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Bard WG Series Installation Instructions Manual

Wall mounted gas/electric
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INSTALLATION INSTRUCTIONS
WALL MOUNTED GAS/ELECTRIC
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.
Models:
WG3S2-B
WG3S2-A
WG4S2-A
WG4S2-B
WG5S2-A
WG5S2-B
WARNING
Bard Manufacturing Company, Inc.
Bryan, Ohio 43506
www.bardhvac.com
WG3S2-C
WG4S2-C
WG5S2-C
Manual :
Supersedes:
Date:
2100-587J
2100-587I
8-29-18
Page
1 of 58

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  • Page 1 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. Bard Manufacturing Company, Inc. Manual : 2100-587J Bryan, Ohio 43506 Supersedes: 2100-587I...

  • Page 2: Table Of Contents

    20. Checking Gas Input Rate ........ 27 Wall Mount Gas/Electric General Information ..5 21. Standard Orifice Sizing and WG Series Model Nomenclature ......5 High Altitude Derate ........29 Ventilation Options ..........5 22. Conversion of Gas Input BTUH from High Air Conditioning Module Options ......
  • Page 3 Page Page FIGURES TABLES Figure 1 Unit Dimensions ........8 Table 1 Specifications ........7 Figure 2A Mounting Instructions for WG3S2 ..11 Table 2 Minimum Installation Clearances ... 16 Figure 2B Mounting Instructions for WG4S2 Table 3 Thermostat Wire Size ......20 and WG5S2 ........

  • Page 4: Getting Other Information And Publications

    Canadian Standards Association Selection 178 Rexdale Boulevard Rexdale, Ontario Canada. M9W 1R3 Canadian Electrical Code ......CSA C22.1 Telephone: (416) 447-4044 Canadian Installation Code ....CAN/CGA B149 BARD MANUFACTURING COMPANY, INC. BRYAN, OHIO 43506 USA Manual 2100-587J Page 4 of 59...

  • Page 5: Wall Mount Gas/Electric General Information

    WALL MOUNT GAS/ELECTRIC GENERAL INFORMATION MODEL NUMBER NOMENCLATURE – REVISION MODEL VENT COLOR CONTROL OPTIONS Wall Mount X = Beige See Table Below (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...

  • Page 6: Air Conditioning Module Options

    AIR CONDITIONING MODULE OPTIONS Factory Installed Field Installed     Code Part CMA-28 STD = Standard equipment  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.
  • Page 7 Manual 2100-587J Page 7 of 59...
  • Page 8 Manual 2100-587J Page 8 of 59...

  • Page 9: Installation

    All internal wiring is complete. Any grille that meets with the 5/8” louver criteria may be used. It is recommended that Bard Return These instructions and any instructions packaged with Air Grille or Return Filter Grille be installed when any separate equipment required to make up the entire no return duct is used.

  • Page 10: Transportation Damage

    5. TRANSPORTATION DAMAGE 8. MOUNTING THE UNIT All units are packed securely in shipping container. 1. These units are secured by wall mounting brackets which secure the unit to the outside wall surface at All units should be carefully inspected upon arrival both sides.
  • Page 11 Manual 2100-587J Page 11 of 59...
  • Page 12 Manual 2100-587J Page 12 of 59...
  • Page 13 FIGURE 3 Combustible Clearance WARNING A minimum of 1" clearance must be maintained between the supply air duct and combustible materials. This is required for the first 3' of ducting. It is important to insure that the 1" 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 5 Wall Mounting Instructions Manual 2100-587J Page 14 of 59...
  • Page 15 FIGURE 6 Common Wall Mounting Installations Manual 2100-587J 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 Outlet Duct 1" first 3' adequate fire protection, adequate combustion air and (from combustible materials) room for service personnel. Vent Terminal While minimum clearances are acceptable for safety * 17"...

  • Page 17: Vent Terminal And Combustion Air 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 (see Figure 7).

  • Page 18: Vent Resizing Instructions

    12. VENT RESIZING INSTRUCTIONS One of several other ventilation options may be installed. Refer to model number and/or supplemental When an existing furnace is removed from a venting installation instructions. system servicing other appliances, the venting system is likely to be too large to properly vent the remaining 14.
  • Page 19 Field-Installed Equipment WARNING Wiring to be done in the field between the furnace and devices not attached to the furnace, or between separate devises which are field installed and located, Failure to provide an electrical power supply shall conform with the temperature limitation for shut off means could result in electric shock Type T wire {63°...

  • Page 20: Wiring - Low Voltage Wiring

    16. WIRING – LOW VOLTAGE WIRING 17. THERMOSTATS Low Voltage Connection TABLE 3 Thermostat Wire Size These units use a 24 volt AC low voltage circuit. The “R” terminal is the hot terminal and the “C” Maximum terminal is grounded. Transformer VA Wire Gauge Distance...

  • Page 21: Figure 7 Figure

    FIGURE 10A Low Voltage Wiring – No Vent Low Voltage Wiring - No Ventilation Package Thermostat Subbase Thermostat Part #8403-058 or T6 Pro 8403-090 Thermostat W1/E D/YO Part #8403-060 Thermostat Part #8403-082 or #8403-084 Unit 24V Terminal Block Factory Installed Jumper Unit Control Panel MIS-2330 F Manual...
  • Page 22 FIGURE 10B Low Voltage Wiring – Commercial Room Ventilator Low Voltage Wiring - Multi-position Commercial Room Ventilator Thermostat Subbase Thermostat Part #8403-058 or T6 Pro 8403-090 Thermostat W1/E D/YO Part #8403-060 (MUST BE CONFIGURED FOR HEAT/COOL) Thermostat Part #8403-082 or #8403-084 Unit 24V Terminal Block...

  • Page 23: Figure 10C Low Voltage Wiring - Economizer

    FIGURE 10C Low Voltage Wiring – Economizer Thermostat YO/D W1/E part #8403-060 A/C UNIT 24V TERMINALS Economizer Wiring Harness Must be energized to enable minimum position. NOTE: Economizer Control Default Setting is 10V (100%). Depending upon application may require setting to lower value. If using this feature, move blue wire from "W1"...
  • Page 24 D/YO Part #8403-060 Thermostat Part #8403-082 or #8403-084 Unit 24V Terminal Block Factory Installed Jumper Unit Control Panel WGSERV-*5 Optional CO2 Controller Bard Part #8403-067 24VAC BLUE BLACK/WHITE CONTROL BLUE WIRES C02 OUT BROWN/WHITE FROM PLUG TEMP-OUT ORANGE MUST INSTALL JUMPER FOR 8403-058 OR OTHER THERMOSTAT THAT DOES NOT HAVE OCCUPANCY OUTPUT / A TERMINAL INSTALL IF YOU REQUIRE VENTILATION ANYTIME BLOWER IS ON.

  • Page 25: Figure 11 Gas Pipe Connection

    FIGURE 11 Gas Pipe Connection Manual 2100-587J Page 25 of 59...

  • Page 26: Gas Supply And 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

    6. Slowly open 1/8" NPT manual shut off valve PROPANE (LP) GAS CONVERSION leading to manometer. This unit may be converted in the field for 7. Read manifold pressure on manometer. use with Propane (LP) gas. Propane gas 8. Adjust manifold pressure by turning gas control conversion kit number WGCK-1 is designed regulator adjusting screw clockwise to increase for conversions of units installed from...

  • Page 28: Manual 2100-587J

    Natural Gas Input Rate Example: Natural gas heating value (BTU/cu. ft.) can vary If gas water heater, dryer, two range burner pilots significantly. Before starting natural gas input check, and one oven pilot were left on, allow: obtain the gas heating value at the location from local Water heater pilot 1,000 BTU per hour supplier.

  • Page 29: Standard Orifice Sizing And High Altitude Derate

    21. STANDARD ORIFICE SIZING AND burned in the furnace must also be reduced. This is called derating. This unit must be derated when HIGH ALTITUDE DERATE installed at altitudes greater than 6,000' above sea level. A high altitude pressure switch must also be This furnace is shipped with fixed gas orifices for use installed for operation above 6,000'.

  • Page 30: Manual 2100-587J

    All Natural Gas factory orifice sizing and standard input ratings based on nominal 1025 BTU/cu ft gas and sea level conditions All other orifice sizes shown are available as individual items. See orifice tables below for part numbers and number required. Bard Part No. Orifice Size (mm) Orifice Diameter...

  • Page 31: Conversion Of Gas Input Btuh From High To Low Rating

    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. To field 5.

  • Page 32: Filters

    FIGURE 13 Access Internal Filter FILTER FILTER SERVICE DOOR MIS-3237 24. FILTERS units do not start at the same time, adjust the delay- on-break timer on each unit to a slightly different A 2" thick throwaway filter is supplied with each unit. delay time.
  • Page 33 The conditions needed for the unit to enter test mode compressor a time period to start even if the voltage are as follows: POT must start at a time less than or has dropped and allows the voltage to recover. This equal to the 40 second mark.

  • Page 34: Phase Monitor

    and generator power didn’t cause a problem. The units lost power, shut off and came back on line normally. With the introduction of almost instantaneous transfer switches, the millisecond long power glitch can be enough that the compressor will start to run backwards. In this scenario, the CCM will catch this and restart the units normally.

  • Page 35: Lighting And Shutdown Instructions

    27. LIGHTING AND SHUTDOWN INSTRUCTIONS FIGURE 15 Lighting and Shutdown Instruction Label BEND & PEEL “HERE” TO REMOVE LABEL LINER FOR YOUR SAFETY READ BEFORE OPERATING WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. This appliance does not have a pilot.

  • Page 36: Service Agency Procedures

    28. SERVICE AGENCY PROCEDURES FIGURE 16 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 37: Replacement Parts

    Routine Maintenance WARNING 1. Air Filters – Check the condition at least monthly when the unit is in use, and replace as necessary. Disconnect electrical power before servicing 2. Lubrication Requirements – The indoor circulating unit. Failure to do so could result in electrical air blower motor and outdoor circulating air fan shock or death.

  • Page 38: Sequence Of Operation - Heating

    31. SEQUENCE OF OPERATION – top of the switch. See Figure 17 for additional HEATING information. On a call for heat from the thermostat, the induced 32. SEQUENCE OF OPERATION – draft blower is energized. Once sufficient draft is COOLING established, the pressure switch contacts close and the ignition system is energized.

  • Page 39: Indoor Blower Operation

    FIGURE 18 Furnace Control Board and Blower Control 33. INDOOR BLOWER OPERATION The indoor blower motor is a constant CFM variable temperature rise across the gas heat exchanger at the speed direct drive motor. The motor is programmed mid-point of the allowable rise range automatically. to respond to individual thermostatic inputs that There are not adjustments that can be made in the field to adjust the airflows for any mode of operation.

  • Page 40: Table 10 Integrated Furnace And Blower Control Operation

    TABLE 10 Integrated Furnace and Blower Control Operation IGNITION SEQUENCE CONTROL Ignition Source 24 VAC DSI Flame Sensing Remote Timings - Prepurge 15 seconds - Postpurge 30 seconds (0 if cycle terminated before valve “on”) - Inter-trial purge 15 seconds - Pressure switch proving period 60 seconds - Trials for ignition...

  • Page 41: Start Up

    START UP These units require R-410A refrigerant and Polyol Ester Three Phase Scroll Compressor Start Up Information oil. Scroll compressors, like several other types of compressors, will only compress in one rotational Application direction. Direction of rotation is not an issue with single phase compressors since they will always start 1.

  • Page 42: Service

    SERVICE COMPRESSOR SOLENOID FAN BLADE SETTING DIMENSIONS (See Sequence of Operation on page 37 for function.) Shown below are the correct fan blade setting A nominal 24-volt direct current coil activates the dimensions for proper air delivery across the outdoor internal compressor solenoid.

  • Page 43: Ecm Tm Motors

    ™ Troubleshooting ECM Motors CAUTION: Symptom Cause/Procedure • Air noise • High static creating high blower speed? Disconnect power from unit before removing or - Is airflow set properly? replacing connectors, or servicing motor. To avoid - Does removing filter cause blower to slow electric shock from the motor’s capacitors, disconnect down? Check filter - Use low-pressure drop filter...

  • Page 44: Manual 2100-587J

    Replacing ECM Control Module Verify that the replacement control is correct for the application. Refer to the manufacturer’s authorized To replace the control module for the GE variable-speed indoor blower replacement list. Using the wrong control will result in motor, take the following steps: improper or no blower operation.

  • Page 45: Pressure Service Ports

    34. PRESSURE SERVICE PORTS WARNING! Do NOT use a Schrader valve core removal tool with these valves. Use of such a tool could result High and low pressure service ports are installed on in eye injuries or refrigerant burns! all units so that the system operating pressures can To change a Coremax valve without first removing the be observed.

  • Page 46: R-410A Refrigerant Charge

    35. R-410A REFRIGERANT CHARGE 36. LOW-NOX BURNER ASSEMBLY “N” SUFFIX MODELS ONLY – U.S. This unit was charged at the factory with the quantity INSTALLATIONS ONLY of refrigerant listed on the serial plate. AHRI capacity and efficiency ratings were determined by testing with Natural Gas Models Only this refrigerant charge quantity.

  • Page 47: Index - Wiring Diagrams And Ladder Diagrams

    INDEX Wiring Diagrams and Ladder Diagrams Model No. Heating Input Input Power Wiring Diagram Ladder Diagram 50,000 4085-154A 4085-155 75,000 4085-156A 4085-157 208/230/60/1 100,000 4085-154A 4085-155 125,000 4085-156A 4085-157 50,000 4085-254A 4085-269 75,000 4085-255A 4085-270 WG3S2 208/230/60/3 100,000 4085-254A 4085-269 125,000 4085-255A 4085-270...

  • Page 48: Figure 14 8201-164 Compressor Control Module

    WG4S2-A 30+10/370 WG5S2-A 40+10/440 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 49 230/208-60-1 Power Source 5 Pin Plug Line 1 Line 2 for Indoor Ground Blower Motor Terminal Block Terminal Block Compressor Compressor Contactor Compressor Dual Can Contactor Capacitor LOW AMBIENT CONTROL (OPT.) INDUCED DRAFT INDUCED DRAFT Outdoor Fan BLOWER MOTOR BLOWER RELAY Motor Crankcase Compressor...

  • Page 50: Manual 2100-587J

    WG4S2-A 30+10/370 WG5S2-A 40+10/440 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 51 230/208-60-1 Power Source 5 Pin Plug Line 1 Line 2 for Indoor Ground Blower Motor Terminal Block Terminal Block Compressor Compressor Contactor Compressor Dual Can Contactor Capacitor LOW AMBIENT CONTROL (OPT.) INDUCED DRAFT INDUCED DRAFT Outdoor Fan BLOWER MOTOR BLOWER RELAY Motor Crankcase Compressor...

  • Page 52: Manual 2100-587J

    10/370 SUITABLE FOR AT LEAST 75° C WG5S2-B 10/370 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 53 230/208-60-3 5 Pin Plug for Indoor Blower Motor Power Source L1 L2 Outdoor Compressor Compressor Contactor Capacitor Fan Motor Low Ambient INDUCED DRAFT INDUCED DRAFT Control (OPT.) BLOWER MOTOR BLOWER RELAY Crankcase Heater Aux. Phase Monitor Use for 208V Operation Transformer 24VAC FURNACE...

  • Page 54: Manual 2100-587J

    PIN PLUG FOR INDOOR BLOWER MOTOR INTEGRATED FURNACE CONTROL VOLTAGE STRIP BROWN YELLOW PRIMARY LIMIT 16 PIN PLUG FOR INDOOR BLOWER MOTOR FUSE FLAME PURPLE ROLLOUT 10 11 RED/WHITE GRAY SPARK IGNITOR 4 5 6 ORANGE 1 2 3 RED/ BLACK/WHITE WHITE SPEED...
  • Page 55 230/208-60-3 5 Pin Plug for Indoor Blower Motor Power Source L1 L2 Outdoor Compressor Compressor Contactor Capacitor Fan Motor Low Ambient INDUCED DRAFT INDUCED DRAFT Control (OPT.) BLOWER MOTOR BLOWER RELAY Crankcase Heater Aux. Phase Monitor Use for 208V Operation Transformer 24VAC FURNACE...

  • Page 56: Manual 2100-587J

    WG4S USE COPPER CONDUCTORS Wire Identification numbers WG4S2-C 15/370 WG5S SUITABLE FOR AT LEAST 75° C for Bard use only. WG5S2-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 57 460-60-3 5 Pin Plug for Indoor Blower Motor Power Source L1 L2 Fuse Transformer Fuse Outdoor Compressor Compressor Contactor Capacitor Fan Motor Low Ambient INDUCED DRAFT INDUCED DRAFT Control (OPT.) BLOWER MOTOR BLOWER RELAY Crankcase Heater Aux. Phase Monitor Use for 208V Operation Transformer 24VAC FURNACE...

  • Page 58: Manual 2100-587J

    WG3S2-C 15/370 USE COPPER CONDUCTORS Wire Identification numbers WG4S2-C 15/370 WG5S SUITABLE FOR AT LEAST 75° C for Bard use only. WG5S2-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...
  • Page 59 460-60-3 5 Pin Plug for Indoor Blower Motor Power Source L1 L2 Fuse Transformer Fuse Outdoor Compressor Compressor Contactor Capacitor Fan Motor Low Ambient INDUCED DRAFT INDUCED DRAFT Control (OPT.) BLOWER MOTOR BLOWER RELAY Crankcase Heater Aux. Phase Monitor Use for 208V Operation Transformer 24VAC FURNACE...

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