Table of Contents
Advertisement
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-1035
ECN 5222-MA 110815
MODELS:
CHX3-75N
CHX3-100N
CHX3-125N
THERMO PRODUCTS, LLC.
BOX 217
NORTH JUDSON, IN 46366
PHONE: (574) 896-2133
CDX3-75N
CDX3-100N
CDX3-125N
MADE IN USA
Advertisement
Table of Contents
Related Manuals for Thermo Pride CHX3-75N
Summary of Contents for Thermo Pride CHX3-75N
- Page 1 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 : 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 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 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. Please read and comply with the statements below.
- Page 5 All installations and services must be performed by qualified service personnel. : 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.
-
Page 6: Table Of Contents
All installations and services must be performed by qualified service personnel. INDEX SECTION BEGINNING PAGE SAFETY INFORMATION FURNACE SPECIFICATIONS III. GENERAL INSTALLATION A. CODES AND CLEARANCES B. FURNACE LOCATION B1.CDX3 HORIZONTAL APPLICATION C. REPLACING EXISTING FURNACE FROM A COMMON VENT D. -
Page 7: Ii. Furnace Specifications
All installations and services must be performed by qualified service personnel. II. 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 71,000 / 49,000 95,000 / 66,000 115,000 / BTU/HR OUTPUT (High fire/ Low fire) 82,000... - Page 8 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 71,000 / 52,000 94,000 / 69,000 116,000 / BTU/HR OUTPUT (High fire / Low fire) 87,000...
- Page 9 All installations and services must be performed by qualified service personnel. INSTALLATION PARTS PACKAGES – CHX3-75 PARTS PACKAGE DESCRIPTION PART # QUANTITY #S00S4413 2-3/8” ID radiator hose 410017 Thermostat lead bushing 350750 PVC trap assembly 320816 #8 x ¾ coated TEK screws for 300283 mounting trap &...
- Page 10 All installations and services must be performed by qualified service personnel. PVC tee assembly, 2 x 3” dia. 320817 CPVC XPVC adapter 320833 Gas Conversion Kit AOPS7683/7419 INSTALLATION PARTS PACKAGES – CDX3-75 PARTS PACKAGE DESCRIPTION PART # QUANTITY #S00S4416 2-3/8” ID radiator hose 410017 Thermostat lead bushing 350750...
- Page 11 All installations and services must be performed by qualified service personnel. Grounding instructions MG-966 Wire nut 300132 3” stainless steel hose clamp 300276 J-box wire bushing 350016 Drain hose grommet 350446 Spring clamp, 11/16” 300299 Installation notice MG-987 PVC tee assembly, 2 x 3” dia. 320817 PVC tee assembly, 2”...
-
Page 12: Iii. General Installation
All installations and services must be performed by qualified service personnel. 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
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 CDX3 series furnaces may be installed in an attic or crawl space. - Page 14 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". 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).
- Page 15 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.
- Page 16 All installations and services must be performed by qualified service personnel. 5. All horizontal runs of exhaust vent pipe shall slope upward at least ¼ 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.
- Page 17 All installations and services must be performed by qualified service personnel. 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.
- Page 18 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 from stainless steel or UV-resistant plastic sheet.
- Page 19 All installations and services must be performed by qualified service personnel. • near soffit vents, crawl space vents, or other areas where condensate or water vapor could create a nuisance, hazard, or cause property damage, and • where wetting of components by condensate, or water vapor, could be detrimental to the operation of pressure regulators, relief valves, or any other equipment.
- Page 20 All installations and services must be performed by qualified service personnel. Figure 4: NFGC Minimum Clearances Between the Vent Terminal and Various Building Features Vent Terminal Location Guidelines...
-
Page 21: E1. Single Pipe (Sidewall) Venting Option
All installations and services must be performed by qualified service personnel. : 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 22 All installations and services must be performed by qualified service personnel. 2. 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 ¾ inch connection allowance at both ends of the pipe.
- Page 23 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.
- Page 24 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 required parts to correctly install each system.
- Page 25 All installations and services must be performed by qualified service personnel. Figure 7: Required Exhaust Vent and Air Intake Piping for CDX3 Furnace in Downflow Applications...
- Page 26 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.
- Page 27 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.
- Page 28 All installations and services must be performed by qualified service personnel. NOTICE: All 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.
- Page 29 All installations and services must be performed by qualified service personnel. DO NOT! SILICONE OR SEAL THIS CONNECTION IN ANYWAY. MUST BE LOOSE FIT WITH LEAKAGE BETWEEN PVC AND METAL COLLAR. Figure 12: Typical Internal Air Intake Piping Arrangement for All Furnace Models d.
- Page 30 All installations and services must be performed by qualified service personnel. Figure 15. TRAP ASSEMBLY MOUNTED ON CDX3 Figure 16. TRAP ASSEMBLY MOUNTED ON CDX3 RIGHT SIDE HORIZONTAL INSTALLATION...
- Page 31 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 CHX3/CDX3’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 32: J. General Gas Piping
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. -
Page 33: J1. Requirements And Sizing Of Ductwork
All installations and services must be performed by qualified service personnel. : 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. - Page 34 All installations and services must be performed by qualified service 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.
- Page 35 All installations and services must be performed by qualified service personnel. DUCT SIZES FOR HOMES, QUIET OFFICES, OR SIMILAR INSTALLATIONS 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"...
-
Page 36: K. Filters
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. - Page 37 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 a filter system for the CHX3 or CDX3 furnaces.
-
Page 38: L. Wiring
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 cooling and a standard permanent filter. - Page 39 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 single-stage thermostat with two-stage operation connect W from thermostat to W1 on control. W2 on control board is not used.
- Page 40 All installations and services must be performed by qualified service personnel. 4. BLOWER AND CONTROL PANEL WIRING Figure 21 : TURN OFF THE ELECTRICAL POWER to the furnace before attempting to disconnect blower wiring. Table 4B S7 DIP Switch Switch Settings Options S7-1 S7-2...
- Page 41 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...
-
Page 42: Iv. Starting The Unit
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 INDUCER FAN FOR 15 SECONDS AND CIRCULATOR BLOWER AT HEATING SPEED UNTIL SITUATION CORRECTION THERMOSTAT CALLS FOR... - Page 43 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 GAS VALVE IS DE-ENERGIZED, IF NOT FLAME IS DETECTED, THE...
- Page 44 All installations and services must be performed by qualified service personnel. IF SYSTEM IS IN LOCKOUT, THE MODULE WILL RESET ITSELF AFTER 60 MINUTES IF THERMOSTAT OR MAY BE MANUALLY W2 CONTACTS RESET BY INTERRUPTING ARE CLOSED THE POWER TO THE FURNACE AT THE DISCONNECT OR INTERRUPTING THE CALL FOR HEAT AT THE THERMOSTAT.
-
Page 45: B. Initial Start-Up
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. -
Page 46: C. Measuring And Adjusting Heat Input Rate
All installations and services must be performed by qualified service personnel. C. 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. - Page 47 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 48 All installations and services must be performed by qualified service personnel. 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.
- Page 49 All installations and services must be performed by qualified service personnel. Figure 23: b. 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.
- Page 50 All installations and services must be 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.
- Page 51 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.
- Page 52 All installations and services must be performed by qualified service personnel. 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.
-
Page 53: D. Furnace Checkout Procedure
All installations and services must be performed by qualified service personnel. D. 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 54: Vi. Troubleshooting
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 warranty on the furnace. - Page 55 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.
- Page 56 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.
- Page 57 All installations and services must be performed by qualified service personnel. CHECK CONTACTS ON LOW FIRE PRESSURE SWITCH IS INDUCER RUNNING AND FOR BLOCKAGE IN FLUE. REPLACE THE ON LOW SPEED? IF OK, REPLACE DUAL 50V51-843 CONTROL. PRESSURE SWITCH. IS THERE VOLTAGE ACROSS IS THE HIGH LIMIT, DOES THE HOT HOT SURFACE IGNITOR...
- Page 58 All installations and services must be performed by qualified service personnel. IS IGNITOR REPOSITION TO POSITIONED CORRECTLY? CORRECT LOCATION CHECK AND CLEAN BURNERS CHECK FOR PROPER LINE DO BURNERS STAY AND MANIFOLD PRESSURE LIT PAST PROOF OF REFERENCE GAS FLAME CHECK? PRESSURE CHART PAGE 31.
- Page 59 All installations and services must be performed by qualified service personnel. IS THERE 24 VOLTS ACROSS "MVH" AND REPLACE THE "MV COM" ON 50V51-843 CONTROL. 50V51-843 CONTROL? CHECK CONNECTIONS TO GAS VALVE. IF OK, REPLACE GAS VALVE. CONFIRM IF EITHER BLOWER WHEEL IS RUBBING AGAINST IS THE VARIABLE...
- Page 60 All installations and services must be performed by qualified service personnel. DOES BURNER SHUT OFF CHECK FOR 24 VOLTS WHEN THERMOSTAT IS REPLACE GAS VALVE AT GAS VALVE. SATISFIED? CHECK FOR SHORT IN WIRE TO THERMOSTAT AND CORRECT IF NECESSARY. DOES THE CIRCULATING AIR BLOWER TURN OFF REFERENCE ECM...
-
Page 61: 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 CHX3-75, CHX3-100 and CHX3-125. - Page 62 All installations and services must be performed by qualified service personnel.
- Page 63 All installations and services must be performed by qualified service personnel. 2. Replacement parts list for CDX3-75, CDX3-100 and CDX3-125.
- Page 64 All installations and services must be performed by qualified service personnel. All installations and services must be performed by qualified service personnel.
-
Page 65: Appendix – B Wiring Diagrams
All installations and services must be performed by qualified service personnel. Appendix – B Wiring Diagrams... - Page 66 All installations and services must be performed by qualified service personnel. All installations and services must be performed by qualified service personnel.