Bard W24G4 User manual

Page 1 of 54
INSTALLATION INSTRUCTIONS
Bard Manufacturing Company, Inc.
Bryan, Ohio 43506
www.bardhvac.com
Manual No.: 2100-721B
Supersedes: 2100-721A
Date: 5-7-20
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.
WALL MOUNTED GAS/ELECTRIC
Models:
W24G4
W24G4D
W30G4
W30G4D
W36G4
W36G4D
W42G4
W42G4D
W48G4
W48G4D
W60G4
W60G4D

Manual 2100-721B
Page 2 of 54
CONTENTS
Getting Other Information and Publications ...4
Wall Mount Gas/Electric General Information ..5
W**G Series Model Nomenclature..................... 5
Ventilation Options .......................................... 5
Air Conditioning Module Options....................... 6
1. Transportation Damage................................... 10
2. Important ..................................................... 10
3. General Information....................................... 10
4. Application ................................................... 10
5. Duct Work..................................................... 10
6. High Altitude Applications.............................. 11
7. Wall Mounting Information ............................. 11
8. Mounting the Unit ......................................... 11
9. Clearances.................................................... 18
10. Vent Terminal and Combustion Inlet Hood........ 19
11. Optional Vertical Venting ................................ 19
12. Vent Resizing Instructions .............................. 20
13. Fresh Air Intake............................................. 20
14. Condensate Drain .......................................... 20
15. Wiring – Main Power ...................................... 20
16. Wiring – Low Voltage Wiring............................ 21
17. Thermostats.................................................. 23
18. Gas Supply and Piping................................... 28
19. Manifold Pressure Adjustment ........................ 29
20. Checking Gas Input Rate................................ 29
21. Standard Orifice Sizing and High
Altitude Derate.............................................. 31
22. Conversion of Gas Input BTUH from High
to Low Rating................................................ 34
23. Measuring Air Temperature Rise...................... 34
24. Filters .......................................................... 34
25. Compressor Control Module ............................ 35
26. Phase Monitor............................................... 37
27. Lighting and Shutdown Instructions ................ 37
28. Service Agency Procedures ............................. 38
29. Maintaining Unit in Good Working Order.......... 38
30. Troubleshooting NIDEC SELECTECH Series
ECM Motors .................................................. 39
31. Replacement Parts ........................................ 41
32. Sequence of Operation – Heating .................... 42
33. Sequence of Operation – Cooling..................... 42
34. Setting Unit Airflow ....................................... 43
35. Pressure Service Ports ................................... 52
36. R-410A Refrigerant Charge ............................ 53
37. Fan Blade Setting Dimensions ........................ 53
38. Low NOx Burner Assembly "N" Suffix
Models Only – U.S. Installations Only.............. 53
INDEX – Wiring Diagrams ..................................... 54
Page Page

Manual 2100-721B
Page 3 of 54
FIGURES
Figure 1 Unit Dimensions ..................................9
Figure 2A Mounting Instructions – W24-36G ....... 13
Figure 2B Mounting Instructions – W42-60G .......14
Figure 3A Combustible Clearance – W24-36G ..... 15
Figure 3B Combustible Clearance – W42-60G...... 15
Figure 4 Wall Mounting Instructions.................. 16
Figure 5 Wall Mounting Instructions.................. 16
Figure 6 Common Wall Mounting Installations.... 17
Figure 7 Location of Vent Terminal in Shipping .. 18
Figure 8 Vent Terminal and Combustion
Air Inlet Hood .................................... 19
Figure 9 Fresh Air Damper ............................... 20
Figure 10 Installation of Flexible Conduit ............ 21
Figure 11 Low Voltage Wiring – All Units Except
Units with Economizers....................... 24
Figure 12 Low Voltage Wiring – Thermostat Using
Separate Temperature and Humidity
Controllers .........................................25
Figure 13 Low Voltage Wiring –
JIFM Economizer................................ 26
Figure 14 Gas Pipe Connection...........................27
Figure 15 Proper Piping Practice ........................28
Figure 16 Access Internal Filter through
Upper Service Door............................. 35
Figure 17
8201-169 Compressor Control Module ... 36
Figure 18 Lighting and Shutdown
Instruction Label ................................ 37
Figure 19 Top View of Gas Control ......................38
Figure 20 Motor Connections..............................40
Figure 21 Motor Connections..............................41
Figure 22 Sequence of Operation –
Electronic Blower Control .................... 42
Figure 23 Increasing Heating Speed ...................43
Figure 24 Increasing Cooling Speed ....................44
Figure 25 Speed Taps........................................ 44
Figure 26 Fan Blade..........................................53
Figure 27 Low NOx Insert ..................................53
TABLES
Table 1A Specifications – W24-36G Models ...........7
Table 1B Specifications – W42-60G Models ...........8
Table 2 Minimum Installation Clearances........... 18
Table 3 Low Voltage Connections for
DDC Control ........................................ 22
Table 4 CO2Controllers ....................................23
Table 5 Thermostat Wire Size............................ 23
Table 6 Wall Thermostats .................................23
Table 7 Humidity Controls ................................ 23
Table 8 Length of Standard Pipe Threads........... 28
Table 9 Gas Pipe Sizes – Natural Gas ................28
Table 10 Natural Gas Derate Capacities
for All Models ...................................... 31
Table 11A Natural Gas Orifice Tables – W24-36G ... 32
Table 11B Natural Gas Orifice Tables – W42-60G ... 33
Table 12 W24G4 Indoor Blower Performance ....... 45
Table 13 W30G4 Indoor Blower Performance ....... 46
Table 14 W36G4 Indoor Blower Performance ....... 47
Table 15 W42G4 Indoor Blower Performance ......48
Table 16 W48G4 Indoor Blower Performance ....... 49
Table 17 W60G4 Indoor Blower Performance ....... 50
Table 18 Integrated Furnace and Blower
Control Operation ................................. 51
Table 19 Cooling Pressure Table.......................... 52
Table 20 Fan Blade Dimension ...........................53
Page Page

Manual 2100-721B
Page 4 of 54
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]
BARD MANUFACTURING COMPANY, INC.
BRYAN, OHIO 43506 USA
These publications can help when installing the
furnace. They can usually be found at the local library
or purchased directly from the publisher. Be sure to
consult the 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 2100-721B
Page 5 of 54
W 42 G 4 – A X C X X X X X X
WALL MOUNT GAS/ELECTRIC GENERAL INFORMATION
MODEL NUMBER NOMENCLATURE
Low ambient control is required with economizer for low temperature compressor operation.
Ventilation Options
Models
W24G, W30G, W36G W42G, W48G, W60G
Description Factory Installed
Code No.
Field Installed
Part No.
Field Installed
Part No.
Barometric Fresh Air Damper X WGBFAD-3 WGBFAD-5
Blank-Off Plate B WGBOP-3 WGBOP-5
Motorized Fresh Air Damper M WGMFAD-3A WGMFAD-5A
Commercial Ventilator – Spring Return V WGCRVS-3A WGCRVS-5A
Commercial Ventilator – Power Return P WGCRVP-3A WGCRVP-5A
Economizer - Fully Modulating E WGJIFM-3 WGJIFM-5
Energy Recovery Ventilator – 230 Volt R WGERV-A3B WGERV-A5B
Energy Recovery Ventilator – 460 Volt R WGERV-C3C WGERV-C5C
1Reference Supplemental Instructions 7960-867 for dehumidification unit information.
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 Outlet
T –Top Outlet
COIL OPTIONS
X –Standard
1 –Phenolic coated evaporator
2 –Phenolic coated condenser
3 –Phenolic coated both coils
COLOR
X –Beige
1 –White
4 –Gray
8 –Bronze
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
C –Canadian Approval
D –Dehumidification1
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 2100-721B
Page 6 of 54
Air Conditioning Module Options
STD – Standard equipment.
 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.
 HPC High pressure control is auto reset. Always used with compressor control module (CCM) which is included. See Note
.
 LPC Low pressure control is auto reset. Always used with compressor control module (CCM) which is included. See Note .
 LAC Low ambient control permits cooling operation down to 0°F. (Includes fan cycling control + Freeze Stat)
 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.
 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.
CCM

HPC

LPC

LAC

SK

Factory Installed
Code
Field Installed
Part
STD STD STD • H CMA-45 (WG4D Units)
CMA-46 (WG4 Units)
• Field Only SK111 or CMC-15

Manual 2100-721B
Page 7 of 54
T
ABLE 1A
Specifications
W24G4, W30G4 and W36G4 Models
*75° C Copper wire size ** Maximum time delay fuse or circuit breaker
Models W24G4-A W24G4-B W24G4-C W30G4-A W30G4-B W30G4-C W36G4-A W36G4-B W36G4-C
Electrical Rating – 60 Hz 230/208-1 230/208-3 460-3 230/208-1 230/208-3 460-3 230/208-1 230/208-3 460-3
Operating Voltage Range 197-253 187-253 414-506 197-253 187-253 414-506 197-253 187-253 414-506
Minimum Circuit Ampacity 20.6 12.6 8 22.6 16.1 8.6 26.4 19 10.6
* Field Wire Size 10 14 14 10 12 14 8 10 14
Ground Wire Size 10 14 14 10 12 14 10 10 14 ** Delay Fuse or Circuit Breaker Max. 30 15 10 30 20 10 35 25 15
Compressor
Voltage 230/208 230/208 460 230/208 230/208 460 230/208 230/208 460
Rated Load Amps 7.6/8.7 4.6/5.3 2.5 9.4/10.7 6/6.9 3.2 12/13.5 7.8/8.7 4.8
Branch Circuit Selection Current 12.9 6.5 3.6 14.2 9 4.2 16.7 10.5 5.8
Lock Rotor Amps 58.3 55.4 28 73 58 28 79 73 38 Compressor Type Scroll Scroll Scroll Scroll Scroll Scroll Scroll Scroll Scroll
Fan Motor and Condenser
Fan Motor – HP/RPM/SPD 1/5-1100-1 1/5-1100-1 1/5-1100-1 1/5-1100-1 1/5-1100-1 1/5-1100-1 1/5-1100-1 1/5-1100-1 1/5-1100-1
Fan Motor – Amps 1.4 1.4 0.8 1.4 1.4 0.8 1.4 1.4 0.8
Fan – DIA/CFM 20” - 2100 20” - 2100 20” - 2100 20” - 2100 20” - 2100 20” - 2100 20” - 2000 20” - 2000 20” - 2000
Blower Motor and Evaporator
Blower Motor – HP/RPM/SPD 1/2-670-5 1/2-670-5 1/2-670-5 1/2-750-5 1/2-750-5 1/2-750-5 1/2-870-5 1/2-870-5 1/2-870-5 Blower Motor – Amps 0.9 0.9 1.2 1.2 1.2 1.2 1.9 1.9 1.2
CFM Cooling and E.S.P. 800 - 0.15 800 - 0.15 800 - 0.15 900 - 0.15 900 - 0.15 900 - 0.15 1100 -
0.15
1100 -
0.15
1100 -
0.15
Filter Size 20 x 25 x 2 20 x 25 x 2 20 x 25 x 2 20 x 25 x 2 20 x 25 x 2 20 x 25 x 2 20 x 25 x 2 20 x 25 x 2 20 x 25 x 2
Shipping Weight – LBS. 500 500 500 530 530 530 540 540 540
Unit Charge (R-410A lb.) 5.750 5.750 5.750 5.750 5.750 5.750 6.625 6.625 6.625

Manual 2100-721B
Page 8 of 54
*75° C Copper wire size ** Maximum time delay fuse or circuit breaker
TABLE 1B
Specifications
W42G, W48G and W60G Models
Models W42G4-A W42G4-B W42G4-C W48G4-A W48G4-B W48G4-C W60G4-A W60G4-B W60G4-C
Electrical Rating – 60 Hz 230/208-1 230/208-3 460-3 230/208-1 230/208-3 460-3 230/208-1 230/208-3 460-3
Operating Voltage Range 197-253 187-253 414-506 197-253 187-253 414-506 197-253 187-253 414-506
Minimum Circuit Ampacity 29 23.4 11.5 34.4 24.4 12 40.2 29.7 13.6 * Field Wire Size 8 10 14 8 10 14 8 8 12
Ground Wire Size 10 10 14 10 10 14 10 10 12 ** Delay Fuse or Circuit Breaker Max. 40 30 15 50 30 15 50 40 20
Compressor
Voltage 230/208 230/208 460 230/208 230/208 460 230/208 230/208 460
Rated Load Amps 15.5/17.4 11.7/13.2 5.9 16.7/19.5 10.6/12.3 6.5 19.5/21.9 12.9/14.4 7
Branch Circuit Selection Current 18 13.6 6 21.8 13.8 6.5 24.4 16 7.8
Lock Rotor Amps 112 88 44 117 83.1 41 144.2 110 52
Compressor Type Scroll Scroll Scroll Scroll Scroll Scroll Scroll Scroll Scroll
Fan Motor and Condenser
Fan Motor – HP/RPM/SPD 1/3-850-1 1/3-850-1 1/3-850-1 1/3-830-1 1/3-830-1 1/3-830-1 1/2-1000-1 1/2-1000-1 1/2-1000-1 Fan Motor – Amps 1.8 1.8 1 1.8 1.8 1 3.8 3.8 2.5
Fan – DIA/CFM 24” - 2900 24” - 2900 24” - 2900 24” - 2700 24” - 2700 24” - 2700 24” - 3400 24” - 3400 24” - 3400
Blower Motor and Evaporator
Blower Motor – HP/RPM/SPD 3/4-850-5 3/4-850-5 3/4-850-5 3/4-940-5 3/4-940-5 3/4-940-5 3/4-1040-5 3/4-1040-5 3/4-1040-5 Blower Motor – Amps 2.4 2.4 1.7 3.1 3.1 1.7 3.7 3.7 1.7
CFM Cooling and E.S.P. 1300 -
0.15
1300 -
0.15
1300 -
0.15
1450 -
0.20
1450 -
0.20
1450 -
0.20
1650 -
0.20
1650 -
0.20
1650 -
0.20
Filter Size 20 x 30 x 2 20 x 30 x 2 20 x 30 x 2 20 x 30 x 2 20 x 30 x 2 20 x 30 x 2 20 x 30 x 2 20 x 30 x 2 20 x 30 x 2
Shipping Weight – LBS. 500 500 500 530 530 530 550 550 550
Unit Charge (R-410A lb.) 6.500 6.500 6.500 7.125 7.125 7.125 9.625 9.625 9.625

Manual 2100-721B
Page 9 of 54
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
B
II
Q
W
COMBUSTION
AIR INTAKE
CONTROL
RIGHT SIDE
ENTRANCES
GAS
RETURN OPENING
4 DEG. PITCH IN TOP
PANEL DOOR
DOOR
LOW VOLTAGE
SUPPLYOPENING
PANEL
BACK
DISCONNECT ACCESS
VESTIBULE
PANEL (LOCKABLE)
CONDENSER AIR INLETS
CONDENSER VENT OPTION
AIR OUTLET
AIR EXHAUST
COMBUSTION ENTRANCES
FRONT
CIRCUIT BREAKER/
MIS-3239
HIGH VOLTAGE
ENTRANCES
FRONT DOOR FILTER SERVICE DOOR
UNIT A B C D E F G H I J K L M N O P QR
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-W36G12 - 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
1.257.25 1.133.75 2.25 3.25
15.31 4.5 2.514.88 30 14.12 15.44
FIGURE 1
Unit Dimensions

Manual 2100-721B
Page 10 of 54
1. TRANSPORTATION DAMAGE
All units are packed securely in shipping containers.
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.
2. 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.
3. GENERAL INFORMATION
This appliance is not intended for use by persons
(including children) with reduced physical, sensory
or mental capabilities, or lack of experience and
knowledge, unless they have been given supervision or
instruction concerning use of the appliance by a person
responsible for their safety.
Children should be supervised to ensure that they do
not play with the appliance.
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.
While these instructions are intended as a general
recommended guide, they do not supersede any
national and/or local codes in any way. Authorities
having jurisdiction should be consulted before the
installation is made. See page 4 for information on
codes and standards.
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.
4. 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.
5. DUCT WORK
The unit is designed for use with or without duct work
(see WARNING). Flanges are provided for attaching
CAUTION
During the initial ring 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 2100-721B
Page 11 of 54
6. 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'. For operation at
elevations above 6,000' and in the absence of specific
recommendations from the local authority having
jurisdiction, equipment ratings shall be reduced as
specified in Section 21.
7. WALL MOUNTING INFORMATION
1. Two holes for the supply and return air openings
must be cut through the wall as detailed in Figure 4.
2. On wood-frame walls, the wall construction must
be strong and rigid enough to carry the weight of
the unit without transmitting any unit vibration.
3. Concrete block walls must be thoroughly inspected
to ensure that they are capable of carrying the
weight of the installed unit.
8. MOUNTING THE UNIT
1. These units are secured by wall mounting brackets
which secure the unit to the outside wall surface at
both sides. A bottom mounting bracket is provided
for ease of installation but is not required.
2.
The W42G, W48G and W60G models are suitable
for 0 clearance on the installation mounting wall and
to the top. For all models the supply air duct flange
and the first 3' of supply air duct require a minimum
of 1" clearance to combustible material. The W24G,
W30G and W36G models are suitable for 0 clearance
on the installation mounting wall, but require 1"
clearance to the top if combustible material overhang
projects above the unit (see Figures 3A and 3B). If
a combustible wall, use a minimum of Figure 1 “A”
dimension plus 2" and “B” dimension plus 2". See
Figures 4 and 5 for details.
the supply and return ducts. 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 12, 13, 14, 15, 16 and 17 for maximum
static pressure available for duct design.
See Figures 3A and 3B 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 1" clearance to combustible material for the first 3'
of duct attached to the outlet air frame is required.
See wall mounting instructions and Figures 2A, 2B, 3A
and 3B 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".
Any grille that meets with the 5/8" 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.
CAUTION
If the bottom bracket is used, be certain the
bracket is secured to the outside wall surface
in a way sufcient to support the entire
weight of the unit during installation until side
mounting brackets are secured.
WARNING
Failure to provide the 1" clearance between
the supply duct and a combustible surface
for the rst 3' of duct can result in re causing
damage, injury or death.
WARNING
In all cases, there must be a metal duct
connection made to the supply air ange, and a 1"
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 1" clearance to combustibles.
Failure to use the sheet metal can cause re
resulting in property damage, injury, or death.

Manual 2100-721B
Page 12 of 54
3. Locate and mark lag bolt locations and bottom
mounting bracket location.
4. Mount bottom mounting bracket.
5. Hook top rain flashing under back bend of top.
Top rain flashing is shipped secured to the right
side of the back.
6. Position unit in opening and secure with 5/16"
lag bolts; use 7/8" diameter flat washers on the
lag bolts. Use lag bolts long enough to support
the unit’s weight when mounted to the structure.
This length may be dependent on the type of
construction.
7. Secure rain flashing to wall and caulk across entire
length of top (see Figures 2A and 2B).
8.
On side-by-side installations, maintain a minimum of
20" clearance on right side to allow access to control
panel and burner compartment, and to allow proper
airflow to the outdoor coil. Additional clearance may
be required to meet local or national codes.

Manual 2100-721B
Page 13 of 54
FIGURE 2A
Mounting Instructions
for W24G, W30G and W36G
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 15/16"
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 15/16"
4 9/16" SUPPLY
AIR DUCT
RETURN
AIR DUCT
Ø2 3/4" GAS OPENING (OPTIONAL)
Ø2 3/4" HIGH VOLTAGE (OPTIONAL)
Ø2" LOW VOLTAGE (OPTIONAL)
(12) FLANGE SCREWS
UNIT SUPPORT
1" MIN.
NECCESSARY NO CLEARANCE
SUPPLY
AIR DUCT
RETURN
AIR DUCT
CONTROL PANEL
VESTIBULE DOOR
WALL STRUCTURE (OUTSIDE)
1" CLEARANCE ON ALL FOUR SIDES OF SUPPLY AIR DUCT IS REQUIRED FROM COMBUSTABLE MATERIALS
NOTE: IT IS RECOMMENDED THAT A BEAD OF SILICONE CAULKING BE PLACED BEHIND THE SIDE MOUNTING FLANGES AND UNDER TOP FLASHING AT TIME OF INSTALLATION
RIGHT SIDE
VIEW WITH UNIT
OUTSIDE WALL WITH
UNIT REMOVED
RAIN FLASHING SUPPLIED
SEAL WITH BEAD OF CAULKING ALONG ENTIRE LENGTH OF TOP
TOP
FOAM AIR SEAL
WALL
MIS-1681

Manual 2100-721B
Page 14 of 54
FIGURE 2B
Mounting Instructions
for W42G, W48G and W60G

Manual 2100-721B
Page 15 of 54
FIGURE 3A
Combustible Clearance
for W24G, W30G and W36G Models
FIGURE 3B
Combustible Clearance
for W42G, W48G and W60G Models
WARNING
A minimum of 1" clearance must be maintained between the supply air duct and combustible materials. This is
required for the rst 3' of ducting.
It is important to insure that the one 1" minimum spacing is maintained at all points.
Failure to do this could result in overheating the combustible material and may result in a re causing damage,
injury or death.

Manual 2100-721B
Page 16 of 54
FIGURE 4
Wall Mounting Instructions
FIGURE 5
Wall Mounting Instructions

Manual 2100-721B
Page 17 of 54
FIGURE 6
Common Wall Mounting Installations

Manual 2100-721B
Page 18 of 54
9. CLEARANCES
Minimum clearances, as specified in Table 2, must
be maintained from adjacent structures to provide
adequate fire protection, adequate combustion air and
room for service personnel.
While minimum clearances are acceptable for safety
reasons, they may not allow adequate air circulation
around the unit for proper operation in the cooling
mode. Whenever possible, it is desirable to allow
additional clearance, especially around the condenser
inlet and discharge openings. DO NOT install the unit
in a location that will permit discharged air from the
condenser to recirculate to the condenser inlet.
TABLE 2
Minimum Installation Clearances
Outlet Duct
(from combustible materials) 1" first 3'
Vent Terminal
(from combustible materials) 17"*
Condenser Inlet 20"
Top See Figures 3A
and 3B
Burner Service 20"
Combustible Base (Wood or Class A,
B or C roof covering material) 0
* See Figures 3A and 3B
FIGURE 7
Location of Vent Terminal in Shipping
WARNING
Clearances from combustible materials must
be maintained as specied. Failure to maintain
clearances could cause re resulting in
property damage, injury or death.

Manual 2100-721B
Page 19 of 54
10. VENT TERMINAL AND
COMBUSTION AIR INLET HOOD
The vent terminal is shipped in the burner
compartment (see Figure 7). Remove the two shipping
screws and separate the two-piece assembly. Install
the vent terminal by using the four screws provided.
Do not cut or trim gasket. Make sure gasket is in
place. See Figure 8. The combustion air intake vent
hood is factory installed.
11. OPTIONAL VERTICAL VENTING
With the optional vertical venting kit (VVK-5), this unit
may 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, annually
inspect the vent system and drain. Replace any portion
of the vent system that shows signs of deterioration.
Make sure drain is open and free of obstruction.
FIGURE 8
Vent Terminal and Combustion Air Intake
CAUTION
Vent 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 combustion air
blower outlet. This is a very critical seal to prevent water and ue products from entering the unit.
Care must be taken to insure this gasket is in place and sealing properly.
MIS-2057
MIS-2126

Manual 2100-721B
Page 20 of 54
12. VENT RESIZING INSTRUCTIONS
When an existing furnace is removed from a venting
system servicing other appliances, the venting system
is likely to be too large to properly vent the remaining
attached appliances.
The following steps shall be followed with each of
the appliances remaining connected to the common
venting system, placed in operation one at a time
while the other appliances remaining connected to the
common venting system are not in operation.
1. Seal any unused openings in the venting system.
2. Inspect the venting system for proper size and
horizontal pitch, as required in the National
Fuel Gas code, ANSI Z223.1 or the CAN/CGA
B149 Installation Codes and these instructions.
Determine that there is no blockage or restriction,
leakage, corrosion and other deficiencies which
could cause an unsafe condition.
3.
In so far as is practical, close all building doors and
windows and all doors between the space in which
the appliance(s) connected to the venting system
are located and other spaces of the building. Turn
on clothes dryers and any appliances not connected
to the venting system. Turn on any exhaust fans,
such as range hoods and bathroom exhausts, so they
will operate at maximum speed. Do not operate a
summer exhaust fan. Close fireplace dampers.
4. Follow the lighting instructions. Place the
appliance being inspected in operation. Adjust
thermostat so appliance shall operate continuously.
5. Test for draft hood equipped appliance spillage at
the draft hood relief opening after 5 minutes of
main burner operation. Use the flame of a match
or candle.
6. After it has been determined that each appliance
connected to the venting system properly vents
when tested as outlined above, return doors,
windows, exhaust fans, fireplace dampers and
any other gas-burning appliances to their previous
conditions of use.
7. If improper venting is observed during any of the
above tests, the venting system must be corrected.
13. FRESH AIR INTAKE
All units are built with fresh air inlet slots punched in
the service panel.
If the unit is equipped with a fresh air damper
assembly, the assembly is shipped already attached
to the unit. The damper blade is locked in the
closed position. To allow the damper to operate, the
maximum and minimum blade position stops must be
installed (see Figure 9).
All capacity, efficiency and cost of operation
information as required for Department of Energy
“Energyguide” Fact Sheets is based upon the fresh
air blank-off plate in place and is recommended for
maximum energy efficiency.
The blank-off plate is available upon request from the
factory and is installed in place of the fresh air damper
shipped with each unit.
One of several other ventilation options may be
installed. Refer to model number and/or supplemental
installation instructions.
14. CONDENSATE DRAIN
A plastic drain hose extends from the drain pan at
the top of the unit down to the unit base. There are
openings in the unit base for the drain hose to pass
through. In the event the drain hose is connected to
a drain system of some type, it must be an open or
vented type system to assure proper drainage.
15. WIRING – MAIN POWER
FIGURE 9
Fresh Air Damper
Refer to unit rating plate for wire sizing information and
maximum fuse or circuit breaker size. Each outdoor
unit is marked with a “Minimum Circuit Ampacity”.
This means that the field wiring used must be sized to
carry that amount of current. All models are suitable
only for connection with copper wire. Each unit and/or
WARNING
For personal safety, turn off electric power
at service entrance panel before making any
electrical connections. Failure to do so could
result in electric shock or re.