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Bard WG3S2-A Installation Instructions Manual

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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.
COMBINATION GAS/ELECTRIC
WG3S2-A
WG4S2-A
WG5S2-A
WARNING
Bard Manufacturing Company, Inc.
Bryan, Ohio 43506
Since 1914...Moving ahead just as planned.
WG - SERIES
WALL-MOUNT
MODELS:
WG3S2-B
WG4S2-B
WG5S2-B
Manual No.:
Supersedes:
File:
Date:
WG3S2-C
WG4S2-C
WG5S2-C
2100-587B
2100-587A
Volume III, Tab 20
09-20-13
Manual 2100-587B
Page
1 of 59

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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 No.: 2100-587B Supersedes: 2100-587A Bryan, Ohio 43506...

  • Page 2: Table Of Contents

    CONTENTS Page Page 21. 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 .......
  • 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 ......

  • Page 4: Getting Other Information And Publications

    Winter and Winter Air Conditioning and Equipment Selection Canadian Standards Association 178 Rexdale Boulevard Rexdale, Ontario Canadian Electrical Code ......CSA C22.1 Canada. M9W 1R3 Telephone: (416) 447-4044 Canadian Installation Code……………CAN/CGA B149 BARD MANUFACTURING COMPANY, INC. BRYAN, OHIO 43506 USA Manual 2100-587B 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 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 e l l e l l 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

    Manual 2100-587B Page 7 of 59...

  • Page 8: Figure 1 Unit Dimensions

    Manual 2100-587B Page 8 of 59...

  • Page 9: Important

    Any grille that meets with the 5/8 inch louver criteria and gas heating unit and the electrical wiring may be used. It is recommended that Bard Return Air connections and gas piping to the unit. The refrigerant Grille or Return Filter Grille be installed when no return system is completely assembled and charged.

  • Page 10: Transportation Damage

    5. TRANSPORTATION DAMAGE 8. MOUNTING THE UNIT All units are packed securely in shipping container. All 1. These units are secured by wall mounting 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 2100-587B Page 11 of 59...

  • Page 12: Figure 2B Mounting Instructions-Wg4S2 & Wg5S2

    Manual 2100-587B 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 2100-587B Page 14 of 59...

  • Page 15: Figure 6 Common Wall Mounting Installations

    FIGURE 6 COMMON WALL MOUNTING INSTALLATIONS Manual 2100-587B 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 b i t ) s l r i f adequate fire protection, adequate combustion air, and b i t ) 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 D Manual 2100-587B 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 WGSCRVMP-5...

  • 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 2100-587B 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.

  • 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 f i r f i r f i r f i r 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 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 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.

  • Page 34: Lighting & Shutdown Instructions

    26. LIGHTING AND SHUTDOWN INSTRUCTIONS FIGURE 14 INSTRUCTION LABEL Manual 2100-587B 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 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 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: Indoor Blower Operation

    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 o i t o " ) " t n I r t - c t i o i t o i t o i t i t l a l f o i t o i t i r u i t (...

  • Page 40: Start Up

    HIGH & LOW PRESSURE SWITCH START UP All models covered by this Manual are supplied with a These units require R-410A refrigerant & Polyol Ester oil. remote reset high pressure switch and low pressure switch. If tripped, this pressure switch may be reset by APPLICATION: turning the thermostat off then back on again.

  • 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 ™ 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: Ecm Tm Motors

    Troubleshooting ECM Motors Cont’d. ™ Replacing ECM Control Module 7. Verify that the replacement control is correct for your 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 This unit was charged at the factory with the quantity of NATURAL GAS MODELS ONLY refrigerant listed on the serial plate. AHRI capacity and Model numbers designated with an “N”...

  • Page 47: Index - Wiring Diagrams

    INDEX WIRING DIAGRAMS and LADDER DIAGRAMS Manual 2100-587B Page 47 of 59...

  • Page 48: Wiring Diagrams

    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 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 4085-155 WG3S2-A, WG4S2-A, WG5S2-A 208/230/60/1 Manual 2100-587B Page 49 of 59...
  • Page 50 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 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 4085-157 WG3S2-A, WG4S2-A, WG5S2-A 208/230/60/1 Manual 2100-587B Page 51 of 59...
  • Page 52 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 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 4085-269 Used WG3S2-B, WG4S2-B, WG5S2-B...
  • 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 4085-270 WG3S2-B, WG4S2-B, WG5S2-B...
  • Page 56 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 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 4085-392 Used WG3S2-C, WG4S2-C, WG5S2-C...
  • Page 58 WG4S2-C 15/370 WG5S SUITABLE FOR AT LEAST 75° C WG5S2-C 15/370 for Bard use only. 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 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 4085-393 Used WG3S2-C, WG4S2-C, WG5S2-C...

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