Bard W24G1-A User manual

Manual 2100-525A
Page 1 of 67
WG - SERIES
COMBINATION GAS/ELECTRIC
WALL-MOUNT
MODELS:
W24G1-A W24G1-B W24G1-C W30G1-A W30G1-B W30G1-C W36G1-A
W36G1-B W36G1-C W42G1-A W42G1-B W42G1-C W48G1-A W48G1-B
W48G1-C W60G1-A W60G1-B W60G1-C
Manual No.: 2100-525A
Supersedes: 2100-525
File: Volume III, Tab 20
Date: 04-07-10
Bard Manufacturing Company, Inc.
Bryan, Ohio 43506
Since 1914...Moving ahead just as planned.
© Copyright 2010
WARNING
READ ALL INSTRUCTIONS CAREFULLY BEFORE
BEGINNING THE INSTALLATION.
THE INSTALLATION MUST COMPLY WITH THESE
INSTRUCTIONS AND THE REQUIREMENTS OF ALL
GOVERNING CODES AND ORDINANCES FOR THE
INSTALLATION LOCATION.
IT IS THE RESPONSIBILITY OF INSTALLER TO KNOW
AND UNDERSTAND ALL OF THESE REQUIREMENTS.
FAILURE TO DO SO COULD CREATE A HAZARD
RESULTING IN PROPERTY DAMAGE, BODILY INJURY,
OR DEATH.
INSTALLATION
INSTRUCTIONS

Manual 2100-525A
Page 2 of 67
CONTENTS
Getting Other Information and Publications .............. 4
W**G Series Model Nomenclature ............................ 5
Ventilation Options .................................................... 5
Air Conditioning Module Options ............................... 6
1. Important ............................................................ 6
2. Application .......................................................... 6
3. Duct Work .................................................. 6 & 10
4. High Altitude Applications ................................. 10
5. Transportation Damage .................................... 10
6. Installation ........................................................ 10
7. Wall Mounting .................................................. 11
8. Mounting the Unit ............................................. 11
9. Clearances ....................................................... 17
10. Vent Terminal and Combustion Inlet Hood ....... 18
11. Optional Vertical Venting .................................. 18
12. Vent Resizing Instructions ................................ 19
13. Fresh Air Intake ................................................ 19
14. Condensate Drain ............................................ 19
15. Wiring – Main Power ........................................ 20
16. Wiring – Low Voltage Wiring ............................ 21
17. Thermostats ...................................................... 21
18. Gas Supply & Piping ........................................ 26
19. Manifold Pressure Adjustment .......................... 27
20. Checking Gas Input Rate ......................... 27 & 28
21. Standard Orifice Sizing & High
Altitude Derate .................................................. 29
22. Conversion of Gas Input BTUH From High
to Low Rating ................................................... 32
23. Measuring Air Temperature Rise ...................... 32
24. Filters ................................................................ 33
25. Compressor Control Module..................... 33 & 34
26. Lighting & Shutdown Instructions ..................... 36
27. Service Agency Procedures ............................. 36
28. Maintaining Unit in Good Working Order .. 36 & 37
29. Replacement Parts ............................................ 37
30. Sequence of Operation – Heating .................... 38
31. Sequence of Operation – Cooling .................... 38
32. Indoor Blower Operation .................................. 39
33. Pressure Service Ports ..................................... 47
34. Refrigerant Charge ........................................... 48
35. Fan Blade Setting Dimensions ......................... 48
36. Low NOx Burner Assembly "N" Suffix
Models Only – U.S. Installations Only .............. 48
Index – Wiring Diagrams ......................................... 49
Wiring Diagrams ............................................. 50 – 67
Page Page

Manual 2100-525A
Page 3 of 67
CONTENTS
FIGURES
Figure 1 Unit Dimensions ..................................... 9
Figure 2 Mounting Instructions – W24-36G ....... 12
Figure 2A Mounting Instructions – W42-60G ....... 13
Figure 3 Combustible Clearance – W24-36G .... 14
Figure 3A Combustible Clearance – W42-60G .... 14
Figure 4 Wall Mounting Instructions ................... 15
Figure 5 Wall Mounting Instructions ................... 15
Figure 6 Common Wall Mounting Installations ... 16
Figure 7 Location of Vent Terminal in Shipping .. 17
Figure 8 Vent Terminal & Combustion
Air Intake .............................................. 18
Figure 9 Fresh Air Damper ................................. 19
Figure 10 Installation of Flexible Conduit ............. 21
Figure 11 Low Voltage Wiring-No Vent Pkg. ........ 22
Figure 12 Low Voltage Wiring .............................. 23
Figure 13 Low Voltage Wiring-EIFM Econo. ........ 24
Figure 14 Gas Pipe Connection ........................... 25
Figure 15 Proper Piping Practice ......................... 26
Figure 16 Access Internal Filter through
Upper Service Door .............................. 33
Figure 17 Lighting & Shutdown Instruction Label . 35
Figure 18 Top View of Gas Control ...................... 36
Figure 19 Sequence of Operation – Electronic
Blower Control ...................................... 38
Figure 20 Furnace Control Board &
Blower Control ...................................... 39
Figure 21 Fan Blade ............................................. 48
Figure 22 Low NOx Insert .................................... 48
TABLES
Table 1 Specifications – W24-36G Models ........... 7
Table 1A Specifications – W42-60G Models ........... 8
Table 2 Minimum Installation Clearances ........... 17
Table 3 Thermostat Wire Size ............................ 21
Table 4 Wall Thermostat ..................................... 21
Table 5 Length of Standard Pipe Threads .......... 26
Table 6 Gas Pipe Sizes – Natural Gas ............... 26
Table 7 Natural Gas Derate Capacities
For All Models ........................................ 29
Table 8 Natural Gas Orifice Tables – W24-36G .. 30
Table 8A Natural Gas Orifice Tables – W42-60G .. 31
Table 9 Motor Speed Taps .................................. 39
Table 10 W24G Indoor Blower Performance ........ 40
Table 11 W30G Indoor Blower Performance ........ 41
Table 12 W36G Indoor Blower Performance ........ 42
Table 13 W42G Indoor Blower Performance ........ 43
Table 14 W48G Indoor Blower Performance ........ 44
Table 15 W60G Indoor Blower Performance ........ 45
Table 16 Integrated Furnace & Blower
Control Operation ................................... 46
Table 17A W24G1-W36G1
Cooling Pressure Table .......................... 47
Table 17B W42G1-W60G1
Cooling Pressure Table .......................... 47
Table 18 Refrigerant Charge ................................ 48
Table 19 Fan Blade Dimension ............................. 48
Page Page

Manual 2100-525A
Page 4 of 67
Getting Other Information and Publications
FOR MORE INFORMATION, CONTACT
THESE PUBLISHERS:
ACCA Air Conditioning Contractors of America
1712 New Hampshire Avenue, NW
Washington, DC 20009
Telephone: [phone]
ANSI American National Standards Institute
11 West Street, 13th Floor
New York, NY 10036
Telephone: [phone]
Fax: [phone]
ASHRAE American Society of Heating Refrigerating,
and Air Conditioning Engineers, Inc.
1791 Tullie Circle, NE.
Atlanta, GA 30329-2305
Telephone: [phone]
Fax: [phone]
NFPA National Fire Protection Association
Batterymarch Park
P.O. Box 9101
Quincy, MA 02269-9901
Telephone: [phone]
Fax: [phone]
CSA Canadian Standards Association
178 Rexdale Boulevard
Rexdale, Ontario
Canada. M9W 1R3
Telephone: [phone]
COPYRIGHT JANUARY 2010
BARD MANUFACTURING COMPANY, INC.
BRYAN, OHIO 43506 USA
Manufactured under the following U.S. patent numbers:
5,485,878; 5,002,116
These publications can help you install the furnace. You
can usually find these at your local library or purchase
them directly from the publisher. Be sure to consult
current 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 90A
of Air Conditioning and Ventilating Systems
Standard for Warm Air ..................... ANSI / NFPA 90B
Heating and Air Conditioning Systems
Standard for Chimneys, ................................. NFPA 211
Fireplaces, Vents, and Solid Fuel Burning Appliances
Load Calculation for............................ ACCA Manual J
Residential Winter and Summer Air Conditioning
Duct Design for Residential ............... ACCA Manual D
Winter and Winter Air Conditioning and Equipment
Selection
Canadian Electrical Code ............................. CSA C22.1
Canadian Installation Code …………… CAN/CGA B149

Manual 2100-525A
Page 5 of 67
W42 G1– A X C X X X X X X
WALL MOUNT GAS/ELECTRIC GENERAL
MODEL NUMBER NOMENCLATURE
1 Low ambient control is required with economizer for low temperature compressor operation.
VENTILATION OPTIONS
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MODEL
Wall Mount
CONTROL OPTIONS
(See Table page 6)
VENT
(See Table
Below)
COOLING
CAPACITY
24 = 2 ton
30 = 2½ton
36 = 3 ton
42 = 3½ton
48 = 4 ton
60 = 5 ton OUTLET
X = Front (Standard)
T=Top
COIL OPTIONS
X = Standard
1 = Phenolic coated evaporator
2 = Phenolic coated condenser
3 = Phenolic coated both coils
COLOR
X = Beige
(Standard)
4 = Gray
FILTER
X = 2" Pleated (Standard)
W = 1" Washable
VOLTAGE
A = 230/208-60-1
B = 230/208-60-3
C = 460-60-3
REVISION
FEATURE
(-) = Standard
D = Dehumidification
C = Canadian Approval
EMISSIONS
X = Standard
N = NOx Certified
*125,000 BTU input model is not NOx certified.
HEATING INPUT
2 - 3 Ton 3.5 - 5 Ton
A = 45,000 B = 75,000
B = 67,500 C= 100,000
C = 90,000 D= 125,000*
GAS/
ELECTRIC

Manual 2100-525A
Page 6 of 67
1. IMPORTANT
The equipment covered in this manual is to be installed
by trained, experienced service and installation
technicians. All duct work or portions thereof not in
the conditioned space should be properly insulated in
order to both conserve energy and prevent condensation
or moisture damage.
2. APPLICATION
This is a fan-assisted forced air gas furnace with
electric air conditioning for outdoor installation. A
fan-assisted furnace is equipped with an integral
mechanical means to draw products of combustion
through the combustion chamber and heat exchanger.
The furnace installation must conform with local
building codes and ordinances or, in their absence, with
the National Fuel Gas Code ANSI Z223.1 or CAN/
CGA-B149.1, latest edition, and the National Electrical
Code ANSI/NFPA-7 or CSA C22.1, latest edition. It is
the personal responsibility and obligation of the
purchaser to contact a qualified installer to assure that
installation is adequate and is in conformance with
governing codes and ordinances.
3. DUCT WORK
The unit is designed for use with or without duct work.
See Warning on Page 10. Flanges are provided for
attaching the supply and return ducts. These
instructions explain the recommended method to install
the air cooled self-contained electric air conditioning
and gas heating unit and the electrical wiring
connections and gas piping to the unit. The refrigerant
system is completely assembled and charged. All
internal wiring is complete.
These instructions and any instructions packaged with
any separate equipment required to make up the entire
heating/cooling system should be carefully read before
beginning the installation. Note particularly “Starting
Procedure” and any tags and/or labels attached to the
equipment.
All duct work, supply and return, must be properly sized
for the design airflow requirement of the equipment.
Air Conditioning Contractors of America (ACCA) is an
excellent guide to proper sizing.
Refer to Tables 10, 11, 12, 13, 14 and 15 in this Manual
for maximum static pressure available for duct design.
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 the
delay-on-break setting. There is no delay-on-make during routine operation of the unit. The module
also provides the lockout feature (with 1 retry) for high and/or low pressure controls, and a 2-minute
timed bypass for low pressure control.
2 HPC High pressure control is auto reset. Always used with compressor control module (CCM) which is
included. See note
1.
3 LPC Low pressure control is auto reset. Always used with compressor control module (CCM) which is
included. See note
1.
4 LAC Low ambient control permits cooling operation down to 0°F.
5 SK CMC-15 is PTCR Start Kit can be used with all -A single phase models. Increases starting torque 2-
3X. Not used for -B or -C 3-phase models. Do not use if SK111 is used.
5 SK SK111 Start Capacitor and Potential Relay Start Kit can be used with all -A single phase models.
Increases starting torque 9x. Not used for -B or -C 3-phase models. Do not use if CMC-15 is used.
1
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2
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3
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4
CAL
5
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CAUTION
During the initial firing of the burners there will probably be some amount of smoke issued to the
circulating air stream as the result of residual oil burning off of the heat exchanger tubes. This oil
is required during the forming process of the stainless steel heat exchanger tubes to facilitate the
bending. OSHA or the National Toxicology Program does not list the oil as a carcinogen. In
vapor form this may be irritating to the eyes or could cause headaches. This is a one-time
occurrence, and ventilation of the space may be required depending upon the space being
conditioned.

Manual 2100-525A
Page 7 of 67
TABLE 1
SPECIFICATIONS
W24G, W30G AND W36G MODELS
*
75 degree C Copper wire size
**
Maximum time delay fuse or HACR Type circuit breaker
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Manual 2100-525A
Page 8 of 67
*
75 degree C Copper wire size
**
Maximum time delay fuse or HACR Type circuit breaker
TABLE 1A
SPECIFICATIONS
W42G, W48G AND W60G MODELS
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Manual 2100-525A
Page 9 of 67
F
G
N
P
DDD FF
GG
HH
A
M
I
C
KJ
L
H
R
S S S S S
T
V Y
AA
X
U
Z
CC
BB
B
EE O
E
WII
Q
B
DISCONNECT ACCESS
RIGHT SIDE
RETURN OPENING
ENTRANCES
PANEL
PANEL (LOCKABLE)
PANEL DOOR
SUPPLY OPENING
BACK
MIS-2773
ENTRANCES GAS
COMBUSTION
LOW VOLTAGE
CIRCUIT BREAKER/
AIR OUTLET
CONDENSER AIR INLETS
CONDENSER
4 DEG. PITCH IN TOP
DOOR VESTIBULE
HINGED DOOR SERVICE/FILTER
AIR EXHAUST COMBUSTION
VENT OPTION
AIR INTAKE
CONTROL
FRONT
HIGH VOLTAGE ENTRANCES
UNIT A B C D E F G H I J K L M N O P Q R
W24G-W30G-W36G 7.88 27.88 13.88 24.25 40 25.63 81.63 27.38 27.5 39.25 5.88 W42G-W48G-W60G 9.88 29.88 15.88 27.25 43.81 31.63 87.5
33.38
28.75 42.88 3.75
UNIT S T U V W X Y Z AA BB CC DD EE FF GG HH II
W24G-W30G-W36G 12 - 7 HOLES 2.88 22.9 38 17.84 4.44 11.44 9 36.25 2 0.38 W42G-W48G-W60G 16 - 6 HOLES 3.88 24.9 42 17.34 8.44 12.19 10 40.25 2.75
0.44
15.31 4.5 2.514.88 30 14.12 15.44
1.257.25 1.133.75 2.25 3.25
FIGURE 1
UNIT DIMENSIONS

Manual 2100-525A
Page 10 of 67
See Figure 3 and clearance information in Section 9
and Table 2 for additional information.
Design the duct work according to methods given by
the Air Conditioning Contractors of America (ACCA).
When duct runs through unheated spaces, it should be
insulated with a minimum of one-inch of insulation.
Use insulation with a vapor barrier on the outside of
the insulation. Flexible joints should be used to
connect the duct work to the equipment in order to
keep the noise transmission to a minimum.
A one-inch clearance to combustible material for the
first three feet of duct attached to the outlet air frame is
required. See Wall Mounting Instructions and Figures
2, 2A, 3 and 3A for further details.
Ducts through the walls must be insulated and all joints
taped or sealed to prevent air or moisture entering the
wall cavity.
Some installations may not require any return air duct.
A metallic return air grille is required with installations
not requiring a return air duct. The spacing between
louvers on the grille shall not be larger than 5/8 inch.
Any grille that meets with the 5/8 inch louver criteria
may be used. It is recommended that Bard Return Air
Grille or Return Filter Grille be installed when no
return duct is used. Contact distributor or factory for
ordering information. If using a return air filter grille,
filters must be of sufficient size to allow a maximum
velocity of 400 fpm.
NOTE: If no return air duct is used, applicable
installation codes may limit this cabinet to
installation only in a single story structure.
4. HIGH ALTITUDE APPLICATIONS
Ratings of gas utilization equipment are based on sea
level operation and need not be changed for operation
at elevations up to 6,000 feet. For operation at
elevations above 6,000 feet and in the absence of
specific recommendations from the local authority
having jurisdiction, equipment ratings shall be reduced
as specified in Section 21.
5. TRANSPORTATION DAMAGE
All units are packed securely in shipping container.
All units should be carefully inspected upon arrival for
damage. 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 be
notified as soon as possible within 15 days after
delivery.
4. Claims for any damage, apparent or concealed,
should be filed with the carrier, using the following
supporting documents:
A. Original Bill of Lading, certified copy, or
indemnity bond.
B. Original paid freight bill of indemnity in lieu
thereof.
C. Original invoice or certified copy thereof
showing trade and other discounts or
deductions.
D. Copy of the inspection report issued by
carrier’s representative at the time damage is
reported to carrier.
6. INSTALLATION
Size of unit for proposed installation should be based
on heat loss/heat gain calculations made according to
methods of Air Conditioning Contractors of America
(ACCA). The air duct should be installed in
accordance with the Standards of the National Fire
Protection Association for the Installation of Air
Conditioning and Ventilating Systems of Other Than
Residence Type, NFPA No. 90A, and Residence Type
Warm Air Heating and Air Conditioning Systems,
NFPA No. 90B. Where local regulations are at a
variance with instructions, installer should adhere to
local codes.
WARNING
In all cases, there must be a metal duct
connection made to the supply air flange, and
a one inch clearance to combustibles must be
maintained to this duct connection.
For free blow applications, a metal sleeve
must be used in the wall opening itself, again
maintaining a one inch clearance to
combustibles.
Failure to use the sheet metal can cause
fire resulting in property damage, injury, or
death.