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Bard WG242 Installation Instructions Manual

Manual is about: WG Series

Summary of WG242

  • Page 1

    Manual 2100-365m page 1 of 74 installation instructions wg - series combination gas/electric wall-mount models: wg242 wg302 wg362 wg423 wg482 wg602 manual no.: 2100-365m supersedes: 2100-365l file: volume iii, tab 20 date: 05-25-06 bard manufacturing company, inc. Bryan, ohio 43506 since 1914...Movi...

  • Page 2

    Manual 2100-365m page 2 of 74 contents getting other information and publications .............. 4 wg series model nomenclature ............................... 5 ventilation options .................................................... 5 air conditioning module options ..................................

  • Page 3

    Manual 2100-365m page 3 of 74 contents figures figure 1 unit dimensions ..................................... 9 figure 2 mounting instructions – wg24-36 ....... 12 figure 2a mounting instructions – wg42-60 ....... 13 figure 3 combustible clearance – wg24-36 .... 14 figure 3a combustible clearance – ...

  • Page 4

    Manual 2100-365m page 4 of 74 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 2100-365m page 5 of 74 wg 42 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 6 3 g w , 0 3 w , 4 2 g w 0 6 g w , 8 4 g w , 2 4 g w n o i ...

  • Page 6

    Manual 2100-365m page 6 of 74 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 2100-365m page 7 of 74 table 1 specifications wg24, wg 30 and wg36 models * 75 degree c copper wire size ** maximum time delay fuse or hacr type circuit breaker l e d o ma - 2 4 2 g wb - 2 4 2 g wc - 2 4 2 g wa - 2 0 3 g wb - 2 0 3 g wc - 2 0 3 g wa - 2 6 3 g wb - 2 6 3 g wc - 2 6 3 g w z h 0...

  • Page 8

    Manual 2100-365m page 8 of 74 * 75 degree c copper wire size ** maximum time delay fuse or hacr type circuit breaker table 1a specifications wg42, wg48 and wg60 models l e d o ma - 3 2 4 g wb - 3 2 4 g wc - 3 2 4 g wa - 2 8 4 g wb - 2 8 4 g wc - 2 8 4 g wa - 2 0 6 g wb - 2 0 6 g wc - 2 0 6 g w z h 0...

  • Page 9

    Manual 2100-365m page 9 of 74 f g r p b dd d gg hh a m i c k j l h ff s s s s s t v y aa x u z cc bb b ee o e w ii q n disconnect access condenser air inlet condenser front panel (lockable) panel back supply opening panel door gas entrances air exhaust combustion air outlets 4 deg. Pitch in top vest...

  • Page 10

    Manual 2100-365m page 10 of 74 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 2100-365m page 11 of 74 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 2100-365m page 12 of 74 figure 2 mounting instructions for wg24, wg30, and wg36 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 re...

  • Page 13

    Manual 2100-365m page 13 of 74 figure 2a mounting instructions for wg42, wg48, and wg60

  • Page 14

    Manual 2100-365m page 14 of 74 figure 3 combustible clearance for wg24, wg30 and wg36 models figure 3a combustible clearance for wg42, wg48 and wg60 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 2100-365m page 15 of 74 figure 4 wall mounting instructions figure 5 wall mounting instructions.

  • Page 16

    Manual 2100-365m page 16 of 74 figure 6 common wall mounting installations.

  • Page 17

    Manual 2100-365m page 17 of 74 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 2100-365m page 18 of 74 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 in...

  • Page 19

    Manual 2100-365m page 19 of 74 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 2100-365m page 20 of 74 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 2100-365m page 21 of 74 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

    Manual 2100-365m page 22 of 74 figure 11 low voltage wiring.

  • Page 23

    Manual 2100-365m page 23 of 74 figure 12 gas pipe connection.

  • Page 24

    Manual 2100-365m page 24 of 74 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 25

    Manual 2100-365m page 25 of 74 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 26

    Manual 2100-365m page 26 of 74 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 27

    Manual 2100-365m page 27 of 74 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 28

    Manual 2100-365m page 28 of 74 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 wg24, wg30 and wg36 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 29

    Manual 2100-365m page 29 of 74 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 wg42, wg48 and wg60 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 30

    Manual 2100-365m page 30 of 74 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. You will need 2 thermometers with 1 degree resolution cap...

  • Page 31

    Manual 2100-365m page 31 of 74 24. Filters a 2" thick throwaway filter is supplied with each unit. This filter is installed by opening the main service door. (see figure 14.) replacement filters are available through your dealer. 25. Compressor control module the compressor control is an anti-short ...

  • Page 32

    Manual 2100-365m page 32 of 74 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 33

    Manual 2100-365m page 33 of 74 26. Lighting and shutdown instructions figure 15 instruction label.

  • Page 34

    Manual 2100-365m page 34 of 74 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 35

    Manual 2100-365m page 35 of 74 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 36

    Manual 2100-365m page 36 of 74 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 37

    Manual 2100-365m page 37 of 74 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 38

    Manual 2100-365m page 38 of 74 figure 19 460 volt blower motor wiring options wg24, wg30 and wg36 models.

  • Page 39

    Manual 2100-365m page 39 of 74 figure 20 460 volt blower motor wiring options wg42, wg48 and wg60 models.

  • Page 40

    Manual 2100-365m page 40 of 74 table 10 wg242 indoor blower performance @ 230 and 460 volts recommended wg242 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...

  • Page 41

    Manual 2100-365m page 41 of 74 table 11 wg302 indoor blower performance @ 230 and 460 volts recommended wg302 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...

  • Page 42

    Manual 2100-365m page 42 of 74 table 12 wg362 indoor blower performance @ 230 and 460 volts recommended wg362 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 vol...

  • Page 43

    Manual 2100-365m page 43 of 74 table 13 wg423 indoor blower performance @ 230 and 460 volts recommended wg423 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 ...

  • Page 44

    Manual 2100-365m page 44 of 74 table 14 wg482 indoor blower performance @ 230 and 460 volts recommended wg482 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 f...

  • Page 45

    Manual 2100-365m page 45 of 74 table 15 wg602 indoor blower performance @ 230 and 460 volts recommended wg602 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 f...

  • Page 46

    Manual 2100-365m page 46 of 74 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 2100-365m page 47 of 74 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. Low side pressure ± 2 psig high side press...

  • Page 48

    Manual 2100-365m page 48 of 74 "a" airflow 34. Refrigerant charge the correct system r-22 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 line temper...

  • Page 49

    Manual 2100-365m page 49 of 74 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 - 2 4 2 g w a 4 3 1 - 5 8 0 4 0 5 a 5 3 1 - 5 8 0 4 1 5 b - 2 4 2 g w a 4 3 2...

  • Page 50

    Manual 2100-365m page 50 of 74 wg242-a 230/208-60-1.

  • Page 51

    Manual 2100-365m page 51 of 74 wg242-a, wg362-a 230/208-60-1.

  • Page 52

    Manual 2100-365m page 52 of 74 wg242-b 230/208-60-3.

  • Page 53

    Manual 2100-365m page 53 of 74 wg242-b, wg362-b 230/208-60-3.

  • Page 54

    Manual 2100-365m page 54 of 74 wg242-c 460-60-3.

  • Page 55

    Manual 2100-365m page 55 of 74 wg242-c, wg362c 460-60-3.

  • Page 56

    Manual 2100-365m page 56 of 74 wg302-a 230/208-60-1.

  • Page 57

    Manual 2100-365m page 57 of 74 wg302-a, wg482-a, wg602-a 230/208-60-1.

  • Page 58

    Manual 2100-365m page 58 of 74 wg302-b 230/208-60-3.

  • Page 59

    Manual 2100-365m page 59 of 74 wg302-b, wg482-b, wg602-b 230/208-60-3.

  • Page 60

    Manual 2100-365m page 60 of 74 wg302-c 460-60-3.

  • Page 61

    Manual 2100-365m page 61 of 74 wg302-c 460-60-3.

  • Page 62

    Manual 2100-365m page 62 of 74 wg362-a 230/208-60-1.

  • Page 63

    Manual 2100-365m page 63 of 74 wg362-b 230/208-60-3.

  • Page 64

    Manual 2100-365m page 64 of 74 wg362-c 460-60-3.

  • Page 65

    Manual 2100-365m page 65 of 74 wg423-a 230/208-60-1.

  • Page 66

    Manual 2100-365m page 66 of 74 wg423-a 230/208-60-1.

  • Page 67

    Manual 2100-365m page 67 of 74 wg423-b 230/208-60-3.

  • Page 68

    Manual 2100-365m page 68 of 74 wg423-b 230/208-60-3.

  • Page 69

    Manual 2100-365m page 69 of 74 wg423-c 460-60-3.

  • Page 70

    Manual 2100-365m page 70 of 74 wg423-c 460-60-3.

  • Page 71

    Manual 2100-365m page 71 of 74 wg482-a, wg602-a 230/208-60-1.

  • Page 72

    Manual 2100-365m page 72 of 74 wg482-b, wg602-b 230/208-60-3.

  • Page 73

    Manual 2100-365m page 73 of 74 wg482-c, wg602-c 460-60-3.

  • Page 74

    Manual 2100-365m page 74 of 74 wg482c, wg602-c 460-60-3.