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Manual 2100-592BPage 1 of 69
Manual No.: 2100-592BSupersedes: 2100-592AFile: Volume III, Tab 20Date: 09-20-13
Bard Manufacturing Company, Inc.Bryan, Ohio 43506
Since 1914...Moving ahead just as planned.
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.
WG - SERIESCOMBINATION GAS/ELECTRIC
WALL-MOUNTwith DEHUMIDIFICATION
MODELS:W24G2DA W30G2DA W36G2DA W42G2DA W48G2DA W60G2DAW24G2DB W30G2DB W36G2DB W42G2DB W48G2DB W60G2DBW24G2DC W30G2DC W36G2DC W42G2DC W48G2DC W60G2DC
INSTALLATIONINSTRUCTIONS
Manual 2100-592BPage 2 of 69
CONTENTS
Getting Other Information and Publications .............. 4W**G Series Model Nomenclature ............................ 5Ventilation Options .................................................... 5Air Conditioning Module Options ............................... 61. Important ............................................................ 62. Application .......................................................... 63. Duct Work .................................................. 6 & 104. High Altitude Applications ................................. 105. Transportation Damage .................................... 106. Installation ........................................................ 107. Wall Mounting .................................................. 118. Mounting the Unit ............................................. 119. Clearances ....................................................... 17
10. Vent Terminal and Combustion Inlet Hood ....... 1811. Optional Vertical Venting .................................. 1812. Vent Resizing Instructions ................................ 1913. Fresh Air Intake ................................................ 1914. Condensate Drain ............................................ 1915. Wiring – Main Power ........................................ 2016. Wiring – Low Voltage Wiring ............................ 2117. Thermostats ...................................................... 2218. Gas Supply & Piping ........................................ 2719. Manifold Pressure Adjustment .......................... 28
20. Checking Gas Input Rate ......................... 28 & 2921. Standard Orifice Sizing & High
Altitude Derate .................................................. 3022. Conversion of Gas Input BTUH From High
to Low Rating ................................................... 3323. Measuring Air Temperature Rise ...................... 3324. Filters ................................................................ 3425. Compressor Control Module ..................... 34 & 3526. Lighting & Shutdown Instructions ..................... 3627. Service Agency Procedures ............................. 3728. Maintaining Unit - Good Working Order .... 37 & 3829. Replacement Parts ............................................ 3830. Sequence of Operation – Heating .................... 3931. Sequence of Operation – Cooling .................... 3932. Indoor Blower Operation .................................. 4133. W**G Dehumidification Relay Logic Board ...... 4934. Pressure Service Ports ..................................... 5035. Dehumidification Circuit .................................... 5036. Refrigerant Charge ........................................... 5137. Fan Blade Setting Dimensions ......................... 5238. Low NOx Burner Assembly "N" Suffix
Models Only – U.S. Installations Only .............. 52Index – Wiring Diagrams ......................................... 53Wiring Diagrams ............................................. 54 – 69
Page Page
Manual 2100-592BPage 3 of 69
CONTENTS
FIGURESFigure 1 Unit Dimensions ..................................... 9Figure 2 Mounting Instructions – W24G-36G ..... 12Figure 2A Mounting Instructions – W42G-60G ..... 13Figure 3 Combustible Clearance – W24G-36G.. 14Figure 3A Combustible Clearance – W42G-60G.. 14Figure 4 Wall Mounting Instructions ................... 15Figure 5 Wall Mounting Instructions ................... 15Figure 6 Common Wall Mounting Installations ... 16Figure 7 Location of Vent Terminal in Shipping .. 17Figure 8 Vent Terminal & Combustion
Air Intake .............................................. 18Figure 9 Fresh Air Damper ................................. 19Figure 10 Installation of Flexible Conduit ............. 21Figure 11A T-Stat Connection using Comb. ........... 23Figure 11B T-Stat using Temp. & Humidity Ctrl. ...... 24Figure 11C MFAD, Classroom Vent. Spring & Power .
& ERV Low Voltage Connections ......... 25Figure 11D Economizer Low Volt. Connections ...... 25Figure 12 Gas Pipe Connection ........................... 26Figure 13 Proper Piping Practice ......................... 27Figure 14 Access Internal Filter through
Upper Service Door .............................. 34Figure 15 Lighting & Shutdown Label .................. 36Figure 16 Top View of Gas Control ...................... 37Figure 17 Sequence of Operation – Electronic
Blower Control ...................................... 40Figure 18 Furnace Control Board &
Blower Control ...................................... 41Figure 19 Circuit Diagrams ................................... 50Figure 20 Fan Blade ............................................. 52Figure 21 Low NOx Insert .................................... 52
TABLESTable 1 Specifications – W24G-36G Models ........ 7Table 1A Specifications – W42G-60G Models ........ 8Table 2 Minimum Installation Clearances ........... 17Table 3 Thermostat Wire Size ............................ 22Table 4A Wall Thermostat ..................................... 22Table 4B Humidistat .............................................. 22Table 5 Length of Standard Pipe Threads .......... 27Table 6 Gas Pipe Sizes – Natural Gas ............... 27Table 7 Natural Gas Derate Capacities
For All Models ........................................ 30Table 8 Natural Gas Orifice Tables – W24G-36G . 31Table 8A Natural Gas Orifice Tables – W42G-60G . 32Table 9 Motor Speed Taps .................................. 41Table 10 W24G Indoor Blower Performance ........ 42Table 11 W30G Indoor Blower Performance ........ 43Table 12 W36G Indoor Blower Performance ........ 44Table 13 W42G Indoor Blower Performance ........ 45Table 14 W48G Indoor Blower Performance ........ 46Table 15 W60G Indoor Blower Performance ........ 47Table 16 Integrated Furnace & Blower
Control Operation ................................... 48Table Dehum. Relay Logic Board Table ........... 49Table 17 Refrigerant Charge-Pressure Tables ...... 51Table 18 Fan Blade Dimension ............................. 52
Page Page
Manual 2100-592BPage 4 of 69
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
BARD MANUFACTURING COMPANY, INC.BRYAN, OHIO 43506 USA
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 and Ventilating Systems
Standard for Warm Air ..................... ANSI / NFPA 90BHeating and Air Conditioning Systems
Standard for Chimneys, ................................. NFPA 211Fireplaces, Vents, and Solid Fuel Burning Appliances
Load Calculation for ............................ ACCA Manual JResidential Winter and Summer Air Conditioning
Duct Design for Residential ............... ACCA Manual DWinter and Winter Air Conditioning and EquipmentSelection
Canadian Electrical Code ............................. CSA C22.1
Canadian Installation Code……………CAN/CGA B149
Manual 2100-592BPage 5 of 69
W 42 G 2 D A X C X X X X X X
WALL MOUNT GAS/ELECTRIC GENERALMODEL NUMBER NOMENCLATURE
1 Low ambient control is required with economizer for low temperature compressor operation.
VENTILATION OPTIONS
sledoM G63W,G03W,G42W G06W,G84W,G24W
noitpircseD
dellatsnIyrotcaF
.oNedoC
dellatsnIdleiF
.oNtraP
dellatsnIdleiF
.oNtraP
repmaDriAhserFcirtemoraB X 3-DAFBGW 5-DAFBGW
etalPffO-knalB B 3-POBGW 5-POBGW
repmaDriAhserFdezirotoM M A3-DAFMGW A5-DAFMGW
nruteRgnirpS-rotalitneVlaicremmoC V A3-SVRCGW A5-SVRCGW
nruteRrewoP-rotalitneVlaicremmoC P A3-PVRCGW A5-PVRCGW
gnitaludoMylluF-rezimonocE 1 E C3-MFIEGW C5-MFIEGW
tloV032-rotalitneVyrevoceRygrenE R B3A-VREGW B5A-VREGW
tloV064-rotalitneVyrevoceRygrenE R B3C-VREGW B5C-VREGW
MODELWall Mount
CONTROL OPTIONS(See Table page 6)
FEATURED = Dehumidification
VOLTAGEA = 230/208-60-1B = 230/208-60-3C = 460-60-3
VENT(See Table Below)
COOLING CAPACITY24 = 2 ton30 = 2½ ton36 = 3 ton42 = 3½ ton48 = 4 ton60 = 5 ton
REVISION
EMISSIONSX = StandardN = NOx Certified FILTER
X = 2" Pleated MERV 8 (Standard)W = 1" Washable
COLORX = Beige(Standard)4 = Buckeye Gray8 = Dark Bronze
OUTLETX = Front (Standard)T = Top
COIL OPTIONSX = Standard1 = Phenolic coated evaporator2 = Phenolic coated condenser3 = Phenolic coated both coils
*125,000 BTU input model is not NOx certified.
HEATING INPUT 2 - 3 Ton 3½ - 5 TonA = 45,000 B= 75,000B = 67,500 C= 100,000C = 90,000 D= 125,000*
GAS/ELECTRIC
Manual 2100-592BPage 6 of 69
AIR CONDITIONING MODULE OPTIONS
STD = Standard equipment.1 CCM Compressor control module has adjustable 30 second to 5 minute delay-on-break timer. On initial
power up, or any time the power is interrupted, the delay-on-make will be 2 minutes plus 10% of thedelay-on-break setting. There is no delay-on-make during routine operation of the unit. The modulealso provides the lockout feature (with 1 retry) for high and/or low pressure controls, and a 2 minutetimed bypass for low pressure control.
2 HPC High pressure control is auto reset. Always used with compressor control module (CCM) which isincluded. See note 1.
3 LPC Low pressure control is auto reset. Always used with compressor control module (CCM) which isincluded. See note 1.
4 LAC Low ambient control permits cooling operation down to 0°F.
1
MCC
2
CPH
3
CPL
4
CAL
dellatsnIyrotcaF
edoC
dellatsnIdleiF
traP
DTS DTS DTS X A/N
DTS DTS DTS � H 82-AMC
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 10. 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 airflow requirement of the equipment.Air Conditioning Contractors of America (ACCA) is anexcellent guide to proper sizing.
Refer to Tables later in this Manual for maximum staticpressure available for duct design.
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 irritating 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.
Manual 2100-592BPage 7 of 69
TAB
LE 1
SP
EC
IFIC
ATI
ON
SW
24G
, W30
G A
ND
W36
G M
OD
ELS
* 7
5 de
gree
C C
oppe
r wire
siz
e**
Max
imum
tim
e de
lay
fuse
or H
AC
R T
ype
circ
uit b
reak
er
ledo
MA
D2
G42
WB
D2
G42
WC
D2
G42
WA
D2
G03
WB
D2
G03
WC
D2
G03
WA
D2
G63
WB
D2
G63
WC
D2
G63
W
ZH06
–gnit
aRlacirt
cel
E1-
06-
802/
032
3-06-
802/
032
3-06-
064
1-06-
802/
032
3-06-
802/
032
3-06-
064
1-06-
802/
032
3-06-
02/
032
3-06-
064
egnaR
egatl
oV
gnit
arepO
352-
791
352-
791
605-
414
352-
791
352-
791
605-
414
352-
791
352-
791
605-
414
yticap
mAtiucri
Cmu
mini
M12
61
932
71
01
82
52
11
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Seri
Wdlei
F01
01
41
801
41
88
41
eziS
eriW
dnuor
G01
21
41
01
21
41
01
01
41
**.x
aM
–esuFyaleD
03
52
51
53
52
51
54
04
51
rosser
pmo
C
epy
Trosser
pmoC
llor
cS
llor
cS
llor
cS
llor
cS
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cS
llor
cS
llor
cS
llor
cS
llor
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stloV
802/
032
802/
032
064
802/
032
802/
032
064
802/
032
802/
032
064
sp
mA
daoL
det
aR
9.01/
9.9
1.7/
4.6
9.3
9.21/
8.11
2.8/
5.7
7.4
7.61/
3.51
6.41/
3.31
1.5
tnerr
uC
noit
celeStiucri
Chcnar
B8.
21
3.8
1.5
1.41
0.9
6.5
9.71
6.51
0.6
sp
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kcoL
46
85
82
77
17
83
211
011
44
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pmo
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PH
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1/0501/
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5/1
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5/1
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5/1
sp
mA
–rot
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5.1
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AID
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0091
–"02
0091
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B3/
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3/
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3/5701/
3/1
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3/1
3/5701/
3/1
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3/1
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3/1
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69
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Manual 2100-592BPage 8 of 69
* 7
5 de
gree
C C
oppe
r wire
siz
e**
Max
imum
tim
e de
lay
fuse
or H
AC
R T
ype
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uit b
reak
er
TAB
LE 1
AS
PE
CIF
ICA
TIO
NS
W42
G, W
48G
AN
D W
60G
MO
DE
LS
ledo
MA
D2
G24
WB
D2
G24
WC
D2
G24
WA
D2
G84
WB
D2
G84
WC
D2
G84
WA
D2
G06
WB
D2
G06
WC
D2
G06
W
ZH06
–gnit
aRlacirt
cel
E1-
06-
802/
032
3-06-
802/
032
3-06-
064
1-06-
802/
032
3-06-
802/
032
3-06-
064
1-06-
802/
032
3-06-
02/
032
3-06-
064
egnaR
egatl
oV
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352-
791
352-
791
605-
414
352-
791
352-
791
605-
414
352-
791
352-
791
605-
414
yticap
mAtiucri
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M23
32
11
43
52
21
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82
41
*/
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dlei
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68
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802/
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032
802/
032
064
802/
032
802/
032
802/
032
802/
032
064
sp
mA
daoL
det
aR
5.71/
5.51
5.11/
2.01
8.4
4.12/
3.91
5.41/
1.31
4.6
7.42/
6.12
7.41/
8.21
8.7
tnerr
uC
noit
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91
1.31
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mA
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Manual 2100-592BPage 9 of 69
FIG
UR
E 1
UN
IT D
IME
NS
ION
S
F G
N
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D
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FF
GG
HH A
M
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H
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OM
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MIS
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9
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ON
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R
FIL
TE
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ER
VIC
ED
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ITA
BC
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FG
HI
JK
LM
NO
PQ
R
W24G
-W30G
-W36G
7.8
827.8
813.8
824.2
540
25.6
381.6
327.3
827.5
39.2
55.8
8
W42G
-W48G
-W60G
9.8
829.8
815.8
827.2
543.8
131.6
387.5
33.3
828.7
542.8
83.7
5
UN
ITS
TU
VW
XY
ZA
AB
BC
CD
DE
EF
FG
GH
HII
W24G
-W30G
-W36G
12 -
7 H
OLE
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822.9
38
17.8
44.4
411.4
49
36.2
52
0.3
8
W42G
-W48G
-W60G
16 -
6 H
OLE
S3.8
824.9
42
17.3
48.4
412.1
910
40.2
52.7
50.4
41.2
57.2
51.1
33.7
52.2
53.2
5
15.3
14.5
2.5
14.8
830
14.1
215.4
4
Manual 2100-592BPage 10 of 69
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, 3 and 3A 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.
Manual 2100-592BPage 11 of 69
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 W42G, W48G and W60G 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 W24G,W30G and W36G 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 Figures 2 & 2A.
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.
Manual 2100-592BPage 12 of 69
FIG
UR
E 2
MO
UN
TIN
G IN
STR
UC
TIO
NS
FOR
W24
G, W
30G
AN
D W
36G
39 3
/16"
29 3
/4"
4 11
/16"
12"
12"
12"
12"
12"
12"
2"
2 1/
4"
10"
28 5
/16"
15"
27"
17 1
5/16
"
11 5
/16"
8 5/
8"
2 15
/16"
2 1/
4"
30"
29"
5 1/
16"
7/16
"
5 9/
16"
4 9/
16"
4 1/
2"
2 15
/16"
18 1
5/16
"
4 9/
16"
SU
PP
LYA
IR D
UC
T
RE
TU
RN
AIR
DU
CT
Ø2
3/4"
GA
S
OP
EN
ING
(OP
TIO
NA
L)
Ø2
3/4"
HIG
HV
OLT
AG
E(O
PT
ION
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Ø2"
LO
W V
OLT
AG
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PT
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(12)
FLA
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CR
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IT S
UP
PO
RT
1" M
IN.
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CC
ES
SA
RY
NO
CLE
AR
AN
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SU
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IR D
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TU
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AIR
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AN
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UC
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(OU
TS
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)
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IDE
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OM
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IS R
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ED
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SID
E M
OU
NT
ING
FLA
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ES
AN
D U
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ER
TO
P F
LAS
HIN
G A
T T
IME
OF
INS
TA
LLA
TIO
N
RIG
HT
SID
EV
IEW
WIT
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OU
TS
IDE
WA
LL W
ITH
UN
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ED
RA
IN F
LAS
HIN
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UP
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ED
SE
AL
WIT
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EA
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AU
LKIN
G
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EN
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GT
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AIR
SE
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WA
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MIS
-168
1
Manual 2100-592BPage 13 of 69
FIG
UR
E 2
AM
OU
NTI
NG
INS
TRU
CTI
ON
SFO
R W
42G
, W48
G A
ND
W60
G
Manual 2100-592BPage 14 of 69
FIGURE 3COMBUSTIBLE CLEARANCE
FOR W24G, W30G AND W36G MODELS
FIGURE 3ACOMBUSTIBLE CLEARANCE
FOR W42G, W48G AND W60G 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.
Manual 2100-592BPage 15 of 69
FIGURE 4WALL MOUNTING INSTRUCTIONS
FIGURE 5WALL MOUNTING INSTRUCTIONS
Manual 2100-592BPage 16 of 69
FIGURE 6COMMON WALL MOUNTING INSTALLATIONS
Manual 2100-592BPage 17 of 69
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
telnIresnednoC sehcni02
poT 3erugiFeeS
ecivreSrenruB sehcni02
B,AssalCrodooW(esaBelbitsubmoC)lairetamgnirevocfoorCro
sehcni0
* A3dna3serugiFeeS
FIGURE 7LOCATION OF VENT TERMINAL IN SHIPPING
WARNINGClearances from combustible materials mustbe maintained as specified. Failure tomaintain clearances could cause fire resultingin property damage, injury, or death.
Manual 2100-592BPage 18 of 69
10. VENT TERMINAL AND COMBUSTIONAIR INLET HOOD
The vent terminal is shipped in the burner compartment.See Figure 7. Remove the two shipping screws andseparate the two-piece assembly. Install the ventterminal by using the four screws provided. Make suregasket is in place. See Figure 8. The combustion airintake 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.
FIGURE 8VENT TERMINAL AND COMBUSTION AIR INTAKE
CAUTIONVent 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 combustionair blower outlet. This is a very critical seal to prevent water and flue products from entering theunit. Care must be taken to ensure this gasket is in place and sealing properly.
Manual 2100-592BPage 19 of 69
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
Manual 2100-592BPage 20 of 69
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.
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.
WARNINGFailure to provide a proper electrical groundcould result in electric shock or fire.
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 supplyshut off means could result in electric shockor fire.
Manual 2100-592BPage 21 of 69
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
042 602–352
802 781–022
16. WIRING – LOW VOLTAGE WIRINGLow Voltage ConnectionThese units use a 24-volt AC low voltage circuit.The “R” terminal is the hot terminal and the “C”terminal is grounded.“G” terminal is the fan input.“Y1” terminal is the compressor input.“R” terminal is 24 VAC hot.“C” terminal is 24 VAC grounded.“A” terminal is the ventilation input. This terminalenergizes any factory or field installed vent option.“2” terminal is the “L” input back to the thermostat ifCCM is tripped.“3” terminal is the dehumidification input. Thisenergizes compressor, blower and 3-waydehumidification valve.“W1” terminal is the heating input.
230/208 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 single primary voltagetransformers and no rewiring is required.
FIGURE 10INSTALLATION OF FLEXIBLE CONDUIT
Direct Digital Controls (DDC)For total and proper control using DDC, a total of 5controlled outputs are required (4 if no ventilation isinstalled).
LOW VOLTAGE CONNECTIONS FOR DDC CONTROLFan Only Energize GCooling Mode Energize G, Y1Heating Mode Energize W1Ventilation Energize G, ADehumidification Energize 3
Manual 2100-592BPage 22 of 69
17. THERMOSTATS
TABLE 3THERMOSTAT WIRE SIZE
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AV ALF eguaGeriW
mumixaM
ecnatsiD
teeFnI
55 3.2 eguag02eguag81eguag61eguag41eguag21
5406001061052
TABLE 4AWALL THERMOSTAT
tatsomrehT serutaeFtnanimoderP
750-3048
)0401D0113HT(
taeHegats1;looCegats1
otua-no:naFlooc-ffo-taeh
elbammargorP-noNcinortcelE
850-3048
)1511D0225HT(
taeHegats2;looCegats2
elbammargorP-noNcinortcelE
revoegnahclaunaMrootuA
060-3048*
)544-0211(
taeHegats3;looCegats3
cinortcelEelbammargorP-noN/elbammargorP
lanoitnevnoCroPH
revoegnahclaunaMrootuA
TABLE 4BHUMIDISTAT
tatsomrehT serutaeFtnanimoderP
060-3048*
)544-0211(
tatsomrehTelbammargorP
tatsidimuHlargetnIhtiw)evoba(
830-3048
)4101A006H(TDPStatsidimuH
740-3048
)01-12-01002H(
%09ot%01egnar(cinortcelE-tatsidimuheD
)laitnereffid%6.3,spotselbatsujdahtiw
* Integrated thermostat and humidistat in one.
Manual 2100-592BPage 23 of 69
FIGURE 11ATHERMOSTAT CONNECTION USING
8403-060 COMBINATION TEMPERATURE & HUMIDITY CONTROLLER
Y1
1G
and HumidityControl
F
BlockRCTerminal A W2 E Y2 Y1 23
L
W1
Y2
Unit 24V
W1/EC
2
Thermostat Subbase
A
Y
NEEDED FOR ECONOMIZER ONLY
(1120-445)
O/B
Unit Control Panel
Factory Installed Jumper
G
Part #8403-060
R1
W2
CONFIGURE THERMOSTAT FOR HEAT/COOL
2
Thermostat
1
D/YO
3
3
MIS-2786 A
INSTALL ONLY IF APPLIED THERMOSTAT DOES NOT HAVEINDIVIDUAL OUTPUT SIGNAL FOR OCCUPENCY, ORE YOUARE NOT APPLYING A CO2 CONTROL.
Manual 2100-592BPage 24 of 69
FIGURE 11BTHERMOSTAT USING SEPARATE
TEMPERATURE & HUMIDITY CONTROLLERS
Y
MIS-2788
RC W RC Y G
LRC Y2
Electronic Humidistat
(TH311DD1040)
C R
Thermostat
Bard part #8403-047
(TH522OD1151)
Thermostat Subbase
W2
Part #8403-057
O/BGPart #8403-058
Thermostat
MUST INSTALL JUMPER FOR 8407-057, 8403-058 OR OTHER THERMOSTAT THAT DOES NOT
1
INSTALL IF YOU REQUIRE VENTILATION ANYTIME BLOWER IS ON.
HAVE OCCUPANCY OUTPUT.
B O
2
3
SET SWITCH ON THERMOSTAT TO "GAS-OIL"
TO 6 (2 HEAT/ 2 COOL CONVENTIONAL).
4
CHANGE "SYSTEM TYPE", SET UP FUNCTION 1, FROM 5 (2 HEAT/ 1 COOL HEAT PUMP)
5
1
NEEDED FOR ECONOMIZER ONLY
3 2Y1Y2EW2AW1
2
F
Block
Unit Control Panel
Y
4
C R G 1
Mechanical Humidistat
(H200-10-21-10)4356
Yellow
TerminalUnit 24V
(H600A 1014)Bard part #8403-038
Red
W
6
6
3
5
6
6
FACTORY INSTALLED JUMPER
2
Manual 2100-592BPage 25 of 69
FIGURE 11CMOTORIZED FRESH AIR DAMPER, CLASSROOM VENTILATOR SPRING,
CLASSROOM VENTILATOR POWER & ERV LOW VOLTAGE CONNECTIONS
WGSEIFM-5
1GY
Unit Control Panel
Unit 24VTerminal
BlockRC W1 A W2 E Y2 Y1 23
BLACK BLUE
PINKYELLOWPURPLE
ORANGEREDRED
WIRESFROMPLUG
THERMISTOR
F
A W2
VENT PACKAGE
OR
AN
GE
RE
D/W
HIT
E
BLA
CK
/WH
ITE
F
Unit Control Panel
Y
Factory Installed
Jumper
INSTALL JUMPER IF YOU REQUIRE VENTILATION ANYTIME BLOWER IS ON, OR IF
Unit 24V
REMOVE ORANGE WIRE FROM "G" TERMINAL, AND TAPE-OFF.
BlockRC W1
BLU
E
WIRING PLUG
Y1 1Y2 G 2E
CONTROLS DON'T HAVE AN OCCUPENCY OUTPUT. NOTE: YOU WILL NEED TO
Jumper
Factory Installed
Terminal
BR
OW
N/W
HIT
E
3
1
1
2
CONNECT ORANGE WIRE TO "G" TERMINAL IF OCCUPENCY-BASED THERMOSTATOR CO2 CONTROLLER FOR DEMAND VENTILATION CONTROL IS APPLIED.2
MIS-2789 B
FIGURE 11D — ECONOMIZER LOW VOLTAGE CONNECTIONS
Manual 2100-592BPage 26 of 69
FIGURE 12GAS PIPE CONNECTION
W24G - W36GW42G - W60G
Manual 2100-592BPage 27 of 69
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.
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 shut off valve.
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 shut off 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. CHECKING THE GAS PIPING
Before turning gas under pressure into piping, allopenings from which gas can escape should be closed.Immediately after turning on gas, the system should bechecked for leaks. This can be done by watching the 1/2cubic foot test dial and allowing 4 minutes to show anymovement, and by soaping each pipe connection andwatching for bubbles. If a leak is found, make thenecessary repairs immediately and repeat the above test.The furnace must be isolated from the gas supply pipingsystem by closing the manual shut off valve on thecombination gas control valve during pressure testing ofthe gas supply piping system at pressures up to 1/2 PSIG.The furnace and its individual shut off valve must bedisconnected from supply piping and supply pipingcapped during any pressure testing of supply pipingsystem at test pressures in excess of 1/2 PSIG.
Defective pipes or fittings should be replaced and notrepaired. Never use a flame or fire in any form to locategas 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.
FIGURE 13PROPER PIPING PRACTICE
TABLE 5LENGTH OF STANDARDPIPE THREADS (INCHES)
eziSepiP
htgneLevitceffE
daerhTfo
htgneLllarevO
daerhTfo
8/3 2/1 61/9
4/3 61/9--2/1 61/31
1 61/9 1
TABLE 6GAS PIPE SIZES - NATURAL GAS
fohtgneL
teeF-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
MIS-897
THIS PRODUCT MUST BE GAS PIPED BYA LICENSED PLUMBER OR GAS FITTER
IN THE COMMONWEALTH OFMASSACHUSETTS.
Manual 2100-592BPage 28 of 69
19. MANIFOLD PRESSUREADJUSTMENTYou will need a 0 to 15 inch water manometer with 0.1inch resolution and a 1/8" NPT manual shut off 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.
1. Turn off gas at equipment shut off 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 shut off valve in holevacated by plug. Make sure shut off valve is in offposition.
4. Attach manometer to 1/8" NPT manual shut offvalve just installed.
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 distributor.
5. Slowly open equipment shut off valve in gas supplyline just ahead of furnace. Start furnace following“Operating Instructions” on front door.
6. Slowly open 1/8" NPT manual shut off valve leadingto manometer.
7. Read manifold pressure on manometer.
8. Adjust manifold pressure by turning gas controlregulator adjusting screw clockwise to increasepressure or turning counterclockwise to decreasepressure. Manifold pressure must be withinallowable range as follows:• 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 shut offvalve 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.
WARNINGWhen converting from propane (LP) gas tonatural gas, the gas orifice spuds and gasvalve spring must be replaced and the gasvalve regulator pressure must be adjustedcorrectly. Failure to do so can result in fire,injury or death. Refer to Tables 8 and 8A forproper orifice sizing.
Natural gas spring kit, Part number 5603-007,can be purchased through your localdistributor.
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.
Manual 2100-592BPage 29 of 69
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 19, “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.
Manual 2100-592BPage 30 of 69
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
G**W
tupnIdetaR
aeS
leveL 000,1 000,2 000,3 000,4 000,5 000,6 000,7 000,8 000,9 000,01
000,14
000,54
005,04
000,54
402,93
065,34
809,73
021,24
216,63
086,04
046,53
006,93
299,43
088,83
281,43
089,73
696,33
044,73
840,33
027,63
346,23
072,63
670,23
046,53
000,16
000,86
057,06
005,76
608,85
043,56
268,65
081,36
819,45
020,16
064,35
004,95
884,25
023,85
372,15
079,65
445,05
061,65
275,94
080,55
569,84
504,45
411,84
064,35
000,57
000,18
000,57
000,18
006,27
804,87
002,07
618,57
008,76
422,37
000,66
082,17
008,46
489,96
003,36
463,86
004,26
293,76
002,16
690,66
054,06
682,56
004,95
251,46
000,09
000,001
000,09
000,001
021,78
008,69
042,48
006,39
063,18
004,09
002,97
000,88
067,77
004,68
069,57
004,48
088,47
002,38
044,37
006,18
045,27
006,08
082,17
002,97
000,311
000,521
005,211
000,521
009,801
000,121
003,501
000,711
007,101
000,311
000,99
000,011
002,79
000,801
059,49
005,501
006,39
000,401
008,19
000,201
576,09
057,001
001,98
000,99
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 Section19, “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.
Manual 2100-592BPage 31 of 69
All other orifice sizes shown are available as individual items. See Orifice tables below for part numbers and number required.
TABLE 8NATURAL GAS ORIFICE TABLES
FOR MODELS W24G, W30G AND W36G
yrotcaF
dradnatS
tupnI
eulaV*taeHsaG
.tF.uC/UTB
oNteeF000,6otpU
tpecxEsegnahC
tnetnoCUTBrof
teeF000,8ot100,6
hctiwSerusserPseriuqeR
egnahCecifirOdnaegnahC
tnetnoCUTBnodesaB t
teeF000,01ot100,8
hctiwSerusserPseriuqeR
egnahCecifirOdnaegnahC
tnetnoCUTBnodesaB t
UTB00522
renruBreP947-007 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.(tiKhctiwSerusserPedutitlAhgiH981-0268redrO
ezisecifirodellatsniyrotcafdradnatsehtsi)03.2( dellatsnidleifroftinuehthtiwdeppihserasecifiro]02.2[
etared%01lanoitpo
lanoitpO
dleiF%01
detrevnoC
etareD
eulaV*taeHsaG
.tF.uC/UTB
oNteeF000,6otpU
tpecxEsegnahC
tnetnoCUTBrof
teeF000,8ot100,6
hctiwSerusserPseriuqeR
egnahCecifirOdnaegnahC
tnetnoCUTBnodesaB
teeF000,01ot100,8
hctiwSerusserPseriuqeR
egnahCecifirOdnaegnahC
tnetnoCUTBnodesaB
UTB05202
renruBreP947-007 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.(tiKhctiwSerusserPedutitlAhgiH981-0268redrO
dellatsnidleifroftinuehthtiwdeppihserasecifiro]02.2[
.etartupni%01lanoitpo
tupnidetarllufrofezisecifirodellatsniyrotcafehtsi)03.2(
***
.ytivargcificeps06.,detarutas,F06,yrucreMsehcni00.03:snoitidnocdradnatstA
levelaesdnasagtfuc/UTB5201lanimonnodesabsgnitartupnidradnatsdnagnizisecifiroyrotcafsaGlarutaNllA
snoitidnoc
deriuqeRsecifirOfo.oN
gnitaRtupnItinUnodesaB
000,14 )2(
000,54 )2(
000,16 )3(
000,86 )3(
000,57 )3(
000,18 )4(
000,09 )4(
000,001 )4(
000,311 )5(
000,521 )5(
.oNtraPdraB )mm(eziSecifirO retemaiDecifirO
290-0109 01.2 6280.0
880-0109 51.2 6480.0
780-0109 02.2 6680.0
680-0109 52.2 5880.0
280-0109 03.2 5090.0
580-0109 53.2 5290.0
970-0109 04.2 5490.0
480-0109 54.2 4690.0
390-0109 05.2 4890.0
490-0109 06.2 4201.0
590-0109 07.2 3601.0
690-0109 57.2 2801.0
790-0109 08.2 2011.1
890-0109 09.2 2411.0
Manual 2100-592BPage 32 of 69
All other orifice sizes shown are available as individual items. See Orifice tables on Page 31 for part numbers and number required.
TABLE 8ANATURAL GAS ORIFICE TABLES
FOR MODELS W42G, W48G AND W60G
yrotcaF
dradnatS
tupnI
*taeHsaG
eulaV
.tF.uC/UTB
oNteeF000,6otpU
tpecxEsegnahC
tnetnoCUTBrof
teeF000,8ot100,6
hctiwSerusserPseriuqeR
ecifirOdnaegnahC
egnahC
tnetnoCUTBnodesaB t
teeF000,01ot100,8
hctiwSerusserPseriuqeR
ecifirOdnaegnahC
egnahC
tnetnoCUTBnodesaB t
UTB00052
renruBreP947-007 09.2 08.2 07.2
997-057 08.2 07.2 06.2
948-008 07.2 06.2 05.2
998-058 06.2 05.2 54.2
949-009 05.2 54.2 )04.2(
999-059 54.2 )04.2( 53.2
**9401-0001 )04.2( 53.2 ]03.2[
0011-0501 ]03.2[ 52.2 02.2
hctiwSerusserP )55.(dradnatS )24.(tiKhctiwSerusserPedutitlAhgiH981-0268redrO
ezisecifirodellatsniyrotcafdradnatsehtsi)04.2( dellatsnidleifroftinuehthtiwdeppihserasecifiro]03.2[
etared%01lanoitpo
lanoitpO
dleiF%01
detrevnoC
etareD
*taeHsaG
eulaV
.tF.uC/UTB
oNteeF000,6otpU
tpecxEsegnahC
tnetnoCUTBrof
teeF000,8ot100,6
hctiwSerusserPseriuqeR
ecifirOdnaegnahC
egnahC
tnetnoCUTBnodesaB
teeF000,01ot100,8
hctiwSerusserPseriuqeR
ecifirOdnaegnahC
egnahC
tnetnoCUTBnodesaB
UTB00522
renruBreP947-007 57.2 07.2 06.2
997-057 07.2 06.2 05.2
948-008 06.2 05.2
998-058 05.2 54.2 )04.2(
949-009 )04.2( 53.2 ]03.2[
999-059 53.2 ]03.2[ 52.2
**9401-0001 ]03.2[ 52.2 02.2
0011-0501 52.2 52.2 02.2
hctiwSerusserP )55.(dradnatS )24.(tiKhctiwSerusserPedutitlAhgiH981-0268redrO
dleifroftinuehthtiwdeppihserasecifiro]03.2[
.etartupni%01lanoitpodellatsni
tupnidetarllufrofezisecifirodellatsniyrotcafehtsi)04.2(
***
.ytivargcificeps06.,detarutas,F06,yrucreMsehcni00.03:snoitidnocdradnatstAaesdnasagtfuc/UTB5201lanimonnodesabsgnitartupnidradnatsdnagnizisecifiroyrotcafsaGlarutaNllA
snoitidnoclevel
Manual 2100-592BPage 33 of 69
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 RATING
All 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, “CheckingGas Input Rate”. If air temperature rise is stillabove temperature rise range specified, moreheating airflow is needed. Check duct work andgrilles to make sure all are 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, “CheckingGas Input Rate”. If air temperature rise is stillbelow temperature rise range specified, lessheating airflow is needed. Adjust dampers orgrilles 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.
Manual 2100-592BPage 34 of 69
24. FILTERSA 2" thick throwaway filter is supplied with each unit.This filter is installed by opening the filter 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-3237
FILTER
FILTER SERVICEDOOR
Manual 2100-592BPage 35 of 69
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.
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
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.
Manual 2100-592BPage 36 of 69
26. LIGHTING AND SHUTDOWN INSTRUCTIONS
FIGURE 15INSTRUCTION LABEL
Manual 2100-592BPage 37 of 69
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.
MIS-165
FIGURE 16TOP VIEW OF GAS CONTROL
CAUTIONLabel all wires prior to disconnection whenservicing controls. Wiring errors can causeimproper and dangerous operation. Verifyproper operation after servicing.
WARNINGUse replacement parts listed in theReplacement Parts list only. The use ofincorrect parts could cause improper unitoperation, resulting in damage, injury ordeath.
WARNINGFollow these procedures before inspectingfurnace. • 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.
Manual 2100-592BPage 38 of 69
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 shut off 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.
Manual 2100-592BPage 39 of 69
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 Tables 10-15 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 mainburner 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 280 PSIG.
DEHUMIDIFICATION – Dehumidification iscontrolled through a humidistat and is independent ofthe thermostat. On a call for dehumidification mode ofoperation the compressor, blower and three way valveof the unit are energized through circuit R-3 to providedehumidification. Dehumidification will continue untilthe humidistat is satisfied.
If there is a cooling call issued through circuit R-Y, itwill cancel dehumidification sequence (de-energize thereheat valve) until the cooling call is satisfied. If thedehumidification call is still present when cooling callis satisfied, the compressor will continue to operate andthe reheat valve is reenergized.
Any time there is a call for heating mode of operationthrough circuit R-W1 the dehumidification mode willcancel and the system will return to heating operation.Dehumidification is delay 45-60 seconds on start upafter any heating cycle is complete.
Any time the indoor coil temperature falls below 32degrees the compressor will be de-energized until thecoil temperature rises above 57 degrees.
(Refer to Section 33 for dehumidification relay logicboard.)
Manual 2100-592BPage 40 of 69
FIGURE 17SEQUENCE OF OPERATION
ELECTRONIC BLOWER CONTROL
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Manual 2100-592BPage 41 of 69
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:
BLOWER MOTOR SPEED CHANGE
1. Disconnect power supply to unit.
2. Place desired blower motor speed lead wire to“COOL” terminal of integrated furnace controlboard.
3. Place desired blower motor speed lead wire to“HEAT” terminal of integrated furnace controlboard.
4. Place unused blower motor speed lead wire to“UNUSED” terminal of integrated furnace controlboard.
5. Energize the system in cooling and heating modes tocheck for proper blower operation.
If it is desirable to have both HEAT/COOL blowermotor speed at the same speed, install a jumper wirebetween “HEAT” and “COOL” terminals of theintegrated furnace control board, and place both unusedmotor speed lead wires on the two “UNUSED” terminalson the integrated furnace control board. (See Figure 18.)
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FIGURE 18FURNACE CONTROL BOARD AND BLOWER CONTROL
* NOTE: On 460 Volt motors, there are two motor isolation leads. The orange must connect with the black highspeed blower motor lead wire for medium and low speed blower operation. The purple wire mustconnect with the blue medium speed blower motor lead wire for low speed blower operation. This is allautomatically accomplished with blower relays HSBR, MSBR and LSBR, and speed changes are allmade by changes at the integrated furnace control board.
TABLE 9230 VOLT MOTOR SPEED TAPS
460 VOLT MOTOR SPEED TAPS
Manual 2100-592BPage 42 of 69
TABLE 10W24G INDOOR BLOWER PERFORMANCE @ 230 AND 460 VOLTS
Recommended W24G 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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0.0 --- --- 098 0531 0211 --- --- 0211 049
1.0 --- --- 028 0621 0611 --- --- 0611 078
2.0 --- 059 077 0021 0101 --- 0021 0101 ---
3.0 --- 088 007 0211 --- --- 0211 049 ---
4.0 --- 097 --- 0301 --- --- 0301 068 ---
5.0 019 017 --- --- --- --- 059 --- ---
6.0 008 --- --- --- --- --- 048 --- ---
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0.0 --- --- 098 0531 0211 049 --- 0211 049
1.0 --- --- 028 0621 0611 078 --- 0611 078
2.0 --- 059 077 0021 0101 --- --- 0101 018
3.0 --- 088 007 0211 019 --- 0211 049 ---
4.0 --- 097 --- 0301 --- --- 0301 068 ---
5.0 019 017 --- 059 --- --- 059 087 ---
6.0 008 --- --- --- --- --- 048 --- ---
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0.0 --- --- 098 --- 0211 049 --- 0211 049
1.0 --- --- 028 0621 0611 078 --- 0611 078
2.0 --- 059 077 0021 0101 018 0021 0101 018
3.0 --- 088 007 0211 049 --- 0211 049 057
4.0 --- 097 --- 0301 068 --- 0301 068 086
5.0 019 017 --- 059 087 --- 059 087 ---
6.0 008 --- --- 048 --- --- 048 --- ---
Manual 2100-592BPage 43 of 69
TABLE 11W30G INDOOR BLOWER PERFORMANCE @ 230 AND 460 VOLTS
Recommended W30G cooling airflow range at rated 1000 CFM @ 0.35 ESP (WC) is 820 - 1150 CFMFactory set on Medium Speed for cooling and 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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0.0 --- --- 0601 0651 0531 0211 0651 0531 0211
1.0 --- --- 0001 0741 0621 0601 0741 0621 0601
2.0 --- 0611 059 0731 0021 0101 0731 0021 0101
3.0 --- 0801 088 0921 0211 049 0921 0211 049
4.0 0511 099 --- 0911 0301 068 0911 0301 068
5.0 0501 019 --- 0901 059 087 0901 059 087
6.0 049 --- --- 089 048 066 089 048 066
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0.0 --- --- 0601 0651 0531 0211 0651 0531 0211
1.0 --- --- 0001 0741 0621 0601 0741 0621 0601
2.0 --- 0611 059 0731 0021 0101 0731 0021 0101
3.0 --- 0801 088 0921 0211 049 0921 0211 049
4.0 0511 099 --- 0911 0301 068 0911 0301 068
5.0 0501 019 --- 0901 059 087 0901 059 087
6.0 049 --- --- 089 048 066 089 048 066
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0.0 --- --- 0601 0651 0531 0211 0651 0531 0211
1.0 --- --- 0001 0741 0621 0601 0741 0621 0601
2.0 --- 0611 059 0731 0021 0101 0731 0021 0101
3.0 --- 0801 088 0921 0211 049 0921 0211 049
4.0 0511 099 --- 0911 0301 068 0911 0301 068
5.0 0501 019 --- 0901 059 087 0901 059 087
6.0 049 --- --- 089 048 066 089 048 066
Manual 2100-592BPage 44 of 69
TABLE 12W36G INDOOR BLOWER PERFORMANCE @ 230 AND 460 VOLTS
Recommended W36G cooling airflow range at rated 1100 CFM @ 0.250 ESP (WC) is 935 - 1265 CFMFactory set on Medium Speed for cooling and 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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0.0 --- --- 0601 --- 0531 0211 --- 0531 0211
1.0 --- 0221 0001 --- 0621 0601 --- 0621 0601
2.0 --- 0611 059 0731 0021 0101 --- 0021 0101
3.0 0521 0801 --- 0921 0211 049 --- 0211 049
4.0 0511 099 --- 0911 0301 --- 0911 0301 068
5.0 0501 --- --- 0901 059 --- 0901 059 ---
6.0 049 --- --- 089 --- --- 089 048 ---
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0.0 --- --- 0601 --- 0531 0211 --- --- 0211
1.0 --- 0221 0001 --- 0621 0601 --- --- 0601
2.0 --- 0611 059 --- 0021 0101 --- --- 0101
3.0 0521 0801 --- --- 0211 049 --- 0211 049
4.0 0511 099 --- 0911 0301 068 --- 0301 068
5.0 0501 --- --- 0901 059 087 0901 059 087
6.0 049 --- --- 089 048 --- 089 048 066
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0.0 --- --- 0601 --- 0531 0211 --- --- 0211
1.0 --- 0221 0001 --- 0621 0601 --- --- 0601
2.0 --- 0611 059 --- 0021 0101 --- 0021 0101
3.0 0521 0801 --- 0921 0211 049 --- 0211 049
4.0 0511 099 --- 0911 0301 068 --- 0301 068
5.0 0501 --- --- 0901 059 087 0901 059 087
6.0 049 --- --- 089 048 066 089 048 066
Manual 2100-592BPage 45 of 69
TABLE 13W42G INDOOR BLOWER PERFORMANCE @ 230 AND 460 VOLTS
Recommended W42G 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
02. --- 0141 0301 0881 0151 --- --- 0151 0901
03. --- 0631 --- 0671 0641 --- --- 0641 ---
04. --- 0521 --- 0761 0431 --- 0761 0431 ---
05. 0641 0511 --- 0651 0421 --- 0651 0421 ---
06. 0431 0401 --- 0341 0311 --- 0341 0311 ---
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01. --- 0351 0411 --- 0361 0321 --- 0361 0321
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
06. 0931 0901 --- 0841 0811 --- 0841 0811 ---
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00. --- --- 0421 --- 0471 0331 --- 0471 0331
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 ---
Manual 2100-592BPage 46 of 69
TABLE 14W48G INDOOR BLOWER PERFORMANCE @ 230 AND 460 VOLTS
Recommended W48G 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.
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 --- --- 0851 0811 --- 0851 0811
02. 0871 0141 --- 0881 0151 --- --- 0151 0111
03. 0761 0631 --- 0671 0641 --- --- 0641 0901
04. 0751 0521 --- 0761 0431 --- 0761 0431 ---
05. 0641 --- --- 0651 0421 --- 0651 0421 ---
06. 0431 --- --- 0341 --- --- 0341 0311 ---
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00. --- 0951 --- --- 0961 0821 --- 0961 0821
01. --- 0351 --- --- 0361 0321 --- 0361 0321
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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01. --- 0851 --- --- 0861 0821 --- 0861 0821
02. --- 0151 --- --- 0161 0121 --- 0161 0121
03. 0571 0641 --- 0681 0651 0911 --- 0651 0911
04. 0761 0431 --- 0771 0441 0701 --- 0441 0701
05. 0651 0621 --- 0661 0431 079 0661 0431 079
06. 0441 --- --- 0351 0321 --- 0351 0321 ---
Manual 2100-592BPage 47 of 69
TABLE 15W60G INDOOR BLOWER PERFORMANCE @ 230 AND 460 VOLTS
Recommended W60G 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.
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. 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 ---
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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 ---
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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 ---
Manual 2100-592BPage 48 of 69
TABLE 16INTEGRATED FURNACE AND BLOWER CONTROL OPERATION
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Manual 2100-592BPage 49 of 69
33. W**G DEHUMIDIFICATION RELAY LOGIC BOARD
DEHUMIDIFICATION RELAY LOGIC BOARD
1 Cooling takes precedence over dehumidification. A cooling call cancels dehumidification.2 First stage heating cancels dehumidification.3 If jumper on RLB is set to “1-2 full-time dehumidification”, outputs will energize. This is the factory default setting. If jumper is set
to “2-3 occupied dehumidification only”, outputs will be off.
lanimreTV42
snoitcennoCkcolB G Y 3 1W
morFstuptuO
draoB
draoBotstupnI G Y D 2W 1G VWT OY
edoMgnilooC deipucconU X X X X
edoMgnilooC deipuccO X X X X
edoMgnilooC 1 muheDhtiw X X X X X
gnitaeHegatSts1 deipucconU X X
gnitaeHegatSts1 deipuccO X X
gnitaeHegatSts1 2 muheDhtiw X X X
gnitaeHegatSdn2 deipucconU X X
gnitaeHegatSdn2 deipuccO X X
gnitaeHegatSdn2 muheDhtiw X X X
noitacifidimuheD deipucconU X 3 3 3
noitacifidimuheD deipuccO X X X X
Manual 2100-592BPage 50 of 69
FIGURE 19CIRCUIT DIAGRAMS
34. PRESSURE SERVICE PORTSHigh and low pressure service ports are installed on all unitsso that the system operating pressures can be observed.
35. DEHUMIDIFICATION CIRCUITThe dehumidification circuit incorporates an independentheat exchanger coil in the supply air stream. This coilreheats the supply air after it passes over the cooling coilwithout requiring the gas burner to be used for reheatpurposes. This results in very high mechanicaldehumidification capability from the air conditioner ondemand without using gas reheat.
The dehumidification refrigerant reheat circuit is controlledby a three way valve directing the refrigerant gas to thenormal condenser during periods when standard airconditioning is required. During periods of time of lowambient temperature (approximately 65° to 75° outdoor) &high indoor humidity, a humidistat senses the need formechanical dehumidification. It then energizes both the
compressor circuit and the three way valve, thus directingthe hot refrigerant discharge gas into a separatedesuperheating condenser circuit, which reheats theconditioned air before it is delivered to the room. Therefrigerant gas is then routed from the desuperheatingcondenser to the system condenser for further heattransfer. A small orifice inserted between the reheat coilreturn line and suction line will prevent liquid fromaccumulating in the reheat coil when it is inactive. Thisdrain does not affect the normal operation of the system.A check valve is located in the reheat oil return line. Ithas a soft spring to hold the ball on the seat. This willmake the method of checking the ball freedom with amagnet difficult. Refer to Figure 19 for the location of thecheck valve and drain back capillary. When thehumidistat is satisfied, the system automatically switchesback to normal air conditioning mode and either continuesto operate or turns off based on the signal from the wallthermostat. The result is separate humidity control atminimum operating cost.
AIR CONDITIONING MODECIRCUIT DIAGRAM
DEHUMIDIFICATION MODECIRCUIT DIAGRAM
Manual 2100-592BPage 51 of 69
36. REFRIGERANT CHARGEThe correct system R-410A charge is shown on the unitrating plate.
You can reference Table 17 to validate proper systemoperation (+2 psig suction, +5 psig discharge). However,it is recommended that if incorrect charge is suspected, thesystem refrigerant be reclaimed, evacuated and charged tothe nameplate charge quantity and type.
TABLE 17REFRIGERANT CHARGE – PRESSURE TABLES
The nameplate charge quantity is optimized for thermalperformance and efficiency of this self-contained packagesystem.
The system operating pressures in Table 17 are basedupon rated airflow across the evaporator during coolingcycle.
Total system charge for these models can be found inTable 1.
ledoM
riAnruteR
erutarepmeT erusserP °06 °56 °07 °57 °08 °58 °09 °59 °001 °501 °011 °511 °021 °521
2G42W
BD.ged57
BW.ged26
ediSwoL
ediShgiH
501
722
801
052
111
372
511
692
811
913
121
243
421
463
721
783
921
514
131
244
431
964
631
794
831
425
041
255
BD.ged08
BW.ged76
ediSwoL
ediShgiH
021
532
321
852
621
282
921
503
131
923
431
253
731
673
041
993
241
724
541
654
741
484
941
215
251
045
551
965
BD.ged58
BW.ged27
ediSwoL
ediShgiH
331
542
631
862
931
292
141
613
441
043
741
363
051
783
351
114
651
044
851
964
161
894
461
725
661
655
961
585
2G03W
BD.ged57
BW.ged26
ediSwoL
ediShgiH
011
832
311
262
611
782
911
113
221
533
521
953
821
383
131
704
331
534
431
364
631
194
831
915
931
745
141
575
BD.ged08
BW.ged76
ediSwoL
ediShgiH
621
642
921
172
131
692
431
123
731
543
931
073
241
593
541
024
641
944
841
774
051
605
251
535
451
465
651
295
BD.ged58
BW.ged27
ediSwoL
ediShgiH
931
752
241
282
541
703
741
233
051
753
351
283
551
704
851
234
061
164
261
194
461
125
661
055
861
085
071
906
2G63W
BD.ged57
BW.ged26
ediSwoL
ediShgiH
211
652
511
082
711
403
021
823
321
253
521
773
821
104
131
524
231
254
331
084
531
805
631
635
831
365
931
195
BD.ged08
BW.ged76
ediSwoL
ediShgiH
821
562
031
092
231
413
531
933
731
463
931
883
241
314
441
834
641
664
741
594
941
425
051
255
251
185
351
016
BD.ged58
BW.ged27
ediSwoL
ediShgiH
141
672
441
103
641
623
841
153
051
673
351
004
551
524
751
054
951
084
161
905
261
935
461
865
661
795
861
726
2G24W
BD.ged57
BW.ged26
ediSwoL
ediShgiH
701
132
901
452
211
772
511
992
811
223
121
543
321
863
621
193
821
714
031
444
231
074
331
794
531
325
731
055
BD.ged08
BW.ged76
ediSwoL
ediShgiH
221
932
421
262
721
682
921
903
231
333
431
653
731
083
931
304
141
034
341
854
541
584
741
215
941
935
151
765
BD.ged58
BW.ged27
ediSwoL
ediShgiH
431
942
731
272
931
692
241
023
441
343
741
763
941
193
251
514
451
344
651
174
951
994
161
725
361
555
561
385
2G84W
BD.ged57
BW.ged26
ediSwoL
ediShgiH
401
142
701
462
011
782
311
113
611
433
911
853
221
183
521
404
621
334
821
264
031
094
231
915
331
845
531
675
BD.ged08
BW.ged76
ediSwoL
ediShgiH
811
942
121
372
421
792
621
123
921
543
231
963
531
393
731
714
931
644
141
674
341
505
541
535
741
565
941
495
BD.ged58
BW.ged27
ediSwoL
ediShgiH
131
952
331
382
631
803
931
233
241
653
441
183
741
404
051
924
251
954
451
984
651
025
951
055
161
185
361
116
2G06W
BD.ged57
BW.ged26
ediSwoL
ediShgiH
801
142
111
762
411
292
611
813
911
343
221
963
521
493
721
024
921
744
031
574
231
305
331
135
531
955
731
785
BD.ged08
BW.ged76
ediSwoL
ediShgiH
321
942
621
572
821
203
131
823
331
453
631
083
831
604
041
334
241
164
441
094
541
915
741
845
941
675
151
506
BD.ged58
BW.ged27
ediSwoL
ediShgiH
631
062
931
682
141
313
441
933
641
663
941
293
151
814
451
544
551
474
751
405
951
435
161
365
361
395
461
226
Low side pressure ± 2 PSIGHigh side pressure ± 5 PSIG
Tables based upon rated CFM (airflow) across the evaporator coil.If there is any doubt as to correct operating charge being in the system, the charge should be reclaimed, systemevacuated and recharged to serial plate instruction.
Manual 2100-592BPage 52 of 69
37. FAN BLADE SETTING DIMENSIONSShown in Figure 20 is the correct fan blade settingdimension for proper air delivery across the outdoor coil.
38. 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 21for 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 21LOW NOx INSERT
"A"
AIRFLOW
MIS-1724
TABLE 18FAN BLADE DIMENSION
ledoM
noisnemiD
A
G42W 52.1
G03W 52.1
G63W 52.1
G24W 57.1
G84W 57.1
G06W 57.1
FIGURE 20FAN BLADE
Manual 2100-592BPage 53 of 69
INDEXWIRING DIAGRAMS
and LADDER DIAGRAMS
tinU.oNledoM
cisaBmargaiDgniriW
launaM.oNegaP
cisaBmargaiDreddaL
launaM.oNegaP
AD2G42W A561-5804 45 661-5804 55
BD2G42W A362-5804 65 462-5804 75
CD2G42W A683-5804 85 783-5804 95
AD2G03W A761-5804 06 861-5804 16
BD2G03W A562-5804 26 662-5804 36
CD2G03W A883-5804 46 983-5804 56
AD2G63W A761-5804 06 861-5804 16
BD2G63W A562-5804 26 662-5804 36
CD2G63W A883-5804 46 983-5804 56
AD2G24W A761-5804 06 861-5804 16
BD2G24W A562-5804 26 662-5804 36
CD2G24W A883-5804 46 983-5804 56
AD2G84W A961-5804 66 071-5804 55
BD2G84W A762-5804 76 862-5804 75
CD2G84W A093-5804 86 193-5804 96
AD2G06W A961-5804 66 071-5804 55
BD2G06W A762-5804 76 862-5804 75
CD2G06W A093-5804 86 193-5804 96
Manual 2100-592BPage 54 of 69
W24G2DA 230/208-60-1
LPC
CC
HP
C
Y
ALR C
LPC
MIN
UT
ES
4
235
R
1
C
MODULE
HE
RM
FAN
HIGH
Compressor
CONTROL
SWITCH
MOTOR
COMPRESSOR
PRESSURE
23
REPLACED, IT MUST BE REPLACED WITH WIRING MATERIAL HAVING A TEMPERATURE RATING OF AT LEAST 105° C EXCEPT THE IGNITION CABLE
WHICH IS 250°C HIGH VOLTAGE CABLE
OUTDOOR FAN
INTEGRATED FURNACE CONTROL 13
VOLTAGESTRIP 11
LOW
CIRCUITBREAKER
CAPACITOR
21
LOWPRESSURE
SWITCH
IF ANY ORIGINAL WIRE AS SUPPLIED WITH THE APPLIANCE MUST BE
16
WIRES CONNECTIF OPTION NOT USED
35
VALVETHREE WAY
GAS VALVE
32 32
37
35
32
32
32
32
59
PRIMARY
ROLLOUT
SPARK IGNITOR
LIMIT
32
FLAME
FLAME SENSOR
36
PRESSURE SWITCH
SR
35
Bard Mfg. Co.
C
Bryan, Ohio
Low Voltage
High Voltage
OptionalFieldFactory
32
LOW AMBIENTCONTROL (OPT.)
44
A
34
20
18
32
32
32
BLOWER SPEED COLOR CODE
HIGH BLACK
MEDIUM BLUE
LOW RED
4085-165 A
BLA
CK
SPEED 150
135
120
BLACK
BLA
CK
FUSE
BLA
CK
/WH
ITE
BLA
CK
/WH
ITE
BLA
CK
/WH
ITE
BLA
CK
BLACK
P3
BROWN
GRAY
BR
OW
N
BLA
CK
/WH
ITE
BLACK
(OPT.)
208/230-60-1
USE COPPER CONDUCTORSSUITABLE FOR AT LEAST 75° C
TERM. BLOCK
BLA
CK
PINK
BLU
E
BLUE
BLUE
1 2 3
4 5 6
8 97
1210 11
BLU
E
BLU
E
L1
L2
A
BLU
E
A
PURPLE
PURPLE
MV
NOC
MV
OR
AN
GE
YELLOW
YELLOW
YE
LLO
W
YELLOW
YELLOW
YE
LLO
W/R
ED
YE
LLOW
YELLOW
Brown
Brown
BROWN/WHITE
35
RED
RE
D
RED/WHITE
RED
RE
D/W
HIT
E
for Bard use only.Wire Identification numbers
RE
D
99
RED
RED/WHITE
32
RED
32
40BLACK
RED40
GROUND TERMINAL
R
C
240V
208V
COM
DRAFT BLOWER
2PL
11
BR
RE
D
INDUCED
Fan MotorIndoor
Capacitor
Evaporator SectionIndoor Fan
CONTACTOR
RED
TRANSFORMER
COMPRESSOR15
RE
D
OPERATION208V TAP FOR 208V
MOVE RED WIRE TO
L1 L2
T1 T2
69
YELLOW
PINK
63
BLACK
LOCKOUT61
CONTROLDEHUM
BR
OW
N
PINK
67
BLACK
65
YE
LLO
W
ORANGE
RELAY
32
PURPLE/WHITE
BLACK/
65
YE
LLO
W
6666 62
BLACK/WHITE
63
RE
D/W
HIT
E
WHITE
ORANGE
PURPLE/WHITE
68
BLA
CK
/WH
ITE
66
37
BLA
CK
32
BLA
CK
Thermostat
Black
32
Black
Freeze
32
64 71
BLACK39
38
42
43RED
38
39
Model C. Breaker Capacitor
W24G2DA 30A 40+5/370
Manual 2100-592BPage 55 of 69
W24G2DA, W48G2DA, W60G2DA 230/208-60-1
Manual 2100-592BPage 56 of 69
W24G2DB 230/208-60-3
LPC
CC
HP
C
Y
ALR C
LPC
MIN
UT
ES
4
235
R
1
IF OPTION WIRES CONNECT
NOT USED
A
PRESSURE
HIGH PRESSURE
SWITCH
LOW
SWITCH
GROUND TERMINAL 15
CAPACITOR
MOTOR
MODULE
23
REPLACED, IT MUST BE REPLACED WITH WIRING MATERIAL HAVING A TEMPERATURE RATING OF AT LEAST 105° C EXCEPT THE IGNITION CABLE
WHICH IS 250°C HIGH VOLTAGE CABLE
OUTDOOR FAN
INTEGRATED FURNACE CONTROL 13 LOW VOLTAGE STRIP 11
CIRCUITBREAKER
21
IF ANY ORIGINAL WIRE AS SUPPLIED WITH THE APPLIANCE MUST BE
16 COMPRESSORCONTROL
Compressor
35
VALVETHREE WAY
GAS VALVE
32 27
37
35
32
32
32
32
59
PRIMARY
ROLLOUT
SPARK IGNITOR
LIMIT
32
FLAME
FLAME SENSOR
36
PRESSURE SWITCH
T3T1
T2
Bard Mfg. Co.
35
Bryan, Ohio
Low Voltage
High Voltage
OptionalField
32
Factory
44
LOW AMBIENTCONTROL (OPT.)
34
20
18
32
32
32
35
BLOWER SPEED COLOR CODE
HIGH BLACK
MEDIUM BLUE
LOW RED
4085-263 A
BLA
CK
SPEED 150
135
120
BLACK
BLA
CK
FUSE
BLACK
BLACK
BLACK/WHITE
BLA
CK
BLACK
P3
BROWN
GRAY
BR
OW
N
BLA
CK
/WH
ITE
BLACK
(OPT.)
208/230-60-3
BLA
CK
BLA
CK
/WH
ITE
BLA
CK
/WH
ITE
USE COPPER CONDUCTORSSUITABLE FOR AT LEAST 75° C
TERM. BLOCK
BLA
CK
/WH
ITE
PINK
L1
BLUE
BLUE
1 2 3
4 5 6
8 97
1210 11
BLU
E
BLU
E
L3
L2
A
BLU
E
A
BLU
E
PURPLE
PURPLE
MV
NOC
MV
32
OR
AN
GE
YELLOW
YELLOW
YE
LLO
W
YELLOW
YELLOW/BLACK
YELLOW/RED
YE
LLOW
YELLOW
YE
LLO
W
YELLOW
YELLOW/BLACK
YELLOW
Brown
Brown
BROWN/WHITE
37
RED
RE
D
RED/WHITE
RED
RE
D/W
HIT
E
for Bard use only.Wire Identification numbers
99
RED
RED/WHITE
32
RED
32
40BLACK
RED
R
C
240V
208V
COM
DRAFT BLOWER
2PL
11
BR
RE
D
INDUCED
Fan MotorIndoor
Capacitor
Evaporator SectionIndoor Fan
CONTACTOR
TRANSFORMER
COMPRESSOR
RE
D
L1 L2
T1 T2
L3
T3
40
PHASE MONITOR
OPERATION208V TAP FOR 208V
MOVE RED WIRE TO
25
RED
28
RED29
3031
41
42
43RE
D
38
39
32
27
38 39
RE
D
69
BLA
CK
/WH
ITE
PURPLE/WHITE
66
ORANGE
RE
D/W
HIT
E
68
BLACK/WHITE
63
626666
YE
LLO
W
PURPLE/WHITE
WHITE
65
ORANGE
BLACK/
32
YE
LLO
W
BLACK
PINK
65
BR
OW
N
67
CONTROLDEHUM
BLACKPINK
YELLOW
61RELAY
LOCKOUT
BLA
CK
63
BLA
CK
64
Thermostat
Black
32
Black
Freeze
71
Model C. Breaker Fan Capacitor
W24G2DB 25A 5/370
Manual 2100-592BPage 57 of 69
W24G2DB, W48G2DB, W60G2DB 230/208-60-3
Manual 2100-592BPage 58 of 69
W24G2DC 460-60-3
LPC
CC
HP
C
Y
ALR C
LPC
MIN
UT
ES
4
235
R
1
MODULE
HIGH
Compressor
CONTROL
SWITCH
MOTOR
COMPRESSOR
PRESSURE
23
REPLACED, IT MUST BE REPLACED WITH WIRING MATERIAL HAVING A TEMPERATURE RATING OF AT LEAST 105° C EXCEPT THE IGNITION CABLE
WHICH IS 250°C HIGH VOLTAGE CABLE
OUTDOOR FAN
INTEGRATED FURNACE CONTROL 13
STRIP 11
LOW VOLTAGE
DISCONNECT
CAPACITOR
21
LOWPRESSURE
SWITCH
IF ANY ORIGINAL WIRE AS SUPPLIED WITH THE APPLIANCE MUST BE
16
WIRES CONNECTIF OPTION NOT USED
L1
OR
AN
GE
32
54
GAS VALVE
32 27
37
35
32
32
32
32
59
PRIMARY
ROLLOUT
SPARK IGNITOR
LIMIT
FLAME
FLAME SENSOR
56
THREE WAYVALVE
36
PRESSURE SWITCH
T3T1
T2
Bard Mfg. Co.
Bryan, Ohio
4085-386 ALow Voltage
High Voltage
OptionalFieldFactory
32
LOW AMBIENTCONTROL (OPT.)
44
A
34
20
18
32
32
32
35
37
2
3
35
1
2
31
2
35
3
4
48
1
57
57
48
57
48
49
45
45
47
57
45
46
25
RE
D
BLOWER SPEED COLOR CODE
HIGH BLACK
MEDIUM BLUE
LOW RED
AUX PURPLE/ORANGE
DEHUM
SPEED 150
135
120
BLACK
WHITE
FUSE
BLACK
CONTROL
BLACK/
BLA
CK
BLACK
P3
BROWN
GRAY
BR
OW
N
BLA
CK
/WH
ITE
BLACK
(OPT.)
460-60-3
BLA
CK
/WH
ITE
BLA
CK
/WH
ITE
BLA
CK
/WH
ITE
BLACK
BLACK/WHITE
BLACK
BLA
CK
BLA
CK
/WH
ITE
BLA
CK
BlackBlack
BLA
CK
BLA
CK
BLACK/WHITE
TERM. BLOCK
USE COPPER CONDUCTORSSUITABLE FOR AT LEAST 75° C
LOCKOUT RELAY
PINK
PINK
PINK PINK
BLUE
BLUE
1 2 3
4 5 6
8 97
1210 11
BLU
E
L2
BLU
E
L3
A
A
BLU
E
BLA
CK
YE
LLOW
PU
RP
LE
BLU
E
PURPLE/WHITE
PURPLE
PURPLE
PURPLE
PURPLE/WHITE
MV
NOC
MV
ORANGE
ORANGE
YE
LLO
W
YELLOW
YE
LLO
WY
ELL
OW
YELLOW/BLACK
YELLOW/RED
YELLOW
YELLOW
YE
LLO
WYELLOW
YELLOW/BLACK
YELLOW
YELLOW
YE
LLO
W
65
YELLOW
BR
OW
N
Brown
Brown
BROWN/WHITE
BROWN/WHITE
1RED
RE
D
RED/WHITE
RED
RE
D/W
HIT
E
66
for Bard use only.Wire Identification numbers
99
RED32
RED/WHITE
64
RED
32
40BLACK
RED
R
C
460V
COM
2PL
1DRAFT BLOWER
BR
INDUCED
MotorFan
Capacitor
Evaporator SectionIndoor Fan
CONTACTOR
40
TRANSFORMER
COMPRESSOR
Indoor
35
GROUND TERMINAL
L1 L2
T1 T2
L3
T3
PHASE MONITOR
15
RED
28
RED29
3031
41
42
43
RE
D
38
39
32
2
31
5
46
RED
27
RE
D
BLOWER RELAYMED. SPEED
RELAY BLOWER
BLOWER RELAYINDUCED DRAFT
LOW SPEED
RELAYBLOWERSPEED HIGH
28
54 55
58
53
ThermostatFreeze
5032
WH
ITE
68
RE
D/W
HIT
E
RE
D/
63
6266 66
69
32
32
65
67
61
63
52
71
Model Fan Capacitor
W30G2DC 5/370
W36G2DC 5/370
W42G2DC 15/370
Manual 2100-592BPage 59 of 69
W24G2DC 460-60-3
Manual 2100-592BPage 60 of 69
W30G2DA, W36G2DA, W42G2DA 230/208-60-1
LPC
CC
HP
C
Y
ALR C
LPC
MIN
UT
ES
4
235
R
1
IF OPTION WIRES CONNECT
NOT USED
A
B
WIRE NOT APPLICABLE TO ALL MODELS
BLACK39
38
42
43RED
38
39
(OPT.)
SPEED 150
135
120
BLA
CK
BLA
CK
/WH
ITE
FUSE
TERM. BLOCK
BLA
CK
BLA
CK
BLACK
P3
BROWN
GRAY
BR
OW
N
BLA
CK
/WH
ITE
BLACK
208/230-60-1
BLA
CK
BLACK
BLA
CK
/WH
ITE
BLA
CK
/WH
ITE
USE COPPER CONDUCTORSSUITABLE FOR AT LEAST 75° C
B
PINK
BLU
E
BLUE
BLUE
1 2 3
4 5 6
8 97
1210 11
BLU
E
BLU
E
L1
L2
A
BLU
E
A
PURPLE
PURPLE
MV
NOC
MV
OR
AN
GE
YELLOW
YELLOW
YE
LLO
W
YELLOW
YELLOW
YE
LLO
W/R
ED
YE
LLOW
YELLOW
Brown
Brown
BROWN/WHITE
RED
RE
D
RE
D
RED/WHITE
RED
RE
D/W
HIT
E
69
for Bard use only.Wire Identification numbers
99
RED
RED/WHITE
32
RED
32
40BLACK
RED40
GROUND TERMINAL
R
C
240V
208V
COM
DRAFT BLOWER
2PL
11
BR
RE
D
INDUCED
Fan MotorIndoor
Capacitor
Evaporator SectionIndoor Fan
CONTACTOR
RED
TRANSFORMER
COMPRESSOR15
RE
D
OPERATION208V TAP FOR 208V
MOVE RED WIRE TO
L1 L2
T1 T2
RE
D
35
RELAY
YELLOW
PINK
63
BLACK
LOCKOUT61
CONTROLDEHUM
BR
OW
N
PINK
67
BLACK
65
YE
LLO
W
ORANGE
WHITE
32
PURPLE/WHITE
BLACK/
65
YE
LLO
W
6666 62
BLACK/WHITE
63
RE
D/W
HIT
E
ORANGE
PURPLE/WHITE
68
BLA
CK
/WH
ITE
66
37
BLA
CK
32
BLA
CK
Thermostat
Black
32
Black
Freeze
32
64
52
71
FAN
C
MODULE
HIGH
SWITCH
MOTOR
HE
RM
PRESSURE
23
REPLACED, IT MUST BE REPLACED WITH WIRING MATERIAL HAVING A TEMPERATURE RATING OF AT LEAST 105° C EXCEPT THE IGNITION CABLE
WHICH IS 250°C HIGH VOLTAGE CABLE
OUTDOOR FAN
INTEGRATED FURNACE CONTROL 13
VOLTAGESTRIP 11
LOW
CIRCUITBREAKER
CAPACITOR
21
LOWPRESSURE
SWITCH
IF ANY ORIGINAL WIRE AS SUPPLIED WITH THE APPLIANCE MUST BE
16 COMPRESSORCONTROL
Compressor
35
VALVETHREE WAY
GAS VALVE
32 32
37
35
32
32
32
32
59
PRIMARY
ROLLOUT
SPARK IGNITOR
LIMIT
32
FLAME
FLAME SENSOR
36
PRESSURE SWITCH
SR
35
C
Bard Mfg. Co.
Bryan, Ohio
Low Voltage
High Voltage
OptionalField
32
Factory
44
LOW AMBIENTCONTROL (OPT.)
34
20
18
32
32
32
BLOWER SPEED COLOR CODE
HIGH BLACK
MEDIUM BLUE
LOW RED
4085-167 A
Model C. Breaker Capacitor
W30G2DA 30A 45+5/370
W36G2DA 35A 45+5/370
W42G2DA 50A 45+10/370
Manual 2100-592BPage 61 of 69
W30G2DA, W36G2DA, W42G2DA 230/208-60-1
Manual 2100-592BPage 62 of 69
W30G2DB, W36G2DB, W42G2DB 230/208-60-3
LPC
CC
HP
C
Y
ALR C
LPC
MIN
UT
ES
4
235
R
1
IF OPTION WIRES CONNECT
NOT USED
A
GROUND TERMINAL 15
SWITCH
HIGH
SWITCH
MOTOR
MODULE
PRESSURE
23
REPLACED, IT MUST BE REPLACED WITH WIRING MATERIAL HAVING A TEMPERATURE RATING OF AT LEAST 105° C EXCEPT THE IGNITION CABLE
WHICH IS 250°C HIGH VOLTAGE CABLE
OUTDOOR FAN
INTEGRATED FURNACE CONTROL 13 LOW VOLTAGE STRIP 11
CIRCUITBREAKER
CAPACITOR
21
LOWPRESSURE
IF ANY ORIGINAL WIRE AS SUPPLIED WITH THE APPLIANCE MUST BE
16 COMPRESSORCONTROL
Compressor
35
B
TO ALL MODELSWIRE NOT APPLICABLE
VALVE
B
GAS VALVE
32 27
37
35
32
32
32
32
59
PRIMARY
ROLLOUT
SPARK IGNITOR
LIMIT
32
FLAME
FLAME SENSOR
36
PRESSURE SWITCH
T3T1
T2
35
Bard Mfg. Co.
Bryan, Ohio
Low Voltage
High Voltage
OptionalField
32
Factory
44
LOW AMBIENTCONTROL (OPT.)
34
20
18
32
32
32
35
THREE WAY
BLOWER SPEED COLOR CODE
HIGH BLACK
MEDIUM BLUE
LOW RED
4085-265 A
BLA
CK
SPEED 150
135
120
BLACK
BLA
CK
FUSE
BLACK
BLACK
BLACK/WHITE
BLA
CK
BLACK
P3
BROWN
GRAY
BR
OW
N
BLA
CK
/WH
ITE
BLACK
(OPT.)
208/230-60-3
BLA
CK
BLA
CK
/WH
ITE
BLA
CK
/WH
ITE
USE COPPER CONDUCTORSSUITABLE FOR AT LEAST 75° C
TERM. BLOCK
BLA
CK
/WH
ITE
PINK
L1
BLUE
BLUE
1 2 3
4 5 6
8 97
1210 11
BLU
E
BLU
E
L3
L2
A
BLU
E
A
BLU
E
PURPLE
PURPLE
MV
NOC
MV
32
OR
AN
GE
YELLOW
YELLOW
YE
LLO
W
YELLOW
YELLOW/BLACK
YELLOW/RED
YE
LLOW
YELLOW
YE
LLO
W
YELLOW
YELLOW/BLACK
YELLOW
Brown
Brown
BROWN/WHITE
RED
RE
D
RE
D
RED/WHITE
RED
RE
D/W
HIT
E
69
for Bard use only.Wire Identification numbers
99
RED
RED/WHITE
32
RED
32
40BLACK
RED
R
C
240V
208V
COM
DRAFT BLOWER
2PL
11
BR
RE
D
INDUCED
Fan MotorIndoor
Capacitor
Evaporator SectionIndoor Fan
CONTACTOR
TRANSFORMER
COMPRESSOR
RE
D
L1 L2
T1 T2
L3
T3
40
PHASE MONITOR
OPERATION208V TAP FOR 208V
MOVE RED WIRE TO
25
RED
28
RED29
3031
41
42
43RE
D
38
39
32
27
38
RE
D
39
37
BLA
CK
/WH
ITE
PURPLE/WHITE
66
ORANGE
RE
D/W
HIT
E
68
BLACK/WHITE
63
626666
YE
LLO
W
PURPLE/WHITE
WHITE
65
ORANGE
BLACK/
32
YE
LLO
W
BLACK
PINK
65
BR
OW
N
67
CONTROLDEHUM
BLACKPINK
YELLOW
61RELAYLOCKOUT
BLA
CK
63
BLA
CK
64
Thermostat
Black
32
Black
Freeze
52
71
Model C. Breaker Fan Capacitor
W30G2DB 25A 5/370
W36G2DB 35A 5/370
W42G2DB 35A 10/370
Manual 2100-592BPage 63 of 69
W30G2DB, W36G2DB, W42G2DB 230/208-60-3
Manual 2100-592BPage 64 of 69
W30G2DC, W36G2DC, W42G2DC 460-60-3
LPC
CC
HP
C
Y
ALR C
LPC
MIN
UT
ES
4
235
R
1
DEHUM
SPEED 150
135
120
BLACK
WHITE
FUSE
BLACK
CONTROL
BLACK/
BLA
CK
BLACK
P3
BROWN
GRAY
BR
OW
N
BLA
CK
/WH
ITE
BLACK
(OPT.)
460-60-3
BLA
CK
/WH
ITE
BLA
CK
/WH
ITE
BLA
CK
/WH
ITE
BLACK
BLACK/WHITE
BLACK
BLA
CK
BLA
CK
/WH
ITE
BLA
CK
BlackBlack
BLA
CK
BLA
CK
BLACK/WHITE
TERM. BLOCK
USE COPPER CONDUCTORSSUITABLE FOR AT LEAST 75° C
LOCKOUT RELAY
PINK
PINK
PINK PINK
BLUE
BLUE
1 2 3
4 5 6
8 97
1210 11
BLU
E
L2
BLU
E
L3
A
A
BLU
E
BLA
CK
YE
LLOW
PU
RP
LE
BLU
E
PURPLE/WHITE
PURPLE
PURPLE
PURPLE
PURPLE/WHITE
MV
NOC
MV
ORANGE
ORANGE
YE
LLO
W
YELLOW
YE
LLO
WY
ELL
OW
YELLOW/BLACK
YELLOW/RED
YELLOW
YELLOW
YE
LLO
WYELLOW
YELLOW/BLACK
YELLOW
YELLOW
YE
LLO
W
65
YELLOW
BR
OW
N
Brown
Brown
BROWN/WHITE
BROWN/WHITE
RE
D
RED
RED/WHITE
RED
RE
D/W
HIT
E
66
for Bard use only.Wire Identification numbers
99
RED32
RED/WHITE
64
RED
32
40BLACK
RED
R
C
460V
COM
DRAFT BLOWER
2PL
11
BR
INDUCED
MotorFan
Capacitor
Evaporator SectionIndoor Fan
CONTACTOR
40
TRANSFORMER
COMPRESSOR
Indoor
35
GROUND TERMINAL
L1 L2
T1 T2
L3
T3
PHASE MONITOR
15
RED
28
RED29
3031
41
42
43
RE
D
38
39
32
2
31
5
46
RED
27
RE
D
BLOWER RELAYMED. SPEED
RELAY BLOWER
BLOWER RELAYINDUCED DRAFT
LOW SPEED
RELAYBLOWERSPEED HIGH
28
54 55
58
53
ThermostatFreeze
5032
WH
ITE
68
RE
D/W
HIT
E
RE
D/
63
6266 66
69
32
32
65
67
61
63
52
71
MODULE
HIGH
Compressor
CONTROL
SWITCH
MOTOR
COMPRESSOR
PRESSURE
23
REPLACED, IT MUST BE REPLACED WITH WIRING MATERIAL HAVING A TEMPERATURE RATING OF AT LEAST 105° C EXCEPT THE IGNITION CABLE
WHICH IS 250°C HIGH VOLTAGE CABLE
OUTDOOR FAN
INTEGRATED FURNACE CONTROL 13
STRIP 11
LOW VOLTAGE
DISCONNECT
CAPACITOR
21
LOWPRESSURE
SWITCH
IF ANY ORIGINAL WIRE AS SUPPLIED WITH THE APPLIANCE MUST BE
16
WIRES CONNECTIF OPTION NOT USED
L1
OR
AN
GE
THREE WAYVALVE
54
56
GAS VALVE
32 27
37
35
32
32
32
32
59
PRIMARY
ROLLOUT
SPARK IGNITOR
LIMIT
32
FLAME
FLAME SENSOR
36
PRESSURE SWITCH
T3T1
T2
Bard Mfg. Co.
Bryan, Ohio
4085-388 ALow Voltage
High Voltage
OptionalFieldFactory
32
LOW AMBIENTCONTROL (OPT.)
44
A
34
20
18
32
32
32
35
37
2
3
35
1
2
31
2
35
3
4
48
1
57
57
48
57
48
49
45
45
47
57
45
46
25
RE
D
BLOWER SPEED COLOR CODE
HIGH BLACK
MEDIUM BLUE
LOW RED
AUX PURPLE/ORANGE
Model Fan Capacitor
W30G2DC 5/370
W36G2DC 5/370
W42G2DC 15/370
Manual 2100-592BPage 65 of 69
W30G2DC, W36G2DC, W42G2DC 460-60-3
Manual 2100-592BPage 66 of 69
W48G2DA, W60G2DA 230/208-60-1
LPC
CC
HP
C
Y
ALR C
LPC
MIN
UT
ES
4
235
R
112
0
SPEED 150
135
BLA
CK
/WH
ITE
BLACK
BLA
CK
FUSE
BLA
CK
BLA
CK
/WH
ITE
BLA
CK
/WH
ITE
BLA
CK
BLACK
P3
BROWN
GRAY
BR
OW
N
BLA
CK
/WH
ITE
BLACK
(OPT.)
208/230-60-1
USE COPPER CONDUCTORSSUITABLE FOR AT LEAST 75° C
TERM. BLOCK
BLA
CK
PINK
3
BLUE
BLUE
BLU
E
21
4 5 6
8 97
1210 11
BLU
E
BLU
E
L1
L2
A
BLU
E
A
PURPLE
PURPLE
MV
NOC
MV
OR
AN
GE
YELLOW
YELLOW
YE
LLO
W
YELLOW
YELLOW
YE
LLO
W/R
ED
YE
LLOW
YELLOW
Brown
Brown
BROWN/WHITE
35
RED
RE
D
RE
D
RED/WHITE
RED
RE
D/W
HIT
E
for Bard use only.Wire Identification numbers
RE
D
99
RED
RED/WHITE
32
RED
32
40BLACK
RED40
GROUND TERMINAL
R
C
240V
208V
COM
DRAFT BLOWER
2PL
11
BR
RE
D
INDUCED
Fan MotorIndoor
Capacitor
CONTACTOR
RED
TRANSFORMER
COMPRESSOR15
RE
D
OPERATION208V TAP FOR 208V
MOVE RED WIRE TO
L1 L2
T1
32
RELAY
Freeze
Black
T2
YELLOW
PINK
63
BLACK
LOCKOUT61
CONTROLDEHUM
BR
OW
N
PINK
67
BLACK
65
YE
LLO
W
ORANGE
WHITE
32
PURPLE/WHITE
BLACK/
65
YE
LLO
W
6666 62
BLACK/WHITE
63
RE
D/W
HIT
E
ORANGE
PURPLE/WHITE
68
BLA
CK
/WH
ITE
66
37
BLA
CK
69
Indoor FanEvaporator Section
Thermostat
Black
32
BLA
CK
32
64 71
BLACK39
38
42
43RED
38
39
C
MODULE
HE
RM
FAN
HIGH
Compressor
CONTROL
SWITCH
COMPRESSOR
MOTOR
PRESSURE
23
REPLACED, IT MUST BE REPLACED WITH WIRING MATERIAL HAVING A TEMPERATURE RATING OF AT LEAST 105° C EXCEPT THE IGNITION CABLE
WHICH IS 250°C HIGH VOLTAGE CABLE
OUTDOOR FAN
INTEGRATED FURNACE CONTROL 13
VOLTAGESTRIP 11
LOW
CIRCUITBREAKER
CAPACITOR
21
LOWPRESSURE
SWITCH
IF ANY ORIGINAL WIRE AS SUPPLIED WITH THE APPLIANCE MUST BE
16
WIRES CONNECTIF OPTION NOT USED
34
35
VALVETHREE WAY
GAS VALVE
32 32
37
35
32
32
32
32
59
PRIMARY
ROLLOUT
SPARK IGNITOR
LIMIT
32
FLAME
FLAME SENSOR
36
PRESSURE SWITCH
SR
C
Bard Mfg. Co.
Bryan, Ohio
Low Voltage
High Voltage
OptionalFieldFactory
32
LOW AMBIENTCONTROL (OPT.)
44
A
35 20
18
32
32
32
BLOWER SPEED COLOR CODE
HIGH BLACK
MEDIUM BLUE
LOW RED
4085-169 A
Model C. Breaker Capacitor
W48G2DA 50A 70+10/370
W60G2DA 60A 80+10/370
Manual 2100-592BPage 67 of 69
W48G2DB, W60G2DB 230/208-60-3
LPC
CC
HP
C
Y
ALR C
LPC
MIN
UT
ES
4
235
R
1
GROUND TERMINAL 15
BLA
CK
SPEED 150
135
120
BLACK
BLA
CK
FUSE
BLACK
BLACK
BLACK/WHITE
BLA
CK
BLACK
P3
BROWN
GRAY
BR
OW
N
BLA
CK
/WH
ITE
BLACK
(OPT.)
208/230-60-3
BLA
CK
BLA
CK
/WH
ITE
BLA
CK
/WH
ITE
USE COPPER CONDUCTORSSUITABLE FOR AT LEAST 75° C
TERM. BLOCK
BLA
CK
/WH
ITE
PINK
L1
BLUE
BLUE
1 2 3
4 5 6
8 97
1210 11
BLU
E
BLU
E
L3
L2
A
BLU
E
A
BLU
E
PURPLE
PURPLE
MV
NOC
MV
32
OR
AN
GE
YELLOW
YELLOW
YE
LLO
WY
ELL
OW
YELLOW/BLACK
YELLOW/RED
YE
LLOW
YELLOW
YE
LLO
W
YELLOW
YELLOW/BLACK
YELLOW
Brown
Brown
BROWN/WHITE
37
RED
RE
D
RE
D
RED/WHITE
RED
RE
D/W
HIT
E
for Bard use only.Wire Identification numbers
99
RED
RED/WHITE
32
RED
32
40BLACK
RED
R
C
240V
208V
COM
DRAFT BLOWER
2PL
11
BR
RE
D
INDUCED
Fan MotorIndoor
Capacitor
Evaporator SectionIndoor Fan
CONTACTOR
TRANSFORMER
COMPRESSOR
RE
D
L1 L2
T1 T2
L3
T3
40
PHASE MONITOR
OPERATION208V TAP FOR 208V
MOVE RED WIRE TO
25
RED
28
RED29
3031
41
42
43RE
D
38
39
32
27
38 39
RE
D
69
BLA
CK
/WH
ITE
PURPLE/WHITE
66
ORANGE
RE
D/W
HIT
E
68
BLACK/WHITE
63
626666
YE
LLO
W
PURPLE/WHITE
WHITE
65
ORANGE
BLACK/
32
YE
LLO
W
BLACK
PINK
65
BR
OW
N
67
CONTROLDEHUM
BLACKPINK
YELLOW
61RELAYLOCKOUT
BLA
CK
63
BLA
CK
64
Thermostat
Black
32
Black
Freeze
71
MODULE
HIGH
Compressor
CONTROL
SWITCH
MOTOR
COMPRESSOR
PRESSURE
23
REPLACED, IT MUST BE REPLACED WITH WIRING MATERIAL HAVING A TEMPERATURE RATING OF AT LEAST 105° C EXCEPT THE IGNITION CABLE
WHICH IS 250°C HIGH VOLTAGE CABLE
OUTDOOR FAN
INTEGRATED FURNACE CONTROL 13 LOW VOLTAGE STRIP 11
CIRCUITBREAKER
CAPACITOR
21
LOWPRESSURE
SWITCH
IF ANY ORIGINAL WIRE AS SUPPLIED WITH THE APPLIANCE MUST BE
16
WIRES CONNECTIF OPTION NOT USED
35
THREE WAYVALVE
ROLLOUTFLAME
GAS VALVE
32 27
37
35
32
32
32
32
59
LIMIT
SPARK IGNITOR
32
PRIMARY
FLAME SENSOR
36
PRESSURE SWITCH
T3T1
T2
Bard Mfg. Co.
35
Bryan, Ohio
Low Voltage
High Voltage
OptionalFieldFactory
32
LOW AMBIENTCONTROL (OPT.)
44
A
34
20
18
32
32
32
35
BLOWER SPEED COLOR CODE
HIGH BLACK
MEDIUM BLUE
LOW RED
4085-267 A
Model C. Breaker Fan Capacitor
W48G2DB 35A 10/370
W60G2DB 40A 10/370
Manual 2100-592BPage 68 of 69
W48G2DC, W60G2DC 460-60-3
LPC
CC
HP
C
Y
ALR C
LPC
MIN
UT
ES
4
235
R
1
DEHUM
SPEED 150
135
120
BLACK
WHITE
FUSE
BLACK
CONTROL
BLACK/
BLA
CK
BLACK
P3
BROWN
GRAY
BR
OW
N
BLA
CK
/WH
ITE
BLACK
(OPT.)
460-60-3
BLA
CK
/WH
ITE
BLA
CK
/WH
ITE
BLA
CK
/WH
ITE
BLACK
BLACK/WHITE
BLACK
BLA
CK
BLA
CK
/WH
ITE
BLACK
BlackBlack
BLA
CK
BLA
CK
BLACK/WHITE
TERM. BLOCK
USE COPPER CONDUCTORSSUITABLE FOR AT LEAST 75° C
LOCKOUTRELAY
PINK
PINK
PINK PINK
11
BLUE
BLUE
1 2 3
4 5 6
8 97
1210
BLU
E
L2
BLU
E
L3
A
A
BLU
E
BLA
CK
YE
LLOW
PU
RP
LE
BLU
E
PURPLE/WHITE
PURPLE
PURPLE
PURPLE
PURPLE/WHITE
MV
NOC
MV
ORANGE
ORANGE
YE
LLO
W
YELLOW
YE
LLO
WY
ELL
OW
YELLOW/BLACK
YELLOW/RED
YELLOW
YELLOW
YE
LLO
WYELLOW
YELLOW/BLACK
YELLOW
YELLOW
YE
LLO
W
65
YELLOW
BR
OW
N
Brown
Brown
BROWN/WHITE
BROWN/WHITE
RED/WHITE
RED
RE
D
RED
RE
D/W
HIT
E
63
for Bard use only.Wire Identification numbers
99
RED32
RED/WHITE
64
RED
32
40BLACK
RED
R
C
460V
COM
DRAFT BLOWER
2PL
11
BR
INDUCED
MotorFan
Capacitor
Evaporator SectionIndoor Fan
CONTACTOR
40
TRANSFORMER
COMPRESSOR
Indoor
35
GROUND TERMINAL
L1 L2
T1 T2
L3
T3
PHASE MONITOR
15
RED
28
RED29
3031
41
42
43
RE
D
38
39
32
2
31
5
46
RED
27
RE
D
BLOWER RELAYMED. SPEED
RELAY BLOWER
BLOWER RELAYINDUCED DRAFT
LOW SPEED
28
RELAYBLOWERSPEED HIGH
5455
58
54
ThermostatFreeze
5032
WH
ITE
68
RE
D/W
HIT
E
RE
D/
63
626666
69
32
32
65
67
61
71
MODULE
HIGH
Compressor
CONTROL
SWITCH
MOTOR
COMPRESSOR
PRESSURE
23
REPLACED, IT MUST BE REPLACED WITH WIRING MATERIAL HAVING A TEMPERATURE RATING OF AT LEAST 105° C EXCEPT THE IGNITION CABLE
WHICH IS 250°C HIGH VOLTAGE CABLE
OUTDOOR FAN
INTEGRATED FURNACE CONTROL 13
STRIP 11
LOW VOLTAGE
DISCONNECT
CAPACITOR
21
LOWPRESSURE
SWITCH
IF ANY ORIGINAL WIRE AS SUPPLIED WITH THE APPLIANCE MUST BE
16
WIRES CONNECTIF OPTION NOT USED
L1
OR
AN
GE
56
66
GAS VALVE
32 27
37
35
32
32
32
32
59
PRIMARY
ROLLOUT
SPARK IGNITOR
LIMIT
32
FLAME
FLAME SENSOR
36
PRESSURE SWITCH
T3T1
T2
Bard Mfg. Co.
Bryan, Ohio
4085-390 ALow Voltage
High Voltage
OptionalFieldFactory
32
LOW AMBIENTCONTROL (OPT.)
44
A
34
20
18
32
32
32
35
37
2
3
35
1
2
31
2
35
3
4
48
1
57
57
48
57
48
49
45
45
47
57
45
46
25
RE
D
54
BLOWER SPEED COLOR CODE
HIGH BLACK
MEDIUM BLUE
LOW RED
AUX PURPLE/ORANGE
Model Fan Capacitor
W48G2DC 15/370
W60G2DC 15/370
Manual 2100-592BPage 69 of 69
W48G2DC, W60G2DC 460-60-3