Thermo Pride GMD2-60N Manual

THERMO PRODUCTS, LLC.
POST OFFICE BOX 237
DENTON, NC 27239
PHONE: [phone]
MG-521
ECN 5625-M 200408
M DE IN US
GAS-FIRED FURNACE
DOWNFLOW & DIRECT VENT (SEALED COMBUSTION)
MODELS: GMD2-60N an GMD2-80N
INSTALLATION AND SERVICE MANUAL
For installation in: Pour l'installation dans :
1. Manufactured Homes 1. Maisons fabriquées
2. Modular Homes/Buildings 2. Maisons modulaires / Bâtiments
3. Site Constructed—Residential 3. Site a construit - Résidentiel
(Single Story Dwellings) (Habitations à étage unique)
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.
VEUILLEZ LIRE CES INSTRUCTIONS AVANT L'INSTALLATION, LA MISE À FEU INITIALE ET AVANT TOUT
ENTRETIEN OU MAINTENANCE. CES INSTRUCTIONS DOIVENT ÊTRE LAISSÉES À L'UTILISATEUR ET
DOIVENT ÊTRE CONSERVÉES POUR RÉFÉRENCE ULTÉRIEURE PAR UN PERSONNEL DE MAINTENANCE
QUALIFIÉ.

All installations an services must be performe by qualifie service personnel.
1
c 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.
c AVERTISSEMENT: Si les informations contenues dans ces instructions ne sont pas suivies
à la lettre, un incendie ou une explosion pourrait en résulter, causant des dommages
matériels, des blessures corporelles ou la mort.
c WARNING: Improper installation, adjustment, 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.
c AVERTISSEMENT: Une installation, un réglage, un entretien ou une maintenance
incorrects peuvent provoquer des blessures ou des dommages matériels. Reportez-vous à ce
manuel. Pour obtenir de l'aide ou des informations supplémentaires, consultez un installateur
qualifié, une agence de service ou un fournisseur de carburant.
c WARNING: 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.
c AVERTISSEMENT: N'utilisez pas cet appareil si une pièce a été immergée. ppelez
immédiatement un technicien qualifié pour inspecter l'appareil et remplacer toute pièce du
système électrique ou de commande sous l'eau.

All installations an services must be performe by qualifie service personnel.
2
I. S FETY SECTION
This page an the following two pages contain various warnings an cautions
foun throughout this furnace Service an Installation Manual. Please rea an
comply with the statements on the cover an 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.
: f the temperature rise exceeds 75°F GMD2-60 / 85°F GMD2-80 , the
heat exchanger may fail voiding the heat exchanger warranty resulting in
property damage, personal injury or loss of life.
: Burner adjustments must be confirmed by instrumentation. Failure to
use accurate or calibrated instrumentation to setup the burner may result in
reduced efficiency, sooting, and/or the production of hazardous carbon
monoxide gas.
: Any attempt to relocate safety controls or replace safety controls with
a control that is not approved or incompatible, may result in personal injury,
substantial property damage or death.
: f you do not follow these instructions exactly, a fire or explosion may
result causing personal injury, loss of life or property damage.
: HAZARD OF ASPHYX AT ON: Negative pressure inside the closet with
closet door closed and the furnace blower operating shall be no more negative
than minus 0.05 inch water column.
: Do not obstruct any return air openings, including the return grille on
the furnace. To do so may cause the furnace to activate the high limit and shut
down or it may cause asphyxiation.
: Because of the potential of odorant fade, a gas leak may not be
detected by smell. f this furnace is installed below grade, contact your gas
supplier for a gas detector.

All installations an services must be performe by qualifie service personnel.
3
: All gas pipe connections must be leak tested using a strong soap and
water solution (with the gas turned on). Any leaks must be repaired immediately
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 PS G 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
PS G or 14.0 inches W.G.
: Copper and brass tubing and fittings (except tin lined) shall not be
used if the gas contains more than a trace (0.3 grains per 100 cubic ft.) of
hydrogen sulfide gas. Check with your gas supplier.
: f you suspect there is a problem with the furnace, the venting system
or any other related problem, immediately contact a qualified service agency. f a
service agency is not available, contact your fuel supplier.
: Personal injury, or property damage, could result from major repair or
service of this furnace by anyone other than a qualified contractor. Only the
routine maintenance described in the user section of this manual should be
performed by the user.
: Do not block or obstruct air openings on the furnace or air openings
communicating with the area in which the furnace is installed.
: Do not allow the outside air intake to be blocked or obstructed by
vegetation, ice, snow or any other materials.
: Do not use this furnace if any part has been underwater. mmediately
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 an services must be performe by qualifie service personnel.
4
This page an the following page contain repro uctions of the various warning
an instruction labels place on the Thermo Pri e Gas Furnace. Please rea an
comply with the contents of these labels.

All installations an services must be performe by qualifie service personnel.
5

All installations an services must be performe by qualifie service personnel.
6
N T. 60 000 #38 5,5 14,0 3,5 POUCES D'E U W. C.
P.L. 60 000 #52 11,0 14,0 10,0 POUCES D'E U W. C.
N T. 80 000 2,45mm 5,5 14,0 3,5 POUCES D'E U W. C.
P.L. 80 000 #53 11,0 14,0 10,0 POUCES D'E U W. C.

All installations an services must be performe by qualifie service personnel.
7
TABLE OF CONTENTS
SECTION BEGINNING PAGE
I. S FETY SECTION 2
II. GENER L INSTRUCTIONS ND CLE R NCES 8
III. FURN CE SPECIFIC TIONS 10
IV. INST LL TION 12
. ROOF J CK 12
B. ST ND RD CHIMNEY 12
C. FURN CE LOC TION 12
D. B SE INST LL TION 14
1. Combustible Floor Base Model: 70-B SE 14
2. Cottage Base Model: 01COT-B SE 15
E. LCOVE INST LL TION 16
F. CLOSET INST LL TION 17
G. COMBUSTION IR 18
H. G S PIPING 20
I. ELECTRIC L WIRING 21
J. INITI L ST RT UP 24
K. DJUSTMENT OF BTU INPUT R TE 24
L. BURNER DJUSTMENT 26
M. SETTING TEMPER TURE RISE 27
N. FURN CE CHECKOUT PROCEDURE 28
V. INST LLER’S INSTRUCTIONS TO USER 29
VI. ST RTING THE UNIT 30
. SEQUENCE OF OPER TIONS 30
VII. TROUBLESHOOTING 32
VIII. DE LER M INTEN NCE 38
. ELECTRIC L 38
B. BURNERS 38
C. INDUCER BLOWER SSEMBLY 39
D. INSPECTING THE VENTING SYSTEM 39
E. G SKETS/SE LING M TERI LS 40
F. HE T EXCH NGER 40
G. HOUSE IR BLOWER 40
H. EXTENDED SHUTDOWN 40
IX. USERS INFORM TION SECTION 41
. W RNINGS & C UTIONS 41
B. COMPONENT LOC TIONS 42
C. INSPECTION RE S 42
D. FILTER LOC TION ND CLE NING 43
PPENDIX – REPL CEMENT P RTS 44
PPENDIX B – WIRING DI GR M 46

All installations an services must be performe by qualifie service personnel.
8
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. ny 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. 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
ir Conditioning Contractors of merica ( CC ) or the merican Society of
Heating, Refrigeration and ir Conditioning Engineers, Inc. ( SHR E).
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 larms, UL 2034, or the CS International
Standard, Residential Carbon Monoxide larming Devises, CS 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. merican National Standard ( NSI-119.2/NFP -501C), for installations of all
recreational vehicles.
c. merican National Standard ( NSI-Z223.1/NFP -54), for installation of all gas-
fired furnaces.
d. merican National Standard Electric Code ( NSI-C1/NFP -70), for installation
of all electrical field wiring.
The gas-fired furnace has been investigated under the NSI Z 21.47-C N/CG 22.3-
2001 CENTR L FURN 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 an services must be performe by qualifie service personnel.
9
: 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, NSI Z223.1-1999/NFP 70-1999, are
as follows:
a. Combustible material:
“...materials ma e of or surface with woo , compresse
paper, plant fibers, or other materials that are capable of
being ignite an burne . Such material shall be
consi ere combustible even though flame proofe , fire-
retar ant treate , or plastere .”
b. Non-combustible material:
“...material that is not capable of being ignite an
burne ; such as material consisting entirely of, or a
combination of, steel, iron, brick, tiles, concrete,
slate, asbestos, glass, an plaster.”
This heating appliance must be installed with clearances to combustible material
surfaces of not less than the minimum distances given below. lso, allow ample
clearances for servicing the furnace for easy access to the air filter, blower assembly,
burner assembly, controls, and vent connections.
MODELS GMD2-60N an GMD2-80N CLOSET ALCOVE
FRONT
B CK
SIDES
ROOF J CK
VENT CONNECTOR
TOP
PLENUM SIDES
TOP ND SIDES OF DUCT
BOTTOM OF DUCT
6”
0”
0”
0”
6”
1”
1”
1”
1”
18”
0”
0”
0”
6”
1”
1”
1”
1”

All installations an services must be performe by qualifie service personnel.
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III. FURNACE SPECIFICATIONS
MODEL GMD2-60 GMD2-80
HE T INPUT R TE (BTUH) 60,000 80,000
HE TING C P CITY (BTUH) 49,000 65,000
BURNER ORIFICE-N T. G S (MM) #38 2.45
BURNER ORIFICE-PROP. G S (DMS) #52 #53
G S SUPPLY PRESSURE (IN.W.G.)
MINIMUM REQUIRED
PROP NE 11 11
N TUR L 5.5 5.5
M XIMUM LLOWED
PROP NE 14.0 14.0
N TUR L 14.0 14.0
G S M NIFOLD PRESSURE (IN. W.G.)
PROP NE 10 + 0.3 10 + 0.3
N TUR L 3.5 + 0.3 3.5 + 0.3
VENT PIPE SIZE (INCHES) 4 4
DESIGN TEMPER TURE RISE (°F) 60 70
SE SON L EFFICIENCY
( FUE*, %) 82 81
* FUE - INCLUDES STE DY ST TE THERM L EFFICIENCY ND OFF CYCLE
LOSSES.
ELECTRIC L R TINGS ND SETTINGS:
ELECTRIC L SUPPLY: 115 V C / 60HZ / 1 PH SE
M XIMUM TIME DEL Y TYPE FUSE OR H CR BRE KER R TING: 15 MPS
TOT L R TED CURRENT ( MPS): 7.15 (GMD2)
NOMIN L HE T NTICIP TOR SETTING -- 0.8 m (GMD2)
DIMENSIONS & WEIGHTS:
C BINET: WIDTH - 18 IN., DEPTH – 25-3/4 IN., HEIGHT - 57 IN.
NO.70 MOBILE HOME B SE: WIDTH - 18-5/16 IN., DEPTH - 24¼ IN., HEIGHT - 4 IN.
W RM IR DUCT: WIDTH – 12 IN., DEPTH – 12 IN.
COTT GE B SE: WIDTH – 18-3/16 IN., DEPTH - 24¼ IN., HEIGHT – 14 IN.
FILTER QU NTITY & SIZE: 1 – 18” x 24 “
PPROXIM TE SHIPPING WEIGHT: 165 LBS.
PRODUCT LISTED UNDER ETL FILE NUMBER –

All installations an services must be performe by qualifie service personnel.
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BLOWER DATA
GMD2-60
M NUF CTURER: MORRISON PRODUCTS, INC.
BLOWER MODEL: 10-7, DIRECT DRIVE
NOMIN L MOTOR POWER OUTPUT (HORSEPOWER): 1/3
TYPIC L IRFLOW @ SPECIFIED EXTERN L
ST TIC PRESSURES (SCFM @. 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
GMD2-80
M NUF CTURER: MORRISON PRODUCTS, INC.
BLOWER MODEL: 10-9, DIRECT DRIVE
NOMIN L MOTOR POWER OUTPUT (HORSEPOWER): 1/3
TYPIC L IRFLOW @ SPECIFIED EXTERN L
ST TIC 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: 1258 1003
LL SPECIFIC TIONS RE SUBJECT TO CH NGE WITHOUT NOTICE.

All installations an services must be performe by qualifie service personnel.
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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.) dapters for pitched roofs as well as extended barrel length roof jacks are
available from other suppliers.
ll 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 GMD2-80N, refer to ppendix G of the latest
edition of the installation standard NFP 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. c 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 1 and 1B for depictions of the No. 70 and
the cottage bases.
4. This furnace is listed for closet, alcove, or freestanding applications. ll applications
must comply with the requirements of this manual.

All installations an services must be performe by qualifie service personnel.
13
Combustible Floor Base
Mo el: 70-BASE
Figure 1A
Cottage Base
Mo el: 01COT-BASE
Figure 1B
Coil Cabinet
Mo el: CE111S
Figure 1C
CE111S

All installations an services must be performe by qualifie service personnel.
14
D. BASE INSTALLATION
1. Combustible Floor Base Model: 70-B SE
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 1/8-
inch larger than the template opening.
Figure 2
fter 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).
c CAUTION: A combustion air duct must be used. f 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).

All installations an services must be performe by qualifie service personnel.
15
f the combustion air passageway cannot terminate outside of the skirting or
enclosure, a permanent opening with a minimum of 50 square inches of
unobstructed infiltration (free area) for ventilation air must be provided for
adequate combustion. This permanent opening must be located no less than 12
inches from the bottom of the enclosure or skirting.
Figure 3
Slit the corners of 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-B SE
The O1COT-B SE 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.

All installations an services must be performe by qualifie service personnel.
16
c 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-B SE cottage
base for additional information.
3. Coil Cabinet: CE111S
The CE111S coil cabinet (figure 1C) is for applications requiring air conditioning.
The coil cabinet is designed to have the combustion air brought in from the bottom
thru a 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 information refer instructions provided with the coil
cabinet.
E. ALCOVE INSTALLATION
In this application, a minimum of 18
inches of clearance must be provided
to the front of the unit. Refer to
Figure 4.
lcove installations must use the No.
70 mobile home base.
Note – access to diagnostic view port.
Refer to section G. COMBUSTION IR
for additional combustion air
requirements.
Figure 4

All installations an services must be performe by qualifie service personnel.
17
F. CLOSET INSTALLATION
c WARNING: HAZARD OF
ASPHYX AT ON: 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 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 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.

All installations an services must be performe by qualifie service personnel.
18
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. t 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 rticle 300-22
of the latest edition of the National Electrical Code, NFP 70.
7. Gas piping shall not be located in, or extend through, the return air duct system.
8. Refer to section G. COMBUSTION IR for additional combustion air requirements.
G. COMBUSTION AIR
c CAUTION: Flexible, spiral, or corrugate uct is not recommen e , ue to the
relatively high-pressure rop associate with air movement through this type of
passageway.
The furnace requires the proper amount of combustion airflow through the combustion
air intake to combust the fuel cleanly and efficiently. n inadequate combustion air
supply can result in unsafe and erratic operation of the burner, sooting of the
combustion chamber and the heat exchanger, and possibly, offensive fuel odors. Refer
to chapter 5.3 of the National Fuel Gas Code, NSI Z223.1 / NFP 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. OPS7402) is through the side of the structure,
skirting, or enclosure. n 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