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INSTALLATION INSTRUCTIONS
BG802UHE
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.
BG802UHE Gas Furnace
The BG802UHE gas furnace is shipped ready for
installation in the upflow or horizontal right position (for
horizontal left position the combustion air pressure switch
must be moved). The furnace is shipped with the bottom
panel in place. The bottom panel must be removed if the
unit is to be installed in a horizontal application. The panel
may also be removed in upflow applications.
Manufactured By
Blue Summit LLC
8201 C National Turnpike
Louisville, KY 40214
508144-01B
This manual must be left with the homeowner for future reference.
WARNING
CAUTION
Table of Contents
BG802UHE Gas Furnace .......................................... 1
Unit Dimensions ........................................................ 2
Parts Arrangement..................................................... 3
Shipping and Packing List ......................................... 4
Safety Information ..................................................... 4
General ...................................................................... 6
Combustion, Dilution & Ventilation Air ....................... 6
Setting Equipment ..................................................... 8
Filters ........................................................................11
Duct System ............................................................ 12
Venting..................................................................... 13
Gas Piping ............................................................... 20
Electrical .................................................................. 22
Integrated Control DIP Switch Settings ................... 32
On-Board Links and Diagnostic Push Button .......... 32
Unit Start-Up ............................................................ 33
Other Unit Adjustments............................................ 36
Heating Sequence of Operation .............................. 36
Service..................................................................... 37
Repair Parts List ...................................................... 39
Blower Performance ................................................ 40
*P508144-01B*
Issue 2228
Warm Air Gas Furnace
Upflow/Horizontal
Left/Right Air Discharge
(P) 508144-01B
Page 1 of 42
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Summary of Contents for Blueridge BG802UHE
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Page 1: Table Of Contents
On-Board Links and Diagnostic Push Button ..32 BG802UHE Gas Furnace Unit Start-Up ............33 Other Unit Adjustments..........36 The BG802UHE gas furnace is shipped ready for Heating Sequence of Operation ......36 installation in the upflow or horizontal right position (for Service..............37 horizontal left position the combustion air pressure switch Repair Parts List ............ -
Page 2: Unit Dimensions
Unit Dimensions • Flue outlet may be horizontal but furnace must be TOP VIEW vented vertically. 3-1/8 (79) • Optional external side return air filter kit cannot be used with the optional RAB Return Air Base. SUPPLY AIR FLUE OUTLET OPENING (Top) OPTIONAL... -
Page 3: Parts Arrangement
Parts Arrangement Make Up Box Heat Exchanger Combustion Air Inducer Combustion Air Pressure Switch Gas Valve and Manifold Assembly Collector Box Indoor Blower and Motor Assembly (installed in cabinet) Limit Switch (under collector box) Constant Torque Indoor Blower Motor (removed from cabinet) Two-Stage Integrated Control Figure 1. -
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 furnace vent pipe or chimney. As a result, combustion ADHERED TO. gases enter the living space creating a potentially dangerous situation. In the absence of local codes concerning air for combustion General and ventilation, use the guidelines and procedures in this section to install these furnaces to ensure efficient and... - Page 7 fireplaces, exhaust fans, or clothes dryers are used at the total input rating of all gas fired equipment in the confined same time as the furnace, much more air is necessary to space. Each opening must be at least 100 square inches ensure proper combustion and to prevent a downdraft.
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Page 8: Setting Equipment
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... - Page 9 Return Air - Upflow Applications Units with 1/2 or 3/4 HP Blower Motor Return air can be brought in through the bottom or either side of the furnace installed in an upflow application. If the furnace is installed on a platform with bottom return, make an airtight seal between the bottom of the furnace and the RIGID LEG remove shipping bolt and washer...
- Page 10 FURNACE FRONT IF BASE 23 (584) 3−1/4 Overall IS USED (83) (Maximum) Minimum WITHOUT 11 (279) IAQ CABINET, INDOOR AIR A SINGLE Maximum 22−7/16 QUALITY Unit side return air RETURN AIR 14 (356) (570) CABINET Opening PLENUM Overall MUST AIR FLOW (Maximum) COVER BOTH UNIT AND...
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Page 11: Filters
Return Air - Horizontal Applications Return air must be brought in through the end of a furnace installed in a horizontal application. The furnace is equipped with a removable bottom panel to facilitate installation. See Figure 11. CAUTION If this unit is being installed in a space serviced by an exhaust fan, power exhaust fan, or other device which Type of Vent Type C... -
Page 12: Duct System
w.c. Higher external static pressures may cause erratic limit operation. WARNING Supply Air Plenum If a high-efficiency filter is being installed as part of this system to ensure better indoor air quality, the filter must If the furnace is installed without a cooling coil, a removable be properly sized. -
Page 13: Venting
If necessary reposition the combustion air inducer, Venting pressure switch and/or make-up box as needed per the following steps. See Figure 18 through Figure 23. A 4 inch diameter flue transition is factory installed on Remove the four mounting screws which secure the the combustion air inducer outlet of all models. - Page 14 Vent Pipe Vent Pipe Pressure Switch Pressure Switch Flue Transition Flue Cover Plate Transition FLOW FLOW Collector Box Cover Plate Collector Box Make-Up Box • Disconnect pressure switch hose from barbed fitting on the Make-Up Box pressure switch assembly. Remove pressure switch assembly (1 screw) and cut wire tie to free pressure switch wires.
- Page 15 Venting Using a Masonry Chimney These series units are classified as fan assisted Category I furnaces when vertically vented according to the latest The following additional requirements apply when a lined edition of National Fuel Gas Code (NFPA 54 / ANSI masonry chimney is used to vent this furnace.
- Page 16 NOTE: Refer to provided venting tables for installations. NOTE: The chimney must be properly sized per provided venting tables or lined with listed metal lining system. Figure 25. Common Venting Using Tile Lined Interior Masonry Chimney and Combined Vent Connector A fan assisted furnace may be commonly vented into an existing lined masonry chimney if the following conditions are met:...
- Page 17 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 18 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 19 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 20: 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 21 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 22: Electrical
Gas Supply This unit is shipped standard for left or right side IMPORTANT installation of gas piping (or top entry in horizontal applications). Connect the gas supply to the piping When testing pressure of gas lines, gas valve must be assembly. - Page 23 Install a separate (properly sized) disconnect switch near the furnace so that power can be turned off for servicing. CAUTION Before connecting the thermostat, check to make sure the Failure to use properly sized wiring and circuit breaker wires will be long enough for servicing at a later date. Make may result in property damage.
- Page 24 Thermostat Install the room thermostat according to the instructions provided with the thermostat. See Table 7 for thermostat designations. If the furnace is being matched with a heat pump, refer to the FM21 installation instruction or appropriate dual fuel thermostat instructions.
- Page 25 120V ACC PRIMARY COMBUSTION AIR (IF USED) INDUCER MOTOR LIMIT VALVE S102 BURNERS HIGH HEAT PRESSURE SWITCH S128 FLAME FLAME IGNITOR FLAME LOW HEAT ROLLOUT SENSOR J159 ROLLOUT PRESSURE SWITCH P159 SWITCH SWITCH JACKPLUG CHART 24VAC TO C J,P48 JACK/PLUG-INDOOR BLOWER-POWER HUMIDIFIER SEE HUM VIEWS TO R OR H ON CS7000...
- Page 26 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 27 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 28 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 29 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 30 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...
- Page 31 UTEC TWO-STAGE CONSTANT TORQUE INTEGRATED FURNACE CONTROL Line Voltage Ignitor and Combustion Accessories Air Inducer Humidifier Neutrals ECM DRIVE - 24VAC Line Voltage Flame Sense On Board Links Thermostat Connections 3/16” QUICK CONNECT TERMINALS THERMOSTAT CONNECTIONS HI COOL (24VAC) DS= Dehumidification signal LO COOL (24VAC) W2= Heat demand from 2 nd stage Tstat HI HEAT (24VAC)
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Page 32: Integrated Control Dip Switch Settings
Integrated Control DIP Switch Settings Switch 3 Switch 4 Seconds BG802UHE 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 33: 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 34 10. Is pressure switch closed? Obstructed flue will cause HIGH FIRE unit to shut off at pressure switch. Check flue and LOW FIRE MANIFOLD ADJUSTMENT ADJUSTMENT PRESSURE TAP outlet for blockages. (under cap) (under cap) 11. Are flame rollout switches tripped? If flame rollout switches are tripped, call the service technician for inspection.
- Page 35 Table 12 shows acceptable combustion for all If necessary, make adjustments. Figure 36 and Figure BG802UHE models. The maximum carbon monoxide 37 show location of high fire and low fire adjustment reading should not exceed 100 ppm.
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Page 36: Other Unit Adjustments
This manually reset switches are located on the baffle The two-stage, variable speed integrated control used plate in the burner assembly. in BG802UHE units has an added feature of an internal Watchguard control. The feature serves as an automatic Pressure Switch... -
Page 37: 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 38 Annual Furnace Maintenance Perform a general system test. Turn on the furnace to check operating functions such as the start-up and shutoff At the beginning of each heating season, and to comply operation. with the Blue Summit Limited Warranty, your system should be checked as follows: 1.
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Page 39: Repair Parts List
Ignitor Retention Rings Rollout Switches Sensor Cross Over Manifold And Gas Valve Figure 38. Burner Removal Repair Parts List Heating Parts following repair parts available through independent Blue Summit dealers. When ordering parts, • Flame sensor include the complete furnace model number listed on •... -
Page 40: Blower Performance
Blower Performance BG802UH070AE12 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 1375 1350 1110 0.10 1350... - Page 41 Low Fire Heating Speeds High Fire Heating Speeds Models Yellow Blue Brown Black Yellow Blue Brown Black Factory Factory 070-12 Allowed Allowed Setting Setting Factory Factory 090-12 Allowed Allowed Allowed Allowed Allowed Setting Allowed Allowed Allowed Setting Factory Factory 090-16 Allowed Allowed Setting...
- Page 42 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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