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INSTALLATION INSTRUCTIONS
WALL MOUNTED GAS/ELECTRIC
W30G4
W24G4
W24G4D
W30G4D
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:
W36G4
W36G4D
WARNING
Bard Manufacturing Company, Inc.
Bryan, Ohio 43506
www.bardhvac.com
W42G4
W48G4
W42G4D
W48G4D
Manual No.:
Supersedes:
Date:
W60G4
W60G4D
2100-721B
2100-721A
5-7-20
Page
1 of 54
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Table of Contents
Summary of Contents for Bard W24G4
- 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 No.: 2100-721B Bryan, Ohio 43506 Supersedes: 2100-721A...
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Page 2: Table Of Contents
CONTENTS Page Page 19. Manifold Pressure Adjustment ......29 Getting Other Information and Publications ...4 20. Checking Gas Input Rate ........ 29 Wall Mount Gas/Electric General Information ..5 21. Standard Orifice Sizing and High W**G Series Model Nomenclature ..... 5 Altitude Derate .......... - Page 3 Low Voltage Wiring – All Units Except Table 11B Natural Gas Orifice Tables – W42-60G ... 33 Units with Economizers ....... 24 Table 12 W24G4 Indoor Blower Performance ..45 Figure 12 Low Voltage Wiring – Thermostat Using Table 13 W30G4 Indoor Blower Performance ..
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Page 4: Getting Other Information And Publications
178 Rexdale Boulevard Rexdale, Ontario Winter and Winter Air Conditioning and Equipment Canada. M9W 1R3 Selection Telephone: (416) 447-4044 Canadian Electrical Code .....CSA C22.1 Canadian Installation Code…………CAN/CGA B149 BARD MANUFACTURING COMPANY, INC. BRYAN, OHIO 43506 USA Manual 2100-721B Page 4 of 54... -
Page 5: Wall Mount Gas/Electric General Information
WALL MOUNT GAS/ELECTRIC GENERAL INFORMATION MODEL NUMBER NOMENCLATURE – REVISION MODEL COLOR VENT CONTROL OPTIONS Wall Mount (See table X – Beige (See table page 6) GAS/ELECTRIC below) 1 – White VOLTAGE 4 – Gray COOLING 230/208-60-1 – 8 – Bronze COIL OPTIONS CAPACITY 230/208-60-3... -
Page 6: Air Conditioning Module Options
Air Conditioning Module Options Factory Installed Field Installed Code Part CMA-45 (WG4D Units) • CMA-46 (WG4 Units) • Field Only SK111 or CMC-15 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. - Page 7 Manual 2100-721B Page 7 of 54...
- Page 8 Manual 2100-721B Page 8 of 54...
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Page 9: Figure 1 Unit Dimensions
Manual 2100-721B Page 9 of 54... -
Page 10: Transportation Damage
CAUTION During the initial firing of the burners there will probably be some amount of smoke issued to the circulating air stream as the result of residual oil burning off of the heat exchanger tubes. This oil is required during the forming process of the stainless steel heat exchanger tubes to facilitate the bending. -
Page 11: High Altitude Applications
Any grille that meets with the 5/8" louver criteria may dimension plus 2" and “B” dimension plus 2". See be used. It is recommended that Bard Return Air Grille Figures 4 and 5 for details. or Return Filter Grille be installed when no return duct is used. - Page 12 3. Locate and mark lag bolt locations and bottom mounting bracket location. 4. Mount bottom mounting bracket. 5. Hook top rain flashing under back bend of top. Top rain flashing is shipped secured to the right side of the back. 6.
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Page 13: Figure 2A Mounting Instructions - W24-36G
Manual 2100-721B Page 13 of 54... -
Page 14: Figure 2B Mounting Instructions - W42-60G
Manual 2100-721B Page 14 of 54... -
Page 15: Figure 3A Combustible Clearance - W24-36G
FIGURE 3A Combustible Clearance for W24G, W30G and W36G Models FIGURE 3B Combustible Clearance for W42G, W48G and W60G Models 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 one 1"... -
Page 16: Figure 5
FIGURE 4 Wall Mounting Instructions FIGURE 5 Wall Mounting Instructions Manual 2100-721B Page 16 of 54... -
Page 17: Common Wall Mounting Installations
FIGURE 6 Common Wall Mounting Installations Manual 2100-721B Page 17 of 54... -
Page 18: Clearances
TABLE 2 9. CLEARANCES Minimum Installation Clearances Minimum clearances, as specified in Table 2, must be maintained from adjacent structures to provide Outlet Duct adequate fire protection, adequate combustion air and 1" first 3' (from combustible materials) room for service personnel. Vent Terminal While minimum clearances are acceptable for safety 17"*... -
Page 19: Vent Terminal And Combustion Inlet Hood
10. VENT TERMINAL AND 11. OPTIONAL VERTICAL VENTING 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 20: Vent Resizing Instructions
12. VENT RESIZING INSTRUCTIONS FIGURE 9 Fresh Air Damper When an existing furnace is removed from a venting system servicing other appliances, the venting system is likely to be too large to properly vent the remaining attached appliances. The following steps shall be followed with each of the appliances remaining connected to the common venting system, placed in operation one at a time while the other appliances remaining connected to the... -
Page 21: Wiring - Low Voltage Wiring
wiring diagram will be marked “Use Copper Conductors Installation of Flexible Conduit Through Return Air Only”. These instructions must be adhered to. Refer Opening to the National Electrical Code (NEC) for complete NOTE: To allow proper clearance between the control current carrying capacity data on the various insulation panel and any vent options, 90°... - Page 22 For low voltage wiring, an 18 gauge copper, color- Unit Shutdown Feature (Standard on All Models) coded cable is recommended. See Table 5 for more The RT terminal is the 24VAC transformer output, information. and the R terminal is the 24VAC hot terminal for the 460 Volt Units operation of the equipment.
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Page 23: Thermostats
If the unit is being installed with any ventilation changeover with Occupancy Sensor, BACnet package, a Bard LAC kit must be installed. Failure to utilize an LAC with any air conditioner can cause coil 2 stage Cool; 2 stage Heat Programmable/Non-Programmable freeze up. -
Page 24: Figure 11
#8403-084 UNIT CONTROL PANEL UNIT LOW VOLTAGE B/W1 TERM. STRIP FACTORY INSTALLED JUMPER Optional CO2 Controller VENT ORANGE Bard Part #8403-067 BROWN/WHITE PACKAGE RED/WHITE 24VAC WIRING BLUE PLUG BLACK/WHITE C02 OUT TEMP-OUT SET SWITCH ON THERMOSTAT TO "GAS-OIL" CONFIGURE THERMOSTAT FOR HEAT/COOL MUST INSTALL JUMPER FOR 8403-057 OR OTHER THERMOSTAT THAT DOES NOT HAVE OCCUPANCY OUTPUT. -
Page 25: Figure 12 Low Voltage Wiring - Thermostat Using Separate Temperature And Humidity Controllers
TERM. STRIP FACTORY INSTALLED JUMPER YELLOW Electronic Humidistat Mechanical Humidistat Bard part # 8403-047 8403-038 Bard part # (H200-10-21-10) (H600A 1014) SET SWITCH ON THERMOSTAT TO "GAS-OIL" CHANGE "SYSTEM TYPE", SET UP FUNCTION 1, FROM 5 (2 HEAT/ 1 COOL HEAT PUMP) TO 6 (2 HEAT/ 2 COOL CONVENTIONAL). -
Page 26: Jifm Economizer
FIGURE 13 Low Voltage Wiring JIFM Economizer Low Voltage Wiring Diagram 8403-058 (TH5220D1151) Thermostat YO/D W1/E part #8403-060 UNIT CONTROL PANEL UNIT LOW B/W1 VOLTAGE FACTORY INSTALLED JUMPER YELLOW/RED PINK WIRES YELLOW FROM BLUE PLUG PURPLE RED/WHITE BLACK/WHITE Must be energized to enable minimum position. NOTE: Economizer Control Default Setting is 10V (100%). -
Page 27: Figure 14 Gas Pipe Connection
FIGURE 14 Gas Pipe Connection W24G – W36G W42G – W60G Manual 2100-721B Page 27 of 54... -
Page 28: Gas Supply And Piping
18. GAS SUPPLY AND PIPING 8. Refer to Table 9 for gas pipe sizes for natural gas. If more than one appliance is supplied from a General Recommendations single line size, capacity must equal or exceed the combined input to all appliances, and the branch 1. -
Page 29: 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 use with propane (LP) gas. - Page 30 Natural Gas Input Rate Example: Natural gas heating value (BTU/cu. ft.) can vary If the gas water heater, dryer, two range burner significantly. Before starting natural gas input check, pilots and one oven pilot were left on, allow: obtain gas heating value at the location from local Water heater pilot 1,000 BTU per hour supplier.
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Page 31: Standard Orifice Sizing And High Altitude Derate
21. STANDARD ORIFICE SIZING AND It is the installer’s responsibility to see that the furnace input rate is adjusted properly. Derating HIGH ALTITUDE DERATE must be achieved by reducing the size of the main This furnace is shipped with fixed gas orifices for use burner orifices. -
Page 32: Table
TABLE 11A Natural Gas Orifice Tables for Models W24G, W30G and W36G 6,001' to 8,000' 8,001' to 10,000' Up to 6,000' No Requires Pressure Switch Factory Standard Gas Heat* Value Requires Pressure Switch Changes Except Change and Orifice Input BTU/Cu. Ft. Change and Orifice Change for BTU Content Change Based on BTU... -
Page 33: Table 4 Table
TABLE 11B Natural Gas Orifice Tables for Models W42G, W48G and W60G 6,001’ to 8,000’ 8,001’ to 10,000’ Up to 6,000’ No Requires Pressure Switch Factory Standard Gas Heat* Value Requires Pressure Switch Changes Except Change and Orifice Input BTU/Cu. Ft. Change and Orifice Change for BTU Content Change Based on BTU... -
Page 34: Conversion Of Gas Input Btuh From High To Low Rating
22. CONVERSION OF GAS INPUT BTUH 4. Make sure filters are clean and in place. FROM HIGH TO LOW RATING 5. Place one thermometer in supply air plenum approximately 2' from furnace. Locate All the derated WG series units are produced with thermometer tip in center of plenum to ensure maximum BTUH input orifices installed. -
Page 35: Compressor Control Module
FIGURE 16 Access Internal Filter Through Upper Service Door FILTER FILTER SERVICE DOOR MIS-3237 25. COMPRESSOR CONTROL MODULE a compressor call is lost, the time period must expire before a new call will be initiated. The compressor control module is standard on models High Pressure Detection covered by this manual. -
Page 36: Figure 17 8201-169 Compressor Control Module
Brownout Protection with Adjustment If a brownout condition is detected by the 8201-169, the troubleshooting light will flash blue. The light will Brownout protection may be necessary if the utility continue to flash until the cooling call is satisfied or power or generator power has inadequate power to power is removed from the Y terminal. -
Page 37: Phase Monitor
26. PHASE MONITOR If phases are reversed, the red fault LED will be lit and compressor operation is inhibited. All units with three phase scroll compressors are If a fault condition occurs, reverse two of the supply equipped with a three phase line monitor to prevent leads to the unit. -
Page 38: Service Agency Procedures
FIGURE 19 28. 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 39: Troubleshooting Nidec Selectech Series Ecm Motors
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 40: Figure 20 Motor Connections
The SelecTech motor is communicated through 24 VAC E. If the motor does not shut off at the end of the NOTE: Bard Models PA13242; PA13302; PA13362-A, -B; PA13422-A, -B, -C; PA13482-A, -B, -C; PA13602-A, -B, -C low voltage (thermostat control circuit wiring). -
Page 41: Replacement Parts
FIGURE 21 FIGURE 11 Motor Connections 24VAC Common 24VAC "R" Signal through thermostat output. Speed Tap 1: Balanced Climate Speed Speed Tap 2: Cool Speed Speed Tap 3: Cool High Speed Speed Tap 4: Heat Speed Speed Tap 5: Heat High Speed 24VAC Common 24VAC "R"... -
Page 42: Sequence Of Operation - Heating
32. SEQUENCE OF OPERATION – Once the problem has been resolved, reset the switch by pressing down on the reset button on top of the HEATING switch. See Figure 22 for additional information. On a call for heat from the thermostat, the induced draft blower is energized. -
Page 43: Setting Unit Airflow
34. SETTING UNIT AIRFLOW • Remove the black wire from the unused terminal and then remove the red wire from the heat All models have multiple speed direct drive blower terminal. motors. If supply and return ducts are connected to •... -
Page 44: Figure 24 Increasing Cooling Speed
To reduce the cooling airflow speed from high to thermostat or other controlling device. Each speed tap rated, reverse the blue and orange wires on the is programmed by Bard at the factory to different motor terminal block below the furnace control board. torque settings (see Figure 25). -
Page 45: Table 7 Table
TABLE 12 W24G4 Indoor Blower Performance @ 230 and 460 VOLTS Recommended W24G cooling airflow range at rated 800 CFM @ 0.10 ESP (WC) is 700 - 910 CFM Factory set on Rated speed for cooling and Medium speed for heating. - Page 46 TABLE 13 W30G4 Indoor Blower Performance @ 230 AND 460 VOLTS Recommended W30G cooling airflow range at rated 900 CFM @ 0.15 ESP (WC) is 750 - 1150 CFM Factory set on Rated speed for cooling and Medium speed for heating. COOLING MODE MANUAL FAN and HEATING MODE Inches...
- Page 47 TABLE 14 W36G4 Indoor Blower Performance @ 230 AND 460 VOLTS Recommended W36G cooling airflow range at rated 1100 CFM @ 0.10 ESP (WC) is 940 - 1250 CFM Factory set on Rated speed for cooling and Medium speed for heating. COOLING MODE MANUAL FAN and HEATING MODE Inches...
- Page 48 TABLE 15 W42G4 Indoor Blower Performance @ 230 AND 460 VOLTS Recommended W42G cooling airflow range at rated 1300 CFM @ .15 ESP (WC) is 1030 - 1480 CFM Factory set on Rated speed for cooling and Medium speed for heating. COOLING MODE MANUAL FAN and HEATING MODE Inches...
- Page 49 TABLE 16 W48G4 Indoor Blower Performance @ 230 AND 460 VOLTS Recommended W48G cooling airflow range at rated 1450 CFM @ .20 ESP (WC) is 1150 - 1680 CFM Factory set on Rated speed for cooling and Medium speed for heating. COOLING MODE MANUAL FAN and HEATING MODE Inches...
- Page 50 TABLE 17 W60G4 Indoor Blower Performance @ 230 AND 460 VOLTS Recommended W60G cooling airflow range at rated 1650 CFM @ .20 ESP (WC) is 1360 - 1850 CFM Factory set on Rated speed for cooling and Medium speed for heating. COOLING MODE MANUAL FAN and HEATING MODE Inches...
- Page 51 TABLE 18 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...
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Page 52: Pressure Service Ports
465.3 493.6 523.2 553.8 80° DB Low Side 128.0 131.1 134.0 136.8 139.4 142.0 144.4 146.7 148.8 150.8 152.7 W24G4 67° WB High Side 305.6 326.7 348.9 372.3 396.8 422.4 449.2 477.2 506.3 536.6 568.0 85° DB Low Side 132.5 135.7... -
Page 53: R-410A Refrigerant Charge
36. R-410A REFRIGERANT CHARGE 38. LOW-NOX BURNER ASSEMBLY “N” SUFFIX MODELS ONLY – This unit was charged at the factory with the quantity U.S. 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 54: Index - Wiring Diagrams
INDEX Wiring Diagrams Unit Basic Model No. Wiring Diagram W24G4-A 4085-177 W24G4-B 4085-277 W24G4-C 4085-400 W30G4-A 4085-177 W30G4-B 4085-277 W30G4-C 4085-400 W36G4-A 4085-177 W36G4-B 4085-277 W36G4-C 4085-400 W42G4-A 4085-177 W42G4-B 4085-277 W42G4-C 4085-400 W48G4-A 4085-177 W48G4-B 4085-277 W48G4-C 4085-400 W60G4-A...