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Bryant 912S User Manual

Bryant 912S
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1
912S
SINGLE STAGE 4WAY MULTIPOISE
CONDENSING GAS FURNACE
Installation, Startup, Operating and
Service and Maintenance Instructions
NOTE: Read the entire instruction manual before starting the installation.
SECTIONS
SAFETY CONSIDERATIONS 3.........................
INTRODUCTION 4...................................
CODES AND STANDARDS 4...........................
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS 5...
ACCESSORIES 5.....................................
LOCATION 8........................................
AIR FOR COMBUSTION AND VENTILATION 9..........
CONDENSATE TRAP 13...............................
CONDENSATE DRAIN 17.............................
INSTALLATION 21...................................
AIR DUCTS 31.......................................
GAS PIPING 33......................................
ELECTRICAL CONNECTIONS 34.......................
VENTING 40........................................
STARTUP, ADJUSTMENT, AND SAFETY CHECK 64......
SERVICE AND MAINTENANCE PROCEDURES 73........
SEQUENCE OF OPERATION 81........................
PARTS REPLACEMENT GUIDE 85......................
CERTIFIED
Use of the AHRI Certified
TM
Mark indicates a
manufacturers participation in the program. For
verification of certification for individual products,
go to www.ahridirectory.org.
Portions of the text and tables are reprinted from current edition of
NFPA 54/ANSI Z223.1, with permission of National Fire
Protection Association, Quincy, MA 02269 and American Gas
Association, Washington DC 20001. This reprinted material is not
the complete and official position of the NFPA or ANSI on the
referenced subject, which is represented only by the standard in its
entirety.
TABLES
Loose Parts Bag 5.....................................
Minimum Clearances to Combustible Materials 5.............
Minimum Free Area Required 11.........................
Minimum Space Volumes 11.............................
Filter Size Information 24...............................
Opening Dimensions 26................................
Air Delivery CFM 32...................................
Maximum Capacity of Pipe 34...........................
Electrical Data 34......................................
Vent Termination Kit for Direct Vent (2Pipe) System 42.......
Hangar Spacing 46.....................................
CombustionAir Vent Pipe, Fitting & Cement Material.. 48.....
Maximum Allowable Exposed Vent Lengths Insulation 49......
Maximum Equivalent Vent Length 50......................
Deductions from Maximum Equivalent Vent Length 50........
Blower Off Delay Setup Switch 67........................
Altitude Derate Multiplier for U.S.A. 68....................
Gas Rate 70..........................................
Orifice Size and Manifold Pressure 71.....................
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Bryant 912S Specifications

General IconGeneral
Model912S
TypeGas Furnace
Blower TypeVariable Speed
StagesSingle-stage
Blower Motor TypeECM
Efficiency RatingHigh Efficiency
Heating Capacity40, 000 - 120, 000 BTU/h
Fuel TypeNatural Gas
AFUE96.0%
AFUE Rating96.0%
Warranty10-year parts limited warranty upon registration

Summary

Safety Considerations

Warning: Fire, Explosion, Electrical Shock, and Carbon Monoxide Poisoning Hazard

Hazards from improper installation, alteration, or use.

Warning: Fire Hazard

Hazards related to combustible solvents and primers.

Caution: Furnace Reliability Hazard

Potential for unit component damage due to installation/operation.

Caution: Cut Hazard

Hazards from sharp sheet metal edges during handling.

Caution: Safety Alert Symbol and Signal Words

Explanation of safety symbols and signal words.

Introduction

Codes and Standards

Electrostatic Discharge (ESD) Precautions Procedure

Caution: Furnace Reliability Hazard

Importance of ESD precautions to prevent component damage.

Accessories

Location

Caution: Personal Injury and/or Property Damage Hazard

Precautions for furnace use during construction.

Warning: Carbon Monoxide Poisoning / Component Damage Hazard

Hazards from corrosive or contaminated air.

Warning: Fire, Injury or Death Hazard

Hazards when installing furnace in a garage.

Air for Combustion and Ventilation

Warning: Fire Hazard

Hazards from improper return air connection or furnace orientation.

Caution: Furnace Corrosion Hazard

Preventing furnace damage from corrosive combustion air.

Warning: Carbon Monoxide Poisoning Hazard

Hazards from negative pressure conditions created by ventilation devices.

Standard Method

Known Air Infiltration Rate Method

Combination of Indoor and Outdoor Air

Condensate Trap

Condensate Trap – Upflow Orientation

Condensate trap installation for upflow orientation.

Condensate Trap – Downflow Orientation

Condensate trap relocation for downflow orientation.

Condensate Trap – Horizontal Orientation

Condensate trap relocation for horizontal orientations.

Notice: Horizontal Drain Trap Grommet

Grommet requirement for direct vent applications.

Condensate Drain Connection

Caution: Frozen and Burst Water Pipe Hazard

Preventing freezing of condensate drain lines.

Caution: Property Damage Hazard

Preventing property damage from plugged condensate drains.

Upflow/Downflow Orientation

Routing condensate drain for upflow/downflow.

For Right Side Condensate Drain

Steps for right side condensate drain connection.

For Left Side Condensate Drain Connection

Steps for left side condensate drain connection.

Installation

Notice: Cabinet Air Leakage

Cabinet air leakage specifications.

Upflow Installation

Pitching requirements for upflow installations.

Supply Air Connections

Connecting supply air ducts.

Return Air Connections

Warning: Fire Hazard

Hazards from improper return air connection.

Bottom Return Air Inlet

Connecting the bottom return air inlet.

Horizontal Installation

Notes for horizontal installation.

Warning: Fire, Explosion, and Carbon Monoxide Poisoning Hazard

Hazards from improper installation orientation.

Filter Arrangement

Warning: Fire, Carbon Monoxide and Poisoning Hazard

Hazards from operating furnace without a filter.

Filter and Return Duct Sizing

Sizing filters and return ductwork.

Air Ducts

Notice: Ductwork Standards

Importance of consulting local codes for ductwork.

General Requirements

General guidelines for duct system design and installation.

Return Duct Sizing

Sizing of return ductwork and filters.

Ductwork Acoustical Treatment

Methods for acoustical treatment of ductwork.

Gas Piping

Warning: Fire or Explosion Hazard

Hazards related to gas piping and purging.

Notice: Massachusetts Gas Piping Requirements

Specific gas piping requirements for Massachusetts.

Caution: Furnace Damage Hazard

Preventing furnace damage during gas pipe connection.

Gas Pipe Grommet

Sealing gas pipe openings for direct vent applications.

Electrical Connections

Warning: Electrical Shock, Fire or Explosion Hazard

Electrical safety warnings during installation and servicing.

Warning: Electrical Shock Hazard

Hazards related to blower door switch.

Warning: Electrical Shock and Fire Hazard

Requirements for proper electrical grounding.

J-Box Installation

Warning: Fire or Electrical Shock Hazard

Hazards related to field-mounted disconnect switches.

External Electrical Box on Furnace Casing

Mounting an external electrical box on the furnace casing.

BX Cable Installation in Furnace J-Box

24-V Wiring

Accessories

Venting

Note: Polypropylene Venting System Instructions

Note on polypropylene venting system installation.

Special Venting Requirements for Installations in Canada

Specific venting requirements for installations in Canada.

Warning: Carbon Monoxide Poisoning Hazard

Procedures to ensure safe venting operation for all appliances.

General

General considerations for furnace venting replacement.

Notice: Recommended Support for Vent Termination

Recommendations for supporting vent terminations.

Ventilated Combustion Air

Venting requirements for ventilated combustion air systems.

Non-Direct Vent / 1-Pipe System

Venting requirements for non-direct vent (1-pipe) systems.

Direct Vent / 2-Pipe System

Venting requirements for direct vent (2-pipe) systems.

Notice: Optional Configuration for Combustion Air Inlet Pipe

Optional configuration for combustion air inlet pipe.

Ventilated Combustion Air Systems

Venting requirements for ventilated combustion air.

Non-Direct Vent (1-pipe) System

Venting requirements for 1-pipe systems.

Termination Requirements for the Provinces of Alberta and Saskatchewan

Specific termination requirements for Alberta and Saskatchewan.

Size the Vent and Combustion Air Pipes

The Maximum Vent Length for the vent and combustion air pipe

Notice: Optional Configuration for Combustion Air Inlet Pipe

Optional configuration for combustion air inlet pipe.

Recommended Combustion Air Inlet Moisture Trap

Installing a moisture trap for the combustion air inlet pipe.

Notice: Additional Information for Polypropylene Venting Systems

Additional information for polypropylene venting systems.

Combustion Air and Vent Piping Insulation Guidelines

Configure the Furnace

Warning: Carbon Monoxide Poisoning Hazard

Hazards related to routing pipes through the blower compartment.

Near Furnace Vent Connections

Install the Vent and Combustion Air Pipes

Warning: Carbon Monoxide Poisoning Hazard

Hazards from improper pipe sealing in the blower compartment.

Warning: Carbon Monoxide Poisoning Hazard

Warning against using cement for polypropylene venting.

Notice: PVC/ABS DWV Vent Piping

Notice for PVC/ABS DWV vent piping installation.

Installing the Vent Termination

Roof Terminations

Installing vent terminations on a roof.

Concentric Vent

Installing concentric vent terminations.

Optional Installation of the Vent Pipe

Notice: Polypropylene Venting Systems

Note on polypropylene venting systems.

Installing the Vent Termination

Roof Terminations

Installing roof vent terminations.

Concentric Vent

Installing concentric vent terminations.

Sidewall Terminations

Installing sidewall vent terminations.

Concentric Vent

Installing sidewall concentric vent terminations.

2-Pipe and 1-Pipe Vent Termination

Notice: Recommended Support for Vent Terminations

Recommendations for supporting vent terminations.

Inducer Outlet Restrictor

Inside Corner Terminations

Inside Corner Terminations

Start-Up, Adjustment, and Safety Check

Notice: Important Installation and Start-up Procedures

Important procedures for installation and start-up.

Prime Condensate Trap with Water

Priming the condensate trap with water.

Warning: Carbon Monoxide Poisoning Hazard

Hazards of not priming the condensate trap.

Caution: Unit Operation Hazard

Importance of proper condensate trap priming for operation.

Caution: Unit Operation Hazard

Caution regarding the manual reset limit switch.

Purge Gas Lines

Procedure for purging gas lines.

Warning: Fire or Explosion Hazard

Hazards during gas line purging and leak testing.

Adjustments

Warning: Fire Hazard

Hazards related to gas valve regulator adjustment.

Caution: Furnace Damage Hazard

Avoiding damage by not redrilling orifices.

Notice: Natural Gas Manifold Pressure Adjustments

Notes on manifold pressure adjustments for natural gas.

Check Inlet Gas Pressure

Checking the inlet gas pressure during operation.

Adjust Manifold Pressure

Notice: Manifold Pressure Limits

Limits for manifold pressure settings.

Adjust Temperature Rise

Procedures for checking and adjusting temperature rise.

Caution: Furnace Damage Hazard

Hazards related to overheating or improper flue gas condensation.

Adjust Blower Off Delay (Heat Mode)

Adjust Cooling Airflow

Adjust Thermostat Heat Anticipator

Check Safety Controls

1. Check Main Limit Switch

Testing the main limit switch function.

2. Check Pressure Switch(es)

Testing the pressure switch function.

Checklist

Service and Maintenance Procedures

Warning: Fire, Injury or Death Hazard

Warnings for personnel performing maintenance.

Caution: Environmental Hazard

Environmental precautions during service.

Warning: Electrical Shock, Fire or Explosion Hazard

Electrical safety warnings before servicing.

Caution: Electrical Operation Hazard

Cautions for electrical wiring errors.

General

General notes on furnace orientation for service.

Electrical Controls and Wiring

Information on electrical controls and wiring.

Warning: Electrical Shock Hazard

Additional electrical shock hazards.

Troubleshooting

Using the troubleshooting guide.

Retrieving Stored Fault Codes

How to retrieve stored fault codes.

Component Self-Test

Warning: Electrical Shock Hazard

Electrical hazards when manually closing the blower door switch.

Care and Maintenance

General care and maintenance recommendations.

Warning: Fire or Explosion Hazard

Storing flammable materials near the furnace.

Warning: Electrical Shock and Fire Hazard

Electrical safety during maintenance.

Warning: Carbon Monoxide Poisoning and Fire Hazard

Never operating furnace without a filter.

Caution: Cut Hazard

Hazards from sharp sheet metal parts.

Blower Motor and Wheel Maintenance

Cleaning Burners and Flame Sensor

Warning: Electrical Operation Hazard

Electrical hazards during burner and flame sensor cleaning.

Warning: Electrical Shock and Fire Hazard

Electrical safety before servicing.

Warning: Carbon Monoxide Poisoning and Fire Hazard

Hazards from operating without a filter or with doors removed.

Caution: Cut Hazard

Hazards from sharp sheet metal parts.

Flushing Collector Box and Drainage System

Warning: Electrical Shock and Fire Hazard

Electrical safety before flushing.

Cleaning Condensate Drain and Trap

To re-install Condensate Drain and Trap:

Checking Heat Pad Operation (If Applicable)

Cleaning Heat Exchangers

Primary Heat Exchangers

Cleaning primary heat exchangers.

Warning: Electrical Shock, Fire or Explosion Hazard

Electrical safety before servicing heat exchangers.

Warning: Electrical Shock and Fire Hazard

Electrical safety before servicing heat exchangers.

Secondary Heat Exchangers

Winterization

Caution: Unit and Property Damage Hazard

Preventing damage from low ambient temperatures.

Caution: Unit Component Damage Hazard

Hazards of using ethylene glycol for winterization.

Troubleshooting Guide

Troubleshooting Guide (Cont)

Parts Replacement Information Guide

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