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This is a safety alert symbol and should never be ignored. When you see this symbol on labels or in manuals, be alert to
the potential for personal injury or death.
Improper installation, adjustment, alteration, service
or maintenance can cause property damage, personal
injury or loss of life. Installation and service must be
performed by a licensed professional installer (or
equivalent), service agency or the gas supplier.
As with any mechanical equipment, personal injury can
result from contact with sharp sheet metal edges. Be
careful when you handle this equipment.
BG802DFE Gas Furnace
The BG802DFE gas furnace is shipped ready for
installation in the downflow position fueled by natural gas.
A conversion kit (ordered separately) is required for use in
LP/ Propane gas applications.
Manufactured By
Blue Summit LLC
8201 C National Turnpike
Louisville, KY 40214
508145-01B
INSTALLATION INSTRUCTIONS
BG802DFE
Warm Air Gas Furnace
Downflow Air Discharge
This manual must be left with the homeowner for future reference.
WARNING
CAUTION
Table of Contents
BG802DFE Gas Furnace .......................................... 1
Unit Dimensions ........................................................ 2
Parts Arrangement..................................................... 3
Shipping and Packing List ......................................... 4
Safety Information ..................................................... 4
General ...................................................................... 6
Combustion, Dilution & Ventilation Air ....................... 6
Downflow Installation ................................................. 9
Filters ........................................................................11
Duct System .............................................................11
Venting..................................................................... 12
Gas Piping ............................................................... 17
Electrical .................................................................. 19
Integrated Control DIP Switch Settings ................... 27
On-Board Links and Diagnostic Push Button .......... 27
Unit Start-Up ............................................................ 28
Other Unit Adjustments............................................ 31
Heating Sequence of Operation .............................. 31
Service..................................................................... 32
Repair Parts List ...................................................... 34
Blower Performance ................................................ 35
*P508145-01B*
Issue 2108
(P) 508145-01B
Page 1 of 36
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Summary of Contents for Alpine Home BG802DFE
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Page 1: Table Of Contents
INSTALLATION INSTRUCTIONS BG802DFE Warm Air Gas Furnace Downflow Air Discharge This manual must be left with the homeowner for future reference. This is a safety alert symbol and should never be ignored. When you see this symbol on labels or in manuals, be alert to the potential for personal injury or death. -
Page 2: Unit Dimensions
Unit Dimensions 3-1/8 9/16 (79) (14) RETURN AIR OPENING FLUE OUTLET 19-7/16 9/16 (Top) (494) (14) 9/16 (14) TOP VIEW 1-1/2 (38) 27-3/4 (705) Front Panel 19-7/16 9/16 9/16 (14) (494) (14) AIR FLOW ELECTRICAL INLET (Either Side) (838) 5-3/8 (137) Right GAS PIPING INLET 2-3/16 (56) Left (Either Side) -
Page 3: Parts Arrangement
Parts Arrangement Top Cap Secondary Limit Indoor Blower Control Box (includes integrated control, transformer and door switch) Internal Flue Pipe Assembly Heat Exchanger Combustion Air Inducer Burner Box Assembly Primary Limit Gas Valve Figure 1. 508145-01B Issue 2108 Page 3 of 36... -
Page 4: Shipping And Packing List
Certifications Shipping and Packing List These units are CSA International certified to ANSI Z21.47. In the USA, installation of gas furnaces must conform with 1 - Assembled Gas Furnace local building codes. In the absence of local codes, units 1 - Bag assembly containing the following: must be installed according to the current National Fuel 2 - Screws Gas Code (ANSI-Z223.1). - Page 5 Installed in Combination with a Cooling Coil Use of Furnace as a Construction Heater When this furnace is used with cooling units, it shall be Units may be used for heating of buildings or structures installed in parallel with, or on the upstream side of, cooling under construction, if the following conditions are met to units to avoid condensation in the heating compartment.
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Page 6: General
ENTITIES. ALL SUCH POLICIES AND CODES MUST BE In the absence of local codes concerning air for combustion ADHERED TO. and ventilation, use the guidelines and procedures in this section to install these furnaces to ensure efficient and safe operation. You must consider combustion air needs and requirements for exhaust vents and gas piping. - Page 7 In addition to providing combustion air, fresh outdoor air dilutes contaminants in the indoor air. These contaminants may include bleaches, adhesives, detergents, solvents and other contaminants which can corrode furnace components. The requirements for providing air for combustion and ventilation depend largely on whether the furnace is installed in an unconfined or a confined space.
- Page 8 NOTE: Each air duct opening shall have a free area of at least one NOTE: The inlet and outlet air openings shall each have a free square inch per 2,000 Btu (645 mm² per .59 kW) per hour of the area of at least one square inch per 4,000 Btu (645 mm²...
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Page 9: Downflow Installation
Front to Rear Side to Side Cabinet Units with 1/2 or 3/4 HP Blower Motor Width A (14-1/2”) 19-3/4 13-1/4 B (17-1/2”) 19-3/4 16-1/4 RIGID LEG remove shipping bolt and washer NOTE - Floor opening dimensions listed are 1/4 inch (6 mm) larger than the unit opening. - Page 10 Return Air Opening -- Downflow Units Front to Rear Side to Side Cabinet The following steps should be taken when installing Width plenum: A (14-1/2”) 15-3/4 1. Bottom edge of plenum should be flanged with a B (17-1/2”) 18-3/4 hemmed edge (see Figure 11). Table 2.
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Page 11: Filters
Downflow Application Filters Allow for clearances to combustible materials as indicated on the unit nameplate. Minimum clearances for closet or This unit is not equipped with a filter or rack. A field provided alcove installations are shown in Figure 14. high velocity filter is required for the unit to operate properly. -
Page 12: Venting
When return air is drawn from a room, a negative pressure is created in the room. If a gas appliance is operating in IMPORTANT a room with negative pressure, the flue products can be pulled back down the vent pipe and into the room. This Once the venting system is installed, attach the reverse flow of the flue gas may result in incomplete “Disconnected Vent”... - Page 13 If the existing chimney will not accommodate a listed meta • The vent connectors and chimney are sized according liner, either the chimney must be rebuilt to accommodate to the provided venting tables. one of these liners or an alternate approved venting method must be found.
- Page 14 General Venting Requirements If the common vertical vent is offset, the maximum common vent capacity listed in the common venting Vent all furnaces according to these instructions: tables should be reduced by 20%, the equivalent 1. Vent diameter recommendations and maximum of two 90°...
- Page 15 21. When connecting this appliance to an existing dedicated or common venting system, you must inspect the venting system’s general condition and look for signs of corrosion. The existing vent pipe size must conform to these instructions and the provided venting tables. If the existing venting system does not meet these requirements, it must be resized. Capacity of Type B Double Wall Vents with Type B Double Wall Connectors Serving a Single Category I Appliance Vent and Connector Diameter - D (inches) Height...
- Page 16 Vent Connector Capacity Type B Double Wall Vents with Type B Double Wall Connectors Serving Two or More Category I Appliances Vent and Connector Diameter - D (inches) Vent Connector 3 inch 4 inch 5 inch 6 inch Height Rise Appliance Input Rating in Thousands of Btu per Hour (feet) (feet)
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Page 17: Gas Piping
Removal of the Furnace from Common Vent Follow the lighting instructions. Turn on the appliance that is being inspected. Adjust the thermostat so that In the event that an existing furnace is removed from the appliance operates continuously. a venting system commonly run with separate gas appliances, the venting system is likely to be too large to After the burners have operated for 5 minutes, test for properly vent the remaining attached appliances. - Page 18 Gas Pipe Capacity - FT³/HR (kL/HR) Internal Length of Pipe - feet (m) Nominal Iron Diameter Pipe Size - - inches inches (mm) (3.048) (6.096) (9.144) (12.192) (15.240) (18.288) (21.336) (24.384) (27.432) (30.480) (mm) .622 (12.7) (17.799) (4.87) (3.34) (2.69) (2.29) (2.03) (1.84)
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Page 19: Electrical
The furnace must be isolated by closing its individual manual shut-off valve and disconnecting from the gas CAUTION supply system the during any pressure testing of the gas supply system at pressures less than or equal to 1/2 psig Failure to use properly sized wiring and circuit breaker (3.48 kPa, 14 inches w.c.). - Page 20 Thermostat Electrically ground the unit according to local codes or, in the absence of local codes, according to the current Install the room thermostat according to the instructions National Electric Code (ANSI/NFPA No. 70). A green provided with the thermostat. See Table 9 for thermostat ground wire is provided in the field make-up box.
- Page 21 COMFORT SYNC ® THERMOSTAT 070-12 090-16 Figure 22. Wiring Diagram 508145-01B Issue 2108 Page 21 of 36...
- Page 22 DIP Switch Settings and On-Board Links Thermostat Wiring Connections DIP Switch 1 On Board Links Must Be Cut To Select System Options FURNACE OUTDOOR T'STAT TERM. STRIP UNIT 1 Heat / 1 Cool NOTE: Use DIP DO NOT CUT ANY switch 2 to set ON-BOARD LINKS sceond-stage heat...
- Page 23 DIP Switch Settings and On-Board Links Thermostat Wiring Connections DIP Switch 1 On Board Links Must Be Cut To Select System Options FURNACE OUTDOOR T'STAT TERM. STRIP UNIT 2 Heat / 2 Cool CUT ON-BOARD LINK W915 2 STAGE COMPR *Not required on all units FURNACE OUTDOOR...
- Page 24 DIP Switch Settings and On-Board Links Thermostat Wiring Connections DIP Switch 1 On Board Links Must Be Cut To Select System Options FURNACE HEAT PUMP TERM. STRIP T'STAT CUT ON-BOARD LINK 67M41* W951 Dual Fuel Single- HEAT Stage Heat Pump PUMP Thermostat w/dual fuel capabilities...
- Page 25 DIP Switch Settings and On-Board Links Thermostat Wiring Connections DIP Switch 1 On Board Links Must Be Cut To Select System Options FURNACE HEAT PUMP TERM. STRIP T'STAT Dual Fuel Single- 67M41* Stage Heat Pump CUT ON-BOARD LINK Thermostat w/dual W951 fuel capabilities HEAT...
- Page 26 24VAC Indoor Ignitor and Combustion Blower Terminals Air Inducer Neutrals Flame Sense S4 DIP Switches Diagnostic Push Button On Board Links 3/16” QUICK CONNECT TERMINALS THERMOSTAT CONNECTIONS (TB1) DS = DEHUMIDIFICATION SIGNAL FLAME SENSE SIGNAL W2 = HEAT DEMAND FROM 2ND STAGE T/STAT HI Cool 24VAC W1 = HEAT DEMAND FROM 1ST STAGE T/STAT HI HEAT 24VAC...
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Page 27: Integrated Control Dip Switch Settings
Blower Off Delay Integrated Control DIP Switch Settings Switch 3 Switch 4 Seconds BG802DFE units are equipped with a two-stage integrated control. This control manages ignition timing, heating 90 (factory) mode fan off delays and indoor blower speeds based on selections made using the control dip switches and jumpers. -
Page 28: Unit Start-Up
On-Board Link W951 Heat Pump (R to O) BEFORE LIGHTING smell all around the appliance area for gas. Be sure to smell next to the floor because some On-board link W951 is a clippable connection between gas is heavier than air and will settle on the floor. terminals R and O on the integrated control. - Page 29 Gas Pressure Adjustment HIGH FIRE Gas Flow (Approximate) LOW FIRE MANIFOLD ADJUSTMENT ADJUSTMENT PRESSURE TAP (under cap) (under cap) Gas Meter Clocking Chart Seconds for One Revolution Natural Capacity 1 cu ft 2 cu ft 1 cu ft 2 cu ft Dial Dial Dial...
- Page 30 High Altitude Shut unit off and remove manometer as soon as an accurate reading has been obtained. Turn the supply The manifold pressure may require adjustment and and manifold 3/32” hex screw one revolution back into combustion air pressure switch may need replacing to the gas valve.
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Page 31: Other Unit Adjustments
Connect selected speed tap at integrated control Other Unit Adjustments speed terminal. Resecure blower access panel. Primary and Secondary Limits Turn on electrical power to furnace. The primary limit is located on the heating compartment Recheck temperature rise. vestibule panel. The secondary limits (if equipped) are located in the blower compartment, attached to the back side of the blower. -
Page 32: Service
If second-stage heat is required, the thermostat After the 20-second warm-up period has ended, the second- stage heat contacts close and send a signal to gas valve is energized on low fire (first stage) and the integrated control. The integrated control initiates ignition occurs. - Page 33 Annual Furnace Maintenance Manual for proper operating range. Thermal Limits should be checked by restricting airflow and not At the beginning of each heating season, and to comply disconnecting the indoor blower. For additional details, with the Blue Summit Limited Warranty, your system please see Service and Application Note H049.
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Page 34: Repair Parts List
12. If a leak is detected, shut gas and electricity off and repair leak. 13. Repeat steps 12 and 13 until no leaks are detected. 14. Replace access panel. Ignitor Retention Rings Rollout Switches Sensor Cross Over Manifold And Gas Valve Figure 25. -
Page 35: Blower Performance
Blower Performance BG802DF070AE12 Performance (Less Filter) Air Volume / Watts at Various Blower Speeds External Static High Medium - High Medium Medium - Low Pressure (Black) (Brown) (Blue) (Yellow) (Red) in. w.c. watts watts watts watts watts 0.00 1475 1345 1190 0.10 1440... - Page 36 Requirements for Commonwealth of Massachusetts Modifications to NFPA-54, Chapter 10 INSPECTION. The state or local gas inspector of the side wall, horizontally vented, gas-fueled equipment Revise NFPA-54 section 10.8.3 to add the following shall not approve the installation unless, upon requirements: inspection, the inspector observes carbon monoxide For all side wall, horizontally vented, gas-fueled equipment...
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