Lodge Manufacturing GMD1-80N User Manual

GAS-FIRED FURNACE

DOWN FLOW & DIRECT VENT (SEALED COMBUSTION)

MODELS: GMD1-80N
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: [phone]

MG-505

ECN 4501-MA

MADE IN USA

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

I. SAFETY SECTION

This page and the following two pages contain various warnings and cautions
found throughout this furnace Service and Installation Manual. Please read and
comply with the statements on the cover and the statements below.

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

: When testing electrical equipment, always follow standard electrical

procedures and precautions.

: The area around the furnace should be kept free and clear of

combustible materials, especially papers and rags.

: This furnace uses an automatic hot surface ignition control. NEVER

try to ignite gas manually.

: If the temperature rise exceeds 85°F, the heat exchanger may fail

voiding the heat exchanger warranty resulting in property damage, personal
injury or loss of life.

: Burner adjustments must be confirmed by instrumentation. Failure to

use accurate or calibrated instrumentation to setup the burner may result in
reduced efficiency, sooting, and/or the production of hazardous carbon
monoxide gas.

: Any attempt to relocate safety controls or replace safety controls with

a control that is not approved or incompatible, may result in personal injury,
substantial property damage or death.

: If you do not follow these instructions exactly, a fire or explosion may

result causing personal injury, loss of life or property damage.

: HAZARD OF ASPHYXIATION: Negative pressure inside the closet with

closet door closed and the furnace blower operating 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 or it may cause asphyxiation.

: 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 pipe connections must be leak tested using a strong soap and

water solution (with the gas turned on). Any leaks must be repaired immediately

1

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

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.

: 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 14.0 inches W.G. The furnace can be isolated from the gas supply
by closing its manual shut off valve at test pressures equal to or less than 1/2
PSIG or 14.0 inches W.G.

: 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.

: If you suspect there is a problem with the furnace, the venting system

or any other related problem, immediately contact a qualified service agency. If a
service agency is not available, contact your fuel supplier.

: Personal injury, or property damage, could result from major repair or

service of this furnace by anyone other than a qualified contractor. Only the
routine maintenance described in the user section of this manual should be
performed by the user.

: Do not block or obstruct air openings on the furnace or air openings

communicating with the area in which the furnace is installed.

: Do not allow the outside air intake to be blocked or obstructed by

vegetation, ice, snow or any other materials.

: Do not use this furnace if any part has been underwater. Immediately

call a qualified service agency to inspect the furnace and to replace any part of
the electrical or control system, which has been underwater.

: Should overheating occur or the gas supply fail to shut off, shut off the

manual gas supply valve to the furnace before shutting off the electrical supply.

2

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

This page and the following page contain reproductions of the various warning
and instruction labels placed on the Thermo Pride Gas Furnace. Please read and
comply with the contents of these labels.

3

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

4

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

TABLE OF CONTENTS

SECTION BEGINNING PAGE

I. SAFETY SECTION 1
II. GENERAL INSTRUCTIONS AND CLEARANCES 6
III. FURNACE SPECIFICATIONS 8
IV. INSTALLATION 10
A. ROOF JACK 10
B. STANDARD CHIMNEY 10

C. FURNACE LOCATION 10
D. BASE INSTALLATION 12

1. Combustible Floor Base Model: 70-BASE 12

2. Cottage Base Model: 01COT-BASE 13
E. ALCOVE INSTALLATION 14
F. CLOSET INSTALLATION 15
G. COMBUSTION AIR 16

H. GAS PIPING 18
I. ELECTRICAL WIRING 19
J. PROPANE CONVERSION 21

K. INITIAL START UP 24

L. ADJUSTMENT OF BTU INPUT RATE 24
M. BURNER ADJUSTMENT 26
N. SETTING TEMPERATURE RISE 27
O. FURNACE CHECKOUT PROCEDURE 27
V. INSTALLER’S INSTRUCTIONS TO USER 29
VI. STARTING THE UNIT 30
A. SEQUENCE OF OPERATIONS 30
VII. TROUBLESHOOTING 32
VIII. DEALER MAINTENANCE 38
A. ELECTRICAL 38

B. BURNERS 38
C. INDUCER BLOWER ASSEMBLY 38
D. INSPECTING THE VENTING SYSTEM 39
E. GASKETS/SEALING MATERIALS 39
F. HEAT EXCHANGER 39
G. HOUSE AIR BLOWER 39
H. EXTENDED SHUTDOWN 39

IX. USERS INFORMATION SECTION 41
A. WARNINGS & CAUTIONS 41

B. COMPONENT LOCATIONS 42

C. INSPECTION AREAS 42
D. FILTER LOCATION AND CLEANING 43
APPENDIX A - REPLACEMENT PARTS LIST 44
APPENDIX B – WIRING DIAGRAM 46

5

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

II. GENERAL INSTRUCTIONS AND CLEARANCES

NOTE: READ THIS SECTION BEFORE STARTING INSTALLATION

1. This furnace is equipped with orifices for operation with natural gas. For
conversion to propane gas, see instructions in Gas Conversion Section of this
manual.

2. Any reference to L.P. or Propane gas in this manual, any other labels, or
markings on this furnace is to be construed to be propane HD-5. A commercial
grade of liquefied petroleum gases composed of a minimum of 90 percent liquid
propane (C8H8).

3. The selection of a furnace heating capacity for a proposed 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).

4. 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 (HUD Total 24,

Part 280).

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

recreational vehicles.

c. American National Standard (ANSI-Z223.1/NFPA-54), for installation of all gas-

fired furnaces.

d. American National Standard Electric Code (ANSI-C1/NFPA-70), for installation of

all electrical field wiring.

The gas-fired furnace has been investigated under the ANSI Z 21.47-CAN/CGA 22.3­2001 CENTRAL FURNACE test standard. This gas fired unit is listed by Intertek
Testing Services and described as, “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.

6

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

5. Definitions of "combustible" and "non-combustible" materials as presented in the

1999 version of the National Fuel Gas Code, ANSI Z223.1-1999/NFPA 70-1999, are
as follows:

a. Combustible material:

“...materials made of or surfaced with wood, compressed
paper, plant fibers, or other materials that are capable of
being ignited and burned. Such material shall be
considered combustible even though flame proofed, fire­retardant treated, or plastered.”

b. Non-combustible material:

“...material that is not capable of being ignited and
burned; such as material consisting entirely of, or a
combination of, steel, iron, brick, tiles, concrete,
slate, asbestos, glass, and plaster.”

This heating appliance must be installed with clearances to combustible material
surfaces of not less than the minimum distances given below. Also, allow ample
clearances for servicing the furnace for easy access to the air filter, blower assembly,
burner assembly, controls, and vent connections.

MODELS GMD1-80N
FRONT
BACK
SIDES
ROOF JACK
VENT CONNECTOR
TOP
PLENUM SIDES
TOP AND SIDES OF DUCT
BOTTOM OF DUCT

CLOSET ALCOVE

6”
0”
0”
0”
6”
1”
1”
1”
1”

18”

0”
0”
0”
6”
1”
1”
1”
1”

7

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

III. FURNACE SPECIFICATIONS

MODEL GMD1-80

HEAT INPUT RATE (BTUH) 80,000
HEATING CAPACITY (BTUH) 65,000
BURNER ORIFICE-NAT. GAS (MM) 2.45
BURNER ORIFICE-PROP. GAS (DMS) #53
GAS SUPPLY PRESSURE (IN.W.G.)
MINIMUM REQUIRED

PROPANE 11

NATURAL 5.5
MAXIMUM ALLOWED
PROPANE 14.0
NATURAL 14.0
GAS MANIFOLD PRESSURE (IN. W.G.)
PROPANE 10 + 0.3
NATURAL 3.5 + 0.3
VENT PIPE SIZE (INCHES) 4
DESIGN TEMPERATURE RISE (°F) 70
SEASONAL EFFICIENCY
(AFUE*, %) 81

*AFUE - INCLUDES STEADY STATE THERMAL EFFICIENCY AND OFF CYCLE
LOSSES.

ELECTRICAL RATINGS AND SETTINGS:
ELECTRICAL SUPPLY: 115 VAC / 60HZ / 1 PHASE
MAXIMUM TIME DELAY TYPE FUSE OR HACR BREAKER RATING: 15 AMPS
TOTAL RATED CURRENT (AMPS): 7.15 (GMD1)
NOMINAL HEAT ANTICIPATOR SETTING -- 0.8 mA (GMD1)

DIMENSIONS & WEIGHTS:
CABINET: WIDTH - 18 IN., DEPTH – 25-1/2 IN., HEIGHT - 57 IN.
NO.70 MOBILE HOME BASE: WIDTH - 18-5/16 IN., DEPTH - 24¼ IN., HEIGHT - 4 IN.
WARM AIR DUCT: WIDTH – 12 IN., DEPTH – 12 IN.
COTTAGE BASE: WIDTH – 18-3/16 IN., DEPTH - 24¼ IN., HEIGHT – 14 IN.
FILTER QUANTITY & SIZE: 1 – 18” x 24 “
APPROXIMATE SHIPPING WEIGHT: 165 LBS.

PRODUCT LISTED UNDER ETL FILE NUMBER –

8

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

BLOWER DATA

MANUFACTURER: MORRISON PRODUCTS, INC.
BLOWER MODEL: 10-9, DIRECT DRIVE
NOMINAL MOTOR POWER OUTPUT (HORSEPOWER): 1/3

TYPICAL AIRFLOW @ SPECIFIED EXTERNAL
STATIC PRESSURES (SCFM @. IN.W.G.):

ESP (IN W.C.) 0.2 0.5

LOW SPEED: 712 640
MEDIUM LOW

SPEED:
MEDIUM HIGH
SPEED:

870 760

1100 886

HIGH SPEED: 1258 1003

ALL SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE.

9

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

IV. INSTALLATION

A. ROOF JACK

The roof jack assembly and accessories must be listed by a nationally recognized
testing agency for the appropriate heating fuel.

The roof jack assembly must be installed according to the vent manufacturer’s
instructions prior to the furnace installation. (Refer to Figure 2 for flue location on
furnace.) Adapters for pitched roofs as well as extended barrel length roof jacks are
available from other suppliers.

All vent seams and connections must be sealed with high temperature silicone caulk.

B. STANDARD CHIMNEY

When installed as a central furnace special type for single story dwelling, venting into a
metal vent system approved by a nationally recognized testing agency for the
appropriate heating fuel type is permitted. Lined masonry chimneys are acceptable
when sized appropriately. The minimum chimney size should equivalent to the inside
free area of the 4-inch diameter vent collar exiting the furnace, or 12.5 square inches.

Maximum chimney sizes and acceptable installation practices are referenced in the
following publication. When installing the GMD1-80N, refer to Appendix G of the latest
edition of the installation standard NFPA 54, National Fuel Gas Code.

C. FURNACE LOCATION

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

2. This furnace is only intended for installation with free air return through the furnace
door louvers. ?

?CAUTION: DO NOT connect a ducted return air system directly to

??

the furnace. Improper installation may create a fire hazard and damage internal
equipment, as well as void all manufacturers’ warranties.

3. This furnace may be installed on combustible flooring when utilizing either the No. 70
counterflow floor base, for below the floor duct systems, or with the cottage base, for
floor level air distribution. See Figures 1A and 1B for depictions of the No. 70 and
the cottage bases.

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

10

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

Combustible Floor Base
Model: 70-BASE

Figure 1A

Cottage Base
Model: 01COT-BASE

Figure 1B

Coil Cabinet
Model: CE111S

Figure 1C

11

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

D. BASE INSTALLATION

1. Combustible Floor Base Model: 70-BASE
Referring to Figure 1A, for applications using a combustion air channel and a supply
air duct, use the base as a template to mark the floor opening locations. See Figure
2 for cutout locations. Cut a square opening in the floor for the supply air duct. Cut
the opening 1-inch larger than the square template opening. Cut the combustion air
duct opening. See Figure 1A for cutout sizes.

Figure 2

Place the bottom base panel in position. Mark the square opening location on the
distribution duct at the connection point of feeder duct. Remove the bottom panel.
Cut an opening in the duct slightly larger than the feeder duct. Cut the feeder duct to
length. (Refer to Figure 3 for location of this cut.) Install the feeder 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 feeder duct. Insert and secure the
combustion air duct. Put the top panel in place.

?

?CAUTION: A combustion air duct must be used. If the underside of the mobile

??

home is skirted or enclosed (e.g. enclosed in a crawlspace), the combustion air
intake should exit through the skirting, or enclosure, if at all possible. All joints
and seams of supply ducts and combustion air ducts must be closed with a
sealing method suitable to the application conditions and temperatures (e.g. high
temperature silicone caulk and/or aluminum tape).

12

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

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 opening must be located no less than 12
inches from the bottom of the enclosure or skirting.

Figure 3

Slit the corners of feeder duct down to the top of the top panel. If metal projects
more than 1 inch above the top panel, trim the flanges down to 1 inch. While pulling
the top of the distribution duct up with one hand, bend down each side of the feeder
duct tightly to the top panel with the other hand. This assures a tight connection
between the top panel and the feeder 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 top panel to the floor with two
screws in the front flange.

2. Cottage Base Model: O1COT-BASE

The O1COT-BASE cottage base (Figure 1B) is required for a freestanding cottage
base installation. The cottage base is designed to permit the installation of a 6-inch x
14-inch register in each of the two side panels and the front panel.

13

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

?

?CAUTION: 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 the interior of the structure to compensate for exhaust fans,
appliances, or vents, which consume air from the interior of the structure.

Refer to the assembly installation instructions included with OM1COT-BASE cottage
base for additional information.

3. Coil Cabinet: CE111S

The CE111S coil cabinet (figure 1C) is for applications requiring air conditioning.
The coil cabinet is designed to have the combustion air brought in from the bottom
thru a duct, supplied with the cabinet. Refer to section G Combustion air of this
manual for further instructions on the combustion air termination and connections.
For additional information refer instructions provided with the CE111S coil cabinet.

E. ALCOVE INSTALLATION

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

4.

Alcove installations must use the No.
70 mobile home base.

Refer to section
G. COMBUSTION AIR for additional
combustion air requirements.

Figure 4

14