INSTALLATION INSTRUCTIONS BG962-V Warm Air Gas Furnace Upflow/Horizontal Left Air Discharge Direct Vent & Non-Direct Vent 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. CAUTION WARNING As with any mechanical equipment, personal injury can result from contact with sharp sheet metal edges.
Unit Dimensions 1 NOTE - C*20 and D*20 (5 Ton) size units installed in upflow applications that require air volumes of 1800 cfm (850 L/s) or greater must have one of the following: 1. Single side return air with transition, to accommodate 20 x 25 x 1 in. (508 x 635 x 25 mm) air filter. 2. Single side return air with optional RAB Return Air Base 3. Bottom return air. 4. Return air from both sides. 5. Bottom and one side return air.
Parts Arrangement Figure 1.
Gas Furnace Shipping and Packing List The BG962-V Category IV gas furnace is shipped ready for installation in the upflow or horizontal position. The furnace is shipped with the bottom panel in place. The bottom panel must be removed if the unit is to be installed in horizontal or upflow applications with bottom return air.
Building Codes In the USA, installation of gas furnaces must conform with local building codes. In the absence of local codes, units must be installed according to the current National Fuel Gas Code (ANSI Z223.1/NFPA 54). The National Fuel Gas Code is available from the American National Standards Institute, Inc., 11 West 42nd Street, New York, NY 10036.
Use of Furnace as a Construction Heater Units may be used for heating of buildings or structures under construction, if the following conditions are met to ensure proper operation. DO NOT USE THE UNIT FOR CONSTRUCTION HEAT UNLESS ALL OF THE FOLLOWING CRITERIA ARE MET: a. Furnace must be in its final location. The vent system must be permanently installed per these installation instructions. b.
Combustion, Dilution & Ventilation Air If this unit is installed as a Non-Direct Vent Furnace, follow the guidelines in this section. NOTE: In Non-Direct Vent Installations, combustion air is taken from indoors and flue gases are discharged outdoors. of ANSI on the referenced subject, which is represented only by the standard in its entirely. In Canada, refer to the CSA B149 Installation codes. CAUTION Do not install the furnace in a corrosive or contaminated atmosphere.
terminate outside the space containing the furnace. This is especially important when the furnace is mounted on a platform in a confined space such as a closet or small equipment room. Even a small leak around the base of the unit at the platform or at the return air duct connection can cause a potentially dangerous negative pressure condition. Air for combustion and ventilation can be brought into the confined space either from inside the building or from outside.
Roof Terminated Exhaust Pipe Ventilation Furnace Louvers (Crawl Space) Coupling or 3 in. to 2 in. Transition (Field Provided) Inlet Air Minimum 12 in. (305mm) above Crawl Space Floor *Intake Debris Screen Provided * See Maximum Vent Lengths table Figure 8. Equipment in Confined Space - All Air from Outside Ventilation Louvers Roof Terminated Exhaust Pipe NOTE-The inlet and outlet air openings shall each have a free area of at least one square inch per 4,000 Btu (645mm2 per 1.
Allow for clearances to combustible materials as indicated on the unit nameplate. Installation Setting Equipment WARNING Do not connect the return air ducts to the back of the furnace. Doing so will adversely affect the operation of the safety control devices, which could result in personal injury or death. WARNING Blower access panel must be securely in place when blower and burners are operating.
Return Air Guidelines 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 platform to ensure that the furnace operates properly and safely. The furnace is equipped with a removable bottom panel to facilitate installation. WARNING Improper installation of the furnace can result in personal injury or death.
Horizontal Applications WARNING Do not install the furnace on its front or its back. See Figure 17. Figure 15. Side Return Air (with transition and filter) Removing the Bottom Panel Figure 17. This furnace can be installed in horizontal applications with either right or left hand air discharge. Remove the two screws that secure the bottom cap to the furnace. Pivot the bottom cap down to release the bottom panel. Once the bottom panel has been removed, reinstall the bottom cap. See Figure 16.
Suspended Installation of Horizontal Unit This furnace may be installed in either an attic or a crawl space. Either suspend the furnace from roof rafters or floor joists, as shown in Figure 19, or install the furnace on a platform, as shown in Figure 20. A horizontal suspension kit (51W10) may be ordered from your distributor or use equivalent. NOTE: Heavy-gauge sheet metal straps may be used to suspend the unit from roof rafters or ceiling joists.
Duct System CAUTION Use industry approved standards to size and install the supply and return air duct system. This will result in a quiet and low-static system that has uniform air distribution. NOTE: This furnace is not certified for operation in heating mode (indoor blower operating at selected heating speed) with an external static pressure which exceeds 0.8 inches w.c. Operation at these conditions may result in improper limit operation.
5. IMPORTANT BG962-V exhaust and intake connections are made of PVC. Use PVC primer and solvent cement when using PVC vent pipe. When using ABS vent pipe, use transitional solvent cement to make connections to the PVC fitting in the unit. Uniformly apply a liberal coat of PVC primer for PVC or use a clean dry cloth for ABS to clean inside socket surface of fitting and male end of pipe to depth of fitting socket. NOTE: Time is critical at this stage. Do not allow primer to dry before applying cement.
Exhaust Piping 1. In areas where piping penetrates joist or interior walls, hole must be large enough to allow clearance on all sides of pipe through center of hole using a hanger. 2. When furnace is installed in a residence where unit is shut down for an extended period of time, such as a vacation home, make provisions for draining condensate collection from trap and lines.
1. Seal any unused openings in the common venting system. 2. Inspect the venting system for proper size and horizontal pitch. Determine that there is no blockage, restriction, leakage, corrosion, or other deficiencies which could cause an unsafe condition. 3. Close all building doors and windows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building.
Use the following steps to correctly size vent pipe diameter. NOTE: All horizontal runs of exhaust pipe must slope back toward unit. A minimum of 1/4” (6 mm) drop for each 12” (305 mm) of horizontal run is mandatory for drainage. NOTE: Exhaust pipe MUST be glued to furnace exhaust fittings.
Maximum Allowable Intake or Exhaust Vent Length in Feet Standard Termination at Elevation 0 - 4,500 ft 1-1/2" Pipe 2" Pipe 2-1/2" Pipe 3" Pipe Capacity Capacity Capacity Capacity Number of 90° Elbows Used 45 70 1 25 2 90 45 70 90 110 45 70 90 110 20 76 61 39 19 110 110 88 20 15 71 56 34 14 105 105 3 15 10 66 51 29 9 100 4 10 61 46 24 56 41 19 51 36 14 46 31 9 41 26 9 36 21 10 31 16 5 n/a 6 7 8 n/a 110 n/a 135 n/a n/a 135 n/a n/a
Maximum Allowable Intake or Exhaust Vent Length in Feet Concentric Termination at Elevation 0 - 4,500 ft 1-1/2" Pipe 2" Pipe 2-1/2" Pipe 3" Pipe Capacity Capacity Capacity Capacity Number of 90° Elbows Used 45 70 1 25 2 90 45 70 90 110 45 70 90 110 20 68 53 37 17 100 100 84 20 15 63 48 32 12 95 95 3 15 10 58 43 27 7 90 4 10 53 38 22 48 33 17 43 28 12 38 23 7 33 18 9 28 13 10 23 8 5 n/a 6 7 8 n/a 110 n/a 135 n/a n/a 135 n/a n/a n
Maximum Allowable Exhaust Vent Lengths with Furnace Installed in a Closet or Basement Using Ventilated Attic or Crawl Space for Intake Air in Feet Standard Termination at Elevation 0 - 4,500 ft 1-1/2" Pipe 2" Pipe 2-1/2" Pipe 3" Pipe Capacity Capacity Capacity Capacity Number of 90° Elbows Used 45 70 1 25 2 90 45 70 90 110 45 70 90 110 20 66 51 29 9 95 95 73 20 15 61 46 24 4 90 90 3 15 10 56 41 19 85 4 10 51 36 14 46 31 9 41 26 4 36 21 31 16 9 26
TYPICAL EXHAUST PIPE CONNECTIONS IN UPFLOW DIRECT OR NON-DIRECT VENT APPLICATIONS Pipe size determined in Table 5 2” 2” 2” 2” 2” or EXHAUST 3” or TRANSITION *2” 045/070 Only 1-1/2” DO NOT transition from smaller to larger pipe in horizontal runs of exhaust pipe. TRANSITION 2” 6” MINIMUM * When transitioning up in pipe size, use the shortest length of 2” PVC pipe possible. NOTE: Exhaust pipe and intake pipe must be the same diameter. Figure 25.
TYPICAL INTAKE PIPE CONNECTIONS IN UPFLOW DIRECT OR NON-DIRECT VENT APPLICATIONS 2” AIR INTAKE or 3” Pipe size determined in Table 5 TRANSITION *2” 2” 2” 2” 2” or * When transitioning up in pipe size, use the shortest length of 2” PVC pipe possible. NOTE: Exhaust pipe and intake pipe must be the same diameter. Figure 27.
intake opening (with the protective screen) should always be directed forward or to either side in the upflow position, and either straight out or downward in the horizontal position. The air intake piping must not terminate too close to the flooring or a platform. Ensure that the intake air inlet will not be obstructed by loose insulation or other items that may clog the debris screen. 2.
At vent termination, care must be taken to maintain protective coatings over building materials (prolonged exposure to exhaust condensate can destroy protective coatings). It is recommended that the exhaust outlet not be located within 6 feet (1.8 m) of a condensing unit because the condensate can damage the painted coating. Roof Terminated Exhaust Pipe Ventilation Furnace Louvers (Crawl Space) Coupling or 3 in. to 2 in.
Maximum Allowable Exhaust Vent Pipe Length3 (in ft.) without Insulation in Unconditioned Space for Winter Design Temperatures Winter Design Temperatures1 ºF (ºC) Unit Input Size Vent Pipe 045 Diameter PVC 32 to 21 (0 to -6) 20 to 1 (-7 to -17) 0 to -20 (-18 to -29) 070 2 PP PVC 090 2 PP PVC 110 2 PP PVC 135 2 PP PVC 2 PP 1-1/2 in. 22 N/A 25 N/A N/A N/A N/A N/A N/A N/A 2 in. 21 18 33 30 46 42 30 30 N/A N/A 2-1/2 in.
VENT TERMINATION CLEARANCES FOR NON-DIRECT VENT INSTALLATIONS IN THE US AND CANADA INSIDE CORNER DETAIL G H A D E B L Fixed Closed Operable F B B C B K AREA WHERE TERMINAL IS NOT PERMITTED AIR SUPPLY INLET VENT TERMINAL M J A B I Fixed Closed Operable US Installations1 A= Clearance above grade, veranda, porch, deck or balcony B= Clearance to window or door that may be opened C= Clearance to permanently closed window D= Vertical clearance to ventilated soffit located above the ter
VENT TERMINATION CLEARANCES FOR DIRECT VENT INSTALLATIONS IN THE USA AND CANADA INSIDE CORNER DETAIL G H A D E B L Fixed Closed Operable F B B C Operable B A B M K J AREA WHERE TERMINAL IS NOT PERMITTED AIR SUPPLY INLET VENT TERMINAL I Fixed Closed US Installations1 A= Clearance above grade, veranda, porch, deck or balcony B= Clearance to window or door that may be opened C= Clearance to permanently closed window D= Vertical clearance to ventilated soffit located above the terminal
Details of Intake and Exhaust Piping Terminations for Direct Vent Installations NOTE: In Direct Vent installations, combustion air is taken from outdoors and flue gases are discharged to outdoors. NOTE: Flue gas may be slightly acidic and may adversely affect some building materials. If any vent termination is used and the flue gasses may impinge on the building material, a corrosion resistant shield (minimum 24 inches square) should be used to protect the wall surface.
7. If intake and exhaust piping must be run up a side wall to position above snow accumulation or other obstructions, piping must be supported every 24” (610 mm) as shown in Figure 44. Exhaust and intake piping that is run up a wall is considered to be in an unconditioned space, so piping should be sized according to Table 6. The intake piping may be equipped with a 90° elbow turndown. Using turndown will add 5 feet (1.5 m) to the equivalent length of the pipe. 8.
FIELD FABRICATED WALL TERMINATION NOTE − FIELD−PROVIDED REDUCER MAY BE REQUIRED TO ADAPT LARGER VENT PIPE SIZE TO TERMINATION 2” (51mm) 3” (76mm) Vent Pipe Vent Pipe D D B C1 A B Intake Elbow C2 A STRAIGHT APPPLICATION * WALL SUPPORT D E D E B B A C1 EXTENDED APPLICATION A C2 A− Minimum clearance above grade or average snow accumulation 12” (305 mm) 12” (305 mm) B− Maximum horizontal separation between intake and exhaust 6” (152 mm) 6” (152 mm) C1 -Minimum from end of exhaust t
Details of Exhaust Piping Terminations for NonDirect Vent Applications Exhaust pipes may be routed either horizontally through an outside wall or vertically through the roof. In attic or closet installations, vertical termination through the roof is preferred. Figure 45 through Figure 48 show typical terminations. 1. Exhaust piping must terminate straight out or up as shown. The termination pipe must be sized as listed in Table 7.
Exhaust through Crawl Space Vent Option All 33” condensing gas furnaces (92%+) are now approved to be vented down through a crawl space. Ensure a vent pipe drain kit, 51W18 (USA) or 15Z70 (Canada), is used as directed through the floor joists and into the crawl space. See the following figures. Exhaust from Furnace To Termination Consult the vent tables for vent lengths and approved materials.
5. Condensate Piping This unit is designed for either right or left side exit of condensate piping in upflow applications. In horizontal applications, the condensate trap must extend below the unit. An 8” service clearance is required for the condensate trap. Refer to Figure 52 and Figure 54 for condensate trap locations. Figure 58 shows trap assembly using 1/2” PVC or 3/4” PVC. Figure 54 and Figure 55 show the furnace and evaporator coil using a separate drain.
*Piping from furnace must slope down a minimum of 1/4” per ft. toward trap. Figure 54. Condensate Trap Locations (Unit shown in horizontal right hand discharge position using a separate drain) Figure 55. Unit with Evaporator Coil Using a Separate Drain Figure 56. Evaporator Coil Using a Common Drain *Piping from furnace must slope down a minimum of 1/4” per ft. toward trap. Figure 57.
Figure 58.
IMPORTANT IMPORTANT A low inlet pressure switch in LP/propane applications is recommended. When combining the furnace and evaporator coil drains together, the A/C condensate drain outlet must be vented to relieve pressure in order for the furnace pressure switch to operate properly. 2. When connecting gas supply, factors such as length of run, number of fittings and furnace rating must be considered to avoid excessive pressure drop. Table 8 lists recommended pipe sizes for typical applications.
Upflow Application Left Side Piping (Standard) Upflow Application Right Side Piping (Alternate) AUTOMATIC GAS VALVE (with manual shut-off valve) MANUAL MAIN SHUT-OFF VALVE MANUAL MAIN SHUT-OFF VALVE GROUND JOINT UNION GROUND JOINT UNION Gas Valve DRIP LEG FIELD PROVIDED AND INSTALLED DRIP LEG Gas Valve In LP/Propane applications, a 4” BIP nipple must be installed to allow clearance for the low inlet pressure switch. NOTE - BLACK IRON PIPE ONLY TO BE ROUTED INSIDE OF CABINET Figure 60.
Gas Pipe Capacity - FT³/HR (kL/HR) Nominal Iron Pipe Size inches (mm) Internal Diameter - inches (mm) Length of Pipe - feet (m) 10 20 30 (3.048) (6.096) (9.144) 40 50 60 70 80 90 100 (12.192) (15.240) (18.288) (21.336) (24.384) (27.432) (30.480) 1/2 .622 175 120 97 82 73 66 61 57 53 50 (12.7) (17.799) (4.96) (3.40) (2.75) (2.32) (2.07) (1.87) (1.73) (1.61) (1.50) (1.42) 3/4 .824 360 250 200 170 151 138 125 118 110 103 (19.05) (20.930) (10.19) (7.
Refer to Figure 72 for field wiring and Figure 73 for schematic wiring diagram and troubleshooting. Electrical 1. ELECTROSTATIC DISCHARGE (ESD) Precautions and Procedures The power supply wiring must meet Class I restrictions. Protected by either a fuse or circuit breaker, select circuit protection and wire size according to unit nameplate. NOTE: Unit nameplate states maximum current draw. Maximum over current protection allowed is shown in Table 10.
9. Install the room thermostat according to the instructions provided with the thermostat. If the furnace is being matched with a heat pump, refer to the instruction packaged with the dual fuel thermostat. Indoor Blower Speeds 1. 2. 3. When the thermostat is set to “FAN ON,” the indoor blower will run continuously at approximately 50% of the second stage cooling speed when there is no cooling or heating demand. See Table 13 for allowable continuous circulation speeds.
Electronic Air Cleaner Terminals are provided on the integrated ignition/blower control board for connection of a 120-volt electronic air cleaner. The “EAC” terminal is energized whenever the thermostat calls for heat, cooling, or continuous blower. See furnace wiring diagram for specific connection information. Variable Speed Features This furnace is equipped with a variable speed circulation air blower motor that will deliver a constant airflow within a wide range of external static pressures.
Sequence of Operation Cooling Heating On a call for heat from the room thermostat, the control board performs a 1 second self check. Upon confirmation that the pressure switch contacts are in an open position, the control energizes the combustion blower on high speed. The control then checks for adequate combustion air by making sure the low-fire pressure switch contacts are closed. The unit is set up at the factory for single stage cooling.
Figure 67. Indoor Blower Operation - 1st Stage-2nd Stage (W1/W2) Heat Call Figure 70. Indoor Blower Operation - Single Stage Cooling Figure 68. Indoor Blower Operation - High Heat (W2) Call * Percentage of High Stage Cooling Figure 69. Indoor Blower Operation - Call for Fan * Percentage of High Stage Cooling Figure 71.
Emergency Replacement Motor Operation If the variable speed motor needs to be replaced in an emergency situation (such as “no heat”) and an exact replacement motor is not immediately available, a standard PSC motor of equivalent frame size, voltage, rotation, and horsepower can be temporarily installed until the correct replacement motor can be obtained.
WARNING: ELECTRIC SHOCK HAZARD, CAN CAUSE INJURY OR DEATH. UNIT MUST BE GROUNDED IN ACCORDANCE WITH NATIONAL AND LOCAL CODES NOTE: IF ANY WIRE IN THIS APPLIANCE IS REPLACED, IT MUST BE REPLACED WITH WIRE OF LIKE SIZE, RATING, INSULATION THICKNESS AND TERMINATION FIELD SUPPLIED ACC. WIRE S145 IS USED WITH HONEYWELL GAS VALVE WHEN APPLIED IN LP GAS UNITS Figure 72.
NOTES: 1. PRESS AND RELEASE FAULT CODE HISTORY BUTTON TO DISPLAY FAULT CODES. TO ERASE CODES, PRESS AND HOLD BUTTON IN FOR MORE THAN 5 SECONDS 2. IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THE FURNACE MUST BE REPLACED, IT MUST BE REPLACED WITH WIRING MATERIAL HAVING A TEMP. RATING OF AT LEAST 90°c. 3. PROPER POLARITY MUST BE OBSERVED FOR FIELD LINE VOLTAGE SUPPLY; IGNITION CONTROL WILL LOCK OUT IF POLARITY IS REVERSED. 4.
Blower Performance 96G2UH045BV12 Temp. Rise High Fire 35-65 Low Fire 20-50 Speed Adjustment + Heating CFM @ 0 - 0.8” w.c. Setting D Setting C Setting B Setting A 745 875 990 1005 Normal 685 765 895 910 - 610 695 785 810 + 685 765 895 910 Normal 620 705 800 820 - 545 625 715 725 Cooling Stage 2nd Stage 1st Stage Cooling CFM @ 0 - 0.8” w.c.
96G2UH090CV12 Temp. Rise High Fire 60-90 Low Fire 35-65 Speed Adjustment Heating CFM @ 0 - 0.8” w.c. Setting D Setting C Setting B Setting A + 1060 1135 1240 1430 Normal 960 1040 1120 1310 - 830 935 980 1175 + 960 1040 1120 1310 Normal 875 945 995 1195 - 790 840 920 1080 Cooling Stage 2nd Stage 1st Stage Cooling CFM @ 0 - 0.8” w.c.
96G2UH110CV20 Temp. Rise High Fire 45-75 Low Fire 35-65 Speed Adjustment Heating CFM @ 0 - 0.8” w.c. Setting D Setting C Setting B Setting A + 1560 1760 1905 2080 Normal 1415 1610 1740 1930 - 1285 1485 1560 1745 + 1155 1325 1420 1565 Normal 1055 1200 1310 1480 - 935 1075 1170 1315 1745 1955 Cooling Stage Cooling CFM @ 0 - 0.8” w.c.
Allowable Heating Speeds Model Number 96G2UH045BV12 96G2UH070BV12 96G2UH090CV12 96G2UH090CV20 96G2UH110CV20 96G2UH135DV20 Speed Adjust Setting "D" Setting "C" Setting "B" Setting "A" +10% Allowed Allowed Allowed Allowed Norm Allowed Allowed Factory Setting Allowed -10% Allowed Allowed Allowed Allowed +10% Allowed Allowed Allowed Not Allowed Norm Allowed Allowed Factory Setting Not Allowed -10% Allowed Allowed Allowed Not Allowed +10% Allowed Allowed Allowed Allow
Placing the Furnace into Operation Unit Start-Up This furnace is equipped with an automatic hot surface ignition system. Do not attempt to manually light burners on this furnace. Each time the thermostat calls for heat, the burners will automatically light. The ignitor does not get hot when there is no call for heat on these units. FOR YOUR SAFETY READ BEFORE OPERATING WARNING Gas Valve Operation Do not use this furnace if any part has been underwater. A flood-damaged furnace is extremely dangerous.
Turning Off Gas to Unit 1. Set the thermostat to the lowest setting. 2. Turn off all electrical power to the unit if service is to be performed. 3. Remove the upper access panel. 4. Move gas valve switch to OFF. 5. Replace the upper access panel. control will then automatically repeat steps 1 through 6 after 60 minutes. To interrupt the 60 minute period, move thermostat from “Heat” to “OFF” then back to “Heat”. Heating sequence then restarts at step 1.
For proper furnace operation the minimum gas supply pressure is 4.5” w.c and the maximum gas supply pressure is 10.5” w.c for natural gas. The minimum gas supply pressure is 10” w.c. and the maximum gas supply pressure is 13” w.c. for LP/propane gas. Pressure Switch Manifold Pressure Measurement Temperature Rise 1. A manifold pressure post located on the gas valve provides access to the manifold pressure. See Figure 74.
3. Service Check amp-draw on the blower motor. Motor Nameplate__________Actual__________ Winterizing and Condensate Trap Care WARNING ELECTRICAL SHOCK, FIRE, OR EXPLOSION HAZARD. Failure to follow safety warnings exactly could result in dangerous operation, serious injury, death or property damage. 1. Turn off power to the furnace. 2. Have a shallow pan ready to empty condensate water. 3. Remove the clean out cap from the condensate trap and empty water.
18. Mark and disconnect any remaining wiring to heating compartment components. Disengage strain relief bushing and pull wiring and bushing through the hole in the blower deck. 39. Secure burner assembly to vestibule panel using four existing screws. Burners are self aligning to center of clam shells. 19. Remove the primary limit from the vestibule panel. 41. Reconnect flame rollout switch wires. 20.
Planned Service A service technician should check the following items during an annual inspection. Power to the unit must be shut off for safety. Fresh air grilles and louvers (on the unit and in the room where the furnace is installed) - Must be open and unobstructed to provide combustion air. Burners - Must be inspected for rust, dirt, or signs of water. Vent pipe - Must be inspected for signs of water, cracked, damaged or sagging pipe, or disconnected joints.
Requirements for Commonwealth of Massachusetts Modifications to NFPA-54, Chapter 10 4. Revise NFPA-54 section 10.8.
