Bard WG Series, Installation Instructions Manual

Page 1: ...WG5S2 B WG3S2 C WG4S2 C WG5S2 C WARNING READ ALL INSTRUCTIONS CAREFULLY BEFORE BEGINNING THE INSTALLATION THE INSTALLATION MUST COMPLY WITH THESE INSTRUCTIONS AND THE REQUIREMENTS OF ALL GOVERNING CO...

Page 2: ...g Gas Input Rate 27 21 Standard Orifice Sizing and High Altitude Derate 29 22 Conversion of Gas Input BTUH from High to Low Rating 31 23 Measuring Air Temperature Rise 31 24 Filters 32 25 Compressor C...

Page 3: ...igure 13 Access Internal Filter 32 Figure 14 8201 164 Compressor Control Module 33 Figure 15 Lighting and Shutdown Instruction Label 35 Figure 16 Top View of Gas Control 36 Figure 17 Sequence of Opera...

Page 4: ...exdale Boulevard Rexdale Ontario Canada M9W 1R3 Telephone 416 447 4044 BARD MANUFACTURING COMPANY INC BRYAN OHIO 43506 USA These publications can help when installing the furnace They can usually be f...

Page 5: ...overy Ventilator 460 Volt R WGSERV C5A WG 4 S 2 A X C X X X X X X MODEL Wall Mount Gas Electric CONTROL OPTIONS See Table page 6 VENT See Table Below COOLING CAPACITY 3 3 ton 4 4 ton 5 5 ton OUTLET X...

Page 6: ...control is auto reset Always used with compressor control module CCM which is included See note LAC Low ambient control permits cooling operation down to 0 F CAUTION During the initial firing of the...

Page 7: ...08 460 Rated Load Amps 11 6 12 9 8 8 9 9 6 7 15 0 17 8 10 4 11 8 5 4 20 9 23 0 12 8 14 1 6 2 Branch Circuit Selection Current 15 3 11 7 5 8 21 2 14 1 6 5 27 2 16 5 7 2 Lock Rotor Amps 83 73 38 104 83...

Page 8: ...INTAKE COMBUSTION ENTRANCES VESTIBULE DOOR AIR INLETS CONTROL ENTRANCES CONDENSER 4 DEG PITCH IN TOP AIR OUTLET HIGH VOLTAGE ENTRANCES FRONT DOOR MIS 3240 A UNIT A B C D E F G H I J K L M N O P Q R W...

Page 9: ...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 duc...

Page 10: ...carry the weight of the unit without transmitting any unit vibration 3 Concrete block walls must be thoroughly inspected to insure that they are capable of carrying the weight of the installed unit 2...

Page 11: ...Manual 2100 587J Page 11 of 59 FIGURE 2A Mounting Instructions for WG3S2...

Page 12: ...Manual 2100 587J Page 12 of 59 FIGURE 2B Mounting Instructions for WG4S2 and WG5S2...

Page 13: ...ned between the supply air duct and combustible materials This is required for the first 3 of ducting It is important to insure that the 1 minimum spacing is maintained at all points Failure to do thi...

Page 14: ...Manual 2100 587J Page 14 of 59 FIGURE 4 Wall Mounting Instructions FIGURE 5 Wall Mounting Instructions...

Page 15: ...Manual 2100 587J Page 15 of 59 FIGURE 6 Common Wall Mounting Installations...

Page 16: ...round the condenser inlet and discharge openings DO NOT install the unit in a location that will permit discharged air from the condenser to recirculate to the condenser inlet TABLE 2 Minimum Installa...

Page 17: ...ncludes a stainless steel transition drain tee silicone sealant and drain tubing If unit is installed with vertical vent kit annually inspect the vent system and drain Replace any portion of the vent...

Page 18: ...iency and cost of operation information as required for Department of Energy Energyguide Fact Sheets is based upon the fresh air blank off plate in place and is recommended for maximum energy efficien...

Page 19: ...6 C when installed in accordance with the manufacturer s instructions Installation of Flexible Conduit Through Return Air Opening NOTE To allow proper clearance between the control panel and any vent...

Page 20: ...rs and no rewiring is required Direct Digital Controls DDC For total and proper control using DDC a total of five controlled outputs are required four if no ventilation is installed TABLE 3 Thermostat...

Page 21: ...W1 E A Y2 D YO Y1 L 17 3 Low Voltage Wiring No Ventilation Package 1 G Y Unit Control Panel 2 6 Block R C W1 A W2 E Y2 Y1 2 3 R C W Y2 RC W2 Y Part 8403 082 8 G Thermostat Subbase Factory Installed Ju...

Page 22: ...R C W Y2 RC W2 INSTALL IF YOU REQUIRE VENTILATION ANYTIME BLOWER IS ON 17 Y CONTROL F 3 6 Factory Installed Jumper Unit Control Panel G 1 Thermostat Part 8403 060 1 Unit 24V Thermostat Subbase Termin...

Page 23: ...be energized to enable minimum position NOTE Economizer Control Default Setting G R 1 Y 2 Y2 Y1 A O B is 10V 100 Depending upon application may require setting to lower value If using this 24V TERMINA...

Page 24: ...M Factory Installed Jumper W2 or T6 Pro Part 8403 060 O B G Thermostat Part 8403 058 Thermostat Thermostat Subbase ORANGE RED BROWN WHITE BLUE PLUG 3 1 Part 8403 082 Thermostat WIRES 4 CONTROL 1 WGSER...

Page 25: ...Manual 2100 587J Page 25 of 59 FIGURE 11 Gas Pipe Connection...

Page 26: ...ing each pipe connection and watching for bubbles If a leak is found make the necessary repairs immediately and repeat the above test The furnace must be isolated from the gas supply piping system by...

Page 27: ...8 Adjust manifold pressure by turning gas control regulator adjusting screw clockwise to increase pressure or turning counterclockwise to decrease pressure Manifold pressure must be within allowable...

Page 28: ...on this is the furnace gas input 9 If water heater dryer or range pilots were left on allow for them in calculating correct furnace gas input A quick way is to allow 1 000 BTU per hour for a water he...

Page 29: ...000 above sea level A high altitude pressure switch must also be installed for operation above 6 000 High altitude pressure switch kit number 8620 189 is designed for this application It is the insta...

Page 30: ...e and Orifice Change Based on BTU Content 8 001 to 10 000 Requires Pressure Switch Change and Orifice Change Based on BTU Content 22500 BTU Per Burner 700 749 2 75 2 70 2 60 750 799 2 70 2 60 2 50 800...

Page 31: ...rom furnace Locate thermometer tip in center of plenum to ensure proper temperature measurement 6 Place second thermometer in return air duct approximately 2 from furnace Locate thermometer tip in cen...

Page 32: ...me adjust the delay on break timer on each unit to a slightly different delay time Short Cycle Protection Delay on Break An anti short cycle timer is included to prevent short cycling the compressor T...

Page 33: ...e compressor a time period to start even if the voltage has dropped and allows the voltage to recover This delay only happens when the CC terminal energizes The delay can be set to 500 milliseconds A...

Page 34: ...is inhibited If a fault condition occurs reverse two of the supply leads to the unit Do not reverse any of the unit factory wires as damage may occur Optional Low Ambient Control An optional low ambie...

Page 35: ...llow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life 1 Set the thermostat to lowest setting 2 Turn off all electric power to the appli...

Page 36: ...the upper tubes of the heat exchanger Check the exterior of the heat exchanger and the interior flue gas passages for any evidence of deterioration due to corrosion cracking or other causes If signs...

Page 37: ...e sure the supply and return air flange sleeves or duct work are securely fastened to unit and physically sound d Supply and return grilles must be open and free from obstructions e Inspect to make su...

Page 38: ...2 full capacity 100 of compressor capacity With Economizer Stage 1 Y1 cooling call goes to economizer controls for decision If enthalpy control decides outdoor conditions are suitable for free cooling...

Page 39: ...trol Motor will deliver consistent CFM through voltage supply range with no deterioration 197 253V for 230 208V models 414 506V for 460V models Continuous CFM is the total air being circulated during...

Page 40: ...uation the inducer will operate for the 30 second post purge and the comfort air blower will operate for the selected off delay If on Manual Fan operation the comfort air blower will continue to opera...

Page 41: ...ion 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...

Page 42: ...res 18 to 28 volts AC The measured DC voltage at the female connectors in the plug should be around 15 to 27 VDC Resistance Check Measure the resistance from the end of one molded plug lead to either...

Page 43: ...s air noise cabinet duct or motor noise interview customer if necessary Symptom Cause Procedure Air noise High static creating high blower speed Is airflow set properly Does removing filter cause blo...

Page 44: ...o not proceed to install the control module The motor is defective and must be replaced Installing the new control module will cause it to fail also 7 Verify that the replacement control is correct fo...

Page 45: ...52 326 153 349 153 372 154 396 156 422 158 449 160 478 162 508 WG5S2 75 DB 62 DB Low Side High Side 118 199 119 217 120 236 122 260 123 285 125 309 126 333 128 357 129 381 130 405 132 432 133 460 135...

Page 46: ...perly before firing Failure to remove the NOx screens can result in improper operation and malfunction of the burner system FIGURE 23 Low NOx Insert 35 R 410A REFRIGERANT CHARGE This unit was charged...

Page 47: ...00 208 230 60 1 4085 154A 4085 155 75 000 4085 156A 4085 157 100 000 4085 154A 4085 155 125 000 4085 156A 4085 157 50 000 208 230 60 3 4085 254A 4085 269 75 000 4085 255A 4085 270 100 000 4085 254A 40...

Page 48: ...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 41 47 28 28 28 FLAME LIMIT SPARK IGNITOR ROLLO...

Page 49: ...or Dual Can Motor H F C T1 L1 Line 1 Low Voltage Term Block C NC Outdoor Fan Contactor Aux Compressor Contactor Compressor Block Terminal BLOWER MOTOR 2 4 INDUCED DRAFT BLOWER RELAY INDUCED DRAFT CONT...

Page 50: ...OR 19 LOW PRESSURE SWITCH INDUCED DRAFT BLOWER RELAY MODULE 5 4 2 1 3 C FAN H E R M 240V 208V COM R CONTROL 23 HEATER C HIGH PRESSURE SWITCH NOT USED CC HPC Y ALR IF ANY ORIGINAL WIRE AS SUPPLIED WITH...

Page 51: ...otor H F C T1 L1 Line 1 Low Voltage Term Block C NC Outdoor Fan Contactor Aux Compressor Contactor Compressor Block Terminal BLOWER MOTOR 2 4 INDUCED DRAFT BLOWER RELAY INDUCED DRAFT CONTROL OPT R CON...

Page 52: ...RAFT BLOWER SWITCH COMPRESSOR CONTACTOR 51 GAS VALVE 20 32 52 37 35 35 40 40 35 35 32 HIGH A 32 32 32 32 34 32 32 62 28 28 28 37 28 27 27 42 44 41 38 36 47 41 33 28 28 28 FLAME LIMIT SPARK IGNITOR ROL...

Page 53: ...URNACE CONTROL BOARD K4 K4 K3 COOL PRIM L1 HIGH PRESSURE 208 24VAC 240 COM Transformer Use for 208V Operation BOARD CONTROL FURNACE VALVE GAS 1 SWITCH PRESSURE K1 K1 K4 K1 K2 K3 12 11 3 Y 6 8 10 7 9 4...

Page 54: ...35 35 40 40 35 35 32 47 T2 32 32 32 32 34 32 32 62 28 28 28 37 28 27 27 42 44 41 38 36 47 41 33 28 28 28 FLAME LIMIT 32 38 PRIMARY FLAME SENSOR 39 PRESSURE SWITCH 32 32 28 35 38 51 51 51 46 46 46 T3...

Page 55: ...ROL BOARD K4 K2 K4 Aux COOL D1 L1 HIGH PRESSURE 208 24VAC 240 COM Transformer 9 Use for 208V Operation CONTROL FURNACE VALVE GAS 1 SWITCH PRESSURE K1 K1 K4 K1 K2 K3 12 11 3 6 8 10 7 ROLLOUT 5 4 2 K3 L...

Page 56: ...IE BLACK WHTIE SOLENOID BLACK WHITE BLACK 27 USE COPPER CONDUCTORS SUITABLE FOR AT LEAST 75 C TERM BLOCK GRAY IF ANY ORIGINAL WIRE AS SUPPLIED WITH THE APPLIANCE MUST BE REPLACED IT MUST BE REPLACED W...

Page 57: ...3 K4 K4 K2 COOL D1 L1 HIGH PRESSURE 208 24VAC 240 COM Transformer Use for 208V Operation BOARD CONTROL FURNACE VALVE GAS 1 SWITCH PRESSURE K1 K1 K4 K1 K2 K3 12 11 3 6 8 10 7 9 5 4 2 LIMIT ROLLOUT FLAM...

Page 58: ...IE SOLENOID BLACK WHITE BLACK BLACK 27 USE COPPER CONDUCTORS SUITABLE FOR AT LEAST 75 C TERM BLOCK GRAY IF ANY ORIGINAL WIRE AS SUPPLIED WITH THE APPLIANCE MUST BE REPLACED IT MUST BE REPLACED WITH WI...

Page 59: ...RD K3 K4 K4 K2 COOL D1 LOW PRESSURE HIGH PRESSURE 208 24VAC 240 COM Transformer Use for 208V Operation 6 BOARD L1 VALVE GAS 1 SWITCH PRESSURE K1 K1 K4 K1 K2 K3 12 11 CONTROL 3 8 10 7 9 5 4 2 W2 ROLLOU...