BG802DF Installation Instructions

ManualsBrandsBlueridge Manualsforced air80% AFUE 70,000 BTU 2 Stage Downflow Furnace

508145-01B Issue 2108 Page 1 of 36

INSTALLATION INSTRUCTIONS

BG802DFE

Warm Air Gas Furnace

Downow Air Discharge

(P) 508145-01B

*P508145-01B*

Manufactured By

Blue Summit LLC

8201 C National Turnpike

Louisville, KY 40214

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.

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.

WARNING

As with any mechanical equipment, personal injury can

result from contact with sharp sheet metal edges. Be

careful when you handle this equipment.

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

Downow 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

BG802DFE Gas Furnace

The BG802DFE gas furnace is shipped ready for

installation in the downow position fueled by natural gas.

A conversion kit (ordered separately) is required for use in

LP/ Propane gas applications.

Summary of content (36 pages)

PAGE 1
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. Table of Contents WARNING Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury or loss of life.
PAGE 2
Unit Dimensions 3-1/8 (79) 9/16 (14) D RETURN AIR OPENING B FLUE OUTLET (Top) 19-7/16 (494) 9/16 (14) 9/16 (14) TOP VIEW A 9/16 (14) B 27-3/4 (705) 1-1/2 (38) Front Panel 19-7/16 (494) 9/16 (14) AIR FLOW 33 (838) ELECTRICAL INLET (Either Side) 5-3/8 (137) Right 2-3/16 (56) Left GAS PIPING INLET (Either Side) 6-5/8 (168) Right 7-1/8 (181) Left 3/4 (19) C Supply Air 19-1/4 (489) 3/4 (19) FRONT VIEW Capacity Supply Air 3/4 (19) SIDE VIEW A B C D in. mm in. mm in. mm in.
PAGE 3
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.
PAGE 4
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 local building codes. In the absence of local codes, units must be installed according to the current National Fuel Gas Code (ANSI-Z223.1). The National Fuel Gas Code is available from the following address.
PAGE 5
Installed in Combination with a Cooling Coil When this furnace is used with cooling units, it shall be installed in parallel with, or on the upstream side of, cooling units to avoid condensation in the heating compartment. With a parallel flow arrangement, a damper (or other means to control the flow of air) must adequately prevent chilled air from entering the furnace (see Figure 2).
PAGE 6
ENTITIES. ALL SUCH POLICIES AND CODES MUST BE ADHERED TO. General These instructions are intended as a general guide and do not supersede local codes in any way. Consult authorities having jurisdiction before installation. In addition to the requirements outlined previously, the following general recommendations must be considered when installing one of these furnaces: • Place the furnace as close to the center of the air distribution system as possible.
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 square inch per 2,000 Btu (645 mm² per .59 kW) per hour of the total input rating of all equipment in the enclosure. If the equipment room is located against an outside wall and the air openings communicate directly with the outdoors, each opening shall have a free area of at least 1 square inch per 4,000 Btu (645 mm² per 1.17 kW) per hour of the total input rating of all other equipment in the enclosure.
PAGE 9
Cabinet Width Units with 1/2 or 3/4 HP Blower Motor RIGID LEG remove shipping bolt and washer Front to Rear Side to Side in in mm mm A (14-1/2”) 19-3/4 502 13-1/4 337 B (17-1/2”) 19-3/4 502 16-1/4 413 NOTE - Floor opening dimensions listed are 1/4 inch (6 mm) larger than the unit opening. See unit dimensions on Page 2. Table 1. Non-Combustible Floor Opening Size Figure 7.
PAGE 10
Cabinet Width Front to Rear Side to Side in in mm Return Air Opening -- Downflow Units The following steps should be taken when installing plenum: mm A (14-1/2”) 22 559 15-3/4 400 B (17-1/2”) 22 559 18-3/4 476 1. Bottom edge of plenum should be flanged with a hemmed edge (see Figure 11). Table 2. Combustible Floor Opening Size PLENUM Installation on Cooling Cabinet (Figure 10) Side View 1.
PAGE 11
Downflow Application Allow for clearances to combustible materials as indicated on the unit nameplate. Minimum clearances for closet or alcove installations are shown in Figure 14. Top Filters This unit is not equipped with a filter or rack. A field provided high velocity filter is required for the unit to operate properly. Table 3 lists recommended filter sizes. A filter must be in place any time the unit is operating.
PAGE 12
When return air is drawn from a room, a negative pressure is created in the room. If a gas appliance is operating in a room with negative pressure, the flue products can be pulled back down the vent pipe and into the room. This reverse flow of the flue gas may result in incomplete combustion and the formation of carbon monoxide gas.
PAGE 13
If the existing chimney will not accommodate a listed meta liner, either the chimney must be rebuilt to accommodate one of these liners or an alternate approved venting method must be found. • The vent connectors and chimney are sized according to the provided venting tables. IMPORTANT Insulation for the flexible vent pipe must be an encapsulated fiberglass sleeve recommended by the flexible vent pipe manufacturer. See Figure 17.
PAGE 14
General Venting Requirements 9. Vent all furnaces according to these instructions: 1. Vent diameter recommendations and maximum allowable piping runs are found in the provided venting tables. 2. 3. 4. In no case should the vent or vent connector diameter be less than the diameter specified in the provided venting tables. The minimum vent capacity determined by the sizing tables must be less than the low fire input rating and the maximum vent capacity must be greater than the high fire input rating.
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.
PAGE 16
Vent Connector Capacity Type B Double Wall Vents with Type B Double Wall Connectors Serving Two or More Category I Appliances Vent Height H (feet) Connector Rise R (feet) 6 8 10 15 20 30 Vent and Connector Diameter - D (inches) 3 inch 4 inch 5 inch 6 inch Appliance Input Rating in Thousands of Btu per Hour MIN MAX MIN MAX MIN MAX MIN MAX 1 22 37 35 66 46 106 58 164 2 23 41 37 75 48 121 60 183 3 24 44 38 81 49 132 62 199 1 22 40 35 72 49 114 64 176 2 2
PAGE 17
Removal of the Furnace from Common Vent In the event that an existing furnace is removed from a venting system commonly run with separate gas appliances, the venting system is likely to be too large to properly vent the remaining attached appliances. Conduct the following test while each appliance is operating and the other appliances (which are not operating) remain connected to the common venting system.
PAGE 18
Gas Pipe Capacity - FT³/HR (kL/HR) Nominal Iron Pipe Size inches (mm) Internal Diameter - inches (mm) Length of Pipe - feet (m) 10 (3.048) 20 (6.096) 30 (9.144) 1/2 (12.7) .622 (17.799) 172 (4.87) 118 (3.34) 95 (2.69) 81 (2.29) 72 (2.03) 65 (1.84) 60 (1.69) 56 (1.58) 52 (1.47) 50 (1.42) 3/4 (19.05) .824 (20.930) 360 (10.19) 247 (7.00) 199 (5.63) 170 (4.81) 151 (4.28) 137 (3.87) 126 (3.56) 117 (3.31) 110 (3.11) 104 (2.94) 1 (25.4) 1.049 (26.645) 678 (19.19) 466 (13.
PAGE 19
The furnace must be isolated by closing its individual manual shut-off valve and disconnecting from the gas supply system the during any pressure testing of the gas supply system at pressures less than or equal to 1/2 psig (3.48 kPa, 14 inches w.c.). CAUTION Failure to use properly sized wiring and circuit breaker may result in property damage. Size wiring and circuit breaker(s) per Technical Specification and unit rating plate.
PAGE 20
Electrically ground the unit according to local codes or, in the absence of local codes, according to the current National Electric Code (ANSI/NFPA No. 70). A green ground wire is provided in the field make-up box. NOTE: This furnace contains electronic components that are polarity sensitive. Make sure that the furnace is wired correctly and is properly grounded. Thermostat Install the room thermostat according to the instructions provided with the thermostat. See Table 9 for thermostat designations.
PAGE 21
COMFORT SYNC® THERMOSTAT 070-12 090-16 Figure 22.
PAGE 22
Thermostat DIP Switch Settings and On-Board Links Wiring Connections DIP Switch 1 On Board Links Must Be Cut To Select System Options T'STAT FURNACE TERM. STRIP OUTDOOR UNIT 1 Heat / 1 Cool NOTE: Use DIP switch 2 to set sceond-stage heat ON delay. OFF - 7 minutes ON - 12 minutes ON DO NOT CUT ANY ON-BOARD LINKS * *Not required on all units T'STAT FURNACE TERM. STRIP OUTDOOR UNIT 1 Heat / 2 Cool NOTE: Use DIP switch 2 to set sceond-stage heat ON delay.
PAGE 23
Thermostat DIP Switch Settings and On-Board Links Wiring Connections DIP Switch 1 On Board Links Must Be Cut To Select System Options T'STAT 2 Heat / 2 Cool OFF FURNACE TERM. STRIP OUTDOOR UNIT * CUT ON-BOARD LINK W915 2 STAGE COMPR *Not required on all units CUT ON-BOARD LINK W915 2 STAGE COMPR 2 Heat / 2 Cool with t’stat with dehumidification mode T'STAT FURNACE OUTDOOR TERM.
PAGE 24
Thermostat DIP Switch Settings and On-Board Links Wiring Connections DIP Switch 1 On Board Links Must Be Cut To Select System Options T'STAT CUT ON-BOARD LINK W951 HEAT PUMP Dual Fuel SingleStage Heat Pump Thermostat w/dual fuel capabilities FURNACE TERM.
PAGE 25
Thermostat DIP Switch Settings and On-Board Links Wiring Connections DIP Switch 1 On Board Links Must Be Cut To Select System Options T'STAT Capable of 2-stage gas heat control with dehumidification mode HEAT PUMP H Dual Fuel SingleStage Heat Pump Thermostat w/dual fuel capabilities FURNACE TERM.
PAGE 26
24VAC Indoor Blower Terminals HUM ACC Ignitor and Combustion Air Inducer Neutrals Flame Sense LED S4 DIP Switches Diagnostic Push Button On Board Links 3/16” QUICK CONNECT TERMINALS FLAME SENSE SIGNAL HI Cool 24VAC HI HEAT 24VAC LO COOL 24VAC LO HEAT 24VAC PARK PARK COMMON 24VAC THERMOSTAT CONNECTIONS (TB1) DS = DEHUMIDIFICATION SIGNAL W2 = HEAT DEMAND FROM 2ND STAGE T/STAT W1 = HEAT DEMAND FROM 1ST STAGE T/STAT R = CLASS 2 VOLTAGE TO THERMOSTAT G = MANUAL FAN FROM T'STAT C = THERMOSTAT SIGNAL GRO
PAGE 27
Integrated Control DIP Switch Settings BG802DFE units are equipped with a two-stage integrated control. This control manages ignition timing, heating mode fan off delays and indoor blower speeds based on selections made using the control dip switches and jumpers. The control includes an internal watchguard feature which automatically resets the ignition control when it has been locked out.
PAGE 28
On-Board Link W951 Heat Pump (R to O) On-board link W951 is a clippable connection between terminals R and O on the integrated control. W951 must be cut when the furnace is installed in applications which include a heat pump unit and a thermostat which features dual fuel use. If the link is left intact, terminal “O” will remain energized eliminating the HEAT MODE in the heat pump.
PAGE 29
MANIFOLD PRESSURE TAP HIGH FIRE ADJUSTMENT (under cap) Gas Pressure Adjustment Gas Flow (Approximate) LOW FIRE ADJUSTMENT (under cap) Gas Meter Clocking Chart Seconds for One Revolution Capacity INLET PRESSURE POST GAS VALVE SHOWN IN ON POSITION LP 1 cu ft Dial 2 cu ft Dial 1 cu ft Dial 2 cu ft Dial -070 55 110 136 272 -090 41 82 102 204 Natural - 1000 btu/cu ft LP - 2500 btu/cu ft Table 13. Figure 24. White Rodgers Gas Valve Turning Off Gas to Unit 1.
PAGE 30
6. Shut unit off and remove manometer as soon as an accurate reading has been obtained. Turn the supply and manifold 3/32” hex screw one revolution back into the gas valve. 7. Start unit and check for gas leaks. Seal if any found. High Altitude The manifold pressure may require adjustment and combustion air pressure switch may need replacing to ensure proper combustion at higher altitudes. Refer to Table 15 for manifold pressure and Table 16 for pressure switch change and gas conversion kits.
PAGE 31
Other Unit Adjustments Primary and Secondary Limits The primary limit is located on the heating compartment vestibule panel. The secondary limits (if equipped) are located in the blower compartment, attached to the back side of the blower. These auto reset limits are factory-set and require no adjustment. Flame Rollout Switches This manually reset switches are located on the baffle plate in the burner assembly.
PAGE 32
5. If second-stage heat is required, the thermostat second- stage heat contacts close and send a signal to the integrated control. The integrated control initiates a 30-second second-stage recognition delay. 6. At the end of the recognition delay, the integrated control energizes the combustion air inducer at high speed. The control also checks the high fire (secondstage) pressure switch to make sure it is closed.
PAGE 33
Annual Furnace Maintenance Manual for proper operating range. Thermal Limits should be checked by restricting airflow and not disconnecting the indoor blower. For additional details, please see Service and Application Note H049. At the beginning of each heating season, and to comply with the Blue Summit Limited Warranty, your system should be checked as follows: 2. Verify that system total static pressure and airflow settings are within specific operating parameters. 3.
PAGE 34
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. Burner Removal Repair Parts List The following repair parts are available through independent Blue Summit dealers. When ordering parts, include the complete furnace model number listed on the CSA International nameplate.
PAGE 35
Blower Performance BG802DF070AE12 Performance (Less Filter) Air Volume / Watts at Various Blower Speeds External Static Pressure in. w.c. High (Black) cfm Medium - High (Brown) watts cfm watts Medium (Blue) cfm Medium - Low (Yellow) watts Low (Red) cfm watts cfm watts 0.00 1475 346 1345 269 1190 192 970 109 785 71 0.10 1440 355 1325 276 1165 198 935 114 775 74 0.20 1410 365 1280 287 1135 207 905 120 740 79 0.
PAGE 36
Requirements for Commonwealth of Massachusetts Modifications to NFPA-54, Chapter 10 4. Revise NFPA-54 section 10.8.