Bosch BGH96 Series Installation, Operation And Maintenance Manual Download Page 42

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Bosch 96% AFUE Gas Furnace

Installation, Operation & Maintenance

04.2019

Bosch Thermotechnology Corp.

Data subject to change

Figure 35

Fault LED

Last error button

Thermostat connections

Fuse

Unused blower terminal

Blower connections

EAC

Blower power input

Unit power input
(115V/60HZ)
Transformer

Humidifier

Neutral terminals

Furnace Control

Figure 36

115V FIELD-

SUPPLIED

DISCONNECT

J-BOX

24V

TERMINAL

BLOCK

FOUR-WIRE

HEATING-ONLY

NOTE 1

NOTE 2

FIELD-SUPPLIED
DISCONNECT

CONDENSING
UNIT

THREE

WIRE

FURNACE

C
O
N

R
O

GND

FIELD 24V WIRING
FIELD 115V, 208/230V, WIRING
FACTORY 24V WIRING
FACTORY 115V WIRING

208/230V

THREE
PHASE

208/230V
SINGLE
PHASE

BLOWER DOOR
SWITCH

WHT

BLK

WHT

BLK

NOTES:

Connect Y1, Y / Y 2 -terminal in furnace as shown for proper blower operation.
Some thermostats require a "C" terminal connection as shown.

If any of the original w ire, as supplied, must be replaced, use
same type or equivalent wire.

GND

(two stage cooling system thermostat)

TERMINALS

1.
2.

Y/Y2

W/W1

NOTE 3

Y1 connect two-stage cooling thermostat Y1(first stage cool) terminal.

Y/Y2 connect two-stage cooling thermostat Y2(second stage cool)
terminal.

Y/Y2 connect single stage cooling system thermostat Y terminal.

NOTE 4

NOTE 5

Please connect W/W1 with single stage heat system thermostat terminal
W,and W2 reserved.

Heating and Cooling Application Wiring Diagram with 2-Stage Thermostat

Summary of Contents for BGH96 Series

Page 1: ...Bosch 96 AFUE Gas Furnace BGH96 Model Condensing Gas Furnace Installation Operation and Maintenance Manual 3124627 ...

Page 2: ...2 Bosch 96 AFUE Gas Furnace Installation Operation Maintenance 04 2019 Bosch Thermotechnology Corp Data subject to change ...

Page 3: ...al 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 ...

Page 4: ...e User s Information Manual for more information SERVICER Use the information in this booklet to service the appliance and aﬃx the booklet adjacent to the appliance after servicing WARNING FIRE OR EXPLOSION HAZARD Do not store or use gasoline or other flammable vapors and liquids 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 tou...

Page 5: ...terminating outside the space containing the furnace See Section 7 5 Air Ducts A gas fired furnace for installation in a residential garage must be installed as specified in the warning box in Section 6 Location 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 WARNING FIRE ...

Page 6: ...not try to light the burner by hand BEFORE OPERATING smell all around the appliance area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle to the floor WARNING A C D B 1 STOP Read the safety information above on this label 2 Set the thermostat to lowest setting 3 Turn off all electric power to the appliance 4 This appliance is equipped with an ignition...

Page 7: ...bustion Air Inlet Gas Pipe Entry Electrical Entry Condensate Drain Thermostat Wiring 24 610mm 26 1 2 672mm 25 3 4 655mm Combustion Air Inlet Vent Outlet Dimensions FurnaceModel A Cabinet Width In mm D Supply Air Width In mm E Return Air Width In mm Shipping Weight lbs kgs BGH96M060B3A 17 5 445 16 406 15 27 32 402 162 5 73 7 BGH96M080B3A 17 5 445 16 406 15 27 32 402 168 5 76 4 BGH96M080C4A 21 533 1...

Page 8: ... to venting In the US this furnace is for use with schedule 40 PVC PVC DWV CPVC or ABS DWV pipe and must not be vented in common with other gas ﬁred appliances For installations in Canada refer to Section 8 5 Vent System of this manual Construction through which vent air intake pipes may be installed is maximum 24 inches 610 mm minimum 3 4 inches 19 mm thickness including rooﬁng materials Remove a...

Page 9: ...nage See Section 7 Installation of this manual for more information Figure 4 1 2 3 4 1 2 3 4 4 Codes and Standards Follow all national and local codes and standards in addition to these instructions The installation must comply with regulations of the serving gas supplier local building heating plumbing and other codes In absence of local codes the installation must comply with the national codes ...

Page 10: ...cedure listed below during furnace installation and servicing to protect the furnace electronic control Precautions will prevent electrostatic discharges from personnel and hand tools which are held during the procedure These precautions will help to avoid exposing the control board to electrostatic discharge by putting the furnace the control board and the person at the same electrostatic potenti...

Page 11: ...failure of parts containing flue gas which could leak into the living space Air for combustion must not be contaminated by halogen compounds which include fluoride chloride bromide and iodide These elements can corrode heat exchangers and shorten furnace life Air contaminants are found in aerosol sprays detergents bleaches cleaning solvents salts air fresheners and other household products Do not ...

Page 12: ...r causing a flame rollout and or drawing combustion products into the structure The furnace is controlled by a thermostat It may not be hot wired to provide heat continuously to the structure without thermostatic control Clean outside air is provided for combustion This is to minimize the corrosive effects of adhesives sealers and other construction materials It also prevents the entrainment of dr...

Page 13: ...nel Figure 7 BOTTOM CLOSURE PANEL BOTTOM FILLER PANEL SCREW SCREW Removing bottom closure panel Figure 8 Upflow 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 W E I V E D I S W E I V T N O R F Upflow Application Setting Equipment Side return air inlet These furnaces are shipped with bottom clos...

Page 14: ...r crawl space on bottom or either the left hand LH or right hand RH side See Figure 9 The furnace can be hung from ﬂoor joists rafters or trusses or installed on a non combustible platform blocks bricks or pad 7 2 1 Furnace Suspension If suspending the furnace from rafters or joists use 3 8 threaded rod and 2 x2 x1 8 angle iron as shown in Figure 10 The length of rod will depend on the application...

Page 15: ...o it is recommended to add foam insulation around the drain line and heat tracing may also be necessary based on the application Leveling Leveling ensures proper condensate drainage from the heat exchanger and induced draft blower For proper ﬂue pipe drainage the furnace must be level lengthwise from end to end The furnace should also have a slight tilt with the access doors downhill minimum 1 2 1...

Page 16: ...AL ASSURE FURNACE IS LEVEL FROM END TO END AND HAS A SLIGHT FORWARD TILT WITH THE FRONT OF THE FURNACE 3 4 BELOW THE BACK OF THE FURNACE TILT OUTWARD TO ALLOW FOR DOOR AND CIRCULATOR BLOWER REMOVAL HOLD DOWN NUTS Horizontal Installation Figure 11 FURNACE MUST BE LEVEL FROM END TO END FURNACE MUST BE SLIGHTLY TILTED FORWARD WITH THE DOORS 1 2 3 4 BELOW THE BACK PANEL 7 MINIMUM DRAIN TRAP CLEARANCE ...

Page 17: ...rd slope toward the drain Do not trap the drain line in any other location than at the drain trap supplied with the furnace Do not route the drain line outside where it may freeze 7 3 1 Standard Right Hand or Left Hand Side Drain Hose Connections Figure 12 DRAIN TRAP MOUNTING BRACKET Ф16 mm HOSE Ф14 mm HOSE Optional Ф14 mm ELBOW Optional Ф16 mm ELBOW DRAIN TRAP Ф21 mm HOSE CLAMPS Ф18 mm HOSE CLAMP...

Page 18: ...mounted remove 2 caps on the side where trap is mounted Mount trap with manufacturer provided screws 4 Remove cap from the inducer drain port see Fig 13 Figure 13 5 Connect Φ16 mm hose between condensate collector box and drain trap and connect Φ14 mm hose between inducer drain port and drain trap see Fig 14 6 Cut the excess hoses as needed 7 Secure and tighten all hoses using manufacturer provide...

Page 19: ...ct the vent outlet pipe Use ﬁled supplied straight 2 diameter pipe If 3 diameter pipes are used use a ﬁeld supplied transition 6 Use provided or ﬁeld supplied if applicable mounting bracket to mount drain trap to the proper location on right side panel 7 Screws for mounting bracket should not interfere with any components inside the furnace 8 Cut and remove 1 4 from the end of the inducer drain po...

Page 20: ...eld supplied elbow and metal hose clamp to make ﬂue vertical Elbows should be as close to the furnace as possible Connect the vent outlet pipe 6 Use provided or ﬁeld supplied if applicable mounting bracket to mount condensate trap on the proper location of the left side panel Figure 16 VENT OUTLET AIR INLET HOSE CLAMP HOSE CLAMP Φ16 mm HOSE DRAIN TRAP DRAIN TRAP MOUNTING BRACKET 14mm HOSE HIGH LOW...

Page 21: ... have only one port Make sure that black port positive is connected to the lower position tap on condensate collector box and gray port negative to higher tap of condensate box Connecting incorrectly will result in failure to protect condensate overflow See Fig 19 Figure 18 Condensate Collector Box B A _ Upﬂow Horizontal Right side A to P1 black port B to P2 grey port Horizontal Le side A to P2 gr...

Page 22: ...NOTICE If disposable ﬁlters are used air passage through ﬁlters should be increased to twice the size of original air opening by using a transition duct or using two ﬁlters in V shape see Fig 19 in normal duct size Figure 19 Furnacecabinetwidth Filter size Filter type Side return Bottom return 17 1 2 16X25 16X25 High Velocity 600 FPM 21 16X25 20X25 High Velocity 600 FPM 24 5 16X25 24X25 High Veloc...

Page 23: ...earance betweem combustible materials and the supply air ductwork for a distance of 36 inch horizontally from the furnace See NFPA 90B or local code for further requirements Ductwork acoustical treatment Metal duct systems that do not have a 90 degree elbow and 10 ft of main duct to the ﬁrst branch take oﬀ may require internal acoustical lining As an alternative ﬁbrous duct work may be used if con...

Page 24: ...46 9 48 9 51 5 54 2 Temp Rise 2nd stage 56 6 58 4 60 2 62 3 64 Mid CFM 1044 1002 968 931 886 841 805 767 718 677 Temp Rise 1st stage 40 8 43 4 45 8 50 5 50 9 54 0 57 6 60 8 64 4 Temp Rise 2nd stage Mid L CFM 825 790 743 698 649 608 457 527 491 463 Temp Rise 1st stage 50 5 53 7 58 4 62 9 Temp Rise 2nd stage Low CFM 786 720 645 598 539 503 436 385 348 302 Temp Rise 1st stage 56 8 62 2 Temp Rise 2nd ...

Page 25: ...711 1657 1609 1560 1506 1453 1402 1350 Temp Rise 1st stage 35 8 36 9 38 2 39 6 41 0 42 6 Temp Rise 2nd stage 48 8 50 3 51 8 53 4 55 0 56 8 58 8 60 9 63 1 Mid L CFM 1487 1417 1360 1296 1241 1183 1123 1064 1005 941 Temp Rise 1st stage 38 7 40 6 42 3 44 4 46 4 48 7 51 3 54 1 57 2 61 1 Temp Rise 2nd stage 59 5 62 5 Low CFM 1122 1036 977 889 802 731 646 586 532 485 Temp Rise 1st stage 55 6 58 9 64 7 Te...

Page 26: ... furnace model the total length of pipe required and the number of elbows required Table 5 Maximum Equivalent Pipe Length lists the maximum equivalent length of pipe allowed for each model of furnace The equivalent length of elbows is shown in Table 7 Equivalent Length of Fittings The equivalent length of the vent system is the total length of straight pipe PLUS the equivalent length of all of the...

Page 27: ...ndard elbow 10 feet of 3 pipe 3 45º standard elbow 5 feet of 3 pipe 2 corrugated connector 10 feet of 2 pipe 3 corrugated connector 10 feet of 3 pipe Table 7 Equivalent Length of Fittings Example An 80 000 BTUH furnace requires 32 feet of pipe and four 90º elbows Using 2 pipe and standard elbows t he total equivalent length will be 32 feet of 2 pipe 32 equivalent feet 4 90º standard 2 elbows 4x10 ...

Page 28: ...rmination b Ventilated combustion air systems from the furnace to the attic or crawl space termination CAUTION Solvent cements are flammable and must be used in well ventilated areas only Keep them away from heat sparks and open flames Do not breathe vapors and avoid contact with skin and eyes 6 Disassemble the combustion air and vent piping apply cement primer and the cement per the manufacturer ...

Page 29: ...r in accordance with local installation codes and the requirements of the gas supplier J Clearance to nonmechanical air supply inlet to building or the combustion air inlet to any other appliance 12 30 5 cm for models 100 000 BTUH 30 kW 36 91 4 cm for models 100 000 BTUH 30 kW Two pipe direct vent applications 9 23 cm for models 50 000 BTUH 15 kW 12 30 5 cm for models 50 000 BTUH 15 kW Single pipe...

Page 30: ... combustion air pipes terminate in the same atmospheric zone Refer to Figures 25 or 26 Figure 24 12 Min 12 Min Exhaust Exhaust Maintain 12 minimum clearance above highest anticipated snow level Maximum 24 above roof Termination Configuration 1 Pipe No Figure 25 Maintain 12 minimum clearance above highest anticipated snow level 12 vertical separation between combustion air intake and vent 12 minimu...

Page 31: ...to Figure 31 for attic and crawl space termination Only the combustion air intake may terminate in the attic The vent must terminate outside 8 6 2 Outdoor Combustion Air Combustion Air Intake Vent Connections This installation requires combustion air to be brought in from outdoors This requires a properly sized pipe shown in Figure 29 that will bring air in from the outdoors to the furnace combust...

Page 32: ...dditional air may need to be provided using the methods described in A conﬁned space section A confined space is an area with less than 50 cu ft 1 42m3 per 1 000 Btu hr 0 2928 kW input rating for all of the appliances installed in that area The following must be considered to obtain proper air for combustion and ventilation in conﬁned spaces Equipment Located in Confined Spaces a All air from insi...

Page 33: ...he bottom of the conﬁned space shall communicate directly or by means of ducts with the outdoors crawl spaces or attic spaces 2 One permanent opening commencing within 12 in 305 mm of the top of the enclosure shall be permitted where the equipment has clearances of at least 1 in 25 4 mm from the sides and back and 6 in 152 4 mm from the front of the appliance The opening shall communicate directly...

Page 34: ...placed into operation while all other appliances connected to the venting system are not in operation 1 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 2 Close all building doors and windows and all doors 3 Turn on clothes dryers and TURN ON any exhaust fans ...

Page 35: ... and gas types The furnace must be equipped to operate on the type of gas applied This includes any conversion kits required for alternate fuels and or high altitude Inlet gas supply pressures must be maintained within the ranges speciﬁed in Table 13 The supply pressure must be constant and available with all other household gas ﬁred appliances operating The minimum gas supply pressure must be mai...

Page 36: ...1 and information provided by the gas supplier to determine the proper oriﬁce size US installation InputRate KBTU H Number of burners Elevation Ft Elevation Ft Elevation Ft Elevation Ft Elevation Ft 0 2000 2000 4000 4000 6000 6000 8000 8000 10000 NG LP NG LP NG LP NG LP NG LP 60 3 45 55 47 56 48 57 49 58 50 59 80 4 45 55 47 56 48 57 49 58 50 59 100 5 45 55 47 56 48 57 49 58 50 59 120 6 45 55 47 56...

Page 37: ...eration or equipment damage due to underﬁring of equipment use the proper size of natural propane gas piping needed when running pipe from the meter tank to the furnace When sizing a trunk line be sure to include all appliances which will operate simultaneously see Table 16 The gas piping supplying the furnace must be properly sized based on the gas ﬂow required speciﬁc gravity of the gas and leng...

Page 38: ...the furnace the installer must supply the following ﬁttings starting from the gas valve 90 degree elbows 2 Close nipple Straight pipe to reach the exterior of the furnace 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 to another pipe size When the gas piping enters through ...

Page 39: ...y utility is suﬃcient to handle load imposed by this equipment Refer to rating plate or Table 17 page 41 for equipment electrical speciﬁcations Make all electrical connections in accordance with National Electrical Code NEC ANSI NFPA 70 latest edition and any local codes or ordinances that might apply WARNING FIRE HAZARD Do not connect aluminum wire between disconnect switch and furnace Use only c...

Page 40: ...lation Connect line voltage leads as shown in Fig 36 Use best practices NEC in U S for wire bushings strain relief etc 13 Reinstall cover to J Box Do not pinch wires between cover and bracket 10 3 Power Cord Installation in Furnace J box Power cords must be able to handle the electrical requirements listed in Table 16 Refer to power cord manufacturer s listings 1 Remove cover from J Box 2 Route li...

Page 41: ...106 5 31 2 2000 10 5 95 40 70 22 39 20 14 170 77 Table 17 Ratings Physical Electrical Data Annual Fuel Utilization Eﬃciency AFUE numbers are determined in accordance with DOE Test procedures National Electrical Code NFPA 70 latest edition and all local codes The furnace shall be installed so that the electrical components are protected from water Optional Switch Positions DIP Switch SW NOMINAL MIN...

Page 42: ...ORY 115V WIRING 208 230V THREE PHASE 208 230V SINGLE PHASE BLOWER DOOR SWITCH WHT BLK WHT BLK NOTES ConnectY1 Y Y2 terminal in furnace as shown for proper blower operation Some thermostats require a C terminal connection as shown If any of the original w ire as supplied must be replaced use same type or equivalent wire GND two stage cooling system thermostat TERMINALS 1 2 3 R G Y Y2 C Y1 W1 W W1 Y...

Page 43: ...his furnace is also equipped with a self diagnosing electronic control module In the event a furnace component is not operating properly the control module LED will ﬂash on and oﬀ in a factory programmed sequence depending on the problem encountered This light can be viewed through the observation window in the blower access panel Refer to the Troubleshooting Chart on pages 50 51 for further expla...

Page 44: ...to the retry sequence The retry sequence provides a 60 second wait with the inducer interpurge following an unsuccessful ignition attempt ﬂame not detected After this wait the ignition attempt is restarted Two retries will be attempted before the control goes into system lockout If ﬂame is established for more than 10 seconds after ignition the controller will clear the ignition attempt or retry c...

Page 45: ...r to the outlet pressure barb ﬁtting of valve to overlap at least 3 8 4 Turn ON system power and set thermostat to a call for heat 5 Using a leak detection solution or non chlorine soap suds check for leaks at hose connection Bubbles forming indicate a leak SHUT OFF GAS AND FIX ALL LEAKS IMMEDIATELY 6 Remove burner access panel 7 Remove regulator screw cover Turn regulator screw either clockwise t...

Page 46: ...t indicated on the unit rating plate 5 Turn ON gas and relight appliances turned oﬀ in step 1 Ensure all the appliances are functioning properly and that all pilot burners are operating 11 7 Temperature Rise Adjustment Air temperature rise is the temperature diﬀerence between supply and return air The proper amount of temperature rise is usually obtained when the unit is operated at the rated inpu...

Page 47: ...GH96M080B3A Mid H 4 Mid 3 High 5 Mid 3 BGH96M080C4A Mid H 4 Mid 3 High 5 Mid 3 BGH96M100C5A Mid 3 Mid L 2 Mid H 4 Mid L 2 BGH96M100D5A Mid 3 Mid L 2 Mid 3 Mid L 2 BGH96M120D5A Mid H 4 Mid 3 Mid H 4 Mid 3 Table 24 Blower Speed Factory Settings To adjust the circulator blower speed proceed as follows 1 Turn OFF power to the furnace 2 Select the heating and cooling blower speeds that match the instal...

Page 48: ...t Switch The fan mounted limit switches are located beside the blower housing They are temperature sensors which are automatically reset They are used to prevent overheating by hot air when the furnace is installed horizontally 13 5 Rollout Switch Resettable The rollout switch resettable controls are mounted on the burner manifold assembly and monitor the burner ﬂame They are manual reset temperat...

Page 49: ...rol or wires 4 Discharge your body to ground before removing a new control from its container Follow steps 1 through 3 if installing the control on a furnace Return any old or new controls to their containers before touching any ungrounded object 14 2 Resetting From Lockout Furnace lockout results when a furnace is unable to achieve ignition after three attempts It is characterized by a non functi...

Page 50: ...ressure switch open with inducer on Pressure switch cycle lockout High fire pressure switch open with high inducer on Pressure switch hose blocked pinched or connected improperly blocked flue or weak induced draft blower Incorrect pressure switch setpoint or malfunctioning switch contacts Loose or improperly connected wiring 1 Inspect pressure switch hose Repair if necessary Inspect ﬂue for blocka...

Page 51: ...fails to operate 10 FLASH Gas valve fault code Valve receives voltage from a short Control module failure 1 Correct the wire connection 2 Replace control module Turn power OFF prior to repair Furnace fails to operate SOLID Control failure Control module failure 1 Replace control module Turn power OFF prior to repair AMBER Normal Operation 1 FLASH Call for heat active Normal Operation 4 FLASH Y the...

Page 52: ...installer must supply ﬁlter s at the time of installation Filter maintenance Improper ﬁlter maintenance is the most common cause of inadequate heating or cooling performance Clean permanent ﬁlter or replace disposable ﬁlter once a month or more frequently as required When replacing a ﬁlter it must be replaced with a ﬁlter of the same type and size Become familiar with ﬁlter location and procedures...

Page 53: ...fied contractor installer or service agency can clean the burners 15 7 Inspecting the Heat Exchanger Qualified Service Technicians Only NOTICE If the heat exchangers get a heavy accumulation of soot and carbon they must be replaced rather than cleaning them A heavy build up of soot and carbon indicates that a problem exists which needs to be corrected such as improper adjustment of manifold pressu...

Page 54: ...Vent 2 Flame Sensor 3 Chamber Limit Switch Fixed 4 Condensate Overﬂow Switch 5 Inducer 6 Door Switch 7 Integrated Control Module 8 Blower 9 Transformer 10 Condensate Trap 11 Juction Box Please contact your local installer or dealer for replacement parts 12 Condensate Collector 13 Pressure Switch 14 Two Stage Gas Valve 15 Hot Surface Ignitor 16 Gas Manifold 17 Air Inlet 18 Burner 19 Rollout Limit S...

Page 55: ...LQ DFWRU 7HVW PRGH 05 05 1 1 09 09 09 09 1 1 36 36 09 09 36 36 72 72 0 52 0 52 05 05 3 3 1 1 1 1 1 1 225 225 6 7 6 7 81 7 21 2 81 7 21 2 1 1 1 6 211 7 6 211 7 1 1 1 1 5 1 5 1 1 1 1 1 1 1 1 1 05 1 05 1 86 86 80 5 80 5 17 5 7 17 5 7 21752 02 8 21752 02 8 6 6 9 9 9 9 67 67 35 6685 6 7 67 67 35 6685 6 7 35 0 5 0 7 35 0 5 0 7 21752 21752 52 287 0 7 52 287 0 7 21752 6 21752 6 9 9 75 16 250 5 75 16 250 5...

Page 56: ...United States and Canada Bosch Thermotechnology Corp 65 Grove Street Watertown MA 02472 Tel 866 642 3198 Fax 603 965 7581 www boschheatingandcooling com BTC 770503101 B 04 2019 ...

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