Bard WG3S1-A WG3S1-B WG3S1-CWG4S1-A Installation Instructions Manual Download

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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 1914...Moving ahead just as planned.

WARNING

READ ALL INSTRUCTIONS CAREFULLY BEFORE
BEGINNING THE INSTALLATION.

THE INSTALLATION MUST COMPLY WITH THESE
INSTRUCTIONS AND THE REQUIREMENTS OF ALL
GOVERNING CODES AND ORDINANCES FOR THE
INSTALLATION LOCATION.

IT IS THE RESPONSIBILITY OF INSTALLER TO KNOW
AND UNDERSTAND ALL OF THESE REQUIREMENTS.

FAILURE TO DO SO COULD CREATE A HAZARD
RESULTING IN PROPERTY DAMAGE, BODILY INJURY,
OR DEATH.

INSTALLATION
INSTRUCTIONS

Summary of Contents for WG3S1-A WG3S1-B WG3S1-CWG4S1-A

Page 1: ...06 Since 1914 Moving ahead just as planned Copyright 2007 WARNING READ ALL INSTRUCTIONS CAREFULLY BEFORE BEGINNING THE INSTALLATION THE INSTALLATION MUST COMPLY WITH THESE INSTRUCTIONS AND THE REQUIRE...

Page 2: ...rifice Sizing 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 Control Module 32 33 26 Lighting Shutd...

Page 3: ...er Service Door 29 Figure 14 Lighting Shutdown Instruction Label 34 Figure 15 Top View of Gas Control 35 Figure 16 Sequence of Operation Electronic Blower Control 37 Figure 17 Furnace Control Board Bl...

Page 4: ...447 4044 COPYRIGHT DECEMBER 2007 BARD MANUFACTURING COMPANY INC BRYAN OHIO 43506 USA Manufactured under the following U S patent numbers 5 485 878 5 002 116 4 924 934 4 875 520 4 4825 936 These public...

Page 5: ...M F I E S G W t l o V 0 3 2 r o t a l i t n e V y r e v o c e R y g r e n E R 5 A V R E S G W t l o V 0 6 4 r o t a l i t n e V y r e v o c e R y g r e n E R 5 C V R E S G W MODEL Wall Mount Gas Elect...

Page 6: ...rly Starting Procedure and any tags and or labels attached to the equipment All duct work supply and return must be properly sized for the design airflow requirement of the equipment Air Conditioning...

Page 7: ...p m A d a o L d e t a R 3 3 1 4 1 1 2 8 5 6 3 3 4 7 1 0 5 1 1 1 1 4 9 5 4 1 3 2 8 9 1 0 5 1 4 3 1 7 6 t n e r r u C n o i t c e l e S t i u c r i C h c n a r B 7 6 1 2 1 1 5 4 2 1 2 5 3 1 5 6 7 5 2 6...

Page 8: ...HINGED DOOR COMBUSTION AIR EXHAUST COMBUSTION AIR INTAKE GAS ENTRANCES CONTROL LOW VOLTAGE CIRCUIT BREAKER VENT OPTION PANEL MIS 2328 HIGH VOLTAGE ENTRANCES UNIT A B C D E F G H I J K L M N O P WG3S1...

Page 9: ...nd in the absence of specific recommendations from the local authority having jurisdiction equipment ratings shall be reduced as specified in Section 21 5 TRANSPORTATION DAMAGE All units are packed se...

Page 10: ...unting bracket location 4 Mount bottom mounting bracket 5 Hook top rain flashing under back bend of top Top rain flashing is shipped secured to the right side of the back 6 Position unit in opening an...

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: ...tween 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 spacing is maintained at all points Fai...

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: ...scharged air from the condenser to recirculate to the condenser inlet TABLE 2 MINIMUM INSTALLATION CLEARANCES s l a i r e t a m e l b i t s u b m o c m o r f t c u D t e l t u O t e e f 3 t s r i f h...

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: ...mpers 4 Follow the lighting instructions Place the appliance being inspected in operation Adjust thermostat so appliance shall operate continuously 5 Test for draft hood equipped appliance spillage at...

Page 19: ...electrical ground could result in electric shock or fire 15 WIRING MAIN POWER Refer to unit rating plate for wire sizing information and maximum fuse or HACR type circuit breaker size Each outdoor uni...

Page 20: ...range for the 240V and 208V taps are 460 VOLT UNITS All models are equipped with single primary voltage transformers and no rewiring is required TABLE 3 THERMOSTAT WIRE SIZE r e m r o f s n a r T A V...

Page 21: ...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 8...

Page 22: ...OWER 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 JUMPER FOR 8403 058 OR OTHER THERMOSTAT THAT DOES NOT W1 E C R Terminal Part 8403 058 Thermostat Subbase Fa...

Page 23: ...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 Unit Control P...

Page 24: ...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 THAT DOES NOT Terminal A W1 E C R Part 8403 058 1 G Thermostat Subbase Thermostat WIRES FROM...

Page 25: ...Manual 2100 483E Page 25 of 59 FIGURE 11 GAS PIPE CONNECTION...

Page 26: ...0 0 0 0 5 0 5 0 0 0 6 5 0 0 0 5 1 1 0 0 0 5 1 2 0 0 0 0 4 4 0 6 0 0 0 0 5 0 0 0 5 0 1 0 0 0 5 9 1 0 0 0 0 0 4 0 7 0 0 0 6 4 0 0 0 6 9 0 0 0 0 8 1 0 0 0 0 7 3 0 8 0 0 0 3 4 0 0 0 0 9 0 0 0 0 7 1 0 0 0...

Page 27: ...kits may be purchased from your local distributor 5 Slowly open equipment shut off valve in gas supply line just ahead of furnace Start furnace following Operating Instructions on front door 6 Slowly...

Page 28: ...the furnace gas input PROPANE LP GAS INPUT RATE 1 Make sure you have proper main burner orifices 2 Gas supply pressure must be between 11 and 13 inches W C for propane LP gas 3 Start furnace followin...

Page 29: ...2 2 4 0 0 5 7 6 0 0 5 7 6 0 4 3 5 6 0 8 1 3 6 0 2 0 1 6 0 0 4 9 5 0 2 3 8 5 0 7 9 6 5 0 0 0 5 7 0 0 0 5 7 0 0 6 2 7 0 0 2 0 7 0 0 8 7 6 0 0 0 6 6 0 0 8 4 6 0 0 3 3 6 0 0 0 0 9 0 0 0 0 9 0 2 1 7 8 0 4...

Page 30: ...d e s a B t e e F 0 0 0 0 1 o t 1 0 0 8 h c t i w S e r u s s e r P s e r i u q e R e c i f i r O d n a e g n a h C e g n a h C t n e t n o C U T B n o d e s a B U T B 0 0 5 2 2 r e n r u B r e P 9 4...

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

Page 32: ...no power interruptions the compressor will operate on demand with no delay HIGH PRESSURE SWITCH AND LOCKOUT SEQUENCE Standard Feature If the high pressure switch opens the compressor contactor will d...

Page 33: ...tion 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 ambient control is available for b...

Page 34: ...Manual 2100 483E Page 34 of 59 26 LIGHTING AND SHUTDOWN INSTRUCTIONS FIGURE 14 INSTRUCTION LABEL...

Page 35: ...ht on small mirror or an extension handle Remove the screws securing the inducer and collector box Now inspect the upper tubes of the heat exchanger Check the exterior of the heat exchanger and the in...

Page 36: ...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 sur...

Page 37: ...he economizer will not operate or close and Step 1 of the compressor will operate If Stage 2 cooling call is issued the compressor will shift to Step 2 full cooling capacity operation FIGURE 16 SEQUEN...

Page 38: ...a t S d n 2 M F C g n i l o o C M F C g n i t a e H 6 5 U T B 0 0 0 0 5 t u p n I U T B 0 0 0 5 7 t u p n I U T B 0 0 0 0 0 1 t u p n I U T B 0 0 0 5 2 1 t u p n I 1 S 3 G W 5 1 0 0 5 0 0 0 8 0 0 8 0...

Page 39: ...c e l e s e h t r o f e t a r e p o l l i w r e w o l b r i a t r o f m o c e h t e t a r e p o o t e u n i t n o c l l i w r e w o l b r i a t r o f m o c e h t n o i t a r e p o S T I N U Y T E F A...

Page 40: ...band type heater located around the bottom of the compressor This heater is controlled by the auxiliary contacts on the side of the compressor contactor The heater is only energized when the compresso...

Page 41: ...his time there will be no negative impact on the durability of the compressor However reverse operation for over one hour may have a negative impact on the bearing due to oil pump out NOTE If compress...

Page 42: ...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 of the two female connect...

Page 43: ...f it s air noise cabinet duct or motor noise interview customer if necessary Air noise High static creating high blower speed Is airflow set properly Does removing filter cause blower to slow down Che...

Page 44: ...r to the manufacturer s authorized replacement list USING THE WRONG CONTROL WILL RESULT IN IMPROPER OR NO BLOWER OPERATION Orient the control module so that the 3 wire motor plug can be inserted into...

Page 45: ...3 1 4 1 1 1 4 3 4 1 8 3 4 5 4 1 5 6 4 6 4 1 2 9 4 8 4 1 9 1 5 B D 5 8 B W 2 7 E D I S W O L E D I S H G I H 7 3 1 6 1 2 9 3 1 7 3 2 0 4 1 8 5 2 1 4 1 9 7 2 2 4 1 0 0 3 3 4 1 1 2 3 6 4 1 6 4 3 8 4 1 0...

Page 46: ...screens can result in improper operation and malfunction of the burner system FIGURE 23 LOW NOX INSERT R 410A 34 REFRIGERANT CHARGE The correct system R 410A charge is shown on the unit rating plate...

Page 47: ...8 0 4 0 0 0 0 0 1 B 0 4 1 5 8 0 4 A 1 4 1 5 8 0 4 0 0 0 5 2 1 B 2 4 1 5 8 0 4 A 3 4 1 5 8 0 4 1 S 4 G W 0 0 0 0 5 3 0 6 0 3 2 8 0 2 B 0 4 2 5 8 0 4 A 1 4 2 5 8 0 4 0 0 0 5 7 B 2 4 2 5 8 0 4 A 3 4 2 5...

Page 48: ...TRANSFORMER 18 GROUND TERMINAL 25 POS TEMP COEFFICIENT RELAY CAPACITOR 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 IF ANY ORIGI...

Page 49: ...Diagram A Dual Can Motor H F C T1 L1 Line 1 Low Voltage Term Block Terminal Capacitor C NC Outdoor Fan Contactor Aux Compressor Compressor Contactor Terminal BLOWER MOTOR Block Start Kit 2 4 INDUCED D...

Page 50: ...P 11 CIRCUIT BREAKER 28 MOVE RED WIRE TO TRANSFORMER OPERATION RELAY 21 POS TEMP COEFFICIENT 208V TAP FOR 208V GROUND TERMINAL MODULE 5 4 2 1 3 C FAN H E R M 240V INDUCED DRAFT 18 208V IF ANY ORIGINAL...

Page 51: ...r Terminal A Dual Can Motor H F C T1 L1 Line 1 Low Voltage Term Block C Capacitor Outdoor Fan NC Compressor Contactor Aux Compressor Block Contactor Terminal BLOWER MOTOR 2 Start Kit INDUCED DRAFT 4 I...

Page 52: ...CONNECT TERM BLOCK GRAY LOW AMBIENT 32 CONTROL OPT A 32 A 61 CONTACTOR COMPRESSOR DRAFT BLOWER INDUCED 51 VALVE GAS 20 32 52 37 35 35 40 40 35 35 32 32 32 32 32 32 34 32 32 62 28 28 28 37 28 27 27 42...

Page 53: ...Y1 2 R FURNACE CONTROL BOARD K3 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...

Page 54: ...OPTION NOT USED 62 High Voltage 47 Factory A WIRES CONNECT 31 Field 30 CONTACTOR COMPRESSOR DRAFT BLOWER INDUCED 51 VALVE GAS 20 32 52 37 35 35 40 40 35 35 32 32 32 32 32 32 34 32 32 62 28 28 28 37 2...

Page 55: ...NACE CONTROL BOARD K3 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...

Page 56: ...TAGE LOW DISCONNECT 28 TRANSFORMER PHASE MONITOR 21 GROUND TERMINAL INDUCED DRAFT CONTROL 18 0V IF ANY ORIGINAL WIRE AS SUPPLIED WITH THE APPLIANCE MUST BE 50 WIRES CONNECT IF OPTION NOT USED PINK PIN...

Page 57: ...K3 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 SEC ROLLOU...

Page 58: ...PHASE MONITOR CAPACITOR 19 LOW PRESSURE SWITCH INDUCED DRAFT BLOWER RELAY CONTROL V COM R 23 C MODULE IF ANY ORIGINAL WIRE AS SUPPLIED WITH THE APPLIANCE MUST BE 50 WIRES CONNECT IF OPTION NOT USED PI...

Page 59: ...K3 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 SEC ROLLOU...

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