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Thermo Pride CDB1-100N, Installation And Operation Manual, Page: 3 / 58

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Thermo Pride CDB1-100N Installation And Operation Manual Download Page 3

All installations and services must be performed by qualified service personnel.

 

 

ii 

This and the previous 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. 

 

Summary of Contents for CDB1-100N

Page 1: ...H 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 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 CONTRACT...

Page 2: ...NFORMATION This and the following 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 ...

Page 3: ...formed by qualified service personnel ii This and the previous 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 ...

Page 4: ...e 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 remove...

Page 5: ... 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 Only the homeowner user routine maintenance described in the Users Information Manual may be performed by t...

Page 6: ...LE PIPE SIDEWALL VENTING OPTION 13 F INSTALLATION OF OUTSIDE VENT AIR INTAKE TERMS 14 G CONNECTING FURNACE TO VENT AIR INTAKE TERMS 16 H CONNECTING FURNACE TO ROOF VENT AIR TERMS 21 I CONDENSATE DRAIN LINE TRAP ASSY 22 J GENERAL GAS PIPING 25 K FILTERS 26 L WIRING 29 IV NATURAL PROPANE GAS CONVERSION 32 V STARTING THE UNIT 35 A SEQUENCE OF OPERATIONS 35 B INITIAL START UP 37 C ADJUSTMENT OF BTU IN...

Page 7: ...TATIC PRESSURE 2 5 2 5 2 5 2 5 HI 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 LO SPEED 610 420 820 700 1340 1220 1670 1550 TEMPERATURE RISE 70 70 70 70 BLOWER MOTOR HP 20 41 50 75 NO OF SPEEDS 3 4 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 F...

Page 8: ...PEED 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 OF 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 b...

Page 9: ...ox 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 Orifice Propane 380039 2 3 Conversion Kit Propane 380605 1 INSTALLATION PARTS PACKAGES CHB1 100 125 PARTS PACKAGE S00S4407 4408 DESCRIPTION PART QUANTITY 2 3 8 ID radiator hose 410017 1 Thermostat lead bushing 350750 1 PVC trap assembly 320816 1 8 x coated T...

Page 10: ...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 320819 1 Pipe 2 dia PVC 15 14401 1 Bracket 14406 1 Orifice Propane 380039 2 3 Conversion Kit Pr...

Page 11: ...furnace vestibule The installation must conform with local codes or in the absence of local codes with the National Fuel Gas Codes ANSI Z223 1 or latest edition and with these instructions 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 r...

Page 12: ...lled in accordance with regulations of the National Board of Fire Underwriters Authorities having jurisdiction should be consulted before installations are made B FURNACE LOCATION 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 ...

Page 13: ...nits 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 CDB1 series units th...

Page 14: ...arance 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 ...

Page 15: ...o Products Size reduction is never permissible The required exhaust vent air intake pipe sizes are nominal 2 inch diameter schedule 40 PVC thermoplastic pipe for models CHB1 50 75 CDB1 50 75 or nominal 3 inch diameter schedule 40 PVC thermoplastic pipe for models CHB1 100 125 CDB1 100 125 4 The furnace model series CHB1 CDB1 shall not be common vented with any other appliance including those burni...

Page 16: ... 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 system we recommend the actual equivalent lengths for both the constructed intake and the exhaust systems have approximately the same value 9 Use a saw designed to cut thermoplastic pipe All...

Page 17: ...to the center of the elbow is 12 inches Figure 2 Proper Direct Vent Terminations RH LH views and Vent Termination Only 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 shie...

Page 18: ...least 1 foot below 1 foot horizontally from or 1 foot 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 over public walkways or over an area where wetting of surfaces by condensate or water vapor could create a nuisance or hazard In addition avoid locations where wettin...

Page 19: ...nd to prevent blockage by snow accumulation or drifting The 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 E1 Single Pipe Sidewall Venting Option This furnace may be horizontally ...

Page 20: ...outside wall of the following sizes for the outdoor terminal s 2 3 8 inch diameter for furnace models CHB1 CDB1 50 and CHB1 CDB1 75 or 3 1 2 inch diameter for the furnace models CHB1 CDB1 100 and CHB1 CDB1 125 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 inch connection allowance at both ends of the pipe...

Page 21: ...all vent applications only refer to Figure 6 The concentric vent kit Thermo Products part no 370171 provides a means for the vent and intake to be installed through one 1 4 1 2 inch diameter hole through the outside wall 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 These optional kits shall be i...

Page 22: ...nsate Drain Connections At Furnace 1 Figures 6 7 and 8 follow depicting typical exhaust vent and air intake connections for the furnace model series CHB1 and the CDB1 respectively as well as a list of required parts to correctly install each system Figure 6 Required Exhaust Vent and Air Intake Piping for CHB1 Furnace ...

Page 23: ...All installations and services must be performed by qualified service personnel 17 Figure 7 Required Exhaust Vent and Air Intake Piping for CDB1 Furnace in Downflow Applications ...

Page 24: ...the length of 2 inch diameter thermoplastic pipe needed to clear the furnace side casing while allowing for installation of a 2 3 8 inch length of reinforced 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 and 11 for assembly details NOTICE For ...

Page 25: ...ections 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 inducer outlet flange Drive one 1 8 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...

Page 26: ...he models CHB1 50 75 and CDB1 50 75 install a 2 inch PVC elbow with sleeve and coupling for models CHB1 100 125 and CDB1 100 125 a 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 t...

Page 27: ...he outside surface of the pipe from sweating H 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 13 below 1 The outlet of the exhaust vent and the inlet of the combustion air intake i e...

Page 28: ... Intake Termination Construction Details I Condensate Drain Line And Trap Assembly 1 The following diagrams depict typical condensate drain and trap connections for the furnace models series CHB1 and CDB1 refer to the illustrations in Figures 14 15 and 16 Figure 14 Condensate Trap Assembly Mounted On the Model Series CHB1 ...

Page 29: ... performed by qualified service personnel 23 Figure 15 Condensate Trap Assembly Mounted On the Model Series CDB1 In a Downflow Application Figure 16 Condensate Trap Assembly Mounted On The Model Series CDB1 In RH Side Horizontal Application ...

Page 30: ...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 free end of the drain hose over the hose barb on one 1 side ...

Page 31: ...heating season This 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 se...

Page 32: ... 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 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...

Page 33: ...e 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 r...

Page 34: ...N 2 328 IN 2 402 IN 2 STANDARD PERMANENT FILTER 500 FT MIN 208 IN 2 304 IN 2 394 IN 2 484 IN 2 DISPOSABLE TYPE FILTER 300 FT MIN 344 IN 2 506 IN 2 656 IN 2 804 IN 2 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 internal stiffeners used in the filter must not be removed although they can be cut ...

Page 35: ... and provide strain relief for the 115 volt power leads from the furnace in the fuse disconnect box A 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 connect...

Page 36: ...ale and are generally marked accordingly 4 BLOWER MOTOR SPEED WIRING Figure 21 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 o...

Page 37: ... Off 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 thermo...

Page 38: ...e to this furnace must be done only by a qualified service agency Follow the installation instructions for the test fire subsequent to this conversion The following instructions outline the procedure for converting the existing burner from one type of gas to another When making a gas conversion it is necessary to replace and or modify several of the existing components Table1 shown below lists the...

Page 39: ... front cover 6 Refer to the instructions provided in the gas valve conversion kit for regulator spring change out procedure 7 Reinstall the manifold into the burner box Make sure that all the orifices are correctly inserted into their respective burners and the groove of the rubber grommet on the manifold lines up on the edge of the burner box to seal around the manifold Secure the manifold in pla...

Page 40: ...All installations and services must be performed by qualified service personnel 34 12 Proceed to Section V Starting The Unit Figure 2 ...

Page 41: ...ENSES ADEQUATE DIFFERENTIAL PRESSURE CONTACTS CLOSE CONTROL BOARD ENERGIZED INDUCER ENERGIZED POWER IS APPLIED TO THE SILICON NITRIDE IGNITOR IGNITOR WARM UP IS 20 SECONDS AFTER IGNITOR WARM UP THE GAS VALVE IS ENERGIZED TO OPEN FLAME MUST BE DETECTED WITHIN 4 SECONDS IF FLAME IS DETECTED THE DELAY TO FAN ON TIME BEGINS 45 SECONDS IF FLAME IS NOT DETECTED THE GAS VALVE IS DE ENERGIZED THE IGNITOR ...

Page 42: ... 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 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 D...

Page 43: ...ulate at floor level at a dangerous concentration For remainder of operating instructions reference Users Information Manual 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 2 for 30 minu...

Page 44: ... 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 the pressure by turning the screw ...

Page 45: ...egrated fan control 1 Check safety limit control as follows a Shut off incoming power b Block return air opening or disconnect blower motor leads c Restore power to furnace d Set thermostat above room temperature calling for heat e When temperatures are reached in furnace at limit control setting with blower out of operation burner should shut off f Shut off electrical power IMPORTANT Remove block...

Page 46: ... power 3 The sequence of operation of the furnace 4 The correct operation and maintenance of the appliance as outlined in the users information manual 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 rea...

Page 47: ... 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...

Page 48: ...E CONTACT IS ROOM TEMPERATURE BELOW THERMOSTAT SETTING IS ROOM TEMPERATURE ABOVE 90 DEGREES F TURN T STAT SETTING ABOVE ROOM TEMP COOL THE THERMOSTAT IS THE TRANSFORMER SUPPLYING 24 VOLTS TO THE THERMOSTAT REPLACE THERMOSTAT IS INTERNAL DAMAGE PRESENT ON THE TRANSFORMER CHECK INPUT POWER DOOR INTERLOCK SERVICE SWITCH AND FUSES No CHECK FOR CONTINUITY PROPER CONNECTIONS No Yes Yes REPLACE TRANSFORM...

Page 49: ...WER TERMINALS IND IND 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 IS THERE VOLTAGE PRESENT AT THE HOT SURFACE IGNITOR TERMINALS IGN IGN N AT THE INTEGRATED CONTROL No No CHECK THE INTEGRATED CONTROL DIAGNOSTIC LED LAMP RESET BY INTERRUPTING POWER ...

Page 50: ... OF FLAME CHECK Yes CHECK ACROSS THE CIRCULATING AIR BLOWER TERMINALS CIR N HEAT FOR PROPER VOLTAGE REPLACE THE INTEGRATED CONTROL No No Yes DOES THE CIRCULATING AIR FAN COME ON WHEN ENERGIZED No DOES BLOWER SPIN FREELY No CONFIRM IF EITHER BLOWER WHEEL IS RUBBING AGAINST HOUSING OR MOTOR SHAFT IS SPINNING FREELY AND REPAIR OR REPLACE AS NECESSARY Yes Yes IS CAPACITOR WORKING PROPERLY No Yes REPLA...

Page 51: ...TISFIED CHECK ALL WIRING FOR LOOSE CONNECTIONS CHECK FOR SHORT IN WIRE TO THERMOSTAT AND CORRECT IF NECESSARY DOES BURNER SHUT OFF WHEN THERMOSTAT IS SATISFIED No DOES THE CIRCULATING AIR BLOWER TURN OFF AFTER THERMOSTAT IS SATISFIED WITHIN 120 SECONDS No No Yes Yes Yes Yes Yes IS LED LIGHT ON INTEGRATED CONTROL FLASHING ...

Page 52: ...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 CHECK COMPLETE SYSTEM OUT LED LIGHT STAYS ...

Page 53: ...All installations and services must be performed by qualified service personnel 47 Appendix A Replacement Parts List 1 Replacement parts list for CHB1 50 CHB1 75 CHB1 100 and CHB1 125 ...

Page 54: ...All installations and services must be performed by qualified service personnel 48 ...

Page 55: ...All installations and services must be performed by qualified service personnel 49 2 Replacement parts list for CDB1 50 CDB1 75 CDB1 100 and CDB1 125 ...

Page 56: ...All installations and services must be performed by qualified service personnel 50 ...

Page 57: ...All installations and services must be performed by qualified service personnel 51 Appendix B Wiring Diagrams ...

Page 58: ...All installations and services must be performed by qualified service personnel 52 ...

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