TWO STAGE CONDENSING GAS FURNACE INSTALLATION AND OPERATION MANUAL MODELS: FOR USE WITH NATURAL GAS CHX3-75N CHX3-100N CHX3-125N OR LP GAS (PROPANE) CDX3-75N CDX3-100N CDX3-125N : IF YOU DO NOT FOLLOW THE SAFETY PRECAUTIONS BELOW AND IN THIS MANUAL, A FIRE OR EXPLOSION MAY RESULT CAUSING PROPERTY DAMAGE, PERSONAL INJURY, OR LOSS OF LIFE. DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS AND LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE.
All installations and services must be performed by qualified service personnel. I. SAFETY INFORMATION This and the following page contain reproductions of the various warning and instruction labels placed on the Thermo Pride Two Stage Condensing Gas Furnaces. Please read and comply with the contents of these labels.
All installations and services must be performed by qualified service personnel. This and the previous page contain reproductions of the various warning and instruction labels placed on the Thermo Pride Two Stage Condensing Gas Furnaces. Please read and comply with the contents of these labels. The following safety information should be read, understood, and followed by the installer.
All installations and services must be performed by qualified service personnel. 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. outdoors. Refer to Section III, D thru H, of this manual. Combustion products must be carried The following pages contain various warnings and cautions found throughout the Thermo Pride Highboy and Dual Poise Two Stage Condensing Gas Furnace Manual.
All installations and services must be performed by qualified service personnel. : The CHX3/CDX3 furnace models are sealed combustion design, which does not require an air shutter adjustment (air shutters are not used) for proper flame characteristics. Burner box access cover must always be secured with all screws in place and tightened before operating furnace. : Personal injury or property damage could result from repair or service of this furnace by anyone other than a qualified heating contractor.
All installations and services must be performed by qualified service personnel. INDEX SECTION I. II. III. IV. V. VI. BEGINNING PAGE SAFETY INFORMATION FURNACE SPECIFICATIONS GENERAL INSTALLATION A. CODES AND CLEARANCES B. FURNACE LOCATION B1.CDX3 HORIZONTAL APPLICATION C. REPLACING EXISTING FURNACE FROM A COMMON VENT D. GENERAL REQUIREMENTS FOR VENTING CHX3/CDX3 E. SIDEWALL VENTING E1. SINGLE PIPE (SIDEWALL) VENTING OPTION F. INSTALLATION OF OUTSIDE VENT/AIR INTAKE TERMS. G.
All installations and services must be performed by qualified service personnel. II. FURNACE SPECIFICATIONS CHX3 SERIES MODEL NO.
All installations and services must be performed by qualified service personnel. CDX3 SERIES MODEL NO.
All installations and services must be performed by qualified service personnel. INSTALLATION PARTS PACKAGES – CHX3-75 PARTS PACKAGE #S00S4413 DESCRIPTION 2-3/8” ID radiator hose Thermostat lead bushing PVC trap assembly #8 x ¾ coated TEK screws for mounting trap & inlet/outlet collars 11/16” OD x 1/2” ID vinyl tubing 2 x 4 electrical J-box 2 x 4 electrical J-box cover #8 x ½ TEK screws for mounting 2 x 4 J-box #10-32 x ½ green ground screw #10-32 hex nut 3/16” dia.
All installations and services must be performed by qualified service personnel. PVC tee assembly, 2 x 3” dia.
All installations and services must be performed by qualified service personnel. Grounding instructions Wire nut 3” stainless steel hose clamp J-box wire bushing Drain hose grommet Spring clamp, 11/16” Installation notice PVC tee assembly, 2 x 3” dia. PVC tee assembly, 2” dia. Pipe 2” dia.
All installations and services must be performed by qualified service personnel. III. GENERAL INSTALLATION These Category Type IV furnaces are shipped completely assembled and wired (internally). See the Dealer Receiving and Freight Claim Procedure Section of the price guide for parts shortage or damage. The furnace and duct system must be adjusted to obtain a temperature rise of 55°F to 85°F through the furnace after installation. (See rating label located on side panel inside the furnace vestibule).
All installations and services must be performed by qualified service personnel. These furnaces may be installed in an alcove or in a closet if the minimum clearances to combustible construction (listed previously) are met. The CDX3 series furnaces may be installed in an attic or crawl space. Refer to section III, B1 of this installation manual. The minimum clearances are listed for fire protection.
All installations and services must be performed by qualified service personnel. NOTE: The hose, when moved, must be shortened (cut) to ensure that no excess hose exists to cause a sag, loop, or "water trap". For a right side horizontal application of the CDX3 series units, the auxiliary limit switch located on the right side of the house air blower must be moved to the bracket on the opposite (left) side of the blower (See Figure 1).
All installations and services must be performed by qualified service personnel. The horizontal furnace installation should be on a service platform large enough to allow for proper clearances on all sides and service access to the front of the furnace (See Table 1). If the furnace is suspended, it must be supported at both ends and in the middle with clearance allowed for removal of both access doors.
All installations and services must be performed by qualified service personnel. 5. All horizontal runs of exhaust vent pipe shall slope upward at least ¼ inch per foot from the outlet of the furnace (for model CHX3), or the outlet of the drain tee (for the model CDX3), to the vent termination, beyond the outside wall. This slope will permit proper drainage of the condensate.
All installations and services must be performed by qualified service personnel. all pipe joints using suitable permanent PVC pipe solvent cement. Joints are NOT to be made by simply gluing raw edges of butted together vent pipe. The piping joints inside the furnace vestibule should be sealed with a silicone caulk, rather than pipe cement, to allow for disassembly and removal of piping, if necessary, during maintenance.
All installations and services must be performed by qualified service personnel. NOTICE: If exterior sidewall building materials are subject to degradation from contact with flue gases or moisture, a minimum 24-inch diameter shield shall be fabricated from stainless steel or UV-resistant plastic sheet. The protective shield shall be installed around the vent pipe on the outside wall. 2.
All installations and services must be performed by qualified service personnel. • • near soffit vents, crawl space vents, or other areas where condensate or water vapor could create a nuisance, hazard, or cause property damage, and where wetting of components by condensate, or water vapor, could be detrimental to the operation of pressure regulators, relief valves, or any other equipment. d.
All installations and services must be performed by qualified service personnel.
All installations and services must be performed by qualified service personnel. : Bushes, shrubs, or any vegetation that may restrict the flow of flue products must be kept away from vent and air intake terminations. Terminations must also be kept clear of any leaves, weeds, combustible materials, snow, and ice build-up. Avoid locating the vent terminal over areas where dripping of condensate, or small pools of acidic condensate, could create a problem.
All installations and services must be performed by qualified service personnel. 2. Measure and cut two (2), 2-inch diameter thermoplastic pipes 1-1/2 inches longer than the depth of the wall. Cutting the pipe longer leaves a ¾ inch connection allowance at both ends of the pipe. (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.
All installations and services must be performed by qualified service personnel. Install these optional kits according to the instructions provided with each kit. The location and clearance requirements are identical to those of the standard vent terminations described in this manual. AOPS7488 / AOPS7489 CONENTRIC VENT KIT 370191 SIDE WALL VENT KIT VERTICAL HORIZONTAL Figure 6: Optional Direct Vent Kits for the CHX3 / CDX3 Model Series of Furnaces G.
All installations and services must be performed by qualified service personnel. H. Exhaust / Intake Piping And Condensate Drain Connections At Furnace 1. Figures 6B, 7, and 8 follow depicting typical exhaust vent and air intake connections for the furnace model series CHX3 and the CDX3, respectively, as well as a list of required parts to correctly install each system.
All installations and services must be performed by qualified service personnel.
All installations and services must be performed by qualified service personnel. Figure 8: Required Exhaust Vent and Air Intake Piping for CDX3 Furnace in Horizontal Applications. 2. Connecting The Exhaust Vent To The Inducer a. Slip the end of the 2-inch diameter PVC elbow (for the model CDX3 in horizontal applications, the 2-inch diameter PVC tee assembly) over the outlet of the inducer blower assembly.
All installations and services must be performed by qualified service personnel. leading away from the furnace must be composed of 3-inch diameter PVC pipe and pipe fittings only. Refer to item E in Figure 8. b. After preparation of the internal 2-inch diameter PVC pipe sections, put a thin bead of a silicone rubber type sealant around the outlet flange of the inducer.
All installations and services must be performed by qualified service personnel. NOTICE: All PVC thermoplastic pipe must be supported beginning directly over the exhaust vent tee assembly, then every 4-feet thereafter, and at every joint. Trial fit the entire exhaust vent and air intake piping systems, making sure the slope and length of the piping are correct, before permanently assembling the pipe components.
All installations and services must be performed by qualified service personnel. DO NOT! SILICONE OR SEAL THIS CONNECTION IN ANYWAY. MUST BE LOOSE FIT WITH LEAKAGE BETWEEN PVC AND METAL COLLAR. Figure 12: Typical Internal Air Intake Piping Arrangement for All Furnace Models d. 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.
All installations and services must be performed by qualified service personnel. Figure 15. TRAP ASSEMBLY MOUNTED ON CDX3 Figure 16.
All installations and services must be performed by qualified service personnel. 2. Determine on which side of furnace the condensate disposal line is to be run (NOTICE: On CHX3/CDX3’s this must be the same side as the flue outlet or bottom of unit). Attach the condensate trap to the furnace casing using the #8x3/4” sheet metal screws provided in the parts package. Pilot holes are provided on both sides of the casing for mounting.
All installations and services must be performed by qualified service personnel. Remove the 11/16” diameter clear tubing from the coil drain nipple and run tap water into the open end of the tubing. This should keep the drain system clean. Replace the tubing by pushing it firmly onto the nipple. Make sure the spring clamp is returned to the original position to prevent leaks. If any of the electrical controls are exposed to water, dry with a soft cloth and wait 24 hours before operating the furnace.
All installations and services must be performed by qualified service personnel. : Care must be taken not to wet electronic components during leak test. Wetting the primary ignition module may damage its circuitry and cause a hazardous situation. Dry moisture from all leads and terminals if wetting occurs. Wait at least 24 hours for the circuit to fully dry before energizing the burner circuit. J1.
All installations and services must be performed by qualified service personnel. Figure 18A All trunk lines, take-offs, registers and grill-free areas must be figured when determining the air handling capacity of a duct system. One can obtain the necessary duct system size by utilizing the chart below. (For example, see Figure 18A.) Use a supplier’s catalog for proper sizing of outlet and return air registers to insure that the register will meet the CFM requirements of the run to which it is connected.
All installations and services must be performed by qualified service personnel. DUCT SIZES FOR HOMES, QUIET OFFICES, OR SIMILAR INSTALLATIONS TABLE 2A Each of the system components (trunk lines, take offs, runs and register and grill-free areas) must be properly sized and matched together to ensure the necessary air handling capacity of a duct system. A 12" 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.
All installations and services must be performed by qualified service personnel. K. FILTERS 1. CHX3 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 CHX3 will require air delivery above 1800 CFM, it is advisable that both sides, a combination of 1 side and the bottom, or the bottom only be used for return air.
All installations and services must be performed by qualified service personnel. 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 CHX3 or CDX3 furnaces. MINIMUM FILTER AREA REQUIRED (LENGTH X WIDTH, SQ. IN.
All installations and services must be performed by qualified service personnel. FORMULA: (tons of cooling) x (400 CFM per ton) (144 square inches per foot) (max. air velocity of filter from table 3 for the filter type) = filter area sq.inches = length x width of filter in inches EXAMPLE: If you had a CHX3-100 furnace and 4 tons of cooling and a standard permanent filter. 4 tons x 400 CFM x 144 = 460 square inches for cooling 500 For heating a CHX3-100 needs 394 square inches of filter.
All installations and services must be performed by qualified service personnel. 3. THERMOSTAT CONNECTIONS AND ANTICIPATOR SETTING NOTICE: For two-stage thermostat wire connectors see wire diagram page 59. For single-stage thermostat with two-stage operation connect W from thermostat to W1 on control. W2 on control board is not used. Thermostat dip switches S7-1 & S7-2 on control board (Fig. 21) will need to set at the desired setting per (Table 4B).
All installations and services must be performed by qualified service personnel. 4. BLOWER AND CONTROL PANEL WIRING Figure 21 : TURN OFF THE ELECTRICAL POWER to the furnace before attempting to disconnect blower wiring.
All installations and services must be performed by qualified service personnel. Modifications to ECM blower speed settings are done using the S3 and S4 dip switch controls. Thermo Pride two-stage furnaces are factory shipped at the CFM settings listed below in Table 4C.
All installations and services must be performed by qualified service personnel. IV. STARTING THE UNIT A.
All installations and services must be performed by qualified service personnel. AFTER IGNITOR WARM-UP, THE 36J54 GAS VALVE IS ENERGIZED TO OPEN ON LOW FIRE SETTING FLAME MUST BE DETECTED WITHIN 4 SECONDS IF FLAME IS DETECTED, THE DELAY-TO-FAN-ON TIME BEGINS (45 SECONDS) IF NOT IF FLAME IS NOT DETECTED, THE GAS VALVE IS DE-ENERGIZED, THE IGNITOR IS TURNED OFF AND THE 50V51-843 CONTROL GOES INTO "RETRY" SEQUENCE THE RETRY SEQUENCE PROVIDES A 60 SECOND WAIT BEFORE IGNITION RETRY.
All installations and services must be performed by qualified service personnel. IF SYSTEM IS IN LOCKOUT, THE MODULE WILL RESET ITSELF AFTER 60 MINUTES 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.
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. Check all wiring for loose connections and proper hook up. 2. Leak test gas piping connections. 3.
All installations and services must be performed by qualified service personnel. C. Measuring And Adjusting Heat Input Rate DO NOT exceed input rating stamped on furnace nameplate or manufacturer's recommended burner manifold pressure for orifice size used. Observe the following precautions when measuring: A. Burner manifold pressure with a pressure gauge. 1. Close the gas valve (turn the gas control knob to the OFF position) BEFORE removing the: a.
All installations and services must be performed by qualified service personnel. NOTICE: A U-tube manometer, measuring pressure in inches of water column, is recommended for all gas pressure measurements. However, an aneroid pressure gauge, in good working condition, capable of reading pressure changes of 0.05 in. W.G., or less, that was recently calibrated (within the last year), is a satisfactory alternate. These two (2) devices will be considered as equivalent and interchangeable.
All installations and services must be performed by qualified service personnel. 5. To obtain an accurate manifold gas pressure reading, the main burner must be cycled on and off several times to stabilize the gas control valve pressure regulator diaphragm. 6. Allow the burner to operate for at least 3 minutes before taking gas pressure readings. 7. Using a pressure gauge, measure the burner manifold gas pressure. 8. If checking the input rate by measuring burner manifold pressure, skip to step 12.
All installations and services must be performed by qualified service personnel. Figure 23: b. Turn the inner plastic adjustment screw clockwise to increase, or counterclockwise to decrease, the gas pressure (and gas flow) to the main burner. c. Replace the regulator cover screw and tighten it firmly to prevent gas leakage. d. Referring to Table 5, measure the gas pressure and to confirm it has been adjusted to within the allowable range. Repeat adjustments (a) through (c), as required.
All installations and services must be performed by qualified service personnel. 18. If the gas pressure is not within the specified high fire manifold pressure range (refer to Table 5), repeat steps 12(a) through 12(d), above, adjusting the high fire gas pressure regulator. If the manifold pressure remains low and it cannot be adjusted into the proper range, the supply pressure may be too low. Follow these steps. a. Turn off the gas at the manual gas shutoff valve. b.
All installations and services must be performed by qualified service personnel. This furnace is designed not to require any burner adjustment. Burner aeration is fixed in this design. Burner flames can be seen by looking through the sight glass located on the burner box. Burner flames should be well-defined, light to medium blue in color, and almost transparent. (refer to Figure 24).
All installations and services must be performed by qualified service personnel. TIME (sec.) FLOW (cfh) 40 41 42 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 62 64 66 68 70 72 74 76 78 80 84 88 92 96 100 105 110 115 120 125 130 135 140 150 160 170 180 90 88 86 82 80 78 77 75 73 72 71 69 68 67 65 64 63 62 61 60 58 56 54 53 51 50 49 47 46 45 43 41 39 38 36 34 33 31 30 29 28 27 26 24 23 21 20 TABLE 6 - CONVERTING GAS FLOW RATE * For one cubic foot per revolution gas meter dials, use Table directly.
All installations and services must be performed by qualified service personnel. D. FURNACE CHECKOUT PROCEDURE Before any system of gas piping is finally put into service, it shall be carefully tested to assure that it is gas tight as indicated in the manual. NOTICE: All controls on the unit should be checked for proper functioning prior to the qualified service personnel leaving the job site.
All installations and services must be performed by qualified service personnel. 5. That failure to maintain and operate this furnace in accordance with these instructions could result in hazardous conditions, bodily injury, property damage and may void the limited warranty on the furnace. 6. Review with and encourage 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. 7.
All installations and services must be performed by qualified service personnel. memory, the LED will flash two green flashes. The control will flash the most recent error first and the oldest error last (last in first out). There will be 2 seconds between codes. Solid LED error codes will not be displayed. DIAGNOSTIC FEATURES The 50V51 control used on this furnace continuously monitors its operation and the operation of the system.
All installations and services must be performed by qualified service personnel. TROUBLESHOOTING GUIDE THE SYSTEM IS STARTED BY SETTING THE THERMOSTAT TO CALL FOR HEAT. THE FOLLOWING SHOULD HELP ESTABLISH THE TYPE OF MALFUNCTION OR DEVIATION FROM THE NORMAL OPERATION. NOTE: REFER TO PAGE 48 FOR DEFINITION OF DIAGNOSTIC LEDS. TO USE THIS DIAGRAM, YOU JUST NEED TO FOLLOW THE INSTRUCTIONS IN THE BOXES.
All installations and services must be performed by qualified service personnel. IS INDUCER RUNNING ON LOW SPEED? NO CHECK CONTACTS ON LOW FIRE PRESSURE SWITCH AND FOR BLOCKAGE IN FLUE. IF OK, REPLACE DUAL PRESSURE SWITCH. REPLACE THE 50V51-843 CONTROL.
All installations and services must be performed by qualified service personnel. IS IGNITOR POSITIONED CORRECTLY? NO REPOSITION TO CORRECT LOCATION YES CHECK AND CLEAN BURNERS DO BURNERS STAY LIT PAST PROOF OF FLAME CHECK? NO CHECK FOR PROPER LINE AND MANIFOLD PRESSURE REFERENCE GAS PRESSURE CHART PAGE 31.
All installations and services must be performed by qualified service personnel. IS THERE 24 VOLTS ACROSS "MVH" AND "MV COM" ON 50V51-843 CONTROL? NO REPLACE THE 50V51-843 CONTROL. YES CHECK CONNECTIONS TO GAS VALVE. IF OK, REPLACE GAS VALVE.
All installations and services must be performed by qualified service personnel. DOES BURNER SHUT OFF WHEN THERMOSTAT IS SATISFIED? NO CHECK FOR 24 VOLTS AT GAS VALVE. NO YES YES DOES THE CIRCULATING AIR BLOWER TURN OFF AFTER THERMOSTAT IS SATISFIED WITHIN 120 SECONDS? CHECK FOR SHORT IN WIRE TO THERMOSTAT AND CORRECT IF NECESSARY.
All installations and services must be performed by qualified service personnel. Appendix –A Replacement Parts List 1. Replacement parts list for CHX3-75, CHX3-100 and CHX3-125.
All installations and services must be performed by qualified service personnel.
All installations and services must be performed by qualified service personnel. 2. Replacement parts list for CDX3-75, CDX3-100 and CDX3-125.
All installations and services must be performed by qualified service personnel.
All installations and services must be performed by qualified service personnel.
All installations and services must be performed by qualified service personnel.
