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INSTALLATION
INSTRUCTIONS
W24G1DA
W30G1DA
W24G1DB
W30G1DB
W24G1DC
W30G1DC
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
WG - SERIES
COMBINATION GAS/ELECTRIC
with DEHUMIDIFICATION
W36G1DA
W42G1DA
W36G1DB
W42G1DB
W36G1DC
W42G1DC
WARNING
Bard Manufacturing Company, Inc.
Bryan, Ohio 43506
Since 1914...Moving ahead just as planned.
WALL-MOUNT
MODELS:
W48G1DA
W48G1DB
W48G1DC
Manual No.:
Supersedes:
File:
Date:
W60G1DA
W60G1DB
W60G1DC
2100-535
NEW
Volume III, Tab 20
03-09-10
Manual
2100-535
Page
1 of 71
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Summary of Contents for Bard W24G1DA
- Page 1 AND UNDERSTAND ALL OF THESE REQUIREMENTS. FAILURE TO DO SO COULD CREATE A HAZARD RESULTING IN PROPERTY DAMAGE, BODILY INJURY, OR DEATH. Manual No.: 2100-535 Bard Manufacturing Company, Inc. Supersedes: Bryan, Ohio 43506 File: Volume III, Tab 20 Since 1914...Moving ahead just as planned.
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Page 2: Table Of Contents
CONTENTS Page Page 20. Checking Gas Input Rate ......28 & 29 Getting Other Information and Publications ....4 21. Standard Orifice Sizing & High W**G Series Model Nomenclature ......5 Altitude Derate ..........30 Ventilation Options ............ 5 22. Conversion of Gas Input BTUH From High Air Conditioning Module Options ....... - Page 3 Figure 16 Top View of Gas Control ...... 37 Table 18 Fan Blade Dimension ......52 Figure 17 Sequence of Operation – Electronic Table 19 W24G1DA Application Data ....53 Blower Control ........40 Table 20 W30G1DA Application Data ....53 Figure 18 Furnace Control Board &...
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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 FEBRUARY 2010 BARD MANUFACTURING COMPANY, INC. BRYAN, OHIO 43506 USA Manufactured under the following U.S. patent numbers: 5,485,878; 5,002,116 Manual 2100-535 Page... -
Page 5: W**G Series Model Nomenclature
WALL MOUNT GAS/ELECTRIC GENERAL MODEL NUMBER NOMENCLATURE VENT REVISION MODEL CONTROL OPTIONS (See Table Below) Wall Mount See Table page 6 GAS/ELECTRIC COIL OPTIONS COOLING CAPACITY VOLTAGE X = Standard 24 = 2 ton A = 230/208-60-1 1 = Phenolic coated evaporator 30 = 2½... -
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 - W24G-36G Models
Manual 2100-535 Page 7 of 71... -
Page 8: Table 1A Specifications - W42G-60G Models
Manual 2100-535 Page 8 of 71... -
Page 9: Figure 1 Unit Dimensions
Manual 2100-535 Page 9 of 71... -
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 - W24G-36G
Manual 2100-535 Page 12 of 71... -
Page 13: Figure 2A Mounting Instructions - W42G-60G
Manual 2100-535 Page 13 of 71... -
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 2100-535 Page 15 of 71... -
Page 16: Figure 6 Common Wall Mounting Installations
FIGURE 6 COMMON WALL MOUNTING INSTALLATIONS Manual 2100-535 Page 16 of 71... -
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
10. VENT TERMINAL AND COMBUSTION 11. OPTIONAL VERTICAL VENTING AIR INLET HOOD With the optional vertical venting kit (VVK-5) this unit The vent terminal is shipped in the burner compartment. may be vented vertically through a roof or overhang. See Figure 7. Remove the two shipping screws and The kit includes a stainless steel transition drain tee, separate the two-piece assembly. -
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 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 21: Wiring - Low Voltage Wiring
FIGURE 10 INSTALLATION OF FLEXIBLE CONDUIT 16. WIRING – LOW VOLTAGE WIRING Low Voltage Connection – 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 TABLE 4A WALL THERMOSTAT ; l o ; l o ; l o TABLE 4B HUMIDISTAT t s i t s i * Integrated thermostat and humidistat in one. Manual 2100-535 Page 22 of 71... -
Page 23: Figure 11A T-Stat Connection Using Comb
FIGURE 11A THERMOSTAT CONNECTION USING 8403-060 COMBINATION TEMPERATURE & HUMIDITY CONTROLLER Thermostat Subbase Thermostat D/YO W1/E and Humidity 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 IF YOU REQUIRE VENTILATION ANYTIME BLOWER IS ON MIS-2786... -
Page 24: Figure 11B T-Stat Using Temp. & Humidity Ctrl
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 11D Economizer Low Volt. Connections
FIGURE 11C MOTORIZED FRESH AIR DAMPER, CLASSROOM VENTILATOR SPRING, CLASSROOM VENTILATOR POWER & ERV LOW VOLTAGE CONNECTIONS Unit 24V Terminal Block Factory Installed Jumper Unit Control Panel VENT PACKAGE WIRING PLUG INSTALL JUMPER IF YOU REQUIRE VENTILATION ANYTIME BLOWER IS ON, OR IF CONTROLS DON'T HAVE AN OCCUPENCY OUTPUT. -
Page 26: Figure 12 Gas Pipe Connection
FIGURE 12 GAS PIPE CONNECTION W24G - W36G W42G - W60G Manual 2100-535 Page 26 of 71... -
Page 27: 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 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 leading use with Propane (LP) gas. - Page 29 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 30: Standard Orifice Sizing & High Altitude Derate
It is the installer’s responsibility to see that the furnace 21. STANDARD ORIFICE SIZING AND 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 31: Table 8 Natural Gas Orifice Tables - W24G-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 32 TABLE 8A NATURAL GAS ORIFICE TABLES FOR MODELS W42G, W48G AND W60G f i r f i r c t i i t l 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...
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Page 33: 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 34: Filters
FIGURE 14 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. If the high pressure switch opens, the compressor This filter is installed by opening the main service door. contactor will de-energize immediately. - Page 35 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 36: Lighting & Shutdown Instructions
26. LIGHTING AND SHUTDOWN INSTRUCTIONS FIGURE 15 INSTRUCTION LABEL Manual 2100-535 Page 36 of 71... -
Page 37: Service Agency Procedures
27. 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 MIS-165 Follow these procedures before inspecting 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. 2. Lubrication Requirements – The indoor circulating Disconnect electrical power before servicing air blower motor and outdoor circulating air fan unit. -
Page 39: Sequence Of Operation - Heating
31. SEQUENCE OF OPERATION – 30. SEQUENCE OF OPERATION – HEATING COOLING On a call for cooling from the room thermostat, the high On a call for heat from the thermostat, the induced draft speed blower relay will be energized as well as the blower is energized. -
Page 40: Figure 17 Sequence Of Operation Electronic Blower Control
FIGURE 17 SEQUENCE OF OPERATION ELECTRONIC BLOWER CONTROL s l l • • c t i o l f s i l • t i n • g i l . s t • t e l t a l f l l •... -
Page 41: Indoor Blower Operation
FIGURE 18 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 42: 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 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. Voltage adjustment – Reduce airflow by 100 CFM for 208 Volt Dehumidification coil adjustment –... -
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. Voltage adjustment – Reduce airflow by 100 CFM for 208 Volt Dehumidification coil adjustment –... -
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 Speed for heating and cooling Voltage adjustment – Reduce airflow by 130 CFM for 208 Volt Top outlet adjustment –... -
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. Voltage adjustment –... -
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. Voltage adjustment –... -
Page 48: 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 49: W**G Dehumidification Relay Logic Board
33. W**G DEHUMIDIFICATION RELAY LOGIC BOARD DEHUMIDIFICATION RELAY LOGIC BOARD Cooling takes precedence over dehumidification. A cooling call cancels dehumidification. First stage heating cancels dehumidification. If jumper on RLB is set to “1-2 full-time dehumidification”, outputs will energize. This is the factory default setting. If jumper is set to “2-3 occupied dehumidification only”, outputs will be off. -
Page 50: Pressure Service Ports
34. PRESSURE SERVICE PORTS compressor circuit and the three way valve, thus directing the hot refrigerant discharge gas into a separate High and low pressure service ports are installed on all units desuperheating condenser circuit, which reheats the so that the system operating pressures can be observed. conditioned air before it is delivered to the room. -
Page 51: Refrigerant Charge
36. REFRIGERANT CHARGE The nameplate charge quantity is optimized for thermal performance and efficiency of this self-contained package The correct system R-410A charge is shown on the unit system. rating plate. The system operating pressures in Table 17 are based upon rated airflow across the evaporator during cooling You can reference Table 17 to validate proper system cycle. -
Page 52: Fan Blade Setting Dimensions
38. LOW-NOX BURNER ASSEMBLY “N” 37. FAN BLADE SETTING DIMENSIONS 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: Application Data
TABLE 19 W24G1D APPLICATION PERFORMANCE DATA f r i TABLE 20 W30G1D APPLICATION PERFORMANCE DATA f r i TABLE 21 W36G1D APPLICATION PERFORMANCE DATA f r i Manual 2100-535 Page 53 of 71... -
Page 54: Table 22 W42G1Da Application Data
TABLE 22 W42G1D APPLICATION PERFORMANCE DATA f r i TABLE 23 W48G1D APPLICATION PERFORMANCE DATA f r i TABLE 24 W60G1D APPLICATION PERFORMANCE DATA f r i Manual 2100-535 Page 54 of 71... -
Page 55: Index - Wiring Diagrams
INDEX WIRING DIAGRAMS and LADDER DIAGRAMS Manual 2100-535 Page 55 of 71... -
Page 56: Wiring Diagrams
Model C. Breaker Capacitor W24G1DA 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 57 W24G1DA, W48G1DA, W60G1DA 230/208-60-1 Manual 2100-535 Page 57 of 71...
- Page 58 Model C. Breaker Fan Capacitor W24G1DB 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 59 W24G1DB, W48G1DB, W60G1DB 230/208-60-3 Manual 2100-535 Page 59 of 71...
- Page 60 VALVE 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 W24G1DC 460-60-3 Manual 2100-535 Page 61 of 71...
- Page 62 W36G1DA 45+5/370 W42G1DA 45+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 63 W30G1DA, W36G1DA, W42G1DA 230/208-60-1 Manual 2100-535 Page 63 of 71...
- Page 64 W36G1DB 5/370 W42G1DB 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 W30G1DB, W36G1DB, W42G1DB 230/208-60-3 Manual 2100-535 Page 65 of 71...
- Page 66 VALVE 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 W30G1DC, W36G1DC, W42G1DC 460-60-3 Manual 2100-535 Page 67 of 71...
- Page 68 W48G1DA 70+10/370 W60G1DA 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 69 W48G1DB 10/370 W60G1DB 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 70 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 71 W48G1DC, W60G1DC 460-60-3 Manual 2100-535 Page 71 of 71...
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