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Installation Instructions
Bosch 96% AFUE Condensing Gas Furnace - BTC 770503101 J (06.2023)
Table of Contents
1 Key to Symbols and Safety Instructions 4
1.1 Key to Symbols 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 Upflow 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 Combustion 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
10.8 Thermostat Settings and Wiring 43
11 Start-Up, Adjustment, and Safety Check 46
11.1 General 46
11.2 Start-Up Procedures 46
11.3 Furnace Start-Up 46
11.4 Sequence of Operation 47
11.5 Gas Manifold Pressure Measurement and Adjustment 48
11.6 Gas Input Rate Measurement (Natural Gas Only) 49
11.7 Temperature Rise Adjustment 49
11.8 Circulator Blower Speed Adjustment 49
12 Operational Checks 51
13 Safety Circuit Description 51
13.1 General 51
13.2 Integrated Control Module 51
13.3 Chamber Limit Switch - Fixed 51
13.4 Fan Mounted Limit Switch 51
13.5 Rollout Switch - Resettable 51
13.6 Overflow Protection Pressure Switch (Overflow Switch) 51
13.7 Pressure Switches 51
13.8 Flame Sensor 51
14 Troubleshooting 52
14.1 Electrostatic Discharge (ESD) Precautions 52
14.2 Resetting From Lockout 52
14.3 Troubleshooting Chart 52
15 Service and Maintenance Procedures 55
15.1 Annual Inspection 55
15.2 Filters 55
15.3 Induced Draft And Circulating Blower Motors 55
15.4 Flame Sensor (Qualified Service Technicians Only) 55
15.5 Ignitor (Qualified Service Technicians Only) 56
15.6 Burners 56
15.7 Inspecting the Heat Exchanger (Qualified Service Technicians Only) 56
15.8 Condensate Drain 56
15.9 Repair and Replacement Parts 56
16 Before Leaving Installation 56
17 Wiring Diagram 58
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