2100-525

2100-525
WG - SERIES
COMBINATION GAS/ELECTRIC
WALL-MOUNT
INSTALLATION
INSTRUCTIONS
MODELS:
W24G1-A
W36G1-B
W48G1-C
W24G1-B
W36G1-C
W60G1-A
W24G1-C
W42G1-A
W60G1-B
W30G1-A
W42G1-B
W60G1-C
W30G1-B
W42G1-C
W30G1-C
W48G1-A
W36G1-A
W48G1-B
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.
Bard Manufacturing Company, Inc.
Bryan, Ohio 43506
Since 1914...Moving ahead just as planned.
Manual No.:
Supersedes:
File:
Date:
2100-525E
2100-525D
Volume III, Tab 20
01-05-11
Manual 2100-525E
Page
1 of 67
CONTENTS
Page
Page
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
Manual 2100-525E
Page
2 of 67
CONTENTS
Page
FIGURES
Figure 1
Figure 2
Figure 2A
Figure 3
Figure 3A
Figure 4
Figure 5
Figure 6
Figure 7
Figure 8
Figure 9
Figure 10
Figure 11
Figure 12
Figure 13
Figure 14
Figure 15
Figure 16
Figure 17
Figure 18
Figure 19
Figure 20
Figure 21
Figure 22
Unit Dimensions ..................................... 9
Mounting Instructions – W24-36G ....... 12
Mounting Instructions – W42-60G ....... 13
Combustible Clearance – W24-36G .... 14
Combustible Clearance – W42-60G .... 14
Wall Mounting Instructions ................... 15
Wall Mounting Instructions ................... 15
Common Wall Mounting Installations ... 16
Location of Vent Terminal in Shipping .. 17
Vent Terminal & Combustion
Air Intake .............................................. 18
Fresh Air Damper ................................. 19
Installation of Flexible Conduit ............. 21
Low Voltage Wiring-No Vent Pkg. ........ 22
Low Voltage Wiring .............................. 23
Low Voltage Wiring-EIFM Econo. ........ 24
Gas Pipe Connection ........................... 25
Proper Piping Practice ......................... 26
Access Internal Filter through
Upper Service Door .............................. 33
Lighting & Shutdown Instruction Label . 35
Top View of Gas Control ...................... 36
Sequence of Operation – Electronic
Blower Control ...................................... 38
Furnace Control Board &
Blower Control ...................................... 39
Fan Blade ............................................. 48
Low NOx Insert .................................... 48
Page
TABLES
Table 1
Table 1A
Table 2
Table 3
Table 4
Table 5
Table 6
Table 7
Specifications – W24-36G Models ........... 7
Specifications – W42-60G Models ........... 8
Minimum Installation Clearances ........... 17
Thermostat Wire Size ............................ 21
Wall Thermostat ..................................... 21
Length of Standard Pipe Threads .......... 26
Gas Pipe Sizes – Natural Gas ............... 26
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
Manual 2100-525E
Page
3 of 67
Getting Other Information and Publications
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.
FOR MORE INFORMATION, CONTACT
THESE PUBLISHERS:
ACCA
Air Conditioning Contractors of America
1712 New Hampshire Avenue, NW
Washington, DC 20009
Telephone: (202) 483-9370
ANSI
American National Standards Institute
11 West Street, 13th Floor
New York, NY 10036
Telephone: (212) 642-4900
Fax: (212) 302-1286
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
ASHRAE American Society of Heating Refrigerating,
and Air Conditioning Engineers, Inc.
1791 Tullie Circle, NE.
Atlanta, GA 30329-2305
Telephone: (404) 636-8400
Fax: (404) 321-5478
NFPA
National Fire Protection Association
Batterymarch Park
P.O. Box 9101
Quincy, MA 02269-9901
Telephone: (800) 344-3555
Fax: (617) 984-7057
CSA
Canadian Standards Association
178 Rexdale Boulevard
Rexdale, Ontario
Canada. M9W 1R3
Telephone: (416) 447-4044
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
COPYRIGHT JANUARY 2010
BARD MANUFACTURING COMPANY, INC.
BRYAN, OHIO 43506 USA
Manufactured under the following U.S. patent numbers:
5,485,878
Manual 2100-525E
Page
4 of 67
WALL MOUNT GAS/ELECTRIC GENERAL
MODEL NUMBER NOMENCLATURE
W
42
MODEL
G
1
–
A
X
C
REVISION
COOLING
CAPACITY
24 = 2 ton
30 = 2½ ton
36 = 3 ton
42 = 3½ ton
48 = 4 ton
60 = 5 ton
X
VOLTAGE
A = 230/208-60-1
B = 230/208-60-3
C = 460-60-3
FEATURE
(-) = Standard
D = Dehumidification
C = Canadian Approval
EMISSIONS
X = Standard
N = NOx Certified
X
X
X
COLOR
X = Beige
(Standard)
4 = Gray
VENT
(See Table
Below)
Wall Mount
GAS/
ELECTRIC
X
FILTER
X = 2" Pleated (Standard)
W = 1" Washable
X
CONTROL OPTIONS
(See Table page 6)
COIL OPTIONS
X = Standard
1 = Phenolic coated evaporator
2 = Phenolic coated condenser
3 = Phenolic coated both coils
OUTLET
X = Front (Standard)
T = Top
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*
*125,000 BTU input model is not NOx certified.
VENTILATION OPTIONS
Mo dels
W24G, W30G, W36G
W42G, W48G, W60G
Facto ry Installed
C o de N o .
Field Installed
P art N o .
Field Installed
P art N o .
Barometri c Fresh Ai r D amper
X
WGBFAD -3
WGBFAD -5
Blank-Off Plate
B
WGBOP-3
WGBOP-5
Motori zed Fresh Ai r D amper
M
WGMFAD -3A
WGMFAD -5A
C ommerci al Venti lator - Spri ng Return
V
WGC RVS-3A
WGC RVS-5A
C ommerci al Venti lator - Power Return
P
WGC RVP-3A
WGC RVP-5A
Economi zer - Fully Modulati ng 1
E
WGEIFM-3C
WGEIFM-5C
Energy Recovery Venti lator - 230 Volt
R
WGERV-A3B
WGERV-A5B
Energy Recovery Venti lator - 460 Volt
R
WGERV-C 3C
WGERV-C 5C
D escriptio n
1 Low ambient control is required with economizer for low temperature compressor operation.
Manual
Page
2100-525E
5 of 67
AIR CONDITIONING MODULE OPTIONS
1
CCM
2
H PC
3
LP C
4
LAC
STD
STD
STD
5
SK
Factory Installed
C ode
Field Installed
Part
H
CMA-28
Field Only
SK111 or CMC-15
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 23X. 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.
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.
1. IMPORTANT
3. DUCT WORK
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.
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.
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.
Manual 2100-525E
Page
6 of 67
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.
Manual
Page
2100-525E
7 of 67
1/5
2.2
230/208-60-1
1/4
2400
1.8
230/208-60-1
1.5
* 75 degree C Copper wire size
** Maximum time delay fuse or HACR Type circuit breaker
Full Load Amps
Volts
Horsepower
Blower M otor
C FM
Full Load Amps
Volts
Horsepower
Fan M otor
Full Load Amps (3-motors)
Volts
58
8.3
6.4/7.1
230/208-3
25
16
230/208-60-1
64
Energy Recovery Ventilator
12.8
Lock Rotor Amps
9.9/10.9
Rated Load Amps
Branch Circuit Selection Current
230/208-1
30
Volts
Com pressor
** Delay Fuse or Circuit Breaker Max.
21
Minimum Circuit Ampacity
197-253
230/208-3
197-253
230/208-1
Electrical Rating – 60HZ
Operating Voltage Range
W24G1-B
W24G1-A
Model
0.8
460-60-1
0.8
460-60-1
28
5.1
3.9
460-3
15
9
414-506
460-3
W24G1-C
1/5
2.2
230/208-60-1
71
9.0
7.5/8.2
230/208-3
25
17
197-253
230/208-3
W30G1-B
1/4
2400
2.2
230/208-60-1
1.5
230/208-60-1
77
14.1
11.8/12.9
230/208-1
35
23
197-253
230/208-1
W30G1-A
TABLE 1
SPECIFICATIONS
W24G, W30G AND W36G MODELS
1.1
460-60-1
0.8
460-60-1
38
5.6
4.7
460-3
15
10
414-506
460-3
W30G1-C
1/5
2.2
230/208-60-1
110
15.6
13.3/14.6
230/208-3
40
25
197-253
230/208-3
W36G1-B
1/4
2400
2.2
230/208-60-1
1.5
230/208-60-1
112
17.9
15.3/16.7
230/208-1
45
28
197-253
230/208-1
W36G1-A
1.1
460-60-1
0.8
460-60-1
44
6.0
5.1
460-3
15
11
414-506
460-3
W36G1-C
Manual 2100-525E
Page
8 of 67
1/3
2.2
230/208-60-1
1/3
3050
3.4
230/208-60-1
2.5
* 75 degree C Copper wire size
** Maximum time delay fuse or HACR Type circuit breaker
Full Load Amps
Volts
Horsepower
Blower M otor
C FM
Full Load Amps
Volts
Horsepower
Fan M otor
Full Load Amps (3-motors)
Volts
83.1
13.1
10.2/11.5
230/208-3
35
23
197-253
230/208-60-1
109
Energy Recovery Ventilator
19.9
Branch Circuit Selection Current
15.5/17.5
Rated Load Amps
Lock Rotor Amps
230/208-1
Volts
Com pressor
50
31
Minimum Circuit Ampacity
** Delay Fuse or Circuit Breaker Max.
197-253
Electrical Rating – 60HZ
Operating Voltage Range
W42G1-B
230/208-3
W42G1-A
230/208-1
Model
1.5
460-60-1
1.3
460-60-1
41
6.1
4.8
460-3
15
11
414-506
460-3
W42G1-C
W48G1-B
1/3
2.2
230/208-60-1
98
14.5
13.1/14.5
230/208-3
35
25
197-253
230/208-3
1/3
3050
3.4
230/208-60-1
2.5
230/208-60-1
135
21.4
19.3/21.4
230/208-1
50
34
197-253
230/208-1
W48G1-A
TABLE 1A
SPECIFICATIONS
W42G, W48G AND W60G MODELS
1.5
460-60-1
1.3
460-60-1
55
6.4
6.4
460-3
15
12
414-506
460-3
W48G1-C
W60G1-A
W60G1-B
1/3
2.2
230/208-60-1
110
15.6
12.8/14.7
230/208-3
40
28
197-253
230/208-3
1/3
3050
3.4
230/208-60-1
2.5
230/208-60-1
134
26.3
21.6/24.7
230/208-1
60
40
197-253
230/208-1
1.5
460-60-1
1.3
460-60-1
52
7.8
7.8
460-3
20
14
414-506
460-3
W60G1-C
Manual
Page
2100-525E
9 of 67
G
F
FRONT
CONDENSER
AIR OUTLET
U
2.88
3.88
C
13.88
15.88
CONTROL
PANEL DOOR
SERVICE/FILTER
HINGED DOOR
COMBUSTION
AIR INTAKE
COMBUSTION
AIR EXHAUST
VESTIBULE
DOOR
N
V
22.9
24.9
D
24.25
27.25
4 DEG. PITCH IN TOP
3.75
T
B
27.88
29.88
VENT OPTION
PANEL
CIRCUIT BREAKER/
DISCONNECT ACCESS
PANEL (LOCKABLE)
S
12 - 7 HOLES
16 - 6 HOLES
UNIT
W24G-W30G-W36G
W42G-W48G-W60G
W
A
7.88
9.88
UNIT
W24G-W30G-W36G
W42G-W48G-W60G
P
W
38
42
DD
Y
4.44
8.44
RIGHT SIDE
CONDENSER
AIR INLETS
D
X
17.84
17.34
E
F
G
40
25.63
14.88
43.81
31.63
J
L
M
2.25
Z
H
81.63
87.5
Z
U
K
C
I
A
FF
GG
HH
AA
11.44
12.19
30
I
FIGURE 1
UNIT DIMENSIONS
H
CC
9
10
LOW VOLTAGE
ENTRANCES
HIGH VOLTAGE
ENTRANCES
V
Y
AA
X
Q
II
7.25
DD
FF
EE
E
1.25
GG
P
B
O
HH
2
2.75
4.5
B
BACK
RETURN OPENING
BB
SUPPLY OPENING
1.13
CC
EE
36.25
40.25
K
L
M
N
O
27.5
39.25
14.12 15.44 15.31
28.75
42.88
GAS
ENTRANCES
3.25
BB
J
27.38
33.38
Q
II
0.38
0.44
2.5
R
MIS-2773
T
S
S
S
S
S
R
5.88
3.75
4. HIGH ALTITUDE APPLICATIONS
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.
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.
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.
Manual 2100-525E
Page
10 of 67
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.
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 insure that they are capable of
carrying the weight of the installed unit.
WARNING
Failure to provide the one inch clearance
between the supply duct and a combustible
surface for the first three feet of duct can
result in fire causing damage, injury or death.
3. Locate and mark lag bolt locations and bottom
mounting bracket location.
4. Mount bottom mounting bracket.
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.
CAUTION
If the bottom bracket is used, be certain the
bracket is secured to the outside wall surface
in a way sufficient to support the entire weight
of the unit during installation until side
mounting brackets are secured.
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 inch 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 dependant on the
type of construction.
7. Secure rain flashing to wall and caulk across
entire length of top. See Figure 3.
8. On side-by-side installations, maintain a
minimum of 20 inches 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.
2. The W42G, W48G and W60G models are
suitable for 0 inch clearance on the installation
mounting wall and to the top. For all models the
supply air duct flange and the first 3 feet of
supply air duct require a minimum of 1-inch
clearance to combustible material. The W24G,
W30G and W36G models are suitable for 0 inch
clearance on the installation mounting wall, but
require 1-inch clearance to the top if combustible
material overhang projects above the unit. See
Figure 3 and 3A. If a combustible wall, use a
minimum of Figure 1 “A” dimension plus 2
inches and “B” dimension plus 2 inches. See
Figures 4 and 5 for details.
Manual
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Manual 2100-525E
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12"
4 11/16"
29 3/4"
39 3/16"
UNIT SUPPORT
5 9/16"
Ø2 3/4" HIGH
VOLTAGE
(OPTIONAL) 2 15/16"
12"
12"
RETURN
AIR DUCT
12"
Ø2" LOW VOLTAGE
(OPTIONAL)
Ø2 3/4" GAS
OPENING
(OPTIONAL)
SUPPLY
AIR DUCT
4 9/16"
30"
2"
8 5/8"
(12) FLANGE
SCREWS
29"
5 1/16"
12"
12"
4 9/16"
OUTSIDE WALL WITH
UNIT REMOVED
2 1/4"
7/16"
4 1/2"
2 15/16"
2 1/4"
FOAM AIR SEAL
TOP
27"
CONTROL
15" PANEL
28 5/16"
10"
VESTIBULE
DOOR
WALL
STRUCTURE
(OUTSIDE)
1" MIN.
RIGHT SIDE
VIEW WITH UNIT
RETURN
AIR DUCT
MIS-1681
NO CLEARANCE
NECCESSARY
SUPPLY
AIR DUCT
1" CLEARANCE ON ALL
FOUR SIDES OF SUPPLY
AIR DUCT IS REQUIRED FROM
COMBUSTABLE MATERIALS
RAIN FLASHING
SUPPLIED
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
WALL
11 5/16"
17 15/16"
18 15/16"
SEAL WITH BEAD OF CAULKING
ALONG ENTIRE LENGTH OF TOP
FIGURE 2
MOUNTING INSTRUCTIONS
FOR W24G, W30G AND W36G
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FIGURE 2A
MOUNTING INSTRUCTIONS
FOR W42G, W48G AND W60G
FIGURE 3
COMBUSTIBLE CLEARANCE
FOR W24G, W30G AND W36G MODELS
FIGURE 3A
COMBUSTIBLE CLEARANCE
FOR W42G, W48G AND W60G MODELS
WARNING
A minimum of one (1) inch clearance must be maintained between the supply air duct and combustible materials.
This is required for the first three (3) feet of ducting.
It is important to insure that the one (1) inch minimum spacing is maintained at all points.
Failure to do this could result in overheating the combustible material and may result in a fire causing damage,
injury or death.
Manual 2100-525E
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FIGURE 4
WALL MOUNTING INSTRUCTIONS
FIGURE 5
WALL MOUNTING INSTRUCTIONS
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FIGURE 6
COMMON WALL MOUNTING INSTALLATIONS
Manual 2100-525E
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TABLE 2
MINIMUM INSTALLATION CLEARANCES
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.
Outlet Duct (from combustible materials)
Vent Terminal (from combustible materials)
1 inch first 3 feet
* 17 inches
Condenser Outlet
20 inches
Top
See Figure 3
Burner Service
20 inches
Combustible Base (Wood or Class A, B
or C roof covering material)
0 inches
* See Figures 3 and 3A
WARNING
Clearances from combustible materials must
be maintained as specified. Failure to
maintain clearances could cause fire resulting
in property damage, injury, or death.
FIGURE 7
LOCATION OF VENT TERMINAL IN SHIPPING
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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 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.
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 flue products from entering the
unit. Care must be taken to insure this gasket is in place and sealing properly.
FIGURE 8
VENT TERMINAL AND COMBUSTION AIR INTAKE
Manual 2100-525E
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12. VENT RESIZING INSTRUCTIONS
13. FRESH AIR INTAKE
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.
All units are built with fresh air inlet slots punched in
the service panel.
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.
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.
FIGURE 9
FRESH AIR DAMPER
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 gasburning 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.
Manual
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15. WIRING – MAIN POWER
WARNING
For your 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 fire.
Refer to unit rating plate for wire sizing information
and maximum fuse or “HACR” type 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 wiring diagram will be marked “Use Copper Conductors Only”. These instructions
must be adhered to. Refer to the National Electrical
Code (NEC) for complete current carrying capacity
data 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° C
copper) for all models.
The unit rating plate lists a “Maximum Time Delay
Relay Fuse” or “HACR” type circuit breaker that is to
be used with the equipment. The correct size must be
used for proper circuit protection and also to assure that
there will be no nuisance tripping due to the momentary
high starting current of the compressor motor.
The disconnect access door on this unit may be locked
to prevent unauthorized access to the disconnect. To
convert for the locking capability bend the tab located
in the bottom left hand corner of the disconnect opening
under the disconnect access panel straight out. This tab
will now line up with the slot in the door. When shut, a
padlock may be placed through the hole in the tab
preventing entry.
See “Start Up” section for important information on
three phase scroll compressor start ups.
WARNING
Failure to provide an electrical power supply
shut off means could result in electric shock
or fire.
Manual 2100-525E
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ELECTRICAL GROUNDING
When installed, the furnace must be electrically
grounded in accordance with local codes or in the
absence of local codes, with the National Electrical
Code, ANSI/NFPA 70, or Canadian Electrical Code,
CSA22.1, latest edition. Use a copper wire from green
ground wire on the furnace to a grounded connection in
the service panel or a properly driven and electrically
grounded ground rod. See Tables 1 & 1A for proper
ground wire size.
WARNING
Failure to provide a proper electrical ground
could result in electric shock or fire.
FIELD INSTALLED EQUIPMENT
Wiring to be done in the field between the furnace and
devices not attached to the furnace, or between separate
devices which are field installed and located, shall
conform with the temperature limitation for Type T
wire {63 degrees F rise (36 degrees C)} when installed
in accordance with the manufacturer’s instructions.
INSTALLATION OF FLEXIBLE CONDUIT
THROUGH RETURN AIR OPENING
NOTE: To allow proper clearance between the
control panel and any vent options, 90°
conduit fittings must be used on the back of
the control panel.
INSTALLING CONDUIT (See Figure 10.)
1. Remove conduit access panel if required to gain
access to area behind control panel.
2. Remove low voltage and high voltage knockouts
located in rear of control panel.
3. Run low voltage conduit through 7/8 bushing located
in conduit entrance plate and secure to low voltage
opening in rear of control panel.
4. Run high voltage conduit through 1-3/4 bushing
located in conduit entrance plate and secure to high
voltage opening in rear of control panel.
5. Replace conduit access panel if required to complete
installation.
6. Seal around conduit in conduit entrance plate.
FIGURE 10
INSTALLATION OF FLEXIBLE CONDUIT
16. WIRING – LOW VOLTAGE WIRING
Low Voltage Connection
These 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 terminal
energizes any factory or field installed vent option.
“W1” terminal is the heat input.
Direct Digital Controls (DDC)
For total and proper control using DDC, a total of 5
controlled outputs are required (4 if no ventilation is
installed).
LOW VOLTAGE CONNECTIONS FOR DDC CONTROL
Fan Only
Cooling Mode
Heating Mode
Ventilation
17. THERMOSTATS
230/208 VOLT UNITS
All models are equipped with dual primary voltage
transformers. All equipment leaves the factory wired
on 240V tap. For 208V operation, reconnect from
240V to 208V tap. The acceptable operating voltage
range for the 240V and 208V taps are:
TAP
RANGE
240
253 – 206
208
220 – 187
NOTE: The voltage should be measured at the field
power connection point in the unit and while
the unit is operating at full load (maximum
amperage operating condition).
460 VOLT UNITS
All models are equipped with single primary voltage
transformers and no rewiring is required.
Energize G
Energize G, Y1
Energize W1
Energize G, A
TABLE 3
THERMOSTAT WIRE SIZE
Transformer
VA
FLA
Wire Gauge
Maximum
D istance
In Feet
55
2.3
20 gauge
18 gauge
16 gauge
14 gauge
12 gauge
45
60
100
160
250
TABLE 4
WALL THERMOSTAT
Thermostat
Predominate Features
1 stage heat, 1 stage cool
8403-057
System: heat-off-cool Fan: on-auto
TH3110D1040
Electronic Non-Programmable
2 stage cool, 2 stage heat
8403-058
Electronic Non-Programmable
TH5220D1151 HP or Conventional
Auto or Manual changeover
8403-060
1120-445
3 stage cool; 3 stage heat
Programmable/Non-Programmable Electronic
HP or Conventional
Auto or Manual changeover
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FIGURE 11
LOW VOLTAGE WIRING
Low Voltage Wiring - No Ventilation Package
Thermostat Subbase
Thermostat
Part #8403-057
TH3110D1040
C
W
Thermostat
Part #8403-060
(1120-445)
C
W1/E
A
R
W2
D/YO
C
W1
A
R
W2
E
1
R
B
Y
G
Y2
Y1
G
O/B
Y2
Y1
G
1
RC
O
2
Unit 24V
Terminal
Block
Y
L
3
2
F
Factory Installed Jumper
Unit Control Panel
1
SET SWITCH ON THERMOSTAT TO "GAS-OIL"
2
CONFIGURE THERMOSTAT FOR HEAT/COOL
MIS-2774
Manual 2100-525E
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FIGURE 12
LOW VOLTAGE WIRING
Low Voltage Wiring -
MOTORIZED FRESH AIR DAMPER,
COMMERCIAL ROOM VENTILATOR-SPRING,
COMMERCIAL ROOM VENTILATOR-POWER
Thermostat Subbase
Thermostat
Part #8403-057
(TH311DD1040)
1
Thermostat
Part #8403-060
(1120-445)
2
RC
C
W
R
C
W1/E
A
R
W2
D/YO
C
W1
A
R
W2
E
Y
G
B
Y2
Y1
G
O/B
Y2
Y1
G
1
O
L
(MUST BE CONFIGURED
FOR HEAT/COOL)
Unit 24V
Terminal
Block
Factory Installed
Jumper
4
Y
3
2
F
3
ORANGE
RED/WHITE
BROWN/WHITE
BLUE
BLACK/WHITE
Unit Control Panel
VENT PACKAGE
WIRING PLUG
1
SET SWITCH ON THERMOSTAT TO "GAS-OIL"
2
CONFIGURE THERMOSTAT FOR HEAT/COOL
3
MUST INSTALL JUMPER FOR 8403-057 OR OTHER THERMOSTAT THAT DOES NOT
HAVE OCCUPANCY OUTPUT.
4
INSTALL IF YOU REQUIRE VENTILATION ANYTIME BLOWER IS ON.
MIS-2775
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FIGURE 13
LOW VOLTAGE WIRING
Low Voltage Wiring - EIFM ECONOMIZER
Thermostat
Part #8403-058
(TH5220D1151)
1
Thermostat
Part #8403-060
(1120-445)
1
Unit 24V
Terminal
Block
C
W
C
W1/E
C
W1
Thermostat Subbase
R
W2
RC
Y2
Y
G
A
R
W2
D/YO
Y2
Y1
G
O/B
A
R
W2
E
Y2
Y1
G
1
Y
L
3
2
F
Factory Installed Jumper
Unit Control Panel
WGSEIFM-5
WIRES
FROM
PLUG
BLACK
BLUE
PINK
YELLOW
PURPLE
ORANGE
RED
RED
THERMISTOR
MIS-2777
1
Manual 2100-525E
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CONFIGURE THERMOSTAT FOR HEAT/COOL
FIGURE 14
GAS PIPE CONNECTION
W24G - W36G
W42G - W60G
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18. GAS SUPPLY AND PIPING
GENERAL RECOMMENDATIONS
1. Be sure the gas line complies with the local codes
and ordinances, or in their absence with the National
Fuel Gas Code, ANSI Z223.1, or Natural Gas
Installation Code, CAN/CGA B149.1, or Propane
Installation Code B149.2, latest edition.
2. A sediment trap or drip leg must be installed in the
supply line to the furnace.
3. A ground joint union shall be installed in the gas line
adjacent to and upstream from the gas valve and
downstream from the manual shut off valve.
4. An 1/8" NPT plugged tapping accessible for test
gauge connection shall be installed immediately
upstream of the gas supply connection to the furnace
for the purpose of determining the supply gas
pressure. This can be omitted if local codes permit
use of plugged tapping in gas valve inlet.
8. Refer to Table 6 for Gas Pipe Sizes for natural gas.
If more than one appliance is supplied from a single
line size, capacity must equal or exceed the
combined input to all appliances, and the branch
lines feeding the individual appliances properly sized
for each input.
THIS PRODUCT MUST BE GAS PIPED BY
A LICENSED PLUMBER OR GAS FITTER
IN THE COMMONWEALTH OF
MASSACHUSETTS.
TABLE 6
GAS PIPE SIZES - NATURAL GAS
Length of
Pipe - Feet
Pipe Capacity - BTU per Hour Input Pipe Siz e
1/2"
3/4"
1"
1-1/4"
10
132,000
278,000
520,000
1,050,000
20
92,000
190,000
350,000
730,000
5. Install listed manual shut off valve in the supply gas
line external to and immediately upstream of the
furnace. See Figure 14.
30
73,000
152,000
285,000
590,000
40
63,000
130,000
245,000
500,000
50
56,000
115,000
215,000
440,000
6. Use steel or wrought iron pipe and fittings.
60
50,000
105,000
195,000
400,000
70
46,000
96,000
180,000
370,000
80
43,000
90,000
170,000
350,000
100
38,000
79,000
150,000
305,000
7. DO NOT thread pipe too far. Valve distortion or
malfunction may result from excess pipe within the
control. Use pipe joint compound resistant to the
action of liquefied petroleum gases on male threads
only. DO NOT use Teflon tape. See Table 5 and
Figure 15.
TABLE 5
LENGTH OF STANDARD
PIPE THREADS (INCHES)
Pipe Siz e
Effective Length
of Thread
Overall Length
of Thread
3/8
1/2
9/16
3/4
1/2 - - 9/16
13/16
1
9/16
1
FIGURE 15
PROPER PIPING PRACTICE
CHECKING THE GAS PIPING
Before turning gas under pressure into piping, all
openings from which gas can escape should be closed.
Immediately after turning on gas, the system should be
checked for leaks. This can be done by watching the 1/2
cubic foot test dial and allowing 4 minutes to show any
movement, and by soaping each pipe connection and
watching for bubbles. If a leak is found, make the
necessary repairs immediately and repeat the above test.
The furnace must be isolated from the gas supply piping
system by closing the manual shut off valve on the
combination gas control valve during pressure testing of
the gas supply piping system at pressures up to 1/2
PSIG. The furnace and its individual shut off valve must
be disconnected from supply piping and supply piping
capped during any pressure testing of supply piping
system at test pressures in excess of 1/2 PSIG.
Defective pipes or fittings should be replaced and not
repaired. Never use a flame or fire in any form to locate
gas leaks; use a soap solution.
MIS-897
Manual 2100-525E
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After the piping and meter have been checked
completely, purge the system of air. DO NOT bleed air
inside the furnace. Be sure to check and relight all the
gas pilots on other appliances that may have been
extinguished because of interrupted gas supply.
PROPANE (LP) GAS CONVERSION
This unit may be converted in the field for
use with Propane (LP) gas. Propane gas
conversion kit number WGCK-1 is designed
for conversions of units installed from
0 – 6,000 feet elevations. Propane gas
conversion kit number WGCK-2 is designed
for conversions of units installed from 6,001
– 10,000 feet elevations. These kits may
be purchased from your local distributor.
WARNING
When converting from propane (LP) gas to
natural gas, the gas orifice spuds and gas
valve spring must be replaced and the gas
valve regulator pressure must be adjusted
correctly. Failure to do so can result in fire,
injury or death. Refer to Tables 8 and 8A for
proper orifice sizing.
Natural gas spring kit, Part number 5603-007,
can be purchased through your local
distributor.
19. MANIFOLD PRESSURE
ADJUSTMENT
You will need a 0 to 15 inch water manometer with 0.1
inch resolution and a 1/8" NPT manual shut off valve to
measure actual manifold pressure.
WARNING
Correct manifold pressure is necessary for
proper ignition and burner operation. Failure
to accurately adjust pressure could cause
heat exchanger failure.
1. Turn off gas at equipment shut off valve in gas
supply line just ahead of furnace.
2. Remove plug from outlet pressure tap in gas control
or gas manifold.
3. Install 1/8" NPT manual shut off valve in hole
vacated by plug. Make sure shut off valve is in off
position.
4. Attach manometer to 1/8" NPT manual shut off
valve just installed.
5. Slowly open equipment shut off valve in gas supply
line just ahead of furnace. Start furnace following
“Operating Instructions” on front door.
6. Slowly open 1/8" NPT manual shut off valve leading
to manometer.
7. Read manifold pressure on manometer.
8. Adjust manifold pressure by turning gas control
regulator adjusting screw clockwise to increase
pressure or turning counterclockwise to decrease
pressure. Manifold pressure must be within
allowable range as follows:
• Natural gas manifold pressure must be between
3.2 and 3.8 inches W.C. Rated pressure is 3.5
inches.
• Propane gas (LP) manifold pressure must be
between 9.7 and 10.3 inches W.C. Rated
pressure is 10 inches.
NOTE: For natural gas, if gas flow rate can't be
properly set within these pressure ranges
then you must change main burner orifices to
obtain proper gas flow rate.
9. Shut off furnace. Turn off gas at equipment shut off
valve in gas supply line just ahead of furnace. Install
outlet pressure tap plug in gas control. Turn on gas.
10. Check regulator adjustment cover screw and gas
control plug for gas leaks. Use a commercial soap
solution made for leak detection.
20. CHECKING GAS INPUT RATE
It is the installer's responsibility to see that the BTU
input rate of the furnace is properly adjusted. Underfiring could cause inadequate heat, excessive
condensation or ignition problems. Overfiring could
cause sooting, flame impingement or overheating of
heat exchanger.
WARNING
Failure to adjust furnace to the proper firing
rate could cause heat exchanger failure.
Depending on your local gas heating value and
elevation, you may need to adjust manifold pressure or
change orifices to get proper gas input rate. Check
with 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 of
more than 6,000 feet above sea level, you
must derate the furnace. See Section 21
“Standard Orifice Sizing and High Altitude
Derate”.
Manual
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NATURAL GAS INPUT RATE
Natural gas heating value (BTU/cu. ft.) can vary
significantly. Before starting natural gas input check,
obtain gas heating value at your location from local
supplier. You will need a stopwatch to measure actual
gas input.
9. If you left water heater, dryer or range pilots on,
allow for them in calculating correct furnace gas
input. A quick way is to allow 1,000 BTU per hour
for a water heater, 500 BTU per hour for dryer and
500 BTU per hour for each range burner pilot.
Example:
1. Gas supply pressure must be between 5 and 7 inches
W.C. for natural gas.
If you left gas water heater, dryer, two range burner
pilots and one oven pilot on, allow:
2. Turn off all other gas appliances. You may leave
pilots on.
Water heater pilot
Dryer pilot
2 range burner pilots
1 range oven pilot
3. Start furnace following “Operating Instructions” on
front door.
4. Let furnace warm up for 6 minutes.
5. Locate gas meter. Determine which dial has the
least cubic feet of gas and how many cubic feet per
revolution it represents. This is usually one-half, one
or two cubic feet per revolution.
6. With stopwatch, measure time it takes to consume
two 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, measure
time for two revolutions.
•
If dial is two cubic feet per revolution, measure
time for one revolution.
7. Divide this time by two. This gives average time for
one cubic foot of gas to flow through meter.
Example: If it took 58 seconds for two cubic feet to
flow, it would take 29 seconds for one cubic foot to
flow.
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 gas
to 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 gas
input.
1,000 BTU per hour
500 BTU per hour
1,000 BTU per hour
500 BTU per hour
3,000 BTU per hour
Subtracting 3,000 BTU per hour from 124,138 BTU
per hour measured above equals 121,138 BTU per
hour. This would be the correct furnace gas input
after allowing for pilots left on.
10. Manifold pressure may be adjusted within the range
of 3.2 inches W.C. to 3.8 inches W.C. to get rated
input ± 2 percent. See Section 19, “Manifold
Pressure Adjustment”. If you cannot get rated input
with manifold pressure within the allowable range,
you must change orifices.
PROPANE (LP) GAS INPUT RATE
WARNING
Propane (LP) gas installations do not have
gas meters to double check input rate.
Measure manifold pressure adjustment with
an accurate manometer. Failure to accurately
adjust pressure could cause heat exchanger
failure, asphyxiation, fire or explosion,
resulting in damage, injury or death.
1. Make sure you have proper main burner orifices.
2. Gas supply pressure must be between 11 and 13
inches W.C. for propane (LP) gas.
3. Start furnace following “Operating Instructions” on
front door.
4. Let furnace warm up for 6 minutes.
5. Adjust manifold pressure to 10.0 W.C. ± 0.3 inches
W.C. See Section 19, “Manifold Pressure
Adjustment”.
WARNING
Do not set Propane (LP) manifold pressure at
11.0 inches W.C. It could cause heat
exchanger failure.
Manual 2100-525E
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28 of 67
21. STANDARD ORIFICE SIZING AND
HIGH ALTITUDE DERATE
This furnace is shipped with fixed gas orifices for use
with Natural Gas and sized for 1000 BTU/cubic foot
gas. Make sure actual gas input does not exceed rating
plate input. You may need to change orifices to get
correct gas input. Whether you do or not depends on
input, and your gas heat value at standard conditions
and elevation. Consult your local gas supplier for gas
heat value and any special derating requirements. See
Section 20 for more information.
At higher altitudes, the density of the air is reduced.
Therefore, for proper combustion, the quantity of gas
burned in the furnace must also be reduced. This is
called derating. This unit must be derated when
installed at altitudes greater than 6,000 feet above sea
level. A high altitude pressure switch must also be
installed for operation above 6,000 feet. High altitude
pressure switch kit number 8620-189 is designed for
this application.
It is the installer’s responsibility to see that the furnace
input rate is adjusted properly. Derating must be
achieved by reducing the size of the main burner
orifices. Derating the furnace by adjusting the manifold
pressure lower than the range specified in the Section
19, “Manifold Pressure Adjustment” is considered to be
an improper procedure.
Above 6,000 feet elevation orifice changes are required,
and capacity reductions are a function of altitude
impact and orifice change. Pressure switch change is
required above 6,000 feet elevation. For Natural Gas
see the Altitude Table 7 below and the Orifice Tables 8
and 8A on following pages.
TABLE 7
NATURAL GAS DERATE CAPACITIES
FOR ALL MODELS
WG Rated
Input
S ea
L evel
1,000
2,000
3,000
4,000
5,000
6,000
7,000
8,000
9,000
41,000
45,000
40,500
45,000
39,204
43,560
37,908
42,120
36,612
40,680
35,640
39,600
34,992
38,880
34,182
37,980
33,696
37,440
33,048
36,720
32,643
36,270
32,076
35,640
61,000
68,000
60,750
67,500
58,806
65,340
56,862
63,180
54,918
61,020
53,460
59,400
52,488
58,320
51,273
56,970
50,544
56,160
49,572
55,080
48,965
54,405
48,114
53,460
75,000
81,000
75,000
81,000
72,600
78,408
70,200
75,816
67,800
73,224
66,000
71,280
64,800
69,984
63,300
68,364
62,400
67,392
61,200
66,096
60,450
65,286
59,400
64,152
90,000
100,000
90,000
100,000
87,120
96,800
84,240
93,600
81,360
90,400
79,200
88,000
77,760
86,400
75,960
84,400
74,880
83,200
73,440
81,600
72,540
80,600
71,280
79,200
113,000
125,000
112,500
125,000
108,900
121,000
105,300
117,000
101,700
113,000
99,000
110,000
97,200
108,000
94,950
105,500
93,600
104,000
91,800
102,000
90,675
100,750
89,100
99,000
Manual
Page
10,000
2100-525E
29 of 67
TABLE 8
NATURAL GAS ORIFICE TABLES
FOR MODELS W24G, W30G AND W36G
Factory
Standard
Input
Gas Heat* Value
BTU/Cu. Ft.
Up to 6,000 Feet No
C h an g es E xcep t
for BTU Content
6,001 to 8,000 Feet
Requires Pressure Sw itch
Change and Orifice Change
Based on BTU Contentt
8,001 to 10,000 Feet
Requires Pressure Sw itch
Change and Orifice Change
Based on BTU Contentt
700-749
2.75
2.70
2.60
750-799
2.70
2.60
2.50
800-849
2.60
2.50
2.45
850-899
2.50
2.45
2.35
900-949
2.45
2.35
(2.30)
950-999
2.35
(2.30)
2.25
1000-1049**
(2.30)
2.25
[2.20]
[2.20]
2.15
22500 B T U
Per Burner
1050-1100
2.25
Pressure Switch
Standard (.55)
(2.30) is the standard factory installed orifice siz e
Optional
10% Field
Converted
Derate
Order 8620-189 High Altitude Pressure Sw itch Kit (.42)
[2.20] orifices are shipped w ith the unit for field installed
optional 10% derate
Gas Heat* Value
BTU/Cu. Ft.
Up to 6,000 Feet No
C h an g es E xcep t
for BTU Content
6,001 to 8,000 Feet
Requires Pressure Sw itch
Change and Orifice Change
Based on BTU Content
8,001 to 10,000 Feet
Requires Pressure Sw itch
Change and Orifice Change
Based on BTU Content
700-749
2.60
2.50
2.45
750-799
2.50
2.45
2.40
800-849
2.45
2.40
(2.30)
850-899
2.40
(2.30)
2.25
900-949
(2.30)
2.25
[2.20]
950-999
2.25
[2.20]
2.15
1000-1049**
[2.20]
2.15
2.10
2.15
2.10
20250 B T U
Per Burner
1050-1100
2.15
Pressure Switch
Standard (.55)
[2.20] orifices are shipped w ith the unit for field installed
optional 10% input rate.
Order 8620-189 High Altitude Pressure Sw itch Kit (.42)
(2.30) is the factory installed orifice siz e for full rated input
* At standard conditions: 30.00 inches Mercury, 60F, saturated, .60 specific gravity.
** All Natural Gas factory orifice sizing and standard input ratings based on nominal 1025 BTU/cu ft gas and sea level
conditions
All other orifice sizes shown are available as individual items. See Orifice charts below for part numbers and number required.
Bard Part No.
Orifice Siz e (mm)
Orifice Diameter
9010-092
2.10
0.0826
9010-088
2.15
0.0846
9010-087
2.20
0.0866
9010-086
2.25
0.0885
9010-082
2.30
0.0905
Manual 2100-525E
Page
30 of 67
No. of Orifices Required
Based on Unit Input Rating
41,000
(2)
45,000
(2)
61,000
(3)
9010-085
2.35
0.0925
9010-079
2.40
0.0945
68,000
(3)
9010-084
2.45
0.0964
75,000
(3)
9010-093
2.50
0.0984
81,000
(4)
9010-094
2.60
0.1024
90,000
(4)
9010-095
2.70
0.1063
9010-096
2.75
0.1082
100,000
(4)
113,000
(5)
125,000
(5)
9010-097
2.80
0.1102
9010-098
2.90
0.1142
TABLE 8A
NATURAL GAS ORIFICE TABLES
FOR MODELS W42G, W48G AND W60G
Factory
Standard
Input
Gas Heat*
Value
BTU/Cu. Ft.
Up to 6,000 Feet No
C h an g es E xcep t
for BTU Content
6,001 to 8,000 Feet
Requires Pressure Sw itch
Change and Orifice
C h an g e
Based on BTU Contentt
25000 B T U
Per Burner
700-749
2.90
2.80
2.70
750-799
2.80
2.70
2.60
800-849
2.70
2.60
2.50
850-899
2.60
2.50
2.45
900-949
2.50
2.45
(2.40)
950-999
2.45
(2.40)
2.35
1000-1049**
(2.40)
2.35
[2.30]
1050-1100
[2.30]
2.25
2.20
Pressure Switch
Standard (.55)
(2.40) is the standard factory installed orifice siz e
Optional
10% Field
Converted
Derate
22500 B T U
Per Burner
8,001 to 10,000 Feet
Requires Pressure Sw itch
Change and Orifice
C h an g e
Based on BTU Contentt
Order 8620-189 High Altitude Pressure Sw itch Kit (.42)
[2.30] orifices are shipped w ith the unit for field installed
optional 10% derate
Gas Heat*
Value
BTU/Cu. Ft.
Up to 6,000 Feet No
C h an g es E xcep t
for BTU Content
6,001 to 8,000 Feet
Requires Pressure Sw itch
Change and Orifice
C h an g e
Based on BTU Content
700-749
2.75
2.70
2.60
750-799
2.70
2.60
2.50
800-849
2.60
2.50
850-899
2.50
2.45
(2.40)
900-949
(2.40)
2.35
[2.30]
950-999
2.35
[2.30]
2.25
1000-1049**
[2.30]
2.25
2.20
1050-1100
2.25
2.25
2.20
Pressure Switch
Standard (.55)
[2.30] orifices are shipped w ith the unit for field
installed optional 10% input rate.
8,001 to 10,000 Feet
Requires Pressure Sw itch
Change and Orifice
C h an g e
Based on BTU Content
Order 8620-189 High Altitude Pressure Sw itch Kit (.42)
(2.40) is the factory installed orifice siz e for full rated input
* At standard conditions: 30.00 inches Mercury, 60F, saturated, .60 specific gravity.
** All Natural Gas factory orifice sizing and standard input ratings based on nominal 1025 BTU/cu ft gas and sea
level conditions
All other orifice sizes shown are available as individual items. See Orifice charts on Page 28 for part numbers and number required.
Manual
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2100-525E
31 of 67
22. CONVERSION OF GAS INPUT BTUH
FROM HIGH TO LOW RATING
All the derated WG series units are produced with
maximum BTUH input orifices installed. To field
convert input, a change to main burner orifices is
required.
NOTE: No change to air orifices is necessary. A set
of low input orifices is shipped with every
unit. They will be found packaged in a bag
behind the burner door. Refer to the unit
rating plate to confirm the proper orifice size.
Proper installation of the orifices is detailed
as 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 are
now accessible and remove orifices.
G. Apply a modest amount of pipe compound to the
new orifices and screw them into the manifold.
H. To assemble burner reverse steps A through G.
WARNING
Failure to follow these instructions could
create a hazard resulting in property damage,
bodily injury, or death.
23. MEASURING AIR TEMPERATURE
RISE
Air temperature rise (supply air temperature minus
return air temperature) must be within allowable air
temperature rise range specified on furnace rating plate.
You will need 2 thermometers with 1 degree resolution
capable of reading up to 200 degrees F. Check
thermometers to make sure they agree, or compensate
accordingly.
Follow this procedure:
1. Open supply air registers and return air grilles.
Make sure the registers and grilles are free of
obstruction from rugs, carpets, drapes or furniture.
Manual 2100-525E
Page
32 of 67
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 plenum
approximately 2 feet from furnace. Locate
thermometer tip in center of plenum to insure proper
temperature measurement.
6. Place second thermometer in return air duct
approximately 2 feet from furnace. Locate
thermometer tip in center of duct to insure proper
temperature measurement.
7. Set room thermostat on highest temperature setting.
Operate furnace 10 minutes. Record supply air and
return air temperatures.
8. Calculate air temperature rise by subtracting return
air temperature from supply air temperature.
• If air temperature rise is above the temperature
rise range on rating plate, furnace is overfired
or has insufficient airflow. Check gas input
following the instructions in Section, “Checking
Gas Input Rate”. If air temperature rise is still
above temperature rise range specified, more
heating airflow is needed. Check duct work and
grilles to make sure all are properly sized.
• If air temperature rise is below the temperature
rise range on rating plate, furnace is underfired
or has too much airflow. Check gas input
following the instructions in Section, “Checking
Gas Input Rate”. If air temperature rise is still
below temperature rise range specified, less
heating airflow is needed. Adjust dampers or
grilles as needed.
• After making adjustments, you must check air
temperature rise to verify that resulting air
temperature rise is within allowable range. If
air temperature rise is still outside the
temperature rise range specified on rating
plate, check duct system design with a
qualified heating engineer. It may be
necessary to re-size the duct work. Recheck
air 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 reduced
system performance.
FIGURE 16
ACCESS INTERNAL FILTER
THROUGH UPPER SERVICE DOOR
24. FILTERS
A 2" thick throwaway filter is supplied with each unit.
This filter is installed by opening the main service door.
(See Figure 16.)
Replacement filters are available through your dealer.
25. COMPRESSOR CONTROL MODULE
The compressor control is an anti-short cycle/lockout
timer with high and low pressure switch monitoring and
alarm output.
ADJUSTABLE DELAY-ON-MAKE AND BREAK
TIMER
On a call for compressor operation the delay-on-make
period begins which will be 10% of the delay-on-break
setting. When the delay-on-make is complete and the
high pressure switch (and low pressure switch if
employed) is closed, the compressor contactor is
energized. Upon shutdown, the delay-on-break timer
starts and prevents restart until the delay-on-break and
delay-on-make periods have expired.
HIGH PRESSURE SWITCH AND LOCKOUT
SEQUENCE (Standard Feature)
If the high pressure switch opens, the compressor
contactor will de-energize immediately. The lockout
timer will go into a soft lockout and stay in soft lockout
until the high pressure switch closes and the delay-onmake time has expired. If the high pressure switch
opens again in this same operating cycle the unit will
go into manual lockout condition and the alarm circuit
will energize. Recycling the wall thermostat resets the
manual lockout.
LOW PRESSURE SWITCH, BYPASS, AND
LOCKOUT SEQUENCE
NOTE: The low pressure switch is an optional
control and the bypass and lockout sequence
are part of the standard compressor control
module.
If the low pressure switch opens for more that 120
seconds, the compressor contactor will de-energize and
go into a soft lockout. Regardless the state of the low
pressure switch, the contactor will reenergize after the
delay-on-make time delay has expired. If the low
pressure switch remains open or opens again for longer
than 120 seconds the unit will go into manual lockout
condition and the alarm circuit will energize.
Recycling the wall thermostat resets the manual
lockout.
Manual
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2100-525E
33 of 67
ALARM OUTPUT
PHASE MONITOR
Alarm terminal is output connection for applications
where alarm signal is desired. This terminal is powered
whenever compressor is locked out due to HPC or LPC
sequences as described.
All units with three phase scroll compressors are
equipped with a three phase line monitor to prevent
compressor damage due to phase reversal.
NOTE: Both high and low pressure switch controls
are inherently automatic reset devices. The
high pressure switch and low pressure switch
cut out and cut in settings are fixed by
specific air conditioner or heat pump unit
model. The lockout features, both soft and
manual, are a function of the Compressor
Control Module.
If phases are reversed, the red fault LED will be lit and
compressor operation is inhibited.
ADJUSTMENTS
ADJUSTABLE DELAY-ON-MAKE AND
DELAY-ON-BREAK TIMER
The potentiometer is used to select Delay-on-Break
time from 30 seconds to 5 minutes. Delay-on-Make
(DOM) timing on power-up and after power
interruptions is equal to 2 minutes plus 10% of Delayon-Break (DOB) setting:
0.5 minute
1.0 minute
2.0 minute
3.0 minute
4.0 minute
5.0 minute
(30 seconds)
(60 seconds)
(120 seconds)
(160 seconds)
(240 seconds)
(300 seconds)
Manual 2100-525E
Page
34 of 67
DOB
DOB
DOB
DOB
DOB
DOB
=
=
=
=
=
=
123 second DOM
126 second DOM
132 second DOM
138 second DOM
144 second DOM
150 second DOM
The phase monitor in this unit is equipped with two
LEDs. If the “Y” signal is present at the phase monitor
and phases are correct, the green LED will light.
If a fault condition occurs, reverse two of the supply
leads to the unit. Do not reverse any of the unit factory
wires as damage may occur.
26. LIGHTING AND SHUTDOWN INSTRUCTIONS
FIGURE 17
INSTRUCTION LABEL
Manual
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2100-525E
35 of 67
27. SERVICE AGENCY PROCEDURES
FIGURE 18
TOP VIEW OF GAS CONTROL
CAUTION
Label all wires prior to disconnection when
servicing controls. Wiring errors can cause
improper and dangerous operation. Verify
proper operation after servicing.
WARNING
Follow these procedures before inspecting
furnace.
• 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.
MAIN BURNER
Observe the main burners in operation. The flame
should be mostly “blue” with possibly a little orange
(not yellow) at the tips of the flame. The flames should
be in the center of the heat exchanger tubes and not
impinging on the heat exchanger surfaces themselves.
Observe the fire until the blower starts (there is a
normal delay period until the heat exchanger warms
up). There should be no change in the size or shape of
the flame. If there is any wavering or blowing of the
flame on blower start-up, it is an indication of a
possible leak in the heat exchanger.
MIS-165
BURNERS / HEAT EXCHANGER / FLUE GAS
PASSAGE WAYS
The burners, heat exchanger and interior flue gas
passages may be inspected using a light on small mirror
or an extension handle. Remove the screws securing
the inducer and collector box. Now inspect the upper
tubes of the heat exchanger.
Check the exterior of the heat exchanger and the
interior flue gas passages for any evidence of
deterioration due to corrosion, cracking or other causes.
If signs of sooting exist, remove the burners and clean
the heat exchanger, as required.
28. MAINTAINING UNIT IN GOOD
WORKING ORDER
The unit should be inspected annually by a qualified
service agency.
WARNING
Use replacement parts listed in the
Replacement Parts list only. The use of
incorrect parts could cause improper unit
operation, resulting in damage, injury or
death.
Manual 2100-525E
Page
36 of 67
WARNING
Disconnect electrical power before servicing
unit. Failure to do so could result in electrical
shock or death.
ROUTINE MAINTENANCE
1. Air Filters – Check the condition at least monthly
when the unit is in use, and replace as necessary.
2. Lubrication Requirements – The indoor circulating
air blower motor and outdoor circulating air fan
motor are permanently lubricated and requires no reoiling. The combustion air blower motor requires no
re-oiling.
ANNUAL MAINTENANCE
Routine inspection and maintenance procedures are the
responsibility of the user and are outlined below.
1. Before inspecting unit:
a. Turn room thermostat to lowest or off setting.
WARNING
Turn off electrical power supply to prevent
injury from moving parts or electric shock.
b. Turn off equipment gas shut off valve.
c. Wait for unit to cool if it was recently
operating.
d. Turn off electrical power to unit.
2. Inspect the following:
a. Vent terminal and combustion air intake
terminal. Make sure both are free from
obstructions.
b. Vertical Vent Applications – Inspect venting
system. Make sure system has no holes, is
physically sound and free from obstructions.
c. Make sure the supply and return air flange
sleeves or duct work are securely fastened to
unit and physically sound.
d. Supply and return grilles must be open and
free from obstructions.
e. Inspect to make sure the unit is securely
fastened to the wall. Seal any possible leaks
between unit and wall with appropriate
exterior sealing material.
f. Inspect burners, heat exchanger, induced
draft blower, and induced draft blower
collector box. There must be no obvious
signs of deterioration.
g. Inspect all electrical connections and wiring.
h. Check all gas piping for leaks with soap
solution used to detect leaks.
i. Inspect, clean, and repair as needed the entire
blower assembly, air filters, draft inducer,
cooling coils, and vent options (if installed).
ROUTINE INSPECTION
1. Inspect the physical support of the unit annually to
make 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 each
heating season and clean as necessary.
3. Inspect the vent terminal and combustion air intake
hood for any obvious deterioration, to make sure it is
free and clear of any obstructions.
29. REPLACEMENT PARTS
WARNING
Use replacement parts listed in Replacement
Parts list. Failure to do so could cause
improper furnace operation, resulting in
property damage, personal injury, or death.
Replacement parts for the gas/electric units are
available through local distributors.
A replacement parts list manual is supplied with each
unit. When ordering parts or making inquires
pertaining to any of the units covered by these
instructions, it is very important to always supply the
complete model number and serial number of the unit.
This is necessary to assure that the correct parts (or an
approved alternate part) are issued to the service
agency.
Manual
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37 of 67
30. SEQUENCE OF OPERATION –
HEATING
On a call for heat from the thermostat, the induced draft
blower is energized. Once sufficient draft is
established, the pressure switch contacts close and the
ignition system is energized. The direct spark ignitor
will be energized allowing gas to flow. At the same
time the main valve is energized, a 30-second blower
delay timer is activated.
After this delay, the heating speed blower relay
energizes. The blower will begin operating and remain
in operation until the set delay time after the call for
heat has been satisfied. (See Tables 10-15 for selectable
blower off time delays.) This timing sequence
guarantees blower on, blower off operation.
This unit is equipped with a flame roll-out switch,
which is wired in series with the control circuit. This is
a manual reset switch and is used for the purpose of
preventing possible fire hazard in the event of a system
malfunction. If this switch has opened the control
circuit, there could be a possible system malfunction.
Some of the conditions that might cause a roll-out to
occur are blockage or sooting of primary heat
exchanger, overfiring of furnace due to improper main
burner orifices or incorrect manifold pressure,
insufficient combustion air, or installation deficiencies
with respect to return air duct design or sizing.
Once the problem has been resolved, reset the switch by
pressing down on the reset button on top of the switch.
See Figure 19 for additional information.
31. SEQUENCE OF OPERATION –
COOLING
On a call for cooling from the room thermostat, the high
speed blower relay will be energized as well as the
compressor contactor. Following termination of the
cooling cycle, the blower motor will continue to run for
one minute.
See Figure 19 for additional information.
The unit may be equipped with a low ambient control
for lower outdoor temperature operation in the cooling
mode. If equipped with this optional control the
condenser fan will not operate immediately upon
compressor start-up, and will cycle on and off until the
condensing pressure remains above 180 PSIG. LAC
energizes the fan motor at 280 PSIG, de-energizes at
180 PSIG.
FIGURE 19
SEQUENCE OF OPERATION
ELECTRONIC BLOWER CONTROL
ACTION
SYSTEM RESPONSE
Combustion air blower is energized.
Air proving switch makes. Air flow is established.
Ignition system is energized.
Gas valve opens and main burner lights.
Heat fan on delay timing begins. When timing is complete, the circulating fan is
energized at heat speed.
Thermostat calls for heat.
(W terminal is energized.)
•
•
•
•
•
Thermostat ends call for heat.
• Ignition system is de-energized and gas valve closes.
• Combustion air blower is de-energized after postpurge timing.
• Heat fan off delay timing begins. When timing is complete, the circulating fan is
de-energized.
Thermostat begins call for cool.
(G and Y terminals re-energized.)
• Cooling contactor is energized.
• Circulating fan is energized on cool speed after cool fan on delay timing.
Thermostat ends call for fan.
(G terminal is de-energized.)
• Circulating fan is de-energized
Limit (flame rollout) opens.
• Thermostat and ignition system are de-energized and gas valve closes.
• Combustion air blower and circulating fan heat speed are energized.
Limit (auto reset) or flame rollout
(manual reset) circuit closed.
• Combustion air blower rremains energized for postpurge timing.
• The circulation fan remains energized for the selected delay off timing.
• Normal operation resumes.
Manual 2100-525E
Page
38 of 67
FIGURE 20
FURNACE CONTROL BOARD AND BLOWER CONTROL
32. INDOOR BLOWER OPERATION
All models have multiple speed direct drive blower
motors. If supply and return ducts are connected to the
unit, the ducts must be of adequate size. Refer to the
appropriate 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 control
board.
3. Place desired blower motor speed lead wire to
“HEAT” terminal of integrated furnace control
board.
4. Place unused blower motor speed lead wire to
“UNUSED” terminal of integrated furnace control
board.
5. Energize the system in cooling and heating modes to
check for proper blower operation.
If it is desirable to have both HEAT/COOL blower
motor speed at the same speed, install a jumper wire
between “HEAT” and “COOL” terminals of the
integrated furnace control board, and place both unused
motor speed lead wires on the two “UNUSED” terminals
on the integrated furnace control board. (See Figure 20.)
TABLE 9
230 VOLT MOTOR SPEED TAPS
S p eed s
3-Speed Blow er Motor
Low
Red
Medium
Blue
High
Black
460 VOLT MOTOR SPEED TAPS
S p eed s
3-Speed Blow er Motor
Low
Red
Medium
Blue
High
Black
Isolation *
Orange
Isolation *
Purple
* NOTE: On 460 Volt motors, there are two motor isolation leads. The orange must connect with the black high
speed blower motor lead wire for medium and low speed blower operation. The purple wire must
connect with the blue medium speed blower motor lead wire for low speed blower operation. This is all
automatically accomplished with blower relays HSBR, MSBR and LSBR, and speed changes are all
made by changes at the integrated furnace control board.
Manual
Page
2100-525E
39 of 67
TABLE 10
W24G INDOOR BLOWER PERFORMANCE @ 230 AND 460 VOLTS
Recommended W24G cooling airflow range at rated 800 CFM @ 0.15 ESP (WC) is 700 - 910 CFM
Factory set on Low Speed for cooling and High for heating.
COOLING MODE
ESP
Inches
H 2O
High
0.1
0.2
MANUAL FAN and HEATING MODE
Wet Coil
90,000 BTU Input
81,000 BTU Input
Medium
Low
High
Medium
Low
High
Medium
Low
---
---
820
1260
1060
---
950
770
1200
1010
---
---
1060
870
---
1200
1010
---
0.3
---
880
700
1120
---
---
1120
940
---
0.4
---
790
---
1030
---
---
1030
860
---
0.5
910
710
---
---
---
---
950
---
---
0.6
800
---
---
---
---
---
840
---
---
COOLING MODE
MANUAL FAN and HEATING MODE
ESP
Inches
H 2O
High
Medium
Low
High
Medium
Low
High
Medium
Low
0.1
---
---
820
1260
1060
870
---
1060
870
Wet Coil
61,000 BTU Input
68,000 BTU Input
0.2
---
950
770
1200
1010
---
---
1010
810
0.3
---
880
700
1120
910
---
1120
940
---
0.4
---
790
---
1030
---
---
1030
860
---
0.5
910
710
---
950
---
---
950
780
---
0.6
800
---
---
---
---
---
840
---
---
COOLING MODE
ESP
Inches
H 2O
MANUAL FAN and HEATING MODE
Wet Coil
High
Medium
45,000 BTU Input
Low
High
Medium
Low
41,000 BTU Input
High
Medium
Low
0.1
---
---
820
1260
1060
870
---
1060
870
0.2
---
950
770
1200
1010
810
1200
1010
810
0.3
---
880
700
1120
910
---
1120
940
750
0.4
---
790
---
1030
860
---
1030
860
680
0.5
910
710
---
950
780
---
950
780
---
0.6
800
---
---
840
---
---
840
---
---
Voltage adjustment – Reduce airflow by 100 CFM for 208 Volt
Dehumidification coil adjustment – Reduce airflow by 35 CFM for dehumidification coil installed
Top outlet adjustment – Increase airflow by 50 CFM for top outlet models
SG-3, RG-3, non-ducted application adjustment – Reduce airflow by 100 CFM for SG-3 and RG-3 installations
Manual 2100-525E
Page
40 of 67
TABLE 11
W30G INDOOR BLOWER PERFORMANCE @ 230 AND 460 VOLTS
Recommended W30G cooling airflow range at rated 1000 CFM @ 0.35 ESP (WC) is 880 - 1150 CFM
Factory set on Medium Speed for cooling and for heating.
COOLING MODE
MANUAL FAN and HEATING MODE
ESP
Inches
H 2O
High
Medium
Low
High
Medium
Low
High
Medium
Low
0.1
---
---
1000
---
1260
1060
---
1260
1060
1010
Wet Coil
90,000 BTU Input
81,000 BTU Input
0.2
---
1160
950
1370
1200
1010
---
1200
0.3
---
1080
880
1290
1120
940
---
1120
940
0.4
1150
990
---
1190
1030
---
1190
1030
860
0.5
1050
910
---
1090
950
---
1090
950
---
0.6
940
---
---
980
---
---
980
840
---
COOLING MODE
ESP
Inches
H 2O
Wet Coil
High
MANUAL FAN and HEATING MODE
68,000 BTU Input
Medium
Low
High
Medium
Low
61,000 BTU Input
High
Medium
Low
0.1
---
---
1000
---
1260
1060
---
---
1060
0.2
---
1160
950
---
1200
1010
---
---
1010
0.3
---
1080
880
---
1120
940
---
1120
940
0.4
1150
990
---
1190
1030
860
---
1030
860
0.5
1050
910
---
1090
950
780
1090
950
780
0.6
940
---
---
980
840
---
980
840
660
COOLING MODE
ESP
Inches
H 2O
MANUAL FAN and HEATING MODE
Wet Coil
High
45,000 BTU Input
Medium
Low
High
Medium
Low
41,000 BTU Input
High
Medium
Low
0.1
---
---
1000
---
1260
1060
---
---
1060
0.2
---
1160
950
---
1200
1010
---
1200
1010
0.3
---
1080
880
1290
1120
940
---
1120
940
0.4
1150
990
---
1190
1030
860
---
1030
860
0.5
1050
910
---
1090
950
780
1090
950
780
0.6
940
---
---
980
840
660
980
840
660
Voltage adjustment – Reduce airflow by 100 CFM for 208 Volt
Dehumidification coil adjustment – Reduce airflow by 35 CFM for dehumidification coil installed
Top outlet adjustment – Increase airflow by 50 CFM for top outlet models
SG-3, RG-3, non-ducted application adjustment – Reduce airflow by 100 CFM for SG-3 and RG-3 installations
Manual
Page
2100-525E
41 of 67
TABLE 12
W36G INDOOR BLOWER PERFORMANCE @ 230 AND 460 VOLTS
Recommended W36G cooling airflow range at rated 1100 CFM @ 0.250 ESP (WC) is 940 - 1250 CFM
Factory set on Medium Speed for cooling and for heating.
COOLING MODE
MANUAL FAN and HEATING MODE
ESP
Inches
H 2O
High
Medium
Low
High
Medium
Low
High
Medium
Low
0.1
---
1220
1000
---
1260
1060
---
1260
1060
Wet Coil
90,000 BTU Input
81,000 BTU Input
0.2
---
1160
950
1370
1200
1010
---
1200
1010
0.3
1250
1080
---
1290
1120
940
---
1120
940
0.4
1150
990
---
1190
1030
---
1190
1030
860
0.5
1050
---
---
1090
950
---
1090
950
---
0.6
940
---
---
980
---
---
980
840
---
COOLING MODE
ESP
Inches
H 2O
Wet Coil
MANUAL FAN and HEATING MODE
68,000 BTU Input
High
Medium
Low
High
Medium
Low
61,000 BTU Input
High
Medium
Low
0.1
---
1220
1000
---
1260
1060
---
---
1060
0.2
---
1160
950
---
1200
1010
---
---
1010
0.3
1250
1080
---
---
1120
940
---
1120
940
0.4
1150
990
---
1190
1030
860
---
1030
860
0.5
1050
---
---
1090
950
780
1090
950
780
0.6
940
---
---
980
840
---
980
840
660
COOLING MODE
MANUAL FAN and HEATING MODE
ESP
Inches
H 2O
High
Medium
Low
High
Medium
Low
High
Medium
Low
0.1
---
1220
1000
---
1260
1060
---
---
1060
Wet Coil
45,000 BTU Input
41,000 BTU Input
0.2
---
1160
950
---
1200
1010
---
1200
1010
0.3
1250
1080
---
1290
1120
940
---
1120
940
0.4
1150
990
---
1190
1030
860
---
1030
860
0.5
1050
---
---
1090
950
780
1090
950
780
0.6
940
---
---
980
840
660
980
840
660
Voltage adjustment – Reduce airflow by 100 CFM for 208 Volt
Dehumidification coil adjustment – Reduce airflow by 35 CFM for dehumidification coil installed
Top outlet adjustment – Increase airflow by 50 CFM for top outlet models
SG-3, RG-3, non-ducted application adjustment – Reduce airflow by 100 CFM for SG-3 and RG-3 installations
Manual 2100-525E
Page
42 of 67
TABLE 13
W42G INDOOR BLOWER PERFORMANCE @ 230 AND 460 VOLTS
Recommended W42G cooling airflow range at rated 1300 CFM @ .35 ESP (WC) is 1030 - 1480 CFM
Factory set on Medium Speed for heating and cooling
COOLING MODE
MANUAL FAN and HEATING MODE
ESP
Inches
H sO
High
Medium
Low
High
Medium
Low
High
Medium
Low
.10
---
1520
1110
---
1580
1180
---
1580
1180
.20
---
1450
1050
1880
1510
---
---
1510
1090
.30
---
1400
---
1760
1460
---
---
1460
---
.40
1480
1290
---
1670
1340
---
1670
1340
---
.50
1390
---
---
1560
1240
---
1560
1240
---
.60
1270
---
---
1430
1130
---
1430
1130
---
Wet Coil
125,000 BTU Input
COOLING MODE
113,000 BTU Input
MANUAL FAN and HEATING MODE
ESP
Inches
H sO
High
Medium
Low
High
Medium
Low
High
Medium
Low
.10
---
1560
1160
---
1630
1230
---
1630
1230
.20
---
1490
1090
---
1560
1160
---
1560
1160
.30
---
1440
1070
1810
1510
1140
---
1510
1140
.40
1530
1330
---
1720
1390
---
1720
1390
1020
.50
1440
1210
---
1610
1290
---
1610
1290
970
.60
1320
---
---
1480
1180
---
1480
1180
---
Wet Coil
100,000 BTU
COOLING MODE
90,000 BTU Input
MANUAL FAN and HEATING MODE
ESP
Inches
H sO
High
Medium
Low
High
Medium
Low
High
Medium
Low
.10
---
1600
1260
---
1680
1280
---
1680
1280
.20
---
1530
1190
---
1610
1210
---
1610
1210
.30
---
1480
1120
1860
1560
1190
---
1560
1190
.40
---
1360
1100
1770
1440
1070
---
1440
1070
.50
1490
1280
---
1660
1340
970
1660
1340
970
.60
1370
---
---
1530
1230
---
1530
1230
---
Wet Coil
75,000 BTU Input
68,000 BTU Input
Voltage adjustment – Reduce airflow by 130 CFM for 208 Volt
Top outlet adjustment – Increase airflow by 65 CFM for top outlet models
SG-5, RG-5, non-ducted application adjustment – Reduce airflow by 170 CFM for SG-5 and RG-5 installations
Manual
Page
2100-525E
43 of 67
TABLE 14
W48G INDOOR BLOWER PERFORMANCE @ 230 AND 460 VOLTS
Recommended W48G cooling airflow range at rated 1550 CFM @ .20 ESP (WC) is 1250 - 1780 CFM
Factory set on Medium Speed for cooling and Medium Speed for heating.
COOLING MODE
MANUAL FAN and HEATING MODE
ESP
Inches
H sO
High
Medium
Low
High
Medium
Low
High
Medium
Low
.10
---
1520
---
---
1580
1180
---
1580
1180
.20
1710
1450
---
1880
1510
---
---
1510
1110
.30
1600
1400
---
1760
1460
---
---
1460
1090
.40
1480
1290
---
1670
1340
---
1670
13 40
---
.50
1390
---
---
1560
1240
---
1560
1240
---
.60
1270
---
---
1430
---
---
1430
1130
---
Wet Coil
125,000 BTU Input
COOLING MODE
113,000 BTU Input
MANUAL FAN and HEATING MODE
ESP
Inches
H sO
High
Medium
Low
High
Medium
Low
High
Medium
Low
.10
---
1560
---
---
1630
1230
---
1630
1230
.20
1760
1490
---
---
1560
1160
---
1560
1160
.30
1630
1440
---
1810
1510
1140
---
1510
1140
.40
1530
1330
---
1720
1390
---
1720
1390
1020
.50
1440
1210
---
1610
1290
---
1610
1290
970
.60
1320
---
---
1480
1180
---
1480
1180
---
Wet Coil
100,000 BTU
COOLING MODE
90,000 BTU Input
MANUAL FAN and HEATING MODE
ESP
Inches
H sO
High
Medium
Low
High
Medium
Low
High
Medium
Low
.10
---
1600
---
---
1680
1280
---
1680
1280
.20
1805
1530
---
---
1610
1210
---
1610
1210
.30
1680
1480
---
1860
1560
1190
---
1560
1190
.40
1580
1360
---
1770
1440
1070
---
1440
1070
.50
1490
1280
---
1660
1340
970
1660
1340
970
.60
1370
---
---
1530
1230
---
1530
1230
---
Wet Coil
75,000 BTU Input
68,000 BTU Input
Voltage adjustment – Reduce airflow by 130 CFM for 208 Volt
Top outlet adjustment – Increase airflow by 65 CFM for top outlet models
SG-5, RG-5, non-ducted application adjustment – Reduce airflow by 170 CFM for SG-5 and RG-5 installations
Manual 2100-525E
Page
44 of 67
TABLE 15
W60G INDOOR BLOWER PERFORMANCE @ 230 AND 460 VOLTS
Recommended W60G cooling airflow range at rated 1650 CFM @ .30 ESP (WC) is 1360 - 1850 CFM
Factory set on High Speed for cooling and Medium Speed for heating.
COOLING MODE
MANUAL FAN and HEATING MODE
ESP
Inches
H sO
High
Medium
Low
High
Medium
Low
High
Medium
Low
.10
1800
1520
---
---
1580
1180
---
1580
1180
.20
1710
1450
---
1880
1510
---
---
1510
1110
.30
1600
1400
---
1760
1460
---
---
1460
1090
.40
1480
---
---
1670
1340
---
1670
13 40
---
.50
1390
---
---
1560
1240
---
1560
1240
---
.60
---
---
---
1430
---
---
1430
1130
---
Wet Coil
125,000 BTU Input
COOLING MODE
113,000 BTU Input
MANUAL FAN and HEATING MODE
ESP
Inches
H sO
High
Medium
Low
High
Medium
Low
High
Medium
Low
.10
1860
1560
---
---
1630
1230
---
1630
1230
.20
1760
1490
---
---
1560
1160
---
1560
1160
.30
1630
1440
---
1810
1510
1140
---
1510
1140
.40
1530
1330
---
1720
1390
---
1720
1390
1020
.50
1440
---
---
1610
1290
---
1610
1290
970
.60
1320
---
---
1480
1180
---
1480
1180
---
Wet Coil
100,000 BTU
COOLING MODE
90,000 BTU Input
MANUAL FAN and HEATING MODE
ESP
Inches
H sO
High
Medium
Low
High
Medium
Low
High
Medium
Low
.10
1910
1600
---
---
1680
1280
---
1680
1280
.20
1805
1530
---
---
1610
1210
---
1610
1210
.30
1680
1480
---
1860
1560
1190
---
1560
1190
.40
1580
1360
---
1770
1440
1070
---
1440
1070
.50
1490
---
---
1660
1340
970
1660
1340
970
.60
1370
---
---
1530
1230
---
1530
1230
---
Wet Coil
75,000 BTU Input
68,000 BTU Input
Voltage adjustment – Reduce airflow by 130 CFM for 208 Volt
Top outlet adjustment – Increase airflow by 65 CFM for top outlet models
SG-5, RG-5, non-ducted application adjustment – Reduce airflow by 170 CFM for SG-5 and RG-5 installations
Manual
Page
2100-525E
45 of 67
TABLE 16
INTEGRATED FURNACE AND BLOWER CONTROL OPERATION
IGNITION SEQUENCE CONTROL
Ignition Source
24 VAC DSI
Flame Sensing
Remote
Timings
-
Prepurge
Postpurge
Inter-trial purge
Pressure switch proving period
Trials for ignition
Trial for ignition
Ignition sequence lockout
seconds
seconds (0 if cycle terminated before valve "on")
seconds
seconds
per ignition sequence
seconds total time to prove flame
minutes (after 3 trials for ignition), auto reset
can be reset during the 60 minute lockout period by opening
thermostat circuit for 3 seconds or more
- Heat blower on - delay
30 seconds (timing starts when ignitor cycles off)
- Heat blower off - delay
90, 120, 150 sconds selectable; factory set at 120
- Cool blower on - delay
7 seconds
- Cool blower off - delay
60 seconds
- Manual fan operations
Operates on selected heating speed and cycles off during
ignition or burner start up sequence.
- High limit control operation
Automatic reset, ignition sequence restart. See Note 1.
- Flame rollout switch operation
Manual reset, igniton sequence initiated after switch is manually
reset. See Note 1.
NOTE 1: After the fourth lim it trip on a given call for heat there will be a 1 hour delay
before the ignition sequence will restart. After either high lim it switch or flam e
rollout switch actuation the inducer will operate for the 30 second post purge and
the com fort air blower will operate for the selected off delay. If on M anual Fan
operation, the com fort air blower will continue to operate.
SAFETY UNITS
High limit / Rollout
Pressure switch
15
30
15
60
3
7
60
-
SPST in 24 Volt
SPST, safe start check
COMFORT FAN CONTROL
Heating Speed Fan
Normal operation
- ON delay
- OFF delay
30 seconds fixed. Timing starts when igniter de-energized
Flame Sense
3 selectable timings -120 seconds standard can be changed to 90
or 150 seconds.
ON when limit OPEN
OFF after OFF delay when limit CLOSES
ON if flame is sensed and there is no call for heat.
Cooling Speed Fan
- ON delay
7 seconds
Limit Operation
- OFF delay
Manual Fan
60 seconds
ON continuously on HEATING speed. When call for cool, the fan
switches to COOLING speed. Then when thermostat satisfied,
the fan switches back to HEATING speed after COOLING OFF
delay.
DIAGNOSTIC INDICATOR
A red LED is provided to indicate system faults as follows:
Steady ON - Control okay in standby, call for heat, cool or fan modes
Steady OFF - Internal control fault or no power. Also check 3A fuse on control.
1 flash - Lockout due to failed ignition or flame dropouts
2 flashes - Pressure switch open with inducer on
3 flashes - Pressure switch is closed with inducer off
4 flashes - Limit switch is open
5 flashes - Flame detected with gas valve closed
6 flashes - Compressor output delayed from short cycle/staging timer
The flash rate is 0.25 seconds on, 0.25 seconds off with 2.0 seconds pause between flash codes.
The flash rate is 0.25 seonds on, 0.25 seconds off with 2.0 seconds pause between flash codes.
Manual 2100-525E
Page
46 of 67
33. PRESSURE SERVICE PORTS
High and low pressure service ports are installed on all units so that the system operating pressures can be observed.
Tables 17A & 17B outlines expected pressures at various indoor and outdoor temperatures.
TABLE 17A
COOLING PRESSURE TABLE
Model
W24G1
W30G1
W36G1
Return Air
Temperature Pressure 60°
65°
70°
75°
80°
85°
75 deg. D B
62 deg. WB
Low S i de
High Side
105
227
108
250
111 115
273 296
118
319
121 124
342 364
90°
80 deg. D B
67 deg. WB
Low S i de
High Side
120
235
123
258
126
282
129
305
131 134
329 352
85 deg. D B
72 deg. WB
Low S i de
High Side
133
245
136
268
139
292
141 144
316 340
75 deg. D B
62 deg. WB
Low S i de
High Side
110
238
113
262
116
287
80 deg. D B
67 deg. WB
Low S i de
High Side
85 deg. D B
72 deg. WB
95° 100° 105° 110° 115° 120° 125°
127
387
129
415
131 134
442 469
136
497
138
524
140
552
137
376
140
399
142
427
145
456
147
484
149
512
152
540
155
569
147
363
150
387
153 156
411 440
158
469
161 164
498 527
166
556
169
585
119 122
311 335
125
359
128
383
131 133
407 435
134
463
136 138
491 519
139
547
141
575
126
246
129 131 134 137
271 296 321 345
139
370
142
395
145
420
146
449
148
477
150
506
152
535
154
564
156
592
Low S i de
High Side
139
257
142
282
145
307
147
332
150
357
153
382
155
407
158
432
160 162 164 166
461 491 521 550
168
580
170
609
75 deg. D B
62 deg. WB
Low S i de
High Side
112
256
115
280
117
304
120
328
123
352
125
377
128 131 132
401 425 452
133
480
135
508
136
536
138
563
139
591
80 deg. D B
67 deg. WB
Low S i de
High Side
128
265
130
290
132
314
135
339
137
364
139
388
142
413
144
438
146
466
147
495
149
524
150
552
152 153
581 610
85 deg. D B
72 deg. WB
Low S i de
High Side
141 144 146
276 301 326
148 150
351 376
153
400
155
425
157
450
159
480
161 162
509 539
164
568
166
597
168
627
TABLE 17B
COOLING PRESSURE TABLE
Model
W42G1
W48G1
W60G1
Return Air
Temperature Pressure 60°
65°
70°
75°
80°
85°
75 deg. D B
62 deg. WB
Low S i de
High Side
107 109
231 254
112
277
115
299
118
322
121 123
345 368
90°
95° 100° 105° 110° 115° 120° 125°
126 128
391 417
80 deg. D B
67 deg. WB
Low S i de
High Side
122
239
124
262
127
286
129
309
132
333
134
356
137
380
139
403
85 deg. D B
72 deg. WB
Low S i de
High Side
134
249
137
272
139
296
142
320
144
343
147
367
149 152
391 415
154
443
75 deg. D B
62 deg. WB
Low S i de
High Side
104 107
241 264
110
287
113 116
311 334
119
358
122 125
381 404
80 deg. D B
67 deg. WB
Low S i de
High Side
118
249
121 124
273 297
126 129
321 345
132
369
135
393
85 deg. D B
72 deg. WB
Low S i de
High Side
131 133
259 283
136
308
139
332
142
356
75 deg. D B
62 deg. WB
Low S i de
High Side
108 111 114
241 267 292
116
318
80 deg. D B
67 deg. WB
Low S i de
High Side
123
249
126
275
128
302
85 deg. D B
72 deg. WB
Low S i de
High Side
136
260
139
286
141 144
313 339
130
444
132
470
133
497
135
523
137
550
141 143
430 458
145
485
147
512
149
539
151
567
156 159
471 499
161 163
527 555
165
583
126
433
128
462
130
490
132
519
133
548
135
576
137
417
139
446
141 143
476 505
145
535
147
565
149
594
144 147
381 404
150
429
152
459
154
489
156
520
159
550
161 163
581 611
119
343
122
369
125
394
127
420
129
447
130
475
132
503
133 135
531 559
137
587
131 133
328 354
136
380
138
406
140
433
142 144
461 490
145
519
147
548
149
576
151
605
149
392
151 154
418 445
155
474
159
534
161 163
563 593
164
622
146
366
157
504
Low side pressure ± 2 PSIG
High 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, system evacuated and recharged to serial plate instruction.
Manual
Page
2100-525E
47 of 67
34. REFRIGERANT CHARGE
The correct system R-410A charge is shown on the unit
rating plate. Optimum unit performance will occur with a
refrigerant charge resulting in a suction line temperature
(6" from compressor) as shown in
Table 18.
The suction line temperatures in Table 18 are based upon
80 degrees F dry bulb / 67 degree wet bulb (50% R.H.)
temperature and rated airflow across the evaporator
during cooling cycle. If charge quantity is in doubt,
reclaim and recharge to factory name plate quantity.
TABLE 18
REFRIGERANT CHARGE
Rated
Airflow
95 D eg . F
OD Temp.
W24G
800
63 - 65
W30G
1000
63 - 65
W36G
1100
62 - 64
W42G
1300
61 - 63
W48G
1550
61 - 63
W60G
1650
59 - 61
NATURAL GAS MODELS ONLY
Model numbers designated with an “N” are designed
for low NOx emissions which comply with all
California Air Quality Management District regulations
for nitrogen oxide emission levels. Refer to Figure 22
for NOx insert information.
* * IMPORTANT * *
Total system charge for these models can be found in
Table 1.
Model
36. LOW-NOX BURNER ASSEMBLY “N”
SUFFIX MODELS ONLY – U.S.
INSTALLATIONS ONLY
For propane (LP) conversions the NOx
reduction screen inserts shown below must
be removed. This is accomplished by
removing the burner box assembly and
removing the NOx screens. Reassemble unit
properly before firing. Failure to remove the
NOx screens can result in improper operation
and malfunction of the burner system.
FIGURE 22
LOW NOX INSERT
35. FAN BLADE SETTING DIMENSIONS
Shown in Figure 21 is the correct fan blade setting
dimension for proper air delivery across the outdoor
coil.
FIGURE 21
FAN BLADE
AIRFLOW
"A"
MIS-1724
TABLE 19
FAN BLADE DIMENSION
Model
Dimension
A
W24G
1.25
W30G
1.25
W36G
1.25
W42G
1.75
W48G
1.75
W60G
1.75
Manual 2100-525E
Page
48 of 67
INDEX
WIRING DIAGRAMS
and LADDER DIAGRAMS
Unit
Model No.
Basic
Wiring Diagram
Manual
P ag e N o .
Basic
Ladder Diagram
Manual
P ag e N o .
W24G1-A
4085-144B
50
4085-145
51
W24G1-B
4085-244C
52
4085-245
53
W24G1-C
4085-365C
54
4085-366
55
W30G1-A
4085-146D
56
4085-147
57
W30G1-B
4085-246E
58
4085-247
59
W30G1-C
4085-367E
60
4085-368
61
W36G1-A
4085-146D
56
4085-147
57
W36G1-B
4085-246E
58
4085-247
59
W36G1-C
4085-367E
60
4085-368
61
W42G1-A
4085-146D
56
4085-147
57
W42G1-B
4085-246E
58
4085-247
59
W42G1-C
4085-367E
60
4085-368
61
W48G1-A
4085-146D
56
4085-147
57
W48G1-B
4085-246E
58
4085-247
59
W48G1-C
4085-367E
60
4085-368
61
W60G1-A
4085-148B
62
4085-145
63
W60G1-B
4085-248C
64
4085-245
65
W60G1-C
4085-369D
66
4085-370
67
Manual
Page
2100-525E
49 of 67
Indoor Fan
Capacitor
Evaporator Section
BLOWER SPEED COLOR CODE
Indoor
Fan Motor
Brown
Brown
HIGH
MEDIUM
LOW
BLACK
BLUE
RED
INTEGRATED FURNACE CONTROL 13
RED
LOW
VOLTAGE
STRIP 11
BLUE
BLACK
32
34
YELLOW
PRIMARY
LIMIT
32
BROWN
RED
32
YELLOW
RED/WHITE
SECONDARY
LIMIT
32
32
RED
32
ORANGE
FUSE
PINK
33
SPARK IGNITOR
P3
10 11 12
7 8 9
4 5 6
BLUE
BLACK
32
RED
32
32
39
38
RED
42
BLACK/WHITE
18
C
43
38
RED
240V
MOVE RED WIRE TO
208V TAP FOR 208V
OPERATION
BLACK
20
T1
YELLOW/RED
BLACK/WHITE
RED
PL1
1
40
2
T2
RED
BLACK
37
PINK
36
YELLOW
FAN
1
BLACK
LPC LPC
3
BLACK
YELLOW
2
C
Y
32
TERM. BLOCK
(OPT.)
A
MINUTES
4
5
CC
ALR
R
HPC
32
RED/WHITE
YELLOW
44
A
35
16 COMPRESSOR
CONTROL
MODULE
LOW AMBIENT
CONTROL (OPT.)
Compressor
RED
RED
BLUE
BLUE
HIGH
PRESSURE
SWITCH
23 CAPACITOR
35
40
15 GROUND TERMINAL
COMPRESSOR
CONTACTOR
L2
39
BLACK/WHITE
COM
L1
208/230-60-1
CIRCUIT 21
BREAKER
RM
R
208V
32
35
BR
L2
BLACK
35
32
32
INDUCED
DRAFT BLOWER
L1
RED
TRANSFORMER
HE
PURPLE
YELLOW
PURPLE
RED/WHITE
MV
32
MV
GAS
VALVE
BLUE
BLACK
NO
PRESSURE
SWITCH
BROWN
BLUE
C
59
BLACK
FLAME SENSOR
35
2 3
135
120
150
1
SPEED
37
BLACK/WHITE
GRAY
C
FLAME
ROLLOUT
C
R
S
OUTDOOR
FAN
MOTOR
LOW
PRESSURE
SWITCH
Model C. Breaker Capacitor
W24G1-A
30A
40+5/440
USE COPPER CONDUCTORS
SUITABLE FOR AT LEAST 75° C
IF ANY ORIGINAL WIRE AS SUPPLIED WITH THE APPLIANCE MUST BE
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
W24G1-A
Manual 2100-525E
Page
50 of 67
99
Wire Identification numbers
for Bard use only.
Factory Field Optional
High Voltage
Low Voltage
230/208-60-1
A
WIRES CONNECT
IF OPTION
NOT USED
Bard Mfg. Co.
Bryan, Ohio
4085-144 B
W24G1-A
230/208-60-1
Manual
Page
2100-525E
51 of 67
Indoor Fan
Capacitor
Evaporator Section
BLOWER SPEED COLOR CODE
Indoor
Fan Motor
Brown
Brown
HIGH
MEDIUM
LOW
BLACK
BLUE
RED
INTEGRATED FURNACE CONTROL 13
RED
LOW
VOLTAGE
STRIP 11
BLACK
BLUE
32
34
YELLOW
PRIMARY
LIMIT
32
BROWN
RED
32
YELLOW
RED/WHITE
SECONDARY
LIMIT
32
32
RED
32
ORANGE
FUSE
PINK
33
10 11 12
7 8 9
4 5 6
SPARK IGNITOR
P3
BLUE
BLACK
135
120
150
32
BLACK
BLUE
C
59
BLACK
FLAME SENSOR
35
2 3
1
SPEED
NO
PRESSURE
SWITCH
BLUE
32
MV
PURPLE
L1
41
38
32
L2
42
BLACK
RED
RED/WHITE
BLACK/WHITE
PURPLE
32
L3
RED
43
208/230-60-3
CIRCUIT 21
BREAKER
YELLOW
MV
39
GAS
VALVE
37
BLACK/WHITE
GRAY
RED
FLAME
ROLLOUT
GROUND TERMINAL
15
YELLOW
32
YELLOW/BLACK
27
PHASE MONITOR
25
32
32
R
C
L1 L2 L3
BLACK/WHITE
BLACK/WHITE
28
18
BLACK
TRANSFORMER
T1 T2 T3
37
YELLOW/RED
23 CAPACITOR
A
1
RED
16 COMPRESSOR
YELLOW
BLACK
3
27
BLACK
LPC LPC
Y
R
HPC
32
TERM. BLOCK
(OPT.)
2
C
A
MINUTES
4
5
CC
ALR
35
RED/WHITE
YELLOW/BLACK
31
BROWN
PINK
BLACK/WHITE
RED
BLACK
30
YELLOW
35
PL1
40
36
CONTROL
MODULE
LOW AMBIENT
CONTROL (OPT.)
Compressor
RED
RED
BLUE
BLUE
HIGH
PRESSURE
SWITCH
COMPRESSOR
CONTACTOR
39
20
40
2
BR
BLACK
COM
44
YELLOW
YELLOW
1
INDUCED
DRAFT BLOWER
35
MOVE RED WIRE TO
208V TAP FOR 208V
OPERATION
208V
32
35
RED
38
RED
240V
29
T2
T1
T3
OUTDOOR
FAN
MOTOR
LOW
PRESSURE
SWITCH
Model C. Breaker Fan Capacitor
W24G1-B
25A
5/370
USE COPPER CONDUCTORS
SUITABLE FOR AT LEAST 75° C
IF ANY ORIGINAL WIRE AS SUPPLIED WITH THE APPLIANCE MUST BE
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
W24G1-B
Manual 2100-525E
Page
52 of 67
99
Wire Identification numbers
for Bard use only.
Factory Field Optional
High Voltage
Low Voltage
230/208-60-3
A
WIRES CONNECT
IF OPTION
NOT USED
Bard Mfg. Co.
Bryan, Ohio
4085-244 C
W24G1-B
230/208-60-3
Manual
Page
2100-525E
53 of 67
Indoor Fan
Capacitor
Evaporator Section
Brown
Brown
LOW
VOLTAGE
STRIP 11
YELLOW
RED
BLACK
32
INTEGRATED FURNACE CONTROL 13
BLUE
ORANGE
PURPLE
PRIMARY
LIMIT
34
BLOWER SPEED COLOR CODE
HIGH
BLACK
MEDIUM
BLUE
LOW
RED
AUX
PURPLE/ORANGE
Indoor
Fan
Motor
32
BROWN
YELLOW 32
RED
RED/WHITE
SECONDARY
LIMIT
32
32
RED
32
ORANGE
FUSE
33
10 11 12
7 8 9
4 5 6
1 2 3
SPEED
BLUE
C
59
BLACK
FLAME SENSOR
28
35
135
120
150
47
58
57
32
55
3
1
BLUE
RED
49
3
LOW SPEED
BLOWER
RELAY
57
43
55
PURPLE
RED
2
45
57
54
L2
L3
42
460-60-3
BLACK
48
L1
41
DISCONNECT 21
YELLOW
3
6
RED/WHITE
BLACK/WHITE
54
2
MV
MV
1
48
2
32
4
PURPLE
HIGH
SPEED
BLOWER
RELAY 46
32
53
BLACK
MED. SPEED 45
BLOWER RELAY
PURPLE
5
GAS
VALVE
32
1
NO
PRESSURE
SWITCH
BLUE
37
50
PINK
P3
BLACK/WHITE
BLACK/WHITE
GRAY
SPARK IGNITOR
RED
FLAME
ROLLOUT
GROUND TERMINAL
15
RED
YELLOW
YELLOW/BLACK
32
27
32
32
R
PHASE MONITOR
25
18 TRANSFORMER
48
RED
38
RED
460V
29
35
56
32
35
20
BLACK/WHITE
BLACK/WHITE
28
BLACK
4
31
37
YELLOW/RED
A
1
16 COMPRESSOR
BLACK
RED
3
27
BLACK
LPC LPC
Y
R
HPC
32
RED/WHITE
YELLOW/BLACK
TERM. BLOCK
(OPT.)
2
C
A
MINUTES
4
5
CC
ALR
35
BROWN
PINK
23 CAPACITOR
44
YELLOW
PL1
1
2
RED
BLACK
BLACK/WHITE
3
YELLOW
YELLOW
INDUCED DRAFT 45
BLOWER RELAY
40
30
YELLOW
35
2
57
T1 T2 T3
36
CONTROL
MODULE
LOW AMBIENT
CONTROL (OPT.)
Compressor
RED
RED
BLUE
BLUE
HIGH
PRESSURE
SWITCH
COMPRESSOR
CONTACTOR
39
BROWN/WHITE
40
BR
BLACK
COM
1
INDUCED
DRAFT BLOWER
L1 L2 L3
C
T2
T1
T3
OUTDOOR
FAN
MOTOR
LOW
PRESSURE
SWITCH
USE COPPER CONDUCTORS
SUITABLE FOR AT LEAST 75° C
IF ANY ORIGINAL WIRE AS SUPPLIED WITH THE APPLIANCE MUST BE
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
W24G1-C
Manual 2100-525E
Page
54 of 67
99
Wire Identification numbers
for Bard use only.
Factory Field Optional
High Voltage
Low Voltage
460-60-3
A
WIRES CONNECT
IF OPTION
NOT USED
Bard Mfg. Co.
Bryan, Ohio
4085-365 C
W24G1-C
460-60-3
Manual
Page
2100-525E
55 of 67
Indoor Fan
Capacitor
Evaporator Section
BLOWER SPEED COLOR CODE
Indoor
Fan Motor
Brown
Brown
HIGH
MEDIUM
LOW
BLACK
BLUE
RED
INTEGRATED FURNACE CONTROL 13
BLACK
LOW
VOLTAGE
STRIP 11
RED
BLUE
32
34
YELLOW
PRIMARY
LIMIT
32
BROWN
YELLOW 32
RED
RED/WHITE
SECONDARY
LIMIT
32
32
RED
32
ORANGE
FUSE
PINK
33
10 11 12
7 8 9
4 5 6
1 2 3
GRAY
SPARK IGNITOR
RED
32
32
39
38
RED
42
MOVE RED WIRE TO
208V TAP FOR 208V
OPERATION
C
BLACK
20
T1
YELLOW/RED
BLACK/WHITE
RED
PL1
1
40
2
BR
T2
RED
BLACK
37
PINK
36
YELLOW
FAN
1
RED
BLACK
LPC LPC
3
BLACK
YELLOW
2
C
Y
32
TERM. BLOCK
(OPT.)
A
MINUTES
4
5
CC
ALR
R
HPC
32
RED/WHITE
YELLOW
44
A
35
16 COMPRESSOR
CONTROL
MODULE
B
LOW AMBIENT
CONTROL (OPT.)
Compressor
RED
RED
BLUE
BLUE
HIGH
PRESSURE
SWITCH
23 CAPACITOR
35
40
15 GROUND TERMINAL
COMPRESSOR
CONTACTOR
L2
39
BLACK/WHITE
COM
L1
RM
208V
32
35
35
43
38
RED
240V
CIRCUIT 21
BREAKER
HE
R
L2
208/230-60-1
BLACK
C
BLACK/WHITE
18
32
32
INDUCED
DRAFT BLOWER
L1
RED
TRANSFORMER
BROWN
PURPLE
YELLOW
PURPLE
RED/WHITE
MV
32
MV
GAS
VALVE
52
BLACK
NO
PRESSURE
SWITCH
BLUE
BLUE
120
32
BLACK
BLUE
C
59
BLACK
FLAME SENSOR
135
150
P3
SPEED
37
35
BLACK/WHITE
FLAME
ROLLOUT
C
R
S
OUTDOOR
FAN
MOTOR
LOW
PRESSURE
SWITCH
Model C. Breaker
W30G1-A
30A
W36G1-A
35A
W42G1-A
50A
W48G1-A
50A
Capacitor
45+5/370
45+5/370
45+10/370
70+10/370
A
USE COPPER CONDUCTORS
SUITABLE FOR AT LEAST 75° C
IF ANY ORIGINAL WIRE AS SUPPLIED WITH THE APPLIANCE MUST BE
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
WIRES CONNECT
Wire Identification numbers
IF OPTION
99
for Bard use only.
NOT USED
Factory Field Optional
High Voltage
Low Voltage
W30G1-A, W36G1-A, W42G1-A, W48G1-A
Manual 2100-525E
Page
56 of 67
B
WIRE NOT APPLICABLE
TO ALL MODELS
230/208-60-1
Bard Mfg. Co.
Bryan, Ohio
4085-146 D
W30G1-A, W36G1-A, W42G1-A, W48G1-A
230/208-60-1
Manual
Page
2100-525E
57 of 67
Indoor Fan
Capacitor
Evaporator Section
BLOWER SPEED COLOR CODE
Indoor
Fan Motor
Brown
Brown
HIGH
MEDIUM
LOW
BLACK
BLUE
RED
INTEGRATED FURNACE CONTROL 13
BLACK
LOW
VOLTAGE
STRIP 11
BLUE
RED
32
34
YELLOW
PRIMARY
LIMIT
32
BROWN
YELLOW 32
RED
RED/WHITE
SECONDARY
LIMIT
32
32
RED
32
ORANGE
FUSE
PINK
33
10 11 12
7 8 9
4 5 6
1 2 3
SPARK IGNITOR
NO
BLUE
BLACK
PRESSURE
SWITCH
BLUE
52
32
BLACK
BLUE
C
59
BLACK
FLAME SENSOR
35
135
120
150
P3
SPEED
32
MV
PURPLE
L1
41
38
32
L2
42
BLACK
RED
RED/WHITE
BLACK/WHITE
PURPLE
32
L3
RED
43
208/230-60-3
CIRCUIT 21
BREAKER
YELLOW
MV
39
GAS
VALVE
37
BLACK/WHITE
GRAY
RED
FLAME
ROLLOUT
GROUND TERMINAL
15
YELLOW
32
YELLOW/BLACK
27
PHASE MONITOR
25
R
C
L1 L2 L3
BLACK/WHITE
BLACK/WHITE
28
18
BLACK
TRANSFORMER
T1 T2 T3
37
PINK
YELLOW/RED
BLACK/WHITE
RED
BLACK
1
YELLOW
BLACK
RED
16 COMPRESSOR
RED
3
TERM. BLOCK
(OPT.)
BLACK
LPC LPC
Y
27
23 CAPACITOR
44
2
C
A
MINUTES
4
5
CC
ALR
R
HPC
32
31
A
35
RED/WHITE
YELLOW/BLACK
30
YELLOW
35
PL1
40
36
CONTROL
MODULE
B
LOW AMBIENT
CONTROL (OPT.)
Compressor
RED
RED
BLUE
BLUE
HIGH
PRESSURE
SWITCH
COMPRESSOR
CONTACTOR
39
20
40
2
BR
BLACK
COM
YELLOW
YELLOW
1
INDUCED
DRAFT BLOWER
35
MOVE RED WIRE TO
208V TAP FOR 208V
OPERATION
208V
32
35
RED
38
RED
240V
BROWN
32
32
29
T2
T1
T3
OUTDOOR
FAN
MOTOR
LOW
PRESSURE
SWITCH
Model C. Breaker Fan Capacitor
W30G1-B
25A
5/370
W36G1-B
35A
5/370
W42G1-B
35A
10/370
W48G1-B
35A
10/370
A
USE COPPER CONDUCTORS
SUITABLE FOR AT LEAST 75° C
IF ANY ORIGINAL WIRE AS SUPPLIED WITH THE APPLIANCE MUST BE
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
WIRES CONNECT
Wire Identification numbers
IF OPTION
99
for Bard use only.
NOT USED
Factory Field Optional
High Voltage
Low Voltage
W30G1-B, W36G1-B, W42G1-B, W48G1-B
Manual 2100-525E
Page
58 of 67
B
WIRE NOT APPLICABLE
TO ALL MODELS
230/208-60-3
Bard Mfg. Co.
Bryan, Ohio
4085-246 E
W30G1-B, W36G1-B, W42G1-B, W48G1-B
230/208-60-3
Manual
Page
2100-525E
59 of 67
Indoor Fan
Capacitor
Evaporator Section
Brown
Brown
BLACK
LOW
VOLTAGE
STRIP 11
YELLOW
RED
32
INTEGRATED FURNACE CONTROL 13
BLUE
ORANGE
PURPLE
PRIMARY
LIMIT
34
BLOWER SPEED COLOR CODE
HIGH
BLACK
MEDIUM
BLUE
LOW
RED
AUX
PURPLE/ORANGE
Indoor
Fan
Motor
32
BROWN
YELLOW 32
RED
RED/WHITE
SECONDARY
LIMIT
32
32
RED
32
ORANGE
FUSE
33
10 11 12
7 8 9
4 5 6
1 2 3
SPEED
C
BLUE
35
47
57
58
32
53
BLUE
3
L1
2
49
3
LOW SPEED
BLOWER
RELAY
RED
2
45
460-60-3
DISCONNECT 21
YELLOW
1
43
55
RED
3
48
PURPLE
57
L2
L3
42
6
RED/WHITE
BLACK/WHITE
55
41
RED
MV
32
MED. SPEED 45
BLOWER RELAY
48
54
BLACK
2
PURPLE
HIGH
SPEED
BLOWER
RELAY 46
32
1
PURPLE
4
MV
53
5
GAS
VALVE
32
1
NO
PRESSURE
SWITCH
BLUE
37
50
PINK
52
59
BLACK
FLAME SENSOR
28
135
120
150
P3
BLACK/WHITE
BLACK/WHITE
GRAY
SPARK IGNITOR
BLACK
FLAME
ROLLOUT
57
GROUND TERMINAL
15
54
YELLOW
YELLOW/BLACK
32
27
32
32
R
PHASE MONITOR
25
18 TRANSFORMER
48
RED
38
RED
460V
29
35
56
32
35
20
BLACK/WHITE
BLACK/WHITE
28
BLACK
1
37
YELLOW/RED
A
1
16 COMPRESSOR
BLACK
RED
3
27
BLACK
LPC LPC
Y
R
HPC
32
RED/WHITE
YELLOW/BLACK
TERM. BLOCK
(OPT.)
2
C
A
MINUTES
4
5
CC
ALR
35
BROWN
PINK
YELLOW
PL1
1
RED
BLACK
BLACK/WHITE
3
2
31
23 CAPACITOR
44
YELLOW
YELLOW
INDUCED DRAFT 45
BLOWER RELAY
40
30
YELLOW
35
2
57
T1 T2 T3
36
CONTROL
MODULE
LOW AMBIENT
CONTROL (OPT.)
Compressor
RED
RED
BLUE
BLUE
HIGH
PRESSURE
SWITCH
COMPRESSOR
CONTACTOR
39
BROWN/WHITE
40
BR
BLACK
COM
4
INDUCED
DRAFT BLOWER
L1 L2 L3
C
T2
T1
T3
OUTDOOR
FAN
MOTOR
LOW
PRESSURE
SWITCH
USE COPPER CONDUCTORS
SUITABLE FOR AT LEAST 75° C
IF ANY ORIGINAL WIRE AS SUPPLIED WITH THE APPLIANCE MUST BE
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
99
Wire Identification numbers
for Bard use only.
Factory Field Optional
High Voltage
Low Voltage
W30G1-C, W36G1-C, W42G1-C, W48G1-C
Manual 2100-525E
Page
60 of 67
A
WIRES CONNECT
IF OPTION
NOT USED
460-60-3
Bard Mfg. Co.
Bryan, Ohio
4085-367 E
W30G1-C, W36G1-C, W42G1-C, W48G1-C
460-60-3
Manual
Page
2100-525E
61 of 67
Indoor Fan
Capacitor
Evaporator Section
BLOWER SPEED COLOR CODE
Indoor
Fan Motor
Brown
Brown
HIGH
MEDIUM
LOW
BLACK
BLUE
RED
INTEGRATED FURNACE CONTROL 13
BLACK
LOW
VOLTAGE
STRIP 11
RED
BLUE
32
34
YELLOW
PRIMARY
LIMIT
32
BROWN
YELLOW 32
RED
RED/WHITE
SECONDARY
LIMIT
32
32
RED
32
ORANGE
FUSE
PINK
33
10 11 12
7 8 9
4 5 6
1 2 3
GRAY
SPARK IGNITOR
RED
BLUE
32
BLACK
32
32
39
38
RED
42
MOVE RED WIRE TO
208V TAP FOR 208V
OPERATION
208V
C
BLACK
COM
L1
20
YELLOW/RED
BLACK/WHITE
RED
PL1
1
T2
RED
BLACK
37
PINK
36
YELLOW
FAN
1
RED
BLACK
LPC LPC
3
BLACK
YELLOW
2
C
Y
32
TERM. BLOCK
(OPT.)
A
MINUTES
4
5
CC
ALR
R
HPC
32
RED/WHITE
YELLOW
44
A
35
16 COMPRESSOR
CONTROL
MODULE
LOW AMBIENT
CONTROL (OPT.)
Compressor
RED
RED
BLUE
BLUE
HIGH
PRESSURE
SWITCH
23 CAPACITOR
35
40
2
BR
T1
40
15 GROUND TERMINAL
COMPRESSOR
CONTACTOR
L2
39
BLACK/WHITE
32
35
35
43
38
RED
240V
CIRCUIT 21
BREAKER
RM
R
L2
208/230-60-1
BLACK
HE
BLACK/WHITE
18
32
32
INDUCED
DRAFT BLOWER
L1
RED
TRANSFORMER
C
PURPLE
YELLOW
PURPLE
RED/WHITE
MV
32
MV
GAS
VALVE
BLUE
BLACK
NO
PRESSURE
SWITCH
BROWN
BLUE
C
59
BLACK
FLAME SENSOR
35
135
120
150
P3
SPEED
37
BLACK/WHITE
FLAME
ROLLOUT
C
R
S
OUTDOOR
FAN
MOTOR
LOW
PRESSURE
SWITCH
USE COPPER CONDUCTORS
SUITABLE FOR AT LEAST 75° C
IF ANY ORIGINAL WIRE AS SUPPLIED WITH THE APPLIANCE MUST BE
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
W60G1-A
Manual 2100-525E
Page
62 of 67
99
Wire Identification numbers
for Bard use only.
Factory Field Optional
High Voltage
Low Voltage
230/208-60-1
A
WIRES CONNECT
IF OPTION
NOT USED
Bard Mfg. Co.
Bryan, Ohio
4085-148 B
W60G1-A
230/208-60-1
Manual
Page
2100-525E
63 of 67
Indoor Fan
Capacitor
Evaporator Section
BLOWER SPEED COLOR CODE
Indoor
Fan Motor
Brown
Brown
HIGH
MEDIUM
LOW
BLACK
BLUE
RED
INTEGRATED FURNACE CONTROL 13
BLACK
LOW
VOLTAGE
STRIP 11
RED
BLUE
32
34
YELLOW
PRIMARY
LIMIT
32
BROWN
YELLOW 32
RED
RED/WHITE
SECONDARY
LIMIT
32
32
RED
32
ORANGE
FUSE
PINK
33
10 11 12
7 8 9
4 5 6
1 2 3
SPARK IGNITOR
RED
BLUE
135
32
BLACK
BLUE
C
59
BLACK
FLAME SENSOR
35
120
150
P3
SPEED
NO
PRESSURE
SWITCH
BLUE
32
MV
PURPLE
L1
41
38
32
L2
42
BLACK
RED
RED/WHITE
BLACK/WHITE
PURPLE
32
L3
RED
43
208/230-60-3
CIRCUIT 21
BREAKER
YELLOW
MV
39
GAS
VALVE
37
BLACK/WHITE
GRAY
BLACK
FLAME
ROLLOUT
GROUND TERMINAL
15
YELLOW
32
YELLOW/BLACK
27
PHASE MONITOR
25
32
32
R
C
BLACK/WHITE
BLACK/WHITE
28
18
BLACK
TRANSFORMER
T1 T2 T3
37
23 CAPACITOR
YELLOW/RED
BLACK
1
YELLOW
BLACK
RED
16 COMPRESSOR
RED
3
LPC LPC
Y
27
TERM. BLOCK
(OPT.)
2
C
A
MINUTES
4
5
CC
ALR
R
HPC
32
RED/WHITE
YELLOW/BLACK
YELLOW
A
35
31
BROWN
PINK
BLACK/WHITE
RED
BLACK
30
YELLOW
35
PL1
40
36
CONTROL
MODULE
LOW AMBIENT
CONTROL (OPT.)
Compressor
RED
RED
BLUE
BLUE
HIGH
PRESSURE
SWITCH
COMPRESSOR
CONTACTOR
YELLOW 44
2
BR
L1 L2 L3
39
20
40
1
INDUCED
DRAFT BLOWER
BLACK
COM
29
35
MOVE RED WIRE TO
208V TAP FOR 208V
OPERATION
208V
32
35
RED
38
RED
240V
T2
T1
T3
OUTDOOR
FAN
MOTOR
LOW
PRESSURE
SWITCH
Model C. Breaker Fan Capacitor
W60G1-B
40A
10/370
USE COPPER CONDUCTORS
SUITABLE FOR AT LEAST 75° C
IF ANY ORIGINAL WIRE AS SUPPLIED WITH THE APPLIANCE MUST BE
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
W60G1-B
Manual 2100-525E
Page
64 of 67
99
Wire Identification numbers
for Bard use only.
Factory Field Optional
High Voltage
Low Voltage
230/208-60-3
A
WIRES CONNECT
IF OPTION
NOT USED
Bard Mfg. Co.
Bryan, Ohio
4085-248 C
W60G1-B
230/208-60-3
Manual
Page
2100-525E
65 of 67
Indoor Fan
Capacitor
Evaporator Section
Brown
Brown
LOW
VOLTAGE
STRIP 11
YELLOW
RED
BLACK
32
INTEGRATED FURNACE CONTROL 13
BLUE
ORANGE
PURPLE
PRIMARY
LIMIT
34
BLOWER SPEED COLOR CODE
HIGH
BLACK
MEDIUM
BLUE
LOW
RED
AUX
PURPLE/ORANGE
Indoor
Fan
Motor
32
BROWN
YELLOW 32
RED
RED/WHITE
SECONDARY
LIMIT
32
32
RED
32
ORANGE
FUSE
33
10 11 12
7 8 9
4 5 6
1 2 3
C
BLUE
35
120
SPEED
28
59
BLACK
FLAME SENSOR
135
150
47
57
58
32
54
BLUE
3
L1
2
55
49
3
LOW SPEED
BLOWER
RELAY
RED
2
45
460-60-3
DISCONNECT 21
YELLOW
1
43
RED
3
48
PURPLE
57
L2
L3
42
6
RED/WHITE
BLACK/WHITE
53
41
RED
MV
32
MED. SPEED 45
BLOWER RELAY
48
55
BLACK
2
PURPLE
HIGH
SPEED
BLOWER
RELAY 46
32
1
PURPLE
4
MV
53
5
GAS
VALVE
32
1
NO
PRESSURE
SWITCH
BLUE
37
50
PINK
P3
BLACK/WHITE
BLACK/WHITE
GRAY
SPARK IGNITOR
BLACK
FLAME
ROLLOUT
57
GROUND TERMINAL
15
54
YELLOW
YELLOW/BLACK
32
27
32
32
R
PHASE MONITOR
25
18 TRANSFORMER
48
RED
38
RED
460V
29
35
56
32
35
20
BLACK/WHITE
BLACK/WHITE
28
BLACK
1
37
YELLOW/RED
1
16 COMPRESSOR
BLACK
RED
3
27
BLACK
LPC LPC
Y
R
HPC
32
TERM. BLOCK
(OPT.)
2
C
A
MINUTES
4
5
CC
ALR
35
RED/WHITE
YELLOW/BLACK
YELLOW
A
BROWN
PINK
YELLOW
PL1
1
RED
BLACK
BLACK/WHITE
3
2
31
23 CAPACITOR
YELLOW 44
INDUCED DRAFT 45
BLOWER RELAY
40
30
YELLOW
35
2
57
T1 T2 T3
36
CONTROL
MODULE
LOW AMBIENT
CONTROL (OPT.)
Compressor
RED
RED
BLUE
BLUE
HIGH
PRESSURE
SWITCH
COMPRESSOR
CONTACTOR
39
BROWN/WHITE
40
BR
BLACK
COM
4
INDUCED
DRAFT BLOWER
L1 L2 L3
C
T2
T1
T3
OUTDOOR
FAN
MOTOR
LOW
PRESSURE
SWITCH
USE COPPER CONDUCTORS
SUITABLE FOR AT LEAST 75° C
IF ANY ORIGINAL WIRE AS SUPPLIED WITH THE APPLIANCE MUST BE
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
W60G1-C
Manual 2100-525E
Page
66 of 67
99
Wire Identification numbers
for Bard use only.
Factory Field Optional
High Voltage
Low Voltage
460-60-3
A
WIRES CONNECT
IF OPTION
NOT USED
Bard Mfg. Co.
Bryan, Ohio
4085-369 D
W60G1-C
460-60-3
Manual
Page
2100-525E
67 of 67
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