Bard WG5S, WG4S, WG3S User Manual

Bard Manufacturing Company, Inc. Bryan, Ohio 43506

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

Manual: 2100-502 Supersedes: NEW File: Vol. I, Tab 20 Date: 01-11-08

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.

Manual 2100-502 Page 1 of 15

CONTENTS

Section 1

Rating Plate Information .............................................. 3

Section 2

Important Safety Precautions ................................ 3 & 4

Section 3

Understanding How Your Furnace and

Air Conditioner Works ........................................... 5 & 6

Section 4

Turning Off Furnace in an Emergency ............... 6, 7 & 9

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

Figures

Figure 1 Typical Gas Piping ..................................... 8

Figure 2 Step-by-Step Instructions

on Lighting Burners .................................. 11

Figure 3 Filter Locations ....................................... 13

Figure 4 Periodic Inspections ............................... 13

Location of Access Panels

Figure 5 Start Up Procedures ................................ 14

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

BARD MANUFACTURING COMPANY, INC.

BRYAN, OHIO USA 43506

Manual 2100-502 Page 2 of 15

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 explanation 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.

Manual 2100-502 Page 3 of 15

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

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

WARNING

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

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.

2.2 STORAGE 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-fired furnaces. 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

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.

Manual 2100-502 Page 4 of 15

WARNING

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

2.3 ALTERATION OF FURNACE CONTROLS

WARNING

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.

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.

There is a 60-second delay 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 for 2-1/2 minutes.

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-short cycle/lockout timer with high and low pressure switch monitoring and alarm relay output.

This furnace is equipped with a vent shut-off system 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.

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 be 2 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-second to 5-minute delay 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.

Manual 2100-502 Page 5 of 15

+ 10 hidden pages