Related Manuals for Bosch BGH96M060B3B
Summary of Contents for Bosch BGH96M060B3B
- Page 1 Installation Instructions 96% AFUE Condensing Gas Furnace Bosch BGH96 Model 3124627...
- Page 2 Installation Instructions Bosch 96% AFUE Condensing Gas Furnace - BTC 770503101 J (06.2023)
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Page 3: Table Of Contents
9.5 Gas Piping Checks 10 Electrical Connections 10.1 115V Wiring 10.2 Electrical Connection to J-box 10.3 Power Cord Installation in Furnace J-box 10.4 BX Cable Installation in Furnace J-box Bosch 96% AFUE Condensing Gas Furnace - BTC 770503101 J (06.2023) -
Page 4: Key To Symbols And Safety Instructions
DO NOT BURN ANY LIQUID FUEL OR SOLID FUEL IN THIS FURNACE. Burning any unapproved fuel will result in damage to the furnace's heat exchanger, which could result in Fire, Personal Injury, and/or Property Damage. Bosch 96% AFUE Condensing Gas Furnace - BTC 770503101 J (06.2023) - Page 5 The furnace may be used for construction heat provided that the furnace installation and operation complies with the first CAUTION in Section 6 "Location" of these instructions. Bosch 96% AFUE Condensing Gas Furnace - BTC 770503101 J (06.2023)
- Page 6 3. Remove access panels. 2. Turn off all electric power to the appliance if 4. Push gas control switch to “OFF”. service is to be performed. 5. Replace access panels. 202082290022 Bosch 96% AFUE Condensing Gas Furnace - BTC 770503101 J (06.2023)
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Page 7: Dimensions
19.5 (495) 19-13/32 (493) 194.6 (88.3) BGH96M100D5B 24.5 (622) 23 (584) 22-27/32 (580) 205.1 (93.0) BGH96M120D5B 24.5 (622) 23 (584) 22-27/32 (580) 209.5 (95.0) Table 1 Dimensions & Weight Bosch 96% AFUE Condensing Gas Furnace - BTC 770503101 J (06.2023) -
Page 8: Introduction
T his product is not to be sold or installed in the State of California in the South Coast Air Quality Management District or San Joaquin Valley Air Basin territory. Bosch 96% AFUE Condensing Gas Furnace - BTC 770503101 J (06.2023) -
Page 9: Codes And Standards
1/2" (12.7 mm) to a maximum of 3/4" (19 mm) forward for proper drainage. International,178 Rexdale Boulevard, Etobicoke (Toronto), See Section 7, "Installation" of this manual for more information. Ontario,M9W 1R3 Canada 1/2”~3/4” 1/2”~3/4” Figure 4 Bosch 96% AFUE Condensing Gas Furnace - BTC 770503101 J (06.2023) -
Page 10: Combustion And Ventilation Air
An ESD service kit (field supplied) may also be used to prevent ESD damage. 4.9 Venting US: NFGC NFPA 54/ANSI Z223.1-latest edition; Chapters 12 and 13 CANADA: CAN/CSA-B149.1-05 Part 8 and Appendix C. Bosch 96% AFUE Condensing Gas Furnace - BTC 770503101 J (06.2023) 1 0 |... -
Page 11: Location
18-IN. met, in addition to all local codes and ordinances. MINIMUM TO BURNERS Figure 6 Installation in a garage Bosch 96% AFUE Condensing Gas Furnace - BTC 770503101 J (06.2023) | 11... - Page 12 HVAC system components after construction is completed. — Verify proper furnace operating conditions including ignition, gas input rate, air temperature rise, and Bosch 96% AFUE Condensing Gas Furnace - BTC 770503101 J (06.2023) 1 2 |...
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Page 13: Installation
Tilt the unit slightly (minimum 1/2 (12.7 mm) to maximum of 3/4 (19 mm)) from back to front to aid in the draining of the heat exchanger. 1/2”~3/4” Figure 8 Upflow Application-Setting Equipment Bosch 96% AFUE Condensing Gas Furnace - BTC 770503101 J (06.2023) | 13... -
Page 14: Horizontal Installation
Tilt the unit slightly (minimum 1/2" (12.7 mm) to maximum of 3/4" (19 mm)) from back to front to aid in the draining of the heat exchanger. Figure 9 Horizontal Application-Setting Equipment Bosch 96% AFUE Condensing Gas Furnace - BTC 770503101 J (06.2023) 1 4 |... - Page 15 Never install the furnace on the ground or allow it to be exposed to water. See Furnace Suspension for further details (See Fig. 10). Bosch 96% AFUE Condensing Gas Furnace - BTC 770503101 J (06.2023) | 15...
- Page 16 DRAIN LINE WITH 1/4” PER FOOT DOWNWARD SLOPE FURNACE MUST BE SUPPORTED AT BOTH ENDS AND MIDDLE 36” MINIMUM SERVICE CLEARANCE REQUIRED Figure 11 Horizontal Installation Bosch 96% AFUE Condensing Gas Furnace - BTC 770503101 J (06.2023) 1 6 |...
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Page 17: Condensate Line And Over Flow Pressure Switch
Included Accessories for Condensate Drain Trap Installation * O nly used when exhaust pipe is vented out of the side of the furnace's cabinet (regardless of installation orientation). Bosch 96% AFUE Condensing Gas Furnace - BTC 770503101 J (06.2023) | 17... - Page 18 14mm hose 16mm hose Figure 14 Model X1/mm X2/mm BGH96M100D5B BGH96M120D5B BGH96M080C4B BGH96M100C5B BGH96M060B3B BGH96M080B3B Table 2 Secure and tighten all hoses using manufacturer provided hose clamps. Bosch 96% AFUE Condensing Gas Furnace - BTC 770503101 J (06.2023) 1 8 |...
- Page 19 BOTTOM INDUCER Φ14/16 mm INDUCER DRAIN PORT ELBOW (optional) Φ14 mm HOSE DRAIN HOSE CLAMP PORT DRAIN TRAP DRAIN TRAP MOUNTING BRACKET Figure 16 Horizontal Right-Hand Side Installation Bosch 96% AFUE Condensing Gas Furnace - BTC 770503101 J (06.2023) | 19...
- Page 20 14mm HOSE Φ14/16 mm ELBOW (optional) Φ16 mm HOSE HOSE CLAMP DRAIN TRAP DRAIN TRAP MOUNTING BRACKET Figure 17 Horizontal Left Side Installation, Vent Through Top Panel Bosch 96% AFUE Condensing Gas Furnace - BTC 770503101 J (06.2023) 2 0 |...
- Page 21 Two pressure switches (one port type switches) should be relocated to other side of furnace side panel to ensure pressure switches are above water tap of condensate collector box. Bosch 96% AFUE Condensing Gas Furnace - BTC 770503101 J (06.2023) | 21...
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Page 22: Filter Arrangement
Side return knockout markings Filter size The Bosch 96% AFUE Gas Furnace BGH96 series does not include a filter from the Dimensions of return air "cut out" must match those shown in Figure 1. manufacturer. The filter and filter rack must be field supplied and field installed. A DO NOT cut outside of the "knockout"... -
Page 23: Air Ducts
Both acoustical lining and fibrous duct work shall comply with NFPA 90B as tested by UL Standard 181 for Class 1 Rigid air ducts. Bosch 96% AFUE Condensing Gas Furnace - BTC 770503101 J (06.2023) | 23... - Page 24 3/4 inch (19 mm) washable media filter is used, assume an additional 0.1 in. WC available external static pressure. ** The manufacturer default fan settings are based on model, refer to Table 24. Bosch 96% AFUE Condensing Gas Furnace - BTC 770503101 J (06.2023) 2 4 |...
- Page 25 3/4 inch (19 mm) washable media filter is used, assume an additional 0.1 in. WC available external static pressure. ** The manufacturer default fan settings are based on model, refer to Table 24. Bosch 96% AFUE Condensing Gas Furnace - BTC 770503101 J (06.2023) | 25...
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Page 26: Combustion Air And Vent System
For downflow or horizontal models, the transition from 2" to 3" pipe should be done immediately after exiting the furnace. Bosch 96% AFUE Condensing Gas Furnace - BTC 770503101 J (06.2023) 2 6 |... - Page 27 An offset using two 45º (degree) elbows will be required for plenum clearance when the vent is increased to 3” (7.6 cm). Bosch 96% AFUE Condensing Gas Furnace - BTC 770503101 J (06.2023) | 27...
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Page 28: Combustion Air And Vent Piping Assembly
Piping should be supported with pipe hangers to prevent sagging. Seal around the openings where the combustion air and / or vent piping pass through the roof or sidewalls. Bosch 96% AFUE Condensing Gas Furnace - BTC 770503101 J (06.2023) 2 8 |... -
Page 29: Combustion Air / Venting
12” (30.5 cm) as specified in CSA B149.1-00. not create a positive pressure in the vicinity of the vent. Bosch 96% AFUE Condensing Gas Furnace - BTC 770503101 J (06.2023) | 29... -
Page 30: Vent System
The combustion air and vent pipes Exhaust must terminate in the same atmospheric zone. Figure 25 Termination Configuration - 1 Pipe, No Bosch 96% AFUE Condensing Gas Furnace - BTC 770503101 J (06.2023) 3 0 |... -
Page 31: Combustion & Ventilation Air Requirements
Only the combustion air intake may terminate in the attic. The vent must terminate outside. Figure 31 Combustion Airflow Path Through The Furnace Cabinet Bosch 96% AFUE Condensing Gas Furnace - BTC 770503101 J (06.2023) | 31... - Page 32 One opening shall be within 12 inches of the top and one within 12 inches of the bottom of the enclosure (See Table 11). Bosch 96% AFUE Condensing Gas Furnace - BTC 770503101 J (06.2023) 3 2 |...
- Page 33 Table 13 ,“Estimated Free Area” to estimate free area. Wood or Metal Louvers or Grilles Wood 20-25%, Metal 60-70% Screens 1/4” mesh or larger 100% Table 13 Estimated Free Area Bosch 96% AFUE Condensing Gas Furnace - BTC 770503101 J (06.2023) | 33...
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Page 34: Vent And Supply (Outside) Air Safety Check Procedure
Propane Installation Code (latest editions). If the vent system must be resized, follow the appropriate tables in Appendix G of the above codes or for this appliance. Bosch 96% AFUE Condensing Gas Furnace - BTC 770503101 J (06.2023) 3 4 |... -
Page 35: Gas Supply And Piping
Inlet Gas Supply Pressure Natural Gas Minimum: 4.5 in. WC Maximum:10.5 in. WC Propane Gas Minimum:11.0 in. WC Maximum:13.0 in. WC Table 14 Inlet Gas Supply Pressure Bosch 96% AFUE Condensing Gas Furnace - BTC 770503101 J (06.2023) | 35... -
Page 36: High Altitude Derate
2000-4500 ft. When an appliance is installed at elevations above 4500 ft, the certified high altitude input rating shall be reduced at the rate of 4% for each additional 1000 ft. Bosch 96% AFUE Condensing Gas Furnace - BTC 770503101 J (06.2023) 3 6 |... -
Page 37: Propane Gas (Lp) Conversion
In some cases, the installer may also need to supply a transition piece from 1/2" pipe to a larger pipe size. Bosch 96% AFUE Condensing Gas Furnace - BTC 770503101 J (06.2023) | 37... -
Page 38: Gas Piping Checks
A ground joint union, drip leg, and manual shutoff valve must also be supplied by the installer. In some cases, the installer may also need to supply a transition piece from 1/2 inch to another pipe size. Bosch 96% AFUE Condensing Gas Furnace - BTC 770503101 J (06.2023) 3 8 |... -
Page 39: Electrical Connections
Proper polarity must be maintained for 115V wiring. If polarity is incorrect, control LED status indicator light will flash rapidly and furnace will NOT operate. Bosch 96% AFUE Condensing Gas Furnace - BTC 770503101 J (06.2023) | 39... -
Page 40: Electrical Connection To J-Box
Fig. 37. Use best practices (NEC in U.S.) for wire bushings, external electrical source is utilized. strain relief, etc. Reinstall cover to J-Box. Do not pinch wires between cover and bracket. Bosch 96% AFUE Condensing Gas Furnace - BTC 770503101 J (06.2023) 4 0 |... - Page 41 Table 20 Heat Off Delay * The factory default settings DIP Switch (SW) NOMINAL (SECONDS) S2-3 S2-4 Table 21 Cool Off Delay * The factory default settings Bosch 96% AFUE Condensing Gas Furnace - BTC 770503101 J (06.2023) | 41...
- Page 42 If any of the original w ire, as supplied, must be replaced, use same type or equivalent wire. Figure 37 Heating and Cooling Application Wiring Diagram with 2-Stage Thermostat Bosch 96% AFUE Condensing Gas Furnace - BTC 770503101 J (06.2023) 4 2 |...
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Page 43: Thermostat Settings And Wiring
10.8.1 Thermostat Settings The Thermostat should be set to either Fossil Fuel or Dual Fuel. Figure 38 The Fan control logic should be set to “Appliance” control. Figure 39 Bosch 96% AFUE Condensing Gas Furnace - BTC 770503101 J (06.2023) | 43... - Page 44 Wiring with 3H/2C thermostat – Bosch BCC50 for example. R/RC H/DH THERMOSTAT Y/Y2 FURNACE Figure 41 Wiring Detail - Furnace and Bosch Connected Control BCC50 Bosch 96% AFUE Condensing Gas Furnace - BTC 770503101 J (06.2023) 4 4 |...
- Page 45 FURNACE / CASED COIL OUTDOOR UNIT is energized based off of the delay timer. Figure 43 Wiring Detail - Furnace/Cased Coil, Bosch IDS Outdoor Unit and Bosch Connected Control BCC50 Bosch 96% AFUE Condensing Gas Furnace - BTC 770503101 J (06.2023) | 45...
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Page 46: Start-Up, Adjustment, And Safety Check
Caution must be taken when manually closing this switch for service purposes. There is an approximate 48 second delay between thermostat energizing and burner firing. Bosch 96% AFUE Condensing Gas Furnace - BTC 770503101 J (06.2023) 4 6 |... -
Page 47: Sequence Of Operation
10 seconds, the control will restart the ignition sequence. Table 22 A momentary loss of gas supply, flame blowout, or a shorted or open condition * These times will vary depending on option switch position. Bosch 96% AFUE Condensing Gas Furnace - BTC 770503101 J (06.2023) | 47... -
Page 48: Gas Manifold Pressure Measurement And Adjustment
Always adjust regulator to provide the correct pressure according to the original equipment manufacturer specifications listed on the appliance rating plate. Bosch 96% AFUE Condensing Gas Furnace - BTC 770503101 J (06.2023) 4 8 |... -
Page 49: Gas Input Rate Measurement (Natural Gas Only)
Adjust temperature rise by adjusting the circulator blower speed. Increase blower speed to reduce temperature rise. Decrease blower speed to increase temperature rise. Refer to the following section for speed changing Bosch 96% AFUE Condensing Gas Furnace - BTC 770503101 J (06.2023) | 49 details. - Page 50 Table 26 Selectable Fan Speeds Turn ON power to furnace. Verify proper temperature rise is as outlined in Temperature Rise section and on the unit nameplate. Bosch 96% AFUE Condensing Gas Furnace - BTC 770503101 J (06.2023) 5 0 |...
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Page 51: Operational Checks
(it is an automatic reset temperature sensor). The limit guards against the overheating resulting from insufficient air passing over the heat exchanger. Bosch 96% AFUE Condensing Gas Furnace - BTC 770503101 J (06.2023) | 51... -
Page 52: Troubleshooting
The red diagnostic LED blinks to assist in troubleshooting the unit. The number of blinks refers to a specific code (See Tables 27 & 28). Bosch 96% AFUE Condensing Gas Furnace - BTC 770503101 J (06.2023) 5 2 |... - Page 53 5. Check induced draft blower for proper — Loose or improperly connected performance. Replace if necessary. wiring. 6. Tighten or correct wiring connection. Table 27 Troubleshooting Chart Bosch 96% AFUE Condensing Gas Furnace - BTC 770503101 J (06.2023) | 53...
- Page 54 1st stage heating 2nd stage heating Operation 1st stage cooling Codes 2nd stage cooling Fan only mode Defrost mode Table 29 Unit Operation Codes Figure 47 Bosch 96% AFUE Condensing Gas Furnace - BTC 770503101 J (06.2023) 5 4 |...
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Page 55: Service And Maintenance Procedures
The flame sensor should be carefully cleaned by a qualified service technician using emery cloth or steel wool. Following cleaning, the flame sense signal should be 1 to 6 microamps at 115 volts. Bosch 96% AFUE Condensing Gas Furnace - BTC 770503101 J (06.2023) | 55... -
Page 56: Ignitor (Qualified Service Technicians Only)
Inspect the metal flue for rust or holes, and make sure it’s supported properly. Bosch 96% AFUE Condensing Gas Furnace - BTC 770503101 J (06.2023) 5 6 |... - Page 57 Door Switch Air Inlet Integrated Control Module Burner Blower Rollout Limit Switch Transformer Condensate Trap Juction Box Please contact your local installer or dealer for replacement parts. Bosch 96% AFUE Condensing Gas Furnace - BTC 770503101 J (06.2023) | 57...
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Page 58: Wiring Diagram
96% machine windshield setting 120D 1 2 3 100D 1 2 3 100C 1 2 3 1 2 3 1 2 3 1 2 3 Figure 49 Bosch 96% AFUE Condensing Gas Furnace - BTC 770503101 J (06.2023) 5 8 |... - Page 59 Installation Instructions NOTES: Bosch 96% AFUE Condensing Gas Furnace - BTC 770503101 J (06.2023) | 59...
- Page 60 United States and Canada Bosch Thermotechnology Corp. 65 Grove St. Watertown, MA 02472 Tel: 866-642-3198 Fax: 954-776-5529 www.bosch-homecomfort.us BTC 770503101 J / 06.2023 Bosch Thermotechnology Corp. reserves the right to make changes without notice due to continuing engineering and technological advances.