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Bard W24G2DA Installation Instructions Manual

Manual is about: WG Series

Summary of W24G2DA

  • Page 1

    Page 1 of 69 installation instructions bard manufacturing company, inc. Bryan, ohio 43506 www.Bardhvac.Com manual no.: 2100-592c supersedes: 2100-592b date: 5-4-15 warning read all instructions carefully before beginning the installation. The installation must comply with these instructions and the ...

  • Page 2: Contents

    Manual 2100-592c page 2 of 69 contents getting other information and publications ...4 wall mount gas/electric general information ..5 w**g series model nomenclature ..................... 5 ventilation options .......................................... 5 air conditioning module options ................

  • Page 3

    Manual 2100-592c page 3 of 69 figures figure 1 unit dimensions .................................. 9 figure 2 mounting instructions – w24g-36g ..... 12 figure 2a mounting instructions – w42g-60g ..... 13 figure 3 combustible clearance – w24g-36g ... 14 figure 3a combustible clearance – w42g-60g.... 1...

  • Page 4

    Manual 2100-592c page 4 of 69 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 2100-592c page 5 of 69 wall mount gas/electric general information model number nomenclature w 42 g 2 d a x c x x x x x x model wall mount control options (see table page 6) vent (see table below) cooling capacity 24 = 2 ton 30 = 2½ ton 36 = 3 ton 42 = 3½ ton 48 = 4 ton 60 = 5 ton outlet x = ...

  • Page 6: Caution

    Manual 2100-592c page 6 of 69 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 2100-592c page 7 of 69 table 1 specifications w24g, w30g and w36g models * 75° c copper wire size ** maximum time delay fuse or circuit breaker models w24g2da w24g2db w24g2dc w30g2da w30g2db w30g2dc w36g2da w36g2db w36g2dc electrical rating – 60 hz 230/208-60-1 230/208-60-3 460-60-3 230/208-6...

  • Page 8

    Manual 2100-592c page 8 of 69 table 1a specifications w42g, w48g and w60g models models w42g2da w42g2db w42g2dc w48g2da w48g2db w48g2dc w60g2da w60g2db w60g2dc electrical rating – 60 hz 230/208-60-1 230/208-60-3 460-60-3 230/208-60-1 230/208-60-3 460-60-3 230/208-60-1 230/208-60-3 460-60-3 operating...

  • Page 9

    Manual 2100-592c page 9 of 69 figure 1 unit dimensions 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 m bu sti 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 l...

  • Page 10: Warning

    Manual 2100-592c page 10 of 69 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: Warning

    Manual 2100-592c page 11 of 69 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 2100-592c page 12 of 69 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 2100-592c page 13 of 69 figure 2a mounting instructions for w42g, w48g and w60g.

  • Page 14: Warning

    Manual 2100-592c page 14 of 69 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 2100-592c page 15 of 69 figure 4 wall mounting instructions figure 5 wall mounting instructions.

  • Page 16

    Manual 2100-592c page 16 of 69 figure 6 common wall mounting installations.

  • Page 17: Warning

    Manual 2100-592c page 17 of 69 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 2100-592c page 18 of 69 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. Make sure gasket is i...

  • Page 19

    Manual 2100-592c page 19 of 69 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: Warning

    Manual 2100-592c page 20 of 69 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 2100-592c page 21 of 69 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). 16. Wiring – low voltage wiring low voltage connection these units use a 24-volt ac low voltage cir...

  • Page 22

    Manual 2100-592c page 22 of 69 17. Thermostats table 3 thermostat wire size table 4a wall thermostat table 4b humidistat thermostat predominant features 8403-057 (th3110d1040) 1 stage cool; 1 stage heat system: heat-off-cool fan: on-auto electronic non-programmable 8403-058 (th5220d1151) 2 stage coo...

  • Page 23: Thermostat Subbase

    Manual 2100-592c page 23 of 69 figure 11a thermostat connection using 8403-060 combination temperature and humidity controller y1 1 g and humidity control f block r c terminal a w2 e y2 y1 2 3 l w1 y2 unit 24v w1/e c 2 thermostat subbase a y needed for economizer only (1120-445) o/b unit control pan...

  • Page 24

    Manual 2100-592c page 24 of 69 figure 11b thermostat using separate temperature and humidity controllers y mis-2788 r c w rc y g l rc y2 electronic humidistat (th311dd1040) c r thermostat bard part #8403-047 (th522od1151) thermostat subbase w2 part #8403-057 o/b g part #8403-058 thermostat must inst...

  • Page 25: Unit Control Panel

    Manual 2100-592c page 25 of 69 figure 11c motorized fresh air damper, classroom ventilator spring, classroom ventilator power and erv low voltage connections purple wires from plug black blue yellow/red pink yellow orange red factory installed terminal unit control panel mis-2789 c factory installed...

  • Page 26

    Manual 2100-592c page 26 of 69 figure 12 gas pipe connection w24g - w36g w42g - w60g.

  • Page 27

    Manual 2100-592c page 27 of 69 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 combined input to all appliances, and the branch lines feeding the individual appliances properly sized for each in...

  • Page 28: Warning

    Manual 2100-592c page 28 of 69 19. Manifold pressure adjustment a 0 to 15" water manometer with 0.1" resolution and a 1/8" npt manual shut off valve is needed to measure actual manifold pressure. Depending on local gas heating value and elevation, the manifold pressure may need to be adjusted or the...

  • Page 29: Warning

    Manual 2100-592c page 29 of 69 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 the location from local supplier. A stopwatch is needed to measure actual gas input. 1. Gas supply pressure must ...

  • Page 30

    Manual 2100-592c page 30 of 69 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. The orifices may need to changed to get t...

  • Page 31

    Manual 2100-592c page 31 of 69 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' no changes ...

  • Page 32

    Manual 2100-592c page 32 of 69 all other orifice sizes shown are available as individual items. See orifice table on page 31 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' no cha...

  • Page 33: Warning

    Manual 2100-592c page 33 of 69 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 and in table 1. Two thermometers with 1° resolution capable of reading up...

  • Page 34

    Manual 2100-592c page 34 of 69 24. Filters a 2" thick throwaway filter is supplied with each unit. This filter is installed by opening the filter service door (see figure 14). Replacement filters are available through a dealer. 25. Compressor control module the compressor control is an anti-short cy...

  • Page 35

    Manual 2100-592c page 35 of 69 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 36

    Manual 2100-592c page 36 of 69 27. Lighting and shutdown instructions figure 15 lighting and shutdown 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 ...

  • Page 37: Caution

    Manual 2100-592c page 37 of 69 28. 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 38: Warning

    Manual 2100-592c page 38 of 69 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 39

    Manual 2100-592c page 39 of 69 31. 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 40

    Manual 2100-592c page 40 of 69 figure 17 sequence of operation electronic blower control action system response thermostat calls for heat (w terminal is energized). • combustion air blower is energized. • air proving switch makes. Airflow is established. • ignition system is energized. • gas valve o...

  • Page 41

    Manual 2100-592c page 41 of 69 33. 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 42

    Manual 2100-592c page 42 of 69 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 43

    Manual 2100-592c page 43 of 69 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 44

    Manual 2100-592c page 44 of 69 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 45

    Manual 2100-592c page 45 of 69 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 dpeed for heating and cooling. Voltage adjustment – reduce airflow by 130 cfm for 208 volt top o...

  • Page 46

    Manual 2100-592c page 46 of 69 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 47

    Manual 2100-592c page 47 of 69 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 48

    Manual 2100-592c page 48 of 69 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 ...

  • Page 49

    Manual 2100-592c page 49 of 69 34. W**g dehumidification relay logic board table 17 dehumidification relay logic board cooling takes precedence over dehumidification. A cooling call cancels dehumidification. First stage heating cancels dehumidification. If jumper on rlb is set to “1-2 full-time dehu...

  • Page 50

    Manual 2100-592c page 50 of 69 figure 19 circuit diagrams 35. Pressure service ports high and low pressure service ports are installed on all units so that the system operating pressures can be observed. 36. Dehumidification circuit the dehumidification circuit incorporates an independent heat excha...

  • Page 51

    Manual 2100-592c page 51 of 69 37. Refrigerant charge the correct system r-410a charge is shown on the unit rating plate. Reference table 18 to validate proper system operation (+2 psig suction, +5 psig discharge). However, it is recommended that if incorrect charge is suspected, the system refriger...

  • Page 52: * *

    Manual 2100-592c page 52 of 69 38. Fan blade setting dimensions shown in figure 20 is the correct fan blade setting dimension for proper air delivery across the outdoor coil. 39. Low-nox burner assembly “n” suffix models only – u.S. Installations only natural gas models only model numbers designated...

  • Page 53

    Manual 2100-592c page 53 of 69 index wiring diagrams and ladder diagrams unit model no. Basic wiring diagram manual page no. Basic ladder diagram manual page no. W24g2da 4085-165 54 4085-166 55 w24g2db 4085-263 56 4085-264 57 w24g2dc 4085-386 58 4085-387 59 w30g2da 4085-167 60 4085-168 61 w30g2db 40...

  • Page 54

    Manual 2100-592c page 54 of 69 w24g2da 230/208-60-1 lpc cc hpc y alr c lpc mi nu tes 4 2 3 5 r 1 pink bl ue blue blue 1 2 3 4 5 6 8 9 7 12 10 bl ue 11 bl ue l2 a l1 a bl ue purple purple mv no c mv or an ge yellow yellow ye ll ow yellow yellow ye ll ow /r ed ye ll ow yellow brown brown brown/white b...

  • Page 55

    Manual 2100-592c page 55 of 69 w24g2da, w48g2da, w60g2da 230/208-60-1.

  • Page 56

    Manual 2100-592c page 56 of 69 w24g2db 230/208-60-3 lpc cc hpc y alr c lpc mi nu tes 4 2 3 5 r 1 a if option wires connect not used pressure high pressure switch low switch ground terminal 15 pink l1 blue blue 1 2 3 4 5 6 8 9 7 12 10 11 bl ue bl ue l3 l2 a bl ue a bl ue purple purple mv no c mv 32 o...

  • Page 57

    Manual 2100-592c page 57 of 69 w24g2db, w48g2db, w60g2db 230/208-60-3.

  • Page 58

    Manual 2100-592c page 58 of 69 w24g2dc 460-60-3 lpc cc hpc y alr c lpc mi nu tes 4 2 3 5 r 1 pink pink pink pink bl ue blue blue 1 2 3 4 5 6 8 9 7 12 10 11 bl ue bl ue l3 a l2 a bl ue purple/white purple purple pu rp le purple purple/white mv no c mv orange orange ye ll ow yellow ye ll ow ye ll ow y...

  • Page 59

    Manual 2100-592c page 59 of 69 w24g2dc 460-60-3.

  • Page 60

    Manual 2100-592c page 60 of 69 w30g2da, w36g2da, w42g2da 230/208-60-1 lpc cc hpc y alr c lpc mi nu tes 4 2 3 5 r 1 a if option wires connect not used b wire not applicable to all models if any original wire as supplied with the appliance must be replaced, it must be replaced with wiring material hav...

  • Page 61

    Manual 2100-592c page 61 of 69 w30g2da, w36g2da, w42g2da 230/208-60-1.

  • Page 62

    Manual 2100-592c page 62 of 69 w30g2db, w36g2db, w42g2db 230/208-60-3 lpc cc hpc y alr c lpc mi nu tes 4 2 3 5 r 1 a if option wires connect not used ground terminal 15 pink l1 blue blue 1 2 3 4 5 6 8 9 7 12 10 11 bl ue bl ue l3 l2 a bl ue a bl ue purple purple mv no c mv 32 or an ge yellow/black ye...

  • Page 63

    Manual 2100-592c page 63 of 69 w30g2db, w36g2db, w42g2db 230/208-60-3.

  • Page 64

    Manual 2100-592c page 64 of 69 w30g2dc, w36g2dc, w42g2dc 460-60-3 lpc cc hpc y alr c lpc mi nu tes 4 2 3 5 r 1 pink pink pink pink bl ue blue blue 1 2 3 4 5 6 8 9 7 12 10 11 bl ue bl ue l3 a l2 a bl ue purple/white purple purple pu rp le purple purple/white mv no c mv orange orange ye ll ow yellow y...

  • Page 65

    Manual 2100-592c page 65 of 69 w30g2dc, w36g2dc, w42g2dc 460-60-3.

  • Page 66

    Manual 2100-592c page 66 of 69 w48g2da, w60g2da 230/208-60-1 lpc cc hpc y alr c lpc mi nu tes 4 2 3 5 r 1 pink bl ue blue blue 1 2 3 4 5 6 8 9 7 12 10 11 bl ue bl ue l2 a l1 a bl ue purple purple mv no c mv or an ge yellow yellow ye ll ow yellow yellow ye ll ow /r ed ye ll ow yellow brown brown brow...

  • Page 67

    Manual 2100-592c page 67 of 69 w48g2db, w60g2db 230/208-60-3 lpc cc hpc y alr c lpc mi nu tes 4 2 3 5 r 1 ground terminal 15 pink a blue blue 1 2 3 4 5 6 8 9 7 12 10 11 bl ue bl ue bl ue l3 l2 l1 a bl ue purple purple mv no c mv 32 or an ge yellow yellow ye ll ow ye ll ow yellow/black yellow/red ye ...

  • Page 68

    Manual 2100-592c page 68 of 69 w48g2dc, w60g2dc 460-60-3 lpc cc hpc y alr c lpc mi nu tes 4 2 3 5 r 1 if any original wire as supplied with the appliance must be replaced, it must be replaced with wiring material having a temperature rating of at least 105° c except the ignition cable which is 250°c...

  • Page 69

    Manual 2100-592c page 69 of 69 w48g2dc, w60g2dc 460-60-3.