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Thermo Pride PGT5-100 Installation And Service Manual

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INSTALLATION AND SERVICE MANUAL
PGT5-100, PGT11-125, PGT16-160,
PGL20-180, PGL33-250, PGL37-312, & PGL39-400
? ? ? ? WARNING
: 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-807C
ECN 4403-MA
MODELS:
THERMO PRODUCTS,LLC.
BOX 217
NORTH JUDSON, IN 46366
PHONE: (574) 896-2133
MADE IN USA

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Summary of Contents for Thermo Pride PGT5-100

  • Page 1 INSTALLATION AND SERVICE MANUAL MODELS: PGT5-100, PGT11-125, PGT16-160, PGL20-180, PGL33-250, PGL37-312, & PGL39-400 ? ? ? ? WARNING : 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.

  • Page 2: Table Of Contents

    TABLE OF CONTENTS SECTION BEGINNING PAGE WARNING AND INSTRUCTION LABELS WARNINGS AND CAUTIONS I. GENERAL INSTRUCTIONS II. GENERAL INSTALLATION A. CODES AND CLEARANCES B. CONSTRUCTION MATERIALS a. COMBUSTIBLE MATERIALS b. NON-COMBUSTIBLE MATERIALS C. FURNACE LOCATION, COMBUSTION AND MAKE-UP AIR D. VENTING E.

  • Page 3: Warning And Instruction Labels

    All installations and services must be performed by qualified service personnel. This page contains reproductions of the various warning and instruction labels placed on the Thermo Pride Power Gas Furnaces. Please read and comply with the contents of these labels.

  • Page 4: Warnings And Cautions

    All installations and services must be performed by qualified service personnel. This page contains various warnings and cautions reproduced from the Power Gas Furnace Manual. Please read and comply with the statements below CAUTION: When installing the burner, it should be noted that the loose fill insulation and fiber chambers are made with ceramic fibers.

  • Page 5: General Instructions

    All installations and services must be performed by qualified service personnel. I. GENERAL INSTRUCTIONS These instructions must be read in their entirety before installing the furnace. It is the installer's responsibility to do the following: 1. Inform and demonstrate to the user, the correct operation and maintenance of the appliance. 2.

  • Page 6: Furnace Location, Combustion And Make-Up Air

    MODEL NO. FROM SIDES FRONT TOP & SIDES FROM THE REAR BOTTOM OF FURNACE OF PLENUM FLUE OR VENT PGT5-100 1 IN. 24 IN. 1 IN. 4 IN. 1 IN. 1 IN. PGT11-125 1 IN. 24 IN. 1 IN. 9 IN.

  • Page 7: Venting

    All installations and services must be performed by qualified service personnel. EXAMPLE: 100,000 BTUH input furnaces requires "two" openings of 100 square inches each. A minimum opening of 100 square inches is required regardless of the input. If the building is tightly constructed and or has an exhaust fan(s) that creates a negative pressure, air for combustion and ventilation must be supplied from the outdoors or from spaces freely communicating with the outdoors.
  • Page 8 All installations and services must be performed by qualified service personnel. Trim or remove nearby trees that could interfere with chimney draft. 5. In cases where the chimney flue extends to the basement floor, the draft can usually be improved by filling the base of the chimney with sand to within 12"...

  • Page 9: Vent Dampers

    Section G of this manual. NOTICE: Thermo Pride power gas units may be sidewall vented with a power sidewall venting system that is appropriate for the application and certified by a nationally recognized testing agency for use with gas fired warm air central furnaces.

  • Page 10: Replacing An Existing Furnace From A Common Vent

    All installations and services must be performed by qualified service personnel. temperature stability. If the chimney is on the homes exterior and condensing occurs, the chimney may be insulated around its exterior to help the flue hold its temperature. Also, check to see if the chimney is too large for the flue gases to heat, if so reduce to proper size by lining.

  • Page 11: Installation Of Natural Gas Piping

    All installations and services must be performed by qualified service personnel. Piping from the natural gas meter to the furnace shall be in accord with requirements of the local utility. Piping from the LP tank to the furnace must follow the recommendations of the gas supplier. 1.

  • Page 12: Installation Of Lp Gas Piping

    TYPICAL PIPING FOR TWO STAGE REGULATION NOTE: Two stage regulation must be installed for liquified petroleum gas when used with any Thermo Pride LP furnace. See illustration above of a typical two stage piping system.

  • Page 13: Burner Installation

    All installations and services must be performed by qualified service personnel. - COPPER TUBING SIZE FOR LIQUIFIED PETROLEUM GASES - All black pipe sizes shown are I.D. Seamless copper tubing may only be used with gases that are not corrosive to it. See note below and check with your LP gas supplier before using.
  • Page 14 All installations and services must be performed by qualified service personnel. TWO PIECE MOUNTING PLATE When mounting the burner, the upper mounting plate must be removed to provide access to the area in front of the combustion chamber. The combustion chamber can then be moved forward or backward slightly to allow for adjustment in positioning the burner tube.
  • Page 15 N on fan & limit position and location). MIDCO RE32 BURNER ADJUSTMENT In order to properly set-up a furnace with a Midco RE32 burner,Thermo Pride’s recommendation is to utilize a Modified version of Midco’s instruction together with combustion equipment and a carbon monoxide detector. It must be emphasized that the gas equipment is operating properly and safely requires combustion equipment and a carbon monoxide detector.
  • Page 16 All installations and services must be performed by qualified service personnel. Furnace Model Orifice Size Manifold Gas Pressure No. Turns Closed* ** PGL16-160 Nat #J (.277) 2.4” W.C. PGL16-160 LP #8(.199) 2.9” PGL20-180Nat #J(.277) 3.0” PGL20-180 LP #3(.213) 3.0” AGL16-160LP #8(.199) 2.9”...

  • Page 17: Requirements And Sizing Of Ductwork

    All installations and services must be performed by qualified service personnel. In summary, setting the combustion air on the Thermo Pride Midco RE32 power gas conversion burner is extremely critical. This adjustment should only be made by following these instructions and confirming the...
  • Page 18 All installations and services must be performed by qualified service personnel. EXAMPLE: Heating output of furnace is 100,000 x 1.4 ÷ 100 = 1400 CFM. 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.
  • Page 19 All installations and services must be performed by qualified service personnel. DUCT WORK/AIR CONDITIONING: If the furnace is used in connection with summer air conditioning (cooling), the furnace should be installed parallel with or on the upstream side of the evaporator coil to avoid condensation in the furnace heat exchanger. If the cooling unit is installed with a parallel flow arrangement, dampers or other means used to control flow of air should be provided to prevent chilled air from entering the furnace.

  • Page 20: Filters

    All installations and services must be performed by qualified service personnel. A. 400 CFM X 3 TON (36,000 BTU'S) = 1,200 CFM FOR COOLING B. 400 CFM X 2.5 TON (30,000 BTU'S) = 1,000 CFM FOR COOLING NOTE: To obtain the proper 50°F to 80°F temperature rise for heating an air conditioning coil is installed, the speed of the blower motor may have to be changed.

  • Page 21: Fan And Limit Position And Location

    All installations and services must be performed by qualified service personnel. N. FAN AND LIMIT POSITION AND LOCATION Power gas furnace models PGL5 through PGL20 are shipped with the fan and limit control pre-mounted in the vestibule. Should the installer prefer to mount the fan and limit control in the supply plenum, the installer must supply additional wire comparable to the original wire size and type which must be routed through either rigid, EMT or flexible metal conduit to the mounting location as described below.

  • Page 22: Wiring

    All installations and services must be performed by qualified service personnel. A. FAN & LIMIT LOCATION WITH H-COIL: The fan & limit control should be mounted between the H-coil cabinet and furnace. For distances from top of plenum and furnace, see chart above. IMPORTANT: Do not mount fan/limit in H-coil cabinet. O.
  • Page 23 All electrical wiring must be installed in strict accordance with local ordinances and codes. In the absence of local ordinances and codes, all electrical wiring must be in accordance with the National Electrical Code (ANSI/NFPA 70- LATEST EDITION). On the following pages are the wiring diagrams for the various Thermo Pride gas furnace models.
  • Page 24 All installations and services must be performed by qualified service personnel.
  • Page 25 All installations and services must be performed by qualified service personnel.
  • Page 26 All installations and services must be performed by qualified service personnel.
  • Page 27 All installations and services must be performed by qualified service personnel.
  • Page 28 All electrical wiring must be installed in strict accordance with local ordinances and codes. In the absence of local ordinances and codes, all electrical wiring must be in accordance with the National Electrical Code (ANSI/NFPA 70- LATEST EDITION). Below and on the following pages are the wiring diagrams for the various Thermo Pride gas furnace models.

  • Page 29: Starting The Unit

    All installations and services must be performed by qualified service personnel. II. STARTING THE UNIT A. INITIAL START UP: 1. Check all wiring for loose connections and proper hook up. 2. Leak test gas piping connections. 3. Check tubing to the pressure switch to make sure it is pushed firmly onto the pressure tap. 4.
  • Page 30 If using the above example, the furnace was a PGT5-100 model the 98,663 BTU input would be acceptable because it was within 2% of the listed input of 100,000.

  • Page 31: Furnace Checkout Procedure

    All installations and services must be performed by qualified service personnel. ORIFICE CHART FURNACE L.P. NAT. MODEL NO. PGT5-100 .113 OR #33 DMS .196 OR #9 DMS PGT11-125 .1285 OR #30 DMS .213 OR #3 DMS PGT16-160 .144 OR #44 DMS .238 OR B DMS...

  • Page 32: Dealer Maintenance

    All installations and services must be performed by qualified service personnel. V. DEALER MAINTENANCE A. ELECTRICAL: 1. Check all wiring for loose connections. 2. Check for correct voltage at the furnace when operating. 3. Check amp-draw on blower motor and burner to assure they are not exceeding name plate amp rating. B.

  • Page 33: Troubleshooting

    All installations and services must be performed by qualified service personnel. Reassemble the furnace to its original construction. Remount the burner being certain that the air tube is properly inserted into the chamber opening (see Burner Installation section). VI. TROUBLESHOOTING For troubleshooting the power gas burner, reference the burner manufactures instructions.

  • Page 34: Replacement Parts - Pgt

    All installations and services must be performed by qualified service personnel. VII. REPLACEMENT PARTS...
  • Page 35 All installations and services must be performed by qualified service personnel.

  • Page 36: Eplacement Parts - Pgl

    All installations and services must be performed by qualified service personnel.
  • Page 37 All installations and services must be performed by qualified service personnel.
  • Page 38 All installations and services must be performed by qualified service personnel.

This manual is also suitable for:

Pgt11-125Pgt16-160Pgl37-312Pgl39-400Pgl20-180Pgl33-250

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