INSTALLATION AND SERVICE MANUAL MODELS: PGT5-100, PGT11-125, PGT16-160, PGL20-180, PGL33-250, PGL37-312, & PGL39-400 ? WARNING: IF YOU DO NOT FOLLOW THE SAFETY PRECAUTIONS BELOW AND IN THIS MANUAL, A FIRE OR EXPLOSION MAY RESULT CAUSING PROPERTY DAMAGE, PERSONAL INJURY, OR LOSS OF LIFE. DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS AND LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE. WHAT TO DO IF YOU SMELL GAS: • • • • • DO NOT TRY TO LIGHT ANY APPLIANCE.
TABLE OF CONTENTS SECTION BEGINNING PAGE WARNING AND INSTRUCTION LABELS 1 WARNINGS AND CAUTIONS 2 I. GENERAL INSTRUCTIONS II. GENERAL INSTALLATION A. CODES AND CLEARANCES B. CONSTRUCTION MATERIALS a. COMBUSTIBLE MATERIALS b. NON-COMBUSTIBLE MATERIALS C. FURNACE LOCATION, COMBUSTION AND MAKE-UP AIR D. VENTING E. VENT DAMPERS F. CONDENSING IN CHIMNEY G. REPLACING AN EXISTING FURNACE FROM A COMMON VENT H. GENERAL GAS PIPING I. INSTALLATION OF NATURAL GAS PIPING J. INSTALLATION OF LP GAS PIPING K.
All installations and services must be performed by qualified service personnel. This page contains reproductions of the various warning and instruction labels placed on the Thermo Pride Power Gas Furnaces. Please read and comply with the contents of these labels.
All installations and services must be performed by qualified service personnel. This page contains various warnings and cautions reproduced from the Power Gas Furnace Manual. Please read and comply with the statements below. CAUTION: When installing the burner, it should be noted that the loose fill insulation and fiber chambers are made with ceramic fibers. Currently, there are no known chronic health effects in humans associated with long term exposure to ceramic fibers.
All installations and services must be performed by qualified service personnel. I. GENERAL INSTRUCTIONS These instructions must be read in their entirety before installing the furnace. It is the installer's responsibility to do the following: 1. Inform and demonstrate to the user, the correct operation and maintenance of the appliance. 2. Inform the user of the hazards of flammable liquids and vapors and to remove such liquids and vapors from the vicinity of the appliance. II.
All installations and services must be performed by qualified service personnel. - MINIMUM CLEARANCES TO COMBUSTIBLE MATERIALS - MODEL NO. FROM SIDES FRONT TOP & SIDES FROM THE OF PLENUM OF FURNACE REAR BOTTOM FLUE OR VENT PGT5-100 1 IN. 24 IN. 1 IN. 4 IN. 1 IN. 1 IN. PGT11-125 1 IN. 24 IN. 1 IN. 9 IN. 1 IN. 1 IN. PGT16-160 1 IN. 24 IN. 1 IN. 9 IN. 1 IN. 1 IN. PGL20-180 1 IN. 24 IN. 1 IN. 18 IN. 1 IN. N/A PGL33-250 1 IN. 24 IN. 1 IN. 18 IN. 1 IN.
All installations and services must be performed by qualified service personnel. EXAMPLE: 100,000 BTUH input furnaces requires "two" openings of 100 square inches each. A minimum opening of 100 square inches is required regardless of the input. If the building is tightly constructed and or has an exhaust fan(s) that creates a negative pressure, air for combustion and ventilation must be supplied from the outdoors or from spaces freely communicating with the outdoors.
All installations and services must be performed by qualified service personnel. Trim or remove nearby trees that could interfere with chimney draft. 5. In cases where the chimney flue extends to the basement floor, the draft can usually be improved by filling the base of the chimney with sand to within 12" of the flue pipe after relocating the cleanout cover. 6. All joints of the vent must be tightly sealed. The inside of the vent should be free of all obstructions. 7.
All installations and services must be performed by qualified service personnel. NOTE: If this furnace replaces an appliance with a vent that was originally installed in a common vent system serving other appliances, the vent system is likely now too large to properly vent the remaining appliances only and must be modified accordingly. Refer to Natural Fuel Gas Code Appendix G Category I vent tables for common venting a PG Series furnace and another fan assisted or natural draft unit.
All installations and services must be performed by qualified service personnel. temperature stability. If the chimney is on the homes exterior and condensing occurs, the chimney may be insulated around its exterior to help the flue hold its temperature. Also, check to see if the chimney is too large for the flue gases to heat, if so reduce to proper size by lining. Be sure to use stainless steel liners such as types 430, 304 or for the toughest corrosion resistant type 316.
All installations and services must be performed by qualified service personnel. Piping from the natural gas meter to the furnace shall be in accord with requirements of the local utility. Piping from the LP tank to the furnace must follow the recommendations of the gas supplier. 1. A readily accessible, certified manual shut off valve with a non-displaceable rotor member should be installed within six feet of the gas equipment it serves.
All installations and services must be performed by qualified service personnel. EXAMPLE: A line must supply a furnace of 110,000 BTU/hr input, a hot water heater of 40,000 BTU/hr input and gas range with a 30,000 BTU/hr input capacity. The total BTU/hr input loading on the line is 180,000 BTU/hr. The 200,000 BTU/hr column on the chart must be used in sizing the pipe.
All installations and services must be performed by qualified service personnel. - COPPER TUBING SIZE FOR LIQUIFIED PETROLEUM GASES - All black pipe sizes shown are I.D. Seamless copper tubing may only be used with gases that are not corrosive to it. See note below and check with your LP gas supplier before using. Seamless copper tubing must comply with standard type K or L for seamless copper water tube, ASTM B 88; or seamless copper tube for air conditioning field service, ASTM B 280.
All installations and services must be performed by qualified service personnel. TWO PIECE MOUNTING PLATE When mounting the burner, the upper mounting plate must be removed to provide access to the area in front of the combustion chamber. The combustion chamber can then be moved forward or backward slightly to allow for adjustment in positioning the burner tube.
All installations and services must be performed by qualified service personnel. to have the possibility of being carcinogenic to humans. IARC has also classified these fibrous materials as group 2A carcinogens when they have undergone long term exposure to temperatures greater than 18000F. A group 2A agent is considered to have the probability of being carcinogenic to humans. For these reasons, we suggest the use of a 3M 9900, 3M 8710, or equivalent mask when working with any ceramic fiber products.
All installations and services must be performed by qualified service personnel. Furnace Model Orifice Size Manifold Gas Pressure ** PGL16-160 Nat #J (.277) 2.4” W.C. PGL16-160 LP #8(.199) 2.9” PGL20-180Nat #J(.277) 3.0” PGL20-180 LP #3(.213) 3.0” AGL16-160LP #8(.199) 2.9” AGL20-180Nat #J(.277) 3.0” AGL20-180LP #3(.213) 3.0” *Air Adjustment screw: Number of turns closed from the fully open position. **PG-160 or PG-180 Power Gas Conversion Burners- use chart for applicable settings. No.
All installations and services must be performed by qualified service personnel. In summary, setting the combustion air on the Thermo Pride Midco RE32 power gas conversion burner is extremely critical. This adjustment should only be made by following these instructions and confirming the set-up with the proper CO2 or O2 combustion analyzer and a carbon monoxide reading of less than 50 PPM. L.
All installations and services must be performed by qualified service personnel. EXAMPLE: Heating output of furnace is 100,000 x 1.4 ÷ 100 = 1400 CFM. Air conditioning installed is 4 tons x 400 CFM = 1600 CFM or 48,000 BTU's. NOTE: The duct system must be sized for the larger CFM requirement for cooling. If only 3 tons 36,000 BTU's of cooling x 400 CFM = 1200 CFM was installed, the duct would have to be sized for the 1400 CFM heating requirement.
All installations and services must be performed by qualified service personnel. DUCT WORK/AIR CONDITIONING: If the furnace is used in connection with summer air conditioning (cooling), the furnace should be installed parallel with or on the upstream side of the evaporator coil to avoid condensation in the furnace heat exchanger.
All installations and services must be performed by qualified service personnel. A. 400 CFM X 3 TON (36,000 BTU'S) = 1,200 CFM FOR COOLING B. 400 CFM X 2.5 TON (30,000 BTU'S) = 1,000 CFM FOR COOLING NOTE: To obtain the proper 50°F to 80°F temperature rise for heating an air conditioning coil is installed, the speed of the blower motor may have to be changed. This depends on the static resistance of an individual duct system and the size of the air conditioner. M.
All installations and services must be performed by qualified service personnel. N. FAN AND LIMIT POSITION AND LOCATION Power gas furnace models PGL5 through PGL20 are shipped with the fan and limit control pre-mounted in the vestibule.
All installations and services must be performed by qualified service personnel. A. FAN & LIMIT LOCATION WITH H-COIL: The fan & limit control should be mounted between the H-coil cabinet and furnace. For distances from top of plenum and furnace, see chart above. IMPORTANT: Do not mount fan/limit in H-coil cabinet. O. WIRING All wiring must conform to the provisions of local codes or in the absence of these codes with the provisions of the National Electrical Code, ANSI/NFPA70 (Latest Edition).
All installations and services must be performed by qualified service personnel. All electrical wiring must be installed in strict accordance with local ordinances and codes. In the absence of local ordinances and codes, all electrical wiring must be in accordance with the National Electrical Code (ANSI/NFPA 70LATEST EDITION). On the following pages are the wiring diagrams for the various Thermo Pride gas furnace models.
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.
All installations and services must be performed by qualified service personnel.
All installations and services must be performed by qualified service personnel. Wiring: All electrical wiring must be installed in strict accordance with local ordinances and codes. In the absence of local ordinances and codes, all electrical wiring must be in accordance with the National Electrical Code (ANSI/NFPA 70LATEST EDITION). Below and on the following pages are the wiring diagrams for the various Thermo Pride gas furnace models.
All installations and services must be performed by qualified service personnel. II. STARTING THE UNIT A. INITIAL START UP: 1. Check all wiring for loose connections and proper hook up. 2. Leak test gas piping connections. 3. Check tubing to the pressure switch to make sure it is pushed firmly onto the pressure tap. 4. Check flue pipe, chimney, and all connections for tightness and to make sure there is no blockage. 5. Make sure air filters are in place.
All installations and services must be performed by qualified service personnel. elevation of 2,000 feet or less, no reduction in input is required. Your gas supplier will supply you with the correct BTU and orifice sizing information. To check the input of your natural gas furnace, proceed as follows: a. Call your gas supplier and ask for the BTU content (heating valve) of one cubic foot of the gas, supplied to the installation area.
All installations and services must be performed by qualified service personnel. FURNACE MODEL NO. ORIFICE CHART L.P. NAT. PGT5-100 .113 OR #33 DMS .196 OR #9 DMS PGT11-125 .1285 OR #30 DMS .213 OR #3 DMS PGT16-160 .144 OR #44 DMS .238 OR B DMS PGL20-180 .213 OR #3 DMS .277 OR J DMS PGL33-250 .265 OR 17/64 DMS .332 OR Q DMS PGL37-312 .297 OR 19/64 DMS .390 OR 25/64 DMS PGL39-400 .332 OR Q DMS .468 OR 15/32 DMS D.
All installations and services must be performed by qualified service personnel. V. DEALER MAINTENANCE A. ELECTRICAL: 1. Check all wiring for loose connections. 2. Check for correct voltage at the furnace when operating. 3. Check amp-draw on blower motor and burner to assure they are not exceeding name plate amp rating. B. CLEANING HEAT EXCHANGER: WARNING: THE HEAT EXCHANGER MUST BE CLEANED BY A QUALIFIED SERVICE TECHNICIAN.
All installations and services must be performed by qualified service personnel. Reassemble the furnace to its original construction. Remount the burner being certain that the air tube is properly inserted into the chamber opening (see Burner Installation section). VI. TROUBLESHOOTING For troubleshooting the power gas burner, reference the burner manufactures instructions. If the burner is producing an excessive combustion sound level, perform the following procedures: 1.
All installations and services must be performed by qualified service personnel. VII.
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.
All installations and services must be performed by qualified service personnel.
