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Bard WG242DA Installation Instructions Manual

Combination gas/electric wall-mount with dehumidification
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INSTALLATION
INSTRUCTIONS
WG242DA WG242DB
WG362DB WG363DC
WG483DC WG602DA
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 2004
COMBINATION GAS/ELECTRIC
with DEHUMIDIFICATION
WG243DC
WG302DA
WG423DA
WG423DB
WG602DB
WG603DC
WARNING
Bard Manufacturing Company, Inc.
Bryan, Ohio 43506
Since 1914...Moving ahead just as planned.
WG - SERIES
WALL-MOUNT
MODELS:
WG302DB
WG303DC
WG424DC
WG482DA
Manual No.:
Supersedes:
File:
Date:
WG362DA
WG482DB
2100-376L
2100-376K
Volume III, Tab 20
03-03-08
Manual 2100-376L
Page
1 of 81

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  • 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.: 2100-376L Bard Manufacturing Company, Inc. Supersedes: 2100-376K 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 ......26 & 27 Getting Other Information and Publications ....4 21. Standard Orifice Sizing & High WG Series Model Nomenclature ....... 5 Altitude Derate ..........28 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 – WG24-36 Models ... 7 Figure 2 Mounting Instructions – WG24-36 ..12 Table 1A Specifications – WG42-60 Models ... 8 Figure 2A Mounting Instructions – WG42-60 ..13 Table 2 Minimum Installation Clearances ...

  • Page 4: Getting Other Information And Publications

    Canadian Electrical Code ......CSA C22.1 Canada. M9W 1R3 Telephone: (416) 447-4044 Canadian Installation Code……………CAN/CGA B149 COPYRIGHT SEPTEMBER 2003 BARD MANUFACTURING COMPANY, INC. BRYAN, OHIO 43506 USA Manufactured under the following U.S. patent numbers: 5,485,878; 5,002,116; 4,924,934; 4,875,520; 4,4825,936 Manual 2100-376L...

  • Page 5: Wg Series Model Nomenclature

    WALL MOUNT GAS/ELECTRIC GENERAL MODEL NUMBER NOMENCLATURE VENT REVISION MODEL CONTROL OPTIONS (See Table Below) Wall Mount Gas/Electric See Table page 6 COOLING CAPACITY COIL OPTIONS VOLTAGE 24 = 2 ton X = Standard A = 230/208-60-1 30 = 2½ ton 1 = Phenolic coated evaporator B = 230/208-60-3 COLOR...

  • 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. There is no delay-on-make during routine operation of the unit.

  • Page 7: Table 1 Specifications - Wg24-36 Models

    Manual 2100-376L Page 7 of 81...

  • Page 8: Table 1A Specifications - Wg42-60 Models

    Manual 2100-376L Page 8 of 81...

  • Page 9: Figure 1 Unit Dimensions

    Manual 2100-376L Page 9 of 81...

  • 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 - Wg24-36

    Manual 2100-376L Page 12 of 81...

  • Page 13: Figure 2A Mounting Instructions - Wg42-60

    Manual 2100-376L Page 13 of 81...

  • Page 14: Figure 3 Combustible Clearance - Wg24-36

    FIGURE 3 COMBUSTIBLE CLEARANCE FOR WG24, WG30 AND WG36 MODELS FIGURE 3A COMBUSTIBLE CLEARANCE FOR WG42, WG48 AND WG60 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 2100-376L Page 15 of 81...

  • Page 16: Figure 6 Common Wall Mounting Installations

    FIGURE 6 COMMON WALL MOUNTING INSTALLATIONS Manual 2100-376L Page 16 of 81...

  • 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 compartment. The kit includes a stainless steel transition drain tee, See Figure 7.

  • 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 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 22: Figure 11 Low Voltage Wiring

    FIGURE 11 LOW VOLTAGE WIRING Manual 2100-376L Page 22 of 81...

  • Page 23: Figure 11A Low Voltage Wiring

    FIGURE 11A LOW VOLTAGE WIRING Manual 2100-376L Page 23 of 81...

  • Page 24: Figure 12 Gas Pipe Connection

    FIGURE 12 GAS PIPE CONNECTION Manual 2100-376L Page 24 of 81...

  • Page 25: 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 26: 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 27 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 28: 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 29: Table 8 Natural Gas Orifice Tables - Wg24-36

    TABLE 8 NATURAL GAS ORIFICE TABLES FOR MODELS WG24, WG30 AND WG36 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 30 TABLE 8A NATURAL GAS ORIFICE TABLES FOR MODELS WG42, WG48 AND WG60 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...

  • 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 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 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 15 INSTRUCTION LABEL Manual 2100-376L Page 34 of 81...

  • Page 35: 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 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 air blower motor and outdoor circulating air fan unit.

  • Page 37: 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 38: 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 39: 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 40: Table 10 Wg24 Indoor Blower Performance

    TABLE 10 WG24 INDOOR BLOWER PERFORMANCE 230 AND 460 VOLTS Recommended WG24 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 Wg30 Indoor Blower Performance

    TABLE 11 WG30 INDOOR BLOWER PERFORMANCE 230 AND 460 VOLTS Recommended WG30 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 Wg36 Indoor Blower Performance

    TABLE 12 WG36 INDOOR BLOWER PERFORMANCE 230 AND 460 VOLTS Recommended WG36 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 Wg42 Indoor Blower Performance

    TABLE 13 WG42 INDOOR BLOWER PERFORMANCE 230 AND 460 VOLTS Recommended WG42 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 Wg48 Indoor Blower Performance

    TABLE 14 WG48 INDOOR BLOWER PERFORMANCE 230 AND 460 VOLTS Recommended WG48 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 Wg60 Indoor Blower Performance

    TABLE 15 WG60 INDOOR BLOWER PERFORMANCE 230 AND 460 VOLTS Recommended WG60 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: Wg Dehumidification Unit Relay Logic

    This relay completes the “Y” or compressor signal to the CCM (Compressor Control Module) during either a call for Cooling or a call for Dehumidification. Part of the Bard Manufacturing Company, Inc. control strategy on Dehumidification units is that Cooling always takes precedence over Dehumidification. This relay opens the circuit to the Dehumidification Solenoid Valve on a call for Cooling, effectively overriding the Dehumidification function in favor of the Cooling call.

  • Page 48: Pressure Service Ports

    34. PRESSURE SERVICE PORTS High and low pressure service ports are installed on all units so that the system operating pressures can be observed. Table 17 outlines expected pressures at various indoor and outdoor temperatures. TABLE 17 COOLING PRESSURE TABLE Low side pressure ±...

  • Page 49: Dehumidification Circuit

    35. DEHUMIDIFICATION CIRCUIT separate desuperheating condenser circuit, which reheats the conditioned air before it is delivered to the The dehumidification circuit incorporates an room. The refrigerant gas is then routed from the independent heat exchanger coil in the supply air desuperheating condenser to the system condenser for stream.

  • Page 50: Refrigerant Charge

    36. REFRIGERANT CHARGE The nameplate charge quantity is optimized for thermal performance and efficiency of this self-contained The correct system R-22 charge is shown on the unit package system. rating plate. The system operating pressures in Table 18 are based You can reference Table 18 to validate proper system upon rated airflow across the evaporator during cooling cycle.

  • Page 51: 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 52: Application Data

    TABLE 20 APPLICATION DATA FOR WG24*DA f r i Values shown in ( ) are BTUH of heating available at these conditions. Latent BTU = Lbs/Hr water * 1060 Sensible BTU = Total - Latent TABLE 21 APPLICATION DATA FOR WG30*DA f r i Values shown in ( ) are BTUH of heating available at these conditions.

  • Page 53: Table 22 Wg36*Da Application Data

    TABLE 22 APPLICATION DATA FOR WG36*DA f r i Values shown in ( ) are BTUH of heating available at these conditions. Latent BTU = Lbs/Hr water * 1060 Sensible BTU = Total - Latent TABLE 23 APPLICATION DATA FOR WG42*DA f r i Values shown in ( ) are BTUH of heating available at these conditions.

  • Page 54: Table 24 Wg48*Da Application Data

    TABLE 24 APPLICATION DATA FOR WG48*DA f r i Values shown in ( ) are BTUH of heating available at these conditions. Latent BTU = Lbs/Hr water * 1060 Sensible BTU = Total - Latent TABLE 25 APPLICATION DATA FOR WG60*DA f r i Values shown in ( ) are BTUH of heating available at these conditions.

  • Page 55: Index - Wiring Diagrams

    INDEX WIRING DIAGRAMS and LADDER DIAGRAMS Manual 2100-376L Page 55 of 81...

  • Page 56: Wiring Diagrams

    WG242DA 230/208-60-1 Manual 2100-376L Page 56 of 81...
  • Page 57 WG242DA, WG362DA 230/208-60-1 Manual 2100-376L Page 57 of 81...
  • Page 58 WG242DB 230/208-60-3 Manual 2100-376L Page 58 of 81...
  • Page 59 WG242DB, WG362DB 230/208-60-3 Manual 2100-376L Page 59 of 81...
  • Page 60 WG243DC 460-60-3 Manual 2100-376L Page 60 of 81...
  • Page 61 WG243DC 460-60-3 Manual 2100-376L Page 61 of 81...
  • Page 62 WG302DA 230/208-60-1 Manual 2100-376L Page 62 of 81...
  • Page 63 WG302DA, WG482DA, WG602DA 230/208-60-1 Manual 2100-376L Page 63 of 81...
  • Page 64 WG302DB 230/208-60-3 Manual 2100-376L Page 64 of 81...
  • Page 65 WG302DB, WG482DB, WG602DB 230/208-60-3 Manual 2100-376L Page 65 of 81...
  • Page 66 WG303DC 460-60-3 Manual 2100-376L Page 66 of 81...
  • Page 67 WG303DC 460-60-3 Manual 2100-376L Page 67 of 81...
  • Page 68 WG362DA 230/208-60-1 Manual 2100-376L Page 68 of 81...
  • Page 69 WG362DB 230/208-60-3 Manual 2100-376L Page 69 of 81...
  • Page 70 WG363DC 460-60-3 Manual 2100-376L Page 70 of 81...
  • Page 71 WG363DC 460-60-3 Manual 2100-376L Page 71 of 81...
  • Page 72 WG423DA 230/208-60-1 Manual 2100-376L Page 72 of 81...
  • Page 73 WG423DA 230/208-60-1 Manual 2100-376L Page 73 of 81...
  • Page 74 WG423DB 230/208-60-3 Manual 2100-376L Page 74 of 81...
  • Page 75 WG423DB 230/208-60-3 Manual 2100-376L Page 75 of 81...
  • Page 76 WG424DC 460-60-3 Manual 2100-376L Page 76 of 81...
  • Page 77 WG424DC 460-60-3 Manual 2100-376L Page 77 of 81...
  • Page 78 WG482DA, WG602DA 230/208-60-1 Manual 2100-376L Page 78 of 81...
  • Page 79 WG482DB, WG602DB 230/208-60-3 Manual 2100-376L Page 79 of 81...
  • Page 80 WG483DC, WG603DC 460-60-3 Manual 2100-376L Page 80 of 81...
  • Page 81 WG483DC, WG603DC 460-60-3 Manual 2100-376L Page 81 of 81...

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