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Bard W24G2-A Installation Instructions Manual

Manual is about: WG Series

Summary of W24G2-A

  • Page 1

    Page 1 of 49 installation instructions bard manufacturing company, inc. Bryan, ohio 43506 www.Bardhvac.Com manual no.: 2100-630 supersedes: new date: 4-1-15 warning read all instructions carefully before beginning the installation. The installation must comply with these instructions and the require...

  • Page 2: Contents

    Manual 2100-630 page 2 of 49 contents getting other information and publications .............. 4 w**g series model nomenclature ........................... 5 ventilation options ................................................ 5 air conditioning module options ............................. 6 1. Imp...

  • Page 3: Contents

    Manual 2100-630 page 3 of 49 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 – w42...

  • Page 4

    Manual 2100-630 page 4 of 49 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 2100-630 page 5 of 49 w 42 g 3 – a x c x x x x x x wall mount gas/electric general model number nomenclature low ambient control is required with economizer for low temperature compressor operation. Ventilation options models w24g, w30g, w36g w42g, w48g, w60g description factory installed cod...

  • Page 6

    Manual 2100-630 page 6 of 49 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-brea...

  • Page 7

    Manual 2100-630 page 7 of 49 table 1 specifica tions w24g, w30g and w36g models * 75 degree c copper wire size ** maximum time delay fuse or circuit breaker models w24g3-a w24g3-b w24g3-c w30g3-a w30g3-b w30g3-c w36g3-a w36g3-b w36g3-c electrical rating - 60 hz 230/208-1 230/208-3 460-3 230/208-1 23...

  • Page 8

    Manual 2100-630 page 8 of 49 * 75 degree c copper wire size ** maximum time delay fuse or circuit breaker table 1a specifica tions w42g, w48g and w60g models models w42g3-a w42g3-b w42g3-c w48g3-a w48g3-b w48g3-c w60g3-a w60g3-b w60g3-c electrical rating - 60 hz 230/208-1 230/208-3 460-3 230/208-1 2...

  • Page 9

    Manual 2100-630 page 9 of 49 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 b ii q w co mb us ti on ai r in ta ke co ntr ol ri gh t s id e en tr an ce s ga s re tu rn ope ni ng 4 de g. Pi tc h in top pa ne l door door lo w v ol ta ge su pp ly ope ni ng pa ne l ba ck ...

  • Page 10: Warning

    Manual 2100-630 page 10 of 49 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 11: Caution

    Manual 2100-630 page 11 of 49 8. Mounting the unit 1. These units are secured by wall mounting brackets which secure the unit to the outside wall surface at both sides. A bottom mounting bracket is provided for ease of installation but is not required. 2. The w42g, w48g and w60g models are suitable ...

  • Page 12

    Manual 2100-630 page 12 of 49 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 2100-630 page 13 of 49 figure 2a mounting instructions for w42g, w48g and w60g.

  • Page 14: Warning

    Manual 2100-630 page 14 of 49 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 fi...

  • Page 15

    Manual 2100-630 page 15 of 49 figure 4 wall mounting instructions figure 5 wall mounting instructions.

  • Page 16

    Manual 2100-630 page 16 of 49 figure 6 common wall mounting installations.

  • Page 17: Warning

    Manual 2100-630 page 17 of 49 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: Caution

    Manual 2100-630 page 18 of 49 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 gask...

  • Page 19

    Manual 2100-630 page 19 of 49 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 a...

  • Page 20: Warning

    Manual 2100-630 page 20 of 49 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 2100-630 page 21 of 49 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). 17. Thermostats 16. Wiring – low voltage wiring low voltage connection these units use a 24-volt ac ...

  • Page 22: Unit Control Panel

    Manual 2100-630 page 22 of 49 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" co...

  • Page 23: Unit Control Panel

    Manual 2100-630 page 23 of 49 part #8403-060 l 1 commercial room ventilator-spring, terminal w1 mis-2775 a r c w rc y g 4 w2 a block unit control panel 4 bl ue y1 d/yo bla ck /wh ite y2 thermostat set switch on thermostat to "gas-oil" r y1 1 wiring plug motorized fresh air damper, commercial room ve...

  • Page 24: Thermostat Subbase

    Manual 2100-630 page 24 of 49 block (1120-445) terminal (th5220d1151) y2 mis-2777 a low voltage wiring - jifm economizer rc c w w2 from y part #8403-060 l y1 2 y w1 r configure thermostat for heat/cool y1 1 wires y2 g w1/e a c c a 1 purple unit 24v r 1 thermostat plug thermostat subbase o/b g w2 1 r...

  • Page 25

    Manual 2100-630 page 25 of 49 figure 14 gas pipe connection w24g - w36g w42g - w60g.

  • Page 26

    Manual 2100-630 page 26 of 49 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: Warning

    Manual 2100-630 page 27 of 49 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 pres...

  • Page 28: Warning

    Manual 2100-630 page 28 of 49 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 m...

  • Page 29

    Manual 2100-630 page 29 of 49 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 cor...

  • Page 30

    Manual 2100-630 page 30 of 49 table 8 natural gas orifice tables for models w24g, w30g and w36g all other orifice sizes shown are available as individual items. See orifice tables below for part numbers and number required. Factory standard input gas heat* value btu/cu. Ft. Up to 6,000 feet no chang...

  • Page 31

    Manual 2100-630 page 31 of 49 all other orifice sizes shown are available as individual items. See orifice table on page 30 for part numbers and number required. Table 8a natural gas orifice tables for models w42g, w48g and w60g factory standard input gas heat* value btu/cu. Ft. Up to 6,000 feet no ...

  • Page 32: Warning

    Manual 2100-630 page 32 of 49 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 two thermometers with 1 ° resolution capable of reading up ...

  • Page 33

    Manual 2100-630 page 33 of 49 24. Filters a 2” thick throwaway filter is supplied with each unit. This filter is installed by opening the filter service door. (see figure 16.) replacement filters are available through your dealer. 25. Compressor control module the compressor control module is standa...

  • Page 34

    Manual 2100-630 page 34 of 49 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 automati...

  • Page 35

    Manual 2100-630 page 35 of 49 26. Lighting and shutdown instructions figure 17 instruction label bend & peel “here” to remove label liner a. This appliance does not have a pilot. It is equipped with an ignition device which automatically lights the burner. Do not try to light the burner by hand. B. ...

  • Page 36: Caution

    Manual 2100-630 page 36 of 49 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 th...

  • Page 37: Warning

    Manual 2100-630 page 37 of 49 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 requir...

  • Page 38

    Manual 2100-630 page 38 of 49 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 a...

  • Page 39

    Manual 2100-630 page 39 of 49 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 stat...

  • Page 40

    Manual 2100-630 page 40 of 49 table 10 w24g indoor blower performance @ 230 and 460 volts recommended w24g cooling airflow range at rated 800 cfm @ 0.15 esp (wc) is 700 - 910 cfm factory set on low speed for cooling and high for heating. Voltage adjustment – reduce airflow by 100 cfm for 208 volt de...

  • Page 41

    Manual 2100-630 page 41 of 49 table 11 w30g indoor blower performance @ 230 and 460 volts recommended w30g cooling airflow range at rated 1000 cfm @ 0.35 esp (wc) is 880 - 1150 cfm factory set on medium speed for cooling and for heating. Voltage adjustment – reduce airflow by 100 cfm for 208 volt de...

  • Page 42

    Manual 2100-630 page 42 of 49 table 12 w36g indoor blower performance @ 230 and 460 volts recommended w36g cooling airflow range at rated 1100 cfm @ 0.250 esp (wc) is 940 - 1250 cfm factory set on medium speed for cooling and for heating. Voltage adjustment – reduce airflow by 100 cfm for 208 volt d...

  • Page 43

    Manual 2100-630 page 43 of 49 table 13 w42g indoor blower performance @ 230 and 460 volts recommended w42g cooling airflow range at rated 1300 cfm @ .35 esp (wc) is 1030 - 1480 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 2100-630 page 44 of 49 table 14 w48g indoor blower performance @ 230 and 460 volts recommended w48g cooling airflow range at rated 1550 cfm @ .20 esp (wc) is 1250 - 1780 cfm factory set on medium speed for cooling and medium speed for heating. Voltage adjustment – reduce airflow by 130 cfm fo...

  • Page 45

    Manual 2100-630 page 45 of 49 table 15 w60g indoor blower performance @ 230 and 460 volts recommended w60g cooling airflow range at rated 1650 cfm @ .30 esp (wc) is 1360 - 1850 cfm factory set on high speed for cooling and medium speed for heating. Voltage adjustment – reduce airflow by 130 cfm for ...

  • Page 46

    Manual 2100-630 page 46 of 49 table 16 integrated furnace and blower control operation ignition sequence control ignition source 24 vac dsi flame sensing remote timings - prepurge - postpurge - inter-trial purge - pressure switch proving period - trials for ignition - trial for ignition - ignition s...

  • Page 47

    Manual 2100-630 page 47 of 49 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 and 17b outline expected pressures at various indoor and outdoor temperatures. Table 17a cooling pressure table t...

  • Page 48: * *

    Manual 2100-630 page 48 of 49 "a" airflow mis-1724 35. Fan blade setting dimensions shown in figure 21 is the correct fan blade setting dimension for proper air delivery across the outdoor coil. Table 18 fan blade dimension figure 21 fan blade 36. Low-nox burner assembly “n” suffix models only – u.S...

  • Page 49

    Manual 2100-630 page 49 of 49 index wiring diagrams and ladder diagrams unit model no. Basic wiring diagram basic ladder diagram w24g3-a 4085-159 4085-160 w24g3-b 4085-257 4085-258 w24g3-c 4085-380 4085-381 w30g3-a 4085-161 4085-162 w30g3-b 4085-259 4085-260 w30g3-c 4085-382 4085-383 w36g3-a 4085-16...