Lodge Manufacturing GMD1-80N User's Manual
Contents
1. Yes Yes CHECK THE INTEGRATED SERIE VOLTAGE CONTROL DIAGNOSTIC LED LS POWER is LAMP RESET BY INTERRUPTING UCER POWER No POWER TO CONTROL FOR MORE TERMINALS IND amp IND N RENE TEE CONTROLS THAN ONE SECOND IF LED STAYS ON CONTINUOUSLY REPLACE INTEGRATED CONTROL Yes CHECK WIRING TO INDUCER AND IF OK REPLACE INDUCER ASSEMBLY Y CHECK THE INTEGRATED CONTROL DOES THE HOT asas NOT AUR ACE DIAGNOSTIC LED LAMP RESET BY SURFACE No No INTERRUPTING POWER TO CONTROL IGNITOR ENERGIZE asss qr Aree gt FOR MORE THAN ONE SECOND IF AND GLOW MEO TAN OTROS LED STAYS ON CONTINUOUSLY REPLACE INTEGRATED CONTROL Yes CHECK WIRING TO HOT SURFACE IGNITOR AND T IF OK REPLACE HOT SURFACE IGNITOR ASSEMLBY Y CHECK ACROSS MV AFTER HOT TERMINALS ON INTEGRATED SURFACE IGNITOR No CONTROL FOR 24 VOLTS DURING No WARM UP DOES gt THE4SECOND FLAME PROVING mu SAME AS ABOVE GAS VALVE OPEN PERIOD AFTER IGNITOR WARM UP IS THERE 24 VOLTS Yes Yes CHECK WIRING TO GAS VALVE AND IF OK Y REPLACE GAS VALVE 35 Allinstallations and services must be performed by qualified service personnel AFTER GAS VALVE OPENS DO THE BURNERS IGNITE No MEASURE MANIFOLD PRESSURE IS PRESSURE ADEQUATE No Yes CHECK IGNITOR VOLTAGE DURING 20 SECOND WARM UP IT SHOULD BE AT LEAST 105 VOLTS Yes ISIGNITOR POS2. ad e 12 7178 ES Figure 1A 3 I ps TNR STION AIR DUCT 8 x 2 1 2 x 14 LONG Cottage Base Model 01COT BASE Figure 1B Coil Cabinet Model CE111S Figure 1C 11 Allinstallations and services must be performed by qualified service personnel D BASE INSTALLATION 1 Combustible Floor Base Model 0 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 8 1 4 LOOR CUTOUT FEEDER DUCT C15 CONNECTIC Ue NN N Z L FLUE I COMBUSTION AIR 4 0D CUTOUT UNE ENTRY 70 BASE BOTTOM TEMPLATE UNIT VIEW TOP VIEW 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
3. you cannot reach your gas supptier call the fire department C Use only your hand to push in or turn the gas control knob or move the gas control switch Never uae tools If the knob will not push In or turn or 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 under water 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 EMEN OPERATING INSTRUCTIONS STOP Read the safety information above on this label Set the thermostat to the towest setting Turn off ali electric power to the appliance This appliance is equipped with a hot surface igniter that automatically lights the burner Do nof try to light the burner by hand 5 Turn gas control knob clockwise to OFF position For gas valves with a switch move the switch to the OFF position Wait five 6 minutes to clear out any gas Then smeh for gas including near thefloor or ground If you smell gaa STOP Follow B in the safety information above on this label if you don t smell gas go to next step Bop E Turn gas control knob counterclockwise to ON position For gas valves with a switch move the switch to the ON position B Turn on ali electric
4. 14 IN FILTER QUANTITY amp SIZE 1 18 x 24 APPROXIMATE SHIPPING WEIGHT 165 LBS PRODUCT LISTED UNDER ETL FILE NUMBER Allinstallations 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 INW C 02 0 5 LOW SPEED 712 640 MEDIUM LOW SPEED 870 760 MEDIUM HIGH S EE 1100 886 HIGH SPEED 1258 1003 ALL SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE Allinstallations 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
5. 4355 44 Allinstallations and services must be performed by qualified service personnel CAUTION A WARNING Mae s N MOVING PARTS 1 DO NOT TRY TO LIGHT ANY APPLIANCE i Oan s ee SPECIAL HOMEOWNE RS INST RUCTIONS 2 DO NOT TOUCH ANY ELECTRICAL SWITCH DO NOT USE ANY PHONE IN YOUR BUILDING E BEFORE 3 IMMEDIATELY CALL YOUR GAS SUPPLIER IMPROPER INSTALLATION ADJUSTMENT ALTERATION SERVICE OR MAINTENANCE CAN CAUSE FROM A NEIGHBOR S PRONE FOLLOW THE PROPERTY DAMAGE PERSONAL INJURY OR LOSS OF LIFE GAS SUPPLIER S INSTRUCTIONS 4 IF YOU CANNOT REACH YOUR GAS e OF THE OWNER AND OR SUPPLIER CALL THE FIRE DEPARTMENT FOR SAFE OPERATION T Is PIPE AT EXCHANGER AN SPECTED FOR YOUR SAFETY DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS AND LIQUIDS IN THE VICINTY OF THS OR ANY OTHER APPLIANCE UALIFIED HEATING CONTRACTOR THIS UNIT MUST BE INSTALLED AND SERVICED BY A QUALIFIED CONTRACTOR ONLY ED INSTALLER SERVICE AGENCY OR THE GAS SUPPLIER OPERATING INSTRUCTIONS ARE LOCATED INSIDE APPLIANCE NEAR BURNER ASSEMBLY z WARNING M THIS COMPARTMENT MUST BE CLOSED UN EXCEPT WHEN SERVICING 390024 NATURALIPROPANE GAS CONVERSION THIS FURNACE IS EQUIPPED FOR NATURAL GAS INSTRUCTIONS This furnace is equipped with orifices sized for operation with natural gas For conversion to propane gas see CONVERSION instructions label on the furnace Orific
6. Qi 1 8r 1nd 1 vi i di o BOSN35 am Fi g MOSN3S INVIA 9 1 Nu 5 T mens fa LINN xmv 1no Ti0N 9 Y aS c oH NOSE NONE MS 55384 Tar M3 T ue BONN 4 ls 5359 Sd E 0 Mm WWA IW1SOWH3HI 1002 91H Sv9 NOLOVINOO 2 V E WNOILAO PE 9 A tC J J FERE J 91 4910 1 y G9V s a ss ETE S9NIL13S AUOLOV3 f Y x W FF L 330 130 7238 081 M YINI ORIN 440 NO 035 021 B qu O29 YUMA xt _ 035 06 TE 035 09 I Nol A8 440 NaNL 23 Nyd AVIS 01 4 NO NO 03s 09 TOTIS x 330 NO 038 Gs E MOTT a A NO 440 aS 0 r X G LENA 440 440 038 Gl H ONI tu zm 1 D Um ZE ME NO NYNL vw g JUMS 13S 1 A3 aanaoaswval 61 zm 71 4906 13 nre 20 01 n 98 paan ih aa SNOUISOd HOIWS NOldO s M H 3NIT Wed Yd H 1009 WAS Q NT 0 Hye e yon 2 J gt NORROO 3IIH ON ROTHA T F 1000 WO 1 038 oH HOT QN 3n amp 1 c V UE f a Bi J OMINOO GIYAN NOV IB 5 v1 G9V0G a 44 lt lt Hd 1 24 09 811 9 n N H WNvUOVId NOLLO3NNOO 3SVHd 1 ZH O9 A GLL 08 LONS 1V9I819113 OUVIN3H3S 830QY1 VA LOGb GG OM 46
7. base with high temperature silicone caulk A 3 inch round to 7 inch x 2 1 4 inch rectangular adapter plate is supplied with the furnace for adapting the 3 inch round flex combustion air duct to the 2 inch x 7 inch combustion air duct 16 Allinstallations and services must be performed by qualified service personnel Recommended materials for the combustion air duct are smooth round galvanized steel duct or schedule 20 PVC pipe The maximum intake duct length allowed is equivalent to 40 feet of straight duct Reduce this length by 6 feet for the intake hood and each 90 degree elbow used and by 3 feet for each 45 degree elbow used the combustion air duct ZA CAUTION Flexible spiral or corrugated duct is not recommended due to the relatively high pressure drop associated with air movement through this type of passageway Optional combustion air a 4 round duct may be used by connecting a 3 x 4 reducer to the 3 flex duct supplied with the furnace Figure 6 FURNACE BURNER BOX AIR INLET HOSE CLAMP COMBUSTION AIR DUCT 17 Allinstallations and services must be performed by qualified service personnel H GAS PIPING AWARNING Because of the potential of the odorant to 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 AWARNING With the gas piping pressurized all gas piping connections must be leak tested using a st
8. block or obstruct air openings on the furnace casing Do not block or obstruct air openings communicating within the area in which the furnace is installed ACAUTION Do not allow the outside air intake to be blocked or obstructed by vegetation ice snow or any other materials A WARNING 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 A WARNING Should overheating occur or the fuel supply fail to shut off shut off the manual fuel supply valve to the furnace before shutting off the electrical supply 41 Allinstallations and services must be performed by qualified service personnel B COMPONENT LOCATIONS The following diagram shows a typical furnace installation and typical position of the components referenced in these instructions FLUE T RETURN AIR AUXILLIARY LIMIT SWITC 1 FILTER LOCATED BEHIND DOOR lt BLOWER I NUT SWITCH PRESSUR H SENSOR CH VESTIBULE FRONT DOOR FRONT VIEW REMOVED CMD1 UNIT W
9. burner by hand Check the following items before the initial start up 1 Check all wiring for proper hook up Tighten any loose connections 2 Using a soap solution leak test gas piping connections 3 Check all tubing connections to the pressure switch inducer burner box and gas valve and make sure they are connected firmly at all their connection points 4 Check flue pipe combustion air inlet and all joints 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 are free from blockage OPERATING INSTRUCTIONS AWARNING 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 See Section IV H of these instructions on the installation of gas piping AWARNING It may be necessary to purge the air out of the gas line for initial start up of the furnace after installation A qualified heating contractor should do this 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 Propane gas is especially dangerous because the specific gravity of propane gas allows it to accumulate at floor level at a dangerous concentration AWARNING Heat exchanger oil will burn off on initial firing creating an unpleasant odor To preve
10. can be taken to help insure a smooth and reliable start ON SHUT DOWN 1 Close the gas supply shutoff valve s 2 Turn the furnace power switch off and disconnect electrical power to the unit 39 Allinstallations and services must be performed by qualified service personnel ON START UP 8 Have the heating system and furnace inspected and started by a qualified service person 9 Set the room thermostat above room temperature 10 Open all shutoff valves in the gas supply line 4 Turn on the main power at the disconnecting switch and at the furnace power switch to start the inducer 5 Follow the BURNER OPERATION AND ADJUSTMENT procedure in Section L 40 Allinstallations and services must be performed by qualified service personnel IX USER INFORMATION SECTION A WARNINGS AND CAUTIONS AWARNING f you suspect there is a problem with the furnace pertaining to 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 A WARNING Personal injury or property damage could result from major repair or service of this furnace by anyone other than a qualified contractor The user should only perform the routine maintenance described in the user section of this manual A WARNING The area around the furnace should be kept free and clear of combustible materials especially papers and rags ACAUTION Do not
11. chamber and the heat exchanger and possibly offensive fuel odors Refer to chapter 5 3 of the National Fuel Gas Code ANSI Z223 1 NFPA 54 1999 or latest edition for application specific combustion air requirements The preferred location of the outside combustion air intake terminal e g an optional stainless steel intake hood part no 370183 is through the side of the structure skirting or enclosure An acceptable alternate location is under the structure in the skirted or crawlspace area providing a minimum of 50 square inches of free area exists around the perimeter for outside combustion air to be drawn through The opening of the termination must be at least 7 inches below the top of the floor The 70 base coil cabinet is shipped with a combustion air duct that must be installed in the bottom of the base enclosure before the furnace is installed This 2 inch by 7 inch duct is shipped in two pieces High temperature silicone sealant should be applied to both vertical seams before it is snapped together with all four flanges on the same end High temperature silicone must be applied to the flanges The combustion air duct can then be inserted through the opening in the floor base model no 70 When the combustion air duct has been inserted completely secure the duct to the combustion adapter with self tapping sheet metal screws refer to Figure 6 Make certain that the flanges duct and adapter are completely sealed to the burner enclosure
12. 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 Allinstallations and services must be performed by qualified service personnel Combustible Floor Base 121 87 Model 70
13. operation A ELECTRICAL 1 Check all wiring for loose connections and any signs of damage or unusual wear 2 Check for correct voltage at the furnace when operating 3 Check amp draw on blower motor and inducer motor to assure they are not exceeding nameplate amp rating 4 Check for correct operation and proper settings if manually adjustable of all controls Shut off gas and disconnect power before continuing B 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 If necessary the burners assembly can be removed by taking out the two screws one on each bracket on top of burner box and removing the burner manifold assembly Assembly must be pulled amp tilted down 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 C INDUCER BLOWER ASSEMBLY Inspect the pressure switch and 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 38 Allinstallations and services must be performed by qualified service personnel D INSPECTING THE VENTING SYSTEM The venting system should be inspected during the annual main
14. power to unit 9 Set thermostat to desired setting and if equipped set the operating mode to HEAT 340 appliance wili not operate follow the instructions To Turn Off Gas To Appliance and cali your service technician or gas supplier 1598 SWITCH cons ruction POSITION INDICATOR NOTCH Gas Control Valve Top View TO TURN OFF cas TO APPLIANCE SSE Set thermostat to lowest setting and if equipped set the set the operating mode to COOL or OFF If service is to be performed turn off all electric power to the appliance To turn off gas control valve remove the burner compartment cover Turn gas control knob clockwise to OFF position For gas valves with a switch move the switch to the OFF position Replace the burner compartment cover n gt p EFFICIENCY CERTIFIED iste CONTROL NO 3018528 MODEL NO GMD1 80N SERIAL NO 00000000 FOR INSTALLATION IN MANUFACTURED HOME DATE OF MANUFACTURE 08 JAN 2003 FOR INSTALLATION AS CENTRAL FURNACE SPECIAL TYPE FOR SINGLE STORY DWELLING ORIFICE LINE PRESSURE IN W C MANIFOLD FUEL TYPE BTUH INPUT ORILL SIZE MIN MAX PRESSURE IN W C NAT 80 000 2 45 MM 5 5 14 0 3 5 INCHES W C L P 80 000 53 11 0 14 0 10 0 INCHES W C APPLIANCE IS SHIPPED FROM FACTORY WITH 2 45 MM ORIFICES FOR NATURAL GAS FOR L P GAS CONVERSION REFER TO INSTRUCTION MANUAL PROVIDED WITH THIS APPLIANCE
15. 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 OTCOT 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 Allinstallations and services must be performed by qualified service personnel AN 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 1115 coil cabinet figure 1C is for applications requiring air con
16. 300 X08 JINNE 29 65 097 OSN3S n 0185005 A I8N3SSv 8nS X09 YINYNE 19 059087 NOLIN 9c 5109 X30704 Y3NYNE 09 18109 13S9 H000 GC G6908 3gni YINYNA 66 199077 yond ve 908027 2300033 ONIHSnH 8G G650G HOLMS LIAM HOIH ec 91091 LIMO HININ 9y0S HOLMS 3405534 e Vev09 ANONS 9G n 119086 OO 1N GS 610 0c 6 908 WA SY DS 191026 Tind 4000 0 9087 103INYWN eq 8 60085005 AlBAGSSV B S B3HVEC ZS L 690S ON0039 SS3NHVH IG vc 8l Nvd HIMO 31338 9 6808 AlddhS SS3NEVH 06 0 8 ATBAGSSV NOLO3NNOO 3011 S 68706 TINGILSSA SS3NuVH 6v 00190 Y 18 08 SS3NSVH 8v 1028 43 00 304 79706 AYZ H3IHOJSNY SL Ly 628 dOL 43400 3019 908086 JOMINOO 0314931 9v 6618 4000 1NO34 705005 ASSV B S TANYd 104109 Gr 6071 350H XT 0 168089 HOLIMS XNY vr 0618 Nvd 830018 6 008 sOLDVdY2 ey 9818 3ds 3143v8 8 00081 13 0v48 ONILNDON 5618 305 3143 L 920097 1008 9NILVT0SNI SOLD y 6087 M3NIVL33 YILT 9 61808 931 INNON YOLON Ov 86181 901 S 81806 QNY8 1NnON YOLOW 6E 1618 1 8 ONISYO 105 99057 YOLON 8 96181 1331 9NISVO 30S 08007 IYO 1093310 15 16180 839NVHOX3 1V3H 19175005 355 905 HMO 9 98181 3579 ALD ON 18V Oll dis0S30 31 A10 ON 13d NOILdISOS 30 51 SLuvd 45 Allinstallations and services must be performed by qualified service personne
17. Clean the filter by soaking it in water with a mild detergent and rinsing it with clean water Allow the filter to air dry before reinstalling it in the furnace Cleaning the air filter frequently may prevent airborne contaminants from going through the furnace and depositing in the furnace duct system and interior of the building See Figure 10 in this section for the location of the return air filter 43 Allinstallations and services must be performed by qualified service personnel APPENDIX A REPLACEMENT PARTS LIST A 777 44 Allinstallations and services must be performed by qualified service personnel y89y0S HOLIMS 100 103 OL y8909 30130 di S 1619 XOR 69 S0909 NOISS3ANOO d s 99108 1359 39NV4 LIINI 89 8068 AIAINSSSY 131 19 CC 00 dV 19 350H 6181 901 N3NHf8 99 181087 3014 13759 I 19981 5519 1H9IS 99 1080 31 19 LIN 0 1359 5519 1H9IS 9 67 eG BC 0 amp L3 SV9 39NOdS 3NOOTTIS 9 6810 L345V9 8c 0209 J
18. ERGIZED PRESSURE SWITCH SENSES ADEQUATE DIFFERENTIAL PRESSURE CONTACTS CLOSE POWER IS APPLIED TO POWER INTERRUPTION THE SILICON NITRIDE SYSTEM SHUTS OFF IGNITOR IGNITOR RESTARTS WHEN WARM UP IS 20 SECONDS POWER IS RESTORED Y START TRIAL AFTER IGNITOR WARM UP FOR IGNITION THE GAS VALVE IS ENERGIZED TO OPEN FLAME MUST BE IF FLAME IS NOT DETECTED WITHIN DETECTED THE GAS VALVE 4 SECONDS IF FLAME IS DE ENERGIZED THE IS DETECTED THE IGNITOR IS TURNED OFF AND DELAY TO FAN ON THE CONTROL BOARD CONTROL TIME BEGINS 45 SECONDS GOES INTO RETRY SEQUENCE Y 30 Allinstallations and services must be performed by qualified service personnel MAIN BURNER OPERATION Y CALL FOR HEAT SATISFIED Y END OF CYCLE AFTER DELAY TO FAN ON PERIOD ENDS CIRCULATING AIR FAN IS ENERGIZED AT HEATING SPEED THE OPTIONAL ELECTRONIC AIR CLEANER AND HUMIDIFIER ARE ENERGIZED WHEN THERMOSTAT IS SATISFIED CONTACTS OPEN AND THE GAS VALVE IS DE ENERGIZED AFTER PROOF OF FLAME LOSS INDUCER STARTS 5 SECOND POST SURGE AND OPTIONAL HUMIDIFIER IS DE ENERGIZED THE DELAY TO FAN OFF PERIOD BEGINS 180 SECONDS AFTER THE DELAY TO FAN OFF PERIOD ENDS THE CIRCULATING AIR FAN AND OPTIONAL ELECTRONIC AIR CLEANER ARE DE ENERGIZED 31 THE RETRY SEQUENCE PROVIDES A 60 SECOND WAIT BEFORE IGNITION RETRY RETRY IS ATTEMPTED WITH AN ADDITIONAL 10 SECONDS OF IGNITOR WARM UP TIME IF I
19. FRONT DOOR REMOVED Figure 10 C INSPECTION AREAS IMPORTANT For safe operation it is the responsibility of the owner and or user that the burner chimney vent pipe heat exchanger and controls should be inspected every year by a qualified heating contractor 42 Allinstallations and services must be performed by qualified service personnel 1 VESTIBULE The furnace vestibule areas or burner compartment should be inspected by removing front door of the furnace and looking for signs of excessive heat such as discoloration of components materials damaged from rust or corrosion soot or carbon build up 2 EXTERIOR OF FURNACES The furnace exterior should be inspected for signs of excessive heat such as discoloration of materials or damage from rust or corrosion 3 VENT CONNECTOR The furnace vent pipe should be inspected for signs of rust corrosion pitting or holes in the pipe Check for leakage around seams in pipe indicated by soot or condensate streaks 4 ROOF JACKS The furnace roof jack should be inspected for signs of rust or corrosion pitting or holes signs of excessive condensation or moisture leaking from roof jack D FILTER LOCATION AND CLEANING CAUTION To avoid injury from moving part hot surfaces or electrical shock shut off the power to the furnace and allow the furnace to cool before removing furnace access door to service filter The air filter should be inspected each month and cleaned when dirty
20. GNITION ATTEMPT IS UNSUCCESSFUL ONE MORE RETRY WILL BE MADE BEFORE THE CONTROL BOARD GOES INTO SYSTEM LOCKOUT IF FLAME IS DETECTED THEN LOST THE CONTROL BOARD WILL REPEAT THE INITIAL IGNITION SEQUENCE FOR TOTAL OF SIX RECYCLES AFTER SIX UNSUCCESSFUL RECYCLE ATTEMPTS THE CONTROL WILL GO INTO SYSTEM LOCKOUT IF SYSTEM IS IN LOCKOUT THE MODULE WILL RESET ITSELF AFTER 60 MINUTES 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 Allinstallations and services must be performed by qualified service personnel Vil TROUBLESHOOTING THIS SECTION IS ONLY TO BE PERFORMED BY TRAINED QUALIFIED SERVICE PERSONNEL AND NOT BY THE FURNACE OWNER NOTICE BEFORE TROUBLESHOOTING FAMILIARIZE YOURSELF WITH THE START UP AND CHECKOUT PROCEDURE ALL INSTALLATION AND SERVICES MUST BE PERFORMED BY QUALIFIED HEATING CONTRACTORS When testing electrical equipment always follow standard electrical procedures and precautions 1 Check for line voltage 110 120VAC to the furnace If there is no line voltage applied to the furnace check that disconnecting switch is fuses or circuit breakers have not blown or tripped 2 Make sure thermostat is calling for heat 3 Check for adequate fuel supply and pressure Are all
21. INSTALLATION APPLIANCE MAY BE INSTALLED IN A CLOSET OR ALCOVE WITH MINIMUM CLEARANCES TO ADJACENT COMBUSTIBLE CONSTRUCTION OF NOT LESS THAN 6 INCHES AT FRONT OF CLOSET 18 INCHES AT FRONT OF ALCOVE O INCH AT BACK O INCH AT SIDES 6 INCHES FROM FLUE PIPE 1 INCH FROM TOP OF APPLIANCE TO CEILING 1 INCH FROM PLENUM SIDES AND WARM AIR DUCT WITHIN 3 FEET OF APPLIANCE AND O INCH FROM ROOF JACK FOR CLOSET INSTALLATION A 250 SQ IN RETURN AIR OPENING MUST BE PROVIDED IN THE CLOSET DOOR SEE INSTRUCTION MANUAL FOR LOCATION DETAILS THIS TYPE FSP APPLIANCE MAY BE INSTALLED WITH A THERMG PRODUCTS LLC MODEL 70 BASE ASSEMBLY MODEL NO VP 1 VENT PIPE AND A LABELED MODEL NO SRJ 1 ROOF JACK OR TYPE B GAS VENT SEE INSTRUCTION MANUAL FOR DETAILS ON INSTALLATION OF BASE VENT PIPE AND ROOF JACK THERMO PRODUCTS LLC 390425 A 0 4443 MA A RAY 517 NAD MINCAN Tu acoce 1000 0T 4443 PERFORMANCE APPLIANCE IS A SEALED COMBUSTION SYSTEM FORCED AIR FURNACE FOR MOBILE HOME OR TRAVEL TRAILER INSTALLATION TESTED AT 0 3 INCHES OF WATER STATIC PRESSURE RISE ae MAXIMUM OUTLET AIR TEMPERATURE 200 F OR LESS WITH A NOMINAL TEMPERATURE 70 ELECTRICAL RATING 115 VOLTS 60 HERTZ 1 PHASE MAXIMUM CURRENT AMPS MINIMUM CIRCUIT AMPACITY MAXIMUM FUSE SIZE WARNING RISK OF FIRE OR ELECTRIC SHOCK ONLY CERTIFIED OR MANUFACTURER QUALIFIED SERVICE PERSONNEL SHALL BE USED TO INSTALL AND PROVIDE MAINTENANCE OF THIS APPLIANCE 290425 8 0 4355 MA 1000 07
22. IRING 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 EFFICIENCY RATING CERTIFIED THERMO PRODUCTS LLC ama POST OFFICE BOX 217 US NORTH JUDSON IN 46366 Lance PHONE 574 896 2133 MG 505 ECN 4501 MA MADE IN USA Allinstallations and services must be performed by qualified service personnel 1 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 AWARNING This furnace is not to be used as a construction heater A WARNING When testing electrical equipment always follow standard electrical procedures and precautions A WARNING The area around the furnace should be kept free and clear of combustible materials especially papers and rags AWARNING This furnace uses an automatic hot surface ignition control NEVER try to ignite gas manually ACAUTION 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 AWARNING 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 produc
23. ITIONED CORRECTLY DO BURNERS STAY LIT PAST PROOF OF FLAME CHECK DOES THE INTEGRATED CONTROL ENERGIZE THE CIRCULATING AIR BLOWER AFTER THE 45 SECOND TIME DELAY DOES THE CIRCULATING AIR FAN COME ON WHEN ENERGIZED Yes CHECK FLAME PROVING CIRCUIT WORKING PROPERLY CHECK ACROSS THE CIRCULATING AIR BLOWER TERMINALS CIR N amp HEAT FOR PROPER VOLTAGE DOES BLOWER SPIN FREELY IS CAPACITOR Y REPLACE CAPACITOR 36 No FOR PROPANE GAS ADJUST TO 3 5 WC FOR NATURAL GAS OR 10 0 WC CORRECT LINE VOLTAGE PROBLEM REPOSITION TO CORRECT LOCATION REPLACE THE INTEGRATED CONTROL CONFIRM IF EITHER BLOWER WHEEL IS RUBBING AGAINST HOUSING OR MOTOR SHAFT IS SPINNING FREELY AND REPAIR OR REPLACE AS NECESARRY REPLACE MOTOR Allinstallations and services must be performed by qualified service personnel DOES SYSTEM RUN UNTIL THERMOSTAT IS SATISFIED Yes Y DOES BURNER SHUT OFF SATISFIED Yes Y DOES THE CIRCULATING AIR BLOWER TURN OFF AFTER THERMOSTAT IS SATISFIED WITHIN 120 SECONDS Yes Y TROUBLESHOOTING COMPLETE IS LED LIGHT S Wine FOR No ONINTEGRATED Mo gt LOOSE CONTROL FLASHING CONNECTIONS No WHEN THERMOSTAT IS jy Yes CHECK FOR SHORT IN WIRE TO THERMOSTA
24. T AND CORRECT IF NECESSARY IF LED FLASHES 1 FLASH THEN PAUSE SYSTEM LOCKOUT 2 FLASHES THEN PAUSE PRESSURE SWITCH STUCK CLOSED 3 FLASHES THEN PAUSE PRESSURE SWITCH STUCK OPEN 4 FLASHES THEN PAUSE OPEN LIMIT SWITCH OR ROLLOUT SWITCH 6 FLASHES THEN PAUSE 115 VOLT AC POWER REVERSED 7 FLASHES THEN PAUSE LOW FLAME SENSE SIGNAL 8 FLASHES THEN PAUSE CHECK IGNITOR OR IMPROPER GROUNDING CONTINUOUS FLASHING FLAME HAS BEEN SENSED WHEN NO FLAME NO PAUSE SHOULD BE PRESENT NO CALL FOR HEAT THE LED WILL ALSO FLASH ONCE AT POWER UP CHECK COMPLETE SYSTEM OUT LED LIGHT STAYS ON CONTINUOUSLY COMPLETE FAILURE REPLACE INTEGRATED CONTROL 37 Allinstallations and services must be performed by qualified service personnel VII DEALER MAINTENANCE A qualified heating contractor should perform the following maintenance procedures at the beginning of each heating season Correct any deficiencies at once A WARNING Personal injury or property damage could result from repair or service of this furnace by anyone other than a qualified heating contractor Only the homeowner user routine maintenance described in the Users Information Manual may be performed by the user WARNING To avoid injury from moving parts shut off the power to the furnace before removing blower compartment door CAUTION Label wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous
25. Thermo Pride GAS FIRED FURNACE DOWN FLOW amp 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 NWARNING 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 e Do not try to light any appliance e Do not touch any electrical switch do not use any phone in your building e Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions e f you cannot reach your gas supplier call the fire department A WARNING 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 A WARNING 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 ANARNING 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 F
26. WC MIN 5 5 WC 3 5 3 WC MAX 14 WC MIN 11 WC 10 0 3 WC 25 Allinstallations and services must be performed by qualified service personnel TABLE 2 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 Z CAUTION 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 sizi
27. 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 Allinstallations 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 TOP VEW ASSEMBLED DUCT ALTERNATE BENT TABS SECURING DUC CONNECTOR TO DISTRUBUTION W ALTERNATE TABS ad WF DUCT OPENING v SHEET METAL SCREW Aw V DISTRUBUTION 4 REQUIRED 1 FAC k P is SIDE ATTACHING X i 1 DUCT CONNECTOR j a JR 7 ASE 0 l i T FLOOR JOIST DISTRIBUTION DUCT DISTRIBUTION DUCT Figure 3 Slit the corners of feeder duct down to the top of the top panel If metal projects more than 1 inch above
28. as been sensed when No pause no flame should be present No call for heat The LED will also flash once at power up 33 Allinstallations and services must be performed by qualified service personnel 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 FOLLOW THE INSTRUCTIONS IN THE BOXES TURN THERMOSTAT TO CALL FOR HEAT DOES THERMOSTAT MAKE CONTACT No Yes IS ROOM TEMPERATURE NE SE s TURN T STAT BELOW THERMOSTAT lt N I TEMPERAT L No X SETTING ABOVE SETTING CMM T ROOM TEMP Yes COOL THE THERMOSTAT Yes Y IS THE TRANSFORMER nA OR VOL S lies d ARE WIRES CONNECTED No CORRECT WIRE TO THE THERMOSTAT e Yes REPLACE THERMOSTAT IS INTERNAL DAMAGE No CHECK INPUT PRESENT ON THE No X POWER SERVICE TRANSFORMER SWITCH AND FUSES Yes REPLACE TRANSFORMER IS THERE 24 VOLTS CHECK FOR IS THE INDUCER No ACROSS TH amp TR No CONTINUITY L gt gt BLOWER OPERATING AT THE INTEGRATED amp PROPER CONTROL CONNECTIONS Yes Yes 34 Allinstallations and services must be performed by qualified service personnel
29. ce and or modify several of the existing components Table 1 shown below describes these components and shows the correct model or size for each type of gas propane or natural Table 1 Contents of the Thermo Pride Gas Conversion Kits NAT TO CONTENTS QUANTITY PROPANE 53 DMS Main Burner Orifice Diameter 0 0595in Gas Valve Pressure Regulator Kit 92 0659 White Rodgers Part No 21 Allinstallations and services must be performed by qualified service personnel MANIFOLD REMOVAL AND ORIFICE CHANGE AWARNING Make sure that pipe dope or sealant certified to be resistant to the action of liquefied petroleum gases is used on all threaded joints ACAUTION The gas supply shall be shut off prior to disconnecting the electrical power before proceeding with the conversion 1 Shut off gas to the furnace at the main manual gas shut off valve and power to the furnace at the disconnect switch 2 Disconnect the furnace from the gas supply system at the pipe union 3 Remove the burner box cover by removing the outer row of screws holding the cover BURNER 9 3 TUBE gt au A NAIT BURNER 3 PLACES 7 BOX Figure 8 22 Allinstallations and services must be performed by qualified service personnel 4 Remove the four screws securing the manifold in the burner box Pull the manifold far enough out of the burner box to access the burner orifices See fi
30. ditioning 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 1115 coil cabinet E ALCOVE INSTALLATION In this application a minimum of 18 ve inches of clearance must be provided d to the front of the unit Refer to Figure d 4 all N Alcove installations must use the No 70 mobile home base ZZ 1111 4 3 LL S ZZ YI Refer to section G COMBUSTION AIR for additional combustion air requirements 777 llill 11 7777 pi Ny ll a NEAREST Figure 4 WA PARTITION 14 Allinstallations and services must be performed by qualified service personnel F CLOSET INSTALLATION A WARNING HAZARD OF ASPHYXIATION A suction effect will occur when the furnace is operating inside the closet with the closet door closed For proper operation the furnace blower shall create no more than a 0 05 inch water column pressure differential between the closet and the adjoining space Figure 5 1 The return air opening into the closet is to have a minimum free area of 250 square inches refer to Figure 5 2 The return air opening may be located in the top the center or ideally the b
31. e regulator cap screw to obtain the required burner manifold pressure refer to the rating label for correct settings 390511 Allinstallations and services must be performed by qualified service personnel TABLE OF CONTENTS SECTION BEGINNING PAGE l SAFETY SECTION 1 I GENERAL INSTRUCTIONS AND CLEARANCES 6 I 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 l 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 VI 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 amp 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 Allinstallations and services must be performed by qualifi
32. ed service personnel I GENERAL INSTRUCTIONS AND CLEARANCES NOTE READ THIS SECTION BEFORE STARTING INSTALLATION m o 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 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 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 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 Federal Manufactured Home Constructions amp Safety Standard HUD Total 24 Part 280 American National Standard ANSI 119 2 NFPA 501C for installations of all recreational vehicles American National Standard ANSI Z223 1 NFPA 54 for installation of all gas fired furnaces American Nat
33. es necessary for propane conversion are An alternate main burner orifice and a gas valve pressure regulator conversion provided in the parts package located on the inside of this furnace kit are supplied with this furnace Remove this label only after the furnace conversion has been made 1 Shut off electric power at the furnace and close the manual gas shutoff valve serving the furnace 2 Disconnect the gas supply pipe from the gas control valve Disconnect the wires and 1 4 tubing if provided from the gas control valve 3 Remove the manifold and gas valve assembly from the furnace 4 Carefully remove and replace all the orifices in the manifold with those supplied in the conversion kit 5 Remove the cap screw from gas valve pressure regulator Turn the plastic regulator screw counter clockwise to remove it 6 Remove the regulator spring and replace it with the spring found in the pressure regulator conversion kit Replace plastic regulator screw and turn the screw clockwise about 6 complete turns Refer to any instructions supplied in the kit 7 Reassemble gas valve and manifold assembly to the furnace Reconnect the gas piping wiring and 1 4 tubing if provided to the gas control valve 8 Open the manual gas shutoff valve and turn on the electrical power 9 Check for gas leaks before placing furnace back in operation 10 During burner operation turn the regulator screw located beneath the gas valve pressur
34. from all leads and terminals if wetting occurs Wait at least 24 hours for the circuit to fully dry before energizing the system A WARNING 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 AWARNING 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 AWARNING 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 A WARNING 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 ACAUTION Do not block or obstruct air openings on the furnace or air openings communicating with the area in which the furnace is installed ACAUTION Do not allow the outside air intake to be blocked or obstructed by vegetation ice snow or any other materials ANARNING Do not use this furnace if an
35. gure 8 5 Remove the main burner orifices from the manifold using a 1 2 inch wrench Replace the existing main burner orifices with conversion orifices as indicated in table 1 6 Refer to the instructions provided in the gas valve conversion kit for regulator spring change out instructions 7 Reinstall the manifold into the burner box Make sure that all orifices go into their respective burners and the groove of the rubber grommet on the manifold lines up on the edge of the burner box to seal around the manifold Secure it with four screws See figure 8 8 Inspect the seal on the burner box cover and if damaged replace it Install and secure the burner box cover Make sure all the fastening screws are used 9 Check to make sure that the electrical connections to the gas valve are tight 10 Check that the plastic hose from the pressure switch is attached securely to the hose barb at the outlet of the gas valve without being kinked ANCAUTION The regulator of the gas valve will not function properly if this hose connection is not made 11 Reconnect the furnace to the gas supply 12 Refer to initial start up and operating instructions for test fire and burner adjustments 23 Allinstallations and services must be performed by qualified service personnel K 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
36. he absence of local codes governing gas piping selection and installation follow the National Fuel Gas Code ANSI Z223 1 NFPA 54 1999 or latest edition A readily accessible manual gas shutoff valve design certified for the applicable gas with a non displaceable rotor member shall be installed within six 6 feet of the furnace A pipe 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 corrosive effects of LP gases Pipe dope or sealant 18 Allinstallations and services must be performed by qualified service personnel design certified 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 gas supply through the left hand side of the furnace For service purposes it is recommended the gas union be located inside the furnace A drip leg must be used on both propane and natural gas installations immediately upstream of the furnace in order to trap oil condensate and other impurities which might otherwise lodge in the gas valve or plug the main 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 drip leg s may void the manufacturer s limited warranty on the furnace For natural gas the maximum su
37. ional 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 3 2001 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 A WARNING The area around the furnace must be kept free and clear of combustible materials especially papers and rags AWARNING This furnace is not to be used as a construction heater Allinstallations 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 fire retardant 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 give
38. l APPENDIX B WIRING DIAGRAM dV 8 0 Iv NOIVdOUINY IW3H 135 IM WNISIG 3HL 40 ANY 3l Z 17 OL 10H 193NNOO 71 IVISONS3HL 5Nr1002 ONUV3H JUMIA TOYLNOD TWNYSINI NO SNONLNNOD 1N3S38d 38 GINOHS JWV14 ON NIHM G3SN3S INVIA HSY14 SNONILNNOI 0 QN0089 NO YOLIND O3HO 929513 8 _ N 2 601 1SVTl Y 30 3HQIVM3dA3l V ONIAVH IVIN3LVA NN9S 3SN3S 3AVI MOT 939815 Prices MM COMNDU ARNOT alid 1 i HIN 38 IS 1030 193 38 GASYINIS WiMOd OV SLL S3HSVH 9 ONIS 12 dW3L NO N3dO HOLIMS pS Q 3 i 2 HOLIMS N3d0 S3HSV Y 1 Sodio N3d0 YOMIS HOIMS 38155384 S3HSVli Qi ON SC 035019 YINIS HOIIMS 330155349 S3HS Z ias 100x901 2145 SOLSONDYIC WO iff 38
39. n 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 CLOSET ALCOVE FRONT BACK SIDES ROOF JACK VENT CONNECTOR TOP PLENUM SIDES TOP AND SIDES OF DUCT BOTTOM OF DUCT 6 0 0 0 6 1 1 1 1 Allinstallations and services must be performed by qualified service personnel II 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 amp WEIGHTS CABINET WIDTH 18 IN DEPTH 25 1 2 IN HEIGHT 57 IN NO 70 MOBILE HOME BASE WIDTH 18 5 16 IN DEPTH 24 IN HEIGHT 4 IN WARM AIR DUCT WIDTH 12 IN DEPTH 12 IN COTTAGE BASE WIDTH 18 3 16 IN DEPTH 2474 IN HEIGHT
40. ng 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 M BURNER ADJUSTMENT A CAUTION The GMD1 80N furnace model utilizes an in shot burner design that does 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 This unit is designed to not require any burner adjustment The flames should be checked by looking through the sight glass located on the burner box Burner flames should be clear blue and almost transparent in color See Figure 9 NOTE It is not unusual to have mostly blue flames with yellow or orange tips visible in the tube for propane gas 26 Allinstallations and services must be performed by qualified service personnel BURNER FLAME Figure 9 N SETTING TEMPERATURE RISE The GMD1 80N is designed and wired at the factory for a heating blower speed that should result in an approximate temperature rise of 70 F The blower motor is wired on medium 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 After 10 to 15 minutes of continuous operation the temperature rise through the furnace m
41. nt this odor from occurring more than once it is suggested that 1 A window s be opened 2 The thermostat be set at highest setting 3 The furnace remains running at conditions 1 amp 2 for 30 minutes or until odor has dissipated L ADJUSTMENT OF HEAT INPUT RATE The orifices for this furnace were 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 rating label 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 24 Allinstallations and services must be performed by qualified service personnel it is mandatory 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 80 000 BTU at sea level must be reduced to a firing rate of 64 000 80 000 x 80 64 000 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 may supply you with the correct orifice sizing information To check the heat input rate of your natural gas furnace allow the unit to operate for 10 to 15 minutes and proceed as follows a Call yo
42. ottom of the closet door or sidewall A WARNING 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 temperature limit and shutdown or it may cause asphyxiation 3 The cross sectional area of the return air grille leading into the closet when located in the floor or ceiling shall not be less than 250 square inches 15 Allinstallations and services must be performed by qualified service personnel 4 The total free area of openings in the floor or ceiling registers serving the return air 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 any other objects 5 Materials located in the return air system must have a flame spread classification of 200 or less 6 Wiring materials located in the return air duct system must conform to Article 300 22 of the latest edition of the National Electrical Code NFPA 70 7T Gas piping shall not be located in or extend through the return air duct system 8 Refer to section G COMBUSTION AIR for additional combustion air requirements G COMBUSTION AIR The furnace requires the proper amount of combustion airflow through the combustion air intake to combust the fuel cleanly and efficiently An inadequate combustion air supply can result in unsafe and erratic operation of the burner sooting of the combustion
43. pply pressure is 14 0 in W G and the minimum supply pressure for purposes of input adjustment is 5 5 in W G For propane gas the maximum supply pressure is 14 0 in W G and the minimum supply pressure for purposes of input adjustment is 11 0 in W G l ELECTRICAL WIRING ACAUTION When testing electrical equipment always follow standard electrical procedures and precautions All electrical wiring must be installed in strict accordance with local ordinances and codes In the absence of local ordinances and codes all electrical wiring must conform to the requirements of the National Electric Code ANSI NFPA 70 1999 or 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 19 Allinstallations and services must be performed by qualified service personnel f Reinstall and secure the junction bo
44. rmostat 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 20 Allinstallations and services must be performed by qualified service personnel J PROPANE CONVERSION Parts are included with this furnace to convert from natural to propane gas See table 1 WARNING This conversion kit shall be installed by a qualified service agency in accordance with the manufacturer s instructions and all applicable codes and requirements of the authority having jurisdiction 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 The qualified service agency performing this work assumes responsibility for the proper conversion of this furnace with this kit The installation of this conversion kit must be done only by qualified service personnel These instructions must be read in their entirety before converting the furnace Follow the start up and operation section of this manual for instructions on the test fire subsequent to this conversion The following instructions will outline the procedure for converting the existing burner from natural to propane gas When making a gas conversion it is necessary to repla
45. rong soap and water solution 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 ACAUTION 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 A WARNING 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 13 9 inches W G The furnace can be isolated from the gas supply by closing the manual gas shutoff valve serving the appliance at test pressures equal to or less than 1 2 PSIG or 13 9 inches W G A WARNING 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 Sizing and installation of fuel lines must be in accordance with federal state and local regulations A qualified installer or service person must install all gas piping and perform all required testing Piping from the natural gas meter to the furnace shall be in accordance with requirements of the local gas utility Piping from the propane tank to the furnace must follow the recommendations of the gas supplier In t
46. s 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 the Users Information section of this manual 5 That failure to maintain and operate this furnace in accordance with these instructions could result in hazardous conditions bodily injury and 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 outlined on the front cover and in sections 1 Il and IIl of this manual and in the Users Information section of this manual 7 Recommend the user has a qualified heating contractor inspect the furnace at the start of each heating season Inform the user of the frequency of inspection required for reach item in the User Information Section of this manual 29 Allinstallations and services must be performed by qualified service personnel VI STARTING THE UNIT A SEQUENCE OF OPERATIONS CONTINUOUS SAFE OPERATION CHECK IF FLAME AT ANY TIME THE SIMULATION CONDITION PRESENT OR ROLL OUT GAS VALVE IS SWITCH OPENS SYSTEM ENERGIZES INDUCER NOT ENERGIZED FAN FOR 15 SECONDS AND CIRCULATOR BLOWER AT HEATING SPEED UNTIL SITUATION CORRECTION START THERMOSTAT CALLS FOR HEAT CONTACTS CLOSE CONTROL BOARD ENERGIZED INDUCER EN
47. tenance check up or during each subsequent service call Check all vent pipes for restrictions due to soot or carbon build up as well as foreign matter or any materials that cause the venting system to restrict the proper venting of combustion products If a restriction is found the flue vent must be cleaned or replaced to ensure proper venting Vent pipes should also be inspected for any signs of corrosion deterioration or leakage that may cause combustion by products to infiltrate the home or indoor environment If signs of corrosion deterioration or leakage are evident the vent pipe must be replaced with a properly sized agency approved vent pipe E GASKETS SEALING MATERIALS Inspect all visible gaskets for signs of degradation especially any seals which were removed as part of the inspection Replace any suspect gaskets F 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 G HOUSE AIR BLOWER Check and clean the blower wheel housing and compartment with a vacuum Check the motor nameplate and follow the motor manufacturers instructions for lubrication if required IMPORTANT Some motors are permanently lubricated and should not be oiled See motor nameplate for specific instructions H EXTENDED SHUTDOWN If this furnace is shut down or off for an extended period of time several steps
48. 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 high air 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 until the pressure switch functions shutting off the main burners 4 Block the inlet gradually until pressure switch functions shutting off the main burners IMPORTANT Remove flue or air inlet blockages when done 28 Allinstallations and services must be performed by qualified service personnel V 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 must be kept along with instructions for any accessories in the plastic pouch near the furnace 2 The location and use of the manual gas shut off valve and furnace electrical disconnect switch Instruct user to alway
49. the fuel shutoff valves open 4 To assist you in troubleshooting this furnace it is equipped with an integrated ignition control with diagnostics These diagnostics evaluate what malfunction the control system has experienced and will activate a flashing light on the control in different sequences to help pinpoint the failure 32 Allinstallations and services must be performed by qualified service personnel DIAGNOSTIC FEATURES AWARNING Power must be disconnected before servicing The 50A65 143 control continuously monitors its own 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 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 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 igniter or improper grounding Continuous flashing Flame h
50. tion of hazardous carbon monoxide gas AWARNING 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 A WARNING If you do not follow these instructions exactly a fire or explosion may result causing personal injury loss of life or property damage AWARNING 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 AWARNING 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 A WARNING 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 AWARNING 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 Allinstallations 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 ACAUTION DO NOT wet electronic components during the leak test Wetting electronic components may damage circuitry and cause a hazardous situation Dry moisture
51. ur 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 b 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 78 678 BTU Input 93 80 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 GMD1 80N model and the input rate is 78 678 BTU hr The input rate would be acceptable because it was within 2 of the listed input of 80 000 c 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 shown in figure 8 GAS PRESSURE CHART FOR ALL GMD1 80 MODEL FURNACES SUPPLY PRESSURE MANIFOLD PRESSURE MAX 14
52. ust fall within a range of 55 F to 85 F If the outlet or supply duct temperature is too high check to make sure the return air filter is clean the return air registers are free from obstruction the outlet registers are properly adjusted and clear and the 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 blower door The speed of the blower must be increased by changing the speed tap from the motor see wiring diagram This is accomplished by locating the control panel attached to the blower housing and switching blue med low blower lead which should be connected to the Heat terminal on the White Rodgers 50A65 143 control with one of the higher speed blower leads attached to a terminal marked Park Be sure to attach any unused blower leads to a terminal marked Park Replace the blower door and turn on the power supply O 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 section IV H Gas Piping of this manual 27 Allinstallations and services must be performed by qualified service personnel NOTICE All controls on the unit should be checked for proper functioning prior to the qualified service personnel leaving the job site Specifically
53. x cover with the original mounting screws 3 Connection Of Room Thermostat Wires NOTE Class 1 thermostat wire must be used inside the furnace burner compartment a Insert 24 VAC wires through the plastic grommet on the left side of the furnace casing b Connect the thermostat wires to the W R 50A65 143 control refer to the wiring diagram c Connect the thermostat wires to the room thermostat 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 GMD refer to the thermostat literature for additional information Five 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 I Maximum Recommended Electrical Wire Diameter Thermostat Wire Length AWG Feet 24 55 22 90 20 140 18 225 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 1 Increase the thermostat setting or create a call for heat 2 Read the value of the thermostat current in milliamps 3 Adjust the heat anticipator of the the
54. y 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 A WARNING 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 Allinstallations 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 SHOULD THIS SEMBLED AS UNIT BE DISASSEMBLED ALL PONENTS PANELS BLOCK OFFS COLLARS GASKETS AND FASTENERS MUST BE REAS ORIGINALLY FACTORY PRODUCED J FOR YOUR SAFETY READ BEFORE OPERATING jll A This appliance does not have a pilot it is equipped with amp hot surface igniter that automatically lights the burner Do nat try to light the burner by hand B BEFORE OPERATING smell alt arq nd the appliance area for gas Be sure to smeli next to the base of unit because some gas isheavier than air and will settle on the floor or ground WHAT TO DO F YOU SMELL GAS Do not try to light any appliance Do not touch any electric switch do not use any phone in your bullding Immediately call your gas supplier from a neighbor s phone Foliow the gas supplier s instructions
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