Thermo Pride GMD1-60N, Installation And Service Manual

Page 1: ... instructions If you cannot reach your gas supplier call the fire department If the information in these instructions is not followed exactly a fire or explosion may result causing property damage personal injury or loss of life Improper installation adjustment alteration service or maintenance can cause injury or property damage Refer to this manual For assistance or additional information consul...

Page 2: ...d 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 c...

Page 3: ... cubic ft of hydrogen sulfide gas Check with your gas supplier If you suspect there is a problem with the furnace the venting system or any other related problem immediately contact a qualified service agency If a service agency is not available contact your fuel supplier Personal injury or property damage could result from major repair or service of this furnace by anyone other than a qualified c...

Page 4: ...his 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 equipped 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 p...

Page 5: ...All installations and services must be performed by qualified service personnel 4 ...

Page 6: ...TRICAL WIRING 19 J INITIAL START UP 21 K ADJUSTMENT OF BTU INPUT RATE 21 L BURNER ADJUSTMENT 23 M SETTING TEMPERATURE RISE 24 N FURNACE CHECKOUT PROCEDURE 25 V INSTALLER S INSTRUCTIONS TO USER 26 VI STARTING THE UNIT 27 A SEQUENCE OF OPERATIONS 27 VII TROUBLESHOOTING 29 VIII DEALER MAINTENANCE 35 A ELECTRICAL 35 B BURNERS 35 C INDUCER BLOWER ASSEMBLY 36 D INSPECTING THE VENTING SYSTEM 36 E GASKETS...

Page 7: ...led 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 installatio...

Page 8: ...aterial 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...

Page 9: ...IZE 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 GMD1 NOMINAL HEAT ANTICIPATOR SETTING 0 8 mA GMD1 DIMENSIONS WEIGHTS CABINET WIDTH 18 IN DEPTH...

Page 10: ...FM IN W G ESP IN W C 0 2 0 5 LOW SPEED 759 694 MEDIUM LOW SPEED 907 809 MEDIUM HIGH SPEED 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 MEDIUM LOW SPEED 870 760 MEDIUM HIGH SPEED 1100 886 HIGH SPEED ...

Page 11: ...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 cen...

Page 12: ...tions 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 ...

Page 13: ...t 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 ...

Page 14: ...mbly 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...

Page 15: ...ion 3 Coil Cabinet CE111S CE211T The CE111S CE211T coil cabinet figure 1C is for applications requiring air conditioning The coil cabinet is designed to have the combustion air brought in from the bottom thru a flexible hose 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 informatio...

Page 16: ...g 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 bottom of the closet door or sidewall 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 ...

Page 17: ...ter 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 AOPS7402 is through the side of the structure skirting or enclosure An acceptable alternate location is under the structure in the skirted or cra...

Page 18: ... 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 Optional combustion air a 4 round duct may be used by connecting a 3 x 4 reducer to the ...

Page 19: ...ng the appliance at test pressures equal to or less than 1 2 PSIG or 13 9 inches W G Copper and brass tubing and fittings except tin lined shall not be used if the gas contains more than a trace 0 3 grains per 100 cubic ft of hydrogen sulfide gas Check with your gas supplier Sizing and installation of fuel lines must be in accordance with federal state and local regulations A qualified installer o...

Page 20: ...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 I ELECTRICAL WIRING 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 elec...

Page 21: ...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 Electrical Wire Diameter Maximum Recommended Thermostat Wire Length AWG Feet 24 55 22 90 20 140 18 225 Once the furnace is installed check the thermostat an...

Page 22: ...rnace 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 Heat exchanger oil will ...

Page 23: ...e 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 exam...

Page 24: ...it is installed on an unmetered propane gas supply Shut off the gas supply to the furnace Remove the pressure gage and re install the pipe plug using a thread compound resistant to the action of LP gases If the rated input cannot be obtained with the present orifice at the correct pressure your local gas supplier may assist in sizing the proper orifice Thermo Products Engineering Department will g...

Page 25: ...mperature 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 t...

Page 26: ...ol 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 IMPO...

Page 27: ...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 an...

Page 28: ...WARM UP IS 20 SECONDS POWER INTERRUPTION SYSTEM SHUTS OFF RESTARTS WHEN POWER IS RESTORED PRESSURE SWITCH SENSES ADEQUATE DIFFERENTIAL PRESSURE CONTACTS CLOSE THERMOSTAT CALLS FOR HEAT CONTACTS CLOSE CONTROL BOARD ENERGIZED INDUCER ENERGIZED CONTINUOUS SAFE OPERATION CHECK IF FLAME SIMULATION CONDITION PRESENT OR ROLL OUT SWITCH OPENS SYSTEM ENERGIZES INDUCER FAN FOR 15 SECONDS AND CIRCULATOR BLOW...

Page 29: ... OF SIX RECYCLES AFTER SIX UNSUCCESSFUL RECYCLE ATTEMPTS THE CONTROL WILL GO INTO SYSTEM LOCKOUT AFTER THE DELAY TO FAN OFF PERIOD ENDS THE CIRCULATING AIR FAN AND OPTIONAL ELECTRONIC AIR CLEANER ARE DE ENERGIZED MAIN BURNER OPERATION END OF CYCLE CALL FOR HEAT SATISFIED IF SYSTEM IS IN LOCKOUT THE MODULE WILL RESET ITSELF AFTER 60 MINUTES OR MAY BE MANUALLY RESET BY INTERRUPTING THE POWER TO THE ...

Page 30: ...e check diagnostic code through view port prior to removal of door 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 on 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 the fuel shutoff valves open 4 To assist you...

Page 31: ...e 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 r...

Page 32: ...LACE THERMOSTAT IS THE TRANSFORMER SUPPLYING 24 VOLTS TO THE THERMOSTAT CHECK FOR CONTINUITY PROPER CONNECTIONS IS THE INDUCER BLOWER OPERATING Yes Yes No No No Yes No No Yes Yes Yes No No No Yes Yes IS ROOM TEMPERATURE ABOVE 90 DEGREES F IS THERE 24 VOLTS ACROSS TH TR AT THE INTEGRATED CONTROL TROUBLESHOOTING GUIDE THE SYSTEM IS STARTED BY SETTING THE THERMOSTAT TO CALL FOR HEAT THE FOLLOWING SHO...

Page 33: ... MORE THAN ONE SECOND IF LED STAYS ON CONTINUOUSLY REPLACE INTEGRATED CONTROL IS THERE LINE VOLTAGE ACROSS HOT SURFACE IGNITOR TERMINALS IGN IGN N AT THE INTEGRATED CONTROL CHECK WIRING TO HOT SURFACE IGNITOR AND IF OK REPLACE HOT SURFACE IGNITOR ASSEMLBY CHECK WIRING TO GAS VALVE AND IF OK REPLACE GAS VALVE CHECK ACROSS MV TERMINALS ON INTEGRATED CONTROL FOR 24 VOLTS DURING THE 4 SECOND FLAME PRO...

Page 34: ... BURNERS STAY LIT PAST PROOF OF FLAME CHECK CHECK FLAME PROVING CIRCUIT DOES THE INTEGRATED CONTROL ENERGIZE THE CIRCULATING AIR BLOWER AFTER THE 45 SECOND TIME DELAY CHECK ACROSS THE CIRCULATING AIR BLOWER TERMINALS CIR N HEAT FOR PROPER VOLTAGE REPLACE THE INTEGRATED CONTROL DOES THE CIRCULATING AIR FAN COME ON WHEN ENERGIZED DOES BLOWER SPIN FREELY CONFIRM IF EITHER BLOWER WHEEL IS RUBBING AGAI...

Page 35: ... SECONDS Yes Yes No No Yes No Yes Yes 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 CONTINUOU...

Page 36: ...dangerous 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 ...

Page 37: ...blower with a damp cloth Vacuum to remove any lint or dust from the motor assembly D INSPECTING THE VENTING SYSTEM The venting system should be inspected during the annual maintenance 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 ven...

Page 38: ...WER 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 can...

Page 39: ...r section of this manual The area around the furnace should be kept free and clear of combustible materials especially papers and rags Do not 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 Do not allow the outside air intake to be blocked or obstructed by vegetation ice snow or any other mat...

Page 40: ... typical furnace installation and typical position of the components referenced in these instructions 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 ...

Page 41: ...ndensate 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 c 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 ser...

Page 42: ...All installations and services must be performed by qualified service personnel 41 APPENDIX A REPLACEMENT PARTS ...

Page 43: ...All installations and services must be performed by qualified service personnel 42 ...

Page 44: ...All installations and services must be performed by qualified service personnel 43 APPENDIX B WIRING DIAGRAM ...