2100-365(H) (2004 05)

WARNINGREAD ALL INSTRUCTIONS CAREFULLY BEFOREBEGINNING THE INSTALLATION.

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

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

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

INSTALLATIONINSTRUCTIONS

WG - SERIESCOMBINATION GAS/ELECTRIC

WALL-MOUNTMODELS:

WG241 WG301 WG361WG422 WG481 WG601

Manual No.: 2100-365HSupersedes: 2100-365GFile: Volume III, Tab 20Date: 05-26-04

Bard Manufacturing CompanyBryan, Ohio 43506

Since 1914...Moving ahead just as planned.

© Copyright 2004

CONTENTS

Getting Other Information and Publications .............. 1WG Series Model Nomenclature............................... 2Ventilation Options .................................................... 2Air Conditioning Module Options ............................... 31. Important ............................................................ 32. Application .......................................................... 33. Duct Work .......................................................... 34. High Altitude Applications ................................... 75. Transportation Damage ...................................... 76. Installation .......................................................... 77. Wall Mounting .................................................... 88. Mounting the Unit ............................................... 89. Clearances ....................................................... 14

10. Vent Terminal and Combustion Inlet Hood ....... 1511. Optional Vertical Venting .................................. 1512. Vent Resizing Instructions ................................ 1613. Fresh Air Intake ................................................ 1614. Condensate Drain ............................................ 1615. Wiring � Main Power ........................................ 1716. Wiring � Low Voltage Wiring ............................ 1817. Thermostats ...................................................... 1818. Gas Supply & Piping ........................................ 2119. Manifold Pressure Adjustment .......................... 22

20. Checking Gas Input Rate ................................. 2221. Standard Orifice Sizing & High

Altitude Derate .................................................. 2422. Conversion of Gas Input BTUH From High

to Low Rating ................................................... 2723. Measuring Air Temperature Rise ...................... 2724. Filters ................................................................ 2825. Compressor Control Module............................. 2826. Lighting & Shutdown Instructions ..................... 3027. Service Agency Procedures ............................. 3128. Maintaining Unit in Good Working Order .......... 3129. Replacement Parts ............................................ 3230. Sequence of Operation � Heating .................... 3331. Sequence of Operation � Cooling .................... 3332. Indoor Blower Operation .................................. 3433. Pressure Service Ports ..................................... 4434. Refrigerant Charge ........................................... 4535. Fan Blade Setting Dimensions ......................... 4536. Low NOx Burner Assembly "N" Suffix

Models Only � U.S. Installations Only .............. 45Index � Wiring Diagrams ......................................... 46Wiring Diagrams ............................................. 47 � 70

Page Page

i.

CONTENTS

FIGURESFigure 1 Unit Dimensions ..................................... 6Figure 2 Mounting Instructions � WG24-36 ......... 9Figure 2A Mounting Instructions � WG42-60 ....... 10Figure 3 Combustible Clearance � WG24-36 ..... 11Figure 3A Combustible Clearnace � WG42-60 ..... 11Figure 4 Wall Mounting Instructions ................... 12Figure 5 Wall Mounting Instructions ................... 12Figure 6 Common Wall Mounting Installations ... 13Figure 7 Location of Vent Terminal in Shipping .. 14Figure 8 Vent Terminal & Combustion

Air Intake .............................................. 15Figure 9 Fresh Air Damper ................................. 16Figure 10 Installation of Flexible Conduit ............. 18Figure 11 Low Voltage Wiring .............................. 19Figure 12 Gas Pipe Connection ........................... 20Figure 13 Proper Piping Practice ......................... 21Figure 14 Acces Internal Filter Thru

Upper Service Door .............................. 28Figure 15 Lighting & Shutdown Instruction Label . 30Figure 16 Top View of Gas Control ...................... 31Figure 17 Sequence of Operation � Electronic

Blower Control ...................................... 33Figure 18 Furnace Control Board &

Blower Control ...................................... 34Figure 19 460V Blower Motor Wiring Options �

WG24-36 Models ................................. 35Figure 20 460V Blower Motor Wiring Options �

WG42-60 Models ................................. 36Figure 21 Fan Blade ............................................. 45Figure 22 Low NOx Insert .................................... 45

TABLESTable 1 Specifications � WG24-36 Models ........... 4Table 1A Specifications � WG42-60 Models ........... 5Table 2 Minimum Installation Clearances ........... 14Table 3 Thermostat Wire Size ............................ 18Table 4 Wall Thermostat &

Subbase Combinations .......................... 18Table 5 Length of Standard Pipe Threads .......... 21Table 6 Gas Pipe Sizes � Natural Gas ............... 21Table 7 Natural Gas Derate Capacities

For All Models ........................................ 24Table 8 Natural Gas Orifice Tables � WG24-36 .. 25Table 8A Natural Gas Orifice Tables � WG42-60 .. 26Table 9 Motor Speed Taps .................................. 34Table 10 WG241 Indoor Blower Performance ...... 37Table 11 WG301 Indoor Blower Performance ...... 38Table 12 WG361 Indoor Blower Performance ...... 39Table 13 WG422 Indoor Blower Performance ...... 40Table 14 WG481 Indoor Blower Performance ...... 41Table 15 WG601 Indoor Blower Performance ...... 42Table 16 Integrated Furnace & Blower

Control Operation ................................... 43Table 17 Cooling Pressure Table .......................... 44Table 18 Refrigerant Charge ................................ 45Table 19 Fan Blade Dimension ............................. 45

Page Page

ii.

Manual 2100-365Page 1

Getting Other Information and Publications

FOR MORE INFORMATION, CONTACTTHESE PUBLISHERS:

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

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

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

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

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

COPYRIGHT SEPTEMBER 2003BARD 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

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

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

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

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

Standard for Warm Air ..................... ANSI / NFPA 90BHeating and Air ConditioningSystems

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

Load Calculation for............................ ACCA Manual JResidential Winter andSummer Air Conditioning

Duct Design for Residential ............... ACCA Manual DWinter and Winter Air Conditioningand Equipment Selection

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


WG 42 1 � A X C X X X X X X

WALL MOUNT GAS/ELECTRIC GENERAL

MODEL NUMBER NOMENCLATURE

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

VENTILATION OPTIONS

sledoM 63GW,03GW,42GW 06GW,84GW,24GW

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tloV032-rotalitneVyrevoceRygrenE R 3A-VREGW 5A-VREGW

tloV064-rotalitneVyrevoceRygrenE R 3C-VREGW 5C-VREGW

MODELWall Mount Gas/Electric

CONTROL OPTIONS(See Table page 3)

FEATURE(-) = StandardD = DehumidificationC = Canadian Approval

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

VENT(See Tablebelow)

COOLING CAPACITY24 = 2 ton30 = 2.5 ton36 = 3 ton42 = 3.5 ton48 = 4 ton60 = 5 ton

REVISIONLEVEL

EMISSIONSX = StandardN = NOx Certified

FILTERX = 2� Pleated (Standard)W = 1� Washable

COLORX = Beige

(Standard)4 = Gray OUTLET

X = Front (Standard)T = Top

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

HEATING INPUT 2 - 3 Ton 3.5 - 5 TonA = 45,000 B= 75,000B = 67,500 C= 100,000C = 90,000 D= 125,000*

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


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

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

3. DUCT WORKThe unit is designed for use with or without duct work.See Warning on Page 7. Flanges are provided forattaching the supply and return ducts. Theseinstructions explain the recommended method to installthe air cooled self-contained electric air conditioningand gas heating unit and the electrical wiringconnections and gas piping to the unit. The refrigerantsystem is completely assembled and charged. Allinternal wiring is complete.

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

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

Refer to Table 9 for maximum static pressure availablefor duct design.

AIR CONDITIONING MODULE OPTIONS

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

timer. On initial power up, or any time the power is interrupted, the delay-on-makewill 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 lockoutfeature (with 1 retry) for high and/or low pressure controls, and a 2 minute timedbypass 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.

1MCC

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3CPL

4CAL

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DTS DTS % G 61-AMC

DTS DTS % % H 81-AMC

DTS DTS % I 6-AMC

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


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

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

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

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

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

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

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

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

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

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

2. Notify carrier promptly, and request an inspection.

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

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

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

B. Original paid freight bill of indemnity in lieuthereof.

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

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

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

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


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

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

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

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

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

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

2. The WG42, WG48 and WG60 models aresuitable for 0 inch clearance on the installationmounting wall and to the top. For all models thesupply air duct flange and the first 3 feet ofsupply air duct require a minimum of 1 inchclearance to combustible material. The WG24,WG30 and WG36 models are suitable for 0 inchclearance on the installation mounting wall, butrequire 1 inch clearance to the top if combustiblematerial overhang projects above the unit. SeeFigure 3 and 3A. If a combustible wall, use aminimum of Figure 1 �A� dimension plus 2inches and �B� dimension plus 2 inches. SeeFigures 4 and 5 for details.

3. Locate and mark lag bolt locations and bottommounting bracket location.

4. Mount bottom mounting bracket.

5. Hook top rain flashing under back bend of top.Top rain flashing is shipped secured to the rightside of the back.

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

7. Secure rain flashing to wall and caulk acrossentire length of top. See Figure 3.

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

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

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


FIG

UR

E 2

MO

UN

TIN

G IN

STR

UC

TIO

NS

FOR

WG

24, W

G30

, AN

D W

G36

MIS

-168

1


FIG

UR

E 2

AM

OU

NTI

NG

INS

TRU

CTI

ON

SFO

R W

G42

, WG

48, A

ND

WG

60

MIS

-147

2


FIGURE 3COMBUSTIBLE CLEARANCE

FOR WG24, WG30 AND WG36 MODELS

FIGURE 3ACOMBUSTIBLE CLEARANCE

FOR WG42, WG48 AND WG60 MODELS

WARNINGA minimum of one (1) inch clearance must be maintained between the supply air duct andcombustible materials. This is required for the first three (3) feet of ducting.

It is important to insure that the one (1) inch minimum spacing is maintained at all points.

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

MIS-1682

MIS-1714


FIGURE 4WALL MOUNTING INSTRUCTIONS

FIGURE 5WALL MOUNTING INSTRUCTIONS

MIS-1475

MIS-1476


FIGURE 6COMMON WALL MOUNTING INSTALLATIONS

MIS-1474


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

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

TABLE 2MINIMUM INSTALLATION CLEARANCES

)slairetamelbitsubmocmorf(tcuDteltuO teef3tsrifhcni1

)slairetamelbitsubmocmorf(lanimreTtneV * sehcni71

teltuOresnednoC sehcni02poT 3erugiFeeS

ecivreSrenruB sehcni02B,AssalCrodooW(esaBelbitsubmoC

)lairetamgnirevocfoorCro sehcni0

* A3dna3serugiFeeS

FIGURE 7LOCATION OF VENT TERMINAL IN SHIPPING

MIS-1689

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


10. VENT TERMINAL AND COMBUSTIONAIR INLET HOOD

The vent terminal is shipped in the burnercompartment. See Figure 7. Remove the two shippingscrews and separate the two-piece assembly. Install thevent terminal by using the four screws provided. Makesure gasket is in place. See Figure 8. The combustionair intake hood is factory installed.

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

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

CAUTIONVent terminal must be installed as shown inFigure 8 for proper operation of the heatingsystem.

FIGURE 8VENT TERMINAL AND COMBUSTION AIR INTAKE

MIS-1469


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

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

1. Seal any unused openings in the venting system;

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

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

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

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

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

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

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

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

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

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

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

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

FIGURE 9FRESH AIR DAMPER

BLADE IS LOCKEDCLOSED FORSHIPPING

MIS-938


ELECTRICAL GROUNDING

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

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

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

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

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

INSTALLING CONDUIT (See Figure 10.)

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

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

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

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

5. Replace conduit access panel if required to completeinstallation.

6. Seal around conduit in conduit entrance plate.

15. WIRING � MAIN POWER

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

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

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

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

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

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

WARNINGFailure to provide an electrical power supplyshutoff means could result in electric shock orfire.


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

PAT EGNAR

042 612--352

802 781--022

17. THERMOSTATS16. WIRING � LOW VOLTAGE WIRING230/208 VOLT UNITSAll models are equipped with dual primary voltagetransformers. All equipment leaves the factory wiredon 240V tap. For 208V operation, reconnect from240V to 208V tap. The acceptable operating voltagerange for the 240V and 208V taps are:

460 VOLT UNITSAll models are equipped with singleprimary voltage transformers and norewiring is required.

TABLE 3THERMOSTAT WIRE SIZE

remrofsnarTAV ALF eguaGeriW

mumixaMecnatsiDteeFnI

55 3.2 eguag02eguag81eguag61eguag41eguag21

5406001061052

FIGURE 10INSTALLATION OF FLEXIBLE CONDUIT

TABLE 4WALL THERMOSTAT AND SUBBASE COMBINATIONS

tatsomrehT esabbuS serutaeFetanimoderP

200-30481113F78T

300-40480221A935Q

,taehegats1 yrucreM;loocegats1otua-no:naFlooc-ffo-taeh:metsyS

140-30489941C4308T --- ,taehegats1 yrucreM;loocegats1

otua-no:naFlooc-ffo-taeh:metsyS

0-3048 94083-39F1 ---

egats2 taeh , egats2 ooc lelbammargorP

cinortcelE

340-3048002MC ---

,taehegats1 loocegats1otua-no:naFlooc-ffo-taeh:metsyS

noitcApanS

840-30483131C0048T ---

loocegats1,taehegats1otua-no:naFlooc-ffo-taeh:metsyS

elbammargorP-noNcinortcelE

MIS-1553


FIGURE 11LOW VOLTAGE WIRING

MIS-1719


FIGURE 12GAS PIPE CONNECTION

MIS-1683


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

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

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

6. Use steel or wrought iron pipe and fittings.

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

18. GAS SUPPLY AND PIPING

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

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

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

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

TABLE 5LENGTH OF STANDARDPIPE THREADS (INCHES)

eziSepiPhtgneLevitceffE

daerhTfohtgneLllarevO

daerhTfo

8/3 2/1 61/9

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

1 61/9 1

fohtgneLteeF-epiP

eziSepiPtupnIruoHrepUTB-yticapaCepiP

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

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

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

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

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

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

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

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

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

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

TABLE 6GAS PIPE SIZES - NATURAL GAS

CHECKING THE GAS PIPINGBefore turning gas under pressure into piping,

all openings from which gas can escape should beclosed. Immediately after turning on gas, the systemshould be checked for leaks. This can be done bywatching the 1/2 cubic foot test dial and allowing 4minutes to show any movement, and by soaping eachpipe connection and watching for bubbles. If a leak isfound, make the necessary repairs immediately andrepeat the above test. The furnace must be isolatedfrom the gas supply piping system by closing themanual shutoff valve on the combination gas controlvalve during pressure testing of the gas supply pipingsystem at pressures up to 1/2 PSIG. The furnace and itsindividual shutoff valve must be disconnected fromsupply piping and supply piping capped during anypressure testing of supply piping system at testpressures in excess of 1/2 PSIG.

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

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

MIS-897

FIGURE 13PROPER PIPING PRACTICE


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

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

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

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

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

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

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

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

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

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

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

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

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

4. Attach manometer to 1/8" NPT manual shutoff valvejust installed.

5. Slowly open equipment shutoff valve in gas supplyline just ahead of furnace. Start furnace following"Operating Instructions" on front door.

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

7. Read manifold pressure on manometer.

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

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

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


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

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

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

3. Start furnace following "Operating Instructions" onfront door.

4. Let furnace warm up for 6 minutes.

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

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

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

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

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

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

8. Calculate gas input using this formula:

Gas Heating Value (BTU/cu. ft.) x 3,600 sec/hr

Gas input = = BTU/hour Time (Seconds for one

cubic foot of gas)

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

1,000 x 3,600 Gas input = = 124,138 BTU 29

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

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

Example:

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

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

3,000 BTU per hour

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

10. Manifold pressure may be adjusted within the rangeof 3.2 inches W.C. to 3.8 inches W.C. to get ratedinput ± 2 percent. See Section 17, "ManifoldPressure Adjustment". If you cannot get rated inputwith manifold pressure within the allowable range,you must change orifices.

PROPANE (LP) GAS INPUT RATE

1. Make sure you have proper main burner orifices.

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

3. Start furnace following "Operating Instructions" onfront door.

4. Let furnace warm up for 6 minutes.

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

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

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


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

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

TABLE 7NATURAL GAS DERATE CAPACITIES

FOR ALL MODELS

detaRGWtupnI

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

005,04000,54

005,04000,54

402,93065,34

809,73021,24

216,63086,04

046,53006,93

299,43088,83

281,43089,73

696,33044,73

840,33027,63

346,23072,63

670,23046,53

057,06005,76

057,06005,76

608,85043,56

268,65081,36

819,45020,16

064,35004,95

884,25023,85

372,15079,65

445,05061,65

275,94080,55

569,84504,45

411,84064,35

000,57000,18

000,57000,18

006,27804,87

002,07618,57

008,76422,37

000,66082,17

008,46489,96

003,36463,86

004,26293,76

002,16690,66

054,06682,56

004,95251,46

000,09000,001

000,09000,001

021,78008,69

042,48006,39

063,18004,09

002,97000,88

067,77004,68

069,57004,48

088,47002,38

044,37006,18

045,27006,08

082,17002,97

005,211000,521

005,211000,521

009,801000,121

003,501000,711

007,101000,311

000,99000,011

002,79000,801

059,49005,501

006,39000,401

008,19000,201

576,09057,001

001,98000,99

It is the installer�s responsibility to see that the furnaceinput rate is adjusted properly. Derating must beachieved by reducing the size of the main burnerorifices. Derating the furnace by adjusting the manifoldpressure lower than the range specified in the Section16, "Manifold Pressure Adjustment" is considered to bean improper procedure.

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


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

TABLE 8NATURAL GAS ORIFICE TABLES

FOR MODELS WG24, WG30 AND WG36

yrotcaFdradnatStupnI

eulaV*taeHsaG.tF.uC/UTB

oNteeF000,6otpUtpecxEsegnahCtnetnoCUTBrof

teeF000,8ot100,6hctiwSerusserPseriuqeRegnahCecifirOdnaegnahC

tnetnoCUTBnodesaB t


tnetnoCUTBnodesaB tUTB00522renruBreP

947-007 57.2 07.2 06.2

997-057 07.2 06.2 05.2

948-008 06.2 05.2 54.2

998-058 05.2 54.2 53.2

949-009 54.2 53.2 )03.2(

999-059 53.2 )03.2( 52.2

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

0011-0501 52.2 ]02.2[ 51.2

hctiwSerusserP )55.(dradnatS )24.(tiKhctiwSerusserPedutitlAhgiH981-0268redrOezisecifirodellatsniyrotcafdradnatsehtsi)03.2( dellatsnidleifroftinuehthtiwdeppihserasecifiro]02.2[

etared%01lanoitpo

lanoitpOdleiF%01detrevnoC

etareDeulaV*taeHsaG

.tF.uC/UTB



tnetnoCUTBnodesaB


tnetnoCUTBnodesaBUTB05202renruBreP

947-007 06.2 05.2 54.2

997-057 05.2 54.2 04.2

948-008 54.2 04.2 )03.2(

998-058 04.2 )03.2( 52.2

949-009 )03.2( 52.2 ]02.2[

999-059 52.2 ]02.2[ 51.2

**9401-0001 ]02.2[ 51.2 01.2

0011-0501 51.2 51.2 01.2

hctiwSerusserP )55.(dradnatS )24.(tiKhctiwSerusserPedutitlAhgiH981-0268redrOdellatsnidleifroftinuehthtiwdeppihserasecifiro]02.2[

.etartupni%01lanoitpotupnidetarllufrofezisecifirodellatsniyrotcafehtsi)03.2(

***

.ytivargcificeps06.,detarutas,F06,yrucreMsehci00.03:snoitidnocdradnatstAlevelaesdnasagtfuc/UTB5201lanimonnodesabsgnitartupnidradnatsdnagnizisecifiroyrotcafsaGlarutaNllA

snoitidnoc

.oNtraPdraB )mm(eziSecifirO retemaiDecifirO290-0109 01.2 6280.0880-0109 51.2 6480.0780-0109 02.2 6680.0680-0109 52.2 5880.0280-0109 03.2 5090.0580-0109 53.2 5290.0970-0109 04.2 5490.0480-0109 54.2 4690.0390-0109 05.2 4890.0490-0109 06.2 4201.0590-0109 07.2 3601.0690-0109 57.2 2801.0790-0109 08.2 2011.1890-0109 09.2 2411.0

deriuqeRsecifirOfo.oNgnitaRtupnItinUnodesaB

005,04 )2(

000,54 )2(

057,06 )3(

005,76 )3(

000,57 )3(

000,18 )4(

000,09 )4(

000,001 )4(

005,211 )5(

000,521 )5(


All other orifice sizes shown are available as individual items. See Orifice charts on Page 25 for part numbers and numberrequired.

TABLE 8ANATURAL GAS ORIFICE TABLES

FOR MODELS WG42, WG48 AND WG60

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23. MEASURING AIR TEMPERATURERISE

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

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

Follow this procedure:

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

22. CONVERSION OF GAS INPUT BTUHFROM HIGH TO LOW RATINGAll the derated WG series units are produced withmaximum BTUH input orifices installed. To fieldconvert input, a change to main burner orifices isrequired.

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

A. Shut off electrical supply to the unit.

B. Shut off gas supply to the unit.

C. Remove burner access panel.

D. Disconnect gas valve from gas supply piping.

E. Disconnect the two wires from the gas valve.

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

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

H. To assemble burner reverse steps A through G.

2. Set balancing dampers in supply duct system.

3. Check duct work for obstructions or leaks.

4. Make sure filters are clean and in place.

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

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

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

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

� If air temperature rise is above the temperaturerise range on rating plate, furnace is overfiredor has insufficient airflow. Check gas inputfollowing the instructions in Section ,"Checking Gas Input Rate". If air temperaturerise is still above temperature rise rangespecified, more heating air flow is needed.Check duct work and grilles to make sure allare properly sized.

� If air temperature rise is below the temperaturerise range on rating plate, furnace is underfiredor has too much airflow. Check gas inputfollowing the instructions in Section ,"Checking Gas Input Rate". If air temperaturerise is still below temperature rise rangespecified, less heating air flow is needed.Adjust dampers or grilles as needed.

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

9. Set room thermostat to desired setting.

10. Remove thermometers and seal duct work holes.

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

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


24. FILTERSA 2� thick throwaway filter is supplied with each unit.This filter is installed by opening the main service door.(See Figure 14.)

Replacement filters are available through your dealer.

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

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

FIGURE 14ACCESS INTERNAL FILTER

THROUGH UPPER SERVICE DOOR

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

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

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

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

MIS-1449


ADJUSTMENTS

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

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

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

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

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

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

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

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


26. LIGHTING AND SHUTDOWN INSTRUCTIONS

FIGURE 15INSTRUCTION LABEL


27. SERVICE AGENCY PROCEDURES

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

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

28. MAINTAINING UNIT IN GOODWORKING ORDER

The unit should be inspected annually by a qualifiedservice agency.

BURNERS / HEAT EXCHANGER / FLUE GASPASSAGE WAYS

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

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

GASINLET

GAS CONTROL KNOBSHOWN IN �OFF� POSITION

PRESSURE REGULATORADJUSTMENT (UNDERCAP SCREW)

INLETPRESSURETAP

OUTLETPRESSURETAP

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

setting. � Turn off manual gas shutoff 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.

FIGURE 16TOP VIEW OF GAS CONTROL

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

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


ROUTINE MAINTENANCE

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

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

ROUTINE INSPECTION

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

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

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

29. REPLACEMENT PARTS

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

1. Before inspecting unit:

a. Turn room thermostat to lowest or off setting.

b. Turn off equipment gas shutoff valve.

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

d. Turn off electrical power to unit.

2. Inspect the following:

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

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

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

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

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

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

g. Inspect all electrical connections and wiring.

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

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

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

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

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

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

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


30. SEQUENCE OF OPERATION �HEATING

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

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

This unit is equipped with a flame rollout switch whichis wired in series with the control circuit. This is amanual reset switch and is used for the purpose ofpreventing possible fire hazard in the event of a systemmalfunction. If this switch has opened the controlcircuit, there could be a possible system malfunction.Some of the conditions that might cause a rollout tooccur are blockage or sooting of primary heatexchanger, overfiring of furnace due to improper main

burner orifices or incorrect manifold pressure,insufficient combustion air, or installation deficiencieswith respect to return air duct design or sizing.

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

31. SEQUENCE OF OPERATION �COOLING

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

See Figure 17 for additional information.

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

FIGURE 17SEQUENCE OF OPERATION

ELECTRONIC BLOWER CONTROLNOITCA ESNOPSERMETSYS

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MIS-1482

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

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

230 VOLT BLOWER MOTOR SPEED CHANGE

1. Disconnect main power supply to unit.

2. Remove and tape off the unwanted indoor motorspeed tap from the heat or cool terminal on thefurnace control board.

3. Next install a jumper wire with multiplier betweenheat and cool terminal and attach desired blowermotor speed to other side of multiplier.

4. Energize the system in cooling and heating modesand check for proper blower operation.

460 VOLT BLOWER MOTOR SPEED CHANGE

Field changeover from the factory blower motor speedsettings can require change several different motorleads, the addition or deletion of a wire.

Refer to blower motor wiring options as shown belowfor the correct wiring of the blower motor for theapplication involved.

TABLE 9MOTOR SPEED TAPS

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FIGURE 18FURNACE CONTROL BOARD AND BLOWER CONTROL

ATTACH JUMPER WIREHERE FOR SINGLESPEED OPERATION

FURNACE CONTROLBOARD


FIGURE 19460 VOLT BLOWER MOTOR WIRING OPTIONS

WG24, WG30 AND WG36 MODELS


FIGURE 20460 VOLT BLOWER MOTOR WIRING OPTIONS

WG42, WG48 AND WG 60 MODELS


TABLE 10WG241 INDOOR BLOWER PERFORMANCE @ 230 AND 460 VOLTS

Recommended WG241 cooling airflow range at rated 800 CFM @ 0.15 ESP (WC) is 680 - 920 CFMFactory set on Low Speed for cooling and High for heating.

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

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Recommended WG301 cooling airflow range at rated 1000 CFM @ 0.35 ESP (WC) is 820 - 1150 CFMFactory set on Medium Speed for cooling and for heating.


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Recommended WG361 cooling airflow range at rated 1100 CFM @ 0.250 ESP (WC) is 935 - 1265 CFMFactory set on Medium Speed for cooling and for heating.


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Recommended WG422 cooling airflow range at rated 1300 CFM @ .35 ESP (WC) is 1500 - 1030 CFMFactory set on Medium Speed for heating and cooling

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

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

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

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

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

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

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

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

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

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

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

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

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

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



Recommended WG481 cooling airflow range at rated 1550 CFM @ .38 ESP (WC) is 1750 - 1280 CFMFactory set on High Speed for cooling and Medium Speed for heating.


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

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

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

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

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

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

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

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

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

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

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

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



Recommended WG601 cooling airflow range at rated 1650 CFM @ .30 ESP (WC) is 1910 - 1340 CFMFactory set on High Speed for cooling and Medium Speed for heating.


PSEsehcnI

HsO




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

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

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

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

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

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

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

PSEsehcnI

HsO




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

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

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

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

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

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

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

PSEsehcnI

HsO




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

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

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

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

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

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

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


TABLE 16INTEGRATED FURNACE AND BLOWER CONTROL OPERATION

LORTNOCECNEUQESNOITINGI

ecruoSnoitingI ISDCAV42

gnisneSemalF etomeR

sgnimiT

-------

-----

--

egruperPegruptsoP

egruplairt-retnIdoirepgnivorphctiwserusserP

noitingirofslairTnoitingiroflairT

tuokcolecneuqesnoitingI

yaled-norewolbtaeHyaled-fforewolbtaeHyaled-norewolblooCyaled-fforewolblooCsnoitareponaflaunaM

noitarepolortnoctimilhgiHnoitarepohctiwstuolloremalF

510351063706-

03,09

706

sdnoces)"no"evlaverofebdetanimretelcycfi0(sdnoces

sdnocessdnoces

ecneuqesnoitingirepemalfevorpotemitlatotsdnoces

teserotua,)noitingirofslairt3retfa(sretunimgninepoybdoireptuokcoletunim06ehtgnirudteserebnac

eromrosdnoces3roftiucrictatsomreht)ffoselcycrotinginehwstratsgnimit(sdnoces021tatesyrotcaf;elbatcelessdnocs051,021

sdnocessdnoces

gnirudffoselcycdnadeepsgnitaehdetcelesnosetarepO.ecneuqesputratsrenrubronoitingi

.1etoNeeS.tratserecneuqesnoitingi,tesercitamotuAyllaunamsihctiwsretfadetaitiniecneuqesnotingi,teserlaunaM

.1etoNeeS.teser:1ETON yaledruoh1aeblliwerehttaehrofllacneviganopirttimilhtruofehtretfA

emalfrohctiwstimilhgihrehtieretfA.tratserlliwecneuqesnoitingiehterofebdnaegruptsopdnoces03ehtrofetarepolliwrecudniehtnoitautcahctiwstuollor

naFlaunaMnofI.yaledffodetcelesehtrofetarepolliwrewolbriatrofmoceht.etarepooteunitnoclliwrewolbriatrofmoceht,noitarepo

STINUYTEFAS

tuolloR/timilhgiHhctiwserusserP

tloV42niTSPSkcehctratsefas,TSPS

LORTNOCNAFTROFMOC

naFdeepSgnitaeHnoitarepolamroN

yaledNO-

yaledFFO-

noitarepOtimiL

esneSemalF

03

3

dezigrene-edretinginehwstratsgnimiT.dexifsdnoces

09otdegnahcebnacdradnatssdnoces021-sgnimitelbatceles.sdnoces051ro

NEPOtimilnehwNOSESOLCtimilnehwyaledFFOretfaFFO

desnessiemalffiNO dna .taehrofllaconsiereht

naFdeepSgnilooC- yaledNO

yaledFFO-

7

06

sdnoces

sdnoces

naFlaunaM nafeht,loocrofllacnehW.deepsGNITAEHnoylsuounitnocNO,deifsitastatsomrehtnehwnehT.deepsGNILOOCotsehctiwsFFOGNILOOCretfadeepsGNITAEHotkcabsehctiwsnafeht

.yaled

ROTACIDNICITSONGAID

:swollofsastluafmetsysetacidniotdedivorpsiDELderAsedomnafrolooc,taehrofllac,ybdnatsniyakolortnoC-NOydaetS

.lortnocnoesufA3kcehcoslA.rewoponrotluaflortnoclanretnI-FFOydaetSstuopordemalfronoitingideliafoteudtuokcoL-hsalf1

norecudnihtiwnepohctiwserusserP-sehsalf2fforecudnihtiwdesolcsihctiwserusserP-sehsalf3

neposihctiwstimiL-sehsalf4desolcevlavsaghtiwdetcetedemalF-sehsalf5

remitgnigats/elcyctrohsmorfdeyaledtuptuorosserpmoC-sehsalf6.sedochsalfneewtebesuapsdnoces0.2htiwffosdnoces52.0,nosdnoces52.0sietarhsalfehT


33. PRESSURE SERVICE PORTSHigh and low pressure service ports are installed on allunits so that the system operating pressures can beobserved. Table 17 outlines expected pressures at variousindoor and outdoor temperatures.

Low side pressure ± 2 PSIGHigh side pressure ± 5 PSIG

TABLE 17COOLING PRESSURE TABLE

ledoMriAnruteRerutarepmeT erusserP 57 08 58 09 59 001 501 011 511

142GW

BD.ged57BW.ged26

ediSwoLediShgiH

27102

47612

67132

77642

97362

18082

28792

38513

58533

BD.ged08BW.ged76

ediSwoLediShgiH

67702

97122

18732

38352

58072

78782

88603

09423

19443

BD.ged58BW.ged27

ediSwoLediShgiH

28412

58922

78542

98262

19082

39892

59613

79633

89653

103GW

BD.ged57BW.ged26

ediSwoLediShgiH

67812

77132

87542

97162

18872

28592

48413

58433

78653

BD.ged08BW.ged76

ediSwoLediShgiH

18322

28732

38152

58762

78582

88303

09223

19343

39563

BD.ged58BW.ged27

ediSwoLediShgiH

78232

88642

09162

19772

39592

49313

69333

89553

001873

163GW

BD.ged57BW.ged26

ediSwoLediShgiH

27222

47832

57552

67272

87092

97803

18623

28643

38663

BD.ged08BW.ged76

ediSwoLediShgiH

77822

97542

18262

28972

48892

58613

78533

88553

98573

BD.ged58BW.ged27

ediSwoLediShgiH

38732

58452

68172

88982

09803

19723

39643

59763

69883

224GW

BD.ged57BW.ged26

ediSwoLediShgiH

66602

96122

17632

37152

57762

67282

87003

97513

18233

BD.ged08BW.ged76

ediSwoLediShgiH

27112

47622

67242

87752

08472

18092

48703

58323

78143

BD.ged58BW.ged27

ediSwoLediShgiH

87912

08432

28052

48662

68382

78992

98613

19433

39253

184GW

BD.ged57BW.ged26

ediSwoLediShgiH

96991

07412

27922

37442

47162

57872

67492

77213

97133

BD.ged08BW.ged76

ediSwoLediShgiH

47502

57022

67532

87152

97862

08582

28203

38123

58043

BD.ged58BW.ged27

ediSwoLediShgiH

08012

18622

38242

48952

58772

68492

88413

98233

19253

106GW

BD.ged57BW.ged26

ediSwoLediShgiH

96132

07842

27562

37382

47103

57913

67833

77653

97673

BD.ged08BW.ged76

ediSwoLediShgiH

47732

57452

67272

77092

97903

08723

18643

28663

48683

BD.ged58BW.ged27

ediSwoLediShgiH

08542

18362

28282

38003

58023

68933

78063

88973

09993


34. REFRIGERANT CHARGEThe correct system R-22 charge is shown on the unitrating plate. Optimum unit performance will occurwith a refrigerant charge resulting in a suction linetemperature (6� from compressor) as shown inTable 18.

The suction line temperatures in Table 18 are basedupon 80 degrees F dry bulb / 67 degree wet bulb (50%R.H.) temperature and rated airflow across theevaporator during cooling cycle.

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

35. FAN BLADE SETTING DIMENSIONSShown in Figure 21 is the correct fan blade settingdimension for proper air delivery across the outdoorcoil.

ledoMnoisnemiD

A

42GW 1

03GW 1

63GW 1

24GW 1

84GW 1

06GW 1

TABLE 19FAN BLADE DIMENSION

FIGURE 21FAN BLADE

A

36. LOW-NOX BURNER ASSEMBLY �N�SUFFIX MODELS ONLY � U.S.INSTALLATIONS ONLY

NATURAL GAS MODELS ONLY

Model numbers designated with an �N� are designedfor low NOx emissions which comply with allCalifornia Air Quality Management District regulationsfor nitrogen oxide emission levels. Refer to Figure 22for NOx insert information.

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

FIGURE 22LOW NOX INSERT

MIS-1481

TABLE 18REFRIGERANT CHARGE

ledoMdetaRwolfriA

F.geD59.pmeTDO

F.geD28.pmeTDO

142GW 008 95-15 26-06

103GW 0001 06-85 26-06

163GW 0011 95-65 26-06

224GW 0031 75-55 86-66

184GW 0551 65-45 66-46

106GW 0561 85-65 86-66


INDEXWIRING DIAGRAMS

and LADDER DIAGRAMS

tinU.oNledoM

cisaBmargaiDgniriW

launaM.oNegaP

cisaBmargaiDreddaL

launaM.oNegaP

A-142GW B231-5804 74 B121-5804 84

B-142GW B232-5804 94 B122-5804 05

C-142GW B133-5804 15 C233-5804 25

A-103GW C031-5804 35 B121-5804 45

B-103GW E032-5804 55 B122-5804 65

C-103GW C723-5804 75 D823-5804 85

A-163GW C031-5804 35 B121-5804 45

B-163GW E032-5804 55 B122-5804 65

C-163GW C723-5804 75 D823-5804 85

A-224GW B621-5804 95 A721-5804 06

B-224GW B622-5804 16 A722-5804 26

C-224GW A323-5804 36 A423-5804 46

A-184GW C021-5804 56 B121-5804 66

B-184GW B022-5804 76 B122-5804 86

C-184GW C713-5804 96 B813-5804 07

A-106GW C021-5804 56 B121-5804 66

B-106GW B022-5804 76 B122-5804 86

C-106GW C713-5804 96 B813-5804 07


WG241-A 230/208-60-1


WG241-A 230/208-60-1


WG241-B 230/208-60-3


WG241-B 230/208-60-3


WG241-C 460-60-3


WG241-C 460-60-3


WG301-A, WG361-A 230/208-60-1


WG301-A, WG361-A 230/208-60-1


WG301-B, WG361-B 230/208-60-3


WG301-B, WG361-B 230/208-60-3


WG301-C, WG361-C 460-60-3


WG301-C, WG361-C 460-60-3


WG422-A 230/208-60-1


WG422-A 230/208-60-1


WG422-B 230/208-60-3


WG422-B 230/208-60-3


WG422-C 460-60-3


WG422-C 460-60-3


WG481-A, WG601-A 230/208-60-1


WG481-A, WG601-A 230/208-60-1


WG481-B, WG601-B 230/208-60-3


WG481-B, WG601-B 230/208-60-3


WG481-C, WG601-C 460-60-3


WG481-C, WG601-C 460-60-3

Documents

2100-365(H) (2004 05)