Thermo Products CHX3-100N manual

MG - 1035 ECN 5 320 - MA 1 30307 TWO STAGE CONDENSING GAS FURNACE INSTA LLA TION A ND OPERA TION MA NUA L MODELS: FOR USE W ITH NA TURA L GA S OR LP GA S ( PROPA NE) CHX3 - 75N CDX3 - 75N CHX3 - 100N CDX3 - 100N CHX3 - 125N CDX3 - 125N : IF YO U DO NO T FO LLOW THE SAF ETY PRECAUT IONS BELO W AN D IN TH IS MANUAL, A FIRE OR EXPLO SION MAY RESULT CA[...]

A ll in stallatio ns and serv ices must be perfo rmed by q ualified servi ce personnel . i I. S AF E T Y I N F OR M AT I ON This and the f ollowing page contain reproductions of the various warning and instruc tion labels placed on the Therm o Pride T wo Stage Condensing Gas F urnaces. Pleas e read and com ply wi th the contents of these labels.[...]

A ll in stallatio ns and serv ices must be perfo rmed by q ualified servi ce personnel . ii This and the pr evious page contain reproduc tions of the various warning and instruction labels placed on the Therm o Pride T wo Stage Condensing Gas F urnaces. Pleas e read and com ply w ith the contents of these labels. The f ollowing safety information s[...]

A ll in stallatio ns and serv ices must be perfo rmed by q ualified servi ce personnel . iii 1. Use only w ith ty pe of gas approved for this f urnace. R efer to f urnace r ating plate. 2. Connect this f ur nace to an appr oved vent system only. Combus tion produc ts m ust be carried outdoors. Refer to Sec tion III, D thru H, of this m anual. The f[...]

A ll in stallatio ns and serv ices must be perfo rmed by q ualified servi ce personnel . iv : The CHX3 /CDX3 fur nace mode ls are seale d combustion de sign, which d o e s not requir e an air shutter a djustment (ai r shutter s are not us ed) for proper fl a me char acteri stics. Burner box access cover m ust always be secu red with al l screws in [...]

A ll in stallatio ns and serv ices must be perfo rmed by q ualified servi ce personnel . v INDEX SECTI ON BEGINNING PA GE I. SAFET Y INFORMAT ION i II. FURNACE SPECIFICA TIONS 1 III. GENERAL IN STALLAT IO N 6 A. CODES AN D CLEARANC ES 6 B. FURNACE LOCATION 7 B1.CDX3 HORIZO NT AL APPLICAT ION 7 C. REPLACING EXISTING FURNACE FROM A COMMON VENT 9 D. G[...]

A ll in stallatio ns and serv ices must be perfo rmed by q ualified servi ce personnel . 1 II. FURNA CE SPE CIFICA TIONS CHX3 SERIES MODEL NO . CHX3 - 75 CHX3 - 100 CHX3 - 125 BTU/HR INPUT (High f ire/ L ow fire) 75,000 / 52,000 100,000 / 70,000 125,000 / 87,500 BTU/HR OUT PUT (High fire/ Low fire) 71,000 / 49,000 95,000 / 66,000 115,000 / 82,000 H[...]

A ll installation s and serv ices must be perfo rmed by qualified service p ersonnel. 2 C DX3 SERIES MODEL NO . CDX3 - 75 CDX3 - 100 CDX3 - 125 BTU/HR INPUT (High f ire / Low fire) 75,000 / 56,250 100,000 / 75,000 125,000 / 93,750 BTU/HR OUT PUT (High fire / Low fire) 71,000 / 52,000 94,000 / 69,000 116,000 / 87,000 HEIGHT OF CASI NG 46 - 1/4” 46[...]

A ll installation s and serv ices must be perfo rmed by qualified service p ersonnel. 3 I N S T AL L AT IO N P AR T S P AC KAGES – CHX3 - 75 PA RTS PACKA GE #S00S4413 DESCRIPT ION P AR T # QUANTITY 2- 3/8” ID radiator hos e 410017 1 Therm os tat lead bushing 350750 1 PVC trap assem bly 320816 1 #8 x ¾ coated T EK screws f or mounting tr ap &am[...]

A ll installation s and serv ices must be perfo rmed by qualified service p ersonnel. 4 PVC tee assem bly, 2 x 3” dia. 320817 1 CPVC XPVC adapter 320833 1 Gas Convers ion Kit AOPS7683/7419 1 INST A LLATION PARTS PACKA G ES – CDX3 - 75 PA RTS PACKA GE #S00S4416 DESCRI PTION P AR T # QUANTITY 2- 3/8” ID radiator hos e 410017 1 Therm os tat lead[...]

A ll installation s and serv ices must be perfo rmed by qualified service p ersonnel. 5 Grounding instruc tions MG - 966 1 W ire nut 300132 2 3” stainless s teel hose clam p 300276 2 J- box wire bushing 350016 1 Drain hose grom m e t 350446 1 Spring clam p, 11/16” 300299 3 Installation notice MG - 987 1 PVC tee assem bly, 2 x 3” dia. 320817 1[...]

A ll installation s and serv ices must be perfo rmed by qualified service p ersonnel. 6 III. GENERA L INSTALLA T ION These C ategory Ty pe IV furnaces are shipped com pletely assem bled and wired (internally ) . See the Dealer Receiving and Freight Claim Procedure Section of the price guide for par ts short age or dam age. The f urnace and duct s y[...]

A ll installation s and serv ices must be perfo rmed by qualified service p ersonnel. 7 These f urnaces m ay be installed in an alcove or in a closet if the m inimum c learances to c ombus tible construc tion (listed previously) are met. T he CDX 3 series f urnaces may be installed in an attic or crawl space. Ref er to sec tion III, B1 of this inst[...]

A ll installation s and serv ices must be perfo rmed by qualified service p ersonnel. 8 For a right s ide horizontal application of the CDX3 s eries units, the aux iliary limit switch loc ated on the right side of the hous e air blower mus t be moved to the brac ket on the opposi te (left) side of the blower (See Figure 1). NOT E: W hen the CDX 3 i[...]

A ll installation s and serv ices must be perfo rmed by qualified service p ersonnel. 9 The horizontal furnac e installation should be on a ser vice platform large enough to allow for pr oper clearances on all sides and service ac cess to the front of the fur nace (See T able 1). If the f urnace is suspended, it m ust be suppor ted at both ends and[...]

A ll installation s and serv ices must be perfo rmed by qualified service p ersonnel. 10 Horizontal runs of air intak e pipe shall slope downward at least ¼ inch per f oot from the outlet of the last elbow or last horizontal run, before ex iting the wall, to the intake term ination bey ond the outside wall. This slope will perm it proper drainage [...]

A ll installation s and serv ices must be perfo rmed by qualified service p ersonnel. 11 NOTICE: DO NO T use sili cone caulk to seal the pipe sleev e or coupl ing to t he metal air intake c ollar o n th e burner b o x . Secu r ing the sl eeve or coup l ing to the col l ar usin g a scre w is suffic ient. 10. Vent connections s hall be check ed for l[...]

A ll installation s and serv ices must be perfo rmed by qualified service p ersonnel. 12 b. The bottom edge of the vent term ination elbow m ust be installed at least 12 - inches above the outlet of intak e term ination elbow. c. The horizontal distance between the inlet and exhaust term inations should be minimized, when possible, and should never[...]

A ll installation s and serv ices must be perfo rmed by qualified service p ersonnel. 13 Figure 4 : NFGC Minimum Clear ances B e tween the Vent Term i nal and V arious B u i lding Featu r es Vent Termina l Locatio n Gui delines[...]

A ll installation s and serv ices must be perfo rmed by qualified service p ersonnel. 14 : Bushes, shrubs, o r any ve g e tation that ma y restr ict the flow of fl ue products must be kep t away from v ent and ai r intake terminati ons. Ter minations mus t also be k ept clear of any leaves, weed s, combust ible materials, sno w, and ice b uild - up[...]

A ll installation s and serv ices must be perfo rmed by qualified service p ersonnel. 15 2. Measure and cut two (2) , 2 - inch diam eter therm oplastic 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. (For 3- inch diameter PVC pipe, leave a 3 - inch allow[...]

A ll installation s and serv ices must be perfo rmed by qualified service p ersonnel. 16 Install these optional k its accor ding to the instructions provided with each kit. T he location and clearance requir ement s are identical to those of the standard vent ter minations described in this manual. Figure 6 : Optional Dir ect Ve nt Kits for the C H[...]

A ll installation s and serv ices must be perfo rmed by qualified service p ersonnel. 17 H. Exha ust / Intak e Piping A nd Condensa te Drai n C onnections A t Furnace 1. Figures 6B, 7, and 8 f ollow depicting ty pic al exhaust vent and air intak e connections for the furnac e model s eries CHX 3 and the CDX3, res pectively, as wel l as a list of r [...]

A ll installation s and serv ices must be perfo rmed by qualified service p ersonnel. 18 Figure 7 : Require d Exhaust V ent and A ir Intake Piping for CDX3 Fur nace in D o wnflow A pplications[...]

A ll installation s and serv ices must be perfo rmed by qualified service p ersonnel. 19 Figure 8 : Require d Exhaust V ent and A ir Intake Piping for CDX3 Fur nace in H o r izontal A pplications. 2. Connecting T he Exhaust Vent T o The Induc er a. Slip the end of the 2 - inch diam eter PVC elbow (for the model CD X3 in horizontal applications, the[...]

A ll installation s and serv ices must be perfo rmed by qualified service p ersonnel. 20 leading away f rom the fur nace m ust be com posed of 3 - inch diam eter PVC pipe and pipe fittings only. Refer to item E in Figure 8. b. After prepar ation of the internal 2 - inch diam eter PVC pipe s ections, put a thin bead of a silicone rubber type sealant[...]

A ll installation s and serv ices must be perfo rmed by qualified service p ersonnel. 21 NOTICE: Al l PVC the rmoplas tic pipe mus t be supporte d beginning di rectly ov er the exhaust v ent tee assemb ly, then every 4 - feet there after, a nd at every joint. Tr ial fit the entire exhaust vent and air intak e piping systems , mak ing sur e the slop[...]

A ll installation s and serv ices must be perfo rmed by qualified service p ersonnel. 22 DO NOT! SI LICONE OR SEAL THIS CONNECTION IN ANYWAY. MUST BE LO O SE FIT WIT H LEAKAGE BETWEE N PVC AND METAL COLLAR. Figure 12: T ypica l Intern a l A ir Intake P iping A rrangement for A ll Furnace Models d. After tr ial fitting the entire com bustion air int[...]

A ll installation s and serv ices must be perfo rmed by qualified service p ersonnel. 23 Figure 15. TRA P A SSEMBL Y M OUNTED ON CDX3 Figure 16. TRA P A SSEMBL Y M OUNTED ON CDX3 RIGHT SIDE HORIZONT A L INSTA LLA TION[...]

A ll installation s and serv ices must be perfo rmed by qualified service p ersonnel. 24 2. Determ ine on which side of f urnace the c ondensate disposal line is to be run ( NOT ICE: On CHX3/CDX 3’s this m ust be the s am e side as the f lue outlet or bottom of unit). Attach t he condensate trap to the fur nace casing us ing the #8x3/4” sheet m[...]

A ll installation s and serv ices must be perfo rmed by qualified service p ersonnel. 25 Rem ove the 11/16” diamet er clear tubing f rom the coil drain nipple and run tap water into the open end of the tubing. This s hould keep the dr ain system clean. Replace the tubing by pushing it firm ly onto the nipple. Make sur e the spring clam p is r etu[...]

A ll installation s and serv ices must be perfo rmed by qualified service p ersonnel. 26 : Care must be taken not to wet electronic components d uring lea k test. W etting the primar y ignition module may dama ge its ci rcuitry and caus e a hazar dous situa tion. Dry moisture from all lea ds and ter minals i f wetting occurs . Wait a t least 2 4 ho[...]

A ll installation s and serv ices must be perfo rmed by qualified service p ersonnel. 27 Figure 18A All trunk lines, tak e - of fs, r egisters and gr ill - free areas mus t be figured when determ ining the air handling capacity of a duct system. O ne can obtain the necess ary duct sy stem size by utilizi ng the chart below. (For exam ple, see Figur[...]

A ll installation s and serv ices must be perfo rmed by qualified service p ersonnel. 28 DUCT SIZES FOR HOM ES, QUIET OFFICES, OR SIMILAR INS TALLA TIO NS T AB L E 2 A Each of the s y stem com ponents ( trunk lines, take of fs , runs and regis ter and grill - fr ee areas) m us t be properly siz ed and matc hed together to ensur e the necessar y air[...]

A ll installation s and serv ices must be perfo rmed by qualified service p ersonnel. 29 K. FILT ERS 1. CHX3 M ODELS: HIGHBOYS It is necessar y to cut the retur n air opening in the bottom or s ide casing depending upon the needs of the specif ic installation. NOTICE: If your CHX3 will require air delivery above 1800 CFM, it is advisable that both [...]

A ll installation s and serv ices must be perfo rmed by qualified service p ersonnel. 30 Figure 2 0 3. USE OF NON - THERM O PRIDE FILTER RETENTIO N MEANS If a m ethod other than the T herm o Pride f ilter rack is selected f or retention of the filter and/or use of a differ ent filter type is desired, see T able 3 for m inim um size guidelines for s[...]

A ll installation s and serv ices must be perfo rmed by qualified service p ersonnel. 31 FORMULA: (tons of cooling) x (400 C FM per ton) (144 s quare inches per foo t) = filter area s q.inches (m ax. air velocity of filter f rom table 3 for the f ilter type) = length x width of filter in inches EXAMPLE: If you had a CHX3 - 100 furnac e and 4 tons o[...]

A ll installation s and serv ices must be perfo rmed by qualified service p ersonnel. 32 3. THERMO STA T CONNECTIONS A ND A NT ICIPA T OR SETT ING NOTICE: For two- stage thermos tat wire connectors see wire diagram page 59. For single - stage ther mos tat with two - stage operation connect W from therm ostat to W 1 on control. W 2 on control board [...]

A ll installation s and serv ices must be perfo rmed by qualified service p ersonnel. 33 4. BLOWER A ND CONTROL PANEL WIRING Figure 2 1 : TURN OFF THE E LECTRICA L POWER to th e furnace be fore attem pting to disconn e ct blower wir ing. Table 4B Options S7-1 S7-2 Tim e Off Off Off * On Off 10 Min Off On Auto On On 20 Min S7-3 S7-4 Tim e Off Off 90[...]

A ll installation s and serv ices must be perfo rmed by qualified service p ersonnel. 34 Modifications to ECM blower speed s ettings are done us ing the S3 and S4 dip switch controls. T herm o Pride two - stage furnac es are f actory shipped at the CFM settings listed below in Table 4C. 2- Stage Bl ower Settings (fr om factory ) Table 4C Unit Contr[...]

A ll installation s and serv ices must be perfo rmed by qualified service p ersonnel. 35 CONTINUOUS SAFE OPERAT ION CHECK IF FLAME SI MULATION CONDIT ION PRESENT OR ROLL-O UT SW ITCH OPENS, SYSTEM ENERG IZES INDUCER FAN FOR 15 SECONDS AND CIRCULATOR BLOW ER AT HEATING SPEED UNTIL SI TUA TION CORRECTION AT ANY TIME THE GAS VALVE IS NOT ENERGIZED A. [...]

A ll installation s and serv ices must be perfo rmed by qualified service p ersonnel. 36 FLAME MUST BE DETECTED W ITHIN 4 SECONDS IF FLAME IS DETECTED, THE DELAY-TO- FAN-ON TIME BEGINS (45 SECONDS) THE RETRY SEQUENCE PROVIDES A 60 SECOND W AIT B E F O RE IG N ITION RETRY. RETRY IS ATTEMPTED W ITH A DIFFERENT VOLTAGE SETTING. IF NO T IF SO AFTER IGN[...]

A ll installation s and serv ices must be perfo rmed by qualified service p ersonnel. 37 IF SYSTEM IS IN LOCKOUT, THE MODULE W ILL RESET ITSELF AFTER 60 MINUTES OR MAY BE MANUALLY RESET BY INTERRUPTING THE POW ER TO THE FURNACE AT THE DISCONNECT OR INTERRUPTI NG THE CALL FOR HEAT AT THE THERMOSTAT. IF THIS DOES NOT RESTART THE SYSTEM, REFER TO THE [...]

A ll installation s and serv ices must be perfo rmed by qualified service p ersonnel. 38 B. INITIAL STA RT UP: This f urnace does not have a pilot. It is equipped with a hot surface igniter, w hich automatic all y l ights the burner. Do not attem pt to light the burner by hand. Check the following items before the initial star t - up. 1. Check all [...]

A ll installation s and serv ices must be perfo rmed by qualified service p ersonnel. 39 C. Measuring And A djusting Heat Input Rate DO NOT exceed input rating stamped on furnace n ameplate o r manufact urer's recomme nde d burner manifol d pr e ssure for ori fice size used. Observe the follow ing pre c autions w hen me asuring: A. Burner m a [...]

A ll installation s and serv ices must be perfo rmed by qualified service p ersonnel. 40 NOTICE: A U - tube manometer , m easuring pres sure in inches of water colum n, is recommen ded f or all gas pressur e m easurem ents. However, an aneroid pr essure gauge , in good working condition, capable of reading pr essure c hanges of 0.05 in. W .G., or l[...]

A ll installation s and serv ices must be perfo rmed by qualified service p ersonnel. 41 5. To obtain an acc urate m anifold gas pr essure r eading, the main bur ner m ust be cycled on and off several tim es to stabilize the gas control valve press ure regulator diaphragm . 6. Allow the burner to operate for at le a st 3 minute s before taking gas [...]

A ll installation s and serv ices must be perfo rmed by qualified service p ersonnel. 42 Figure 23: b. Turn the inner plastic adjus tm ent screw clock wise to incr ease, or counter clock wise to decrease, the gas press ure (and gas f low) to the main bur ner. c. Replace the regulator cover s crew and tighten it firm ly to prevent gas leakage. d. Re[...]

A ll installation s and serv ices must be perfo rmed by qualified service p ersonnel. 43 18. If the gas pr essur e is not within the s pecifie d high fire m a nifold pre ssure r ange (re fer to Table 5) , repeat steps 12(a) through 12(d) , above, adjust ing the high fire gas pr essure r egulator. If the m anifold pres sure rem ains low and it canno[...]

A ll installation s and serv ices must be perfo rmed by qualified service p ersonnel. 44 This f urnace is designed not to require any burner adjustm ent. Burner aer ation is fixed in this design. Burner flam es c an be seen by looking through the sight glass located on the burner box. Burner flam es should be well - defined, light to m edium blue i[...]

A ll installation s and serv ices must be perfo rmed by qualified service p ersonnel. 45 TIME (s ec.) FLOW (c fh) TABLE 6 - CONVERTING GAS FLOW RA T E 40 90 41 88 * For one cubic f oot per revolution gas m eter dials , 42 86 use T able directly. 44 82 45 80 * For 1/2 cubic f oot per revolution gas m eter dials : 46 78 1. Determ ine tim e for two di[...]

A ll installation s and serv ices must be perfo rmed by qualified service p ersonnel. 46 D. FURNA CE CHECKOUT PROCEDURE Before any system of gas piping is f inally put into service, it shall be c aref ully tested to assure that it is gas tight as indicated in the m anual. NOTICE: All controls on the unit should be check ed for proper f unctioning p[...]

A ll installation s and serv ices must be perfo rmed by qualified service p ersonnel. 47 5. That f ailure to m aintain and operate this furnac e in accordanc e with these instructions c ould result in hazardous conditions, bodily i njury, property damage and may void the limited warranty on the furnac e. 6. Review with and encourage the user to rea[...]

A ll installation s and serv ices must be perfo rmed by qualified service p ersonnel. 48 mem or y , the LED will flash two green flashes . The c ontrol will flash the m ost recent er ror f irst and the oldest error las t (last in fir st out). T here will be 2 seconds between codes . Solid LED error codes will not be display ed. DIA G NOSTIC FEA TUR[...]

A ll installation s and serv ices must be perfo rmed by qualified service p ersonnel. 49 SET THERMOSTAT TO CALL FOR HEAT (MAKE CER TAIN ROOM TEM PERATURE IS BELOW THERMOSTAT SETTING) CHECK INPUT POW ER, DOOR INTERLOCK, SERVICE SW ITCH AND FUSES IS THE I NDUCER BLOW ER OPERATING? CHECK 115 VO LT CONNECTIONS. IF OK, REPLACE TRANSFORMER YES NO YES YES[...]

A ll installation s and serv ices must be perfo rmed by qualified service p ersonnel. 50 IS INDUCE R RUNNING ON LOW SPEED? DOES THE HOT SURFACE IGNI TOR ENERGIZE AND GLOW ? CHECK W IRING TO HOT SURFACE IGNI TOR AND IF OK, REPLACE HOT SURFACE IGNI TOR ASSEMBLY AFTER HOT SURFACE IGNITOR W ARM-UP, DOES GAS VALVE OPEN? NO NO NO NO YES YES YES CHECK CON[...]

A ll installation s and serv ices must be perfo rmed by qualified service p ersonnel. 51 IS IGN ITOR POS ITIONE D CORRECT L Y? R EP O S I TIO N TO CORRE CT LOC AT ION CHE CK AND CL EA N BURNERS DO BURNER S STAY LI T PA ST PR O O F O F FL AM E C H EC K ? IS W 2 ENERGIZED? DOES I NDUCER GO TO HIGH S PEED? IS T HER E LINE VOLT AGE ACROS S INDUC ER P O[...]

A ll installation s and serv ices must be perfo rmed by qualified service p ersonnel. 52 CHECK CO NNECTIO NS TO G AS VALVE. IF O K, REPLACE GAS VALVE. IS THE VARIABLE SPEED AIR FAN OPERATI NG? DOES BLO W ER SPIN FREELY ? CONF IRM I F EIT HER BLOWER W HEEL IS RUBBING AG AI NST HOU S IN G OR M OT OR SHAFT IS SPINNING FREELY AND REPAIR OR REPLACE AS N[...]

A ll installation s and serv ices must be perfo rmed by qualified service p ersonnel. 53 DOES BURN ER SHU T OF F W HE N T HER M OST A T I S SAT I SF I ED? CHE CK F OR 24 VOL T S AT G AS VAL VE. REP LACE G AS VAL V E CHECK F OR SHORT I N W I RE T O T HE RM OST A T AND CORREC T I F NE CESSA RY. DOES T HE C I RCUL A T I NG AI R B L OW ER T URN OF F AF[...]

A ll installation s and serv ices must be perfo rmed by qualified service p ersonnel. 54 Appendix – A Replacem ent Parts List 1. Replacement parts list fo r CHX3 - 75, CHX3 - 100 and CHX3 - 125.[...]

A ll installation s and serv ices must be perfo rmed by qualified service p ersonnel. 55[...]

A ll installation s and serv ices must be perfo rmed by qualified service p ersonnel. 56 2. Replacement parts list fo r CDX3 - 75 , CDX3 - 100 and CDX3 - 125.[...]

A ll installation s and serv ices must be perfo rmed by qualified service p ersonnel. 57[...]

A ll installation s and serv ices must be perfo rmed by qualified service p ersonnel. 58 Appendix – B W iring Diagram s[...]

A ll installation s and serv ices must be perfo rmed by qualified service p ersonnel. 59[...]