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Thermo Products CBD1-100N Furnace User Manual

1. WD 539 5153 MA WIRING DIAGRAM i N 1 50 5 100 125 E o 1 50 5 100 125 i ra BLOWER MOTOR DOOR SEE NOTE 4 Lo Buck D WHIF BLACK HIGH RED LOW BLUE MD LOW YELLOW MD HICH WHITE COMMON BLACK GREEN PARK PARK LUINE H O CH OPTIONAL WHITE 1 HUMIDIFIER RANSFORMER 950A65 143 a LNE N 115v HUM N 2 84 OPTIONAL LA Pasa CD L ELECTRONIC AR XY XR CLEANER 24v 4 CIR N YELLOW ON DELAY 45 SEC L FAN OFF DELAY 120 SEC OUO 5 OHF Gy 3 USED ON CDB RED FUSE MODELS ONLY yt YW RG CO Heu FREGO ud sma 1 O ADX LIMIT ls us 7 INDUCER OPTIONAL Y W R6 A C CONTACTOR HIG COOL THERMOSTAT 1 GNITOR RED PRESS SW YELLOW BROW BROWN CES Lamm GAS HIGH LIMIT REAME VALVE amp h LAN SENSOR BLUE BLUE USED MODE
2. UNIT CHB1 50 1 75 CHB1 100 1 125 PARTS DESCRIPTION PART NO QTY PART NO QTY PART NO QTY PART NO QTY 1 HEAT EXCHANGER 38137 1 38138 1 38139 1 38140 1 2 BLOWER ASSEMBLY 50054419 1 50054420 1 50054421 1 50054422 1 8 10926 1 10926 1 10720 1 10721 1 4 CASING BACK 610925 1 510925 1 610772 1 610773 1 5 SIDE CASING RIGHT 620105 1 620105 1 620105 1 820105 1 6 SIDE CASING LEFT 620104 1 620104 1 620104 1 620104 1 7 TOP CENTER PANEL 610929 1 610929 1 610952 1 610953 1 8 PLENUM STRIPS 613382 2 613382 2 513382 2 613382 2 9 FRONT DOOR 610933 1 610933 1 610769 1 610770 1 10 BLOWER ACCESS DOOR 620927 1 620927 1 620717 1 620718 1 11 Pus GRANGER 12394 1 12394 1 12394 1 12394 1 12 BLOWER PAN 18363 1 18363 1 18364 1 18365 1 15 LIMIT SWITCH ROLLOUT 350485 1 350485 1 350485 1 350485 1 SIDE CASINGNCANGUE 14329 1 14329 1 14329 1 15 DOOR PULL 320157 2 320157 2 320157 2 320157 2 16 SIGHT GLASS GASKET 330135 1 330135 1 330135 1 330135 1 17 SIGHT GLASS 15887 1 15887 1 15887 1 15887 1 18 INDUCER WN GASKET AOPS7416 1 AOPS7416 1 AOPS7416 1 AOPS7416 1 19 INDUCER GASKET 330137 1 330137 1 330137 1 330137 1 200 SEETER uis 2 1 1 ED 1 21 572 IN WIDE GASKET 330141 23 25 330141 28 50 330141 5425 330141 39 50 22 dcs ad JARE 330140 21 330140 26 50 330140 32 25 330140 23 BURNER TUBE 380595 2 38059
3. FIXED CLOSED FIXED OPERABLE OPERABLE ous pleat AJ mide f gt Walkway Front View of a Typical Single Story House Plan View of an L Shaped House LEGEND V Vent terminal Air supply inlet Vent terminal instollation prohibited within this reqion Dimension Clearance Definition Requirement for US Instollations A Distance above grade veranda porch deck or balcany 12 inches B Distance to window or door that may be opened 12 inches C Distance to permanently closed window 12 inches D Distance to ventillated soffit located above the terminal within a horizontal 24 inches distance af 2 feet from the centerline of the terminal Distance to unventilated soffit 24 inches F Distance to outside corner 24 inches G Distance to inside corner feet H Distance to each side of centerline extended above meter regulator 4 feet assembly Distance to service regulator vent outlet J Distance to nonmechanical air supply inlet to building or the combustion 12 inches air inlet to any other appliance Distance to mechanical air supply inlet 5 feet above i
4. 75 amp CDB1 50 75 or nominal 3 inch diameter IPS Schedule 40 series PVC thermoplastic pipe for models CHB1 100 125 amp CDB1 100 125 The furnace model series CDBI shall not be common vented with any other appliance including those burning solid fuels horizontal runs of exhaust vent pipe shall slope upward at least 4 inch per foot from the outlet of the furnace for the model series CHB1 or the outlet of the drain tee for the model series CDB1 to the vent termination beyond the outside wall This slope will permit proper drainage of the condensate Horizontal runs of air intake pipe shall slope downward at least 1 4 inch per foot from the outlet of the last elbow or last horizontal run before exiting the wall to the intake termination beyond the outside wall This slope will permit proper drainage of any precipitation that enters the intake pipe The exhaust vent pipe shall be supported at every joint no more than 4 feet between supports to prevent pipe blockage due to condensate trapped at a local low point or sag in the vent system The maximum permissible length of piping consisting of a combination of straight pipe and a corresponding number of elbows permitted is e 75 equivalent feet for the exhaust vent system and e 70 equivalent feet for the combustion air intake system The maximum quantity of Schedule 40 series type DW V thermoplastic pipe elbows allowed in each system i
5. 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 15 All installations and services must be performed by qualified service personnel 57488 57489 370191 SIDE WALL VENT KIT REDUCING COUPLING howe FIELD SUPPLIED IF NEEDED VERTICAL gt og t 3 PIPING D P d Li tel 3 PIPING E SIDE WALL 2 HORIZONTAL Figure 6 Optional Direct Vent Kits for the CHB1 CDB1 Model Series of Furnaces G Connecting The Furnace To Roof Exhaust Intake Terminations If it is not desirable or feasible to vent the furnace through a sidewall it may be vertically vented through the roof Installation shall conform to the following guidelines which are illustrated in Figure 6A below 1 The outlet of the exhaust vent and the inlet of the combustion air intake i e the terminations shall be a minimum of 12 inches above highest anticipated snow level 2 exhaust vent outlet must be installed a minimum of 12 inches above the air intake inlet 3 Where exposed to prevailing winds the combustion air intake shall be installed upwind of the vent outlet 4 exhaust vent an
6. See Figure 1 For a left side horizontal application of CDBI series units the hose from the single tap pressure switch bottom switch must be moved to the lower front tap on the face of the collector box Use the black cap removed from this tap to plug the original pressure switch tap 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 CDB 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 NOTE When the CDB1 is installed as horizontal unit it is imperative that the auxiliary limit switch and bracket be located on the upper side of the house air blower the burner rollout switch located on the burner box be relocated to the side of the burner box and that the hose from the single tap pressure switch be connected to the lower tap on the front of the collector box See Figure 1 All installations and services must be performed by qualified service personnel AUXILIARY LIMIT SWITCH AUXILIARY LIMIT SWITCH BRACKET HOUSE AIR BLOWER CDB UNIT GAS SUPPLY IN A RIGHT SIDE LINE HORIZONTAL APPLICATION DRIP LEG FRONT DOOR BLOWER eee URN Al ACCESS R DOOR Dues LUGGED PRESSURE WITCH TAP ON PPER FRONT FACE F COLLECTOR BOX UTILIZE FOR LEFT DE HORI
7. 3 Installation notice MG 987 1 PVC tee assembly 2 dia 320819 1 Pipe 2 dia PVC 15 14401 1 Bracket 14406 1 CPVC XPVC adapter 320833 1 Gas Conversion Kit AOPS7677 7678 1 INSTALLATION PARTS PACKAGES CDB1 100 125 PARTS PACKAGE 0054411 4412 DESCRIPTION PART QUANTITY 2 3 8 ID radiator hose 410017 1 Thermostat lead bushing 350750 1 trap assembly 320816 1 8 x 3 4 coated screws for mounting trap amp inlet outlet collars 5 11 16 OD x 1 27 ID vinyl tubing 410060 24 2 x 4 electrical J box 350024 1 2 x 4 electrical J box cover 350020 1 All installations and services must be performed by qualified service personnel 8 screws for 300208 2 mounting 2 x 4 J box 10 32 x 1 green ground screw 300109 1 10 32 hex nut 300110 1 3 16 dia star washer 300270 1 Grounding instructions MG 966 1 Wire nut 300132 2 3 stainless steel hose clamp 300276 2 J box wire bushing 350016 1 Drain hose grommet 350446 1 Spring clamp 11 16 300299 3 Installation notice MG 987 1 PVC tee assembly 2 x 3 dia 320817 1 PVC tee assembly 2 dia 320819 1 Pipe 2 dia PVC 15 14401 1 Bracket 14406 1 Reducer 2 x 3 PVC 320067 1 CPVC XPVC adapter 320833 1 Gas Conversion Kit AOPS7679 7664 1 III GENERAL INSTALLATION This furnace is equipped with orifices size for operation with natural gas For conversion
8. 3 IN SCHED 40 PVC PIPE USED ON CDB 100 125 ONLY E 2 IN X 3 IN PVC REDUCER SUPPLIED W UNIT USED ON CDB 100 125 ONLY F RADIATOR HOSE AND 2 SPRING CLAMPS SUPPLIED W UNIT G 2 IN DRAIN TEE ASSEMBLY SUPPLIED W UNIT H 2 IN SCHED 40 PVC 90 ELBOW USED ON CDB 50 75 ONLY 3 IN SCHED 40 PVC 90 ELBOW USED ON 100 125 ONLY J 2 IN SCHED 40 PVC 90 ELBOW CDB 50 75 3 IN SCHED 40 PVC 90 ELBOW CDB 100 125 X BLACK COATED 8 x 3 4 SCREWS SUPPLIED W UNIT Y SILCONE TYPE CAULKING COMPOUND BURNER BOX MUST BE USED TO SEAL THESE JOINTS O Z PVC CEMENT NOT SHOWN MUST BE USED TO SEAL ALL OTHER JOINTS NOTE X EXCEPT AS NOTED DO NOT USE SEALANT AT CONNECTION TO METAL INLET NOTE THE HOSE BARB FOR THE DRAIN TEE PVC VENT INLET PIPE SLOPES DOWNWARD 1 4 PER FOOT FROM BEGINNING OF LAST HORIZONTAL RUN TO OUTDOOR VENT ELBOW PVC VENT PIPE SLOPES UPWARD 1 4 PER FOOT TO OUTDOOR VENT ELBOW KAGE ASSEMBLY IS LOCATED IN THE PARTS PAC AND MUST BE FIELD INSTALLED BASIC VENT CONNECTION CDB1 SERIES SHOWN IN A RIGHT SID ONTAI E APPLICATION Figure 8 Required Exhaust Vent and Air Intake Piping for CDB1 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 CDX1 in horizontal applications the 2 inch diameter PVC tee assem
9. AND 2 SPRING CLAMPS B SUPPLIED W UNIT J G DRAIN TEE ASSEMBLY SUPPLIED W UNIT gt 2 IN USED ON CDB 50 75 ONLY 2 x 3 IN SHOWN USED ON CDB 100 125 ONLY H 2 IN SCHED 40 PVC 90 ELBOW USED ON CDB 50 75 ONLY 3 IN SCHED 40 PVC 90 ELBOW USED ON CDB 100 125 ONLY NOTE BURNER BOX NOT USE J 2 IN SCHED 40 PVC 90 ELBOW CDB 50 75 2 3 IN SCHED 40 PVC 90 ELBOW CDB 100 125 VON MEET ON TO METAL INLET X BLACK COATED 8 x 3 4 SCREWS SUPPLIED W UNIT NOTES The HOSE BARB FOR THE DRAIN Y SILCONE TYPE CAULKING COMPOUND TEE ASSEMBLY IS MUST BE USED TO SEAL THESE JOINTS LOCATED IN THE PARTS PACKAGE AND Z PVC CEMENT NOT SHOWN MUST BE MUST BE FIELD USED TO SEAL ALL OTHER JOINTS INSTALLED EXCEPT AS NOTED BASIC VENT CONNECTION CDB1 SERIES Figure 7 Required Exhaust Vent and Air Intake Piping for CDB1 Furnace Downflow Applications 18 All installations and services must be performed by qualified service personnel COMPONENIS REQUIRED FOR VENT AND AIR INLET CONNECTION A 2 IN SCHED 40 PVC PIPE SLEEVE AND 2 SCHED 40 PVC COUPLING 50 75 3 IN SCHED 40 PVC PIPE SLEEVE 100 125 NOTE LENGTH IS DEPENDENT ON WHICH SIDE VENT IS ON NOTE DO NOT USE SEALANT AT CONNECTION TO METAL INLET OF BURNER BOX THE SCREW WILL SUFFICE B 2 IN SCHED 40 PVC PIPE SUPPLIED W UNIT D 2 IN SCHED 40 PVC PIPE USED ON CDB 50 75 ONLY
10. COMBUSTIBLE CONSTRUCTION AS SHOWN TOP FRONT BACK 15 95 FLUE PIPE INCHES 1 6 0 0 FOR INSTALLATION ON COMBUSTIBLE FLOORING THIS FURNACE REQUIRES A SPECIAL VENTING SYSTEM REFER TO INSTALLATION INSTRUCTIONS NO MG 1006 FOR PARTS LIST AND METHOD OF INSTALLATION MAX VENT LENGTH 35 FEET MIN VENT LENGTH BFEET MIN WALL THICKNESS THROUGH WHICH THE VENT AI3 INTAKE PIPES MAY PASS IS 2 INCHES AND THE MAX IS 8 INCHES FILTERS MUST INSTALLED EXTERNAL TO THE FURNACE CASING THIS FURNACE MUST BE INSTALLED IN ACCORDANCE WITH THERMO PRODUCTS INSTRUCTIONS AND LOCAL CODES IN ABSENCE OF LOCAL CODES FOLLOW THE NATIONAL FUEL GAS CODE ANSI 2223 1 THERMO PRODUCTS LLC pny a P 0 BOX 217 NORTH JUDSON IN 46366 CLOSED MUST B N SERVICING THIS COM ENT EXC T 0 THIS FURNACE MUST BE INSTALLED SO THERE ARE PROVISIONS FOR VENTILATING AIR simt REMOVE THIS PANEL FIRST IN ORDER TO REMOVE BLOWER DOOR INSTALLATION AND USERS MANUALS ARE LOCATED BEHIND BLOWER DOOR 390289 OUTSIDE POWER SOURCE CONNECT 115 60Hz COMMON 590229 L1 HOT AND L2 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 Condensi
11. INTAKE PIPES MAY PASS IS 2 INCHES AND THE MAX 1518 INCHES FILTERS MUST BE INSTALLED EXTERNAL TO THE FURNACE CASING THIS FURNACE MUST BE INSTALLED IN ACCORDANCE WITH THERMO PRODUCTS INSTRUCTIONS AND LOCAL CODES IN ABSENCE OF LOCAL CODES FOLLOW THE NATIONAL FUEL GAS CODE ANSI 2223 1 THERMO PRODUCTS LLC P O BOX 217 NORTH JUDSON IN 46366 FLUE PIPE 0 r Sta wa 1005 8 ry ua AWARNING Inspect rubber hose connecting inducer outlet to PVC tee and all vent system joints for leak free connections before furnace operation Hazardous flue gas Can cause personal injury or loss of life 390411 MODEL 1 125 SERIAL nof 00020000 DIRECT VENT FORCED AIR FURNACE FOR INDOOR INSTALLATION IN BUILDING CONSTRUCTED ON SITE Zu ee CERTIFIED CONFORMS TO ANS 221 47 gt 2 3 2012 CENTRAL FURN CATEGORY IV TYPE FSP 115V 1PH GOCY MAX TOTAL INPUT AMPS 20 0 OUTPUT ne BTU HR 125 000 116 000 FACTORY EQUIPPED WITH 42 ORIFICES FOR NAT GAS SUITABLE FOR L GAS WHEN EQUIPPED WITH 54 ORIFICES NORMAL MANIFOLD PRESS 3 5 WC NAT 10 0 IN WC LP MIN GAS SUPPLY PRESS FOR INPUT ADJUSTMENT 4 5 TN WC NAT 11 0 IN WC LP MAX GAS SUPPLY PRESS 14 0 IN AIR TEMPERATURE RISE 55 F TO 85 F EXTERNAL STATIC PRESSURE 0 50 INCHES MAXIMUM OUTLET AIR TEMPERATURE 190 F CERTIFIED FOR CLOSET INSTALLATION AT MINIMUM CLEARANCES TO
12. SYSTEM SHUTS OFF IGNITOR IGNITOR RESTARTS WHEN POWER WARM UP IS 20 SECONDS IS RESTORED Y 2 AFTER IGNITOR WARM UP THE GAS VALVE IS ENERGIZED TO OPEN FLAME MUST BE DETECTED IF FLAME IS NOT DETECTED THE WITHIN 4 SECONDS IF GAS VALVE IS DE ENERGIZED FLAME IS DETECTED THE gt THE IGNITOR IS TURNED OFF AND DELAY TO FAN ON TIME THE CONTROL BOARD CONTROL GOES Y BEGINS 45 SECONDS INTO RETRY SEQUENCE 34 All installations and services must be performed by qualified service personnel MAIN BURNER OPERATION CALL FOR HEAT SATISFIED Y END OF CYCLE AFTER DELAY TO FAN ON PERIOD ENDS CIRCULATING AIR FAN IS ENERGIZED AT HEATING SPEED THE OPTIONAL ELECTRONIC AIR CLEANER AND HUMIDIFIER ARE ENERGIZED WHEN THERMOSTAT IS SATISFIED CONTACTS OPEN AND THE GAS VALVE IS DE ENERGIZED AFTER PROOF OF FLAME LOSS INDUCER STARTS 5 SECOND POST SURGE AND OPTIONAL HUMIDIFIER ARE DE ENERGIZED THE DELAY TO FAN OFF PERIOD BEGINS 120 SECONDS AFTER THE DELAY TO FAN OFF PERIOD ENDS THE RETRY SEQUENCE PROVIDES A 60 SECOND WAIT BEFORE IGNITION RETRY RETRY IS ATTEMPTED WITH AN ADDITIONAL 10 SECONDS OF IGNITOR WARM UP TIME IF IGNITION ATTEMPT IS UNSUCCESSFUL ONE MORE RETRY WILL BE MADE BEFORE THE CONTROL BOARD GOES INTO SYSTEM LOCKOUT IF FLAME IS DETECTED THEN LOST THE CONTROL BOARD WILL REPEAT THE INITIAL IGN
13. Set Switch turn on by 1 2 15 sec Off Off 30 sec Off On 45 sec On Off 60 sec On On To delay fan Set Switch turn off by 3 4 60 sec On On 90 sec Off On 120 sec On Off 180 sec Off Off Factory Settings For Optimal Performance 5 FIELD WIRING AND REPLACING WIRING Field wiring between the furnace and devices not attached to the furnace shall conform with the temperature limitation for Type T wire 63 F rise 35 C when installed with the manufacturers instructions If any of the original factory supplied furnace wiring is replaced or a separate device other than the thermostat is wired internal to the unit 105 C thermoplastic or equivalent wire must be used 33 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 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 HEAT CONTACTS CLOSE CONTROL BOARD ENERGIZED INDUCER ENERGIZED PRESSURE SWITCH SENSES Eee ET ADEQUATE DIFFERENTIAL PRESSURE gt CONTACTS CLOSE CDB1 SERIES ONLY POWER IS APPLIED TO POWER INTERRUPTION THE SILICON NITRIDE
14. a suspended ceiling it must be insulated with a 1 inch thick foil faced fiberglass insulation or an equivalent product to help prevent the outside surface of the pipe from sweating L Condensate Drain Line And Trap Assembly 1 The following diagrams depict typical condensate drain and trap connections for the furnace models series and CDB1 refer to the illustrations in Figures 14 15 and 16 DUCER HOSE FROM DRAIN TO DRAIN OR CONDENSATE 1 4412 INL fh TRAP ASSEMBLY DRAIN HOSE FROM CONDENSING COIL COVER GROMMET FOR DRAIN HOSE Figure 14 Condensate Trap Assembly Mounted On the Model Series CHB1 22 All installations and services must be performed by qualified service personnel TEE ASSEMBLY E O GROMMET FOR DRAIN HOSE TO DRAIN OR CONDENSATE PUMP TRAP ASSEMBLY DRAIN HOSE FROM CONDENSING COIL COVER Figure 15 Condensate T
15. and AOPS7375 for CHB1 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 Place the securing flange against the casing for locating the return air opening SECURING FLANGE FILTER FLANGE UNIT DIMENSION H W 1 50 15 24 1 2 j 75 amp 100 1 125 19 23 3 4 sss END INTO WHICH FILTER SLIDES j Figure 19 PLEASE NOTE While scribing the return air opening the filter rack can be held into position by tape or similar means Position the open end of the filter rack so that it is accessible for filter replacement Once the filter rack is positioned correctly scribe a line along the inside of the securing flange of the filter rack on three of the sides To scribe a line on the fourth side on the open end use the open end support for a guide Remove the filter rack and cut the return air opening in the casing Now the filter rack can be permanently attached to the furnace with screws or pop rivets along the securing flange Connect the return plenum to the filter rack and slide the filter into place 2 CDB1 MODELS COUNTERFLOWS This CDB1 furnace has been factory supplied with
16. condensation between the gas meter and the furnace Failure to install a drip leg may void the limited warranty on the furnace A WARNING gas piping must be leak tested using a soap and water solution when the gas is turned on following the procedure outlined in Section III J of this manual A final test for gas leakage must be made after purging the gas line refer to Section IV B of this manual This test must be conducted with the unit operating and should include the furnace piping and gas valve Never use an open flame to check for a gas leak A CAUTION 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 Wait at least 24 hours for the circuit to fully dry before energizing the burner circuit 1 REQUIREMENTS AND SIZING OF DUCT WORK The duct system must be sized and installed by a qualified installer or service person following the design standards of the Air Conditioning Contractors of America ACCA or ASHRAE 1 When it is located in the same room as the furnace a return air register must be installed a minimum of 20 feet away from the furnace 2 The return air duct shall also be sealed to the furnace and also terminate outside of the furnace space if supply ducts carry circulated air to areas outside the space containing the furnace 3 The return
17. free end of the drain hose over the hose barb on one 1 side of the plastic hose barb tee provided in the CPVC chlorinated polyvinyl chloride thermoplastic condensate trap assembly Secure the drain hose with the spring type hose clamp provided in the parts package 4 Trial fit the second drain hose a length of 11 16 inch O D clear colorless tubing provided in the furnace parts package from the hose barb on the bottom of the PVC exhaust vent drain tee to the plastic hose barb tee provided in the condensate trap assembly Make sure the hose is long enough not to kink or be otherwise restricted once installed Mark the minimum length of drain hose required for the application Remove any extra length from the drain hose Attach the drain hose to the hose barb on the other side of the condensate trap tee Slip the other end of the drain hose on to the hose barb of the PVC drain tee assembly refer to Figure 15 for an illustration Use the spring type hose clamp s provided in the parts package to secure all connections 5 Plan source and install a condensate drain line using 2 inch diameter CPVC chlorinated polyvinyl chloride thermoplastic pipe and pipefittings Route the line in the shortest possible manner to reach a nearby drain Secure all joints using CPVC cement For gravity drainage the condensate drain line must maintain a minimum inch per foot downward slope toward the drain The drain line must be watertight supported and secured
18. furnaces to allow their installations on combustible flooring These furnaces may be installed in an alcove or in a closet if the minimum clearances to combustible construction listed previously are met The CDB1 series furnaces may be installed in an attic or crawl space Refer to section B1 of this installation manual The minimum clearances are listed for fire protection Clearance for servicing the front of the furnaces and to all points on the furnace requiring access must be 247 For horizontal furnace installation refer to section III B1 of this installation manual Equipment must be installed in accordance with regulations of the National Board of Fire Underwriters Authorities having jurisdiction should be consulted before installations are made B FURNACE LOCATION ANCAUTION These high efficiency condensing furnaces are not certified for and shall not be vented into a standard or any type of chimney The following shall be considered for locating the furnace 1 For best performance locate the furnace so that it is centralized with respect to the duct system and as near as possible to a floor drain since condensate drainage must be provided 2 Place the unit so that proper venting can be achieved with a minimum number of elbows in accord with the instructions in this manual 3 furnace must be located on a level dry surface The furnace must be installed so that the electrical components are protected fro
19. not be detected by smell If this furnace is installed below grade contact your gas supplier for a gas detector AWARNING Turn off power to furnace before it is placed into service The gas piping system must have been leak tested by a qualified heating contractor A WARNING It may be necessary to purge the air out of the gas line for initial start up of the furnace after installation This should be done by a qualified heating contractor If excessive gas escapes when purging the gas supply at the union allow the area to ventilate for at least 15 minutes before attempting to start the furnace LP gas is especially dangerous because the specific gravity of LP gas allows it to accumulate at floor level at a dangerous concentration For remainder of operating instructions reference Users Information Manual AWARNING Heat exchanger oil will burn off on initial firing creating an unpleasant odor To prevent this odor from occurring more than once it is suggested that 1 Awindow s be opened 2 The thermostat set at highest setting 3 The furnace remain running at conditions 1 amp 2 for 30 minutes or until odor has dissipated iii All installations and services must be performed by qualified service personnel A CAUTION The CHBI CDB1 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 wit
20. qualified service personnel CDB1 SERIES MODEL NO CDB1 50 CDB1 75 CDB1 100 CDB1 125 BTU HR INPUT 50 000 75 000 100 000 125 000 BTU HR OUTPUT 47 000 70 000 94 000 116 000 HT OF CASING 46 1 4 46 1 4 46 1 4 46 1 4 WIDTH CASING 17 17 21 24 DEPTH CASING 27 1 2 27 1 2 27 1 2 27 1 2 WARM AIR OUTLET 15x 18 15x 18 19x 18 22x 18 RETURN AIR INLET 15 x 22 15x22 19x22 22x22 DIA OF FLUE 27 2 3 3 DIA OF COMBUSTION 2 2 3 3 AIR INTAKE CFM 2 amp 5 27 2 2 2 2 29 2 23 EXTERNAL STATIC PRESSURE mos iie 39 ili GHI SPEED 1120 930 1530 1340 1830 1590 2280 2010 MH SPEED 1000 750 1270 1110 1660 1460 1830 1650 ML SPEED 1050 930 1520 1340 1750 1570 LO SPEED 616 420 850 720 1370 1230 1660 1530 TEMPERATURE RISE 70 70 70 70 BLOWER MOTOR HP 20 41 50 75 NO SPEEDS 3 4 4 4 RUN CAPACITOR 10 mfd 10 mfd 10 mfd 15 mfd LARGEST RECOMMEDED AIR CONDITIONER 2 Ton 3 5 Ton 4 Ton 5 Ton SIZE OF FILTERS 21 3 4 x 14 2 21 3 4 x 14 2 21 3 4 x 14 2 21 3 4 x 14 2 NOTES 1 BTU output based on annual fuel utilization efficiency rated by manufacturer 2 Onall outlet and inlet dimensions the first dimension is width 3 To permit largest recommended air conditioning at 5 static pressure selection of the highest motor speed is required 4 Electrical characteristics at 115 volts 60 Hz 1 phase less than 15 amps for all models 5 All specifications are s
21. s of furnace output based on its steady state efficiency and a 55 to 85 temperature rise EXAMPLE Heating output of a furnace is 100 000 BTU HR 100 000 x 14cfm 1400 1000 Air conditioning installed is 4 tons x 400 1600 48 000 BTU s NOTE The duct system must be sized for the larger CFM requirement for cooling If only 3 tons 36 000 BTUs of cooling x 400 1200 was installed the duct would have to be sized for the 1400 Cfm heating requirement 10 6 200 0596 7280 MAIN TRUNK 10 6 200 _ 3 6 100 8x12 400 CFM Wd pU 235700 8x12 400 10x6 wo 800CFM C A MAIN TRUNK MAIN TRUNK LINE LINE 10x6 2 12 PLENUM 8x12 10x6 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 The main trunk lines take offs registers and grills of the supply return air duct system must have an adequate square inch area to move the desired in order to achieve proper
22. to Propane Gas see instruction in Gas Conversion Section of this manual 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 35 F to 65 F 1 75 through the furnace after installation See rating label located on side panel inside the furnace vestibule The installation must conform with local codes or in the absence of local codes with the National Fuel Gas Codes ANSI 7223 1 or latest edition and with these instructions A WARNING This furnace is not to be used for temporary heating of buildings or structures under construction Many of the chemicals used during construction when burned form acid bearing condensate that can substantially reduce the life of the heat exchanger It is recommended that a commercially available CO alarm be installed in conjunction with any fossil fuel burning appliance The CO alarm shall be installed according to the alarm manufacturer s installation instructions and be listed in accordance with the latest edition of the UL Standard for Single and Multiple Station Carbon Monoxide Alarms UL 2034 or the CSA International Standard Residential Carbon Monoxide Alarming Devises CSA 6 19 A CODES AND CLEARANCES The following items must be considered when choos
23. two high quality reusable filters rated at 600 ft min These filters are designed to be mounted on the return air plenum opening on the top of the furnace in the double vee style rack provided see Figure 20 If feasible it is recommended that slits be cut in the return front to allow for easier access of the filters 29 All installations and services must be performed by qualified service personnel FILTERS BLOWER ACCESS BON DOOR Nu S FILTERS BLOWER ACCESS DOOR CDBT SERIES CDB1 SERIES COUNTERFLOW APPLICATION RIGHT SIDE HORIZONTAL APPLICATION Figure 20 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 CHB1 or CDB1 furnaces MINIMUM FILTER AREA REQUIRED LENGTH X WIDTH SQ IN TABLE 3 FILTER TYPE MAXIMUM REQUIRED CFM FILTER VELOCITY RATING X 144 RATE FILTER IN AIR VELOCITY FURNACE MODEL _ C C y O J A CHBLCDBI 50 CHB1 CDB1 75 CHB1 CDB1 100 CHB1 CDB1 125 THERMO PRODUCTS 600 FT MIN 172 IN 254 IN 328 IN 402 IN SUPPLIED PERMANENT FILTER PERMANENT FILTER FILTER The Thermo Products supplied filter can be cut to size to fit other filter retention systems as long as the minimum size requirement is met NOTICE Any
24. x 4 electrical J box cover 350020 1 8 x 1 2 TEK screws for mounting 2 x 4 J box 4 10 32 x 1 2 green ground screw 300109 1 10 32 hex nut 300110 1 3 16 dia star washer 300270 1 Grounding instructions 966 1 Wire nut 300132 2 3 stainless steel hose clamp 300276 2 J box wire bushing 350016 1 All installations and services must be performed by qualified service personnel Drain hose grommet 350446 1 Spring clamp 11 16 300299 3 Installation notice MG 987 1 PVC tee assembly 2 x 3 dia 320817 1 CPVC XPVC adapter 320833 1 Gas Conversion Kit AOPS7679 7664 1 INSTALLATION PARTS PACKAGES CDB1 50 75 PARTS PACKAGE 0054409 4410 DESCRIPTION PART QUANTITY 2 3 8 ID radiator hose 410017 1 Thermostat lead bushing 350750 1 trap assembly 320816 1 8 x 3 4 coated screws for mounting trap amp inlet outlet collars 9252 11 16 OD x 1 2 ID vinyl tubing 410060 24 2 x 4 electrical J box 350024 1 2 x 4 electrical J box cover 350020 1 1 8 x e TEK screws for 300208 2 mounting 2 x 4 J box 10 32 x 1 2 green ground screw 300109 1 10 32 hex nut 300110 1 3 16 dia star washer 300270 1 Grounding instructions MG 966 1 Wire nut 300132 2 3 stainless steel hose clamp 300276 2 J box wire bushing 350016 1 Drain hose grommet 350446 1 Spring clamp 11 16 300299
25. 48x8 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 x 8 duct with a 400 CFM capacity for example will not flow 400 CFM if the register s to which it connects only flow a total of 200 CFM The speed of the blower motor may have to be changed to obtain the proper 55 F to 85 F 35 F to 65 F 1 75 temperature rise for heating when an air conditioning coil is installed This depends on the static resistance of an individual duct system and the size of the air conditioner 28 All installations and services must be performed by qualified service personnel K FILTERS 1 CHBI MODELS HIGHBOYS It is necessary to cut the return air opening in the bottom or side casing depending upon the needs of the specific installation NOTICE If your CHB1 will require air delivery above 1800 CFM it is advisable that both sides a combination of side and the bottom or the bottom only be used for return air If a return is cut in the bottom it should be as large as the return opening in the equivalent CDB1 model See specification sheet in beginning of this manual This CHB1 furnace has been factory supplied with a high quality re usable filter rated for air velocities up to 600 ft min An optional Thermo Products filter rack assembly part no AOPS7547 for 1 50 thru 100
26. 5 install a 2 inch PVC elbow with sleeve and coupling for models CHB1 100 125 and CDB1 100 amp 125 3 inch PVC elbow with sleeve on the inlet of the burner box Measure the length of pipe needed to clear the casing Be sure to allow sufficient length to account for insertion of the pipe into the elbow at the burner box and the elbow or coupling fitting on the end Cut the pipe to length After preparation of the thermoplastic pipe drive one 1 8 x 3 4 inch sheet metal screw with black protective coating supplied with furnace through the PVC coupling or sleeve into the metal collar of the burner box to secure the piping in place NOTICE DO NOT apply silicone rubber type sealant or PVC cement to the joint at the thermoplastic piping connection to the metal burner box collar Attach the PVC elbow to the sleeve and then to the coupling where required using silicone rubber type sealant refer to Figure 12 Insert the precut 2 inch or 3 inch thermoplastic pipe into the elbow at the burner box and to the elbow or coupler just outside the furnace using a silicone rubber type sealant To properly make these seals run a thin bead of silicone type sealant around the circumference of the PVC pipe about 3 8 inch from either end Insert the straight pipe section into the appropriate couplings and elbows and rotate 1 4 turn Silicone rubber type sealants remain pliable after the initial setup period has passed allowing for relatively eas
27. 5 3 380595 4 380595 5 24 GAS VALVE w LP KIT AOPS7674 1 AOPS7674 1 AOPS7674 1 AOPS7674 1 380600 380600 380600 380600 25 ORIFICE 2 3 4 5 LP 380039 380039 380039 380039 26 BUTTON PLUG 350046 2 350046 2 350046 2 350046 2 27 SENSOR 350759 1 350759 1 350759 1 350759 1 28 IGNITER 380650 1 380650 1 380650 1 380650 1 29 COVER 15922 1 15923 1 15924 1 15825 1 30 LIMIT SWITCH 350473 1 350473 1 350473 1 350473 1 31 HARNESS VESTIBULE 350778 1 350778 1 350778 1 350778 1 32 HARNESS BLOWER 350466 1 350486 1 350466 1 350466 1 53 CONTROL INTEGRATED 350836 1 350836 1 350836 1 350836 1 54 PRESSURE SWITCH 350498 1 350498 1 350498 1 350498 1 35 HARNESS SUPPLY 350704 1 350704 1 350704 1 350704 1 36 DOOR INTERLOCK SWITCH 350139 1 350139 1 350139 1 350139 1 37 eaPAcTOR ano 0 57357 0 57655 0 57652 0 57358 38 MOTOR WN CAPACITOR 1 5 H P 1 1 3 H P 1 1 2 H P 1 3 4 H P 1 7126 3710 5 191 HE3LO92N 7126 3533 39 MOTOR MOUNT BRACKET AOPS7670 1 57670 1 57670 1 AOPS7670 1 40 41 TRANSFORMER 24v 350464 1 350464 1 350464 1 350464 1 42 L P CONVERSION KIT AOPS7677 1 AOPS7878 1 AOPS7679 1 AOPS7664 1 43 FILTER RACK KIT AOPS7547 1 AOPS7547 1 AOPS7547 1 0 57375 1 44 CONCENTRIC VENT KIT 370171 1 370171 1 370171 1 370171 1 45 NAT CONVERSION KIT AOPS7665 1 AOPS7665 1 AOPS7665 1 AOPS7665 1 46 SIDEWALL VENT KIT 370191 1 370191 1 370191 1 370191 1 47 OPTI
28. AT THE INTEGRATED CONTROL Yes CHECK WIRING TO INDUCER Y AND IF OK REPLACE INDUCER ASSEMBLY P A No IS THERE VOLTAGE PRESENT No IGNITORENERGIZE gt THE HOT SURFACE ANS GLOW IGNITOR TERMINALS IGN amp IGN N AT THE INTEGRATED CONTROL CHECK THE INTEGRATED CONTROL DIAGNOSTIC LED LAMP RESET BY INTERRUPTING POWER TO CONTROL FOR MORE THAN ONE SECOND IF LED STAYS ON CONTINUOUSLY REPLACE INTEGRATED CONTROL Yes Yes HOT SURFACE IGNITOR ASSEMBLY CHECK WIRING TO HOT SURFACE IGNITOR AND IF OK REPLACE Y AFTER HOT SURFACE No IGNITOR WARM UP DOES GAS VALVE OPEN CHECK ACROSS MV TERMINALS ON INTEGRATED CONTROL FOR 24 VOLTS DURING THE 4 SECOND FLAME PROVING PERIOD AFTER IGNITOR WARM UP IS THERE 24VOLTS AS ABOVE Yes CHECK WIRING TO GAS VALVE AND IF OK REPLACE GAS VALVE 42 All installations and services must be performed by qualified service personnel Yes AFTER GAS VALVE OPENS DO THE BURNERS IGNITE No Yes Y DO BURNERS STAY LIT PAST PROOF OF FLAME CHECK Yes DOES THE INTEGRATED CONTROL ENERGIZE THE CIRCULATING AIR BLOWER CHECK FOR PROPER MANIFOLD PRESSURE ADJUST TO 3 5 FOR NATURAL GAS OR 10 0 WC FOR LP GAS POSITIONED CORRECTLY Yes IS IGNITOR No CHEC
29. C PIPE 9 INCH LENGTH SLEEVE Y USED ON 100 125 RIGHT SIDE VENT ONLY NOTE 5 _ DO NOT USE X BLACK COATED 8 x 5 4 SCREWS SEALANT SUPPLIED W UNIT CONNECTION TO METAL INLET Y SILCONE TYPE CAULKING COMPOUND UST BE USED TO SEAL THESE JOINTS K d Z PVC CEMENT NOT SHOWN MUST BE Me E USED TO SEAL ALL OTHER JOINTS EXCEPT AS NOTED BASIC VENT CONNECTION CHB1 SERIES Figure 6B Required Exhaust Vent and Air Intake Piping for CHB1 Furnace 17 All installations and services must be performed by qualified service personnel PVC VENT INLET PIPE SLOPES DOWNWARD 1 4 PER FOOT FROM BEGINNING OF LAST HORIZONTAL RUN OUTDOOR VENT ELBOW PVC VENT P UPWARD 1 4 TO OUTDOOR VENT ELBOW COMPONENTS REQUIRED FOR VENT AND AIR INLET CONNECTION IPE SLOPES PER FOOT A 2 IN SCHED 40 PVC PIPE SLEEVE AND 2 IN SCHED 40 PVC COUPLING CDB50 75 3 IN SCHED 40 PVC PIPE SLEEVE CDB 100 125 n NOTE LENGTH 15 DEPENDENT ON WHICH SIDE VENT IS ON NOTE DO NOT USE SEALANT AT CONNECTION TO METAL INLET OF BURNER BOX THE SCREW WILL SUFFICE B 2 IN SCHED 40 PVC PIPE SUPPLIED W UNIT T INDUCER C 2 IN SCHED 40 PVC 90 ELBOW 5 D 2 IN SCHED 40 PIPE USED ON CDB 50 75 ONLY 3 IN SCHED 40 PVC PIPE USED ON CDB 100 125 ONLY c F RADIATOR HOSE
30. CLOSED PRESSURE SWITCH STUCK OPEN OPEN LIMIT SWITCH OR ROLLOUT SWITCH 115 VOLT AC POWER REVERSED LOW FLAME SENSE SIGNAL CHECK IGNITOR OR IMPROPER GROUNDING FLAME HAS BEEN SENSED WHEN NO FLAME SHOULD BE PRESENT NO CALL FOR HEAT THE LED WILL ALSO FLASH ONCE AT POWER UP CHECK COMPLETE SYSTEM OUT LED LIGHT STAYS ON CONTINUOUSLY COMPLETE FAILURE REPLACE INTEGRATED CONTROL TROUBLESHOOTING COMPLETE 45 All installations and services must be performed by qualified service personnel 1 Replacement parts list for CHB1 50 CHB1 75 1 100 and 1 125 Appendix A Replacement Parts List gt 5 mi a 2 6 oe 55 555525 i 552 S gas M zu 0 555505502 o CHIOT 1 300602046040 lt oe de Z 2 B NOTE SEE SPECIFICATION SECTION THIS MANUAL FOR PART NUMBERS RELATED TO PARTS PACKAGE COMPONENTS 46 72744 All installations and services must be performed by qualified service personnel
31. ER 380650 1 380650 1 380650 1 380650 1 37 HARNESS VESTIBULE 350780 1 350780 1 350780 1 350780 1 38 HARNESS BLOWER 350781 1 350781 1 350781 1 350781 1 38 CONTROL INTEGRATED FAN 350836 1 350836 1 350836 1 350836 1 40 LIMIT SWITCH 350473 1 350473 1 350473 1 350473 1 41 PRESSURE SWITCH 350498 1 350498 1 350498 1 350498 1 42 HARNESS SUPPLY 350705 1 350705 1 350705 1 350705 1 43 DOOR INTERLOCK SWITCH 350139 1 350139 1 350139 1 350139 1 capacitor AOPS7357 AOPS7655 AOPS7652 AOPS7358 45 MOTOR WN CAPACITOR 1 5 1 1 3 1 1 2 1 3 4 1 7126 3710 HE3J181N HE3LO82N 7126 3533 46 MOTOR MOUNT BRACKET AOPS7670 1 AOPS7670 1 AOPS7670 1 AOPS7670 1 47 48 TRANSFORMER 24v 350464 1 350464 1 350464 1 350464 1 48 LIMIT BRACKET 14149 1 14149 1 14149 1 14149 1 50 AUX LIMIT SWITCH 350472 1 350472 1 350472 1 350472 1 51 LP CONVERSION KIT AOPS7677 1 AOPS7678 1 AOPS7679 1 AOPS7664 1 52 CONCENTRIC VENT KIT 370171 1 370171 1 370171 1 370171 1 53 NAT CONVERSION KIT AOPS7665 1 AOPS7665 1 AOPS7665 1 0 57665 1 54 SIDEWALL VENT KIT 370191 1 370191 1 370191 1 370191 1 49 OPTIONAL ITEMS NOT SHOWN All installations and services must be performed by qualified service personnel Appendix B Wiring Diagrams
32. IPATOR 0 8 AMP V2mamr 53 ilk 3 4 Df EARTH GROUND G 1 50 5 100 125 TEE CDB1 50 75 100 125 SUE 50A65 143 77 INTERGRATED CONTROL 8022801 HEAT H BLOWER i MOTOR 4 COOL H BC2 n 77 4 EAC H po me HUM H BC IC El y IND H INDUCER C FER N 0 IG IG NITRIDE IGNITER uc 50A65 143 la s 3 24 V GAS VALVE M Bc COLL BOX USED ON CDB Ps MODELS ONLY INDUCER Hl HLO 63 HIGH ROLL OUT AUX LIMIT Mi MODELS ONLY 603 FP FLAME SENSOR IC TR GND Z PRESSURE SWITCH N O TEMPERATURE SWITCH OPEN ON TEMP RISE CHASSIS GROUND BLOWER CONTROL W R 50A65 143 IGNITION CONTROL W R 50A65 143 51
33. ITION SEQUENCE FOR A TOTAL OF SIX RECYCLES AFTER SIX UNSUCCESSFUL RECYCLE ATTEMPTS THE CONTROL WILL GO INTO SYSTEM LOCKOUT THE CIRCULATING AIR FAN AND OPTIONAL ELECTRONIC AIR CLEANER ARE DE ENERGIZED IF SYSTEM IS IN LOCKOUT THE MODULE WILL RESET ITSELF AFTER 60 MINUNTES OR MAY BE MANUALLY RESET BY INTERRUPTING THE POWER TO THE FURNACE AT THE DISCONNECT OR INTERRUPTING THE CALL FOR HEAT AT THE THERMOSTAT IF THIS DOES NOT RESTART THE SYSTEM REFER TO THE TROUBLESHOOTING SECTION OF THIS MANUAL 35 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 Checkall wiring for loose connections and proper hook up Leak test gas piping connections 3 Check all tubing to the pressure switch and drains to make sure they are connected firmly at all their connection points 4 Check flue pipe combustion air inlet and all PVC connections for tightness and to make sure there is no blockage Make sure air filter is in place 6 Make sure the outside vent and air intakes are installed according to instructions and that they are free from blockage 7 Make sure that the drain trap is properly connected to the furnace and to the buildings drain s
34. K ACROSS THE No CIRCULATING AIR AFTER THE 45 SECOND CIR N amp HEAT TIME DELAY FOR PROPER VOLTAGE Yes DOES THE CIRCULATING AIR FAN COME ON WHEN ENERGIZED I BLOWER TERMINALS REPOSITION TO CORRECT LOCATION No REPLACE THE INTEGRATED CONTROL poEsBLOWER o SPIN FREELY Yes CONFIRM IF EITHER BLOWER WHEEL IS RUBBING AGAINST HOUSING OR MOTOR SHAFT IS SPINNING FREELY AND REPAIR OR REPLACE AS NECESSARY Yes IS CAPACITOR WORKING PROPERLY REPLACE MOTOR Ne REPLACE CAPACITOR 43 All installations and services must be performed by qualified service personnel Yes DOES SYSTEM RUN UNTIL IS LED LIGHT CHECK ALL THERMOSTAT IS SATISFIED ON INTEGRATED CONTROL FLASHING WIRING FOR 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 120 SECONDS Yes 44 All installations and services must be performed by qualified service personnel Yes Yes IF LED LIGHT FLASHES 1 FLASH THEN PAUSE 2 FLASHES THEN PAUSE 3 FLASHES THEN PAUSE 4 FLASHES THEN PAUSE 6 FLASHES THEN PAUSE 7 FLASHES THEN PAUSE 8 FLASHES THEN PAUSE CONTINUOUS FLASHING NO PAUSE SYSTEM LOCKOUT PRESSURE SWITCH STUCK
35. LS ONLY COLLECTOR RED STI BOX SW ORANGE aes PRESSURE SWITCH N O 1 CONNECT HOT TO Li AND _ E TEMPERATURE SWITCH 2 IF ANY OF THE ORIGINAL WIRES OPEN ON TEMP RISE AS SUPPLIED WITH THE FURNACE MUST BE REPLACED H MUST BE M G REPLACED WITH WIRING MATERIAL E E P7 2 FLASHES PRESSURE SWITCH STUCK CLOSED N CHASSIS GROUND QUU TEAST NOt 3 FLASHES PRESSURE SWITCH STUCK OPEN D 4 FLASHES OPEN LIMIT SWITCH aie ese NATO ATO ub 6 FLAHSES 115 VOLT AC POWER REVERSED EARTH GROUND 7 FLASHES LOW FLAME SENSE SICNAL 4 CHB1 75 WIRED TO MH SPEED FOR 8 FLASHES CHECK IGNITOR OR IMPROPER GROUND gut FIELD WIRING CDB1 75 WIRED TO ML SPEED FOR CONTINUOUS FLASH FLAME SENSED WHEN NO HTG CHB1 CDB1 50 HAS A 3 SP MOTOR FLAME SHOULD BE PRESENT CONTINUOUS ON INTERNAL CONTROL FAILURE 50 All installations and services must be performed by qualified service personnel WD S40 4282 MA HEATING COOLING THERMOSTAT WIRING DIAGRAM LADDER 1 CONNECT HOT TO L1 AND COMMON TO 2 IF ANY OF THE ORIGINAL WIRES AS SUPPLIED WITH THE FURNACE MUST BE REPLACED IT MUST BE REPLACED WITH WIRING MATERIAL HAVING A TEMPERATURE RATING OF AT LEAST 105 C 3 SET HEAT ANTIC
36. ME 0 MANIFOLD BURNER Figure 22 A CAUTION The CHBI CDB1 furnace models are an in shot burner 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 E 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 controls on the unit should be checked for proper functioning prior to the qualified service personnel leaving the job site Specifically the following should be checked With furnace in normal heating operation check to make certain blower will start and stop automatically under control of integrated fan control 1 Check safety limit control as follows a Shutoff incoming power Block return air opening or disconnect blower motor leads Restore power to furnace Set thermostat above room temperature calling for heat When temperatures are reached in furnace at limit control setting with blower out of operation burner should shut off f Shutoffelectrical power IMPORTANT Remove blockage or reconnect blower motor and restore power 2 Make certain thermostat will automatically start and stop furnace 3 Block the flue pipe outlet gradually with a flat piece of metal until th
37. N CAUSE IT IS THE RESPONSIBILITY OF THE OWNER AND OR USER THAT THE BURNER CHIMNEY VENT HEAT EXCHANGER AND CONTROLS SHOULD BE INSPECTED EVERY YEAR BY A QUALIFIED HEATING CONTRACTOR PROPERTY DAMAGE PERSONAL INJURY OR LOSS OF LIFE FOR ASSISTANCE OR ADDITIONAL INFORMATION CONSULT QUALIFIED INSTALLER SERVICE AGENCY OR THE GAS SUPPLIER ANY DEFICIENCIES NOTED MUST BE CORRECTED AT ONCE BY A QUALIFIED HEATING CONTRACTOR THE OWNER AND OR USER SHOULD ALSO CONDUCT PERIODIC VISUAL INSPECTIONS 3 lt E a E ps na me lt Zz BE 8 Turn on all electric power to the appliance 5 Ed 9 Set thermostat to desired setting and if equipped set the operating g mode to HEAT z 10 If appliance will not operate follow the instructions Turn E I lt Gas To Appliance and call your service technician gas supplier lt GAS CONTROL VALVE GAS CONTROL VALVE a 2 STAGE 2 S H ra amp z lt L D ot Zo t gz a L Sse Cos e TOGGLE SWITCH TOGGLE SWITCH EN Gas APPLIANCE 1 Set thermostat to lowest setting and if equipped set the operating mode to COOL or OFF 2 If service is to be perfo
38. OM BEGINNING OF LAST HORIZONTAL RUN T TO OUTDOOR VENT ELBOW no MOUSE PVC VENT PIPE SLOPES pe SEALANT UPWARD 1 4 PER FOOT CONNECTION BURNER BOX TO OUTDOOR VENT ELBOW TO METAL INLET COMPONENTS REQUIRED FOR E VENT AND AIR INLET CONNECTIO e O A A 2 IN SCHED 40 PVC PIPE SLEEVE AND 2 IN n S SCHED 40 PVC COUPLING CHB50 75 42 3 IN SCHED 40 PVC PIPE SLEEVE CHB100 125 e NOTE LENGTH IS DEPENDENT ON WHICH SIDE VENT IS ON B NOTE DO NOT USE SEALANT AT CONNECTION TO METAL INLET OF BURNER BOX THE SCREW WILL SUFFICE 1 LL X 49 B 2 IN SCHED 40 PIPE 1 INDUCER C 2 IN SCHED 40 90 ELBOW Lil BLOWER D 2 IN SCHED 40 PIPE USED 50 75 ONLY 5 3 IN SCHED 40 PVC PIPE USED ON CHB 100 125 ONLY A F RADIATOR HOSE AND 2 SPRING CLAMPS BUE 2 DEDE SS SUPPLIED W UNIT TEE ASSEMBLY 15 G DRAIN TEE ASSEMBLY SUPPLIED W UNIT LOCATED IN THE h 2 IN USED ON CHB 50 75 ONLY 2 ar AND Wim 2 3 IN USED ON CHB 100 125 ONLY COMES S Isl n H 2 IN SCHED 40 PVC 90 ELBOW USED ON CHB 50 75 ONLY z 3 IN SCHED 40 PVC 90 ELBOW USED ON CHB 100 125 ONLY J 2 IN SCHED 40 PVC 90 ELBOW CHB 50 75 3 SCHED 40 PVC 90 ELBOW CHB 100 125 RIGHT SIDE VENT DETAIL SEE ALSO RIGHT SIDE VENT DETAIL 100 125 ONLY K 3 IN SCHED 40 PVC 45 ELBOW USED ON 100 125 RIGHT RIGHT SIDE VENT ONLY BURNER BOX _ ae OF L 3 IN SCHED 40 PV
39. ONAL ITEMS NOT SHOWN All installations and services must be performed by qualified service personnel 50 amp 100 SERIES ONLY REQ D ON ADDITIONAL ASSEMBLY INSTRUCTIONS REFER TO SHEETS 3 amp 4 FOR NOTE 2 Replacement parts list for CDB1 50 CDB1 75 CDB1 100 and CDB1 125 All installations and services must be performed by qualified service personnel UNIT CDB1 50 CDB1 75 CDB1 100 CDB1 125 PARTS DESCRIPTION PART NO QTY PART NO QTY PART NO QTY PART NO QTY 1 HEAT EXCHANGER 38141 1 38142 1 38143 1 38144 1 2 BLOWER ASSEMBLY 50054430 1 50054431 1 50054432 1 50054433 1 3 BASE 18121 1 18121 1 10775 1 10776 1 4 CASING BACK 610931 1 810931 1 610732 1 610733 1 5 SIDE CASING RIGHT 620107 1 620107 1 620107 1 620107 1 6 SIDE CASING LEFT 620106 1 620106 1 620106 1 620106 1 7 TOP CENTER PANEL 618124 1 618124 1 610737 1 610738 1 8 PLENUM STRIPS 613403 2 613403 2 613403 2 613403 2 9 FRONT DOOR 620932 1 620932 1 620728 1 620730 1 10 BLOWE
40. P Read the safety information above on this label Set the thermostat to the lowest setting Turn off all electric power to the appliance This appliance is equipped with a hot surface igniter that automatically lights the burner Do not try to light the burner by hand 5 Move the gas control switch to the OFF position 6 Wait five 5 minutes to clear out any gas Then smell for gas including near the floor or ground If you smell gas STOP Follow B in the safety information above on this label If you don t smell gas go to the next step 7 Move the gas control switch to the ON position Lu L lt tc 2 o gt a o FOR YOUR SAFETY DO NOT STORE OR USE GASOLINE OR OTHER DO NOT USE ANY PHONE IN YOUR BUILDING FLAMMABLE VAPORS AND LIGUIDS IN THE 3 IMMEDIATELY CALL YOUR GAS SUPPLIER FROM A NEIGHBOR S PHONE FOLLOW THE 1 DO NOT TRY TO LIGHT ANY APPLIANCE 2 DO NOT TOUCH ANY ELECTRICAL SWITCH GAS SUPPLIER S INSTRUCTIONS 4 IF YOU CANNOT REACH YOUR GAS SUPPLIER CALL THE FIRE DEPARTMENT VICINITY OF THIS OR ANY OTHER APPLIANCE THIS UNIT MUST BE INSTALLED AND SERVICED BY QUALIFIED CONTRACTOR ONLY INSIDE APPLIANCE NEAR BURNER ASSEMBLY WHAT TO DO IF YOU SMELL GAS OPERATING INSTRUCTIONS ARE LOCATED REFER TO THE USERS INFORMATION INSTRUCTIONS RNIN PLUS INS WAR SPECIAL HOMEOWNERS IMPROPER INSTALLATION ADJUSTMENT ALTERATION SERVICE OR MAINTENANCE CA
41. R ACCESS DOOR 610930 1 610930 1 610727 1 610728 1 11 TRIM PLATE TOP 18172 1 18172 1 18174 1 18175 1 12 FRONT CENTER PANEL 510928 1 610928 1 610753 1 610754 1 13 BLOWER PAN 28120 i 28120 i 28178 1 28179 1 14 SUPPORT 22385 1 22385 1 22385 2 22385 2 15 LIMIT SWITCH ROLLOUT 350485 1 350485 1 350485 1 350485 1 16 SIDE CASING ANGLE 14329 1 1 14329 1 17 DOOR PULL 320157 2 320157 2 320157 2 320157 2 18 SIGHT GLASS GASKET 330135 1 330135 1 330135 1 330135 1 19 SIGHT GLASS 15887 1 15887 1 15887 1 15887 1 20 INDUCER WN GASKET AOPS7416 1 AOPS7416 1 AOPS7416 1 AOPS7416 1 21 INDUCER GASKET 330137 1 330137 1 330137 1 330137 1 22 runs NC C ONCE sha 23 GASKET 330141 23 25 330141 28 50 330141 33 75 330141 39 50 24 WDE JARE 330140 21 330140 26 50 330140 32 25 330140 38 25 BURNER TUBE 380595 2 380595 3 380595 4 380595 5 26 GAS VALVE w LP KIT 0 57674 1 AOPS7674 1 AOPS7674 1 AOPS7674 1 NAT 380600 380600 380600 380600 27 ORIFICE 2 3 4 5 LP 380039 380039 380039 380039 28 PLENUM STRIP 18122 2 18122 2 13412 4 13412 4 29 BUTTON PLUG 350046 2 350046 2 350046 2 350046 2 30 FILTER RACK 624803 1 624803 1 624803 1 624803 1 31 ANGLE SEPARATOR 18372 1 18372 1 18373 1 18374 1 32 COVER 15922 1 15923 1 15924 i 15925 1 33 PLENUM STRIP 18123 2 18123 2 13413 2 34 SENSOR 350759 1 350759 1 350758 1 350759 1 35 PRESSURE SWITCH 350442 1 350442 1 350442 1 350442 1 36 IGNIT
42. S i PIPE S E EXTERIOR WALL EXTERIOR WALL PVC ELBOW TYPICAL INSTALLATION USING ELBOWS TYPICAL INSTALLATION USING COUPLINGS FLUSH AGAINST THE EXTERIOR WALL FLUSH AGAINST THE EXTERIOR WALL Figure 5 Typical Construction Details of Sidewall Vent and Air Intake Terminations Finish the vent installation by caulking the annulus to seal around the two 2 holes where the thermoplastic pipes pass through the wall 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 320226 for 3 vent and 320219 for 2 vent Optional Direct Vent Terminations Three optional vent kits are available for direct vent terminations refer to Figure 6 e The concentric vent kits Thermo Products p n 57488 amp AOPS7489 provide a means for the vent and intake to be installed through a single opening in the roof or exterior wall Kit p n AOPS7488 requires a 4 inch diameter hole and is used on furnace models CHB1 CDB1 50 amp 75 Kit p n AOPS7489 requires a 5 inch diameter hole and is used on furnace models CHB1 CDB1 100 amp 125 e The sidewall vent cap Thermo Products part no 370191 is a cover installed over the exhaust vent and air intake pipes on the exterior of the building For horizontal sidewall vent applications only This kit may be used on any size furnace in the CHB1 CDB1 family
43. TIONS CHB1 SERIES MODEL NO 1 50 1 75 1 100 1 125 BTU HR INPUT 50 000 75 000 100 000 125 000 BTU HR OUTPUT 47 000 72 000 94 000 116 000 HT CASING 44 1 4 44 1 4 44 1 4 44 1 4 WIDTH OF CASING 17 17 21 24 DEPTH OF CASING 27 1 2 27 1 2 27 1 2 27 1 2 WARM AIR OUTLET 15x 18 15x 18 19x 18 22x18 RETURN AIR INLET 25x16 25x16 25x16 25x16 DIA OF FLUE 2 2 3 35 DIA OF COMBUSTION 2 2 3 3 AIR INTAKE CFM 2 amp 5 2 2 2 29 2 2 2 2 EXTERNAL STATIC PRESSURE aiu ene RS vat GHI SPEED 1100 860 1600 1380 1940 1700 2770 2060 MH SPEED 1000 720 1250 1150 1720 1540 1800 1700 ML SPEED 1030 930 1530 1380 1730 1600 GLO SPEED 610 420 820 700 1340 1220 1670 1550 TEMPERATURE RISE 70 70 70 70 BLOWER MOTOR HP 20 41 50 25 NO OF SPEEDS 3 4 4 RUN CAPACITOR 10 mfd 10 mfd 10 mfd 10 mfd LARGEST RECOMMEDED AIR CONDITIONER 2 Ton 3 5 Ton 4 Ton 5 Ton SIZE OF FILTERS 24 3 4 x 15 3 4 24 3 4 x 15 3 4 24 3 4 x 15 3 4 24 3 4 x 19 3 4 NOTES 1 BTU output based on annual fuel utilization efficiency rated by manufacturer 2 Onall outlet and inlet dimensions the first dimension is width 3 To permit largest recommended air conditioning at 5 static pressure selection of the highest motor speed is required All installations and services must be performed by
44. TU CU FT X NUMBER OF CU FT X 3600 SECONDS INPUT BTU HR EAMPLE 1025 BTU CU FT X 2 CU FT X 3600 98 633 INPUT 74 8 SECONDS Check for the model number of this furnace its input the type of gas and the manifold pressure on the information plate located on the vestibule panel behind the upper front panel If using the above example the furnace was a CHB 100 model and the 98 663 BTUinput would be acceptable because it was within 2 of the listed input of 100 000 Make sure that the gas supply pressure to the furnace falls within the maximum range of 4 V2 to 14 wc pressure on natural gas and 11 0 to 14 0 w c on Propane gas The pressure to the furnace must be checked while the furnace burner and any other gas appliances on the same supply system are operating using the 1 8 in plugged tap shown in Section J Fig 18 of this manual GAS PRESSURE CHART FOR ALL CHB1 MODEL FURNACES TABLE 4 EN SUPPLY PRESURE MANIFOLD PRESSURE MAX 14 WC MAX 14 WC This gas furnace is equipped with a fixed orifice sized for the manifold pressure shown on the information plate The input can only be increased or decreased by adjusting the manifold pressure Remove the 1 8 threaded pipe plug located on the top right side of the gas valve Us a U tube manometer or pressure gage to measure the pressure To adjust the pressure remove the screw from the regulator on the outlet side of the gas valve and using the adjustment allen screw decrease
45. Thermo Pride CONDENSING GAS FURNACE INSTALLATION AND OPERATION MANUAL MODELS CHB1 50N CDB1 50N CHB1 75N CDB1 75N CHB1 100N CDB1 100N CHB1 125N CDB1 125N A WARNING YOU DO NOT FOLLOW THE SAFETY PRECAUTIONS BELOW AND IN THIS MANUAL 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 e 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 THERMO PRODUCTS LLC YT T 217 CERTIFIED NORTH JUDSON IN 46366 www ahridirectory org PHONE 574 896 2133 MADE IN USA MG 1006 ECN 5355 MA 140303 I SAFETY INFORMATION This and the f
46. ZONTAL PPLICATION S SINGLE TAP nom PRESSURE SWITCH ROLLOUT SWITCH LOCATION FOR i U COLLECTOR BOX HORIZONTAL APPLICATION 58 gt PRESSURE SWITCH BURNER BOX PRESSURE SWITCH TAP HOSE ENSURE THAT NO EXCESS HOSE ON LOWER FRONT FACE EXISTS TO FORM A SAG LOOP OR OF COLLECTOR BOX WATER SHORTEN CUT IF NECESSARY CDB1 UNIT SHOWN IN RIGHT SIDE HORIZONTAL APPLICATION Figure 1 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 Gas supply line contact is only permissible between lines formed by the intersection of the top and two sides of the furnaces casing and the building joists studs or framing See Figure 1 Equipment must be installed in accordance with regulations of the National Board of Fire Underwriters and the National Fuel Gas Code Authorities having jurisdiction should be consulted before installations are made C Replacing An Existing Furnace From A Common Vent AWARNING These furnaces may NOT be common vented with any other appliance All installations and services must be performed by qua
47. air duct system must equal the supply air duct system in its capabilities Use a supplier s catalog for proper sizing of outlet and return air registers and grills to ensure that they meet the CFM requirements of the run to which they are connected 26 All installations and services must be performed by qualified service personnel 4 If the furnace is used in connection with an air conditioning evaporator coil the furnace must be installed parallel with or on the upstream side of the coil to prevent condensation in the heat exchanger If the evaporator coil is installed with a parallel flow arrangement dampers or other means to control flow of air should be installed to prevent chilled air from entering the furnace If such a device is manually operated it must be equipped with a means to prevent operation of either the furnace or air conditioner unless it is in the full heat or cool position We recommend that the outlet duct be equipped with a removable access panel to allow for visual inspection of the heat exchanger to check for leakage or to allow for insertion of a probe sampler in the air stream This removable access cover should be attached to ensure there is no air leakage 5 The duct system shall be sized for the maximum CFM requirement of the installation whether it is for heating or cooling Two common rules for heating and cooling follow A 400 CFM 1200 BTU s per ton of cooling is required B 14 CFM of heating per 1000 BTU
48. bly over the outlet of the inducer blower assembly Measure the length of 2 inch diameter thermoplastic pipe needed to c installation of a 2 3 8 inch length of reinforced lear the furnace side casing while allowing for rubber hose used as a coupling within the casing of the furnace Cut the measured lengths of 2 inch diameter PVC pipe being sure to allow a sufficient length of pipe for connections Refer to Figures 9 10 NOTICE For the models CDB1 50 75 a and 11 for assembly details length of 2 inch diameter PVC pipe and a 2 inch diameter PVC tee assembly are supplied with each furnace For the models CDB1 100 125 a 3 inch x 2 inch diameter PVC reducer is also supplied 19 All installations and services must be performed by qualified service personnel NOTICE For models CDB1 100 and CDB1 125 used in horizontal applications immediately transition from 2 inch to 3 inch diameter pipe by installing the 3 inch x 2 inch diameter PVC reducer just outside the furnace casing The remainder of the venting system leading away from the furnace must be composed of 3 inch diameter PVC pipe and pipefittings 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 Slip the 2 inch diameter PVC elbow for the model series CDB1 in horizontal applications a 2 inch diameter PVC tee over the induce
49. d combustion air intake shall be a minimum of 3 inches and a maximum of 24 inches apart NOTICE When the vent termination is installed correctly a draft should NOT be present in the system during the furnace off cycle 2 90 VENT AIR ELBOWS INTAKE MEDIUM 12 IN MIN mee P MIN 12 IN ABOVE HIGHEST ANTICIPATED SNOW LEVEL AIR INTAKE Pd PREVAILING WINDS CK Figure 6A Typical Rooftop Vent and Air Intake Termination Construction Details VERTICAL VENT TERMINATION 16 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 and the CDB1 respectively as well as a list of required parts to correctly install each system PVC VENT INLET PIPE SLOPES DOWNWARD 1 47 PER FOOT FR
50. de the furnace vestibule will specify which gas your furnace is orificed for If the furnace is installed at an altitude that is more than 2 000 feet above sea level it is mandatory that the input to the burner be reduced 4 096 for every 1 000 feet that it is above sea level If the furnace is installed at an elevation of 5 000 feet its input must be reduced 20 0 Example a furnace rated at 100 000 BTU at sea level must be reduced to a firing rate of 80 000 100 000 X 80 2 80 000 at an elevation of 5 000 feet If the furnace is installed at an elevation of 2 000 feet or less no reduction in input is required Your gas supplier will supply you with the correct orifice sizing information To check the input of your natural gas furnace allow the unit to operate for 10 to 15 minutes and proceed as follows a Call your gas supplier and ask for the BTU content heating value of one cubic foot of the gas supplied to the installation area An alternate approach is to assume a value of 1025 BTU Cu Ft which is the national average b With all other gas appliances turned off and using a stopwatch clock the time required for the small dial on the gas meter to make one full revolution The meter will state how many cubic feet is flowed for one revolution usually one two or five The unit must have been in operation at least 10 minutes before clocking 36 All installations and services must be performed by qualified service personnel FORMULA B
51. dition when an external electrical source is utilized 2 ELECTRONIC AIR CLEANER EAC AND HUMIDIFIER INSTALLATION The ignition module on this furnace has designated terminals to control the operation of an electronic air cleaner and or humidifier These terminals provide line voltage 110 20V AC for the control of these accessories See Figure 21 NOTICE It is important to confirm that the operating voltage of the humidifier or EAC being installed matches the output of this control If not a field supplied relay or transformer may be necessary to provide the proper control and supply voltage for the accessory being installed See the manufacturers instructions for the humidifier or EAC for additional instructions 3 THERMOSTAT ANTICIPATOR SETTING Proper control of the indoor temperature can only be achieved if the thermostat is calibrated to the heating and or cooling cycle A vital consideration of this calibration is related to the thermostat heat anticipator The proper thermostat heat anticipator setting is 0 8 AMPS for furnace operation only To increase length of cycle increase setting of heat scale to decrease length of cycle decrease setting of heat scale Anticipators for the cooling operation are generally pre set by the thermostat manufacturer and require no adjustment 31 All installations and services must be performed by qualified service personnel Anticipators for the heating operation are of two types pre set and adj
52. e casing for mounting the trap NOTICE When the CDB1 series unit is used a horizontal application the connection of the drain hose to the collector box must be changed from the standard factory supplied location to a lower location on the collector box to permit proper drainage of condensate from the furnace A knockout has been provided in the furnace side casing for the drain hose to exit The connection change can be accomplished as follows Refer to Figure 16 for a depiction of a properly completed relocation 8 Locate and disconnect the drain hose from the standard connection location at the collector box b Locate and uncap the drain at the bottom with the furnace lying on a side of the collector box C Connect the drain hose from Step a to the uncapped bottom drain from Step b d Close off the previous drain connection from Step a with the cap removed in Step b 3 Attach one 1 drain hose a length of 11 16 inch O D clear colorless tubing to the front connection on the model series CHB1 or the bottom connection on the model series CDB1 of the condensing coil cover plate Insert the snap in place plastic bushing provided in the furnace parts package into the proper hole in the furnace casing to prevent cuts in the drain tubing Route the drain tubing through the bushing When making connections with the clear tubing carefully route the tubing in a manner to prevent kinking or abrasion of the tubing Slip the
53. e pipe sidewall venting a furnace combustion air is drawn from the indoor space This type of installation is not classified as a direct vent installation However the same exhaust venting guidelines apply as for a direct vent installation except the exhaust termination will be similar to the air intake of the two pipe direct vent installation Refer to depictions of proper intake terminal installations in Figures 2 and 3 Referring to the left hand LH sketch in Figure 2 vent termination will consist of one 1 90 elbow opening downward When indoor air is used for combustion measures should be taken to prevent drawing in corrosive chemicals vapors or gases with the combustion air supply Such chemicals include but are not limited to chlorinated and or fluorinated hydrocarbons such as found in refrigerants aerosol propellants dry cleaning fluids degreasers and removers Other harmful compounds may come from bleaches air fresheners or mastics Vapors from such products can form reactive acid producing chemical species when burned in a gas flame The life of the furnace could be reduced should acidic compounds form within the furnace Installation Of Outside Exhaust Intake Terminations 1 After determining appropriate installation locations suitable locations must observe all clearances specified in this manual mark and cut two 2 holes in the outside wall of the following sizes for the outdoor terminal s e 2 3 8 inch diamete
54. e pressure switch functions shutting off the main burners 4 Block the PVC pipe inlet gradually with a flat piece of metal until pressure switch functions shutting off the main burners IMPORTANT Remove flue air inlet blockage when done 5 Remove the blower compartment access door with the furnace operating The door interrupt switch is in the 120 volt circuit and will shut down the entire system Replace the blower door and the furnace start up cycle will begin 38 All installations and services must be performed by qualified service personnel V 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 these instructions and the users information manual must be kept along with instructions for any accessories in the plastic pouch on the inside of the furnace The location and use of the manual gas shut off valve and furnace electrical disconnect switch Instruct user to always shut off gas before shutting off electric power The sequence of operation of the furnace The correct operation and maintenance of the appliance as outlined in the users information manual 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 Review with and enco
55. eet elbow and a straight pipe For the purposes of service it is recommended that the gas union be located inside the furnace when possible 25 All installations and services must be performed by qualified service personnel 1 8 N P T PLUGGED TAPPING GAS VALVE STREET ELBOW GROUND JOINT N z al PRET 2 MANUAL GAS SHUT OFF MANUAL CAS B f OEE le lt VALVE U i VALVE Tm i ipe 0 DRIP LEG 5 FT 5 FT Ld I GROUND STREET lo UN ELBOW f 8 uu Rr a GAS VALVE i 4 CUL pP LEG 8 N P T PLUGGED TAPPING Figure 18 2 A drip leg must be used both LP and natural gas installations prior to the furnace in order to trap oil condensate and other impurities which might otherwise lodge in the gas valve or plug the burner orifice A drip leg shall be provided at the outlet of the gas meter when there is excessive
56. f within 10 feet horizontally L Distance above paved sidewalk or paved driveway located on public property 7 feet Distance below veranda porch deck or balcany 24 inches In accordance with the current edition of the National Fuel Gas Code ANSI Z223 1 NFPA 54 n non direct vent applications i e sidewall venting only the required clearance is 4 feet below or to the side of the opening 1 foot above opening Clearance in accordance with local installation codes the requirements of the gas supplier and the manufacturer s installation instructions n direct vent applications clearance in accordance with local installation codes the requirements of the gas supplier and the manufacturer s installation instructions In non direct vent applications i e sidewall venting only the required clearance is 7 feet Figure 4 NFGC Minimum Clearances Between the Vent Terminal and Various Building Features 4 Vent Terminal Location Guidelines 13 All installations and services must be performed by qualified service personnel ANCAUTION 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 Avoid locating the vent terminal over areas where dripping of condensate or small pools of acidic condensate could create a problem In addi
57. h all screws in place and tightened before operating furnace A WARNING Personal injury or property damage could result from repair or service of this furnace by anyone other than a qualified heating contractor Only the homeowner user routine maintenance described in the Users Information Manual may be performed by the user iv All installations and services must be performed by qualified service personnel INDEX SECTION I II SAFETY INFORMATION FURNACE SPECIFICATIONS GENERAL INSTALLATION A CODES AND CLEARANCES B FURNACE LOCATION B1 CDB1 HORIZONTAL APPLICATION C REPLACING EXISTING FURNACE FROM A COMMON VENT D GENERAL REQUIREMENTS FOR VENTING CHB1 CDB1 E SIDEWALL VENTING El SINGLE PIPE SIDEWALL VENTING OPTION F INSTALLATION OF OUTSIDE VENT AIR INTAKE TERMS G CONNECTING FURNACE TO ROOF VENT AIR TERMS H CONNECTING FURNACE TO VENT AIR INTAKE TERMS I CONDENSATE DRAIN LINE amp TRAP ASSY J GENERAL GAS PIPING J1 REQUIREMENTS amp SIZING OF DUCTWORK K FILTERS L WIRING STARTING THE UNIT A SEQUENCE OF OPERATIONS B INITIAL START UP ADJUSTMENT OF BTU INPUT RATE D BURNER ADJUSTMENT E FURNACE CHECKOUT PROCEDURE INSTALLER S INSTRUCTIONS TO USER TROUBLESHOOTING APPENDIX A REPLACEMENT PARTS LIST APPENDIX B WIRING DIAGRAMS BEGINNING PAGE All installations and services must be performed by qualified service personnel IL FURNACE SPECIFICA
58. his will ensure trouble free operation and will keep the acidity level well above a pH of 3 4 i e more towards neutral To flush the condensate drain system follow these steps a Turn off electrical power to the furnace at the disconnecting switch and adjust the room thermostat to OFF or to the lowest temperature setting b Flush the drain system by removing the drain hose from the secondary heat exchanger coil drain nipple and running tap water into the open end of the tubing Run at least a quart of water through the drain system or more until the water leaving the drain system is clear and colorless in color and free of any particulate matter c Replace the drain tubing by pushing it firmly onto the nipple Make sure the spring type hose clamp is returned to the original position to prevent leaks d If any of the electrical controls are inadvertently wetted during the flushing process dry them with a soft cloth and wait 24 hours before operating the furnace e Adjust the room thermostat to the HEAT position or to the desired temperature and restore electrical power to the furnace J GENERAL GAS PIPING AWARNING Because of the potential of odorant fade a gas leak may not be detected by smell If this furnace is installed below grade contact your gas supplier for a gas detector 1 Left and right gas supply piping These furnaces are set up to be gas piped through either the left or right side by using a str
59. ied 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 TO USE THIS DIAGRAM YOU JUST NEED TO FOLLOW THE INSTRUCTIONS IN THE BOXES TURN THERMOSTAT TO CALL FOR HEAT DOES THERMOSTAT MAKE CONTACT No Y IS ROOM TEMPERATURE NO IS ROOM N TURN T STAT Yes BELOW THERMOSTAT TEMPERATURE SETTING ABOVE SETTING ABOVE 90 DEGREES F ROOM TEMP COOL THE THERMOSTAT IS THE TRANSFORMER No SUPPLYING 24 VOLTS TO THE THERMOSTAT CORRECT WIRE ARE WIRES CONNECTED CONNECTIONS PROPERLY Yes CHECK INPUT REPLACE IS INTERNAL DAMAGE POWER DOOR THERMOSTAT PRESENT ON THE INTERLOCK TRANSFORMER SERVICE SWITCH AND FUSES Y Yes REPLACE TRANSFORMER IS THE INDUCER No IS THERE 24 VOLTS No IR BLOWER OPERATING ACROSS TH amp TR amp PROPER AT THE INTEGRATED CONTROL MODEL Yes 41 All installations and services must be performed by qualified service personnel Yes CHECK THE INTEGRATED CONTROL DIAGNOSTIC LED LAMP RESET BY INTERRUPTING POWER TO CONTROL FOR MORE THAN ONE SECOND IF LED STAYS ON CONTINUOUSLY REPLACE INTEGRATED CONTROL Yes IS THERE LINE VOLTAGE No ACROSS INDUCER POWER TERMINALS IND amp IND N
60. ified service personnel PVC tee Couple the drain tee assembly to the pre cut 2 inch diameter PVC pipe using the reinforced rubber hose and the two 2 band clamps supplied 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 If the vent piping is run through an unconditioned space it must be insulated with 1 inch thick foil faced fiberglass insulation or an equivalent product 3 Connecting The Combustion Air Intake Piping A CAUTION Outside combustion air must NOT be drawn from an area directly adjacent to a pool hot tub or spa Measures should be taken to prevent the entry of corrosive chemicals or vapors into the combustion air supply Such chemicals include but are not limited to chlorinated and or fluorinated hydrocarbons such as found in refrigerants aerosol propellants dry cleaning fluids degreasers and removers Other harmful compounds may come from bleaches air fresheners or mastics Vapors from such products can form reactive acid producing chemical species when burned in a gas flame Should acidic compounds form in the furnace they may significantly reduce the useful life of the furnace a For the models 1 50 75 and 1 50 7
61. ing the size and location of the furnace 1 local codes and or regulations take precedence over the instructions in this manual and should be followed accordingly In the absence of local codes installation must conform with these instructions regulations of the National Fire Protection Association provisions of National Electrical Code ANSI NFPA70 or latest edition and the National Fuel Gas Code ANSI Z223 1 or latest edition All installations and services must be performed by qualified service personnel 2 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 ASHRAE 3 MINIMUM CLEARANCES TO COMBUSTIBLE MATERIALS TABLE 1 FROM SIDES OF TOPOF FROMTHE SIDEOF MODEL NO FURNACE amp REAR FRONT PLENUM FLUE OR VENT PLENUM 1 50 LOIN 0N IN IN 1 75 1 100 The 1 50 75 100 and 125 furnaces may be installed on combustible flooring The furnace shall not be installed directly on carpeting tile or other combustible material other than wood flooring The CDB1 50 75 100 and 125 furnaces are to be installed on non combustible flooring only The non combustible floor bases model 50 DA base for CDB1 50 75 model no 100 CA base for the model no CDB1 100 and model no 125 CA base for CDB1 125 are available for the counterflow
62. internal stiffeners used in the filter must not be removed although they can be cut to size as needed NOTICE The filter areas in table 3 are the minimum areas required based on the CFM generated by the furnace for standard heating speeds only The following formula can be used to determine the minimum filter area required for cooling if the unit is equipped with cooling This value should then be compared to the value shown in table 3 and the larger of the two should then be used for determining the minimum filter area required for that installation 30 All installations and services must be performed by qualified service personnel FORMULA tons of cooling x 400 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 CHB1 100 furnace and 4 tons of cooling and a standard permanent filter 4 tons x 400 x 144 460 square inches for cooling 500 For heating a CHB1 100 needs 394 square inches of filter The filter system must be designed for the larger CFM requirement determined for cooling of 460 square inches A filter would have to be sized so that the area length X width was at least 460 sq in L WIRING 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
63. lified service personnel D General Requirements For Venting Models CHB1 CDB1 The CHB1 CDB1 furnace venting system must be installed by a qualified service person in accordance with local installation codes and these instructions In the absence of applicable local codes conform to the National Fuel Gas Code NFPA 54 ANSI Z223 1 2002 or latest edition thereof Installation shall at least conform to the following requirements 1 The exhaust vent combustion air intake terminations specified by Thermo Products in this manual shall be used All plastic pipe and pipefittings sourced to complete the exhaust vent and air intake systems shall be constructed of rigid PVC polyvinyl chloride thermoplastic All components shall have wall thickness equivalent to Schedule 40 series materials In addition all sourced PVC components shall be listed by a nationally recognized testing agency e g NSF UL etc as conforming to one 1 or more of the following design standards PVC Pipe Designation Design Standard Cellular Core ASTM F891 DWV Drain Waste Vent ASTM D2665 Schedule 40 ASTM D1785 The exhaust vent pipe and combustion air pipe shall be at least as large as the exhaust vent air intake pipe specified by Thermo Products Size reduction is never permissible The required exhaust vent air intake pipe sizes are nominal 2 inch diameter IPS Schedule 40 series PVC thermoplastic pipe for models 1 50
64. m water If the area becomes wet or damp at times the furnace should be raised above the floor using a concrete base bricks patio blocks etc NOTICE Ensure furnace is level after installation to ensure proper drainage and operation All installations and services must be performed by qualified service personnel 4 This furnace must be connected to a drain in accordance with these instructions If it is not practical to connect the unit to a drain a condensate pump must be used and can be ordered as an accessory part number 350225 If an acid neutralizer kit is required by local code or the customer it is available under part number 320095 B1 CDB1 HORIZONTAL APPLICATION The CDB1 50 75 100 and 125 furnaces may be installed in a horizontal position by placing the furnace on the left or right side as viewed from the front in the upright position For left or right horizontal applications of the CDB1 series units the rollout switch located on the burner box must be moved to the pre punched mounting holes on the side of the burner box Screws are provided in pre punched holes at the required limit location Remove these screws and use them to mount the limit to new location Utilize previously removed limit mounting screws to fill voided holes at previous limit location See Figure 1 For a right side horizontal application of the CDB1 series units the hose from the single tap pressure switch top switch is already connected correctly
65. movement The following chart shows the air handling capability based on a 0 1 SP loss in the supply duct system The total external static pressure should not exceed 2 inches water column 27 All installations and services must be performed by qualified service personnel DUCT SIZES FOR HOMES QUIET OFFICES OR SIMILAR INSTALLATIONS CFM DIA SQ RECTANGULAR DUCT DIMENSIONS INCHES 45 4 12 5 65 5 19 6 100 6 28 6x6 9x4 150 2 36 3x6 12x4 200 8 50 Ox6 14 4 250 9 63 8x8 2x6 18x4 500 9 63 0x8 4x6 20x4 400 0 78 2 8 6x6 25 4 500 2 125 Ox10 4x8 9x6 50x4 600 2 E 2x10 6x8 22x6 38x4 700 2 4 10 8x8 26x6 500 4 54 212 15x10 20x8 28x6 900 4 54 4x12 17x10 22x8 32x6 000 6 20 5 12 18 10 24x8 34x6 100 6 20 4x14 6x12 20x10 26x8 40x6 200 G 20 5x14 17x12 22x10 28x8 42x6 500 6 2 6 14 8x12 22x10 30x8 46x6 400 8 259 6x14 19x12 24x10 32x8 48x6 500 a 255 7X14 20 12 26x10 34x8 50x6 600 8 255 16x16 18x14 22x12 26x10 36x8 54x6 700 8 255 17x16 20x14 22x12 28x10 38x8 58x6 800 8 255 18x16 20x14 24x12 30x10 40x8 62x6 900 20 514 18x16 22x14 26x12 52x10 4458 64x6 20900 29 514 20 16 22x14 26 12 54x10 46x8 erOQ 20 514 18x18 20x16 24x16 28 12 36 10
66. nace will be when turning off power or removing the blower door which is equipped with door interlock switch which will reset the control Should this occur it will be necessary to restart the furnace and have the failure occur again DIAGNOSTIC FEATURES The 50A65 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 the case the entire control should be replaced as the control is not field repairable If the sensed failure is in the system external to the control the LED will flash in the following flash pause sequences to indicate failure status each flash will last approximately 0 25 seconds and each pause will last approximately 2 seconds 1 flash then pause System lockout 2 flashes then pause Pressure switch stuck closed 3 flashes then pause Pressure switch stuck open 4 flashes then pause Open limit switch or rollout switch 6 flashes then pause 115 Volt AC power reversed 7 flashes then pause Low flame sense signal 8 flashes then pause Check ignitor or improper grounding Continuous flashing Flame has been sensed when no pause no flame should be present no call for heat The LED will also flash once at power up A WARNING Power must be disconnected before servicing 40 All installations and services must be performed by qualif
67. ng Gas Furnaces Please read and comply with the contents of these labels al ron YOUR SAFETY READ BEFORE OPERATING WARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life A This appliance does not have a pilot It is equipped with a hot surface igniter that automatically lights the burner Do not try to light the burner by hand B BEFORE OPERATING smell all around the appliance area for gas Be sure to smell next to the base of unit because some gas is heavier than air and will settle on the floor or ground WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electric switch do not use any phone in your building 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 C Use only your hand to move the gas control switch Never use tools If the switch will not move by hand don t try to repair it call a qualified service technician Force or attempted repair may result in a fire or explosion D Do not use this appliance if any part has been underwater Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been underwater INSTRUCTIONS STO
68. ollowing 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 MODEL NO 195N rm SERIAL No 00020000 FAR CERTIFIE Wew abridirectory org DIRECT VENT FORCED AIR FURNACE FOR INDOOR INSTALLATION IN BUILDING CONSTRUCTED ON SITE NN CONFORMS TO ANS 221 47 CSA 2 3 2012 CENTRAL FURN CATEGORY IV TYPE FSP X 115V 7 5V 1PH pu MAX TUAL AMPS 20 0 BTU HR 125 000 116 000 FACTORY EQUIPPED WITH 442 ORIFICES FOR GAS SUITABLE FOR LP GAS WHEN EQUIPPED WITH 854 ORIFICES NORMAL MANIFOLO PRESS 3 5 IN WC NAT 10 0 IN WC LP MIN GAS SUPPLY PRESS FOR INPUT ADJUSTMENT 4 5 IN WC NAT MAX GAS SUPPLY PRESS14 0 IN WC ism AIR TEMPERATURE RISE 55 F TO 85 F MAX EXTERNAL STATIC PRESSURE 0 50 INCHES WC MAXIMUM OUTLET AIR TEMPERATURE 190 F CERTIFIED FOR CLOSET INSTALLATION AT MINIMUM CLEARANCES TO COMBUSTIBLE CONSTRUCTION AS SHOWN TOP FRONT BACK LS RS INCHES 1 6 0 FOR INSTALLATION ON NON COMBUSTIBLE FLOORS ONLY FOR INSTALLATION ON COMBUSTIBLE FLOORING ONLY WHEN INSTALLED ON SPECIAL BASE PART NO 125CA BASE THIS FURNACE REQUIRES A SPECIAL VENTING SYSTEM REFER TO INSTALLATION INSTRUCTIONS NO MG 1006 FOR PARTS LIST AND METHOD OF INSTALLATION MAX VENT LENGTH 35 FEET MIN VENT LENGTH 8 FEET MIN WALL THICKNESS THROUGH WHICH THE VENT AIA
69. r for furnace models CHB1 CDB1 50 and CHB1 CDB1 75 or e 3 1 2 inch diameter for the furnace models CHB1 1 100 and CHBI CDB1 125 14 All installations and services must be performed by qualified service personnel 5 PVC COUPLINGS 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 34 inch connection allowance at both ends of the pipe For 3 inch diameter PVC pipe leave a 3 inch allowance for end connections Using PVC pipe cement glue a PVC elbow or coupling fitting to one 1 end of each pipe Before inserting the pipe through the wall mark the other end of the pipe so the elbow orientation can be determined Also if a protective shield refer to Section E passage 1 of this manual will be used on the exterior surface of the wall it should be installed at this time From the inside glue a coupling fitting to each pipe using PVC pipe cement while being careful to maintain the proper orientation of the termination elbow s Complete the assembly of the outlet and inlet as shown in Figure 5 making sure that the spacing between the inlet and outlet complies with that noted in Figure 3 PREGLUED SECTION OF PVC PIPE W COUPLING NOTE PIPE LENGTH APPROX THICKNESS OF WALL PREGLUED SECTION OF PVC PIPE W ELBOW NOTE PVC PIPE LENGTH APPROX THICKNESS OF WALL E 0 PVC ELBOW E 7 EW COUPLING
70. r outlet flange Drive one 1 48 x 3 4 inch sheet metal screw with black protective coating supplied with furnace through the elbow and into the outlet flange of the inducer to secure the elbow in place Figure 9 Typical Internal Vent Piping Arrangement for the Furnace Model Series CHBI Figure 10 Typical Internal Vent Piping Arrangement for the Furnace Model Series CDB1 100 125 Figure 11 Typical Internal Vent Piping Arrangement for the Furnace Model Series CDB1 100 125 in RH Horizontal Applications S f VENT TEE ASSEMPL rea NI T ASSEMBL SIDE OF FURNACE SERIE INDUCEI HOSE VENT TEE ASSEMBL 7 i LAMI TRAF ASSEMBL be SIDE OF FURNACE DB SERIE DIA REDUCER e SIDE OF FURNACE DB ERIES ONL FIELD CUT PVC LAMI _ E INDUCER lt gt FIELI T F ENT TEE ASSEMBL 7 IDE a FURNACE DB SERIES IN RIGHT HAND HORIZONTAL APPLICATION C Using PVC cement glue the pre cut 2 inch diameter thermoplastic pipe from step a above to the 2 inch diameter PVC elbow for the model series CDB1 in horizontal applications the 2 inch diameter 20 All installations and services must be performed by qual
71. rap Assembly Mounted On the Model Series CDB1 In a Downflow Application CAPPED DRAIN FACTORY SHIPPED H ipp j j DRAIN HOSE LOCATION COLLECTOR t17 BOX k 4 2 E AR DRAIN LOCATION u Fee og BOTTOM OF COLLECTOR PVC BOX ASSEMBLY m 2 INCHES MINI GROMMET FOR TS DORUM OR DRAIN HOSE CONDENSATE s ene p12 1 4 LARGE DRAIN HOSE FROM CONDENSING COIL COVER HOSE CUT TO LENGTH BRACKET OS CENE CPVC DRAIN MAY BE MOVED HORIZONALLY ALONG SIDE TRAP ASSEMBLY CASING OR MOUNTED BELOW UNIT AS LONG AS 2 INCH MIN TRAP CLEARANCE IS MAINTAINED Figure 16 Condensate Trap Assembly Mounted On The Model Series CDB1 In RH Side Horizontal Application 2 Determine from which side of the furnace the condensate disposal line will be run 23 All installations and services must be performed by qualified service personnel NOTICE On the model series CDB1 the condensate disposal line must be on the same side as the flue outlet or in the case of a horizontal application the bottom of unit Drive two 2 8 x 3 4 inch sheet metal screws with black protective coating supplied with furnace to attach the condensate trap to the furnace casing Pilot holes are provided on both sides of th
72. rd or any type of chimney AWARNING These furnaces may not be common vented with any other appliance A CAUTION 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 Avoid locating the terminals in areas where standing water or condensate drippage may be a problem A WARNING This CHBI CDBI furnace has been designed to be installed as a direct vent system The failure to install the vent air intake system as specified in these instructions will void the heat exchanger warranty and may result in property damage personal injury or loss of life A CAUTION Outside combustion air must not come from an area that is directly adjacent to a pool hot tub or spa Measures should be taken to prevent the entry of corrosive chemicals or vapors to the combustion and ventilation air supply Such chemicals include but are not limited to chlorinated and or fluorinated hydrocarbons such as found in refrigerants aerosol propellants dry cleaning fluids degreasers and removers Other harmful compounds may come from bleaches air fresheners or mastics Vapors from such products can form acid compounds when burned in a gas flame Should acid compounds form in your furnace it may reduce the life of the furnace A WARNING Because of the potential of odorant fade a gas leak may
73. rmed turn off all electric power to the appliance 3 To turn off gas control valve remove the burner compartment cover Move the gas control switch to the OFF position 5 Replace the burner compartment cover a lt a n x gt 2 m o z o CAUTION MOVING PARTS 390540 CAN CAUSE SEVERE PERSONAL INJURY SHUT OFF FURNACE BEFORE FILTER MAINTENANCE WHEN IT BECOMES NECESSARY TO REPLACE OR WASH FILTER REMOVE THE DIRTY FILTER FROM THE RACKS PROVIDED AND WASH OR REPLACE WITH IDENTICAL NEW FILTERS REMOVING THIS PANEL 390231 i All installations and services must be performed by qualified service personnel The following safety information should be read understood and followed by the installer 1 Use only with type of gas approved for this furnace Refer to furnace rating plate 2 Connect this furnace to an approved vent system only 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 Condensing Gas Furnace Manual Please read and comply with the statements below AWARNING This furnace is not to be used for temporary heating of buildings or structures under construction ANCAUTION These high efficiency condensing furnaces are not certified for and shall not be vented into a standa
74. s When Sidewall Venting 3 Exhaust Vent Terminal Location Clearance Requirements a The vent terminal shall be located at least 3 feet above any forced air inlet located within 10 feet Refer to Figure 4 for a depiction of the minimum required clearances between vent terminations and building features according to the National Fuel Gas Code NFGC b The vent terminal shall be at least 12 inches below 12 inches horizontally from or 12 inches above any door window or gravity air inlet into a building The bottom of the vent terminal shall be located at least 12 inches above grade c The vent terminal shall not be located e over public walkways or over an area where wetting of surfaces by condensate or water vapor could create a nuisance or hazard e 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 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 12 All installations and services must be performed by qualified service personnel E JJ gt
75. s listed in Table 2 When counting pipe elbows all elbows used in the exhaust vent or combustion air All installations and services must be performed by qualified service personnel intake systems must be considered This includes all elbows or equivalent pipefittings used inside the furnace jacket in addition to those used to construct the termination Furthermore a credit of 5 feet of straight pipe may be taken for each elbow up to maximum of three 3 elbows which is dropped from the maximum permissible number for each system Table 2 Maximum Permissible Exhaust Vent and Combustion Air Intake Lengths When Using the Maximum Quantity of Elbows Thermoplastic Pipe Vent Size 2 in Diameter IPS 3 in Diameter IPS Nominal Exhaustor Maximum i Exhaustor Maximum Furnace Model Intake Qty of Intake Qty of Straight Exhaust Straight Exhaust Pipe Elbows Pipe Elbows Length ft 5 mm Itl lk 11 12 13 Superscripts The drain tee supplied with CHB1 CDB1 furnace model series is considered equivalent to one 1 90 elbow Two 2 45 elbows can be substituted for one 1 90 elbow Care should be taken to design the shortest possible intake and exhaust systems Each system should contain as few elbows as possible to insure the satisfactory operation of the furnace However system length should never be less than 8 ft of pipe with two 2 90 deg elbows For best overall operation of the combustion sy
76. stem we recommend the actual equivalent lengths for both the constructed intake and the exhaust systems have approximately the same value Use a saw designed to cut thermoplastic pipe All cuts should be made at right angles to the pipe wall Smooth jagged edges and remove all burrs and strings All pipe joints must utilize standard PVC Schedule 40 series DWV type elbows couplings and fittings Clean all pipe surfaces at connections using a fine abrasive material or approved PVC cleaner primer Secure 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 Piping joints inside the furnace vestibule should be sealed with silicone caulk rather than pipe cement to allow for disassembly and removal of piping if necessary during maintenance NOTICE DO NOT use silicone caulk to seal the pipe sleeve or coupling to the metal air intake collar on the burner box Securing the sleeve or coupling to the collar using a screw is sufficient Vent connections shall be checked for leakage with the furnace induced draft blower running and with the vent termination blocked Use a mild soap and water solution to check for leaks Vent pipe passing through an unheated space shall be insulated with 1 inch thick foil faced fiberglass insulation or equivalent to prevent freezing of condensate within the pipe No clearance is required from the outer surface of the
77. such that it cannot be easily moved NOTICE If an air conditioning condensate drain line is combined with the furnace condensate drain line the air conditioning evaporator coil must have a separate trap installed ahead of the connection joint 24 All installations and services must be performed by qualified service personnel 6 Acondensate pump may be required when a suitable drain is not present the drain is above the trap outlet level on the furnace or drain line cannot be sloped downward its full length to the drain If gravity drainage of the condensate from the furnace to a drain is impractical for any of these reasons a condensate pump part 350225 is available from Thermo Products Follow the pump manufacturer s instructions for proper installation 7 CAUTION Continual exposure to condensate may injure plants and damage certain building materials including many metals wood stone and concrete Flue gas condensate is slightly acidic with a pH of about 3 5 A pH level of 7 0 is considered neutral Carbonated cola drinks with a pH of 3 1 are actually slightly more acidic than condensate If local codes require an acid neutralizing kit a kit is available from Thermo Products under part no 320095 Follow the instructions enclosed with the neutralizing kit for proper installation 8 The condensate piping in the furnace and the drain system should be flushed out at the start of every heating season T
78. the pressure by turning the screw counterclockwise or increase it by turning the screw clockwise ADJUSTMENTS TO THE LISTED PRESSURE MUST NOT EXCEED 0 3 w c A 0 3 w c Adjustment will increase or decrease the input approximately 4 0 Replace screw cap when adjustment is complete The correct input can be assumed if the furnace manifold pressure is the same as that shown on the information label if a gas meter is not available for natural gas or the unit is installed on liquefied petroleum gases which are not metered Shut off the gas supply to the furnace Remove the pressure gage and re install the pipe plug using a thread compound resistant to the action of Liquefied Petroleum gases If the rated input cannot be obtained with the present orifice at the correct pressure your local gas supplier will assist in sizing the proper orifice Our Engineering Department will gladly assist in sizing the orifice if you provide them with the heating value in BTU per cubic foot and the specific gravity of the gas D BURNER ADJUSTMENT This unit is designed to not require any burner adjustment The flames should be checked by looking through the sight glass located on the burner box Burner flames should be clear blue and almost transparent in color See Figure 23 NOTE It is not unusual to have orangish flames visible in the tube for Propane gas 37 All installations and services must be performed by qualified service personnel SOLID BLUE FLA
79. thermoplastic piping to combustible materials for fire hazard prevention Thermo Products does not require screens be installed in the exhaust vent and air intake piping However optional stainless steel screens are available from Thermo Products should the homeowner request them 10 All installations and services must be performed by qualified service personnel NOTICE The furnace model series CHB1 CDB1 may be vented either through the sidewall or the roof For sidewall instructions continue to the following section For roof venting refer to Section III G of this manual E Direct Venting Through a Sidewall 1 Vent and combustion air pipes may pass through a maximum wall thickness of 18 inches The minimum wall thickness is 2 inches Referring to Figure 2 the maximum distance from the outer wall to the center of the elbow is 12 inches VENT OUTLET COMBUSTION AIR INLET E 12 MAX 4 MIN P 12 MAX VENT TERMINATION T MN COUPLING COUPLING UNLESS ELBOW UNLESS ELBOW 15 ELBOW 15 FLUSH FLUSH COMBUSTION AIR INLET TERMINATION MN 4 4 ELBOW COUPLING COUPLING TERMINATION TERMINATION POINTING DOWN INSIDE OUTSIDE INSIDE OUTSIDE STRUCTURE STRUCTURE STRUCTURE STRUCTURE 18 MAX 18 MAX 2 MIN 2 MI Figure 2 Proper Direct Vent Terminations RH amp LH views and Vent Termination Only
80. tion to following any local code requirements when possible utilize the guidelines below in locating the vent terminal to help insure trouble free operation of a sidewall vented furnace e Avoid locating the vent terminal on a wall facing prevailing winds and wide open areas When impractical choose a location that protects the vent from strong winds such as behind a fence or hedge e geographical areas with considerable snowfall it is advisable to locate the vent terminal much higher than the minimum 12 inches above ground to prevent blockage by snow accumulation or drifting e vent and combustion air terminations shall be checked periodically at least at the start of each heating season for restriction or blockage from foreign material in the exhaust vent or in the air intake piping Clean the air intake and vent terminations when necessary Single Pipe Sidewall Venting Option F NOTICE When possible we recommend all furnace of the model series CHB1 CDB1 be installed to utilize outside combustion air The use of outside combustion air usually results in the most energy efficient nuisance free and long lived operation of the furnace NOTICE Heat exchanger failure accelerated by contaminated combustion air will void the furnace heat exchanger limited lifetime warranty This furnace may be horizontally i e sidewall vented using an exhaust vent pipe alone without drawing in outside combustion air When singl
81. ubject to change without notice All installations and services must be performed by qualified service personnel INSTALLATION PARTS PACKAGES 1 50 75 PARTS PACKAGE 4S0084405 4406 DESCRIPTION PART QUANTITY 2 3 8 ID radiator hose 410017 1 Thermostat lead bushing 350750 1 PVC trap assembly 320816 1 8 x coated TEK screws for 300283 4 mounting trap amp inlet outlet collars 11 16 OD x 1 2 ID vinyl tubing 410060 24 2 x 4 electrical J box 350024 1 2 x 4 electrical J box cover 350020 1 8 x screws for 300208 2 mounting 2 x 4 J box 10 32 x 1 2 green ground screw 300109 1 10 32 hex nut 300110 1 3 16 dia star washer 300270 1 Grounding instructions MG 966 1 Wire nut 300132 2 3 stainless steel hose clamp 300276 2 J box wire bushing 350016 1 Drain hose grommet 350446 1 Spring clamp 11 16 300299 3 Installation notice MG 987 1 PVC tee assembly 2 dia 320818 1 CPVC XPVC adapter 320833 1 Gas Conversion Kit AOPS7677 7678 1 INSTALLATION PARTS PACKAGES CHB1 100 125 PARTS PACKAGE 4S0084407 4408 DESCRIPTION PART QUANTITY 2 3 8 ID radiator hose 410017 1 Thermostat lead bushing 350750 1 trap assembly 320816 1 8 x 34 coated screws for mounting trap amp inlet outlet collars 309253 4 11 16 OD x 1 2 ID vinyl tubing 410060 24 2 x 4 electrical J box 350024 1 2
82. urage the user to read the label reproductions and all warnings and instructions outlined on the front cover and in sections I II and III of this manual and in the Users Information Manual Recommend that the user have a qualified heating contractor inspect the furnace at the start of each heating season Inform the user of the frequency of inspection required for each item in Section III of the Users Manual HEAT EXCHANGER ASS Y PRESSURE SWITCH BURNER BOX ASS Y BURNER DRAWER ASS Y BURNER BOX COVER 4 ASSY N INDUCER INDUCER GASKET Figure 23 39 All installations and services must be performed by qualified service personnel VI TROUBLESHOOTING NOTICE BEFORE TROUBLESHOOTING FAMILIARIZE YOURSELF WITH THE START UP AND CHECKOUT PROCEDURE ALL INSTALLATION AND SERVICES MUST BE PERFORMED BY QUALIFIED HEATING CONTRACTORS To assist you in troubleshooting this furnace it is equipped with an integrated ignition control with diagnostics These diagnostics evaluate what control system has experienced a failure and will activate a flashing light on the control in different sequences to help pinpoint the failure which has occurred IMPORTANT For your convenience Thermo Products has installed a sight glass in the blower door of this furnace The number of flashes in groups should be observed through this sight glass and recorded before turning off power to the furnace Otherwise power to the fur
83. ustable Those that are pre set will not have an adjustment scale and are generally marked accordingly 4 BLOWER MOTOR SPEED WIRING CAPACITOR OPTIONAL BLOWER DELAY SWITCHES COMMON WHITE MED HIGH SPEED YELLOW MED LOW SPEED BLUE LOW SPEED RED HIGH SPEED BLACK NOTE CHB1 CDB1 50 100 125 USE LOW SPEED FOR HEATING TRANSFORMER CENT CHB1 75 USE MED HIGH SPEED FOR PARK TERMINALS HEATING FOR UNUSED TERMINAL HEATING SPEED SPEEDS CDB1 75 USE MED LOW SPEED FOR HEATING CHB1 CDB1 50 HAS A 3 SPEED MOTOR Figure 21 A WARNING TURN OFF THE ELECTRICAL POWER to the furnace before attempting to change blower speed wiring A 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 The unused speeds should then be reconnected to the module in the park positions B The optional blower delay switches on the W R integrated control figure 21 are used to determine the length of the heat delay to fan on and delay to fan off periods The following tables show the time periods that will result from the various switch positions 32 All installations and services must be performed by qualified service personnel BLOWER DELA Y SETTINGS To delay fan
84. w o Outside Combustion Air Intake RH view 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 The protective shield shall be installed around the vent pipe on the outside wall 2 The exhaust vent termination elbow shall be installed in accordance with these instructions and any applicable local codes Refer to Figures 2 and 3 for typical examples of proper terminations a exhaust vent termination must be installed in the same atmospheric pressure zone i e on the same wall as the air intake termination b The bottom edge of the vent termination elbow must be installed at least 12 inches above the outlet of intake termination elbow c horizontal distance between the inlet and exhaust terminations should be minimized when possible and should never exceed 24 inches d The vent and intake systems should utilize the same numbers of elbows and approximately the same length of straight pipe to reach the outside termination 11 All installations and services must be performed by qualified service personnel MEDIUM NOTE THE HORIZONTAL DISTANCE BETWEEN THE INLET AND THE OUTLET SHOULD BE KEPT TO A MINIMUM 10 PREVENT RECIRCULATION RADIUS a HORIZONTAL SIDEWALL VENTING TERMINATION Figure 3 Typical Relative Locations of Direct Vent Termination
85. with the National Electrical Code ANSI NFPA 70 or latest edition 1 The following items are guidelines to complete the wiring portion of the installations a separate power supply circuit with over current protection and a disconnect switch must be provided See furnace specifications or furnace rating label for maximum fuse size b All CHB1 and CDBI Series furnaces are supplied with a fuse disconnect switch box to be mounted on the outside surface of the right or left side casing so a fuse disconnect can be mounted on the furnace Make the 115 volt supply connection in this junction box A green screw and a strain relief are provided in order to connect the power supply ground wire and provide strain relief for the 115 volt power leads from the furnace in the fuse disconnect box disconnect switch can be field mounted on the 2x4 box provided If not the disconnect switch must be located reasonably close to and within sight of the furnace NOTICE The hot surface igniter and operation of this furnace depends on correct polarity The hot leg of the supply circuit must be connected to the black line lead and the common leg to the white line lead in the field mounted junction box The hot leg must pass through the disconnect switch in all cases to prevent the hazard of electrical shock when servicing IMPORTANT The furnace must be grounded in accordance with local codes and with the National Electrical Code ANSI NFPA NO 70 or latest e
86. y disconnection of the air intake system should the burner assembly require removal at a later date refer to Figure 12 NOTICE When applying silicone sealants ensure that no excess sealant is pushed into the inside opening of the pipe This may cause flow restriction within the piping If possible always apply the sealant to the male component of the piping joint 21 All installations and services must be performed by qualified service personnel SEAL THESE JOINTS W SILICONE TYPE CAULKING COMPOUND PVC ELBOW 50 75 2 PVC ELBOW OR TE hone ad PVC ELBOW CHB CDB 100 125 2 IN FOR CHB CDB50 75 a 2 IN OR 3 IN SLEEVE AS REQUIRED 3 IN FOR CHB CDB100 125 4 2 IN PVC COUPLING REQ D ON 50 75 3 IN SLEEVE ATTACHES DIRECTLY TO INLET COLLAR O 8 x 3 4 BLACK COATED SHEET METAL SCREW SIDE OF DO NOT SILICONE OR SEAL RURNAGE BURNER BOX 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 After trial fitting the entire combustion air intake system use a PVC cement to glue all connections in place except the length of pipe between the combustion air fitting on the burner box and the first fitting e Ifthe combustion air piping is installed in a warm humid place such as a laundry room or above
87. ystem OPERATING INSTRUCTIONS AWARNING Turn off power to furnace before it is placed into service The gas piping system must have been leak tested by a qualified heating contractor See Section J of these instructions on the installation of gas piping AWARNING it may be necessary to purge the air out of the gas line for initial start up of the furnace after installation This should be done by a qualified heating contractor If excessive gas escapes when purging the gas supply at the union allow the area to ventilate for at least 15 minutes before attempting to start the furnace LP gas is especially dangerous because the specific gravity of LP gas allows it to accumulate at floor level at a dangerous concentration For remainder of operating instructions reference Users Information Manual AWARNING Heat exchanger oil will burn off on initial firing creating an unpleasant odor To prevent this odor from occurring more than once it is suggested that 1 A window s be opened 2 The thermostat be set at highest setting 3 The furnace remain running at conditions 1 amp 2 for 30 minutes or until odor has dissipated 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 The information plate insi

Thermo Products CBD1-100N Furnace User Manual

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