Thermo Products OH11-105, OL39-320, OL33-200, OT5-85, OL20-151 User Manual

OIL FIRED FURNACE

INSTALLATION AND OPERATION MANUAL

WITH USERS INFORMATION SECTION

MODELS:

OC2-56 OL2-56 OH2-56
OC5-85 OL5-85 OH3-72

OL11-105 OH5-85

OT5-85 OL16-125 OH11-105
OT11-105 OL20-151 OH16-125

OT16-125 OL33-200
OL37-250
OL39-320

???? WARNING: IF THE INFORMATION IN THESE INSTRUCTIONS IS NOT FOLLOWED EXACTLY, A FIRE

OR EXPLOSION MAY RESULT CAUSING PROPERTY DAMAGE, PERSONAL INJURY, OR LOSS OF LIFE.

DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS AND LIQUIDS IN THE VICINITY OF
THIS OR ANY OTHER APPLIANCE.

???? WARNING: IMPROPER INSTALLATION, ADJUSTMENT, ALTERATION, SERVICE, OR MAINTENANCE

CAN CAUSE INJURY OR PROPERTY DAMAGE. REFER TO THIS MANUAL. FOR ASSISTANCE OR
ADDITIONAL INFORMATION CONSULT A QUALIFIED INSTALLER, OR SERVICE AGENCY.

PLEASE READ THESE INSTRUCTIONS PRIOR TO INSTALLATION, INITIAL FIRING, AND BEFORE
PERFORMING ANY SERVICE OR MAINTENANCE. THESE INSTRUCTIONS MUST BE LEFT WITH THE
USER AND SHOULD BE RETAINED FOR FUTURE REFERENCE BY QUALIFIED SERVICE PERSONNEL.

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

MO-100G
ECN 4385-MA

I. SAFETY SECTION

This page contains various warnings and cautions found throughout the Oil Furnace
Manual. Please read and comply with the statements below.

????WARNING AND CAUTIONS:

????WARNING: This furnace is not to be used as a construction heater. See Page 1.

???? CAUTION MUST BE TAKEN NOT TO EXCEED 90° ROTATION (OF THE FLUE

ELBOW) COUNTERCLOCKWISE FROM THE VERTICAL POSITION. See Page 2.

????WARNING: When cutting openings in the casing DO NOT CUT ANY SUPPORTING
CLIPS OR ANGLES. See Page 5.

????WARNING: The predetermined fan and limit locations on all of the Thermo Pride oil fired
furnaces have been tested and approved by Thermo Products, LLC. in conjunction with
Underwriters Laboratories, Inc. Any attempt to relocate these safety controls or replace these
safety controls with a control that is not approved, or is incompatible, may result in personal
injury, substantial property damage or death. See Page 6.

????WARNING: THE HEAT EXCHANGER MUST BE CLEANED BY A QUALIFIED
SERVICE PERSON. See Page 11.

????CAUTION: DO NOT ATTEMPT TO MAKE REPAIRS YOURSELF! See Page 13.

????WARNING: The area around the furnace should be kept free and clear of combustible

liquids and material, especially papers and rags. See Page 13.

????WARNING:

NEVER burn garbage or refuse in your furnace. Never try to ignite oil by

tossing burning papers or other material into your furnace. See Page 13.

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

See Page

13.

????CAUTION: DO NOT ATTEMPT TO START THE BURNER WHEN:

1. Excess oil has accumulated,

2. The furnace is full of vapors

3. The combustion chamber is very hot.
IF ONE OR MORE OF THESE CONDITIONS EXIST, CONTACT A QUALIFIED
SERVICE PERSON. See Page 13.

i

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

This page contains reproductions of the various instruction and warning labels placed on
the Thermo Pride Oil Furnaces. Please read and comply with the contents of these labels.

ii

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

TABLE OF CONTENTS
SECTION BEGINNING PAGE

I. SAFETY SECTION i
II. GENERAL INSTRUCTIONS 1

A. DRAFT REGULATORS 3
B. DUCT WORK/AIR CONDITIONING 3
C. FILTERS MOUNTED EXTERNAL TO FURNACE 4
D. FAN AND LIMIT POSITION AND LOCATION 6
E. BURNER INSTALLATION 6
F. HORIZONTAL FURNACE POSITIONS 8
G. EXTERNAL WIRE HARNESS LOCATIONS 8
H. BURNER SPECIFICATIONS AND APPLICATIONS 9
I. HEAT EXCHANGER CLEANING INSTRUCTIONS 11

III. USERS INFORMATION SECTION 12

A. OIL SUPPLY 12

B. COMBUSTION AIR SUPPLY 12

C. INSPECTION AREAS 13

D. STARTING THE BURNER 13

E. FILTER CLEANING AND LOCATIONS 13

APPENDIX – A REPLACEMENT PARTS LIST 16

APPENDIX – B WIRING DIAGRAMS 26

iii

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

II. GENERAL INSTRUCTIONS - READ BEFORE START OF INSTALLATION

1. The heating output capacity of the furnace proposed for installation should be based on a heat loss calculation
made according to the manuals provided by the Air Conditioning Contractors of America (ACCA) or the American
Society of Heating, Refrigeration and Air Conditioning Engineers, Inc. (ASHRAE).

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

(ANSI/NFPA 70-1999 or

latest edition).

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

4. A furnace installed in a residential garage must be installed so the burner and ignition source are located higher
than 18 inches above the floor, 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.

????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.

TYPE OF UNIT

LOWBOYS

HIGHBOYS

COUNTERFLOWS

TYPE OF UNIT

HORIZONTALS2

Notes: 1The above are abbreviated model numbers.

MINIMUM CLEARANCES TO COMBUSTIBLE MATERIALS

MODEL

1

NO.

FROM SIDES

OF FURNACE

FRONT

TOP &

SIDES OF

PLENUM

FROM THE

FLUE/VENT

REAR

OL2 1” 2” 1” 4” 1”

OL5,11,16 1” 24” 1” 6” 1”

OL20 1” 24” 1” 18” 1”

OL33,37,39 1” 24” 1” 18” 1”

OH3,11 1” 24” 1” 9” 1”

OH5 1” 24” 1” 6” 1”

OH16 1” 24” 1” 9” 1”

OH2 1” Note

3

2” 9” 1”
OC2 1” 4” 1” 6” 1”
OC5 1” 4” 1” 9” 1”

MODEL

NO.

FRONT TOP REAR BOTTOM FROM THE

1

FLUE/VENT

ANY SIDE

OF

PLENUM

OT5 24” 1” 1” 1” 4” 1”

OT11,16 24” 1” 1” 1” 9” 1”

2

Horizontal units are not approved for attic installation.

3

OH2 front clearance for 6” for Closet, 18” for Alcove.

1

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

The minimum clearances listed in the preceding table are for fire protection. Clearance for servicing the front of the
furnace and the rear of the lowboy models should be at least 24 inches. A clearance of 24 inches is recommended
for passage to all points on the furnace requiring service access.

The OH2-3-5-11-16 furnaces may be installed on combustible flooring. The OL2-5-11-16-20-33-37-39 and OC2-5
furnaces are to be installed on non-combustible flooring only. A non-combustible floor base is available for the
counterflow models OC2-5, which then allows these models to be adapted for installation on combustible flooring
(use non-combustible floor base Model No.125 for OC5, Model No 56 for OC2).

NOTE: The OH2 furnace is approved for closet installation. If the OH2 is installed in a closet, it requires two
openings in the closet door for combustion air, each having a minimum area of 162 sq. inches. This free area for the
OH2 intentionally exceeds the recommended minimum free area of 2 square inches per 1000 BTUH of input rate.

NOTE: When power venting a Thermo Pride oil fired furnace with a power venting system other than the system
supplied by Thermo Pride, a fiber chamber and an isolated combustion air kit (PVB or Beckett boot) is to be used
with the other manufacturers power venting system.

NOTE: On the front flue, lowboy, all highboy or counterflow models, it is possible to rotate the flue elbow (which is
factory installed for vertical discharge) 90° counterclockwise from the vertical position to adapt to various venting
systems. (See following page for details)

???? CAUTION MUST BE TAKEN NOT TO EXCEED 90° ROTATION (OF THE FLUE

ELBOW) COUNTERCLOCKWISE OR RIGHT FROM THE VERTICAL POSITION.

ROTATION OF FRONT FLUE ELBOW

When an installation requires that the flue exit out the left hand side casing on a front flue unit, remove screw
securing the 90 deg. elbow and rotate it 90° counterclockwise.
center point for the exit of the flue for the particular size furnace. Once the center has been located, use a scribe to
mark the hole size, listed in the chart, which corresponds with the furnace being used. Cut hole out and extend flue
through side casing.

A trim collar may be ordered from Thermo Products to hide the gap around the flue pipe. This trim collar, however,
is not required for operation.

Then, by following dimensions in Table 1, locate the

2

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

NOTE: ROTATION OF FLUE PIPE IS ONLY ALLOWED FOR LEFT HAND SIDE VENTING
APPLICATIONS.

TABLE 1: Suggested sizes and positions of flue pipe opening on left hand side of casing.

TRIM COLLAR/
UNIT DIA. HOLE “X” DIM. “Y” DIM. FLUE DIA. GASKET PART #

OC2 5-1/2” 3-5/8” 28-3/8” 5” 14121/330073
OC5 6-1/2” 4-3/4” 31-7/16” 6” 14131/330005
OH2 5-1/2” 3/5/8” 28-3/8” 5” 14121/330073
OH3 6-1/2” 4-9/16” 32-3/16” 6” 14131/330005
OH5 6-1/2” 4-3/4” 33-1/16” 6” 14131/330005
OH11 6-1/2” 4-3/4” 35-1/4” 6” 14131/330005
OH16 7-1/2” 4-5/16” 41-3/8” 7” 14132/330006
OL2* 5-1/2” 3-5/8” 28-5/16” 5” 14121/330073
OL5* 6-1/2” 4-5/8” 34-15/16” 6” 14131/330005
OL11* 6-1/2” 4-1/2” 37-5/8” 6” 14131/330005
OL16* 7-1/2” 4-1/2” 39-1/8” 7” 14132/330006
OL20* 7-1/2” 4-1/2” 43-1/4” 7” 14132/330006

* FRONT FLUE MODELS ONLY
“X” DIMENSION IS MEASURED FROM SEPARATOR PANEL.
“Y” DIMENSION IS MEASURED FROM THE BLOWER PAN ON “H” MODELS AND FROM THE BASE ON
“L” AND “C” MODELS.

Fig 1: Recommended location for drilling hole to connect

vent pipe to the furnace through the left hand side casing.

A. DRAFT REGULATORS:

A draft regulator is supplied with the furnace and should be installed according to the regulator manufacturers
recommendations. With the burner operating, use a draft gauge to adjust the regulator to the proper setting. (refer to
the instructions enclosed with draft regulator to adjust to the proper setting). When the burner air supply and draft are
properly adjusted, the overfire draft should be a negative (-).01" to (-).02" WC, as measured at the 5/16" overfire air
tap (See Fig. T). This tap is provided in the upper burner mounting plate. To measure the flue draft, punch a small
hole in the vent connector pipe as close to the furnace as possible and always before the draft regulator.

B. DUCT WORK/AIR CONDITIONING:

If the furnace is used in connection with summer air conditioning (cooling), the furnace should be installed parallel
with or on the upstream side of the evaporator coil to avoid condensation in the furnace heat exchanger. If the
cooling unit is installed with a parallel flow arrangement, dampers or other means used to control flow of air should
be provided to prevent chilled air from entering the furnace. If such a damper is manually operated, it must be
equipped with a means to prevent operation of either unit, unless the damper is in the full heat or cool position.

3

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

The duct system should again follow the current design standard of Air Conditioning Contractors of America
(ACCA) or ASHRAE Fundamentals

The most common location for the A-shaped coil (A style) is shown in Fig. 2.

Fig 2: Acceptable locations for the air conditioner evaporator coil.

NOTICE: The minimum coil pan clearance for a sectional or drum type heat exchanger is three inches unless

specified otherwise by the individual coil manufacturer.

A slab coil (H-style) is available for the horizontal air flow application on the OT5-11-16 furnaces refer to Fig. 3.

volume.

Fig. 3: An acceptable location for the air conditioner evaporator coil when used with a horizontal furnace.

To obtain proper airflow with an air conditioning coil installed on a belt drive unit, the motor and/or blower pulley
may need to be changed. On a direct drive unit, the blower motor speed may need to be changed depending upon the
size of the air conditioning system installed and the airflow resistance of the duct system.

NOTE: The horizontal units have direct drive blowers and no pulley or motor change is required.

C. FILTERS MOUNTED EXTERNAL TO THE FURNACE:

The filters of the OC2-5 mount in the return air plenum on the top opening on the top of the furnace. (For
installation detail, see figure 4).

Fig. 4: Air filter mounting location for the OC2-5 furnace.

4

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

On highboy furnaces, it is necessary to cut the return air opening in the side or rear casing, depending upon the
needs of the specific installation.

The filter rack provided with the furnace, refer to Fig. 5, will serve as a template to scribe a mark for the return air
opening on the casing. Place the filter rack on the casing one inch up from the bottom of the furnace and centered
from side to side. Place the securing flange against the casing when locating the return air opening.

Fig. 5: A typical filter rack and dimensions for the highboy furnaces.

PLEASE NOTE:

temporary means.

Position the open end of the filter rack so as to provide access for filter replacement. Once the filter rack is
positioned correctly, scribe a line along the inside of the securing flange on three of the sides. To scribe a line on the
fourth side (the open end), use the open end support as a guide.

Remove the filter rack and cut the return air opening in the casing. Now the filter rack can be anchored to the furnace
with screws or pop-rivets through the securing flange of the filter rack.

While scribing the return air opening, the filter rack can be held in position by tape or similar

????WARNING: When cutting openings in the casing DO NOT CUT ANY SUPPORTING
CLIPS OR ANGLES. Cut as close to the scribed line as possible, but do not cut the base clip or

blower pan support angle. (See Fig. 6).

Fig. 6: Cutaway view of fan section of a typical highboy furnace.

Connect the return air plenum to the filter rack and slide the filter into place. Dimensions for adapting the return air
plenum to the filter rack are provided on the bottom of the previous page.

5

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

D. FAN AND LIMIT POSITION AND LOCATION

????WARNING: The predetermined fan and limit locations on all of the Thermo Pride oil fired
furnaces have been tested and approved by Thermo Products, LLC. in conjunction with
Underwriters Laboratories, Inc. Any attempt to relocate these safety controls or replace these
safety controls with a control that is not approved, or is incompatible, may result in personal
injury, substantial property damage or death.

The units listed in the table below must have the fan and limit control installed at the time of unit installation. A
locating bracket is provided with each of the units below.

TABLE 2: Installation location of
the fan and limit control for each
furnace

Fig. 7: Fan and limit location for lowboys, horizontal units and highboys.

FAN & LIMIT LOCATION FOR HORIZONTAL UNITS WITH AIR CONDITIONING COIL:

The fan & limit control should be mounted between the H-coil cabinet and furnace. For distances from top of plenum
and furnace, see Fig. 7. IMPORTANT: Do not try to mount fan/limit in H-coil cabinet.

NOTE:

capacity of filtering down to a 10 micron particle. This is to assure the small diameter burner nozzles in the low
heating capacity furnaces are installed with a fine filter to help prevent nozzle clogging.

E. BURNER INSTALLATION:

NOTICE:

The OL2, OC2 and OH2 only, come standard with an oil filter packaged with the furnace. This filter has the

Remove all cardboard packing from around chamber before installing burner.

6