Thermo Products GMD1-80N manual

THERMO PRODUCT S, LLC. POST O FFICE BOX 217 NORTH JUDSON, IN 46366 PHONE: (574) 896- 2133 MG -505 ECN 4501-MA MADE IN USA GAS-FIRED FURNACE DOWN FLOW & DIRECT VENT (SEA LED COMBUSTION) MODELS: GMD1-80N INSTA LLA TION A ND SERVICE MA NUA L For installatio n in: 1. Manufactured Homes 2. Modular H omes/Buildings 3. Site Constructed—Residential ([...]

All installations and ser vices must be performed by qualifie d service per sonnel. 1 I. SA FETY SECTION This page and the follow ing two pages contain various w arnings and cautions found throughout this furnace Service and Installation Manual. Please read and comply w ith the statement s on the cover and the stat ements below . : This furnace is [...]

All installations and ser vices must be performed by qualifie d service per sonnel. 2 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 a[...]

All installations and ser vices must be performed by qualifie d service per sonnel. 3 This page and the follow ing page contain reproductions of the v a rious warning and instruction labels placed on the Thermo Pride Gas Furnace. Please read and comply w ith the contents of these labels.[...]

All installations and ser vices must be performed by qualifie d service per sonnel. 4[...]

All installations and ser vices must be performed by qualifie d service per sonnel. 5 TA BLE OF CONTENTS SECTION B E G I N N I N G P A G E I. SAFETY SECTION 1 II. GENERAL INSTRUCTIONS AND CLEARANCES 6 III. FURNACE SPECIFICATIONS 8 IV. INSTALLATION 10 A . R O O F J A C K 1 0 B. ST ANDARD CHIMNEY 10 C. FURNACE LOCA TION 1 0 D. BASE INSTALLATION 12 1.[...]

All installations and ser vices must be performed by qualifie d service per sonnel. 6 II. GENERA L INSTRUCTIONS A ND CLEARA NCES NOTE: REA D THIS SECTION BEFORE STA RTING INSTA LLATION 1. This furnace is equi pped with orifices for operation w ith natural g as. For conversi on to propane gas, see instructions in Gas Conv ersion Section of this manu[...]

All installations and ser vices must be performed by qualifie d service per sonnel. 7 5. Definitions of "combustible" and "non-combusti ble" materials as presented in the 1999 vers ion of the National Fuel Gas Code , ANSI Z223.1-1999/NFPA 70-1999, are as follo ws: a. Combustible material: “...materials made of or surfaced w it[...]

All installations and ser vices must be performed by qualifie d service per sonnel. 8 III. FURNA CE SPECIFICA TIONS MODEL G M D 1 - 8 0 HEAT INPUT RA TE (BT UH) 80,00 0 HEATING CAPACITY ( BT UH) 65,000 BURNER ORIFICE-NAT. GA S (MM) 2.45 BURNER ORIFICE-PROP. GAS (DMS) #53 GAS SUPPLY PRESSURE (IN.W .G.) MINIMUM REQUIRED PROPANE 11 NATURAL 5.5 MAXIMUM[...]

All installations and ser vices must be performed by qualifie d service per sonnel. 9 BLOWER DA TA MANUFACTURER: MORRIS ON PRODUCTS, INC. BLOW ER MODEL: 10-9, DIRE CT DRIVE NOMINAL M OT OR POW ER OUTPUT (HORSEPOW ER): 1/3 TYPICAL AIRFLOW @ SPECIFIED EX T ERNAL STATIC PRESSURES (SCFM @. IN.W .G.): ESP (IN W .C.) 0.2 0.5 LOW SPEED: 712 640 MEDIUM LOW[...]

All installations and ser vices must be performed by qualifie d service per sonnel. 10 IV. INSTA LLA TION A . ROOF JA CK The roof jack assembly and accessori es must be listed by a nationall y recogniz ed testing ag ency for the appropriate heating f uel. The roof jack assembly must be instal led according to the vent manufacturer ’s instructions[...]

All installations and ser vices must be performed by qualifie d service per sonnel. 11 Combustible Floor Base Model: 70-BA SE Figure 1A Cottage B ase Model: 01COT-BA SE Figure 1B Coil Cabinet Model: CE111S Figure 1C[...]

All installations and ser vices must be performed by qualifie d service per sonnel. 12 D. BASE INSTALLA T ION 1. Combustible Floor Base Model: 70-BASE Referring to Fi gure 1A, for applications using a combustion air channel and a supply air duct, use the base as a template to mar k the f loor opening locations. See Figure 2 for cutout locations. Cu[...]

All installations and ser vices must be performed by qualifie d service per sonnel. 13 If the combustion air passageway cannot terminate outside of the skirting or enclosure, a permanent opening with a minimum of 50 square inches of unobstructed infiltration (free area) for ventilation air must be provided for adequate combustion. This permanent op[...]

All installations and ser vices must be performed by qualifie d service per sonnel. 14 ? ? ? ? CA UTION: A permanent opening with a minimum of 50 square inches of unobstructed infiltration (free area) for ventilation and combustion air must be provided to the interior of the structure. Additional make-up air may need to be supplied to t[...]

All installations and ser vices must be performed by qualifie d service per sonnel. 15 F. CLOSET INSTA LLA TION ? ? ? ? WA RNING: HAZARD OF ASPHYXIATION: A suction effect will occur when th e furnace is operating inside the closet with the closet door closed. For proper operation, the furnace blower shall creat e no more than a 0.05-inch water colu[...]

All installations and ser vices must be performed by qualifie d service per sonnel. 16 4. The total free area of openings in the floor or ceiling regi sters serving the return air system must be at least 350 sq uare inches. At least one register must be located wher e it is not likely to be covered by carpeting, boxes, furnitur e, or any other obje[...]

All installations and ser vices must be performed by qualifie d service per sonnel. 17 Recommended material s f or the combustion air duct are smooth, round, galv anized steel duct or schedule 20 PVC pipe. The maximum intake duct leng th allowed is equiv alent to 40-feet of straight duct. Reduce this leng th by 6-feet for the intake hood and each 9[...]

All installations and ser vices must be performed by qualifie d service per sonnel. 18 H. GA S PIPING : Because of the potential of the odorant to fade, a gas leak may not be detected by smell. If th is furnace is installed below grade, contact your gas supplier for a gas detector. : With the gas piping pressurized, all gas piping connections must [...]

All installations and ser vices must be performed by qualifie d service per sonnel. 19 design-cer tified to be resistant to the action of the LP gases should be used on all threaded joints. The burner is setup to be piped to the g as supply throug h the lef t-hand side of the furnace. For serv ice purposes, it is recommended the g as union be locat[...]

All installations and ser vices must be performed by qualifie d service per sonnel. 20 f. Reinstall and secur e the junction box cover with the orig inal mounting screw s. 3. Connection Of Room Thermostat W ires NOTE: Class 1 thermost at w ire must be used inside the furnace burner compartment. a. Insert 24 VAC w ires through the plasti c grommet o[...]

All installations and ser vices must be performed by qualifie d service per sonnel. 21 J. PROPA NE CONVERSION Parts are incl uded with this furnace to conver t f rom natural to propane gas. See table 1 This conversion kit shall be installed by a qualified service agency in accordance wi th the manufacturer's instructions and all applicable cod[...]

All installations and ser vices must be performed by qualifie d service per sonnel. 22 MA NIFOLD REMOVAL A ND ORIFICE CHA NGE : Make sure that pipe dope or sealant certified to be resistant to the action of liquefied petr oleum gases is used on all threaded j oints. : The gas supply shal l be shut off prior to disconnecti ng the electrical pow er b[...]

All installations and ser vices must be performed by qualifie d service per sonnel. 23 4. Remove the four screw s securing the mani f old in the burner box . Pull the manifold far enough out of the burner box to access the burner orifices. (See figur e 8) 5. Remove the mai n burner orifices from the manifold using a 1/2- inch wrench. Replace the ex[...]

All installations and ser vices must be performed by qualifie d service per sonnel. 24 K. INITIA L STA RT UP: This furnace does not have a pil ot. It is equipped wi th a hot surface ig niter, w hich 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 w ir[...]

All installations and ser vices must be performed by qualifie d service per sonnel. 25 it is mandator y the input to the burner be r educed 4.0% for every 1,000 feet that it is above sea lev el. If the f urnace is i nstalled at an elevation of 5,000 feet, its input must be reduced 20.0%. Exampl e: a f urnace rated at 80,000 BTU at sea level must be[...]

All installations and ser vices must be performed by qualifie d service per sonnel. 26 TA BLE 2 This gas furnace is eq uipped with a fixed or ifice sized for the manifold pressure show n on the rating l abel. The input can only be increased, or decreased, by adjusting the manifold pressure. Remov e the 1/8" threaded pipe plug l ocated on the g[...]

All installations and ser vices must be performed by qualifie d service per sonnel. 27 Figure 9 N. SETTING TEMPERATURE RISE The GMD1-80N i s designed and wi red at the f actory f or a heating blower speed that should result i n an approximate temperature r ise of 70 ° F. The blow er motor is wi red on medium low speed f or heating mode. The temper[...]

All installations and ser vices must be performed by qualifie d service per sonnel. 28 NOTICE: All controls on the unit shoul d be checked for proper f unctioning prior to the qualified serv ice personnel leaving the job site. Specificall y the following should be checked: W ith furnace in normal heating operation, check to make certain blower will[...]

All installations and ser vices must be performed by qualifie d service per sonnel. 29 V. INSTA LLER'S INSTRUCTIONS TO USER: After completing the installation, the installer shal l inform and/or demonstrate to the homeowner : 1. The location of all the i nstructions in the furnace must be kept along w ith instructions for any accessor ies in t[...]

All installations and ser vices must be performed by qualifie d service per sonnel. 30 VI. STA RTING THE UNIT FLAME MUST BE DETECTED W ITHIN 4 SECONDS IF FLAME IS DET ECTE D, THE DELA Y-TO-FAN-O N TIME BEGINS (45 SECONDS) IF FL AME IS N OT DETECTED, THE GAS VALVE IS DE-E NERG IZED, TH E IGNITOR IS TURNED OFF AND THE CONTROL BOARD CONTROL GOES INTO [...]

All installations and ser vices must be performed by qualifie d service per sonnel. 31 AFTER DELAY-TO-FAN--ON PERIOD ENDS, CIRCULATING AIR FAN IS ENERGIZED AT HEATING SPEED. THE (OPTIONAL) ELECTRONIC AIR CLEANER AND HUMIDIFIER ARE ENERGIZED. IF IGNITION ATT EMPT IS UNSUCCESSFUL, ONE MORE RETRY W ILL BE MADE BEFORE THE CONTROL BOARD GOES INTO SYSTEM[...]

All installations and ser vices must be performed by qualifie d service per sonnel. 32 VII. TROUBLESHOOTING THIS SECTION IS ONLY TO BE PERFORMED BY TRA INED, QUALIFIED SERVICE PERSONNEL, AND NOT BY THE FURNA CE OWNER. NOTICE: BEFORE TROUBLESHOOTING, FAMILIARIZE YOUR SELF W ITH THE START UP AND CHECKOUT PROCEDURE. ALL INST ALLATION AND SERVICES MUST[...]

All installations and ser vices must be performed by qualifie d service per sonnel. 33 DIA GNOSTIC FEATURES : Power must be disconnected befo re servicing . The 50A65-143 control continuousl y monitors its ow n operation and the operation of the system. If a failure occurs, the LED will indicate a failure code as shown below. If the failure is inte[...]

All installations and ser vices must be performed by qualifie d service per sonnel. 34 TROUBLESHOOTING GUIDE THE SYSTEM IS STAR TED BY SETTING THE THERM OSTAT TO CALL FOR HEAT. THE FOLL OW ING SHOULD HELP ESTABLISH THE TYPE OF MALFUNCTION OR DE VIATI ON FROM THE NORMAL OPERA TION. TO USE THIS DIAG RAM, FOLLOW THE INSTRUCTION S IN THE BOXES. TURN TH[...]

All installations and ser vices must be performed by qualifie d service per sonnel. 35 CHECK THE INTEG RATED CONTROL DIAGNOSTIC LED LAMP. RESET BY INTERRUPTING POW ER TO CONTROL FOR MORE THAN ONE SECOND. IF LED ST AYS ON CONTINUOUSLY, REPL ACE INTEGRATED CONTROL. CHECK W IRING TO INDUCER AND IF OK, REPLACE INDUCER ASSEMBLY. DOES THE HOT SURFACE IGN[...]

All installations and ser vices must be performed by qualifie d service per sonnel. 36 AFTER GAS VALVE OPENS, DO THE BURNERS IGNITE? MEASURE MANIFOLD PRESSURE. IS PRESSURE ADEQUATE? ADJUST TO 3.5" W C FOR NATURAL GAS OR 10.0" W C FOR PROPANE GAS CHECK IGNITOR VOLTAGE DURING 20 SECOND W ARM-UP, IT SHOULD BE AT LEAST 105 VOLTS. CORRECT LINE[...]

All installations and ser vices must be performed by qualifie d service per sonnel. 37 TROUBLESHOOTING COM PLETE. CHECK ALL W IRING FOR LOOSE CONNECTIONS IS LED LIGH T ON INTEGRATED CONTROL FLASHING? DOES SYSTEM RUN UNTIL THERMOST AT IS SATISFIED? DOES BURNER SHUT OFF W HEN THERMOST AT IS SATISFIED? CHECK FOR SHORT IN W IRE TO T HERMOSTAT AND CORRE[...]

All installations and ser vices must be performed by qualifie d service per sonnel. 38 VIII. DEA LER MA INTENA NCE A qualified heating contractor should perform the follow ing maintenance procedures at the beginning of each heat ing season. Correct any deficiencies at once. ? ? ? ? WA RNING: Personal injury or property damage could result from repa[...]

All installations and ser vices must be performed by qualifie d service per sonnel. 39 D. INSPECTING TH E VENTING SYSTEM The venting system should be inspected during the annual maintenance check-up or during each subseq uent service call . Check all v ent pipes for restrictions due to soot, or carbon bui ld-up, as well as foreign matter, or any ma[...]

All installations and ser vices must be performed by qualifie d service per sonnel. 40 ON START-UP: 8. Have the heati ng system (and furnace) inspected and star ted by a qualified servi ce person. 9. Set the room thermostat abov e room temperature. 10. Open all shutoff valv es in the gas supply l ine. 4. Turn “on” the main pow er at the disconn[...]

All installations and ser vices must be performed by qualifie d service per sonnel. 41 IX. USER INFORMA TION SECTION A . WARNINGS A ND CA UTIONS: : If you suspect th ere is a problem with the furnace, pertaining to th e venting system or any other related problem, immediat ely contact a qualified service agency. If a service agency is not available[...]

All installations and ser vices must be performed by qualifie d service per sonnel. 42 B. COMPONENT LOCA TIONS The following diagram shows a ty pical furnace installati on and typical position of the components referenced in these instructions . Figure 10 C. INSPECTION A REA S IMPORTA NT: For safe operation it is the responsibility of the owner and[...]

All installations and ser vices must be performed by qualifie d service per sonnel. 43 1. VESTIBULE: The furnace vestibule areas or burner compartment should be inspected by r emoving front door of the furnace and looking for sig ns of excessiv e heat such as discoloration of components, materials damag ed from rust or corrosi on, soot or carbon bu[...]

All installations and ser vices must be performed by qualifie d service per sonnel. 44 A PPENDIX A . REPLA CEMENT PA RTS LIST[...]

All installations and ser vices must be performed by qualifie d service per sonnel. 45[...]

All installations and ser vices must be performed by qualifie d service per sonnel. 46 APPENDIX B – WIRI NG DIAGRAM[...]