Thermo Products Thermo Pride Air Conditioner Opb 24 User Manual

OUTDOOR COMBINATION OIL-FIRED

FURNACE AND AIR CONDITIONING UNIT

MODEL OPB (24,30,36)- 80

INSTALLATION AND SERVICE MANUAL

: If the information in this manual 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.

− WHAT TO DO IF YOU FIND AN OIL LEAK:

• Do not try to light any appliance.

• Immediately call your oil supplier.

• If you cannot reach your oil supplier, call the fire department.

− Installation and service must be performed by a qualified installer, service

agency or the oil supplier. (These entities are referred to in these instructions

as a qualified heating contractor).

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.

Thermo Products, LLC

PO Box 217

MO-455

ECN 4979-MA

North Judson, IN 46366

Phone: (574) 896-2133

Made In USA

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

APPENDIX A: SOURCES FOR REFERENCED STANDARDS .............…. 61

APPENDIX B: CALCULATIONS ...........................................................….. 62

XI.

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

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.

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.

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, NFPA 31-

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.

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.

: Do not run the oil pump dry for more than five minutes, as irreparable

damage may result.

: Before troubleshooting, familiarize yourself with the start up and check out

procedures.

: Never burn garbage or refuse in this appliance. Never try to ignite oil by

tossing burning papers or other material into the combustion chamber.

: Oil-fired appliances produced by Thermo Products are designed for burning

No. 2 distillate (domestic heating) fuel oil. Never use gasoline or a mixture of oil and

gasoline.

: Do not attempt to make repairs yourself. Contact your local qualified heating

contractor.

: 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.

: Do not attempt to operate the cooling section on a day when outdoor

temperatures are 45°F or cooler.

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.

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.

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 70-

1996, 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.”

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 Top

Side Rear Front

Bottom Vent Terminal

(in.) (in.)

No.

(in.)

(in.) (in.)

OPB

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 well-

tamped gravel fill beneath the blocks or bricks to prevent settling.

Notice: Do not install the unit on any type of combustible base.

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

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.

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.

FIGURE 2: Vent Terminal Mounting Position

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.

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.

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

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 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.

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.

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

Table 2: Burner Specifications and High and Low Fire Heating Performance

Oil

Heat

Oil Pump

Pressure

(PSIG)

Heat Input

Rate*

(BTUH)

Heating

Mode

Flowrate @

Nozzle

Output Burner Model

Rate**

(BTUH)

Air Tube

Combination

Nozzle

Type

Number

(GPH)

²0.75

Simplex, 80

AFG-TP1502 AF42 BNHSSS deg., hollow

cone

High Fire

Low Fire

130

120

105,000

85,000

67,000

¹0.6

* Based on #2 fuel (domestic heating) oil having higher heating value of 140,000

BTU per gallon.

** Based on an assumed steady state, thermal efficiency of 80%.

¹Factory installed.

²Provided by installer.

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.

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.

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 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 flowrate.

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.

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.

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)

Maximum

Filter Type

Air Velocity

(ft/min)

Model Number

OPB24 OPB30 OPB36

*Thermo Products

Supplied

600

500

300

192

230

384

240

288

480

288

346

576

Permanent

Standard

Permanent

Disposable

∗ 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.

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.

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

Recommend

ed Time

Delay Type Recommended

Fuse or 75 deg. C.

Inverse Time Copper Power

Circuit

Breaker Size

(Amps)

Maximum

Time Delay

Type Fuse

or Inverse

Time Circuit

Breaker

Compressor Compressor Condenser Supply/Retur Burner

Minimum

Running

Load

Current

Locked

Rotor

Current

Fan Full n Air Blower Assembly

Potential/Frequency

/No. of Phases

(V/Hz/Ph)

Load

Current

Full Load Full Load

Current Current

(Amps) @ (Amps) @ (Amps) @ (Amps) @ (Amps)

Model

Wiring Size

(AWG)

200 VAC

115 VAC

@ 115

VAC

Size (Amps)

OPB24

OPB30

14.3

58.3

208-240/60/1

0.8

9.6

5.8

OPB36

18.6

OPB42

18 4

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.

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.

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.

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

2. Thermostat Anticipator Setting

Proper control of the indoor air temperature can only be achieved if the

thermostat is calibrated to the heating and/or cooling cycle. Calibration will

help to produce a more constant indoor temperature by adjusting the length of

the heating/cooling cycle to fit the application. A vital consideration of this

calibration is related to the thermostat heat anticipator.

The proper thermostat heat anticipator setting is 0.1 ampere. To increase the

length of the cycle, increase the setting of the heat scale; to decrease the

length of the cycle, decrease the setting of the heat scale.

Anticipators for the cooling operation are generally pre-set by the thermostat

manufacturer and require no adjustment.

Anticipators for the heating operation are of two types, pre-set and adjustable.

Those that are pre-set will not have an adjustment scale and are generally

marked accordingly.

Thermostat models having a scale as shown in Figure 5 must be adjusted to

each application.

Figure 5: 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:

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

Preferred method of adjustment:

Using an analog ammeter on the lowest scale, such as an Amp Check,

connect the meter across terminals “R” and “W” on the sub-base (“RH” &

“W” on an isolating thermostat sub-base). If the reading is too low to move

the needle on to the measurement scale of the instrument, proceed as

follows.

i. Wrap 10 loops of single strand, insulated, thermostat wire around the

prongs of an ammeter, refer to Figure 6. Set the scale to the 1 to 5 or 1

to 6 amp. scale.

Figure 6: Analog Ammeter w/ Wire Loops to Boost Reading

ii. Connect the bare ends of this wire jumper across terminals “R” and

“W” on the sub-base (“RH” and “W” on an isolating thermostat sub-

base). This test must be performed without the thermostat attached to

the sub-base.

iii. Let the heating system operate in this position for about one minute.

Read the amp meter scale. Regardless of the value of the meter

reading, divide the value by 10 (for 10 loops of wire).

This formula can be used to calculate the correct setting for the

adjustable heat anticipator:

Ammeter reading = Anticipator Setting.

No. of wire loops

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

Or in this case,

_2.5 A. = 0.25 A. (Anticipator Setting)

iv. Adjust the position of the anticipator indicator to match the calculated

ammeter setting. If a slightly longer cycle is desired, the pointer should

be moved to a higher setting. Slightly shorter cycles can be achieved

by moving to a lower setting.

v. Remove the meter jumper wire and reconnect the thermostat. Check

the thermostat in the heating mode for proper operation.

If a digital ammeter is used, read the current draw directly from meter.

(Steps 1 through 3 are not required.) The meter reading is the correct

anticipator setting.

3. Blower Motor Speed Selection

: Turn off the electrical power to the unit, before attempting

to change supply air blower speed wiring.

The OPB comes from the factory with the proper cooling speed selected

and the heat rise set to approximately 65°F on low-fire.

The heat rise is determined by the nozzle size and the switch selection on

the control board located in the vestibule compartment.

Switches 1, 2 & 3 of switch block SW1 (the six switch red block) are used

to select the proper blower speed. Please refer to the table below:

SW1 POSITION

LOW- HIGH FIRE

FIRE HEAT RISE

OPERATION IN THIS RANGE MAY FORCE THE

SAFETY LIMIT TO OPERATE REDUCING

PERFORMANCE

OFF

FACTORY

SET

OFF

OPERATION IN THIS RANGE MAY CAUSE

COMBUSTION GASES TO CONDENSE AND VOID

THE WARRANTY

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

IV. 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 the air out of the oil line. A qualified heating contractor

should do this.

Review the following items before the initial startup. It may be helpful to review

the Sequence of Operations in Appendix D of this manual, also.

a. Check all wiring for loose connections and proper hook-up. Refer to the

connection diagram.

b. Leak test all field oil piping connections. Generally, this will involve

pressurizing the oil piping with air while being careful to isolate the oil tank at

high test pressures. A qualified heating contractor should perform this

service.

c. Check to see that the vent terminal is correctly installed and the terminal

openings are clear and free from blockage.

d. Make sure the air filter is in place and relatively clean of dirt and debris.

e. Make sure the thermostat is set in the heating mode of operation.

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

For Your Safety Read Before Operating:

: If you do not follow these instructions exactly, a

fire or explosion may result causing property damage,

personal injury or loss of life.

• This appliance does not have a pilot light. It is equipped with

an ignition system that automatically lights the burner. Do not

attempt to light the burner by hand.

• Do not use this appliance if any part has been under water.

Immediately call a qualified service technician to inspect the

appliance and to replace any part of the control system and

any oil control that has been under water.

Operating Instructions:

i. STOP! Read the safety information above.

ii. Set the thermostat to the lowest setting.

iii. Turn off all electric power to the appliance.

iv. This appliance is equipped with an ignition system that

automatically lights the burner. Do not try to light the burner by

hand.

v. Rotate the manual oil shutoff valve to the “ON” position.

vi. Turn on the electric power to the appliance.

vii. Set the thermostat to the desired setting.

viii. If the appliance will not operate, call your qualified service

technician or oil supplier.

To Turn Off Oil to Appliance:

i. Set the thermostat to the lowest setting and set the operating

mode switch to “OFF”.

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

ii. If service is to be performed, turn off the electrical power to the

appliance.

iii. Turn the manual oil shutoff valve to the “OFF” position.

2. Adjustment of Burner Combustion:

: Maximum gross stack temperature must not exceed 550°F

(288°C) under any circumstances.

: Do not run the oil pump dry for more than five minutes, as

irreparable damage may result.

NOTICE: Read the burner operation and service instructions, Model

AFG Oil Burner Instruction Manual, before continuing.

To initially adjust and successfully service the oil burner in the appliance

heating section, the following test instruments are required:

• A smoke density measuring and rating device,

• A carbon-dioxide (CO₂) or oxygen (O₂) analyzer,

• A flue gas temperature measuring device (e.g., thermocouple or

thermister probe with readout device),

• An analog or digital multimeter, and

• An oil pressure gauge capable of reading 0-150 PSIG.

To initially fire the oil burner, proceed in the following manner.

a. Turn the disconnecting switch, which provides power to the

appliance, to the "OFF" position.

b. Set the room thermostat above room temperature.

c. Verify the oil tank is filled with sufficient fuel oil to operate the

appliance.

d. Open all valves in the oil supply line to the burner.

e. Remove the burner compartment cover from the appliance.

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

Open the inspection cover on the upper mounting plate above the

burner.

g. Turn the disconnecting switch to “ON”.

h. Prime the pump to remove air in the oil supply line.

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 the range of “2” to “7”, refer to Figure 8.

Figure 8: Preliminary Adjustment of Burner Air Band and Air Shutter

Replace the inspection cover above the burner.

After the appliance is warmed up to a steady state condition (about

15 minutes), the final burner adjustment should be made using

combustion instrumentation for smoke, carbon dioxide (CO₂) or

excess oxygen (O₂), and flue gas temperature. In order to achieve the

most efficient combustion, the following steps must be taken:

i. SMOKE: A smoke sample should be drawn from the heat

exchanger flue passageway, which is covered by the vent terminal.

(Remove a large machine screw from the front face of the vent

terminal for direct access to the flue through the opening.) If the first

smoke reading is zero (0), close the air band, or shutter, on the

burner until a trace smoke reading is measured.

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

NOTICE: To achieve proper combustion and the efficiencies

listed in sales brochures, instruments must be used to secure

CO₂or O₂readings.

ii.

CARBON DIOXIDE (CO₂) OR OXYGEN (O₂): Take a CO₂sample

from flue passageway. It is possible to achieve readings of up to

14% CO₂(or 2% O₂), but it is better to have a slightly lower CO₂(or

higher O₂) reading with zero smoke measured. To achieve a lower

CO₂reading, open the air band, or shutter, on the burner until zero

smoke is measured.

For example, if a 13% CO₂(or 3.5% O₂) is recorded at a trace of

smoke, open the air shutter until zero smoke is measured with a

12% CO₂(or 4.5% O₂).

Adjustment of the burner to achieve a slightly lower CO₂reading is

recommended, although it slightly reduces combustion efficiency, to

keep the heating system within normal operating conditions though

external conditions may vary. Some “out-of-spec” conditions which

may adversely affect burner performance are, low oil supply

temperature, dirty (contaminated) oil, low heating content (BTU/gal)

oil, cold heat exchanger surfaces, and downdraft conditions. By

adjusting the burner in this manner, an operational tolerance is

established allowing the burner to function well, even under less

than ideal conditions. This results in less service and maintenance

during a heating season.

iii.

FLUE GAS TEMPERATURE: The flue gas temperature will vary to

some extent depending on the heat input rate, duct design, and the

amount of air flow across the heat exchanger. The suggested

minimum net flue gas temperature is 350⁰F, and the maximum

gross flue gas temperature is 550⁰F. The lower the flue gas

temperature, the higher the heating efficiency. However, stack

temperatures under 350⁰F may result in condensation of water

vapor in the flue gases, which in turn promotes corrosion of the

heat exchanger.

iv.

TEMPERATURE RISE: Temperature rise is equal to the supply air

temperature minus return air temperature. Under steady state

operating conditions, the temperature rise across the heating

section should be approximately 65⁰F. A higher temperature rise

will slightly lower the heating efficiency. A lower temperature rise

will slightly raise efficiency, but may cause condensation.

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

The supply air temperature should be measured in the supply air

trunkline approximately 12 inches downstream of the supply air

outlet of the appliance.

NOTICE: Minimum temperature rise is 50⁰F.; maximum

temperature rise is 80⁰F.

l. After final adjustments are completed, tighten all screws to fix the

positions of the burner air band.

m. Check for the presence of oil leaks. Correct any oil leaks found.

n. Reassemble the burner compartment cover.

o. Start and stop the unit several times while checking for proper ignition of

the burner. The flame should ignite and stabilize without any significant

rumbles or pulsations.

3. Adjustment Of Heat Input Rate

This appliance was shipped from the factory with one, fixed, main burner nozzle

sized to produce the low-fire input rate using no. 2 fuel oil at the pump pressure

shown on the rating label. The input rate can be changed to the high-fire by

switching to the larger burner nozzle and increasing the pump pressure.

The main burner oil nozzles for this unit were selected based upon the following

assumed characteristic values of the fuel oil suitable for use with this appliance

design:

• For no. 2 distillate fuel (domestic heating) oil having a higher heating value

of 140,000 BTU per gallon and a specific gravity of 0.88 @ 60 deg. F. (or

“gravity” of 30 deg. API @ 60 deg. F.).

It is possible to make minor adjustments to the heat input rate by adjusting the

pump pressure. Sizeable changes in input rate (especially reductions) should be

made by replacing the burner nozzle. To adjust the pump pressure to the main

burner:

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 13. 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 may be necessary to remove the oil pump to attach the

plumbing required to connect a pressure gage to the pump.

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

b. Turn on the fuel oil and cause the appliance to activate the heating section

by answering a “call for heat”.

NOTICE: It may be necessary to bleed air from the oil line before the

burner can be fired.

c. Allow the heating section to operate for 10 to 15 minutes.

d. Note the oil pressure at the pump.

e. To adjust the pressure, use a common screwdriver to turn in the pressure

adjustment screw, located on the upper front of the oil pump body.

f. Allow the fuel flow rate to stabilize for a moment. Recheck the oil

pressure.

g. If required, repeat the oil pressure adjustment again.

h. When the input rate adjustment has been completed, shut off the fuel oil to

the appliance. Remove the pressure gage. Reinstall the pipe plug using a

thread compound resistant to the action of LP gases and fuel oil.

NOTICE: It may be necessary to bleed air from the oil line before the

burner can be fired.

To insure the combustion air supply is adequate, it is now necessary to repeat

the steps in the previous Initial Burner Adjustment section of this manual.

4. Setting Supply Air Temperature Rise

: 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.

All OPB models are designed and wired at the factory for a blower speed

during heating that should result in an approximate temperature rise of 65°F.

The temperature rise through the heating section, for any given blower speed,

may vary depending on a number of factors. A few of these factors are

variations in, the actual resistance of the duct system to airflow at any time,

the return air temperatures, and the fuel oil heating value.

Also, fouling of the heat exchanger surfaces will reduce temperature rise. In

general, a lower temperature rise through the heating section will result in

higher heating efficiency.

Temperature rise = supply air temperature - return air temperature.

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

After 15 to 20 minutes of continuous operation, the temperature rise through

the furnace must fall within a range of 50° to 80° F. If the outlet or supply

duct temperature is too high, check to make sure the return air filter is clean,

the return air registers are free from obstruction, the outlet registers are

properly adjusted and clear, and the supply and return air ducts are open.

The circulating air blower is not moving enough air if the supply air

temperature is still too high. Before proceeding further, turn off the power

supply to the appliance and remove the vestibule cover. The speed of the

blower must be increased by changing the switch setting on the control board,

please refer to the table in Section 3.

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 prior to the qualified service personnel leaving the job site.

Specifically the following should be checked:

a. With heating system in normal heating operation, check to make certain

blower will start and stop automatically under control of the indoor

thermostat.

b. Check safety limit control as follows:

i. Shut off incoming power.

ii. Block return air opening or disconnect blower motor leads.

iii. Restore power to appliance.

iv. In the heating mode, set the thermostat above room temperature

producing “a call for heat”.

v. When high air temperatures are reached within the heating section, the

high limit control should act to shutdown the burner.

vi. Shut off the electrical power.

IMPORTANT: Remove blockage or reconnect blower motor and

restore power.

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

c. Make certain the thermostat will automatically start and stop the

appliance.

NOTICE: Heat exchanger oil will burn off on initial firing creating an

unpleasant odor. To prevent this odor from occurring more than once, it

is suggested the heating section be allowed to run for 30 minutes, or

until odor has dissipated.

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

B. Cooling Section

1. Initial Startup:

: 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!

On cool days (65°F or lower), attempts to operate the cooling section and take

gauged pressure readings may be unsuccessful as unusually low pressure will

be observed on the suction line. This type of operation may give the impression

of an undercharged unit. This is not necessarily the case. A low refrigerant

pressure reading may occur due to the combined action of the large condenser

surface area and cold ambient air removing a large amount of heat from the

refrigerant. As a result, subcooling of the refrigerant occurs and very low

refrigerant pressures can be measured. Adding refrigerant in cold weather will

result in an overcharged unit. During warm or hot weather, high ambient

temperatures will greatly increase the refrigerant pressure which may then cause

the high limit pressure switch to shutdown the unit. Due to the high probability of

taking a false reading, suction line pressure should not be taken for test purposes

when the outdoor temperature is below 70° F.

When the outdoor air temperature is cooler than the indoor air temperature,

refrigerant vapor will condense in the compressor. If the compressor is started

when it contains liquid refrigerant, the lubricating oil in the crankcase will be

diluted. Bearing damage may result under these conditions.

The appliance is equipped with gauge ports to connect both liquid and suction

line pressure gauges. These ports are located near the base of the unit, inside

the burner compartment. Refrigerant hoses must be the types that incorporate a

“finger” to depress the valve core. Connections may be made to these ports at

any time, even while unit is in operation. Follow EPA guidelines in connecting

service equipment to refrigerant lines. For example, using quick connects and

short service hoses is recommended to minimize refrigerant losses.

Line pressures on an operating air conditioning unit will vary with outdoor

temperatures. As outdoor temperatures rise, pressures will also rise. Refer to a

pressure-temperature chart on the unit for approximate system line pressures at

various temperatures.

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

The suction pressure and condenser subcooling are the most significant

readings. If a unit is suspected of having a low refrigerant charge, the unit should

be recharged using the suction pressure then topped off using subcooling. Any

additional refrigerant may cause damage or unintended problems.

The pressure/temperature chart on the wiring diagram is to serve only as a

guide. Pressures shown are realistic averages which will vary somewhat with

changes in air temperatures, air flowrate across the evaporator and condenser

coils and humidity – both inside and outside.

If a charge must be added to the system, connect to the suction service port of

the service valve and add a vapor charge only while the system is operating.

Addition of liquid refrigerant at the suction port may damage the compressor.

2. Definition of Subcooling:

Subcooling is extra heat removed from refrigerant below the saturation

pressure/temperature of the refrigerant. A certain amount of refrigerant

subcooling is usually beneficial and needed to help assure the best operation of

the cooling system. Subcooling takes place in the condenser. It is a function of

the amount of airflow into the condenser, the outside ambient air temperature,

the refrigerant pressure into the condenser, and pressure drop through the

condenser.

Refrigerant with low subcooling may partially change back into vapor, or “flash to

gas”, while flowing to the evaporator. The resulting gas bubbles can block or

interrupt flow through refrigerant controls causing the evaporator to “starve” for

liquid refrigerant. The consequences are poor evaporator efficiency, high

superheat, and generally poor cooling of the conditioned space. Unless very well-

insulated, long liquid lines from the condenser to the evaporator, specifically

liquid lines exposed to high ambient temperatures, are prone to reduce

refrigerant subcooling. To insure sub-cooled liquid refrigerant reaches the

evaporator under all conditions, it is usually advisable to take subcooling

measurements during the warmest part of the day. Test measurements taken

during this time would provide results typical of the most adverse conditions

under which the cooling system would operate. Installing a liquid line sight glass

at the inlet to the evaporator is a simple, but effective, way to prove liquid is

feeding the evaporator. If the sight glass shows all liquid flow without bubbles this

is a good indication that the amount of subcooling is adequate.

NOTICE: Do not attempt a superheat measurement when the ambient

temperature is less than 60° F. Low loading on the cooling system will

result in low or erroneous superheat measurements.

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

3. Condenser Subcooling:

Before taking subcooling measurements, allow the system to stabilize through

continuous operation for at least 15 minutes. To determine subcooling, measure

the refrigerant pressure at the liquid line as it leaves the condenser. It is

preferable to measure pressure of the liquid line at the evaporator, but most

manufacturers, including Thermo Pride, do not include test ports (or Schraeder

valves) at the evaporator. Typically, it would be necessary to compensate for the

pressure drop through the line connecting the condenser and the expansion

valve. However, due to the close proximity of these components, the pressure

drop will be small and can be neglected.

Once the liquid line pressure is known, the refrigerant temperature must be taken

on the liquid line as it enters the evaporator. Use a good resistive thermometer or

thermocouple protected with a rag or insulation. Subtract the measured

temperature from the saturation temperature of the refrigerant. The result is the

degree of refrigerant subcooling.

Refer to Example 4, in Appendix B: Calculations of this manual, for a sample

calculation of how to figure the degree of subcooling for the condenser. In

general, Thermo Pride recommends the evaporator operate with a subcooling of

between 10°F and 15°F.

4. Definition of Superheat:

Superheat is extra heat added to refrigerant above the vaporization

pressure/temperature of the refrigerant. A small amount of refrigerant superheat

is usually beneficial and needed to help assure the best operation of the cooling

system.

Superheat cannot be measured with a pressure gauge alone. Both pressure and

temperature readings of the suction line are required to evaluate the amount of

refrigerant superheating. The degree of superheating gives an indication of two

important system-operating parameters. Superheat at the suction line outlet of

the evaporator indicates the efficiency of the evaporator coil. Superheated vapor

at the suction line inlet to the compressor insures that liquid refrigerant is not

being pumped into the compressor.

Highly superheated vapor is also detrimental to system operation. The highly

superheated refrigerant may overheat the compressor, resulting in premature

failure and/or intermittent thermal cutout of the compressor. High superheat at

the evaporator also indicates the evaporator is operating very inefficiently by

vaporizing the refrigerant too quickly in the evaporator coil. High superheat at

the evaporator results in some loss of the evaporator heat removal capacity.

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

5. Evaporator Superheat:

Before taking a superheat measurement allow the system to stabilize for 15

minutes under continuous operation. To measure superheat at the evaporator, a

suction pressure reading at the outlet of the evaporator would be desirable. Since

most residential cooling systems (including Thermo Pride evaporators) do not

provide a test port (sometimes referred to as a Schraeder port) at the evaporator,

the suction pressure must be read at the suction inlet to the compressor.

Typically, it would be necessary to compensate for the pressure drop through the

line connecting the evaporator and the compressor. However, due to the close

proximity of these components, the pressure drop will be small and can be

neglected. A good resistive-type thermometer or thermocouple-based sensor

should be used to measure the suction line temperature exiting the evaporator.

On evaporators using thermal expansion valves, read the temperature directly

under the expansion bulb, located on the side of the suction line exiting the

evaporator.

Measure refrigerant temperature at the 2:00 or 10:00 positions on the outer

surface of the evaporator suction tube. Wrap the thermometer or thermocouple

with a rag, or insulation, to insure system airflow does not influence the

temperature readings.

Refer to Example 3, in Appendix B: Calculations of this manual, for a sample

calculation of how to figure the degree of superheat for the evaporator. In

general, Thermo Pride recommends an operating evaporator superheat of

between 5° and 12°F.

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

V. INSTALLER'S INSTRUCTIONS TO USER

After completing the installation, the installer shall inform and/or demonstrate to the

homeowner:

1. The location of these instructions in the appliance. These instructions must be

kept along with instructions for any accessories in the plastic pouch on the inside

of the appliance.

2. The location and use of the manual oil shutoff valve and appliance electrical

disconnecting device. The end user must be instructed to always shut off the

electric power to the appliance, before shutting off the oil supply.

3. The sequence of operation of the appliance.

4. The correct operation and maintenance of the appliance, as outlined in the

Homeowner/User Information and Routine Maintenance section of this

manual.

5. That failure to maintain and operate this appliance in accordance with these

instructions could result in hazardous conditions, property damage, and bodily

injury. It may also void the limited warranty on the appliance.

6. Review with and encourage the user to read the label reproductions and all

warnings and instructions outlined on the front cover and in Sections I, II, and III,

of this manual.

7. Recommend the user have a qualified heating contractor inspect the entire

appliance at least once a year. Inform the user of the frequency of inspection

required for each item in the Dealer Maintenance section of this manual.

8. Inform the user to maintain adequate clearances around air openings into the

appliance housing and not to block or restrict the entrance of air into the

condenser coil or the burner compartment air openings.

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

VI. DEALER MAINTENANCE

SAFETY DURING SERVICING AND INSPECTION

: Personal injury or property damage could result from repair or

service of this appliance by anyone other than a qualified heating contractor.

The user may only perform the activities described in 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 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.

IMPORTANT: Verify the proper operation of this appliance after any servicing

is performed.

A qualified heating contractor should perform the following maintenance

procedures at the beginning of each heating season. Correct any deficiencies at

once.

A. General Inspection

: Shut off oil and disconnect power before continuing w/ this

inspection.

1. Vent terminal - Visually inspect the terminal for restrictions, loose or missing

fasteners, external damage, and carbon build-up. Clean the vent terminal and the

screen(s) covering any opening in the terminal. Repair any minor damage. If

necessary, replace a severely damaged or degraded vent terminal.

2. Burner – Visually check the burner, and below the burner, for indications of oil

leaks. Correct any, if found. Remove the burner and measure the ignition

electrode gap. It should be set to 5/32 inch. Adjust it, if necessary. Clean any

accumulation of dust, dirt, or debris from the air shutter or air band openings. If

necessary, clean housing and blower wheel with a damp cloth. Use a vacuum to

remove any lint or dust from motor assembly. Add a few drops of non-detergent

oil to each of the motor lubrication holes.

3. Combustion Chamber - Inspect the liner for deterioration, oil and carbon build-up.

If the accumulation of oil or carbon is significant, this is a strong indicator that the

burner is out of adjustment. Inspect the burner nozzle for partial blockage and

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

excessive wear. Replace it, if required. Check and adjust oil pump pressure, if

needed. Refer to Initial Heating System Adjustments section of this manual.

4. Heat Exchanger – Visually inspect the heat exchanger for excessive carbon

(soot) build-up. Refer to the Heat Exchanger section of the manual.

5. Oil Filter – Replace the supply line oil filter cartridge with a new filter of the same

type and rating. Clean the body of, or mounting plate for, the oil filter.

6. Evaporator and Condenser Coils – Inspect both the evaporator and the

condenser coils for dust, dirt, debris, and insects lodged between the fins.

Remove any foreign materials found using a vacuum cleaner with a brush

attachment or a water spray from a garden hose. Carefully straighten any bent

fins with a thin piece of wood or a fin comb.

7. Labels and Markings - Clean all appliance labels, markings, and instruction

plates, as necessary, and verify that all are still legible. Any illegible or missing

markings must be replaced. Replacements can be obtained by contacting

Thermo Products.

B. Heat Exchanger

: 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 heat transfer, resulting in less

heating efficiency.

Also, look for loose or deteriorated gaskets and insulation around the flue pipe, the

burner, and accessible areas of the heat exchanger. If this inspection indicates heat

exchanger cleaning is necessary, follow the heat exchanger cleaning instructions

below.

1. Disassembly to Access Heat Exchanger

To clean the heat exchanger, first turn off all electrical power to the unit. Next,

remove the cleanout access panel inside the burner compartment to gain entry to

the cleanout covers, refer to Figure 9.

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

Figure 9, OPB Heat Exchanger Clean-out Ports and Related Components

Remove the clean-out covers. Also, remove the burner compartment cover, the

burner, and the burner mounting plate. When removing the clean-out covers, special

care must be taken not to damage the gaskets. Should any of the gaskets separate,

show evidence of cracks or breaks, or otherwise be unable to provide the necessary

seal, the gasket must be replaced before reattaching the clean-out covers, refer to

Figure 10.

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

With access to the inside of the heat exchanger through the burner area, cleanout

openings, and vent terminal connection, it is now possible to use a long, flexible wire

brush and an industrial type vacuum cleaner to remove any soot build-up.

NOTICE: A one inch (outside diameter) vacuum cleaner hose will fit into the

radiator.

To vacuum and brush the horizontal drum of the heat exchanger, enter the drum

through the clean-out openings in both directions.

2. Heat Exchanger Reassembly

After the heat exchanger has been cleaned, install the heat exchanger and

reassemble the components to their factory produced state, in reverse order of

disassembly and removal, refer to figures 9 and 10. Remount the burner being

certain that the air tube is properly inserted into the chamber opening. If heavy

soot deposits were found in the heat exchanger, this indicates that the burner

may be out of adjustment. Reset the burner, as indicated under the Initial

Burner Operation section.

Figure 10: View of OPB Heat Exchanger

Replace any damaged or corroded components. All gaskets and insulation must

be inspected, and replaced, if they show any signs of damage.

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

3. Operational Check

: 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. Observe the main burner flame. If the flame appears strange or abnormal in

character, look for a component or components that were not reassembled

correctly. If the components have been reassembled correctly, check for a

blocked vent, malfunctioning combustion air blower or fuel pump, and partially

blocked burner nozzle.

C. Electrical System

: When servicing controls, label all wires prior to disconnecting.

Correctly reconnect any wires removed during servicing. Wiring errors can

cause improper and dangerous operation. Dangerous operation can result in

injury or damage.

1. Check all wiring for loose connections and any signs of damage, or unusual

wear. Replace any damaged or frayed wiring and tighten any loose connections.

2. Use a voltmeter, or a multimeter, to check for adequate voltage at the field

connections when the appliance operating.

3. Use an ammeter, or a multimeter, to check the current draws of the blower

motor, burner assembly, and air conditioning compressor to assure they are not

exceeding rating label current specifications for each component. Also, refer to

Table 5 for electrical specifications on these components.

4. Check for correct operation and proper settings (if manually adjustable) of all

controls.

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

D. Supply/Return Air Blower

Check in the blower compartment for dust, dirt, debris, and for the presence of

insects. Remove any foreign material. Clean the blower wheel, housing, and

compartment of dust and lint with a vacuum.

The blower motor has sealed bearings that are permanently lubricated. The blower

motor bearings do not require oil or any type of additional lubrication.

E. Supply/Return Air Filter

A permanent-type air filter is provided in the return section of this unit. This filter

should be inspected regularly. When the filter is dirty, it should be cleaned or

replaced to assure proper heating/cooling system operation. Follow the cleaning,

removal and replacement procedure below.

1. Filter maintenance procedure

The filter rack is located behind an access panel on the left-hand side of the

unit, refer to Figure 12. Shut off the electrical power to the unit. Remove the

screws retaining the access panel to the housing. Remove the access panel.

Slide the dirty air filter out of the filter rack. Clean the filter by either

vacuuming, rinsing with tap water, hosing, or dipping in an ordinary detergent

solution. After cleaning and drying the filter, replace the completely dry filter in

the rack. If the filter has a supporting mesh, the mesh side of the filter must be

placed towards the furnace.

Figure 12: Location of the OPB Supply/Return Air Filter

2. 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.

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

NOTICE: Remind the homeowner of the importance of monthly filter

inspections during operation to ensure maximum operating efficiency.

F. Extended Appliance Shutdown

: Do not attempt to start burner when:

• Primary reset has been engaged more than two times.

• Excess oil has accumulated in the combustion chamber or beneath the

burner assembly.

• The combustion chamber or the heat exchanger is full of fuel vapor.

• The combustion chamber is very hot.

Should the appliance be shutdown or turned off for an extended period of time,

several steps can be taken to help insure a smooth and reliable restart of the

heating system.

ON SHUTDOWN:

1. Close oil supply (or manual shutoff) valve.

2. Disconnect all electrical power to the unit.

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 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 for recommendations.

3. Change the oil filter cartridge and clean the canister.

4. Set the room thermostat above room temperature.

5. Open all valves in the oil supply line.

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

6. Open the inspection cover on the upper mounting plate.

7. Turn on the electrical power to start the burner. If the burner does not start,

immediately reset the manual overload switch on the motor (if so equipped)

and the safety switch of the burner primary control. Bleed air from the fuel oil

line as soon as the burner motor starts rotating. To bleed the fuel pump,

attach a clear plastic hose over the vent plug, refer to Figure 13. Loosen the

plug and catch the expelled oil in an empty container. Tighten the plug when

all the trapped air appears to be purged. If the burner stops during bleeding,

wait three to five minutes for the control safety switch to cool. Then manually

reset the switch. Continue bleeding the line until the air is completely

removed.

Figure 13: Location of Oil Pump Vent Plug

8. Follow the previous Initial Burner Operation procedures.

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

VII. HOMEOWNER/USER INFORMATION AND ROUTINE MAINTENANCE

: Never burn garbage or refuse in this appliance. Never try to ignite oil by

tossing burning papers or other material into the combustion chamber.

: Oil-fired appliances produced by Thermo Products are designed for

burning No. 2 distillate (domestic heating) fuel oil. Never use gasoline or a

mixture of oil and gasoline.

: 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 off the

electrical power to the appliance, before shutting off the manual oil valve.

: 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.

: Do not attempt to make repairs yourself. Contact your local qualified

heating contractor.

Under normal conditions, this appliance will operate in either heating or cooling mode,

depending upon the mode of operation set at the thermostat. The unit will cycle on and

off automatically, as required, to maintain the air temperature within the residence as

closely as possible to the thermostat setting. However, in rare cases, the unit may

shutdown automatically during a normal cycle or may not operate under seemingly

normal conditions.

If the unit will not operate in the heating mode, it may be possible to reactivate the

unit by resetting one of the burner controls. To attempt resetting of the burner controls,

follow this procedure.

1. Turn the thermostat temperature setting down and set the operating mode to

“OFF” or “COOLING”.

2. Remove the burner compartment cover.

3. Check to see if the LED on the burner primary (ignition) control module is

flashing at a rapid rate. If so, the control may have “locked out”. To recycle the

control system, depress the reset button. Refer to Figure 14.

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

4. Check to see if the high temperature limit switch reset button, on the burner

motor, has “popped out”. If so, the control has activated. To reactivate the

control, depress the reset button.

5. Replace and secure the burner compartment cover.

6. Set the operating mode on the thermostat to “HEATING” and turn the thermostat

temperature setting up.

Figure 14: Location of Reset Buttons on the Burner Primary Control and the

Burner Motor

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. However, under certain circumstances, the

appliance may not be able to fire the burner. For instance, if the manual oil

shutoff valve has been closed or the oil tank is out of fuel, the oil line may have

air trapped in it. It will be necessary to purge the air by bleeding the supply line

from the tank to the burner again for the heating system to operate. Refer to the

instructions under the Extended Appliance Shutdown section of this manual.

NOTICE: Thermo Products recommends that the user/homeowner, contact

a qualified service agency for assistance in bleeding the fuel line(s) and

lighting off the heating section.

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

The following maintenance points should be reviewed periodically to assure the heating

and cooling systems continue to function properly.

: 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.

1. At least every three months, under normal usage conditions, check and clean all air

filters in the appliance and, if present, in the duct system. If excessively dirty air

filters are not cleaned, or changed, poor system performance will result due to

reduced airflow. Low airflow places unnecessary strain on the compressor, possibly

causing the system to shutdown on the refrigerant high-pressure switch. Refer to

Figure 16 for a sketch of the filter location.

2. Keep the outside condenser coil clean by carefully spraying the finned area with

plain water, from the inside of the coil outward.

3. Carefully remove any leaves, twigs, debris, trash, and insect or small animal nests/

homes from in and around any openings in the appliance housing.

4. Visually inspect the vent terminal for restrictions and blockages. With the heating

system in operation, the vent terminal will be hot. Shut off the unit and allow the

vent terminal to cool before removing any foreign materials from within the vent

terminal.

5. Inspect the exterior of the appliance for signs of excessive heat such as

discoloration of materials, damage from rust or corrosion, or evidence of oil leakage.

Pay special attention to the mounting base the appliance is resting upon. If the base

is severely damaged, deteriorated, or unstable, shutdown the unit and call a

qualified heating contractor for recommendations on repair or replacement of the

base.

6. Do not allow the fuel oil tank to run completely empty. During the summer, keep the

tank full to reduce condensation of moisture on the inside surface of the tank.

If the fuel tank runs completely dry, it may be necessary to bleed air from the fuel

lines. Contact a qualified heating contractor to bleed the lines and restart the

burner.

7. Check the supply and return air connections to the appliance to insure the seals

between the duct and appliance and the appliance and home are intact. Check the

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

ducts for any signs of collapse, holes, or excessive corrosion. Repair or replace

components as required.

8. It is advisable to wax the outer surface of the appliance housing yearly to provide the

surface finish protection from excessive degradation by sunlight and inclement

weather. A good grade of automotive wax should be used to protect the finish.

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

VIII. TROUBLESHOOTING

: Power must be disconnected before servicing.

Refer to the appendices of this manual for an electrical schematic, a connection

diagram, flowcharts to assist in troubleshooting, product specifications, and a

replacement parts list follow for this appliance.

A. Heating System:

Qualified HVAC and cooling contractors must perform all service.

NOTICE: Before troubleshooting, familiarize yourself with the Initial Startup,

Checkout Procedure, and Heating System Troubleshooting Flowchart.

To assist in troubleshooting the heating section of this appliance, it is equipped with

an integrated safety and ignition control with diagnostics. These diagnostics include

an indicator light that relays the operational status of the control and can help in

diagnosing the condition of the flame sensor.

Diagnostic Features

The Honeywell brand model R7184B (or alternate R7184U) safety and ignition

control module used on this unit continuously monitors the operation of the heating

system. If an abnormal condition occurs, the LED light on the control will rapidly

flash indicating the operational status of the unit. In event this control

malfunctions, the entire control should be replaced. It is not field-repairable.

In the event of an operational failure of the burner system, the rate of flashes, if any,

of the ignition control module LED should be noted, before turning off power to the

unit. Otherwise, power to the heating section will be interrupted and the control LED

will not furnish the diagnostic flashing. It may be necessary to restart the furnace and

have the failure occur again. For the model R7184B, under normal operating

conditions, the LED will be continuously lit while the burner is operating.

If either control has sensed a flame failure, which was uncorrected by initiating

another trial-for-ignition, the control will cease ignition trials and shutdown the

burner, or “lockout”. The LED will continuously flash at a high rate (approximately

1/2-second “on”; 1/2 second “off”, for the model R7184B.

: If the appliance fails to relight after resetting the primary control twice

contact a qualified service company. DO NOT continue to reset primary control.

The operational condition of the flame sensor, or “cad cell”, can be checked by

depressing the reset button on the control module, while the burner is operating.

Count the number of flashes of the LED and compare them to the table below.

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

Number of flashes

Cad Cell Resistance (in ohms)

Model R7184B

1 ......................................... 0 to 400

2 ......................................... 400 to 800

3 ......................................... 800 to 1600

4 ......................................... 1600 <

If it is necessary to troubleshoot the flame sensor independently of the burner

primary, the following procedure may be used.

CAD CELL CHECKOUT PROCEDURE:

1. Stop burner and shutoff electrical power to the appliance.

2. Open burner junction box (on top of the burner blower) and remove the plug-

in portion of the cad cell by pulling it forward from and clear of the

receptacle. Connect an ohmmeter across cad cell pins. With the cell

exposed to direct room light, the measured resistance should be less than

2500 ohms (in fact, it may be less than 200 ohms).

3. Check the resistance across the cad cell pins with the cell covered

(protected from exposure to ambient light). The resistance should be greater

than 20,000 ohms.

4. If cell resistances are different from above, replace the plug-in portion of cell,

(Honeywell Part No. 130367).

5. Carefully reinsert the plug-in portion of the cad cell into the receptacle. If the

cad cell appears to be functioning correctly, troubleshoot the fan control

module and the safety and ignition control (primary control) module,

according to the Honeywell instructions covering the devices.

B. Cooling System:

NOTICE: Before troubleshooting, familiarize yourself with the Initial Startup

and the Cooling System Troubleshooting Flowchart.

If the air conditioning system will not operate, check the following points before

calling a qualified heating contractor.

1. Is the disconnect switch or the circuit breaker serving the appliance switched on?

If equipped, have the disconnect switch fuses “blown” or has the circuit breaker

tripped? If an electrical fault has occurred more than once, call your qualified

service person to diagnose the cause and perform the required repair(s).

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

2. Is the sub-base of the thermostat switched to the “COOL” position?

3. Is the temperature setting on the thermostat low enough to bring the cooling

system on?

4. Has the unit stopped cooling, making it necessary to wait several hours before

the unit will restart? The fan motor, or compressor, may have shutdown on

thermal-overload due to overheating. If this event frequently occurs, call your

qualified heating contractor.

5. Has it been longer than four minutes since the last cooling cycle finished or since

power was restored form an outage.

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

IX. REFERENCES

1. International Approval Services-U.S. Inc. and the National Fire Protection

Association, 1996, National Fuel Gas Code, ANSI Z223.1-1996/NFPA 54-1996, 6th

Ed., pp. 10 & 13.

2. Earley, M.W., Sheehan, J.V., Caloggero, J.M., 1999, National Electrical Code

Handbook, 8th Ed., National Fire Protection Assoc., Inc., pp. 142, 143, 256, & 502-

510.

3. American Society of Heating, Refrigerating, and Air-Conditioning Engineers, Inc.,

1997, ASHRAE Handbook – Fundamentals, pp. 19.9, 32.1-32.50.

4. Lindeberg, M.R., 1984, Mechanical Engineering Review Manual, 7th Ed.,

Professional Engineering Registration Program, San Carlos, CA, pp. 5-8 & 5-9.

5. Avallone, E.A., Baumeister III, T., 1996, Marks’ Standard Handbook for Mechanical

Engineers, 10th Ed., McGraw-Hill, New York, pp. 12-88 & 12-89.

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

X. APPENDIX A: SOURCES FOR REFERENCED STANDARDS

1. Air Conditioning Contractors of America

1712 New Hampshire Avenue, NW

Washington, D.C. 20009

(202) 483-9370

2. American National Standards Institute, Inc.,

Attn: Customer Service

11 West 42^ndStreet

New York, New York 10036

(212) 642-4900

3. American Society of Heating, Refrigeration, and Air-Conditioning Engineers, Inc.,

1791 Tullie Circle N.E.

Atlanta, Georgia 30329

(404) 636-8400

4. National Fire Protection Association,

1 Batterymarch Park

Quincy, Massachusetts 02269

(800) 344-3555

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

XI. APPENDIX B: CALCULATIONS

Example 1:

Problem: It is desired to install a warm-air furnace w/ an air conditioning

evaporator coil at a residence. The net output of the furnace is 100,000 BTU/hr

and the evaporator will provide 4 tons of cooling to the space. Estimate the

minimum required airflow for the system to operate satisfactorily.

Solution: From the heat output of furnace, the heating airflow requirements can

be estimated:

100,000 BTU/hr x 14 CFM/1000 BTU/hr = 1400 CFM.

From the required cooling performance, the cooling airflow requirements can be

estimated:

4 tons x 400 CFM/ton = 1600 CFM.

The larger of the two airflow figures should be selected, i.e. 1600 CFM cooling

requirement.

If only 3 tons (36,000 BTU/hr) was installed, the required cooling airflow is:

3 tons x 400 CFM/ton = 1200 CFM.

Then, the duct system should be sized for the 1400 CFM heating requirement.

Example 2:

Problem: A plan view of a residence with 1600 sq. ft. living area is shown in

Figure 15. The supply registers and the OPB unit have been positioned.

Ductwork interconnecting the registers is also shown. What is the required air

flowrate at each register? What is the required duct size for each segment of the

duct system?

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

Figure 15: Plan View of a Typical Residence

Solution: If certain flowrates are desired, for heating or cooling reasons, or are

required, by local codes, those guidelines should be followed. In lieu of other

requirements, room floor area can be used to select flowrates for each room.

For instance, the floor area of the living room is 400-sq. ft. Using the result of our

previous example, the required minimum air flowrate for the residence is 1400

CFM. The air flowrate for the living room will be the total flowrate multiplied by

the ratio of the living room area to the total floor area or,

⎛

⎞

400sq. ft.

⎜

⎟

CFM_{Living Rm}= 1400CFM *

= 350CFM.

1600 sq. ft.

⎝

⎠

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

This procedure can be repeated to determine the airflow for each room in the

residence. The results of these calculations are given in Table 6, below.

Table 6: Required Room Air Flowrates Based on Floor

Area for Example 2

Room

Room Air

Flowrate per

(CFM)

Number of

Registers

Room Floor Area Flowrate

(Sq. Ft.)

400

(CFM)

350

1 @ 120

2 @ 115

Living

Dining

120

144

105

126

105

126

Kitchen

Master

Bedroom

360

315

2 @ 157

Bedroom

224

196

Master

Bathroom

Total

1600

1400

We will assume the airflow is approximately equally split between all registers in

a particular room. This completes steps (a) through (d) of the duct sizing method.

For step (e), static pressure drops for each system, branch, and component must

be selected. Since the appliance circulating blower can only tolerate a maximum

pressure of 0.4 in. W.G., the combined resistance of the supply and return air

systems cannot exceed this amount.

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

Therefore, choose a supply system static pressure drop of 0.2 in. W.G. (Then,

the return air system will also have a static pressure drop of 0.2 in. W.G.)

Furthermore, we will assume that the static pressure drops for all registers in the

supply system will be 0.1 in. W.G.

This leaves a static pressure drop of only 0.1 in. W.G. for all the ducting between

the outlet flange of the appliance to each of the registers. (We will assume that

the pressure drop through any short piece of ductwork connecting a branch to a

size of the ducting for each segment of the duct system can begin.

For the branch of the duct system, which includes segments “A”, “B”, “C”, “F”,

and “H”, the pressure drop cannot exceed 0.1 in. W.G. This branch of the duct

system has two 90-degree turns. The total length of this branch is the sum of the

lengths of each segment,

Le_AH= L_A+ L_B+ L_C+ L_F+ L_H

(

11 ft. + 6 ft.

)

+11 ft. + 6 ft. + 22 ft. +12 ft. + 3 ft.

= 71 ft.

Using the flowrate, total length of the duct, and the pressure drop, the required

size of the duct can be determined using the following equation.

0.2058

*V (CFM )^1.82

⎡

⎤

0.00123174* Le

(

ft.

)

in.

( )

⎢

⎣

⎥

⎦

ΔP

(

in.W.G.

)

**See page 75 for a copy of the ASHRAE chart.

This equation is applicable to standard air between 50 to 90 degrees F flowing

through clean, round, galvanized ductwork with approximately 40 joints per 100

feet. Using duct lengths in feet, flowrate in CFM, and pressure drop in inches

W.G., the equation will calculate the required circular duct diameter in inches. (If

it is desired to substitute rectangular duct for circular duct, refer to Table 7 for

equivalent sizes.)

Returning to the example, for a total length of 71 ft., a flowrate of 120 CFM (from

the farthest register on segment “A”), and a pressure drop of 0.1 in. W.G., the

required duct diameter is,

0.2058

1.82

⎡

⎤

0.00123174*71*120

0.1

D =

= 5.85 in. ≅ 6 in.

⎢

⎣

⎥

⎦

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

However, there are two, 90 degree turns in the branch that will cause a large

pressure drop, not accounted for in our calculations. To compensate for this

drop, we should increase the effective length of the branch. For a 90 degree,

mitered elbow, the equivalent straight duct length is given by the following

formula,

(

in.

)

L_{90 elbow}

(

ft.

)

= 65*

For a 6-inch diameter 90-degree elbow, the equivalent straight duct length is,

L_{90 elbow}= 65* = 32.5 ft.

So, the total equivalent straight duct length is,

Le = 71 ft. + 2*32.5 ft. = 136 ft. .

Now, the required duct diameter should be recalculated,

0.2058

1.82

⎡

⎤

0.00123174*136*120

0.1

D_A=

= 6.67 in. ≅ 7 in.

⎢

⎣

⎥

⎦

Thus, for section ”A”, the required duct diameter is 7 inches.

Now, it is necessary to determine the allowable pressure drops for all other

segments in the branch. The equation for duct diameter can be rearranged to

give the pressure drop for any flowrate, providing the duct length, the flowrate,

and the duct diameter are known. The equation looks like this,

1.82

0.00123174* Le

(

ft.

)

(

CFM

)

ΔP

(

in.W.G.

)

(

in. ^4.86

)

For section “B”, if the flowrate is 120 CFM, the length is 11 ft., and the duct

diameter 7-in., the pressure drop will be,

0.00123174*11*120^1.82

ΔP =

= 0.00644 in.W.G. .

7^4.86

For section “C”, including a 7-inch, 90-degree elbow, the pressure drop is,

*120^1.82

0.00123174*

(

6 + 37.9

)

ΔP =

= 0.0257 in.W.G. .

7^4.86

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

Likewise, the pressure drops for the two remaining segments in this branch can

be calculated in the same manner. They are,

ΔP = 0.0129 in.W.G. and

ΔP = 0.00702 in.W.G. .

Referring to section (f) and (g) of the method, it is now necessary to resize each

of these duct segments for the actual required flowrate while maintaining the

pressure drops calculated above.

For instance, to maintain the pressure drop through segment “B” at the design

flowrate of 120 CFM + 115 CFM = 235 CFM, the required duct diameter is,

0.2058

1.82

⎡

⎤

0.00123174*11*235

0.00644

D_B=

= 9.04 in. ≅ 9 in.

⎢

⎣

⎥

⎦

For segment “C”, the design flowrate is 235 CFM + 115 CFM = 350 CFM, while

the pressure drop is 0.0257 in. W.G., then required duct diameter is,

0.2058

1.82

⎡

⎤

0.00123174*6*350

0.00257

D_C=

= 11.1 in. ≅ 11 in.

⎢

⎣

⎥

⎦

Including an 11 in., 90 degree elbow in segment “C”, the required diameter would

be,

0.2058

⎡

⎤

0.00123174*

(

6 + 59.6

)

*350^1.82

D_C=

= 11.4 in. ≅ 11 in.,

⎢

⎣

⎥

⎦

0.00257

or approximately the same as without the elbow.

For the segments “F” and “H” at 742 CFM and 798 CFM, respectively, the

required duct diameters are,

D_F= 13.9 in. ≅ 14 in. and

D_H= 14.3 in. ≅ 14 in..

Next, the branch of the system, which includes segments “D” and “E” can be

evaluated. To balance the system, the pressure drop for segments “D” and “E”

combined must be approximately equal to the pressure drops of segments “A”,

“B” and “C” combined. Thus,

ΔP + ΔP = ΔP_A+ ΔP + ΔP .

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

Using the previous pressure drop equation, the pressure drop through segment

“A” is 0.0321 in. W.G. Then, the pressure drop for the “D” and “E” branch is,

ΔP + ΔP = 0.0321 in.W.G. + 0.0644 in.W.G. + 0.0257 in.W.G.

= 0.0643 in.W.G..

The duct diameter required to pass 196 CFM @ 0.0643 in. W.G. pressure drop

is,

0.2058

⎡

⎤

0.00123174*

(

)

*196^1.82

D_E=

= 5.73 in. ≅ 6 in.,

⎢

⎣

⎥

⎦

0.0643

Including a 6 in., 90-degree elbow in segment “E”, the required diameter would

be,

0.2058

⎡

⎤

0.00123174*

(

17 + 32.5

)

*196^1.82

D_E=

= 7.14 in. ≅ 7 in.,

⎢

⎣

⎥

⎦

0.0643

or approximately 1 inch larger than without the elbow.

The pressure drop through segment “D” should be calculated for a 5-ft. straight

section with a 7-in., 90-degree elbow. From our previous equation, the pressure

drop is about,

0.00123174*

(

5 + 37.9

)

*196^1.82

ΔP =

= 0.0614 in.W.G. .

7^4.86

The flowrate through section “D” is 392 CFM (196 CFM + 196 CFM). With the

required pressure drop, the duct diameter is,

0.2058

⎡

⎤

0.00123174*

(

5 + 37.9

)

*392^1.82

D_D=

= 9.07 in. ≅ 9 in. .

⎢

⎣

⎥

⎦

0.0614

Recalculating the duct size considering the effective length of a 9 in., 90 degree

elbow,

0.2058

⎡

⎤

0.00123174*

(

5 + 48.75

)

*392^1.82

D_D=

= 9.50 in. ≅ 10 in. ,

⎢

⎣

⎥

⎦

0.0614

or an increase in duct size of about 1 inch in diameter.

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

The pressure drops for the remaining branches of the system must be set. This

includes segment “G”; segments “I” and “J”; and segments “K”, “L”, and “M”. To

balance the system, the pressure drop for each branch must be approximately

equal to the pressure drops of the other branches. For example, segment “G”

must equal segments “D”, “E” and “F” combined. Thus,

ΔP = ΔP + ΔP + ΔP .

Likewise for the other branches,

ΔP + ΔP = 0.1 in.W.G.

ΔP + ΔP + ΔP = 0.1 in.W.G. .

Using the previous technique, duct sizes can be found for all the remaining

segments. The duct sizes adequate for the entire supply system are summarized

in Table 7, below.

Table 7: Required Duct Sizes for the Residence in Example 2

Equivalent

Air

Circular Air Velocity in

Duct

Segment

Rectangular

Duct Dim.s

(in.)

Flowrate Duct Dia. Circular Duct

(CFM)

(in.)

(FPM)

120

235

350

392

196

742

449

532

530

719

733

694

1141

746

924

864

678

688

587

6 x 6

8 x 8

10 x 10

9 x 9

6 x 6

13 x 13

N/A

798

126

231

370

304

157

13 x 13

N/A

6 x 6

9 x 9

8 x 8

6 x 6

N/A - Not Applicable

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

Example 3:

Problem: Refrigerant measurements are made on the cooling system of a typical

OPB installation. The suction line pressure, measured at the condenser unit,

suction line, charging port, is 135 PSIG. The temperature of the refrigerant

(R410A) at the evaporator suction line connection is measured as 55°F. What is

the degree of superheat for this system?

Solution: Calculate the pressure of the refrigerant at the evaporator suction line

connection. With the estimated refrigerant pressure and measured temperature

at the same point, tabulated data on R410A from the refrigerant manufacturer,

or ASHRAE, can be used to evaluate the degree of superheat.

135 PSIG (Suction pressure measured at condenser)

+ 0 PSIG (Added for pressure drop of suction line)

------------------

135 PSIG = Estimated pressure of refrigerant at evaporator exit

From the R410A pressure/temperature chart, at 135 PSIG, the saturation

temperature is approximately 47°F

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

Now, the degree of superheat can be calculated.

55°F

- 47°F

(Suction line temperature at outlet of evaporator)

(Saturation temperature for R410A at 68 PSIG)

-----------------------

8°F

Degree of evaporator superheat.

Example 4:

Problem: Additional refrigerant measurements are made on the cooling system

of our typical OPB installation. The liquid line pressure, measured at the

condenser unit, liquid line, charging port, is 340 PSIG. The temperature of the

refrigerant (R410A) at the evaporator liquid line connection is measured as 95°F.

What is the degree of subcooling for this system?

Solution: Calculate the pressure of the refrigerant at the evaporator liquid line

connection. With the estimated refrigerant pressure and measured temperature

at the same point, tabulated data on R410A from the refrigerant manufacturer,

or ASHRAE, can be used to evaluate the degree of subcooling.

340 PSIG (Liquid line pressure measured at condenser)

+ 0 PSIG (Added for pressure drop of liquid line)

------------------

340 PSIG = Estimated pressure of refrigerant at evaporator inlet

From the R410A pressure/temperature chart, at 340 PSIG, the saturation

temperature is approximately 105°F

Now, the degree of subcooling can be calculated.

105°F

- 95°F

------------------

(Saturation temperature for R410A at 340 PSIG)

(Suction line temperature at outlet of evaporator)

10°F

Degree of condenser subcooling

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

XII.

APPENDIX C: ELECTRICAL SCHEMATIC AND CONNECTION DIAGRAM

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

XIII. APPENDIX D: SEQUENCE OF OPERATIONS

OPB

1 of 2

A. SEQUENCE OF OPERATIONS FOR THE HEATING SYSTEM

Mode of Operation

Control System Action

Standby

(At any time the oil

valve is not energized)

Continous safe operation check. If

flame simulation condition present,

system shuts off oil valve,ignitor,

and burner motor; activates fast

flashing LED.

Start

Thermostat calls for heat,

contacts close

Ignition electrodes spark.

Burner motor energized.

On power interruption, system

shuts off, restarts when

power is restored.

Oil valve energized after

15 second time delay.

Start trial for

ignition

If flame is not detected, the

oil valve is de-energized,

the ignitor is turned off and

the ignition control module

goes into the "retry" sequence.

Flame must be detected

after 45 seconds.

The retry sequence provides a

60 second wait before ignition

is attempted again.

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

OPB

2 of 2

Control System Action

After 45 second delay, the

ignition electrodes are de-

energized. The circulating

air fan is energized at heating

speed. The (optional) electronic

air cleaner & humidifier are

Main Burner

Operation

energized.

If ignition attempt is unsuccessful,

the ignition control module goes into

system lockout.

Repeat Ignition

Trial

When thermostat is satisfied,

contacts open and the oil

valve is de-energized. After

a 2 minute burner off delay,

burner motor is de-energized.

Call for Heat

The 2 minute delay- to- fan-off

Satisfied

period begins.

If system is in lockout,(check if LED

is flashing fast) try to recycle the

system by depressing the RESET button

on the ignition control module.

System Lockout

After the delay-to-fan-off

period ends, the circulating

air fan and {optional)

electronic air cleaner are

de-energized.

End of Cycle

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

XIV. APPENDIX E: TROUBLESHOOTING FLOWCHARTS

OPB

1 of 2

A. SEQUENCE OF OPERATIONS FOR THE HEATING SYSTEM

Mode of Operation

Control System Action

Standby

(At any time the oil

valve is not energized)

Continous safe operation check. If

flame simulation condition present,

system shuts off oil valve,ignitor,

and burner motor; activates fast

flashing LED.

Start

Thermostat calls for heat,

contacts close

Ignition electrodes spark.

Burner motor energized.

On power interruption, system

shuts off, restarts when

power is restored.

Oil valve energized after

15 second time delay.

Start trial for

ignition

If flame is not detected, the

oil valve is de-energized,

the ignitor is turned off and

the ignition control module

goes into the "retry" sequence.

Flame must be detected

after 45 seconds.

The retry sequence provides a

60 second wait before ignition

is attempted again.

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

TURN THERMOSTAT TO CALL FOR HEAT

DOES THERMOSTAT MAKE CONTACT?

IS ROOM TEMPERATURE

TURN T'STAT SETTING

ABOVE ROOM

IS ROOM TEMPERATURE

BELOW THERMOSTAT SETTING?

TEMPERATURE

Yes

ALLOW THE ROOM

AIR TO COOL

CHECK IN PUT POWER,

DISCONNECTING SWITCH,

AND FUSE(S), IF EQUIPPED.

DOES BURNER MOTOR

START?

CHECK FOR LINE VOLTAGE

@ FAN CONTROL MODULE.

IF NOT 115 VAC, CHECK FOR

BLOWN FUSE OR TURN ON

IS THE BURNER

PRIMARY LOCKED

OUT ON SAFETY ?

IS VOLTAGE PRESENT

AT BURNER MOTOR?

POWER. IF 115 VAC PRESENT,

CHECK OUT FAN CONTROL

MODULE & PRIMARY MODULE

ACCORDING TO MANUFACTURER'S

INSTRUCTIONS.

Yes

PUSH IN PRIMARY RESET BUTTON

IS THE OIL PUMP

MECHANICALLY

LOCKED-UP?

IS BURNER MOTOR RESET

BUTTON POPPED OUT

REPLACE BURNER

MOTOR

Yes

REPLACE OIL PUMP

PUSH IN MOTOR RESET BUTTON

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

Yes

IS IGNITION ESTABLISHED?

IS IGNITION TRANSFORMER

CAPABLE OF PRODUCING A

3/4" ARC? (10,000 VAC)

ARE THE ELECTRODES

ARCING?

REPLACE IGNITION

TRANSFORMER

Yes

DETERMINE IF THE ELECTRODES ARE

ALIGNED, CONTACT SPRINGS TOUCHING

ELECTRODE RODS, & PORCELAIN

INSULATORS CLEAN AND

Yes

UNCRACKED. ADJUST OR REPLACE,

AS NECESSARY.

Yes

IS THE COUPLING BETWEEN

THE BURNER MOTOR AND

THE PUMP STRIPPED?

IS THE OIL PUMP

OPERATING?

REPLACE PUMP

Yes

REPLACE COUPLER

VERIFY ALL OIL VALVE(S) ARE OPEN,

OIL TANK IS SUFFICIENTLY FULL,

AND OIL LINE CONTAINS OIL.

IS OIL AVAILABLE TO THE BURNER?

FURNACE OPERATES FOR

COMPLETE CYCLE?

IS HEAT ANTICAPATOR SET

TO MILLIAMP SETTING

MEASURED ON SUBBASE?

MEASURE MILLIAMPS BETWEEN 'W' &'R'

ON THE T'STAT SUBBASE AND SET HEAT

ANTICIPATOR ACCORDINGLY

BURNER RUN NORMAL

CYCLE?

Yes

IF PROBLEM PERSISTS CONTINUE TO NEXT SECTION.

Yes

BLOWER RUNS

NORMAL CYCLE?

IS TEMPERATURE RISE

CHECK-BLOWER SPEED

AND RETURN AIR TEMPERATURE

Yes

CHECK FAN ON & OFF (DIP SWITCH)

SETTINGS ON FAN CONTROL

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

PROPER COMBUSTION ACHIEVED?

IS THE AIR TUBE INSERTION

0-1/4" BACK FROM INSIDE

OF REFRACTORY?

CORRECT INSERTION OR

AIR TUBE BURNOFF

MAY OCCUR.

Yes

IS THE PROBLEM DELAYED

IGNITION?

Yes

ALIGN ELECTRODES PER

BURNER INSTRUCTION

MANUAL SPECIFICATIONS

ARE THE ELECTRODES

PROPERLY ALIGNED?

Yes

ADJUST TO 100-120 PSI

UNLESS COMBUSTION

AIR OR OIL BELOW 50

deg. F IS PRESENT (THIS

IS CONSIDERED BELOW)

IS PUMP PRESSURE SET

ACCORDING TO BURNER

APPLICATION CHART

Yes

ARE VENT TERMINAL AND HEAT

EXCHANGER CLEAN?

ADJUST AIR TO A TRACE OF

SMOKE, THEN TAKE CO2 OR

O2 READING, NEXT SUBTRACT

1% FROM THE CO2 OR ADD 1%

TO O2 . THEN, ADJUST AIR TO

OBTAIN NEW CO2 OR O2 VALUES.

IS BURNER SET TO

PRODUCE A TRACE

OF SMOKE AND

IS THE NOZZLE

PLUGGING?

THEN "DETUNED".

Yes

IS WATER, DIRT, OR

SLUDGE PRESENT IN

THE OIL SYSTEM?

IS COMBUSTION AIR

Yes

TRY TO RAISE ROOM & OIL

IF THIS CANNOT BE DONE DO

THE FOLLOWING:

REPAIR OR REPLACE TANK

TO PREVENT FUTURE

PROBLEMS. MIX

IN PROPER ADDITIVES

TO REMOVE WATER

AND SLUDGE

DECREASE NOZZLE SIZE AND

INCREASE PUMP PRESSURE.

CHOOSE SMALLER NOZZLE

SIZE AND PUMP PRESSURE

FROM "EFFECTS OF PRESSURE

ON NOZZLE FLOW RATES" AT

THE END OF THE TROUBLE

SHOOTING SECTION.

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

Yes

DOES FURNACE OPERATE

WITHOUT CONDENSING?

IS STACK TEMPERATURE

IS BURNER SET AS INDICATED

IN ABOVE SECTION?

ADJUST BURNER COMBUSTION

TO PRODUCE ZERO SMOKE.

Yes

SLOW THE BLOWER SPEED

TO RAISE TEMPERATURE

RISE.

IS THE TEMPERATURE

DIFFERENCE BETWEEN SUPPLY

Yes

INCREASE LENGTH OF BURNER ON CYCLE

BY RESETTING BURNER PRIMARY CONTROL

DIP SWITCHES FOR A LONGER OFF DELAY.

TROUBLE SHOOTING ENDS.

REPEAT PROCEDURE UNTIL TROUBLE FREE OPERATION IS OBTAINED.

EFFECTS OF PRESSURE ON NOZZLE FLOW RATE

NOZZLE

RATING

NOZZLE

RATING

NOZZLE FLOW RATES IN

GALLONS PER HOUR (Approx.)

NOZZLE FLOW RATES IN

GALLONS PER HOUR (Approx.)

80PSI

120PSI

140PSI

80 PSI

120 PSI

140 PSI

100 PSI

1.35

1.50

1.65

1.75

2.00

2.25

2.50

2.75

3.00

1.21

1.34

1.48

1.57

1.79

2.01

2.21

2.44

2.69

1.48

1.64

1.81

1.92

2.19

2.47

2.74

3.00

3.29

1.60

1.78

1.95

2.07

2.37

2.66

2.96

3.24

3.55

.50

.65

.75

.85

.90

1.00

1.10

1.20

1.25

0.45

0.58

0.67

0.76

0.81

0.89

0.99

1.07

1.12

0.55

0.71

0.82

0.93

0.99

1.10

1.21

1.31

1.37

0.59

0.77

0.89

1.00

1.07

1.18

1.30

1.41

1.48

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

Notes for Air Conditioning Troubleshooting Guide

1.101.0 Check to see if the contactor has not pulled in. If the coil has not pulled in the

contactor, check for 24 VAC to the coil on the contactor.

1.101.1 Check to make sure the control transformer is powering the 115 VAC circuit.

1.101.2 Check for 115 VAC to the control transformer. Check control fuse for 115 VAC

supply.

1.101.3 Check to see if the thermostat is closing to complete the 24 VAC circuit.

Remove thermostat and jump terminals R-Y and R-G. If jumping the sub-base

works, replace thermostat.

1.101.4 If the contactor is reading 24 VAC on the coil, but is not pulling in the contactor,

replace the contactor.

1.101.5 Check the entire 24 VAC circuit between the thermostat, fan control, and

contactor for loose connections and wires pulled away from terminations or

terminals. These conditions can cause an open circuit.

1.101.6 Check for 24 VAC across the refrigerant high-pressure switch. If 24 VAC is

present, check for high liquid pressure or broken wires.

1.201.0 If the contactor is closed and line voltage is measured across lines L1 and L2

but the unit does not run, proceed with the following checks.

1.201.1 Check 240-volt wire leads to the capacitors and the compressor. Make sure

the terminals on the compressor and capacitors are not touching or loose.

1.201.2 Check for continuity across the three terminals of the compressor. (If

continuity is not measured, the compressor windings are opened.)

1.201.3 Check for grounded compressor windings by checking continuity to ground.

1.201.4 The compressor may be tapped with a rubber mallet, or piece of wood, to jar

the compressor loose.

1.201.5 Allow the compressor to cool below 130°F. Check for continuity between

terminals S and C on the compressor. If you do not have continuity, the thermal

protector may require more time to cool down.

1.201.6 Check capacitance of the run capacitor.

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

2.101.0 Check to see if the condenser fan motor is excessively hot as to cause the

thermal-overload to function. Possible causes for outdoor fan motor to kick off

on overload are:

1) Loose wire connections.

2) Excessive current (amp) draw, possibly due to low operating voltage.

3) Bad motor bearings.

4) Excessively dirty coil causing restricted airflow.

5) Excessively hot air being pulled into unit.

6) Stalled fan due to blockage of rotation

2.101.1 Make sure wire leads to the motor are making good connections. A loose

connection can cause an excessive current draw and overheat the motor.

2.101.2 Check for defective fan run capacitor. Use an ohmmeter on highest resistance

scale (i.e. R X 100,000 scale) or continuity. Full needle deflection or no audible

sound indicates the capacitor is open. Replace the capacitor.

2.101.3 Check for continuity of the motor windings, as the motor itself may be

damaged.

2.102.0 Make sure the discharged hot air is not recirculating back through the coil fins.

2.103.0 A slight restriction in the outdoor coil might cause an excessive head pressure

that over time may cause the compressor to function on thermal-overload.

Note: Water in the system may cause restriction after a period of time.

2.104.0 Check for refrigerant overcharge by excessive liquid and suction line pressures.

2.105.0 If the suction pressure is low, add charge to see if the pressure comes up to the

specified value on the appliance-rating label.

2.106.0 Check line voltage to the compressor to see if it is excessively high or low.

2.107.0 A defective run capacitor can also cause the compressor to overheat. Check

out the run capacitor.

2.108.0 The compressor may be drawing excessive current due to an internal defect

such as severely worn or damaged bearings.

2.109.0 Possible causes of a high superheat (15 deg. F. or higher) could be a faulty

expansion valve or an extremely low charge.

3.101.0 A low suction pressure that could indicate the system is low on refrigerant

charge. However, first review the following items.

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

3.101.1 Dirty air filters may restrict the airflow across the evaporator coil resulting in

frost on the coil.

3.101.2 Are the duct system and air blower setup to move enough air to have an 18-20

degree F. drop across the coil?

3.101.3 Are there any registers or dampers closed restricting the airflow of the duct

system?

3.101.4 If the evaporator coil frosts, this indicates a low charge or insufficient air

movement.

3.101.5 The coil may not frost up, but still not cool properly. Is the system slightly low

on refrigerant? Check for an 18°F temperature drop across the coil.

3.101.6 Make sure the liquid line has not kinked or collapsed slightly causing a

restriction.

3.101.7 Hold bulb in hand to see if the pressure changes (this action should increase

the suction pressure).

3.101.8 Check out the supply/return air blower to make sure it is functioning properly.

3.201.0 Check the following items for high suction pressure and low liquid pressure.

Allow at least 5 minutes off time for valve to close when pressures have

equalized if compressor has internal pressure relief valve.

3.201.1 There may be a restriction in the condenser coil. This could be caused by

water or other contaminants in the system. A restriction in the coil is a very

rare problem.

3.201.2 Check the expansion valve for restriction of the metering orifice.

3.301.0 For high suction pressure and low superheat temperatures, review the following

items.

3.301.1 If the system is overcharged with refrigerant, the system will become flooded.

Consequently, the evaporator coil will not effectively absorb heat from the

airflow. The temperature drop across the evaporator coil will be low.

3.301.2 Check for a properly sized expansion valve.

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

XV. APPENDIX F: SPECIFICATION SHEETS

Model No.:

OPB24-80

OPB30-80

OPB36-80

Heating Performance (using # 2 fuel oil):

Input rate (BTUH), Maximum / Minimum :

Heating capacity (BTUH), Maximum / Minimum :

Design temp. rise (deg. F.) on LOW fan speed:

Burner nozzle & oil pressure for max. input rate:

Burner nozzle & oil pressure for min. input rate:

105,000 / 85,000

85,000 / 68,000

0.75 GPH @ 130 PSIG, 80 deg., hollow cone type

0.60 GPH @ 120 PSIG, 80 deg., hollow cone type

Cooling Performance:

Cooling capacity (tons):

2.5

Fan speed:

SEER

800

1000

1200

HCFC-410A (R-410A)

Refrigerant:

Factory refrigerant charge (by weight, in ounces):

Nominal Electrical Power Requirements:

208-240V / 60 Hz / 1 Ph. current (Amps):

Min. fuse or circuit breaker rating (Amps):

18.7

24.9

27.8

Circulating Fan, Motor, & Air Filter:

Blower wheel design and size:

Airflow @ 0.4 in. W.G. external static pressure:

High speed (SCFM):

Directly-driven, DWDI FC centrifugal, 12 in. O.D.

1250

1090

970

Medium-high speed (SCFM):

Medium-low speed (SCFM):

Low speed (SCFM):

800

ECM, air-over, 48Y

Blower motor type & frame:

Nominal blower motor output (HP):

Blower motor full load current (Amps):

Number of blower speeds:

Maximum Rotation speed (RPM):

Direction of rotation (from shaft end):

Motor housing diameter (in.):

Motor housing length (in.):

3/4

9.6

Variable

1400

Clockwise

5.59

6.96

0.5

Shaft diameter (in.):

3.5

Shaft length (in.):

Permanent

1 - 20 x 25

Filter type:

Number and size of air filters (in.):

Dimensions & Weight:

Height of housing (in.):

Width of housing (in.):

Depth of housing (in.):

20 x 12

610

Supply air outlet, width (in.) x height (in.):

Return air inlet, width (in.) x height (in.):

Approx. shipping weight (including packaging, lbs):

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

XVI. APPENDIX G: REPLACEMENT PARTS LIST

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

APPENDIX H: OPB HEATING AND COOLING SYSTEMS TEST FORM

Complete this form for each Thermo Pride OPB appliance installed. Read the instruction manual carefully

before making tests. Retain this form with appliance.

Name:

Customer

Appliance

Address:

City, State, & Zip Code:

Model No.:

Serial No.:

AFG-TP1502

Burner Model No.:

Mfgr & Model of Fuel Oil Filter:

Combustion Tests *

Combustion Chamber Condition:

Nozzle Size & Type:

Oil Pump Pressure (PSIG):

CO2 (%):

Initial Installation

Service # 1 Service # 2 Service # 3

O2 (%):

Smoke No.:

Approximate Air Shutter Opening

(% of max.):

Heating System

Gross Flue Gas Temp. (deg. F):

Ambient Air Temp. (deg. F):

Net Flue Gas Temp. (deg. F):

Thermal Efficiency (%):

Is Control Operation OK?

Any Oil Leaks?

Initial Installation

Refrigeration Tests *

Service # 1 Service # 2 Service # 3

Suction Line Pressure (PSIG):

Suction Line Temp. (deg. F.):

Sat. Temp. @ Evap.(deg. F.):

Evaporator Superheat (deg. F.):

Liquid Line Pressure (PSIG):

Sat. Temp. @ Cond.(deg. F.):

Liquid Line Temp. (deg. F.):

Condenser Subcooling (deg. F.):

Cooling System

Is Control Operation OK?

Any Refrigerant Leaks?

Tests Performed By:

Date:

Technician

Installer

Notes:

Name:

Address:

Phone No:

* Operate system for at least 10 minutes before taking measurements.

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