Olsen G95V80, Installation, Operation & Maintenance Manual

Page 1: ...ertified Company G95V NATURAL AND PROPANE GAS TWO STAGE HIGH EFFICIENCY CONDENSING WARM AIR FURNACE INSTALLATION OPERATION MAINTENANCE MANUAL Manufactured by ECR International Inc 2201 Dwyer Avenue Ut...

Page 2: ...Using Indoor Combustion Air 15 11 Determining Combustion Air 15 12 Venting Guidelines 18 13 Terminations 22 14 Vent Clearances 26 15 Vent And Draining Options Up ow 29 16 Condensate Drains 33 17 Gas...

Page 3: ...mercial heating applications from 60 000 to 120 000 BTU Hr The 95 efficient furnace series is CSA design certified as a Category IV indirect or direct vent central forced air furnace When installed as...

Page 4: ...line or other flammable vapors and liquids or other combustible materials in the vicinity of this or any other appliance WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any...

Page 5: ...INS FOIL COVERED FIBER GLASS INSULATION Inhalation of fiberglass particles is associated with respiratory disease including cancer WARNING Natural gas and propane are normally odorized by the fuel sup...

Page 6: ...IBLES Figure 1 Furnace Dimensions D FRONT SIDE S B A C C C FILTER VENT D AIRFLOW Table 2 FURNACE CLEARANCE TO COMBUSTIBLES SIDE Distance A 1 or Non Combustible Floor B 0 Service Clearance 24 or more C...

Page 7: ...ctly 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 DIRE...

Page 8: ...Draft Blower 1 4 Two Stage Gas Valve 1 14 Pressure Switch Assembly 1 5 Air High Temperature Limit 1 15 Front Manifold Cover Pressure Tap 2 6 Vent and Drain Assembly 1 16 PFC Choke Coil 1 7 Drain for...

Page 9: ...als of the Heating Refrigeration and Air Conditioning Institute of Canada HRAI or by any other method which is suitable for local condi tions provided the results obtained are in substantial agreement...

Page 10: ...alled in the horizontal position the furnace may be supported from the bottom or suspended Figure 3 I If the furnace is to be installed in a commercial repair ga rage the burners and ignition source m...

Page 11: ...n and threaded rod Secure the furnace with 2 minimum slot ted angle or equivalent as shown in Figure 4 The furnace must be supported in such a way as to not allow twisting or sagging of the cabinet Po...

Page 12: ...e the furnace to cycle on the high temperature limit and may damage the heat exchanger Excessive airflow may result in an excessively noisy duct system and may result in undesirable consequences such...

Page 13: ...d the base Models capable of 5 tons of airflow for air conditioning must have dual return air inlets for optimal airflow and air filtration If not specifically stated by the filter manufacturer for ef...

Page 14: ...Natural Gas or Propane Installation Code In the United States refer to the latest ANSI Z223 1 National Fuel Gas Code NEPA 54 or AGA GAMA Venting Tables for Category I furnaces The furnace products of...

Page 15: ...on the criteria used when calculating the air supply for a confined space Exposure to the following substances in the combustion air supply but not limited to the following will also require OUTDOOR...

Page 16: ...wn negative pressure could be a problem if natural infiltration from the outdoors does not match the rate at which air is exhausted Figure 5 Combustion Dilution Air From Heated Inside Sources Case 2 C...

Page 17: ...ut which requires a pair of 8 round pipes to obtain sufficient combustion and ventilation air the duct could be an equiv alent rectangular duct 8 x 7 for example Based on 50 free area for the inlet gr...

Page 18: ...ufac turer s instructions DO NOT COMMON VENT WITH ANY OTHER APPLI ANCE If venting vertically do not vent up a chimney serving another appliance or install in a chase with a metal or high temperature p...

Page 19: ...uld have a 1 or 2 snorkel intake fitting Figure 9 6 Include the 2 vestibule elbows when calculating total vent length for all models 2 75 70 65 60 55 50 45 3 100 95 90 85 80 75 70 80 2 50 45 40 35 30...

Page 20: ...on may be located at the end of a patio deck Piping running beneath the deck must be suitably insulated and suspended in a manner to prevent condensate from collecting and freezing Do not locate the t...

Page 21: ...ustion air is greatly reduced The direct vent configuration is unaffected by any other ap pliances exhaust fans or other devices that tend to create negative pressure conditions while operating No ven...

Page 22: ...6 foot radius of the termi nation Do not terminate under a deck unless there is adequate clearance to prevent damage from the flue gases A termination may be located at the end of a patio deck Piping...

Page 23: ...urfaces that may be periodi cally exposed to flue gases are present consider treating with a sealer such as Thompson s Water Seal Additional information about seal ers may be obtained from the Thompso...

Page 24: ...ric clothes dryer except in the case where two or more of these furnaces are multi vented See Multiple Venting Refer to Figures 17A and 17B for terminal clearances FURNACE CONNECTION NOTICE IMPORTANT...

Page 25: ...t tool will punch too deep and open holes Use caulking on the inside of the cabinet to seal any holes Insure that the combustion door gasket is in good condition NOTICE IMPORTANT Keep pressure switch...

Page 26: ...14 VENT CLEARANCES Figure 17A 17B Direct Vent Non Direct Termination Clearances 26...

Page 27: ...upply inlet to building or the combustion air inlet to any other appliance 6 inches 15 cm for appliances 10 000 Btuh 3kW 12 inches 30 cm for appliances 10 000 Btuh 3kW and 100 000 Btuh 30 kW 36 inches...

Page 28: ...air supply inlet to building or the combustion air inlet to any other appliance 6 inches 15 cm for appliances 10 000 Btuh 3kW 12 inches 30 cm for appliances 10 000 Btuh 3kW and 100 000 Btuh 30 kW 36 i...

Page 29: ...hose clamps Tubing should slope towards drain trap with no sags Instructions for Upflow with Top Venting 1 Connect two 2 2 Street elbows in parts bag to the coupler on the exhauster Add 2 nipple for...

Page 30: ...l Left with Top Venting 1 Remove 2 5 knockout and connect 2 nipple approximately 2 5 long field supplied to the coupler on the exhauster Ensure exhauster coupler drain outlet is facing downward 15 6 R...

Page 31: ...ION HORIZONTAL RIGHT Instructions for Horizontal Right with Right Side Venting 1 Connect two 2 2 Street elbows in parts bag to the coupler on the exhauster Add 2 nipple for 120K BTU units Ensure exhau...

Page 32: ...h supplied hose clamps Tubing should slope towards drain trap with no sags Instructions for Downflow with Right Side Venting 1 Remove 2 5 knockout and connect 2 nipple approximately 7 long field suppl...

Page 33: ...nough to reach either side panel however it must be cut near the blower division panel This is to prevent kinking in the drain lines CAUTION The two inlets to the drain trap are for vent pipe and con...

Page 34: ...al route of the drain tube to create a vapor lock which will prevent condensate from draining away freely and result in erratic furnace operation A typical configuration would be to cement the side br...

Page 35: ...possible Some local codes call for the manual gas shut off valve to be located between 4 to 5 feet above floor level to prevent tampering by small children Ensure that the valve is readily acces sibl...

Page 36: ...plate to alert subsequent service technicians of the conversion LP TO NATURAL GAS Although the furnace is manufactured initially as a natural gas appliance if after an LP gas conversion it becomes nec...

Page 37: ...tural Gas regulator springs color coded silver plain from regulator sleeves 12 Insert the L P regulator springs provided in the conversion kit and color coded white into the regulator sleeves 13 Repla...

Page 38: ...alibrated U tube manometer to the outlet pressure boss Hose should overlap boss 3 8 The manometer must have a scale range of at least 0 to 15 of water column 3 Turn on the gas supply and electrical po...

Page 39: ...rmers condensate pumps and electronic air cleaners If adding ac cessory equipment to the furnace circuit ensure that the combined amperages listed on the appliance rating plates does not exceed the ra...

Page 40: ...furnace The ignition control may not sense flame if L1 and L2 are reversed The ground is also essential NOTICE IMPORTANT Electrical wiring and components must be protected from moisture including wat...

Page 41: ...arby lamps or appliances exposure to sunlight heat from inside wall stacks etc Thermostat Heat Anticipator Setting 0 1 AMP Honeywell The low voltage terminals are located in the control box mounted to...

Page 42: ...point above room temperature to light the furnace 7 After the burners are lit set the room thermostat to the desired temperature To Shut Down The Furnace 1 Set the room thermostat to its lowest settin...

Page 43: ...nal when the gas valve de energizes and starts a programmed soft stop slowly ramp down delay period In The Event Of Flame Failure If flame is lost the control de energizes the gas valve within 2 sec o...

Page 44: ...c Input A C Tonnage ADJUST Jumper COOL Jumper CFM 60000 3 Ton NORM A 1200 B 1000 C 800 D 600 80000 3 Ton NORM A 1200 B 1000 C 800 D 600 80000 4 Ton NORM A 1600 B 1200 C 1000 D 800 100000 5 Ton NORM A...

Page 45: ...irect measurement with elec tronic or sloped manometers and velometers or by counting the number of times the amber CFM LED on the control board flashes Each flash signifies 100 CFM count the flashes...

Page 46: ...the ECM variable speed motor will slowly ramp down This feature allows for increased energy efficiency and reduced noise levels Continuous Fan Operation When the thermostat continuous fan G switch is...

Page 47: ...precipita tion to remove dust are an excellent filtration device A 16 x 25 model is an ideal fit with this furnace in the case of a side mounted return air inlet The furnace control module is supplie...

Page 48: ...ollowing HEAT EXCHANGER The heat exchanger should be inspected for corrosion The flue passages heat exchanger tubes should be free of scale or excessive corrosion The top row of heat exchanger tubing...

Page 49: ...sion can significantly increase the internal resistance of the connection A relatively small increase in resistance can result in a large decrease in flame signal DRAINAGE The condensate drainage syst...

Page 50: ...25 TROUBLESHOOTING FLOWCHART 50...

Page 51: ...Obstruction or restrictions in venting preventing proper air flow 3 Flashes Pressure switches closed with inducer off Pressure switches stuck closed Pressure switches mis wired or jumpered 4 Flashes...

Page 52: ...han 5 seconds 26 DIAGNOSTIC CODES FOR STATUS LED A RED LED is provided to indicate furnace operating status LED Condition Fault Condition Check 8 Flashes Lockout due to too many flame dropouts Check s...

Page 53: ...27 WIRE DIAGRAM FOR TWO STAGE FURNACE WITH ECM Figure 38 Wire Diagram For Two Stage Furnace With ECM 53...

Page 54: ...damage Clamp and gasket all vent exits to furnace panels to insure airtight seal Equivalent vent length must be less than the allowable length in Table 6 Direct and Non Direct Vent Lengths If there i...

Page 55: ...ONT MANIFOLD COVER 100 5 120 5 PLASTIC FRONT MANIFOLD COVER WITH GASKETS 11 550001660 PFC CHOKE COIL 80 4 100 5 120 5 12 550001532 DOOR SWITCH ALL MODELS 13 550001657 1HP ECM MOTOR 120 5 550001861 1HP...

Page 56: ...G95V NATURAL AND PROPANE GAS TWO STAGE HIGH EFFICIENCY CONDENSING WARM AIR FURNACE ECR International 2201 Dwyer Avenue Utica New York 13504 USA www ecrinternational com 56...