Thermo Products GMD1-60N, GDM1-80N User Manual

GAS-FIRED FURNACE

DOWN FLOW & DIRECT VENT (SEALED COMBUSTION)

MODELS: GMD1-60N and GMD1-80N
INSTALLATION AND SERVICE MANUAL

For installation in:

1. Manufactured Homes

2. Modular Homes/Buildings

3. Site Constructed—Residential (S ingle 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 i n structions 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 informati o n , 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 b een 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 5320-MA 130307

MADE IN USA

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

1

I. SAFETY SECTION

This page and the following two pages contain various warnings and cautions
found throughout this furnace Service and Installation Ma nual. 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 wa r r anty 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 inj ur y, 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 c olumn.

: 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 l eak tested using a strong soap a nd

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

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

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 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 w i th 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 descri bed 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 bl ocked 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.

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

3

WARNING:

If you do not follow these instructions exactly, a
fire or explosion may result causing property damage,
personal injury or loss of life.

390540

1. Set thermostat to lowest setting, and, if equipped , set the operating
mode to "COOL" or "OFF".

2. If service is to be performed, turn off all electric power to the
appliance.

3. To turn off gas control valve, remove the burner compartment cover.

4. Move the gas control switch to the "OFF" position.

5.

Replace the burner compartment cover.

1. STOP! Read the safety information above on this label.

2. Set the thermostat to the lowest setting.

3. Turn off all electric power to the appliance.

4. This appliance is equipped with a hot surface igniter that
automatically lights the burner. D o not try to lig ht the burner by
hand.

5. Move the gas control switch to the "OFF" position.

6.

Wait five (5) minutes to clear out any gas. Then sm e ll for gas,
including near the floor or ground. If you smell gas, STOP! Follow
"B" in the safety information above on this label. If you don't smell
gas, go to the next step.

7. Move the gas control switch to the "ON" position.

8. Turn on all electric power to the appliance.

9. Set thermostat to desired setting, and, if equ ipped, set the operating
mode to "HEAT".

10.If appliance will not operate, follow the instructions "To Turn Off
Gas To Appliance" and call your service technician or gas supplier.

A. This appliance does not have a pilot. It is equipped with a hot

surface igniter that automatically lights the burner. Do not try to
light the burner by hand.

B. BEFORE OPERATING smell all around the appliance area for gas.

Be sure to smell next to the base of unit because some gas is
heavier than air and will settle on the floor or ground.
WHAT TO DO IF YOU SMELL GAS

?

Do not try to light any appliance.

?

Do not touch any electric switch; do not use any phone in your

building.

?

Immediately call your gas supplier from a neigh bor's phone.

Follow the gas supplier's instructions.

?

If you cannot reach your gas supp lier, call the fire department.

C.

Use only your hand to move the gas control switch. Never use tools.
If the switch will not move by hand, don't try to repair it, call a
qualified service technician. Force or attempted repair may result in
a fire or explosion.

D.

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 control system and any gas
control which has been underwater.

This page and the followi ng 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.

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

4

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

5

TABLE OF CONTENTS

SECTION BEGINNING PAGE

I. SAFETY SECTION 1
II. GENERAL INSTRUCT IONS 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. INITIAL STA RT UP 21

K. ADJUSTMENT OF B TU INPUT RATE 21
L. BURNER ADJUSTMENT 23
M. SETTING TEMPERATURE RISE 24
N. FURNACE CHECKOUT PROCEDURE 25
V. I NSTALLER’S INSTRUCTIONS TO USER 26
VI. STARTI NG THE UNIT 27
A. SEQUENCE OF OPERATIONS 27
VII. TROUBLESHOOTING 29
VIII. DEALER MAINTENANCE 35
A. ELECT RICAL 35

B. BURNERS 35
C. INDUCER BLOWER ASSEMBLY 36
D. INSPECTING THE VENTING SYSTEM 36
E. GASKETS/SEALING MATERIALS 37
F. HEAT EXCHANGER 37
G. HOUSE AIR BLOWER 37
H. EXTENDED SHUTDOWN 37

IX. USERS INFORMATION SE CTION 38
A. W ARNINGS & CAUTIONS 38

B. COMPONENT LOCATIO NS 39

C. INSPECTION AREAS 39
D. FILTER LOCAT ION AND CLEANING 40
APPENDIX A – REPLACEMENT PARTS 41
APPENDIX B – WIRING DIAGRAM 43

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

6

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. It is recommended that a commercial available CO alarm be installed in
conjunction with any fossil fuel burning appliance. The CO alarm shall be
installed according to the alarm manufacturer’s installation instructions and be
listed in accordance with the latest edition of the UL Standard for Single and
Multiple Station Carbon Monoxide Alarms, UL 2034, or the CSA International
Standard, Residential Carbon Monoxide Alarming Devises, CSA 6.19.

5. The installer shall be familiar with and comply with all codes and regulations

applicable to the installation of these heating appliances and related equipment.
In lieu of local codes, the installation shall be in accordance with the current
provisions of one or more of the following standards.

a. Federal Manufactured Home Constructions & Safety Standard (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 FURNA CE 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.”

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

7

FRONT

BOTTOM OF DUCT

6”

1”

18”

1”

: 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. 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 materi al shall be
considered combustible even though flame proofe d, 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 GMD1-60N and GMD1-80N CLOSET ALCOVE

BACK
SIDES
ROOF JACK
VENT CONNECTOR
TOP
PLENUM SIDES
TOP AND SIDES OF DUCT

0”
0”
0”
6”
1”
1”
1”

0”
0”
0”
6”
1”
1”
1”

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

8

III. FURNACE SPECIFICATIONS

MODEL GMD1-60 GMD1-80

HEAT INPUT RAT E (BTUH) 60,000 80,000
HEATING CAPACITY (BTUH) 49,000 65,000
BURNER ORIFICE-NAT. GAS (MM) #38 2.45
BURNER ORIFICE-PROP. GAS (DMS) #52 #53
GAS SUPPLY PRESSURE (IN.W.G.)
MINIMUM REQUIRED

PROPANE 11 11

NATURAL 5.5 5.5
MAXIMUM ALLOWED
PROPANE 14.0 14.0
NATURAL 14.0 14.0
GAS MANIFOLD PRESSURE (IN. W.G.)
PROPANE 10 + 0.3 10 + 0.3
NATURAL 3.5 + 0.3 3.5 + 0.3
VENT PIPE SIZE (INCHES) 4 4
DESIGN TEMPERATURE RISE (°F) 70 70
SEASONAL EFFICIENCY
(AFUE*, %) 82 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 (G MD1)
NOMINAL HEAT ANTICIPATOR SETTING -- 0.8 mA (GMD1)

DIMENSIONS & WEIGHTS:
CABINET: WIDTH - 18 I N., DEPTH – 25-3/4 IN., HEIGHT - 57 IN.
NO.70 MOBILE HOME BASE: WIDTH - 18-5/16 IN., DEPTH - 24¼ IN., HEIGHT - 4 IN.
WARM A IR 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 UNDE R ETL FILE NUMBER –

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

9

MEDIUM LOW
SPEED:

MEDIUM HIGH
SPEED:

MEDIUM LOW
SPEED:

MEDIUM HIGH
SPEED:

BLOWER DATA

GMD1-60

MANUFACTURER: MORRISON PRODUCTS, INC.
BLOWER MODEL: 10-7, 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: 759 694

907 809

1096 934

HIGH SPEED: 1207 1029

GMD1-80

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

HIGH SPEED: 1258 1003

870 760

1100 886

ALL SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE.

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

10

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.

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

11

Combustible Floor Base
Model: 70-BASE

Figure 1A

Cottage Base
Model: 01COT-BASE

Figure 1B

Coil Cabinet
Model: CE111S / CE211T

Figure 1C

CE111S CE211T

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

12



D. 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). Cut a combustion air duct opening in the floor 1/8­inch larger than the template opening.

Figure 2

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
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. Insert and secure the combustion air duct. Put
the base top assembly in place (see Figure-3).

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 c om bustion air ducts must be closed with a
sealing method suitable to the appli cation conditions and temperatures (e .g. high
temperature silicone caulk and/or aluminum tape).

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

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 perma nent opening must be located no less tha n 12
inches from the bottom of the enclosure or skirting.

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: 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.