Blue Summit BG961UHE Installation Instructions Manual Download Page 55

Page: 55 / 56

507768-02B

Page 55 of 56

Issue 1904

Repair Parts List

The following repair parts are available through Blue Summit dealers. When ordering parts, include the complete furnace

model number listed on the CSA nameplate. All service must be performed by a licensed professional installer (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

•

Main Burner Orifices

•

Pressure Switch

•

Ignitor

•

Primary Limit Control

•

Flame Rollout Switches

Table 13. Diagnostic Codes

-03 Integrated Control LED Codes

Red LED Flash Code

Diagnostic Codes / Status of Furnace

LED Off

No power to control or control hardware fault detected

Heartbeat

Normal operation - idle, continuous fan, cool

Continuous Rapid Flash Call for heat / burner operation

1 Flash

Reverse line voltage polarity

2 Flashes

Improper earth ground

3 Flashes

Burner failed to light, or lost flame during heat demand

4 Flashes

Low flame signal - check flame sensor

5 Flashes

Watchguard - burner failed to light, exceeded maximum number of retries or recycles

6 Flashes

Not used

7 Flashes

Primary or Secondary limit open or watchguard mode - limit switch open longer than 3 minutes

8 Flashes

Rollout switch open

9 Flashes

Pressure switch failed to close or opened during heat demand

10 Flashes

Watchguard - Pressure switch opened 5 times during one heat demand

11 Flashes

Pressure switch stuck closed prior to activation of combustion air inducer

12 Flashes

Flame sensed without gas valve energized

13 Flashes

Low line voltage

A “heartbeat” is indicated by a “slow flash” - 1 sec on 1 sec off, repeating

Error codes are indicated by a “rapid flash” - the LED flashes X times at 1/2 sec on, 1/2 sec off, remains off for 3 sec, then repeats

NOTE

: Last 10 error codes are stored in memory, including when power is shut off to the unit. To 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.

Summary of Contents for BG961UHE

Page 1: ...personal injury or 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 ...

Page 2: ...r side 23 3 4 603 25 635 3 3 8 86 D 1 NOTE C 20 5 Ton size units installed in upflow applications that require air volumes of 1800 cfm 850 L s or greater must have one of the following 1 Single side return air with transition to accommodate 20 x 25 x 1 in 508 x 635 x 25 mm cleanable air filter Required to maintain proper air velocity 2 Single side return air with optional RAB Return Air Base 3 Bot...

Page 3: ...507768 02B Page 3 of 56 Issue 1904 Figure 1 Parts Arrangement ...

Page 4: ... 2 diameter debris screen 1 3 4 Threaded street elbow NOTE The required bellows grommet is field provided See 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 w...

Page 5: ...operation of either the heating or the cooling unit 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 Protect...

Page 6: ...nd unsafe operation When the furnace is installed in 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...

Page 7: ...combustion and ventilation depend largely on whether the furnace is installed in an unconfined or a confined space Unconfined Space An unconfined space is an area such as a basement or large equipment room with a volume greater than 50 cubic feet 1 42 m per 1 000 Btu 29 kW per hour of the combined input rating of all appliances installed in that space This space also includes adjacent rooms which ...

Page 8: ...hey 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 blocking effect of louvers grilles or screens must be considered If the design and free area of protective covering is not known for calculating the size opening required it may be assum...

Page 9: ...Crawl Space and Outlet Air to Outside Shipping Bolt Removal Units with 1 2 hp 3 4 hp blower motor are equipped with three flexible legs and one rigid leg The rigid leg is equipped with a shipping bolt and a flat white plastic washer rather than the rubber mounting grommet used with a flexible mounting leg See Figure 11 The bolt and washer must be removed before the furnace is placed into operation...

Page 10: ...nected to or from other heating devices such as a fireplace or stove etc Fire explosion carbon monoxide poisoning personal injury and or property damage could result WARNING Figure 13 Installation Clearances Upflow Applications Top Bottom Floor Left Side Right Side Top Plenum 1 in 25 mm Front 0 Back 0 Sides 0 Vent 0 Floor 0 Front clearance in alcove installation must be 24 in 610 mm Maintain a min...

Page 11: ...panel to facilitate installation Markings are provided on both sides of the furnace cabinet for installations that require side return air Cut the furnace cabinet at the maximum dimensions shown on Page 2 Furnace applications which include side return air and a condensate trap installed on the same side of the cabinet trap can be installed remotely within 5 ft require either a return air base or f...

Page 12: ...610 mm Maintain a minimum of 24 in 610 mm for front service access An 8 service clearance must be maintained below the unit to provide for servicing of the condensate trap For installations on a combustible floor do not install the furnace directly on carpeting tile or other combustible materials other than wood flooring Top Plenum 1 in 25 mm Front 0 Back 0 Sides 0 Vent 0 Floor 0 Front clearance i...

Page 13: ...16 Filters This unit is not equipped with a filter or rack Afield provided filter is required for the unit to operate properly Table 1 lists recommended filter sizes A filter must be in place whenever the unit is operating Table 1 Furnace Cabinet Width Filter Size Side Return Bottom Return 17 1 2 16 x 25 x 1 1 16 x 25 x 1 1 21 20 x 25 x 1 1 Duct System Use industry approved standards to size and i...

Page 14: ...o either PVC or CPVC Low temperature solvent cement is recommended during cooler weather Metal or plastic strapping may be used for 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 Canadian Applications Only Pipe fittings primer and solvent cement used to...

Page 15: ...e to the connector if desired Use a drill or self tapping screw to make a pilot hole DANGER OF EXPLOSION Fumes from PVC glue may ignite during system check Allow fumes to dissipate for at least 5 minutes before placing unit into operation DANGER 1 Measure and cut vent pipe to desired length 2 Debur and chamfer end of pipe removing any ridges or rough edges If end is not chamfered edge of pipe may ...

Page 16: ...g system are not in operation WARNING 1 Seal any unused openings in the common venting system 2 Inspect the venting system for proper size and horizontal pitch Determine that there is no blockage restriction leakage 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...

Page 17: ... sealed to prevent leakage of combustion products into the living space CAUTION Vent Piping Guidelines This gas furnace can be installed as either a Non Direct Vent or a Direct Vent gas central furnace NOTE In non Direct Vent installations combustion air is taken from indoors and flue gases are discharged outdoors In Direct Vent installations combustion air is taken from outdoors and flue gases ar...

Page 18: ...gths Capacity Min Vent Length 045 070 090 110 15 ft or 5 ft plus 2 elbows or 10 ft plus 1 elbow Any approved termination may be added to the minimum length listed Figure 24 045 070 090 110 Standard or Concentric See Table 3 Intake or Exhaust 2 2 1 2 or 3 Furnace capacity 1 Which termination 2 Which needs most elbows 3 How many 4 Desired pipe size 5 What is the altitude 6 Use Table 5 to find max pi...

Page 19: ...97 97 78 78 9 36 21 70 55 23 92 92 73 73 10 31 16 65 50 18 87 87 68 68 Standard Termination at Elevation 4 501 10 000 ft Number of 90 Elbows Used 2 Pipe 2 1 2 Pipe 3 Pipe Capacity Capacity Capacity 045 070 090 110 045 070 090 110 045 070 090 110 1 76 61 39 n a 110 95 63 38 132 132 113 113 2 71 56 34 105 90 58 33 127 127 108 108 3 66 51 29 100 85 53 28 122 122 103 103 4 61 46 24 95 80 48 23 117 117...

Page 20: ...24 81 81 74 74 9 28 13 60 45 19 76 76 69 69 10 23 8 55 40 14 71 71 64 64 Concentric Termination Elevation 4501 10 000 ft Number of 90 Elbows Used 2 Pipe 2 1 2 Pipe 3 Pipe Capacity Capacity Capacity 045 070 090 110 045 070 090 110 045 070 090 110 1 68 53 37 n a 100 85 59 34 116 116 109 109 2 63 48 32 95 80 54 29 111 111 104 104 3 58 43 27 90 75 49 24 106 106 99 99 4 53 38 22 85 70 44 19 101 101 94 ...

Page 21: ... 73 72 53 53 10 21 6 50 50 28 68 67 48 48 Standard Termination Elevation 4 501 10 000 ft Number of 90 Elbows Used 2 Pipe 2 1 2 Pipe 3 Pipe Capacity Capacity Capacity 045 070 090 110 045 070 090 110 045 070 090 110 1 66 51 29 n a 95 95 73 38 113 112 93 93 2 61 46 24 90 90 68 33 108 107 88 88 3 56 41 19 85 85 63 28 103 102 83 83 4 51 36 14 80 80 58 23 98 97 78 78 5 46 31 9 85 85 53 18 93 92 73 73 6 ...

Page 22: ...507768 02B Page 22 of 56 Issue 1904 Figure 25 Figure 26 ...

Page 23: ...wed Follow the next two steps when installing the unit in Direct Vent applications where combustion air is taken from outdoors and flue gases are discharged outdoors The provided air intake screen must not be used in direct vent applications outdoors 1 Use transition solvent cement or a sheet metal screw to secure the intake pipe to the inlet air connector 2 Route piping to outside of structure Co...

Page 24: ...ength must not exceed those listed in Table 5C If 3 diameter pipe is used reduce to 2 diameter pipe at the termination point to accommodate the debris screen 3 Use a sheet metal screw to secure the intake pipe to the connector if desired If this unit is being installed in an application with combustion air coming in from a space serviced by an exhaust fan power exhaust fan or other device which ma...

Page 25: ...tion care must be taken to maintain protective coatings over building materials prolonged exposure to exhaust condensate can destroy protective coatings It is recommended that the exhaust outlet not be located within 6 feet 1 8 m of a condensing unit because the condensate can damage the painted coating NOTE See Table 6 for maximum allowed exhaust pipe length without insulation in unconditioned sp...

Page 26: ... 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 Centrotherm NOTE Maximum uninsulated vent lengths listed may include the termination vent pipe exterior to the structure and cannot exceed 5 linear feet or the maximum allowable intake or exhaust vent length list...

Page 27: ... Clearance under veranda 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 fe...

Page 28: ...ches 152mm for appliances 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 N...

Page 29: ...re Figure 38 2 Intake and exhaust pipes should be placed as close together as possible at termination end refer to illustrations Minimum separation is 3 76 mm on roof terminations and 6 152 mm on sidewall terminations 3 On roof terminations the intake piping should terminate straight down using two 90 elbows see Figure 36 4 Exhaust piping must terminate straight out or up as shown A reducer may be...

Page 30: ...rance above 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 ...

Page 31: ...piping may be equipped with a 90 elbow turndown Using turndown will add 5 feet 1 5 m to the equivalent length of the pipe 8 A multiple furnace installation may use a group of up to four terminations assembled together horizontally as shown in Figure 41 Figure 40 Figure 41 Figure 42 Figure 43 Figure 44 Direct Vent Application Using Existing Chimney 3 8 76MM 203MM STRAIGHT CUT OR ANGLE CUT IN DIRECT...

Page 32: ... SNOW ACCUMULATION SIZE PER EXHAUST PIPE TERMINATION SIZE REDUCTION TABLE Figure 46 Non Direct Vent Field Supplied Wall Termination SIZE TERMINATION PER EXHAUST PIPE TERMINATION SIZE REDUCTION TABLE 3 If exhaust piping must be run up a sidewall to position above snow accumulation or other obstructions piping must be supported every 24 610 mm as shown in Figure 47 When exhaust piping must be run up...

Page 33: ...Termination Drain Trap assembled Figure 49 Kit 51W18 USA 15Z70 Canada Parts Identification and Assembly Exhaust from Furnace To Termination Exhaust from Furnace To Termination Kit 51W18 is shown Figure 50 Crawl Space Vent Pipe Drain Trap Assembled Incorrectly Figure 51 Upflow or Downflow Furnace with Exhaust through Crawl Space KIT 51W18 USA Basement Floor To Termination 1 2 PVC to Code Approved D...

Page 34: ...ee Figure 57 and Figure 58 Upflow furnace Figure 53 In upflow furnace applications the field provided vent must be a minimum 1 to a maximum 2 length above the condensate drain outlet connection Any length above 2 may result in a flooded heat exchanger if the combined primary drain line were to become restricted Horizontal furnace Figure 55 In horizontal furnace applications the field provided vent...

Page 35: ...ing from furnace must slope down a minimum of 1 4 per ft toward trap Figure 54 Condensate Trap with Optional Overflow Switch 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 WARNING ...

Page 36: ...ce must slope down a minimum of 1 4 per ft toward trap Figure 56 Unit with Cooling Coil Using Separate Drain Figure 57 Evaporator Coil Using a Common Drain Figure 58 Evaporator Coil Using a Common Drain Piping from furnace and evaporator coil must slope down a minimum 1 4 per ft toward trap ...

Page 37: ...507768 02B Page 37 of 56 Issue 1904 Figure 59 Trap Drain Assembly Using 1 2 PVC or 3 4 PVC ...

Page 38: ...sing 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 60 6 In some localities codes may require installation of a manual main shut off valve and union furnished by installer external to the unit Union must be of the g...

Page 39: ...507768 02B Page 39 of 56 Issue 1904 Figure 61 Gas Piping Upflow Applications Figure 62 Gas Piping Horizontal Applications ...

Page 40: ...0 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 18 41 620 17 56 2 50 8 2 067 52 502 3950 111 85 2750 77 87 2200 62 30 1900 53 80 1680 47 57 1520 43 04 1400 39 64 1300 36 81 1220 34 55 1150 32 56 2 1 2 63 5 2 469 67 713 6300 178 39 4350 123 17 3520 99 67 3000 84 95 2650 75 04 2400...

Page 41: ...tat check to make sure the wires will be long enough for servicing at a later date Make sure that thermostat wire is long enough to facilitate future removal of blower for service Complete the wiring connections to the equipment Use the provided unit wiring diagram and the field wiring diagram shown in Figure 66 Use 18 gauge wire or larger that is suitable for Class II rating for thermostat connec...

Page 42: ... the fan speed when there is no cooling or heating demand 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 run on the cooling speed Generator Use Voltage Requirements The furnace requires 120 volts 10 Range 108 volts to 132 volts The furnace operates at 60 Hz 5 Range 57 Hz to 63 Hz The furnace ...

Page 43: ...507768 02B Page 43 of 56 Issue 1904 Figure 67 Typical Wiring Diagram ...

Page 44: ...or 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 e...

Page 45: ...s supplier s instructions If you do not smell gas go to next step 8 Move gas valve switch to ON See Figure 69 9 Replace the upper 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 Turni...

Page 46: ...an result in permanent damage to gas valve or overfire On multiple unit installations each unit should be checked separately with and without other units operating Supply pressure must fall within range listed in Table 11 Manifold Pressure Measurement 1 Remove the threaded plug from the outlet side of the gas valve and install a field provided barbed fitting Connect to a manometer to measure manif...

Page 47: ...set and require no adjustment Table 12 Burner Orifice Conversion Kits at Varying Altitudes Capacity 0 7 500 ft 0 2 286m 7 501 10 000 ft 2 286 3 048 m Natural to LP Propane LP Propane to Natural High Altitude Natural Burner Orifice Kit High Altitude LP Propane Burner Orifice Kit 045 11K50 73W80 51W01 11K45 070 090 110 Conversion requires installation of a gas valve regulator spring which is provide...

Page 48: ... 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 49: ...e Figure 70 Figure 70 Constant Torque Motor These units are equipped with a constant torque ECM motor It has a DC motor coupled to an electronic control 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...

Page 50: ...25 75 0 10 1445 335 1275 230 1170 180 905 94 860 80 0 20 1415 345 1240 240 1125 190 870 101 800 85 0 30 1380 355 1205 250 1090 200 830 109 760 95 0 40 1345 370 1175 265 1055 210 790 117 710 105 0 50 1315 385 1150 280 1020 220 735 129 665 115 0 60 1275 390 1110 290 985 230 685 137 625 125 0 70 1210 395 1075 300 950 240 640 146 565 130 0 80 N A N A 1030 305 915 250 595 148 535 135 BG961UH090CE16 Per...

Page 51: ...460 1750 345 1660 285 1430 195 0 10 2185 680 1925 460 1750 345 1625 285 1440 200 2155 705 1885 480 1720 360 1610 295 1415 205 0 20 2150 705 1880 480 1710 365 1590 300 1390 220 2130 725 1855 495 1685 380 1565 305 1380 220 0 30 2110 720 1850 495 1680 380 1560 320 1350 230 2085 745 1825 510 1655 390 1535 325 1335 230 0 40 2080 735 1810 520 1650 405 1515 330 1310 245 2060 760 1795 530 1625 405 1495 34...

Page 52: ...y to empty condensate water 3 Remove the clean out cap from the condensate trap and empty water Inspect the trap then reinstall the clean out cap Cleaning Heat Exchanger If cleaning the heat exchanger becomes necessary follow the below procedures and refer to Figure 1 when disassembling unit Use papers or protective covering in front of furnace while removing heat exchanger assembly 1 Turn off ele...

Page 53: ... the 2 pin plug to the wire harness 38 Reconnect drain tubes between flue collar and cold end header box 39 Secure burner assembly to vestibule panel using four existing screws Burners are self aligning to center of clam shells 40 Reconnect gas supply line to gas valve 41 Reconnect flame rollout switch wires 42 Reconnect sensor wire and reconnect 2 pin plug from ignitor 43 Reconnect wires to gas v...

Page 54: ...ovide a seal between the return air and the room where the furnace is installed Return air duct Must be properly attached and provide an air seal to the unit Operating performance Unit must be observed during operation to monitor proper performance of the unit and the vent system Combustion gases Flue products must be analyzed and compared to the unit specifications Problems detected during the in...

Page 55: ...rner operation 1 Flash Reverse line voltage polarity 2 Flashes Improper earth ground 3 Flashes Burner failed to light or lost flame during heat demand 4 Flashes Low flame signal check flame sensor 5 Flashes Watchguard burner failed to light exceeded maximum number of retries or recycles 6 Flashes Not used 7 Flashes Primary or Secondary limit open or watchguard mode limit switch open longer than 3 ...

Page 56: ...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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