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Bryant 987MA User Manual

Bryant 987MA
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1
987MA
MODULATING 4--WAY MULTIPOISE
CONDENSING GAS FURNACE
SERIES B
.
Installation, Start--up, Operating and
Service and Maintenance Instructions
NOTE: Read the entire instruction manual before starting the
installation.
SAFETY CONSIDERATIONS 3.........................
INTRODUCTION 4...................................
CODES AND STANDARDS 4...........................
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS 5...
ACCESSORIES 5.....................................
LOCATION 5........................................
AIR FOR COMBUSTION AND VENTILATION 10.........
CONDENSATE TRAP 12...............................
Upflow 12........................................
Downflow 12.....................................
Horizontal 12......................................
CONDENSATE DRAIN 16.............................
INSTALLATION 19...................................
Upflow 19........................................
Downflow 20.....................................
Horizontal 20......................................
Filter Arrangement 21...............................
AIR DUCTS 29.......................................
Ductwork Acoustical Treatment 29.....................
GAS PIPING 33......................................
ELECTRICAL CONNECTIONS 34.......................
115--V Wiring 34...................................
J--Box Installation 35................................
24--V Wiring 35....................................
Accessories 36.....................................
Alternate Power Supplies 36..........................
VENTING 41........................................
Special Venting Requirements for Installations in Canada 41.
Materials 42.......................................
Venting Systems 42.................................
Locating Vent Termination 43.........................
Size the Vent and Combustion Air Pipes 44...............
Combustion Air and Vent Piping Insulation Guidelines 45...
Configure the Furnace 45............................
Installing the Vent Termination 47......................
Venting System Length Calculations 51.................
START--UP, ADJUSTMENT, AND SAFETY CHECK 63......
Select Setup Switch Positions 63........................
Prime Condensate Trap 64.............................
Purge Gas Lines 64...................................
Adjustments 64......................................
Check Safety Controls 68..............................
Checklist 68........................................
SERVICE AND MAINTENANCE PROCEDURES 78........
Cleaning Heat Exchangers 83...........................
SEQUENCE OF OPERATION 90........................
PARTS REPLACEMENT GUIDE 95......................
TABLE
Loose Parts Bag Contents 7..............................
Minimum Clearances to Combustible Materials 7.............
Minimum Free Area Required 11.........................
Minimum Space Volumes 11.............................
Filter Size Information 23...............................
Opening Dimensions 25................................
Air Delivery CFM 30...................................
Maximum Capacity of Pipe 34...........................
Electrical Data 36......................................
Vent Termination Kit for Direct Vent (2--Pipe) Systems 43......
Combustion--Air 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........
Altitude Derate Multiplier for U.S.A. 73....................
Blower Off Delay Setup Switch 73........................
Gas Rate 73..........................................
Orifice Size and Manifold Pressure 76.....................
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 NFPA 54/ANSI
Z223.1--2012E, 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.

Table of Contents

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Bryant 987MA Specifications

General IconGeneral
Model987MA
Heating Capacity40, 000 - 120, 000 BTU/h
StagesModulating
Fuel TypeNatural Gas
Blower TypeVariable Speed
Blower MotorECM
Heat ExchangerStainless Steel

Summary

Installation, Start-up, Operating, and Service and Maintenance Instructions

Safety Considerations

General safety precautions and warnings for installation and operation.

Introduction

Provides an overview of the furnace features and applications.

Codes and Standards

Lists national and local codes for installation compliance.

Electrostatic Discharge (ESD) Precautions Procedure

Details precautions to prevent damage to electronic components from static discharge.

Air for Combustion and Ventilation

Explains requirements for air supply for proper combustion and ventilation.

Condensate Trap

Instructions for handling and installing the condensate trap.

Condensate Drain

Details how to connect and route the condensate drain line.

Installation

Covers general installation procedures for the furnace.

Air Ducts

Guidelines for connecting and sizing air ducts.

Gas Piping

Instructions for safe and compliant gas piping installation.

Electrical Connections

Details on making correct electrical connections for the furnace.

Venting

Provides instructions for proper venting system installation and configuration.

Start-Up, Adjustment, and Safety Check

Covers procedures for initial startup, adjustments, and safety checks.

Required Notice for Massachusetts Installations

Important Massachusetts Installation Requirements

Highlights important regulatory requirements for Massachusetts installations.

Safety Considerations

Major Safety Warnings

Major safety warnings concerning fire, explosion, electrical shock, and carbon monoxide.

Fire Hazard Warnings

Specific warnings about fire hazards related to solvents and combustible materials.

Furnace Reliability Cautions

Cautions regarding potential damage to furnace components due to improper handling.

Cut Hazard Warning

Warning about sharp edges on sheet metal parts and the need for protective gear.

Safety-Alert Symbol and Signal Words

Explains the meaning of the safety-alert symbol and signal words (DANGER, WARNING, CAUTION).

General Installation Requirements

Lists essential installation requirements for safe and proper furnace operation.

Codes and Standards

Safety Codes

Lists safety codes like NFGC and NFPA 90B for US and Canada.

General Installation Standards

Lists general installation standards like NFGC, NFPA 90B for US and Canada.

Combustion and Ventilation Air Codes

Specifies codes related to air for combustion and ventilation.

Duct System Standards

Lists standards for duct system design and sizing.

Acoustical Lining and Fibrous Glass Duct Standards

Mentions standards for duct lining and fibrous glass ducts.

Gas Piping and Pressure Testing Codes

Details codes for gas piping installation and pressure testing.

Massachusetts Installation Requirements

Lists specific requirements for installations within Massachusetts.

Electrical Connection Codes

Lists electrical codes like NEC and CSA for connections.

Condensate Drain Connection Codes

Specifies codes for condensate drain connections.

Electrostatic Discharge (ESD) Precautions Procedure

Furnace Reliability Cautions

Cautions to prevent damage to electronic components from static discharge.

Location

Important considerations for choosing the furnace location.

Location Hazards

Warnings about hazards associated with improper location choice for the furnace.

General Location Requirements

Garage Installation Warnings

Specific warnings for installing the furnace in a residential garage.

Corrosive Atmosphere Warnings

Warnings about corrosive air contaminants and their effect on furnace components.

Furnace Orientation Warnings

Warning against installing the furnace on its back or with the control compartment facing downward.

Air for Combustion and Ventilation

Introduction to Air Requirements

Introduces the section on air for combustion and ventilation requirements.

Direct Vent (2-pipe) Air Requirements

Details air requirements for direct vent (2-pipe) installations.

Ventilated Combustion Air Requirements

Explains air requirements for ventilated combustion air systems.

Furnace Corrosion Hazard

Caution regarding corrosive air contaminants and furnace damage.

Carbon Monoxide Poisoning Hazard

Warning about negative pressure conditions and make-up air.

Outdoor Combustion Air Methods

Describes methods for providing outdoor air for combustion and ventilation.

Condensate Trap Installation

Upflow Orientation Condensate Trap

Instructions for condensate trap in upflow installation.

Downflow Orientation Condensate Trap

Instructions for relocating the condensate trap in downflow orientation.

Horizontal Orientation Condensate Trap

Instructions for repositioning the condensate trap in horizontal orientations.

Horizontal Drain Trap Grommet Notice

Notes the requirement for a drain trap grommet for direct vent applications.

Horizontal Position Clearance Notice

Notes required clearance for the condensate trap in horizontal position.

Relocating the Condensate Trap

Step-by-step guide for relocating the condensate trap.

Condensate Drain Connection

Frozen/Burst Water Pipe Hazard Caution

Warnings about protecting the drain line from freezing.

Property Damage Hazard Caution

Cautions regarding potential property damage from frozen drain lines or pumps.

Right Side Condensate Drain Instructions

Instructions for routing the condensate drain to the right side.

Left Side Condensate Drain Instructions

Instructions for routing the condensate drain to the left side.

Installation

Leakage Certification Notice

Notes the furnace's certified leakage rate for AC CFM.

Upflow Installation

Provides instructions for installing the furnace in an upflow orientation.

Bottom Return Air Inlet Preparation

Explains how to prepare the bottom return air opening.

Side Return Air Inlet Requirements

Details the use of side return air inlets and panel requirements.

Leveling Legs Installation

Instructions for installing leveling legs for furnace stability.

Horizontal Installation

Furnace Orientation Hazards

Hazards associated with incorrect furnace orientation.

Attic Installation Drain Pan Caution

Caution regarding drain pans for attic installations.

Platform Furnace Support

Guidelines for supporting the furnace on a platform.

Suspended Furnace Support

Instructions for supporting the furnace when suspended.

Flame Roll-Out Protection

Requirements for flame roll-out protection.

Filter Arrangement

Filter Safety Warnings

Critical warnings about operating without a filter or with access doors removed.

Duct System Design Notice

Emphasizes designing the duct system first to determine filter pressure drop allowance.

Filter and Return Duct Sizing

Guidance on sizing filters and return ducts based on pressure drop.

Gas Piping

Gas Piping Fire/Explosion Hazards

Major warnings regarding fire and explosion hazards related to gas piping.

Gas Control Damage Caution

Caution about avoiding damage to gas controls during connection.

Massachusetts Gas Connection Requirements

Notes specific gas connection requirements for Massachusetts.

Gas Pipe Grommet Installation

Instructions for using the gas pipe grommet for direct vent applications.

Electrical Connections

General Electrical Safety Warnings

Major warnings about electrical hazards during installation and servicing.

Blower Door Switch Electrical Hazard

Warning about the blower door switch and 115-v power.

Electrical Grounding Safety

Warnings about electrical grounding requirements and hazards.

Grounding for Furnace Operation Caution

Caution about proper grounding for furnace operation.

115-V Wiring

USA Electrical Connection Requirements

Electrical connection requirements for US installations per NEC.

Canada Electrical Connection Requirements

Electrical connection requirements for Canadian installations per CSA.

Aluminum Wire Fire Hazard Warning

Warning against using aluminum wire for electrical connections.

J-Box Installation

Procedure for installing the J-Box electrical connection.

J-Box Installation Hazards

Hazards associated with J-Box installation.

Casing-Mounted Electrical Box Installation

Instructions for installing an electrical box on the furnace casing.

Furnace J-Box Power Cord Installation

Steps for installing a power cord into the J-Box.

Furnace J-Box BX Cable Installation

Steps for installing BX cable into the J-Box.

24-V Wiring

Details on making field 24-v connections.

Thermostat Setup

Accessory Connections

Mentions connecting accessories like electronic air cleaners and humidifiers.

Alternate Power Supply Information

Information on using alternate power supplies like generators.

Venting

Venting System Planning

Advice on planning the venting system in conjunction with other components.

Canadian Venting Requirements

Specific venting requirements for installations in Canada per CSA B149.

French Canadian Venting Requirements

French instructions for Canadian venting requirements.

Venting Safety and General Information

Carbon Monoxide Poisoning Hazard

Critical warnings about carbon monoxide poisoning related to venting.

General Venting Notes

General notes regarding furnace replacement and vent systems.

Approved Venting Materials

Specifies approved materials for vent pipes, fittings, primers, and solvents.

Venting System Types

Describes direct vent and ventilated combustion air venting systems.

Venting Configuration Safety Warnings

Warnings about carbon monoxide poisoning for all venting configurations.

Vent Termination Support Recommendations

Recommendations for supporting vent terminations.

Vent Termination Installation

Roof Terminations

Instructions for installing vent terminations through the roof.

Concentric Vent Termination

Details for installing concentric vent terminations.

Two-Pipe and Single-Pipe Terminations

Instructions for terminating direct vent and ventilated combustion air systems.

Vent Termination Support Recommendations

Recommendations for supporting vent terminations.

Sidewall Terminations

Instructions for terminating vents on sidewalls.

Concentric Vent Sidewall Termination

Instructions for installing concentric vent terminations on sidewalls.

Size the Vent and Combustion Air Pipes

General Pipe Sizing

General notes on sizing vent and combustion air pipes.

Optional Combustion Air Inlet Pipe

Notes about optional combustion air inlet pipe configurations.

Optional Combustion Air Inlet Moisture Trap

Information on installing a moisture trap in the combustion air inlet pipe.

Venting System Length Calculations

Polypropylene Venting Systems Information

Notes regarding polypropylene venting systems and their equivalent lengths.

Combustion Air and Vent Piping Insulation

Guidelines for insulating combustion air and vent piping.

Furnace Configuration

Procedure for configuring the furnace settings.

Carbon Monoxide Hazard in Configuration

Warnings about carbon monoxide poisoning during furnace configuration.

Install the Vent and Combustion Air Pipes

PVC/ABS DWV Vent Piping Restriction

States that specific techniques are only for PVC/ABS DWV vent piping.

Vent Pipe and Combustion Air Pipe Adapter Installation

Procedure for installing vent pipe and combustion air pipe adapters.

Adapter Installation Carbon Monoxide Hazard

Warnings about carbon monoxide from improper adapter installation.

Polypropylene Venting System Cement Restriction

Warning against using cement with polypropylene venting systems.

Polypropylene Venting System Materials Notice

Notes that all materials for polypropylene systems must be from the same manufacturer.

Start-Up, Adjustment, and Safety Check

Important Start-Up Procedures Notice

Notes on initial startup procedures and potential smoke/odor.

General Start-Up Steps

General steps for startup, including power supply and thermostat connections.

Unit Operation Hazard Caution

Caution regarding intermittent operation or dissatisfaction due to improper setup.

Setup Switches Overview

Explains the purpose and location of setup switches for configuration.

SW1 Setup Switches

Details the function of SW1 setup switches for furnace operation.

SW2 Air Conditioning Setup Switches

Explains SW2 switches for matching furnace airflow to cooling units.

SW3 Continuous Fan Setup Switches

Details SW3 switches for continuous fan or low-cooling airflow.

SW4 Additional Setup Switches

Explains additional SW4 switches for heat stages and airflow adjustment.

Prime Condensate Trap

Trap Priming Carbon Monoxide Hazard

Warnings about carbon monoxide from improper trap priming.

Trap Priming Operation Hazard

Caution regarding improper draining or priming of the condensate trap.

Purge Gas Lines

Procedure for purging gas lines after connections are made.

Gas Line Purging Fire/Explosion Hazard

Warnings about fire and explosion hazards when purging gas lines.

Adjustments

Furnace Damage Hazard Caution

Caution to prevent furnace damage from improper adjustments.

Gas Valve Adjustment Fire Hazard

Warning about potential damage from forcing gas valve adjusting screws.

Orifice Adjustment Furnace Damage Hazard

Caution about not redrilling orifices to avoid damage.

Gas Input Rate and Altitude Notice

Notes on gas input rate, altitude derating, and heating value.

Check Inlet Gas Pressure

Max Heat Manifold Pressure Adjustment

Steps for adjusting manifold pressure for maximum heat operation.

Maximum Heat Manifold Pressure Notice

Notes on the acceptable range for maximum heat manifold pressure.

Adjust Manifold Pressure - Minimum Heat

Minimum Heat Manifold Pressure Adjustment

Steps for adjusting manifold pressure for minimum heat operation.

Clocking The Meter Procedure

Procedure for verifying gas input rate by clocking the meter.

Gas Valve Plug Fire Hazard Warning

Warning about reinstalling the manifold pressure tap plug to prevent gas leaks.

Adjust Temperature Rise

Temperature Rise Furnace Damage Hazard

Cautions to prevent furnace damage from overheating or component damage.

Locking Furnace in Minimum Heat

Steps to lock the furnace into minimum heat operation for adjustment.

Locking Furnace in Intermediate Heat

Steps to lock the furnace into intermediate heat operation for adjustment.

Locking Furnace in Maximum Heat

Steps to lock the furnace into maximum heat operation for adjustment.

Manifold Pressure Plug Fire Hazard

Warning about reinstalling the manifold pressure tap plug.

Service and Maintenance Procedures

General Service Safety Warnings

Major safety warnings for service and maintenance personnel.

Environmental Hazard Caution

Caution regarding proper disposal of components.

Electrical Safety Warnings

Warnings about electrical hazards during installation, modification, or servicing.

Improper Operation Electrical Caution

Caution about improper furnace operation due to wiring errors.

General Service Information

General notes for service procedures and furnace orientation.

Electrical Controls and Wiring

Details on electrical controls, wiring, and troubleshooting.

Electrical Supply and Polarity Warnings

Warnings about electrical supply and polarity.

Furnace Troubleshooting Guide

Guidance on troubleshooting furnace operation problems using status codes.

Retrieving Stored Fault Codes

Steps to retrieve stored fault codes from the furnace control.

Component Self-Test

Self-Test Electrical Shock Hazard

Warnings about electrical shock when manually closing the blower door switch.

Care and Maintenance

Procedures for routine care and maintenance of the furnace.

Flammable Materials Fire Hazard

Warnings about storing flammable materials near the furnace.

Maintenance Electrical and Fire Safety

Safety precautions before performing maintenance or service.

Filter Safety Warnings

Warnings about operating without a filter or with access doors removed.

Sheet Metal Cut Hazard

Warning about sharp edges on sheet metal parts.

Blower Motor and Wheel Maintenance

Air Filter Cleaning or Replacement

Steps for cleaning or replacing the air filter.

Filter Safety Warnings

Warnings about operating without a filter or with access doors removed.

Filter Maintenance Electrical Safety

Safety precautions before performing filter maintenance.

Cleaning Burners and Flame Sensor

Burner Service Electrical Safety

Safety precautions before servicing burners.

Burner Service Electrical Safety

Safety precautions before servicing burners.

Flushing Collector Box and Drainage System

Flushing Electrical Safety

Safety precautions before flushing the collector box and drainage system.

Condensate Drain and Trap Cleaning

Steps for cleaning the condensate drain and trap.

Primary Heat Exchangers

Heat Exchanger Service Electrical Safety

Safety precautions before servicing heat exchangers.

Heat Exchanger Service Electrical Safety

Safety precautions before servicing heat exchangers.

WINTERIZATION

Winterization Unit/Property Damage Hazard

Cautions regarding freezing and property damage during winterization.

Winterization Component Damage Hazard

Cautions to prevent component damage from ethylene glycol.

Troubleshooting Guide

Troubleshooting Guide Diagram

Flowchart to diagnose furnace operational issues based on status codes.

Sequence of Operation

Unit Operation Hazard Caution

Caution regarding intermittent unit operation.

Communicating Control and Adaptive Heating

Explains operation with communicating controls and adaptive heating modes.

Single-Stage Thermostat and Adaptive Heating

Details operation with single-stage thermostats and adaptive heating.

Two-Stage Thermostat Heating Operation

Explains operation with two-stage thermostats for heating.

Transition from Max to Intermediate Heat

Describes the transition from maximum to intermediate heat operation.

Cooling Mode Operation

Explains how the furnace operates in cooling mode.

Single-Speed Cooling Operation

Details single-speed cooling operation with thermostats.

Adaptive Mode Cooling Operation

Explains adaptive mode for two-speed cooling with single-stage thermostats.

Two-Stage Thermostat Heating Operation

Transition from Max to Intermediate Heat

Describes the transition from maximum to intermediate heat operation.

Transition from Max to Minimum Heat

Describes the transition from maximum to minimum heat operation.

Cooling Mode Operation

Explains how the furnace operates in cooling mode.

Single-Speed Cooling Operation

Details single-speed cooling operation with thermostats.

Adaptive Mode Cooling Operation

Explains adaptive mode for two-speed cooling with single-stage thermostats.

Cooling Mode Operation

Adaptive Mode Cooling Operation

Explains adaptive mode for two-speed cooling with single-stage thermostats.

Two-Stage Thermostat Cooling Operation

Explains two-stage thermostat control for two-speed cooling.

Dehumidification Mode Operation

Explains the dehumidification mode of operation.

Super Dehumidify Mode Operation

Explains the super dehumidify mode of operation.

Continuous Blower Mode Operation

Details the operation of the continuous blower mode.

Continuous Blower Speed Selection

How to select continuous blower speed using the thermostat.

Heat Pump Operation

Explains furnace operation when used with a heat pump.

Component Self Test Reference

Refers to page 79 for component self-test instructions.

Heat Pump Operation

Component Self Test Reference

Refers to page 79 for component self-test instructions.

Parts Replacement Information Guide

Obtaining Replacement Parts

Instructions on how to obtain replacement parts.

Model Nomenclature Explanation

Explains the model nomenclature for identification.

Parts Replacement Hazard Warning

Major warnings regarding hazardous operation from improper parts.

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