Bard 5S User Manual

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Bard Manufacturing Company, Inc.

Manual:

2100-502A

Supersedes:

2100-502

Bryan, Ohio 43506

File:

Vol. I, Tab 20

 

Since 1914...Moving ahead, just as planned.

Date:

09-05-08

 

 

 

USER'S INFORMATION MANUAL

WG3S, 4S & 5S - Series Combination Gas/Electric Wall-Mount

We're pleased you've chosen our air conditioner/gas furnace to supply your cooling/heating needs. Please keep this manual in a safe, yet readily available place. It contains important and useful information.

ATTENTION, INSTALLER: After installing air conditioner/gas furnace, give the user:

• User's Information Manual

• Parts List

• Installation Instructions

• Warranty Information

ATTENTION, USER! Your installer should give you the above four important documents relating to your air conditioner/gas furnace. Keep these as long as you do your equipment. Pass these documents on to later purchasers or furnace users. If any of the four documents are missing or damaged, contact your installer or manufacturer for replacement. For efficient service, please give your unit model and serial number, from Section 1 or from your serial rating plate.

WARNING

If the information in this manual is not followed exactly, a fire or explosion may result causing property damage, personal injury or loss of life.

Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.

WHAT TO DO IF YOU SMELL GAS

Do not try to light any appliance.

Do not touch any electrical switch; do not use any phone in your building.

Immediately call your gas supplier from a neighbor's phone. Follow the gas supplier's instructions.

If you cannot reach your gas supplier, call the fire department.

Installation and service must be performed by a qualified installer or the gas supplier.

WARNING

Read and follow all safety information in this manual, operating instructions and furnace safety labels. Failure to follow safety precautions could result in damage, injury or death.

IMPORTANT SAFETY NOTE: You must know how to turn off gas and electricity to air conditioner/gas furnace. Your qualified installer, service agency or gas supplier can teach you to use controls and switches.

WARNING

Do not use this air conditioner/gas furnace if any part has been under water. Immediately call a qualified service technician to inspect the unit and to replace any part of the control system and any gas control which has been underwater.

Thank you for reading these safety statements.

Please read on so you will know how to maintain your air conditioner/gas furnace for years of dependable service.

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CONTENTS

Section 1

 

Figures

 

 

Rating Plate Information ..............................................

3

Figure 1 Typical Gas Piping

8

 

 

Section 2

 

Figure 2 Step-by-StepInstructions

 

Important Safety Precautions

3 & 4

 

 

on Lighting Burners

11

 

 

 

Section 3

 

Figure 3

Filter Locations

13

Understanding How Your Furnace and

 

 

 

 

 

Air Conditioner Works ...........................................

5 & 6

Figure 4

Periodic Inspections

13

 

 

Section 4

 

 

Location of Access Panels

 

 

 

 

 

Turning Off Furnace in an Emergency ...............

6, 7 & 9

Figure 5 Start Up Procedures

14

 

 

Section 5

 

 

 

 

Operating Your Furnace.............................................

10

 

 

 

Section 6

 

 

 

 

Proper Maintenance of Your Furnace

 

 

 

 

and Air Conditioner ......................................

10, 12 & 14

 

 

 

Section 7

 

 

 

 

Air Conditioning Start Up Procedure

 

 

 

 

Crankcase Heater ......................................................

14

 

 

 

Section 8

 

 

 

 

Ventilation Options.....................................................

15

 

 

 

Section 9

 

 

 

 

Replacement Parts ....................................................

15

 

 

 

Section 10

 

 

 

 

Outdoor Coil ..............................................................

15

 

 

 

Manufactured under the following U.S. Patent Numbers: 5,485,878; 5,022,116; 4,924,934;

4,875,520; 4,825,936

COPYRIGHT DECEMBER 2007

BARD MANUFACTURING COMPANY, INC.

BRYAN, OHIO USA 43506

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SECTION 1 • RATING PLATE INFORMATION

Record the manufacturer’s name, unit model number and serial number below. These are your furnace rating plate. Record installation date which is important for warranty purposes.

YOUR FURNACE INFORMATION

Furnace Type ________________________________________________________________

Manufacturer’s Name__________________________________________________________

Model Number _______________________________________________________________

Serial Number _______________________________________________________________

Date Installed ________________________________________________________________

Installer/Servicer _____________________________________________________________

Address _____________________________________________________________________

City/State/Zip Code ___________________________________________________________

Telephone Number _____________________________________________________

SECTION 2 • IMPORTANT SAFETY PRECAUTIONS

2.A HAZARD ALERT SYMBOL

An exclamation point surrounded by a triangle.

2.B SIGNAL WORDS

Years of safe, dependable service are assured when you understand and follow all safety precautions.

Signal words “WARNING” and “CAUTION” alert you to potential hazards.

“WARNING” indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

“CAUTION” indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices. It can also be used to signal property damage only potential.

2.C. SAFETY PRECAUTIONS

These are some of our most important safety precautions; others are throughout this manual. Please read and follow them.

THIS PRODUCT MUST BE GAS PIPED BY A LICENSED PLUMBER OR GAS FITTER IN THE COMMONWEALTH OF MASSACHUSETTS.

2.1 GAS AND COMBUSTION PRODUCTS

WARNING

Any condition that will allow gas or combustion products to enter furnace area can cause nausea, asphyxiation or fire resulting in damage, injury or death.

Natural gas and propane (LP) gas have characteristic odors. When your furnace is operating correctly, you should not smell any unfamiliar odor. Normally, burning gas with air produces combustion products which contain carbon dioxide, oxygen and water vapor. Under abnormal conditions, combustion products can contain aldehydes and carbon monoxide.

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Aldehydes have a strong pungent, acrid smell that can cause nausea.

Carbon monoxide is tasteless, colorless and odorless. It can cause headaches, flu-likesymptoms or nausea. We refer to all these symptoms as nausea in this manual. It can also cause death by asphyxiation.

WARNING

Any unfamiliar smell can alert you to presence of gas or aldehydes. If you detect any unfamiliar odor follow instruction in Section 4.B.1. Otherwise, nausea, asphyxiation or fire could occur resulting in damage, injury or death.

WARNING

Do not block or cover combustion openings in the furnace. Blocking or covering these openings could cause nausea, asphyxiation or fire resulting in damage, injury or death.

WARNING

A loud noise may mean faulty burner ignition. If your furnace makes a loud noise, turn it off. Follow instructions in

Section 4.B.2. If you don’t turn off your furnace, it could cause fire or an explosion resulting in damage, injury or death.

WARNING

Do not operate furnace with blower door open or removed. Do not alter furnace to allow operation with blower door removed.

Doing either could allow combustion products to circulate throughout the furnace area causing nausea, asphyxiation or fire resulting in damage, injury or death.

WARNING

Front door must be in place during furnace operation. Hot surfaces behind front door.

2.2STORAGE AND USE OF FLAMMABLE, CORROSIVE AND COMBUSTIBLE PRODUCTS NEAR YOUR FURNACE

WARNING

Never store or use flammable liquids or vapors near or on your furnace. These include gasoline, kerosene, cigarette lighter fluid, cleaning fluids, solvents, paint thinners or painting compounds. Flammable vapors can travel great distances before igniting.

WARNING

Never store or use anything near or on your furnace that can produce vapors that are corrosive to gas-firedfurnaces. Vapors from products containing chlorines, fluorines, bromines and iodines can cause vent system or heat exchanger failure. Examples of such products are spray or aerosol containers, detergents, bleaches, cat litter, waxes, adhesives, solvents and other cleaning compounds. Vent system or heat exchanger failure could cause nausea, asphyxiation or fire resulting in damage, injury or death.

WARNING

Never store anything combustible near or on your unit. A fire could occur resulting in damage, injury or death.

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2.3 ALTERATION OF FURNACE CONTROLS

WARNING

Do not alter any gas or electrical controls (gas control or safety controls) in any manner. Altering them could cause furnace to operate unsafely resulting in damage, injury or death.

SECTION 3 • UNDERSTANDING HOW YOUR FURNACE WORKS

Your installer should have given you a detailed explanation of how the furnace operates. Shown below are the basic operation characteristics and sequence of operation. If you have any questions consult your installer and/or service agency.

* * IMPORTANT * *

There are many types of thermostats compatible with this furnace. Make sure you understand the specific type installed.

Ask installer for detailed explanation, and retain thermostat instruction manual for reference.

This furnace is equipped with a vent shut-offsystem which monitors the combustion air into the burners by means of a pressure sensing device. When the vent becomes blocked, this device turns off the gas valve circuit to prevent flue products from entering the structure. In the event that this occurs, shut off furnace and contact a qualified service agency.

3.1 BASIC OPERATION – HEATING CYCLE

This furnace is operated by an Integrated Furnace Control (IFC) and a gas control system which controls all functions of the furnace.

On a call for heat from the thermostat, the IFC first turns on the inducer motor. The pressure switch then closes signaling the ignition control to proceed with ignition function.

The ignition system consists of a direct spark igniter (DSI) and remote sensor. When the thermostat calls for heat the DSI sparks to light main burner gas. Once ignited the remote sensor confirms flame carry over to all burners.

There is a 60-seconddelay after main burner is on until the comfort air blower starts on heating speed. After the thermostat is satisfied, the burners will go off as gas valve closes. The inducer will continue to run for 30 seconds, and the comfort air blower will continue to run for2-1/2minutes.

3.2 BASIC OPERATION – COOLING CYCLE

On a call for cool the compressor and condenser fan will start immediately, and the comfort air blower will start 7 seconds later on cooling speed. Note: Some models may be equipped with optional Low Ambient Control that will cycle the condenser fan motor to maintain proper refrigerant pressures under lower outdoor temperature conditions. When the thermostat is satisfied the compressor and condenser fan will stop and the comfort air blower will continue to operate for 60 seconds.

3.2.1 COMPRESSOR CONTROL MODULE (CCM)

All models are equipped with a compressor control module. This control is an anti-shortcycle/lockout timer with high and low pressure switch monitoring and alarm relay output.

Delay on Make Timer and Break Time Delay

On initial power up, or any time the power is interrupted to the unit, the delay on make period begins. This delay will be2 minutes plus 10% of the delay on break setting. This feature assures that pressures will be equalized for normal start up if there are brief power interruptions, and can accommodate staggered starts for dual unit installations as long as the off delay periods are set differently for the two units.

During routine operation of the unit with no power interruptions the compressor will operate on demand with no delay as long as off delay time has been met.

Adjustable 30-secondto5-minutedelay on break timer assures that pressures can equalize if units are short cycled by the operating controls or personnel. Recommended settings would be 2 minutes for unit 1 and 3 minutes for Unit 2.

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High Pressure Switch and Lockout Sequence

If the high pressure switch opens, the compressor contactor will de-energizeimmediately. The lockout time in the CCM will go into asoft lockout and stay locked out until the high pressure switch closes and the delay on break has expired.

If the high pressure switch opens again during the same operating cycle the CCM will go into a manual lockout condition.

Recycling the wall thermostat resets the manual lockout.

Low Pressure Switch, Bypass and Lockout

Sequence (Optional)

If the low pressure switch opens for more than 120 seconds the compressor contactor will deenergize and the CCM will go into soft lockout.

Regardless of the state of the low pressure switch the compressor contactor will reenergize after the delay on break time has expired.

If the low pressure switch remains open, or opens again for longer than 120 seconds, the CCM will go into a manual lockout and the alarm relay circuit will energize.

Recycling the wall thermostat resets the manual lockout.

NOTE: Both high and low pressure switch controls are inherently automatic reset devices. The high pressure switch opens at 425 and closes at 325 psig, and the low pressure switch opens at 14 and closes at 30 psig. The lockout features, both soft and manual, are a function of the Compressor Control Module.

Alarm Relay Output

Alarm terminal on Compressor Control Module is 24V AC output connection for applications where signal is desired. This terminal is powered whenever compressor is in manual lockout due to high pressure or low pressure sequences as described.

PHASE MONITOR

All units with three phase scroll compressors are equipped with a three phase line monitor to prevent compressor damage due to phase reversal.

The phase monitor in this unit is equipped with two LEDs. If the “&” signal is present at the phase monitor and phases are correct, the green LED will light.

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

3.3MANUAL FAN (CONTINUOUS AIRFLOW) OPERATION

If wall thermostat is set to MANUAL (ON) position to operate comfort air blower continuously to provide air circulation throughout the building, the blower will operate at a level that is lower than cooling or heating airflows. This permits the air to circulate as desired but helps keep the operating noise level down as well a conserving energy.

During a call for cooling, the blower automatically shifts up to cooling speed, and remains there until 60 seconds after thermostat is satisfied then drops back to heating speed.

SECTION 4 • TURNING OFF FURNACE IN AN EMERGENCY

WARNING

Have a qualified installer, service agency or gas supplier teach you location and operation of gas and electrical shut-offdevices. Ask them any questions you have about this section. If you don’t turn off your furnace in an emergency damage, injury or death could result.

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In an emergency you must know how to turn off gas and electricity. Find out howbefore the emergency.

WARNING

Should overheating occur or the gas supply fail to shut off, shut off the manual gas valve to the furnace before shutting off the electrical supply. Failure to do so can cause a fire or explosion which could result in damage, injury or death.

4.A GAS AND ELECTRICAL SHUT-OFF

DEVICES

1.GAS SHUT-OFFDEVICES

In an emergency, you may not be able to reach all the gas shut-offdevices. You must know how to turn off gas using any one of the three manual types:

a.Manual Shut-offSwitch on Gas Control Gas control location is behind the access panel on the right side. See Lighting and Shutdown Instructions in Section 5 for more information.

To turn gas control furnace knob OFF, turn it to “OFF” position. Use this same procedure when you leave a vacation home vacant and do not want the furnace to operate.

b.Manual In-LineShut-offValve in Gas Supply Line.

This valve could be next to furnace. Figure 1 shows a typical installation.

Normally, gas is ON when you turn the shut-offvalve handle parallel to gas pipe. Gas is OFF when you turn handle 90° from gas pipe.

c.Manual Shut-offValve at Natural Gas Meter or Propane (LP) Gas Tank.

Normally, natural gas is ON when you turn shut-offparallel to gas pipe. Gas is OFF when you turnshut-off90° from gas pipe. Some valves require a wrench or other tools.

2. ELECTRICAL SHUT-OFFDEVICES

In an emergency, you may not be able to reach both of your electrical shut-offdevices. Therefore, you must know how to turn off electricity using either one of them. Here are two types of electricalshut-offdevices:

a.There should be an electrical shut-offdevice located on or immediately adjacent to the furnace.

b.There should be a separate circuit breaker or fuse serving only the furnace located in the main circuit breaker or fuse panel.

Know its location and make sure this device is clearly identified.

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FIGURE 1

TYPICAL GAS PIPING

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4.B POSSIBLE EMERGENCIES AND

RECOMMENDED ACTIONS

WARNING

If gas or electricity is off due to an emergency, only a qualified installer, service agency or gas supplier should turn it back on. Doing it yourself could result in damage, injury or death.

1.Possible Emergency: Smelling gas or other unfamiliar smell; or not knowing what may be wrong or what to do about it.

ACTION: For your safety –

a.Leave your house or building immediately.

b.Go to a neighbor’s or another building.

c.Use their telephone.

d.Call your gas supplier. Tell them you smell gas and give them your name and address.

e.If you cannot reach gas supplier, call fire department.

WARNING

Three important things not to do

1.Don’t try to light any gas appliances.

2.Don’t touch any electrical switches

3.Don’t use the telephone in your house or building.

Any of the above may cause a spark, which could cause a fire or explosion resulting in damage, personal injury or death.

2.Possible Emergency: Your thermostat is set below room temperature; yet even though the blower is on, the air coming from your room registers continually gets hotter.

ACTION:

a.Turn room thermostat to its lowest or OFF setting.

b.If you can do so safely, turn gas off. Use manual shut-offvalve at gas meter or on propane (LP) gas tank. You may need a wrench or tools. If you can safely turn off electricity at the main circuit panel, do so. If you cannot do these things safely, leave your home or building immediately. Call your gas supplier or fire department from a neighbor’s phone for help.

3.Possible Emergency: Your thermostat is set above room temperature. The blower is on but the air coming from your room registers is hot, then cold, then hot, then cold in a continuing cycle. This condition indicates lack of airflow through furnace.

ACTION:

a.Make sure air filter is clean and installed correctly.

b.Check that registers and return air grilles are open and unobstructed.

c.If condition continues, call your local qualified service technician or gas supplier.

4.Possible Emergency: While furnace is operating, you smell unfamiliar odors that go away when furnace is off.

WARNING

Unfamiliar odors may mean gas or aldehydes are present which could result in damage, injury or death.

ACTION:

a.Turn thermostat to its lowest or OFF setting.

b.Move gas valve control knob to OFF position.

c.If blower is not operating, immediately turn off electricity to furnace using shut-offdevice near furnace or at main circuit panel.

d.If blower is operating, wait five minutes for furnace to cool down and then turn off electricity to furnace using shut-offdevice near furnace or at main circuit panel.

e.Call your local qualified service technician or gas supplier.

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5.Possible Emergency: Main electrical circuit breaker for furnace cannot be reset without tripping again or new fuses continue to blow.

ACTION:

a.Move gas valve control knob to OFF.

b.Call your local qualified service technician or gas supplier.

SECTION 5 • OPERATING YOUR FURNACE

After reading the Safety Information and Precautions follow Operating Instructions on front door of furnace and instructions repeated on Page 11.

WARNING

If you do not follow these instructions exactly a fire or explosion could occur resulting in damage, injury or death.

WARNING

Never use tools to move gas control knob. Only use your hand. If gas control knob will not move by hand, do not force it or try to repair it. Call a qualified installer, service agency or gas supplier. Forcing knob can cause gas to leak which could result in fire or explosion resulting in damage, injury or death.

Properly operating your furnace requires certain abilities, mechanical skills and tools. If you are uncertain about your abilities or if you lack proper skills or tools, do not proceed. Instead, contact a qualified installer, service agency or gas supplier.

An automatic ignition device lights the burners. Do not try to light manually. See Figure 2 on Page 11 for step by step instructions.

SECTION 6 • PROPER MAINTENANCE OF YOUR FURNACE

You need special abilities, mechanical skills and tools to maintain your furnace properly. If you are uncertain about your abilities or if you lack proper skills or tools, do not try to maintain or repair your furnace yourself. Instead, contact a qualified installer, service agency or gas supplier.

6.A IF YOU SMELL GAS OR ANY UNFAMILIAR

SMELL WHILE WORKING ON YOUR FURNACE:

1.Do not try to light main burners.

2.Do not touch or turn on any electrical switch.

3.Do not use any phone in your building.

4.Immediately call your gas supplier from a neighbor’s phone. Follow gas supplier’s instructions.

5.If you cannot reach your gas supplier, call fire department.

6.B LUBRICATION REQUIREMENTS

The main blower motor, outdoor fan motor, and the induced draft blower motor are permanently lubricated, and no maintenance is required.

6.C MAKE SURE AIR FILTER(S) IS IN PLACE

Ask your installer, local qualified service technician or gas supplier to make sure your filter(s) is in place properly. Become familiar with its location and procedures for removing, cleaning and replacing it.

Recommended filter sizes are shown below.

Main System Filter: 20x30x2 throwaway for WG3S, WG4S & WG5S models.

See Figure 3 on Page 13 for filter locations.

WARNING

Operating furnace without clean air filter(s) can damage blower motor, heat exchanger or air conditioning system components.

This can cause system failure which could result in damage or injury.

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