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Thermo Products CDX1-100N Installation And Operation Manual

Thermo products installation and operation manual two stage condensing gas furnace chx1-75n, cdx1-75n, chx1-100n, cdx1-100n, chx1-125n, cdx1-125n.

 
TWO STAGE CONDENSING GAS FURNACE
INSTALLATION AND OPERATION MANUAL
FOR USE WITH NATURAL GAS OR LP GAS (PROPANE)
: IF 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.
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.
MG-1010
ECN4470-MA
MODELS:
CHX1-75N
CHX1-100N
CHX1-125N
THERMO PRODUCTS, LLC.
BOX 217
NORTH JUDSON, IN 46366
PHONE: (574) 896-2133
CDX1-75N
CDX1-100N
CDX1-125N
MADE IN USA

Summary of Contents

  • Page 1

    PERFORMING ANY SERVICE OR MAINTENANCE. THESE INSTRUCTIONS MUST BE LEFT WITH THE HOMEOWNER AND SHOULD BE RETAINED FOR FUTURE REFERENCE BY QUALIFIED SERVICE PERSONNEL. MG-1010 ECN4470-MA MODELS: CHX1-75N CDX1-75N CHX1-100N CDX1-100N CHX1-125N CDX1-125N THERMO PRODUCTS, LLC. BOX 217 NORTH JUDSON, IN 46366 PHONE: (574) 896-2133 MADE IN USA...

  • Page 2

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

  • Page 3

    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.

  • Page 4

    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 H, 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.

  • Page 5

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

  • Page 6: Table Of Contents

    SECTION SAFETY INFORMATION FURNACE SPECIFICATIONS III. GENERAL INSTALLATION A. CODES AND CLEARANCES B. FURNACE LOCATION B1.CDX1 HORIZONTAL APPLICATION C. REPLACING EXISTING FURNACE FROM A COMMON VENT D. GENERAL REQUIREMENTS FOR VENTING CHX1/CDX1 E. SIDEWALL VENTING E1. SINGLE PIPE (SIDEWALL) VENTING OPTION F.

  • Page 7

    II. FURNACE SPECIFICATIONS CHX1 SERIES MODEL NO. BTU/HR INPUT (High fire/ Low fire) BTU/HR OUTPUT (High fire/ Low fire) HEIGHT OF CASING WIDTH OF CASING DEPTH OF CASING WARM AIR OUTLET RETURN AIR INLET DIA. OF FLUE DIA. OF COMBUSTION AIR INTAKE CFM from .2”...

  • Page 8

    CDX1 SERIES MODEL NO. BTU/HR INPUT (High fire / Low fire) BTU/HR OUTPUT (High fire / Low fire) HEIGHT OF CASING WIDTH OF CASING DEPTH OF CASING WARM AIR OUTLET RETURN AIR INLET DIA. OF FLUE DIA. OF COMBUSTION AIR INTAKE CFM from .2”...

  • Page 9

    INSTALLATION PARTS PACKAGES – CHX1-75 PARTS PACKAGE #S00S4378 2-3/8” ID radiator hose Thermostat lead bushing PVC trap assembly #8 x ¾ coated TEK screws for mounting trap & inlet/outlet collars 11/16” OD x 1/2” ID vinyl tubing 2 x 4 electrical J-box 2 x 4 electrical J-box cover #8 x ½...

  • Page 10

    INSTALLATION PARTS PACKAGES – CDX1-75 PARTS PACKAGE #S00S4380 2-3/8” ID radiator hose Thermostat lead bushing PVC trap assembly #8 x ¾ coated TEK screws for mounting trap & inlet/outlet collars 11/16” OD x ½” ID vinyl tubing 2 x 4 electrical J-box 2 x 4 electrical J-box cover #8 x ½...

  • Page 11

    INSTALLATION PARTS PACKAGES – CDX1-100-125 PARTS PACKAGE #S00S4381 2-3/8” ID radiator hose Thermostat lead bushing PVC trap assembly #8 x ¾ coated TEK screws for mounting trap & inlet/outlet collars 11/16” OD x 1/2” ID vinyl tubing 2 x 4 electrical J-box 2 x 4 electrical J-box cover #8 x ½...

  • Page 12: Iii. General Installation, A. Codes And Clearances

    III. 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 adjusted to obtain a temperature rise of 55°F to 85°F through the furnace after installation.

  • Page 13: B. Furnace Location

    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 : These high efficiency condensing furnaces are not certified for and shall not be vented into a standard or any type of chimney.

  • Page 14

    All installations and services must be performed by qualified service personnel. NOTE: When the CDX1 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;...

  • Page 15

    The following items and local code requirements must be followed: 1. The vent/air intake terminations outlined by Thermo Products in this manual must be used. 2. The entire vent/air intake system must be made of PVC Schedule 40 pipe.

  • Page 16: E. Sidewall Venting

    11. Minimum clearance from the PVC pipe to combustible material is zero inches. 12. Screens are not required by Thermo Products for the vent and intake. However, optional stainless steel screens are available from Thermo Products, should the homeowner request them.

  • Page 17

    NOTICE: If exterior sidewall building materials are subject to degradation from flue gases or moisture, a minimum 12” diameter shield made from stainless steel or high density plastic shall be used for protection. 2. The PVC vent termination elbow must be installed in accord with local codes and these instructions. The bottom edge of the vent termination elbow must be installed at least 12 in.

  • Page 18: E1. Single Pipe (sidewall) Venting Option

    : 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 materials. Keep the vent hood clear of snow. Avoid locating the terminals in areas where standing water or condensate drippage may be a problem.

  • Page 19

    F. INSTALLATION OF OUTSIDE VENT/AIR INTAKE TERMINATIONS NOTICE: Installation of the outside exhaust and combustion air vents must be performed by a qualified installer or service person in accord with local codes, the National Fuel Gas Code (NFPA 54, ANSI Z223.1 or latest edition) and the sections on venting in this manual.

  • Page 20

    All installations and services must be performed by qualified service personnel. G. CONNECTING FURNACE TO THE VENT/AIR INTAKE TERMINATION AND DRAIN 1. The following diagrams show the typical vent and air inlet connection for a CHX1 and CDX1 furnace as well as a list of the parts that will be needed to install each. Figure 6...

  • Page 21

    All installations and services must be performed by qualified service personnel. Figure 7...

  • Page 22

    All installations and services must be performed by qualified service personnel. 2. CONNECTING THE EXHAUST VENT TO THE INDUCER a. Insert the end of the 2”dia. PVC elbow (2" dia. PVC tee assembly for CDX1 horizontal installations) onto the outlet of the inducer blower assembly. Measure the length of 2” dia. PVC pipe needed to clear the furnace side casing, while allowing for the 2-3/8”...

  • Page 23

    IMPORTANT: Horizontal installations of CDX1-100 and CDX1-125 units must utilize the 2" x 3" dia. PVC reducer as soon as the vent inlet exits the side casing of the unit. The CDX1-100 and CDX1-125 series units must be vented with 3" dia. PVC. Refer to Figure 8. b.

  • Page 24

    NOTICE: The exhaust vent piping must slope upward at least 1/4” per foot from the furnace to outdoor vent terminal. The inlet vent piping must slope downward at least 1/4” per foot from the beginning of the last horizontal run of pipe to the outdoor vent terminal. The PVC pipe must be supported directly over the vent tee assembly (CDX1) or (CHX1), every four feet thereafter and at every joint.

  • Page 25

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

  • Page 26

    I. CONDENSATE DRAIN LINE AND TRAP ASSEMBLY 1. The following diagrams show the typical drain and trap connection for a CHX1 and CDX1 furnace. Figure 14. TRAP ASSEMBLY MOUNTED ON CHX1 Figure 15. TRAP ASSEMBLY MOUNTED ON CDX1...

  • Page 27

    Figure 16. TRAP ASSEMBLY MOUNTED ON CDX1 RIGHT SIDE HORIZONTAL INSTALLATION 2. Determine on which side of furnace the condensate disposal line is to be run (NOTICE: On CHX1/CDX1’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 #8x3/4”...

  • Page 28: J. General Gas Piping

    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 CHX1/CDX1’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).

  • Page 29: K. Filters

    2. A drip 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.

  • Page 30

    This CHX1 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 CHX1-75 thru 100 and AOPS7375 for CHX1-125) is available which is sized for the filter provided.

  • Page 31: L. Wiring

    300 FT./MIN. 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.

  • Page 32

    a. 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 CHX1 and CDX1 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.

  • Page 33

    BLOWER AND CONTROL PANEL WIRING : TURN OFF THE ELECTRICAL POWER to the furnace before attempting to disconnect blower wiring. STAGE DELAY FOR SINGLE STAGE THERMOSTATS Figure 21 DIP SWITCH (S1): HEAT “OFF” DELAY SECS. 60 SEC. 90 SEC. 120 SEC. 180 SEC.

  • Page 34

    Modifications to ECM blower speed settings are done using the S3 and S4 dip switch controls. (Labeled 1 to 8 in Figure 21). Thermo Pride two-stage furnaces are factory shipped at the CFM settings listed below in Table 4. Control Board Unit Dip Switch Settings...

  • Page 35: Iv. Starting The Unit, A. Sequence Of Operations

    IV. STARTING THE UNIT A. SEQUENCE OF OPERATIONS AT ANY TIME THE GAS VALVE IS IF FLAME SIMULATION CONDITION PRESENT OR ROLL-OUT SWITCH NOT ENERGIZED OPENS, SYSTEM ENERGIZES INDUCER FAN FOR 15 SECONDS AND CIRCULATOR BLOWER AT HEATING SPEED UNTIL SITUATION CORRECTION THERMOSTAT CALLS FOR HEAT W1 OR W1 &...

  • Page 36

    AFTER IGNITOR WARM-UP, THE 36E54 GAS VALVE IS ENERGIZED TO OPEN ON LOW FIRE SETTING FLAME MUST BE DETECTED WITHIN 4 SECONDS IF IF NOT FLAME IS DETECTED, THE DELAY-TO-FAN-ON TIME BEGINS (45 SECONDS) IF SO IF FLAME IS NOT DETECTED, THE GAS VALVE IS DE-ENERGIZED, THE IGNITOR IS TURNED OFF AND THE 50V61-143 CONTROL GOES...

  • Page 37

    IF THERMOSTAT W2 CONTACTS ARE CLOSED OTHERWISE AFTER DELAY-TO-FAN-ON PERIOD ENDS (45 SECONDS), CIRCULATING AIR FAN IS ENERGIZED AT LOW FIRE HEATING SPEED OR HIGH FIRE IF W2 IS ENERGIZED. THE (OPTIONAL) ELECTRONIC AIR CLEANER AND HUMIDIFIER ARE ENERGIZED. NO CALL HIGH FIRE WHEN THERMOSTAT W1 IS SATISFIED, CONTACTS OPEN AND THE GAS...

  • Page 38

    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.

  • Page 39

    Measuring And Adjusting Heat Input Rate 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. Close the gas valve (turn the gas control knob to the OFF position) BEFORE removing the: a.

  • Page 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.

  • Page 41

    5. 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. 6. Allow the burner to operate for at least 3 minutes before taking gas pressure readings. 7.

  • Page 42

    Figure 23: Outlet view of two-stage, automatic gas control valve b. Using a 3/32-in. hex key (or Allen wrench), turn the inner adjustment screw clockwise to increase, or counterclockwise to decrease, the gas pressure (and gas flow) to the main burner.

  • Page 43

    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. 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.

  • Page 44

    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).

  • Page 45

    TIME (sec.) FLOW (cfh) TABLE 6 - CONVERTING GAS FLOW RATE * For one cubic foot per revolution gas meter dials, use Table directly. * For 1/2 cubic foot per revolution gas meter dials: 1. Determine time for two dial revolutions 2.

  • Page 46: C. Furnace Checkout Procedure, V. Installer's Instructions To User

    C. FURNACE CHECKOUT PROCEDURE 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.

  • Page 47: Vi. Troubleshooting

    IMPORTANT: 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.

  • Page 48

    DIAGNOSTIC FEATURES The 50V61 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): 1 flash, then pause...

  • Page 49

    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: IF LED LIGHT IS FLASHING, REFER TO PAGE 34 FOR A QUICK TROUBLESHOOTING GUIDE. TO USE THIS DIAGRAM, YOU JUST NEED TO FOLLOW THE INSTRUCTIONS IN THE BOXES.

  • Page 50

    IS INDUCER RUNNING ON LOW SPEED? DOES THE HOT SURFACE IGNITOR ENERGIZE AND GLOW? AFTER HOT SURFACE IGNITOR WARM-UP, DOES GAS VALVE OPEN? AFTER GAS VALVE OPENS, DO THE BURNERS IGNITE? CHECK CONTACTS ON LOW FIRE PRESSURE SWITCH AND FOR BLOCKAGE IN FLUE. IF OK, REPLACE DUAL PRESSURE SWITCH.

  • Page 51

    DO BURNERS STAY LIT PAST PROOF OF FLAME CHECK? DOES INDUCER IS W2 ENERGIZED? HIGH SPEED? DOES BURNER STEP TO HIGH FIRE? IS IGNITOR POSITIONED CORRECTLY? CHECK AND CLEAN BURNERS CHECK FOR PROPER LINE AND MANIFOLD PRESSURE REFERENCE GAS PRESSURE CHART PAGE 31. CHECK FLAME PROB2 AND WIRE AND CHECK POLARITY ON INCOMING...

  • Page 52

    IS THE VARIABLE SPEED AIR FAN OPERATING? DOES SYSTEM RUN UNTIL THERMOSTAT IS SATISFIED? IS THERE 24 VOLTS ACROSS "MVH" AND "MV COM" ON 50V61-143 CONTROL? CHECK CONNECTIONS TO GAS VALVE. IF OK, REPLACE GAS VALVE. DOES BLOWER SPIN FREELY? REFERENCE ECM OPERATION MANUAL IS LED LIGHT...

  • Page 53

    DOES BURNER SHUT OFF WHEN THERMOSTAT IS SATISFIED? DOES THE CIRCULATING AIR BLOWER TURN OFF AFTER THERMOSTAT IS SATISFIED WITHIN 120 SECONDS? TROUBLE SHOOTING COMPLETE CHECK FOR 24 VOLTS AT GAS VALVE. CHECK FOR SHORT IN WIRE TO THERMOSTAT AND CORRECT IF NECESSARY.

  • Page 54: Appendix – A Replacement Parts List

    All installations and services must be performed by qualified service personnel. Appendix –A Replacement Parts List 1. Replacement parts list for CHX1-75, CHX1-100 and CHX1-125.

  • Page 55

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

  • Page 56

    All installations and services must be performed by qualified service personnel. 2. Replacement parts list for CDX1-75, CDX1-100 and CDX1-125.

  • Page 57

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

  • Page 58: Appendix – B Wiring Diagrams

    All installations and services must be performed by qualified service personnel. Appendix – B Wiring Diagrams...

  • Page 59

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

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