BDP Furnace Manual

The BDP Furnace is a high-efficiency heating system designed for residential and light commercial use, featuring advanced combustion technology, multiple heating stages, smart thermostat compatibility, energy-saving modes, safety shut-off systems, and easy maintenance access. Below are key sections for safety, features, installation, operation, maintenance, and troubleshooting.

Features at a Glance

Key components: High-efficiency heat exchanger, multi-speed blower motor, electronic ignition system, pressure switches, flame sensor, and control board.

Feature	Description
Heat Exchanger	Stainless steel construction for maximum efficiency and durability
Blower Motor	Variable speed ECM motor for quiet operation and energy savings
Ignition System	Hot surface igniter for reliable startup
Pressure Switches	Safety monitoring of air flow and venting
Flame Sensor	Ensures proper burner operation
Control Board	Microprocessor-based for precise temperature control
Gas Valve	Modulating for consistent heat output
Air Filter	Standard 1-inch or 4-inch media filter compatible
Thermostat Connection	Compatible with most 24VAC smart thermostats
Service Lights	LED status indicators for diagnostics

Installation

Unpack and inspect all components. Ensure proper clearances and ventilation.

1. Position furnace: Place on stable, level surface with adequate clearance.
2. Connect gas line: Use approved gas piping and fittings; pressure test for leaks.
3. Connect electrical: 120V AC power supply with proper grounding.
4. Connect ductwork: Secure supply and return air ducts properly.
5. Connect venting: Install approved PVC vent pipes according to local codes.
6. Connect thermostat: Run 18-gauge thermostat wire to control location.

WARNING! Installation must be performed by qualified HVAC technician. Gas leaks can cause explosion or fire.

First-Time Setup

Power on furnace; follow startup sequence.

1. Verify gas supply: Ensure gas valve is open and pressure is correct.
2. Check electrical: Confirm proper voltage at furnace terminals.
3. Set thermostat: Install batteries and configure basic settings.
4. Test operation: Set thermostat to heat mode and verify ignition sequence.
5. Adjust airflow: Balance supply registers for even temperature distribution.
6. Program settings: Configure fan operation, temperature limits, and schedules.

CAUTION! Do not bypass safety devices. Ensure proper ventilation during initial operation.

Specifications

• Heating Capacity: 40,000-120,000 BTU/h (model dependent)
• Efficiency: 95% AFUE or higher
• Gas Type: Natural gas or LP (conversion kit required)
• Electrical: 120V AC, 60Hz, 15A circuit
• Airflow: 800-2000 CFM variable
• Sound Level: Less than 70 dB at 1 meter
• Venting: 2-3 inch PVC pipe
• Dimensions: Varies by model (typical: 21"W x 21"D x 45"H)
• Warranty: 10-year heat exchanger, 5-year parts
• Operating Temp Range: -30°F to 120°F ambient

Controls and Settings

Access control board via front panel. Status lights indicate system operation.

Control Board: POWER switch, SERVICE light, DIAGNOSTIC codes, DIP switches for configuration.

Temperature Settings: Heat anticipator, fan delay, temperature limits. Operation Modes: Heat, Fan Only, Emergency Heat. Advanced Settings: Staging control, airflow adjustment, lockout timers. Safety: Limit switches, pressure switches, flame rollout protection.

Connecting Thermostat

Compatible with most 24VAC heating thermostats. Standard 5-wire connection.

1. Turn off power to furnace at circuit breaker.
2. Remove thermostat cover and label existing wires.
3. Connect wires to control board: R (power), W (heat), G (fan), C (common), Y (cooling if applicable).
4. Secure connections and replace covers.
5. Restore power and test operation.

Tip: Use wire nuts and ensure proper grounding. Follow thermostat manufacturer instructions.

Operating Modes

Multiple operating modes for efficiency and comfort.

1. Heat Mode: Primary heating operation with variable output.
2. Fan Only: Continuous or intermittent air circulation.
3. Emergency Heat: Backup heating element (if equipped).
4. Vacation Mode: Reduced temperature setting for energy savings.
5. Smart Recovery: Learns cycle times to reach set temperature.
6. Filter Alert: Reminds when filter needs replacement.
7. Dehumidification: Reduces humidity in cooling mode.

WARNING! Do not operate without proper airflow. Restricted airflow can damage heat exchanger.

Safety Features

Flame Rollout Switch: Shuts off gas if flame detected outside burner. High Limit Switch: Prevents overheating. Pressure Switches: Ensure proper venting. Ignition Lockout: Prevents repeated ignition attempts. Gas Valve: Automatic shut-off if no flame detected.

Maintenance & Cleaning

Regular maintenance ensures optimal performance and safety.

1. Monthly: Check and replace air filter as needed.
2. Seasonal: Inspect burners, heat exchanger, and venting.
3. Annual: Professional inspection and cleaning recommended.
4. Clean: Blower assembly, drain lines, and condensate trap.
5. Lubricate: Blower motor if required (most are sealed).

CAUTION! Turn off power and gas supply before performing any maintenance. Use only approved replacement parts.

Regulatory Information

UL certified for safety standards. ANSI Z21.47 compliant for gas appliances. Meets DOE energy efficiency requirements. EPA compliant for emissions. For technical support, visit www.bdpfurnace.com or contact 1-800-555-HEAT. Serial number located on rating plate inside furnace door.

Troubleshooting

Symptom	Possible Cause	Corrective Action
Furnace won't start	Power, thermostat, safety switch	Check circuit breaker, thermostat settings, reset door switch
No heat	Gas supply, ignition, filter	Verify gas valve open, check igniter, replace dirty filter
Short cycling	Dirty filter, limit switch	Clean/replace filter, check airflow, reset limit switch
Blower runs continuously	Thermostat setting, control board	Check fan setting, inspect control board relay
Unusual noises	Motor, blower wheel, ducts	Lubricate motor, clean blower, secure duct connections
Pilot light issues	Thermocouple, gas pressure	Clean thermocouple, adjust gas pressure

Reset: Turn power off for 30 seconds, then restore. Check diagnostic lights for error codes.

Service: 1-800-555-HEAT; www.bdpfurnace.com