance with local
codes. The disconnecting switch must be located reasonably close to and within
sight of the unit.
Three-wire service, two “hot” leads (L1 and L2) and a neutral (N), plus a ground
conductor, is required. Connect power to the appliance control system at the
junction box in the burner compartment. (A knockout fitting is provided on the
exterior of the burner compartment for this purpose.) A ground wire must be
connected to the grounding lug, or screw, marked “Equipment Ground”, in the
junction box.
Field wiring of power circuits to the appliance should consist of copper
conductors rated for at least 240 VAC with an insulation temperature rating of at
least 75°C temperature rise. Depending upon code requirements, rigid or flexible
conduit is recommended, and may be required. Connect the electric power
supply as shown in the wiring diagram located on the inside of the burner
compartment cover, or in this manual. The cooling system operates on 208-240
VAC electric power, from supply wires L1 and L2. The heating system operates
on 120 VAC electric power, from supply wires L1 and N.
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All installations and services must be performed by qualified service personnel.
Typically, control wiring between the outdoor appliance and the indoor
thermostat, and if used, electronic air cleaner or humidifier, will be required. Field
wiring of control circuits should consist of copper conductors rated for at least
240 VAC with an insulation temperature rating conforming to Type T wire, 35°C
temperature rise. Depending upon code requirements, rigid or flexible conduit is
recommended, and may be required. Make connections between the thermostat,
and electronic air cleaner or humidifier (if used), and the fan control module,
inside the burner compartment. Consult the wiring diagram for the appropriate
connection points on the thermostat and the fan control module.
Table 5: Typical Electrical Requirements for Various OPB Models
Oil
Compressor
Potential/Frequency
Model
OPB24 15 58.3 40 30 10
OPB30 14.3 64 40 30 10
OPB36 18.6 79 50 35 8
/No. of Phases
(V/Hz/Ph)
Running
Load
Current
(Amps) @
200 VAC
Compressor
Locked
Rotor
Current
(Amps) @
200 VAC
Condenser
Fan Full
Load
Current
(Amps) @
200 VAC
Supply/Retur
n Air Blower
Full Load
Current
(Amps) @
115 VAC
9.6 5.8208-240/60/1 0.8
Burner
Assembly
Full Load
Current
(Amps)
@ 115
VAC
Maxi mum
Time Delay
Type Fuse
or Inverse
Time Circuit
Breaker
Size (Amps)
Recommend
ed Time
Delay Type
Fuse or
Inverse Time
Circuit
Breaker Size
(Amps)
Mi ni mum
Recommended
75 deg. C.
Copper Power
Wiring Size
(AWG)
Wire size selections in Table 5 are based upon Table 310-16 of the National
Electrical Code for three copper conductors, with insulation rated for 75 degrees
Celsius, contained in raceway at 30 degrees Celsius. For other wire insulation
temperature ratings and ambient conditions, refer to the National Electrical Code
for the minimum wire sizing requirements.
NOTICE: Before the unit is started, the installer and/or electrician must
check the following items.
1. Check every electrical connection of “push-on” or “screw-on” type terminals to
ensure that all wires and wire connectors are firmly secured. A loose terminal
can cause poor flow of electrical power to motors and to the refrigeration
compressor. This may result in very high current draws by these components.
If great enough, high current draw will cause blown fuses, burned wires and
contactor points, and pre-mature motor or compressor failure. Each electrical
connection has been factory checked, however, connections may loosen, due
to vibration, while the appliance is in transit. Please be certain that all
electrical connections remain tight.
2. Review wiring diagram for proper routing and connection of all field wiring.
25
All installations and services must be performed by qualified service personnel.
3. All wiring sizes must comply with local codes or the National Electrical Code.
To minimize voltage drop to the appliance, the next larger size wire should be
used when long wiring runs, in excess of 100 ft., are employed. Refer to the
wiring diagrams when wiring or servicing.
NOTICE: Proper operation of the heating section of this unit depends upon
correctly connecting the electrical power source. The hot leg, L1, of the
supply circuit must be connected to the black line lead and the neutral leg,
N, to the white line lead in the burner compartment junction box. All
ungrounded circuit conductors must be broken by the disconnecting
switch to prevent the hazard of electrical shock when servicing this
appliance.
In the event a circuit breaker trips or a fuse blows as a result of the operation of
this appliance, investigate the appliance electrical system to determine the
cause. Correct any electrical faults and abnormal conditions before putting the
unit back into operation. Do not put in a larger fuse and do not exceed
maximum fuse size listed on the rating label in order to temporarily “fix”
the problem. The rating label is located on the inside of the burner compartment
cover.
The appliance control system contains a 15 amp. circuit breaker to protect
the heating system control circuitry. The control fuse is located within the
junction box, which is located in the burner compartment. In the event of a main
circuit breaker trip, this may need to be reset as well.
1. Electronic Air Cleaner (EAC) and Humidifier Installation
The fan timer on this unit has designated terminals to control the operation of
an electronic air cleaner and/or humidifier. These terminals provide line
voltage for the control of these accessories, refer to Figure 4.
Connection between EAC and N6 provides a switched 115 vac to power an
electronic fan cleaner.
The same switched 115 vac is available between Fan and N7 and may be
used in conjunction with a humidistat to control a humidifier.
These terminals are energized whenever the blower is active.
26
All installations and services must be performed by qualified service personnel.
Figure 4: The Fan Control Module
NOTICE: It is important to confirm that the operating voltage of the
humidifier or EAC being installed matches the output of this control. If
not, a field supplied relay or transformer may be necessary to provide
the proper control and supply voltage for the accessory being installed.
Refer to the manufacturer’s instructions for the humidifier or EAC for
additional information.
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