Thermo Products 30, OPB (24, 36)- 80 service manual B.Cooling .Initial Startup

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B.Cooling Section

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

B.Cooling Section

1.Initial Startup:

Manual backgroundManual backgroundManual backgroundManual backgroundManual backgroundManual backgroundManual backgroundManual backgroundManual backgroundManual backgroundManual backgroundManual backgroundManual backgroundManual backgroundManual backgroundManual backgroundManual background: 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.

Manual backgroundManual backgroundManual backgroundManual backgroundManual backgroundManual backgroundManual backgroundManual backgroundManual backgroundManual backgroundManual backgroundManual backgroundManual backgroundManual backgroundManual background : 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.

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Contents Page Contents SECTION I. SAFETY INFORMATION Page IF YOU DO NOT FOLLOW THESE INSTRUCTIONS EXACTLY, A FIRE OR EXPLOSION MAY RESULT CAUSING PROPERTY DAMAGE, PERSONAL INJURY, OR LOSS OF LIFE 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 For initial start-upof the appliance after installation, it may be necessary to purge the air out of the oil line. A qualified heating contractor should do this 1.This appliance shall be used with only the type of fuel oil for which it is approved. Refer to the appliance-ratinglabel for the required type of fuel II. GENERAL INSTRUCTIONS III.GENERAL INSTALLATIONb.Non-combustiblematerial A. Codes and Clearancesa.Combustible material B.Selection of Installation Location 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 C.Venting of Combustion Products D. Condensate Drain FIGURE 2 Vent Terminal Mounting PositionE. Oil Tank and Piping 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 F. Oil Filter G. Burner Specifications And PerformanceOil Pump H. Airflow Requirements and Sizing of Duct Work 6.The following method can be used to size ductwork when air velocities are low to moderate h.The resistance of the take-offand 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-sectionalarea of the ductwork should be changed in order to adjust the pressure drop to a suitable value 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 I.Air Filters 1.Filter Installation J. Electrical Wiring 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, 35C 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 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 Figure 4 The Fan Control Module Figure 5 Heat Anticipator Adjustment Scale 2. Thermostat Anticipator SettingPreferred method of adjustment 3. Blower Motor Speed Selection IV. STARTUP PROCEDURES A.Heating System i.STOP! Read the safety information above For Your Safety Read Before OperatingOperating Instructions To Turn Off Oil to Appliance2.Adjustment of Burner Combustion g.Turn the disconnecting switch to “ON” ii.CARBON DIOXIDE CO2 OR OXYGEN O2 Take a CO2 sample 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 CO2 reading, open the air band, or shutter, on the burner until zero smoke is measured 3.Adjustment Of Heat Input Rate 4.Setting Supply Air Temperature Rise 5.Checkout Procedure Page B.Cooling Section 1.Initial Startup 2.Definition of Subcooling 4.Definition of Superheat 3.Condenser Subcooling5.Evaporator Superheat V. INSTALLERS INSTRUCTIONS TO USER VI. DEALER MAINTENANCE B.Heat Exchanger Remove the clean-outcovers. Also, remove the burner compartment cover, the burner, and the burner mounting plate. When removing the clean-outcovers, 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-outcovers, refer to Figure Figure 10 View of OPB Heat Exchanger Burner Operation sectionC.Electrical System 2.Filter replacement 1.Filter maintenance procedureD. Supply/Return Air Blower E. Supply/Return Air FilterF. Extended Appliance Shutdown Figure 13 Location of Oil Pump Vent Plug 2.Remove the burner compartment cover Burner Motor The following maintenance points should be reviewed periodically to assure the heating and cooling systems continue to function properly ducts for any signs of collapse, holes, or excessive corrosion. Repair or replace components as required Power must be disconnected before servicing VIII. TROUBLESHOOTINGDiagnostic Features A.Heating SystemNumber of flashes CAD CELL CHECKOUT PROCEDURECad Cell Resistance in ohms Model R7184B2.Is the sub-baseof the thermostat switched to the “COOL” position? IX. REFERENCES X. APPENDIX A SOURCES FOR REFERENCED STANDARDS XI. APPENDIX B CALCULATIONS Example Figure 15 Plan View of a Typical Residence Area for Example See page 75 for a copy of the ASHRAE chart So, the total equivalent straight duct length is or approximately the same as without the elbow 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 Likewise for the other branches PSIG Page Now, the degree of superheat can be calculated Page All installations and services must be performed by qualified service personnel Standby At any time the oil A. SEQUENCE OF OPERATIONS FOR THE HEATING SYSTEMvalve is not energized Start Start trial for ignitionControl System Action Standby At any time the oil A. SEQUENCE OF OPERATIONS FOR THE HEATING SYSTEMvalve is not energized Start Start trial for ignitionPage Page ARE VENT TERMINAL AND HEAT EXCHANGER CLEAN? IS THE PROBLEM DELAYED IGNITION?PROPER COMBUSTION ACHIEVED? CORRECT INSERTION OR AIR TUBE BURNOFF MAY OCCUREFFECTS OF PRESSURE ON NOZZLE FLOW RATE Page 1.201.6 Check capacitance of the run capacitor 1Loose wire connections 3.301.2 Check for a properly sized expansion valve Nominal Electrical Power Requirements Heating Performance using # 2 fuel oilDimensions & Weight Model NoXVI. APPENDIX G REPLACEMENT PARTS LIST Page
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