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COMFORT-AIRE Century GDD95C Series, Installation Instructions Manual

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COMFORT-AIRE Century GDD95C Series Installation Instructions Manual Download Page 37

507735-03

Page 37 of 53

Issue 1933

Figure 58. Integrated Control

(Automatic Hot Surface Ignition System)

Terminal Designations

120 HUM

Humidifier (120 VAC)

LINE

Input (120 VAC)

XFMR

Transformer (120 VAC)

CIRC

Indoor Blower (120 VAC)

EAC

Electronic Air Cleaner (120 VAC)

COOL

Blower - Cooling Speed (24 VAC)

HEAT

Blower - Heating Speed (24 VAC)

FAN

Blower - Fan Speed (24 VAC)

PARK

Dead terminals to park all speed taps

NEUTRALS

Neutral Terminals (120 VAC)

FS

Flame Sense

24 COM

Common (24 VAC)

HUM 24

Humidifier (24 VAC)

Unit Start-Up

FOR YOUR SAFETY READ BEFORE OPERATING

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

A  flood-damaged  furnace  is  extremely  dangerous. 

Attempts to use the furnace can result in fire or explosion. 

Immediately call a qualified service technician to inspect 

the  furnace  and  to  replace  all  gas  controls,  control 

system parts, and electrical parts that have been wet or 

to replace the furnace, if deemed necessary.

 WARNING

Danger  of  explosion.  Can  cause  injury  or 

product or property damage. Should the gas 

supply  fail  to  shut  off  or  if  overheating 

occurs, shut off the gas valve to the furnace 

before  shutting  off  the  electrical  blower 

deck,  before  performing  any  service 

procedure.

 WARNING

Before  attempting  to  perform  any  service  or 

maintenance,  turn the electrical  power  to unit OFF at 

disconnect switch.

 CAUTION

BEFORE LIGHTING

 the unit, smell all around the furnace 

area for gas. Be sure to smell next to the floor because 

some gas is heavier than air and will settle on the floor.

The gas valve on the unit is equipped with a gas control 

switch (lever). Use only your hand to move switch. Never 

use tools. If the switch will not move by hand, do not try to 

repair it. Force or attempted repair may result in a fire or 

explosion.

Placing the Furnace into Operation

This  furnace  is  equipped  with  an  automatic  hot  surface 

ignition system. Do not attempt to manually light burners 

on this furnace. Each time the thermostat calls for heat, the 

burners will automatically light. The ignitor does not get hot 

when there is no call for heat on these units.

Summary of Contents for Century GDD95C Series

Page 1: ...loss of life Installation and service must be performed by a licensed professional installer or equivalent service agency or the gas supplier WARNING As with any mechanical equipment personal injury can result from contact with sharp sheet metal edges Be careful when you handle this equipment CAUTION Table of Contents Unit Dimensions 2 Parts Arrangement 3 Gas Furnace 4 Shipping and Packing List 4 ...

Page 2: ...89 9 1 8 232 Right 6 9 16 167 Left 2 51 Either Side 3 4 19 B Supply Air 9 16 14 9 16 14 9 16 14 19 7 16 494 CONDENSATE TRAP CONNECTION 5 127 6 1 2 165 Either Side 2 1 4 57 Either Side 1 25 Front Panel 705 AIR FLOW 33 838 C 3 4 19 3 4 19 FRONT VIEW Supply Air 9 16 14 9 229 Unit Dimensions Capacity A B C in mm in mm in mm 045 3 070 4 17 1 2 446 16 3 8 416 16 406 090 4 110 5 21 533 19 7 8 504 19 1 2 ...

Page 3: ...and door switch BAG ASSEMBLY BLOWER MOTOR hidden COMBUSTION AIR INDUCER BURNER BOX ASSEMBLY includes flame sensor rollout switches and ignitor GAS VALVE BLOWER DECK HEAT EXCHANGER COLD END HEADER BOX PRIMARY LIMIT BLOWER ACCESS PANEL HEATING ACCESS PANEL COMPARTMENT COMPARTMENT Parts Arrangement ...

Page 4: ...the Gas Piping section for relevant diagrams Check equipment for shipping damage If you find any damage immediately contact the last carrier Please refer to specification sheets for available accessories Safety Information DANGER OF EXPLOSION There are circumstances in which odorant used with LP Propane gas can lose its scent In case of a leak LP Propane gas will settle close to the floor and may ...

Page 5: ...t unless it is in the full HEAT or COOL setting When installed this furnace must be electrically grounded according to local codes In addition in the United States installation must conform with the current National Electric Code ANSI NFPA No 70 The National Electric Code ANSI NFPA No 70 is available from the following address National Fire Protection Association 1 Battery March Park Quincy MA 022...

Page 6: ...n a non direct vent applications do not block the furnace combustion air opening with clothing boxes doors etc Air is needed for proper combustion and safe unit operation When the furnace is installed in an attic or other insulated space keep insulation away from the furnace When the furnace is installed in an unconditioned space consider provisions required to prevent freezing of the condensate d...

Page 7: ... the combined input rating of all appliances installed in that space This space also includes adjacent rooms which are not separated by a door Though an area may appear to be unconfined it might be necessary to bring in outdoor air for combustion if the structure does not provide enough air by infiltration Do not install the furnace in a corrosive or contaminated atmosphere Meet all combustion and...

Page 8: ...g shall have a minimum free area of 1 square inch 645 mm per 2 000 Btu 56 kW per hour of the total input rating of all equipment in the enclosure See Figure 7 When ducts are used they shall be of the same cross sectional area as the free area of the openings to which they connect The minimum dimension of rectangular air ducts shall be no less than 3 inches 75 mm In calculating free area the blocki...

Page 9: ...nstall the furnace on its front back or in the horizontal position See Figure 12 Do no connect the return air ducts to the back of the furnace Doing so will adversely affect the operation of the safety control devices which could result in personal injury or death CAUTION Select a location that allows for the required clearances that are listed on the unit nameplate Also consider gas supply connec...

Page 10: ...applications Top Bottom Left Side Right Side Top 0 Front 0 Back 0 Sides 0 Vent 0 Floor NC Front clearance in alcove installation must be 24 in 610 mm Maintain a minimum of 24 in 610 mm for front service access Allow proper clearances to accommodate condensate trap Thefurnacemaybeinstalledonacombustiblewoodfloorifanoptional additive base is installed between the furnace and the combustible floor Fi...

Page 11: ...o the combustible flooring base until plenum flanges seal against fiberglass strips NOTE Be careful not to damage fiberglass strips Check for a tight seal 5 Set the furnace over the plenum 6 Ensure that the seal between the furnace and plenum is adequate Installation on Cooling Coil Cabinet See Figure 16 NOTE Downflow combustible flooring kit is not used 1 Refer to reverse flow coil installation i...

Page 12: ... appliance i e water heater or carbon monoxide producing device i e wood fireplace is installed When return air is drawn from a room a negative pressure is created in the room If a gas appliance is operating in a room with negative pressure the flue products can be pulled back down the vent pipe and into the room This reverse flow of the flue gas may result in incomplete combustion and the formati...

Page 13: ...ther PVC or CPVC Low temperature solvent cement is recommended during cooler weather Metal or plastic strapping may be used as vent pipe hangers Uniformly apply a liberal coat of PVC primer for PVC or use a clean dry cloth for ABS to clean inside socket surface of fitting and male end of pipe to depth of fitting socket Table 5 Outdoor Termination Kits Usage Capacity Vent Pipe Dia in Standard Conce...

Page 14: ...care to keep excess cement out of socket Apply second coat to end of pipe NOTE Time is critical at this stage Do Not allow Primer to dry before applying cement 7 Immediately after applying last coat of cement to pipe and while both inside socket surface and end of pipe are wet with cement forcefully insert end of pipe into socket until it bottoms out Turn PVC pipe 1 4 turn during assembly but not ...

Page 15: ...tdoors In Direct Vent installations combustion air is taken from outdoors and flue gases are discharged outdoors Intake and exhaust pipe sizing Size pipe according to Table 6 and Table 7 Table 6 lists the minimum vent pipe lengths permitted Table 7 lists the maximum pipe lengths permitted Regardless of the diameter of pipe used the standard roof and wall terminations described in section Exhaust P...

Page 16: ... 11 65 45 n a 92 92 73 73 9 21 n a 60 40 87 87 68 68 10 16 55 35 82 82 63 63 Concentric Termination Elevation 0 10 000 ft Number of 90 Elbows Used 1 1 2 Pipe 2 Pipe 2 1 2 Pipe 3 Pipe Capacity Capacity Capacity Capacity 045 070 090 110 045 070 090 110 045 070 090 110 045 070 090 110 1 15 10 n a n a 53 38 22 n a 90 70 39 n a 111 111 104 104 2 10 n a 48 33 17 85 65 34 106 106 99 99 3 n a 43 28 12 80 ...

Page 17: ...Installed in a Closet or Basement Using Ventilated Attic or Crawl Space for Intake Air in Feet Standard Termination at Elevation 0 10 000 ft Number of 90 Elbows Used 1 1 2 Pipe 2 Pipe 2 1 2 Pipe 3 Pipe Capacity Capacity Capacity Capacity 045 070 090 110 045 070 090 110 045 070 090 110 045 070 090 110 1 15 10 n a n a 61 46 24 n a 100 80 43 n a 127 127 108 108 2 10 n a 56 41 19 95 75 38 122 122 103 ...

Page 18: ... the inlet air connector 2 Route piping to outside of structure Continue with installation following instructions given in general guide lines for piping terminations and intake and exhaust piping terminations for direct vent sections Refer to Table 7 for pipe sizes Follow the next steps when installing the unit in Non Direct Vent applications where combustion air is taken from indoors and flue ga...

Page 19: ...fied as a direct vent Category IV gas furnace In both Non Direct Vent and Direct Vent applications the vent termination is limited by local building codes In the absence of local codes refer to the current National Fuel Gas Code ANSI Z223 1 NFPA 54 in U S A and current CSA B149 Natural Gas and Propane Installation Codes in Canada for details Position termination according to location given in Figu...

Page 20: ... 18 16 32 29 30 30 2 1 2 in 5 N A 13 N A 24 N A 34 N A 3 in N A N A 8 8 19 19 26 26 0 to 20 18 to 29 1 1 2 in 10 N A 15 N A N A N A N A N A 2 in 5 3 12 10 22 19 30 27 2 1 2 in N A N A 7 N A 15 N A 22 N A 3 in N A N A N A N A 10 10 16 16 1 Refer to 99 Minimum Design Temperature table provided in the current edition of the ASHRAE Fundamentals Handbook 2 Poly Propylene vent pipe PP by Duravent and Ce...

Page 21: ...randa porch deck or balcony 12 Equal to or greater than soffit depth 3 feet 9m 12 3 feet 9m within a height 15 feet 4 5m above the meter regulator assembly 3 feet 9m 6 inches 152mm for appliances 10 000 Btuh 3kw 12 inches 305mm for appliances 10 000 Btuh 3kw and 100 000 Btuh 30kw 36 inches 9m for appliances 100 000 Btuh 30kw 3 feet 9m above if within 10 feet 3m horizontally 6 feet 1 8m 7 feet 2 1m...

Page 22: ...liances 10 000 pliances 10 000 Btuh 3kw and 50 000 pliances 50 000 Btuh 15kw 6 inches 152mm for appliances 10 000 Btuh 3kw 12 inches 305mm for appliances 10 000 Btuh 3kw and 100 000 Btuh 30kw 36 inches 9m for appliances 100 000 Btuh 30kw 3 feet 9m above if within 10 feet 3m horizontally 6 feet 1 8m 7 feet 2 1m 12 inches 305mm 1 In accordance with the current ANSI Z223 1 NFPA 54 Natural Fuel Gas Co...

Page 23: ...Termination Size Reduction Capacity Exhaust Pipe Size Termination Pipe Size 045 and 070 2 51 mm 2 1 2 64 mm 3 76 mm 1 1 2 38 mm 090 2 51 mm 110 3 76 mm 045 070 and 090 units with the flush mount termination must use the 1 1 2 accelerator supplied with the kit 5 On field supplied terminations for side wall exit exhaust piping may extend a maximum of 12 inches 305 mm for 2 PVC and 20 inches 508 mm f...

Page 24: ... grade or average snow accumulation B Horizontal separation between intake and exhaust C Minimum from end of exhaust to inlet of intake D Exhaust pipe length E Wall support distance from top of each pipe intake exhaust 12 305 mm Min 12 305 mm Min 6 152 mm Min 24 610 mm Max 9 227 mm Min 12 305 mm Min 16 405 mm Max 6 152 mm Max 6 152 mm Min 24 610 mm Max 9 227 mm Min 12 305 mm Min 20 508 mm Max 6 15...

Page 25: ...e top of chimney and terminate as illustrated In any exterior portion of chimney the exhaust vent must be insulated Figure 34 Direct Vent Application Using Existing Chimney Figure 35 Direct Vent Concentric Wall Termination 71M80 69M29 or 60L46 US 44W92 or 44W93 Canada INTAKE AIR EXHAUST AIR INTAKE AIR INTAKE AIR EXHAUST AIR OUTSIDE WALL GRADE CLAMP Not Furnished FIELD PROVIDED REDUCER MAY BE REQUI...

Page 26: ...R EXHAUST LINES 12 305MM ABOVE AVE SNOW ACCUMULATION SIZE PER EXHAUST PIPE TERMINATION SIZE REDUCTION TABLE Figure 39 Non Direct Vent Field Supplied Wall Termination SIZE TERMINATION PER EXHAUST PIPE TERMINATION SIZE REDUCTION TABLE FIELD PROVIDED REDUCER MAY BE REQUIRED TO ADAPT DIFFERENT VENT PIPE SIZE TO TERMINATION Figure 40 Non Direct Vent Field Supplied Wall Termination Extended SIZE TERMINA...

Page 27: ...Termination Drain Trap assembled Figure 42 Kit 51W18 USA 15Z70 Canada Parts Identification and Assembly Exhaust from Furnace To Termination Exhaust from Furnace To Termination Kit 51W18 is shown Figure 43 Crawl Space Vent Pipe Drain Trap Assembled Incorrectly Figure 44 Upflow or Downflow Furnace with Exhaust through Crawl Space KIT 51W18 USA Basement Floor To Termination 1 2 PVC to Code Approved D...

Page 28: ...trap Secure with clamp See Figure 50 4 Install drain trap using appropriate PVC fittings glue all joints Glue the provided drain trap as shown in Figure 50 Route the condensate line to an open drain Condensate line must maintain a 1 4 downward slope from the furnace to the drain 5 If unit will be started immediately upon completion of installation prime trap per procedure outlined in Unit Start Up...

Page 29: ...n DO NOT connect the condensate trap drain into the drain line from the evaporator coil CAUTION When combining the furnace and evaporator coil drains together the A C condensate drain outlet must be vented to relieve pressure in order for the furnace pressure switch to operate properly IMPORTANT Figure 48 Evaporator Coil Using a Common Drain Figure 49 Condensate Trap with Optional Overflow Switch ...

Page 30: ...507735 03 Page 30 of 53 Issue 1933 Figure 50 Trap Drain Assembly Using 1 2 PVC or 3 4 PVC ...

Page 31: ...10 feet 2 44 to 3 05 m using suitable hangers or straps Install a drip leg in vertical pipe runs to serve as a trap for sediment or condensate 5 A 1 8 N P T plugged tap or pressure post is located on the gas valve to facilitate test gauge connection See Figure 51 6 In some localities codes may require installation of a manual main shut off valve and union furnished by installer external to the uni...

Page 32: ... 4 28 138 3 91 125 3 54 118 3 34 110 3 11 103 2 92 1 25 4 1 049 26 645 680 19 25 465 13 17 375 10 62 320 9 06 285 8 07 260 7 36 240 6 80 220 6 23 205 5 80 195 5 52 1 1 4 31 75 1 380 35 052 1400 39 64 950 26 90 770 21 80 660 18 69 580 16 42 530 15 01 490 13 87 460 13 03 430 12 18 400 11 33 1 1 2 38 1 1 610 40 894 2100 59 46 460 41 34 1180 33 41 990 28 03 900 25 48 810 22 94 750 21 24 690 19 54 650 ...

Page 33: ...corrosion or other deficiencies which could cause an unsafe condition 3 Close all building doors and windows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building Turn ON clothes dryers and any appliances not connected to the common venting system Turn ON any exhaust fans such as range hoods and bathroo...

Page 34: ...ng connections to the equipment Use the provided unit wiring diagram and the field wiring diagram shown in Figure 56 Use 18 gauge wire or larger that is suitable for Class II rating for thermostat connections Electrically ground the unit according to local codes or in the absence of local codes according to the current National Electric Code ANSI HFPA No 70 for the USA and current Canadian Electri...

Page 35: ... fuel thermostat instructions Indoor Blower Speeds 1 When the thermostat is set to FAN ON the indoor blower will run continuously on the fan speed when there is no cooling or heating demand See Table 17 for allowable continuous circulation speeds 2 When the furnace is running in the heating mode the indoor blower will run on the heating speed 3 When there is a cooling demand the indoor blower will...

Page 36: ...507735 03 Page 36 of 53 Issue 1933 045B3 070B4 090C4 110C5 Figure 57 Typical Wiring Diagram ...

Page 37: ...WARNING Danger of explosion Can cause injury or product or property damage Should the gas supply fail to shut off or if overheating occurs shut off the gas valve to the furnace before shutting off the electrical blower deck before performing any service procedure WARNING Before attempting to perform any service or maintenance turn the electrical power to unit OFF at disconnect switch CAUTION BEFOR...

Page 38: ...s valve switch to ON See Figure 59 9 Replace the heating compartment access panel 10 Turn on all electrical power to the unit 11 Set the thermostat to desired setting NOTE When unit is initially started steps 1 through 11 may need to be repeated to purge air from gas line 12 If the appliance will not operate follow the instructions Turning Off Gas to Unit and call your service technician or gas su...

Page 39: ...to reach steady state 3 While waiting for the unit to stabilize observe the flame Flame should be stable and should not lift from burner Natural gas should burn blue 4 After allowing unit to stabilize for 5 minutes record manifold pressure and compare to value given in Table 14 NOTE Shut unit off and remove manometer as soon as an accurate reading has been obtained Take care to remove barbed fitti...

Page 40: ...ersion requires installation of a gas valve regulator spring which is provided with the gas conversion kit LP kits include low line pressure switch Pressure Switch Requirements at Varying Altitudes Capacity 0 4500 ft 0 1 373m 4501 7500 ft 1371 2286m 7501 10000 ft 2286 3048m 045 No Change No Change 11J09 070 No Change 11J12 10U93 090 No Change 11U70 10U93 110 No Change 11J12 10U93 Pressure switch i...

Page 41: ... 2 Visually inspect the venting system for proper size and horizontal pitch Determine there is no blockage or restriction leakage corrosion or other deficiencies which could cause an unsafe condition 3 To the extent that it is practical close all building doors and windows and all doors between the space in which the appliances connected to the venting system are located and other spaces of the bu...

Page 42: ...ol module both contained in the same motor housing The motor is programmed to provide constant torque at each of the five selectable speeds The motor has five speed taps Each tap requires 24 volts to energize Thermostat Heat Anticipation Set the heat anticipator setting if adjustable according to the amp draw listed on the wiring diagram that is attached to the unit Figure 60 Heat Fan OFF Time in ...

Page 43: ...tts cfm watts cfm watts 0 00 1770 510 1550 340 1355 220 1255 180 1035 115 0 10 1720 520 1510 355 1315 230 1200 185 980 105 0 20 1705 535 1470 365 1265 245 1165 195 895 110 0 30 1665 640 1430 380 1235 250 1120 205 835 120 0 40 1605 555 1390 395 1185 260 1070 210 775 130 0 50 1585 565 1335 400 1155 275 1015 225 690 140 0 60 1540 565 1300 410 1100 290 970 235 625 145 0 70 n a n a 1260 420 1050 295 91...

Page 44: ...aust pipe will cause unit to shut off at pressure switch Check termination for blockages 3 Obstructed pipe or termination may cause rollout switches to open Reset manual flame rollout switches on burner box assembly if necessary ELECTRICAL SHOCK FIRE OR EXPLOSION HAZARD Failure to follow safety warnings exactly could result in dangerous operation serious injury death or property damage Improper se...

Page 45: ...nnect wires from flame rollout switches 7 Loosen clamps at vent elbow Disconnect condensate drain tubing from flue collar and remove the vent elbow 8 Remove four burner box screws at the vestibule panel and remove burner box Set burner box assembly aside NOTE If necessary clean burners at this time Follow procedures outlined in Burner Cleaning section 9 Mark and disconnect all combustion air press...

Page 46: ... 31 Reconnect flame rollout switch wires 32 Reconnect sensor wire and reconnect 2 pin plug from ignitor 33 Secure burner box assembly to vestibule panel using four existing screws Make sure burners line up in center of burner ports 34 Reinstall gas valve manifold assembly Reconnect gas supply line to gas valve 35 Reconnect 2 wires to gas valve 36 Replace the blower compartment access panel 37 Refe...

Page 47: ...recall press and release button Most recent will be displayed first LED off for 3 sec then next error code is displayed etc To clear error codes depress and hold button longer than 5 seconds Table 18 Diagnostic Codes for 02 Control 02 Integrated Control LED Codes Red LED Flash Code Diagnostic Codes Status of Furnace LED Off No power to control or control hardware fault detected Heartbeat1 Control ...

Page 48: ...507735 03 Page 48 of 53 Issue 1933 Troubleshooting Heating Sequence of Operation ...

Page 49: ...507735 03 Page 49 of 53 Issue 1933 Troubleshooting Heating Sequence of Operation continued ...

Page 50: ...507735 03 Page 50 of 53 Issue 1933 Troubleshooting Cooling Sequence of Operation ...

Page 51: ...507735 03 Page 51 of 53 Issue 1933 Troubleshooting Continuous Fan Sequence of Operation ...

Page 52: ... or equivalent service agency or gas supplier Cabinet Parts Upper Access Panel Blower Access Panel Top Cap Control Panel Parts Transformer Integrated Control Board Door Interlock Switch Blower Parts Blower Wheel Motor Motor Mounting Frame Motor Capacitor Blower Housing Cutoff Plate Heating Parts Flame Sensor Heat Exchanger Assembly Gas Manifold Combustion Air Inducer Gas Valve Main Burner Cluster ...

Page 53: ...m height of eight 8 feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment The sign shall read in print size no less than one half 1 2 inch in size GAS VENT DIRECTLY BELOW KEEP CLEAR OF ALL OBSTRUCTIONS 4 INSPECTION The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not app...

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