2100-592(B) (2013 09) - Bard HVACB).… · New York, NY 10036 Telephone: (212) 642-4900 Fax: (212) 302-1286 ASHRAE American Society of Heating Refrigerating, and Air Conditioning

Manual 2100-592BPage 1 of 69

Manual No.: 2100-592BSupersedes: 2100-592AFile: Volume III, Tab 20Date: 09-20-13

Bard Manufacturing Company, Inc.Bryan, Ohio 43506

Since 1914...Moving ahead just as planned.

WARNINGREAD ALL INSTRUCTIONS CAREFULLY BEFOREBEGINNING THE INSTALLATION.

THE INSTALLATION MUST COMPLY WITH THESEINSTRUCTIONS AND THE REQUIREMENTS OF ALLGOVERNING CODES AND ORDINANCES FOR THEINSTALLATION LOCATION.

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

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

WG - SERIESCOMBINATION GAS/ELECTRIC

WALL-MOUNTwith DEHUMIDIFICATION

MODELS:W24G2DA W30G2DA W36G2DA W42G2DA W48G2DA W60G2DAW24G2DB W30G2DB W36G2DB W42G2DB W48G2DB W60G2DBW24G2DC W30G2DC W36G2DC W42G2DC W48G2DC W60G2DC

INSTALLATIONINSTRUCTIONS


CONTENTS

Getting Other Information and Publications .............. 4W**G Series Model Nomenclature ............................ 5Ventilation Options .................................................... 5Air Conditioning Module Options ............................... 61. Important ............................................................ 62. Application .......................................................... 63. Duct Work .................................................. 6 & 104. High Altitude Applications ................................. 105. Transportation Damage .................................... 106. Installation ........................................................ 107. Wall Mounting .................................................. 118. Mounting the Unit ............................................. 119. Clearances ....................................................... 17

10. Vent Terminal and Combustion Inlet Hood ....... 1811. Optional Vertical Venting .................................. 1812. Vent Resizing Instructions ................................ 1913. Fresh Air Intake ................................................ 1914. Condensate Drain ............................................ 1915. Wiring – Main Power ........................................ 2016. Wiring – Low Voltage Wiring ............................ 2117. Thermostats ...................................................... 2218. Gas Supply & Piping ........................................ 2719. Manifold Pressure Adjustment .......................... 28

20. Checking Gas Input Rate ......................... 28 & 2921. Standard Orifice Sizing & High

Altitude Derate .................................................. 3022. Conversion of Gas Input BTUH From High

to Low Rating ................................................... 3323. Measuring Air Temperature Rise ...................... 3324. Filters ................................................................ 3425. Compressor Control Module ..................... 34 & 3526. Lighting & Shutdown Instructions ..................... 3627. Service Agency Procedures ............................. 3728. Maintaining Unit - Good Working Order .... 37 & 3829. Replacement Parts ............................................ 3830. Sequence of Operation – Heating .................... 3931. Sequence of Operation – Cooling .................... 3932. Indoor Blower Operation .................................. 4133. W**G Dehumidification Relay Logic Board ...... 4934. Pressure Service Ports ..................................... 5035. Dehumidification Circuit .................................... 5036. Refrigerant Charge ........................................... 5137. Fan Blade Setting Dimensions ......................... 5238. Low NOx Burner Assembly "N" Suffix

Models Only – U.S. Installations Only .............. 52Index – Wiring Diagrams ......................................... 53Wiring Diagrams ............................................. 54 – 69

Page Page


CONTENTS

FIGURESFigure 1 Unit Dimensions ..................................... 9Figure 2 Mounting Instructions – W24G-36G ..... 12Figure 2A Mounting Instructions – W42G-60G ..... 13Figure 3 Combustible Clearance – W24G-36G.. 14Figure 3A Combustible Clearance – W42G-60G.. 14Figure 4 Wall Mounting Instructions ................... 15Figure 5 Wall Mounting Instructions ................... 15Figure 6 Common Wall Mounting Installations ... 16Figure 7 Location of Vent Terminal in Shipping .. 17Figure 8 Vent Terminal & Combustion

Air Intake .............................................. 18Figure 9 Fresh Air Damper ................................. 19Figure 10 Installation of Flexible Conduit ............. 21Figure 11A T-Stat Connection using Comb. ........... 23Figure 11B T-Stat using Temp. & Humidity Ctrl. ...... 24Figure 11C MFAD, Classroom Vent. Spring & Power .

& ERV Low Voltage Connections ......... 25Figure 11D Economizer Low Volt. Connections ...... 25Figure 12 Gas Pipe Connection ........................... 26Figure 13 Proper Piping Practice ......................... 27Figure 14 Access Internal Filter through

Upper Service Door .............................. 34Figure 15 Lighting & Shutdown Label .................. 36Figure 16 Top View of Gas Control ...................... 37Figure 17 Sequence of Operation – Electronic

Blower Control ...................................... 40Figure 18 Furnace Control Board &

Blower Control ...................................... 41Figure 19 Circuit Diagrams ................................... 50Figure 20 Fan Blade ............................................. 52Figure 21 Low NOx Insert .................................... 52

TABLESTable 1 Specifications – W24G-36G Models ........ 7Table 1A Specifications – W42G-60G Models ........ 8Table 2 Minimum Installation Clearances ........... 17Table 3 Thermostat Wire Size ............................ 22Table 4A Wall Thermostat ..................................... 22Table 4B Humidistat .............................................. 22Table 5 Length of Standard Pipe Threads .......... 27Table 6 Gas Pipe Sizes – Natural Gas ............... 27Table 7 Natural Gas Derate Capacities

For All Models ........................................ 30Table 8 Natural Gas Orifice Tables – W24G-36G . 31Table 8A Natural Gas Orifice Tables – W42G-60G . 32Table 9 Motor Speed Taps .................................. 41Table 10 W24G Indoor Blower Performance ........ 42Table 11 W30G Indoor Blower Performance ........ 43Table 12 W36G Indoor Blower Performance ........ 44Table 13 W42G Indoor Blower Performance ........ 45Table 14 W48G Indoor Blower Performance ........ 46Table 15 W60G Indoor Blower Performance ........ 47Table 16 Integrated Furnace & Blower

Control Operation ................................... 48Table Dehum. Relay Logic Board Table ........... 49Table 17 Refrigerant Charge-Pressure Tables ...... 51Table 18 Fan Blade Dimension ............................. 52

Page Page


Getting Other Information and Publications

FOR MORE INFORMATION, CONTACTTHESE PUBLISHERS:

ACCA Air Conditioning Contractors of America1712 New Hampshire Avenue, NWWashington, DC 20009Telephone: (202) 483-9370

ANSI American National Standards Institute11 West Street, 13th FloorNew York, NY 10036Telephone: (212) 642-4900Fax: (212) 302-1286

ASHRAE American Society of Heating Refrigerating,and Air Conditioning Engineers, Inc.1791 Tullie Circle, NE.Atlanta, GA 30329-2305Telephone: (404) 636-8400Fax: (404) 321-5478

NFPA National Fire Protection AssociationBatterymarch ParkP.O. Box 9101Quincy, MA 02269-9901Telephone: (800) 344-3555Fax: (617) 984-7057

CSA Canadian Standards Association178 Rexdale BoulevardRexdale, OntarioCanada. M9W 1R3Telephone: (416) 447-4044

BARD MANUFACTURING COMPANY, INC.BRYAN, OHIO 43506 USA

These publications can help you install the furnace. Youcan usually find these at your local library or purchasethem directly from the publisher. Be sure to consultcurrent edition of each standard.

National Fuel Gas Code ......... ANSI Z223.1 / NFPA 54

National Electrical Code ..................... ANSI / NFPA 70

Standard for the Installation ............. ANSI / NFPA 90Aof Air Conditioning and Ventilating Systems

Standard for Warm Air ..................... ANSI / NFPA 90BHeating and Air Conditioning Systems

Standard for Chimneys, ................................. NFPA 211Fireplaces, Vents, and Solid Fuel Burning Appliances

Load Calculation for ............................ ACCA Manual JResidential Winter and Summer Air Conditioning

Duct Design for Residential ............... ACCA Manual DWinter and Winter Air Conditioning and EquipmentSelection

Canadian Electrical Code ............................. CSA C22.1

Canadian Installation Code……………CAN/CGA B149


W 42 G 2 D A X C X X X X X X

WALL MOUNT GAS/ELECTRIC GENERALMODEL NUMBER NOMENCLATURE

1 Low ambient control is required with economizer for low temperature compressor operation.

VENTILATION OPTIONS

sledoM G63W,G03W,G42W G06W,G84W,G24W

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nruteRgnirpS-rotalitneVlaicremmoC V A3-SVRCGW A5-SVRCGW

nruteRrewoP-rotalitneVlaicremmoC P A3-PVRCGW A5-PVRCGW

gnitaludoMylluF-rezimonocE 1 E C3-MFIEGW C5-MFIEGW

tloV032-rotalitneVyrevoceRygrenE R B3A-VREGW B5A-VREGW

tloV064-rotalitneVyrevoceRygrenE R B3C-VREGW B5C-VREGW

MODELWall Mount

CONTROL OPTIONS(See Table page 6)

FEATURED = Dehumidification

VOLTAGEA = 230/208-60-1B = 230/208-60-3C = 460-60-3

VENT(See Table Below)

COOLING CAPACITY24 = 2 ton30 = 2½ ton36 = 3 ton42 = 3½ ton48 = 4 ton60 = 5 ton

REVISION

EMISSIONSX = StandardN = NOx Certified FILTER

X = 2" Pleated MERV 8 (Standard)W = 1" Washable

COLORX = Beige(Standard)4 = Buckeye Gray8 = Dark Bronze

OUTLETX = Front (Standard)T = Top

COIL OPTIONSX = Standard1 = Phenolic coated evaporator2 = Phenolic coated condenser3 = Phenolic coated both coils

*125,000 BTU input model is not NOx certified.

HEATING INPUT 2 - 3 Ton 3½ - 5 TonA = 45,000 B= 75,000B = 67,500 C= 100,000C = 90,000 D= 125,000*

GAS/ELECTRIC


AIR CONDITIONING MODULE OPTIONS

STD = Standard equipment.1 CCM Compressor control module has adjustable 30 second to 5 minute delay-on-break timer. On initial

power up, or any time the power is interrupted, the delay-on-make will be 2 minutes plus 10% of thedelay-on-break setting. There is no delay-on-make during routine operation of the unit. The modulealso provides the lockout feature (with 1 retry) for high and/or low pressure controls, and a 2 minutetimed bypass for low pressure control.

2 HPC High pressure control is auto reset. Always used with compressor control module (CCM) which isincluded. See note 1.

3 LPC Low pressure control is auto reset. Always used with compressor control module (CCM) which isincluded. See note 1.

4 LAC Low ambient control permits cooling operation down to 0°F.

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4

CAL

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DTS DTS DTS X A/N

DTS DTS DTS � H 82-AMC

1. IMPORTANTThe equipment covered in this manual is to be installedby trained, experienced service and installationtechnicians. All duct work or portions thereof not inthe conditioned space should be properly insulated inorder to both conserve energy and prevent condensationor moisture damage.

2. APPLICATIONThis is a fan-assisted forced air gas furnace withelectric air conditioning for outdoor installation. A fan-assisted furnace is equipped with an integralmechanical means to draw products of combustionthrough the combustion chamber and heat exchanger.The furnace installation must conform with localbuilding codes and ordinances or, in their absence, withthe National Fuel Gas Code ANSI Z223.1 or CAN/CGA-B149.1, latest edition, and the National ElectricalCode ANSI/NFPA-7 or CSA C22.1, latest edition. It isthe personal responsibility and obligation of thepurchaser to contact a qualified installer to assure thatinstallation is adequate and is in conformance withgoverning codes and ordinances.

3. DUCT WORKThe unit is designed for use with or without duct work.See Warning on Page 10. Flanges are provided forattaching the supply and return ducts. Theseinstructions explain the recommended method to installthe air cooled self-contained electric air conditioningand gas heating unit and the electrical wiringconnections and gas piping to the unit. The refrigerantsystem is completely assembled and charged. Allinternal wiring is complete.

These instructions and any instructions packaged withany separate equipment required to make up the entireheating/cooling system should be carefully read beforebeginning the installation. Note particularly “StartingProcedure” and any tags and/or labels attached to theequipment.

All duct work, supply and return, must be properly sizedfor the design airflow requirement of the equipment.Air Conditioning Contractors of America (ACCA) is anexcellent guide to proper sizing.

Refer to Tables later in this Manual for maximum staticpressure available for duct design.

CAUTIONDuring the initial firing of the burners there will probably be some amount of smoke issued to thecirculating air stream as the result of residual oil burning off of the heat exchanger tubes. This oilis required during the forming process of the stainless steel heat exchanger tubes to facilitate thebending. OSHA or the National Toxicology Program does not list the oil as a carcinogen. Invapor form this may be irritating to the eyes or could cause headaches. This is a one timeoccurrence, and ventilation of the space may be required depending upon the space beingconditioned.


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4


See Figure 3 and clearance information in Section 9and Table 2 for additional information.

Design the duct work according to methods given bythe Air Conditioning Contractors of America (ACCA).When duct runs through unheated spaces, it should beinsulated with a minimum of one-inch of insulation.Use insulation with a vapor barrier on the outside ofthe insulation. Flexible joints should be used toconnect the duct work to the equipment in order tokeep the noise transmission to a minimum.

A one-inch clearance to combustible material for thefirst three feet of duct attached to the outlet air frame isrequired. See Wall Mounting Instructions and Figures2, 2A, 3 and 3A for further details.

Ducts through the walls must be insulated and all jointstaped or sealed to prevent air or moisture entering thewall cavity.

Some installations may not require any return air duct.A metallic return air grille is required with installationsnot requiring a return air duct. The spacing betweenlouvers on the grille shall not be larger than 5/8 inch.

Any grille that meets with the 5/8 inch louver criteriamay be used. It is recommended that Bard Return AirGrille or Return Filter Grille be installed when noreturn duct is used. Contact distributor or factory forordering information. If using a return air filter grille,filters must be of sufficient size to allow a maximumvelocity of 400 fpm.

NOTE: If no return air duct is used, applicableinstallation codes may limit this cabinet toinstallation only in a single story structure.

4. HIGH ALTITUDE APPLICATIONSRatings of gas utilization equipment are based on sealevel operation and need not be changed for operationat elevations up to 6,000 feet. For operation atelevations above 6,000 feet and in the absence ofspecific recommendations from the local authorityhaving jurisdiction, equipment ratings shall be reducedas specified in Section 21.

5. TRANSPORTATION DAMAGEAll units are packed securely in shipping container.All units should be carefully inspected upon arrival fordamage. In the event of damage, the consignee should:

1. Note on delivery receipt of any damage to container.

2. Notify carrier promptly, and request an inspection.

3. In case of concealed damage, the carrier must benotified as soon as possible within 15 days afterdelivery.

4. Claims for any damage, apparent or concealed,should be filed with the carrier, using the followingsupporting documents:

A. Original Bill of Lading, certified copy, orindemnity bond.

B. Original paid freight bill of indemnity in lieuthereof.

C. Original invoice or certified copy thereofshowing trade and other discounts ordeductions.

D. Copy of the inspection report issued bycarrier’s representative at the time damage isreported to carrier.

6. INSTALLATIONSize of unit for proposed installation should be basedon heat loss/heat gain calculations made according tomethods of Air Conditioning Contractors of America(ACCA). The air duct should be installed inaccordance with the Standards of the National FireProtection Association for the Installation of AirConditioning and Ventilating Systems of Other ThanResidence Type, NFPA No. 90A, and Residence TypeWarm Air Heating and Air Conditioning Systems,NFPA No. 90B. Where local regulations are at avariance with instructions, installer should adhere tolocal codes.

WARNING In all cases, there must be a metal ductconnection made to the supply air flange, anda one inch clearance to combustibles must bemaintained to this duct connection. For free blow applications, a metal sleevemust be used in the wall opening itself, againmaintaining a one inch clearance tocombustibles. Failure to use the sheet metal can causefire resulting in property damage, injury, ordeath.


7. WALL MOUNTING INFORMATION1. Two holes for the supply and return air

openings must be cut through the wall asdetailed in Figure 4.

2. On wood-frame walls, the wall constructionmust be strong and rigid enough to carry theweight of the unit without transmitting any unitvibration.

3. Concrete block walls must be thoroughlyinspected to insure that they are capable ofcarrying the weight of the installed unit.

8. MOUNTING THE UNIT1. These units are secured by wall mounting

brackets which secure the unit to the outsidewall surface at both sides. A bottom mountingbracket is provided for ease of installation butis not required.

2. The W42G, W48G and W60G models aresuitable for 0 inch clearance on the installationmounting wall and to the top. For all models thesupply air duct flange and the first 3 feet ofsupply air duct require a minimum of 1-inchclearance to combustible material. The W24G,W30G and W36G models are suitable for 0 inchclearance on the installation mounting wall, butrequire 1-inch clearance to the top if combustiblematerial overhang projects above the unit. SeeFigure 3 and 3A. If a combustible wall, use aminimum of Figure 1 “A” dimension plus 2inches and “B” dimension plus 2 inches. SeeFigures 4 and 5 for details.

3. Locate and mark lag bolt locations and bottommounting 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 rightside of the back.

6. Position unit in opening and secure with 5/16lag bolts; use 7/8 inch diameter flat washers onthe lag bolts. Use lag bolts long enough tosupport the unit’s weight when mounted to thestructure. This length may be dependant on thetype of construction.

7. Secure rain flashing to wall and caulk acrossentire length of top. See Figures 2 & 2A.

8. On side-by-side installations, maintain aminimum of 20 inches clearance on right sideto allow access to control panel and burnercompartment, and to allow proper airflow to theoutdoor coil. Additional clearance may berequired to meet local or national codes.

WARNINGFailure to provide the one inch clearancebetween the supply duct and a combustiblesurface for the first three feet of duct canresult in fire causing damage, injury or death.

CAUTIONIf the bottom bracket is used, be certain thebracket is secured to the outside wall surfacein a way sufficient to support the entire weightof the unit during installation until sidemounting brackets are secured.


FIG

UR

E 2

MO

UN

TIN

G IN

STR

UC

TIO

NS

FOR

W24

G, W

30G

AN

D W

36G

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 1

5/16

"

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 1

5/16

"

4 9/

16"

SU

PP

LYA

IR D

UC

T

RE

TU

RN

AIR

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CT

Ø2

3/4"

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(OP

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FIG

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E 2

AM

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NG

INS

TRU

CTI

ON

SFO

R W

42G

, W48

G A

ND

W60

G


FIGURE 3COMBUSTIBLE CLEARANCE

FOR W24G, W30G AND W36G MODELS

FIGURE 3ACOMBUSTIBLE CLEARANCE

FOR W42G, W48G AND W60G MODELS

WARNINGA minimum of one (1) inch clearance must be maintained between the supply air duct andcombustible 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.

Failure to do this could result in overheating the combustible material and may result in a firecausing damage, injury or death.


FIGURE 4WALL MOUNTING INSTRUCTIONS

FIGURE 5WALL MOUNTING INSTRUCTIONS


FIGURE 6COMMON WALL MOUNTING INSTALLATIONS


9. CLEARANCESMinimum clearances, as specified in Table 2, must bemaintained from adjacent structures to provideadequate fire protection, adequate combustion air, androom for service personnel.

While minimum clearances are acceptable for safetyreasons, they may not allow adequate air circulationaround the unit for proper operation in the coolingmode. Whenever possible, it is desirable to allowadditional clearance, especially around the condenserinlet and discharge openings. DO NOT install the unitin a location that will permit discharged air from thecondenser to recirculate to the condenser inlet.

TABLE 2MINIMUM INSTALLATION CLEARANCES

)slairetamelbitsubmocmorf(tcuDteltuO teef3tsrifhcni1

)slairetamelbitsubmocmorf(lanimreTtneV * sehcni71

telnIresnednoC sehcni02

poT 3erugiFeeS

ecivreSrenruB sehcni02

B,AssalCrodooW(esaBelbitsubmoC)lairetamgnirevocfoorCro

sehcni0

* A3dna3serugiFeeS

FIGURE 7LOCATION OF VENT TERMINAL IN SHIPPING

WARNINGClearances from combustible materials mustbe maintained as specified. Failure tomaintain clearances could cause fire resultingin property damage, injury, or death.


10. VENT TERMINAL AND COMBUSTIONAIR INLET HOOD

The vent terminal is shipped in the burner compartment.See Figure 7. Remove the two shipping screws andseparate the two-piece assembly. Install the ventterminal by using the four screws provided. Make suregasket is in place. See Figure 8. The combustion airintake hood is factory installed.

11. OPTIONAL VERTICAL VENTINGWith the optional vertical venting kit (VVK-5) this unitmay be vented vertically through a roof or overhang.The kit includes a stainless steel transition drain tee,silicone sealant, and drain tubing.

If unit is installed with vertical vent kit, annuallyinspect the vent system and drain. Replace any portionof the vent system that shows signs of deterioration.Make sure drain is open and free of obstruction.

FIGURE 8VENT TERMINAL AND COMBUSTION AIR INTAKE

CAUTIONVent terminal must be installed as shown in Figure 8 for proper operation of the heating system.

NOTE: The inner vent hood gasket is designed to stretch over and seal around the combustionair blower outlet. This is a very critical seal to prevent water and flue products from entering theunit. Care must be taken to ensure this gasket is in place and sealing properly.


12. VENT RESIZING INSTRUCTIONSWhen an existing furnace is removed from a ventingsystem servicing other appliances, the venting system islikely to be too large to properly vent the remainingattached appliances.

The following steps shall be followed with each of theappliances remaining connected to the common ventingsystem, placed in operation one at a time while theother appliances remaining connected to the commonventing system are not in operation.

1. Seal any unused openings in the venting system.

2. Inspect the venting system for proper size andhorizontal pitch, as required in the National Fuel Gascode, ANSI Z223.1 or the CAN/CGA B149Installation Codes and these instructions. Determinethat there is no blockage or restriction, leakage,corrosion and other deficiencies which could causean unsafe condition.

3. In so far as is practical, close all building doors andwindows and all doors between the space in whichthe appliance(s) connected to the venting system arelocated and other spaces of the building. Turn onclothes dryers and any appliances not connected tothe venting system. Turn on any exhaust fans, suchas range hoods and bathroom exhausts, so they willoperate at maximum speed. Do not operate asummer exhaust fan. Close fireplace dampers.

4. Follow the lighting instructions. Place the appliancebeing inspected in operation. Adjust thermostat soappliance shall operate continuously.

5. Test for draft hood equipped appliance spillage at thedraft hood relief opening after 5 minutes of mainburner operation. Use the flame of a match orcandle.

6. After it has been determined that each applianceconnected to the venting system properly vents whentested as outlined above, return doors, windows,exhaust fans, fireplace dampers and any other gas-burning appliances to their previous conditions ofuse.

7. If improper venting is observed during any of theabove tests, the venting system must be corrected.

13. FRESH AIR INTAKEAll units are built with fresh air inlet slots punched inthe service panel.

If the unit is equipped with a fresh air damperassembly, the assembly is shipped already attached tothe unit. The damper blade is locked in the closedposition. To allow the damper to operate, themaximum and minimum blade position stops must beinstalled. See Figure 9.

All capacity, efficiency and cost of operationinformation as required for Department of Energy“Energyguide” Fact Sheets is based upon the fresh airblank-off plate in place and is recommended formaximum energy efficiency.

The blank-off plate is available upon request from thefactory and is installed in place of the fresh air dampershipped with each unit.

One of several other ventilation options may beinstalled. Refer to model number and/or supplementalinstallation instructions.

14. CONDENSATE DRAINA plastic drain hose extends from the drain pan at thetop of the unit down to the unit base. There areopenings in the unit base for the drain hose to passthrough. In the event the drain hose is connected to adrain system of some type, it must be an open or ventedtype system to assure proper drainage.

FIGURE 9FRESH AIR DAMPER


ELECTRICAL GROUNDING

When installed, the furnace must be electricallygrounded in accordance with local codes or in theabsence of local codes, with the National ElectricalCode, ANSI/NFPA 70, or Canadian Electrical Code,CSA22.1, latest edition. Use a copper wire from greenground wire on the furnace to a grounded connection inthe service panel or a properly driven and electricallygrounded ground rod. See Table 1 for proper groundwire size.

FIELD INSTALLED EQUIPMENTWiring to be done in the field between the furnace anddevices not attached to the furnace, or between separatedevises which are field installed and located, shallconform with the temperature limitation for Type Twire {63 degrees F rise (36 degrees C)} when installedin accordance with the manufacturer’s instructions.

INSTALLATION OF FLEXIBLE CONDUITTHROUGH RETURN AIR OPENINGNOTE: To allow proper clearance between the

control panel and any vent options, 90°conduit fittings must be used on the back ofthe control panel.

INSTALLING CONDUIT (See Figure 10.)

1. Remove conduit access panel if required to gainaccess to area behind control panel.

2. Remove low voltage and high voltage knockoutslocated in rear of control panel.

3. Run low voltage conduit through 7/8 bushing locatedin conduit entrance plate and secure to low voltageopening in rear of control panel.

4. Run high voltage conduit through 1-3/4 bushinglocated in conduit entrance plate and secure to highvoltage opening in rear of control panel.

5. Replace conduit access panel if required to completeinstallation.

6. Seal around conduit in conduit entrance plate.

WARNINGFailure to provide a proper electrical groundcould result in electric shock or fire.

15. WIRING – MAIN POWER

Refer to unit rating plate for wire sizing informationand maximum fuse or “HACR” type circuit breakersize. Each outdoor unit is marked with a “MinimumCircuit Ampacity”. This means that the field wiringused must be sized to carry that amount of current. Allmodels are suitable only for connection with copperwire. Each unit and/or wiring diagram will be marked -“Use Copper Conductors Only”. These instructionsmust be adhered to. Refer to the National ElectricalCode (NEC) for complete current carrying capacitydata on the various insulation grades of wiring material.All wiring must conform to NEC and all local codes.

The electrical data lists fuse and wire sizes (75° Ccopper) for all models.

The unit rating plate lists a “Maximum Time DelayRelay Fuse” or “HACR” type circuit breaker that is tobe used with the equipment. The correct size must beused for proper circuit protection and also to assure thatthere will be no nuisance tripping due to the momentaryhigh starting current of the compressor motor.

The disconnect access door on this unit may be lockedto prevent unauthorized access to the disconnect. Toconvert for the locking capability bend the tab locatedin the bottom left hand corner of the disconnect openingunder the disconnect access panel straight out. This tabwill now line up with the slot in the door. When shut, apadlock may be placed through the hole in the tabpreventing entry.

See “Start Up” section for important information onthree phase scroll compressor start ups.

WARNINGFor your personal safety, turn off electricpower at service entrance panel beforemaking any electrical connections. Failure todo so could result in electric shock or fire.

WARNINGFailure to provide an electrical power supplyshut off means could result in electric shockor fire.


NOTE: The voltage should be measured at the fieldpower connection point in the unit and whilethe unit is operating at full load (maximumamperage operating condition).

PAT EGNAR

042 602–352

802 781–022

16. WIRING – LOW VOLTAGE WIRINGLow Voltage ConnectionThese units use a 24-volt AC low voltage circuit.The “R” terminal is the hot terminal and the “C”terminal is grounded.“G” terminal is the fan input.“Y1” terminal is the compressor input.“R” terminal is 24 VAC hot.“C” terminal is 24 VAC grounded.“A” terminal is the ventilation input. This terminalenergizes any factory or field installed vent option.“2” terminal is the “L” input back to the thermostat ifCCM is tripped.“3” terminal is the dehumidification input. Thisenergizes compressor, blower and 3-waydehumidification valve.“W1” terminal is the heating input.

230/208 VOLT UNITSAll models are equipped with dual primary voltagetransformers. All equipment leaves the factory wiredon 240V tap. For 208V operation, reconnect from240V to 208V tap. The acceptable operating voltagerange for the 240V and 208V taps are:

460 VOLT UNITSAll models are equipped with single primary voltagetransformers and no rewiring is required.

FIGURE 10INSTALLATION OF FLEXIBLE CONDUIT

Direct Digital Controls (DDC)For total and proper control using DDC, a total of 5controlled outputs are required (4 if no ventilation isinstalled).

LOW VOLTAGE CONNECTIONS FOR DDC CONTROLFan Only Energize GCooling Mode Energize G, Y1Heating Mode Energize W1Ventilation Energize G, ADehumidification Energize 3


17. THERMOSTATS

TABLE 3THERMOSTAT WIRE SIZE

remrofsnarT

AV ALF eguaGeriW

mumixaM

ecnatsiD

teeFnI

55 3.2 eguag02eguag81eguag61eguag41eguag21

5406001061052

TABLE 4AWALL THERMOSTAT

tatsomrehT serutaeFtnanimoderP

750-3048

)0401D0113HT(

taeHegats1;looCegats1

otua-no:naFlooc-ffo-taeh

elbammargorP-noNcinortcelE

850-3048

)1511D0225HT(


elbammargorP-noNcinortcelE

revoegnahclaunaMrootuA

060-3048*

)544-0211(


cinortcelEelbammargorP-noN/elbammargorP

lanoitnevnoCroPH

revoegnahclaunaMrootuA

TABLE 4BHUMIDISTAT

tatsomrehT serutaeFtnanimoderP

060-3048*

)544-0211(

tatsomrehTelbammargorP

tatsidimuHlargetnIhtiw)evoba(

830-3048

)4101A006H(TDPStatsidimuH

740-3048

)01-12-01002H(

%09ot%01egnar(cinortcelE-tatsidimuheD

)laitnereffid%6.3,spotselbatsujdahtiw

* Integrated thermostat and humidistat in one.


FIGURE 11ATHERMOSTAT CONNECTION USING

8403-060 COMBINATION TEMPERATURE & HUMIDITY CONTROLLER

Y1

1G

and HumidityControl

F

BlockRCTerminal A W2 E Y2 Y1 23

L

W1

Y2

Unit 24V

W1/EC

2

Thermostat Subbase

A

Y

NEEDED FOR ECONOMIZER ONLY

(1120-445)

O/B

Unit Control Panel

Factory Installed Jumper

G

Part #8403-060

R1

W2

CONFIGURE THERMOSTAT FOR HEAT/COOL

2

Thermostat

1

D/YO

3

3

MIS-2786 A

INSTALL ONLY IF APPLIED THERMOSTAT DOES NOT HAVEINDIVIDUAL OUTPUT SIGNAL FOR OCCUPENCY, ORE YOUARE NOT APPLYING A CO2 CONTROL.


FIGURE 11BTHERMOSTAT USING SEPARATE

TEMPERATURE & HUMIDITY CONTROLLERS

Y

MIS-2788

RC W RC Y G

LRC Y2

Electronic Humidistat

(TH311DD1040)

C R

Thermostat

Bard part #8403-047

(TH522OD1151)

Thermostat Subbase

W2

Part #8403-057

O/BGPart #8403-058

Thermostat

MUST INSTALL JUMPER FOR 8407-057, 8403-058 OR OTHER THERMOSTAT THAT DOES NOT

1

INSTALL IF YOU REQUIRE VENTILATION ANYTIME BLOWER IS ON.

HAVE OCCUPANCY OUTPUT.

B O

2

3

SET SWITCH ON THERMOSTAT TO "GAS-OIL"

TO 6 (2 HEAT/ 2 COOL CONVENTIONAL).

4

CHANGE "SYSTEM TYPE", SET UP FUNCTION 1, FROM 5 (2 HEAT/ 1 COOL HEAT PUMP)

5

1

NEEDED FOR ECONOMIZER ONLY

3 2Y1Y2EW2AW1

2

F

Block

Unit Control Panel

Y

4

C R G 1

Mechanical Humidistat

(H200-10-21-10)4356

Yellow

TerminalUnit 24V

(H600A 1014)Bard part #8403-038

Red

W

6

6

3

5

6

6

FACTORY INSTALLED JUMPER

2


FIGURE 11CMOTORIZED FRESH AIR DAMPER, CLASSROOM VENTILATOR SPRING,

CLASSROOM VENTILATOR POWER & ERV LOW VOLTAGE CONNECTIONS

WGSEIFM-5

1GY

Unit Control Panel

Unit 24VTerminal

BlockRC W1 A W2 E Y2 Y1 23

BLACK BLUE

PINKYELLOWPURPLE

ORANGEREDRED

WIRESFROMPLUG

THERMISTOR

F

A W2

VENT PACKAGE

OR

AN

GE

RE

D/W

HIT

E

BLA

CK

/WH

ITE

F

Unit Control Panel

Y

Factory Installed

Jumper

INSTALL JUMPER IF YOU REQUIRE VENTILATION ANYTIME BLOWER IS ON, OR IF

Unit 24V

REMOVE ORANGE WIRE FROM "G" TERMINAL, AND TAPE-OFF.

BlockRC W1

BLU

E

WIRING PLUG

Y1 1Y2 G 2E

CONTROLS DON'T HAVE AN OCCUPENCY OUTPUT. NOTE: YOU WILL NEED TO

Jumper

Factory Installed

Terminal

BR

OW

N/W

HIT

E

3

1

1

2

CONNECT ORANGE WIRE TO "G" TERMINAL IF OCCUPENCY-BASED THERMOSTATOR CO2 CONTROLLER FOR DEMAND VENTILATION CONTROL IS APPLIED.2

MIS-2789 B

FIGURE 11D — ECONOMIZER LOW VOLTAGE CONNECTIONS


FIGURE 12GAS PIPE CONNECTION

W24G - W36GW42G - W60G


8. Refer to Table 6 for Gas Pipe Sizes for natural gas.If more than one appliance is supplied from a singleline size, capacity must equal or exceed thecombined input to all appliances, and the branchlines feeding the individual appliances properlysized for each input.

18. GAS SUPPLY AND PIPING

GENERAL RECOMMENDATIONS1. Be sure the gas line complies with the local codes

and ordinances, or in their absence with the NationalFuel Gas Code, ANSI Z223.1, or Natural GasInstallation Code, CAN/CGA B149.1, or PropaneInstallation Code B149.2, latest edition.

2. A sediment trap or drip leg must be installed in thesupply line to the furnace.

3. A ground joint union shall be installed in the gas lineadjacent to and upstream from the gas valve anddownstream from the manual shut off valve.

4. An 1/8" NPT plugged tapping accessible for testgauge connection shall be installed immediatelyupstream of the gas supply connection to the furnacefor the purpose of determining the supply gaspressure. This can be omitted if local codes permituse of plugged tapping in gas valve inlet.

5. Install listed manual shut off valve in the supply gasline external to and immediately upstream of thefurnace. See Figure 12.

6. Use steel or wrought iron pipe and fittings.

7. DO NOT thread pipe too far. Valve distortion ormalfunction may result from excess pipe within thecontrol. Use pipe joint compound resistant to theaction of liquefied petroleum gases on male threadsonly. DO NOT use Teflon tape. See Table 5 andFigure 13. CHECKING THE GAS PIPING

Before turning gas under pressure into piping, allopenings from which gas can escape should be closed.Immediately after turning on gas, the system should bechecked for leaks. This can be done by watching the 1/2cubic foot test dial and allowing 4 minutes to show anymovement, and by soaping each pipe connection andwatching for bubbles. If a leak is found, make thenecessary repairs immediately and repeat the above test.The furnace must be isolated from the gas supply pipingsystem by closing the manual shut off valve on thecombination gas control valve during pressure testing ofthe gas supply piping system at pressures up to 1/2 PSIG.The furnace and its individual shut off valve must bedisconnected from supply piping and supply pipingcapped during any pressure testing of supply pipingsystem at test pressures in excess of 1/2 PSIG.

Defective pipes or fittings should be replaced and notrepaired. Never use a flame or fire in any form to locategas leaks; use a soap solution.

After the piping and meter have been checkedcompletely, purge the system of air. DO NOT bleed airinside the furnace. Be sure to check and relight all thegas pilots on other appliances that may have beenextinguished because of interrupted gas supply.

FIGURE 13PROPER PIPING PRACTICE

TABLE 5LENGTH OF STANDARDPIPE THREADS (INCHES)

eziSepiP

htgneLevitceffE

daerhTfo

htgneLllarevO

daerhTfo

8/3 2/1 61/9

4/3 61/9--2/1 61/31

1 61/9 1

TABLE 6GAS PIPE SIZES - NATURAL GAS

fohtgneL

teeF-epiP

eziSepiPtupnIruoHrepUTB-yticapaCepiP

"2/1 "4/3 "1 "4/1-1

01 000,231 000,872 000,025 000,050,1

02 000,29 000,091 000,053 000,037

03 000,37 000,251 000,582 000,095

04 000,36 000,031 000,542 000,005

05 000,65 000,511 000,512 000,044

06 000,05 000,501 000,591 000,004

07 000,64 000,69 000,081 000,073

08 000,34 000,09 000,071 000,053

001 000,83 000,97 000,051 000,503

MIS-897

THIS PRODUCT MUST BE GAS PIPED BYA LICENSED PLUMBER OR GAS FITTER

IN THE COMMONWEALTH OFMASSACHUSETTS.


19. MANIFOLD PRESSUREADJUSTMENTYou will need a 0 to 15 inch water manometer with 0.1inch resolution and a 1/8" NPT manual shut off valve tomeasure actual manifold pressure.

Depending on your local gas heating value andelevation, you may need to adjust manifold pressure orchange orifices to get proper gas input rate. Checkwith your local gas supplier to determine heating value(BTU/cu. ft.) of natural gas in your area.

NOTE: If furnace is being installed at an altitude ofmore than 6,000 feet above sea level, youmust derate the furnace. See Section 21“Standard Orifice Sizing and High AltitudeDerate”.

20. CHECKING GAS INPUT RATEIt is the installer's responsibility to see that the BTUinput rate of the furnace is properly adjusted. Under-firing could cause inadequate heat, excessivecondensation or ignition problems. Overfiring couldcause sooting, flame impingement or overheating ofheat exchanger.

1. Turn off gas at equipment shut off valve in gassupply line just ahead of furnace.

2. Remove plug from outlet pressure tap in gas controlor gas manifold.

3. Install 1/8" NPT manual shut off valve in holevacated by plug. Make sure shut off valve is in offposition.

4. Attach manometer to 1/8" NPT manual shut offvalve just installed.

PROPANE (LP) GAS CONVERSIONThis unit may be converted in the field foruse with Propane (LP) gas. Propane gasconversion kit number WGCK-1 is designedfor conversions of units installed from0 – 6,000 feet elevations. Propane gasconversion kit number WGCK-2 is designedfor conversions of units installed from 6,001– 10,000 feet elevations. These kits maybe purchased from your local distributor.

5. Slowly open equipment shut off valve in gas supplyline just ahead of furnace. Start furnace following“Operating Instructions” on front door.

6. Slowly open 1/8" NPT manual shut off valve leadingto manometer.

7. Read manifold pressure on manometer.

8. Adjust manifold pressure by turning gas controlregulator adjusting screw clockwise to increasepressure or turning counterclockwise to decreasepressure. Manifold pressure must be withinallowable range as follows:• Natural gas manifold pressure must be between

3.2 and 3.8 inches W.C. Rated pressure is 3.5inches.

• Propane gas (LP) manifold pressure must bebetween 9.7 and 10.3 inches W.C. Ratedpressure is 10 inches.

NOTE: For natural gas, if gas flow rate can't beproperly set within these pressure rangesthen you must change main burner orifices toobtain proper gas flow rate.

9. Shut off furnace. Turn off gas at equipment shut offvalve in gas supply line just ahead of furnace. Installoutlet pressure tap plug in gas control. Turn on gas.

10. Check regulator adjustment cover screw and gascontrol plug for gas leaks. Use a commercial soapsolution made for leak detection.

WARNINGWhen converting from propane (LP) gas tonatural gas, the gas orifice spuds and gasvalve spring must be replaced and the gasvalve regulator pressure must be adjustedcorrectly. Failure to do so can result in fire,injury or death. Refer to Tables 8 and 8A forproper orifice sizing.

Natural gas spring kit, Part number 5603-007,can be purchased through your localdistributor.

WARNINGCorrect manifold pressure is necessary forproper ignition and burner operation. Failureto accurately adjust pressure could causeheat exchanger failure.

WARNINGFailure to adjust furnace to the proper firingrate could cause heat exchanger failure.


NATURAL GAS INPUT RATENatural gas heating value (BTU/cu. ft.) can varysignificantly. Before starting natural gas input check,obtain gas heating value at your location from localsupplier. You will need a stopwatch to measure actualgas input.

1. Gas supply pressure must be between 5 and 7 inchesW.C. for natural gas.

2. Turn off all other gas appliances. You may leavepilots on.

3. Start furnace following “Operating Instructions” onfront door.

4. Let furnace warm up for 6 minutes.

5. Locate gas meter. Determine which dial has theleast cubic feet of gas and how many cubic feet perrevolution it represents. This is usually one-half, oneor two cubic feet per revolution.

6. With stopwatch, measure time it takes to consumetwo cubic feet of gas.

• If dial is one-half cubic foot per revolution,measure time for four revolutions.

• If dial is one cubic foot per revolution, measuretime for two revolutions.

• If dial is two cubic feet per revolution, measuretime for one revolution.

7. Divide this time by two. This gives average time forone cubic foot of gas to flow through meter.Example: If it took 58 seconds for two cubic feet toflow, it would take 29 seconds for one cubic foot toflow.

8. Calculate gas input using this formula:

Gas Heating Value (BTU/cu. ft.)

x 3,600 sec/hr Gas input = = BTU/hour Time (Seconds for one

cubic foot of gas)

Example:Assume it took 29 seconds for one cubic foot of gasto flow and heating value of 1,000 BTU/cu. ft.

1,000 x 3,600 Gas input = = 124,138 BTU

29

If you left no other pilots on, this is the furnace gasinput.

9. If you left water heater, dryer or range pilots on,allow for them in calculating correct furnace gasinput. A quick way is to allow 1,000 BTU per hourfor a water heater, 500 BTU per hour for dryer and500 BTU per hour for each range burner pilot.

Example:

If you left gas water heater, dryer, two range burnerpilots and one oven pilot on, allow:

Water heater pilot 1,000 BTU per hourDryer pilot 500 BTU per hour2 range burner pilots 1,000 BTU per hour1 range oven pilot 500 BTU per hour

3,000 BTU per hour

Subtracting 3,000 BTU per hour from 124,138 BTUper hour measured above equals 121,138 BTU perhour. This would be the correct furnace gas inputafter allowing for pilots left on.

10. Manifold pressure may be adjusted within the rangeof 3.2 inches W.C. to 3.8 inches W.C. to get ratedinput ± 2 percent. See Section 19, “ManifoldPressure Adjustment”. If you cannot get rated inputwith manifold pressure within the allowable range,you must change orifices.

PROPANE (LP) GAS INPUT RATE

1. Make sure you have proper main burner orifices.

2. Gas supply pressure must be between 11 and 13inches W.C. for propane (LP) gas.

3. Start furnace following “Operating Instructions” onfront door.

4. Let furnace warm up for 6 minutes.

5. Adjust manifold pressure to 10.0 W.C. ± 0.3 inchesW.C. See Section 19, “Manifold PressureAdjustment”.

WARNINGPropane (LP) gas installations do not havegas meters to double check input rate.Measure manifold pressure adjustment withan accurate manometer. Failure to accuratelyadjust pressure could cause heat exchangerfailure, asphyxiation, fire or explosion,resulting in damage, injury or death.

WARNINGDo not set Propane (LP) manifold pressure at11.0 inches W.C. It could cause heatexchanger failure.


21. STANDARD ORIFICE SIZING AND HIGH ALTITUDE DERATEThis furnace is shipped with fixed gas orifices for usewith Natural Gas and sized for 1000 BTU/cubic footgas. Make sure actual gas input does not exceed ratingplate input. You may need to change orifices to getcorrect gas input. Whether you do or not depends oninput, and your gas heat value at standard conditionsand elevation. Consult your local gas supplier for gasheat value and any special derating requirements. SeeSection 20 for more information.

At higher altitudes, the density of the air is reduced.Therefore, for proper combustion, the quantity of gasburned in the furnace must also be reduced. This iscalled derating. This unit must be derated wheninstalled at altitudes greater than 6,000 feet above sealevel. A high altitude pressure switch must also beinstalled for operation above 6,000 feet. High altitudepressure switch kit number 8620-189 is designed forthis application.

TABLE 7NATURAL GAS DERATE CAPACITIES

FOR ALL MODELS

G**W

tupnIdetaR

aeS

leveL 000,1 000,2 000,3 000,4 000,5 000,6 000,7 000,8 000,9 000,01

000,14

000,54

005,04

000,54

402,93

065,34

809,73

021,24

216,63

086,04

046,53

006,93

299,43

088,83

281,43

089,73

696,33

044,73

840,33

027,63

346,23

072,63

670,23

046,53

000,16

000,86

057,06

005,76

608,85

043,56

268,65

081,36

819,45

020,16

064,35

004,95

884,25

023,85

372,15

079,65

445,05

061,65

275,94

080,55

569,84

504,45

411,84

064,35

000,57

000,18

000,57

000,18

006,27

804,87

002,07

618,57

008,76

422,37

000,66

082,17

008,46

489,96

003,36

463,86

004,26

293,76

002,16

690,66

054,06

682,56

004,95

251,46

000,09

000,001

000,09

000,001

021,78

008,69

042,48

006,39

063,18

004,09

002,97

000,88

067,77

004,68

069,57

004,48

088,47

002,38

044,37

006,18

045,27

006,08

082,17

002,97

000,311

000,521

005,211

000,521

009,801

000,121

003,501

000,711

007,101

000,311

000,99

000,011

002,79

000,801

059,49

005,501

006,39

000,401

008,19

000,201

576,09

057,001

001,98

000,99

It is the installer’s responsibility to see that the furnaceinput rate is adjusted properly. Derating must beachieved by reducing the size of the main burnerorifices. Derating the furnace by adjusting the manifoldpressure lower than the range specified in the Section19, “Manifold Pressure Adjustment” is considered to bean improper procedure.

Above 6,000 feet elevation orifice changes are required,and capacity reductions are a function of altitudeimpact and orifice change. Pressure switch change isrequired above 6,000 feet elevation. For Natural Gassee the Altitude Table 7 below and the Orifice Tables 8and 8A on following pages.


All other orifice sizes shown are available as individual items. See Orifice tables below for part numbers and number required.

TABLE 8NATURAL GAS ORIFICE TABLES

FOR MODELS W24G, W30G AND W36G

yrotcaF

dradnatS

tupnI

eulaV*taeHsaG

.tF.uC/UTB

oNteeF000,6otpU

tpecxEsegnahC

tnetnoCUTBrof

teeF000,8ot100,6

hctiwSerusserPseriuqeR

egnahCecifirOdnaegnahC

tnetnoCUTBnodesaB t

teeF000,01ot100,8



tnetnoCUTBnodesaB t

UTB00522

renruBreP947-007 57.2 07.2 06.2

997-057 07.2 06.2 05.2

948-008 06.2 05.2 54.2

998-058 05.2 54.2 53.2

949-009 54.2 53.2 )03.2(

999-059 53.2 )03.2( 52.2

**9401-0001 )03.2( 52.2 ]02.2[

0011-0501 52.2 ]02.2[ 51.2

hctiwSerusserP )55.(dradnatS )24.(tiKhctiwSerusserPedutitlAhgiH981-0268redrO

ezisecifirodellatsniyrotcafdradnatsehtsi)03.2( dellatsnidleifroftinuehthtiwdeppihserasecifiro]02.2[

etared%01lanoitpo

lanoitpO

dleiF%01

detrevnoC

etareD

eulaV*taeHsaG

.tF.uC/UTB

oNteeF000,6otpU

tpecxEsegnahC

tnetnoCUTBrof

teeF000,8ot100,6



tnetnoCUTBnodesaB

teeF000,01ot100,8



tnetnoCUTBnodesaB

UTB05202

renruBreP947-007 06.2 05.2 54.2

997-057 05.2 54.2 04.2

948-008 54.2 04.2 )03.2(

998-058 04.2 )03.2( 52.2

949-009 )03.2( 52.2 ]02.2[

999-059 52.2 ]02.2[ 51.2

**9401-0001 ]02.2[ 51.2 01.2

0011-0501 51.2 51.2 01.2


dellatsnidleifroftinuehthtiwdeppihserasecifiro]02.2[

.etartupni%01lanoitpo

tupnidetarllufrofezisecifirodellatsniyrotcafehtsi)03.2(

***

.ytivargcificeps06.,detarutas,F06,yrucreMsehcni00.03:snoitidnocdradnatstA

levelaesdnasagtfuc/UTB5201lanimonnodesabsgnitartupnidradnatsdnagnizisecifiroyrotcafsaGlarutaNllA

snoitidnoc

deriuqeRsecifirOfo.oN

gnitaRtupnItinUnodesaB

000,14 )2(

000,54 )2(

000,16 )3(

000,86 )3(

000,57 )3(

000,18 )4(

000,09 )4(

000,001 )4(

000,311 )5(

000,521 )5(

.oNtraPdraB )mm(eziSecifirO retemaiDecifirO

290-0109 01.2 6280.0

880-0109 51.2 6480.0

780-0109 02.2 6680.0

680-0109 52.2 5880.0

280-0109 03.2 5090.0

580-0109 53.2 5290.0

970-0109 04.2 5490.0

480-0109 54.2 4690.0

390-0109 05.2 4890.0

490-0109 06.2 4201.0

590-0109 07.2 3601.0

690-0109 57.2 2801.0

790-0109 08.2 2011.1

890-0109 09.2 2411.0


All other orifice sizes shown are available as individual items. See Orifice tables on Page 31 for part numbers and number required.

TABLE 8ANATURAL GAS ORIFICE TABLES

FOR MODELS W42G, W48G AND W60G

yrotcaF

dradnatS

tupnI

*taeHsaG

eulaV

.tF.uC/UTB

oNteeF000,6otpU

tpecxEsegnahC

tnetnoCUTBrof

teeF000,8ot100,6


ecifirOdnaegnahC

egnahC

tnetnoCUTBnodesaB t

teeF000,01ot100,8


ecifirOdnaegnahC

egnahC

tnetnoCUTBnodesaB t

UTB00052

renruBreP947-007 09.2 08.2 07.2

997-057 08.2 07.2 06.2

948-008 07.2 06.2 05.2

998-058 06.2 05.2 54.2

949-009 05.2 54.2 )04.2(

999-059 54.2 )04.2( 53.2

**9401-0001 )04.2( 53.2 ]03.2[

0011-0501 ]03.2[ 52.2 02.2


ezisecifirodellatsniyrotcafdradnatsehtsi)04.2( dellatsnidleifroftinuehthtiwdeppihserasecifiro]03.2[

etared%01lanoitpo

lanoitpO

dleiF%01

detrevnoC

etareD

*taeHsaG

eulaV

.tF.uC/UTB

oNteeF000,6otpU

tpecxEsegnahC

tnetnoCUTBrof

teeF000,8ot100,6


ecifirOdnaegnahC

egnahC

tnetnoCUTBnodesaB

teeF000,01ot100,8


ecifirOdnaegnahC

egnahC

tnetnoCUTBnodesaB

UTB00522

renruBreP947-007 57.2 07.2 06.2

997-057 07.2 06.2 05.2

948-008 06.2 05.2

998-058 05.2 54.2 )04.2(

949-009 )04.2( 53.2 ]03.2[

999-059 53.2 ]03.2[ 52.2

**9401-0001 ]03.2[ 52.2 02.2

0011-0501 52.2 52.2 02.2


dleifroftinuehthtiwdeppihserasecifiro]03.2[

.etartupni%01lanoitpodellatsni

tupnidetarllufrofezisecifirodellatsniyrotcafehtsi)04.2(

***

.ytivargcificeps06.,detarutas,F06,yrucreMsehcni00.03:snoitidnocdradnatstAaesdnasagtfuc/UTB5201lanimonnodesabsgnitartupnidradnatsdnagnizisecifiroyrotcafsaGlarutaNllA

snoitidnoclevel


23. MEASURING AIR TEMPERATURERISE

Air temperature rise (supply air temperature minusreturn air temperature) must be within allowable airtemperature rise range specified on furnace rating plateand in Table 1.

You will need 2 thermometers with 1 degree resolutioncapable of reading up to 200 degrees F. Checkthermometers to make sure they agree, or compensateaccordingly.

Follow this procedure:

1. Open supply air registers and return air grilles.Make sure the registers and grilles are free ofobstruction from rugs, carpets, drapes or furniture.

22. CONVERSION OF GAS INPUT BTUHFROM HIGH TO LOW RATING

All the derated WG series units are produced withmaximum BTUH input orifices installed. To fieldconvert input, a change to main burner orifices isrequired.

NOTE: No change to air orifices is necessary. A setof low input orifices is shipped with everyunit. They will be found packaged in a bagbehind the burner door. Refer to the unitrating plate to confirm the proper orifice size.Proper installation of the orifices is detailedas follows:

A. Shut off electrical supply to the unit.

B. Shut off gas supply to the unit.

C. Remove burner access panel.

D. Disconnect gas valve from gas supply piping.

E. Disconnect the two wires from the gas valve.

F. Remove the manifold assembly so that orifices arenow accessible and remove orifices.

G. Apply a modest amount of pipe compound to thenew orifices and screw them into the manifold.

H. To assemble burner reverse steps A through G.

2. Set balancing dampers in supply duct system.

3. Check duct work for obstructions or leaks.

4. Make sure filters are clean and in place.

5. Place one thermometer in supply air plenumapproximately 2 feet from furnace. Locatethermometer tip in center of plenum to ensure propertemperature measurement.

6. Place second thermometer in return air ductapproximately 2 feet from furnace. Locatethermometer tip in center of duct to ensure propertemperature measurement.

7. Set room thermostat on highest temperature setting.Operate furnace 10 minutes. Record supply air andreturn air temperatures.

8. Calculate air temperature rise by subtracting returnair temperature from supply air temperature.

• If air temperature rise is above the temperaturerise range on rating plate, furnace is overfiredor has insufficient airflow. Check gas inputfollowing the instructions in Section, “CheckingGas Input Rate”. If air temperature rise is stillabove temperature rise range specified, moreheating airflow is needed. Check duct work andgrilles to make sure all are properly sized.

• If air temperature rise is below the temperaturerise range on rating plate, furnace is underfiredor has too much airflow. Check gas inputfollowing the instructions in Section, “CheckingGas Input Rate”. If air temperature rise is stillbelow temperature rise range specified, lessheating airflow is needed. Adjust dampers orgrilles as needed.

• After making adjustments, you must check airtemperature rise to verify that resulting airtemperature rise is within allowable range. Ifair temperature rise is still outside thetemperature rise range specified on ratingplate, check duct system design with aqualified heating engineer. It may benecessary to re-size the duct work. Recheckair temperature rise after revising duct systems.

9. Set room thermostat to desired setting.

10. Remove thermometers and seal duct work holes.

NOTE: Failure to seal holes could result in reducedsystem performance.

WARNINGFailure to follow these instructions couldcreate a hazard resulting in property damage,bodily injury, or death.


24. FILTERSA 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 your dealer.

25. COMPRESSOR CONTROL MODULEThe compressor control is an anti-short cycle/lockouttimer with high and low pressure switch monitoring andalarm output.

ADJUSTABLE DELAY-ON-MAKE AND BREAKTIMEROn a call for compressor operation the delay-on-makeperiod begins which will be 10% of the delay-on-breaksetting. When the delay-on-make is complete and thehigh pressure switch (and low pressure switch ifemployed) is closed, the compressor contactor isenergized. Upon shutdown the delay-on-break timerstarts and prevents restart until the delay-on-break anddelay-on-make periods have expired.

FIGURE 14ACCESS INTERNAL FILTER

THROUGH UPPER SERVICE DOOR

HIGH PRESSURE SWITCH AND LOCKOUTSEQUENCE (Standard Feature)If the high pressure switch opens, the compressorcontactor will de-energize immediately. The lockouttimer will go into a soft lockout and stay in soft lockoutuntil the high pressure switch closes and the delay-on-make time has expired. If the high pressure switchopens again in this same operating cycle the unit willgo into manual lockout condition and the alarm circuitwill energize. Recycling the wall thermostat resets themanual lockout.

LOW PRESSURE SWITCH, BYPASS, ANDLOCKOUT SEQUENCENOTE: The low pressure switch is an optional

control and the bypass and lockout sequenceare part of the standard compressor controlmodule.

If the low pressure switch opens for more that 120seconds, the compressor contactor will de-energize andgo into a soft lockout. Regardless the state of the lowpressure switch, the contactor will reenergize after thedelay-on-make time delay has expired. If the lowpressure switch remains open or opens again for longerthan 120 seconds the unit will go into manual lockoutcondition and the alarm circuit will energize.Recycling the wall thermostat resets the manuallockout.

MIS-3237

FILTER

FILTER SERVICEDOOR


ALARM OUTPUTAlarm terminal is output connection for applicationswhere alarm signal is desired. This terminal is poweredwhenever compressor is locked out due to HPC or LPCsequences as described.

NOTE: Both high and low pressure switch controlsare inherently automatic reset devices. Thehigh pressure switch and low pressure switchcut out and cut in settings are fixed byspecific air conditioner or heat pump unitmodel. The lockout features, both soft andmanual, are a function of the CompressorControl Module.

ADJUSTMENTS

ADJUSTABLE DELAY-ON-MAKE ANDDELAY-ON-BREAK TIMERThe potentiometer is used to select Delay-on-Breaktime from 30 seconds to 5 minutes. Delay-on-Make(DOM) timing on power-up and after powerinterruptions is equal to 2 minutes plus 10% of Delay-on-Break (DOB) setting:

0.5 minute (30 seconds) DOB = 123 second DOM1.0 minute (60 seconds) DOB = 126 second DOM2.0 minute (120 seconds) DOB = 132 second DOM3.0 minute (160 seconds) DOB = 138 second DOM4.0 minute (240 seconds) DOB = 144 second DOM5.0 minute (300 seconds) DOB = 150 second DOM

PHASE MONITORAll units with three phase scroll compressors areequipped with a three phase line monitor to preventcompressor damage due to phase reversal.

The phase monitor in this unit is equipped with twoLEDs. If the “&” signal is present at the phase monitorand phases are correct, the green LED will light.

If phases are reversed, the red fault LED will be lit andcompressor operation is inhibited.

If a fault condition occurs, reverse two of the supplyleads to the unit. Do not reverse any of the unit factorywires as damage may occur.


26. LIGHTING AND SHUTDOWN INSTRUCTIONS

FIGURE 15INSTRUCTION LABEL


27. SERVICE AGENCY PROCEDURES

MAIN BURNERObserve the main burners in operation. The flameshould be mostly “blue” with possibly a little orange(not yellow) at the tips of the flame. The flames shouldbe in the center of the heat exchanger tubes and notimpinging on the heat exchanger surfaces themselves.

Observe the fire until the blower starts (there is anormal delay period until the heat exchanger warmsup). There should be no change in the size or shape ofthe flame. If there is any wavering or blowing of theflame on blower start-up, it is an indication of apossible leak in the heat exchanger.

28. MAINTAINING UNIT IN GOODWORKING ORDER

The unit should be inspected annually by a qualifiedservice agency.

BURNERS / HEAT EXCHANGER / FLUE GASPASSAGE WAYS

The burners, heat exchanger and interior flue gaspassages may be inspected using a light on small mirroror an extension handle. Remove the screws securingthe inducer and collector box. Now inspect the uppertubes of the heat exchanger.

Check the exterior of the heat exchanger and theinterior flue gas passages for any evidence ofdeterioration due to corrosion, cracking or other causes.If signs of sooting exist, remove the burners and cleanthe heat exchanger, as required.

MIS-165

FIGURE 16TOP VIEW OF GAS CONTROL

CAUTIONLabel all wires prior to disconnection whenservicing controls. Wiring errors can causeimproper and dangerous operation. Verifyproper operation after servicing.

WARNINGUse replacement parts listed in theReplacement Parts list only. The use ofincorrect parts could cause improper unitoperation, resulting in damage, injury ordeath.

WARNINGFollow these procedures before inspectingfurnace. • Turn room thermostat to its lowest or off

setting. • Turn off manual gas shut off valve. • Wait at least 5 minutes for furnace to cool

if it was recently operating. • Turn off furnace electrical power; failure

to do so could result in injury or death.


ROUTINE MAINTENANCE

1. Air Filters – Check the condition at least monthlywhen the unit is in use, and replace as necessary.

2. Lubrication Requirements – The indoor circulatingair blower motor and outdoor circulating air fanmotor are permanently lubricated and require no re-oiling. The combustion air blower motor requires nore-oiling.

ROUTINE INSPECTION

1. Inspect the physical support of the unit annually tomake sure it is securely fastened to the building.Also look for any obvious signs of deterioration.

2. Inspect the main burners at the beginning of eachheating season and clean as necessary.

3. Inspect the vent terminal and combustion air intakehood for any obvious deterioration, to make sure it isfree and clear of any obstructions.

29. REPLACEMENT PARTS

ANNUAL MAINTENANCERoutine inspection and maintenance procedures are theresponsibility of the user and are outlined below.

1. Before inspecting unit:

a. Turn room thermostat to lowest or off setting.

b. Turn off equipment gas shut off valve.

c. Wait for unit to cool if it was recentlyoperating.

d. Turn off electrical power to unit.

2. Inspect the following:

a. Vent terminal and combustion air intaketerminal. Make sure both are free fromobstructions.

b. Vertical Vent Applications – Inspect ventingsystem. Make sure system has no holes, isphysically sound and free from obstructions.

c. Make sure the supply and return air flangesleeves or duct work are securely fastened tounit and physically sound.

d. Supply and return grilles must be open andfree from obstructions.

e. Inspect to make sure the unit is securelyfastened to the wall. Seal any possible leaksbetween unit and wall with appropriateexterior sealing material.

f. Inspect burners, heat exchanger, induceddraft blower, and induced draft blowercollector box. There must be no obvioussigns of deterioration.

g. Inspect all electrical connections and wiring.

h. Check all gas piping for leaks with soapsolution used to detect leaks.

i. Inspect, clean, and repair as needed the entireblower assembly, air filters, draft inducer,cooling coils, and vent options (if installed).

Replacement parts for the gas/electric units areavailable through local distributors.

A replacement parts list manual is supplied with eachunit. When ordering parts or making inquirespertaining to any of the units covered by theseinstructions, it is very important to always supply thecomplete model number and serial number of the unit.This is necessary to assure that the correct parts (or anapproved alternate part) are issued to the serviceagency.

WARNINGDisconnect electrical power before servicingunit. Failure to do so could result in electricalshock or death.

WARNINGTurn off electrical power supply to preventinjury from moving parts or electric shock.

WARNINGUse replacement parts listed in ReplacementParts list. Failure to do so could causeimproper furnace operation, resulting inproperty damage, personal injury, or death.


30. SEQUENCE OF OPERATION –HEATING

On a call for heat from the thermostat, the induced draftblower is energized. Once sufficient draft isestablished, the pressure switch contacts close and theignition system is energized. The direct spark ignitorwill be energized allowing gas to flow. At the sametime the main valve is energized, a 30-second blowerdelay timer is activated.

After this delay, the heating speed blower relayenergizes. The blower will begin operating and remainin operation until the set delay time after the call forheat has been satisfied. (See Tables 10-15 for selectableblower off time delays.) This timing sequenceguarantees blower on, blower off operation.

This unit is equipped with a flame rollout switch whichis wired in series with the control circuit. This is amanual reset switch and is used for the purpose ofpreventing possible fire hazard in the event of a systemmalfunction. If this switch has opened the controlcircuit, there could be a possible system malfunction.Some of the conditions that might cause a rollout tooccur are blockage or sooting of primary heatexchanger, overfiring of furnace due to improper mainburner orifices or incorrect manifold pressure,insufficient combustion air, or installation deficiencieswith respect to return air duct design or sizing.

Once the problem has been resolved, reset the switch bypressing down on the reset button on top of the switch.See Figure 17 for additional information.

31. SEQUENCE OF OPERATION –COOLING

On a call for cooling from the room thermostat, the highspeed blower relay will be energized as well as thecompressor contactor. Following termination of thecooling cycle, the blower motor will continue to run forone minute.

See Figure 17 for additional information.

The unit may be equipped with a low ambient controlfor lower outdoor temperature operation in the coolingmode. If equipped with this optional control thecondenser fan will not operate immediately uponcompressor start up, and will cycle on and off until thecondensing pressure remains above 280 PSIG.

DEHUMIDIFICATION – Dehumidification iscontrolled through a humidistat and is independent ofthe thermostat. On a call for dehumidification mode ofoperation the compressor, blower and three way valveof the unit are energized through circuit R-3 to providedehumidification. Dehumidification will continue untilthe humidistat is satisfied.

If there is a cooling call issued through circuit R-Y, itwill cancel dehumidification sequence (de-energize thereheat valve) until the cooling call is satisfied. If thedehumidification call is still present when cooling callis satisfied, the compressor will continue to operate andthe reheat valve is reenergized.

Any time there is a call for heating mode of operationthrough circuit R-W1 the dehumidification mode willcancel and the system will return to heating operation.Dehumidification is delay 45-60 seconds on start upafter any heating cycle is complete.

Any time the indoor coil temperature falls below 32degrees the compressor will be de-energized until thecoil temperature rises above 57 degrees.

(Refer to Section 33 for dehumidification relay logicboard.)


FIGURE 17SEQUENCE OF OPERATION

ELECTRONIC BLOWER CONTROL

NOITCA ESNOPSERMETSYS

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32. INDOOR BLOWER OPERATIONAll models have multiple speed direct drive blowermotors. If supply and return ducts are connected to theunit, the ducts must be of adequate size. Refer to theappropriate blower tables. See Tables 10, 11, 12, 13,14 and 15 for maximum static pressures acceptable.Note the minimum CFM for cooling operation.

If voltage and duct design permit, (see blower tables)single speed operation can be achieved as follows:

BLOWER MOTOR SPEED CHANGE

1. Disconnect power supply to unit.

2. Place desired blower motor speed lead wire to“COOL” terminal of integrated furnace controlboard.

3. Place desired blower motor speed lead wire to“HEAT” terminal of integrated furnace controlboard.

4. Place unused blower motor speed lead wire to“UNUSED” terminal of integrated furnace controlboard.

5. Energize the system in cooling and heating modes tocheck for proper blower operation.

If it is desirable to have both HEAT/COOL blowermotor speed at the same speed, install a jumper wirebetween “HEAT” and “COOL” terminals of theintegrated furnace control board, and place both unusedmotor speed lead wires on the two “UNUSED” terminalson the integrated furnace control board. (See Figure 18.)

sdeepS rotoMrewolBdeepS-3

woL deR

muideM eulB

hgiH kcalB

sdeepS rotoMrewolBdeepS-3

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*noitalosI egnarO

*noitalosI elpruP

FIGURE 18FURNACE CONTROL BOARD AND BLOWER CONTROL

* NOTE: On 460 Volt motors, there are two motor isolation leads. The orange must connect with the black highspeed blower motor lead wire for medium and low speed blower operation. The purple wire mustconnect with the blue medium speed blower motor lead wire for low speed blower operation. This is allautomatically accomplished with blower relays HSBR, MSBR and LSBR, and speed changes are allmade by changes at the integrated furnace control board.

TABLE 9230 VOLT MOTOR SPEED TAPS

460 VOLT MOTOR SPEED TAPS


TABLE 10W24G INDOOR BLOWER PERFORMANCE @ 230 AND 460 VOLTS

Recommended W24G cooling airflow range at rated 800 CFM @ 0.15 ESP (WC) is 680 - 920 CFMFactory set on Low Speed for cooling and High for heating.

Voltage adjustment – Reduce airflow by 100 CFM for 208 VoltDehumidification coil adjustment – Reduce airflow by 35 CFM for dehumidification coil installedTop outlet adjustment – Increase airflow by 50 CFM for top outlet modelsSG-3, RG-3, non-ducted application adjustment – Reduce airflow by 100 CFM for SG-3 and RG-3 installations

PSE

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hgiH muideM woL hgiH muideM woL hgiH muideM woL

0.0 --- --- 098 0531 0211 --- --- 0211 049

1.0 --- --- 028 0621 0611 --- --- 0611 078

2.0 --- 059 077 0021 0101 --- 0021 0101 ---

3.0 --- 088 007 0211 --- --- 0211 049 ---

4.0 --- 097 --- 0301 --- --- 0301 068 ---

5.0 019 017 --- --- --- --- 059 --- ---

6.0 008 --- --- --- --- --- 048 --- ---

PSE

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0.0 --- --- 098 0531 0211 049 --- 0211 049

1.0 --- --- 028 0621 0611 078 --- 0611 078

2.0 --- 059 077 0021 0101 --- --- 0101 018

3.0 --- 088 007 0211 019 --- 0211 049 ---

4.0 --- 097 --- 0301 --- --- 0301 068 ---

5.0 019 017 --- 059 --- --- 059 087 ---

6.0 008 --- --- --- --- --- 048 --- ---

PSE

sehcnI

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0.0 --- --- 098 --- 0211 049 --- 0211 049

1.0 --- --- 028 0621 0611 078 --- 0611 078

2.0 --- 059 077 0021 0101 018 0021 0101 018

3.0 --- 088 007 0211 049 --- 0211 049 057

4.0 --- 097 --- 0301 068 --- 0301 068 086

5.0 019 017 --- 059 087 --- 059 087 ---

6.0 008 --- --- 048 --- --- 048 --- ---



Recommended W30G cooling airflow range at rated 1000 CFM @ 0.35 ESP (WC) is 820 - 1150 CFMFactory set on Medium Speed for cooling and for heating.


PSE

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0.0 --- --- 0601 0651 0531 0211 0651 0531 0211

1.0 --- --- 0001 0741 0621 0601 0741 0621 0601

2.0 --- 0611 059 0731 0021 0101 0731 0021 0101

3.0 --- 0801 088 0921 0211 049 0921 0211 049

4.0 0511 099 --- 0911 0301 068 0911 0301 068

5.0 0501 019 --- 0901 059 087 0901 059 087

6.0 049 --- --- 089 048 066 089 048 066

PSE

sehcnI

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0.0 --- --- 0601 0651 0531 0211 0651 0531 0211

1.0 --- --- 0001 0741 0621 0601 0741 0621 0601

2.0 --- 0611 059 0731 0021 0101 0731 0021 0101

3.0 --- 0801 088 0921 0211 049 0921 0211 049

4.0 0511 099 --- 0911 0301 068 0911 0301 068

5.0 0501 019 --- 0901 059 087 0901 059 087

6.0 049 --- --- 089 048 066 089 048 066

PSE

sehcnI

H2O




0.0 --- --- 0601 0651 0531 0211 0651 0531 0211

1.0 --- --- 0001 0741 0621 0601 0741 0621 0601

2.0 --- 0611 059 0731 0021 0101 0731 0021 0101

3.0 --- 0801 088 0921 0211 049 0921 0211 049

4.0 0511 099 --- 0911 0301 068 0911 0301 068

5.0 0501 019 --- 0901 059 087 0901 059 087

6.0 049 --- --- 089 048 066 089 048 066



Recommended W36G cooling airflow range at rated 1100 CFM @ 0.250 ESP (WC) is 935 - 1265 CFMFactory set on Medium Speed for cooling and for heating.


PSE

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0.0 --- --- 0601 --- 0531 0211 --- 0531 0211

1.0 --- 0221 0001 --- 0621 0601 --- 0621 0601

2.0 --- 0611 059 0731 0021 0101 --- 0021 0101

3.0 0521 0801 --- 0921 0211 049 --- 0211 049

4.0 0511 099 --- 0911 0301 --- 0911 0301 068

5.0 0501 --- --- 0901 059 --- 0901 059 ---

6.0 049 --- --- 089 --- --- 089 048 ---

PSE

sehcnI

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0.0 --- --- 0601 --- 0531 0211 --- --- 0211

1.0 --- 0221 0001 --- 0621 0601 --- --- 0601

2.0 --- 0611 059 --- 0021 0101 --- --- 0101

3.0 0521 0801 --- --- 0211 049 --- 0211 049

4.0 0511 099 --- 0911 0301 068 --- 0301 068

5.0 0501 --- --- 0901 059 087 0901 059 087

6.0 049 --- --- 089 048 --- 089 048 066

PSE

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0.0 --- --- 0601 --- 0531 0211 --- --- 0211

1.0 --- 0221 0001 --- 0621 0601 --- --- 0601

2.0 --- 0611 059 --- 0021 0101 --- 0021 0101

3.0 0521 0801 --- 0921 0211 049 --- 0211 049

4.0 0511 099 --- 0911 0301 068 --- 0301 068

5.0 0501 --- --- 0901 059 087 0901 059 087

6.0 049 --- --- 089 048 066 089 048 066



Recommended W42G cooling airflow range at rated 1300 CFM @ .35 ESP (WC) is 1500 - 1030 CFMFactory set on Medium Speed for heating and cooling

Voltage adjustment – Reduce airflow by 130 CFM for 208 VoltTop outlet adjustment – Increase airflow by 65 CFM for top outlet modelsSG-5, RG-5, non-ducted application adjustment – Reduce airflow by 170 CFM for SG-5 and RG-5 installations

PSE

sehcnI

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00. --- 0451 0411 --- 0461 0321 --- 0461 0321

01. --- 0841 0901 --- 0851 0811 --- 0851 0811

02. --- 0141 0301 0881 0151 --- --- 0151 0901

03. --- 0631 --- 0671 0641 --- --- 0641 ---

04. --- 0521 --- 0761 0431 --- 0761 0431 ---

05. 0641 0511 --- 0651 0421 --- 0651 0421 ---

06. 0431 0401 --- 0341 0311 --- 0341 0311 ---

PSE

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HsO


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00. --- --- 0911 --- 0961 0821 --- 0961 0821

01. --- 0351 0411 --- 0361 0321 --- 0361 0321

02. --- 0641 0701 --- 0651 0611 --- 0651 0611

03. --- 0141 0501 0181 0151 0411 --- 0151 0411

04. --- 0031 --- 0271 0931 --- 0271 0931 0201

05. 0151 0021 --- 0161 0921 --- 0161 0921 079

06. 0931 0901 --- 0841 0811 --- 0841 0811 ---

PSE

sehcnI

HsO




00. --- --- 0421 --- 0471 0331 --- 0471 0331

01. --- --- 0911 --- 0861 0821 --- 0861 0821

02. --- 0151 0211 --- 0161 0121 --- 0161 0121

03. --- 0641 0011 0681 0651 0911 --- 0651 0911

04. --- 0431 --- 0771 0441 0701 --- 0441 0701

05. --- 0621 --- 0661 0431 079 0661 0431 079

06. 0441 0411 --- 0351 0321 --- 0351 0321 ---



Recommended W48G cooling airflow range at rated 1550 CFM @ .38 ESP (WC) is 1750 - 1280 CFMFactory set on High Speed for cooling and Medium Speed for heating.


PSE

sehcnI

HsO




00. --- 0451 --- --- 0461 0321 --- 0461 0321

01. --- 0841 --- --- 0851 0811 --- 0851 0811

02. 0871 0141 --- 0881 0151 --- --- 0151 0111

03. 0761 0631 --- 0671 0641 --- --- 0641 0901

04. 0751 0521 --- 0761 0431 --- 0761 0431 ---

05. 0641 --- --- 0651 0421 --- 0651 0421 ---

06. 0431 --- --- 0341 --- --- 0341 0311 ---

PSE

sehcnI

HsO




00. --- 0951 --- --- 0961 0821 --- 0961 0821

01. --- 0351 --- --- 0361 0321 --- 0361 0321

02. --- 0641 --- --- 0651 0611 --- 0651 0611

03. 0071 0141 --- 0181 0151 0411 --- 0151 0411

04. 0261 0031 --- 0271 0931 --- 0271 0931 0201

05. 0151 --- --- 0161 0921 --- 0161 0921 079

06. 0931 --- --- 0841 0811 --- 0841 0811 ---

PSE

sehcnI

HsO




00. --- --- 0461 --- 0471 0331 --- 0471 0331

01. --- 0851 --- --- 0861 0821 --- 0861 0821

02. --- 0151 --- --- 0161 0121 --- 0161 0121

03. 0571 0641 --- 0681 0651 0911 --- 0651 0911

04. 0761 0431 --- 0771 0441 0701 --- 0441 0701

05. 0651 0621 --- 0661 0431 079 0661 0431 079

06. 0441 --- --- 0351 0321 --- 0351 0321 ---



Recommended W60G cooling airflow range at rated 1650 CFM @ .30 ESP (WC) is 1910 - 1340 CFMFactory set on High Speed for cooling and Medium Speed for heating.


PSE

sehcnI

HsO




00. 0391 0451 --- --- 0461 0321 --- 0461 0321

01. 0581 0841 --- --- 0851 0811 --- 0851 0811

02. 0871 0141 --- 0881 0151 --- --- 0151 0111

03. 0761 0631 --- 0671 0641 --- --- 0641 0901

04. 0751 --- --- 0761 0431 --- 0761 0431 ---

05. 0641 --- --- 0651 0421 --- 0651 0421 ---

06. 0431 --- --- 0341 --- --- 0341 0311 ---

PSE

sehcnI

HsO




00. --- 0951 --- --- 0961 0821 --- 0961 0821

01. 0091 0351 --- --- 0361 0321 --- 0361 0321

02. 0381 0641 --- --- 0651 0611 --- 0651 0611

03. 0071 0141 --- 0181 0151 0411 --- 0151 0411

04. 0261 --- --- 0271 0931 --- 0271 0931 0201

05. 0151 --- --- 0161 0921 --- 0161 0921 079

06. 0931 --- --- 0841 0811 --- 0841 0811 ---

PSE

sehcnI

HsO




00. --- 0461 --- --- 0471 0331 --- 0471 0331

01. 0591 0851 --- --- 0861 0821 --- 0861 0821

02. 0881 0151 --- --- 0161 0121 --- 0161 0121

03. 0571 0641 --- 0681 0651 0911 --- 0651 0911

04. 0761 0431 --- 0771 0441 0701 --- 0441 0701

05. 0651 --- --- 0661 0431 079 0661 0431 079

06. 0441 --- --- 0351 0321 --- 0351 0321 ---


TABLE 16INTEGRATED FURNACE AND BLOWER CONTROL OPERATION

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33. W**G DEHUMIDIFICATION RELAY LOGIC BOARD

DEHUMIDIFICATION RELAY LOGIC BOARD

1 Cooling takes precedence over dehumidification. A cooling call cancels dehumidification.2 First stage heating cancels dehumidification.3 If jumper on RLB is set to “1-2 full-time dehumidification”, outputs will energize. This is the factory default setting. If jumper is set

to “2-3 occupied dehumidification only”, outputs will be off.

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edoMgnilooC deipuccO X X X X

edoMgnilooC 1 muheDhtiw X X X X X

gnitaeHegatSts1 deipucconU X X

gnitaeHegatSts1 deipuccO X X

gnitaeHegatSts1 2 muheDhtiw X X X

gnitaeHegatSdn2 deipucconU X X

gnitaeHegatSdn2 deipuccO X X

gnitaeHegatSdn2 muheDhtiw X X X

noitacifidimuheD deipucconU X 3 3 3

noitacifidimuheD deipuccO X X X X


FIGURE 19CIRCUIT DIAGRAMS

34. PRESSURE SERVICE PORTSHigh and low pressure service ports are installed on all unitsso that the system operating pressures can be observed.

35. DEHUMIDIFICATION CIRCUITThe dehumidification circuit incorporates an independentheat exchanger coil in the supply air stream. This coilreheats the supply air after it passes over the cooling coilwithout requiring the gas burner to be used for reheatpurposes. This results in very high mechanicaldehumidification capability from the air conditioner ondemand without using gas reheat.

The dehumidification refrigerant reheat circuit is controlledby a three way valve directing the refrigerant gas to thenormal condenser during periods when standard airconditioning is required. During periods of time of lowambient temperature (approximately 65° to 75° outdoor) &high indoor humidity, a humidistat senses the need formechanical dehumidification. It then energizes both the

compressor circuit and the three way valve, thus directingthe hot refrigerant discharge gas into a separatedesuperheating condenser circuit, which reheats theconditioned air before it is delivered to the room. Therefrigerant gas is then routed from the desuperheatingcondenser to the system condenser for further heattransfer. A small orifice inserted between the reheat coilreturn line and suction line will prevent liquid fromaccumulating in the reheat coil when it is inactive. Thisdrain does not affect the normal operation of the system.A check valve is located in the reheat oil return line. Ithas a soft spring to hold the ball on the seat. This willmake the method of checking the ball freedom with amagnet difficult. Refer to Figure 19 for the location of thecheck valve and drain back capillary. When thehumidistat is satisfied, the system automatically switchesback to normal air conditioning mode and either continuesto operate or turns off based on the signal from the wallthermostat. The result is separate humidity control atminimum operating cost.

AIR CONDITIONING MODECIRCUIT DIAGRAM

DEHUMIDIFICATION MODECIRCUIT DIAGRAM


36. REFRIGERANT CHARGEThe correct system R-410A charge is shown on the unitrating plate.

You can reference Table 17 to validate proper systemoperation (+2 psig suction, +5 psig discharge). However,it is recommended that if incorrect charge is suspected, thesystem refrigerant be reclaimed, evacuated and charged tothe nameplate charge quantity and type.

TABLE 17REFRIGERANT CHARGE – PRESSURE TABLES

The nameplate charge quantity is optimized for thermalperformance and efficiency of this self-contained packagesystem.

The system operating pressures in Table 17 are basedupon rated airflow across the evaporator during coolingcycle.

Total system charge for these models can be found inTable 1.

ledoM

riAnruteR

erutarepmeT erusserP °06 °56 °07 °57 °08 °58 °09 °59 °001 °501 °011 °511 °021 °521

2G42W

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ediSwoL

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501

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801

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692

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121

243

421

463

721

783

921

514

131

244

431

964

631

794

831

425

041

255

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ediSwoL

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532

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852

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741

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964

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894

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961

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431

942

731

272

931

692

241

023

441

343

741

763

941

193

251

514

451

344

651

174

951

994

161

725

361

555

561

385

2G84W

BD.ged57

BW.ged26

ediSwoL

ediShgiH

401

142

701

462

011

782

311

113

611

433

911

853

221

183

521

404

621

334

821

264

031

094

231

915

331

845

531

675

BD.ged08

BW.ged76

ediSwoL

ediShgiH

811

942

121

372

421

792

621

123

921

543

231

963

531

393

731

714

931

644

141

674

341

505

541

535

741

565

941

495

BD.ged58

BW.ged27

ediSwoL

ediShgiH

131

952

331

382

631

803

931

233

241

653

441

183

741

404

051

924

251

954

451

984

651

025

951

055

161

185

361

116

2G06W

BD.ged57

BW.ged26

ediSwoL

ediShgiH

801

142

111

762

411

292

611

813

911

343

221

963

521

493

721

024

921

744

031

574

231

305

331

135

531

955

731

785

BD.ged08

BW.ged76

ediSwoL

ediShgiH

321

942

621

572

821

203

131

823

331

453

631

083

831

604

041

334

241

164

441

094

541

915

741

845

941

675

151

506

BD.ged58

BW.ged27

ediSwoL

ediShgiH

631

062

931

682

141

313

441

933

641

663

941

293

151

814

451

544

551

474

751

405

951

435

161

365

361

395

461

226

Low side pressure ± 2 PSIGHigh side pressure ± 5 PSIG

Tables based upon rated CFM (airflow) across the evaporator coil.If there is any doubt as to correct operating charge being in the system, the charge should be reclaimed, systemevacuated and recharged to serial plate instruction.


37. FAN BLADE SETTING DIMENSIONSShown in Figure 20 is the correct fan blade settingdimension for proper air delivery across the outdoor coil.

38. LOW-NOX BURNER ASSEMBLY “N”SUFFIX MODELS ONLY – U.S.INSTALLATIONS ONLY

NATURAL GAS MODELS ONLY

Model numbers designated with an “N” are designedfor low NOx emissions which comply with allCalifornia Air Quality Management District regulationsfor nitrogen oxide emission levels. Refer to Figure 21for NOx insert information.

* * IMPORTANT * *For propane (LP) conversions the NOxreduction screen inserts shown below mustbe removed. This is accomplished byremoving the burner box assembly andremoving the NOx screens. Reassemble unitproperly before firing. Failure to remove theNOx screens can result in improper operationand malfunction of the burner system.

FIGURE 21LOW NOx INSERT

"A"

AIRFLOW

MIS-1724

TABLE 18FAN BLADE DIMENSION

ledoM

noisnemiD

A

G42W 52.1

G03W 52.1

G63W 52.1

G24W 57.1

G84W 57.1

G06W 57.1

FIGURE 20FAN BLADE


INDEXWIRING DIAGRAMS

and LADDER DIAGRAMS

tinU.oNledoM

cisaBmargaiDgniriW

launaM.oNegaP

cisaBmargaiDreddaL

launaM.oNegaP

AD2G42W A561-5804 45 661-5804 55

BD2G42W A362-5804 65 462-5804 75

CD2G42W A683-5804 85 783-5804 95

AD2G03W A761-5804 06 861-5804 16

BD2G03W A562-5804 26 662-5804 36

CD2G03W A883-5804 46 983-5804 56

AD2G63W A761-5804 06 861-5804 16

BD2G63W A562-5804 26 662-5804 36

CD2G63W A883-5804 46 983-5804 56

AD2G24W A761-5804 06 861-5804 16

BD2G24W A562-5804 26 662-5804 36

CD2G24W A883-5804 46 983-5804 56

AD2G84W A961-5804 66 071-5804 55

BD2G84W A762-5804 76 862-5804 75

CD2G84W A093-5804 86 193-5804 96

AD2G06W A961-5804 66 071-5804 55

BD2G06W A762-5804 76 862-5804 75

CD2G06W A093-5804 86 193-5804 96


W24G2DA 230/208-60-1

LPC

CC

HP

C

Y

ALR C

LPC

MIN

UT

ES

4

235

R

1

C

MODULE

HE

RM

FAN

HIGH

Compressor

CONTROL

SWITCH

MOTOR

COMPRESSOR

PRESSURE

23

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 HIGH VOLTAGE CABLE

OUTDOOR FAN

INTEGRATED FURNACE CONTROL 13

VOLTAGESTRIP 11

LOW

CIRCUITBREAKER

CAPACITOR

21

LOWPRESSURE

SWITCH

IF ANY ORIGINAL WIRE AS SUPPLIED WITH THE APPLIANCE MUST BE

16

WIRES CONNECTIF OPTION NOT USED

35

VALVETHREE WAY

GAS VALVE

32 32

37

35

32

32

32

32

59

PRIMARY

ROLLOUT

SPARK IGNITOR

LIMIT

32

FLAME

FLAME SENSOR

36

PRESSURE SWITCH

SR

35

Bard Mfg. Co.

C

Bryan, Ohio

Low Voltage

High Voltage

OptionalFieldFactory

32

LOW AMBIENTCONTROL (OPT.)

44

A

34

20

18

32

32

32

BLOWER SPEED COLOR CODE

HIGH BLACK

MEDIUM BLUE

LOW RED

4085-165 A

BLA

CK

SPEED 150

135

120

BLACK

BLA

CK

FUSE

BLA

CK

/WH

ITE

BLA

CK

/WH

ITE

BLA

CK

/WH

ITE

BLA

CK

BLACK

P3

BROWN

GRAY

BR

OW

N

BLA

CK

/WH

ITE

BLACK

(OPT.)

208/230-60-1

USE COPPER CONDUCTORSSUITABLE FOR AT LEAST 75° C

TERM. BLOCK

BLA

CK

PINK

BLU

E

BLUE

BLUE

1 2 3

4 5 6

8 97

1210 11

BLU

E

BLU

E

L1

L2

A

BLU

E

A

PURPLE

PURPLE

MV

NOC

MV

OR

AN

GE

YELLOW

YELLOW

YE

LLO

W

YELLOW

YELLOW

YE

LLO

W/R

ED

YE

LLOW

YELLOW

Brown

Brown

BROWN/WHITE

35

RED

RE

D

RED/WHITE

RED

RE

D/W

HIT

E

for Bard use only.Wire Identification numbers

RE

D

99

RED

RED/WHITE

32

RED

32

40BLACK

RED40

GROUND TERMINAL

R

C

240V

208V

COM

DRAFT BLOWER

2PL

11

BR

RE

D

INDUCED

Fan MotorIndoor

Capacitor

Evaporator SectionIndoor Fan

CONTACTOR

RED

TRANSFORMER

COMPRESSOR15

RE

D

OPERATION208V TAP FOR 208V

MOVE RED WIRE TO

L1 L2

T1 T2

69

YELLOW

PINK

63

BLACK

LOCKOUT61

CONTROLDEHUM

BR

OW

N

PINK

67

BLACK

65

YE

LLO

W

ORANGE

RELAY

32

PURPLE/WHITE

BLACK/

65

YE

LLO

W

6666 62

BLACK/WHITE

63

RE

D/W

HIT

E

WHITE

ORANGE

PURPLE/WHITE

68

BLA

CK

/WH

ITE

66

37

BLA

CK

32

BLA

CK

Thermostat

Black

32

Black

Freeze

32

64 71

BLACK39

38

42

43RED

38

39

Model C. Breaker Capacitor

W24G2DA 30A 40+5/370


W24G2DA, W48G2DA, W60G2DA 230/208-60-1


W24G2DB 230/208-60-3

LPC

CC

HP

C

Y

ALR C

LPC

MIN

UT

ES

4

235

R

1

IF OPTION WIRES CONNECT

NOT USED

A

PRESSURE

HIGH PRESSURE

SWITCH

LOW

SWITCH

GROUND TERMINAL 15

CAPACITOR

MOTOR

MODULE

23



OUTDOOR FAN

INTEGRATED FURNACE CONTROL 13 LOW VOLTAGE STRIP 11

CIRCUITBREAKER

21


16 COMPRESSORCONTROL

Compressor

35

VALVETHREE WAY

GAS VALVE

32 27

37

35

32

32

32

32

59

PRIMARY

ROLLOUT

SPARK IGNITOR

LIMIT

32

FLAME

FLAME SENSOR

36

PRESSURE SWITCH

T3T1

T2

Bard Mfg. Co.

35

Bryan, Ohio

Low Voltage

High Voltage

OptionalField

32

Factory

44


34

20

18

32

32

32

35


HIGH BLACK

MEDIUM BLUE

LOW RED

4085-263 A

BLA

CK

SPEED 150

135

120

BLACK

BLA

CK

FUSE

BLACK

BLACK

BLACK/WHITE

BLA

CK

BLACK

P3

BROWN

GRAY

BR

OW

N

BLA

CK

/WH

ITE

BLACK

(OPT.)

208/230-60-3

BLA

CK

BLA

CK

/WH

ITE

BLA

CK

/WH

ITE


TERM. BLOCK

BLA

CK

/WH

ITE

PINK

L1

BLUE

BLUE

1 2 3

4 5 6

8 97

1210 11

BLU

E

BLU

E

L3

L2

A

BLU

E

A

BLU

E

PURPLE

PURPLE

MV

NOC

MV

32

OR

AN

GE

YELLOW

YELLOW

YE

LLO

W

YELLOW

YELLOW/BLACK

YELLOW/RED

YE

LLOW

YELLOW

YE

LLO

W

YELLOW

YELLOW/BLACK

YELLOW

Brown

Brown

BROWN/WHITE

37

RED

RE

D

RED/WHITE

RED

RE

D/W

HIT

E


99

RED

RED/WHITE

32

RED

32

40BLACK

RED

R

C

240V

208V

COM

DRAFT BLOWER

2PL

11

BR

RE

D

INDUCED

Fan MotorIndoor

Capacitor


CONTACTOR

TRANSFORMER

COMPRESSOR

RE

D

L1 L2

T1 T2

L3

T3

40

PHASE MONITOR


MOVE RED WIRE TO

25

RED

28

RED29

3031

41

42

43RE

D

38

39

32

27

38 39

RE

D

69

BLA

CK

/WH

ITE

PURPLE/WHITE

66

ORANGE

RE

D/W

HIT

E

68

BLACK/WHITE

63

626666

YE

LLO

W

PURPLE/WHITE

WHITE

65

ORANGE

BLACK/

32

YE

LLO

W

BLACK

PINK

65

BR

OW

N

67

CONTROLDEHUM

BLACKPINK

YELLOW

61RELAY

LOCKOUT

BLA

CK

63

BLA

CK

64

Thermostat

Black

32

Black

Freeze

71

Model C. Breaker Fan Capacitor

W24G2DB 25A 5/370


W24G2DB, W48G2DB, W60G2DB 230/208-60-3


W24G2DC 460-60-3

LPC

CC

HP

C

Y

ALR C

LPC

MIN

UT

ES

4

235

R

1

MODULE

HIGH

Compressor

CONTROL

SWITCH

MOTOR

COMPRESSOR

PRESSURE

23



OUTDOOR FAN


STRIP 11

LOW VOLTAGE

DISCONNECT

CAPACITOR

21

LOWPRESSURE

SWITCH


16


L1

OR

AN

GE

32

54

GAS VALVE

32 27

37

35

32

32

32

32

59

PRIMARY

ROLLOUT

SPARK IGNITOR

LIMIT

FLAME

FLAME SENSOR

56

THREE WAYVALVE

36

PRESSURE SWITCH

T3T1

T2

Bard Mfg. Co.

Bryan, Ohio

4085-386 ALow Voltage

High Voltage


32


44

A

34

20

18

32

32

32

35

37

2

3

35

1

2

31

2

35

3

4

48

1

57

57

48

57

48

49

45

45

47

57

45

46

25

RE

D


HIGH BLACK

MEDIUM BLUE

LOW RED

AUX PURPLE/ORANGE

DEHUM

SPEED 150

135

120

BLACK

WHITE

FUSE

BLACK

CONTROL

BLACK/

BLA

CK

BLACK

P3

BROWN

GRAY

BR

OW

N

BLA

CK

/WH

ITE

BLACK

(OPT.)

460-60-3

BLA

CK

/WH

ITE

BLA

CK

/WH

ITE

BLA

CK

/WH

ITE

BLACK

BLACK/WHITE

BLACK

BLA

CK

BLA

CK

/WH

ITE

BLA

CK

BlackBlack

BLA

CK

BLA

CK

BLACK/WHITE

TERM. BLOCK


LOCKOUT RELAY

PINK

PINK

PINK PINK

BLUE

BLUE

1 2 3

4 5 6

8 97

1210 11

BLU

E

L2

BLU

E

L3

A

A

BLU

E

BLA

CK

YE

LLOW

PU

RP

LE

BLU

E

PURPLE/WHITE

PURPLE

PURPLE

PURPLE

PURPLE/WHITE

MV

NOC

MV

ORANGE

ORANGE

YE

LLO

W

YELLOW

YE

LLO

WY

ELL

OW

YELLOW/BLACK

YELLOW/RED

YELLOW

YELLOW

YE

LLO

WYELLOW

YELLOW/BLACK

YELLOW

YELLOW

YE

LLO

W

65

YELLOW

BR

OW

N

Brown

Brown

BROWN/WHITE

BROWN/WHITE

1RED

RE

D

RED/WHITE

RED

RE

D/W

HIT

E

66


99

RED32

RED/WHITE

64

RED

32

40BLACK

RED

R

C

460V

COM

2PL

1DRAFT BLOWER

BR

INDUCED

MotorFan

Capacitor


CONTACTOR

40

TRANSFORMER

COMPRESSOR

Indoor

35

GROUND TERMINAL

L1 L2

T1 T2

L3

T3

PHASE MONITOR

15

RED

28

RED29

3031

41

42

43

RE

D

38

39

32

2

31

5

46

RED

27

RE

D

BLOWER RELAYMED. SPEED

RELAY BLOWER

BLOWER RELAYINDUCED DRAFT

LOW SPEED

RELAYBLOWERSPEED HIGH

28

54 55

58

53

ThermostatFreeze

5032

WH

ITE

68

RE

D/W

HIT

E

RE

D/

63

6266 66

69

32

32

65

67

61

63

52

71

Model Fan Capacitor

W30G2DC 5/370

W36G2DC 5/370

W42G2DC 15/370


W24G2DC 460-60-3


W30G2DA, W36G2DA, W42G2DA 230/208-60-1

LPC

CC

HP

C

Y

ALR C

LPC

MIN

UT

ES

4

235

R

1


NOT USED

A

B

WIRE NOT APPLICABLE TO ALL MODELS

BLACK39

38

42

43RED

38

39

(OPT.)

SPEED 150

135

120

BLA

CK

BLA

CK

/WH

ITE

FUSE

TERM. BLOCK

BLA

CK

BLA

CK

BLACK

P3

BROWN

GRAY

BR

OW

N

BLA

CK

/WH

ITE

BLACK

208/230-60-1

BLA

CK

BLACK

BLA

CK

/WH

ITE

BLA

CK

/WH

ITE


B

PINK

BLU

E

BLUE

BLUE

1 2 3

4 5 6

8 97

1210 11

BLU

E

BLU

E

L1

L2

A

BLU

E

A

PURPLE

PURPLE

MV

NOC

MV

OR

AN

GE

YELLOW

YELLOW

YE

LLO

W

YELLOW

YELLOW

YE

LLO

W/R

ED

YE

LLOW

YELLOW

Brown

Brown

BROWN/WHITE

RED

RE

D

RE

D

RED/WHITE

RED

RE

D/W

HIT

E

69


99

RED

RED/WHITE

32

RED

32

40BLACK

RED40

GROUND TERMINAL

R

C

240V

208V

COM

DRAFT BLOWER

2PL

11

BR

RE

D

INDUCED

Fan MotorIndoor

Capacitor


CONTACTOR

RED

TRANSFORMER

COMPRESSOR15

RE

D


MOVE RED WIRE TO

L1 L2

T1 T2

RE

D

35

RELAY

YELLOW

PINK

63

BLACK

LOCKOUT61

CONTROLDEHUM

BR

OW

N

PINK

67

BLACK

65

YE

LLO

W

ORANGE

WHITE

32

PURPLE/WHITE

BLACK/

65

YE

LLO

W

6666 62

BLACK/WHITE

63

RE

D/W

HIT

E

ORANGE

PURPLE/WHITE

68

BLA

CK

/WH

ITE

66

37

BLA

CK

32

BLA

CK

Thermostat

Black

32

Black

Freeze

32

64

52

71

FAN

C

MODULE

HIGH

SWITCH

MOTOR

HE

RM

PRESSURE

23



OUTDOOR FAN


VOLTAGESTRIP 11

LOW

CIRCUITBREAKER

CAPACITOR

21

LOWPRESSURE

SWITCH



Compressor

35

VALVETHREE WAY

GAS VALVE

32 32

37

35

32

32

32

32

59

PRIMARY

ROLLOUT

SPARK IGNITOR

LIMIT

32

FLAME

FLAME SENSOR

36

PRESSURE SWITCH

SR

35

C

Bard Mfg. Co.

Bryan, Ohio

Low Voltage

High Voltage

OptionalField

32

Factory

44


34

20

18

32

32

32


HIGH BLACK

MEDIUM BLUE

LOW RED

4085-167 A


W30G2DA 30A 45+5/370

W36G2DA 35A 45+5/370

W42G2DA 50A 45+10/370


W30G2DA, W36G2DA, W42G2DA 230/208-60-1


W30G2DB, W36G2DB, W42G2DB 230/208-60-3

LPC

CC

HP

C

Y

ALR C

LPC

MIN

UT

ES

4

235

R

1


NOT USED

A

GROUND TERMINAL 15

SWITCH

HIGH

SWITCH

MOTOR

MODULE

PRESSURE

23



OUTDOOR FAN


CIRCUITBREAKER

CAPACITOR

21

LOWPRESSURE



Compressor

35

B

TO ALL MODELSWIRE NOT APPLICABLE

VALVE

B

GAS VALVE

32 27

37

35

32

32

32

32

59

PRIMARY

ROLLOUT

SPARK IGNITOR

LIMIT

32

FLAME

FLAME SENSOR

36

PRESSURE SWITCH

T3T1

T2

35

Bard Mfg. Co.

Bryan, Ohio

Low Voltage

High Voltage

OptionalField

32

Factory

44


34

20

18

32

32

32

35

THREE WAY


HIGH BLACK

MEDIUM BLUE

LOW RED

4085-265 A

BLA

CK

SPEED 150

135

120

BLACK

BLA

CK

FUSE

BLACK

BLACK

BLACK/WHITE

BLA

CK

BLACK

P3

BROWN

GRAY

BR

OW

N

BLA

CK

/WH

ITE

BLACK

(OPT.)

208/230-60-3

BLA

CK

BLA

CK

/WH

ITE

BLA

CK

/WH

ITE


TERM. BLOCK

BLA

CK

/WH

ITE

PINK

L1

BLUE

BLUE

1 2 3

4 5 6

8 97

1210 11

BLU

E

BLU

E

L3

L2

A

BLU

E

A

BLU

E

PURPLE

PURPLE

MV

NOC

MV

32

OR

AN

GE

YELLOW

YELLOW

YE

LLO

W

YELLOW

YELLOW/BLACK

YELLOW/RED

YE

LLOW

YELLOW

YE

LLO

W

YELLOW

YELLOW/BLACK

YELLOW

Brown

Brown

BROWN/WHITE

RED

RE

D

RE

D

RED/WHITE

RED

RE

D/W

HIT

E

69


99

RED

RED/WHITE

32

RED

32

40BLACK

RED

R

C

240V

208V

COM

DRAFT BLOWER

2PL

11

BR

RE

D

INDUCED

Fan MotorIndoor

Capacitor


CONTACTOR

TRANSFORMER

COMPRESSOR

RE

D

L1 L2

T1 T2

L3

T3

40

PHASE MONITOR


MOVE RED WIRE TO

25

RED

28

RED29

3031

41

42

43RE

D

38

39

32

27

38

RE

D

39

37

BLA

CK

/WH

ITE

PURPLE/WHITE

66

ORANGE

RE

D/W

HIT

E

68

BLACK/WHITE

63

626666

YE

LLO

W

PURPLE/WHITE

WHITE

65

ORANGE

BLACK/

32

YE

LLO

W

BLACK

PINK

65

BR

OW

N

67

CONTROLDEHUM

BLACKPINK

YELLOW

61RELAYLOCKOUT

BLA

CK

63

BLA

CK

64

Thermostat

Black

32

Black

Freeze

52

71


W30G2DB 25A 5/370

W36G2DB 35A 5/370

W42G2DB 35A 10/370


W30G2DB, W36G2DB, W42G2DB 230/208-60-3


W30G2DC, W36G2DC, W42G2DC 460-60-3

LPC

CC

HP

C

Y

ALR C

LPC

MIN

UT

ES

4

235

R

1

DEHUM

SPEED 150

135

120

BLACK

WHITE

FUSE

BLACK

CONTROL

BLACK/

BLA

CK

BLACK

P3

BROWN

GRAY

BR

OW

N

BLA

CK

/WH

ITE

BLACK

(OPT.)

460-60-3

BLA

CK

/WH

ITE

BLA

CK

/WH

ITE

BLA

CK

/WH

ITE

BLACK

BLACK/WHITE

BLACK

BLA

CK

BLA

CK

/WH

ITE

BLA

CK

BlackBlack

BLA

CK

BLA

CK

BLACK/WHITE

TERM. BLOCK


LOCKOUT RELAY

PINK

PINK

PINK PINK

BLUE

BLUE

1 2 3

4 5 6

8 97

1210 11

BLU

E

L2

BLU

E

L3

A

A

BLU

E

BLA

CK

YE

LLOW

PU

RP

LE

BLU

E

PURPLE/WHITE

PURPLE

PURPLE

PURPLE

PURPLE/WHITE

MV

NOC

MV

ORANGE

ORANGE

YE

LLO

W

YELLOW

YE

LLO

WY

ELL

OW

YELLOW/BLACK

YELLOW/RED

YELLOW

YELLOW

YE

LLO

WYELLOW

YELLOW/BLACK

YELLOW

YELLOW

YE

LLO

W

65

YELLOW

BR

OW

N

Brown

Brown

BROWN/WHITE

BROWN/WHITE

RE

D

RED

RED/WHITE

RED

RE

D/W

HIT

E

66


99

RED32

RED/WHITE

64

RED

32

40BLACK

RED

R

C

460V

COM

DRAFT BLOWER

2PL

11

BR

INDUCED

MotorFan

Capacitor


CONTACTOR

40

TRANSFORMER

COMPRESSOR

Indoor

35

GROUND TERMINAL

L1 L2

T1 T2

L3

T3

PHASE MONITOR

15

RED

28

RED29

3031

41

42

43

RE

D

38

39

32

2

31

5

46

RED

27

RE

D


RELAY BLOWER


LOW SPEED


28

54 55

58

53

ThermostatFreeze

5032

WH

ITE

68

RE

D/W

HIT

E

RE

D/

63

6266 66

69

32

32

65

67

61

63

52

71

MODULE

HIGH

Compressor

CONTROL

SWITCH

MOTOR

COMPRESSOR

PRESSURE

23



OUTDOOR FAN


STRIP 11

LOW VOLTAGE

DISCONNECT

CAPACITOR

21

LOWPRESSURE

SWITCH


16


L1

OR

AN

GE

THREE WAYVALVE

54

56

GAS VALVE

32 27

37

35

32

32

32

32

59

PRIMARY

ROLLOUT

SPARK IGNITOR

LIMIT

32

FLAME

FLAME SENSOR

36

PRESSURE SWITCH

T3T1

T2

Bard Mfg. Co.

Bryan, Ohio


High Voltage


32


44

A

34

20

18

32

32

32

35

37

2

3

35

1

2

31

2

35

3

4

48

1

57

57

48

57

48

49

45

45

47

57

45

46

25

RE

D


HIGH BLACK

MEDIUM BLUE

LOW RED

AUX PURPLE/ORANGE

Model Fan Capacitor

W30G2DC 5/370

W36G2DC 5/370

W42G2DC 15/370


W30G2DC, W36G2DC, W42G2DC 460-60-3


W48G2DA, W60G2DA 230/208-60-1

LPC

CC

HP

C

Y

ALR C

LPC

MIN

UT

ES

4

235

R

112

0

SPEED 150

135

BLA

CK

/WH

ITE

BLACK

BLA

CK

FUSE

BLA

CK

BLA

CK

/WH

ITE

BLA

CK

/WH

ITE

BLA

CK

BLACK

P3

BROWN

GRAY

BR

OW

N

BLA

CK

/WH

ITE

BLACK

(OPT.)

208/230-60-1


TERM. BLOCK

BLA

CK

PINK

3

BLUE

BLUE

BLU

E

21

4 5 6

8 97

1210 11

BLU

E

BLU

E

L1

L2

A

BLU

E

A

PURPLE

PURPLE

MV

NOC

MV

OR

AN

GE

YELLOW

YELLOW

YE

LLO

W

YELLOW

YELLOW

YE

LLO

W/R

ED

YE

LLOW

YELLOW

Brown

Brown

BROWN/WHITE

35

RED

RE

D

RE

D

RED/WHITE

RED

RE

D/W

HIT

E


RE

D

99

RED

RED/WHITE

32

RED

32

40BLACK

RED40

GROUND TERMINAL

R

C

240V

208V

COM

DRAFT BLOWER

2PL

11

BR

RE

D

INDUCED

Fan MotorIndoor

Capacitor

CONTACTOR

RED

TRANSFORMER

COMPRESSOR15

RE

D


MOVE RED WIRE TO

L1 L2

T1

32

RELAY

Freeze

Black

T2

YELLOW

PINK

63

BLACK

LOCKOUT61

CONTROLDEHUM

BR

OW

N

PINK

67

BLACK

65

YE

LLO

W

ORANGE

WHITE

32

PURPLE/WHITE

BLACK/

65

YE

LLO

W

6666 62

BLACK/WHITE

63

RE

D/W

HIT

E

ORANGE

PURPLE/WHITE

68

BLA

CK

/WH

ITE

66

37

BLA

CK

69

Indoor FanEvaporator Section

Thermostat

Black

32

BLA

CK

32

64 71

BLACK39

38

42

43RED

38

39

C

MODULE

HE

RM

FAN

HIGH

Compressor

CONTROL

SWITCH

COMPRESSOR

MOTOR

PRESSURE

23



OUTDOOR FAN


VOLTAGESTRIP 11

LOW

CIRCUITBREAKER

CAPACITOR

21

LOWPRESSURE

SWITCH


16


34

35

VALVETHREE WAY

GAS VALVE

32 32

37

35

32

32

32

32

59

PRIMARY

ROLLOUT

SPARK IGNITOR

LIMIT

32

FLAME

FLAME SENSOR

36

PRESSURE SWITCH

SR

C

Bard Mfg. Co.

Bryan, Ohio

Low Voltage

High Voltage


32


44

A

35 20

18

32

32

32


HIGH BLACK

MEDIUM BLUE

LOW RED

4085-169 A


W48G2DA 50A 70+10/370

W60G2DA 60A 80+10/370


W48G2DB, W60G2DB 230/208-60-3

LPC

CC

HP

C

Y

ALR C

LPC

MIN

UT

ES

4

235

R

1

GROUND TERMINAL 15

BLA

CK

SPEED 150

135

120

BLACK

BLA

CK

FUSE

BLACK

BLACK

BLACK/WHITE

BLA

CK

BLACK

P3

BROWN

GRAY

BR

OW

N

BLA

CK

/WH

ITE

BLACK

(OPT.)

208/230-60-3

BLA

CK

BLA

CK

/WH

ITE

BLA

CK

/WH

ITE


TERM. BLOCK

BLA

CK

/WH

ITE

PINK

L1

BLUE

BLUE

1 2 3

4 5 6

8 97

1210 11

BLU

E

BLU

E

L3

L2

A

BLU

E

A

BLU

E

PURPLE

PURPLE

MV

NOC

MV

32

OR

AN

GE

YELLOW

YELLOW

YE

LLO

WY

ELL

OW

YELLOW/BLACK

YELLOW/RED

YE

LLOW

YELLOW

YE

LLO

W

YELLOW

YELLOW/BLACK

YELLOW

Brown

Brown

BROWN/WHITE

37

RED

RE

D

RE

D

RED/WHITE

RED

RE

D/W

HIT

E


99

RED

RED/WHITE

32

RED

32

40BLACK

RED

R

C

240V

208V

COM

DRAFT BLOWER

2PL

11

BR

RE

D

INDUCED

Fan MotorIndoor

Capacitor


CONTACTOR

TRANSFORMER

COMPRESSOR

RE

D

L1 L2

T1 T2

L3

T3

40

PHASE MONITOR


MOVE RED WIRE TO

25

RED

28

RED29

3031

41

42

43RE

D

38

39

32

27

38 39

RE

D

69

BLA

CK

/WH

ITE

PURPLE/WHITE

66

ORANGE

RE

D/W

HIT

E

68

BLACK/WHITE

63

626666

YE

LLO

W

PURPLE/WHITE

WHITE

65

ORANGE

BLACK/

32

YE

LLO

W

BLACK

PINK

65

BR

OW

N

67

CONTROLDEHUM

BLACKPINK

YELLOW

61RELAYLOCKOUT

BLA

CK

63

BLA

CK

64

Thermostat

Black

32

Black

Freeze

71

MODULE

HIGH

Compressor

CONTROL

SWITCH

MOTOR

COMPRESSOR

PRESSURE

23



OUTDOOR FAN


CIRCUITBREAKER

CAPACITOR

21

LOWPRESSURE

SWITCH


16


35

THREE WAYVALVE

ROLLOUTFLAME

GAS VALVE

32 27

37

35

32

32

32

32

59

LIMIT

SPARK IGNITOR

32

PRIMARY

FLAME SENSOR

36

PRESSURE SWITCH

T3T1

T2

Bard Mfg. Co.

35

Bryan, Ohio

Low Voltage

High Voltage


32


44

A

34

20

18

32

32

32

35


HIGH BLACK

MEDIUM BLUE

LOW RED

4085-267 A


W48G2DB 35A 10/370

W60G2DB 40A 10/370


W48G2DC, W60G2DC 460-60-3

LPC

CC

HP

C

Y

ALR C

LPC

MIN

UT

ES

4

235

R

1

DEHUM

SPEED 150

135

120

BLACK

WHITE

FUSE

BLACK

CONTROL

BLACK/

BLA

CK

BLACK

P3

BROWN

GRAY

BR

OW

N

BLA

CK

/WH

ITE

BLACK

(OPT.)

460-60-3

BLA

CK

/WH

ITE

BLA

CK

/WH

ITE

BLA

CK

/WH

ITE

BLACK

BLACK/WHITE

BLACK

BLA

CK

BLA

CK

/WH

ITE

BLACK

BlackBlack

BLA

CK

BLA

CK

BLACK/WHITE

TERM. BLOCK


LOCKOUTRELAY

PINK

PINK

PINK PINK

11

BLUE

BLUE

1 2 3

4 5 6

8 97

1210

BLU

E

L2

BLU

E

L3

A

A

BLU

E

BLA

CK

YE

LLOW

PU

RP

LE

BLU

E

PURPLE/WHITE

PURPLE

PURPLE

PURPLE

PURPLE/WHITE

MV

NOC

MV

ORANGE

ORANGE

YE

LLO

W

YELLOW

YE

LLO

WY

ELL

OW

YELLOW/BLACK

YELLOW/RED

YELLOW

YELLOW

YE

LLO

WYELLOW

YELLOW/BLACK

YELLOW

YELLOW

YE

LLO

W

65

YELLOW

BR

OW

N

Brown

Brown

BROWN/WHITE

BROWN/WHITE

RED/WHITE

RED

RE

D

RED

RE

D/W

HIT

E

63


99

RED32

RED/WHITE

64

RED

32

40BLACK

RED

R

C

460V

COM

DRAFT BLOWER

2PL

11

BR

INDUCED

MotorFan

Capacitor


CONTACTOR

40

TRANSFORMER

COMPRESSOR

Indoor

35

GROUND TERMINAL

L1 L2

T1 T2

L3

T3

PHASE MONITOR

15

RED

28

RED29

3031

41

42

43

RE

D

38

39

32

2

31

5

46

RED

27

RE

D


RELAY BLOWER


LOW SPEED

28


5455

58

54

ThermostatFreeze

5032

WH

ITE

68

RE

D/W

HIT

E

RE

D/

63

626666

69

32

32

65

67

61

71

MODULE

HIGH

Compressor

CONTROL

SWITCH

MOTOR

COMPRESSOR

PRESSURE

23



OUTDOOR FAN


STRIP 11

LOW VOLTAGE

DISCONNECT

CAPACITOR

21

LOWPRESSURE

SWITCH


16


L1

OR

AN

GE

56

66

GAS VALVE

32 27

37

35

32

32

32

32

59

PRIMARY

ROLLOUT

SPARK IGNITOR

LIMIT

32

FLAME

FLAME SENSOR

36

PRESSURE SWITCH

T3T1

T2

Bard Mfg. Co.

Bryan, Ohio


High Voltage


32


44

A

34

20

18

32

32

32

35

37

2

3

35

1

2

31

2

35

3

4

48

1

57

57

48

57

48

49

45

45

47

57

45

46

25

RE

D

54


HIGH BLACK

MEDIUM BLUE

LOW RED

AUX PURPLE/ORANGE

Model Fan Capacitor

W48G2DC 15/370

W60G2DC 15/370


W48G2DC, W60G2DC 460-60-3

Documents

2100-592(B) (2013 09) - Bard HVACB).… · New York, NY 10036 Telephone: (212) 642-4900 Fax: (212) 302-1286 ASHRAE American Society of Heating Refrigerating, and Air Conditioning