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INSTALLATION INSTRUCTIONS
WG SERIES WALL MOUNTED GAS/ELECTRIC
WITH DEHUMIDIFICATION
W30G2DA
W24G2DA
W24G2DB
W30G2DB
W30G2DC
W24G2DC
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:
W36G2DA
W36G2DB
W36G2DC
WARNING
Bard Manufacturing Company, Inc.
Bryan, Ohio 43506
www.bardhvac.com
W42G2DA
W48G2DA
W42G2DB
W48G2DB
W42G2DC
W48G2DC
Manual No.:
Supersedes:
Date:
W60G2DA
W60G2DB
W60G2DC
2100-592C
2100-592B
5-4-15
Page
1 of 69
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Summary of Contents for Bard W24G2DA
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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.: 2100-592C Bryan, Ohio 43506 Supersedes: 2100-592B... -
Page 2: Table Of Contents
CONTENTS Page Page 21. Standard Orifice Sizing and High Getting Other Information and Publications ...4 Altitude Derate ..........30 Wall Mount Gas/Electric General Information ..5 22. Conversion of Gas Input BTUH from High W**G Series Model Nomenclature ..... 5 to Low Rating ..........33 Ventilation Options .......... - Page 3 Page Page FIGURES TABLES Figure 1 Unit Dimensions ........9 Table 1 Specifications – W24G-36G Models ..7 Figure 2 Mounting Instructions – W24G-36G ..12 Table 1A Specifications – W42G-60G Models ..8 Figure 2A Mounting Instructions – W42G-60G ..13 Table 2 Minimum Installation Clearances ...
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Page 4: Getting Other Information And Publications
Winter and Winter Air Conditioning and Equipment 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 2100-592C Page 4 of 69... -
Page 5: Wall Mount Gas/Electric General Information
WALL MOUNT GAS/ELECTRIC GENERAL INFORMATION MODEL NUMBER NOMENCLATURE W 42 REVISION MODEL COLOR VENT 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 8 = Dark Bronze B = 230/208-60-3 CAPACITY... -
Page 6: Air Conditioning Module Options
Air Conditioning Module Options Factory-Installed Field-Installed Code Part • CMA-28 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. There is no delay-on-make during routine operation of the unit. - Page 7 Manual 2100-592C Page 7 of 69...
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Page 8: Table 1A Specifications - W42G-60G Models
Manual 2100-592C Page 8 of 69... -
Page 9: Figure 1 Unit Dimensions
Manual 2100-592C Page 9 of 69... -
Page 10: High Altitude Applications
Any grille that meets with the 5/8" louver criteria may Size of unit for proposed installation should be based be used. It is recommended that Bard Return Air Grille on heat loss/heat gain calculations made according to or Return Filter Grille be installed when no return duct methods of Air Conditioning Contractors of America is used. -
Page 11: Wall Mounting Information
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 Failure to provide the 1" clearance between the supply duct and a combustible surface for the 2. -
Page 12: Figure 2 Mounting Instructions - W24G-36G
Manual 2100-592C Page 12 of 69... -
Page 13: Figure 2A Mounting Instructions - W42G-60G
Manual 2100-592C Page 13 of 69... -
Page 14: Figure 3 Combustible Clearance - W24G-36G
FIGURE 3 Combustible Clearance for W24G, W30G and W36G Models FIGURE 3A Combustible Clearance for W42G, W48G and W60G Models WARNING 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 2100-592C Page 15 of 69... -
Page 16: Figure 6 Common Wall Mounting Installations
FIGURE 6 Common Wall Mounting Installations Manual 2100-592C Page 16 of 69... -
Page 17: 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 18: 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 19: Vent Resizing Instructions
12. VENT RESIZING INSTRUCTIONS 13. FRESH AIR INTAKE When an existing furnace is removed from a venting All units are built with fresh air inlet slots punched in system servicing other appliances, the venting system the service panel. 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 personal safety, turn off electric power ground wire on the furnace to a grounded connection at service entrance panel before making any... -
Page 21: Wiring - Low Voltage Wiring
FIGURE 10 Installation of Flexible Conduit 16. WIRING – LOW VOLTAGE WIRING Range Low Voltage Connection 253 – 206 220 – 187 These units use a 24-volt AC low voltage circuit. The “R” terminal is the hot terminal and the “C” NOTE: The voltage should be measured at the field terminal is grounded. -
Page 22: Thermostats
17. THERMOSTATS TABLE 3 Thermostat Wire Size Maximum Transformer Wire Gauge Distance in Feet 20 gauge 18 gauge 16 gauge 14 gauge 12 gauge TABLE 4A Wall Thermostat Thermostat Predominant Features 1 Stage Cool; 1 Stage Heat 8403-057 System: heat-off-cool Fan: on-auto (TH3110D1040) Electronic Non-Programmable 2 Stage Cool;... -
Page 23: Figure 11A Thermostat Connection Using Combination Temperature And Humidity Controller
FIGURE 11A Thermostat Connection Using 8403-060 Combination Temperature and Humidity Controller Thermostat Subbase Thermostat D/YO and Humidity W1/E Control Part #8403-060 (1120-445) Unit 24V Terminal Block Factory Installed Jumper Unit Control Panel CONFIGURE THERMOSTAT FOR HEAT/COOL NEEDED FOR ECONOMIZER ONLY INSTALL ONLY IF APPLIED THERMOSTAT DOES NOT HAVE INDIVIDUAL OUTPUT SIGNAL FOR OCCUPENCY, ORE YOU ARE NOT APPLYING A CO2 CONTROL. -
Page 24: Figure 11B Thermostat Using Separate Temperature And Humidity Controllers
Part #8403-058 (TH522OD1151) Unit 24V Terminal Block Unit Control Panel Electronic Humidistat Bard part #8403-047 (H200-10-21-10) Mechanical Humidistat Yellow Bard part #8403-038 (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 25: Figure 11C Mfad, Classroom Ventilation Spring And Power And Erv Low Voltage Connections
Block Unit 24V Factory Installed Terminal Jumper Block Factory Installed Jumper Unit Control Panel Optional CO2 Controller Unit Control Panel Bard Part #8403-067 Optional CO2 Controller 24VAC Bard Part #8403-067 BLUE C02 OUT 24VAC BLUE TEMP-OUT VENT PACKAGE C02 OUT... -
Page 26: Figure 12 Gas Pipe Connection
FIGURE 12 Gas Pipe Connection W24G - W36G W42G - W60G Manual 2100-592C Page 26 of 69... -
Page 27: 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 28: 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 29: Manual 2100-592C
Natural Gas Input Rate 9. If water heater, dryer or range pilots were left 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 30: 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 burner orifices. Derating the furnace by adjusting the This furnace is shipped with fixed gas orifices for use manifold pressure lower than the range specified in with natural gas and sized for 1000 BTU/cubic foot... -
Page 31: Manual 2100-592C
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. -
Page 32: Table 8A
TABLE 8A 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 33: Conversion Of Gas Input Btuh From High To Low Rating
22. CONVERSION OF GAS INPUT BTUH 5. Place one thermometer in supply air plenum approximately 2’ from furnace. Locate FROM HIGH TO LOW RATING thermometer tip in center of plenum to ensure All the derated WG series units are produced with proper temperature measurement. -
Page 34: Filters
FIGURE 14 Access Internal Filter Through Upper Service Door 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. If the high pressure switch opens, the compressor This filter is installed by opening the filter service door contactor will de-energize immediately. -
Page 35: Phase Monitor
26. 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. -
Page 36: 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. -
Page 37: 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 38: 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 39: Sequence Of Operation - Heating
32. SEQUENCE OF OPERATION – 31. SEQUENCE OF OPERATION – COOLING HEATING On a call for cooling from the room thermostat, the On a call for heat from the thermostat, the induced high speed blower relay will be energized as well as draft blower is energized. -
Page 40: Figure 17 Sequence Of Operation - Electronic Blower Control
FIGURE 17 Sequence of Operation Electronic Blower Control Action System Response Thermostat calls for heat • Combustion air blower is energized. (W terminal is energized). • Air proving switch makes. Airflow is established. • Ignition system is energized. • Gas valve opens and main burner lights. •... -
Page 41: Indoor Blower Operation
FIGURE 18 Furnace Control Board and Blower Control 33. INDOOR BLOWER OPERATION If it is desirable to have both HEAT/COOL blower motor speed at the same speed, install a jumper wire between All models have multiple speed direct drive blower “HEAT”... -
Page 42: Table 10
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. COOLING MODE MANUAL FAN and HEATING MODE Inches... -
Page 43: 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. COOLING MODE MANUAL FAN and HEATING MODE Inches Wet Coil... -
Page 44: 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. COOLING MODE MANUAL FAN and HEATING MODE Inches Wet Coil... -
Page 45: 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 dpeed for heating and cooling. COOLING MODE MANUAL FAN and HEATING MODE Inches Wet Coil... -
Page 46: 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. COOLING MODE MANUAL FAN and HEATING MODE Inches... -
Page 47: 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. COOLING MODE MANUAL FAN and HEATING MODE Inches... -
Page 48: Table 16 Integrated Furnace And Blower Control Operation
TABLE 16 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 49: W**G Dehumidification Relay Logic Board
34. W**G DEHUMIDIFICATION RELAY LOGIC BOARD TABLE 17 Dehumidification Relay Logic Board 24V Terminal Block Connections Outputs from Board Inputs to Board Cooling Mode Unoccupied Cooling Mode Occupied with Dehum Cooling Mode 1st Stage Heating Unoccupied 1st Stage Heating Occupied 1st Stage Heating ... -
Page 50: Pressure Service Ports
35. PRESSURE SERVICE PORTS then energizes both the compressor circuit and the three way valve, thus directing the hot refrigerant High and low pressure service ports are installed on discharge gas into a separate desuperheating all units so that the system operating pressures can be condenser circuit, which reheats the conditioned air observed. -
Page 51: Refrigerant Charge
37. REFRIGERANT CHARGE The nameplate charge quantity is optimized for thermal performance and efficiency of this self-contained The correct system R-410A charge is shown on the unit package system. rating plate. The system operating pressures in Table 18 are based Reference Table 18 to validate proper system operation upon rated airflow across the evaporator during cooling (+2 psig suction, +5 psig discharge). -
Page 52: Fan Blade Setting Dimensions
38. FAN BLADE SETTING DIMENSIONS 39. LOW-NOX BURNER ASSEMBLY “N” SUFFIX MODELS ONLY – U.S. Shown in Figure 20 is the correct fan blade setting INSTALLATIONS ONLY dimension for proper air delivery across the outdoor coil. Natural Gas Models Only Model numbers designated with an “N”... -
Page 53: Index - Wiring Diagrams And Ladder Diagrams
INDEX Wiring Diagrams and Ladder Diagrams Unit Basic Manual Basic Manual Model No. Wiring Diagram Page No. Ladder Diagram Page No. W24G2DA 4085-165 4085-166 W24G2DB 4085-263 4085-264 W24G2DC 4085-386 4085-387 W30G2DA 4085-167 4085-168 W30G2DB 4085-265 4085-266 W30G2DC 4085-388 4085-389 W36G2DA... -
Page 54: Wiring Diagrams And Ladder Diagrams
Model C. Breaker Capacitor W24G*DA 40+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 55: Manual 2100-592C
W24G2DA, W48G2DA, W60G2DA 230/208-60-1 Manual 2100-592C Page 55 of 69... -
Page 56: Manual 2100-592C
Model C. Breaker Fan Capacitor W24G*DB 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 57: Manual 2100-592C
W24G2DB, W48G2DB, W60G2DB 230/208-60-3 Manual 2100-592C Page 57 of 69... -
Page 58: Manual 2100-592C
W36G*DC 5/370 W42G*DC 15/370 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 59: Manual 2100-592C
W24G2DC 460-60-3 Manual 2100-592C Page 59 of 69... -
Page 60: Manual 2100-592C
45+5/370 W42G*DA 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 TEMPERATURE RATING OF AT LEAST 105°... -
Page 61: Manual 2100-592C
W30G2DA, W36G2DA, W42G2DA 230/208-60-1 Manual 2100-592C Page 61 of 69... -
Page 62: Manual 2100-592C
5/370 W42G*DB 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 TEMPERATURE RATING OF AT LEAST 105°... -
Page 63: Manual 2100-592C
W30G2DB, W36G2DB, W42G2DB 230/208-60-3 Manual 2100-592C Page 63 of 69... -
Page 64: Manual 2100-592C
W36G*DC 5/370 W42G*DC 15/370 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: Manual 2100-592C
W30G2DC, W36G2DC, W42G2DC 460-60-3 Manual 2100-592C Page 65 of 69... -
Page 66: Manual 2100-592C
W48G*DA 70+10/370 W60G*DA 80+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 67: Manual 2100-592C
W48G*DB 10/370 W60G*DB 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 68: Manual 2100-592C
W48G*DC 15/370 W60G*DC 15/370 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 69 W48G2DC, W60G2DC 460-60-3 Manual 2100-592C Page 69 of 69...