Thermo Products CHX1-100N manual

MG -1010 ECN4470-MA TWO STAGE CONDENSING GAS FURNACE INSTA LLA TION A ND OPERA TION MA NUA L MODELS: FOR USE WITH NATURA L GA S OR LP GA S (PROPA NE) CHX1-75N CDX1-75N CHX1-100N CDX1-100N CHX1-125N CDX1-125N : IF YOU DO NO T FOLLO W TH E SAFETY PRECAUTIONS BELO W AND IN T HIS MANUAL, A FIRE OR EXPLO SION MAY RESULT CAUSING PROPERTY DAMAGE, PERSONAL[...]

A ll installations and services must be performed by qualified service personnel. i I. SA FET Y INFORM A T ION This and the following 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.[...]

A ll installations and services must be performed by qualified service personnel. ii This and the previous page contain repr oductions of the various warning and instr uction 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 inform ation should [...]

A ll installations and services must be performed by qualified service personnel. iii 1. Use only w ith type of gas approved f or this f urnace. Refer to furnace r ating plate. 2. Connect this f urnace to an approved vent s y s tem only. Combus tion products m ust be carried outdoors. Refer to Sec tion III, D thru H, of this m anual. The following [...]

A ll installations and services must be performed by qualified service personnel. iv : Person al injury or property d amage could resu lt from repair o r service of this fu rnace by anyone other than a qualified heating contractor. Only the homeowner/user routine maintenance describ ed in the Users Inf ormation Manual may be performed by the user.[...]

A ll installations and services must be performed by qualified service personnel. v INDEX SECTIO N B E G I N N I N G P A G E I. SAFETY INFORMATIO N i II. FURNACE SPECIFICATIO NS 1 III. GENERAL INSTALLATIO N 6 A. CODES AND CLEARANCES 6 B. FURNACE LOCAT ION 7 B1.CDX1 HORIZONT AL APPLICAT ION 7 C. REPLACING EXISTING FURNACE FROM A COMMON VENT 9 D. GEN[...]

A ll installations and services must be performed by qualified service personnel. 1 II. FURNA CE SPECIF ICA T IONS CHX1 SERIES MO DEL NO. CHX1-75 CHX1-100 CHX1-125 BTU/HR INPUT (High fire/ Low fire) 75,000 / 52,000 100,000 / 70,000 125,000 / 87,500 BTU/HR OUT PUT (High fire/ Low fire) 70,875 / 49,612 94,500 / 66,150 117,500 / 82,250 HEIGHT OF CASIN[...]

A ll installations and services must be performed by qualified service personnel. 2 CDX1 SERIES MO DEL NO. CDX1-75 CDX1-100 CDX1-125 BTU/HR INPUT (High fire / Low fire) 75,000 / 56,250 100,000 / 75,000 125,000 / 93,750 BTU/HR OUT PUT (High fire / Low fire) 69,750 / 52,312 93,000 / 69,750 116,250 / 87,187 HEIGHT OF CASING 46-1/4” 46-1/4” 46- 1/4[...]

A ll installations and services must be performed by qualified service personnel. 3 INSTALLA T ION PARTS PA CKAGES – CHX1-75 PA RT S PA CKAGE #S00S4378 DESCRIPTION PART # QUA NT ITY 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 scr ews for mounting tr ap & inlet/outlet c[...]

A ll installations and services must be performed by qualified service personnel. 4 INSTALLA T ION PARTS PA CKAGES – CDX1-75 PA RT S PA CKAGE #S00S4380 DESCRIPTION PART # QUA NT ITY 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 scr ews for mounting tr ap & inlet/outlet c[...]

A ll installations and services must be performed by qualified service personnel. 5 INSTALLA T ION PARTS PA CKAGES – CDX1-100-125 PA RT S PA CKAGE #S00S4381 DESCRIPTION PART # QUA NT ITY 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 scr ews for mounting tr ap & inlet/out[...]

A ll installations and services must be performed by qualified service personnel. 6 III. GENERA L INST A LLATION Thes e Category Type IV furnaces are shipped com pletely assemb led and wired (internally). See the Dealer Receiving and Fr eight Claim Proc edure Section of the price guide for parts shor tage or dam age. The f urnace and duct s y s tem[...]

A ll installations and services must be performed by qualified service personnel. 7 Equipment must be installed in accordance w ith regu lations of t he National Board of Fire Underwriters. A uthorities having juri sdiction should be consulte d before installations are made . B. FURNA CE LOCA T ION : These high efficiency condensing furnaces are no[...]

A ll installations and services must be performed by qualified service personnel. 8 NOTE: W hen the CDX1 is ins talled as horizontal unit, it is im perative that the auxiliary limit s witch and brack et be located on the upper side of the house air blower; the burner rollout switch located on the burner box be r elocated to the side of the burner b[...]

A ll installations and services must be performed by qualified service personnel. 9 Equipment must be installed in accordance w ith regu lations of t he National Board of Fire Underwriters and the National Fuel Gas Code. A uthorities having jurisdiction should be consulted before installations are made. C. REPLA CING AN EXISTING FURNA CE FROM A COM[...]

A ll installations and services must be performed by qualified service personnel. 10 NOTES: 1 The drain tee s upplied with CHX1/CDX1 furnac es count as 1 elbow. 2 (2) 45° elbows can be s ubstituted for ( 1) 90° elbow. Care should be tak en to plan out the vent system to be as s hort as poss ible (but not shorter than 8 f t.) and to contain as f e[...]

A ll installations and services must be performed by qualified service personnel. 11 NOTICE: If exterior sidewall building m aterials are s ubject to degradation f rom flue gases or m oisture, a minim um 12” diam eter shield m ade f rom stainless steel or high density plastic shall be us ed for protec tion. 2. The PVC vent term ination elbow m us[...]

A ll installations and services must be performed by qualified service personnel. 12 Figure 4 : The vent and air intake elbo ws must be kept away from bu shes, 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. Ke ep the vent hood clear of snow. Avoid[...]

A ll installations and services must be performed by qualified service personnel. 13 F. INSTALLA TION O F OUTSIDE VENT /A IR INT A KE TERM INA T IONS NOTICE: Ins tallation of the outside exhaus t and com bustion air vents m ust be per form ed by a qualified installer or s ervice pers on in accord with local codes , the National Fuel Gas Code ( NFPA[...]

A ll installations and services must be performed by qualified service personnel. 14 G. CONNECTING FURNACE TO THE VENT /A IR INT A KE T ERMINATION A ND DRA IN 1. The following diagrams show the ty pic al vent and air inlet connection f or a CHX1 and CDX 1 furnac e as well as a list of the parts that will be needed to install each. Figure 6[...]

A ll installations and services must be performed by qualified service personnel. 15 Figure 7[...]

A ll installations and services must be performed by qualified service personnel. 16 Figure 8 2. CONNECTING T HE EXHAUST VENT T O THE INDUCER a. Insert the end of the 2”dia. PVC elbow (2" dia. PVC tee ass embly for CDX1 hor izontal installations) onto the outlet of the inducer blower assem bly . Measure the length of 2” dia. PVC pipe neede[...]

A ll installations and services must be performed by qualified service personnel. 17 IMPO RTANT: Horizontal installations of CDX 1-100 and CDX1- 125 units m ust utilize the 2" x 3" dia. PVC reducer as soon as the vent inlet exits the side casing of the unit. T he CDX1- 100 and CDX1-125 series units m ust be vented with 3" dia. PVC. R[...]

A ll installations and services must be performed by qualified service personnel. 18 NOTICE: The ex haust vent piping m ust slope upward at least 1/4” per foot fr om the f urnace to outdoor vent term inal. The inlet vent piping m ust s lope downw ard at least 1/4” per foot fr om the beginning of the last horizontal run of pipe to the outdoor ve[...]

A ll installations and services must be performed by qualified service personnel. 19 : Outsid e combustion air must not co me from an area that is directly adjacent t o a pool, hot tub or spa. M easures should be taken to prevent the entry of corrosive chemicals or vapors to the c ombustion and ventilation ai r supply. Suc h chemicals inc lude but [...]

A ll installations and services must be performed by qualified service personnel. 20 I. CONDENSA T E DRAIN LINE A ND TRAP A SSEMBL Y 1. T he following diagram s show the ty pic al drain and trap connec tion for a CHX 1 and CDX1 furnac e. Figure 14. T RA P ASSEMBLY M OUNT ED ON CHX1 Figure 15. T RA P ASSEMBLY M OUNT ED ON CDX1[...]

A ll installations and services must be performed by qualified service personnel. 21 Figure 16. T RA P ASSEMBLY M OUNT ED ON CDX1 RIGHT SIDE HORIZONT A L INSTALLA T ION 2. Determine on which side of f urnace the c ondensate disposal line is to be run (NOT ICE: On CHX1/CDX1’s this m ust be the sam e side as the f lue outlet or bottom of unit). Att[...]

A ll installations and services must be performed by qualified service personnel. 22 4. Measure the drain hose (11/16” o.d. clear tubing) provided and rem ove any extra length, mak ing sure that the hose has suf ficient length not to k ink or otherwise be restrict ed once installed. Attach the drain hose (11/16” o.d. c lear tubing) to the other[...]

A ll installations and services must be performed by qualified service personnel. 23 Figure 18 2. A drip leg m ust be us ed on both LP and natural gas installations prior to the fur nace in order to trap oil, condensate and other im purities which might other wise lodge in the gas valve or plug the burner orific e. A drip leg shall be provided at t[...]

A ll installations and services must be performed by qualified service personnel. 24 This CHX1 fur nace has been f actory supplied with a high quality re-us able filter rated for air velocities up to 600 f t/m in. An optional T herm o Products f ilter rack ass embly (part no. AOPS7547 for CHX1-75 thru 100 and AOPS7375 for CHX1-125) is available whi[...]

A ll installations and services must be performed by qualified service personnel. 25 3. USE OF NON-T HERM O PRIDE FILT ER RETENT ION M EA NS If a m ethod other than the T herm o Pride filter r ack is selected f or retention of the filter and/or us e of a diff erent filter type is desired, s ee Table 3 f or m inimum size guidelines fo r selecting a [...]

A ll installations and services must be performed by qualified service personnel. 26 a. A separate power s upply c ircuit with over current pr otection and a disconnec t switch m ust be provided. The m inim um fuse or circuit break er s ize is 20 amp. b. All CHX1 and CDX 1 Series fur naces are supplied with a fus e disconnect s witch box to be m ou[...]

A ll installations and services must be performed by qualified service personnel. 27 4. BLOW ER A ND CONT ROL PA NEL WIRING Figure 21 : TURN OFF THE ELECTRICAL POWER to the furnace before attempting to disconnect blower wiring. DIP SW ITCH (S1): HEAT “O FF” DELAY SW 1 SW 2 SECS. ON OFF *ON OFF ON ON OFF OFF 60 SEC. 90 SEC. 120 SEC. 180 SEC. 2 N[...]

A ll installations and services must be performed by qualified service personnel. 28 Modifications to ECM blower speed settings are done us ing the S3 and S4 dip switch controls . (Labeled 1 to 8 in Figure 21). T herm o Pride two-stage f urnaces are f actory shipped at the CFM settings lis ted below in Table 4. 2-Stage Blow er Setti ngs (from facto[...]

A ll installations and services must be performed by qualified service personnel. 29 CONTINUO US SAFE OPERATION CHECK IF FLAM E SIMULATION CO NDITION PRESENT OR ROLL-O UT SW ITCH OPENS, SYSTEM ENERGIZES INDUCER FAN FOR 15 SECO NDS AND CIRCULATOR BLO W ER AT HEATING SPEED UNTIL SI TUATION CO RRECTION AT ANY TIM E THE GAS VALVE IS NOT ENERGI ZED A. S[...]

A ll installations and services must be performed by qualified service personnel. 30 AFTER IGNITOR W ARM-UP, THE 36E54 GAS VALVE IS ENERGIZED TO OPEN ON LOW FIRE SETTING FLAME MUST BE DETECTED W ITHIN 4 SECONDS IF FLAME IS DETECTED, THE DELAY-TO-FAN-ON TIME BEGINS (45 SECONDS) IF FLAME IS NOT DETECTED, TH E GAS VALVE IS DE-ENERGIZED, THE IGNITOR IS[...]

A ll installations and services must be performed by qualified service personnel. 31 IF SYSTEM IS IN L OCKOUT, THE MOD ULE W ILL RESET ITSELF AFTER 60 MINU TES OR M AY BE MANUALLY RESET BY INTE RRUPTING THE PO W ER TO THE FURNACE AT THE DI SCONNECT OR INTERRUP TING THE CA LL FOR HEAT AT THE THER MOSTAT. IF THIS DOES N OT RESTART THE SYSTEM, R EFER [...]

A ll installations and services must be performed by qualified service personnel. 32 B. INITIAL STA RT UP: This fur nace does not have a pilot. It is equipped with a hot surf ace igniter, which autom atically lights the burner. Do not attem pt to light the burner by hand. Check the f ollowing items bef ore the initial start- up. 1. Check all wiring[...]

A ll installations and services must be performed by qualified service personnel. 33 Measuring A nd A djusting Heat Input Rate DO NOT exceed input rating stamped on furnace nameplate or manufacturer's recommended burner manifold pressure for orifice size used. Observe th e following precautions w hen measuring: A . B urner manifold pressure w [...]

A ll installations and services must be performed by qualified service personnel. 34 NOTICE: A U-tube manometer , meas uring press ure in inches of water colum n, is recommended for all gas press ure m easurem ents. However, an anero id pressure gau ge , in good working condition, capable of r eading pressure c hanges of 0.05 in. W .G., or less, th[...]

A ll installations and services must be performed by qualified service personnel. 35 5. T o obtain an accurate m anifold gas pressur e reading, the m ain burner m ust be cycled on and off several tim es to s tabilize the gas control valve press ure regulator diaphr agm. 6. Allow the burner to operat e for at least 3 minu tes before tak ing gas pres[...]

A ll installations and services must be performed by qualified service personnel. 36 Figure 23: O utlet view of t wo- stage, automat ic gas control v alve b. Using a 3/32-in. hex key (or Allen wrench), turn the inner adjustm ent scr ew clockwise to increase, or counterclock wise to decreas e, the gas press ure (and gas f low) to the main burner. c.[...]

A ll installations and services must be performed by qualified service personnel. 37 17. If chec king the input rate by measuring burner manifold pressure, proceed to step 18 . If meas uring the input rate by clocking the gas meter, repeat steps 9 through 11 , above . 18. If the gas p ressure is not w ithin t he specified hig h fire manifo ld press[...]

A ll installations and services must be performed by qualified service personnel. 38 This furnac e is designed not to require any burner adjus tment. Burner aeration is f ixed in this design. Burner f lames c an be seen by looking through the sight glass located on the burner box. Bur ner flam es should be well-def ined, light to medium blue in col[...]

A ll installations and services must be performed by qualified service personnel. 39 TIME (s ec.) FLOW ( cfh) TABLE 6 - CONVERT ING GA S FLOW RATE 40 90 41 88 * For one cubic f oot per revolution gas m eter dials, 42 86 use Table direct ly . 44 82 45 80 * For 1/2 cubic f oot per revolution gas meter dials: 46 78 1. Determ ine time for two dial revo[...]

A ll installations and services must be performed by qualified service personnel. 40 C. FURNA CE CHECKOUT PROCEDURE Before any sy s tem of gas piping is finally put into service, it shall be car efully tested to assure that it is gas tight as indicated in the m anual. NOTICE: All c ontrols on the unit should be c hecked f or proper functioning pr i[...]

A ll installations and services must be performed by qualified service personnel. 41 5. T hat failure to m aintain and operate this furnac e in accordanc e with these instructions could result in hazardous conditions, bodily injury, property dam age and m ay void the limited warr anty on the furnac e. 6. Review with and encourage the us er to read [...]

A ll installations and services must be performed by qualified service personnel. 42 DIA GNOST IC FEATURES The 50V61 c ontrol used on this f urnace continuous ly m onitors its operation and the operation of the sy stem. If the sens ed failure is in the system (ex ternal to the control) , the red LED will flash in the f ollowing flash- pause sequenc[...]

A ll installations and services must be performed by qualified service personnel. 43 SET THERMOSTAT TO CALL FOR HEAT (MAKE CERTAIN ROOM TEMPERATURE IS BELOW THERMOSTAT SETTING) CHECK INPUT POW ER, DOOR INTERLOCK, SERVICE SW ITCH AND FUSES IS THERE 120 VOLTS ACROSS "L1" AND "NEUTRAL" AT THE 50V61-143 CONTROL MODULE? IS THE INDUCE[...]

A ll installations and services must be performed by qualified service personnel. 44 IS INDUCER RUNNING ON LOW SPEED? DOES THE HOT SURFACE IGNITOR ENERGIZE AND GLOW ? CHECK W IRING TO HOT SURFACE IGNITOR AND IF OK, REPLACE HOT SURFACE IGNITOR ASSEMBLY CHECK ACROSS "MVL" AND "MV COM" TERMINALS ON 50V61-143 CONTROL FOR 24 VOLTS DU[...]

A ll installations and services must be performed by qualified service personnel. 45 IS IGNIT OR POSITIONED CORRECTLY? REPOSITION TO CORRECT LOCATION CHECK AND CLEAN BURNERS DO BURNERS STAY LIT PAST PROOF OF FLAME CHECK? IS W 2 ENERGIZED? DOES INDUCER GO TO HIGH SPEED? IS THERE LINE VOLTAGE ACROSS INDUCER POW ER TERMINALS "IND HI" TO &quo[...]

A ll installations and services must be performed by qualified service personnel. 46 IS THERE 24 VOLTS ACROSS "M VH" AND "MV CO M" ON 50V61-143 CONTROL? REPLACE THE 50V61-143 CONTROL. CHECK CONNECTIO NS TO GAS VALVE. IF OK, REPLACE GAS VALVE. IS THE VARIABLE SPEED AIR FAN OPERATING ? DOES BLOWER SPIN FREELY? CONFIR M IF EITHER B[...]

A ll installations and services must be performed by qualified service personnel. 47 DOES BURNER SHUT OFF W HEN THERMO STAT IS SATISFIED? CHECK FOR 24 VOLTS AT GAS VALVE. REPLACE GAS VALVE CHECK FOR SHORT I N W I RE TO THERMOSTAT AND CORRECT IF NECESSARY. DOES THE CIRCULATI NG AIR BLOW ER TURN OFF AFTER THERMOSTAT IS SATISFIED W ITHI N 120 SECONDS?[...]

A ll installations and services must be performed by qualified service personnel. 48 Appendix –A Replacem ent Parts List 1. Replacement parts list for CHX1- 75, CHX1-100 and CHX1-125.[...]

A ll installations and services must be performed by qualified service personnel. 49[...]

A ll installations and services must be performed by qualified service personnel. 50 2. Replacement part s list for CDX1-75, CDX1-100 an d CDX1-125.[...]

A ll installations and services must be performed by qualified service personnel. 51[...]

A ll installations and services must be performed by qualified service personnel. 52 Appendix – B W iring Diagram s[...]

A ll installations and services must be performed by qualified service personnel. 53[...]