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
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