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INSTALLATION
INSTRUCTIONS
W24G1-A
W24G1-B
W36G1-B
W36G1-C
W48G1-C
W60G1-A
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 2010
COMBINATION GAS/ELECTRIC
WALL-MOUNT
W24G1-C
W30G1-A
W42G1-A
W42G1-B
W60G1-B
W60G1-C
WARNING
Bard Manufacturing Company, Inc.
Bryan, Ohio 43506
Since 1914...Moving ahead just as planned.
WG - SERIES
MODELS:
W30G1-B
W42G1-C
Manual No.:
Supersedes:
File:
Date:
W30G1-C
W36G1-A
W48G1-A
W48G1-B
2100-525A
2100-525
Volume III, Tab 20
04-07-10
Manual 2100-525A
Page
1 of 67
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Summary of Contents for Bard W24G1-A
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Page 1: Installation Instructions
AND UNDERSTAND ALL OF THESE REQUIREMENTS. FAILURE TO DO SO COULD CREATE A HAZARD RESULTING IN PROPERTY DAMAGE, BODILY INJURY, OR DEATH. Manual No.: 2100-525A Bard Manufacturing Company, Inc. Supersedes: 2100-525 Bryan, Ohio 43506 File: Volume III, Tab 20 Since 1914...Moving ahead just as planned. -
Page 2: Table Of Contents
CONTENTS Page Page 20. Checking Gas Input Rate ......27 & 28 Getting Other Information and Publications ....4 W**G 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 ........9 Table 1 Specifications – W24-36G Models ... 7 Figure 2 Mounting Instructions – W24-36G ..12 Table 1A Specifications – W42-60G Models ... 8 Figure 2A Mounting Instructions – W42-60G ..13 Table 2 Minimum Installation Clearances ...
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Page 4: Getting Other Information And Publications
Rexdale, Ontario Canadian Electrical Code ......CSA C22.1 Canada. M9W 1R3 Telephone: (416) 447-4044 Canadian Installation Code……………CAN/CGA B149 COPYRIGHT JANUARY 2010 BARD MANUFACTURING COMPANY, INC. BRYAN, OHIO 43506 USA Manufactured under the following U.S. patent numbers: 5,485,878; 5,002,116 Manual 2100-525A Page... -
Page 5: W**G Series Model Nomenclature
WALL MOUNT GAS/ELECTRIC GENERAL MODEL NUMBER NOMENCLATURE – REVISION COLOR MODEL VENT CONTROL OPTIONS X = Beige See Table Wall Mount (See Table page 6) GAS/ (Standard) Below VOLTAGE ELECTRIC 4 = Gray COOLING A = 230/208-60-1 COIL OPTIONS CAPACITY B = 230/208-60-3 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. -
Page 7: Table 1 Specifications - W24-36G Models
Manual 2100-525A Page 7 of 67... -
Page 8: Table 1A Specifications - W42-60G Models
Manual 2100-525A Page 8 of 67... -
Page 9: Figure 1 Unit Dimensions
Manual 2100-525A Page 9 of 67... -
Page 10: 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 11: 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 12: Figure 2 Mounting Instructions - W24-36G
Manual 2100-525A Page 12 of 67... -
Page 13: Figure 2A Mounting Instructions - W42-60G
Manual 2100-525A Page 13 of 67... -
Page 14: Figure 3 Combustible Clearance - W24-36G
FIGURE 3 COMBUSTIBLE CLEARANCE FOR W24G, W30G AND W36G MODELS FIGURE 3A COMBUSTIBLE CLEARANCE FOR W42G, W48G AND W60G MODELS 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. -
Page 15: Figure 4 Wall Mounting Instructions
FIGURE 4 WALL MOUNTING INSTRUCTIONS FIGURE 5 WALL MOUNTING INSTRUCTIONS Manual 2100-525A Page 15 of 67... -
Page 16: Figure 6 Common Wall Mounting Installations
FIGURE 6 COMMON WALL MOUNTING INSTALLATIONS Manual 2100-525A Page 16 of 67... -
Page 17: 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 18: 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 19: 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 If the unit is equipped with a fresh air damper attached appliances. -
Page 20: 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 21: Wiring - Low Voltage Wiring
FIGURE 10 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 22: Figure 11 Low Voltage Wiring-No Vent Pkg
FIGURE 11 LOW VOLTAGE WIRING Low Voltage Wiring - No Ventilation Package Thermostat Subbase Thermostat Part #8403-057 TH3110D1040 Thermostat Part #8403-060 W1/E D/YO (1120-445) Unit 24V Terminal Block Factory Installed Jumper Unit Control Panel SET SWITCH ON THERMOSTAT TO "GAS-OIL" CONFIGURE THERMOSTAT FOR HEAT/COOL MIS-2774 Manual 2100-525A... -
Page 23: Figure 12 Low Voltage Wiring
FIGURE 12 LOW VOLTAGE WIRING MOTORIZED FRESH AIR DAMPER, Low Voltage Wiring - COMMERCIAL ROOM VENTILATOR-SPRING, COMMERCIAL ROOM VENTILATOR-POWER Thermostat Subbase Thermostat Part #8403-057 (TH311DD1040) Thermostat W1/E D/YO Part #8403-060 (1120-445) (MUST BE CONFIGURED FOR HEAT/COOL) Unit 24V Terminal Block Factory Installed Jumper Unit Control Panel... -
Page 24: Figure 13 Low Voltage Wiring-Eifm Econo
FIGURE 13 LOW VOLTAGE WIRING Low Voltage Wiring - EIFM ECONOMIZER Thermostat Subbase Thermostat Part #8403-058 (TH5220D1151) Thermostat W1/E D/YO Part #8403-060 (1120-445) Unit 24V Terminal Block Factory Installed Jumper Unit Control Panel WGSEIFM-5 BLACK BLUE PINK WIRES YELLOW FROM PURPLE PLUG ORANGE... -
Page 25: Figure 14 Gas Pipe Connection
FIGURE 14 GAS PIPE CONNECTION W24G - W36G W42G - W60G Manual 2100-525A Page 25 of 67... -
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
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 It is the installer’s responsibility to see that the furnace HIGH ALTITUDE DERATE input rate is adjusted properly. Derating must be achieved by reducing the size of the main burner This furnace is shipped with fixed gas orifices for use orifices. -
Page 30: Table 8 Natural Gas Orifice Tables - W24-36G
TABLE 8 NATURAL GAS ORIFICE TABLES FOR MODELS W24G, W30G AND W36G f i r f i r c t i i t l 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: Table 8A Natural Gas Orifice Tables - W42-60G
TABLE 8A NATURAL GAS ORIFICE TABLES FOR MODELS W42G, W48G AND W60G f i r f i r i t l c t i f i r f i r f i r f i r i t l c t i f i r f i r , y r... -
Page 32: 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 33: Filters
FIGURE 16 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 16.) contactor will de-energize immediately. - Page 34 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 35: Lighting & Shutdown Instructions
26. LIGHTING AND SHUTDOWN INSTRUCTIONS FIGURE 17 INSTRUCTION LABEL Manual 2100-525A Page 35 of 67... -
Page 36: Service Agency Procedures
FIGURE 18 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 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. 2. Lubrication Requirements – The indoor circulating Disconnect electrical power before servicing air blower motor and outdoor circulating air fan unit. -
Page 38: Sequence Of Operation - Heating
burner orifices or incorrect manifold pressure, 30. SEQUENCE OF OPERATION – insufficient combustion air, or installation deficiencies HEATING with respect to return air duct design or sizing. On a call for heat from the thermostat, the induced draft Once the problem has been resolved, reset the switch by blower is energized. -
Page 39: Indoor Blower Operation
FIGURE 20 FURNACE CONTROL BOARD AND BLOWER CONTROL 32. INDOOR BLOWER OPERATION If it is desirable to have both HEAT/COOL blower motor speed at the same speed, install a jumper wire All models have multiple speed direct drive blower between “HEAT” and “COOL” terminals of the motors. -
Page 40: Table 10 W24G Indoor Blower Performance
TABLE 10 W24G INDOOR BLOWER PERFORMANCE 230 AND 460 VOLTS Recommended W24G cooling airflow range at rated 800 CFM @ 0.15 ESP (WC) is 680 - 920 CFM Factory set on Low Speed for cooling and High for heating. Voltage adjustment – Reduce airflow by 100 CFM for 208 Volt Dehumidification coil adjustment –... -
Page 41: Table 11 W30G Indoor Blower Performance
TABLE 11 W30G INDOOR BLOWER PERFORMANCE 230 AND 460 VOLTS Recommended W30G cooling airflow range at rated 1000 CFM @ 0.35 ESP (WC) is 820 - 1150 CFM Factory set on Medium Speed for cooling and for heating. Voltage adjustment – Reduce airflow by 100 CFM for 208 Volt Dehumidification coil adjustment –... -
Page 42: Table 12 W36G Indoor Blower Performance
TABLE 12 W36G INDOOR BLOWER PERFORMANCE 230 AND 460 VOLTS Recommended W36G cooling airflow range at rated 1100 CFM @ 0.250 ESP (WC) is 935 - 1265 CFM Factory set on Medium Speed for cooling and for heating. Voltage adjustment – Reduce airflow by 100 CFM for 208 Volt Dehumidification coil adjustment –... -
Page 43: Table 13 W42G Indoor Blower Performance
TABLE 13 W42G INDOOR BLOWER PERFORMANCE 230 AND 460 VOLTS Recommended W42G cooling airflow range at rated 1300 CFM @ .35 ESP (WC) is 1500 - 1030 CFM Factory set on Medium Speed for heating and cooling Voltage adjustment – Reduce airflow by 130 CFM for 208 Volt Top outlet adjustment –... -
Page 44: Table 14 W48G Indoor Blower Performance
TABLE 14 W48G INDOOR BLOWER PERFORMANCE 230 AND 460 VOLTS Recommended W48G cooling airflow range at rated 1550 CFM @ .38 ESP (WC) is 1750 - 1280 CFM Factory set on High Speed for cooling and Medium Speed for heating. Voltage adjustment –... -
Page 45: Table 15 W60G Indoor Blower Performance
TABLE 15 W60G INDOOR BLOWER PERFORMANCE 230 AND 460 VOLTS Recommended W60G cooling airflow range at rated 1650 CFM @ .30 ESP (WC) is 1910 - 1340 CFM Factory set on High Speed for cooling and Medium Speed for heating. Voltage adjustment –... -
Page 46: Table 16 Integrated Furnace & Blower Control Operation
TABLE 16 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 47: 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. Tables 17A & 17B outlines expected pressures at various indoor and outdoor temperatures. TABLE 17A COOLING PRESSURE TABLE °... -
Page 48: Refrigerant Charge
34. REFRIGERANT CHARGE 36. LOW-NOX BURNER ASSEMBLY “N” SUFFIX MODELS ONLY – U.S. The correct system R-410A charge is shown on the unit INSTALLATIONS ONLY rating plate. Optimum unit performance will occur with a refrigerant charge resulting in a suction line temperature NATURAL GAS MODELS ONLY (6"... -
Page 49: Index - Wiring Diagrams
INDEX WIRING DIAGRAMS and LADDER DIAGRAMS Manual 2100-525A Page 49 of 67... -
Page 50: Wiring Diagrams
Model C. Breaker Capacitor W24G1-A 40+5/440 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 W24G1-A 230/208-60-1 Manual 2100-525A Page 51 of 67...
- Page 52 Model C. Breaker Fan Capacitor W24G1-B 5/370 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 53 W24G1-B 230/208-60-3 Manual 2100-525A Page 53 of 67...
- Page 54 OUTDOOR MOTOR PRESSURE SWITCH 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 55 W24G1-C 460-60-3 Manual 2100-525A Page 55 of 67...
- Page 56 45+5/370 W42G1-A 45+10/370 WIRES CONNECT Wire Identification numbers IF OPTION USE COPPER CONDUCTORS for Bard use only. NOT USED 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 High Voltage Bard Mfg.
- Page 57 W30G1-A, W36G1-A, W42G1-A 230/208-60-1 Manual 2100-525A Page 57 of 67...
- Page 58 5/370 W42G1-B 10/370 WIRES CONNECT Wire Identification numbers IF OPTION USE COPPER CONDUCTORS for Bard use only. NOT USED 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 High Voltage Bard Mfg.
- Page 59 W30G1-B, W36G1-B, W42G1-B 230/208-60-3 Manual 2100-525A Page 59 of 67...
- Page 60 OUTDOOR MOTOR PRESSURE SWITCH 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 61 W30G1-C, W36G1-C, W42G1-C 460-60-3 Manual 2100-525A Page 61 of 67...
- Page 62 OUTDOOR MOTOR PRESSURE SWITCH 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 63 W48G1-A, W60G1-A 230/208-60-1 Manual 2100-525A Page 63 of 67...
- Page 64 W48G1-B 10/370 W60G1-B 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 65 W48G1-B, W60G1-B 230/208-60-3 Manual 2100-525A Page 65 of 67...
- Page 66 OUTDOOR MOTOR PRESSURE SWITCH 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 67 W48G1-C, W60G1-C 460-60-3 Manual 2100-525A Page 67 of 67...