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INSTALLATION
INSTRUCTIONS
READ ALL INSTRUCTIONS CAREFULLY BEFORE
BEGINNING THE INSTALLATION.
THE INSTALLATION MUST COMPLY WITH THESE
INSTRUCTIONS AND THE REQUIREMENTS OF ALL
GOVERNING CODES AND ORDINANCES FOR THE
INSTALLATION LOCATION.
IT IS THE RESPONSIBILITY OF INSTALLER TO KNOW
AND UNDERSTAND ALL OF THESE REQUIREMENTS.
FAILURE TO DO SO COULD CREATE A HAZARD
RESULTING IN PROPERTY DAMAGE, BODILY INJURY,
OR DEATH.
© Copyright 2007
WG - SERIES
COMBINATION GAS/ELECTRIC
WALL-MOUNT
WG3S1-A
WG4S1-A
WG5S1-A
WARNING
Bard Manufacturing Company, Inc.
Bryan, Ohio 43506
Since 1914...Moving ahead just as planned.
MODELS:
WG3S1-B
WG4S1-B
WG5S1-B
Manual No.:
Supersedes:
File:
Date:
WG3S1-C
WG4S1-C
WG5S1-C
2100-483E
2100-483D
Volume III, Tab 20
08-12-08
Manual 2100-483E
Page
1 of 59
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Table of Contents
Related Manuals for Bard WG3S1-A WG3S1-B WG3S1-CWG4S1-A
Summary of Contents for Bard WG3S1-A WG3S1-B WG3S1-CWG4S1-A
- Page 1 AND UNDERSTAND ALL OF THESE REQUIREMENTS. FAILURE TO DO SO COULD CREATE A HAZARD RESULTING IN PROPERTY DAMAGE, BODILY INJURY, OR DEATH. Manual No.: 2100-483E Bard Manufacturing Company, Inc. Supersedes: 2100-483D Bryan, Ohio 43506 File: Volume III, Tab 20 Since 1914...Moving ahead just as planned.
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Page 2: Table Of Contents
CONTENTS Page Page 20. Checking Gas Input Rate ......27 & 28 Getting Other Information and Publications ....4 WG Series Model Nomenclature ....... 5 21. Standard Orifice Sizing & High Altitude Derate ..........29 Ventilation Options ............ 5 22. Conversion of Gas Input BTUH From High Air Conditioning Module Options ....... - Page 3 CONTENTS Page Page FIGURES TABLES Figure 1 Unit Dimensions ........8 Table 1 Specifications ........... 7 Figure 2A Mounting Instructions – WG3S1 ... 11 Table 2 Minimum Installation Clearances ... 16 Figure 2B Mounting Instructions–WG4S1 & WG5S1 ..Table 3 Thermostat Wire Size ......
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Page 4: Getting Other Information And Publications
Canadian Electrical Code ......CSA C22.1 Canada. M9W 1R3 Telephone: (416) 447-4044 Canadian Installation Code……………CAN/CGA B149 COPYRIGHT DECEMBER 2007 BARD MANUFACTURING COMPANY, INC. BRYAN, OHIO 43506 USA Manufactured under the following U.S. patent numbers: 5,485,878; 5,002,116; 4,924,934; 4,875,520; 4,4825,936 Manual 2100-483E... -
Page 5: Wg Series Model Nomenclature
WALL MOUNT GAS/ELECTRIC GENERAL MODEL NUMBER NOMENCLATURE – REVISION VENT MODEL COLOR CONTROL OPTIONS Wall Mount See Table Below X = Beige (See Table page 6) Gas/Electric (Standard) VOLTAGE 4 = Buckeye Gray A = 230/208-60-1 COOLING COIL OPTIONS B = 230/208-60-3 CAPACITY X = Standard C = 460-60-3... -
Page 6: Air Conditioning Module Options
AIR CONDITIONING MODULE OPTIONS STD = Standard equipment. CCM Compressor control module has adjustable 30 second to 5 minute delay-on-break timer. On initial power up, or any time the power is interrupted, the delay-on-make will be 2 minutes plus 10% of the delay-on-break setting. There is no delay-on- make during routine operation of the unit. -
Page 7: Table 1 Specifications
Manual 2100-483E Page 7 of 59... -
Page 8: Figure 1 Unit Dimensions
Manual 2100-483E Page 8 of 59... -
Page 9: High Altitude Applications
Any grille that meets with the 5/8 inch louver criteria on heat loss/heat gain calculations made according to may be used. It is recommended that Bard Return Air methods of Air Conditioning Contractors of America Grille or Return Filter Grille be installed when no (ACCA). -
Page 10: Wall Mounting
7. WALL MOUNTING INFORMATION WARNING 1. Two holes for the supply and return air openings must be cut through the wall as detailed in Figure 4. Failure to provide the one inch clearance 2. On wood-frame walls, the wall construction between the supply duct and a combustible must be strong and rigid enough to carry the surface for the first three feet of duct can... -
Page 11: Figure 2A Mounting Instructions - Wg3S1
Manual 2100-483E Page 11 of 59... -
Page 12: Figure 2B Mounting Instructions-Wg4S1 & Wg5S1
Manual 2100-483E Page 12 of 59... -
Page 13: Figure 3 Combustible Clearance
FIGURE 3 COMBUSTIBLE CLEARANCE WARNING A minimum of one (1) inch clearance must be maintained between the supply air duct and combustible materials. This is required for the first three (3) feet of ducting. It is important to insure that the one (1) inch minimum spacing is maintained at all points. Failure to do this could result in overheating the combustible material and may result in a fire causing damage, injury or death. -
Page 14: Figure 4 Wall Mounting Instructions
FIGURE 4 WALL MOUNTING INSTRUCTIONS FIGURE 5 WALL MOUNTING INSTRUCTIONS Manual 2100-483E Page 14 of 59... -
Page 15: Figure 6 Common Wall Mounting Installations
FIGURE 6 COMMON WALL MOUNTING INSTALLATIONS Manual 2100-483E Page 15 of 59... -
Page 16: Clearances
9. CLEARANCES TABLE 2 MINIMUM INSTALLATION CLEARANCES Minimum clearances, as specified in Table 2, must be maintained from adjacent structures to provide t e l ) s l r i f adequate fire protection, adequate combustion air, and ) s l room for service personnel. -
Page 17: Vent Terminal And Combustion Inlet Hood
11. OPTIONAL VERTICAL VENTING 10. VENT TERMINAL AND COMBUSTION AIR INLET HOOD With the optional vertical venting kit (VVK-5) this unit may be vented vertically through a roof or overhang. The vent terminal is shipped in the burner The kit includes a stainless steel transition drain tee, compartment. -
Page 18: Vent Resizing Instructions
12. VENT RESIZING INSTRUCTIONS 13. FRESH AIR INTAKE All units are built with fresh air inlet slots punched in When an existing furnace is removed from a venting the service panel. system servicing other appliances, the venting system is likely to be too large to properly vent the remaining The default unit is built with blank-off plates installed. -
Page 19: Wiring - Main Power
15. WIRING – MAIN POWER ELECTRICAL GROUNDING When installed, the furnace must be electrically WARNING grounded in accordance with local codes or in the absence of local codes, with the National Electrical Code, ANSI/NFPA 70, or Canadian Electrical Code, CSA22.1, latest edition. Use a copper wire from green For your personal safety, turn off electric ground wire on the furnace to a grounded connection in power at service entrance panel before... -
Page 20: Wiring - Low Voltage Wiring
FIGURE 9 INSTALLATION OF FLEXIBLE CONDUIT Direct Digital Controls (DDC) 16. WIRING – LOW VOLTAGE WIRING For total and proper control using DDC, a total of 5 Low Voltage Connection controlled outputs are required (4 if no ventilation is These units use a 24-volt AC low voltage circuit. installed). -
Page 21: Figure 10A Low Voltage Wiring - No Vent
FIGURE 10A LOW VOLTAGE WIRING - NO VENT Low Voltage Wiring - No Ventilation Package Thermostat Subbase Thermostat Part #8403-058 Thermostat W1/E D/YO Part #8403-060 Unit 24V Terminal Block Factory Installed Jumper Unit Control Panel MIS-2330 C Manual 2100-483E Page 21 of 59... -
Page 22: Figure 10B Low Voltage Wiring - Crv
FIGURE 10B LOW VOLTAGE WIRING - COMMERCIAL ROOM VENTILATOR Low Voltage Wiring - Multi-position Commercial Room Ventilat Thermostat Subbase Thermostat Part #8403-058 Thermostat W1/E D/YO Part #8403-060 Unit 24V Terminal Block Factory Installed Jumper Unit Control Panel WGCRVMP-5 WIRING HARNESS STOP ORANGE CONTROL... -
Page 23: Figure 10C Low Voltage Wiring - Economizer
FIGURE 10C LOW VOLTAGE WIRING - ECONOMIZER Low Voltage Wiring - EIFM ECONOMIZER Thermostat Subbase Thermostat Part #8403-058 Thermostat W1/E D/YO Part #8403-060 Unit 24V Terminal Block Factory Installed Jumper Unit Control Panel WGSEIFM-5 BLACK BLUE PINK WIRES YELLOW FROM PURPLE PLUG ORANGE... -
Page 24: Figure 10D Low Voltage Wiring - Erv
FIGURE 10D LOW VOLTAGE WIRING - ENERGY RECOVERY VENTILATOR Low Voltage Wiring - WGSERV-*5 Energy Recovery Ventilato Thermostat Subbase Thermostat Part #8403-058 Thermostat W1/E D/YO Part #8403-060 Unit 24V Terminal Block Factory Installed Jumper Unit Control Panel WGSERV-*5 BLACK CONTROL WIRES BLUE FROM... -
Page 25: Figure 11 Gas Pipe Connection
FIGURE 11 GAS PIPE CONNECTION Manual 2100-483E Page 25 of 59... -
Page 26: Gas Supply & Piping
18. GAS SUPPLY AND PIPING 8. Refer to Table 6 for Gas Pipe Sizes for natural gas. If more than one appliance is supplied from a single line size, capacity must equal or exceed the GENERAL RECOMMENDATIONS combined input to all appliances, and the branch 1. -
Page 27: Manifold Pressure Adjustment
5. Slowly open equipment shut off valve in gas supply PROPANE (LP) GAS CONVERSION line just ahead of furnace. Start furnace following “Operating Instructions” on front door. This unit may be converted in the field for 6. Slowly open 1/8" NPT manual shut off valve leading use with Propane (LP) gas. - Page 28 NATURAL GAS INPUT RATE 9. If you left water heater, dryer or range pilots on, allow for them in calculating correct furnace gas Natural gas heating value (BTU/cu. ft.) can vary input. A quick way is to allow 1,000 BTU per hour significantly.
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Page 29: Standard Orifice Sizing & High Altitude Derate
21. STANDARD ORIFICE SIZING AND burned in the furnace must also be reduced. This is HIGH ALTITUDE DERATE called derating. This unit must be derated when installed at altitudes greater than 6,000 feet above sea This furnace is shipped with fixed gas orifices for use level. -
Page 30: Table 8 Natural Gas Orifice Tables- Wg3,4,5S
TABLE 8 NATURAL GAS ORIFICE TABLES FOR MODELS WG3S, WG4S AND WG5S f i r f i r i t l c t i f i r f i r f i r f i r c t i i t l f i r f i r , y r... -
Page 31: Conversion Of Gas Input Btuh From High To Low Rating
22. CONVERSION OF GAS INPUT BTUH 2. Set balancing dampers in supply duct system. FROM HIGH TO LOW RATING 3. Check duct work for obstructions or leaks. All the derated WG series units are produced with 4. Make sure filters are clean and in place. maximum BTUH input orifices installed. -
Page 32: Filters
FIGURE 13 ACCESS INTERNAL FILTER THROUGH UPPER SERVICE DOOR 24. FILTERS HIGH PRESSURE SWITCH AND LOCKOUT SEQUENCE (Standard Feature) A 2" thick throwaway filter is supplied with each unit. This filter is installed by opening the main service door. If the high pressure switch opens, the compressor (See Figure 13.) contactor will de-energize immediately. - Page 33 ALARM OUTPUT PHASE MONITOR Alarm terminal is output connection for applications All units with three phase scroll compressors are where alarm signal is desired. This terminal is powered equipped with a three phase line monitor to prevent whenever compressor is locked out due to HPC or LPC compressor damage due to phase reversal.
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Page 34: Lighting & Shutdown Instructions
26. LIGHTING AND SHUTDOWN INSTRUCTIONS FIGURE 14 INSTRUCTION LABEL Manual 2100-483E Page 34 of 59... -
Page 35: Service Agency Procedures
FIGURE 15 27. SERVICE AGENCY PROCEDURES TOP VIEW OF GAS CONTROL CAUTION Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing. WARNING Follow these procedures before inspecting MIS-165 furnace. -
Page 36: Replacement Parts
ROUTINE MAINTENANCE WARNING 1. Air Filters – Check the condition at least monthly when the unit is in use, and replace as necessary. 2. Lubrication Requirements – The indoor circulating Disconnect electrical power before servicing air blower motor and outdoor circulating air fan unit. -
Page 37: Sequence Of Operation - Heating
30. SEQUENCE OF OPERATION – 31. SEQUENCE OF OPERATION – HEATING COOLING NON-ECONOMIZER On a call for heat from the thermostat, the induced draft blower is energized. Once sufficient draft is Stage 1 (Y1) cooling call activates Step 1 (partial established, the pressure switch contacts close and the capacity, 66%) of compressor capacity. -
Page 38: Figure 17 Furnace Control Board
FIGURE 17 FURNACE CONTROL BOARD AND BLOWER CONTROL 32. INDOOR BLOWER OPERATION The indoor blower motor is a constant CFM variable speed direct drive motor. The motor is programmed to respond to individual thermostatic inputs that will determine the speed/airflow at which the motor operates. -
Page 39: Table 10 Integrated Furnace & Blower Control Operation
TABLE 10 INTEGRATED FURNACE AND BLOWER CONTROL OPERATION t i n o " ) " t n I r t - c t i t i n t i n t i n i t l a l f t i n t i n i t ( t i n... -
Page 40: Start Up
FIGURE 18 START UP START-UP LABEL These units require R-410A refrigerant & Polyol Ester oil. IMPORTANT APPLICATION: These procedures must be followed at 1. Use separate service and manufacturing equipment initial start-up and at any time power to avoid cross contamination of oil and refrigerants. has been removed for 12 hours or longer. -
Page 41: Three Phase Scroll Compressor
THREE PHASE SCROLL COMPRESSOR All three phase ZPS compressors are wired identically START UP INFORMATION internally. As a result, once the correct phasing is determined for a specific system or installation, Scroll compressors, like several other types of connecting properly phased power leads to the same compressors, will only compress in one rotational Fusite terminal should maintain proper rotation direction. -
Page 42: Troubleshooting
Troubleshooting FAN BLADE SETTING DIMENSIONS COMPRESSOR SOLENOID Shown in the drawing below are the correct fan blade (See Sequence of Operation on Page 37 for function.) setting dimensions for proper air delivery across the A nominal 24-volt direct current coil activates the outdoor coil. -
Page 43: Ge Ecm Tm Motors
Troubleshooting GE ECM 2.3 Motors ™ CAUTION: Symptom Cause/Procedure • Noisy blower or cabinet • Check for loose blower housing, panels, etc. Disconnect power from unit before removing or replacing • High static creating high blower speed? connectors, or servicing motor. To avoid electric shock - Check for air whistling through seams in from the motor’s capacitors, disconnect power and wait at ducts, cabinets or panels... -
Page 44: Ge Ecm Tm Motors
Troubleshooting GE ECM Motors Cont’d. ™ 7. Verify that the replacement control is correct for your Replacing ECM Control Module application. Refer to the manufacturer's authorized replacement list. To replace the control module for the GE variable-speed indoor blower USING THE WRONG CONTROL WILL RESULT IN motor you need to take the following steps: IMPROPER OR NO BLOWER OPERATION. -
Page 45: Pressure Service Ports
33. PRESSURE SERVICE PORTS High and low pressure service ports are installed on all units so that the system operating pressures can be observed. Table 12 outlines expected pressures at various indoor and outdoor temperatures. TABLE 12 COOLING PRESSURE (ALL TEMPERATURES °F) °... -
Page 46: R-410A Refrigerant Charge
35. LOW-NOX BURNER ASSEMBLY “N” R-410A SUFFIX MODELS ONLY – U.S. INSTALLATIONS ONLY 34. REFRIGERANT CHARGE NATURAL GAS MODELS ONLY The correct system R-410A charge is shown on the unit rating plate. Optimum unit performance will occur with Model numbers designated with an “N” are designed a refrigerant charge resulting in a liquid line temperature for low NOx emissions which comply with all (the cooling expansion device) as shown in Table 13 or... -
Page 47: Index - Wiring Diagrams
INDEX WIRING DIAGRAMS and LADDER DIAGRAMS Manual 2100-483E Page 47 of 59... -
Page 48: Wiring Diagrams
WG4S1-A 45+10/370 WG5S1-A 80+10/370 Wire Identification numbers USE COPPER CONDUCTORS for Bard use only. SUITABLE FOR AT LEAST 75° C Factory Field Optional IF ANY ORIGINAL WIRE AS SUPPLIED WITH THE APPLIANCE MUST BE REPLACED, IT MUST BE REPLACED WITH WIRING MATERIAL HAVING A... - Page 49 16 Pin Plug for INDUCED DRAFT 14 12 10 6 2 13 3 1 Indoor Blower Motor BLOWER RELAY Ladder Diagram Factory Optional Bard Mfg. Co. High Voltage Wires Connect Bryan, Ohio if Option Not Low Voltage Used 4085-141 A...
- Page 50 WG4S1-A 45+10/370 WG5S1-A 80+10/370 Wire Identification numbers USE COPPER CONDUCTORS for Bard use only. SUITABLE FOR AT LEAST 75° C Factory Field Optional IF ANY ORIGINAL WIRE AS SUPPLIED WITH THE APPLIANCE MUST BE REPLACED, IT MUST BE REPLACED WITH WIRING MATERIAL HAVING A...
- Page 51 16 Pin Plug for INDUCED DRAFT 14 12 10 6 2 13 3 1 Indoor Blower Motor BLOWER RELAY Ladder Diagram Factory Optional Bard Mfg. Co. High Voltage Wires Connect Bryan, Ohio if Option Not Low Voltage Used 4085-143 A...
- Page 52 USE COPPER CONDUCTORS WG5S1-B 10/370 SUITABLE FOR AT LEAST 75° C Wire Identification numbers for Bard use only. Factory Field Optional IF ANY ORIGINAL WIRE AS SUPPLIED WITH THE APPLIANCE MUST BE REPLACED, IT MUST BE REPLACED WITH WIRING MATERIAL HAVING A...
- Page 53 16 Pin Plug for INDUCED DRAFT 14 12 10 6 2 13 3 1 Indoor Blower Motor BLOWER RELAY Ladder Diagram Factory Optional Bard Mfg. Co. High Voltage Wires Connect Bryan, Ohio if Option Not Low Voltage Used 4085-241 A...
- Page 54 IF ANY ORIGINAL WIRE AS SUPPLIED WITH THE APPLIANCE MUST BE REPLACED, IT MUST BE REPLACED WITH WIRING MATERIAL HAVING A High Voltage WIRES CONNECT Bard Mfg. Co. TEMPERATURE RATING OF AT LEAST 105° C EXCEPT THE IGNITION CABLE Bryan, Ohio IF OPTION Low Voltage WHICH IS 250°C HIGH VOLTAGE CABLE...
- Page 55 16 Pin Plug for INDUCED DRAFT 14 12 10 6 2 13 3 1 Indoor Blower Motor BLOWER RELAY Ladder Diagram Factory Optional Bard Mfg. Co. High Voltage Wires Connect Bryan, Ohio if Option Not Low Voltage Used 4085-243 A...
- Page 56 15/370 WG4S USE COPPER CONDUCTORS Wire Identification numbers WG4S1-C 15/370 WG5S SUITABLE FOR AT LEAST 75° C for Bard use only. WG5S1-C 15/370 Factory Field Optional IF ANY ORIGINAL WIRE AS SUPPLIED WITH THE APPLIANCE MUST BE WIRES CONNECT REPLACED, IT MUST BE REPLACED WITH WIRING MATERIAL HAVING A High Voltage Bard Mfg.
- Page 57 16 Pin Plug for INDUCED DRAFT 14 12 10 6 2 13 3 1 Indoor Blower Motor BLOWER RELAY Ladder Diagram Factory Optional Bard Mfg. Co. High Voltage Wires Connect Bryan, Ohio if Option Not Low Voltage Used 4085-362 A...
- Page 58 WG4S USE COPPER CONDUCTORS Wire Identification numbers WG4S1-C 15/370 WG5S SUITABLE FOR AT LEAST 75° C for Bard use only. WG5S1-C 15/370 Factory Field Optional IF ANY ORIGINAL WIRE AS SUPPLIED WITH THE APPLIANCE MUST BE REPLACED, IT MUST BE REPLACED WITH WIRING MATERIAL HAVING A...
- Page 59 16 Pin Plug for INDUCED DRAFT 14 12 10 6 2 13 3 1 Indoor Blower Motor BLOWER RELAY Ladder Diagram Factory Optional Bard Mfg. Co. High Voltage Wires Connect Bryan, Ohio if Option Not Low Voltage Used 4085-364 A...