Bard WG3S2-A Installation Instructions Manual
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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-A
WG3S2-B
WG4S2-A
WG4S2-B
WG5S2-B
WG5S2-A
WARNING
Bard Manufacturing Company, Inc.
Bryan, Ohio 43506
www.bardhvac.com
WG3S2-C
WG4S2-C
WG5S2-C
Manual No.:
Supersedes:
Date:
2100-587C
2100-587B
10-30-14
Page
1 of 59
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Table of Contents
Related Manuals for Bard WG3S2-A
Summary of Contents for Bard WG3S2-A
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Page 1: Installation Instructions
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.: 2100-587C Bryan, Ohio 43506... -
Page 2: Table Of Contents
CONTENTS Page Page 2 1. Standard Orifice Sizing & High Getting Other Information and Publications....4 Altitude Derate ...........29 WG Series Model Nomenclature ........ 5 22. Conversion of Gas Input BTUH From High Ventilation Options............5 to Low Rating .............31 Air Conditioning Module Options ........ 6 23. - Page 3 CONTENTS Page Page FIGURES TABLES Figure 1 Unit Dimensions ........8 Table 1 Specifications ..........7 Figure 2A Mounting Instructions – WG3S2 .... 11 Table 2 Minimum Installation Clearances ....16 Figure 2B Mounting Instructions–WG4S2 & WG5S2 ..Table 3 Thermostat Wire Size ......20 Figure 3 Combustible Clearance ......
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Page 4: Getting Other Information And Publications
Winter and Winter Air Conditioning and Equipment 178 Rexdale Boulevard Selection 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 2100-587C Page 4 of 59... -
Page 5: Wg Series Model Nomenclature
WALL MOUNT GAS/ELECTRIC GENERAL MODEL NUMBER NOMENCLATURE – REVISION VENT MODEL 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 C = 460-60-3... -
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-breaktimer. 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
Manual 2100-587C Page 7 of 59... -
Page 8: Figure 1 Unit Dimensions
Manual 2100-587C Page 8 of 59... -
Page 9: Important
Any grille that meets with the 5/8 inch louver criteria may be used. It is recommended that Bard Return Air and gas heating unit and the electrical wiring connections and gas piping to the unit. The refrigerant Grille or Return Filter Grille be installed when 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 All units should be carefully inspected upon arrival for brackets which secure the unit to the outside damage. -
Page 11: Figure 2A Mounting Instructions - Wg3S2
Manual 2100-587C Page 11 of 59... -
Page 12: Figure 2B Mounting Instructions-Wg4S2 & Wg5S2
Manual 2100-587C 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 2100-587C Page 14 of 59... -
Page 15: Figure 6 Common Wall Mounting Installations
FIGURE 6 COMMON WALL MOUNTING INSTALLATIONS Manual 2100-587C 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 inch first 3 feet adequate fire protection, adequate combustion air, and (from combustible materials) room for service personnel. Vent Terminal While minimum clearances are acceptable for safety * 17 inches (from combustible materials) -
Page 17: Vent Terminal And Combustion Inlet Hood
10. VENT TERMINAL AND COMBUSTION 11. OPTIONAL VERTICAL VENTING 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 compartment. See Figure 7. Remove the two shipping The kit includes a stainless steel transition drain tee, silicone sealant, and drain tubing. -
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 attached appliances. -
Page 19: Wiring - Main Power
15. WIRING – MAIN POWER ELECTRICAL GROUNDING When installed, the furnace must be electrically grounded in accordance with local codes or in the WARNING 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 16. WIRING – LOW VOLTAGE WIRING Direct Digital Controls (DDC) 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 D Manual 2100-587C 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 Ventilator Thermostat Subbase Thermostat Part #8403-058 Thermostat W1/E D/YO Part #8403-060 (MUST BE CONFIGURED FOR HEAT/COOL) Unit 24V Terminal Block Factory Installed Jumper Unit Control Panel STEP CONTROL ASSEMBLY... -
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 Ventilator 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/WHITE CONTROL BLUE WIRES BROWN/WHITE... -
Page 25: Figure 11 Gas Pipe Connection
FIGURE 11 GAS PIPE CONNECTION Manual 2100-587C 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: 1. Standard Orifice Sizing & High Altitude Derate
21. STANDARD ORIFICE SIZING AND gas burned in the furnace must also be reduced. This HIGH ALTITUDE DERATE is 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
[2.30] orifices are shipped with the unit for field installed (2.40) is the factory installed orifice size for full rated optional 10% input rate input At standard conditions: 30.00 inches Mercury, 60F, saturated, .60 specific gravity. 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 No. of Orifices Required Based on Unit Input Rating 9010-092 2.10 0.0826... -
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 FILTER FILTER SERVICE DOOR MIS-3237 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 removing the filter access If the high pressure switch opens, the compressor panel. - Page 33 PHASE MONITOR ALARM OUTPUT 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 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 35: Service Agency Procedures
27. SERVICE AGENCY PROCEDURES FIGURE 15 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: 9. 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 37: Sequence Of Operation - Heating
30. SEQUENCE OF OPERATION – 31. SEQUENCE OF OPERATION – HEATING COOLING On a call for heat from the thermostat, the induced NON-ECONOMIZER 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: Indoor Blower Operation
FIGURE 17 FURNACE CONTROL BOARD AND BLOWER CONTROL 32. INDOOR BLOWER OPERATION system is ducted or free blow. It will also maintain the The indoor blower motor is a constant CFM variable speed direct drive motor. The motor is programmed temperature rise across the gas heat exchanger at the to respond to individual thermostatic inputs that mid-point of the allowable rise range automatically. -
Page 39: Table 10 Integrated Furnace & 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 40: Start Up
START UP These units require R-410A refrigerant & Polyol Ester oil. APPLICATION: 1. Use separate service and manufacturing equipment to avoid cross contamination of oil and refrigerants. 2. Use recovery equipment rated for R-410A refrigerant. 3. Use manifold gauges rated for R-410A (800 psi/ 250 psi low). -
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: Ecm Tm Motors
Troubleshooting ECM Motors ™ Symptom Cause/Procedure CAUTION: • 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 from - Check for air whistling through seams in the motor’s capacitors, disconnect power and wait at least 5 ducts, cabinets or panels... -
Page 44: Ecm Tm Motors
Troubleshooting ECM Motors Cont’d. ™ Replacing ECM Control Module BLOWER OPERATION. Orient the control module so that the 3-wire motor plug can be inserted into the socket in the control. Carefully insert To replace the control module for the GE variable-speed indoor blower the plug and press it into the socket until it latches. -
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) High Capacity Cooling Air Temperature Entering Outdoor Coil Degree F Return Air... -
Page 46: R-410A Refrigerant Charge
R-410A 35. LOW-NOX BURNER ASSEMBLY “N” SUFFIX MODELS ONLY – U.S. 34. REFRIGERANT CHARGE INSTALLATIONS ONLY This unit was charged at the factory with the quantity of NATURAL GAS MODELS ONLY refrigerant listed on the serial plate. AHRI capacity and efficiency ratings were determined by testing with this Model numbers designated with an “N”... -
Page 47: Index - Wiring 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: Manual 2100-587C
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: Manual 2100-587C
INDUCED DRAFT 14 12 10 6 2 13 3 1 Indoor Blower Motor BLOWER RELAY Ladder Diagram Factory Optional High Voltage Wires Connect if Option Not Low Voltage 4085-155 Used WG3S2-A, WG4S2-A, WG5S2-A 208/230/60/1 Manual 2100-587C Page 49 of 59... -
Page 50: Manual 2100-587C
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 INDUCED DRAFT 14 12 10 6 2 13 3 1 Indoor Blower Motor BLOWER RELAY Ladder Diagram Factory Optional High Voltage Wires Connect if Option Not Low Voltage 4085-157 Used WG3S2-A, WG4S2-A, WG5S2-A 208/230/60/1 Manual 2100-587C Page 51 of 59...
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Page 52: Manual 2100-587C
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: Manual 2100-587C
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 2100-587C
PIN PLUG FOR INDOOR BLOWER MOTOR INTEGRATED FURNACE CONTROL VOLTAGE STRIP BROWN YELLOW PRIMARY LIMIT 16 PIN PLUG FOR INDOOR BLOWER MOTOR FUSE PURPLE FLAME ROLLOUT 10 11 RED/WHITE GRAY SPARK IGNITOR 4 5 6 ORANGE 1 2 3 RED/ BLACK/WHITE WHITE SPEED... -
Page 55: Manual 2100-587C
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 2100-587C
15/370 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 WIRES CONNECT REPLACED, IT MUST BE REPLACED WITH WIRING MATERIAL HAVING A High Voltage TEMPERATURE RATING OF AT LEAST 105°... -
Page 57: Manual 2100-587C
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 2100-587C
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 59: Ladder Diagram
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...