Page 2 - CONTENTS
i CONTENTS SECTION PAGE I. SAFETY SECTION 1 A. CODES AND CLEARANCES 3 B. MAKE-UP AIR 4 II. GENERAL INSTRUCTIONS 5 A. CHIMNEY 6 B. VENTING 10 C. DRAFT REGULATORS 11 D. DUCT WORK/AIR CONDITIONING 11 E. AIR FILTER(S) 15 F. LIMIT POSITION AND LOCATION 17 G. BURNER INSTALLATION 18 H. BURNER SPECIFICATION...
Page 3 - ii; Model Number Digit
ii Model Number Digit 1 2 3 4 5 6 7 8 9 10 11 12 Fue l Configur a tion Heat E xch an g e r Ide n tifie r Flue F eat u re Cap acit y Cap acit y Cap acit y Blowe r Ty p e Clg Airflow C a p. Clg Airflow C a p. Burner Oil Furnace Model Nomenclature Example Model Numbers O H 6 F A 0 7 2 D 4 8 B O H 6 F A...
Page 4 - This furnace is not to be used as a construction heater.; WARNING: DO NOT START BURNER UNLESS BLOWER DOOR IS SECURED IN
1 I. SAFETY SECTION This page and the following contains various warnings and cautions found throughout the Oil Furnace Manual. Please read and comply with the statements below. χ WARNING AND CAUTIONS: χ WARNING: This furnace is not to be used as a construction heater. See Page 3 χ WARNING: The pred...
Page 6 - explained in the; Homeowner/User Information and Routine Maintenance; section of this manual.; Combustible material:
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...
Page 7 - Airflow Requirements and Sizing of; Airflow Requirements and Sizing of Ductwork; THESE OPENINGS MUST BE FREE AND UNOBSTRUCTED.
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...
Page 8 - Combustible Material:; Table 1: MINIMUM CLEARANCES TO COMBUSTIBLE MATERIALS; FRONT; Note
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...
Page 9 - The; inside area of the chimney liner; should equal, at minimum, the area of the vent pipe exiting the; minimum; inside area of the chimney. If more than one appliance vent
6 A. CHIMNEY : The furnace must be connected to an adequate chimney or an approved vent in accordance with these instructions. An adequate chimney is one that is sealed and lined with the capability of producing a (-).04" WC flue draft and having the capacity to handle the amount of stack gases ...
Page 11 - Fig. 4: Proper insertion of the vent connector in the chimney.
8 Fig. 4: Proper insertion of the vent connector in the chimney. 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 th...
Page 12 - REDUCTION OF CLEARANCES WITH SPECIFIED FORMS OF PROTECTION:; in each direction to make C equal to A.
9 Fig. 6: Suggested method to accommodate vent connector passage through a wall composed of a combustible material. 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 co...
Page 13 - Notice; : Blocked Vent Switch Installation; CAUTION MUST BE TAKEN NOT TO EXCEED 90°; Table 2: Sidewall vent kits; Beckett AFG
10 The vent connector pipe between the furnace and chimney shall be of equal diameter as the flue outlet of the furnace. The vent connector pipe must be made of 24 gauge (or thicker) corrosion-resistant steel. The vent connector pipe should be as short as possible and installed so that it has a cont...
Page 14 - Note: Do not use with Direct Vent application.; unless specified otherwise by the individual coil manufacturer.
11 The side wall vent may be installed either through the knock-out on the right or left side casing of the unit or vertically out the top opening of the vestibule. The combustion air inlet can be installed through the either the lower left side casing knockout or the lower right side casing knockou...
Page 15 - Airflow Requirements and Sizing of Duct Work:; This furnace has been designed to; steady state operation and a 50° to 80° temperature rise.
12 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 Engine...
Page 16 - this method for sizing the supply side ductwork for a
13 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 flow rate for each branch of the supply and return air systems. The total airflow rate, by adding the airflow rate of each br...
Page 17 - RETURN AIR DUCT SYSTEM; should equal the warm air duct system in airflow capabilities.
14 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,...
Page 18 - E. Air Filter Mounted External to Furnace:; On; highboy
15 SIZING THE DUCT WORK FOR A COMBINATION HEATING AND COOLING SYSTEM: Two formulas must be used in determining the CFM requirements of a combustion heating and cooling system. 1. HEATING CFM: HEAT OUTPUT OF FURNACE (BTUH) 1.1 X TR (TEMPERATURE RISE, °F) = HEATING(CFM) EXAMPLES: A. 110,000 BTUH OUTPU...
Page 19 - performance and/or void the warranty on this unit.
16 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 (See Fig. 10a & 10b). Fig. 10a: A typical filter rack and dimensions for the OH6 furnace. Fig. 10b: A typical filter rack and dimensi...
Page 20 - Model Number; Disposable
17 Filter Type MaximumAir Velocity(ft/min) Model Number OH6 OH8 *Thermo Products Supplied Permanent 600 384 in² 480 in² Standard Permanent 500 461 in² 576 in² Disposable 300 768 in² 960 in² Table 4: Minimum Required Filter Area (in square inches) * The Thermo Products supplied filter can be cut to s...
Page 22 - DO NOT CHANGE POSITION OF THE CHAMBER!; H. BURNER SPECIFICATIONS AND APPLICATIONS:; Table 6: Beckett & Riello burners specifications; For more specific burner information, contact:
19 Fig. 13: Burner insertion illustration (Top view) When mounting the burner, the mounting plate (Fig. 12) must be removed to provide access to the area in front of the combustion chamber. A fiber insulating sleeve or amulet is provided on the burner tube of specific Thermo Pride burners.(see Fig. ...
Page 23 - Table 7: Oil nozzle capacity; BURNER G5D; Table 8: Riello burner application; OIL NOZZLE CAPACITY CHART
20 Table 7: Oil nozzle capacity All rates shown achieved with 120 PSIG pump pressure for Beckett and 140 PSIG pump pressure for Riello. * Based on #2 domestic heating fuel oil having heating value of 140,000 BTU per gallon. ** Based on thermal efficiency of 84%-85%. Riello 2-stage burner specificati...
Page 25 - Where practical, provide rigid supports for the piping.; Avoid running tubing against any type of heating unit and across; If possible, install the tubing under the floor.; Do; Avoid the use of tube fittings in inaccessible locations.
22 Verify that the installed burner is lightly leaned towards the button. (See figure 14-1) The burner is designed to allow entry of the flexible oil-lines on either side of the burner. I. OIL TANK AND PIPING: : All local codes and ordinances take precedence with regard to selection and installation...
Page 26 - C temperature rise. Depending upon
23 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. When the oil tank is located below the level of the...
Page 27 - Table 10: Typical Electrical Requirements; Please be certain that all; The rating
24 Typically, control wiring between the 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 15 amp service with an insulation temperature rating conforming t...
Page 28 - Figure 15: The Fan Control Module; Thermostat Anticipator Setting:
25 in conjunction with a humidistat to control a humidifier. These terminals are energized whenever the blower is active. 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 no...
Page 29 - Figure 16: Heat Anticipator Adjustment Scale; Preferred method of adjustment:; Figure 17: Analog Ammeter w/ Wire Loops to Boost Reading
26 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...
Page 30 - If a slightly
27 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...
Page 31 - Heating Speed Set-ups; Furnace; Low Fire
28 Heating Speed Set-ups OH6FA072DV4 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...
Page 32 - Furnace Motor Current; Low Fire Med Fire High Fire
29 Heating Speed Set-ups OH8FA119DV5 Furnace Motor Current Draw (Amps / Watts) vs. External Static Pressure (in W.C) Low Fire Med Fire High Fire BTUH 101,000 119,000 132,000 Fan Control SW 1 Switch Settings Heating CFM Aprox. Rise (F 0 ) Aprox. Rise (F 0 ) Aprox. Rise (F 0 ) 0.1 0.2 0.3 0.4 0.5 0.6 ...
Page 34 - Figure 18-3: Cooling blower motor speed chart
31 Cooling Speed Set-ups OH6F*072DV4 Furnace Motor Current Draw (Amps / Watts) vs. External Static Pressure (in W.C) NOTE: All information is approximate. Results will vary by installation. Figure 18-3: Cooling blower motor speed chart Fan Control SW 1 Switch Settings Clg. Tonnage Cool Continuous 0....
Page 35 - Air Flow
32 Cooling Speed Set-ups OH8FA119DV5 Furnace Motor Current Draw (Amps/Watts) vs. External Static Pressure (in W.C.) Air Flow Fan Control SW 1 Switch Settings Clg. Tonnage Cool Continuous Dehum 0.1 0.2 0.3 0.4 0.5 0.6 0.7 6-OFF 5-OFF 4-OFF 2 800 500 557 0.8/69 1.0/88 1.3/112 1.5/132 1.7/147 1.9/169 2...
Page 38 - M. BLOWER CONTROLLER INFORMATION FOR PSC MOTOR
35 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 Connector P1 Pin 1- Limit switch connector. Pin 2- 120 VAC Line connection. Pin 3- Burner pilot contact. ...
Page 41 - Heat Mode; Table 11: ON and OFF Blower Delay Time Switch Settings
38 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...
Page 42 - DIAGNOSTIC FEATURES; The red Board Status LED has two functions:
39 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...
Page 43 - Operating Instructions:; For Your Safety Read Before Operating:; : If you do not follow these instructions exactly, a fire or
40 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 ...
Page 45 - Replace the inspection cover above the burner.; COMBUSTION HEAD SETTING FOR 2-STAGE RIELLO BURNER:
42 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...
Page 46 - AIR DAMPER ADJUSTMENT:
43 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...
Page 47 - In this way the burner will remain permanently in the 1; nd; In this way the burner remains permanently in the 2
44 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...
Page 49 - Initial Burner Adjustment; Setting Supply Air Temperature Rise:; Temperature rise = supply air temperature - return air temperature.
46 a. W ith 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 ...
Page 50 - Heating System Initial Startup
47 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...
Page 51 - III. USERS INFORMATION SECTION; The burner requires a generous amount of clean combustion air; EXTERIOR OF FURNACE:; The furnace vent pipe should be inspected for signs of rust,; CAUTION: DO NOT ATTEMPT TO MAKE REPAIRS YOURSELF!
48 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...
Page 52 - Set thermostat substantially above room temperature.; Fig 23: Filter Location for Typical Highboy Furnace
49 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...
Page 53 - Information and Routine Maintenance; Dealer
50 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...
Page 55 - A one inch (outside diameter) vacuum cleaner hose will fit into the
52 χ 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 insulator and reduce...
Page 56 - Vacuum Hose Length
53 Figure 24: Heat Exchanger Clean-Outs Vacuum Hose Length OH6 8FT OH8 8FT Fig. 25: Recommended method and device for cleaning inside of heat exchanger.
Page 57 - check out procedures; Filter maintenance procedure:
54 4. Operational Check: χ 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...
Page 58 - Figure 26: Location of Supply/Return Air Filter; Air Filters; Disconnect all electrical power to the unit.; Primary reset has been engaged more than two times.
55 Figure 26: Location of Supply/Return Air Filter 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. N...
Page 59 - Figure 27: Location of Oil Pump Vent Plug; Follow the previous; Initial Burner Operation
56 ON STARTUP: 1. Have system inspected and started by a qualified heating contractor. 2. Check oil level in tank. If the tank has not been filled with fresh oil, inspect the remaining oil for signs of contamination with water, algae, dirt or other impurities. If excessive, consult your oil supplier...
Page 60 - If the unit will not operate in the heating mode,; it may be possible to reactivate the unit by resetting
57 : 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 oil control that has been under water. : Should overheating occur, or the oil supply fail to shut off, shut of...
Page 61 - Figure 28: Location of oil primary control reset button; THIS SECTION IS ONLY TO BE PERFORMED BY TRAINED, QUALIFIED SERVICE
58 Beckett Burner Riello Burner Figure 28: Location of oil primary control reset button If this action does not reactivate the unit, contact a qualified service agency for assistance. In general, if the thermostat is set in the heating mode, the heating system functions entirely automatically. Howev...
Page 62 - Diagnostic Features:; In event this control; to
59 1. Check for 115VAC line supply voltage to the furnace. If there is no supply voltage, check fuses and service switch. χ CAUTION: When testing electrical equipment, always follow standard electrical procedures. 2. Make sure thermostat is calling for burner operation. 3. Check oil supply and make ...
Page 64 - VIII. Sequence of Operations Flow Chart:
Page 72 - Appendix – A
69 Appendix – A Replacement Parts: Replacement Parts for OH6FA072D**
