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ECR International G95V Installation Manual And Operating Instructions

Natural and propane gas two stage high efficiency (condensing) warm air furnace
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MODEL G95V NATURAL AND PROPANE GAS TWO STAGE
HIGH EFFICIENCY (CONDENSING) WARM AIR FURNACE
ECR INTERNATIONAL LTD.
P.O. Box 900, 6800 Base Line
Wallaceburg, ON N8A 5E5
Canada
2201 Dwyer Avenue,
Utica, New York, 13504
USA
85 Middle Road,
Dunkirk, New York, 14048
USA
An ISO 9001-2000 Certified Company
www.ecrltd.com
P/N 240006743, Rev. A [07/07]

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  • Page 1 MODEL G95V NATURAL AND PROPANE GAS TWO STAGE HIGH EFFICIENCY (CONDENSING) WARM AIR FURNACE ECR INTERNATIONAL LTD. P.O. Box 900, 6800 Base Line Wallaceburg, ON N8A 5E5 Canada 2201 Dwyer Avenue, Utica, New York, 13504 85 Middle Road, Dunkirk, New York, 14048 An ISO 9001-2000 Certified Company...

  • Page 2: Table Of Contents

    MODEL 95V WARM AIR FURNACE INSTALLATION MANUAL AND OPERATING INSTRUCTIONS Printed in Canada • Made In Canada TABLE OF CONTENTS vent furnace, all combustion air is supplied to the furnace burners through the air intake system. (See Section 7, “Ventilation and Combustion Air.”) 1 - Introduction ..........2 2 - Safety Symbols and Warnings .....2 All models may be fired by natural gas or LP gas...
  • Page 3 WARNING WARNING IF THE INFORMATION IN THESE INSTRUC- THESE INSTRUCTIONS ARE INTENDED AS TIONS IS NOT FOLLOWED EXACTLY, A FIRE AN AID TO QUALIFIED SERVICE PERSON- OR EXPLOSION MAY RESULT, CAUSING NEL FOR PROPER INSTALLATION, ADJUST- PROPERTY DAMAGE, PERSONAL INJURY MENT AND OPERATION OF THIS FURNACE.
  • Page 4 8. A gas-fired furnace for installation in a residential National Fire Protection Association garage must be installed so that the burners and ig- 1 Batterymarch Park nitor are no less than 18” above the floor. The fur- Quincy, MA, 02169-7471 nace must be located, or protected to avoid physical Phone: (617) 770-3000 damage by vehicles.
  • Page 5 WARNING WHEN THIS FURNACE IS INSTALLED IN A RESIDENTIAL GARAGE, IT MUST BE INSTALLED SO THE BURNERS AND IGNITION SOURCE ARE LOCATED NO LESS THAN 18” ABOVE THE FLOOR TO PREVENT THE RISK OF IGNITING FLAMMABLE VAPORS WHICH MAY BE PRES- ENT IN THE GARAGE.
  • Page 6 INSTALLATION REQUIREMENTS SPECIFIC TO THE STATE OF MASSACHUSETTS FOR DIRECT VENT, MECHANICAL VENT, AND DOMESTIC HOT WATER APPLIANCES. 3. SIGNAGE: For all side wall horizontally vented gas fueled A metal or plastic identification plate shall be per- equipment installed in every dwelling, building or manently mounted to the exterior of the building at structure used in whole or in part for residential pur- a minimum height of eight (8) feet above grade di-...
  • Page 7 6(B) MANUFACTURER REQUIREMENTS - GAS FIGURE 2 – FURNACE COMPONENTS EQUIPMENT VENTING SYSTEM NOT PROVID- ED. When the manufacturer of a Product Approved side wall horizontally vented gas fueled equipment does not provide the parts for venting the flue gas- es, but Identifies “special venting systems”, the fol- lowing requirements shall be satified by the manu- facturer:...

  • Page 8: Furnace Sizing

    3 - FURNACE SIZING TABLE 1A - RANGE OF TEMPERATURE RISE Furnace Model Temperature Rise The maximum hourly heat loss for each heated High Fire (HF) 35 - 65°F space shall be calculated in accordance with the 60, 80, 100, 120 procedures described in the manuals of the Heat- Low Fire (LF) 25 - 55°F ing, Refrigeration and Air Conditioning Institute of...

  • Page 9: Location Of Unit

    f. The furnace should be installed on a firm base 4 - LOCATION OF UNIT when installed in the upflow position. This would typically be the concrete floor if installing the fur- 1. GENERAL GUIDELINES nace in a basement. a. Select a location where the exhaust and com- g.
  • Page 10 • Ammonia, as is commonly found in perma- 3. INSTALLATION IN UPFLOW, DOWNFLOW OR HORIZONTAL POSITIONS nent wave solutions used in women’s hair dressing salons UPFLOW INSTALLATION: Vent positioning, • Anti-static fabric softeners used in clothes pressure switch location and drain locations shall dryers be performed in accordance with instructions in •...

  • Page 11: Combustible Clearances

    WARNING IMPORTANT: If the furnace and air conditioner is above a finished space, install a drain pan THIS FURNACE IS DESIGN CERTIFIED FOR underneath the unit. INSTALLATION ON COMBUSTIBLE FLOORS. THIS SHALL BE INTERPRETED AS A WOOD NOTE: It is not permissible to use a rear return on this FLOOR ONLY.

  • Page 12: Ductwork

    6 - DUCTWORK WARNING Proper airflow is required for the correct operation NEVER ALLOW THE PRODUCTS OF COM- of this furnace. Insufficient airflow may cause er- BUSTION FROM THE FLUE TO ENTER THE ratic operation, could cause the furnace to cycle on RETURN AIR OR SUPPLY AIR DUCTWORK.

  • Page 13: Ventilation And Combustion Air

    to prevent entraining combustion gases from an ad- IMPORTANT: Some high efficiency filters have jacent fuel burning appliance, or entraining combus- a greater than normal resistance to airflow. This tion air for this furnace or adjacent fuel burning ap- can adversely affect furnace operation. pliances.

  • Page 14: Venting And Combustion Air Piping

    Remove the vent connector of the furnace being re- 4. Follow the lighting instructions of the appli- placed, seal off the inlet to the vent from that furnace, ance being tested and turn it on to continuous then test the remaining appliances connected to the operation.

  • Page 15: Non-Direct Vent Furnace Installations

    The optional Concentric Vent Termination Kits are The combustion air piping does not have flue gas- certified for use until July 1, 2008. Use the ap- es traveling through it and may be installed with proved transition cement certified by the ULC S636 common ABS, PVC or CPVC piping or fittings.

  • Page 16: Determining Combustion Air

    10 - DETERMINING COMBUSTION AIR CASE 1 - FURNACE LOCATED IN AN UNCON- FIGURE 4 - COMBUSTION/DILUTION AIR FROM FINED SPACE HEATED INSIDE SOURCES (CASE 2) Unconfined space does not necessarily mean that ventilation will not have to be introduced from the outdoors, particularly in airtight homes.
  • Page 17 The other opening may communicate freely with a IMPORTANT: If the attic has an exhaust fan ventilated the attic. If using the attic air, ensure that (power vent), it may create a negative pres- the opening is ducted from the ceiling high enough sure sufficiently large enough to prevent the to be above the insulation.

  • Page 18: Venting Guidelines

    FIGURE 6 - OUTDOOR AIR FOR COMBUSTION, WARNING HORIZONTAL (CASE 4) READ AND FOLLOW ALL INSTRUCTIONS IN THIS SECTION. FAILURE TO PROPERLY VENT THIS FURNACE CAN CAUSE CARBON MONOXIDE POISONING OR AN EXPLOSION OR FIRE RESULTING IN PROPERTY DAM- AGE, PERSONAL INJURY OR LOSS OF LIFE. NOTE: Combustion air intake and exhaust termination should be inspected periodically to ensure they are clear of obstructions.
  • Page 19 All exhaust piping must be installed in accordance FIGURE 8 - STANDARD (STRAIGHT) HORIZON- with CAN/CGA-B149.in Canada; the latest edition TAL VENT DETAIL of National Fuel Gas Code, NFPA 54 / ANSI Z223.1 in the United States, as well as in accordance with local codes.
  • Page 20 Exterior vent pipe greater than 24” should be insu- FIGURE 9 - PERISCOPED VENT DETAIL lated with ½” insulation to prevent moisture from freezing within the pipe and accumulating. Size the exhaust pipe as specified in Table 4 - Di- rect and Non-Direct Vent Lengths.
  • Page 21 • Within 6 feet of any service regulator vent • The vent shall not terminate over public walk- outlet; ways or over an area where condensate or • Less than 12” above grade level or anticipat- vapor could create a nuisance or hazard. ed snow level;...
  • Page 22 IMPORTANT: The supplied adapter is made of IMPORTANT: If the furnace is to be installed in PVC. If planning to use ABS pipe, use an all- the vicinity of other fuel burning appliances, ad- purpose cleaner and ABS to PVC transition ce- equate combustion air must be available for the ment.
  • Page 23 Do not locate the terminal on the side of the build- CONCENTRIC VENTING KIT ing facing the prevailing winter winds. Concentric venting terminal kits may be used for CAUTION this series furnace. They provide a means of ob- taining combustion air and exhausting products of Improper location or installation can result in combustion utilizing a single penetration through structural damage to the building, damage to...
  • Page 24 IN CANADA FIGURE 12 - MULTIPLE VENTING (STANDARD HORIZONTAL) In addition to the general guidelines, both non-di- rect and direct vent exhaust shall not terminate: • Directly above a paved sidewalk or paved driveway which is located between two single- family dwellings and serves both dwellings;...
  • Page 25 • Locate the vent terminal 3 feet horizontally WARNING from the vent of any side wall vented fuel gas appliance or electric clothes dryer, except in THE VENT MUST BE CLAMPED TO THE the case where two or more of these furnaces FURNACE PANEL USING THE GASKET AND are multi-vented.
  • Page 26 Complete the venting as installation requires. If exiting the top panel, use two street elbows IMPORTANT: Keep pressure switch hose above to route the vent. One elbow secured to the in- heat exchanger drain. ducer, will angle toward the front of cabinet with ORIENTATION ROTATE RECOMMEND...
  • Page 27 FIGURE 21A - DIRECT VENT TERMINAL CLEARANCES...
  • Page 28 FIGURE 21B - NON-DIRECT VENT TERMINAL CLEARANCES...
  • Page 29 FIGURE 22 - UPFLOW VENT AND DRAINING OPTION Instructions for Upflow with Top Venting Connect two (2) 2” Street elbows (in parts bag) to the coupler on the ex- hauster (Add 2” nipple for 120K BTU units). Ensure exhauster coupler drain outlet is facing downward 15°.
  • Page 30 Instructions for Upflow with Right Side Venting 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°. Connect 2” elbow and 2” vent pipe (field supplied) Install gasket on panel then vent bracket, use three (3) self tapping screws (all parts from parts bag).
  • Page 31 FIGURE 24 - HORIZONTAL RIGHT VENT AND DRAINING OPTION Instructions for Horizontal Right with Right Side Venting Connect two (2) 2” Street elbows (in parts bag) to the coupler on the exhauster Remove two (2) 7/8” knockouts and install the condensate trap bracket by (Add 2”...
  • Page 32 FIGURE 25 - DOWNFLOW VENT AND DRAINING OPTION Instructions for Downflow with Left Side Venting 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°. Connect 2”...

  • Page 33: Condensate Drains

    13 - CONDENSATE DRAINS The furnace may condense as much as a 4½ ½” drain tube on the exhauster coupling drain. Fasten by tightening the tube clamp approxi- pounds of water per hour (approximately 2 imperial mately ⅛” from the end of the tube. quarts, 2½...
  • Page 34 IMPORTANT: If an air conditioning evapora- FIGURE 27 - CONDENSATE BYPASS tor coil drain is to share the furnace drain line, it should be connected with a tee fitting down- stream from the trap. Do not connect the evapo- rator coil condensate drain upstream of the fur- nace drain trap assembly.

  • Page 35: Gas Supply And Piping

    14 - GAS SUPPLY AND PIPING FIGURE 28 - FURNACE GAS PIPE CONNECTIONS GAS SUPPLY (NOTE RUBBER GROMMET) WARNING THIS FURNACE IS FACTORY EQUIPPED TO BURN NATURAL GAS ONLY. CONVERSION TO LP GAS REQUIRES SPECIAL NATURAL GAS TO LP CONVERSION KIT. FAILURE TO USE THE PROPER CONVERSION KIT CAN CAUSE FIRE, EXPLOSION, CARBON MONOXIDE POISONING, PROPERTY DAM-...

  • Page 36: Conversions

    Gas piping that has not been pressure tested, from GAS INLET PRESSURE the manual shut-off valve to the furnace gas valve for example, should be leak tested using an elec- The natural gas inlet supply pressure should be 5” tronic combustible gas detector, a commercially to 7”...
  • Page 37 TABLE 6 - HIGH ALTITUDE SPECIFICATIONS TABLE 7 - HIGH ALTITUDE SPECIFICATIONS (CANADA) (U.S.A.) ORIFICE SIZE (DMS) ALTITUDE INPUT OUTPUT MODEL QTY. ORIFICE SIZE (DMS) (FT) BTU/HR BTU/HR ALTITUDE NATURAL LP GAS MODEL (FT) NATURAL LP GAS 0 - 2000 60000 57000 0-2000...
  • Page 38 13. Replace the High regulator adjustment 5. Measure furnace gas inlet pressure with screw and adjust approximately 12 turns to the burners firing. Inlet pressure must be within the range specified on the furnace rating plate. bottom. 5-7” w.c (Natural Gas) or 11-14” w.c. (LP). If the inlet pressure differs from the rating plate, 14.
  • Page 39 If problems were encountered with obtaining enough FIGURE 34 - REGULATOR ADJUSTMENT pressure on the manifold, first examine the gas pip- ing system to ensure that it is correctly sized. Pipe sizing is specified in CAN/CGA-B-149.1 & 2, and in NFPA 54 / ANSI Z223.1. Be sure to check for restrictions, partially closed valves, etc.

  • Page 40: Electrical Specifications

    16 - ELECTRICAL SPECIFICATIONS Although a suitably located circuit may serve as ELECTRICAL WIRING & CONNECTIONS a service switch, a separate service switch is rec- ommended. A separate service switch is necessary Before proceeding with the electrical connections, if the circuit breaker is in a location where access- ensure that the available electrical supply is com- ing it would require getting close to the furnace, or patible with the voltage, frequency and phase listed...

  • Page 41: Low Voltage Wiring

    be moved to the right hand side. The junction box 4. Fasten the junction box to the right hand panel. contains a BLACK wire to be connected with L1 (hot), a WHITE wire to be connected with L2, the NOTE: L1 (hot) and L2 (neutral) polarity must be observed when making field connections to the Neutral, and a GREEN wire to be connected to the furnace.

  • Page 42: Optional Accessories

    uous low heat operation. Once high heat is started THERMOSTAT LOCATION from automatic staging, the demand for high heat remains until the heat call is satisfied. The thermostat should be located approximately 5 * Factory Setting feet above the floor, on an inside wall where there is good natural air circulation, and where the thermostat TWO STAGE THERMOSTAT will be exposed to average room temperatures.
  • Page 43 Green LED will flash. If the High pressure switch NOTE: On initial startup, the drain trap assembly will be is closed the Green LED will be on. High gas dry. A dry trap will allow flue gases to flow through the re- covery coil drain, which will prevent the condensate from valve drops out while High pressure switch is draining from the recovery coil.

  • Page 44: Air Flow

    Any adjustments to the burner manifold pressure Heating Value of Gas x 3600 Input = should be carried out with the use of a manometer Time in Sec. for 1 cu. ft. or calibrated magnehelic gauge. Do not adjust the where: gas valve pressure regulator more than ±0.3”...
  • Page 45 2. Insert a duct thermometer in the return air Output duct as close to the furnace as practical. Ensure CFM = ∆T 1.085 x that the thermometer location will be unaffected by humidifier bypass ducts, etc. Choose a loca- where: tion well within the main air stream.
  • Page 46 TABLE 3 - HEATING CFM 95V100-5 ESP 0.1” to 1.0” w.c. HEAT ADJUST Low-Fire High-Fire 95V060-3 ESP 0.1” to 1.0” w.c. Jumper Jumper HEAT ADJUST Low-Fire High-Fire Jumper Jumper NORM 1200 1620 NORM 1050 NORM 1400 1820 NORM 1105 NORM 1100 1474 NORM...

  • Page 47: Maintenance And Troubleshooting

    Additional dehumidification can be achieved by CONTINUOUS FAN OPERATION connecting a humidistat to the DEHUM and R ter- minals on the integrated furnace control board. In When the thermostat continuous fan (G) switch is this setup, the variable speed motor will operate at on without a call for heat or cooling, the indoor fan a 10% reduction in the normal cooling airflow rate is immediately energized up to 50% of the cooling...
  • Page 48 Some paper media high efficiency filters, some- TERMINATIONS times identified as HEPA filters can do an effective and excellent filtration of the air; however, some The combustion air and exhaust terminals should models may also cause a large pressure drop be inspected occasionally to ensure that they are across the filter.
  • Page 49 7. Keep combustible articles at least 3 feet away The flame sensor should be inspected and cleaned from the furnace. Do not block access for ser- with fine steel wool or Scotch-Brite™ scrubbing vicing the furnace Do not use the combustion pad.

  • Page 50: Sequence Of Operation

    TROUBLESHOOTING FLOWCHART SEQUENCE OF OPERATION Troubleshouting Flowchart Apply Power To Furnace Thermostat Calls For Heat Wait For Limit Circuit Air Proving Switches Wait For Air Proving Switch to Close and/or Reset Proved Open & Limit to Open. Flash(3) of Flame Rollout. Circuit Closed Flash(1) Combustion Air Blower On...
  • Page 51 DIAGNOSTIC CODES FOR STATUS LED A RED LED is provided to indicate furnace operating status LED Condition Fault Condition Check LED ON Normal operation No action required. Control OK. LED OFF No power to control or Line voltage input power at L1 and Neutral control connectors control board.
  • Page 52 DIAGNOSTIC CODES FOR STATUS LED A RED LED is provided to indicate furnace operating status LED Condition Fault Condition Check 6 Flashes Not Used 7 Flashes Pressure switch cycle Pressure switches operation, tubing and wiring. lockout Obstruction or restrictions in venting preventing proper air flow.
  • Page 53 22 - WIRE DIAGRAM FOR TWO STAGE FURNACE WITH ECM � � � �� ��� ��� ��� � ����� ����� �� ��� ��� ������� ����� ���� �� ����� � ����� �� � ����� ����� �� ���� ����� �� �� ����� ���...

  • Page 54: Venting Checklist

    VENTING CHECKLIST  Vent pipe must be sloped to drain from outlet back to furnace. Exposed vents and drains must be heat traced. Vents exiting house must be well sealed to prevent exhausts from re-enter- ing the house. Vents and intake must be 12” above grade. For Massachusetts see page 6. In Canada all venting material must be identified as ULC S636 and be read- ily accessible for visual inspection for the first 3ft.

  • Page 55: Replacement Parts List

    24 - REPLACEMENT PARTS LIST REPLACEMENT PARTS LIST HIGH EFFICIENCY TWO STAGE GAS FURNACE Replacement Parts List Item Kit Number Repair Parts List for 95% Two Stage High Efficient Furnace FLAME ROLLOUT SWITCH 350F, ALL MODELS 550001515 550001528 FLAME SENSOR, ALL MODELS 550001656 TWO STAGE GAS VALVE 36G54, ALL MODELS 550001514...
  • Page 56 Replacement Parts List Item Kit Number Repair Parts List for 95% Two Stage High Efficient Furnace 550001515 KIT,FLAME ROLLOUT SWITCH 350F, ALL MODELS 550001528 KIT,FLAME SENSOR, ALL MODELS 550001656 KIT,GAS VALVE, HIGH 2ST, ALL MODELS White Rodgers 36G54 Two Stage 24V gas valve set for NG 550001514 KIT,LIMIT SWITCH 160F 100-5, 120-5 550001525...

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