Thermo Products CBD1-50N, CHB1-125N, CHB1-100N, CBD1-125N, CBD1-100N User Manual
...
CONDENSING GAS FURNACE
INSTALLATION AND OPERATION MANUAL
MODELS:
CHB1-50N CDB1-50N
CHB1-75N CDB1-75N
CHB1-100N CDB1-100N
CHB1-125N CDB1-125N
: 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.
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.
• 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.
BOX 217
NORTH JUDSON, IN 46366
PHONE: (5 7 4) 896-2133
THERMO PRODUCTS, LLC.
MADE IN USA
MG-1006
ECN 5355-MA 140303
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.
i
All installations and services must be performed by qualified service personnel.
WARNING:
If you do not follow these instructions exactly, a
fire or explosion may result causing property damage,
personal injury or loss of life.
390540
1. Set thermostat to lowest setting, and, if equipped, set the operating
mode to "COOL" or "OFF".
2. If service is to be performed, turn off all electric power to the
appliance.
3. To turn off gas control valve, remove the burner compartment cover.
4. Move the gas control switch to the "OFF" position.
5. Replace the burner compartment cover.
1. STOP! Read the safety information above on this label.
2. Set the thermostat to the lowest setting.
3. Turn off all electric power to the appliance.
4. This appliance is equipped with a hot surface igniter that
automatically lights the burner. Do not tr y t o 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.
8. Turn on all electric power to the appliance.
9. Set thermostat to desired setting, and, if equipped, set the operating
mode to "HEAT".
10.If appliance will not operate, follow the instructions "To Turn Off
Gas To Appliance" and call your service technician or gas supplier.
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 t o move the gas control switch. Never use tools.
If the switch will not move by hand, don't try to re pair it, call a
qualified service technician. Force or attempted repair may result in
a fire or explosion.
D. Do not use this a ppliance 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.
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.
ii
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 page s cont ain v ar ious w a rning s and ca utio ns fo und thro ugho ut t he Thermo Pride Highbo y and
Dual Poise Condensing Gas Furna ce Manual. Plea se r e ad 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.
: These furnaces may not be common vented with any other appliance.
: 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 CHB1/CDB1 furnace has been designed to be installed as a direct vent system. The failure to
install the vent/air intake system as spec ified in these instructions will void the heat exchange r warra nty 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.
: T urn off power to furnace before it is placed into service. The gas piping system must have been
leak tested by a qualified heating contractor.
: It m ay be necessary to purge the air out o f the gas line for initial start-up of the furnace af ter
installation. This should be done by a qualified heating contractor. If excessive gas escapes when purging the
gas supply at the union, a llow the a rea to ventilate for at lea st 15 minutes b efore attem pting 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.
: 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 for 30 minutes or until odor has dissipated.
iii
All installations and services must be performed by qualified service personnel.
: The CHB1/CDB1 f u rn ace model s are sealed combustion design, which does not require an air
shutter adjustment (air shutters are not used) for proper flame characteristics. Burn er box access c over 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 he ating contracto r. Only the home owner/user routine maint enance 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 BEGINNING PAGE
I. SAFETY INFORMATION i
II. FURNACE SPECIFICATIONS 1
III. GENERAL INSTALLATION 5
A. CODES AND CLEARANCES 5
B. FURNACE LOCATION 6
B1.CDB1 HORIZONTAL APPLICATION 7
C. REPLACING EXISTING FURNACE FROM A COMMON VENT 8
D. GENERAL REQUIREMENTS FOR VENTING CHB1/CDB1 9
E. SIDEWALL VENTING
11
E1. SINGLE PIPE (SIDEWALL) VENTING OPTION 14
F. INSTALLATION OF OUTSIDE VENT/AIR INTAKE TERMS. 14
G. CONNECTING FURNACE TO ROOF VENT/AIR TERMS. 16
H. CONNECTING FURNACE TO VENT/AIR INTAKE TERMS. 17
I. CONDENSATE DRAIN LINE & TRAP ASSY. 22
J. GENERAL GAS PIPING 25
J1. REQUIREMENTS & SIZING OF DUCTWORK 26
K. FILTERS 29
L. WIRING 31
IV. STARTING THE UNIT 34
A. SEQUENCE OF OPERATIONS 34
B. INITIAL START-UP 36
C. ADJUSTMENT OF BTU INPUT RATE 36
D. BURNER ADJUSTMENT 37
E. FURNACE CHECKOUT PROCEDURE 38
VI. INSTALLER’S INSTRUCTIONS TO USER 39
VII. TROUBLESHOOTING 40
APPENDIX – A REPLACEMENT PARTS LIST 46
APPENDIX – B WIRING DIAGRAMS 50
v
All installations and services must be performed by qualified service personnel.
MODEL NO.
CHB1-50
CHB1-75
CHB1-100
CHB1-125
BTU/HR INPUT
50,000
75,000
100,000
125,000
BTU/HR OUTPUT
47,000
72,000
94,000
116,000
HT. OF 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
15 x 18
15 x 18
19 x 18
22 x 18
RETURN AIR INLET
25 x 16
25 x 16
25 x 16
25 x 16
DIA. OF FLUE
2”
2”
3”
3”
DIA. OF COMBUSTION
AIR INTAKE
CFM @ .2” & .5” w.c.
EXTERNAL STATIC PRESSURE
@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
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”
II. FURNACE SPECIFICATIONS
CHB1 SERIES
2” 2” 3” 3”
.2” .5” .2” .5” .2” .5” .2” .5”
2 Ton 3.5 Ton 4 Ton 5 Ton
NOTES:
1. BTU output based on annual fuel utilization efficiency rated by manufacturer.
2. On all 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.
1
All installations and services must be performed by qualified service personnel.
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 OF CASING
17”
17”
21”
24”
DEPTH OF CASING
27-1/2”
27-1/2”
27-1/2”
27-1/2”
WARM AIR OUTLET
15 x 18
15 x 18
19 x 18
22 x 18
RETURN AIR INLET
15 x 22
15 x 22
19 x 22
22 x 22
DIA. OF FLUE
2”
2”
3”
3”
DIA. OF COMBUSTION
AIR INTAKE
CFM @ .2” & .5” w.c.
EXTERNAL STATIC PRESSURE
@HI 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. OF SPEEDS
3 4 4
4
RUN CAPACITOR
10 mfd
10 mfd
10 mfd
15 mfd
LARGEST RECOMMEDED
AIR CONDITIONER
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)
CDB1 SERIES
2” 2” 3” 3”
.2” .5” .2” .5” .2” .5” .2” .5”
2 Ton 3.5 Ton 4 Ton 5 Ton
NOTES:
1. BTU output based on annual fuel utilization efficiency rated by manufacturer.
2. On all outlet and inlet dimensions, the first dimension is width.
3. To permit largest recommended air conditioning (at .5 static p r e ssure) , 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 subject to change without notice.
2
All installations and services must be performed by qualified service personnel.
PARTS PACKAGE
#S00S4405/4406
2-3/8” ID radiator hose
410017
1
Thermostat lead bushing
350750
1
PVC trap assembly
320816
1
#8 x ¾ coated TEK screws for
mounting trap & 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 ½ TEK screws for
mounting 2 x 4 J-box
#10-32 x ½ green gro und screw
300109
1
#10-32 hex nut
300110
1
3/16” dia. star washer
300270
1
Grounding instr uctions
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
320833
1
Gas Conversio n Kit
AOPS7677/7678
1
PARTS PACKAGE
#S00S4407/4408
2-3/8” ID radiator hose
410017
1
Thermostat lead bushing
350750
1
PVC trap assembly
320816
1
#8 x ¾ coated TEK screws for
mounting trap & 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 ½ TEK screws for
mounting 2 x 4 J-box
#10-32 x ½ green gro und screw
300109
1
#10-32 hex nut
300110
1
3/16” dia. star washer
300270
1
Grounding instr uctions
MG-966
1
Wire nut
300132
2
3” stainless steel hose clamp
300276
2
J-box wire bushing
350016
1
INSTALLATION PARTS PACKAGES - CHB1-50/75
DESCRIPTION PART # QUANTITY
300283 4
300208 2
CPVC XPVC adapter
INSTALLATION PARTS PACKAGES - CHB1-100/125
DESCRIPTION PART # QUANTITY
300283 4
300208 2
3
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 Conversio n Kit
AOPS7679/7664
1
PARTS PACKAGE
#S00S4409/4410
2-3/8” ID radiator hose
410017
1
Thermostat lead bushing
350750
1
PVC trap assembly
320816
1
#8 x ¾ coated TEK screws for
mounting trap & 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 ½ TEK screws for
mounting 2 x 4 J-box
#10-32 x ½ green gro und screw
300109
1
#10-32 hex nut
300110
1
3/16” dia. star washer
300270
1
Grounding instr uctions
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
PARTS PACKAGE
#S00S4411/4412
2-3/8” ID radiator hose
410017
1
Thermostat lead bushing
350750
1
PVC trap assembly
320816
1
#8 x ¾ coated TEK screws for
mounting trap & 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
INSTALLATION PARTS PACKAGES - CDB1-50/75
DESCRIPTION PART # QUANTITY
300283 6
CPVC XPVC adapter 320833 1
Gas Conversio n Kit AOPS7677/7678 1
INSTALLATION PARTS PACKAGES - CDB1-100/125
DESCRIPTION PART # QUANTITY
300208 2
300283 4
4
All installations and services must be performed by qualified service personnel.
#8 x ½ TEK screws for
mounting 2 x 4 J-box
#10-32 x ½ green gro und screw
300109
1
#10-32 hex nut
300110
1
3/16” dia. star washer
300270
1
Grounding instr uctions
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
Gas Conversio n Kit
AOPS7679/7664
1
300208 2
CPVC XPVC adapter 320833 1
III. GENERAL INSTALLATION
This furnace is equipped with orifices size for operation with natural gas. For conversion to Propane Gas see
instruction in Gas Conversion Se ction 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 CHB1-75) 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 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.
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 o f 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 choosing the size and location of the furnace.
1. All local codes and/or regulations take precedence over the instructions in this manual and should be followed
accordingly. In the absence o f local codes, installation must conform with these instructions, regulations of the
National Fire Prote ction Association, provisions of National Electrical Code (ANSI/NFPA70 or latest e dition),
and the National Fuel Gas Code (ANSI Z223.1 or latest edition).
5
All installations and services must be performed by qualified service personnel.
FROM SIDES OF
FURNACE & REAR
TOP OF
PLENUM
FROM THE
FLUE OR VENT
SIDE OF
PLENUM
CHB1-50
0 IN.
6 IN.
0 IN.
0 IN.
1 IN.
CHB1-75
0 IN.
6 IN.
0 IN.
0 IN.
1 IN.
CHB1-100
0 IN.
6 IN.
0 IN.
0 IN.
1 IN.
CHB1-125
0 IN.
6 IN.
0 IN.
0 IN.
1 IN.
CDB1-50
0 IN.
6 IN.
0 IN.
0 IN.
1 IN.
CDB1-75
0 IN.
6 IN.
0 IN.
0 IN.
1 IN.
CDB1-100
0 IN.
6 IN.
0 IN.
0 IN.
1 IN.
CDB1-125
0 IN.
6 IN.
0 IN.
0 IN.
1 IN.
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 CO MBUSTIBLE MATERIALS
TABLE 1
MODEL NO.
FRONT
The CHB1-50, 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 no. 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 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 III,
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 24”*.
*For horizontal furnace installation, refer to section III, B1 o f this installation manual.
Equipment must be installed in accordance with regulations of the Nat ional Board of Fir e U nde rwriters.
Authorities having jur isdic tion should be consulted befor e 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 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. The furnace must be located on a level, dry surface. The furnace must be installed so that the electrical
components are protected from water. If the area becomes wet or damp at times, the
above the floor using a concrete base, bricks, patio blocks, etc.
NOTICE: Ensure furnace is level after installation to ensure proper drainage and operation.
furnace should be raised
6
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
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 ser ies units, the rollout switch located on the burner box must
be moved to the pre-punched mounting holes on t he side of the burner box. Screws are provided in p re-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 hor izontal application of the CDB1 series units, the hose from the single tap pressure switch (top
switch) is already connected correctly (See Figure 1).
For a left side horizontal applica tion of the CDB1 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: T he 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, 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).
accessory, part number 350225. If
7
All installations and services must be performed by qualified service personnel.
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
joists, studs, or framing (See Figure 1).
Equipment must be installed in accordance with regulations of the Nat ional Board of Fir e U nde rwriters and
the National Fuel Gas Co de . Authorities having jur isdic tion should be consulted before installations are
made.
formed by the intersection of the top and two sides of the furnaces casing and the buil di ng
C. Replacing An Existing Furnac e From A Common Vent
: These furnaces may NOT be common vented with any other appliance.
8
All installations and services must be performed by qualified 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.
2. All plastic pipe and pipefitting s sourced to complete the exhaust vent and air intake systems shall be
constructed of rigid PVC (polyvinyl chloride) thermoplastic. All components shall have a wall
thickness equivalent to Schedule 40 series materials.
In addition, all sourced PVC components shall be listed b y 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 Sta ndard
Cellular Core ASTM-F891
DWV (Drain-Waste-Vent) ASTM-D2665
Schedule 40 ASTM-D1785
3. 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 req uired exhaust vent / air intake
pipe sizes are:
• nominal 2-inch diameter IPS, Schedule 40 series, PVC thermoplastic pipe, for models CHB1–50 / –
75 & CDB1–50 / –75, or
• nominal 3-inch diameter IPS, Schedule 40 series, 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 app liance, includ ing
those burning so lid fuels.
5. All horizontal runs of exhaust vent pipe shall slope upward at least ¼ 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.
Horizonta l runs of air intake pipe shall slope downward at least ¼ 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.
6. 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.
7. The maximum permissible length of pipi ng (consisting of a combination of straight pipe and a
corresponding number of elbows) permitted is:
• 75 equivalent feet, for the exhaust vent system, and
• 70 equivalent feet, for the combustion air intake system
8. The maximum quantity of Schedule 40 series, type DWV thermoplastic pipe elbows allowed in each system
is listed in Table 2. When counting pipe elbo ws, all elbows used in the exhaust vent or combusti on air
9
All installations and services must be performed by qualified service personnel.
Thermoplastic
(Nominal)
Exhaust or
Length (ft.)
Maximum
Maximu
Elbows 2
Exhaust or
Length (ft.)
Maximum
Maximu
Elbows 2
CHB1 / CDB1-50
35 8 7 - -
-
CHB1 / CDB1-75
CHB1 / CDB1-100
Not Permitted
35 8 7
CHB1 / CDB1-125
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
Pipe Vent Size
Furnace Model
Intake
Straight
Pipe
2 in. Diameter IPS
Qty. of
Exhaust
Elbows
1,2
m
Qty. of
Intake
Intake
Straight
Pipe
3 in. Diameter IPS
Qty. of
Exhaust
Elbows
1, 2
m
Qty. of
Intake
Superscripts:
1
The drain tee supplied with CHB1 / CDB1 furnace model series is considered equivalent to one (1),
90° elbow.
2
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 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 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 f ittings. 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.
10. 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.
11. Vent pipe passing through an unhe ated space s hall be insulate d with 1-inch thick, foil-faced fiberglass
insulation, or equivalent, to prevent freezing of condensate within the pipe.
12. No clearance is required from the outer surface of the thermoplastic piping to combustible materials for fire
hazard prevention.
13. 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. Ve nt and combustion air pipes may pass t hrough a maximum wall thickness of 18 i nches. 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.
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 de gra dation from contact with flue gases or
moisture, a min imum 24-inch diameter shield shall be fabricated from stainless steel or UV-resistant plastic
sheet. The protective shield shall be installed aro und the vent pip e 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. T he 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. The 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.
Figure 3: Typical Relative Locations of Direct Vent Terminations 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:
• over public walkways or over an area where wetting of surfaces by condensate, or water vapor,
could create a nuisance or hazard,
• 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 component s 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.
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