Installation, Operation & Maintenance Manual
Bosch 96% AFUE Gas Furnace
| 3
Bosch Thermotechnology Corp.
|
04.2019
Data subject to change
Table of Contents
1 Key to Symbols and Safety Instructions
4
1.2 Safety
4
2 Dimensions
7
3 Introduction
8
4 Codes and Standards
9
4.1 Safety
9
4.2 General Installation
9
4.3 Combustion and Ventilation Air
10
4.4 Duct Systems
10
4.5 Acoustical Lining and Fibrous Glass Duct
10
4.6 Gas Piping and Gas Pipe Pressure Testing
10
4.7 Electrical Connections
10
4.8 Electrical Power Supply
10
4.9 Venting
10
5 Electrostatic Discharge (ESD) Precautions Procedure
10
6 Location
11
6.1 General
11
7 Installation
13
7.1 Upfl ow Installation
13
7.2 Horizontal Installation
14
7.3 Condensate Line and Over Flow Pressure Switch
17
7.4 Filter Arrangement
22
7.5 Air Ducts
23
8 Combustion Air and Vent System
26
8.1 Combustion Air and Vent Safety
26
8.2 Combustion Air/Vent Pipe Sizing
26
8.3 Comnustion Air And Vent Piping Assembly
28
8.4 Combustion Air / Venting
29
8.5 Vent System
30
8.6 Combustion & Ventilation Air Requirements
31
8.7 Vent and Supply (Outside) Air Safety Check Procedure
34
9 Gas Supply and Piping
35
9.1 General
35
9.2 High Altitude Derate
36
9.3 Propane Gas (LP) Conversion
37
9.4 Gas Piping Connections
37
9.5 Gas Piping Checks
38
10 Electrical Connections
39
10.1 115V Wiring
39
10.2 Electrical Connection to J-box
40
10.3 Power Cord Installation in Furnace J-box
40
10.4 BX Cable Installation in Furnace J-box
40
10.5 24-V Wiring
40
10.6 Accessories (Field Supplied)
40
10.7 Grounding
40
11 Start-Up, Adjustment, and Safety Check
43
11.1 General
43
11.2 Start-Up Procedures
43
11.3 Furnace Start-Up
43
11.4 Sequence of Operation
44
44
11.5 Gas Manifold Pressure Measurement and Adjustment
45
11.6 Gas Input Rate Measurement (Natural Gas Only)
46
11.7 Temperature Rise Adjustment
46
11.8 Circulator Blower Speed Adjustment
47
12 Operational Checks
48
13 Safety Circuit Description
48
13.1 General
48
13.2 Integrated Control Module
48
13.3 Chamber Limit Switch - Fixed
48
13.4 Fan Mounted Limit Switch
48
13.5 Rollout Switch - Resettable
48
13.6 Overfl ow Protection Pressure Switch (Overfl ow Switch)
48
13.7 Pressure Switches
48
13.8 Flame Sensor
48
14 Troubleshooting
49
14.1 Electrostatic Discharge (ESD) Precautions
49
14.2 Resetting From Lockout
49
14.3 Troubleshooting Chart
49
15 Service and Maintenance Procedures
52
15.1 Annual Inspection
52
15.2 Filters
52
15.3 Induced Draft And Circulating Blower Motors
52
15.4 Flame Sensor (Qualifi ed Service Technicians Only)
52
15.5 Ignitor (Qualifi ed Service Technicians Only)
53
15.6 Burners
53
15.7 Inspecting the Heat Exchanger (Qualifi ed Service Technicians Only)
53
15.8 Condensate Drain
53
15.9 Repair and Replacement Parts
53
16 Before Leaving Installation
53
17 Wiring Diagram
55
