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Furnace
BGH96M120D5A
Installation, operation and maintenance manual
Bosch BGH96M120D5A Installation, Operation And Maintenance Manual
96% afue gas furnace
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Table of Contents
1 Key to Symbols and Safety Instructions
Safety
2 Dimensions
3 Introduction
4 Codes and Standards
Safety
General Installation
Combustion and Ventilation Air
Duct Systems
Acoustical Lining and Fibrous Glass Duct
Gas Piping and Gas Pipe Pressure Testing
Electrical Connections
Electrical Power Supply
Venting
5 Electrostatic Discharge (ESD) Precautions Procedure
6 Location
General
7 Installation
Upfl Ow Installation
Horizontal Installation
Condensate Line and over Flow Pressure Switch
Filter Arrangement
Air Ducts
8 Combustion Air and Vent System
Combustion Air and Vent Safety
Combustion Air/Vent Pipe Sizing
Comnustion Air and Vent Piping Assembly
Combustion Air / Venting
Vent System
Combustion & Ventilation Air Requirements
Vent and Supply (Outside) Air Safety Check Procedure
9 Gas Supply and Piping
General
High Altitude Derate
Propane Gas (LP) Conversion
Gas Piping Connections
Gas Piping Checks
10 Electrical Connections
Wiring
Electrical Connection to J-Box
Power Cord Installation in Furnace J-Box
BX Cable Installation in Furnace J-Box
24-V Wiring
Accessories (Field Supplied)
Grounding
11 Start-Up, Adjustment, and Safety Check
General
Start-Up Procedures
Furnace Start-Up
Sequence of Operation
Gas Manifold Pressure Measurement and Adjustment
Gas Input Rate Measurement (Natural Gas Only)
Temperature Rise Adjustment
Circulator Blower Speed Adjustment
12 Operational Checks
13 Safety Circuit Description
General
Integrated Control Module
Chamber Limit Switch - Fixed
Fan Mounted Limit Switch
Rollout Switch - Resettable
Overfl Ow Protection Pressure Switch (Overfl Ow Switch)
Pressure Switches
Flame Sensor
14 Troubleshooting
Electrostatic Discharge (ESD) Precautions
Resetting from Lockout
Troubleshooting Chart
15 Service and Maintenance Procedures
Annual Inspection
Filters
Induced Draft and Circulating Blower Motors
Flame Sensor (Qualifi Ed Service Technicians Only)
Ignitor (Qualifi Ed Service Technicians Only)
Burners
Inspecting the Heat Exchanger (Qualifi Ed Service Technicians Only)
Condensate Drain
Repair and Replacement Parts
16 Before Leaving Installation
17 Wiring Diagram
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Dimensions
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24-V Wiring
3
Circulator Blower Speed Adjustment
4
Troubleshooting Chart
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Bosch 96% AFUE Gas Furnace BGH96 Model
Condensing Gas Furnace
Installation, Operation, and Maintenance Manual
3124627
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Summarization of Contents
Key to Symbols and Safety Instructions
Key to Symbols
Explains warning symbols and keywords used in the manual.
General Safety Guidelines
Provides guidance for installers, users, and servicers on manual usage.
Furnace Dimensions and Specifications
Dimensions and Weight Data
Provides detailed physical dimensions and weight for various furnace models.
Furnace Introduction
General Information and Requirements
Overview of the furnace type, certifications, and basic installation requirements.
Codes and Standards Compliance
Safety, Installation, and Technical Standards
Lists safety, installation, and technical standards relevant to furnace installation.
Electrostatic Discharge Precautions
Outlines steps to prevent damage from electrostatic discharge during installation/servicing.
Furnace Location Requirements
General Location Guidelines
General guidelines for selecting a suitable furnace installation location.
Furnace Installation Procedures
Upflow and Horizontal Installation
Instructions for installing the furnace in upflow and horizontal configurations.
Condensate Drain System Installation
Guidelines for installing the condensate drain line and overflow switch.
Air Ducting and Filters
Filter Arrangement and Maintenance
Guidelines on filter types, sizes, and placement for optimal furnace performance.
Air Duct Requirements
General guidelines for designing and installing air duct systems for furnaces.
Combustion Air and Vent System
Safety and Pipe Sizing
Safety requirements for combustion air and vent systems and pipe sizing.
Vent Clearances and Terminations
Details required clearances for vent terminals and termination location considerations.
Combustion Air Supply Methods
Details the three methods for supplying combustion air: outdoor, ambient, and ventilated.
Vent and Supply Air Safety Check
Procedure to ensure proper ventilation and detect carbon monoxide hazards.
Gas Supply and Piping
General Supply, Pressure, and Altitude Derate
Overview of gas supply, pressure, altitude derate, and LP conversion.
Gas Piping Connections and Checks
Details on proper sizing, connection, and leak testing of gas piping.
Electrical Connections and Grounding
Wiring, Junction Box, and Accessories
Guidelines for 115V wiring, junction box relocation, connections, and accessories.
Electrical Grounding Requirements
Requirements for proper electrical grounding of the furnace.
Start-Up, Adjustment, and Safety Checks
General Start-Up and Shutdown Procedures
Step-by-step procedures for initiating, adjusting, and safely shutting down furnace operation.
Sequence of Operation and Performance Adjustments
Explains operational sequence and procedures for gas pressure, input rate, and blower speed adjustments.
Operational Checks and Safety Circuits
Burner Flame Inspection
How to visually inspect burner flames for proper operation and identify issues.
Safety Circuit Functions
Overview of furnace safety circuits and their monitoring by the control module.
Furnace Troubleshooting Guide
Troubleshooting Procedures and Charts
Procedures for diagnosing operational problems using LED codes and lockout resets.
Service and Maintenance Procedures
Annual Inspection and Filter Maintenance
Checklist for annual furnace inspection and guidelines for filter maintenance.
Component Service and Replacement Parts
Procedures for servicing key components and information on replacement parts.
Final Installation Checks
Final checks and homeowner orientation before leaving the installation site.
Wiring Diagram
Furnace Wiring Schematic
Provides the electrical wiring schematic for the furnace controls and components.
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