Bard WG 242D, WG 302D, WG 362D, WG 423D, WG 482D, WG 602D combination gas/electric wall-mount furnace Installation instructions

WG - SERIES
COMBINATION GAS/ELECTRIC
WALL-MOUNT
INSTALLATION
with DEHUMIDIFICATION
INSTRUCTIONS
MODELS:
WG242D
WG423D
WG302D
WG482D
WG362D
WG602D
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
Bryan, Ohio 43506
Since 1914...Moving ahead just as planned.
© Copyright 2004
Manual No.:
Supersedes:
File:
Date:
2100-376H
2100-376G
Volume III, Tab 20
01-18-06
Manual
Page
2100-376H
1 of 80
CONTENTS
Page
Getting Other Information and Publications .............. 4
WG 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 ........................................ 25
19. Manifold Pressure Adjustment .......................... 26
Manual 2100-376H
Page
2 of 80
Page
20. Checking Gas Input Rate ......................... 26 & 27
21. Standard Orifice Sizing & High
Altitude Derate .................................................. 28
22. Conversion of Gas Input BTUH From High
to Low Rating ................................................... 31
23. Measuring Air Temperature Rise ...................... 31
24. Filters ................................................................ 32
25. Compressor Control Module ............................. 32
26. Lighting & Shutdown Instructions ..................... 34
27. Service Agency Procedures ............................. 35
28. Maintaining Unit in Good Working Order .......... 35
29. Replacement Parts ............................................ 36
30. Sequence of Operation – Heating .................... 37
31. Sequence of Operation – Cooling .................... 37
32. Indoor Blower Operation .................................. 39
33. Pressure Service Ports ..................................... 49
34. Dehumidification Circuit .................................... 50
35. Refrigerant Charge ........................................... 51
36. Fan Blade Setting Dimensions ......................... 51
37. Low NOx Burner Assembly "N" Suffix
Models Only – U.S. Installations Only .............. 51
Application Data .............................................. 52 – 54
Index – Wiring Diagrams ......................................... 55
Wiring Diagrams ............................................. 56 – 80
CONTENTS
Page
FIGURES
Figure 1
Figure 2
Figure 2A
Figure 3
Figure 3A
Figure 4
Figure 5
Figure 6
Figure 7
Figure 8
Unit Dimensions ..................................... 9
Mounting Instructions – WG24-36 ....... 12
Mounting Instructions – WG42-60 ....... 13
Combustible Clearance – WG24-36 .... 14
Combustible Clearance – WG42-60 .... 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
Figure 9 Fresh Air Damper ................................. 19
Figure 10 Installation of Flexible Conduit ............. 21
Figure 11 Low Voltage Wiring .............................. 22
Figure 11A Low Voltage Wiring .............................. 23
Figure 12 Gas Pipe Connection ........................... 24
Figure 13 Proper Piping Practice ......................... 25
Figure 14 Access Internal Filter through
Upper Service Door .............................. 32
Figure 15 Lighting & Shutdown Instruction Label . 34
Figure 16 Top View of Gas Control ...................... 35
Figure 17 Sequence of Operation – Electronic
Blower Control ...................................... 38
Figure 18 Furnace Control Board &
Blower Control ...................................... 39
Figure 19 460V Blower Motor Wiring Options –
WG24-36 Models ................................. 40
Figure 20 460V Blower Motor Wiring Options –
WG42-60 Models ................................. 41
Figure 21 Circuit Diagrams ................................... 50
Figure 22 Fan Blade ............................................. 51
Figure 23 Low NOx Insert .................................... 51
Page
TABLES
Table 1
Table 1A
Table 2
Table 3
Table 4
Table 5
Table 6
Table 7
Table 8
Table 8A
Table 9
Table 10
Table 11
Table 12
Table 13
Table 14
Table 15
Table 16
Table 17
Table 18
Table 19
Table 20
Table 21
Table 22
Table 23
Table 24
Table 25
Specifications – WG24-36 Models ........... 7
Specifications – WG42-60 Models ........... 8
Minimum Installation Clearances ........... 17
Thermostat Wire Size ............................ 21
Wall Thermostat &
Subbase Combinations .......................... 21
Length of Standard Pipe Threads .......... 25
Gas Pipe Sizes – Natural Gas ............... 25
Natural Gas Derate Capacities
For All Models ........................................ 28
Natural Gas Orifice Tables – WG24-36 .. 29
Natural Gas Orifice Tables – WG42-60 .. 30
Motor Speed Taps .................................. 39
WG242 Indoor Blower Performance ...... 42
WG302 Indoor Blower Performance ...... 43
WG362 Indoor Blower Performance ...... 44
WG423 Indoor Blower Performance ...... 45
WG482 Indoor Blower Performance ...... 46
WG602 Indoor Blower Performance ...... 47
Integrated Furnace & Blower
Control Operation ................................... 48
Cooling Pressure Table .......................... 49
Refrigerant Charge ................................ 51
Fan Blade Dimension ............................. 51
WG242DA Application Data ................... 52
WG302DA Application Data ................... 52
WG362DA Application Data ................... 53
WG423DA Application Data ................... 53
WG482DA Application Data ................... 54
WG602DA Application Data ................... 54
Manual
Page
2100-376H
3 of 80
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
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
Standard for Chimneys, ................................. NFPA 211
Fireplaces, Vents, and Solid
Fuel Burning Appliances
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 SEPTEMBER 2003
BARD MANUFACTURING COMPANY
BRYAN, OHIO 43506 USA
Manufactured under the following U.S. patent numbers:
5,485,878; 5,002,116; 4,924,934; 4,875,520; 4,4825,936
Manual 2100-376H
Page
4 of 80
WALL MOUNT GAS/ELECTRIC GENERAL
MODEL NUMBER NOMENCLATURE
WG
42
1
D
A
X
C
X
X
X
X
VENT
REVISION
MODEL
X
CONTROL OPTIONS
(See Table page 6)
(See Table Below)
Wall Mount Gas/Electric
COOLING CAPACITY
24 = 2 ton
30 = 2½ ton
36 = 3 ton
42 = 3½ ton
48 = 4 ton
60 = 5 ton
VOLTAGE
A = 230/208-60-1
B = 230/208-60-3
C = 460-60-3
FEATURE
D = Dehumidification
EMISSIONS
X = Standard
N = NOx Certified
X
COLOR
X = Beige
(Standard)
4 = Gray
8 = Dark Bronze
COIL OPTIONS
X = Standard
1 = Phenolic coated evaporator
2 = Phenolic coated condenser
3 = Phenolic coated both coils
OUTLET
X = Front (Standard)
T = Top
FILTER
X = 2" Pleated (Standard)
P = 1" Washable
HEATING INPUT
2 - 3 Ton
3½ - 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
Models
WG24, WG30, WG36
WG42, WG48, WG60
Factory Installed
C ode N o.
Field Installed
Part No.
Field Installed
Part No.
Barometric Fresh Air Damper
X
WGBFAD-3
WGBFAD-5
Blank-Off Plate
B
WGBOP-3
WGBOP-5
Motorized Fresh Air Damper
M
WGMFAD-3
WGMFAD-5
Commercial Ventilator - Spring Return
V
WGCRVS-3
WGCRVS-5
Commercial Ventilator - Power Return
P
WGCRVP-3
WGCRVP-5
Economizer - Fully Modulating 1
E
WGEIFM-3
WGEIFM-5
Energy Recovery Ventilator - 230 Volt
R
WGERV-A3
WGERV-A5
Energy Recovery Ventilator - 460 Volt
R
WGERV-C3
WGERV-C5
Description
1 Low ambient control is required with economizer for low temperature compressor operation.
Manual
Page
2100-376H
5 of 80
AIR CONDITIONING MODULE OPTIONS
1
CCM
2
H PC
3
LP C
STD
STD
STD
STD
STD
STD
4
LAC
Factory Installed
C ode
Field Installed
Part
G
CMA-16
H
CMA-18
I
CMA-6
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.
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 fanassisted 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 2100-376H
Page
6 of 80
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 air flow requirement of the equipment.
Air Conditioning Contractors of America (ACCA) is an
excellent guide to proper sizing.
Refer to Tables later in this Manual for maximum static
pressure available for duct design.
Manual
Page
2100-376H
7 of 80
WG242-B
13
12
12
20
18
10
10
25
Ground Wire Size
** Delay Fuse – Max.
Recp.
230/208
230/208
Volts
Rated Load Amps
51/15
56/56
Lock Rotor Amps
20" – 1900
20" – 1900
1.8
800 – .25
20 x 25 2
77
1.8
800 – .25
20 x 25 2
77
CFM Cooing & E.S.P.
Filter Sizes (Inches)
* 75 degree C Copper wire size
** Maximum time delay fuse or HACR Type circuit breaker
Charge (R-22 oz.)
WG302-B
73/73
14.1
12.5/13.5
230/208
Scroll
40
10
10
23
197-253
63/63
9.5
9.0/9.5
230/208
Scroll
25
12
12
17
187-253
230/208-60-1 230/208-60-3
WG302-A
31/31
5
5
460
Scroll
15
14
14
9
414-506
460-60-3
WG302-C
WG362-B
78/78
16
14/16
230/208
Recp.
40
10
8
26
197-253
72/72
10
9.5/10
230/208
Recp.
25
10
10
18
187-253
230/208-60-1 230/20-60-3
WG362-A
45/45
5
5
460
Recp.
15
14
14
9
414-506
460-60-3
WG362-C
20" – 1900
0.8
20" – 1900
1.5
20" – 1900
1.5
20" – 1900
0.8
20" – 1900
1.5
20" – 1900
1.5
20" – 1900
0.8
77
20 x 25 2
800 – .25
0.8
97
20 x 25 2
1000 – .35
2.2
97
20 x 25 2
1000 – .35
2.2
97
20 x 25 2
1000 – .35
1.1
86
20 x 25 2
1100 – .25
2.2
86
20 x 25 2
1100 – .25
2.2
86
20 x 25 2
1100 – .25
1.1
1/4 / 950 / 3 1/4 / 950 / 3 1/4 / 950 / 3 1/3 / 1075/3 1/3 / 1075/3 1/3 / 1075/3 1/3 / 1075/3 1/3 / 1075/3 1/3 / 1075/3
1.5
1.5
Blower Motor – Amps
Blower Motor – HP/RPM/SPD
M otor and Evaporator
Fan – DIA/CFM
Fan Motor – Amps
Fan Motor – HP/RPM/SPD
25
3.5
3.3
460
Recp.
15
14
14
7
414-506
460-60-3
WG242-C
1/5 / 1050 /1 1/5 / 1050/1 1/5 / 1050/1 1/5 / 1050/1 1/5 / 1050/1 1/5 / 1050/1 1/5 / 1050/1 1/5 / 1050/1 1/5 / 1050/1
6.7
10.5
Fan M otor and Com pressor
6.2/6.6
9.5/10.5
Branch Circuit Selection Current
Compressor Type
Recp.
Com pressor
* Field Wire Size
187-253
197-253
Operating Voltage Range
230/208-60-1 230/208-60-3
WG242-A
Minimum Circuit Ampacity
Electrical Rating – 60HZ
Model
TABLE 1
SPECIFICATIONS
WG24, WG 30 AND WG36 MODELS
Manual 2100-376H
Page
8 of 80
10
50
Ground Wire Size
** Delay Fuse – Max.
101
101
* 75 degree C Copper wire size
** Maximum time delay fuse or HACR Type circuit breaker
Charge (R-22 oz.)
20 x 30 x 2
20 x 30 x 2
Filter Sizes (Inches)
1300 - .35
1300 - .35
CFM Cooing & E.S.P.
3.4
1/2-1050-3
24"-2700
2.5
1/3-850-2
88/88
3.4
1/2-1050-3
24"-2700
2.5
1/3-850-2
127/127
15
13.5/14.5
21/19.5
21
230/208
230/208
Scroll
35
10
8
26
187 - 253
Blower Motor – Amps
Blower Motor – HP/RPM/SPD
M otor and Evaporator
Fan – DIA/CFM
Fan Motor – Amps
Fan Motor – HP/RPM/SPD
Fan M otor and Com pressor
Lock Rotor Amps
Branch Circuit Selection Current
Rated Load Amps
Volts
Compressor Type
Scroll
8
34
* Field Wire Size /
197 - 253
Minimum Circuit Ampacity
Com pressor
WG423-B
230/208-60-1 230/208-60-3
WG423-A
Operating Voltage Range
Electrical Rating – 60HZ
Model
101
20 x 30 x 2
1300 - .35
1.5
1/2-1050-3
24"-2700
1.3
1/3-850-1
44
7.6
8
230/208
Scroll
15
14
14
13
414 - 506
460-60-3
WG423-C
WG482-B
116
20 x 30 x 2
1550 - .38
3.4
1/2-1050-3
24"-2700
2.5
1/3-850-2
131/131
116
20 x 30 x 2
1550 - .38
3.4
1/2-1050-3
24"-2700
2.5
1/3-850-2
91/81
13
12.5/13
21/21.5
22
230/208
Scroll
35
10
8
24
187 - 253
460
Scroll
50
10
8
35
197 - 253
230/208-60-1 230/208-60-3
WG482-A
TABLE 1A
SPECIFICATIONS
WG42, WG48 AND WG60 MODELS
116
20 x 30 x 2
1550 - .38
1.5
1/2-1050-3
24"-2700
1.3
1/3-850-1
46
6.4
6.2
230/208
Scroll
15
14
14
12
414 - 506
460-60-3
WG482-C
WG602-B
143
20 x 30 x 2
1650 - .30
3.4
1/2-1050-3
24"-2700
2.5
1/3-850-2
169/169
30
27/30
230/208
Scroll
60
10
8
45
197 - 253
143
20 x 30 x 2
1650 - .30
3.4
1/2-1050-3
24"-2700
2.5
1/3-850-2
137/137
19.5
17/19.5
230/208
Scroll
45
10
8
32
187 - 253
230/208-60-1 230/20-60-3
WG602-A
143
20 x 30 x 2
1650 - .30
1.5
1/2-1050-3
24"-2700
1.3
1/3-850-1
62
9
9
460
Scroll
20
12
12
15
414 - 506
460-60-3
WG602-C
Manual
Page
2100-376H
9 of 80
G
F
S
12 - 7 HOLES
16 - 6 HOLES
UNIT
WG242-WG302-WG362
WG423-WG482-WG602
FRONT
CONDENSER
AIR INLET
W
A
7.88
9.88
UNIT
WG242-WG302-WG362
WG423-WG482-WG602
U
2.88
3.88
C
13.88
15.88
N
VENT OPTION
PANEL
CIRCUIT BREAKER/
DISCONNECT ACCESS
PANEL (LOCKABLE)
CONTROL
PANEL DOOR
SERVICE/FILTER
HINGED DOOR
COMBUSTION
AIR INTAKE
COMBUSTION
AIR EXHAUST
VESTIBULE
DOOR
V
22.9
24.9
D
24.25
27.25
4 DEG. PITCH IN TOP
3.75
T
B
27.88
29.88
P
W
38
42
DD
Y
4.44
8.44
G
25.63
31.63
RIGHT SIDE
CONDENSER
AIR OUTLETS
D
X
17.84
17.34
E
F
40
14.88
43.81
J
L
M
2.25
Z
Z
K
C
I
A
H
AA
11.44
12.19
30
I
FF
GG
HH
U
H
81.63
87.5
FIGURE 1
UNIT DIMENSIONS
CC
9
10
K
27.5
28.75
ENTRANCES
L
M
N
AA
X
Q
II
7.25
DD
V
CC
EE
36.25
40.25
EE
E
1.25
GG
O
39.25
42.88
B
O
HH
2
2.75
4.5
P
B
BACK
RETURN OPENING
BB
SUPPLY OPENING
1.13
FF
14.12 15.44 15.31
HIGH VOLTAGE Y
LOW VOLTAGE
ENTRANCES
GAS
ENTRANCES
3.25
BB
J
27.38
33.38
II
0.38
0.44
2.5
Q
MIS-2123
T
S
S
S
S
S
R
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 and 3 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 2100-376H
Page
10 of 80
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 WG42, WG48 and WG60 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 WG24,
WG30 and WG36 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
Page
2100-376H
11 of 80
Manual 2100-376H
Page
12 of 80
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 WG24, WG30, AND WG36
Manual
Page
2100-376H
13 of 80
FIGURE 2A
MOUNTING INSTRUCTIONS
FOR WG42, WG48, AND WG60
FIGURE 3
COMBUSTIBLE CLEARANCE
FOR WG24, WG30 AND WG36 MODELS
FIGURE 3A
COMBUSTIBLE CLEARANCE
FOR WG42, WG48 AND WG60 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 2100-376H
Page
14 of 80
FIGURE 4
WALL MOUNTING INSTRUCTIONS
FIGURE 5
WALL MOUNTING INSTRUCTIONS
Manual
Page
2100-376H
15 of 80
FIGURE 6
COMMON WALL MOUNTING INSTALLATIONS
Manual 2100-376H
Page
16 of 80
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
Manual
Page
2100-376H
17 of 80
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. 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 ensure this gasket is in place and sealing properly.
FIGURE 8
VENT TERMINAL AND COMBUSTION AIR INTAKE
MIS-2057
Manual 2100-376H
Page
18 of 80
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.
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.
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
7. If improper venting is observed during any of the
above tests, the venting system must be corrected.
MIS-938
Manual
Page
2100-376H
19 of 80
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 2100-376H
Page
20 of 80
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 Table 1 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
devises 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
Direct Digital Controls (DDC)
Low Voltage Connection
For total and proper control using DDC, a total of 5
controlled outputs are required (4 if no ventilation is
installed).
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.
“Y” terminal is the compressor input.
“R” terminal is 24 VAC hot.
“C” terminal is 24 VAC grounded.
“E” terminal is the ventilation input. This terminal
energizes any factory or field installed vent option.
“F” terminal is the dehumidification input. This
energizes compressor, blower and 3-way
dehumidification valve.
LOW VOLTAGE CONNECTIONS FOR DDC CONTROL
Fan Only
Cooling Mode
Heating Mode
Ventilation
Dehumidification
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, Y
Energize W1
Energize G, E
Energize F
TABLE 3
THERMOSTAT WIRE SIZE
Transformer
VA
FLA
Wire Gauge
Maximum
Distance
In Feet
55
2.3
20 gauge
18 gauge
16 gauge
14 gauge
12 gauge
45
60
100
160
250
TABLE 4
WALL THERMOSTAT AND SUBBASE COMBINATIONS
Thermostat
S u b b ase
Predominate Features
8403-002
T87F3111
8404-003
Q539A1220
8403-049
1F93-380
---
2 stage heat, 2 stage cool
Electronic Programmable
8403-048
T8400C1313
---
1 stage heat, 1 stage cool
System: heat-off-cool Fan: on-auto
Electronic Non-Programmable
1 stage heat, 1 stage cool; Mercury
System: heat-off-cool Fan: on-auto
Manual
Page
2100-376H
21 of 80
FIGURE 11
LOW VOLTAGE WIRING
Manual 2100-376H
Page
22 of 80
FIGURE 11A
LOW VOLTAGE WIRING
Manual
Page
2100-376H
23 of 80
FIGURE 12
GAS PIPE CONNECTION
Manual 2100-376H
Page
24 of 80
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.
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.
TABLE 6
GAS PIPE SIZES - NATURAL GAS
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.
5. Install listed manual shut off valve in the supply gas
line external to and immediately upstream of the
furnace. See Figure 12.
Length of
Pipe - Feet
Pipe Capacity - BTU per Hour Input Pipe Siz e
1/2"
3/4"
1"
10
132,000
278,000
20
92,000
190,000
350,000
730,000
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
520,000
1-1/4"
1,050,000
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
6. Use steel or wrought iron pipe and fittings.
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 13.
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 13
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.
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.
MIS-897
Manual
Page
2100-376H
25 of 80
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.
Manual 2100-376H
Page
26 of 80
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”.
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
= 124,138 BTU
Gas input =
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
Page
2100-376H
27 of 80
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 2100-376H
Page
28 of 80
10,000
TABLE 8
NATURAL GAS ORIFICE TABLES
FOR MODELS WG24, WG30 AND WG36
Factory
Standard
Input
22500 B T U
Per Burner
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]
1050-1100
2.25
[2.20]
2.15
Pressure Switch
Standard (.55)
Order 8620-189 High Altitude Pressure Sw itch Kit (.42)
(2.30) is the standard factory installed orifice siz e
Optional
10% Field
Converted
Derate
20250 B T U
Per Burner
[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
1050-1100
2.15
2.15
2.10
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
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)
9010-097
2.80
1.1102
113,000
(5)
9010-098
2.90
0.1142
125,000
(5)
Manual
Page
2100-376H
29 of 80
TABLE 8A
NATURAL GAS ORIFICE TABLES
FOR MODELS WG42, WG48 AND WG60
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
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
22500 B T U
Per Burner
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 29 for part numbers and number
required.
Manual 2100-376H
Page
30 of 80
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
and in Table 1.
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.
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 ensure proper
temperature measurement.
6. Place second thermometer in return air duct
approximately 2 feet from furnace. Locate
thermometer tip in center of duct to ensure 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 air flow 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 air flow 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.
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
Page
2100-376H
31 of 80
FIGURE 14
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 14.)
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.
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
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.
Manual 2100-376H
Page
32 of 80
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.
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.
The phase monitor in this unit is equipped with two
LEDs. If the “&” 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.
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)
DOB
DOB
DOB
DOB
DOB
DOB
=
=
=
=
=
=
123 second DOM
126 second DOM
132 second DOM
138 second DOM
144 second DOM
150 second DOM
Manual
Page
2100-376H
33 of 80
26. LIGHTING AND SHUTDOWN INSTRUCTIONS
FIGURE 15
INSTRUCTION LABEL
Manual 2100-376H
Page
34 of 80
27. SERVICE AGENCY PROCEDURES
FIGURE 16
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
Page
2100-376H
35 of 80
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 require 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).
Manual 2100-376H
Page
36 of 80
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.
30. SEQUENCE OF OPERATION –
HEATING
31. SEQUENCE OF OPERATION –
COOLING
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.
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.
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 Table 15 for selectable
blower off time delays.) This timing sequence
guarantees blower on, blower off operation.
This unit is equipped with a flame rollout 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 rollout 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 17 for additional information.
See Figure 17 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 280 PSIG.
DEHUMIDIFICATION – Dehumidification is
controlled through a humidistat and is independent of
the thermostat. On a call for dehumidification mode of
operation the compressor and three way valve of the
unit are energized through circuit R-F to provide
dehumidification. Dehumidification will continue until
the humidistat is satisfied.
If there is a cooling call issued through circuit R-Y, it
will cancel dehumidification sequence (de-energize the
reheat valve) until the cooling call is satisfied. If the
dehumidification call is still present when cooling call
is satisfied, the compressor will continue to operate and
the reheat valve is reenergized.
Any time there is a call for heating mode of operation
through circuit R-W1 the dehumidification mode will
cancel and the system will return to heating operation.
Dehumidification is delay 45-60 seconds on start up
after any heating cycle is complete.
Any time the indoor coil temperature falls below 32
degrees the compressor will be de-energized until the
coil temperature rises above 57 degrees.
If the room temperature falls below 65 degrees the
dehumidification mode will discontinue until the room
temperature rises above 72 degrees.
Manual
Page
2100-376H
37 of 80
FIGURE 17
SEQUENCE OF OPERATION
ELECTRONIC BLOWER CONTROL
ACTION
SYSTEM RESPONSE
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 begins 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 2100-376H
Page
38 of 80
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.
FIGURE 18
FURNACE CONTROL BOARD AND BLOWER CONTROL
32. INDOOR BLOWER OPERATION
460 VOLT BLOWER MOTOR SPEED CHANGE
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.
Field changeover from the factory blower motor speed
settings can require change several different motor
leads, the addition or deletion of a wire.
Refer to blower motor wiring options as shown below
for the correct wiring of the blower motor for the
application involved.
If voltage and duct design permit, (see blower tables)
single speed operation can be achieved as follows:
230 VOLT BLOWER MOTOR SPEED CHANGE
TABLE 9
MOTOR SPEED TAPS
1. Disconnect main power supply to unit.
2. Remove and tape off the unwanted indoor motor
speed tap from the heat or cool terminal on the
furnace control board.
3. Next install a jumper wire with multiplier between
heat and cool terminal and attach desired blower
motor speed to other side of multiplier.
S p eed s
3 Speed Motor
Low
Red
Medium
Blue
High
Black
4. Energize the system in cooling and heating modes
and check for proper blower operation.
Manual
Page
2100-376H
39 of 80
FIGURE 19
460 VOLT BLOWER MOTOR WIRING OPTIONS
WG24, WG30 AND WG36 MODELS
Manual 2100-376H
Page
40 of 80
FIGURE 20
460 VOLT BLOWER MOTOR WIRING OPTIONS
WG42, WG48 AND WG 60 MODELS
Manual
Page
2100-376H
41 of 80
TABLE 10
WG242 INDOOR BLOWER PERFORMANCE @ 230 AND 460 VOLTS
Recommended WG242 cooling airflow range at rated 800 CFM @ 0.15 ESP (WC) is 680 - 920 CFM
Factory set on Low Speed for cooling and High for heating.
COOLING MODE
ESP
Wet Coil
Inches
High Medium Low
H 2O
MANUAL FAN and HEATING MODE
90,000 BTU Input
81,000 BTU Input
High
Medium
Low
High
Medium
Low
0.0
---
---
890
1350
1120
---
---
1120
940
0.1
---
---
820
1260
1160
---
---
1160
870
0.2
---
950
770
1200
1010
---
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
ESP
Wet Coil
Inches
High Medium Low
H 2O
0.0
---
---
890
MANUAL FAN and HEATING MODE
68,000 BTU Input
61,000 BTU Input
High
Medium
Low
High
Medium
Low
1350
1120
940
---
1120
940
0.1
---
---
820
1260
1160
870
---
1160
870
0.2
---
950
770
1200
1010
---
---
1010
810
0.3
---
880
700
1120
910
---
1120
940
---
0.4
---
790
---
103 0
---
---
1030
860
---
0.5
910
710
---
950
---
---
950
780
---
0.6
800
---
---
---
---
---
840
---
---
COOLING MODE
ESP
Wet Coil
Inches
High Medium Low
H 2O
MANUAL FAN and HEATING MODE
45,000 BTU Input
High
Medium
41,000 BTU Input
Low
High
Medium
Low
0.0
---
---
890
---
1120
940
---
1120
940
0.1
---
---
820
1260
1160
870
---
1160
870
0.2
---
950
770
1200
1010
810
1200
1010
810
0.3
---
880
700
1120
940
---
1120
940
750
0.4
---
790
---
103 0
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 2100-376H
Page
42 of 80
TABLE 11
WG302 INDOOR BLOWER PERFORMANCE @ 230 AND 460 VOLTS
Recommended WG302 cooling airflow range at rated 1000 CFM @ 0.35 ESP (WC) is 820 - 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
0.0
---
---
1060
1560
1350
1120
1560
1350
1120
0.1
---
---
1000
1470
1260
1060
1470
1260
1060
0.2
---
1160
950
1370
1200
1010
1370
1200
1010
0.3
---
1080
880
1290
1120
940
1290
1120
940
Wet Coil
90,000 BTU Input
Medium
Low
81,000 BTU Input
High
Medium
Low
0.4
1150
990
---
1190
1030
860
1190
1030
860
0.5
1050
910
---
1090
950
780
1090
950
780
0.6
940
---
---
980
840
660
980
840
660
COOLING MODE
MANUAL FAN and HEATING MODE
ESP
Inches
H 2O
High
Medium
Low
High
0.0
---
---
1060
1560
1350
1120
1560
1350
1120
0.1
---
---
1000
1470
1260
1060
1470
1260
1060
0.2
---
1160
950
1370
1200
1010
1370
1200
1010
0.3
---
1080
880
1290
1120
940
1290
1120
940
Wet Coil
68,000 BTU Input
Medium
Low
61,000 BTU Input
High
Medium
Low
0.4
1150
990
---
1190
1030
860
1190
1030
860
0.5
1050
910
---
1090
950
780
1090
950
780
0.6
940
---
---
980
840
660
980
840
660
COOLING MODE
MANUAL FAN and HEATING MODE
ESP
Inches
H 2O
High
Medium
Low
High
0.0
---
---
1060
1560
1350
1120
1560
1350
1120
0.1
---
---
1000
1470
1260
1060
1470
1260
1060
0.2
---
1160
950
1370
1200
1010
1370
1200
1010
0.3
---
1080
880
1290
1120
940
1290
1120
940
860
Wet Coil
45,000 BTU Input
Medium
Low
41,000 BTU Input
High
Medium
Low
0.4
1150
990
---
1190
1030
860
1190
1030
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
2100-376H
43 of 80
TABLE 12
WG362 INDOOR BLOWER PERFORMANCE @ 230 AND 460 VOLTS
Recommended WG362 cooling airflow range at rated 1100 CFM @ 0.250 ESP (WC) is 935 - 1265 CFM
Factory set on Medium Speed for cooling and for heating.
COOLING MODE
ESP
Inches
H 2O
High
0.0
0.1
Wet Coil
MANUAL FAN and HEATING MODE
90,000 BTU Input
Medium
Low
High
Medium
---
---
1060
---
---
1220
1000
---
81,000 BTU Input
Low
High
Medium
Low
1350
1120
---
1350
1120
1260
1060
---
1260
1060
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
High
0.0
0.1
Wet Coil
MANUAL FAN and HEATING MODE
68,000 BTU Input
Medium
Low
High
Medium
---
---
1060
---
---
1220
1000
---
61,000 BTU Input
Low
High
Medium
Low
1350
1120
---
---
1120
1260
1060
---
---
1060
1010
0.2
---
1160
950
---
1200
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
ESP
Inches
H 2O
High
0.0
0.1
MANUAL FAN and HEATING MODE
Wet Coil
45,000 BTU Input
Medium
Low
High
Medium
---
---
1060
---
---
1220
1000
---
0.2
---
1160
950
---
0.3
1250
1080
---
1290
0.4
1150
990
---
1190
0.5
1050
---
---
1090
0.6
940
---
---
980
41,000 BTU Input
Low
High
Medium
Low
1350
1120
---
---
1120
1260
1060
---
---
1060
1200
1010
---
1200
1010
1120
940
---
1120
940
1030
860
---
1030
860
950
780
1090
950
780
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 2100-376H
Page
44 of 80
TABLE 13
WG423 INDOOR BLOWER PERFORMANCE @ 230 AND 460 VOLTS
Recommended WG423 cooling airflow range at rated 1300 CFM @ .35 ESP (WC) is 1500 - 1030 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
.00
---
1540
1140
---
1640
1230
---
1640
1230
.10
---
1480
1090
---
1580
1180
---
1580
1180
.20
---
1410
1030
1880
1510
---
---
1510
1090
.30
---
1360
---
1760
1460
---
---
1460
---
.40
---
1250
---
1670
1340
---
1670
1340
---
.50
1460
1150
---
1560
1240
---
1560
1240
---
.60
1340
1040
---
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
.00
---
---
1190
---
1690
1280
---
1690
1280
.10
---
1530
1140
---
1630
1230
---
1630
1230
.20
---
1460
1070
---
1560
1160
---
1560
1160
.30
---
1410
1050
1810
1510
1140
---
1510
1140
.40
---
1300
---
1720
1390
---
1720
1390
1020
.50
1510
1200
---
1610
1290
---
1610
1290
970
.60
1390
1090
---
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
.00
---
---
1240
---
1740
1330
---
1740
1330
.10
---
---
1190
---
1680
1280
---
1680
1280
.20
---
1510
1120
---
1610
1210
---
1610
1210
.30
---
1460
1100
1860
1560
1190
---
1560
1190
.40
---
1340
---
1770
1440
1070
---
1440
1070
.50
---
1260
---
1660
1340
970
1660
1340
970
.60
1440
1140
---
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
2100-376H
45 of 80
TABLE 14
WG482 INDOOR BLOWER PERFORMANCE @ 230 AND 460 VOLTS
Recommended WG482 cooling airflow range at rated 1550 CFM @ .38 ESP (WC) is 1750 - 1280 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
.00
---
1540
---
---
1640
1230
---
1640
1230
.10
---
1480
---
---
1580
1180
---
1580
1180
.20
1780
1410
---
1880
1510
---
---
1510
1110
.30
1670
1360
---
1760
1460
---
---
1460
1090
.40
1570
1250
---
1670
1340
---
1670
1340
---
.50
1460
---
---
1560
1240
---
1560
1240
---
.60
1340
---
---
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
.00
---
1590
---
---
1690
1280
---
1690
1280
.10
---
1530
---
---
1630
1230
---
1630
1230
.20
---
1460
---
---
1560
1160
---
1560
1160
.30
1700
1410
---
1810
1510
1140
---
1510
1140
.40
1620
1300
---
1720
1390
---
1720
1390
1020
.50
1510
---
---
1610
1290
---
1610
1290
970
.60
1390
---
---
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
.00
---
---
1640
---
1740
1330
---
1740
1330
.10
---
1580
---
---
1680
1280
---
1680
1280
.20
---
1510
---
---
1610
1210
---
1610
1210
.30
1750
1460
---
1860
1560
1190
---
1560
1190
.40
1670
1340
---
1770
1440
1070
---
1440
1070
.50
1560
1260
---
1660
1340
970
1660
1340
970
.60
1440
---
---
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 2100-376H
Page
46 of 80
TABLE 15
WG602 INDOOR BLOWER PERFORMANCE @ 230 AND 460 VOLTS
Recommended WG602 cooling airflow range at rated 1650 CFM @ .30 ESP (WC) is 1910 - 1340 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
.00
1930
1540
---
---
1640
1230
---
1640
1230
.10
1850
1480
---
---
1580
1180
---
1580
1180
.20
1780
1410
---
1880
1510
---
---
1510
1110
.30
1670
1360
---
1760
1460
---
---
1460
1090
.40
1570
---
---
1670
1340
---
1670
1340
---
.50
1460
---
---
1560
1240
---
1560
1240
---
.60
1340
---
---
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
.00
---
1590
---
---
1690
1280
---
1690
1280
.10
1900
1530
---
---
1630
1230
---
1630
1230
.20
1830
1460
---
---
1560
1160
---
1560
1160
.30
1700
1410
---
1810
1510
1140
---
1510
1140
.40
1620
---
---
1720
1390
---
1720
1390
1020
.50
1510
---
---
1610
1290
---
1610
1290
970
.60
1390
---
---
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
.00
---
1640
---
---
1740
1330
---
1740
1330
.10
1950
1580
---
---
1680
1280
---
1680
1280
.20
1880
1510
---
---
1610
1210
---
1610
1210
.30
1750
1460
---
1860
1560
1190
---
1560
1190
.40
1670
1340
---
1770
1440
1070
---
1440
1070
.50
1560
---
---
1660
1340
970
1660
1340
970
.60
1440
---
---
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
2100-376H
47 of 80
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
minuters (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 2100-376H
Page
48 of 80
33. PRESSURE SERVICE PORTS
High and low pressure service ports are installed on all
units so that the system operating pressures can be
observed. Table 17 outlines expected pressures at various
indoor and outdoor temperatures.
TABLE 17
COOLING PRESSURE TABLE
Model
WG242
WG302
WG362
WG423
WG482
WG602
Return Air
Temperature
Pressure
75 deg. D B
62 deg. WB
Low S i de
High Side
72
201
74
216
76
231
77
246
79
263
81
280
82
297
83
315
85
335
80 deg. D B
67 deg. WB
Low S i de
High Side
76
207
79
221
81
237
83
253
85
270
87
287
88
306
90
324
91
344
85 deg. D B
72 deg. WB
Low S i de
High Side
82
214
85
229
87
245
89
262
91
280
93
298
95
316
97
336
98
356
75 deg. D B
62 deg. WB
Low S i de
High Side
76
218
77
231
78
245
79
261
81
278
82
295
84
314
85
334
87
356
80 deg. D B
67 deg. WB
Low S i de
High Side
81
223
82
237
83
251
85
267
87
285
88
303
90
322
91
343
93
365
85 deg. D B
72 deg. WB
Low S i de
High Side
87
232
88
246
90
261
91
277
93
295
94
313
96
333
98
355
100
378
75 deg. D B
62 deg. WB
Low S i de
High Side
72
222
74
238
75
255
76
272
78
290
79
308
81
326
82
346
83
366
80 deg. D B
67 deg. WB
Low S i de
High Side
77
228
79
245
81
262
82
279
84
298
85
316
87
335
88
355
89
375
85 deg. D B
72 deg. WB
Low S i de
High Side
83
237
85
254
86
271
88
289
90
308
91
327
93
346
95
367
96
388
75 deg. D B
62 deg. WB
Low S i de
High Side
66
206
69
221
71
236
73
251
75
267
76
282
78
300
79
315
81
332
80 deg. D B
67 deg. WB
Low S i de
High Side
72
211
74
226
76
242
78
257
80
274
81
290
84
307
85
323
87
341
85 deg. D B
72 deg. WB
Low S i de
High Side
78
219
80
234
82
250
84
266
86
283
87
299
89
316
91
334
93
352
75 deg. D B
62 deg. WB
Low S i de
High Side
69
199
70
214
72
229
73
244
74
261
75
278
76
294
77
312
79
331
80 deg. D B
67 deg. WB
Low S i de
High Side
74
205
75
220
76
235
78
251
79
268
80
285
82
302
83
321
85
340
85 deg. D B
72 deg. WB
Low S i de
High Side
80
210
81
226
83
242
84
259
85
277
86
294
88
314
89
332
91
352
75 deg. D B
62 deg. WB
Low S i de
High Side
69
231
70
248
72
265
73
283
74
301
75
319
76
338
77
356
79
376
80 deg. D B
67 deg. WB
Low S i de
High Side
74
237
75
254
76
272
77
290
79
309
80
327
81
346
82
366
84
386
85 deg. D B
72 deg. WB
Low S i de
High Side
80
245
81
263
82
282
83
300
85
320
86
339
87
360
88
379
90
399
75
80
85
90
95
100
105
110
115
Low side pressure ± 2 PSIG
High side pressure ± 5 PSIG
Manual
Page
2100-376H
49 of 80
34. DEHUMIDIFICATION CIRCUIT
The dehumidification circuit incorporates an
independent heat exchanger coil in the supply air
stream. This coil reheats the supply air after it passes
over the cooling coil without requiring the gas burner
to be used for reheat purposes. This results in very
high mechanical dehumidification capability from the
air conditioner on demand without using gas reheat.
The dehumidification refrigerant reheat circuit is
controlled by a three way valve directing the
refrigerant gas to the normal condenser during periods
when standard air conditioning is required. During
periods of time of low ambient temperature
(approximately 65° to 75° outdoor) and high indoor
humidity, a humidistat senses the need for mechanical
dehumidification. It then energizes both the
compressor circuit and the three way valve, thus
directing the hot refrigerant discharge gas into a
separate desuperheating condenser circuit, which
reheats the conditioned air before it is delivered to the
room. The refrigerant gas is then routed from the
desuperheating condenser to the system condenser for
further heat transfer. A small orifice inserted between
the reheat coil return line and suction line will prevent
liquid from accumulating in the reheat coil when it is
inactive. This drain does not affect the normal
operation of the system. A check valve is located in the
reheat oil return line. It has a soft spring to hold the
ball on the seat. This will make the method of checking
the ball freedom with a magnet difficult. Refer to
Figure 21 for the location of the check valve and drain
back capillary. When the humidistat is satisfied, the
system automatically switches back to normal air
conditioning mode and either continues to operate or
turns off based on the signal from the wall thermostat.
The result is separate humidity control at minimum
operating cost.
FIGURE 21
CIRCUIT DIAGRAMS
AIR CONDITIONING MODE
CIRCUIT DIAGRAM
MIS-1200
DEHUMIDIFICATION MODE
CIRCUIT DIAGRAM
MIS-1199
Manual 2100-376H
Page
50 of 80
35. REFRIGERANT CHARGE
37. LOW-NOX BURNER ASSEMBLY “N”
SUFFIX MODELS ONLY – U.S.
INSTALLATIONS ONLY
The correct system R-22 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.
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.
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.
Total system charge for these models can be found in
Table 1.
* * IMPORTANT * *
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.
TABLE 18
REFRIGERANT CHARGE
Model
Rated
Airflow
95 D eg . F
OD Temp.
82 D eg . F
OD Temp.
WG242
800
51 - 59
60 - 62
WG302
1000
58 - 60
60 - 62
WG362
1100
56 - 59
60 - 62
WG423
1300
55 - 57
66 - 68
WG482
1550
54 - 56
64 - 66
WG602
1650
56 - 58
66 - 68
FIGURE 23
LOW NOx INSERT
36. FAN BLADE SETTING DIMENSIONS
Shown in Figure 21 is the correct fan blade setting
dimension for proper air delivery across the outdoor coil.
FIGURE 22
FAN BLADE
AIRFLOW
TABLE 19
FAN BLADE DIMENSION
Model
Dimension
A
WG24
1
WG30
1
WG36
1
WG42
1
WG48
1
WG60
1
"A"
MIS-1724
Manual
Page
2100-376H
51 of 80
TABLE 20
APPLICATION DATA FOR WG242DA
Outdoor
Indoor Conditions Ambient
System Capacity
Airflow
C FM
Approx.
Supply
Air
DB/WB
Mode
DB/WB
% RH
DB
Total
B TU
Sensible
B TU
Latent
B TU
S/T %
P ounds
Water
Lbs/Hr
65/63
90
65
27,300
12,200
15,100
45
14.24
800
52/51.5
A/C
65/63
90
65
11,600
(2,400)
14,000
0
13.3
800
67.6/58.3
D eh u m
75/62.5
50
75
25,800
19,800
6,000
77
5.64
800
53/51.3
A/C
75/62.5
50
75
8,100
2,800
5,300
34
4.96
800
72.4/59.3
D eh u m
75/65.5
60
75
27,600
19,300
8,300
70
7.88
800
56/54.3
A/C
75/65.5
60
75
10,500
1,300
9,200
12
8.64
800
74/61.6
D eh u m
75/68
70
75
28,600
17,100
11,500
60
10.84
800
58/57
A/C
75/68
70
75
10,600
(600)
11,200
0
10.52
800
75.7/63.7
D eh u m
80/67
50
95
23,800
17,200
6,600
72
6.26
800
59.1/57.2
A/C
80/67
50
95
2,900
(2,200)
5,100
0
4.84
800
82.5/66
D eh u m
Airflow
C FM
Approx.
Supply
Air
DB/WB
Mode
Values shown in ( ) are BTUH of heating available at these conditions.
Latent BTU = Lbs/Hr water * 1060
Sensible BTU = Total - Latent
TABLE 21
APPLICATION DATA FOR WG302DA
Outdoor
Indoor Conditions Ambient
System Capacity
DB/WB
% RH
DB
Total
B TU
Sensible
B TU
Latent
B TU
S/T %
P ounds
Water
Lbs/Hr
65/63
90
65
33,800
15,800
18,000
47
17.04
1,000
52/51
A/C
65/63
90
65
14,900
(3,500)
18,400
0
17.32
1,000
68/58.5
D eh u m
75/62.5
50
75
31,800
24,200
7,600
76
7.16
1,000
52.9/51.7
A/C
75/62.5
50
75
9,700
3,500
6,200
36
5.84
1,000
71.9/59.5
D eh u m
75/65.5
60
75
33,500
21,500
12,000
64
11.4
1,000
55/54.5
A/C
75/65.5
60
75
11,900
2,400
9,500
20
8.96
1,000
74/62
D eh u m
75/68
70
75
35,600
19,100
16,500
54
15.6
1,000
57.7/57
A/C
75/68
70
75
12,800
(1,100)
13,900
0
13.12
1,000
73/64
D eh u m
80/67
50
95
29,800
22,340
7,460
75
7.04
1,000
58.5/57.4
A/C
50
95
4,350
(2,260)
6,610
0
6.24
1,000
82/66
D eh u m
80/67
Values shown in ( ) are BTUH of heating available at these conditions.
Latent BTU = Lbs/Hr water * 1060
Sensible BTU = Total - Latent
Manual 2100-376H
Page
52 of 80
TABLE 22
APPLICATION DATA FOR WG362DA
Outdoor
Indoor Conditions Ambient
System Capacity
Airflow
C FM
Approx.
Supply
Air
DB/WB
Mode
DB/WB
% RH
DB
Total
B TU
Sensible
B TU
Latent
B TU
S/T %
P ounds
Water
Lbs/Hr
65/63
90
65
39,100
18,200
20,900
46
19.72
1,100
51/50.5
A/C
65/63
90
65
16,480
(4,320)
20,800
0
19.64
1,100
68.7/58.5
D eh u m
75/62.5
50
75
36,400
27,630
8,770
76
8.28
1,100
52.7/51
A/C
75/62.5
50
75
10,270
2,470
7,800
24
7.36
1,100
73/59.5
D eh u m
75/65.5
60
75
39,000
24,800
14,200
64
13.36
1,100
55/54
A/C
75/65.5
60
75
11,900
0
11,900
0
11.24
1,100
75/62
D eh u m
75/68
70
75
40,780
21,220
19,560
52
18345
1,100
57.4/56.6
A/C
75/68
70
75
13,080
(2,310)
15,690
0
14.52
1,100
73.8/64
D eh u m
80/67
50
95
35,000
25,800
9,200
74
8.68
1,100
59/57
A/C
80/67
50
95
5,425
(3,575)
9,000
0
8.46
1,100
83/66
D eh u m
Airflow
C FM
Approx.
Supply
Air
DB/WB
Mode
Values shown in ( ) are BTUH of heating available at these conditions.
Latent BTU = Lbs/Hr water * 1060
Sensible BTU = Total - Latent
TABLE 23
APPLICATION DATA FOR WG423DA
Outdoor
Indoor Conditions Ambient
System Capacity
DB/WB
% RH
DB
Total
B TU
Sensible
B TU
Latent
B TU
S/T %
P ounds
Water
Lbs/Hr
65/63
90
65
47,000
21,200
25,800
45
24.4
1300
50.8/50.2
A/C
65/63
90
65
18,000
(6,400)
24,400
0
23
1,300
69.5/58.2
D eh u m
75/62.5
50
75
43,700
33,100
10,600
76
10.06
1,300
51.8/50.7
A/C
75/62.5
50
75
12,500
4,000
8,500
32
8
1,300
72.3/59.1
D eh u m
75/65.5
60
75
47,200
29,200
18,000
62
17.04
1,300
54.6/53.6
A/C
75/65.5
60
75
16,600
600
16,000
3.6
15.1
1,300
74.8/61.3
D eh u m
75/68
70
75
49,700
27,000
22,700
54
21.4
1,300
56.9/55.9
A/C
75/68
70
75
19,550
(2,850)
22,400
0
21.1
1,300
77/63.5
D eh u m
80/67
50
95
42,000
31,600
10,400
75
9.9
1,300
58/57
A/C
80/67
50
95
7,860
(2,640)
10,500
0
9.96
1,300
81.7/65.5
D eh u m
Values shown in ( ) are BTUH of heating available at these conditions.
Latent BTU = Lbs/Hr water * 1060
Sensible BTU = Total - Latent
Manual
Page
2100-376H
53 of 80
TABLE 24
APPLICATION DATA FOR WG482DA
Outdoor
Indoor Conditions Ambient
System Capacity
Airflow
C FM
Approx.
Supply
Air
DB/WB
Mode
DB/WB
% RH
DB
Total
B TU
Sensible
B TU
Latent
B TU
S/T %
P ounds
Water
Lbs/Hr
65/63
90
65
51,400
22,900
28,500
44
26.9
1,550
52.5/51.7
A/C
65/63
90
65
22,300
(4,500)
26,800
0
25.3
1,550
68.7/58.4
D eh u m
75/62.5
50
75
46,200
36,200
10,000
78
9.48
1,550
52.8/51.7
A/C
75/62.5
50
75
15,700
7,200
8,500
45
8.1
1,550
71.3/59.2
D eh u m
75/65.5
60
75
51,400
34,000
17,400
66
16.4
1,550
55.7/54.7
A/C
75/65.5
60
75
19,000
3,300
15,700
17
14.9
1,550
73.8/61.8
D eh u m
75/68
70
75
54,500
30,600
23,900
56
22.5
1,550
58/57
A/C
75/68
70
75
19,000
(2,100)
21,100
0
19.9
1,550
76.1/64
D eh u m
80/67
50
95
47,000
36,200
10,800
77
10.2
1,550
59.2/57.6
A/C
80/67
50
95
7,050
(1,000)
8,050
0
7.6
1,550
80.7/65.7
D eh u m
Values shown in ( ) are BTUH of heating available at these conditions.
Latent BTU = Lbs/Hr water * 1060
Sensible BTU = Total - Latent
TABLE 25
APPLICATION DATA FOR WG602DA
Outdoor
Indoor Conditions Ambient
System Capacity
Airflow
C FM
Approx.
Supply
Air
DB/WB
Mode
DB/WB
% RH
DB
Total
B TU
Sensible
B TU
Latent
B TU
S/T %
P ounds
Water
Lbs/Hr
65/63
90
65
64,000
28,600
35,400
45
33.4
1,650
50/49.4
A/C
65/63
90
65
26,700
(8,300)
35,000
0
33.1
1,650
70.2/57.8
D eh u m
75/62.5
50
75
61,400
44,800
16,600
73
15.7
1,650
50.6/49.4
A/C
75/62.5
50
75
20,800
4,900
15,900
23.5
15
1,650
72.6/58.5
D eh u m
75/65.5
60
75
65,200
39,900
25,300
61
23.9
1,650
53.5/52.4
A/C
75/65.5
60
75
23,900
(500)
24,400
0
23
1,650
75./61.2
D eh u m
75/68
70
75
68,500
36,100
32,400
53
30.6
1650
56.9/54.9
A/C
75/68
70
75
27,300
(4,000)
31,300
0
29.5
1,650
77.7/63.3
D eh u m
80/67
50
95
60,000
42,200
17,800
70
16.8
1,650
56.6/55.2
A/C
80/67
50
95
11,300
(4,700)
16,000
0
15.1
1,650
81.5/64.6
D eh u m
Values shown in ( ) are BTUH of heating available at these conditions.
Latent BTU = Lbs/Hr water * 1060
Sensible BTU = Total - Latent
Manual 2100-376H
Page
54 of 80
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 .
WG242DA
4085-136
56
4085-137
57
WG242DB
4085-236
58
4085-237
59
WG242DC
4085-336
60
4085-337
61
WG302DA
4085-133D
62
4085-125C
63
WG302DB
4085-233E
64
4085-225C
65
WG302DC
4085-333E
66
4085-334D
67
WG362DA
4085-139
68
4085-137
57
WG362DB
4085-239
69
4085-237
59
WG362DC
4085-339
70
4085-337
61
WG423DA
4085-128E
71
4085-129C
72
WG423DB
4085-228E
73
4085-229C
74
WG423DC
4085-325D
75
4085-326C
76
WG482DA
4085-124D
77
4085-125C
63
WG482DB
4085-222E
78
4085-225C
65
WG482DC
4085-319E
79
4085-322A
80
WG602DA
4085-124D
77
4085-125C
63
WG602DB
4085-222E
78
4085-225C
65
WG602DC
4085-319E
79
4085-322A
80
Manual
Page
2100-376H
55 of 80
WG242DA
Manual 2100-376H
Page
56 of 80
230/208-60-1
WG242DA, WG362DA
230/208-60-1
Manual
Page
2100-376H
57 of 80
WG242DB
Manual 2100-376H
Page
58 of 80
230/208-60-3
WG242DB, WG362DB
230/208-60-3
Manual
Page
2100-376H
59 of 80
WG242DC
Manual 2100-376H
Page
60 of 80
460-60-3
WG242DC, WG362DC
460-60-3
Manual
Page
2100-376H
61 of 80
WG302DA
Manual 2100-376H
Page
62 of 80
230/208-60-1
WG302DA, WG482DA, WG602DA
230/208-60-1
Manual
Page
2100-376H
63 of 80
WG302DB
Manual 2100-376H
Page
64 of 80
230/208-60-3
WG302DB, WG482DB, WG602DB
230/208-60-3
Manual
Page
2100-376H
65 of 80
WG302DC
Manual 2100-376H
Page
66 of 80
460-60-3
WG302DC
460-60-3
Manual
Page
2100-376H
67 of 80
WG362DA
Manual 2100-376H
Page
68 of 80
230/208-60-1
WG362DB
230/208-60-3
Manual
Page
2100-376H
69 of 80
WG362DC
Manual 2100-376H
Page
70 of 80
460-60-3
WG423DA
230/208-60-1
Manual
Page
2100-376H
71 of 80
WG423DA
Manual 2100-376H
Page
72 of 80
230/208-60-1
WG423DB
230/208-60-3
Manual
Page
2100-376H
73 of 80
WG423DB
Manual 2100-376H
Page
74 of 80
230/208-60-3
WG423DC
460-60-3
Manual
Page
2100-376H
75 of 80
WG423DC
Manual 2100-376H
Page
76 of 80
460-60-3
WG482DA, WG602DA
230/208-60-1
Manual
Page
2100-376H
77 of 80
WG482DB, WG602DB
Manual 2100-376H
Page
78 of 80
230/208-60-3
WG482DC, WG602DC
460-60-3
Manual
Page
2100-376H
79 of 80
WG482DC, WG602DC
Manual 2100-376H
Page
80 of 80
460-60-3