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Bard WG3S1-A Installation Instructions Manual

Other manuals for WG3S1-A: Manual
Manual is about: WG Series

Summary of WG3S1-A

  • Page 1

    Manual 2100-483e page 1 of 59 wg - series combination gas/electric wall-mount models: wg3s1-a wg3s1-b wg3s1-c wg4s1-a wg4s1-b wg4s1-c wg5s1-a wg5s1-b wg5s1-c manual no.: 2100-483e supersedes: 2100-483d file: volume iii, tab 20 date: 08-12-08 bard manufacturing company, inc. Bryan, ohio 43506 since 1...

  • Page 2

    Manual 2100-483e page 2 of 59 contents getting other information and publications .............. 4 wg series model nomenclature ............................... 5 ventilation options .................................................... 5 air conditioning module options ..................................

  • Page 3

    Manual 2100-483e page 3 of 59 contents figures figure 1 unit dimensions ..................................... 8 figure 2a mounting instructions – wg3s1 ........... 11 figure 2b mounting instructions–wg4s1 & wg5s1 ..... 12 figure 3 combustible clearance ........................ 13 figure 4 wall mount...

  • Page 4

    Manual 2100-483e page 4 of 59 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 2100-483e page 5 of 59 wg 4 s 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 s 5 g w , s 4 g w , s 3 g w n o i t p i r c s e d d e l l a...

  • Page 6

    Manual 2100-483e page 6 of 59 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 2100-483e page 7 of 59 * 75 degree c copper wire size ** maximum time delay fuse or hacr type circuit breaker table 1 specifications el è d o ma - 1 s 3 g wb - 1 s 3 g wc - 1 s 3 g wa - 1 s 4 g wb - 1 s 4 g wc - 1 s 4 g wa - 1 s 5 g wb - 1 s 5 g wc - 1 s 5 g w z h 0 6 - g nit a r l a cir t c ...

  • Page 8

    Manual 2100-483e page 8 of 59 ii q f g n p d dd ff gg a m i c k j l hh h s s s s r s v y aa u z x cc bb b ee o e w t b re t urn o p e ni ng ba ck rig h t side f r on t en t r an c es pan el d o o r pan el ( lo c kabl e) di s co nne ct a cce s s su ppl y o pen in g co nde ns e r a ir in le t co nde n...

  • Page 9

    Manual 2100-483e page 9 of 59 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 minim...

  • Page 10

    Manual 2100-483e page 10 of 59 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 11

    Manual 2100-483e page 11 of 59 figure 2a mounting instructions for wg3s1.

  • Page 12

    Manual 2100-483e page 12 of 59 figure 2b mounting instructions for wg4s1 and wg5s1.

  • Page 13

    Manual 2100-483e page 13 of 59 figure 3 combustible clearance warning a 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 spacin...

  • Page 14

    Manual 2100-483e page 14 of 59 figure 4 wall mounting instructions figure 5 wall mounting instructions.

  • Page 15

    Manual 2100-483e page 15 of 59 figure 6 common wall mounting installations.

  • Page 16

    Manual 2100-483e page 16 of 59 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 17

    Manual 2100-483e page 17 of 59 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 18

    Manual 2100-483e page 18 of 59 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 19

    Manual 2100-483e page 19 of 59 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 20

    Manual 2100-483e page 20 of 59 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 21

    Manual 2100-483e page 21 of 59 w2 thermostat factory installed jumper w2 thermostat low voltage wiring - no ventilation package 1 r c g y unit control panel block r c w1 f thermostat subbase e y2 y1 2 3 r c w y2 rc w2 y g l y1 d/yo y2 a part #8403-060 o/b g terminal part #8403-058 w1/e unit 24v mis-...

  • Page 22

    Manual 2100-483e page 22 of 59 w2 stop have occupancy output. Low voltage wiring - multi-position commercial room ventilat 1 wiring harness wgcrvmp-5 assembly install if you require ventilation anytime blower is on. Block r c w1 f e control y2 y1 2 3 r c w y2 rc w2 y g l y1 d/yo y2 a must install ju...

  • Page 23: Thermostat Subbase

    Manual 2100-483e page 23 of 59 r factory installed jumper unit 24v w2 thermostat from low voltage wiring - eifm economizer part #8403-058 1 g part #8403-060 o/b g block r c w1 f w2 e y2 y1 2 3 r c w y2 rc w2 y g l y1 d/yo y2 thermostat plug thermistor wgseifm-5 terminal a w1/e c thermostat subbase u...

  • Page 24

    Manual 2100-483e page 24 of 59 f have occupancy output. Low voltage wiring - wgserv-*5 energy recovery ventilato wgserv-*5 control install if you require ventilation anytime blower is on. Block r c w1 w2 e y2 y1 2 3 r c w y2 rc w2 y g l y1 d/yo y2 must install jumper for 8403-058 or other thermostat...

  • Page 25

    Manual 2100-483e page 25 of 59 figure 11 gas pipe connection.

  • Page 26

    Manual 2100-483e page 26 of 59 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 2100-483e page 27 of 59 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 2100-483e page 28 of 59 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 2100-483e page 29 of 59 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 2100-483e page 30 of 59 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 wg3s, wg4s and wg5s 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 f . U...

  • Page 31

    Manual 2100-483e page 31 of 59 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 32

    Manual 2100-483e page 32 of 59 24. Filters a 2" thick throwaway filter is supplied with each unit. This filter is installed by opening the main service door. (see figure 13.) replacement filters are available through your dealer. 25. Compressor control module the compressor control module is standar...

  • Page 33

    Manual 2100-483e page 33 of 59 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 34

    Manual 2100-483e page 34 of 59 26. Lighting and shutdown instructions figure 14 instruction label.

  • Page 35

    Manual 2100-483e page 35 of 59 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 36

    Manual 2100-483e page 36 of 59 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 37

    Manual 2100-483e page 37 of 59 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 38

    Manual 2100-483e page 38 of 59 32. Indoor blower operation the indoor blower motor is a constant cfm variable speed direct drive motor. The motor is programmed to respond to individual thermostatic inputs that will determine the speed/airflow at which the motor operates. The motor software maintains...

  • Page 39

    Manual 2100-483e page 39 of 59 table 10 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 40

    Manual 2100-483e page 40 of 59 start up these units require r-410a refrigerant & polyol ester oil. Application: 1. Use separate service and manufacturing equipment to avoid cross contamination of oil and refrigerants. 2. Use recovery equipment rated for r-410a refrigerant. 3. Use manifold gauges rat...

  • Page 41

    Manual 2100-483e page 41 of 59 three phase scroll compressor start up information scroll compressors, like several other types of compressors, will only compress in one rotational direction. Direction of rotation is not an issue with single phase compressors since they will always start and run in t...

  • Page 42

    Manual 2100-483e page 42 of 59 compressor solenoid (see sequence of operation on page 37 for function.) a nominal 24-volt direct current coil activates the internal compressor solenoid. The input control circuit voltage must be 18 to 28 volt ac. The coil power requirement is 20 va. The external elec...

  • Page 43

    Manual 2100-483e page 43 of 59 troubleshooting ge ecm 2.3 ™ motors caution: disconnect power from unit before removing or replacing connectors, or servicing motor. To avoid electric shock from the motor’s capacitors, disconnect power and wait at least 5 minutes before opening motor. Symptom cause/pr...

  • Page 44

    Manual 2100-483e page 44 of 59 troubleshooting ge ecm ™ motors cont’d. Replacing ecm control module to replace the control module for the ge variable-speed indoor blower motor you need to take the following steps: 1. You must have the correct replacement module. The controls are factory programmed f...

  • Page 45

    Manual 2100-483e page 45 of 59 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 12 outlines expected pressures at various indoor and outdoor temperatures. Low side pressure ± 2 psig high side press...

  • Page 46

    Manual 2100-483e page 46 of 59 35. Low-nox burner assembly “n” suffix models only – u.S. Installations only natural gas models only model numbers designated with an “n” are designed for low nox emissions which comply with all california air quality management district regulations for nitrogen oxide ...

  • Page 47

    Manual 2100-483e page 47 of 59 index wiring diagrams and ladder diagrams . O n l e d o m t u p n i g n i t a e h r e w o p t u p n i m a r g a i d g n i r i w m a r g a i d r e d d a l 1 s 3 g w 0 0 0 , 0 5 1 / 0 6 / 0 3 2 / 8 0 2 b 0 4 1 - 5 8 0 4 a 1 4 1 - 5 8 0 4 0 0 0 , 5 7 b 2 4 1 - 5 8 0 4 a 3...

  • Page 48

    Manual 2100-483e page 48 of 59 wg3s1-a, wg4s1-a, wg5s1-a 208/230/60/1 t2 nc c l2 l3 au x. L1 t1 t3 lpc cc hpc y alr c lpc minutes 4 2 3 5 r 1 61 62 induced draft blower compressor contactor 51 gas valve 20 32 32 37 35 35 40 40 35 35 32 32 32 32 32 32 34 32 62 28 28 28 37 28 27 27 42 43 41 38 36 47 4...

  • Page 49

    Manual 2100-483e page 49 of 59 wg3s1-a, wg4s1-a, wg5s1-a 208/230/60/1 if option not a wires connect used bard mfg. Co. Bryan, ohio 4085-141 a indoor blower motor 14 12 10 6 2 13 3 1 16 pin plug for 15 w1 c heat unused g high voltage optional low voltage factory w2 control crankcase blower relay y2 c...

  • Page 50

    Manual 2100-483e page 50 of 59 wg3s1-a, wg4s1-a, wg5s1-a 208/230/60/1 t2 nc c l2 l3 au x. L1 t1 t3 lpc cc hpc y alr c lpc minutes 4 2 3 5 r 1 15 factory 60 low ambient 60 control (opt.) 32 a 62 contactor compressor draft blower induced 51 valve gas 20 32 32 37 35 35 40 40 35 35 32 32 32 32 32 32 34 ...

  • Page 51

    Manual 2100-483e page 51 of 59 wg3s1-a, wg4s1-a, wg5s1-a 208/230/60/1 if option not a wires connect used bard mfg. Co. Bryan, ohio 4085-143 a indoor blower motor 14 12 10 6 2 13 3 1 16 pin plug for 15 w1 c heat unused g high voltage optional low voltage factory control induced draft blower relay y2 ...

  • Page 52

    Manual 2100-483e page 52 of 59 wg3s1-b, wg4s1-b, wg5s1-b 208/230/60/3 t2 nc c l2 l3 au x. L1 t1 t3 bryan, ohio 4085-240 b bard mfg. Co. Lpc cc hpc y alr c lpc minutes 4 2 3 5 r 1 pink pi n k l1 l3 blue blue 5 4 3 gr blue blue 1 2 3 4 5 6 8 9 7 12 10 11 bl u e bl u e l2 blue purple purple purple no c...

  • Page 53

    Manual 2100-483e page 53 of 59 wg3s1-b, wg4s1-b, wg5s1-b 208/230/60/3 if option not a wires connect used bard mfg. Co. Bryan, ohio 4085-241 a indoor blower motor 14 12 10 6 2 13 3 1 16 pin plug for 15 w1 c heat unused g high voltage optional low voltage factory 4 l3 l2 l2 c yo y ladder diagram low v...

  • Page 54

    Manual 2100-483e page 54 of 59 wg3s1-b, wg4s1-b, wg5s1-b 208/230/60/3 t2 nc c l2 l3 au x. L1 t1 t3 bryan, ohio 4085-242 b bard mfg. Co. Lpc cc hpc y alr c lpc minutes 4 2 3 5 r 1 pink pi n k 10 11 bl u e bl u e l2 l1 blue blue 5 4 3 gr blue blue 1 2 3 4 5 6 8 9 7 12 blue purple purple purple mv no c...

  • Page 55

    Manual 2100-483e page 55 of 59 wg3s1-b, wg4s1-b, wg5s1-b 208/230/60/3 if option not a wires connect used bard mfg. Co. Bryan, ohio 4085-243 a indoor blower motor 14 12 10 6 2 13 3 1 16 pin plug for 15 w1 c heat unused g high voltage optional low voltage factory c yo y ladder diagram low voltage term...

  • Page 56

    Manual 2100-483e page 56 of 59 wg3s1-c, wg4s1-c, wg5s1-c 460/60/3 460v 230v lpc cc hpc y alr c lpc minutes 4 2 3 5 r 1 t2 nc c l2 l3 au x. L1 t1 t3 l3 yellow 30 low ambient 29 control (opt.) 32 32 a c o n tac to r c o m pr esso r heater crankcase 33 draft blower induced 51 valve gas 20 32 52 37 35 3...

  • Page 57

    Manual 2100-483e page 57 of 59 wg3s1-c, wg4s1-c, wg5s1-c 460/60/3 if option not a wires connect used bard mfg. Co. Bryan, ohio 4085-362 a indoor blower motor 14 12 10 6 2 13 3 1 16 pin plug for 15 w1 c heat unused g high voltage optional low voltage factory ladder diagram low volt age term . Block r...

  • Page 58

    Manual 2100-483e page 58 of 59 wg3s1-c, wg4s1-c, wg5s1-c 460/60/3 t2 nc c l2 l3 au x. L1 t1 t3 lpc cc hpc y alr c lpc minutes 4 2 3 5 r 1 460v 230v l3 yellow c o m pr esso r c o n tac to r 62 induced draft blower 47 crankcase heater 51 gas valve 20 32 52 37 35 35 40 40 35 35 32 32 32 32 32 32 34 32 ...

  • Page 59

    Manual 2100-483e page 59 of 59 wg3s1-c, wg4s1-c, wg5s1-c 460/60/3 if option not a wires connect used bard mfg. Co. Bryan, ohio 4085-364 a indoor blower motor 14 12 10 6 2 13 3 1 16 pin plug for 15 w1 c heat unused g high voltage optional low voltage factory ladder diagram low voltage term . Block r ...