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Thermo Products 125n User's Manual

1. PARTS PACKAGE 30084413 DESCRIPTION PART QUANTITY 2 3 8 ID radiator hose 410017 1 Thermostat lead bushing 350750 1 PVC trap assembly 320816 1 8 x 34 coated screws for mounting trap amp inlet outlet collars 200263 11 16 OD x 1 2 ID vinyl tubing 410060 24 2 x 4 electrical J box 350024 1 2 x 4 electrical J box cover 350020 1 8 x Ye TEK screws for mounting 2 x 4 J box 50850 2 10 32 x Ye green ground screw 300109 1 10 32 hex nut 300110 1 3 16 dia star washer 300270 1 Grounding instructions MG 966 1 Wire nut 300132 2 3 stainless steel hose clamp 300276 2 J box wire bushing 350016 1 Drain hose grommet 350446 1 Spring clamp 11 16 300299 3 Installation notice MG 987 1 PVC tee assembly 2 dia 320818 1 CPVC XPVC adapter 320833 1 Gas Conversion Kit AOPS7682 1 INSTALLATION PARTS PACKAGES CHX3 100 125 PARTS PACKAGE 50054414 4415 DESCRIPTION PART QUANTITY 2 3 8 ID radiator hose 410017 1 Thermostat lead bushing 350750 1 PVC trap assembly 320816 1 8 x 34 coated screws for mounting trap amp inlet outlet collars putes 4 11 16 OD x 12 ID vinyl tubing 410060 24 2 x 4 electrical J box 350024 1 2 x 4 electrical J box cover 350020 1 8 x Ye screws for mounting 2 x 4 J box 300206 10 32 x Ye green ground screw 300109 1 10 32 hex nut 300110 1 3 16 dia star washer
2. OPTIONAL 77 i PR CONTROL 16x4 BOX IUMIDIFIER 5 OPTIONA Vv TRANSFORMER 4 24v sse NG 4 0 OPTIONAL DEH HUMIDITY Mo 2R THERMOSTAT 16 WIRES TO BLOWER MOTOR CONTROL WHITE NO FLAME SHOULD BLACK CK RED CK CLOSED be 6 CH STUCK INDUCER BLUE 77 LOCKOUT WHITE IGNTOR BROWN BROWN GH LIMIT I gv GREY C YELLOW LMI RED WITH NO AME SENSE CURRENT 1 CONNECT HOT TO L1 AND CO LEGEND 2 IF ANY OF M BLUE FURNACE MUS i PL FIELD WIRING R c FACTORY WIRING GREY 77 CHASSIS GROUND 3 SET HEAT ANTICI Wr EARTH GROUND 59 All installations and services must be performed by qualified service personnel ES TS INDUCER IND RIDE IGNITER 164 BOX ps P CDX S ONLY FLAME SENSOR 1 CONNECT HOT TO L1 AND COMMC ANY OF THE ORIGINAL WIRES AS AUST BE REPLACED 2 1
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4. VERTICAL d Q gt 5 HORIZONTAL Figure 6 Optional Direct Vent Kits for the CHX3 CDX3 Model Series of Furnaces G Connecting The Furnace To Roof Exhaust Intake Terminations If it is not desirable or feasible to vent the furnace through a sidewall it may be vertically vented through the roof Installation shall conform to the following guidelines which are illustrated in Figure 6A below 1 The outlet of the exhaust vent and the inlet of the combustion air intake i e the terminations shall be a minimum of 12 inches above highest anticipated snow level 2 The exhaust vent outlet must be installed a minimum of 12 inches above the air intake inlet 3 Where exposed to prevailing winds the combustion air intake shall be installed upwind of the vent outlet 4 The exhaust vent and combustion air intake can be a minimum of 3 inches and a maximum of 24 inches apart NOTICE When the vent termination is installed correctly a draft should NOT be present in the system during the furnace off cycle i Figure 6A Typical Rooftop Vent and Air Intake Termination Construction Details 17 All installations and services must be performed by qualified service personnel H Exhaust Intake Piping And Condensate Drain Connections At Furnace 1 Figures 6B 7 and 8 follow depicting typical exhaust vent and air intake connections for the furnace model series CHX3 and the CDX3 respectively as well as a list of
5. LOW FIRE 45 F TO 75 F LOW FIRE 45 F TO 75 F ERNAL STATIC PRESSURE 0 50 INCHES WC MAX EXTERNAL STATIC PRESSURE 0 50 INCHES WC MAXIMUM OUTLET AIR TEMPERATURE 190 F MAXIMUM OUTLET AIR TEMPERATURE 190 F CERTIFIED FOR CLOSET INSTALLATION AT MINIMUM CLEARANCES 7 c TO COMBUSTIBLE CONSTRUCTION AS SHOWN 70 COMBUSTIBLE CONSTRUCTION AS SHOWN nid TOP FRONT 08 85 PIPE INCHES i x b iksi T FRONT BACK LS RS FLUE PIPE FOR INSTALLATION ON COMBUSTIBLE FLOORING FOR INSTALLATION ON NON COMBUSTIBLE FLOORS ONLY FCR INSTALLATION ON COMBUSTIBLE FLOORING ONLY WHEN INSTALLED ON SPECIAL BASE PART NO THIS FURNACE REQUIRES A SPECIAL VENTING SYSTEM REFER TO THIS F REQUIRES A SPECIAL VENTING SYSTEM REFER INSTALLATION INSTRUCTIONS NO MG FOR PARTS LIST AND ME 7 FOR PARTS AND METHOD OF INSTALLATION METHOD OF INSTALLATION MAX VENT LENGTH 35 FEET MIN VENT LENGTH 8 FEET MAX VENT LENGTH 35 FEET MIN VENT LENGTH B FEET MIN WALL THICKNESS THROUGH WHICH THE VENT AIR INTAKE MIN WALL THICKNESS THROUGH WHICH THE VENT AIA INTAKE PIPES MAY PASS 15 2 INCHES AND THE MAX IS 18 INCHES R PIPES MAY PASS IS 2 INCHES AND THE MAX 1518 INCHES FILTERS MUST BE INSTALLED EXTERNAL TO THE FURNACE CASING FILTERS MUST BE INSTALLED EXTERNAL TO THE FURNACE CASING THIS FURNACE MUST BE INSTALLED IN ACCORDANCE WITH THIS FURNACE MUST BE INSTALLED IN ACCORDANCE WITH THERMO PRODUCTS INSTRUCTIONS AND LOC
6. Figure 14 TRAP ASSEMBLY MOUNTED ON CHX3 23 All installations and services must be performed by qualified service personnel n Figure 15 TRAP ASSEMBLY MOUNTED ON CDX3 Figure 16 TRAP ASSEMBLY MOUNTED ON CDX3 RIGHT SIDE HORIZONTAL INSTALLATION 24 All installations and services must be performed by qualified service personnel 2 Determine on which side of furnace the condensate disposal line is to be run NOTICE On CHXS CDXS s this must be the same side as the flue outlet or bottom of unit Attach the condensate trap to the furnace casing using the 48x3 4 sheet metal screws provided in the parts package Pilot holes are provided on both sides of the casing for mounting NOTE When the series unit is used in a horizontal application the drain hose from the collector box will require a location change from it s factory shipped connection A knockout has been provided in the unit side casing for the drain hose to exit The connection change can be accomplished as follows Refer to Figure 16 8 Locate and disconnect the drain hose at the collector box from its factory shipped connection location b Locate and uncap the drain at the bottom as it is oriented of the collector box Connect the drain hose from step a to the uncapped bottom drain from step b d Cap the previous drain connection from step a with the existing cap removed in step b 3 Attach the drain hose 11 16 diameter clear tubing from th
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8. 5 a 2 If service is to be performed turn off all electric power to the 2 5 appliance 4 3 To turn off gas control valve remove the burner compartment cover B E 4 Move the gas control switch to the OFF position m 5 Replace the burner compartment cover e 390540 Pi A a LE 5 ey 2 4 o z lt o MOVING PARTS All installations and services must be performed by qualified service personnel 1 Use only with type of gas approved for this furnace Refer to furnace rating plate 2 Connect this furnace to an approved vent system only Combustion products must be carried outdoors Refer to Section III D thru of this manual The following pages contain various warnings and cautions found throughout the Thermo Pride Highboy and Dual Poise Two Stage Condensing Gas Furnace Manual Please read and comply with the statements below A WARNING This furnace is not to be used for temporary heating of buildings or structures under construction A CAUTION These high efficiency condensing furnaces are not certified for and shall not be vented into a standard or any type of chimney A WARNING These furnaces may not be common vented with any other appliance A CAUTION The vent and air intake elbows must be kept away from bushes shrubs or any vegetation that may restrict the flow of flue products It must also be kept clear of any leaves weeds or other combustible mat
9. For a right side horizontal application of the CDX3 series units the auxiliary limit switch located on the right side of the house air blower must be moved to the bracket on the opposite left side of the blower See Figure 1 NOTE When the CDXG3 is installed as horizontal unit it is imperative that the auxiliary limit switch and bracket be located on the upper side of the house air blower the burner rollout switch located on the burner box be relocated to the side of the burner box and that the hose from the single tap pressure switch be connected to the lower tap on the front of the collector box See Figure 1 2A Figure 1 All installations and services must be performed by qualified service personnel The horizontal furnace installation should be on a service platform large enough to allow for proper clearances on all sides and service access to the front of the furnace See Table 1 If the furnace is suspended it must be supported at both ends and in the middle with clearance allowed for removal of both access doors Gas supply line contact is only permissible between lines formed by the intersection of the top and two sides of the furnaces casing and the building joists studs or framing See Figure 1 Equipment must be installed in accordance with regulations of the National Board of Fire Underwriters and the National Fuel Gas Code Authorities having jurisdiction should be consulted before installations are made C
10. For models CDX3 100 and CDX3 125 used in horizontal applications immediately transition from 2 inch to 3 inch diameter pipe by installing the 3 inch x 2 inch diameter PVC reducer just outside the furnace casing The remainder of the venting system 20 All installations and services must be performed by qualified service personnel leading away from the furnace must be composed of 3 inch diameter PVC pipe and pipe fittings only Refer to item E in Figure 8 b After preparation of the internal 2 inch diameter PVC pipe sections put a thin bead of a silicone rubber type sealant around the outlet flange of the inducer Slip the 2 inch diameter PVC elbow for the model series CDX3 in horizontal applications a 2 inch diameter PVC tee over the inducer outlet flange Drive one 1 48 x 3 4 inch sheet metal screw with black protective coating supplied with furnace through the elbow and into the outlet flange of the inducer to secure the elbow in place Figure 9 Typical Internal Vent Piping Arrangement for the Furnace Model Series CHX3 f 1 i Figure 10 Typical Internal Vent Piping Arrangement for the Furnace Model Series CDX3 100 125 xA a lo La 414 Figure 11 Typical Internal Vent Piping Arrangement for the Furnace Model Series CDX3 100 125 in RH Horizontal Applications Q2 X 3 C REDUCER 7 D AA OL Aa gt gt E b Y A c Using PVC cement glue the pre cut 2 inch diameter thermoplastic pipe from step
11. 000 66 000 115 000 82 000 HEIGHT OF CASING 44 1 4 44 1 4 44 1 4 WIDTH OF CASING 17 21 24 DEPTH OF CASING 27 1 2 27 1 2 27 1 2 WARM AIR OUTLET 15x18 19x18 22 x 18 RETURN AIR INLET 25x 16 25 x16 25 x 16 DIA OF FLUE 2 3 3 DIA OF COMBUSTION 2 3 3 AIR INTAKE CFM from 2 amp 5 w c EXTERNAL STATIC PRESSURE COOLING COOLING COOLING COOLING TAP A 1000 1200 1400 COOLING TAP B 800 1000 1200 COOLING TAP C 1200 1400 1600 COOLING TAP D 1400 1600 2000 HEATING HEATING HEATING HEATING TAP A High fire Low fire 931 760 1243 1015 1556 1270 TEMPERATURE RISE 70 60 70 60 70 60 BLOWER MOTOR HP 5 75 1 POWER CHOKES 2 65 Mh 2 1 Mh LARGEST RECOMMEDED AIR CONDITIONER 3 5 Ton 4 Ton 5 Ton SIZE OF FILTERS 24 3 4 x 15 3 4 24 3 4 x 15 3 4 24 3 4 x 19 3 4 NOTES 1 BTU output based on annual fuel utilization efficiency rated by manufacturer 2 Onall outlet and inlet dimensions the first dimension is width 3 To permit largest recommended air conditioning at 5 static pressure selection of the highest motor speed is required All installations and services must be performed by qualified service personnel CDX3 SERIES MODEL NO CDX3 75 CDX3 100 CDX3 125 BTU HR INPUT High fire Low fire 75 000 56 250 100 000 125 000 75 000 93 750 BTU HR OUTPUT High fire Low fire
12. 2 000 feet 600 m For operation at elevations above 2 000 feet 600 m equipment ratings shall be reduced at the rate of 4 percent for each 1 000 feet 300 m above sea level For additional information refer to the latest edition of the National Fuel Gas Code Checking The Burner Flame CAUTION The furnace model series CDX3 and CHX3 are sealed combustion designs that do not require an air shutter adjustment air shutters are not used for proper flame characteristics The burner box access cover must always be secured with all screws in place and tightened before operating furnace Once the input rate has been confirmed correct for a specific application the burner flames should be checked for proper adjustment 44 All installations and services must be performed by qualified service personnel This furnace is designed not to require any burner adjustment Burner aeration is fixed in this design Burner flames can be seen by looking through the sight glass located on the burner box Burner flames should be well defined light to medium blue in color and almost transparent refer to Figure 24 Figure 24 Sketch of Typical Main Burner Flames During Operation NOTICE When operating on propane gas it is not unusual for flames to have yellow or orange colored tips If combustion problems are evident it may indicate problems with either the furnace air supply or the vent system Refer to the installation and mai
13. 300270 1 Grounding instructions MG 966 1 Wire nut 300132 2 3 stainless steel hose clamp 300276 2 J box wire bushing 350016 1 Drain hose grommet 350446 1 Spring clamp 11 16 300299 3 Installation notice MG 987 1 All installations and services must be performed by qualified service personnel PVC tee assembly 2 x 3 dia 320817 1 CPVC XPVC adapter 320833 1 Gas Conversion Kit AOPS7683 7419 1 INSTALLATION PARTS PACKAGES CDX3 75 PARTS PACKAGE 50054416 DESCRIPTION PART QUANTITY 2 3 8 ID radiator hose 410017 1 Thermostat lead bushing 350750 1 PVC trap assembly 320816 1 8 x 34 coated screws for mounting trap amp inlet outlet collars 056 11 16 OD x 12 ID vinyl tubing 410060 24 2 x 4 electrical J box 350024 1 2 x 4 electrical J box cover 350020 1 8 x Ye screws for mounting 2 x 4 J box 90020 10 32 x Ye green ground screw 300109 1 10 32 hex nut 300110 1 3 16 dia star washer 300270 1 Grounding instructions MG 966 1 Wire nut 300132 2 3 stainless steel hose clamp 300276 2 J box wire bushing 350016 1 Drain hose grommet 350446 1 Spring clamp 11 16 300299 3 Installation notice MG 987 1 PVC tee assembly 2 dia 320819 1 Pipe 2 dia PVC 15 14401 1 Bracket 14406 1 CPVC XPVC adapter 320833 1 Gas Conversion Kit AOPS7682 1 INSTALLATION
14. 71 000 52 000 94 000 69 000 116 000 87 000 HEIGHT OF CASING 46 1 4 46 1 4 46 1 4 WIDTH OF CASING 17 21 24 DEPTH OF CASING 27 1 2 27 1 2 27 1 2 WARM AIR OUTLET 15x 18 19 x 18 22x18 RETURN AIR INLET 15 x 22 19x 22 22 x 22 DIA OF FLUE 2 3 3 DIA OF COMBUSTION 2 3 AIR INTAKE CFM from 2 amp 5 w c EXTERNAL STATIC PRESSURE COOLING COOLING COOLING COOLING TAP A 1000 1200 1400 COOLING TAP B 800 1000 1200 COOLING TAP C 1200 1400 1600 COOLING TAP D 1400 1600 2000 HEATING HEATING HEATING HEATING TAP C High fire Low 1012 826 1340 1094 1673 1366 fire TEMPERATURE RISE 65 60 65 60 65 60 BLOWER MOTOR HP 5 75 1 POWER CHOKES 2 65Mh 2 1Mh LARGEST RECOMMEDED 3 5 Ton 4 Ton 5 Ton AIR CONDITIONER SIZE OF FILTERS 21 3 4 x 14 2 21 3 4 x 14 2 21 3 4 x 14 2 NOTES 1 BTU output based on annual fuel utilization efficiency rated by manufacturer 2 On all outlet and inlet dimensions the first dimension is width 3 To permit largest recommended air conditioning at 5 static pressure selection of the highest motor speed is required 4 Electrical characteristics at 115 volts 60 Hz 1 phase less than 15 amps for all models 5 All specifications are subject to change without notice All installations and services must be performed by qualified service personnel INSTALLATION PARTS PACKAGES CHX3 75
15. NECESSARY REFERENCE ECM SATISFIED WITHIN 120 SECONDS TROUBLE SHOOTING COMPLETE OPERATION MANUAL 54 All installations and services must be performed by qualified service personnel Appendix A Replacement Parts List 1 Replacement parts list for CHX3 75 CHX3 100 and CHX3 125 REPLACEMENT PARTS NOTE SEE SPECIFICATION SECTION OF THIS MANUAL FOR PART NUMBER LA O PARTS PACKAGE COMPONENTS 55 All installations and services must be performed by qualified service personnel 56 All installations and services must be performed by qualified service personnel 2 Replacement parts list for CDX3 75 CDX3 100 and CDX3 125 REPLACEMEN NOTE SEE SPECIFICATION NUMBERS RELATED ANUAL FOR PART OMPONENTS 57 All installations and services must be performed by qualified service personnel 58 All installations and services must be performed by qualified service personnel Appendix B Wiring Diagrams ECM BLI MOTOR POWER BLACK BLACK
16. PARTS PACKAGES CDX3 100 125 PARTS PACKAGE 3450054381 DESCRIPTION PART QUANTITY 2 3 8 ID radiator hose 410017 1 Thermostat lead bushing 350750 1 PVC trap assembly 320816 1 8 x 34 coated screws for mounting trap amp inlet outlet collars 599885 11 16 OD x 1 2 ID vinyl tubing 410060 24 2 x 4 electrical J box 350024 1 2 x 4 electrical J box cover 350020 1 8 x Ye screws for mounting 2 x 4 J box dc 5 10 32 x Ye green ground screw 300109 1 10 32 hex nut 300110 1 3 16 dia star washer 300270 1 All installations and services must be performed by qualified service personnel Grounding instructions MG 966 1 Wire nut 300132 2 3 stainless steel hose clamp 300276 2 J box wire bushing 350016 1 Drain hose grommet 350446 1 Spring clamp 11 16 300299 3 Installation notice MG 987 1 PVC tee assembly 2 x 3 dia 320817 1 PVC tee assembly 2 dia 320819 1 Pipe 2 dia PVC 15 14401 1 Bracket 14406 1 Reducer 2 x 3 PVC 320067 1 CPVC XPVC adapter 320833 1 Gas Conversion Kit AOPS7683 7419 1 All installations and services must be performed by qualified service personnel lil GENERAL INSTALLATION These Category Type IV furnaces are shipped completely assembled and wired internally See the Dealer Receiving and Freight Claim Procedure Section of the price guide for parts shortage or damage The furnace and duct system must be adjuste
17. SET HEAT ANTICIPATOR 0 4 PRESSURE SWITCH N O CH OPEN ON TEMP RISE TEMPERATURE SWITC CHASSIS GROUND EARTH GROUND 02 2 BLOWER INTERFACE IC INTERGRATED CONTROL 60 VIN S80S NO3 2670 diz eyeis Aio ON 5 ON SPO sueuMo diz ejejs AUD A SsoJppy Jo ejeg ww 12 968 V48 ss lppy 99 9p euelpu uospnr 212 O d wey 1 971 5 SHJHLO HO 343AO Idll SIH H3svHOMfd AHL ASNSIW HO FSN SLI dO 39N30038NOO JHL ALIMAVI TIY 52140557 LN3l dIno3 SIHL HO IHL ANY ANY JO 35 VIAVO TVILN3003SNOO ALFIISVIT ON SAINNSSYV 277 SL9ngosd OWYSHL 7S3NNVIN ALNVSWVM SIHL 30 SWH3L IHL AJIGONW YALTV OL ALIHOHLOV NOSH3d ON OTI SLONGOYd OWHSHL JO SNOLLVOTTSO ANY S3LLNVHSVM YSHLO 59035 43375 AT89S3HdX3 ALNVHSYM SIHL AAOGY 8151 S3LLNVSHVAA TIY GIOA TIM SNOILIQNOO 3AO8V 30 HLIAA ATdlNOO OL 33fY1Iv4 pod spoe 1o pue anpes Aue ajqisuodsal jou eys O77 spnpoig ouueu SseJppe uonejejsur sj pun eu 2
18. Turn the inner plastic adjustment screw clockwise to increase or counterclockwise to decrease the gas pressure and gas flow to the main burner c Replace the regulator cover screw and tighten it firmly to prevent gas leakage d Referring to Table 5 measure the gas pressure and to confirm it has been adjusted to within the allowable range Repeat adjustments a through c as required Table 5 Design Gas Pressures for each Furnace Model Series Operating Mode and Type of Fuel Operating Mode and _ CHX Low Low CHX Low CDX Low Model Series High Fire Fire High Fire Fire Normal Manifold 10 0 0 3 4 8 0 3 5 6 0 3 3 5 0 3 1 8 0 3 20403 Pressure in W G Minimum Gas Supply Pressure in W G n e Q o lt 4 5 13 Adjust the room thermostat so the burner will operate on high fire only 14 To obtain an accurate manifold gas pressure reading the main burner must be cycled on and off several times to stabilize the gas control valve pressure regulator diaphragm 15 Allow the burner to operate for at least 3 minutes before taking gas pressure readings 16 Using a pressure gauge measure the burner manifold gas pressure 17 If checking the input rate by measuring burner manifold pressure proceed to step 18 If measuring the input rate by clocking the gas meter repeat steps 9 through 11 above 43 All installations and services must be
19. a above to the 2 inch diameter PVC elbow for the model series CDX3 in horizontal applications the 2 inch diameter PVC tee Couple the drain tee assembly to the pre cut 2 inch diameter PVC pipe using the reinforced rubber hose and the two 2 band clamps supplied 21 All installations and services must be performed by qualified service personnel NOTICE AII PVC thermoplastic pipe must be supported beginning directly over the exhaust vent tee assembly then every 4 feet thereafter and at every joint Trial fit the entire exhaust vent and air intake piping systems making sure the slope and length of the piping are correct before permanently assembling the pipe components If the vent piping is run through an unconditioned space it must be insulated with 1 inch thick foil faced fiberglass insulation or an equivalent product 3 Connecting The Combustion Air Intake Piping ANCAUTION Outside combustion air must NOT be drawn from an area directly adjacent to a pool hot tub or spa Measures should be taken to prevent the entry of corrosive chemicals or vapors into the combustion air supply Such chemicals include but are not limited to chlorinated and or fluorinated hydrocarbons such as found in refrigerants aerosol propellants dry cleaning fluids degreasers and removers Other harmful compounds may come from bleaches air fresheners or mastics Vapors from such products can form reactive acid producing chemical species when burned
20. air out of the gas line for initial start up of the furnace after installation This should be done by a qualified heating contractor If excessive gas escapes when purging the gas supply at the union allow the area to ventilate for at least 15 minutes before attempting to start the furnace LP gas is especially dangerous because the specific gravity of LP gas allows it to accumulate at floor level at a dangerous concentration For remainder of operating instructions reference Users Information Manual A WARNING Heat exchanger oil will burn off on initial firing creating an unpleasant odor prevent this odor from occurring more than once it is suggested that 1 window s be opened 2 thermostat set at highest setting 3 The furnace remain running at conditions 1 amp 2 for 30 minutes or until odor has dissipated All installations and services must be performed by qualified service personnel A CAUTION The CHX3 CDX3 furnace models are sealed combustion design which does not require an air shutter adjustment air shutters are not used for proper flame characteristics Burner box access cover must always be secured with all screws in place and tightened before operating furnace AWARNING Personal injury or property damage could result from repair or service of this furnace by anyone other than a qualified heating contractor Only the homeowner user routine maintenance described in the Users Information Manual may be perf
21. building The bottom of the vent terminal shall be located at least 12 inches above grade The vent terminal shall not be located e over public walkways or over an area where wetting of surfaces by condensate or water vapor could create a nuisance or hazard 12 All installations and services must be performed by qualified service personnel e near soffit vents crawl space vents or other areas where condensate or water vapor could create a nuisance hazard or cause property damage and e where wetting of components by condensate or water vapor could be detrimental to the operation of pressure regulators relief valves or any other equipment d The vent terminal shall be installed a minimum of 14 inches from any obstruction and 3 feet from an inside corner of an L shaped structure 13 All installations and services must be performed by qualified service personnel p NN SS Pe 5 ro M SSSI le em eeN NN A EU 4 Figure 4 NFGC Minimum Clearances Between the Vent Terminal and Various Building Features Vent Terminal Location Guidelines 14 All installations and services must be performed by qualified service personnel A CAUTION Bushes shrubs or any vegetation that may restrict the flow of flue products must be kept away from vent and air intake terminations Terminations must also be kept clear of any leaves weeds combustible mat
22. desired setting and if equipped set the operating mode to HEAT 10 If appliance will not operate follow the instructions To Turn Off Gas To Appliance and call your service technician or gas supplier gt lt o a x o gt a o LL FOR YOUR SAFETY DO NOT STORE OR USE GASOLINE OR OTHER DO NOT USE ANY PHONE IN YOUR BUILDING FLAMMABLE VAPORS AND LIQUIDS IN THE 3 IMMEDIATELY CALL YOUR GAS SUPPLIER FROM A NEIGHBOR S PHONE FOLLOW THE GAS SUPPLIER S INSTRUCTIONS 4 IF YOU CANNOT REACH YOUR GAS SUPPLIER CALL THE FIRE DEPARTMENT VICINITY OF THIS OR ANY OTHER APPLIANCE 1 DO NOT TRY TO LIGHT ANY APPLIANCE 2 DO NOT TOUCH ANY ELECTRICAL SWITCH THIS UNIT MUST BE INSTALLED AND SERVICED BY A QUALIFIED CONTRACTOR ONLY INSIDE APPLIANCE NEAR BURNER ASSEMBLY WHAT TO DO IF YOU SMELL GAS OPERATING INSTRUCTIONS ARE LOCATED INSTRUCTIONS m HOMEOWNERS IMPROPER INSTALLATION ADJUSTMENT ALTERATION SERVICE OR MAINTENANCE CAN CAUSE PROPERTY DAMAGE PERSONAL INJURY OR LOSS OF LIFE GAS CONTROL VALVE GAS CONTROL VALVE zz 2 STAGE x O E 47 L E a Oo a o t 21017 lt o 4 gt TOGGLE SWITCH TOGGLE SWITCH on 2 _ 1 Set thermostat to lowest setting and if equipped set the operating 78 mode to COOL or OFF
23. hour CFH NOTICE Some gas meters will require more than one 1 cubic foot of gas pass through the meter for reasons of accuracy When more than one 1 cubic foot of gas is consumed divide the total time by the number of cubic feet for comparison to the figures in Table 6 Compare actual heat input rate with our recommended input printed on the furnace rating label To convert the rating label input rate given in BTUH to the equivalent gas flowrate in CFH use the following formula Heat input rate in BTUH BTU Fuel gas higher heating value x Fuel gas flowrate in CFH 3 t or Heat input rate in BTUH Fuel gas flowrate in CFH I Fuel gas higher heating value ETJ t If the measured input rate is above or below the rating label value by more than 2 adjust the manifold gas pressure using the gas control valve pressure regulator to obtain the input rating within a 2 range Refer to steps 12 a through 12 d If the gas pressure is not within the specified low fire manifold pressure range refer to Table 5 use the following procedure to adjust the low fire gas pressure regulator to match the specified low fire manifold pressure a Remove the regulator cover screw from the gas valve Refer to Figure 23 42 All installations and services must be performed by qualified service personnel REGULATOR COVER SCREW REGULATOR SPRING e y PLASTIC ADJUST SCREW Figure 23 b
24. is installed with a parallel flow arrangement dampers or other means to control flow of air should be installed to prevent chilled air from entering the furnace If such a device is manually operated it must be equipped with a means to prevent operation of either the furnace or air conditioner unless it is in the full heat or cool position We recommend that the outlet duct be equipped with a removable access panel to allow for visual inspection of the heat exchanger to check for leakage or to allow for insertion of a probe sampler in the air stream This removable access cover should be attached to ensure there is no air leakage 5 The duct system shall be sized for the maximum CFM requirement of the installation whether it is for heating or cooling Two common rules for heating and cooling follow A 400 CFM 1200 BTU s per ton of cooling is required B 14 CFM of heating per 1000 BTU s of furnace output based on its steady state efficiency and a 55 to 85 temperature rise EXAMPLE Heating output of a furnace is 100 000 BTU HR 100 000 BTUx14cfm 1400 CFM 1000 BTU Air conditioning installed is 4 tons x 400 CFM 1600 CFM or 48 000 BTU s NOTE The duct system must be sized for the larger CFM requirement for cooling If only 3 tons 36 000 BTUs of cooling x 400 CFM 1200 CFM was installed the duct would have to be sized for the 1400 Cfm heating requirement 27 All installations and services must be performed by qualified service
25. performed by qualified service personnel 18 If the gas pressure is not within the specified high fire manifold pressure range refer to Table 5 repeat steps 12 a through 12 d above adjusting the high fire gas pressure regulator If the manifold pressure remains low and it cannot be adjusted into the proper range the supply pressure may be too low Follow these steps a Turn off the gas at the manual gas shutoff valve b Remove the automatic gas control valve inlet pressure tap and attach another pressure gauge to the inlet tap Turn on the gas and repeat steps 14 and 15 above d Adjust the upstream inlet gas pressure to 14 0 in W G or as close as possible e Using a pressure gauge measure and adjust the burner manifold gas pressure If it is still not possible increase the manifold gas pressure to within the required range there is too little gas supply to operate the furnace at full high fire input rate under present conditions If necessary consult your gas supplier or qualified heating contractor for recommendations to alleviate the problem 19 Turn off the gas at the manual gas shutoff valve turn handle to the OFF position 20 Remove all pressure gauges and replace all pressure tap plugs 21 Go to Checkout Procedure below Adjusting Burner Input For Altitudes Above 2000 Feet Ratings of gas utilization equipment are based on sea level operation and shall not be changed for operation at elevations up to
26. personnel 1 SAFETY INFORMATION This and the following page contain reproductions of the various warning and instruction labels placed on the Thermo Pride Two Stage Condensing Gas Furnaces Please read and comply with the contents of these labels exe 9 SERIAL NO 00000000 DIRECT VENT FORCED AIR FURNACE FOR INDOOR INSTALLATION IN BUILOING MODEL NO Y SERIAL NO 00000000 DIRECT VENT FORCED AIA FURNACE CONSTRUCTED ON SITE FOR INDOOR INSTALLATION IN BUILOING CONSTRUCTED ON SITE CONFORMS TO redo ANS 221 47b CSA 2 3b 2008 CENTRAL FURN ND curabo CATEGORY TYPE FSP CATEGORY IV TYPE FSP o n 115V B0CY TOTAL INPUT AMPS A ape diei aka TOTAL E ae gt arcane Ne OUTPUT mpu QUTAUT cm BTUH HIGH FIRE BTUH HIGH FIRE LOW FIRE LOW FIRE FACTORY EQUIPPED WITH 42 ORIFICES FOR NAT GAS SUITABLE FOR LP GAS WHEN EQUIPPED WITH 1 5 ORIFICES FACTORY EQUIPPED WITH 842 ORIFICES FOR GAS SUITABLE FOR LP GAS WHEN EQUIPPED WITH 1 5 WM ORIFICES NORMAL MANIFOLD PRESS PINE n IN WC NAT 16 0 IN WC LP NORMAL MANIFOLD PRESS HIGH FIRE 3 5 IN WC NAT 10 0 IN WC LP LOW FIRE 2 0 5 6 MIN GAS SUPPLY PRESS FOR INPUT ADJUSTMENT i co Iu c LPS MIN GAS SUPPLY PRESS FOR INPUT ADJUSTMENT 4 5 IN WC NAT MAX GAS SUPPLY PRESSURE 14 0 IN WC MAX GAS SUPPLY PRESSURE 14 0 IN WC 11 0 IN WC LP AIR TEMPERATURE RISE HIGH FIRE 55 F TO 85 F AIR TEMPERATURE AISE HIGH FIRE 55 F TO 85 F
27. personnel Figure 18A All trunk lines take offs registers and grill free areas must be figured when determining the air handling capacity of a duct system One can obtain the necessary duct system size by utilizing the chart below For example see Figure 18A Use a supplier s catalog for proper sizing of outlet and return air registers to insure that the register will meet the CFM requirements of the run to which it is connected The main trunk lines take offs registers and grills of the supply return air duct system must have an adequate square inch area to move the desired CFM in order to achieve proper movement The following chart shows the CFM air handling capability based on a 0 1 SP loss in the supply duct system The total external static pressure should not exceed 2 inches water column 28 Z All installations and services must be performed by qualified service personnel DUCT SIZES FOR HOMES QUIET OFFICES OR SIMILAR INSTALLATIONS 2 Z 2 2 C 2 2 2 2 4 7 Ly 2 5 2 Z TABLE 2A Each of the system components trunk lines take offs runs and register and grill free areas must be properly sized and matched together to ensure the necessary air handling capacity of a duct system A 12 x 8 duct with a 400 CFM capacity for example will not flow 400 CFM if the register s to which it connects only flow a total of 200 CFM The speed of the blower motor may have to be changed to obtain t
28. required parts to correctly install each system ae Ny ZA a PA Figure 6B Required Exhaust Vent and Air Intake Piping for Furnace 18 All installations and services must be performed by qualified service personnel 2 _ j Figure 7 Required Exhaust Vent and Air Intake Piping for CDX3 Furnace in Downflow Applications 19 All installations and services must be performed by qualified service personnel Figure 8 Required Exhaust Vent and Air Intake Piping for CDX3 Furnace in Horizontal Applications 2 Connecting The Exhaust Vent To The Inducer a Slip the end of the 2 inch diameter PVC elbow for the model CDX3 in horizontal applications the 2 inch diameter PVC tee assembly over the outlet of the inducer blower assembly Measure the length of 2 inch diameter thermoplastic pipe needed to clear the furnace side casing while allowing for installation of a 2 3 8 inch length of reinforced rubber hose used as a coupling within the casing of the furnace Cut the measured lengths of 2 inch diameter PVC pipe being sure to allow a sufficient length of pipe for connections Refer to Figures 9 10 and 11 for assembly details NOTICE For the model CDX3 75 a length of 2 inch diameter PVC pipe and a 2 inch diameter PVC tee assembly are supplied with each furnace For the models CDX3 100 and CDX3 125 a 3 inch x 2 inch diameter PVC reducer is also supplied NOTICE
29. single stage thermostat with two stage operation connect W from thermostat to W1 on control W2 on control board is not used Thermostat dip switches S7 1 amp S7 2 on control board Fig 21 will need to set at the desired setting per Table 4B In this configuration the furnace will light and burn on low fire If thermostat has not been satisfied in set delay time for second stage the control will step up to high fire until thermostat is satisfied The auto setting will allow the control to calculate the delay for second stage based on demand The average calculated duty cycle chart below Table 4A shows how the control calculates staging based on demand Table 4A Average Calculated Duty Cycle or is less Low to High Equals Stage Delay 0 Proper control of the indoor temperature can only be achieved if the thermostat is calibrated to the heating and or cooling cycle A vital consideration of this calibration is related to the thermostat heat anticipator The proper thermostat heat anticipator setting is 0 4 AMPS for furnace operation only To increase length of cycle increase setting of heat scale to decrease length of cycle decrease setting of 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 gener
30. the furnaces and to all points on the furnace requiring access must be 24 For horizontal furnace installation refer to section IIl B1 of this installation manual Equipment must be installed in accordance with regulations of the National Board of Fire Underwriters Authorities having jurisdiction should be consulted before installations are made B FURNACE LOCATION A CAUTION These high efficiency condensing furnaces are not certified for and shall not be vented into a standard or any type of chimney The following shall be considered for locating the furnace 1 For best performance locate the furnace so that it is centralized with respect to the duct system and as near as possible to a floor drain since condensate drainage must be provided 2 Place the unit so that proper venting can be achieved with a minimum number of elbows in accord with the instructions in this manual 3 The furnace must be located on a level dry surface The furnace must be installed so that the electrical components are protected from water If the area becomes wet or damp at times the furnace should be raised above the floor using a concrete base bricks patio blocks etc NOTICE Ensure furnace is level after installation to ensure proper drainage and operation 4 This furnace must be connected to a drain in accordance with these instructions If it is not practical to connect the unit to a drain a condensate pump must be used and can be order
31. 26 All installations and services must be performed by qualified service personnel A CAUTION Care must be taken not to wet electronic components during leak test Wetting the primary ignition module may damage its circuitry and cause a hazardous situation Dry moisture from all leads and terminals if wetting occurs Wait at least 24 hours for the circuit to fully dry before energizing the burner circuit J1 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 ASHRAE 1 When it is located in the same room as the furnace a return air register must be installed a minimum of 20 feet away from the furnace 2 The return air duct shall also be sealed to the furnace and also terminate outside of the furnace space if supply ducts carry circulated air to areas outside the space containing the furnace 3 The return air duct system must equal the supply air duct system in its capabilities Use a supplier s catalog for proper sizing of outlet and return air registers and grills to ensure that they meet the CFM requirements of the run to which they are connected 4 If the furnace is used in connection with an air conditioning evaporator coil the furnace must be installed parallel with or on the upstream side of the coil to prevent condensation in the heat exchanger If the evaporator coil
32. 43 HIGH SPEED TERMINALS IND HI CONTROL TO IND N YES CHECK CONNECTIONS YES TO INDUCER IF OK REPLACE INDUCER CHECK CONTACTS IN HIGH FIRE SWITCH IS THE HIGH FIRE DOES BURNER NO NO AND FOR STEP TO HIGH FIRE PRESSURE SWITCH BLOCKAGE IN FLUE IF OK REPLACE DUAL PRESSURE YES YES SWITCH 52 All installations and services must be performed by qualified service personnel IS THERE 24 VOLTS ACROSS MVH AND NO REPLACE THE MV COM ON 50V51 843 CONTROL 50V51 843 CONTROL YES CHECK CONNECTIONS TO GAS VALVE IF OK REPLACE GAS VALVE CONFIRM IF EITHER BLOWER WHEEL IS RUBBING AGAINST HOUSING OR MOTOR SHAFT IS SPINNING FREELY AND REPAIR OR REPLACE AS NECESSARY IS THE VARIABLE SPEED AIR FAN OPERATING YES REFERENCE ECM OPERATION MANUAL DOES BLOWER SPIN FREELY DOES SYSTEM RUN UNTIL THERMOSTAT IS SATISFIED ewe NO CHECK ALL WIRING FOR YES REFERENCE LED CHART ON PG 48 OF THIS MANUAL 53 All installations and services must be performed by qualified service personnel DOES BURNER SHUT OFF WHEN THERMOSTAT IS SATISFIED YES DOES THE CIRCULATING AIR BLOWER TURN OFF AFTER THERMOSTAT IS NO CHECK FOR 24 VOLTS NO AT GAS VALVE REPLACE GAS VALVE YES CHECK FOR SHORT IN WIRE TO THERMOSTAT AND CORRECT IF
33. AL CODES IN THERMO PRODUCTS INSTRUCTIONS AND LOCAL CODES IN ABSENCE OF LOCAL CODES FOLLOW THE NATIONAL FUEL ABSENCE OF LOCAL CODES FOLLOW THE NATIONAL FUEL CODE ANSI 2223 1 GAS CODE ANSI 2223 1 THERMO PRODUCTS LLC ey R PS UOK 217 JUDON IN 40306 ISEA P o MOL JUDSON IN 46886 OUTSIDE POWER SOURCE REMOVE THIS PANEL FIRST IN ORDER CONNECT 115v 60Hz TO TO REMOVE BLOWER DOOR L1 HOT AND L2 COMMON All installations and services must be performed by qualified service personnel This and the previous page contain reproductions of the various warning and instruction labels placed on the Thermo Pride Two Stage Condensing Gas Furnaces Please read and comply with the contents of these labels The following safety information should be read understood and followed by the installer a For YOUR SAFETY READ BEFORE OPERATING WARNING If you do not follow these instructions exactly fire or explosion may result causing property damage personal injury or loss of life A This appliance does not have a pilot It is equipped with a hot surface igniter that automatically lights the burner Do not try to light the burner by hand B BEFORE OPERATING smell all around the appliance area for gas Be sure to smell next to the base of unit because some gas is heavier than air and will settle on the floor or ground WHAT TO DO IF YOU SME
34. DUCER FAN FOR 15 SECONDS AND CIRCULATOR BLOWER AT HEATING SPEED UNTIL SITUATION CORRECTION l THERMOSTAT CALLS FOR HEAT W1 OR W1 amp W2 CONTACTS CLOSE 50V51 843 CONTROL ENERGIZED INDUCER ENERGIZED ON HIGH SPEED LOW FIRE PRESSURE SWITCHES SENSES ADEQUATE DIFFERENTIAL PRESSURE CONTACTS CLOSE Y PREPURGE IGNITION DELAY INDUCER RUNS FOR 15 SECONDS Y INDUCER REDUCES TO LOW SPEED LOW PRESSURE SWITCH SENSES ADEQUATE PRESSURE DIFFERENTIAL CONTACTS STAY CLOSED POWER IS APPLIED TO THE WHITE RODGERS SILICON NITRIDE IGNITOR IGNITOR WARM UP IS 17 SECONDS 36 All installations and services must be performed by qualified service personnel AFTER IGNITOR WARM UP THE 36J54 GAS VALVE IS ENERGIZED TO OPEN ON LOW FIRE SETTING FLAME MUST BE DETECTED IF FLAME IS NOT DETECTED THE WITHIN 4 SECONDS IF IF NOT GAS VALVE IS DE ENERGIZED FLAME IS DETECTED THE THE IGNITOR IS TURNED OFF AND DELAY TO FAN ON TIME THE 50V51 843 CONTROL GOES BEGINS 45 SECONDS INTO RETRY SEQUENCE THE RETRY SEQUENCE PROVIDES A 60 SECOND WAIT BEFORE IGNITION RETRY RETRY IS ATTEMPTED WITH A DIFFERENT VOLTAGE SETTING IF IGNITION ATTEMPT IS IF SO UNSUCCESSFUL ONE MORE RETRY WILL BE MADE BEFORE THE 50V51 843 GOES INTO SYSTEM LOCKOUT IF FLAME IS DETECTED THEN LOS
35. GV error micro and frequency check double 2 stage pressure switch stuck open inducer error The LED will also flash once at power up Amber LED Flash DS1 1 normal call for first stage heat 2 normal call for second stage heat 3 W2 present with no W1 4 Y present with no G call Rapid low flame sense current Green LED indicator DS2 is present to obtain an estimate of the air flow rate in CFM produced by the house air blower This LED cycles regularly by providing a constant light followed by a sequence of flashes Each flash can be translated to programmed CFM by using the following 1 flash per 100 programmed CFM A WARNING Power must be disconnected before servicing 49 All installations and services must be performed by qualified service personnel TROUBLESHOOTING GUIDE THE SYSTEM IS STARTED BY SETTING THE THERMOSTAT TO CALL FOR HEAT THE FOLLOWING SHOULD HELP ESTABLISH THE TYPE OF MALFUNCTION OR DEVIATION FROM THE NORMAL OPERATION NOTE REFER TO PAGE 48 FOR DEFINITION OF DIAGNOSTIC LEDS TO USE THIS DIAGRAM YOU JUST NEED TO FOLLOW THE INSTRUCTIONS IN THE BOXES SET THERMOSTAT TO CALL FOR HEAT MAKE CERTAIN ROOM TEMPERATURE IS BELOW THERMOSTAT SETTING Bc DUANE S CHECK INPUT POWER IS THE INDUCER NO DOOR INTERLOCK BLOWER OPERATING SERVICE SWITCH 50V51 843 CONTROL DNE RECS MODULE IS THERE 24 VOLTS ACROSS
36. LL GAS Do not try to light any appliance Do not touch any electric switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department C Use only your hand to move the gas control switch Never use tools If the switch will not move by hand don t try to repair it call a qualified service technician Force or attempted repair may result in a fire or explosion D Do not use this appliance if any part has been underwater Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been underwater EN OPERATNG INSTRUCTIONS EI STOP Read the safety information above on this label Set the thermostat to the lowest setting Turn off all electric power to the appliance This appliance is equipped with a hot surface igniter that automatically lights the burner Do not try to light the burner by hand Move the gas control switch to the OFF position 6 Wait five 5 minutes to clear out any gas Then smell for gas including near the floor or ground If you smell gas STOP Follow B in the safety information above on this label If you don t smell gas go to the next step 7 Move the gas control switch to the ON position Turn on all electric power to the appliance 9 Set thermostat to
37. NFPA70 or latest edition and the National Fuel Gas Code ANSI Z223 1 or latest edition 2 The BTU output capacity of the furnace proposed for installation should be based on a heat loss calculation made according to the manuals provided by the Air Conditioning Contractors of America ACCA or ASHRAE 3 MINIMUM CLEARANCES TO COMBUSTIBLE MATERIALS TABLE 1 FROM SIDES OF TOP OF FROM THE SIDE OF MODEL NO FURNACE amp REAR FRONT PLENUM FLUE OR VENT PLENUM CHX3 75 CHX3 100 The CHX3 75 100 and 125 furnaces may be installed on combustible flooring The furnace shall not be installed directly on carpeting tile or other combustible material other than wood flooring The CDX3 75 100 and 125 furnaces are to be installed on non combustible flooring only The non combustible floor bases model no 50 DA base for CDX3 75 model no 100 CA base for the model no CDX3 100 and model no 125 CA base for CDX3 125 are available for the counterflow furnaces to allow their installations on combustible flooring All installations and services must be performed by qualified service personnel These furnaces may be installed in an alcove or in a closet if the minimum clearances to combustible construction listed previously are met The CDXS series furnaces may be installed in an attic or crawl space Refer to section III B1 of this installation manual The minimum clearances are listed for fire protection Clearance for servicing the front of
38. NS 120 SECONDS AFTER THE DELAY TO FAN OFF PERIOD ENDS THE CIRCULATING AIR FAN AND OPTIONAL ELECTRONIC AIR CLEANER ARE DE ENERGIZED 38 All installations and services must be performed by qualified service personnel B INITIAL START UP This furnace does not have a pilot It is equipped with a hot surface igniter which automatically lights the burner Do not attempt to light the burner by hand Check the following items before the initial start up 1 Check all wiring for loose connections and proper hook up 2 Leak test gas piping connections 3 Check all tubing to the pressure switch and drains to make sure they are connected firmly at all their connection points 4 Check flue pipe combustion air inlet and all PVC connections for tightness and to make sure there is no blockage 5 Make sure air filter is in place 6 Make sure the outside vent and air intakes are installed according to instructions and that they are free from blockage 7 Make sure that the drain trap is properly connected to the furnace and to the buildings drain system OPERATING INSTRUCTIONS A WARNING Turn off power to furnace before it is placed into service The gas piping system must have been leak tested by a qualified heating contractor See Section Ill J of these instructions on the installation of gas piping A WARNING It may be necessary to purge the air out of the gas line for initial start up o
39. Note If the burner was initially operating in high fire the burner will first reduce rate to the low fire setting As the flue becomes more blocked the pressure switch will function and completely shut off the main burners IMPORTANT Remove flue air inlet blockage when done 5 Remove the blower compartment access door with the furnace operating The door interrupt switch is in the 120 volt circuit and will shut down the entire system Replace the blower door and the furnace start up cycle will begin V INSTALLER S INSTRUCTIONS TO USER After completing the installation the installer shall inform and or demonstrate to the homeowner 1 The location of all the instructions in the furnace and that these instructions and the users information manual must be kept along with instructions for any accessories in the plastic pouch on the inside of the furnace 2 The location and use of the manual gas shut off valve and furnace electrical disconnect switch Instruct user to always shut off gas before shutting off electric power 3 The sequence of operation of the furnace 4 The correct operation and maintenance of the appliance as outlined in the users information manual 47 All installations and services must be performed by qualified service personnel 5 That failure to maintain and operate this furnace in accordance with these instructions could result in hazardous conditions bodily injury property damage and may void the limited warr
40. OCEDURE Before any system of gas piping is finally put into service it shall be carefully tested to assure that it is gas tight as indicated in the 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 With furnace in normal heating operation check to make certain blower will start and stop automatically under control of integrated fan control 1 Check safety limit control as follows Shut off incoming power Disconnect blower motor leads Restore power to furnace Set thermostat above room temperature calling for heat When temperatures are reached in furnace at limit control setting with blower out of operation burner should shut off Shut off electrical power IMPORTANT Remove blockage or reconnect blower motor and restore power 2 Make certain thermostat will automatically start and stop furnace 3 Block the flue pipe gradually with a flat piece of metal until the pressure switch functions shutting off the main burners Note If the burner was initially operating in high fire the burner will first reduce rate to the low fire setting As the flue becomes more blocked the pressure switch will function and completely shut off the main burners 4 Block the PVC pipe inlet gradually with a flat piece of metal until pressure switch functions shutting off the main burners
41. Replacing An Existing Furnace From A Common Vent A WARNING These furnaces may NOT be common vented with any other appliance D General Requirements For Venting Models CHX3 CDX3 The CDX3 furnace venting system must be installed by a qualified service person in accordance with local installation codes and these instructions In the absence of applicable local codes conform to the National Fuel Gas Code NFPA 54 ANSI Z223 1 2002 or latest edition thereof Installation shall at least conform to the following requirements 1 The exhaust vent combustion air intake terminations specified by Thermo Products in this manual shall be used 2 All plastic pipe and pipe fittings sourced to complete the exhaust vent and air intake systems shall be constructed of rigid PVC polyvinyl chloride thermoplastic All components shall have a wall thickness equivalent to Schedule 40 series materials In addition all sourced PVC components shall be listed by a nationally recognized testing agency e g NSF UL etc as conforming to one 1 or more of the following design standards PVC Pipe Designation Design Standard Cellular Core ASTM F891 DWV Drain Waste Vent ASTM D2665 Schedule 40 ASTM D1785 3 The exhaust vent pipe and combustion air pipe shall be at least as large as the exhaust vent air intake pipe specified by Thermo Products Size reduction is never permissible The required exhaust vent air intake pipe sizes are
42. T THE 50V51 843 WILL REPEAT THE INITIAL IGNITION SEQUENCE FOR A TOTAL OF TEN RECYCLES AFTER TEN UNSUCCESSFUL RECYCLE ATTEMPTS THE CONTROL WILL GO INTO SYSTEM LOCKOUT 37 All installations and services must be performed by qualified service personnel IF SYSTEM IS IN LOCKOUT THE MODULE WILL RESET IF THERMOSTAT ITSELF AFTER 60 MINUTES W2 CONTACTS OR MAY BE MANUALLY ARE CLOSED RESET BY INTERRUPTING THE POWER TO THE FURNACE AT THE DISCONNECT OR INTERRUPTING THE CALL FOR HEAT AT THE THERMOSTAT IF THIS DOES NOT RESTART OTHERWISE THE SYSTEM REFER TO THE TROUBLESHOOTING SECTION OF THIS MANUAL Y AFTER DELAY TO FAN ON PERIOD ENDS 45 SECONDS CIRCULATING AIR FAN IS ENERGIZED AT LOW FIRE HEATING SPEED OR HIGH THERMOSTAT CLOSES W2 Ex ce FIRE IF W2 IS ENERGIZED THE CALL da ie OPTIONAL ELECTRONIC AIR FOR CLEANER AND HUMIDIFIER HIGH ARE ENERGIZED FIRE GAS VALVE INDUCER AND AIR FAN ARE ENERGIZED TO HIGH FIRE SETTINGS NO CALL FOR WHEN THERMOSTAT HAS HIGH FIRE SATISFIED W2 CONTACTS OPEN AND THE GAS VALVE AND AIR FAN HIGH FIRE SETTINGS ARE DE ENERGIZED AFTER 30 SECOND DELAY Y WHEN THERMOSTAT W1 IS SATISFIED CONTACTS OPEN AND THE GAS VALVE IS DE ENERGIZED AFTER PROOF OF FLAME LOSS INDUCER P STARTS 5 SECOND POST PURGE AND OPTIONAL HUMIDIFIER IS DE ENERGIZED THE DELAY TO FAN OFF PERIOD BEGI
43. TH amp TR NO CHECK 115 VOLT AT THE INTEGRATED CONNECTIONS IF OK CONTROL MODEL REPLACE TRANSFORMER 50V51 843 YES YES IS THERE 24V NO CHECK FUSE ON ACROSS R AND B C W R 50V51 843 YES IS THERE 24 VOLTS YES CHECK WIRING TO ACROSS R AND W1 THERMOSTAT IF OK REPLACE THERMOSTAT NO IS THERE LINE VOLTAGE ACROSS INDUCER POWER TERMINALS IND HI TO NO REPLACE THE IND N OR IND LO TO 50V51 843 CONTROL IND N AT THE 50V51 843 CONTROL YES CHECK WIRING TO INDUCER AND IF OK REPLACE INDUCER ASSEMBLY 50 All installations and services must be performed by qualified service personnel IS INDUCER RUNNING ON LOW SPEED YES DOES THE HOT SURFACE IGNITOR ENERGIZE AND GLOW YES Y AFTER HOT SURFACE IGNITOR WARM UP DOES GAS VALVE OPEN NO YES Y L NO AND FOR BLOCKAGE IN FLUE NO gt CHECK CONTACTS LOW FIRE PRESSURE SWITCH IF OK REPLACE DUAL PRESSURE SWITCH IS THERE VOLTAGE ACROSS HOT SURFACE IGNITOR TERMINALS IGN amp IGN N AT THE 50V51 843 CONTROL AFTER 17 SECOND PREPURGE p CHECK WIRING TO HOT SURFACE IGNITOR AND IF OK REPLACE HOT SURFACE IGNITOR ASSEMBLY CHECK ACROSS MVL AND MV COM TERMINALS ON 50V51 843 CONTROL FOR 24 VOLTS DURING THE 4 SECOND FLAME PROVING PERIOD AFTER IGNITOR WARM
44. Thermo Pride gt _ lt TWO STAGE CONDENSING GAS FURNACE INSTALLATION AND OPERATION MANUAL MODELS FOR USE WITH NATURAL GAS OR LP GAS PROPANE CHX3 75N CDX3 75N CHX3 100N CDX3 100N CHX3 125N CDX3 125N AWARNING YOU DO NOT FOLLOW THE SAFETY PRECAUTIONS BELOW AND IN THIS MANUAL 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 SMELL GAS DO NOT TRY TO LIGHT ANY APPLIANCE DO NOT TOUCH ANY ELECTRICAL SWITCH DO NOT USE ANY PHONE IN YOUR BUILDING LEAVE THE BUILDING IMMEDIATELY IMMEDIATELY CALL YOUR GAS SUPPLIER FROM A NEIGHBOR S PHONE FOLLOW THE GAS SUPPLIER S INSTRUCTIONS e IF YOU CANNOT REACH YOUR GAS SUPPLIER CALL THE FIRE DEPARTMENT INSTALLATION AND SERVICE MUST BE PERFORMED BY A QUALIFIED INSTALLER SERVICE AGENCY OR THE GAS SUPPLIER 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 LEFT WITH THE HOMEOWNER AND SHOULD BE RETAINED FOR FUTURE REFERENCE BY QUALIFIED SERVICE PERSONNEL THERMO PRODUCTS LLC BOX 217 NORTH JUDSON IN 46366 PHONE 574 896 2133 MADE IN USA MG 1035 ECN 5222 MA 110815 All installations and services must be performed by qualified service
45. UP IS THERE 24 VOLTS n IS COLLECTOR BOX PRESSURE SWITCH CLOSED YES CHECK WIRING TO GAS VALVE AND IF OK REPLACE GAS VALVE AFTER GAS VALVE OPENS DO THE BURNERS IGNITE NO CHECK FOR PROPER LINE AND MANIFOLD PRESSURE REFERENCE GAS PRESSURE CHART PAGE 31 YES OK 51 NO NO oH REPLACE THE 50V51 843 CONTROL m IS THE HIGH LIMIT ROLL OUT LIMIT AND AUX LIMIT ON CDX MODELS SWITCHES CLOSED IF HIGH LIMIT OR AUX LIMIT OPEN CHECK FOR RESTRICTED FILTERS OR DUCT WORK IF ROLL OUT SWITCH OPEN INSPECT FLUE FOR RESTRICTIONS REPLACE THE 50V51 843 CONTROL CHECK DRAIN FOR BLOCKAGE WATER TRAPPED IN HOSE REPLACE SWITCH All installations and services must be performed by qualified service personnel DO BURNERS STAY LIT PAST PROOF FLAME CHECK YES IS W2 ENERGIZED NO IS IGNITOR NO REPOSITION TO POSITIONED CORRECTLY CORRECT LOCATION YES CHECK AND CLEAN BURNERS CHECK FOR PROPER LINE NO AND MANIFOLD PRESSURE REFERENCE GAS PRESSURE CHART PAGE 31 OK CHECK FLAME PROB2 AND WIRE AND CHECK POLARITY ON INCOMING POWER AND GROUND IS THERE LINE DOES INDUCER VOLTAGE ACROSS qo REPLACE Goto HNO 54 INDUCER POWER THE 50V61 1
46. a filter system for the CHX3 or CDX3 furnaces MINIMUM FILTER AREA REQUIRED LENGTH X WIDTH SQ IN TABLE 3 FILTER TYPE MAXIMUM Required Filter Velocity Rating x 144 min filter RATE in AIR VELOCITY FURNACE MODEL CHXS CDX3 75 CHX3 CDX3 100 CHX3 CDX3 125 THERMO 600 FT MIN 254 IN 328 IN 402 IN PRODUCTS SUPPLIED PERMANENT FILTER PERMANENT FILTER FILTER 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 NOTICE The filter areas in table 3 are the minimum areas required based on the CFM generated by the furnace for standard heating speeds only The following formula can be used to determine the minimum filter area required for cooling if the unit is equipped with cooling This value should then be compared to the value shown in table 3 and the larger of the two should then be used for determining the minimum filter area required for that installation 31 All installations and services must be performed by qualified service personnel FORMULA tons of cooling x 400 CFM per ton 144 square inches per foot filter area sq inches max air velocity of filter from table 3 for the filter type length x width of filter in inches EXAMPLE If you had a CHX3 100 furnace and 4 tons of cool
47. ally marked accordingly 33 All installations and services must be performed by qualified service personnel 4 BLOWER AND CONTROL PANEL WIRING Figure 21 A WARNING TURN OFF THE ELECTRICAL POWER to the furnace before attempting to disconnect blower wiring Table 4B S7 DIP Switch Switch Settings ___ NENNEN Options eres ea Factory Setting 2 Stage Thermostat setting 34 All installations and services must be performed by qualified service personnel Modifications to ECM blower speed settings are done using the S3 and S4 dip switch controls Thermo Pride two stage furnaces are factory shipped at the CFM settings listed below in Table 4C 2 Stage Blower Settings from factory Table 4C Control Board Heating Heating Unit Dip Switch CFM CFM eee Fan ge Settings low fire high fire SW3 1 4 Off CDX3 75 SWA 1 3 Off 885 1012 500 1000 SW4 4 On SW3 1 4 Off CHX3 75 SWA 1 4 Off 760 931 500 1000 SW3 1 4 Off CDX3 100 SWA 1 3 Off 1094 1340 600 1200 SW4 4 On SW3 1 4 Off CHX3 100 SWA 1 4 Off 1015 1243 600 1200 SW3 1 4 Off CDX3 125 SWA 1 3 Off 1366 1673 700 1400 SW4 4 On SW3 1 4 Off CHX3 125 SWA 1 4 1270 1556 700 1400 For adjustments to the Cooling CFM settings as well as all additional CFM changes please reference the dip switch tables listed in the ECM operation manual Included with every furnace 5 DE HUMIDIFICATION The ECM motor in conjunction w
48. anty on the furnace 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 II and IIl of this manual and in the Users Information Manual 7 Recommend that the user have a qualified heating contractor inspect the furnace at the start of each heating season Inform the user of the frequency of inspection required for reach item in Section III of the Users Manual Figure 25 VI TROUBLESHOOTING NOTICE BEFORE TROUBLESHOOTING FAMILIARIZE YOURSELF WITH THE START UP AND CHECKOUT PROCEDURE ALL INSTALLATION AND SERVICES MUST BE PERFORMED BY QUALIFIED HEATING CONTRACTORS To assist you in troubleshooting this furnace it is equipped with an integrated ignition control with diagnostics These diagnostics evaluate what control system has experienced a failure and will activate a flashing light on the control in different sequences to help pinpoint the failure which has occurred For your convenience Thermo Products has installed a sight glass in the blower door of this furnace The number of flashes in groups should be observed through this sight glass and recorded before turning off power to the furnace Turning off power to the furnace or removing the blower door which is equipped with a door interlock switch will reset the control Should this occur use the fault code retrieval process as described below To retrieve fault codes push and r
49. d to obtain a temperature rise of 55 F to 85 F through the furnace after installation See rating label located on side panel inside the furnace vestibule The installation must conform with local codes or in the absence of local codes with the National Fuel Gas Codes ANSI Z223 1 or latest edition and with these instructions A WARNING This furnace is not to be used for temporary heating of buildings or structures under construction Many of the chemicals used during construction when burned form acid bearing condensate that can substantially reduce the life of the heat exchanger It is recommended that a commercially available CO alarm be installed in conjunction with any fossil fuel burning appliance The CO alarm shall be installed according to the alarm manufacturer s installation instructions and be listed in accordance with latest edition of the UL Standard for Single and Multiple Station Carbon Monoxide Alarms UL 2034 or the CSA International Standard Residential Carbon Monoxide Alarming Devices CSA 6 19 A CODES AND CLEARANCES The following items must be considered when choosing the size and location of the furnace 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 with these instructions regulations of the National Fire Protection Association provisions of National Electrical Code ANSI
50. e Set the room thermostat to the desired temperature and restore electrical power to the furnace J GENERAL GAS PIPING A WARNING Because of the potential of odorant fade a gas leak may not be detected by smell If this furnace is installed below grade contact your gas supplier for a gas detector 1 Leftand right gas supply piping These furnaces are set up to be gas piped through either the left or right side by using a street elbow and a straight pipe For the purposes of service it is recommended that the gas union be located inside the furnace when possible Figure 18 2 Adrip leg must be used on both LP and natural gas installations prior to the furnace in order to trap oil condensate and other impurities which might otherwise lodge in the gas valve or plug the burner orifice A drip leg shall be provided at the outlet of the gas meter when there is excessive condensation between the gas meter and the furnace Failure to install a drip leg may void the limited warranty on the furnace A WARNING gas piping must be leak tested using a soap and water solution when the gas is turned on following the procedure outlined in Section Ill J of this manual A final test for gas leakage must be made after purging the gas line refer to Section IV B of this manual This test must be conducted with the unit operating and should include the furnace piping and gas valve Never use an open flame to check for a gas leak
51. e front CHX3 or bottom CDX3 of the condensing coil cover plate to one side of the PVC tee provided in the trap assembly Secure the drain hose 11 16 o d tubing with the silver clamp provided in the parts package Be careful to route the tubing through the proper hole in the furnace casing using the Heyco bushing provided While making all connections with the clear tubing be careful to route the tubing in a manner to prevent kinking or abrasion of the tubing 4 Measure the drain hose 11 16 o d clear tubing provided and remove any extra length making sure that the hose has sufficient length not to kink or otherwise be restricted once installed Attach the drain hose 11 16 o d clear tubing to the other side of the condensate trap tee On CHX3 CDX3 s this hose is shipped in the parts package and it will be necessary to attach the other end to the PVC drain tee assembly see Figure 15 Use the silver clamp s provided in the parts package to secure all connections 5 Install field supplied 1 2 CPVC drain pipe and elbows using CPVC cement to reach a nearby drain A minimum 1 4 per foot downward slope toward the drain must be maintained The drain line must be water tight supported and secured so that it can t be moved The length of the drain must be kept as short as possible IMPORTANT If an air conditioning condensate drain line is combined with the furnace condensate drain line it must have a separate trap ahead of the joint c
52. e nominal 2 inch diameter IPS Schedule 40 series PVC thermoplastic pipe for models CHX3 75 amp CDX3 75 or e nominal 3 inch diameter IPS Schedule 40 series PVC thermoplastic pipe for models CHX3 100 125 amp CDX3 100 125 4 The furnace model series CHX3 CDX3 shall not be common vented with any other appliance including those burning solid fuels All installations and services must be performed by qualified service personnel 5 All horizontal runs of exhaust vent pipe shall slope upward at least 1 4 inch per foot from the outlet of the furnace for model CHX3 or the outlet of the drain tee for the model CDX3 to the vent termination beyond the outside wall This slope will permit proper drainage of the condensate Horizontal runs of air intake pipe shall slope downward at least 1 4 inch per foot from the outlet of the last elbow or last horizontal run before exiting the wall to the intake termination beyond the outside wall This slope will permit proper drainage of any precipitation that enters the intake pipe 6 The exhaust vent pipe shall be supported at every joint no more than 4 feet between supports to prevent pipe blockage due to condensate trapped at a local low point or sag in the vent system 7 The maximum permissible length of piping consisting of a combination of straight pipe and a corresponding number of elbows permitted is e 75 equivalent feet for the exhaust vent system and e 70 equivale
53. ecks and adjustments must be made at both high fire high adjustment and low fire low adjustment 1 Shut off the gas at the automatic gas control valve turn gas control switch to the OFF position 2 Remove the outlet pressure tap plug from gas burner manifold and connect a pressure gauge Refer to Figure 22 below Figure 22 Exploded View of CDX CHX Gas Control System 3 Turn on the gas at the automatic gas control valve turn gas control switch to the ON position 4 Adjust the room thermostat so the furnace will operate on low fire only 41 All installations and services must be performed by qualified service personnel 10 11 12 To obtain an accurate manifold gas pressure reading the main burner must be cycled on and off several times to stabilize the gas control valve pressure regulator diaphragm Allow the burner to operate for at least 3 minutes before taking gas pressure readings Using a pressure gauge measure the burner manifold gas pressure If checking the input rate by measuring burner manifold pressure skip to step 12 If measuring the input rate using a gas meter proceed to step 9 Using a clock or watch capable of measuring time in seconds carefully clock the gas meter to determine the time for one 1 complete revolution of the gas meter dial or reel At least one 1 cubic foot of gas flow should be measured Use Table 6 to determine the main burner gas flow rate in cubic feet per
54. ed as an accessory part number 350225 If an acid neutralizer kit is required by local code or the customer it is available under part number 320095 B1 CDX3 HORIZONTAL APPLICATION The CDX3 75 100 and 125 furnaces may be installed in a horizontal position by placing the furnace on the left or right side as viewed from the front in the upright position For left or right horizontal applications of the CDX3 series units the rollout switch located on the burner box must be moved to the pre punched mounting holes on the side of the burner box Screws are provided in pre punched holes at the required limit location Remove these screws and use them to mount the limit to new location Utilize previously removed limit mounting screws to fill voided holes at previous limit location See Figure 1 For a right side horizontal application of the CDX3 series units the hose from the single tap pressure switch top switch is already connected correctly See Figure 1 For a left side horizontal application of the CDX3 series units the hose from the single tap pressure switch bottom switch must be moved to the lower front tap on the face of the collector box Use the black cap removed from this tap to plug the original pressure switch tap All installations and services must be performed by qualified service personnel NOTE The hose when moved must be shortened cut to ensure that no excess hose exists to cause a sag loop or water trap
55. elease the LAST ERROR button for more than 1 5 second and less than 5 seconds Control will indicate this period by solid GREEN for 1 5 second to 5 seconds The LED will flash up to five stored fault codes beginning with the most recent If there are no fault codes in 48 All installations and services must be performed by qualified service personnel memory the LED will flash two green flashes The control will flash the most recent error first and the oldest error last last in first out There will be 2 seconds between codes Solid LED error codes will not be displayed DIAGNOSTIC FEATURES The 50V51 control used on this furnace continuously monitors its operation and the operation of the system If the sensed failure is in the system external to the control the red LED will flash in the following flash pause sequences to indicate failure status each flash will last approximately 0 25 seconds and each pause will last approximately 2 seconds Red LED Flash DS1 1 flame sensed when no flame should be present 2 pressure switch stuck closed inducer error 3 1 stage pressure switch stuck open inducer error 4 open limit switch 5 open rollout aux limit 6 pressure switch cycle lockout 7 external lockout retries 8 external lockout recycles 9 grounding or reversed polarity 10 gas flow with no call for heat 11 limit switch open blower failure 12 ignitor failure Solid internal
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57. erials Keep the vent hood clear of snow Avoid locating the terminals in areas where standing water or condensate drippage may be a problem A WARNING This CHX3 CDX3 furnace has been designed to be installed as a direct vent system The failure to install the vent air intake system as specified in these instructions will void the heat exchanger warranty and may result in property damage personal injury or loss of life A CAUTION Outside combustion air must not come from an area that is directly adjacent to a pool hot tub or spa 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 such as found in refrigerants aerosol propellants dry cleaning fluids degreasers and removers Other harmful compounds may come from bleaches air fresheners or mastics Vapors from such products can form acid compounds when burned in a gas flame Should acid compounds form in your furnace it may reduce the life of the furnace A WARNING Because of the potential of odorant fade a gas leak may not be detected by smell If this furnace is installed below grade contact your gas supplier for a gas detector A WARNING Turn off power to furnace before it is placed into service The gas piping system must have been leak tested by a qualified heating contractor A WARNING It may be necessary to purge the
58. erials snow and ice build up Avoid locating the vent terminal over areas where dripping of condensate or small pools of acidic condensate could create a problem In addition to following any local code requirements when possible utilize the guidelines below in locating the vent terminal to help insure trouble free operation of a sidewall vented furnace e Avoid locating the vent terminal on a wall facing prevailing winds and wide open areas When impractical choose a location that protects the vent from strong winds such as behind a fence or hedge e In geographical areas with considerable snowfall it is advisable to locate the vent terminal much higher than the minimum 12 inches above ground to prevent blockage by snow accumulation or drifting e The vent and combustion air terminations shall be checked periodically at least at the start of each heating season for restriction or blockage from foreign material in the exhaust vent or in the air intake piping Clean the air intake and vent terminations when necessary E1 Single Pipe Sidewall Venting Option NOTICE When possible we recommend all model series CHX3 CDX3 furnaces be installed to utilize outside combustion air The use of outside combustion air usually results in the most energy efficient nuisance free and long lived operation of the furnace NOTICE Heat exchanger failure accelerated by contaminated combustion air will void the furnace heat exchanger limited life
59. f the furnace after installation This should be done by a qualified heating contractor If excessive gas escapes when purging the gas supply at the union allow the area to ventilate for at least 15 minutes before attempting to start the furnace LP gas is especially dangerous because the specific gravity of LP gas allows it to accumulate at floor level at a dangerous concentration For remainder of operating instructions reference Users Information Manual A WARNING 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 that 1 A window s be opened 2 The thermostat be set at highest setting 3 The furnace remain running at conditions 1 amp 2 for 30 minutes or until odor has dissipated 39 All installations and services must be performed by qualified service personnel C Measuring And Adjusting Heat Input Rate NCAUTION DO NOT exceed input rating stamped on furnace nameplate or manufacturer s recommended burner manifold pressure for orifice size used Observe the following precautions when measuring A Burner manifold pressure with a pressure gauge 1 3 Close the gas valve turn the gas control knob to the OFF position BEFORE removing the a burner manifold pressure tap plug to connect the manometer or calibrated pressure gauge b manometer or gauge and replacing the pressure tap plug Shut off the gas supply at
60. ght of the furnace NOTICE The hot surface igniter and operation of this furnace depends on correct polarity The hot leg of the supply circuit must be connected to the black line lead and the common leg to the white line lead in the field mounted junction box The hot leg must pass through the disconnect switch in all cases to prevent the hazard of electrical shock when servicing IMPORTANT The furnace must be grounded in accordance with local codes and with the National Electrical Code ANSI NFPA NO 70 or latest edition when an external electrical source is utilized 2 ELECTRONIC AIR CLEANER EAC AND HUMIDIFIER INSTALLATION The ignition module on this furnace has designated terminals to control the operation of an electronic air cleaner and or humidifier These terminals provide line voltage 110 20VAC for the control of these accessories See Figure 21 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 See the manufacturers instructions for the humidifier or EAC for additional instructions 32 All installations and services must be performed by qualified service personnel 3 THERMOSTAT CONNECTIONS AND ANTICIPATOR SETTING NOTICE For two stage thermostat wire connectors see wire diagram page 59 For
61. he proper 55 F to 85 F temperature rise for heating when an air conditioning coil is installed This depends on the static resistance of an individual duct system and the size of the air conditioner 29 All installations and services must be performed by qualified service personnel K FILTERS 1 CHX3 MODELS HIGHBOYS It is necessary to cut the return air opening in the bottom or side casing depending upon the needs of the specific installation NOTICE f your will require air delivery above 1800 CFM it is advisable that both sides a combination of 1 side and the bottom or the bottom only be used for return air If a return is cut in the bottom it should be as large as the return opening in the equivalent CDX3 model See specification sheet in beginning of this manual This CHX3 furnace has been factory supplied with a high quality re usable filter rated for air velocities up to 600 ft min An optional Thermo Products filter rack assembly part no AOPS7547 for CHX3 75 thru 100 and AOPS7375 for CHX3 125 is available which is sized for the filter provided If an optional Thermo Pride filter rack AOPS7547 figure 19 is used with the furnace it will serve as a template to scribe a mark for the return air opening on the casing Place the filter rack on the casing one inch up from the bottom of the furnace and centered from side to side Place the securing flange against the casing for locating the return air opening Fig
62. in a gas flame Should acidic compounds form in the furnace they may significantly reduce the useful life of the furnace a For the models CDX3 75 install a 2 inch PVC elbow with sleeve and coupling for models CHX3 CDX3 100 amp 125 a 3 inch PVC elbow with sleeve on the inlet of the burner box Measure the length of pipe needed to clear the casing Be sure to allow sufficient length to account for insertion of the pipe into the elbow at the burner box and the elbow or coupling fitting on the end Cut the pipe to length After preparation of the thermoplastic pipe drive one 1 48 x 3 4 inch sheet metal screw with black protective coating supplied with furnace through the PVC coupling or sleeve into the metal collar of the burner box to secure the piping in place NOTICE DO NOT apply silicone rubber type sealant or PVC cement to the joint at the thermoplastic piping connection to the metal burner box collar Attach the PVC elbow to the sleeve and then to the coupling where required using silicone rubber type sealant refer to Figure 12 Insert the precut 2 inch or 3 inch thermoplastic pipe into the elbow at the burner box and to the elbow or coupler just outside the furnace using a silicone rubber type sealant To properly make these seals run a thin bead of silicone type sealant around the circumference of the PVC pipe about 3 8 inch from either end Insert the straight pipe section into the appropriate coupling
63. ing and a standard permanent filter 4 tons x 400 CFM x 144 460 square inches for cooling 500 For heating a CHX3 100 needs 394 square inches of filter The filter system must be designed for the larger CFM requirement determined for cooling of 460 square inches A filter would have to be sized so that the area length X width was at least 460 sq in L WIRING All wiring shall be performed by a qualified electrician or service person The wiring must comply with local codes the instructions in this manual and in the absence of codes with the National Electrical Code ANSI NFPA 70 or latest edition 1 The following items are guidelines to complete the wiring portion of the installations A separate power supply circuit with over current protection and a disconnect switch must be provided The minimum fuse or circuit breaker size is 20 amp b All CHX3 and CDX3 Series furnaces are supplied with a fuse disconnect switch box to be mounted on the outside surface of the right or left side casing so a fuse disconnect can be mounted on the furnace Make the 115 volt supply connection in this junction box A green screw and a strain relief are provided in order to connect the power supply ground wire and provide strain relief for the 115 volt power leads from the furnace in the fuse disconnect box A disconnect switch can be field mounted on the 2x4 box provided If not the disconnect switch must be located reasonably close to and within si
64. ith the W R 50V51 843 has a feature to enhance de humidification in the cooling mode In the dehumidify mode the indoor blower motor ECM reduces CFM By reducing airflow the indoor coil runs colder and thus extracts more moisture from the air The W R 50V51 843 is shipped from the factory with dipswitch S5 2 set to on for system that do not have a dehumidification connection from the thermostat For systems using a thermostat that provides dehumidification option move dip switch S5 2 to OFF With the S5 2 switch in the OFF position the air conditioning fan speed will be reduced 3096 from the normal CFM setting when the humidity in the home is higher than the set point of the dehumidistat 6 FIELD WIRING AND REPLACING WIRING Field wiring between the furnace and devices not attached to the furnace shall conform with the temperature limitation for Type T wire 63 F rise 35 when installed in accordance with the manufacturer s instructions If any of the original factory supplied furnace wiring is replaced or a separate device other than the thermostat is wired internal to the unit 105 C thermoplastic or equivalent wire must be used 35 All installations and services must be performed by qualified service personnel IV STARTING THE UNIT A SEQUENCE OF OPERATIONS AT ANY TIME THE CONTINUOUS SAFE OPERATION CHECK GAS VALVE IS IF FLAME SIMULATION CONDITION PRESENT OR ROLL OUT SWITCH NOT ENERGIZED OPENS SYSTEM ENERGIZES IN
65. ked Use a mild soap and water solution to check for leaks Vent pipe passing through an unheated space shall be insulated with 1 inch thick foil faced fiberglass insulation or equivalent to prevent freezing of condensate within the pipe No clearance is required from the outer surface of the thermoplastic piping to combustible materials for fire hazard prevention Thermo Products does not require screens be installed in the exhaust vent and air intake piping However optional stainless steel screens are available from Thermo Products should the homeowner request them NOTICE The CHX3 CDX3 furnace models may be vented either through the sidewall or the roof For sidewall instructions continue to the following section For roof venting refer to Section G of this manual E Direct Venting Through a Sidewall 1 Vent and combustion air pipes may pass through a maximum wall thickness of 18 inches The minimum wall thickness is 2 inches Referring to Figure 2 the maximum distance from the outer wall to the center of the elbow is 12 inches Figure 2 Proper Direct Vent Terminations RH amp LH views and Vent Termination Only w o Outside Combustion Air Intake RH view 11 All installations and services must be performed by qualified service personnel NOTICE If exterior sidewall building materials are subject to degradation from contact with flue gases or moisture a minimum 24 inch diameter shield shall be fabricated fr
66. l clearances specified in this manual mark and cut two 2 holes in the outside wall of the following sizes for the outdoor terminal s a 2 3 8 inch diameter for furnace models CHX3 CDX3 75 or b 3 1 2 inch diameter for the furnace models CHX3 CDX3 100 and CHX3 CDX3 125 15 All installations and services must be performed by qualified service personnel 2 5 Measure and cut two 2 2 inch diameter thermoplastic pipes 1 1 2 inches longer than the depth of the wall Cutting the pipe longer leaves a 34 inch connection allowance at both ends of the pipe For 3 inch diameter PVC pipe leave a 3 inch allowance for end connections Using PVC pipe cement glue a PVC elbow or coupling fitting to one 1 end of each pipe Before inserting the pipe through the wall mark the other end of the pipe so the elbow orientation can be determined Also if a protective shield refer to Section E passage 1 of this manual will be used on the exterior surface of the wall it should be installed at this time From the inside glue a coupling fitting to each pipe using PVC pipe cement while being careful to maintain the proper orientation of the termination elbow s Complete the assembly of the outlet and inlet as shown in Figure 5 making sure that the spacing between the inlet and outlet complies with that noted in Figure 3 Figure 5 Typical Sidewall Vent and Air Intake Termination Construction Details Finish the vent installation b
67. nt feet for the combustion air intake system 8 The maximum quantity of Schedule 40 series type DWV thermoplastic pipe elbows allowed in each system is listed in Table 2 When counting pipe elbows all elbows used in the exhaust vent or combustion air intake systems must be considered This includes all elbows or equivalent pipe fittings used inside the furnace jacket in addition to those used to construct the termination Furthermore a credit of 5 feet of straight pipe may be taken for each elbow up to maximum of three 3 elbows which is dropped from the maximum permissible number for each system Table 2 Maximum Permissible Exhaust Vent and Combustion Air Intake Lengths When Using the Maximum Quantity of Elbows Thermoplastic Pipe Vent Size 2 in Diameter IPS in Diameter IPS Nominal Exhaust or Maximum Qty Maximum Exhaust or Maximum Qty Maximum Furnace Model Intake of Exhaust Qty of Intake Intake of Exhaust Qty of Intake Straight Elbows Elbows Straight Pipe Elbows 2 Elbows Pa Length Length ft CHX3 CDX3 75 8 CHX3 CDX3 100 Not CHX3 CDX3 125 Superscripts The drain tee supplied with the model series CHX3 furnaces is considered equivalent to one 1 90 elbow Two 2 45 elbows can be substituted for one 1 90 elbow Care should be taken to design the shortest possible intake and exhaust systems Each system should contain as few elbows as possible to insure the sa
68. ntenance sections of this manual or contact Thermo Products at 574 896 2133 Checkout Procedure 1 Confirm the furnace exhaust vent and combustion air intake are constructed as outlined in the installation and service manual They must not be blocked or otherwise obstructed 2 Place system in operation and observe at least one 1 complete cycle to ensure all controls are operating properly The main burner must light reliably under all conditions 3 Perform gas leakage test on all gas pipe connections and pressure tap plugs 45 All installations and services must be performed by qualified service personnel TIME sec FLOW cfh TABLE 6 CONVERTING GAS FLOW RATE 40 90 41 88 For one cubic foot per revolution gas meter dials 42 86 use Table directly 44 82 45 80 For 1 2 cubic foot per revolution gas meter dials 46 78 1 Determine time for two dial revolutions 47 77 2 Use Table directly 48 75 49 73 For two cubic foot per revolution gas meter dials 50 72 1 Determine time for one complete dial revolutions 51 71 2 Divide time by two 52 69 3 Use Table directly 53 68 54 67 55 65 56 64 57 63 58 62 59 61 60 60 62 58 64 56 66 54 68 53 70 51 72 50 74 49 76 47 78 46 80 45 84 43 88 41 92 39 96 38 100 36 105 34 110 33 115 31 120 30 125 29 130 28 135 27 140 26 150 24 160 23 170 21 180 20 46 All installations and services must be performed by qualified service personnel D FURNACE CHECKOUT PR
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70. om stainless steel or UV resistant plastic sheet The protective shield shall be installed around the vent pipe on the outside wall 2 The exhaust vent termination elbow shall be installed in accordance with these instructions and any applicable local codes Refer to Figures 2 and 3 for typical examples of proper terminations a The exhaust vent termination must be installed in the same atmospheric pressure zone i e on the same wall as the air intake termination The bottom edge of the vent termination elbow must be installed at least 12 inches above the outlet of intake termination elbow The horizontal distance between the inlet and exhaust terminations should be minimized when possible and should never exceed 24 inches The vent and intake systems should utilize the same numbers of elbows and approximately the same length of straight pipe to reach the outside termination Figure 3 Typical Relative Locations of Direct Vent Terminations When Sidewall Venting 3 Exhaust Vent Terminal Location Clearance Requirements a The vent terminal shall be located at least 3 feet above any forced air inlet located within 10 feet Refer to Figure 4 for a depiction of the required minimum clearances between vent terminations and building features according to the National Fuel Gas Code NFGC The vent terminal shall be at least 12 inches below 12 inches horizontally from or 12 inches above any door window or gravity air inlet into a
71. onnection 6 drain is not readily available or is above the trap outlet level on the furnace or the drain line cannot be sloped downward its full length to the drain then a condensate pump part 350225 can be ordered from the factory Follow the pump manufacturers installation instructions 7 The furnace condensate is slightly acidic with a pH of 3 5 Cola drinks with a pH of 3 1 are actually more acidic If local codes require a neutralizing kit the kit may be ordered using part no 320095 Instructions included with the neutralizing kit must be followed for its proper installation 8 The condensate piping in the furnace and the drain system must be flushed out at the start of every heating season This will assure trouble free operation and will keep the acidity level well above 3 4 pH To flush the condensate drain system turn off power to the furnace at the electrical disconnect switch and turn the thermostat to the lowest setting 25 All installations and services must be performed by qualified service personnel Remove the 11 16 diameter clear tubing from the coil drain nipple and run tap water into the open end of the tubing This should keep the drain system clean Replace the tubing by pushing it firmly onto the nipple Make sure the spring clamp is returned to the original position to prevent leaks If any of the electrical controls are exposed to water dry with a soft cloth and wait 24 hours before operating the furnac
72. ormed by the user All installations and services must be performed by qualified service personnel INDEX SECTION BEGINNING PAGE l SAFETY INFORMATION FURNACE SPECIFICATIONS 1 GENERAL INSTALLATION 6 A CODES AND CLEARANCES 6 B FURNACE LOCATION 7 B1 CDX3 HORIZONTAL APPLICATION 7 C REPLACING EXISTING FURNACE FROM A COMMON VENT 9 D GENERAL REQUIREMENTS FOR VENTING CHX3 CDX3 9 E SIDEWALL VENTING 11 E1 SINGLE PIPE SIDEWALL VENTING OPTION 15 F INSTALLATION OF OUTSIDE VENT AIR INTAKE TERMS 15 G CONNECTING FURNACE TO ROOF VENT AIR TERMS 17 H CONNECTING FURNACE TO VENT AIR INTAKE TERMS 18 CONDENSATE DRAIN LINE amp TRAP ASSY 23 J GENERAL GAS PIPING 26 J1 REQUIREMENTS AND SIZING OF DUCTWORK 27 K FILTERS 30 L WIRING 32 IV STARTING THE UNIT 36 A SEQUENCE OF OPERATIONS 36 B INITIAL START UP 39 C MEASURING AND ADJUSTING HEAT INPUT RATE 70 D FURNACE CHECKOUT PROCEDURE 47 V INSTALLER S INSTRUCTIONS TO USER 47 VI TROUBLESHOOTING 48 APPENDIX A REPLACEMENT PARTS LIST 55 APPENDIX B WIRING DIAGRAMS 59 WARRANTY 61 All installations and services must be performed by qualified service personnel Il FURNACE SPECIFICATIONS CHX3 SERIES MODEL NO CHX3 75 CHX3 100 CHX3 125 BTU HR INPUT High fire Low fire 75 000 52 000 100 000 125 000 70 000 87 500 BTU HR OUTPUT High fire Low fire 71 000 49 000 95
73. s and elbows and rotate 1 4 turn Silicone rubber type sealants remain pliable after the initial setup period has passed allowing for relatively easy disconnection of the air intake system should the burner assembly require removal at a later date refer to Figure 12 NOTICE When applying silicone sealants ensure that no excess sealant is pushed into the inside opening of the pipe This may cause flow restriction within the piping If possible always apply the sealant to the male component of the piping joint 22 All installations and services must be performed by qualified service personnel DO NOT SILICONE OR SEAL LOX THIS CONNECTION IN ANYWAY MUST LOOSE FIT WITH LEAKAGE BETWEEN PVC AND METAL COLLAR Figure 12 Typical Internal Air Intake Piping Arrangement for All Furnace Models d After trial fitting the entire combustion air intake system use a PVC cement to glue all connections in place except the length of pipe between the combustion air fitting on the burner box and the first fitting e Ifthe combustion air piping is installed in a warm humid place such as a laundry room or above a suspended ceiling it must be insulated with a 1 inch thick foil faced fiberglass insulation or an equivalent product to help prevent the outside surface of the pipe from sweating 1 CONDENSATE DRAIN LINE AND TRAP ASSEMBLY 1 The following diagrams show the typical drain and trap connection for a CHX3 and CDX3 furnace
74. the appliance service manual gas shutoff valve or for LP gases shut off the gas at the storage tank service valve BEFORE removing the a gas valve inlet pressure tap plug b manometer or gauge and replacing the inlet pressure tap plug Perform a gas leakage test at the gas valve inlet and burner manifold pressure tap plugs B Gas flowrate by clocking gas meter 1 To determine the amount of flow through the gas meter due to the operation of the furnace a Turn off all other appliances and extinguish their pilot flames if equipped or b Deduct the gas consumption of all other operating appliances from the total meter reading Convert the gas flowrate to the heat input rate in BTUH as described in step 10 in the following section and compare the value to the heat input rating on the furnace nameplate 40 All installations and services must be performed by qualified service personnel NOTICE A U tube manometer measuring pressure in inches of water column is recommended for all gas pressure measurements However an aneroid pressure gauge in good working condition capable of reading pressure changes of 0 05 in W G or less that was recently calibrated within the last year is a satisfactory alternate These two 2 devices will be considered as equivalent and interchangeable Either device is referred to below as a pressure gauge NOTICE This 2 stage gas valve has two separate gas pressure regulators Ch
75. time warranty This furnace may be horizontally i e sidewall vented using an exhaust vent pipe alone without drawing in outside combustion air When single pipe sidewall venting a furnace combustion air is drawn from the indoor space This type of installation is not classified as a direct vent installation However the same exhaust venting guidelines apply as for a direct vent installation except the exhaust termination will be similar to the air intake of the two pipe direct vent installation Refer to depictions of proper intake terminal installations in Figures 2 and 3 Referring to the left hand LH sketch in Figure 2 vent termination will consist of one 1 90 elbow opening downward When indoor air is used for combustion measures should be taken to prevent drawing in corrosive chemicals vapors or gases with the combustion air supply Such chemicals include but are not limited to chlorinated and or fluorinated hydrocarbons such as found in refrigerants aerosol propellants dry cleaning fluids degreasers and removers Other harmful compounds may come from bleaches air fresheners or mastics Vapors from such products can form reactive acid producing chemical species when burned in a gas flame The life of the furnace could be reduced should acidic compounds form within the furnace F Installation Of Outside Exhaust Intake Terminations 1 After determining appropriate installation locations Suitable locations must observe al
76. tisfactory operation of the furnace However system length should never be less than 8 ft of pipe with two 2 90 deg elbows For best overall operation of the combustion system we recommend the actual equivalent lengths for both the constructed intake and the exhaust systems have approximately the same value 9 Usea saw designed to cut thermoplastic pipe All cuts should be made at right angles to the pipe wall Smooth jagged edges and remove all burrs and strings All pipe joints must utilize standard PVC Schedule 40 series DWV type elbows couplings and fittings Clean all pipe surfaces at connections using a fine abrasive material or approved PVC cleaner primer Secure 10 All installations and services must be performed by qualified service personnel 10 11 12 13 all pipe joints using suitable permanent PVC pipe solvent cement Joints are NOT to be made by simply gluing raw edges of butted together vent pipe The piping joints inside the furnace vestibule should be sealed with a silicone caulk rather than pipe cement to allow for disassembly and removal of piping if necessary during maintenance NOTICE DO NOT use silicone caulk to seal the pipe sleeve or coupling to the metal air intake collar on the burner box Securing the sleeve or coupling to the collar using a screw is sufficient Vent connections shall be checked for leakage with the furnace induced draft blower running and with the vent termination bloc
77. ure 19 PLEASE NOTE While scribing the return air opening the filter rack can be held into position by tape or similar means Position the open end of the filter rack so that it is accessible for filter replacement Once the filter rack is positioned correctly scribe a line along the inside of the securing flange of the filter rack on three of the sides To scribe a line on the fourth side on the open end use the open end support for a guide Remove the filter rack and cut the return air opening in the casing Now the filter rack can be permanently attached to the furnace with screws or pop rivets along the securing flange Connect the return plenum to the filter rack and slide the filter into place 2 CDX3 MODELS COUNTERFLOWS This CDXS furnace has been factory supplied with two high quality reusable filters rated at 600 ft min These filters are designed to be mounted on the return air plenum opening on the top of the furnace in the double vee style rack provided see Figure 20 If feasible it is recommended that slits be cut in the return front to allow for easier access of the filters 30 All installations and services must be performed by qualified service personnel Figure 20 3 USE OF NON THERMO PRIDE FILTER RETENTION MEANS If a method other than the Thermo Pride filter rack is selected for retention of the filter and or use of a different filter type is desired see Table 3 for minimum size guidelines for selecting
78. y caulking the annulus to seal around the two 2 holes where the thermoplastic pipes pass through the wall To prevent foreign material insects or small animals from entering the pipes an optional vent or intake terminal stainless steel screen is available from Thermo Products 3 part no 320226 2 partit 320219 Optional Direct Vent Terminations Three optional vent kits are available for direct vent terminations refer to Figure 6 e The concentric vent kits Thermo Products p n AOPS7488 amp AOPS7489 provide a means for the vent and intake to be installed through a single opening in the roof or exterior wall Kit p n AOPS7488 requires a 4 inch diameter hole and is used on furnace models CHX3 CDX3 75 Kit p n AOPS7489 requires a 5 inch diameter hole and is used on furnace models CHXS CDX3 100 amp 125 e The sidewall vent cap Thermo Products part no 370191 is a cover installed over the exhaust vent and air intake pipes on the exterior of the building For horizontal sidewall vent applications only This kit may be used on any size furnace in the CHX3 CDX3 family 16 All installations and services must be performed by qualified service personnel Install these optional kits according to the instructions provided with each kit The location and clearance requirements are identical to those of the standard vent terminations described in this manual AOPS7488 AOPS7489 370191 CONENTRIC VENT KIT SIDE WALL VENT KIT

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