OIL FIRED FURNACE
INSTALLATION AND OPERATION MANUAL
WITH USERS INFORMATION SECTION
MODEL:
OH5-85DXE
c 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.
c 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: (574) 896-2133
MO-444
ECN 4673AMA
MADE IN USA
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All installations and services must be performed by qualified service personnel.
TABLE OF CONTENTS
SECTION
BEGINNING PAGE
I. SAFETY SECTION
i
II. GENERAL INSTRUCTIONS
A. VENTING
1
2
2
3
3
5
5
7
8
B. DRAFT REGULATORS
C. DUCT WORK/AIR CONDITIONING
D. FILTERS MOUNTED EXTERNAL TO FURNACE
E. LIMIT POSITION AND LOCATION
F. BURNER INSTALLATION
G. BURNER SPECIFICATIONS AND APPLICATIONS
H. HEAT EXCHANGER CLEANING INSTRUCTIONS
III. USERS INFORMATION SECTION
A. OIL SUPPLY
9
9
B. COMBUSTION AIR SUPPLY
C. INSPECTION AREAS
9
9
D. STARTING THE BURNER
E. FILTER CLEANING AND LOCATIONS
9
10
APPENDIX – A
APPENDIX – B
REPLACEMENT PARTS LIST
WIRING DIAGRAMS
12
13
ii
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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.
cWARNING: 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.
MINIMUM CLEARANCES TO COMBUSTIBLE MATERIALS
FROM
SIDES OF
FURNACE
TOP &
FRONT SIDES OF
PLENUM
FROM THE
FLUE/VENT
TYPE OF UNIT
HIGHBOY
MODEL NO.1
REAR
OH5-85DXE***
1
24
1
6
1
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 OH5-85DXE*** furnaces may be installed on combustible flooring.
NOTE: The OH5-85DXE*** furnace is approved for closet installation. If the OH5-85DXE*** 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 OH5-85DXE*** 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.
1
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A. VENTING:
NOTE: On the OH5-85DXE*** 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.
c 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. Then, by following the dimensions listed below,
locate the center point for the exit of the flue. Once the center has been located, use a scribe to mark the hole size.
Cut hole 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. Trim collar/gasket part numbers(s) 14121 / 330073.
TABLE 1: Suggested size and position of flue pipe opening on left hand side of casing.
TRIM COLLAR/
UNIT
DIA. HOLE
“X” DIM.
“Y” DIM.
FLUE DIA.
GASKET PART #
OH5-85DXE
6-1/2”
4-3/4”
33-1/16”
6”
14131/330005
*
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.
NOTE: ROTATION OF FLUE PIPE IS ONLY ALLOWED FOR LEFT HAND SIDE VENTING
APPLICATIONS.
The OH5-85DXE*** may be vented through a standard correctly sized chimney.
B. 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
1
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. 8). 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.
2
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C. 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.
The duct system should again follow the current design standard of Air Conditioning Contractors of America
(ACCA) or ASHRAE Fundamentals volume.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.
D. FILTERS MOUNTED EXTERNAL TO FURNACE
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 a side casing approximately 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. For your convenience, (4) locator knock-outs have been placed at the proper locations on both the left and
right side casings.
PLEASE NOTE: While scribing the return air opening, the filter rack can be held in position by tape or similar
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.
3
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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. 5).
Fig. 5: A typical filter rack and dimensions for the OH5-85DXE*** furnace.
PLEASE NOTE: While scribing the return air opening, the filter rack can be held in position by tape or similar
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.
cWARNING: 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.
4
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E. LIMIT POSITION AND LOCATION
cWARNING: 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 is incompatible,
may result in personal injury, substantial property damage or death.
The unit listed in the table below must have the fan and limit control installed at the time of unit installation.
TABLE 2: Installation location of
the fan and limit control for each
furnace
Fig. 7: Limit location for OH5-85DXE***
F. BURNER INSTALLATION:
The oil burner will mount on three stud mounting bolts on the lower mounting plate covering the opening in the
front of the heat exchanger. The end of the burner tube should be inserted no further than 1/4 inch back from the
inside surface of the combustion chamber. A distance further than 1/4 inch back from the inside chamber wall may
cause impingement and sooting.
NOTE: OVERFIRE AIR TAP MAY BE LOCATED ON EITHER SIDE OF FLAME INSPECTION
COVER. (See Fig. 8).
RIELLO MOUNTING PLATE
Fig. 8: Typical location of the overfire air tap
5
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Fig. 9: (Top view) Burner insertion illustration
When mounting the burner, the upper mounting plate (Fig. 8) must be removed to provide access to the area in front
of the combustion chamber. The combustion chamber can then be moved forward or backward slightly to allow for
adjustment in positioning the burner tube. Do not allow the burner tube or end cone to physically touch or protrude
into the chamber, as excess heat transfer could result in destruction of the tube, end cone or both. The burner
tube/end cone is properly positioned, when the end is ¼ inch back from the inside surface of the combustion
chamber wall.
NOTE: The loose-fill insulation that is included in a brown paper bag should be lightly placed around the burner
tube between the front of the combustion chamber and the burner mounting plate. (DO NOT PACK THE
INSULATION DOWN). The loose-fill insulation should be placed in such a fashion that the surface of the
insulation is sloped from the top of the combustion chamber to the top of the lower mounting plate. The purpose of
the loose insulation is to help protect the burner tube, mounting plates and vestibule area from excessive
temperatures.
NOTE: Do not place loose insulation around chamber sides and back .
Fig. 10: (Side view) Burner insertion illustration
6
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G. BURNER SPECIFICATIONS AND APPLICATIONS
RIELLO BURNER APPLICATION CHART
MODEL
OH5 2 STAGE
PART
MTG. PLATE
35750
PART NO.
MTG. PLATE
GASKET
PART NO.
330088
**NOZZLE
SIZE
.70 X 45° W
NOZZLE
PART NO.
380702
130 LOW
OIL PUMP
PRESSURE
170
G-51
380695
HIGH
BURNER
BURNER
PART NO.
* INSULATOR S = SLEEVE OR N = NONE
THE NOZZLE SIZE GIVES THE NOMINAL FLOWRATE, IN GPH, FOLLOWED BY THE SPRAY
ANGLE, IN DEGREE’S, AND THE SPRAY PATTERN, EITHER “H” FOR HOLLOW CONE OR “S”
FOR SOLID CONE. FOR EXAMPLE, A NOZZLE RATED AT 0.65 GPH @ 100 PSIG THAT PROVIDES
AN 80° SPRAY ANGLE AND A HOLLOW SPRAY PATTERN WOULD BE ABBREVIATED IN THE
TABLE AS “0.65 X 80°H”.
** NOTE: The reason the Riello burner nozzle sizes are smaller than the standard Thermo Pride burner nozzles is
that pre-set pump pressures are higher, therefore achieving the same firing rate with a smaller nozzle.
For more specific burner information, specifications or service information, reference the training manual enclosed
with each Riello burner or contact:
Riello Corporation of America,
5 Pond Park Road
Hingham, Massachusetts 02043
(617) 749-8292
2 STAGE FIRING RATES
EFFECTIVE**
HEATING
CAPACITY
85,000
NOZZLE SIZE
Riello
INPUT RATE*
(BTU/HR)
106,250/170psi
OH5-85DXE***
HIGH FIRE
LOW FIRE
.70 X 45° W
85,000/130psi
74,000
* Based on #2 domestic heating fuel oil having heating value of 140,000 BTU per gallon.
** Based on thermal efficiency of 84%-85%.
7
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H. HEAT EXCHANGER CLEANING INSTRUCTIONS:
cWARNING: THE HEAT EXCHANGER MUST BE CLEANED BY A QUALIFIED
SERVICE PERSON.
It is important to inspect and clean the heat exchanger once a year, or as necessary, to remove any build-up of soot.
A layer of soot on the inside of the heat exchanger will act as an insulator and reduce heat transfer, resulting in less
efficiency.
To clean the heat exchanger, first turn off all power to the unit. Next, remove the access panel (see below and
beginning of following page) immediately above the burner to gain entry to the clean-out covers, refer to figure 15.
This panel is identified with a label. Remove clean-out covers, the vent connector pipe to the chimney, the burner,
and the burner mounting plates. When removing the clean-out covers, special care must be taken not to damage the
gaskets. Should the gaskets separate, crack, break, or be unsuitable for reuse, the gasket must be replaced before
reattaching the clean-out covers.
Fig. 15: (Side view) Burner insertion illustration
With access to the inside of the heat exchanger through the burner area, clean-out openings, and vent pipe
connection, it is possible to use a long, flexible wire brush and an industrial type vacuum cleaner to remove any soot
build-up. NOTE: A one inch (outside diameter) vacuum cleaner hose will fit into the radiator.
To vacuum and brush the outer radiator of the heat exchanger, go through the clean-out openings in both directions,
as shown in figure 16, below.
Fig. 16: Recommended method and device for cleaning inside of heat exchanger.
8
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Reassemble the furnace to its original construction. Remount the burner being certain that the air tube is properly
inserted into the chamber opening (see section E). If heavy soot deposits were found in the heat exchanger, this may
indicate the burner is out of adjustment.
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 air. Contact a qualified technician to bleed the lines and restart the burner.
OIL SUPPLY VALVE: Turn the oil supply valve off if the burner is shut down for an extended period of time.
B. COMBUSTION AIR SUPPLY: The burner requires a generous amount of clean combustion air to operate
safely. Lack of adequate combustion air can result in erratic operation of the burner, noisy combustion, or fuel odors
in the air. NEVER BLOCK THE FURNACE FROM THE SUPPLY OF COMBUSTION AIR. If there is an exhaust
fan, dryer or return air grill in the furnace room, there should be increased concern and additional efforts may be
required to provide adequate combustion oil to the furnace at all times.
0-+
C. INSPECTION AREAS
VESTIBULE: The furnace vestibule area or burner compartment should be inspected by removing the front door
of the furnace and looking for signs of excessive heat such as discoloration of components materials damage, from
rust or corrosion, soot or carbon build-up.
EXTERIOR OF FURNACE: The furnace exterior should be inspected for signs of excessive heat such as
discoloration of materials and damage from rust or corrosion.
FLUE PIPE, VENT PIPE OR CONNECTOR: The furnace vent pipe should be inspected for signs of rust,
corrosion pitting or holes in pipe, and leakage around seams in pipe, indicated by soot or condensate streaks.
CHIMNEY OR VENTING SYSTEM: The furnace venting system should be inspected for signs of rust,
corrosion pitting or holes, and signs of condensation or moisture leakage from the venting system.
If any of the above symptoms are evident, call a qualified heating contractor for assistance.
cCAUTION: DO NOT ATTEMPT TO MAKE REPAIRS YOURSELF!
cWARNING: The area around the furnace should be kept free and clear of combustible
liquids and material, especially papers and rags.
cWARNING: NEVER burn garbage or refuse in your furnace. Never try to ignite oil by
tossing burning papers or other material into your furnace.
cWARNING: Thermo Pride oil furnaces are designed to burn No. 1 or No. 2 distilate fuel
oil. NEVER USE GASOLINE OR A MIXTURE OF OIL AND GASOLINE.
cCAUTION: 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.
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.
9
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4. Turn service switch to furnace "ON". If burner starts and runs, but stops again on lockout, it may be necessary to
bleed the lines or make burner combustion air adjustments. Contact a qualified service person to adjust and start
burner.
E. FILTER CLEANING AND LOCATION:
The air filters should be inspected each month and cleaned when dirty. Cleaning the air filters frequently may
reduce airborne contaminants from entering the furnace and depositing in the furnace, duct system and home.
cWARNING: To avoid injury from moving parts, hot surfaces, or electrical shock, shut
off the power to the furnace before removing any furnace access doors to service the air
filters.
The filter rack will be located between the return air plenum and the return air opening on the side of the furnace,
refer to figure 18. Slide the dirty filter out, clean it with a mild soap and water solution. Make sure filter is
thoroughly dry before replacing.
Fig. 18: Location of the air filter on the typical highboy furnace.
10
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COMBUSTION AND EFFICIENCY TESTING FOR THERMO PRIDE
OIL FIRED CENTRAL FURNACES.
Complete this form for each Thermo Pride furnace installed. Read instruction
manual carefully before making tests. Retain this form with furnace.
CUSTOMER
NAME
ADDRESS
CITY, STATE
BURNER MODEL NO. BLAST TUBE LGTH.
AIR SHUTTER OPENING
HEATING
SYSTEM
INS.
% OF MAX. (EST)
CONDITION
MATERIAL FURNACE MODEL
COMBUSTION CHAMBER
TYPE OF VENTING SYSTEM
MASONRY
CHIMNEY
METAL
METAL
SIDEWALL
POWER VENTER
MASONRY
CHIMNEY
W/INDUCER
CHIMNEY
MASONRY CHIMNEY
W/METAL LINER
CHIMNEY
W/INDUCER
FUEL LINE FILTER
DRAFT CONTROL
FURNACE SERIAL NUMBER
INITIAL
INSTALLATION
COMBUSTION
TESTS
SERVICE SERVICE SERVICE
CO2 in stack pipe
Draft Over-fire
(Operate burner
at least 10
Draft in stack pipe
Smoke number
minutes before
starting tests.)
Gross stack temp.
Furnace room temp.
Net stack temp.
(Gross stack minus
furnace room temp.)
Efficiency
Nozzle size and spray
Oil pump pressure
Operation of Controls
Burner Safety Controls
Check for oil leaks
Tests taken by
Date
NOTES:
INSTALLER NAME & ADDRESS
11
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APPENDIX-A Replacement Parts List
12
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APPENDIX-B Wiring Diagram
13
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