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Bard W24G1-A Installation instructions manual

Other manuals for W24G1-A: Installation Instructions Manual
Manual is about: WG - SERIES COMBINATION GAS/ELECTRIC WALL-MOUNT

Summary of W24G1-A

  • Page 1

    Manual 2100-525a page 1 of 67 wg - series combination gas/electric wall-mount models: w24g1-a w24g1-b w24g1-c w30g1-a w30g1-b w30g1-c w36g1-a w36g1-b w36g1-c w42g1-a w42g1-b w42g1-c w48g1-a w48g1-b w48g1-c w60g1-a w60g1-b w60g1-c manual no.: 2100-525a supersedes: 2100-525 file: volume iii, tab 20 da...

  • Page 2

    Manual 2100-525a page 2 of 67 contents getting other information and publications .............. 4 w**g series model nomenclature ............................ 5 ventilation options .................................................... 5 air conditioning module options ............................... ...

  • Page 3

    Manual 2100-525a page 3 of 67 contents figures figure 1 unit dimensions ..................................... 9 figure 2 mounting instructions – w24-36g ....... 12 figure 2a mounting instructions – w42-60g ....... 13 figure 3 combustible clearance – w24-36g .... 14 figure 3a combustible clearance – ...

  • Page 4

    Manual 2100-525a page 4 of 67 getting other information and publications for more information, contact these publishers: acca air conditioning contractors of america 1712 new hampshire avenue, nw washington, dc 20009 telephone: (202) 483-9370 ansi american national standards institute 11 west street...

  • Page 5

    Manual 2100-525a page 5 of 67 w 42 g 1 – a x c x x x x x x wall mount gas/electric general model number nomenclature 1 low ambient control is required with economizer for low temperature compressor operation. Ventilation options s l e d o m g 6 3 w , g 0 3 w , g 4 2 w g 0 6 w , g 8 4 w , g 2 4 w n o...

  • Page 6

    Manual 2100-525a page 6 of 67 1. Important the equipment covered in this manual is to be installed by trained, experienced service and installation technicians. All duct work or portions thereof not in the conditioned space should be properly insulated in order to both conserve energy and prevent co...

  • Page 7

    Manual 2100-525a page 7 of 67 table 1 specifications w24g, w30g and w36g models * 75 degree c copper wire size ** maximum time delay fuse or hacr type circuit breaker l e d o ma - 1 g 4 2 wb - 1 g 4 2 wc - 1 g 4 2 wa - 1 g 0 3 wb - 1 g 0 3 wc - 1 g 0 3 wa - 1 g 6 3 wb - 1 g 6 3 wc - 1 g 6 3 w z h 0 ...

  • Page 8

    Manual 2100-525a page 8 of 67 * 75 degree c copper wire size ** maximum time delay fuse or hacr type circuit breaker table 1a specifications w42g, w48g and w60g models l e d o ma - 1 g 2 4 wb - 1 g 2 4 wc - 1 g 2 4 wa - 1 g 8 4 wb - 1 g 8 4 wc - 1 g 8 4 wa - 1 g 0 6 wb - 1 g 0 6 wc - 1 g 0 6 w z h 0...

  • Page 9

    Manual 2100-525a page 9 of 67 f g n p d dd ff gg hh a m i c k j l h r s s s s s t v y aa x u z cc bb b ee o e w ii q b di s co nne ct a cce s s right side re t urn op e n in g en t r an c es pan el pan el ( lo c kabl e) pan el d o o r su ppl y o pen in g ba ck m is -2773 en t r an c es ga s co m b u...

  • Page 10

    Manual 2100-525a page 10 of 67 see figure 3 and clearance information in section 9 and table 2 for additional information. Design the duct work according to methods given by the air conditioning contractors of america (acca). When duct runs through unheated spaces, it should be insulated with a mini...

  • Page 11

    Manual 2100-525a page 11 of 67 7. Wall mounting information 1. Two holes for the supply and return air openings must be cut through the wall as detailed in figure 4. 2. On wood-frame walls, the wall construction must be strong and rigid enough to carry the weight of the unit without transmitting any...

  • Page 12

    Manual 2100-525a page 12 of 67 figure 2 mounting instructions for w24g, w30g and w36g 39 3/16" 29 3/4" 4 11/16" 12" 12" 12" 12" 12" 12" 2" 2 1/4" 10" 28 5/16" 15" 27" 17 15/16" 11 5/16" 8 5/8" 2 15/16" 2 1/4" 30" 29" 5 1/16" 7/16" 5 9/16" 4 9/16" 4 1/2" 2 15/16" 18 15/16" 4 9/16" supply air duct ret...

  • Page 13

    Manual 2100-525a page 13 of 67 figure 2a mounting instructions for w42g, w48g and w60g.

  • Page 14

    Manual 2100-525a page 14 of 67 figure 3 combustible clearance for w24g, w30g and w36g models figure 3a combustible clearance for w42g, w48g and w60g models warning a minimum of one (1) inch clearance must be maintained between the supply air duct and combustible materials. This is required for the f...

  • Page 15

    Manual 2100-525a page 15 of 67 figure 4 wall mounting instructions figure 5 wall mounting instructions.

  • Page 16

    Manual 2100-525a page 16 of 67 figure 6 common wall mounting installations.

  • Page 17

    Manual 2100-525a page 17 of 67 9. Clearances minimum clearances, as specified in table 2, must be maintained from adjacent structures to provide adequate fire protection, adequate combustion air, and room for service personnel. While minimum clearances are acceptable for safety reasons, they may not...

  • Page 18

    Manual 2100-525a page 18 of 67 10. Vent terminal and combustion air inlet hood the vent terminal is shipped in the burner compartment. See figure 7. Remove the two shipping screws and separate the two-piece assembly. Install the vent terminal by using the four screws provided. Do not cut or trim gas...

  • Page 19

    Manual 2100-525a page 19 of 67 12. Vent resizing instructions when an existing furnace is removed from a venting system servicing other appliances, the venting system is likely to be too large to properly vent the remaining attached appliances. The following steps shall be followed with each of the ...

  • Page 20

    Manual 2100-525a page 20 of 67 electrical grounding when installed, the furnace must be electrically 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...

  • Page 21

    Manual 2100-525a page 21 of 67 note: the voltage should be measured at the field power connection point in the unit and while the unit is operating at full load (maximum amperage operating condition). P a t e g n a r 0 4 2 6 0 2 – 3 5 2 8 0 2 7 8 1 – 0 2 2 17. Thermostats 16. Wiring – low voltage wi...

  • Page 22: Unit Control Panel

    Manual 2100-525a page 22 of 67 r y2 y l y1 rc d/yo 3 2 w r a factory installed jumper terminal y1 b unit 24v c mis-2774 low voltage wiring - no ventilation package 1 g y unit control panel g block w1/e g w1 1 c a w2 e y2 o f c o/b r w2 thermostat subbase 2 1 2 set switch on thermostat to "gas-oil" c...

  • Page 23: Low Voltage Wiring -

    Manual 2100-525a page 23 of 67 2 d/yo a low voltage wiring - r y1 w have occupancy output. Y g l w1/e black/white c w1 a factory installed 4 r terminal y1 part #8403-057 (th311dd1040) y2 1 thermostat unit control panel (1120-445) thermostat subbase jumper g rc vent package g part #8403-060 thermosta...

  • Page 24: Unit Control Panel

    Manual 2100-525a page 24 of 67 c rc w2 terminal w1/e unit control panel y low voltage wiring - eifm economizer 1 y g l y1 unit 24v plug y2 r thermostat subbase factory installed jumper w2 o/b g red wires block r c w1 a w2 e y2 y1 from c 2 3 r purple a w g thermistor d/yo orange y2 wgseifm-5 red 1 bl...

  • Page 25

    Manual 2100-525a page 25 of 67 figure 14 gas pipe connection w24g - w36g w42g - w60g.

  • Page 26

    Manual 2100-525a page 26 of 67 18. Gas supply and piping general recommendations 1. Be sure the gas line complies with the local codes and ordinances, or in their absence with the national fuel gas code, ansi z223.1, or natural gas installation code, can/cga b149.1, or propane installation code b149...

  • Page 27

    Manual 2100-525a page 27 of 67 19. Manifold pressure adjustment you will need a 0 to 15 inch water manometer with 0.1 inch resolution and a 1/8" npt manual shut off valve to measure actual manifold pressure. Depending on your local gas heating value and elevation, you may need to adjust manifold pre...

  • Page 28

    Manual 2100-525a page 28 of 67 natural gas input rate natural gas heating value (btu/cu. Ft.) can vary significantly. Before starting natural gas input check, obtain gas heating value at your location from local supplier. You will need a stopwatch to measure actual gas input. 1. Gas supply pressure ...

  • Page 29

    Manual 2100-525a page 29 of 67 21. Standard orifice sizing and high altitude derate this furnace is shipped with fixed gas orifices for use with natural gas and sized for 1000 btu/cubic foot gas. Make sure actual gas input does not exceed rating plate input. You may need to change orifices to get co...

  • Page 30

    Manual 2100-525a page 30 of 67 all other orifice sizes shown are available as individual items. See orifice charts below for part numbers and number required. Table 8 natural gas orifice tables for models w24g, w30g and w36g y r o t c a f d r a d n a t s t u p n i e u l a v * t a e h s a g . T f . U...

  • Page 31

    Manual 2100-525a page 31 of 67 all other orifice sizes shown are available as individual items. See orifice charts on page 28 for part numbers and number required. Table 8a natural gas orifice tables for models w42g, w48g and w60g y r o t c a f d r a d n a t s t u p n i * t a e h s a g e u l a v . T...

  • Page 32

    Manual 2100-525a page 32 of 67 23. Measuring air temperature rise air temperature rise (supply air temperature minus return air temperature) must be within allowable air temperature rise range specified on furnace rating plate. You will need 2 thermometers with 1 degree resolution capable of reading...

  • Page 33

    Manual 2100-525a page 33 of 67 24. Filters a 2" thick throwaway filter is supplied with each unit. This filter is installed by opening the main service door. (see figure 16.) replacement filters are available through your dealer. 25. Compressor control module the compressor control is an anti-short ...

  • Page 34

    Manual 2100-525a page 34 of 67 alarm output alarm terminal is output connection for applications where alarm signal is desired. This terminal is powered whenever compressor is locked out due to hpc or lpc sequences as described. Note: both high and low pressure switch controls are inherently automat...

  • Page 35

    Manual 2100-525a page 35 of 67 26. Lighting and shutdown instructions figure 17 instruction label.

  • Page 36

    Manual 2100-525a page 36 of 67 27. Service agency procedures main burner observe the main burners in operation. The flame should be mostly “blue” with possibly a little orange (not yellow) at the tips of the flame. The flames should be in the center of the heat exchanger tubes and not impinging on t...

  • Page 37

    Manual 2100-525a page 37 of 67 routine maintenance 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 air blower motor and outdoor circulating air fan motor are permanently lubricated and requi...

  • Page 38

    Manual 2100-525a page 38 of 67 30. Sequence of operation – heating on a call for heat from the thermostat, the induced draft blower is energized. Once sufficient draft is established, the pressure switch contacts close and the ignition system is energized. The direct spark ignitor will be energized ...

  • Page 39

    Manual 2100-525a page 39 of 67 32. Indoor blower operation all models have multiple speed direct drive blower motors. If supply and return ducts are connected to the unit, the ducts must be of adequate size. Refer to the appropriate blower tables. See tables 10, 11, 12, 13, 14 and 15 for maximum sta...

  • Page 40

    Manual 2100-525a page 40 of 67 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 d...

  • Page 41

    Manual 2100-525a page 41 of 67 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 d...

  • Page 42

    Manual 2100-525a page 42 of 67 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 ...

  • Page 43

    Manual 2100-525a page 43 of 67 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 ou...

  • Page 44

    Manual 2100-525a page 44 of 67 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 – reduce airflow by 130 cfm for...

  • Page 45

    Manual 2100-525a page 45 of 67 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 – reduce airflow by 130 cfm for...

  • Page 46

    Manual 2100-525a page 46 of 67 table 16 integrated furnace and blower control operation l o r t n o c e c n e u q e s n o i t i n g i e c r u o s n o i t i n g i i s d c a v 4 2 g n i s n e s e m a l f e t o m e r s g n i m i t - - - - - - - - - - - - - - e g r u p e r p e g r u p t s o p e g r u p ...

  • Page 47

    Manual 2100-525a page 47 of 67 33. Pressure service ports high and low pressure service ports are installed on all units so that the system operating pressures can be observed. Tables 17a & 17b outlines expected pressures at various indoor and outdoor temperatures. Table 17a cooling pressure table t...

  • Page 48

    Manual 2100-525a page 48 of 67 "a" airflow mis-1724 34. Refrigerant charge the correct system r-410a charge is shown on the unit rating plate. Optimum unit performance will occur with a refrigerant charge resulting in a suction line temperature (6" from compressor) as shown in table 18. The suction ...

  • Page 49

    Manual 2100-525a page 49 of 67 index wiring diagrams and ladder diagrams t i n u . O n l e d o m c i s a b m a r g a i d g n i r i w l a u n a m . O n e g a p c i s a b m a r g a i d r e d d a l l a u n a m . O n e g a p a - 1 g 4 2 w b 4 4 1 - 5 8 0 4 0 5 5 4 1 - 5 8 0 4 1 5 b - 1 g 4 2 w b 4 4 2 -...

  • Page 50

    Manual 2100-525a page 50 of 67 w24g1-a 230/208-60-1 lp c cc hp c y al r c lp c m inut e s 4 2 3 5 r 1 32 orange 35 35 valve gas 32 32 37 35 32 32 32 32 37 limit flame limit primary 59 rollout spark ignitor 32 flame sensor secondary switch s r c bard mfg. Co. Bryan, ohio 4085-144 b low voltage high v...

  • Page 51

    Manual 2100-525a page 51 of 67 w24g1-a 230/208-60-1.

  • Page 52

    Manual 2100-525a page 52 of 67 w24g1-b 230/208-60-3 lp c cc hp c y al r c lp c m inut e s 4 2 3 5 r 1 32 orange 37 35 35 valve gas 32 27 37 35 32 32 32 32 limit flame limit primary 59 rollout spark ignitor 32 flame sensor secondary switch t3 t1 t2 bard mfg. Co. Bryan, ohio 4085-244 b low voltage hig...

  • Page 53

    Manual 2100-525a page 53 of 67 w24g1-b 230/208-60-3.

  • Page 54

    Manual 2100-525a page 54 of 67 w24g1-c 460-60-3 lp c cc hp c y al r c lp c m inut e s 4 2 3 5 r 1 32 orange l1 or a n g e factory optional 55 valve gas 53 32 27 37 35 32 32 32 32 limit flame limit primary 59 rollout spark ignitor 32 flame sensor secondary switch t3 t1 t2 bard mfg. Co. Bryan, ohio lo...

  • Page 55

    Manual 2100-525a page 55 of 67 w24g1-c 460-60-3.

  • Page 56

    Manual 2100-525a page 56 of 67 w30g1-a, w36g1-a, w42g1-a 230/208-60-1 32 orange lp c cc hp c y al r c lp c m inut e s 4 2 3 5 r 1 b wire not applicable to all models 38 39 42 43 red 38 39 black r 35 a gas valve 32 32 37 35 32 32 32 32 59 primary limit flame limit spark ignitor rollout 32 secondary f...

  • Page 57

    Manual 2100-525a page 57 of 67 w30g1-a, w36g1-a, w42g1-a 230/208-60-1.

  • Page 58

    Manual 2100-525a page 58 of 67 w30g1-b, w36g1-b, w42g1-b 230/208-60-3 lp c cc hp c y al r c lp c m inut e s 4 2 3 5 r 1 a if option wires connect not used 32 orange 37 35 35 valve gas 32 27 37 35 32 32 32 32 limit flame limit primary 59 rollout spark ignitor 32 flame sensor secondary switch t3 t1 t2...

  • Page 59

    Manual 2100-525a page 59 of 67 w30g1-b, w36g1-b, w42g1-b 230/208-60-3.

  • Page 60

    Manual 2100-525a page 60 of 67 w30g1-c, w36g1-c, w42g1-c 460-60-3 lp c cc hp c y al r c lp c m inut e s 4 2 3 5 r 1 32 orange l1 or a n g e 45 45 47 57 45 46 re d 25 54 valve gas 56 32 27 37 35 primary rollout secondary switch t3 t1 limit t2 32 bard mfg. Co. Flame 32 limit bryan, ohio 32 low voltage...

  • Page 61

    Manual 2100-525a page 61 of 67 w30g1-c, w36g1-c, w42g1-c 460-60-3.

  • Page 62

    Manual 2100-525a page 62 of 67 w48g1-a, w60g1-a 230/208-60-1 lp c cc hp c y al r c lp c m inut e s 4 2 3 5 r 1 32 orange 38 39 38 42 43 red 39 black 35 37 35 valve gas 32 32 37 35 32 32 32 32 limit flame limit primary 59 rollout spark ignitor 32 flame sensor secondary switch s r c bard mfg. Co. Brya...

  • Page 63

    Manual 2100-525a page 63 of 67 w48g1-a, w60g1-a 230/208-60-1.

  • Page 64

    Manual 2100-525a page 64 of 67 w48g1-b, w60g1-b 230/208-60-3 32 orange lp c cc hp c y al r c lp c m inut e s 4 2 3 5 r 1 37 35 valve gas 32 27 37 35 32 32 32 32 35 limit flame limit primary 59 rollout spark ignitor 32 flame sensor secondary switch t3 t1 t2 bard mfg. Co. Bryan, ohio 4085-248 a low vo...

  • Page 65

    Manual 2100-525a page 65 of 67 w48g1-b, w60g1-b 230/208-60-3.

  • Page 66

    Manual 2100-525a page 66 of 67 w48g1-c, w60g1-c 460-60-3 lp c cc hp c y al r c lp c m inut e s 4 2 3 5 r 1 32 orange l1 o ra nge re d 54 25 valve gas 56 32 27 37 35 32 32 32 32 limit flame limit primary 59 rollout spark ignitor 32 flame sensor secondary switch t3 t1 t2 bard mfg. Co. Bryan, ohio low ...

  • Page 67

    Manual 2100-525a page 67 of 67 w48g1-c, w60g1-c 460-60-3.