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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.
Bard Manufacturing Company
Bryan, Ohio 43506
Since 1914...Moving ahead, just as
planned.
WG - SERIES
COMBINATION GAS/ELECTRIC
WALL-MOUNT
WG421
WARNING
:
MODELS
WG481 WG601
Manual No.:
2100-365B
Supersedes:
2100-365A
File:
Volume III, Tab 20
Date:
08-25-00
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Summary of Contents for Bard WG421
- 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.: 2100-365B Bard Manufacturing Company Supersedes: 2100-365A Bryan, Ohio 43506 File: Volume III, Tab 20 Since 1914...Moving ahead, just as...
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Page 2: Table Of Contents
CONTENTS Page Page Getting Other Information and Publications ...... 1 20. Checking Gas Input Rate ......... 20 WG Series Model Nomenclature ........2 21. Standard Orifice Sizing & High Altitude Derate ..21 Ventilation Options ............2 22. Conversion of Gas Input BTUH From High Air Conditioning Module Options ........ - Page 3 Installations Only .......... 23 Figure 9 Fresh Air Damper ........14 Table 9 WG421 Indoor Blower Performance ..... 32 Figure 10 Installation of Flexible Conduit ....16 Table 10 WG482 Indoor Blower Performance ..... 33 Figure 11 Low Voltage Wiring ........17 Table 11 WG601 Indoor Blower Performance .....
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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 COPYRIGHT AUGUST, 2000 BARD MANUFACTURING COMPANY 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; 4,432,409 Manual 2100-365 Page 1... -
Page 5: Wg Series Model Nomenclature
WALL MOUNT GAS/ELECTRIC GENERAL MODEL NUMBER NOMENCLATURE WG 42 1 – A X C X X X X X X CONTROL OPTIONS MODEL (See Table page 3) Wall Mount Gas/Electric COOLING CAPACITY COIL OPTIONS 24 = 2 ton X = Standard REVISION 30 = 2-1/2 ton 1 = Phenolic coated evaporator... -
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
TABLE 1 SPECIFICATIONS a t l i n i t i u y t i l l o l l o l l o l l o l l o l l o s t l t i u " 4 "... -
Page 8: Figure 1 Unit Dimensions
FIGURE 1 UNIT DIMENSIONS MIS-1352... -
Page 9: High Altitude Applications
5/8 inch. 6. INSTALLATION Any grille that meets with the 5/8 inch louver criteria may be used. It is recommended that Bard Return Size of unit for proposed installation should be based Air Grille RG5 or Return Filter Grille RFG5 be on heat loss/heat gain calculations made according to installed when no return duct is used. -
Page 10: 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 between the supply duct and a combustible 2. -
Page 11: Figure 2 Vent Terminal & Combustion Air Intake
FIGURE 2 VENT TERMINAL AND COMBUSTION AIR INTAKE MIS-1469 FIGURE 3 INTERNAL FILTER ACCESS THROUGH UPPER SERVICE DOOR MIS-1449 Manual 2100-365 Page 8... -
Page 12: Figure 4 Mounting Instructions
FIGURE 4 MOUNTING INSTRUCTIONS MIS-1472... -
Page 13: Figure 5 Combustible Clearance
FIGURE 5 COMBUSTIBLE CLEARANCE MIS-1473 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 14: Figure 6 Wall Mounting Instructions
FIGURE 6 WALL MOUNTING INSTRUCTIONS MIS-1475 FIGURE 7 WALL MOUNTING INSTRUCTIONS MIS-1476 Manual 2100-365 Page 11... -
Page 15: Figure 8 Common Wall Mounting Installations
FIGURE 8 COMMON WALL MOUNTING INSTALLATIONS MIS-1474 Manual 2100-365 Page 12... -
Page 16: Clearances
9. CLEARANCES CAUTION Minimum clearances, as specified in Table 2, must be maintained from adjacent structures to provide adequate fire protection, adequate combustion air, Vent terminal must be installed as shown in and room for service personnel. Figure 2 for proper operation of the heating system. -
Page 17: Fresh Air Intake
15. WIRING – MAIN POWER 13. FRESH AIR INTAKE All units are built with fresh air inlet slots punched in the service panel. WARNING If the unit is equipped with a fresh air damper assembly, the assembly is shipped already attached to the unit. - Page 18 ELECTRICAL GROUNDING INSTALLATION OF FLEXIBLE CONDUIT THROUGH RETURN AIR OPENING When installed, the furnace must be electrically NOTE: To allow proper clearance between the grounded in accordance with local codes or in the control panel and any vent options, 90° absence of local codes, with the National Electrical conduit fittings must be used on the back of Code, ANSI/NFPA 70, or Canadian Electrical Code,...
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Page 19: Wiring - Low Voltage Wiring
17. THERMOSTATS 16. WIRING – LOW VOLTAGE WIRING TABLE 3 230/208 VOLT UNITS THERMOSTAT WIRE SIZE All models are equipped with dual primary voltage transformers. All equipment leaves the factory wired on 240V tap. For 208V operation, reconnect from 240V to 208V tap. The acceptable operating voltage range for the 240V and 208V taps are: NOTE: The voltage should be measured at the field power connection point in the unit and while... -
Page 20: Figure 11 Low Voltage Wiring
FIGURE 11 LOW VOLTAGE WIRING MIS-1162 Manual 2100-365 Page 17... -
Page 21: Figure 12 Gas Pipe Connection
FIGURE 12 GAS PIPE CONNECTION MIS-1478 Manual 2100-365 Page 18... -
Page 22: 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 23: Manifold Pressure Adjustment
19. MANIFOLD PRESSURE ADJUSTMENT 20. CHECKING GAS INPUT RATE You will need a 0 to 15 inch water manometer with It is the installer's responsibility to see that the BTU 0.1 inch resolution and a 1/8" NPT manual shut-off input rate of the furnace is properly adjusted. Under- valve to measure actual manifold pressure. -
Page 24: Standard Orifice Sizing & High Altitude Derate
6. With stopwatch, measure time it takes to consume 10. Manifold pressure may be adjusted within the two cubic feet of gas. range of 3.2 inches W.C. to 3.8 inches W.C. to get rated input ± 2 percent. See Section 17, "Manifold •... -
Page 25: Table 7 High Altitude Derate Charts - U.s. Installations Only
Standard factory installed orifice size. 2.30 is shipped with the unit for field installed optional 10% derate. All orifice sizes not shown with black background are available in U.S. Natural Gas High Altitude Kit, Bard Part No. GCK-US-N1. Orifice sizes shown with black background available separately. -
Page 26: Table 8 High Altitude Derate Charts - Canadian Installations Only
2.40 is the factory installed orifice size for full rated input. All other orifice sizes not shown with black background are available in U.S. Natural Gas High Altitude Kit, Bard Part No. GCK-US-N1. Orifice sizes shown on black background are available separately. Manual 2100-365... -
Page 27: Conversion Of Gas Input Btuh From High To Low Rating
2. Set balancing dampers in supply duct system. 22. CONVERSION OF GAS INPUT BTUH FROM HIGH TO LOW RATING 3. Check duct work for obstructions or leaks. 4. Make sure filters are clean and in place. All the derated WG series units are produced with maximum BTUH input orifices installed. -
Page 28: Filters
24. FILTERS low pressure switch remains open or opens again for longer than 120 seconds the unit will go into manual A 20 x 30 x 2 throwaway filter is supplied with each lockout condition and the alarm circuit will energize. unit. -
Page 29: Lighting & Shutdown Instructions
26. LIGHTING AND SHUTDOWN INSTRUCTIONS FIGURE 14 INSTRUCTION LABEL Manual 2100-365 Page 26... -
Page 30: Service Agency Procedures
27. SERVICE AGENCY PROCEDURES FIGURE 15 TOP VIEW OF GAS CONTROL CAUTION INLET PRESSURE REGULATOR PRESSURE ADJUSTMENT (UNDER CAP SCREW) Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing. INLET WARNING OUTLET... -
Page 31: 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 32: Sequence Of Operation - Heating
30. SEQUENCE OF OPERATION – main burner orifices or incorrect manifold pressure, insufficient combustion air, or installation HEATING deficiencies with respect to return air duct design or sizing. On a call for heat from the thermostat, the induced draft blower is energized. Once sufficient draft is Once the problem has been resolved, reset the switch established, the pressure switch contacts close and by pressing down on the reset button on top of the... -
Page 33: Indoor Blower Operation
230 VOLT BLOWER MOTOR SPEED CHANGE 2. Cooling operation and heating operation on 1. Disconnect main power supply to unit. medium speed. (Standard WG421 factory setting) See Figure 18 B. 2. Remove the unwanted indoor motor speed tap (red low, blue medium, black high) from the blower 3. -
Page 34: Figure 18 460V Blower Motor Wiring Options
FIGURE 18 460 VOLT BLOWER MOTOR WIRING OPTIONS MIS-1487 Manual 2100-365 Page 31... -
Page 35: Table 9 Wg421 Indoor Blower Performance
WG421 INDOOR BLOWER PERFORMANCE 230 and 460 VOLTS Recommended WG421 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 36: Table 10 Wg482 Indoor Blower Performance
TABLE 10 WG481 INDOOR BLOWER PERFORMANCE 230 and 460 VOLTS Recommended WG481 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 37: Table 11 Wg601 Indoor Blower Performance
TABLE 11 WG601 INDOOR BLOWER PERFORMANCE 230 and 460 VOLTS Recommended WG601 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 38: Table 12 Integrated Furnace & Blower Control Operation
TABLE 12 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 39: 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 13 outlines expected pressures at various indoor and outdoor temperatures. TABLE 13 COOLING PRESSURE TABLE Low side pressure ±... -
Page 40: Fan Blade Setting Dimensions
35. FAN BLADE SETTING DIMENSIONS Any service work requiring removal or adjustment in the fan and/or motor area will require that the Shown in Figure 19 is the correct fan blade setting dimension below be checked and blade adjusted in or dimension for proper air delivery across the outdoor out on the motor shaft accordingly. -
Page 41: Wiring Diagrams
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