Thermo Products Burner CMA1 50N User Manual

GAS FIRED HIGH EFFICIENCY FURNACE  
DOWN FLOW & DIRECT VENT (SEALED COMBUSTION)  
MODEL: CMA1-50N & CMA2-75N  
INSTALLATION AND SERVICE MANUAL  
For installation in:  
1. Manufactured Homes  
2. Modular Homes/Buildings  
3. Site Constructed—Residential (Single Story Dwellings)  
FOR YOUR SAFETY  
Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this  
or any other appliance.  
WHAT TO DO IF YOU SMELL GAS  
Do not try to light any appliance.  
Do not touch any electrical switch; do not use any phone in your building.  
Immediately call your gas supplier from a neighbor’s phone.  
Follow the gas supplier’s instructions.  
If you cannot reach your gas supplier, call the fire department.  
: If the information in these instructions is not followed exactly, a fire or explosion may  
result causing property damage, personal injury, or loss of life.  
: Improper installation, adjustment, alteration, service, or maintenance can cause  
injury or property damage. Refer to this manual. For assistance or additional information,  
consult a qualified installer, service agency, or fuel supplier.  
: Do not use this appliance if any part has been underwater. Immediately call a  
qualified service technician to inspect the appliance and to replace any part of the electrical or  
control system that has been underwater.  
PLEASE READ THESE INSTRUCTIONS PRIOR TO INSTALLATION, INITIAL FIRING, AND BEFORE  
PERFORMING ANY SERVICE OR MAINTENANCE. THESE INSTRUCTIONS MUST BE LEFT WITH THE USER  
AND SHOULD BE RETAINED FOR FUTURE REFERENCE BY QUALIFIED SERVICE PERSONNEL.  
THERMO PRODUCTS, LLC.  
POST OFFICE BOX 217  
NORTH JUDSON, IN 46366  
PHONE: (574) 896-2133  
MG-508  
ECN 5135-MA 100615  
MADE IN USA  
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All installations and services must be performed by qualified service personnel.  
I. SAFETY INFORMATION  
This and the following page contain reproductions of the various warning and instruction  
labels placed on the Thermo Pride Condensing Gas Furnaces. Please read and comply  
with the contents of these labels.  
1
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All installations and services must be performed by qualified service personnel.  
This and the previous page contain reproductions of the various safety and instruction  
labels placed on the Thermo Pride Condensing Gas Furnaces. Please read and comply  
with the contents of these labels.  
2
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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.  
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: The vent and air intake elbows must be kept away from bushes,  
shrubs or any vegetation that may restrict the flow of flue products. It must also  
be kept clear of any leaves, weeds or other combustible materials. Keep the vent  
hood clear of snow. Avoid locating the terminals in areas where standing water or  
condensate drippage may be a problem.  
: This CMA furnace has been designed to be installed as a direct vent  
system and must have its combustion air brought in from outside the conditioned  
space. The failure to install the vent/air intake system as specified in these  
instructions will void the heat exchanger warranty and may result in property  
damage, personal injury or loss of life.  
: Outside combustion air must not come from an area that is directly  
adjacent to a pool, hot tub or spa. Measures should be taken to prevent the entry  
of corrosive chemicals or vapors to the combustion and ventilation air supply.  
Such chemicals include but are not limited to chlorinated and/or fluorinated  
hydrocarbons such as found in refrigerants, aerosol propellants, dry cleaning  
fluids, degreasers and removers. Other harmful compounds may come from  
bleaches, air fresheners or mastics. Vapors from such products can form acid  
compounds when burned in a gas flame. Should acid compounds form in your  
furnace, it may reduce the life of the furnace.  
: Because of the potential of odorant fade, a gas leak may not be  
detected by smell. If this furnace is installed below grade, contact your gas  
supplier for a gas detector.  
: All gas piping must be leak tested methods approved by State, Local  
and National Codes including the National Fuel Gas Code NFPA 54/ANSI-Z233.1  
(Latest Edition). A final test for gas leakage must be made after purging the gas  
line. This test must be conducted with the unit operating and should include the  
furnace piping and gas valve. Never use an open flame to check for a gas leak.  
: Care must be taken not to wet electronic components during leak test.  
Wetting the primary ignition module may damage its circuitry and cause a  
hazardous situation. Dry moisture from all leads and terminals if wetting occurs.  
Wait at least 24 hours for the circuit to fully dry before energizing the burner  
circuit.  
: The furnace and its individual gas shutoff valve must be disconnected  
from the gas supply during pressure testing of the gas supply system at  
pressures in excess of 1/2 PSIG or 14.0" w.c. The furnace must be isolated from  
the gas supply by closing its manual shut off valve at test pressures equal to or  
greater than 1/2 PSIG or 14.0" w.c.  
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: 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 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.  
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II. FURNACE SPECIFICATIONS - CMA SERIES  
MODEL  
CMA1-50  
CMA2-75  
INPUT IN BTUH  
50,000  
48,000  
75,000  
72,000  
OUTPUT IN BTUH  
MAIN ORIFICE-NAT.  
MAIN ORIFICE-LP  
GAS SUPPLY PRESSURE  
L.P. MINIMUM  
NAT. MINIMUM  
L.P. MAXIMUM  
NAT. MAXIMUM  
GAS MANIFOLD PRESSURE  
L.P.  
#42  
1.5 mm  
11” IN.W.C.  
4.5”IN.W.C.  
14” IN.W.C.  
14” IN.W.C.  
10.0” + .03 IN.W.C.  
NAT.  
3.5” + .03 IN. W.C.  
INTAKE SIZE IN INCHES  
VENT SIZE IN INCHES  
2”  
2”  
NOMINAL TEMPERATURE RISE  
SEASONAL EFFICIENCY (AFUE*)  
*ANNUAL FUEL UTILIZATION EFFICIENCY  
55°F  
95%  
DIMENSIONS  
CABINET SIZE  
SUPPLY AIR OUTLET  
WIDTH 18” DEPTH 25-3/4" HEIGHT 57"  
WIDTH 12” DEPTH 12"  
ELECTRICAL SUPPLY  
FUSE OR HACR BREAKER  
TOTAL CURRENT AMPS  
115 VOLTS-- 60HZ --1/PH  
15 AMPS  
7.15 AMPS  
NOMINAL ANTICIPATOR SETTING  
0.8 MILLIAMPS  
FILTER SIZE  
APPROXIMATE SHIPPING WEIGHT  
(1) 18” X 24” X 1”  
175 LBS.  
BLOWER DATA  
BLOWER MODEL  
MOTOR HORSEPOWER  
MOTOR RPM  
12-9T DIRECT DRIVE  
1/2  
1065 (HIGH SPEED)  
CFM @ .2 & .5 IN. W.C.  
SPEED  
LOW  
MD-LOW  
MD-HIGH  
HIGH  
.2”  
805  
1010  
1196  
1338  
.5”  
695  
860  
1038  
1162  
|
|
|
|
|
.2”  
797  
995  
1210  
1420  
.5”  
668  
869  
1076  
1259  
FOR BURNER COMBUSTION INFORMATION REFER TO INITIAL STARTUP.  
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INSTALLATION PARTS PACKAGE  
CMA*-50  
S00S4179  
PART #  
350020  
300132  
300276  
410017  
320833  
AOPS7677  
CMA*-75  
PARTS PKG#  
S00S4114  
PART #  
350020  
300132  
300276  
410017  
320833  
AOPS7678  
DESCRIPTION  
QTY  
QTY  
J-box cover  
wire nut  
1
2
4
2
1
1
1
2
4
2
1
1
3" stainless steel hose clamp  
2-3/8" radiator hose  
CPVC adapter  
LP conversion kit  
III. GENERAL INSTRUCTIONS AND CLEARANCES – READ BEFORE START OF  
INSTALLATION  
1. The BTU output capacity of the furnace proposed for installation should be based  
on a heat loss calculation made according to the manuals provided by the Air  
Conditioning Contractors of America (ACCA) or the American Society of Heating,  
Refrigeration and Air Conditioning Engineers, Inc. (ASHRAE).  
2. This furnace is equipped with orifices sized for operation with natural gas. For  
conversion to Propane Gas see instruction MG-799 in Gas Conversion Kit  
AOPS7678.  
3. These Category Type IV furnaces are shipped completely assembled and wired  
(internally). See the Dealer Receiving and Freight Claim Procedure Section of the  
price guide for parts shortage or damage. The furnace and duct system must be  
adjusted to obtain a temperature rise of 40°F to 70°F through the furnace after  
installation. (See rating label located on separator panel inside the furnace  
vestibule). The installation must conform with local codes, or in the absence of local  
codes, with the National Fuel Gas Codes (ANSI Z223.1 or latest edition) and with  
these instructions.  
: This furnace is not to be used for temporary heating of buildings or  
structures under construction.  
Many of the chemicals used during construction, when burned, form acid bearing  
condensate that can substantially reduce the life of the heat exchanger.  
4. It is recommended that a commercially available CO alarm be installed in  
conjunction with any fossil fuel burning appliance. The CO alarm shall be installed  
according to the alarm manufacturer’s installation instructions and be listed in  
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accordance with the latest edition of the UL Standard for Single and Multiple Station  
Carbon Monoxide Alarms, UL 2034, or the CSA International Standard, Residential  
Carbon Monoxide Alarming Devises, CSA 6.19.  
5. The installer shall be familiar with and comply with all codes and regulations  
applicable to the installation of these heating appliances and related equipment. In  
lieu of local codes, the installation shall be in accordance with the current provisions  
of one or more of the following standards.  
a. Federal Manufactured Home Constructions & Safety Standard (H.U.D. Total  
24, Part 280.)  
b. American National Standard (ANSI-119.2/NFPA-501C) for all recreational  
vehicle installations.  
c. American National Standard (ANSI-Z223.1/NFPA-54) for all gas-fired  
furnaces.  
d. American National Standard (ANSI-C1/NFPA-70 Electric Code for all  
electrical field wiring.  
e. These gas-fired units have been investigated under standards ANSI Z 21.47  
CAN/CGA Z223-2001 Central Furnace test standards.  
f. These gas-fired units have been listed by ETL “For installation as central  
furnace special type for single story dwelling.”  
: The area around the furnace must be kept free and clear of  
combustible materials, especially papers and rags.  
: This furnace is not to be used as a construction heater.  
Listed below are definitions of “ COMBUSTIBLE MATERIAL” and “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.  
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MODELS CMA  
FRONT  
BACK  
CLOSET  
ALCOVE  
6”  
0”  
0”  
0”  
0”  
1”  
1”  
1”  
18”  
0”  
0”  
0”  
0”  
1”  
1”  
1”  
SIDES  
VENT CONNECTOR(PVC)  
TOP  
PLENUM SIDES  
TOP AND SIDES OF DUCT  
BOTTOM OF DUCT  
Table 1  
This heating appliance must be installed with clearances not less than the minimums  
shown above as well as ample clearance for easy access to the air filter, blower  
assembly, burner assembly, controls, and vent connections.  
IV. GENERAL INSTALLATION  
A. FURNACE LOCATION  
1. For best performance, locate the furnace so that it is centralized with respect  
to the duct system.  
2. The furnace installation is only intended for free air return through the furnace  
door louvers. DO NOT connect a ducted return air system directly to the furnace.  
An improper return air installation may create a hazard and damage equipment,  
as well as void all warranties.  
3. This furnace may be installed on a combustible floor when utilizing either the  
No. 70 counterflow floor base or CE111S / CE211T coil cabinet for below the  
floor duct systems, or the cottage base for floor level air distribution. See Figure  
1A for description of Combustible Floor Base and Figure 1C for Cottage Base.  
This furnace is ETL listed for closet, alcove or free standing applications. All  
applications must comply with the requirements of this manual.  
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Combustible Floor Base  
Model: 70-BASE  
Figure 1A.  
Coil Cabinet  
Model: CE113S  
Note: This cabinet cannot be utilized as a cottage base.  
Figure 1B.  
10  
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Cottage Base  
Model: 01COT-BASE  
Figure 1C.  
NOTE: Serves as a plenum for single story applications with exposed supply air  
systems.  
11  
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B. BASE INSTALLATION  
1. Combustible Floor Base Model: 70 BASE  
Use the base bottom panel as a template to mark floor opening locations (see  
Figure 2). Cut a square opening in the floor for the supply air connector duct. Cut  
the opening 1-inch larger than the square template opening. (duct requires 1-inch  
clearance to combustible floor).  
Figure 2.  
Figure 3.  
After cutting openings in the floor, place the bottom panel in position. Mark the  
square opening location on the distribution duct at the connection point of the  
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connector duct. Remove the bottom panel. Cut an opening in the distribution duct  
slightly larger than the connector duct. (refer to Figure 2 for location of this cut.)  
Cut the connector duct to length. Install the connector duct. Bend over each tab.  
Insure an airtight seal by using high temperature sealant or tape on the joint.  
Reinstall the bottom panel over the connector duct. Put the base top assembly in  
place (see Figure-3).  
Slit the corners of connector duct down to the top of the base assembly. If metal  
projects more than 1-inch above the top of the base assembly, trim the flanges  
down to 1-inch. While the top of distribution duct is being pulled up with one  
hand, bend down each side of the connector duct tightly to the base assembly  
with the other hand. This assures a tight connection between the base assembly  
and the connector duct and that the distribution duct will be full size. Use high  
temperature tape and/or high temperature silicone caulking on all joints and  
seams to minimize air leakage. Secure the base assembly to the floor with two  
screws in the front flange.  
2. Cottage Base Model: 01COT BASE  
The 01COT BASE cottage base (Figure 1C) is required for a freestanding  
cottage base installation. The cottage base allows the two sides and rear to have  
an 8” x 12” register installed. IMPORTANT: All joints and seams of supply  
ducts must be sealed with a sealing method suitable to the application  
conditions and temperatures (I.E. High temperature silicone and/or  
aluminum tape). Refer to assembly and installation instructions included with  
cottage base for additional information.  
C. ALCOVE INSTALLATION  
In this application, a minimum of 18 inches of clearance  
must be provided to the front of the unit. See Figure 4.  
Note – access to diagnostic view port.  
Figure 4.  
13  
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D. CLOSET INSTALLATION  
1. The return air opening into the closet  
is to have a minimum free area of 250  
sq. in. (see Figure 5).  
2. The return air opening may be  
located in the top, center or (ideally) bottom  
of the closet door or side wall.  
Figure 5.  
: Do not obstruct any return air openings, including the return  
grille on the furnace. To do so may cause the furnace to activate the high  
limit and shut down.  
3. The cross-sectional area of the return system leading into the closet (when  
located in the floor or ceiling) shall not be less than 250 square inches.  
4. The total free area of openings in the floor or ceiling registers serving the  
return duct system must be at least 350 square inches. At least one register must  
be located where it is not likely to be covered by carpeting, boxes, furniture or  
other objects.  
5. Materials located in the return duct system must have a flame spread  
classification of 200 or less.  
6. Non-combustible pans having one inch upturned flanges are to be located  
beneath openings in a floor return duct system.  
7. Wiring materials located in the return duct system must conform to articles  
300-22 of the National Electrical Code NFPA70 (Latest Edition).  
8. Gas piping is not to be located in or through the return duct system .  
14  
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E. FUEL PIPING  
Sizing and installation of fuel lines must be in accordance with Federal, State &  
Local regulations. Including the National Fuel Gas Code NFPA 54/ANSI-Z233.1  
(Latest Edition).  
NOTE: These furnaces are designed to be gas piped through the left side or the  
bottom. For service purposes, it is recommended that the gas union be located  
inside the furnace when possible.  
: Because of the potential of odorant fade, a gas leak may not be  
detected by smell. If this furnace is installed below grade, contact your gas  
supplier for a gas detector.  
A qualified installer or service person must perform all gas piping and testing.  
Piping from the natural gas meter to the furnace shall be in accordance with  
requirements of the local gas utility. Piping from the LP tank to the furnace must  
follow the recommendations of the gas supplier.  
A readily accessible manual shut off valve (certified for the applicable gas) with a  
non-displaceable rotor member shall be installed within six feet of the gas  
equipment it serves.  
A union or flanged connection shall be provided directly up stream of the burner  
to allow burner removal. Unions must be of a ground joint type or flange-jointed  
type using a gasket resistant to the applicable gas. Pipe dope or sealant certified  
to be resistant to the action of the applicable gases should be used on all  
threaded joints.  
A drip leg must be used on both LP and Natural gas installations prior to the  
furnace in order to trap oil, condensate and other impurities which might  
otherwise lodge in the gas valve or plug the burner orifice.  
A drip leg shall be provided at the outlet of the gas meter when there is excessive  
condensation between the gas meter and the furnace. Failure to install a drip leg  
may void the limited warranty on the furnace.  
: All gas pipe connections must be leak tested using methods  
approved by State, Local and National Fuel Gas Code NFPA 54/ANSI-Z233.1  
(Latest Edition). Any leaks must be repaired immediately after turning off  
the gas supply. A final test for gas leakage must be made after purging the  
gas line.  
: DO NOT wet electronic components during the leak test.  
Wetting electronic components may damage circuitry and cause a  
hazardous situation. Dry moisture from all leads and terminals if wetting  
occurs. Wait at least 24 hours for the circuit to fully dry before energizing  
the system.  
15  
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: 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 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 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 requires 2” Schedule 40 PVC pipe.  
4. This CMA 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.  
16  
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MAXIMUM VENT LENGTH  
VENT SIZE  
FURNACE  
MODEL  
2 IN. PVC  
COMBUSTION AIR INTAKE  
VENT  
LENGTH  
(FT.)  
EXHAUST  
VENT  
ELBOWS  
(NO.)  
ELBOWS (NO.)  
CMA  
30  
8*  
7**  
*Note the drain elbow supplied with CMA furnaces count as 1 elbow.  
**Note the two 45° elbows supplied w/CMA 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 furnace models are vented through the roof. For  
roof venting refer to Section IV, J, of this manual.  
17  
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G. CONNECTING THE EXHAUST VENT AND COMBUSTION AIR INTAKE  
Figure 6. shows the typical exhaust vent and combustion air intake connection  
for CMA furnace.  
Figure 6. (CMA*-75 SHOWN)  
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 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.  
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NOTICE: The furnace model series CMA 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  
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.  
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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.  
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.  
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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  
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.  
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Figure 9: NFGC Minimum Clearances Between the Vent Terminal and Various  
Building Features  
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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  
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inlet as shown in Figure 10, making sure that the spacing between the inlet and  
outlet complies with that noted in Figure 8.  
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 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.  
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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.  
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.  
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When the PVC vent and combustion air intake pipes pass through a ceiling, and  
a fire stop is required. Refer to the following:  
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 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.  
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3. An optional condensate pump (P/N 350225) is available. This pump will not fit  
into the vestibule of the furnace and must be installed below the furnace for  
operation. Instructions will be included with pump if this option is utilized.  
Figure 14.  
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.  
3. Connection Of Room Thermostat Wires  
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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.  
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 (refer to the thermostat literature for additional information).  
Four-conductor thermostat wire is recommended for 24 VAC, low-voltage,  
control circuit wiring. How ever only 2 wires are required for the furnace (a  
heating application only).  
Maximum Recommended  
Electrical Wire Diameter  
Thermostat Wire Length  
(AWG)  
(Feet)  
24  
22  
20  
18  
55  
90  
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.  
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  
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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.  
4. BLOWER MOTOR SPEED WIRING  
Figure 15.  
BLOWER DELAY SETTINGS  
To delay fan  
turn-on by:  
15 sec.  
30 sec.  
*45 sec.  
Set Switch  
#2  
Off  
#1  
Off  
Off  
On  
On  
On  
Off  
On  
60 sec,  
To delay fan  
turn-off by:  
60 sec.  
Set Switch  
#3  
#4  
On  
Off  
On  
Off  
On  
On  
Off  
Off  
90 sec.  
*120 sec.  
180 sec.  
*Factory Settings For Optimal Performance  
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CMA1-50  
ALTERATIONS REQ’D FOR A/C @ DESIGN EXTERNAL STATIC PRESSURE  
COOLING UNIT HTG Speed  
Recommended CLG Speed  
24,000  
30,000  
36,000  
LOW  
LOW  
LOW  
MED-LOW  
MED-HIGH  
HIGH  
Furnace Airflow (CFM) vs. External Static pressure (in. WC.)  
Speed Tap \  
Static  
Pressure  
Low  
ML  
MH  
0.1  
836  
1044  
1250  
1339  
0.2  
805  
1010  
1196  
1338  
0.3  
773  
972  
1146  
1283  
0.4  
743  
914  
1101  
1233  
0.5  
695  
860  
1038  
1162  
0.6  
620  
826  
977  
1086  
0.7  
566  
752  
902  
1008  
High  
Temperature Rise vs. External Static Pressure (in. WC.)  
Speed Tap \  
Static  
Pressure  
Low  
ML  
MH  
0.1  
53  
42  
35  
31  
0.2  
55  
44  
37  
33  
0.3  
57  
45  
38  
34  
0.4  
59  
48  
40  
36  
0.5  
63  
51  
42  
38  
0.6  
71  
53  
45  
41  
0.7  
78  
59  
49  
44  
High  
Speed Tap \  
Static  
Pressure  
Low  
ML  
MH  
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  
3.3  
4.0  
4.6  
5.3  
3.2  
3.8  
4.4  
5.1  
3.1  
3.6  
4.2  
5.0  
3.0  
3.5  
4.1  
4.9  
2.9  
3.4  
4.0  
4.7  
2.7  
3.2  
3.8  
4.6  
2.6  
3.1  
3.6  
4.4  
High  
Blower Motor Watts vs. External Static pressure (in. WC.)  
Speed Tap \  
Static  
Pressure  
Low  
ML  
MH  
0.1  
0.2  
311  
390  
467  
555  
0.3  
304  
376  
452  
544  
0.4  
300  
363  
441  
530  
0.5  
292  
351  
427  
513  
0.6  
281  
342  
412  
493  
0.7  
275  
330  
394  
477  
315  
400  
485  
573  
High  
= Recommended operation range  
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CMA2-75  
ALTERATIONS REQ’D FOR A/C @ DESIGN EXTERNAL STATIC PRESSURE  
COOLING UNIT HTG Speed  
Recommended CLG Speed  
24,000  
30,000  
36,000  
MED-LOW  
MED-LOW  
MED-LOW  
MED-LOW  
MED-HIGH  
HIGH  
Furnace Airflow (CFM) vs. External Static pressure (in. WC.)  
Speed Tap \  
Static  
Pressure  
Low  
ML  
MH  
0.1  
817  
1019  
1257  
1470  
0.2  
797  
995  
1210  
1420  
0.3  
773  
959  
1174  
1366  
0.4  
730  
918  
1125  
1312  
0.5  
668  
869  
1076  
1259  
0.6  
620  
821  
1024  
1196  
0.7  
555  
760  
959  
1127  
High  
Temperature Rise vs. External Static Pressure (in. WC.)  
Speed Tap \  
Static  
Pressure  
Low  
ML  
MH  
0.1  
81  
65  
52  
45  
0.2  
83  
66  
55  
46  
0.3  
85  
69  
56  
48  
0.4  
90  
72  
59  
50  
0.5  
90  
76  
61  
52  
0.6  
106  
80  
64  
55  
0.7  
119  
87  
69  
59  
High  
Speed Tap \  
Static  
Pressure  
Low  
ML  
MH  
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  
3.1  
3.9  
4.8  
5.7  
3.0  
3.8  
4.6  
5.5  
2.9  
3.6  
4.4  
5.4  
2.8  
3.5  
4.2  
5.2  
2.7  
3.3  
4.1  
5.1  
2.6  
3.2  
4.0  
5.0  
2.5  
3.1  
3.8  
4.8  
High  
Blower Motor Watts vs. External Static pressure (in. WC.)  
Speed Tap \  
Static  
Pressure  
Low  
ML  
MH  
0.1  
0.2  
303  
390  
490  
605  
0.3  
298  
381  
478  
591  
0.4  
291  
366  
462  
573  
0.5  
280  
354  
447  
556  
0.6  
273  
342  
432  
542  
0.7  
264  
330  
413  
522  
312  
400  
513  
624  
High  
= Recommended operation range  
31  
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: 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.  
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V. STARTING THE UNIT  
A. SEQUENCE OF OPERATIONS  
AT ANY TIME THE  
GAS VALVE IS  
CONTINUOUS SAFE OPERATION CHECK  
IF FLAME SIMULATION CONDITION  
NOT ENERGIZED  
PRESENT OR ROLL-OUT SWITCH OPENS, SYSTEM  
ENERGIZES INDUCER FAN FOR 15 SECONDS AND CIRCULATOR BLOWER AT  
HEATING SPEED UNTIL SITUATION CORRECTION  
START  
THERMOSTAT CALLS FOR  
HEAT, CONTACTS CLOSE  
CONTROL BOARD ENERGIZED,  
INDUCER ENERGIZED  
PRESSURE SWITCH SENSES  
ADEQUATE DIFFERENTIAL PRESSURE,  
CONTACTS CLOSE  
POWER IS APPLIED TO  
THE SILICON NITRIDE  
IGNITOR. IGNITOR  
POWER INTERRUPTION  
SYSTEM SHUTS OFF,  
RESTARTS WHEN POWER  
IS RESTORED.  
WARM-UP IS 20 SECONDS.  
START  
TRIAL  
FOR  
AFTER IGNITOR WARM-UP,  
THE GAS VALVE IS  
ENERGIZED TO OPEN  
IGNITION  
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.  
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AFTER DELAY-TO-FAN-ON  
PERIOD ENDS, CIRCULATING  
AIR FAN IS ENERGIZED AT  
HEATING SPEED. THE (OPTIONAL)  
ELECTRONIC AIR CLEANER  
AND HUMIDIFIER ARE  
THE RETRY SEQUENCE  
MAIN  
BURNER  
OPERATION  
PROVIDES A 60 SECOND  
WAIT BEFORE IGNITION  
RETRY. RETRY IS  
ATTEMPTED WITH AN  
ADDITIONAL 10 SECONDS  
OF IGNITOR WARM-UP  
TIME.  
ENERGIZED.  
WHEN THERMOSTAT IS  
SATISFIED, CONTACTS  
OPEN AND THE GAS  
IF IGNITION ATTEMPT IS  
UNSUCCESSFUL, ONE MORE  
RETRY WILL BE MADE  
BEFORE THE CONTROL BOARD  
GOES INTO SYSTEM LOCKOUT.  
CALL  
FOR  
HEAT  
VALVE IS DE-ENERGIZED.  
AFTER PROOF OF FLAME  
LOSS, INDUCER STARTS 5 SECOND  
POST SURGE AND (OPTIONAL)  
HUMIDIFIER ARE  
SATISFIED  
DE-ENERGIZED. THE DELAY-  
TO-FAN-OFF PERIOD  
BEGINS (120 SECONDS)  
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.  
AFTER THE DELAY-TO-  
FAN-OFF PERIOD ENDS,  
THE CIRCULATING AIR  
FAN AND (OPTIONAL)  
ELECTRONIC AIR CLEANER  
ARE DE-ENERGIZED.  
END  
OF CYCLE  
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.  
34  
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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.  
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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.  
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GAS PRESSURE CHART FOR CMA* MODEL FURNACES  
SUPPLY PRESSURE MANIFOLD PRESSURE  
MAX 14” WC  
NAT  
3.5 + .3” WC  
MIN 4.5” WC  
MAX 14” WC  
MIN 11” WC  
PROPANE  
10.0” + .3” WC  
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  
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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.  
Figure 16.  
: The CMA 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 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 the blue (med. low) blower lead, which  
should be connected to the “Heat” terminal on the White-Rodgers 50A65-143  
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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.  
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.  
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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.  
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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 burners assembly can be removed by taking out the two screws/one on each  
bracket on the bottom of the box on CMA’s or on top of the box and removing the  
burner drawer assembly. Assembly must be pulled & tilted away from the blower  
compartment in order to remove from box. If necessary, the individual tubes can  
be cleaned out using compressed air to blow out the individual tubes. 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.  
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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.  
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FILTER MAINTENANCE PROCEDURE  
The filter is located inside front door of the CMA. 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  
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3 flashes, then pause  
4 flashes, then pause  
6 flashes, then pause  
7 flashes, then pause  
8 flashes, then pause  
pressure switch stuck open  
open high limit switch  
115 volt AC power reversed  
low flame sense signal  
check ignitor or improper grounding  
Continuous flashing  
(no pause)  
Flame has been sensed when  
no flame should be present  
(no call for heat)  
The LED will also flash once at power-up.  
: Power must be disconnected before servicing.  
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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.  
TURN THERMOSTAT TO CALL FOR HEAT  
DOES THERMOSTAT MAKE CONTACT?  
No  
No  
No  
IS ROOM TEMPERATURE  
BELOW THERMOSTAT  
SETTING?  
IS ROOM  
TEMPERATURE  
ABOVE 90 DEGREES F?  
TURN T'STAT  
SETTING ABOVE  
ROOM TEMP.  
Yes  
Yes  
Yes  
COOL THE THERMOSTAT  
IS THE TRANSFORMER No  
SUPPLYING 24 VOLTS  
TO THE THERMOSTAT?  
No  
CORRECT WIRE  
CONNECTIONS  
ARE WIRES CONNECTED  
PROPERLY?  
Yes  
Yes  
CHECK INPUT  
POWER, DOOR  
INTERLOCK,  
SERVICE SWITCH  
AND FUSES.  
No  
REPLACE  
THERMOSTAT  
IS INTERNAL DAMAGE  
PRESENT ON THE  
TRANSFORMER?  
Yes  
Yes  
REPLACE TRANSFORMER  
No  
No  
CHECK FOR  
CONTINUITY  
& PROPER  
IS THE INDUCER  
BLOWER OPERATING?  
IS THERE 24 VOLTS  
ACROSS "TH" & "TR"  
AT THE INTEGRATED  
CONTROL MODEL?  
CONNECTIONS  
Yes  
Yes  
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Yes  
Yes  
IS THERE LINE VOLTAGE  
ACROSS INDUCER POWER  
TERMINALS "IND" & "IND 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.  
Yes  
CHECK WIRING TO INDUCER  
AND IF OK, REPLACE  
INDUCER ASSEMBLY.  
DOES THE HOT  
SURFACE  
IGNITOR ENERGIZE  
AND GLOW?  
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.  
No IS THERE VOLTAGE PRESENT No  
AT THE HOT SURFACE  
IGNITOR TERMINALS  
"IGN" & "IGN N" AT THE  
INTEGRATED CONTROL?  
Yes  
CHECK WIRING TO  
HOT SURFACE IGNITOR  
AND IF OK, REPLACE  
Yes  
HOT SURFACE IGNITOR ASSEMBLY.  
CHECK ACROSS "MV"  
TERMINALS ON INTEGRATED  
CONTROL FOR 24 VOLTS DURING  
THE 4 SECOND FLAME PROVING  
PERIOD AFTER IGNITOR WARM-UP.  
IS THERE 24VOLTS?  
AFTER HOT SURFACE  
IGNITOR WARM-UP,  
DOES GAS VALVE OPEN?  
No  
No  
SAME AS ABOVE.  
Yes  
Yes  
CHECK WIRING TO GAS  
VALVE AND IF OK,  
REPLACE GAS VALVE.  
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Yes  
AFTER GAS VALVE  
OPENS, DO THE  
BURNERS IGNITE?  
No  
CHECK FOR PROPER  
MANIFOLD PRESSURE.  
ADJUST TO 3.5" FOR NATURAL GAS  
OR 10.0" WC FOR LP GAS  
Yes  
Yes  
IS IGNITOR  
No  
REPOSITION TO  
POSITIONED CORRECTLY?  
CORRECT LOCATION.  
DO BURNERS STAY  
LIT PAST PROOF  
OF FLAME CHECK?  
Yes  
DOES THE INTEGRATED CONTROL  
ENERGIZE THE  
CHECK ACROSS THE  
CIRCULATING AIR  
BLOWER TERMINALS  
"CIR N" & "HEAT"  
No  
No  
REPLACE THE  
INTEGRATED CONTROL.  
CIRCULATING AIR BLOWER  
AFTER THE 45 SECOND  
TIME DELAY.  
FOR PROPER VOLTAGE.  
Yes  
CONFIRM IF  
EITHER BLOWER WHEEL  
IS RUBBING AGAINST  
HOUSING OR MOTOR  
SHAFT IS SPINNING  
DOES THE CIRCULATING  
AIR FAN COME ON  
No  
No  
DOES BLOWER  
SPIN FREELY?  
WHEN ENERGIZED?  
FREELY AND REPAIR  
OR REPLACE AS NECESSARY.  
Yes  
Yes  
Yes  
IS CAPACITOR  
REPLACE MOTOR  
WORKING PROPERLY  
No  
REPLACE CAPACITOR  
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Yes  
No  
No  
DOES SYSTEM RUN UNTIL  
THERMOSTAT IS SATISFIED?  
IS LED LIGHT  
ON INTEGRATED  
CHECK ALL  
WIRING FOR  
CONTROL FLASHING?  
LOOSE CONNECTIONS.  
Yes  
Yes  
DOES BURNER SHUT OFF  
WHEN THERMOSTAT IS  
SATISFIED?  
No  
CHECK FOR SHORT IN WIRE TO  
THERMOSTAT AND CORRECT  
IF NECESSARY.  
Yes  
DOES THE CIRCULATING  
AIR BLOWER TURN OFF  
AFTER THERMOSTAT IS  
SATISFIED WITHIN  
120 SECONDS?  
Yes  
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Yes  
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  
(NO PAUSE)  
FLAME HAS BEEN SENSED WHEN  
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.  
TROUBLESHOOTING COMPLETE.  
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APPENDIX – A REPLACEMENT PARTS  
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APPENDIX – B WIRING DIAGRAM  
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