Thermo Products Pride Furnace Cma3 50D36N Users Manual

CMC1-75DV3N to the manual 30eb0262-3082-4f5f-ad96-98e4dd837e61

2015-02-03

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FOR YOUR SAFETY
WHAT TO DO IF YOU SMELL GAS
- NATIONAL FUEL GAS CODE NATIONAL FIRE PROTECTION ASSOCIATION
- III. GENERAL INSTRUCTIONS AND CLEARANCES – READ BEFORE START OF INSTALLATION
  - A. FURNACE LOCATION
    - B. BASE INSTALLATION – CMA3 models only
    - C. ALCOVE INSTALLATION
  - E. FUEL PIPING
    - F. GENERAL VENTING REQUIREMENTS
    - 1. The vent/air intake terminations outlined by Thermo Products in this manual must be used.
Table 2
If the heat anticipator is set too high, the furnace may delay activation of a heating cycle for too long. If the heat anticipator is set too low, the furnace may cycle too frequently. Either condition may not provide optimal comfort to the homeowner.
CMA3-50D36
CMA3-75D36
CMC1-50D36
CMC1-75D36
CMC1-50DV3
CMC1-75DV3
Mg-517 printing specifications.pdf
- Individual page specifications:

GAS FIRED HIGH EFFICIENCY FURNACE

DOWNFLOW & DIRECT VENT (SEALED COMBUSTION)

MODELS:

CMA3-50D36N, CMA3-75D36N,

CMC1-50D36N, CMC1-75D36N,

CMC1-50DV3N, CMC1-75DV3N

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.

THERMO PRODUCTS, LLC.

POST OFFICE BOX 217

NORTH JUDSON, IN 46366

PHONE: (574) 896-2133

MG-517

ECN 5295-MA 140106 MADE IN USA

TABLE OF CONTENTS

SECTION BEGINNING PAGE

I. SAFETY INFORMATION 1

II. FURNACE SPECIFICATIONS 7

III. GENERAL INSTRUCTIONS AND CLEARANCES 11

IV. GENERAL INSTALLATION 13

A. FURNACE LOCATION 13

B. BASE INSTALLATION 15

C. ALCOVE INSTALLATION 16

D. CLOSET INSTALLATION 14

E. FUEL PIPING 19

F. GENERAL VENTING REQUIREMENTS 20

G. CONNECTING THE EXHAUST VENT, AND COMBUSTION 22

AIR INTAKE

H. DIRECT VENTING THROUGH A SIDEWALL 24

I. INSTALLATION OF OUTSIDE EXHAUST/INTAKE TERMINATIONS 27

J. CONNECTING THE FURNACE TO ROOF VENT/ INTAKE TERMINATIONS 28

K. CONDENSATE DRAIN LINE AND TRAP ASSEMBLY 30

L. ELECTRICAL WIRING 31

V. STARTING THE UNIT 41

A. SEQUENCE OF OPERATION 41

B. INITIAL START-UP 43

C. ADJUSTMENT OF BTU INPUT RATE 44

D. BURNER ADJUSTMENT 45

E. SETTING TEMPERATURE RISE 46

F. FURNACE CHECK-OUT PROCEDURE 47

VI. INSTALLER'S INSTRUCTIONS TO USER 48

VII. DEALER MAINTENANCE 48

A. ELECTRICAL 49

B. GENERAL INSPECTION 49

C. HEAT EXCHANGER 50

D. HOUSE AIR BLOWER 50

E. RETURN AIR FILTER 50

VIII. TROUBLE SHOOTING 51

APPENDIX-A REPLACEMENT PARTS 58

APPENDIX-B WIRING DIAGRAM 62

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

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.

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.

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.

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/ANSI-

Z233.1 (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.

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/CMC 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.

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 start-

up 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/CMC 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.

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

II. FURNACE SPECIFICATIONS

MODEL

CMA3-50D36

CMA3-75D36

INPUT IN BTUH

50,000

75,000

OUTPUT IN BTUH

48,000

72,000

MAIN ORIFICE-NAT.

#42

MAIN ORIFICE-LP

#54

GAS SUPPLY PRESSURE

L.P. MINIMUM

11” IN.W.C.

NAT. MINIMUM

4.5”IN.W.C.

L.P. MAXIMUM

14” IN.W.C.

NAT. MAXIMUM

14” IN.W.C.

GAS MANIFOLD PRESSURE

L.P.

10.0” + .03 IN.W.C.

NAT.

3.5” + .03 IN. W.C.

INTAKE SIZE IN INCHES

2”

VENT SIZE IN INCHES

2”

NOMINAL TEMPERATURE RISE

55°F

65°F

SEASONAL EFFICIENCY (AFUE*)

95%

*ANNUAL FUEL UTILIZATION

EFFICIENCY

DIMENSIONS

CABINET SIZE

WIDTH 18” DEPTH 25-3/4" HEIGHT 57"

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.

185 LBS.

BLOWER DATA

BLOWER MODEL

12-9T DIRECT DRIVE

MOTOR HORSEPOWER

1/2 PSC

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.

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

MODEL

CMC1-50D36

CMC1-75D36

INPUT IN BTUH

50,000

75,000

OUTPUT IN BTUH

48,000

72,000

MAIN ORIFICE-NAT.

#42

MAIN ORIFICE-LP

#54

GAS SUPPLY PRESSURE

L.P. MINIMUM

11” IN.W.C.

NAT. MINIMUM

4.5”IN.W.C.

L.P. MAXIMUM

14” IN.W.C.

NAT. MAXIMUM

14” IN.W.C.

GAS MANIFOLD PRESSURE

L.P.

10.0” + .03 IN.W.C.

NAT.

3.5” + .03 IN. W.C.

INTAKE SIZE IN INCHES

2”

VENT SIZE IN INCHES

2”

NOMINAL TEMPERATURE RISE

55°F

65°F

SEASONAL EFFICIENCY (AFUE*)

95%

*ANNUAL FUEL UTILIZATION

EFFICIENCY

DIMENSIONS

CABINET SIZE

WIDTH 18” DEPTH 25-3/4" HEIGHT 57"

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

195 LBS.

205 LBS.

BLOWER DATA

BLOWER MODEL

12-9T DIRECT DRIVE

MOTOR HORSEPOWER

1/2 PSC

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.

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

MODEL

CMC1-50DV3

CMC1-75DV3

INPUT IN BTUH

50,000

75,000

OUTPUT IN BTUH

48,000

72,000

MAIN ORIFICE-NAT.

#42

MAIN ORIFICE-LP

#54

GAS SUPPLY PRESSURE

L.P. MINIMUM

11” IN.W.C.

NAT. MINIMUM

4.5”IN.W.C.

L.P. MAXIMUM

14” IN.W.C.

NAT. MAXIMUM

14” IN.W.C.

GAS MANIFOLD PRESSURE

L.P.

10.0” + .03 IN.W.C.

NAT.

3.5” + .03 IN. W.C.

INTAKE SIZE IN INCHES

2”

VENT SIZE IN INCHES

2”

NOMINAL TEMPERATURE RISE

55°F

65°F

SEASONAL EFFICIENCY (AFUE*)

95%

*ANNUAL FUEL UTILIZATION

EFFICIENCY

DIMENSIONS

CABINET SIZE

WIDTH 18” DEPTH 25-3/4" HEIGHT 57"

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

195 LBS.

205 LBS.

BLOWER DATA

BLOWER MODEL

12-9T DIRECT DRIVE

MOTOR HORSEPOWER

1/2 ECM

MOTOR RPM

1075 (HIGH SPEED)

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

.2”

.5”

.2”

.5”

LOW

639

437

935

802

MD-LOW

834

653

998

880

MED

948

811

1113

1007

MD-HIGH

1145

1026

1177

1083

HIGH

1365

1265

1272

1177

FOR BURNER COMBUSTION INFORMATION REFER TO INITIAL STARTUP.

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

INSTALLATION PARTS PACKAGES

PARTS PKG#

DESCRIPTION

CMA3-50D36N

CMA3-75D36N

S00S4248

S00S4249

PART #

QTY

PART #

QTY

J-box cover

350020

Wire nut

300132

3" stainless steel hose clamp

300276

2-3/8" radiator hose

410017

CPVC adapter

320833

LP conversion kit

AOPS7741

AOPS7742

PARTS PKG#

DESCRIPTION

CMC1-50D36N

CMC1-75D36N

S00S4190

S00S4191

PART #

QTY

PART #

QTY

J-box cover

350020

Wire nut

300132

3" stainless steel hose clamp

300276

2-3/8" radiator hose

410017

CPVC adapter

320833

LP conversion kit

AOPS7741

AOPS7742

Gasket, drain knock-out

330355

Grommet, vinyl 3/8"

350040

Grommet, vinyl 7/8"

350009

Screw, #8 x 1/2 Tek

300208

Coil trim panel

619113

PARTS PKG#

DESCRIPTION

CMC1-50DV3N

CMC1-75DV3N

S00S4244

S00S4245

PART #

QTY

PART #

QTY

J-box cover

350020

Wire nut

300132

3" stainless steel hose clamp

300276

2-3/8" radiator hose

410017

CPVC adapter

320833

LP conversion kit

AOPS7741

AOPS7742

Gasket, drain knock-out

330355

Grommet, vinyl 3/8"

350040

Grommet, vinyl 7/8"

350009

Screw, #8 x 1/2 Tek

300208

Coil trim panel

619113

Tape, aluminum 2"

390111

42"

390111

42"

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

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-815 in Gas Conversion Kit

AOPS7743.

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. For the Energy Star Eco Tech models the temperature rises are 40°F to

70°F for the 50 series and 50°F to 80°F for the 75 series. (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

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.

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

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 “NON-

COMBUSTIBLE 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.

MODELS CMA3/CMC1

CLOSET

ALCOVE

FRONT

BACK

SIDES

VENT CONNECTOR(PVC)

TOP

PLENUM SIDES

TOP AND SIDES OF DUCT

BOTTOM OF DUCT

6”

0”

1”

18”

0”

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.

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

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. Model CMA3 furnace may be installed on a combustible floor when utilizing

either the No. 70 counterflow floor base or CE113S / CE213T 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.

4. Model CMC1 furnace is designed to be installed directly on a combustible

floor and is not required to be installed on a base.

This furnace is ETL listed for closet, alcove or free standing applications. All

applications must comply with the requirements of this manual.

Combustible Floor Base Model: 70-BASE

For CMA3 models only.

Figure 1A.

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

Coil Cabinet Model: CE113S / CE213T

Note: Coil cabinet cannot be utilized as a cottage base.

CE113S CE213T

Figure 1B.

Cottage Base Model: 01COT-BASE

For CMA3 models only.

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

systems.

Figure 1C.

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

B. BASE INSTALLATION – CMA3 models only

1. Combustible Floor Base Model: 70 BASE (for CMA3 models only)

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

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 (for CMA3 models only)

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.

The model CMC does not require a base for installation. The integrated coil

cabinet serves as a base. The duct connection will be made to the bottom of the

furnace. A sheet metal cover plate may be installed to protect any exposed

combustible flooring.

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

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.

CMA3 SERIES CMC1 SERIES

Figure 4.

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.

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

CMA3 SERIES CMC1 SERIES

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.

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

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

occurs. Wait at least 24 hours for the circuit to fully dry before energizing

the system.

: The furnace and its gas 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 inches w.c

F. GENERAL VENTING REQUIREMENTS

The CMA/CMC furnace venting system must be installed by a qualified service

person in accordance with local codes, the National Fuel Gas Code NFPA

54/ANSI-Z223.1 (Latest Edition) and these instructions.

The following items and local code requirements must be followed:

1. The vent/air intake terminations outlined by Thermo Products in this

manual must be used.

2. The entire vent/air intake system must be made of PVC Schedule 40 pipe

except for the concentric vent kit. NOTE: All CMA/CMC furnaces must be

installed with outside combustion air.

3. The flue vent pipe and combustion air pipe must be at least as large as the

exhaust vent/air intake pipe specified by Thermo Products. No reduction in

size is permissible. The CMA/CMC requires 2” Schedule 40 PVC pipe.

4. This furnace shall not be common vented with any other appliance

including those burning solid fuels.

5. The maximum permissible vent length of straight pipe and number of

elbows permitted for the exhaust vent and combustion air inlet is shown in

Table 2. The elbows shown are in addition to the length of straight pipe

permitted. When counting elbows, all elbows used in the exhaust vent or

combustion air intake must be counted. This includes elbows used inside the

furnace jacket and termination elbows.

Care should be taken to plan out the vent system to be as short as possible

(but not shorter than 8 ft.) and to contain as few elbows as possible to insure

the best possible operation of the furnace.

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

MAXIMUM VENT LENGTH

VENT SIZE

2 IN. PVC

FURNACE

MODEL

VENT

LENGTH

(FT.)

EXHAUST

VENT

ELBOWS

(NO.)

COMBUSTION AIR INTAKE

ELBOWS (NO.)

CMA*/CMC*

7**

*Note the drain elbow supplied with furnace count as 1 elbow.

**Note the two 45° elbows supplied with furnace count as 1 elbow.

Table 2

6. A hack saw may be used to cut the PVC pipe. It must be cut smoothly at

right angles with all burrs removed. All joints must use standard PVC

Schedule 40 elbows and couplings. Joints are not to be made by gluing,

except where noted, and butting together the cut or raw edges of the vent

pipe. (The joints inside the vestibule should be sealed with a silicone caulk to

allow for maintenance.) Notice: Do not use silicone caulk to seal the PVC

sleeve or coupling to the metal air intake collar on the burner box. The

screw securing the sleeve or coupling to the collar is sufficient.

7. Use the two radiator hose clamps to connect both the exhaust vent and

combustion air vent pipes to the venting system (included in the parts

package.) This will aid in the serviceability of the vent should it need to be

removed in the future. (Refer to figure 6).

8. Vent connections shall be checked for leakage with the furnace induced

draft blower running and with the vent termination blocked. A mild soap and

water solution may be used to check for leaks.

9. Vent pipe passing through an unheated space must be insulated with 1.0”

thick foil faced fiberglass insulation or its equivalent to prevent freezing of any

condensate within the pipe.

10. Minimum clearance from the PVC pipe to combustible material is zero

inches.

IMPORTANT: The CMA/CMC furnace models are vented through the roof.

For roof venting refer to Section IV, J, of this manual.

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

G. CONNECTING THE EXHAUST VENT AND COMBUSTION AIR INTAKE

Figure 6. shows the typical exhaust vent and combustion air intake connection

for CMA/CMC furnace.

Figure 6.

Models CMA and CMC have a removable top front panel that will allow for

improved access to assist installation of the exhaust vent and combustion air

intake connection to the top of the furnace. Access is gained by removal of two

screws in the upper right and left of the furnace. The top front access panel is

then removed by pulling forward. Once the vent connections are made, the top

front access panel is replace. Be sure the access panel fits the around the two

grommets that secure the vent pipes and the rear tab locks below the top rear

panel. For Energy Star models, adhesive backed aluminum tape has been

provided to seal the access panel to the furnace top to make an air tight seal at

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

the conclusion of the vent pipe installation. This will insure a leak free return air

compartment. Refer to Figure 6A.

Figure 6A.

NOTICE: The exhaust vent pipe must be supported every 4 feet. After making

sure the length of the piping is correct glue all connections in place.

: This CMA/CMC 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.

NOTICE: The furnace model series CMA/CMC may be vented either

through the sidewall or the roof. For sidewall instructions, continue to the

following section. For roof venting, refer to Section IV J, of this manual.

NOTICE: The air intake pipe must be supported every 4 feet. After making sure

the length of the piping is correct, glue all connections in place except the

connection to the burner box.

If the combustion air piping is installed in a warm humid place, such as a laundry

room or above a suspended ceiling, it must be insulated with a 1.0” foil faced

insulation or its equivalent.

If the vent piping is run through an unconditioned space, it must be insulated with

a 1.0” foil faced insulation or its equivalent.

: 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

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

gas flame. Should acid compounds form in your furnace, it may reduce the

life of the furnace.

H. Direct Venting Through a Sidewall

1. Vent And Combustion Air Pipes

Vent and combustion air pipes may pass through a maximum wall thickness

of 18 inches. The minimum wall thickness is 2 inches. Referring to Figure

7, the maximum distance from the outer wall to the center of the elbow is 12

inches.

Figure 7: 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 shield shall be installed around the vent pipe on the outside wall.

2. Exhaust Vent Termination Elbow

The exhaust vent termination elbow shall be installed in accordance with

these instructions and any applicable local codes. Refer to Figures 7 and 8 for

typical examples of proper terminations.

a. The exhaust vent termination must be installed in the same

atmospheric pressure zone (i.e. on the same wall) as the air intake

termination.

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

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.

Figure 8: 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 9 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

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

• where wetting of components by condensate, or water vapor, could

be detrimental to the operation of pressure regulators, relief valves,

or any other equipment.

d. 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.

Figure 9: NFGC Minimum Clearances Between the Vent Terminal and Various

Building Features

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

4. Vent Terminal Location Guidelines

: Bushes, shrubs, or any vegetation that may restrict the flow of

flue products must be kept away from vent and air intake terminations.

Terminations must also be kept clear of any leaves, weeds, combustible

materials, snow, and ice build-up. Avoid locating the vent terminal over

areas where dripping of condensate, or small pools of acidic condensate,

could create a problem.

In addition to following any local code requirements, when possible, utilize the

guidelines below in locating the vent terminal to help insure trouble-free operation

of a sidewall vented furnace:

• Avoid locating the vent terminal on a wall facing prevailing winds and wide-

open areas. When impractical, choose a location that protects the vent from

strong winds, such as behind a fence or hedge.

• In geographical areas with considerable snowfall, it is advisable to locate the

vent terminal much higher than the minimum 12-inches above ground 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.

I. Installation Of Outside Exhaust / Intake Terminations

1. After determining appropriate installation locations (suitable locations must

observe all clearances specified in this manual), mark and cut two (2), 2-3/8 inch

diameter holes in the outside wall for the outdoor terminal(s)

2. Measure and cut two (2), 2-inch diameter thermoplastic pipes 1-1/2 inches

longer than the depth of the wall. (Cutting the pipe longer leaves a ¾ inch

connection allowance at both ends of the pipe.) Using PVC pipe cement, glue a

PVC elbow or coupling fitting to one (1) end of each pipe.

Before inserting the pipe through the wall, mark the other end of the pipe so the

elbow orientation can be determined. Also, if a protective shield (refer to Section

H., passage 1. of this manual) will be used on the exterior surface of the wall, it

should be installed at this time. From the inside, glue a coupling fitting to each

pipe, using PVC pipe cement, while being careful to maintain the proper

orientation of the termination elbow(s). Complete the assembly of the outlet and

inlet as shown in Figure 10, making sure that the spacing between the inlet and

outlet complies with that noted in Figure 8.

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

Figure 10: Typical Construction Details of Sidewall Vent and Air Intake

Terminations

3. Finish the vent installation by caulking the annulus to seal around the two (2)

holes where the thermoplastic pipes pass through the wall.

4. To prevent foreign material, insects, or small animals from entering the pipes,

an optional vent or intake terminal (stainless steel) screen is available from

Thermo Products under part no. 320219.

J. CONNECTING THE FURNACE TO ROOF VENT / AIR TERMINATIONS

The CMA/CMC is designed to be vented with either a concentric vent assembly

or twin 2” pvc stacks. The concentric vent (AOPS7483) can be vented through

the ceiling/roof either thru the existing roof jack or thru the 3” ceiling/roof flashing

plate.

Concentric vent utilizing existing roof jack as a chase.

Follow instructions included with concentric vent kit AOPS7483.

Concentric vent without roof jack as a chase.

Follow instructions included with concentric vent kit AOPS7483.

Dual 2” vent/air termination kit AOPS7484

1. Remove roof jack assembly.

2. Place a 2” (2-holes) ceiling/roof flashing plate to the ceiling centering it

over existing hole.

3. Place second flashing plate on roof over existing hole.

4. Plate must be sealed to roof to ensure a weather proof seal.

5. Secure plate to roof.

6. Drop pvc pipes thru holes in flashing plates.

7. Secure with hose clamps to flashing plate.

8. Seal with silicone type caulk.

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

The furnace may be vented vertically through the roof. The outlet/inlet of the vent

and air intake terminations shall be a minimum of 12 inches above highest

anticipated snow level. The vent outlet must be installed a minimum of 12 in.

above the air intake inlet. The combustion air intake shall be installed upwind of

the vent outlet when exposed to prevailing winds. The exhaust vent and

combustion air intake can be a minimum of 3 in. and a max. of 24 in. apart (see

Figures 11 & 12). When installing dual 2” PVC pipes and the 2” flashing plates

(AOPS7484) on pitched roof, slope adapter may be used to simplify installation.

Figure 11.

Figure 12.

When the PVC vent and combustion air intake pipes pass through a ceiling, and

a fire stop is required. Refer to the following:

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

CEILING: Frame out area around where PVC pipe is to penetrate ceiling. Cut a

2-3/8” diameter hole for 2” PVC in the ceiling and a corresponding hole in a

firestop to be made of a minimum of 18 gauge galvanized metal large enough to

cover the entire framed area. Cut PVC pipe so that it extends up past the fire

stop far enough to engage a PVC coupling that will rest on the fire stop and act

as a support. Seal between the pipe coupling and fire stop with high temperature

RTV silicone sealant (see Figure 13). Continue installing PVC pipe to exhaust

vent and combustion air intake termination as described previously.

Figure 13.

K. CONDENSATE DRAIN LINE AND TRAP ASSEMBLY

1. Figure 14 illustrates the typical drain

trap connection for a CMA/CMC furnace.

(Trap will be installed at factory.)

Connect condensate drain trap to

building drain system.

2. An optional condensate neutralizer kit

(P/n 320095) is available when gas

furnace condensate needs to be

neutralized (pH increased) prior to

discharge into drain system.

3. An optional mini condensate pump

(P/N 350224) is available. This pump

will fit into the vestibule of the furnace.

Instructions will be included with pump if

this option is utilized.

Figure 14.

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

L. ELECTRICAL WIRING

All wiring shall be performed by a qualified electrician or service person. The

wiring must comply with local codes, the instructions in this manual, and in the

absence of codes with the National Electrical Code ANSI/NFPA-70 (LATEST

EDITION).

1. Electrical Branch Supply Circuit

Route all electrical wiring to the left side of the furnace. The power supply

circuit to the furnace must be installed and grounded in accordance with the

provisions of the National Electrical Code, ANSI/NFPA-70-1999, or latest

edition, and all local codes having jurisdiction.

2. Connection Of Power Supply Wires

a. Remove the cover from junction box.

b. Insert 115 VAC wires through the strain relief bushing (or conduit

connection as applicable) on the left side of the furnace junction box.

c. Connect the “hot” wire to the black wire.

d. Connect the “neutral” wire to the white wire.

e. Connect the “ground” wire to the green wire.

f. Reinstall and secure the junction box cover with the original mounting

screws.

NOTICE: The hot surface igniter and operation of this furnace depends on

correct polarity. The hot leg of the supply circuit must be connected to the

black line lead (L1) and the common leg (L2) to the white line lead in the field

mounted junction box. The hot leg must pass through the disconnect switch in

all cases to prevent the hazard of electrical shock when servicing.

IMPORTANT: The furnace must be grounded in accordance with local codes

and with the National Electrical Code, ANSI/NFPA NO. 70 (Latest Edition)

when an external electrical source is utilized.

3. Connection Of Room Thermostat Wires

NOTE: Class 1 thermostat wire must be used inside the furnace burner

compartment.

a. Insert 24 VAC wires through the plastic grommet on the left side of the

furnace casing.

b. Connect the thermostat wires to the W/R 50A65-143 control (refer to the

wiring diagram).

c. Connect the thermostat wires to the room thermostat.

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

IMPORTANT: The room thermostat should be installed 4 to 5 feet above

the floor on an interior wall which is relatively free from direct sources of

heat (sunlight or supply airflow) or exposure to cold (drafts from open

windows and doors). The nominal anticipator setting is 0.8 amperes, for

the CMA/CMC (refer to the thermostat literature for additional information).

Four-conductor thermostat wire is recommended for 24 VAC, low-voltage,

control circuit wiring. However, only 2 wires are required for the furnace (a

heating application only).

Electrical Wire

Diameter

Maximum Recommended

Thermostat Wire Length

(AWG)

(Feet)

140

225

Once the furnace is installed, check the thermostat anticipator for proper

nominal setting.

1. Connect a multimeter, capable of reading milliamps (mA), in series

with the low voltage wires to the thermostat.

2. Increase the thermostat setting, or create a “call for heat”.

3. Read the value of the thermostat current, in milliamps.

4. Adjust the heat anticipator of the thermostat to the value read by the

multimeter.

If the heat anticipator is set too high, the furnace may delay activation of a

heating cycle for too long. If the heat anticipator is set too low, the furnace

may cycle too frequently. Either condition may not provide optimal

comfort to the homeowner.

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

4. BLOWER MOTOR SPEED WIRING

Figure 15.

BLOWER DELAY SETTINGS

To delay fan

turn-on by:

Set Switch

#1 #2

15 sec.

30 sec.

*45 sec.

60 sec,

Off Off

Off On

On Off

On On

To delay fan

turn-off by:

Set Switch

#3 #4

60 sec.

90 sec.

*120 sec.

180 sec.

On On

Off On

On Off

Off Off

*Factory Settings For Optimal Performance

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

CMA3-50D36

ALTERATIONS REQ’D FOR A/C @ DESIGN EXTERNAL STATIC PRESSURE

COOLING UNIT HTG Speed Recommended CLG Speed

24,000

LOW

MED-LOW

30,000

LOW

MED-HIGH

36,000

LOW

HIGH

Speed Tap \

Static

Pressure

Furnace Airflow (CFM) vs. External Static pressure (in. WC.)

0.1

0.2

0.3

0.4

0.5

0.6

0.7

Low

836

805

773

743

695

620

566

1044

1010

972

914

860

826

752

1250

1196

1146

1101

1038

977

902

High

1339

1338

1283

1233

1162

1086

1008

Speed Tap \

Static

Pressure

Temperature Rise vs. External Static Pressure (in. WC.)

0.1

0.2

0.3

0.4

0.5

0.6

0.7

Low

High

Speed Tap

\ Static

Pressure

Blower Motor Current Draw (Amps) vs. External Static pressure (in. WC.)

0.1 0.2 0.3 0.4 0.5 0.6 0.7

Low

3.3

3.2

3.1

3.0

2.9

2.7

2.6

4.0

3.8

3.6

3.5

3.4

3.2

3.1

4.6

4.4

4.2

4.1

4.0

3.8

3.6

High

5.3

5.1

5.0

4.9

4.7

4.6

4.4

Speed Tap \

Static

Pressure

Blower Motor Watts vs. External Static pressure (in. WC.)

0.1

0.2

0.3

0.4

0.5

0.6

0.7

Low

315

311

304

300

292

281

275

400

390

376

363

351

342

330

485

467

452

441

427

412

394

High

573

555

544

530

513

493

477

= Recommended operation range

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

CMA3-75D36

ALTERATIONS REQ’D FOR A/C @ DESIGN EXTERNAL STATIC PRESSURE

COOLING UNIT HTG Speed Recommended CLG Speed

24,000

MED-LOW

30,000

MED-LOW

MED-HIGH

36,000

MED-LOW

HIGH

Speed Tap \

Static

Pressure

Furnace Airflow (CFM) vs. External Static pressure (in. WC.)

0.1

0.2

0.3

0.4

0.5

0.6

0.7

Low

817

797

773

730

668

620

555

1019

995

959

918

869

821

760

1257

1210

1174

1125

1076

1024

959

High

1470

1420

1366

1312

1259

1196

1127

Speed Tap \

Static

Pressure

Blower Motor Current Draw (Amps) vs. External Static pressure (in. WC.)

0.1 0.2 0.3 0.4 0.5 0.6 0.7

Low

3.1

3.0

2.9

2.8

2.7

2.6

2.5

3.9

3.8

3.6

3.5

3.3

3.2

3.1

4.8

4.6

4.4

4.2

4.1

4.0

3.8

High

5.7

5.5

5.4

5.2

5.1

5.0

4.8

Speed Tap \

Static

Pressure

Blower Motor Watts vs. External Static pressure (in. WC.)

0.1

0.2

0.3

0.4

0.5

0.6

0.7

Low

312

303

298

291

280

273

264

400

390

381

366

354

342

330

513

490

478

462

447

432

413

High

624

605

591

573

556

542

522

Speed Tap \

Static

Pressure

Temperature Rise vs. External Static Pressure (in. WC.)

0.1

0.2

0.3

0.4

0.5

0.6

0.7

Low

106

119

High

= Recommended operation range

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

CMC1-50D36

ALTERATIONS REQ’D FOR A/C @ DESIGN EXTERNAL STATIC PRESSURE

COOLING UNIT HTG Speed Recommended CLG Speed

24,000

LOW

MED-LOW

30,000

LOW

MED-HIGH

36,000

LOW

HIGH

Speed Tap \

Static

Pressure

Furnace Airflow (CFM) vs. External Static pressure (in. WC.)

0.1

0.2

0.3

0.4

0.5

0.6

0.7

Low

836

805

773

743

695

620

566

1044

1010

972

914

860

826

752

1250

1196

1146

1101

1038

977

902

High

1339

1338

1283

1233

1162

1086

1008

Speed Tap \

Static

Pressure

Temperature Rise vs. External Static Pressure (in. WC.)

0.1

0.2

0.3

0.4

0.5

0.6

0.7

Low

High

Speed Tap

\ Static

Pressure

Blower Motor Current Draw (Amps) vs. External Static pressure (in. WC.)

0.1 0.2 0.3 0.4 0.5 0.6 0.7

Low

3.3

3.2

3.1

3.0

2.9

2.7

2.6

4.0

3.8

3.6

3.5

3.4

3.2

3.1

4.6

4.4

4.2

4.1

4.0

3.8

3.6

High

5.3

5.1

5.0

4.9

4.7

4.6

4.4

Speed Tap \

Static

Pressure

Blower Motor Watts vs. External Static pressure (in. WC.)

0.1

0.2

0.3

0.4

0.5

0.6

0.7

Low

315

311

304

300

292

281

275

400

390

376

363

351

342

330

485

467

452

441

427

412

394

High

573

555

544

530

513

493

477

= Recommended operation range

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

CMC1-75D36

ALTERATIONS REQ’D FOR A/C @ DESIGN EXTERNAL STATIC PRESSURE

COOLING UNIT HTG Speed Recommended CLG Speed

24,000

MED-LOW

30,000

MED-LOW

MED-HIGH

36,000

MED-LOW

HIGH

Speed Tap \

Static

Pressure

Furnace Airflow (CFM) vs. External Static pressure (in. WC.)

0.1

0.2

0.3

0.4

0.5

0.6

0.7

Low

817

797

773

730

668

620

555

1019

995

959

918

869

821

760

1257

1210

1174

1125

1076

1024

959

High

1470

1420

1366

1312

1259

1196

1127

Speed Tap \

Static

Pressure

Blower Motor Current Draw (Amps) vs. External Static pressure (in. WC.)

0.1 0.2 0.3 0.4 0.5 0.6 0.7

Low

3.1

3.0

2.9

2.8

2.7

2.6

2.5

3.9

3.8

3.6

3.5

3.3

3.2

3.1

4.8

4.6

4.4

4.2

4.1

4.0

3.8

High

5.7

5.5

5.4

5.2

5.1

5.0

4.8

Speed Tap \

Static

Pressure

Blower Motor Watts vs. External Static pressure (in. WC.)

0.1

0.2

0.3

0.4

0.5

0.6

0.7

Low

312

303

298

291

280

273

264

400

390

381

366

354

342

330

513

490

478

462

447

432

413

High

624

605

591

573

556

542

522

Speed Tap \

Static

Pressure

Temperature Rise vs. External Static Pressure (in. WC.)

0.1

0.2

0.3

0.4

0.5

0.6

0.7

Low

106

119

High

= Recommended operation range

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

CMC1-50DV3

ALTERATIONS REQ’D FOR A/C @ DESIGN EXTERNAL STATIC PRESSURE

COOLING UNIT HTG Speed Recommended CLG Speed

24,000

LOW

MED-LOW

30,000

LOW

MED-HIGH

36,000

LOW

HIGH

Speed Tap \

Static

Pressure

Furnace Airflow (CFM) vs. External Static pressure (in. WC.)

0.1

0.2

0.3

0.4

0.5

0.6

0.7

Low

700

639

567

497

437

387

332

876

834

781

725

653

602

556

MED

990

948

907

857

811

756

700

1174

1145

1107

1066

1026

987

942

High

1398

1365

1326

1299

1265

1252

1190

Speed Tap \

Static

Pressure

Temperature Rise vs. External Static Pressure (in. WC.)

0.1

0.2

0.3

0.4

0.5

0.6

0.7

Low

101

114

132

MED

High

Speed Tap

\ Static

Pressure

Blower Motor Current Draw (Amps) vs. External Static pressure (in. WC.)

0.1 0.2 0.3 0.4 0.5 0.6 0.7

Low

1.1

1.2

1.3

1.4

1.7

1.8

1.9

2.0

MED

2.2

2.3

2.4

2.5

3.4

3.5

3.6

3.7

High

5.2

5.3

5.4

5.5

Speed Tap \

Static

Pressure

Blower Motor Watts vs. External Static pressure (in. WC.)

0.1

0.2

0.3

0.4

0.5

0.6

0.7

Low

123

127

133

137

141

145

148

MED

168

173

178

183

188

192

197

266

272

277

284

290

296

301

High

438

442

445

450

455

461

468

= Recommended operation range

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

CMC1-75DV3

ALTERATIONS REQ’D FOR A/C @ DESIGN EXTERNAL STATIC PRESSURE

COOLING UNIT HTG Speed Recommended CLG Speed

24,000

MED-LOW

30,000

MED-LOW

MED-HIGH

36,000

MED-LOW

HIGH

Speed Tap \

Static

Pressure

Furnace Airflow (CFM) vs. External Static pressure (in. WC.)

0.1

0.2

0.3

0.4

0.5

0.6

0.7

Low

970

935

898

846

802

765

710

1043

998

968

928

880

830

785

MED

1148

1113

1080

1051

1007

968

929

1212

1177

1142

1119

1083

1047

1023

High

1300

1272

1229

1211

1177

1144

1117

Speed Tap \

Static

Pressure

Blower Motor Current Draw (Amps) vs. External Static pressure (in. WC.)

0.1 0.2 0.3 0.4 0.5 0.6 0.7

Low

2.4

2.5

2.6

2.7

2.8

2.9

3.0

3.1

3.2

MED

3.6

3.7

3.8

3.9

4.2

4.3

4.4

4.5

High

4.8

4.9

5.0

5.1

5.2

Speed Tap \

Static

Pressure

Blower Motor Watts vs. External Static pressure (in. WC.)

0.1

0.2

0.3

0.4

0.5

0.6

0.7

Low

187

190

195

200

204

206

211

225

229

233

238

244

248

252

MED

290

295

299

303

310

315

320

341

347

353

356

364

369

371

High

408

414

423

428

435

441

445

Speed Tap \

Static

Pressure

Temperature Rise vs. External Static Pressure (in. WC.)

0.1

0.2

0.3

0.4

0.5

0.6

0.7

Low

103

MED

High

= Recommended operation range

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

: TURN OFF THE ELECTRICAL POWER to the furnace

before attempting to change blower speed wiring.

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 obtain the desired CFM. The unused speeds should then be

reconnected to the module in the “park” positions. (Refer to figure 15)

Refer to section II for blower speed and air flow performance for A/C

installation.

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 35 C wire. If any of the original

factory supplied furnace wiring is replaced or a separate device other than the

thermostat is wired internal to the unit 105°C thermoplastic or equivalent wire

must be used.

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

V. STARTING THE UNIT

A. SEQUENCE OF OPERATIONS

START

TRIAL

FOR

IGNITION

CONTINUOUS SAFE OPERATION CHECK

IF FLAME SIMULATION CONDITION

PRESENT OR ROLL-OUT SWITCH OPENS, SYSTEM

ENERGIZES INDUCER FAN FOR 15 SECONDS AND CIRCULATOR BLOWER AT

HEATING SPEED UNTIL SITUATION CORRECTION

THERMOSTAT CALLS FOR

HEAT, CONTACTS CLOSE

POWER INTERRUPTION

SYSTEM SHUTS OFF,

RESTARTS WHEN POWER

IS RESTORED.

PRESSURE SWITCH SENSES

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 IS TURNED OFF AND

THE CONTROL BOARD CONTROL GOES

INTO "RETRY" SEQUENCE.

START

AT ANY TIME THE

GAS VALVE IS

NOT ENERGIZED

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

MAIN

BURNER

OPERATION

END

OF CYCLE

CALL

FOR

HEAT

SATISFIED

AFTER DELAY-TO-FAN-ON

PERIOD ENDS, CIRCULATING

AIR FAN IS ENERGIZED AT

HEATING SPEED. THE (OPTIONAL)

ELECTRONIC AIR CLEANER

AND HUMIDIFIER ARE

ENERGIZED.

AFTER THE DELAY-TO-

FAN-OFF PERIOD ENDS,

THE CIRCULATING AIR

FAN AND (OPTIONAL)

ELECTRONIC AIR CLEANER

ARE DE-ENERGIZED.

THE RETRY SEQUENCE

PROVIDES A 60 SECOND

WAIT BEFORE IGNITION

RETRY. RETRY IS

ATTEMPTED WITH AN

ADDITIONAL 10 SECONDS

OF IGNITOR WARM-UP

TIME.

WHEN THERMOSTAT IS

SATISFIED, CONTACTS

OPEN 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 DOES NOT RESTART THE SYSTEM,

REFER TO THE TROUBLESHOOTING

SECTION OF THIS MANUAL.

IF IGNITION ATTEMPT IS

UNSUCCESSFUL, ONE MORE

RETRY WILL BE MADE

BEFORE THE CONTROL BOARD

GOES INTO SYSTEM LOCKOUT.

IF FLAME IS DETECTED,

THEN LOST, THE CONTROL BOARD

WILL REPEAT THE INITIAL IGNITION

SEQUENCE FOR A TOTAL OF SIX

RECYCLES. AFTER SIX UNSUCCESSFUL

RECYCLE ATTEMPTS, THE CONTROL

WILL GO INTO SYSTEM LOCKOUT.

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

B. INITIAL START UP:

This furnace does not have a pilot. It is equipped with a hot surface igniter which

automatically lights the burner. Do not attempt to light the burner by hand. Check

the following items before the initial start-up.

1. Check all wiring for loose connections and proper hook up.

2. Leak test gas piping connections.

3. Check all tubing to the pressure switch and drains to make sure they are

connected firmly at all their connection points.

4. Check flue pipe, combustion air inlet and all pvc connections for tightness and

to make sure there is no blockage.

5. Make sure air filter is in place.

6. Make sure the outside vent and air intakes are installed according to

instructions and that they are free from blockage.

7. Make sure that the drain trap is properly connected to the furnace and to the

drain system.

OPERATING INSTRUCTIONS:

: 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

start-up 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 as noted above for 15 minutes or until odor

has dissipated.

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

C. ADJUSTMENT OF BTU INPUT RATE:

The orifice for this furnace was sized: 1) for natural gas having a heating value of

1025 BTU per cubic foot and a specific gravity of .65, or 2) for liquefied propane

gas with a heating value of 2500 BTU per cubic foot and a specific gravity of

1.55. The information plate inside the furnace vestibule will specify which gas

your furnace is orificed for. If the furnace is installed at an altitude that is more

than 2,000 feet above sea level, it is mandatory that the input to the burner be

reduced 4.0% for every 1,000 feet that it is above sea level. If the furnace is

installed at an elevation of 5,000 feet, its input must be reduced 20.0%. Example:

a furnace rated at 75,000 BTU at sea level must be reduced to a firing rate of

60,000 (75,000 x .80 = 60,000) at an elevation of 5,000 feet. If the furnace is

installed at an elevation of 2,000 feet or less, no reduction in input is required.

Your gas supplier or Thermo Products will supply you with the correct orifice

sizing information.

To check the input of your natural gas furnace, allow the unit to operate for 10 to

15 minutes and proceed as follows:

1. Call your gas supplier and ask for the BTU content (heating value) of one

cubic foot of the gas, supplied to the installation area. An alternate

approach is to assume a value of 1025 BTU/Cu Ft which is the national

average.

2. With all other gas appliances turned off and using a stopwatch, clock the

time required for the (small) dial on the gas meter to make one full

revolution. The meter dial will state the cubic feet of flow for one

revolution usually one, two or five.

FORMULA: BTU/Cu Ft x Number of Cu Ft x 3600 Seconds = Input BTU/hr

Seconds for one revolution

EXAMPLE: 1025 BTU/Cu Ft x 2 Cu Ft x 3600 = 73,505 BTU Input

100.40 Seconds

Check the model number of the furnace, the input rate, the type of gas,

and the manifold pressure on the rating label located in the burner

vestibule. If using the above example, the furnace is a CMA2-75N model

and the input rate is 73,505 BTU/hr. The input rate would be acceptable

because it was within + 2% of the listed input of 75,000.

3. Make sure that the gas supply pressure to the furnace is within the

allowable range of 5.5" to 14" WC pressure on natural gas and 11.0" to

14.0" WC on propane gas. The pressure to the furnace must be checked

while the furnace burner and any other gas appliances on the same

supply system are operating, using the 1/8 in. NPT manifold pressure tap.

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

GAS PRESSURE CHART FOR CMA*/CMC* MODEL FURNACES

TABLE 3

This gas furnace is equipped with a fixed orifice sized for the manifold

pressure shown on the rating label. The input can only be increased, or

decreased, by adjusting the manifold pressure. Remove the 1/8" threaded

pipe plug located on the gas manifold.

Use a U tube manometer or recently calibrated pressure gage to measure

the pressure. To adjust the pressure, remove the screw cap from the

regulator on the gas valve and using the adjustment screw. Decrease the

pressure by turning the screw counterclockwise or increase it by turning

the screw clockwise.

: ADJUSTMENTS TO THE LISTED PRESSURE MUST NOT

EXCEED 0.3" WC. A 0.3" WC adjustment will increase or decrease the

input approximately 4.0%.

Replace screw (cap) when adjustment is complete.

The correct input can be assumed if the furnace manifold pressure is the

same as that shown on the rating label if a gas meter is not available for

natural gas or the unit is installed on an unmetered propane gas supply.

Shut off the gas supply to the furnace. Remove the pressure gage and re-

install the pipe plug using a thread compound resistant to the action of LP

gases.

If the rated input cannot be obtained with the present orifice at the correct

pressure, your local gas supplier may assist in sizing the proper orifice.

Thermo Products Engineering Department will gladly assist in sizing the

orifice if you provide them with the heating value in BTU per cubic foot and

the specific gravity of the fuel gas.

D. BURNER ADJUSTMENT

This unit is designed to not require any burner adjustment. The flames should be

checked by looking through the sight glass located on the burner box. Burner

flames should be clear, blue and almost transparent in color. (see Figure 16).

NOTE: It is not unusual to have orangish flames visible in the tube for LP gas.

SUPPLY PRESSURE MANIFOLD PRESSURE

NAT MAX 14” WC

MIN 4.5” WC 3.5 + .3” WC

PROPANE MAX 14” WC

MIN 11” WC 10.0” + .3” WC

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

Figure 16.

: The CMA/CMC furnace models are 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.

E. SETTING TEMPERATURE RISE

All CMA/CMC Models are designed and wired at the factory for a heating blower

speed that should result in an approximate temperature rise of 60°F. The blower

motors are wired on med-low speed for heating mode. The temperature rise

through the furnace may vary depending on the duct system, elevation, heating

value, etc. for each installation. A lower temperature rise will result in a higher

efficiency. Temperature rise = supply air temperature - return air temperature.

After 10 to 15 minutes of continuous operation, the temperature rise through the

furnace must fall within a range of 40°F to 70°F. If the outlet or supply duct

temperature is too high, you should check to make sure that your return air filter

is clean, your return air openings are free from obstruction, your outlet registers

are properly adjusted and clear and your supply and return air ducts are open.

The circulating air blower is not moving enough air if the supply air temperature is

still too high. Before proceeding further, turn off the power supply to the furnace

and remove the front door of the unit.

The speed of the blower must be increased by changing the speed tap from the

motor (see figure 15). This is accomplished by locating the control panel attached

to the blower housing and switching blower lead connected to the “Heat” terminal

on the White-Rodgers 50A65-143 control, with one of the higher speed blower

leads attached to a terminal marked “Park”. Be sure to attach any unused blower

leads to a terminal marked “Park”. Replace the blower door and turn on the

power supply.

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

F. FURNACE CHECKOUT PROCEDURE

Before any system of gas piping is finally put into service, it shall be carefully

tested to assure that it is gas tight as indicated in the Fuel Piping Section of this

Furnace Manual.

NOTICE: All controls on the unit should be checked for proper functioning prior to

the qualified service personnel leaving the job site. Specifically the following

should be checked:

With furnace in normal heating operation, check to make certain blower will start

and stop automatically under control of integrated 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 blockage or reconnect blower motor and restore power.

2. Make certain thermostat will automatically start and stop furnace.

3. Block the flue pipe outlet gradually with a flat piece of metal, until the pressure

switch functions shutting off the main burners. IMPORTANT: Remove flue outlet

blockage when done.

4. Block the PVC pipe inlet gradually with a flat piece of metal until pressure

switch functions shutting off the main burners. IMPORTANT: Remove air inlet

blockage when done.

5. Remove the blower compartment access door with the furnace operating. The

door interrupt switch is in the 120 volt circuit and will shut down the entire

system. Replace the blower door and the furnace start-up cycle will begin.

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

VI. INSTALLER'S INSTRUCTIONS TO USER:

After completing the installation, the installer shall inform and/or demonstrate to the

homeowner:

1. The location of all the instructions in the furnace and that the instructions must

be kept along with instructions for any accessories in the plastic pouch.

2. The location and use of the manual gas shut off valve and furnace electrical

disconnect switch. Instruct user to always shut off gas before shutting off electric

power.

3. The sequence of operation of the furnace.

4. The correct operation and maintenance of the appliance as outlined in this

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 read the label reproductions and all

warnings and instructions in this manual.

7. Recommend that the user have a qualified heating contractor inspect the

furnace at the start of each heating season. Inform the user of the frequency of

inspection required for each component.

8. Should the furnace not operate after installation – note diagnostic code

through view port prior to removing door.

VII. DEALER MAINTENANCE

The following maintenance procedures should be performed at the beginning

of each heating season by a qualified heating contractor. Correct any

deficiencies at once.

: Personal injury or property damage could result from repair or

service of this furnace by anyone other than a qualified heating contractor.

: To avoid injury from moving parts, shut off the power to the

furnace before removing blower compartment door.

: Label wires prior to disconnection when servicing controls. Wiring

errors can cause improper and dangerous operation.

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

A. ELECTRICAL:

1. Check diagnostic code through view port prior to removing access door.

2. Check all wiring for loose connections and any signs of damage or unusual

wear.

3. Check for correct voltage at the furnace when operating.

4. Check amp-draw on blower motor and inducer motor to assure they are not

exceeding name plate amp rating.

5. Check for correct operation and proper settings (if manually adjustable) of all

controls.

Shut off gas and disconnect power before continuing.

B. GENERAL INSPECTION

1. VENT PIPE COMBUSTION AIR INTAKE

a. Remove the vent and check the vent for signs of carbon build-up and for

signs of blockage.

b. The entire length of vent and combustion air inlet pipe and their

terminations should be inspected for restrictions, loose or loosely sealed

joints, carbon build-up. Also inspect the outside vent and combustion air

terminals and ensure that they are clear and unobstructed.

2. CONDENSATE LINE/TRAP ASSEMBLY

The condensate line must be inspected to make sure it is not blocked. All of the

lines should be flushed with water to remove any build-up of sediment.

3. BURNERS

If it appears that material is accumulating in the burner box, the burner box cover

can be removed and the box and burners can be vacuumed. (NOTE: The igniter

& flame sensor must be removed before removing the assembly.) If necessary,

the burner assembly can be removed by taking out the two screws/one on each

bracket at the bottom of the box. Assembly must be pulled & tilted away from the

burner compartment in order to remove from box. If necessary, the individual

tubes can be cleaned out by using compressed air.Care must be taken not to

damage the igniter.

4. INDUCER BLOWER ASSEMBLY

Inspect the pressure switch and drain tubing connections and inspect the

blower/assembly for warpage, deterioration and carbon or other build-up. If

necessary, clean the accessible portions of the housing and blower with a damp

cloth. Vacuum to remove any lint or dust from the motor assembly.

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

5. GASKETS/SEALING MATERIALS

Inspect all visible gaskets for signs of degradation or liquid seepage, especially

any seals which were removed as part of the inspection. Replace any suspect

gaskets.

C. HEAT EXCHANGER

Inspect for corrosion, pitting, warpage, deterioration, carbon build-up and loose

gaskets in the flue pipe, burner box and accessible areas of the heat exchanger.

1. CLEANING THE COIL AIR SIDE

a. Remove the blower from the blower compartment. In order to remove the

blower, it will first be necessary to disconnect the furnace from the outside

power supply and disconnect the blower wire harness from the furnace at

the blower pan quick connect.

b. Clean the coil with a vacuum cleaner by going through the blower pan

opening being careful not to bend or damage any of the fins.

c. Once all components are cleaned, they must be re-installed to their factory

produced state. Any seals or joints in the flue system which have been

removed or loosened must be reconnected and sealed if necessary. Do

this in accordance with the installation instructions.

: The inducer motor mounting plate gasket and the collector box

gasket must be replaced.

D. HOUSE AIR BLOWER

Check and clean the blower wheel, housing and compartment with a vacuum.

Check the motor name plate and follow the motor manufacturers instructions for

lubrication, if required.

IMPORTANT: Some motors are permanently lubricated and should not be

oiled. See motor name plate for specific instructions.

E. RETURN AIR FILTER

The Return Air Filter(s): Provided with this unit is a permanent type filter. This

filter(s) should be inspected and when dirty, cleaned or replaced, if necessary to

assure proper furnace operation. Follow the cleaning, removal and replacement

procedure below.

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

FILTER MAINTENANCE PROCEDURE

The filter is located inside front door of the CMA/CMC. Remove filter retaining rod

and remove dirty filter. Clean the filter by vacuuming, rinsing with tap water,

hosing or dipping in an ordinary detergent solution. After cleaning, replace the

completely dry filter and retain with retaining rod. If the filter has a mesh, the

mesh side of the filter must be towards the furnace.

FILTER REPLACEMENT

Should the filter require replacement, replace with like size and type filter as

originally supplied with furnace.

IMPORTANT: Remind homeowner of importance of monthly filter inspections

during the heating season to ensure efficient and trouble-free operation of their

furnace.

VIII. TROUBLESHOOTING

NOTICE: BEFORE TROUBLESHOOTING, FAMILIARIZE YOURSELF WITH THE

START UP AND CHECKOUT PROCEDURE.

ALL INSTALLATION AND SERVICES MUST BE PERFORMED BY QUALIFIED

HEATING CONTRACTORS.

To assist you in troubleshooting this furnace, it is equipped with an integrated

ignition control with diagnostics. These diagnostics evaluate what control system has

experienced a failure and will activate a flashing light on the control in different

sequences to help pinpoint the failure which has occurred.

Note – check diagnostic code through view port prior to removing access door.

DIAGNOSTIC FEATURES

The 50A65 control used on this furnace continuously monitors its operation and the

operation of the system. If a failure occurs, the LED light on the control will flash a

code. If the failure is internal to the control, the light will stay on continuously.

In this case, the entire control should be replaced, as the control is not field-

repairable.

If the sensed failure is in the system (external to the control), the LED will flash in the

following flash-pause sequences to indicate failure status (each flash will last

approximately 0.25 seconds, and each pause will last approximately 2 seconds).

1 flash, then pause system locked

2 flashes, then pause pressure switch stuck closed

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

3 flashes, then pause pressure switch stuck open

4 flashes, then pause open high limit 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.

: Power must be disconnected before servicing.

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

TURN THERMOSTAT TO CALL FOR HEAT

DOES THERMOSTAT MAKE 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

Yes

REPLACE TRANSFORMER

Yes

No No

Yes

ARE WIRES CONNECTED

PROPERLY?

CORRECT WIRE

CONNECTIONS

Yes

IS THE INDUCER

BLOWER OPERATING?

Yes

IS THERE 24 VOLTS

ACROSS "TH" & "TR"

AT THE INTEGRATED

CONTROL MODEL?

TROUBLESHOOTING GUIDE

THE SYSTEM IS STARTED BY SETTING THE THERMOSTAT TO CALL FOR

HEAT. THE FOLLOWING SHOULD HELP ESTABLISH THE TYPE OF

MALFUNCTION OR DEVIATION FROM THE NORMAL OPERATION.

TO USE THIS DIAGRAM, YOU JUST NEED TO FOLLOW THE INSTRUCTIONS IN THE BOXES.

NOTE: CHECK DIAGNOSTIC CODE THROUGH VIEW PORT PRIOR TO REMOVING ACCESS DOOR.

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

CHECK WIRING TO INDUCER

AND IF OK, REPLACE

INDUCER ASSEMBLY.

AFTER HOT SURFACE

IGNITOR WARM-UP,

DOES GAS VALVE OPEN?

CHECK WIRING TO

HOT SURFACE IGNITOR

AND IF OK, REPLACE

HOT SURFACE IGNITOR ASSEMBLY.

Yes

Yes Yes

CHECK WIRING TO GAS

VALVE AND IF OK,

REPLACE GAS VALVE.

DOES THE HOT

SURFACE

IGNITOR ENERGIZE

AND GLOW?

IS THERE LINE VOLTAGE

ACROSS INDUCER POWER

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 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.

SAME AS ABOVE.

CHECK ACROSS "MV"

TERMINALS ON INTEGRATED

CONTROL FOR 24 VOLTS DURING

THE 4 SECOND FLAME PROVING

PERIOD AFTER IGNITOR WARM-UP.

IS THERE 24VOLTS?

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

CHECK FOR PROPER

MANIFOLD PRESSURE.

Yes

AFTER GAS VALVE

OPENS, DO THE

BURNERS IGNITE?

ADJUST TO 3.5" FOR NATURAL GAS

OR 10.0" WC FOR LP GAS

IS IGNITOR

POSITIONED CORRECTLY? REPOSITION TO

CORRECT LOCATION.

DO BURNERS STAY

LIT PAST PROOF

OF FLAME CHECK?

Yes

CHECK ACROSS THE

CIRCULATING AIR

BLOWER TERMINALS

"CIR N" & "HEAT"

FOR PROPER VOLTAGE.

REPLACE THE

INTEGRATED CONTROL.

NoNo

Yes

DOES THE CIRCULATING

AIR FAN COME ON

WHEN ENERGIZED?

No DOES BLOWER

SPIN FREELY?

CONFIRM IF

EITHER BLOWER WHEEL

IS RUBBING AGAINST

HOUSING OR MOTOR

SHAFT IS SPINNING

FREELY AND REPAIR

OR REPLACE AS NECESSARY.

Yes

IS CAPACITOR

WORKING PROPERLY

Yes

REPLACE CAPACITOR

DOES THE INTEGRATED CONTROL

ENERGIZE THE

CIRCULATING AIR BLOWER

AFTER THE 45 SECOND

TIME DELAY.

REPLACE MOTOR

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

DOES SYSTEM RUN UNTIL

THERMOSTAT IS SATISFIED? 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?

DOES THE CIRCULATING

AIR BLOWER TURN OFF

AFTER THERMOSTAT IS

SATISFIED WITHIN

120 SECONDS?

No No

Yes

IS LED LIGHT

ON INTEGRATED

CONTROL FLASHING?

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

Yes

TROUBLESHOOTING COMPLETE.

Yes

IF LED LIGHT FLASHES:

1 FLASH, THEN PAUSE SYSTEM LOCKOUT

2 FLASHES, THEN PAUSE PRESSURE SWITCH STUCK CLOSED

3 FLASHES, THEN PAUSE PRESSURE SWITCH 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)

CHECK COMPLETE SYSTEM OUT.

THE LED WILL ALSO FLASH ONCE AT POWER-UP.

LED LIGHT STAYS ON CONTINUOUSLY,

COMPLETE FAILURE - REPLACE

INTEGRATED CONTROL.

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

APPENDIX – A REPLACEMENT PARTS

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

APPENDIX – B WIRING DIAGRAMS

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

Thermo Products Pride Furnace Cma3 50D36N Users Manual

CMC1-75DV3N to the manual 30eb0262-3082-4f5f-ad96-98e4dd837e61

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