Thermo Products CMA1-50N, CMA2-75N User Manual

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GAS FIRED HIGH EFFICIENCY FURNACE

DOWN FLOW & DIRECT VENT (SEALED COMBUSTION)

MODEL: CMA1-50N & CMA2-75N

INSTALLATION AND SERVICE MANUAL

For installation in:

1.Manufactured Homes

2.Modular Homes/Buildings

3.Site Constructed—Residential (Single Story Dwellings)

FOR YOUR SAFETY

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.

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.

: If the information in these instructions is not followed exactly, a fire or explosion may result causing property damage, personal injury, or loss of life.

: Improper installation, adjustment, alteration, service, or maintenance can cause injury or property damage. Refer to this manual. For assistance or additional information, consult a qualified installer, service agency, or fuel supplier.

: 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 electrical or control system that has been underwater.

PLEASE READ THESE INSTRUCTIONS PRIOR TO INSTALLATION, INITIAL FIRING, AND BEFORE PERFORMING ANY SERVICE OR MAINTENANCE. THESE INSTRUCTIONS MUST BE LEFT WITH THE USER AND SHOULD BE RETAINED FOR FUTURE REFERENCE BY QUALIFIED SERVICE PERSONNEL.

MG-508

ECN 5135-MA 100615

THERMO PRODUCTS, LLC.

POST OFFICE BOX 217

NORTH JUDSON, IN 46366

PHONE: (574) 896-2133

MADE IN USA

 

 

 

TABLE OF CONTENTS

 

SECTION

 

BEGINNING PAGE

I.

SAFETY INFORMATION

 

1

II.

FURNACE SPECIFICATIONS

 

6

III. GENERAL INSTRUCTIONS AND CLEARANCES

7

IV. GENERAL INSTALLATION

 

9

 

A. FURNACE LOCATION

 

9

 

B. BASE INSTALLATION

 

12

 

C. ALCOVE INSTALLATION

 

13

 

D. CLOSET INSTALLATION

 

14

 

E. FUEL PIPING

 

15

 

F. GENERAL VENTING REQUIREMENTS

16

 

G. CONNECTING THE EXHAUST VENT, AND COMBUSTION

18

 

AIR INTAKE

 

 

 

H. DIRECT VENTING THROUGH A SIDEWALL

19

 

I. INSTALLATION OF OUTSIDE EXHAUST/INTAKE TERMINATIONS

23

 

J. CONNECTING THE FURNACE TO ROOF VENT/ INTAKE TERMINATIONS

24

 

K. CONDENSATE DRAIN LINE AND TRAP ASSEMBLY

26

 

L. ELECTRICAL WIRING

 

27

V.

STARTING THE UNIT

 

32

 

A. SEQUENCE OF OPERATION

32

 

B. INITIAL START-UP

 

34

 

C. ADJUSTMENT OF BTU INPUT RATE

35

 

D. BURNER ADJUSTMENT

 

36

 

E. SETTING TEMPERATURE RISE

37

 

F. FURNACE CHECK-OUT PROCEDURE

38

VI. INSTALLER'S INSTRUCTIONS TO USER

39

VII. DEALER MAINTENANCE

 

39

 

A. ELECTRICAL

 

40

 

B. GENERAL INSPECTION

 

40

 

C. HEAT EXCHANGER

 

41

 

D. HOUSE AIR BLOWER

 

41

 

E. RETURN AIR FILTER

 

41

VIII. TROUBLE SHOOTING

 

42

APPENDIX-A

REPLACEMENT PARTS

49

APPENDIX-B

WIRING DIAGRAM

51

WARRANTY

 

 

52

REFERENCED PUBLICATIONS:

FOR COPIES CONTACT:

 

NATIONAL FUEL GAS CODE

NATIONAL FIRE PROTECTION ASSOCIATION

 

NFPA 54/ANSI-Z233.1

 

1 BATTERYMARCH PARK

 

(LATEST EDITION)

 

P.O. BOX 9101

 

 

 

 

QUINCY, MA 02269-9101

 

Thermo Products CMA1-50N, CMA2-75N User Manual

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 Condensing Gas Furnaces. Please read and comply with the contents of these labels.

1

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

This and the previous page contain reproductions of the various safety and instruction labels placed on the Thermo Pride Condensing Gas Furnaces. Please read and comply with the contents of these labels.

2

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.Do not install this furnace where it could be exposed to drafts or other wind or moisture conditions. Refer to Section IV of this manual.

3.Provide adequate ventilation air to the furnace space. Refer to Section IV, C and D, of this manual.

4.Connect this furnace to an approved vent system only. Combustion products must be carried outdoors. Refer to Section IV, F thru J, of this manual.

5.Never test for gas leaks with an open flame. Leak test methods must comply with

State, Local and National codes including the National Fuel Gas Code NFPA 54/ANSIZ233.1 (Latest Edition).

6.Always install furnace with a duct system that has an external static pressure within the allowable range referenced in specifications.

7.Make sure supply air ducts are completely sealed to the furnace casing. Refer to Section IV.

The following pages contain various warnings and cautions found throughout the Thermo Pride Gas Fired High Efficiency Furnace Manual. Please read and comply with the statements below.

: This furnace is not to be used for temporary heating of buildings or structures under construction.

: These high efficiency condensing furnaces are not certified for and shall not be vented into a standard or any type of chimney.

: Negative pressure inside the closet with closet door closed and the furnace blower operating on high speed shall be no more negative than minus 0.05 inch water column.

: Do not obstruct any return air openings, including the return grille on the furnace. To do so may cause the furnace to activate the high limit and shut down.

3

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

: 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.

: This CMA furnace has been designed to be installed as a direct vent system and must have its combustion air brought in from outside the conditioned space. 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.

: 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.

: 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.

: All gas piping must be leak tested methods approved by State, Local and National Codes including the National Fuel Gas Code NFPA 54/ANSI-Z233.1 (Latest Edition). A final test for gas leakage must be made after purging the gas line. 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 24 hours for the circuit to fully dry before energizing the burner circuit.

: The furnace and its individual gas shutoff valve must be disconnected from the gas supply during pressure testing of the gas supply system at pressures in excess of 1/2 PSIG or 14.0" w.c. The furnace must be isolated from the gas supply by closing its manual shut off valve at test pressures equal to or greater than 1/2 PSIG or 14.0" w.c.

4

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

: Copper and brass tubing and fittings (except tin lined) shall not be used if the gas contains more than a trace (0.3 grains per 100 cubic ft.) of hydrogen sulfide gas. Check with your gas supplier.

: TURN OFF THE ELECTRICAL POWER to the furnace before attempting to change blower speed wiring.

: 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 in accordance with State, Local and National Codes including the National Fuel Gas Code NFPA 54/ANSI-Z233.1 (Latest Edition).

: It may be necessary to purge the air out of the gas line for initial startup 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.

: 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 set at highest setting.

3.The furnace remain running at conditions 1&2 above for 15 minutes or until odor has dissipated.

: The CMA furnace models are of direct vent design and do 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.

: Label wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation.

: The inducer motor mounting plate gasket and the collector box gasket must be replaced if they show any sign of having been damaged.

: Power must be disconnected before servicing.

5

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

II. FURNACE SPECIFICATIONS - CMA SERIES

MODEL

CMA1-50

 

 

 

CMA2-75

INPUT IN BTUH

50,000

 

 

 

75,000

OUTPUT IN BTUH

48,000

 

#42

 

72,000

MAIN ORIFICE-NAT.

 

 

 

 

MAIN ORIFICE-LP

 

 

1.5 mm

 

 

GAS SUPPLY PRESSURE

 

11” IN.W.C.

 

L.P. MINIMUM

 

 

NAT. MINIMUM

 

4.5”IN.W.C.

 

L.P. MAXIMUM

 

14” IN.W.C.

 

NAT. MAXIMUM

 

14” IN.W.C.

 

GAS MANIFOLD PRESSURE

 

10.0” + .03 IN.W.C.

 

L.P.

 

 

NAT.

 

3.5” + .03 IN. W.C.

 

INTAKE SIZE IN INCHES

 

 

2”

 

 

VENT SIZE IN INCHES

 

 

2”

 

 

NOMINAL TEMPERATURE RISE

 

 

55°F

 

 

SEASONAL EFFICIENCY (AFUE*)

 

 

95%

 

 

*ANNUAL FUEL UTILIZATION EFFICIENCY

 

 

 

 

 

DIMENSIONS

WIDTH 18” DEPTH 25-3/4" HEIGHT 57"

CABINET SIZE

SUPPLY AIR OUTLET

 

WIDTH 12” DEPTH 12"

 

ELECTRICAL SUPPLY

 

115 VOLTS-- 60HZ --1/PH

 

FUSE OR HACR BREAKER

 

 

15 AMPS

 

 

TOTAL CURRENT AMPS

 

7.15 AMPS

 

NOMINAL ANTICIPATOR SETTING

 

0.8 MILLIAMPS

 

FILTER SIZE

 

(1) 18” X 24” X 1”

 

APPROXIMATE SHIPPING WEIGHT

 

 

175 LBS.

 

 

BLOWER DATA

 

12-9T DIRECT DRIVE

 

BLOWER MODEL

 

 

MOTOR HORSEPOWER

 

 

1/2

 

 

MOTOR RPM

 

1065 (HIGH SPEED)

 

CFM @ .2 & .5 IN. W.C. SPEED

.2”

.5”

|

.2”

.5”

LOW

805

695

|

797

668

MD-LOW

1010

860

|

995

869

MD-HIGH

1196

1038

|

1210

1076

HIGH

1338

1162

|

1420

1259

FOR BURNER COMBUSTION INFORMATION REFER TO INITIAL STARTUP.

6

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

INSTALLATION PARTS PACKAGE

PARTS PKG#

CMA*-50

 

CMA*-75

 

S00S4179

 

S00S4114

 

DESCRIPTION

 

 

PART #

QTY

PART #

QTY

 

J-box cover

350020

1

350020

1

wire nut

300132

2

300132

2

3" stainless steel hose clamp

300276

4

300276

4

2-3/8" radiator hose

410017

2

410017

2

CPVC adapter

320833

1

320833

1

LP conversion kit

AOPS7677

1

AOPS7678

1

III. GENERAL INSTRUCTIONS AND CLEARANCES – READ BEFORE START OF INSTALLATION

1.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 the American Society of Heating,

Refrigeration and Air Conditioning Engineers, Inc. (ASHRAE).

2.This furnace is equipped with orifices sized for operation with natural gas. For conversion to Propane Gas see instruction MG-799 in Gas Conversion Kit

AOPS7678.

3.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 40°F to 70°F through the furnace after installation. (See rating label located on separator 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 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 reduce the life of the heat exchanger.

4. 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

7

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

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.

5. The installer shall be familiar with and comply with all codes and regulations applicable to the installation of these heating appliances and related equipment. In lieu of local codes, the installation shall be in accordance with the current provisions of one or more of the following standards.

a.Federal Manufactured Home Constructions & Safety Standard (H.U.D. Total 24, Part 280.)

b.American National Standard (ANSI-119.2/NFPA-501C) for all recreational vehicle installations.

c.American National Standard (ANSI-Z223.1/NFPA-54) for all gas-fired furnaces.

d.American National Standard (ANSI-C1/NFPA-70 Electric Code for all electrical field wiring.

e.These gas-fired units have been investigated under standards ANSI Z 21.47 CAN/CGA Z223-2001 Central Furnace test standards.

f.These gas-fired units have been listed by ETL “For installation as central furnace special type for single story dwelling.”

: The area around the furnace must be kept free and clear of combustible materials, especially papers and rags.

: This furnace is not to be used as a construction heater.

Listed below are definitions of “ COMBUSTIBLE MATERIAL” and “NONCOMBUSTIBLE MATERIAL.”

COMBUSTIBLE MATERIAL:

Material made of or surfaced with wood, compressed paper, plant fibers, plastics or other material that will ignite.

NON-COMBUSTIBLE MATERIAL:

Material that will not ignite and burn. Such materials consist entirely of steel, iron, brick, tile, concrete, slate, glass or a plaster combination thereof.

8

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

MODELS CMA

CLOSET

ALCOVE

FRONT

6”

18”

BACK

0”

0”

SIDES

0”

0”

VENT CONNECTOR(PVC)

0”

0”

TOP

0”

0”

PLENUM SIDES

1”

1”

TOP AND SIDES OF DUCT

1”

1”

BOTTOM OF DUCT

1”

1”

Table 1

This heating appliance must be installed with clearances not less than the minimums shown above as well as ample clearance for easy access to the air filter, blower assembly, burner assembly, controls, and vent connections.

IV. GENERAL INSTALLATION

A.FURNACE LOCATION

1.For best performance, locate the furnace so that it is centralized with respect to the duct system.

2.The furnace installation is only intended for free air return through the furnace door louvers. DO NOT connect a ducted return air system directly to the furnace.

An improper return air installation may create a hazard and damage equipment, as well as void all warranties.

3.This furnace may be installed on a combustible floor when utilizing either the No. 70 counterflow floor base or CE111S / CE211T coil cabinet for below the floor duct systems, or the cottage base for floor level air distribution. See Figure

1A for description of Combustible Floor Base and Figure 1C for Cottage Base.

This furnace is ETL listed for closet, alcove or free standing applications. All applications must comply with the requirements of this manual.

9

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

Combustible Floor Base

Model: 70-BASE

Figure 1A.

Coil Cabinet

Model: CE113S Note: This cabinet cannot be utilized as a cottage base.

Figure 1B.

10

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

Cottage Base

Model: 01COT-BASE

Figure 1C.

NOTE: Serves as a plenum for single story applications with exposed supply air systems.

11

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

B. BASE INSTALLATION

1. Combustible Floor Base Model: 70 BASE

Use the base bottom panel as a template to mark floor opening locations (see Figure 2). Cut a square opening in the floor for the supply air connector duct. Cut the opening 1-inch larger than the square template opening. (duct requires 1-inch clearance to combustible floor).

Figure 2.

Figure 3.

After cutting openings in the floor, place the bottom panel in position. Mark the square opening location on the distribution duct at the connection point of the

12

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

connector duct. Remove the bottom panel. Cut an opening in the distribution duct slightly larger than the connector duct. (refer to Figure 2 for location of this cut.) Cut the connector duct to length. Install the connector duct. Bend over each tab.

Insure an airtight seal by using high temperature sealant or tape on the joint. Reinstall the bottom panel over the connector duct. Put the base top assembly in place (see Figure-3).

Slit the corners of connector duct down to the top of the base assembly. If metal projects more than 1-inch above the top of the base assembly, trim the flanges down to 1-inch. While the top of distribution duct is being pulled up with one hand, bend down each side of the connector duct tightly to the base assembly with the other hand. This assures a tight connection between the base assembly and the connector duct and that the distribution duct will be full size. Use high temperature tape and/or high temperature silicone caulking on all joints and seams to minimize air leakage. Secure the base assembly to the floor with two screws in the front flange.

2. Cottage Base Model: 01COT BASE

The 01COT BASE cottage base (Figure 1C) is required for a freestanding cottage base installation. The cottage base allows the two sides and rear to have an 8” x 12” register installed. IMPORTANT: All joints and seams of supply ducts must be sealed with a sealing method suitable to the application conditions and temperatures (I.E. High temperature silicone and/or aluminum tape). Refer to assembly and installation instructions included with cottage base for additional information.

C. ALCOVE INSTALLATION

In this application, a minimum of 18 inches of clearance must be provided to the front of the unit. See Figure 4.

Note – access to diagnostic view port.

Figure 4.

13

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

D. CLOSET INSTALLATION

1. The return air opening into the closet is to have a minimum free area of 250 sq. in. (see Figure 5).

2. The return air opening may be

located in the top, center or (ideally) bottom of the closet door or side wall.

Figure 5.

: Do not obstruct any return air openings, including the return grille on the furnace. To do so may cause the furnace to activate the high limit and shut down.

3.The cross-sectional area of the return system leading into the closet (when located in the floor or ceiling) shall not be less than 250 square inches.

4.The total free area of openings in the floor or ceiling registers serving the return duct system must be at least 350 square inches. At least one register must be located where it is not likely to be covered by carpeting, boxes, furniture or other objects.

5.Materials located in the return duct system must have a flame spread classification of 200 or less.

6.Non-combustible pans having one inch upturned flanges are to be located beneath openings in a floor return duct system.

7.Wiring materials located in the return duct system must conform to articles 300-22 of the National Electrical Code NFPA70 (Latest Edition).

8.Gas piping is not to be located in or through the return duct system .

14

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

E. FUEL PIPING

Sizing and installation of fuel lines must be in accordance with Federal, State &

Local regulations. Including the National Fuel Gas Code NFPA 54/ANSI-Z233.1 (Latest Edition).

NOTE: These furnaces are designed to be gas piped through the left side or the bottom. For service purposes, it is recommended that the gas union be located inside the furnace when possible.

: 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.

A qualified installer or service person must perform all gas piping and testing.

Piping from the natural gas meter to the furnace shall be in accordance with requirements of the local gas utility. Piping from the LP tank to the furnace must follow the recommendations of the gas supplier.

A readily accessible manual shut off valve (certified for the applicable gas) with a non-displaceable rotor member shall be installed within six feet of the gas equipment it serves.

A union or flanged connection shall be provided directly up stream of the burner to allow burner removal. Unions must be of a ground joint type or flange-jointed type using a gasket resistant to the applicable gas. Pipe dope or sealant certified to be resistant to the action of the applicable gases should be used on all threaded joints.

A drip leg must be used on 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 condensation between the gas meter and the furnace. Failure to install a drip leg may void the limited warranty on the furnace.

: All gas pipe connections must be leak tested using methods approved by State, Local and National Fuel Gas Code NFPA 54/ANSI-Z233.1 (Latest Edition). Any leaks must be repaired immediately after turning off the gas supply. A final test for gas leakage must be made after purging the gas line.

: DO NOT wet electronic components during the leak test. Wetting electronic components may damage 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 system.

15

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