Thermo Pride OPA Manual

OUTDOOR COMBINATION OIL-FIRED

FURNACE AND AIR CONDITIONING UNIT

MODEL OPA

INSTALLATION AND SERVICE MANUAL

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-424 North Judson, IN 46366

ECN 4650-MA Phone: (574) 896-2133 Made In USA

: 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).

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

Contents

SECTION PAGE

I. SAFETY INFORMATION .............................…………………………………….3

II. GENERAL INSTRUCTIONS ...........................................………………….…..9

III. GENERAL INSTALLATION .....................................................………………. 9

A. Codes and Clearances .......................................................……………. 10

B. Selection of Installation Location .........................................…………… 11

C. Venting Of Combustion Products ............................................………….13

D. Condensate Drain ....................................................................…………14

E. Oil Tank and Piping ..................................................................... ……... 15

F. Oil Filter .......................................................................................……… 17

G. Burner Specifications and Performance .......................................…….. 17

H. Airflow Requirements and Sizing of Ductwork ..............................…….. 19

I. Air Filters ......................................................................................…….. 23

1. Filter Installation ......................................................................…….. 23

2. Use of non-Thermo Pride Filters or Retention Means ..............……. 23

J. Electrical Wiring .............................................................................……. 24

1. Electronic Air Cleaner (EAC) and Humidifier Installation ..........…… 26

2. Thermostat Anticipator Setting.................................................…….. 28

3. Blower Motor Speed Selection .................................................……. 30

IV. STARTUP PROCEDURES.........................................................................…….32

A. HEATING SYSTEM

1. Initial Startup .............................................................................…….32

2. Adjustment of Burner Combustion .............................................…… 34

3. Adjustment of Heat Input Rate ...................................................……37

4. Setting Supply Air Temperature Rise .....................................……... 38

5. Checkout Procedure ................................................................…….. 39

B. COOLING SYSTEM

1. Initial Startup ......................................................................….……... 41

2. Definition of Superheat .......................................................... ……... 42

3. Evaporator Superheat ...........................................................………. 43

4. Definition of Subcooling ..........................................................…….. 44

5. Condenser Subcooling ...........................................................…….. 44

6. Recommendations for Operation at Low Temperatures ............… 45

V. INSTALLER'S INSTRUCTIONS TO USER ..........................................….. 46

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

Contents

SECTION PAGE

VI. DEALER MAINTENANCE ................................................................ ……... 47

A. General Inspection ...................................................................... ……... 47

B. Heat Exchanger ........................................................................………. 48

1. Disassembly to Access Heat Exchanger ...............................……… 48

2. Reassembly of Unit ................................................................……… 50

3. Operational Check ..................................................................…….. 51

C. Electrical System ...........................................................................……. 51

D. Supply/Return Air Blower .............................................................……... 52

E. Supply/Return Air Filter ................................................................…….. 52

1. Filter Maintenance ...................................................................…….. 52

2. Filter Replacement ...................................................................……. 52

F. Extended Appliance Shutdown ....................................................……... 53

VII. HOMEOWNER/USER INFORMATION AND ROUTINE MAINTENANCE ..55

VIII. TROUBLESHOOTING .........................................................................…… 59

A. Heating System ................................................................................….. 59

B. Cooling System .................................................................................…. 60

IX. REFERENCES .......................................................................................…. 62

X. APPENDIX A: SOURCES FOR REFERENCED STANDARDS .............…. 63

XI. APPENDIX B: CALCULATIONS ...........................................................….. 64

XII. APPENDIX C: ELECTRICAL SCHEMATIC AND CONNECTION DIAGRAM

.................................................................................................................….75

XIII. APPENDIX D: SEQUENCE OF OPERATIONS ....................................….. 76

XIV. APPENDIX E: TROUBLESHOOTING FLOWCHARTS .........................….. 78

XV. APPENDIX F: SPECIFICATION SHEETS .............................................…. 86

XVI. APPENDIX G: REPLACEMENT PARTS ...............................................….. 87

XVII. APPENDIX H: OPA 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 gas-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 OPA 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.

I: 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.

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