Thermo Pride CMA4-50D36N Installation And Service Manual

Thermo Pride CMA4-50D36N Installation And Service Manual

Gas fired high efficiency furnace
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GAS FIRED HIGH EFFICIENCY FURNACE
DOWNFLOW & DIRECT VENT (SEALED COMBUSTION)
For installation in:
1. Manufactured Homes
2. Modular Homes/Buildings
3. Site Constructed—Residential
(Single Story Dwellings)
PLEASE READ THESE INSTRUCTIONS PRIOR TO INSTALLATION, INITIAL FIRING, AND BEFORE PERFORMING
ANY SERVICE OR MAINTENANCE. THESE INSTRUCTIONS MUST BE LEFT WITH THE USER AND SHOULD BE
RETAINED FOR FUTURE REFERENCE BY QUALIFIED SERVICE PERSONNEL.
VEUILLEZ LIRE CES INSTRUCTIONS AVANT L'INSTALLATION, LA MISE À FEU INITIALE ET AVANT TOUT
ENTRETIEN OU MAINTENANCE. CES INSTRUCTIONS DOIVENT ÊTRE LAISSÉES À L'UTILISATEUR ET DOIVENT
ÊTRE CONSERVÉES POUR RÉFÉRENCE ULTÉRIEURE PAR UN PERSONNEL DE MAINTENANCE QUALIFIÉ.
MG-522
ECN 5580-MA 190515
MODELS:
CMA4-50D36N, CMA4-75D36N
CMC2-50D36N, CMC2-75D36N
CMC2-50DV3N, CMC2-75DV3N
INSTALLATION AND SERVICE MANUAL
THERMO PRODUCTS, LLC.
P.O. BOX 237
DENTON, NC 27239
PHONE: 800-476-4328
Pour l'installation dans :
1. Maisons fabriquées
2. Maisons modulaires / Bâtiments
3. Site a construit - Résidentiel
(Habitations à étage unique)
MADE IN USA

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Summary of Contents for Thermo Pride CMA4-50D36N

  • Page 1 GAS FIRED HIGH EFFICIENCY FURNACE DOWNFLOW & DIRECT VENT (SEALED COMBUSTION) MODELS: CMA4-50D36N, CMA4-75D36N CMC2-50D36N, CMC2-75D36N CMC2-50DV3N, CMC2-75DV3N INSTALLATION AND SERVICE MANUAL For installation in: Pour l'installation dans : 1. Manufactured Homes 1. Maisons fabriquées 2. Modular Homes/Buildings 2. Maisons modulaires / Bâtiments 3.
  • Page 3: Table Of Contents

    TABLE OF CONTENTS LIST OF SECTIONS BEGINNING PAGE SAFETY INFORMATION………………………………………………………...………… 1 FURNACE SPECIFICATIONS………………………………………………………..7 CMA4 series……………………………………………………………………………… 7 CMC2 series……………………………………………………………………………... 8 Installation Parts Packages…………………………………………………………..10 III. GENERAL INSTRUCTIONS AND CLEARANCES…………………………..………… 11 IV. GENERAL INSTALLATION…………………………………………………..…………… 13 Furnace Location………………………………………………………………………… 13 Base Installation………………………………………………………………………….. 15 Combustible Floor Base……………………………………………………………..
  • Page 4 House Air Blower………………………………………………………………………… 50 Return Air Filter…………………………………………………………………………... 50 Filter Maintenance Procedure……………………………………………………… 51 Filter Replacement…………………………………………………………………... 51 VIII. TROUBLE SHOOTING…………………………………………………………………... 51 Diagnostic Features……………………………………………………………………… 52 Troubleshooting Guide…………………………………………………………………... 53 APPENDIX-A REPLACEMENT PARTS……………………………………………… 57 APPENDIX-B WIRING DIAGRAM…………………………………………………….. 61 LIST OF FIGURES Combustible Floor Base……………………………………………………………..…………... 13 Coil Cabinets……………………………………………………………………………………….
  • Page 5 c WARNING: If the information in these instructions is not followed exactly, a fire or explosion may result causing property damage, personal injury, or loss of life. c AVERTISSEMENT: Si les informations contenues dans ces instructions ne sont pas suivies à...
  • Page 6: Safety Information

    I. SAFETY INFORMATION This and the following page contain reproductions of the various warning and instruction labels placed on the Thermo Pride Condensing Gas Furnaces. Please read and comply with the contents of these labels.
  • Page 7 This and the previous page contain reproductions of the various safety and instruction labels placed on the Thermo Pride Condensing Gas Furnaces. Please read and comply with the contents of these labels.
  • Page 8 This and the previous page contain reproductions of the various safety and instruction labels placed on the Thermo Pride Condensing Gas Furnaces. Please read and comply with the contents of these labels.
  • Page 9 Section IV. The following pages contain various warnings and cautions found throughout the Thermo Pride Gas Fired High Efficiency Furnace Manual. Please read and comply with the statements below. : This furnace is not to be used for temporary heating of buildings or structures under construction.
  • Page 10 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.
  • Page 11 : Copper and brass tubing and fittings (except tin lined) shall not be used if the gas contains more than a trace (0.3 grains per 100 cubic ft.) of hydrogen sulfide gas. Check with your gas supplier. : TURN OFF THE ELECTRICAL POWER to the furnace before attempting to change blower speed wiring.
  • Page 12: Furnace Specifications

    II. FURNACE SPECIFICATIONS MODEL CMA4-50D36 CMA4-75D36 INPUT IN BTUH 50,000 75,000 OUTPUT IN BTUH 48,000 72,000 MAIN ORIFICE-NAT. MAIN ORIFICE-LP GAS SUPPLY PRESSURE L.P. MINIMUM 11” IN.W.C. NAT. MINIMUM 4.5”IN.W.C. L.P. MAXIMUM 14” IN.W.C. NAT. MAXIMUM 14” IN.W.C. GAS MANIFOLD PRESSURE L.P.
  • Page 13: Cmc2 Series

    MODEL CMC2-50D36 CMC2-75D36 INPUT IN BTUH 50,000 75,000 OUTPUT IN BTUH 48,000 72,000 MAIN ORIFICE-NAT. MAIN ORIFICE-LP GAS SUPPLY PRESSURE L.P. MINIMUM 11” IN.W.C. NAT. MINIMUM 4.5”IN.W.C. L.P. MAXIMUM 14” IN.W.C. NAT. MAXIMUM 14” IN.W.C. GAS MANIFOLD PRESSURE L.P. 10.0” + 0.3 IN.W.C. NAT.
  • Page 14 MODEL CMC2-50DV3 CMC2-75DV3 INPUT IN BTUH 50,000 75,000 OUTPUT IN BTUH 48,000 72,000 MAIN ORIFICE-NAT. MAIN ORIFICE-LP GAS SUPPLY PRESSURE L.P. MINIMUM 11” IN.W.C. NAT. MINIMUM 4.5”IN.W.C. L.P. MAXIMUM 14” IN.W.C. NAT. MAXIMUM 14” IN.W.C. GAS MANIFOLD PRESSURE L.P. 10.0” + 0.3 IN.W.C. NAT.
  • Page 15: Installation Parts Packages

    INSTALLATION PARTS PACKAGES CMA4-50D36N CMA4-75D36N PARTS PKG# S00S4248 S00S4249 DESCRIPTION PART # PART # J-box cover 350020 350020 Wire nut 300132 300132 3" stainless steel hose clamp 300276 300276 2-3/8" radiator hose 410017 410017 CPVC adapter 320833 320833 LP conversion kit...
  • Page 16: General Instructions And Clearances

    III. GENERAL INSTRUCTIONS AND CLEARANCES – READ BEFORE START OF INSTALLATION 1. 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 the American Society of Heating, Refrigeration and Air Conditioning Engineers, Inc.
  • Page 17: List Of Tables Minimum Clearances

    b. American National Standard (ANSI-119.2/NFPA-501C) for all recreational vehicle installations. c. American National Standard (ANSI-Z223.1/NFPA-54) for all gas-fired furnaces. d. American National Standard (ANSI-C1/NFPA-70 Electric Code for all electrical field wiring. e. These gas-fired units are in compliance with ANSI Z 21.47 CAN/CGA Z223- 2001 Central Furnace test standard.
  • Page 18: General Installation

    IV. GENERAL INSTALLATION A. FURNACE LOCATION 1. For best performance, locate the furnace so that it is centralized with respect to the duct system. 2. The furnace installation is only intended for free air return through the furnace door louvers. DO NOT connect a ducted return air system directly to the furnace. An improper return air installation may create a hazard and damage equipment, as well as void all warranties.
  • Page 19: Coil Cabinets

    Coil Cabinet Model: CE111S Note: Coil cabinet cannot be utilized as a cottage base. CE111S Figure 1B. Cottage Base Model: 01COT-BASE For CMA4 models only. NOTE: Serves as a plenum for single story applications with exposed supply air systems.
  • Page 20: Base Installation

    Figure 1C. B. BASE INSTALLATION – CMA4 models only 1. Combustible Floor Base Model: 70 BASE (for CMA4 models only) Use the base bottom panel as a template to mark floor opening locations (see Figure 2). Cut a square opening in the floor for the supply air connector duct. Cut the opening 1-inch larger than the square template opening.
  • Page 21: Cottage Base

    After cutting openings in the floor, place the bottom panel in position. Mark the square opening location on the distribution duct at the connection point of the connector duct. Remove the bottom panel. Cut an opening in the distribution duct slightly larger than the connector duct.
  • Page 22: Alcove Installation

    C. ALCOVE INSTALLATION In this application, a minimum of 18 inches of clearance must be provided to the front of the unit. See Figure 4. Note – access to diagnostic view port. CMA4 SERIES CMC2 SERIES Figure 4. D. CLOSET INSTALLATION 1.
  • Page 23: Closet Installation Clearances

    must be aligned with the furnace return air opening. CMA4 SERIES CMC2 SERIES Figure 5. Do not obstruct any return air openings, including the return grille on the furnace. To do so may cause the furnace to activate the high limit and shut down.
  • Page 24: Fuel Piping

    7. Gas piping is not to be located in or through the return duct system. E. FUEL PIPING Sizing and installation of fuel lines must be in accordance with Federal, State & Local regulations. Including the National Fuel Gas Code NFPA 54/ANSI-Z233.1 (Latest Edition).
  • Page 25: General Venting Requirements

    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 system. The furnace and its gas valve must be disconnected from the gas supply during pressure testing of the gas supply system at pressures in excess of 1/2 PSIG or 14 inches w.c F.
  • Page 26: Maximum Vent Length

    MAXIMUM VENT LENGTH VENT SIZE 2 IN. PVC FURNACE VENT EXHAUST COMBUSTION AIR INTAKE MODEL LENGTH VENT ELBOWS (NO.) (FT.) ELBOWS (NO.) CMA*/CMC* *Note the drain elbow supplied with furnace count as 1 elbow. **Note the two 45 elbows supplied with furnace count as 1 elbow. Table 2 6.
  • Page 27: Connecting Exhaust Vent And Combustion Air Intake

    G. CONNECTING THE EXHAUST VENT AND COMBUSTION AIR INTAKE Figure 6. shows the typical exhaust vent and combustion air intake connection for CMA/CMC furnace. Figure 6. Models CMA and CMC have a removable top front panel that will allow for improved access to assist installation of the exhaust vent and combustion air intake connection to the top of the furnace.
  • Page 28: Top Front Access Panel

    the conclusion of the vent pipe installation. This will insure a leak free return air compartment. Refer to Figure 6A. Figure 6A. NOTICE: The exhaust vent pipe must be supported every 4 feet. After making sure the length of the piping is correct glue all connections in place. : This CMA/CMC furnace has been designed to be installed as a direct vent system and must have its combustion air brought in from outside the conditioned space.
  • Page 29: Direct Venting Through A Sidewall

    gas flame. Should acid compounds form in your furnace, it may reduce the life of the furnace. H. Direct Venting Through a Sidewall 1. Vent And Combustion Air Pipes Vent and combustion air pipes may pass through a maximum wall thickness of 18 inches.
  • Page 30: Exhaust Vent Terminal Location Clearance Requirements

    b. The bottom edge of the vent termination elbow must be installed at least 12-inches above the outlet of intake termination elbow. c. The horizontal distance between the inlet and exhaust terminations should be minimized, when possible, and should never exceed 24- inches.
  • Page 31: Minimum Clearances Between Vent Terminal And Various Building Features

     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. Figure 9: NFGC Minimum Clearances Between the Vent Terminal and Various Building Features...
  • Page 32: Vent Terminal Location Guidelines

    4. Vent Terminal Location Guidelines : 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 materials, snow, and ice build-up.
  • Page 33: Connecting The Furnace To Roof Vent/ Intake Terminations

    Figure 10: Typical Construction Details of Sidewall Vent and Air Intake Terminations 3. Finish the vent installation by caulking the annulus to seal around the two (2) holes where the thermoplastic pipes pass through the wall. 4. 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 under part no.
  • Page 34: Construction Details Of Vertical Vent And Air Intake Terminations

    The furnace may be vented vertically through the roof. The outlet/inlet of the vent and air intake terminations shall be a minimum of 12 inches above highest anticipated snow level. The vent outlet must be installed a minimum of 12 in. above the air intake inlet.
  • Page 35: Condensate Drain Line And Trap Assembly

    CEILING: Frame out area around where PVC pipe is to penetrate ceiling. Cut a 2-3/8” diameter hole for 2” PVC in the ceiling and a corresponding hole in a firestop to be made of a minimum of 18 gauge galvanized metal large enough to cover the entire framed area.
  • Page 36: Electrical Wiring

    L. ELECTRICAL 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 (LATEST EDITION).
  • Page 37: Maximum Recommended Thermostat Wire Length

    IMPORTANT: The room thermostat should be installed 4 to 5 feet above the floor on an interior wall which is relatively free from direct sources of heat (sunlight or supply airflow) or exposure to cold (drafts from open windows and doors). The nominal anticipator setting is 0.8 amperes, for the CMA/CMC (refer to the thermostat literature for additional information).
  • Page 38: Blower Motor Speed Wiring

    4. BLOWER MOTOR SPEED WIRING Figure 15.
  • Page 39 CMA4-50D36 ALTERATIONS REQ’D FOR A/C @ DESIGN EXTERNAL STATIC PRESSURE COOLING UNIT HTG Speed Recommended CLG Speed 24,000 MED-LOW 30,000 MED-HIGH 36,000 HIGH Furnace Airflow (CFM) vs. External Static pressure (in. WC.) Speed Tap \ Static Pressure 1044 1010 1250 1196 1146 1101...
  • Page 40 CMA4-75D36 ALTERATIONS REQ’D FOR A/C @ DESIGN EXTERNAL STATIC PRESSURE HTG Speed Recommended CLG Speed COOLING UNIT 24,000 MED-LOW MED-LOW 30,000 MED-LOW MED-HIGH 36,000 MED-LOW HIGH Speed Tap \ Furnace Airflow (CFM) vs. External Static pressure (in. WC.) Static Pressure 1019 1257 1210...
  • Page 41 CMC2-50D36 ALTERATIONS REQ’D FOR A/C @ DESIGN EXTERNAL STATIC PRESSURE COOLING UNIT HTG Speed Recommended CLG Speed 24,000 MED-LOW 30,000 MED-HIGH 36,000 HIGH Furnace Airflow (CFM) vs. External Static pressure (in. WC.) Speed Tap \ Static Pressure 1044 1010 1250 1196 1146 1101...
  • Page 42 CMC2-75D36 ALTERATIONS REQ’D FOR A/C @ DESIGN EXTERNAL STATIC PRESSURE HTG Speed Recommended CLG Speed COOLING UNIT 24,000 MED-LOW MED-LOW 30,000 MED-LOW MED-HIGH 36,000 MED-LOW HIGH Speed Tap \ Furnace Airflow (CFM) vs. External Static pressure (in. WC.) Static Pressure 1019 1257 1210...
  • Page 43 CMC2-50DV3 ALTERATIONS REQ’D FOR A/C @ DESIGN EXTERNAL STATIC PRESSURE COOLING UNIT HTG Speed Recommended CLG Speed 24,000 MED-LOW 30,000 MED-HIGH 36,000 HIGH Furnace Airflow (CFM) vs. External Static pressure (in. WC.) Speed Tap \ Static Pressure 1174 1145 1107 1066 1026 High...
  • Page 44 CMC2-75DV3 ALTERATIONS REQ’D FOR A/C @ DESIGN EXTERNAL STATIC PRESSURE HTG Speed Recommended CLG Speed COOLING UNIT 24,000 MED-LOW MED-LOW 30,000 MED-LOW MED-HIGH 36,000 MED-LOW HIGH Speed Tap \ Furnace Airflow (CFM) vs. External Static pressure (in. WC.) Static Pressure 1043 1148 1113...
  • Page 45: Field And Replacement Wiring

    : TURN OFF THE ELECTRICAL POWER to the furnace before attempting to change blower speed wiring. The furnace is factory wired to the ignition control with standard heating and cooling speeds. When changing motor speeds, simply switch the needed speed to either the heating or cooling terminal as applicable on the module to obtain the desired CFM.
  • Page 46: Starting The Unit

    V. STARTING THE UNIT A. SEQUENCE OF OPERATIONS AT ANY TIME THE CONTINUOUS SAFE OPERATION CHECK GAS VALVE IS IF FLAME SIMULATION CONDITION NOT ENERGIZED PRESENT OR ROLL-OUT SWITCH OPENS, SYSTEM ENERGIZES INDUCER FAN FOR 15 SECONDS AND CIRCULATOR BLOWER AT HEATING SPEED UNTIL SITUATION CORRECTION START THERMOSTAT CALLS FOR...
  • Page 47 AFTER DELAY-TO-FAN-ON THE RETRY SEQUENCE MAIN PERIOD ENDS, CIRCULATING PROVIDES A 60 SECOND BURNER AIR FAN IS ENERGIZED AT WAIT BEFORE IGNITION OPERATION HEATING SPEED. THE (OPTIONAL) RETRY. RETRY IS ELECTRONIC AIR CLEANER ATTEMPTED WITH AN AND HUMIDIFIER ARE ADDITIONAL 10 SECONDS ENERGIZED.
  • Page 48: Initial Start Up

    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 49: Adjustment Of Btu Input Rate

    C. ADJUSTMENT OF BTU INPUT RATE: The orifice for this furnace was sized: 1) for natural gas having a heating value of 1025 BTU per cubic foot and a specific gravity of .65, or 2) for liquefied propane gas with a heating value of 2500 BTU per cubic foot and a specific gravity of 1.55.
  • Page 50: Burner Adjustment

    GAS PRESSURE CHART FOR CMA*/CMC* MODEL FURNACES SUPPLY PRESSURE MANIFOLD PRESSURE MAX 14” WC 3.5 + .3” WC MIN 4.5” WC MAX 14” WC PROPANE 10.0” + .3” WC MIN 11” WC TABLE 3 This gas furnace is equipped with a fixed orifice sized for the manifold pressure shown on the rating label.
  • Page 51: Setting Temperature Rise

    Figure 16. The CMA/CMC furnace models are direct vent design and do 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. E.
  • Page 52: Furnace Checkout Procedure

    F. 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 Fuel Piping Section of this Furnace Manual. NOTICE: All controls on the unit should be checked for proper functioning prior to the qualified service personnel leaving the job site.
  • Page 53: Installer's Instructions To User

    VI. 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 the instructions must be kept along with instructions for any accessories in the plastic pouch. 2.
  • Page 54: Electrical

    Label wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. A. ELECTRICAL: 1. Check diagnostic code through view port prior to removing access door. 2. Check all wiring for loose connections and any signs of damage or unusual wear.
  • Page 55: Gasket/Sealing Materials

    necessary, clean the accessible portions of the housing and blower with a damp cloth. Vacuum to remove any lint or dust from the motor assembly. 5. GASKETS/SEALING MATERIALS Inspect all visible gaskets for signs of degradation or liquid seepage, especially any seals which were removed as part of the inspection.
  • Page 56: Filter Maintenance Procedure

    assure proper furnace operation. Follow the cleaning, removal and replacement procedure below. FILTER MAINTENANCE PROCEDURE The filter is located inside front door of the CMA/CMC. Remove filter retaining rod and remove dirty filter. Clean the filter by vacuuming, rinsing with tap water, hosing or dipping in an ordinary detergent solution.
  • Page 57: Diagnostic Features

    DIAGNOSTIC FEATURES The integrated control continuously monitors its own operation and the operation of the system. If a failure occurs, the LED will indicate a failure code as shown below. If the failure is internal to the control, the light will stay on continuously. In this case, the entire control should be replaced, as the control is not field- repairable.
  • Page 58: Troubleshooting Guide

    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. TO USE THIS DIAGRAM, YOU JUST NEED TO FOLLOW THE INSTRUCTIONS IN THE BOXES. TURN THERMOSTAT TO CALL FOR HEAT DOES THERMOSTAT MAKE? IS ROOM...
  • Page 59 IS THERE LINE VOLTAGE CHECK THE INTEGRATED ACROSS INDUCER POWER CONTROL DIAGNOSTIC LED TERMINALS "IND" & "IND N" LAMP. RESET BY INTERRUPTING AT THE INTEGRATED CONTROL? POWER TO CONTROL FOR MORE THAN ONE SECOND. IF LED STAYS ON CONTINUOUSLY, REPLACE INTEGRATED CONTROL.
  • Page 60 AFTER GAS VALVE CHECK FOR PROPER ADJUST TO 3.5" FOR NATURAL GAS OPENS, DO THE MANIFOLD PRESSURE. OR 10.0" WC FOR LP GAS BURNERS IGNITE? IS IGNITOR REPOSITION TO POSITIONED CORRECTLY? CORRECT LOCATION. DO BURNERS STAY LIT PAST PROOF OF FLAME CHECK? CHECK ACROSS THE DOES THE INTEGRATED CONTROL CIRCULATING AIR...
  • Page 61 DOES SYSTEM RUN UNTIL IS LED LIGHT CHECK ALL THERMOSTAT IS SATISFIED? ON INTEGRATED WIRING FOR CONTROL FLASHING? LOOSE CONNECTIONS. DOES BURNER SHUT OFF CHECK FOR SHORT IN WIRE TO WHEN THERMOSTAT IS THERMOSTAT AND CORRECT SATISFIED? IF NECESSARY. DOES THE CIRCULATING AIR BLOWER TURN OFF AFTER THERMOSTAT IS SATISFIED WITHIN...
  • Page 62: Appendix-Areplacement Parts

    APPENDIX – A REPLACEMENT PARTS...
  • Page 66: Appendix-Bwiring Diagram

    APPENDIX – B WIRING DIAGRAMS...

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