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Bard WG241 Installation Instructions Manual

Wg-series combination gas/electric wall-mount
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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.
WG - SERIES
COMBINATION GAS/ELECTRIC
WALL-MOUNT
WG241
WG422
WARNING
Bard Manufacturing Company
Bryan, Ohio 43506
Since 1914...Moving ahead just as planned.
MODELS:
WG301
WG361
WG481
WG601
Manual No.:
Supersedes:
File:
Date:
2100-365G
2100-365F
Volume III, Tab 20
09-09-03
© Copyright 2003

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Summary of Contents for Bard WG241

  • Page 1: Installation Instructions

    AND UNDERSTAND ALL OF THESE REQUIREMENTS. FAILURE TO DO SO COULD CREATE A HAZARD RESULTING IN PROPERTY DAMAGE, BODILY INJURY, OR DEATH. Manual No.: 2100-365G Bard Manufacturing Company Supersedes: 2100-365F 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 ......... 22 Getting Other Information and Publications ....1 WG Series Model Nomenclature ....... 2 21. Standard Orifice Sizing & High Altitude Derate ..........24 Ventilation Options ............ 2 22. Conversion of Gas Input BTUH From High Air Conditioning Module Options .......
  • Page 3 Table 9 Motor Speed Taps ........34 Figure 10 Installation of Flexible Conduit ..... 18 Table 10 WG241 Indoor Blower Performance ..37 Figure 11 Low Voltage Wiring ......19 Table 11 WG301 Indoor Blower Performance ..38 Figure 12 Gas Pipe Connection ......20 Table 12 WG361 Indoor Blower Performance ..

  • Page 4: Getting Other Information And Publications

    Canada. M9W 1R3 and Equipment Selection Telephone: (416) 447-4044 Canadian Electrical Code ......CSA C22.1 COPYRIGHT SEPTEMBER 2003 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 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 = 2.5 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 - Wg24-36 Models

    TABLE 1 SPECIFICATIONS WG24, WG 30 AND WG36 MODELS – 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 l l o l l o l l o...

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

    TABLE 1A SPECIFICATIONS WG42, WG48 AND WG60 MODELS – 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 l l o l l o l l o...

  • Page 9: Figure 1 Unit Dimensions

    5.88 14.88 14.12 15.44 15.31 WG422-WG481-WG601 9.88 29.88 15.88 27.25 43.81 31.63 87.5 33.38 28.75 42.88 3.75 U N IT WG241-WG301-WG361 12 - 7 H O LES 2.88 22.9 17.84 4.44 11.44 36.25 0.38 3.75 2.25 3.25 7.25 1.13 1.25 WG422-WG481-WG601 16 - 6 H O LES 3.88...

  • Page 10: High Altitude Applications

    Any grille that meets with the 5/8 inch louver criteria methods of Air Conditioning Contractors of America may be used. It is recommended that Bard Return Air (ACCA). The air duct should be installed in Grille or Return Filter Grille be installed when no accordance with the Standards of the National Fire return duct is used.

  • 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 result...

  • Page 12: Figure 2 Mounting Instructions - Wg24-36

    FIGURE 2 MOUNTING INSTRUCTIONS FOR WG24, WG30, AND WG36 MIS-1681...

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

    FIGURE 2A MOUNTING INSTRUCTIONS FOR WG42, WG48, AND WG60 MIS-1472...

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

    FIGURE 3 COMBUSTIBLE CLEARANCE FOR WG24, WG30 AND WG36 MODELS MIS-1682 FIGURE 3A COMBUSTIBLE CLEARANCE FOR WG42, WG48 AND WG60 MODELS MIS-1714 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 MIS-1475 FIGURE 5 WALL MOUNTING INSTRUCTIONS MIS-1476 Manual 2100-365 Page 12...

  • Page 16: Figure 6 Common Wall Mounting Installations

    FIGURE 6 COMMON WALL MOUNTING INSTALLATIONS MIS-1474 Manual 2100-365 Page 13...

  • Page 17: Clearances

    TABLE 2 9. CLEARANCES MINIMUM INSTALLATION CLEARANCES Minimum clearances, as specified in Table 2, must be t e l ) s l r i f maintained from adjacent structures to provide 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 The kit includes a stainless steel transition drain tee, compartment.

  • 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 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 21: Wiring - Low Voltage Wiring

    FIGURE 10 INSTALLATION OF FLEXIBLE CONDUIT MIS-1553 17. THERMOSTATS 16. WIRING – LOW VOLTAGE WIRING 230/208 VOLT UNITS TABLE 3 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.

  • Page 22: Figure 11 Low Voltage Wiring

    FIGURE 11 LOW VOLTAGE WIRING MIS-1719 Manual 2100-365 Page 19...

  • Page 23: Figure 12 Gas Pipe Connection

    FIGURE 12 GAS PIPE CONNECTION MIS-1683 Manual 2100-365 Page 20...

  • Page 24: Gas Supply & Piping

    8. Refer to Table 6 for Gas Pipe Sizes for natural gas. 18. GAS SUPPLY AND PIPING 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 25: Manifold Pressure Adjustment

    8. Adjust manifold pressure by turning gas control PROPANE (LP) GAS CONVERSION regulator adjusting screw clockwise to increase pressure or turning counterclockwise to decrease This unit may be converted in the field for pressure. Manifold pressure must be within use with Propane (LP) gas. Propane gas allowable range below: conversion kit number WGCK-1 is designed •...
  • Page 26 9. If you left water heater, dryer or range pilots on, NATURAL GAS INPUT RATE 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 27: Standard Orifice Sizing & High Altitude Derate

    21. STANDARD ORIFICE SIZING AND It is the installer’s responsibility to see that the furnace 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 28: 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 i t l c t i 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 29 TABLE 8A NATURAL GAS ORIFICE TABLES FOR MODELS WG42, WG48 AND WG60 f i r f i r i t l c t i 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 30: 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. All the derated WG series units are produced with 4. Make sure filters are clean and in place. maximum BTUH input orifices installed.

  • Page 31: Filters

    FIGURE 14 ACCESS INTERNAL FILTER THROUGH UPPER SERVICE DOOR MIS-1449 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 contactor will de-energize immediately.
  • Page 32 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 equipped with a three phase line monitor to prevent powered whenever compressor is locked out due to compressor damage due to phase reversal.

  • Page 33: Lighting & Shutdown Instructions

    26. LIGHTING AND SHUTDOWN INSTRUCTIONS FIGURE 15 INSTRUCTION LABEL Manual 2100-365 Page 30...

  • Page 34: Service Agency Procedures

    27. SERVICE AGENCY PROCEDURES FIGURE 16 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 35: 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 36: Sequence Of Operation - Heating

    30. SEQUENCE OF OPERATION – burner orifices or incorrect manifold pressure, HEATING insufficient combustion air, or installation 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 the by pressing down on the reset button on top of the...

  • Page 37: Indoor Blower Operation

    FIGURE 18 FURNACE CONTROL BOARD AND BLOWER CONTROL FURNACE CONTROL BOARD ATTACH JUMPER WIRE HERE FOR SINGLE SPEED OPERATION MIS-1482 460 VOLT BLOWER MOTOR SPEED CHANGE 32. INDOOR BLOWER OPERATION Field changeover from the factory blower motor speed All models have multiple speed direct drive blower settings can require change several different motor motors.

  • Page 38: Figure 19 460V Blower Motor Wiring Options - Wg24-36 Models

    FIGURE 19 460 VOLT BLOWER MOTOR WIRING OPTIONS WG24, WG30 AND WG36 MODELS Manual 2100-365 Page 35...

  • Page 39: Figure 20 460V Blower Motor Wiring Options - Wg42-60 Models

    FIGURE 20 460 VOLT BLOWER MOTOR WIRING OPTIONS WG42, WG48 AND WG 60 MODELS Manual 2100-365 Page 36...

  • Page 40: Table 10 Wg241 Indoor Blower Performance

    WG241 INDOOR BLOWER PERFORMANCE 230 AND 460 VOLTS Recommended WG241 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 Wg301 Indoor Blower Performance

    TABLE 11 WG301 INDOOR BLOWER PERFORMANCE 230 AND 460 VOLTS Recommended WG301 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 Wg361 Indoor Blower Performance

    TABLE 12 WG361 INDOOR BLOWER PERFORMANCE 230 AND 460 VOLTS Recommended WG361 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 Wg422 Indoor Blower Performance

    TABLE 13 WG422 INDOOR BLOWER PERFORMANCE 230 AND 460 VOLTS Recommended WG422 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 Wg481 Indoor Blower Performance

    TABLE 14 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 45: Table 15 Wg601 Indoor Blower Performance

    TABLE 15 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 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: 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 17 outlines expected pressures at various indoor and outdoor temperatures. TABLE 17 COOLING PRESSURE TABLE Low side pressure ±...

  • Page 48: Refrigerant Charge

    34. REFRIGERANT CHARGE 36. LOW-NOX BURNER ASSEMBLY “N” SUFFIX MODELS ONLY – U.S. The correct system R-22 charge is shown on the unit INSTALLATIONS ONLY rating plate. Optimum unit performance will occur with a refrigerant charge resulting in a suction line NATURAL GAS MODELS ONLY temperature (6”...

  • Page 49: Index - Wiring Diagrams

    INDEX WIRING DIAGRAMS and LADDER DIAGRAMS Manual 2100-365 Page 46...

  • Page 50: Wiring Diagrams

    WG241-A 230/208-60-1 Manual 2100-365 Page 47...
  • Page 51 WG241-A 230/208-60-1 Manual 2100-365 Page 48...
  • Page 52 WG241-B 230/208-60-3 Manual 2100-365 Page 49...
  • Page 53 WG241-B 230/208-60-3 Manual 2100-365 Page 50...
  • Page 54 WG241-C 460-60-3 Manual 2100-365 Page 51...
  • Page 55 WG241-C 460-60-3 Manual 2100-365 Page 52...
  • Page 56 WG301-A, WG361-A 230/208-60-1 Manual 2100-365 Page 53...
  • Page 57 WG301-A, WG361-A 230/208-60-1 Manual 2100-365 Page 54...
  • Page 58 WG301-B, WG361-B 230/208-60-3 Manual 2100-365 Page 55...
  • Page 59 WG301-B, WG361-B 230/208-60-3 Manual 2100-365 Page 56...
  • Page 60 WG301-C, WG361-C 460-60-3 Manual 2100-365 Page 57...
  • Page 61 WG301-C, WG361-C 460-60-3 Manual 2100-365 Page 58...
  • Page 62 WG422-A 230/208-60-1 Manual 2100-365 Page 59...
  • Page 63 WG422-A 230/208-60-1 Manual 2100-365 Page 60...
  • Page 64 WG422-B 230/208-60-3 Manual 2100-365 Page 61...
  • Page 65 WG422-B 230/208-60-3 Manual 2100-365 Page 62...
  • Page 66 WG422-C 460-60-3 Manual 2100-365 Page 63...
  • Page 67 WG422-C 460-60-3 Manual 2100-365 Page 64...
  • Page 68 WG481-A, WG601-A 230/208-60-1 Manual 2100-365 Page 65...
  • Page 69 WG481-A, WG601-A 230/208-60-1 Manual 2100-365 Page 66...
  • Page 70 WG481-B, WG601-B 230/208-60-3 Manual 2100-365 Page 67...
  • Page 71 WG481-B, WG601-B 230/208-60-3 Manual 2100-365 Page 68...
  • Page 72 WG481-C, WG601-C 460-60-3 Manual 2100-365 Page 69...
  • Page 73 WG481-C, WG601-C 460-60-3 Manual 2100-365 Page 70...

This manual is also suitable for:

Wg301Wg481Wg361Wg601Wg422

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