Bosch BGH96M060B3A Installation, Operation And Maintenance Manual
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Bosch BGH96M060B3A Installation, Operation And Maintenance Manual

96% afue gas furnace
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Bosch 96% AFUE Gas Furnace BGH96 Model
Condensing Gas Furnace
Installation, Operation, and Maintenance Manual
3124627
Table of Contents
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Summary of Contents for Bosch BGH96M060B3A

  • 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: Table Of Contents

    Installation, Operation & Maintenance Manual Bosch 96% AFUE Gas Furnace | 3 Table of Contents 1 Key to Symbols and Safety Instructions 10.5 24-V Wiring 10.6 Accessories (Field Supplied) 1.2 Safety 10.7 Grounding 2 Dimensions 11 Start-Up, Adjustment, and Safety Check 3 Introduction 11.1 General...

  • Page 4: Key To Symbols And Safety Instructions

    4 | Bosch 96% AFUE Gas Furnace Installation, Operation & Maintenance 1 Key to Symbols and Safety Instructions 1.2 Safety Please read all instruction in the manual and retain all manuals for future reference. 1.1 Key to Symbols  INSTALLER: Use the information in this booklet to install the appliance Warnings and affi...
  • Page 5 Installation, Operation & Maintenance Manual Bosch 96% AFUE Gas Furnace | 5 WARNING: FOLLOW ALL SAFETY CODES WARNING: FIRE HAZARD  Wear safety glasses, protective clothing, and work gloves.  Always install furnace to operate within the furnace's Have a fire extinguisher available. Read these instructions...
  • Page 6 6 | Bosch 96% AFUE Gas Furnace Installation, Operation & Maintenance CAUTION: WARNING: FIRE, EXPLOSION   Before heating season begins, examine the furnace to See instructions for lighting/shutdown operation (as ensure that: shown at the bottom of this page, as well as on a sticker All fl...

  • Page 7: Dimensions

    Installation, Operation & Maintenance Manual Bosch 96% AFUE Gas Furnace | 7 2 Dimensions Combustion Air Inlet Combustion Air Inlet 19-1/2”(495mm) Gas Pipe Entry Gas Pipe Entry Electrical Entry Electrical Entry Condensate Drain Condensate Drain 33-3/4”(857mm) Thermostat Wiring Thermostat Wiring 14”(355mm)

  • Page 8: Introduction

    8 | Bosch 96% AFUE Gas Furnace Installation, Operation & Maintenance 3 Introduction CAUTION: This 3-way Multipoise Category IV Fan-assisted furnace is AHRI and ETL design-  INSTALLATION certifi ed. A Category IV Fan-assisted furnace is an appliance equipped with an...

  • Page 9: Codes And Standards

    Installation, Operation & Maintenance Manual Bosch 96% AFUE Gas Furnace | 9 4 Codes and Standards Clearance arrows do not change with furnace orientation 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.

  • Page 10: Combustion And Ventilation Air

    1 0 | Bosch 96% AFUE Gas Furnace Installation, Operation & Maintenance 4.3 Combustion and Ventilation Air 5 Electrostatic Discharge (ESD) Precautions Procedure  US: Section 9.3 of the NFGC, NFPA 54/ANSI Z223.1-latest edition Air for Combustion and Ventilation NOTICE: FURNACE RELIABILITY HAZARD ...

  • Page 11: Location

    Installation, Operation & Maintenance Manual Bosch 96% AFUE Gas Furnace | 11 6 Location If air is exposed to the following substances, it should not be used for combustion air, and outdoor air may be required for combustion:  6.1 General Permanent wave solutions ...
  • Page 12 1 2 | Bosch 96% AFUE Gas Furnace Installation, Operation & Maintenance WARNING: FIRE, INJURY OR DEATH HAZARD  When the furnace is installed in a residential garage, the burners and ignition sources must be located at least 18 inches above the floor. The furnace must be located or protected to avoid damage by vehicles.

  • Page 13: Installation

    Installation, Operation & Maintenance Manual Bosch 96% AFUE Gas Furnace | 13 7 Installation Side return air inlet These furnaces are shipped with bottom closure panel installed in bottom return-air This furnace can be installed in upfl ow or horizontal orientations.

  • Page 14: Horizontal Installation

    1 4 | Bosch 96% AFUE Gas Furnace Installation, Operation & Maintenance 7.2 Horizontal Installation WARNING: FIRE, EXPLOSION, AND CARBON MONOXIDE POISONING HAZARD  Failure to follow this warning could result in personal injury, death, and/or property damage. Do not install the furnace on its back or hang furnace with control compartment facing downward.
  • Page 15 Installation, Operation & Maintenance Manual Bosch 96% AFUE Gas Furnace | 15 7.2.2 Horizontal Applications Horizontal applications, in particular, may dictate many of the installation’s specifi cs such as airfl ow direction, ductwork connections, fl ue and combustion air pipe connections, etc. The basic application of this furnace as a horizontal furnace diff...
  • Page 16 1 6 | Bosch 96% AFUE Gas Furnace Installation, Operation & Maintenance PROVIDE 8" MINMUM CLEARANCE BETWEEN CENTER ROD AND FURNACE CABINET TO ALLOW FOR CIRCULATOR BLOWER REMOVAL 3/8" DIAMETER THREADED ROD (6 PLACES) ASSURE FURNACE IS LEVEL FROM END TO END AND HAS A SLIGHT FORWARD TILT WITH THE FRONT OF THE FURNACE 3/4"...

  • Page 17: Condensate Line And Over Flow Pressure Switch

    Installation, Operation & Maintenance Manual Bosch 96% AFUE Gas Furnace | 17 7.3 Condensate Line and Over Flow Pressure Switch If the drain line is routed through an area which may see  temperatures near or below freezing, precautions must be taken to prevent condensate from freezing within the drain line.
  • Page 18 1 8 | Bosch 96% AFUE Gas Furnace Installation, Operation & Maintenance 7.3.2 For Upfl ow Installation Top venting (see Fig. 14) AIR INLET Connect vent pipe and air intake pipe (if applicable) to the couplers on the COUPLER EXHAUST COUPLER furnace top panel.
  • Page 19 Installation, Operation & Maintenance Manual Bosch 96% AFUE Gas Furnace | 19 7.3.3 For Horizontal Installations For installations with right air discharge and venting outlet through furnace top panel (see Figure 15). Remove cap from left side panel of furnace and cut the insulation accordingly.
  • Page 20 2 0 | Bosch 96% AFUE Gas Furnace Installation, Operation & Maintenance For installations with left air discharge and venting outlet through furnace Screws for mounting bracket should not interfere with any components top panel (see Figures 16 and 17).
  • Page 21 Installation, Operation & Maintenance Manual Bosch 96% AFUE Gas Furnace | 21 NOTICE:  In this installation, hoses connecting between ports of overflow protection pressure switch (overflow switch) and pressure tabs on the condensate collector box MUST be switched. The overflow switch has two ports, which is different from two other regular pressure switches that have only one port.

  • Page 22: Filter Arrangement

    Figure 20 Side return knockout markings The Bosch 96% AFUE Gas Furnace BGH96 series does not include a fi lter from the Dimensions of return air "cut out" must match those shown in Figure 1. manufacturer. The fi lter and fi lter rack must be fi eld supplied and fi eld installed. A DO NOT cut outside of the "knockout"...

  • Page 23: Air Ducts

    Installation, Operation & Maintenance Manual Bosch 96% AFUE Gas Furnace | 23 7.5 Air Ducts Supply air connections General requirements For a furnace not equipped with a cased coil, the outlet duct shall be provided with a removable access panel. This opening shall be accessible when the furnace is...
  • Page 24 2 4 | Bosch 96% AFUE Gas Furnace Installation, Operation & Maintenance External static pressure (in. WC) Furnace Return-air Speed size inlet 1430 1390 1350 1320 1280 1240 1200 1160 1110 1065 Temp Rise-1st stage ℉ 30.7 32.2 33.6 Temp Rise-2nd stage ℉...
  • Page 25 Installation, Operation & Maintenance Manual Bosch 96% AFUE Gas Furnace | 25 External static pressure (in. WC) Furnace Return-air Speed size inlet 2195 2158 2116 2072 2031 1985 1940 1896 1852 1862 Temp Rise-1st stage ℉ Temp Rise-2nd stage ℉...

  • Page 26: Combustion Air And Vent System

    2 6 | Bosch 96% AFUE Gas Furnace Installation, Operation & Maintenance 8 Combustion Air and Vent System 8.1 Combustion Air and Vent Safety Remove cap This Category IV, dual certifi ed (AHRI and ETL) direct vent furnace is designed for residential applications.
  • Page 27 Installation, Operation & Maintenance Manual Bosch 96% AFUE Gas Furnace | 27 In Canada, vents shall be certifi ed to ULC S636, Standard for Type BH Gas Fitting Equivalent Length Venting Systems. IPEX System 636 PVC is certifi ed to this standard.

  • Page 28: Comnustion Air And Vent Piping Assembly

    2 8 | Bosch 96% AFUE Gas Furnace Installation, Operation & Maintenance 8.3 Comnustion Air And Vent Piping Assembly The fi nal assembly procedure for the combustion air and vent piping is as follows: Cut piping to the proper length beginning at the furnace.

  • Page 29: Combustion Air / Venting

    Installation, Operation & Maintenance Manual Bosch 96% AFUE Gas Furnace | 29 8.4 Combustion Air / Venting Vent Clearances VENT TERMINAL FIXED AIR SUPPLY CLOSED AREA WHERE TERMINAL IS NOT PERMITTED FIXED CLOSED OPERABLE Figure 23 Direct Vent Terminal Clearances Canadian Installations ¹...

  • Page 30: Vent System

    3 0 | Bosch 96% AFUE Gas Furnace Installation, Operation & Maintenance 12” vertical separation CAUTION: between combustion air Maintain 12” minimum 12” minimum intake and vent.  The vent must be installed with the minimum required clearance above below overhang...

  • Page 31: Combustion & Ventilation Air Requirements

    Installation, Operation & Maintenance Manual Bosch 96% AFUE Gas Furnace | 31 8.6.2 Outdoor Combustion Air Combustion Air Intake/Vent Connections This installation requires combustion air to be brought in from outdoors. This VENT requires a properly sized pipe (shown in Figure 29) that will bring air in from the outdoors to the furnace combustion air intake collar on the burner box.
  • Page 32 3 2 | Bosch 96% AFUE Gas Furnace Installation, Operation & Maintenance Vent Vent Gable Vent Gable Vent Vent Ventilated Ventilated Attic Attic Optional Top Above Inlet (a) Top Above Insulation Insulation Outlet Soffit Air (a) Soffit Vent Outlet Outlet...
  • Page 33 Installation, Operation & Maintenance Manual Bosch 96% AFUE Gas Furnace | 33 Air Supply Openings and Ducts 8.6.4 Ventilated Combustion Air An opening may be used in lieu of a duct to provide the outside air supply The ventilated attic space or a crawl space from which the combustion air is taken must comply with the requirements specifi...

  • Page 34: Vent And Supply (Outside) Air Safety Check Procedure

    3 4 | Bosch 96% AFUE Gas Furnace Installation, Operation & Maintenance 8.7 Vent and Supply (Outside) Air Safety Check Procedure WARNING: CARBON MONOXIDE POISONING HAZARD For Category IV furnaces, vent installations shall be in accordance with Parts 7 Failure to follow the steps outlined below for each appliance and 11 of the National Fuel Gas Code, ANSI Z223.1/NFPA 54 and/or Section 7...

  • Page 35: Gas Supply And Piping

    Installation, Operation & Maintenance Manual Bosch 96% AFUE Gas Furnace | 35 9 Gas Supply and Piping NOTICE: WARNING: FIRE OR EXPLOSION HAZARD  Adjusting the minimum supply pressure below the limits in Table 12 could lead to unreliable ignition. Gas input to ...

  • Page 36: High Altitude Derate

    3 6 | Bosch 96% AFUE Gas Furnace Installation, Operation & Maintenance 9.2 High Altitude Derate Alternately, in high altitude applications, a standard derate for altitude from National Fuel Gas Code ANSI Z223.1 of 4% per 1000 feet above sea level may be taken.

  • Page 37: Propane Gas (Lp) Conversion

    Installation, Operation & Maintenance Manual Bosch 96% AFUE Gas Furnace | 37 9.3 Propane Gas (LP) Conversion 9.4 Gas Piping Connections To avoid possible unsatisfactory operation or equipment damage due to underfi ring WARNING: FIRE OR EXPLOSION HAZARD of equipment, use the proper size of natural/propane gas piping needed when running pipe from the meter/tank to the furnace.

  • Page 38: Gas Piping Checks

    3 8 | Bosch 96% AFUE Gas Furnace Installation, Operation & Maintenance The following stipulations apply when connecting gas piping.  Use pipe joint compound on male threads only. Pipe joint compound Location of Manual value must be resistant to the action of the fuel used.

  • Page 39: Electrical Connections

    Installation, Operation & Maintenance Manual Bosch 96% AFUE Gas Furnace | 39 10 Electrical Connections Junction box relocation If factory location of J-Box is acceptable, go to next section WARNING: ELECTRICAL SHOCK HAZARD Electrical Connection to J-box.  Blower access panel door switch opens 115V power to control.

  • Page 40: Electrical Connection To J-Box

    4 0 | Bosch 96% AFUE Gas Furnace Installation, Operation & Maintenance 10.2 Electrical Connection to J-box 10.3 Power Cord Installation in Furnace J-box Field-Supplied Electrical Box on Furnace J-Box Bracket Power cords must be able to handle the electrical requirements listed in See Fig.
  • Page 41 Installation, Operation & Maintenance Manual Bosch 96% AFUE Gas Furnace | 41 Max. Nominal Input Output Air Temp. Rise Over-Current Max. Outlet Air Temp MAX. Unit Min. Wire Size Airfl ow AFUE Protection Amps (AWG) @ 75 ft ° F °...
  • Page 42 4 2 | Bosch 96% AFUE Gas Furnace Installation, Operation & Maintenance Thermostat connections Last error button Fault LED Unused blower terminal Blower connections Blower power input Unit power input (115V/60HZ) Transformer Humidifier Neutral terminals Fuse Figure 35 Furnace Control...

  • Page 43: Start-Up, Adjustment, And Safety Check

    Installation, Operation & Maintenance Manual Bosch 96% AFUE Gas Furnace | 43 11 Start-Up, Adjustment, and Safety Check This furnace is also equipped with a self-diagnosing electronic control module. In the event a furnace component is not operating properly 11.1 General the control module LED will fl...

  • Page 44: Sequence Of Operation

    4 4 | Bosch 96% AFUE Gas Furnace Installation, Operation & Maintenance Furnace shutdown A momentary loss of gas supply, fl ame blowout, or a shorted or open condition in the fl ame probe circuit will be sensed within 2 seconds. The gas valve will de- In case of furnace malfunction, use the following steps to shut the unit down: energize and the control will restart the ignition sequence.

  • Page 45: Gas Manifold Pressure Measurement And Adjustment

    Installation, Operation & Maintenance Manual Bosch 96% AFUE Gas Furnace | 45 When using a single stage thermostat, second stage delay is based on the setting of Replace regulator screw cover and fi nger-tighten securely. switch S1-1, S1-2 shown below.

  • Page 46: Gas Input Rate Measurement (Natural Gas Only)

    4 6 | Bosch 96% AFUE Gas Furnace Installation, Operation & Maintenance 11.6 Gas Input Rate Measurement (Natural Gas Only) Adjust temperature rise by adjusting the circulator blower speed. Increase blower speed to reduce temperature rise. Decrease blower speed to The gas input rate to the furnace must never be greater than that specifi...

  • Page 47: Circulator Blower Speed Adjustment

    Installation, Operation & Maintenance Manual Bosch 96% AFUE Gas Furnace | 47 11.8 Circulator Blower Speed Adjustment WARNING: ELECTRICAL SHOCK HAZARD  Turn OFF power to the furnace before changing speed taps. This furnace is equipped with an X13 ECM circulator blower motor. This blower provides ease in adjusting blower speeds.

  • Page 48: Operational Checks

    4 8 | Bosch 96% AFUE Gas Furnace Installation, Operation & Maintenance 12 Operational Checks 13.4 Fan Mounted Limit 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 DANGER: FIRE, EXPLOSION, ELECTRICAL SHOCK, AND overheating by hot air when the furnace is installed horizontally.

  • Page 49: Troubleshooting

    Installation, Operation & Maintenance Manual Bosch 96% AFUE Gas Furnace | 49 14 Troubleshooting 14.2 Resetting From Lockout Furnace lockout results when a furnace is unable to achieve ignition after 14.1 Electrostatic Discharge (ESD) Precautions three attempts. It is characterized by a non-functioning furnace, refer to the Troubleshooting chart (pg 50-51) which describes what errors LED fl...
  • Page 50 5 0 | Bosch 96% AFUE Gas Furnace Installation, Operation & Maintenance Symptoms of Associated Abnormal Fault Description(s) Possible Reason Corrective Action Cautions And Notes Operation — No 115 volt power to 1. Assure 115 and 24 volt power to —...
  • Page 51 Installation, Operation & Maintenance Manual Bosch 96% AFUE Gas Furnace | 51 Symptoms of Associated Abnormal Fault Description(s) Possible Reason Corrective Action Cautions And Notes Operation 1. Turn the gas valve switch to “On" — The gas valve switched off 2.

  • Page 52: Service And Maintenance Procedures

    5 2 | Bosch 96% AFUE Gas Furnace Installation, Operation & Maintenance 15 Service and Maintenance Procedures 15.2 Filters A return air fi lter is not supplied with this furnace; however there must be a means of fi ltering the return air. The installer must supply fi lter(s) at the time of WARNING: ELECTRICAL SHOCK, FIRE OR EXPLOSION HAZARD installation.

  • Page 53: Ignitor (Qualifi Ed Service Technicians Only)

    Installation, Operation & Maintenance Manual Bosch 96% AFUE Gas Furnace | 53 15.5 Ignitor (Qualifi ed Service Technicians Only) 15.8 Condensate Drain If the ignitor and the surrounding air are at about 70°F and the  Inspect all condensate drain tubes and condensate trap assembly for ignitor wires are not connected to any other electrical components.
  • Page 54 5 4 | Bosch 96% AFUE Gas Furnace Installation, Operation & Maintenance Figure 41 COMPONENT IDENTIFICATION: Outlet Flue Vent Condensate Collector Flame Sensor Pressure Switch Chamber Limit Switch-Fixed Two-Stage Gas Valve Condensate Overfl ow Switch Hot Surface Ignitor Inducer Gas Manifold...

  • Page 55: Wiring Diagram

    Installation, Operation & Maintenance Manual Bosch 96% AFUE Gas Furnace | 55 17 Wiring Diagram E192 E192 E190 E190 E8 E8 SPEED TAPS MEDIUM LOW MEDIUM MEDIUM HIGH HIGH *FACTORY DEFAULT SPEED CHOOSE TABLE Figure 42 Bosch Thermotechnology Corp. | 04.2019...
  • 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...

This manual is also suitable for:

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