Thermo Pride OL6RA072DV5(B/R) - Manuals

3 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 Informatio...

4 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.” : Carefully read and thoroughly understand the following guidelines and warni...

5 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 He...

6 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 comply with local codes and NFPA Standard for Chimneys, Fireplaces,...

8 5. PROPER CHIMNEY BOTTOM LEVEL: In cases where the chimney extends to the basement floor, the draft can usually be improved by filling the base of the chimney with sand to within 12 inches of the vent connector pipe after relocating the clean-out door. (See Fig. 5). Fig. 5: Suggested method to imp...

9 Fig. 7: Alternate constructions that allow reduced clearances to combustible materials. REDUCTION OF CLEARANCES WITH SPECIFIED FORMS OF PROTECTION: Type of protection applied to and covering all surfaces of combustible material within the distance specified as the required clearance with no protec...

10 NOTE: On the OL6 it is possible to rotate the flue elbow (which is factory installed for vertical discharge) 90° counter clockwise from the vertical position to adapt to various venting systems. Notice : Blocked Vent Switch Installation The blocked vent switch kit must be installed to comply with...

11 to (-).02" WC, as measured at the 5/16" over fire air tap (See Fig. 12). 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. Note: Draft...

13 The ASHRAE Handbook – Fundamentals is an excellent 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 flow rate. h. The resis...

14 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...

15 E. Air Filters Mounted Internal to Furnace: Fig. 10: Internal filter rack. : 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 internal Thermo Pride filter rack is selected for retention of the ...

16 F. LIMIT POSITION AND LOCATION c WARNING: The predetermined limit locations on all of the Thermo Pride oil fired furnaces have been tested and approved by Thermo Products, LLC. Any attempt to relocate these safety controls or replace these safety controls with a control that is not approved, or i...

18 H. BURNER SPECIFICATIONS AND APPLICATIONS: FURNACE MODEL THERMO PRIDE’S BURNER SPEC NO. * INS BECKETT BURNER MODEL & TUBE LENGTH HEAD STATIC PLATE MAXIMUM NOZZLE SIZE** SHIPPED NOZZLE SIZE OIL PUMP PRESSURE (PSIG) OL6*A072D**B TP2501 N AFG-4.5” F3 3-5/8 0.75X80 ° H 0.60X80 ° H 120 The optiona...

20 MOUNTING THE 2-STAGE RIELLO BURNER: It is necessary that the insulation gasket be placed between the mounting plate and the burner flange. The insulating gasket has six holes, which, if necessary, can be modified as shown. (see figure 14-1) Figure 14-1: Burner gasket and mounting Figure 14-2: Bur...

21 5. A readily accessible, design-certified, manual oil shutoff valve, with a non-displaceable 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 per...

22 J. OIL FILTER: It is strongly recommended that an oil filter assembly be installed in the oil supply line to the unit. This filter should have 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 b...

23 Wire size selections in Table 10 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 Na...

24 Figure 15: 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 acce...

25 Figure 16: Heat Anticipator Adjustment Scale In many cases, this setting can be found in the thermostat installation instructions. If this information is not available, or if the correct setting is questioned, the following procedures should be followed: Preferred method of adjustment: Using an a...

26 This formula can be used to calculate the correct setting for the adjustable heat anticipator: Ammeter reading = Anticipator Setting. No. of wire loops Or in this case, _2.5 A. = 0.25 A. (Anticipator Setting) 10 4. Adjust the position of the anticipator indicator to match the calculated ammeter s...

27 Heating Speed Set-ups OL6*A072DV5 Furnace Motor Current Draw (Amps/ / Watts) vs. External Static Pressure (in W.C.) Low Fire Med Fire High Fire BTUH 60,000 72,000 90,000 Fan Control SW 1 Switch Settings Heating CFM Aprox. Rise (F 0 ) Aprox. Rise (F 0 ) Aprox. Rise (F 0 ) 0.2 0.4 0.6 3-OFF 2-OFF 1...

28 Heating Speed Set-ups ( 2 – Stage ) OL6*X072DV5 LOW CAPACITY HIGH CAPACITY BTUH LOW FIRE 60,000 HI FIRE 72,000 LOW FIRE 72,000 HI FIRE 90,000 FAN CONTROL SW 1 SWITCH SETTINGS HEATING CFM APPROX. CFM/RISE (ºF) AMPS/WATTS APPROX. CFM/RISE (ºF) AMPS/WATTS APPROX. CFM/RISE (ºF) AMPS/WATTS APPROX. CFM...

31 Speed vs. color code for PSC Motor: Low = Orange Med-Low = Red Med= Blue Med-High = Yellow High = Black M. BLOWER CONTROLLER INFORMATION FOR PSC MOTOR (Note: for ECM blower controller information see: ECM Operation Manual document # Mo-440) TERMINAL DEFINITIONS & FIELD WIRING Burner Harness C...

34 Heat Mode When a call for heat (“W”) is received from the thermostat, if the “Cool” mode is not already active, the “T-T” terminal is energized and the blower on delay is started. The on-off pattern of DIP switch SW2 (positions 1 and 2) select one of four blower on delay values (see Table 11). Wh...

35 PSC TROUBLE SHOOTING DIAGNOSTIC FEATURES The control board is equipped with 4 green Input Status LEDs and 1 red Board Status LED. These are intended to provide a quick view into furnace performance without requiring a voltmeter. The green Input Status LEDs are driven by the “Y”, “W”, “G”, and “DE...

36 N. STARTUP PROCEDURES: A. Heating System 1. Initial Startup: : 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. : For initial start-up of the appliance after installation, it may be necessary to purge ...

38 Figure 19: Preliminary Adjustment of Burner Air Band and Air Shutter i. When ignition is established, make a preliminary burner air adjustment to attain a clean combustion flame. Generally, the burner bulk air band should be about 3/16 inch open and the opening of the burner air shutter set in th...

39 The setting of the fan output according to the installation should be done only through the air damper. Should you want to adjust the setting of the combustion head, with the burner running, turn the rod (1) with a 6mm wrench (2) as follows: TURN TO THE RIGHT: (SIGN + ) In order to increase the v...

40 Figure 22 1 st STAGE ADJUSTMENT: Adjustment of air shutter: place the small plug (9) of the economizer (10) into the position I (Item A). In this way the burner will remain permanently in the 1 st stage. Loosen the nut (2), turn the screw (3) until the air shutter (1) reaches the position desired...

42 a. With the oil shut off, remove the 1/8 in. NPT threaded pipe plug located on the lower rear side of the oil pump, refer to Figure 22. Attach a pressure gage, capable of measuring pressure in pounds per square inch gage, PSIG, in this opening, on the discharge side, of the oil pump. NOTICE: It m...

43 5. Checkout Procedure: Before any system of oil piping is finally put into service, it shall be carefully tested to assure that it is “gas-tight”, as indicated in the Heating System Initial Startup section of this manual. NOTICE: All controls on the unit should be checked for proper functioning p...

44 III. USERS INFORMATION SECTION A. OIL SUPPLY: Do not allow the fuel tank to run completely empty. During the summer, keep the tank full to prevent condensation of moisture on the inside surface of the tank. If the fuel tank runs completely dry, it may be necessary to purge the lines of trapped ai...

45 D. STARTING THE BURNER: 1. Turn the main service switch to "OFF" position. 2. Set thermostat substantially above room temperature. 3. Open shut-off valves in oil supply line to burner. 4. Turn service switch to furnace "ON". If burner starts and runs, but stops again on lockout, i...

46 IV. INSTALLER'S INSTRUCTIONS TO USER: After completing the installation, the installer shall inform and/or demonstrate to the homeowner the following items: 1. The location of these instructions. The instructions must be kept along with instructions for any accessories in the plastic pouch with t...

48 B. HEAT EXCHANGER: c WARNING: A qualified heating contractor must clean the heat exchanger. At least once a year, inspect the heat exchanger for evidence of corrosion, pitting, warpage, deterioration, and carbon (soot) build-up. A layer of soot on the inside of the heat exchanger will act as an i...

49 Figure 24: Heat Exchanger Clean-Outs Vacuum Hose Length OL6 8FT Fig. 25: Recommended method and device for cleaning inside of heat exchanger.

50 4. Operational Check: c CAUTION: Before troubleshooting, familiarize yourself with the start up and check out procedures NOTICE: After reassembling the appliance, check for fuel oil leakage from the supply piping. a. Check proper operation of the ignition system and for proper combustion. b. Obse...

51 Figure 26: Location of Supply/Return Air Filters Filter replacement: To ensure an adequate replacement filter is selected, should the filter require replacing, refer to Table 4, in Air Filters section of this manual, for the minimum filter areas required for different types of available filters. ...

52 3. Fill the oil tank to reduce water condensation in the tank. 4. If the shutdown period will exceed one heating season, an oil stabilizer should be added to the oil tank. Consult your oil supplier for recommendations. ON STARTUP: 1. Have system inspected and started by a qualified heating contra...

53 VI. HOMEOWNER/USER INFORMATION AND ROUTINE MAINTENANCE: c WARNING: Never burn garbage or refuse in this appliance. Never try to ignite oil by tossing burning papers or other material into the combustion chamber. c WARNING: Oil-fired appliances produced by Thermo Products are designed for burning ...

55 VII. TROUBLESHOOTING: THIS SECTION IS ONLY TO BE PERFORMED BY TRAINED, QUALIFIED SERVICE PERSONNEL, AND NOT BY THE FURNACE OWNER. NOTICE: Before troubleshooting, familiarize yourself with the Initial Startup, Checkout Procedure, and Troubleshooting Flowchart. Refer to the appendices of this manua...

65 Appendix – A Replacement Parts: Replacement Parts for OL6F*072D**