Bard W24G4 Installation Instructions Manual

INSTALLATION INSTRUCTIONS Bard Manufacturing Company, Inc. Bryan, Ohio 43506 www.bardhvac.com Manual No.: 2100-721B Supersedes: 2100-721A Date: 5-7-20 WARNING READ ALL INSTRUCTIONS CAREFULLY BEFORE BEGINNING THE INSTALLATION. THE INSTALLATION MUST COMPLY WITH THESE INSTRUCTIONS AND THE REQUIREMENTS OF ALL GOVERNING CODES AND ORDINANCES FOR THE INSTALLATION LOCATION. IT IS THE RESPONSIBILITY OF INSTALLER TO KNOW AND UNDERSTAND ALL OF THESE REQUIREMENTS. FAILURE TO DO SO COULD CREATE A HAZARD RESULTING IN PROPERTY DAMAGE, BODILY INJURY, OR DEATH. WALL MOUNTED GAS/ELECTRIC Models: W24G4 W24G4D W30G4 W30G4D W36G4 W36G4D W42G4 W42G4D W48G4 W48G4D W60G4 W60G4D

CONTENTS Getting Other Information and Publications....4 Wall Mount Gas/Electric General Information...5 W**G Series Model Nomenclature...................... 5 Ventilation Options........................................... 5 Air Conditioning Module Options........................ 6 1. Transportation Damage.................................... 10 2. Important...................................................... 10 3. General Information........................................ 10 4. Application.................................................... 10 5. Duct Work...................................................... 10 6. High Altitude Applications............................... 11 7. Wall Mounting Information.............................. 11 8. Mounting the Unit.......................................... 11 9. Clearances..................................................... 18 10. Vent Terminal and Combustion Inlet Hood......... 19 11. Optional Vertical Venting................................. 19 12. Vent Resizing Instructions............................... 20 13. Fresh Air Intake.............................................. 20 14. Condensate Drain........................................... 20 15. Wiring – Main Power....................................... 20 16. Wiring – Low Voltage Wiring............................. 21 17. Thermostats................................................... 23 18. Gas Supply and Piping.................................... 28 19. Manifold Pressure Adjustment......................... 29 20. Checking Gas Input Rate................................. 29 21. Standard Orifice Sizing and High Altitude Derate............................................... 31 22. Conversion of Gas Input BTUH from High to Low Rating................................................. 34 23. Measuring Air Temperature Rise....................... 34 24. Filters........................................................... 34 25. Compressor Control Module............................. 35 26. Phase Monitor................................................ 37 27. Lighting and Shutdown Instructions................. 37 28. Service Agency Procedures.............................. 38 29. Maintaining Unit in Good Working Order........... 38 30. Troubleshooting NIDEC SELECTECH Series ECM Motors................................................... 39 31. Replacement Parts......................................... 41 32. Sequence of Operation – Heating..................... 42 33. Sequence of Operation – Cooling..................... 42 34. Setting Unit Airflow........................................ 43 35. Pressure Service Ports.................................... 52 36. R-410A Refrigerant Charge............................. 53 37. Fan Blade Setting Dimensions......................... 53 38. Low NOx Burner Assembly "N" Suffix Models Only – U.S. Installations Only............... 53 INDEX – Wiring Diagrams...................................... 54 Page Page

FIGURES Figure 1 Unit Dimensions...................................9 Figure 2A Mounting Instructions – W24-36G........13 Figure 2B Mounting Instructions – W42-60G........14 Figure 3A Combustible Clearance – W24-36G ......15 Figure 3B Combustible Clearance – W42-60G.......15 Figure 4 Wall Mounting Instructions...................16 Figure 5 Wall Mounting Instructions...................16 Figure 6 Common Wall Mounting Installations.....17 Figure 7 Location of Vent Terminal in Shipping...18 Figure 8 Vent Terminal and Combustion Air Inlet Hood.....................................19 Figure 9 Fresh Air Damper................................20 Figure 10 Installation of Flexible Conduit.............21 Figure 11 Low Voltage Wiring – All Units Except Units with Economizers........................24 Figure 12 Low Voltage Wiring – Thermostat Using Separate Temperature and Humidity Controllers..........................................25 Figure 13 Low Voltage Wiring – JIFM Economizer.................................26 Figure 14 Gas Pipe Connection............................27 Figure 15 Proper Piping Practice.........................28 Figure 16 Access Internal Filter through Upper Service Door..............................35 Figure 17 8201-169 Compressor Control Module.... 36 Figure 18 Lighting and Shutdown Instruction Label.................................37 Figure 19 Top View of Gas Control.......................38 Figure 20 Motor Connections...............................40 Figure 21 Motor Connections...............................41 Figure 22 Sequence of Operation – Electronic Blower Control.....................42 Figure 23 Increasing Heating Speed....................43 Figure 24 Increasing Cooling Speed.....................44 Figure 25 Speed Taps.........................................44 Figure 26 Fan Blade...........................................53 Figure 27 Low NOx Insert...................................53 TABLES Table 1A Specifications – W24-36G Models............7 Table 1B Specifications – W42-60G Models............8 Table 2 Minimum Installation Clearances............18 Table 3 Low Voltage Connections for DDC Control.........................................22 Table 4 CO2 Controllers.....................................23 Table 5 Thermostat Wire Size.............................23 Table 6 Wall Thermostats..................................23 Table 7 Humidity Controls.................................23 Table 8 Length of Standard Pipe Threads............28 Table 9 Gas Pipe Sizes – Natural Gas.................28 Table 10 Natural Gas Derate Capacities for All Models.......................................31 Table 11A Natural Gas Orifice Tables – W24-36G....32 Table 11B Natural Gas Orifice Tables – W42-60G....33 Table 12 W24G4 Indoor Blower Performance........45 Table 13 W30G4 Indoor Blower Performance........46 Table 14 W36G4 Indoor Blower Performance........47 Table 15 W42G4 Indoor Blower Performance .......48 Table 16 W48G4 Indoor Blower Performance........49 Table 17 W60G4 Indoor Blower Performance........50 Table 18 Integrated Furnace and Blower Control Operation..................................51 Table 19 Cooling Pressure Table...........................52 Table 20 Fan Blade Dimension............................53 Page Page

Getting Other Information and Publications For more information, contact these publishers: ACCA Air Conditioning Contractors of America 1712 New Hampshire Avenue, NW Washington, DC 20009 Telephone: (202) 483-9370 ANSI American National Standards Institute 11 West Street, 13th Floor New York, NY 10036 Telephone: (212) 642-4900 Fax: (212) 302-1286 ASHRAE American Society of Heating Refrigerating, and Air Conditioning Engineers, Inc. 1791 Tullie Circle, NE. Atlanta, GA 30329-2305 Telephone: (404) 636-8400 Fax: (404) 321-5478 NFPA National Fire Protection Association Batterymarch Park P.O. Box 9101 Quincy, MA 02269-9901 Telephone: (800) 344-3555 Fax: (617) 984-7057 CSA Canadian Standards Association 178 Rexdale Boulevard Rexdale, Ontario Canada. M9W 1R3 Telephone: (416) 447-4044 BARD MANUFACTURING COMPANY, INC. BRYAN, OHIO 43506 USA These publications can help when installing the furnace. They can usually be found at the local library or purchased directly from the publisher. Be sure to consult the current 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 90A of Air Conditioning and Ventilating Systems Standard for Warm Air ............... ANSI / NFPA 90B Heating and Air Conditioning Systems Standard for Chimneys, ........................NFPA 211 Fireplaces, Vents, and Solid Fuel Burning Appliances Load Calculation for ......................ACCA Manual J Residential Winter and Summer Air Conditioning Duct Design for Residential .........ACCA Manual D Winter and Winter Air Conditioning and Equipment Selection Canadian Electrical Code......................CSA C22.1 Canadian Installation Code…………CAN/CGA B149

W 42 G 4 – A X C X X X X X X WALL MOUNT GAS/ELECTRIC GENERAL INFORMATION MODEL NUMBER NOMENCLATURE  Low ambient control is required with economizer for low temperature compressor operation. Ventilation Options Models W24G, W30G, W36G W42G, W48G, W60G Description Factory Installed Code No. Field Installed Part No. Field Installed Part No. Barometric Fresh Air Damper X WGBFAD-3 WGBFAD-5 Blank-Off Plate B WGBOP-3 WGBOP-5 Motorized Fresh Air Damper M WGMFAD-3A WGMFAD-5A Commercial Ventilator – Spring Return V WGCRVS-3A WGCRVS-5A Commercial Ventilator – Power Return P WGCRVP-3A WGCRVP-5A Economizer - Fully Modulating  E WGJIFM-3 WGJIFM-5 Energy Recovery Ventilator – 230 Volt R WGERV-A3B WGERV-A5B Energy Recovery Ventilator – 460 Volt R WGERV-C3C WGERV-C5C 1 Reference Supplemental Instructions 7960-867 for dehumidification unit information. MODEL Wall Mount CONTROL OPTIONS (See table page 6) VENT (See table below) COOLING CAPACITY 24 – 2 ton 30 – 2½ ton 36 – 3 ton 42 – 3½ ton 48 – 4 ton 60 – 5 ton OUTLET X – Front Outlet T – Top Outlet COIL OPTIONS X – Standard 1 – Phenolic coated evaporator 2 – Phenolic coated condenser 3 – Phenolic coated both coils COLOR X – Beige 1 – White 4 – Gray 8 – Bronze FILTER X – 2" Pleated (Standard) W – 1" Washable VOLTAGE A – 230/208-60-1 B – 230/208-60-3 C – 460-60-3 REVISION FEATURE C – Canadian Approval D – Dehumidification1 EMISSIONS X = Standard N = NOx Certified *125,000 BTU input model is not NOx certified. HEATING INPUT 2 - 3 Ton 3.5 - 5 Ton A – 45,000 B – 75,000 B – 67,500 C – 100,000 C – 90,000 D – 125,000* GAS/ELECTRIC

Air Conditioning Module Options STD – Standard equipment.  CCM Compressor control module has adjustable 30 second to 5 minute delay-on-break timer. On initial power up, or any time the power is interrupted, the delay-on-make will be 2 minutes plus 10% of the delay-on-break setting. There is no delay-on-make during routine operation of the unit. The module also provides the lockout feature (with 1 retry) for high and/or low pressure controls, and a 2-minute timed bypass for low pressure control.  HPC High pressure control is auto reset. Always used with compressor control module (CCM) which is included. See Note .  LPC Low pressure control is auto reset. Always used with compressor control module (CCM) which is included. See Note .  LAC Low ambient control permits cooling operation down to 0°F. (Includes fan cycling control + Freeze Stat)  SK CMC-15 is PTCR Start Kit can be used with all -A single phase models. Increases starting torque 2-3X. Not used for -B or -C 3-phase models. Do not use if SK111 is used.  SK SK111 Start Capacitor and Potential Relay Start Kit can be used with all -A single phase models. Increases starting torque 9x. Not used for -B or -C 3-phase models. Do not use if CMC-15 is used. CCM  HPC  LPC  LAC  SK  Factory Installed Code Field Installed Part STD STD STD • H CMA-45 (WG4D Units) CMA-46 (WG4 Units) • Field Only SK111 or CMC-15

TABLE 1A Specifications W24G4, W30G4 and W36G4 Models * 75° C Copper wire size ** Maximum time delay fuse or circuit breaker Models W24G4-A W24G4-B W24G4-C W30G4-A W30G4-B W30G4-C W36G4-A W36G4-B W36G4-C Electrical Rating – 60 Hz 230/208-1 230/208-3 460-3 230/208-1 230/208-3 460-3 230/208-1 230/208-3 460-3 Operating Voltage Range 197-253 187-253 414-506 197-253 187-253 414-506 197-253 187-253 414-506 Minimum Circuit Ampacity 20.6 12.6 8 22.6 16.1 8.6 26.4 19 10.6 * Field Wire Size 10 14 14 10 12 14 8 10 14 Ground Wire Size 10 14 14 10 12 14 10 10 14 ** Delay Fuse or Circuit Breaker Max. 30 15 10 30 20 10 35 25 15 Compressor Voltage 230/208 230/208 460 230/208 230/208 460 230/208 230/208 460 Rated Load Amps 7.6/8.7 4.6/5.3 2.5 9.4/10.7 6/6.9 3.2 12/13.5 7.8/8.7 4.8 Branch Circuit Selection Current 12.9 6.5 3.6 14.2 9 4.2 16.7 10.5 5.8 Lock Rotor Amps 58.3 55.4 28 73 58 28 79 73 38 Compressor Type Scroll Scroll Scroll Scroll Scroll Scroll Scroll Scroll Scroll Fan Motor and Condenser Fan Motor – HP/RPM/SPD 1/5-1100-1 1/5-1100-1 1/5-1100-1 1/5-1100-1 1/5-1100-1 1/5-1100-1 1/5-1100-1 1/5-1100-1 1/5-1100-1 Fan Motor – Amps 1.4 1.4 0.8 1.4 1.4 0.8 1.4 1.4 0.8 Fan – DIA/CFM 20” - 2100 20” - 2100 20” - 2100 20” - 2100 20” - 2100 20” - 2100 20” - 2000 20” - 2000 20” - 2000 Blower Motor and Evaporator Blower Motor – HP/RPM/SPD 1/2-670-5 1/2-670-5 1/2-670-5 1/2-750-5 1/2-750-5 1/2-750-5 1/2-870-5 1/2-870-5 1/2-870-5 Blower Motor – Amps 0.9 0.9 1.2 1.2 1.2 1.2 1.9 1.9 1.2 CFM Cooling and E.S.P. 800 - 0.15 800 - 0.15 800 - 0.15 900 - 0.15 900 - 0.15 900 - 0.15 1100 - 0.15 1100 - 0.15 1100 - 0.15 Filter Size 20 x 25 x 2 20 x 25 x 2 20 x 25 x 2 20 x 25 x 2 20 x 25 x 2 20 x 25 x 2 20 x 25 x 2 20 x 25 x 2 20 x 25 x 2 Shipping Weight – LBS. 500 500 500 530 530 530 540 540 540 Unit Charge (R-410A lb.) 5.750 5.750 5.750 5.750 5.750 5.750 6.625 6.625 6.625

* 75° C Copper wire size ** Maximum time delay fuse or circuit breaker TABLE 1B Specifications W42G, W48G and W60G Models Models W42G4-A W42G4-B W42G4-C W48G4-A W48G4-B W48G4-C W60G4-A W60G4-B W60G4-C Electrical Rating – 60 Hz 230/208-1 230/208-3 460-3 230/208-1 230/208-3 460-3 230/208-1 230/208-3 460-3 Operating Voltage Range 197-253 187-253 414-506 197-253 187-253 414-506 197-253 187-253 414-506 Minimum Circuit Ampacity 29 23.4 11.5 34.4 24.4 12 40.2 29.7 13.6 * Field Wire Size 8 10 14 8 10 14 8 8 12 Ground Wire Size 10 10 14 10 10 14 10 10 12 ** Delay Fuse or Circuit Breaker Max. 40 30 15 50 30 15 50 40 20 Compressor Voltage 230/208 230/208 460 230/208 230/208 460 230/208 230/208 460 Rated Load Amps 15.5/17.4 11.7/13.2 5.9 16.7/19.5 10.6/12.3 6.5 19.5/21.9 12.9/14.4 7 Branch Circuit Selection Current 18 13.6 6 21.8 13.8 6.5 24.4 16 7.8 Lock Rotor Amps 112 88 44 117 83.1 41 144.2 110 52 Compressor Type Scroll Scroll Scroll Scroll Scroll Scroll Scroll Scroll Scroll Fan Motor and Condenser Fan Motor – HP/RPM/SPD 1/3-850-1 1/3-850-1 1/3-850-1 1/3-830-1 1/3-830-1 1/3-830-1 1/2-1000-1 1/2-1000-1 1/2-1000-1 Fan Motor – Amps 1.8 1.8 1 1.8 1.8 1 3.8 3.8 2.5 Fan – DIA/CFM 24” - 2900 24” - 2900 24” - 2900 24” - 2700 24” - 2700 24” - 2700 24” - 3400 24” - 3400 24” - 3400 Blower Motor and Evaporator Blower Motor – HP/RPM/SPD 3/4-850-5 3/4-850-5 3/4-850-5 3/4-940-5 3/4-940-5 3/4-940-5 3/4-1040-5 3/4-1040-5 3/4-1040-5 Blower Motor – Amps 2.4 2.4 1.7 3.1 3.1 1.7 3.7 3.7 1.7 CFM Cooling and E.S.P. 1300 - 0.15 1300 - 0.15 1300 - 0.15 1450 - 0.20 1450 - 0.20 1450 - 0.20 1650 - 0.20 1650 - 0.20 1650 - 0.20 Filter Size 20 x 30 x 2 20 x 30 x 2 20 x 30 x 2 20 x 30 x 2 20 x 30 x 2 20 x 30 x 2 20 x 30 x 2 20 x 30 x 2 20 x 30 x 2 Shipping Weight – LBS. 500 500 500 530 530 530 550 550 550 Unit Charge (R-410A lb.) 6.500 6.500 6.500 7.125 7.125 7.125 9.625 9.625 9.625

F G N P D DD FF GG HH A M I C K J L H R S S S S S T V Y AA X U Z CC BB B EE O E B II Q W COMBUSTION AIR INTAKE CONTROL RIGHT SIDE ENTRANCES GAS RETURN OPENING 4 DEG. PITCH IN TOP PANEL DOOR DOOR LOW VOLTAGE SUPPLY OPENING PANEL BACK DISCONNECT ACCESS VESTIBULE PANEL (LOCKABLE) CONDENSER AIR INLETS CONDENSER VENT OPTION AIR OUTLET AIR EXHAUST COMBUSTION ENTRANCES FRONT CIRCUIT BREAKER/ MIS-3239 HIGH VOLTAGE ENTRANCES FRONT DOOR FILTER SERVICE DOOR UNIT A B C D E F G H I J K L M N O P Q R W24G-W30G-W36G 7.88 27.88 13.88 24.25 40 25.63 81.63 27.38 27.5 39.25 5.88 W42G-W48G-W60G 9.88 29.88 15.88 27.25 43.81 31.63 87.5 33.38 28.75 42.88 3.75 UNIT S T U V W X Y Z AA BB CC DD EE FF GG HH II W24G-W30G-W36G 12 - 7 HOLES 2.88 22.9 38 17.84 4.44 11.44 9 36.25 2 0.38 W42G-W48G-W60G 16 - 6 HOLES 3.88 24.9 42 17.34 8.44 12.19 10 40.25 2.75 0.44 1.25 7.25 1.13 3.75 2.25 3.25 15.31 4.5 2.5 14.88 30 14.12 15.44 FIGURE 1 Unit Dimensions

1. TRANSPORTATION DAMAGE All units are packed securely in shipping containers. All units should be carefully inspected upon arrival for damage. In the event of damage, the consignee should: 1. Note on delivery receipt of any damage to container. 2. Notify carrier promptly, and request an inspection. 3. In case of concealed damage, the carrier must be notified as soon as possible within 15 days after delivery. 4. Claims for any damage, apparent or concealed, should be filed with the carrier, using the following supporting documents: A. Original Bill of Lading, certified copy or indemnity bond. B. Original paid freight bill of indemnity in lieu thereof. C. Original invoice or certified copy thereof showing trade and other discounts or deductions. D. Copy of the inspection report issued by carrier’s representative at the time damage is reported to carrier. 2. IMPORTANT The equipment covered in this manual is to be installed by trained, experienced service and installation technicians. All duct work or portions thereof not in the conditioned space should be properly insulated in order to both conserve energy and prevent condensation or moisture damage. 3. GENERAL INFORMATION This appliance is not intended for use by persons (including children) with reduced physical, sensory or mental capabilities, or lack of experience and knowledge, unless they have been given supervision or instruction concerning use of the appliance by a person responsible for their safety. Children should be supervised to ensure that they do not play with the appliance. These instructions explain the recommended method to install the air cooled self-contained electric air conditioning and gas heating unit and the electrical wiring connections and gas piping to the unit. The refrigerant system is completely assembled and charged. All internal wiring is complete. These instructions and any instructions packaged with any separate equipment required to make up the entire heating/ cooling system should be carefully read before beginning the installation. While these instructions are intended as a general recommended guide, they do not supersede any national and/or local codes in any way. Authorities having jurisdiction should be consulted before the installation is made. See page 4 for information on codes and standards. Size of unit for proposed installation should be based on heat loss/heat gain calculations made according to methods of Air Conditioning Contractors of America (ACCA). The air duct should be installed in accordance with the Standards of the National Fire Protection Association for the Installation of Air Conditioning and Ventilating Systems of Other Than Residence Type, NFPA No. 90A, and Residence Type Warm Air Heating and Air Conditioning Systems, NFPA No. 90B. Where local regulations are at a variance with instructions, installer should adhere to local codes. 4. APPLICATION This is a fan-assisted forced air gas furnace with electric air conditioning for outdoor installation. A fan-assisted furnace is equipped with an integral mechanical means to draw products of combustion through the combustion chamber and heat exchanger. The furnace installation must conform with local building codes and ordinances or, in their absence, with the National Fuel Gas Code ANSI Z223.1 or CAN/CGA-B149.1, latest edition, and the National Electrical Code ANSI/NFPA-7 or CSA C22.1, latest edition. It is the personal responsibility and obligation of the purchaser to contact a qualified installer to assure that installation is adequate and is in conformance with governing codes and ordinances. 5. DUCT WORK The unit is designed for use with or without duct work (see WARNING). Flanges are provided for attaching CAUTION During the initial firing of the burners there will probably be some amount of smoke issued to the circulating air stream as the result of residual oil burning off of the heat exchanger tubes. This oil is required during the forming process of the stainless steel heat exchanger tubes to facilitate the bending. OSHA or the National Toxicology Program does not list the oil as a carcinogen. In vapor form this may be irritating to the eyes or could cause headaches. This is a one-time occurrence, and ventilation of the space may be required depending upon the space being conditioned.

6. HIGH ALTITUDE APPLICATIONS Ratings of gas utilization equipment are based on sea level operation and need not be changed for operation at elevations up to 6,000'. For operation at elevations above 6,000' and in the absence of specific recommendations from the local authority having jurisdiction, equipment ratings shall be reduced as specified in Section 21. 7. WALL MOUNTING INFORMATION 1. Two holes for the supply and return air openings must be cut through the wall as detailed in Figure 4. 2. On wood-frame walls, the wall construction must be strong and rigid enough to carry the weight of the unit without transmitting any unit vibration. 3. Concrete block walls must be thoroughly inspected to ensure that they are capable of carrying the weight of the installed unit. 8. MOUNTING THE UNIT 1. These units are secured by wall mounting brackets which secure the unit to the outside wall surface at both sides. A bottom mounting bracket is provided for ease of installation but is not required. 2. The W42G, W48G and W60G models are suitable for 0 clearance on the installation mounting wall and to the top. For all models the supply air duct flange and the first 3' of supply air duct require a minimum of 1" clearance to combustible material. The W24G, W30G and W36G models are suitable for 0 clearance on the installation mounting wall, but require 1" clearance to the top if combustible material overhang projects above the unit (see Figures 3A and 3B). If a combustible wall, use a minimum of Figure 1 “A” dimension plus 2" and “B” dimension plus 2". See Figures 4 and 5 for details. the supply and return ducts. All duct work, supply and return, must be properly sized for the design airflow requirement of the equipment. Air Conditioning Contractors of America (ACCA) is an excellent guide to proper sizing. Refer to Tables 12, 13, 14, 15, 16 and 17 for maximum static pressure available for duct design. See Figures 3A and 3B and clearance information in Section 9 and Table 2 for additional information. Design the duct work according to methods given by the Air Conditioning Contractors of America (ACCA). When duct runs through unheated spaces, it should be insulated with a minimum of one-inch of insulation. Use insulation with a vapor barrier on the outside of the insulation. Flexible joints should be used to connect the duct work to the equipment in order to keep the noise transmission to a minimum. A 1" clearance to combustible material for the first 3' of duct attached to the outlet air frame is required. See wall mounting instructions and Figures 2A, 2B, 3A and 3B for further details. Ducts through the walls must be insulated and all joints taped or sealed to prevent air or moisture entering the wall cavity. Some installations may not require any return air duct. A metallic return air grille is required with installations not requiring a return air duct. The spacing between louvers on the grille shall not be larger than 5/8". Any grille that meets with the 5/8" louver criteria may be used. It is recommended that Bard Return Air Grille or Return Filter Grille be installed when no return duct is used. Contact distributor or factory for ordering information. If using a return air filter grille, filters must be of sufficient size to allow a maximum velocity of 400 fpm. NOTE: If no return air duct is used, applicable installation codes may limit this cabinet to installation only in a single story structure. CAUTION If the bottom bracket is used, be certain the bracket is secured to the outside wall surface in a way sufficient to support the entire weight of the unit during installation until side mounting brackets are secured. WARNING Failure to provide the 1" clearance between the supply duct and a combustible surface for the first 3' of duct can result in fire causing damage, injury or death. WARNING In all cases, there must be a metal duct connection made to the supply air flange, and a 1" clearance to combustibles must be maintained to this duct connection. For free blow applications, a metal sleeve must be used in the wall opening itself, again maintaining a 1" clearance to combustibles. Failure to use the sheet metal can cause fire resulting in property damage, injury, or death.

3. Locate and mark lag bolt locations and bottom mounting 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 right side of the back. 6. Position unit in opening and secure with 5/16" lag bolts; use 7/8" diameter flat washers on the lag bolts. Use lag bolts long enough to support the unit’s weight when mounted to the structure. This length may be dependent on the type of construction. 7. Secure rain flashing to wall and caulk across entire length of top (see Figures 2A and 2B). 8. On side-by-side installations, maintain a minimum of 20" clearance on right side to allow access to control panel and burner compartment, and to allow proper airflow to the outdoor coil. Additional clearance may be required to meet local or national codes.

FIGURE 2A Mounting Instructions for W24G, W30G and W36G 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 15/16" 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 15/16" 4 9/16" SUPPLY AIR DUCT RETURN AIR DUCT Ø2 3/4" GAS OPENING (OPTIONAL) Ø2 3/4" HIGH VOLTAGE (OPTIONAL) Ø2" LOW VOLTAGE (OPTIONAL) (12) FLANGE SCREWS UNIT SUPPORT 1" MIN. NECCESSARY NO CLEARANCE SUPPLY AIR DUCT RETURN AIR DUCT CONTROL PANEL VESTIBULE DOOR WALL STRUCTURE (OUTSIDE) 1" CLEARANCE ON ALL FOUR SIDES OF SUPPLY AIR DUCT IS REQUIRED FROM COMBUSTABLE MATERIALS NOTE: IT IS RECOMMENDED THAT A BEAD OF SILICONE CAULKING BE PLACED BEHIND THE SIDE MOUNTING FLANGES AND UNDER TOP FLASHING AT TIME OF INSTALLATION RIGHT SIDE VIEW WITH UNIT OUTSIDE WALL WITH UNIT REMOVED RAIN FLASHING SUPPLIED SEAL WITH BEAD OF CAULKING ALONG ENTIRE LENGTH OF TOP TOP FOAM AIR SEAL WALL MIS-1681

FIGURE 3A Combustible Clearance for W24G, W30G and W36G Models FIGURE 3B Combustible Clearance for W42G, W48G and W60G Models WARNING A minimum of 1" clearance must be maintained between the supply air duct and combustible materials. This is required for the first 3' of ducting. It is important to insure that the one 1" minimum spacing is maintained at all points. Failure to do this could result in overheating the combustible material and may result in a fire causing damage, injury or death.

FIGURE 4 Wall Mounting Instructions FIGURE 5 Wall Mounting Instructions

9. CLEARANCES Minimum clearances, as specified in Table 2, must be maintained from adjacent structures to provide adequate fire protection, adequate combustion air and room for service personnel. While minimum clearances are acceptable for safety reasons, they may not allow adequate air circulation around the unit for proper operation in the cooling mode. Whenever possible, it is desirable to allow additional clearance, especially around the condenser inlet and discharge openings. DO NOT install the unit in a location that will permit discharged air from the condenser to recirculate to the condenser inlet. TABLE 2 Minimum Installation Clearances Outlet Duct (from combustible materials) 1" first 3' Vent Terminal (from combustible materials) 17"* Condenser Inlet 20" Top See Figures 3A and 3B Burner Service 20" Combustible Base (Wood or Class A, B or C roof covering material) 0 * See Figures 3A and 3B FIGURE 7 Location of Vent Terminal in Shipping WARNING Clearances from combustible materials must be maintained as specified. Failure to maintain clearances could cause fire resulting in property damage, injury or death.

10. VENT TERMINAL AND COMBUSTION AIR INLET HOOD The vent terminal is shipped in the burner compartment (see Figure 7). Remove the two shipping screws and separate the two-piece assembly. Install the vent terminal by using the four screws provided. Do not cut or trim gasket. Make sure gasket is in place. See Figure 8. The combustion air intake vent hood is factory installed. 11. OPTIONAL VERTICAL VENTING With the optional vertical venting kit (VVK-5), this unit may be vented vertically through a roof or overhang. The kit includes a stainless steel transition drain tee, silicone sealant and drain tubing. If unit is installed with vertical vent kit, annually inspect the vent system and drain. Replace any portion of the vent system that shows signs of deterioration. Make sure drain is open and free of obstruction. FIGURE 8 Vent Terminal and Combustion Air Intake CAUTION Vent terminal must be installed as shown in Figure 8 for proper operation of the heating system. NOTE: The inner vent hood gasket is designed to stretch over and seal around the combustion air blower outlet. This is a very critical seal to prevent water and flue products from entering the unit. Care must be taken to insure this gasket is in place and sealing properly. MIS-2057 MIS-2126

12. VENT RESIZING INSTRUCTIONS When an existing furnace is removed from a venting system servicing other appliances, the venting system is likely to be too large to properly vent the remaining attached appliances. The following steps shall be followed with each of the appliances remaining connected to the common venting system, placed in operation one at a time while the other appliances remaining connected to the common venting system are not in operation. 1. Seal any unused openings in the venting system. 2. Inspect the venting system for proper size and horizontal pitch, as required in the National Fuel Gas code, ANSI Z223.1 or the CAN/CGA B149 Installation Codes and these instructions. Determine that there is no blockage or restriction, leakage, corrosion and other deficiencies which could cause an unsafe condition. 3. In so far as is practical, close all building doors and windows and all doors between the space in which the appliance(s) connected to the venting system are located and other spaces of the building. Turn on clothes dryers and any appliances not connected to the venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they will operate at maximum speed. Do not operate a summer exhaust fan. Close fireplace dampers. 4. Follow the lighting instructions. Place the appliance being inspected in operation. Adjust thermostat so appliance shall operate continuously. 5. Test for draft hood equipped appliance spillage at the draft hood relief opening after 5 minutes of main burner operation. Use the flame of a match or candle. 6. After it has been determined that each appliance connected to the venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers and any other gas-burning appliances to their previous conditions of use. 7. If improper venting is observed during any of the above tests, the venting system must be corrected. 13. FRESH AIR INTAKE All units are built with fresh air inlet slots punched in the service panel. If the unit is equipped with a fresh air damper assembly, the assembly is shipped already attached to the unit. The damper blade is locked in the closed position. To allow the damper to operate, the maximum and minimum blade position stops must be installed (see Figure 9). All capacity, efficiency and cost of operation information as required for Department of Energy “Energyguide” Fact Sheets is based upon the fresh air blank-off plate in place and is recommended for maximum energy efficiency. The blank-off plate is available upon request from the factory and is installed in place of the fresh air damper shipped with each unit. One of several other ventilation options may be installed. Refer to model number and/or supplemental installation instructions. 14. CONDENSATE DRAIN A plastic drain hose extends from the drain pan at the top of the unit down to the unit base. There are openings in the unit base for the drain hose to pass through. In the event the drain hose is connected to a drain system of some type, it must be an open or vented type system to assure proper drainage. 15. WIRING – MAIN POWER FIGURE 9 Fresh Air Damper Refer to unit rating plate for wire sizing information and maximum fuse or circuit breaker size. Each outdoor unit is marked with a “Minimum Circuit Ampacity”. This means that the field wiring used must be sized to carry that amount of current. All models are suitable only for connection with copper wire. Each unit and/or WARNING For personal safety, turn off electric power at service entrance panel before making any electrical connections. Failure to do so could result in electric shock or fire.

FIGURE 10 Installation of Flexible Conduit Electrical Grounding When installed, the furnace must be electrically grounded in accordance with local codes, or in the absence of local codes, with the National Electrical Code, ANSI/NFPA 70 or Canadian Electrical Code, CSA22.1, latest edition. Use a copper wire from green ground wire on the furnace to a grounded connection in the service panel or a properly driven and electrically grounded ground rod. See Tables 1A and 1B for proper ground wire size. Field-Installed Equipment Wiring to be done in the field between the furnace and devices not attached to the furnace, or between separate devices which are field installed and located, shall conform with the temperature limitation for Type T wire {63° F rise (36° C)} when installed in accordance with the manufacturer’s instructions. WARNING Failure to provide a proper electrical ground could result in electric shock or fire. Installation of Flexible Conduit Through Return Air Opening NOTE: To allow proper clearance between the control panel and any vent options, 90° conduit fittings must be used on the back of the control panel. Installing Conduit (See Figure 10) 1. Remove conduit access panel if required to gain access to area behind control panel. 2. Remove low voltage and high voltage knockouts located in rear of control panel. 3. Run low voltage conduit through 7/8 bushing located in conduit entrance plate and secure to low voltage opening in rear of control panel. 4. Run high voltage conduit through 1-3/4 bushing located in conduit entrance plate and secure to high voltage opening in rear of control panel. 5. Replace conduit access panel if required to complete installation. 6. Seal around conduit in conduit entrance plate. 16. WIRING – LOW VOLTAGE WIRING 230/208 Volt Units All 230/208V 1 phase and 3 phase equipment have dual primary voltage transformers. All equipment leaves the factory wired on 240V tap. For 208V operation, reconnect from 240V to 208V tap. The acceptable operating voltage range for the 240 and 208V taps are: Tap: 240 Range: 253 – 216 Tap: 208 Range: 220 – 187 NOTE: The voltage should be measured at the field power connection point in the unit and while the unit is operating at full load (maximum amperage operating condition). WARNING Failure to provide an electrical power supply shut off means could result in electric shock or fire. wiring diagram will be marked “Use Copper Conductors Only”. These instructions must be adhered to. Refer to the National Electrical Code (NEC) for complete current carrying capacity data on the various insulation grades of wiring material. All wiring must conform to NEC and all local codes. The electrical data lists fuse and wire sizes (75° C copper) for all models. The unit rating plate lists a “Maximum Time Delay Relay Fuse” or circuit breaker that is to be used with the equipment. The correct size must be used for proper circuit protection and also to assure that there will be no nuisance tripping due to the momentary high starting current of the compressor motor. The disconnect access door on this unit may be locked to prevent unauthorized access to the disconnect. To convert for the locking capability bend the tab located in the bottom left hand corner of the disconnect opening under the disconnect access panel straight out. This tab will now line up with the slot in the door. When shut, a padlock may be placed through the hole in the tab preventing entry.

Low Voltage (24VAC) Connections These units use a 24-volt AC low voltage circuit. C terminal is the 24VAC common and is grounded. G terminal is the indoor blower input. Y1 terminal is the 1st Stage cooling input. Economizer stage when used. Balanced Climate stage when used. Y2 terminal is the 2nd Stage cooling input. Compressor cooling stage when economizer or Balanced Climate is used. B/W1 terminal is the gas heat. A terminal is the ventilation option input. This terminal energizes any factory-installed ventilation option and indoor blower. D terminal is the dehumidification input. If installed, this terminal energizes any factory-installed dehumidification option. L terminal is 24 volt alarm active output. Unit Shutdown Feature (Standard on All Models) The RT terminal is the 24VAC transformer output, and the R terminal is the 24VAC hot terminal for the operation of the equipment. RT and R are connected with a brass jumper bar which can be removed and RT and R connected to an external NC (normally closed) contact such as a fire/smoke detector that will cause shutdown of the equipment upon activation. Balanced Climate™ Feature (Standard on All Models) All units are equipped with the capability of running in Balanced Climate mode. This mode is designed to enhance the comfort level by reducing the indoor airflow amount and extending the run time to help extract more humidity during cooling operation. The Y1 terminal is the 24VAC input for Balanced Climate compressor cooling operation. The Y2 terminal is the 24VAC input for compressor cooling standard operation. Y1 and Y2 are connected with a brass jumper bar which can be removed to enable Balanced Climate mode. Units with an economizer will not have the brass jumper installed. Refer to vent manuals for instructions on how Balanced Climate works with each vent. To operate in Balanced Climate mode, a 2-stage cooling thermostat is required. The lower indoor airflow operation is overridden by utilizing a 2-stage thermostat. If the call for cooling is not satisfied within a given time frame or temperature differential (specified by the thermostat), the thermostat will send a signal to Y2 which then increases the blower speed back to the selected speed. See pages 43 – 44 for blower speed selection options. In units with an economizer vent installed, Balanced Climate mode should not be used. The Y1 and Y2 jumper must remain installed. Dehumidification Feature (Optional) The D terminal is the 24VAC input for dehumidification operation on dehumidification hot gas reheat equipped units. When 24VAC is applied to the D terminal, a 3-way valve solenoid is energized. The reheat coil located behind the evaporator coil is then active to reheat the supply air during cooling mode. This allows humidity to be removed from the air entering the unit without a large amount of sensible cooling capacity. During dehumidification, the indoor blower speed is reduced to help with the humidity removal. A humidity sensing thermostat or humidistat is required to control dehumidification operation. See Supplemental Instructions 7960-867 for additional information on dehumidification unit operation. Ventilation Features (Optional) See ventilation instructions provided with unit for low voltage wiring. Low Ambient Control (LAC) The low ambient control is a pressure switch that is attached to the liquid line of the system and monitors Standard Units Units w/ Economizers Fan Only Energize G Energize G 1st Stage Cooling Mode/Bal- anced Climate Energize Y1, G Energize Y1, G 2nd Stage Cooling Mode Energize Y2 to overide Bal- anced Climate mode when Y1-Y2 jumper is removed Energize Y1, Y2, G Gas Heating Energize B/W1 Energize B/W1 Ventilation Energize A Energize A Dehumidification (if employed) Energize D Energize D For low voltage wiring, an 18 gauge copper, color- coded cable is recommended. See Table 5 for more information. 460 Volt Units All models are equipped with single primary voltage transformers and no rewiring is required. Direct Digital Controls (DDC) For total and proper control using DDC, a total of six controlled outputs are required (five if no ventilation is installed). TABLE 3 Low Voltage Connections for DDC Control

TABLE 6 Wall Thermostats Thermostat Predominant Features 8403-060 1120-445 3 Stage Cool; 3 Stage Heat Programmable/Non-Programmable Electronic HP or Conventional Auto or Manual changeover 8403-082 (VT8600U5500B) 2 stage Cool; 2 stage Heat Programmable/Non-Programmable Electronic HP or Conventional, Auto or Manual changeover with Occupancy Sensor, BACnet 8403-084 (VT8600U5000B) 2 stage Cool; 2 stage Heat Programmable/Non-Programmable Electronic HP or Conventional, Auto or Manual changeover with BACnet 8403-089 (T4 Pro) 1 stage Cool; 1 stage Heat – Heat Pump 1 stage Cool; 1 stage Heat – Conventional Programmable/Non-Programmable Electronic Auto or Manual changeover 8403-090 (T6 Pro) 2 stage Cool; 3 stage Heat – Heat Pump 2 stage Cool; 2 stage Heat – Conventional Programmable/Non-Programmable Electronic Auto or Manual changeover 8403-091 (T701-FEMA) 1 stage Cool, 1 stage Heat Non-Programmable FEMA use 8403-092 (T6 Pro Wi-Fi) 2 stage Cool, 3 stage Heat – Heat Pump 2 stage Cool, 2 stage Heat – Conventional Programmable/Non-Programmable Electronic Auto or Manual changeover Wi-Fi high side pressure. Operation of the LAC occurs as outdoor temperatures drop below 60°F. On/Off and modulating controls are used which operate based on pressure changes caused by outdoor temperature changes. On/Off LAC operation cycles the condenser fan on/off to maintain desired liquid pressure while modulating LAC operation is factory adjusted and slows the condenser fan speed (rpm). Outdoor Temperature Switch and Freeze Protection Thermostat An outdoor temperature switch and an evaporator freeze protection thermostat is supplied with all units that have a low ambient control. The outdoor switch disables Balanced Climate mode (if enabled) when the temperature drops below 50°F. This prevents potential evaporator coil freeze up issues. The freeze thermostat cuts out compressor operation if the evaporator begins to freeze up. Balanced Climate Mode If the application is likely to require air conditioning operation below 60°F outdoor conditions, a low ambient control (LAC) kit must be installed. If the unit is being installed with any ventilation package, a Bard LAC kit must be installed. Failure to utilize an LAC with any air conditioner can cause coil freeze up. Balanced Climate can readily be applied to duct-free (supply and return air grille) applications. It may also be applied to ducted applications with limited rated static (total including both supply and return statics). Consult Bard Application Engineering for details prior to implementation. CAUTION: Balanced Climate is not a replacement for a dehumidification (hot gas reheat) unit for extreme applications, but rather an enhancement feature for limited climates and applications. 17. THERMOSTATS TABLE 7 Humidity Controls Part Number Predominate Features 8403-038 (H600A1014) SPDT switching, pilot duty 50VA @ 24V; Humidity range 20-80% RH 8403-047 (H200-10-21-10) Electronic dehumidstat SPST closes- on-rise; Humidity range 10-90% with adjustable stops TABLE 4 CO2 Controllers Part Number Predominate Features 8403-056 CO2 ventilation control with digital display. Normally Open SPST (Default: Close at 800ppm) 8403-067 Normally Open SPST relay closes-on-rise 24V dual wave length sensor. Default setting 950ppm, adjustable to 0-2000ppm Default off setting 1000ppm, adjustable to 0-200 ppm can be calibrated TABLE 5 Thermostat Wire Size Transformer VA FLA Wire Gauge Maximum Distance in Feet 55 2.3 20 gauge 18 gauge 16 gauge 14 gauge 12 gauge 45 60 100 160 250

6 5 4 3 2 1 TEMP-OUT C02 OUT 24VAC Optional CO2 Controller Bard Part #8403-067 B/W1 W2 Y1 6 C A 4 1 RT L G Y2 2 D W3 5 3 R 4 Y W2 Y2 8 4 W R 1 W1/E 5 C Y1 17 L R RC O/B G 6 A B O 3 R G 7 C JUMPER 2 or #8403-084 Thermostat (1120-445) Part #8403-060 Thermostat HAVE OCCUPANCY OUTPUT. 2 FOR HEAT/COOL) BLUE (MUST BE CONFIGURED THERMOSTAT SUBBASE 1 INSTALL IF YOU REQUIRE VENTILATION ANYTIME BLOWER IS ON. 3 RED 4 CONFIGURE THERMOSTAT FOR HEAT/COOL 1 RED/WHITE 5 SET SWITCH ON THERMOSTAT TO "GAS-OIL" MODE. Part #8403-057 or T4 Pro 8403-089 MODE. (TH311DD1040) A 2-STAGE THERMOSTAT IS RECOMMENDED FOR BALANCED CLIMATE™ UNIT CONTROL PANEL TERM. STRIP VOLTAGE UNIT LOW MUST INSTALL JUMPER FOR 8403-057 OR OTHER THERMOSTAT THAT DOES NOT BLACK/WHITE INSTALLED BROWN/WHITE BLUE ORANGE 3 Thermostat Part #8403-082 D/YO BALANCED CLIMATE™ 5 FACTORY INSTALLED JUMPER. REMOVE TO ACTIVATE FACTORY VENT PACKAGE WIRING PLUG RED MIS-2775 H 12 2 FIGURE 11 Low Voltage Wiring All Units Except Units with Economizers

B C Y RC G O R W Y W C G R W2 L RC Y2 O/B A 6 4 3 C Y1 Y2 G RT R L D 5 W3 2 W2 1 B/W1 4 6 3 4 6 5 INSTALLED (TH522OD1151) or T6 Pro 8403-090 3 1 MUST INSTALL JUMPER FOR 8407-057, 8403-058 OR OTHER THERMOSTAT THAT DOES NOT HAVE OCCUPANCY OUTPUT. 2 MIS-2788 D 7 (H200-10-21-10) Bard part # 5 TERM. STRIP VOLTAGE Thermostat JUMPER FACTORY INSTALLED JUMPER. 8403-047 4 IF THIS "A" TO "G" JUMPER IS INSTALLED, YOU MUST INSURE TO REMOVE VENTILATION PACKAGE ORANGE WIRE FROM TERMINAL "G". YELLOW UNIT CONTROL PANEL (TH311DD1040) Part #8403-057 Thermostat CHANGE "SYSTEM TYPE", SET UP FUNCTION 1, FROM 5 (2 HEAT/ 1 COOL HEAT PUMP) Mechanical Humidistat TO 6 (2 HEAT/ 2 COOL CONVENTIONAL). 2 1 8403-038 or T4 Pro 8403-089 2 (H600A 1014) UNIT LOW Part #8403-058 Electronic Humidistat Bard part # RED THERMOSTAT SUBBASE INSTALL IF YOU REQUIRE VENTILATION ANYTIME BLOWER IS ON. SET SWITCH ON THERMOSTAT TO "GAS-OIL" 3 5 FACTORY FACTORY INSTALLED JUMPER. REMOVE TO ACTIVATE BALANCED CLIMATE™ MODE. A 2-STAGE THERMOSTAT IS RECOMMENDED FOR BALANCED CLIMATE™ MODE. 5 6 7 MIS-2788D FIGURE 12 Low Voltage Wiring Thermostat Using Separate Temperature and Humidity Controllers

Must be energized to enable minimum position. NOTE: Economizer Control Default Setting is 10V (100%). Depending upon application may require setting to lower value. BLACK/WHITE to 6 (2 heat/ 2 cool conventional). O/B FROM BLUE Change model configuration from heat pump to heat/cool, and must be configured for economizer for YO/D output to be active as first stage cooling. JUMPER 4 W2 5 (TH5220D1151) R W2 Change "system type", set up function 1, from 5 (2 heat/ 1 cool heat pump) Y2 RC 3 L B/W1 8403-058 C Y UNIT CONTROL PANEL W L G Low Voltage Wiring Diagram W1/E RT A G RED/WHITE 1 Thermostat 3 part #8403-060 4 WIRES YO/D C G VOLTAGE UNIT LOW YELLOW 5 5 YELLOW/RED PINK R 4 W3 2 W2 Factory installed jumper. 1 move blue wire to "A" terminal. PURPLE 3 6 C Y1 2 PLUG R For demand ventilation and/or to disable ventilation on call for heat, D Y2 2 1 A FACTORY INSTALLED 1 Y1 Y2 MIS-3349 C 6 Balance Climate is unavailable with economizer. Leave the jumper installed. 6 FIGURE 13 Low Voltage Wiring JIFM Economizer

18. GAS SUPPLY AND PIPING General Recommendations 1. Be sure the gas line complies with the local codes and ordinances, or in their absence with the National Fuel Gas Code, ANSI Z223.1, or Natural Gas Installation Code, CAN/CGA B149.1, or Propane Installation Code B149.2, latest edition. 2. A sediment trap or drip leg must be installed in the supply line to the furnace. 3. A ground joint union shall be installed in the gas line adjacent to and upstream from the gas valve and downstream from the manual shut-off valve. 4. An 1/8" NPT plugged tapping accessible for test gauge connection shall be installed immediately upstream of the gas supply connection to the furnace for the purpose of determining the supply gas pressure. This can be omitted if local codes permit use of plugged tapping in gas valve inlet. 5. Install listed manual shut-off valve in the supply gas line external to and immediately upstream of the furnace (see Figure 14). 6. Use steel or wrought iron pipe and fittings. 7. DO NOT thread pipe too far. Valve distortion or malfunction may result from excess pipe within the control. Use pipe joint compound resistant to the action of liquefied petroleum gases on male threads only. DO NOT use Teflon tape. See Table 8 and Figure 15. TABLE 8 Length of Standard Pipe Threads (Inches) TABLE 9 Gas Pipe Sizes – Natural Gas Checking the Gas Piping Before turning gas under pressure into piping, all openings from which gas can escape should be closed. Immediately after turning on gas, the system should be checked for leaks. This can be done by watching the 1/2 cubic foot test dial, allowing 4 minutes to show any movement, soaping each pipe connection and watching for bubbles. If a leak is found, make the necessary repairs immediately and repeat the above test. The furnace must be isolated from the gas supply piping system by closing the manual shut-off valve on the combination gas control valve during pressure testing of the gas supply piping system at pressures up to 1/2 PSIG. The furnace and its individual shut-off valve must be disconnected from supply piping and supply piping capped during any pressure testing of supply piping system at test pressures in excess of 1/2 PSIG. Defective pipes or fittings should be replaced and not repaired. Never use a flame or fire in any form to locate gas leaks; use a soap solution. After the piping and meter have been checked completely, purge the system of air. DO NOT bleed air inside the furnace. Be sure to check and relight all the gas pilots on other appliances that may have been extinguished because of interrupted gas supply. FIGURE 15 Proper Piping Practice 8. Refer to Table 9 for gas pipe sizes for natural gas. If more than one appliance is supplied from a single line size, capacity must equal or exceed the combined input to all appliances, and the branch lines feeding the individual appliances properly sized for each input. Pipe Size Effective Length of Thread Overall Length of Thread 3/8 1/2 9/16 3/4 1/2 – 9/16 13/16 1 9/16 1 Length of Pipe - Feet Pipe Capacity - BTU per Hour Input Pipe Size 1/2" 3/4" 1" 1-1/4" 10 132,000 278,000 520,000 1,050,000 20 92,000 190,000 350,000 730,000 30 73,000 152,000 285,000 590,000 40 63,000 130,000 245,000 500,000 50 56,000 115,000 215,000 440,000 60 50,000 105,000 195,000 400,000 70 46,000 96,000 180,000 370,000 80 43,000 90,000 170,000 350,000 100 38,000 79,000 150,000 305,000 MIS-897 THIS PRODUCT MUST BE GAS PIPED BY A LICENSED PLUMBER OR GAS FITTER IN THE COMMONWEALTH OF MASSACHUSETTS.

19. MANIFOLD PRESSURE ADJUSTMENT A 0 to 15" water manometer with 0.1" resolution and a 1/8" NPT manual shut-off valve is needed to measure actual manifold pressure. Depending on local gas heating value and elevation, the manifold pressure may need to be adjusted or the orifices changed to get proper gas input rate. Check with the local gas supplier to determine heating value (BTU/cu. ft.) of natural gas in the area. NOTE: If furnace is being installed at an altitude of more than 6,000' above sea level, you must derate the furnace. See Section 21 “Standard Orifice Sizing and High Altitude Derate”. 1. Turn off gas at equipment shut-off valve in gas supply line just ahead of furnace. 2. Remove plug from outlet pressure tap in gas control or gas manifold. 3. Install 1/8" NPT manual shut-off valve in hole vacated by plug. Make sure shut-off valve is in OFF position. 4. Attach manometer to 1/8" NPT manual shut-off valve just installed. PROPANE (LP) GAS CONVERSION This unit may be converted in the field for use with propane (LP) gas. Propane gas conversion kit number WGCK-1 is designed for conversions of units installed from 0 – 6,000' elevations. Propane gas conversion kit number WGCK-2 is designed for conversions of units installed from 6,001' – 10,000' elevations. These kits may be purchased from the ocal distributor. 5. Slowly open equipment shut-off valve in gas supply line just ahead of furnace. Start furnace following “Operating Instructions” on front door. 6. Slowly open 1/8" NPT manual shut-off valve leading to manometer. 7. Read manifold pressure on manometer. 8. Adjust manifold pressure by turning gas control regulator adjusting screw clockwise to increase pressure or turning counterclockwise to decrease pressure. Manifold pressure must be within allowable range as follows: • Natural gas manifold pressure must be between 3.2" and 3.8" W.C. Rated pressure is 3.5" W.C. • Propane gas (LP) manifold pressure must be between 9.7" and 10.3" W.C. Rated pressure is 10" W.C. NOTE: For natural gas, if gas flow rate can’t be properly set within these pressure ranges, the main burner orifices must be changed to obtain proper gas flow rate. 9. Shut off furnace. Turn off gas at equipment shut-off valve in gas supply line just ahead of furnace. Install outlet pressure tap plug in gas control. Turn on gas. 10. Check regulator adjustment cover screw and gas control plug for gas leaks. Use a commercial soap solution made for leak detection. 20. CHECKING GAS INPUT RATE It is the installer’s responsibility to see that the BTU input rate of the furnace is properly adjusted. Under-firing could cause inadequate heat, excessive condensation or ignition problems. Overfiring could cause sooting, flame impingement or overheating of heat exchanger. WARNING Failure to adjust furnace to the proper firing rate could cause heat exchanger failure. WARNING When converting from propane (LP) gas to natural gas, the gas orifice spuds and gas valve spring must be replaced and the gas valve regulator pressure must be adjusted correctly. Failure to do so can result in fire, injury or death. Refer to Tables 11A and 11B for proper orifice sizing. Natural gas spring kit, part number 5603-007, can be purchased through the local distributor. WARNING Correct manifold pressure is necessary for proper ignition and burner operation. Failure to accurately adjust pressure could cause heat exchanger failure.

Natural Gas Input Rate Natural gas heating value (BTU/cu. ft.) can vary significantly. Before starting natural gas input check, obtain gas heating value at the location from local supplier. A stopwatch will be needed to measure actual gas input. 1. Gas supply pressure must be between 5" and 7" W.C. for natural gas. 2. Turn off all other gas appliances. The pilots may be left on. 3. Start furnace following “Operating Instructions” on front door. 4. Let furnace warm up for 6 minutes. 5. Locate gas meter. Determine which dial has the least cubic feet of gas and how many cubic feet per revolution it represents. This is usually one- half, one or two cubic feet per revolution. 6. With stopwatch, measure time it takes to consume two cubic feet of gas. • If dial is one-half cubic foot per revolution, measure time for four revolutions. • If dial is one cubic foot per revolution, measure time for two revolutions. • If dial is two cubic feet per revolution, measure time for one revolution. 7. Divide this time by two. This gives average time for one cubic foot of gas to flow through meter. Example: If it took 58 seconds for two cubic feet to flow, it would take 29 seconds for one cubic foot to flow. 8. Calculate gas input using this formula: Gas Heating Value (BTU/cu. ft.) x 3,600 sec/hr Gas input = = BTU/hour Time (Seconds for one cubic foot of gas) Example: Assume it took 29 seconds for one cubic foot of gas to flow and heating value of 1,000 BTU/cu. ft. 1,000 x 3,600 Gas input = = 124,138 BTU 29 If no other pilots were left on, this is the furnace gas input. 9. If the water heater, dryer or range pilots were left on, allow for them in calculating correct furnace gas input. A quick way is to allow 1,000 BTU per hour for a water heater, 500 BTU per hour for dryer and 500 BTU per hour for each range burner pilot. 1. Make the main burner orifices are correct. 2. Gas supply pressure must be between 11" and 13" W.C. for propane (LP) gas. 3. Start furnace following “Operating Instructions” on front door. 4. Let furnace warm up for 6 minutes. 5. Adjust manifold pressure to 10.0" W.C. ± 0.3". See Section 19, “Manifold Pressure Adjustment”. WARNING Propane (LP) gas installations do not have gas meters to double check input rate. Measure manifold pressure adjustment with an accurate manometer. Failure to accurately adjust pressure could cause heat exchanger failure, asphyxiation, fire or explosion, resulting in damage, injury or death. WARNING Do not set propane (LP) manifold pressure at 11.0" W.C. It could cause heat exchanger failure. Example: If the gas water heater, dryer, two range burner pilots and one oven pilot were left on, allow: Water heater pilot 1,000 BTU per hour Dryer pilot 500 BTU per hour 2 range burner pilots 1,000 BTU per hour 1 range oven pilot 500 BTU per hour 3,000 BTU per hour Subtracting 3,000 BTU per hour from 124,138 BTU per hour measured above equals 121,138 BTU per hour. This would be the correct furnace gas input after allowing for pilots left on. 10. Manifold pressure may be adjusted within the range of 3.2" W.C. to 3.8" W.C. to get rated input ± 2 percent. See Section 19, “Manifold Pressure Adjustment.” If rated input with manifold pressure cannot be gotten within the allowable range, orifices must be changed. Propane (LP) Gas Input Rate

21. STANDARD ORIFICE SIZING AND HIGH ALTITUDE DERATE This furnace is shipped with fixed gas orifices for use with natural gas and sized for 1000 BTU/cubic foot gas. Make sure actual gas input does not exceed rating plate input. The orifices may need to changed to get the correct gas input. Whether they need changed or not depends on input and the gas heat value at standard conditions and elevation. Consult the local gas supplier for gas heat value and any special derating requirements. See Section 20 for more information. At higher altitudes, the density of the air is reduced. Therefore, for proper combustion, the quantity of gas burned in the furnace must also be reduced. This is called derating. This unit must be derated when installed at altitudes greater than 6,000' above sea level. A high altitude pressure switch must also be installed for operation above 6,000'. High Altitude Pressure Switch Kit number 8620-189 is designed for this application. TABLE 10 Natural Gas Derate Capacities for All Models W**G Rated Input Sea Level 1000 2000 3000 4000 5000 6000 7000 8000 9000 10,000 41,000 45,000 40,500 45,000 39,204 43,560 37,908 42,120 36,612 40,680 35,640 39,600 34,992 38,880 34,182 37,980 33,696 37,440 33,048 36,720 32,643 36,270 32,076 35,640 61,000 68,000 60,750 67,500 58,806 65,340 56,862 63,180 54,918 61,020 53,460 59,400 52,488 58,320 51,273 56,970 50,544 56,160 49,572 55,080 48,965 54,405 48,114 53,460 75,000 81,000 75,000 81,000 72,600 78,408 70,200 75,816 67,800 73,224 66,000 71,280 64,800 69,984 63,300 68,364 62,400 67,392 61,200 66,096 60,450 65,286 59,400 64,152 90,000 100,000 90,000 100,000 87,120 96,800 84,240 93,600 81,360 90,400 79,200 88,000 77,760 86,400 75,960 84,400 74,880 83,200 73,440 81,600 72,540 80,600 71,280 79,200 113,000 125,000 112,500 125,000 108,900 121,000 105,300 117,000 101,700 113,000 99,000 110,000 97,200 108,000 94,950 105,500 93,600 104,000 91,800 102,000 90,675 100,750 89,100 99,000 It is the installer’s responsibility to see that the furnace input rate is adjusted properly. Derating must be achieved by reducing the size of the main burner orifices. Derating the furnace by adjusting the manifold pressure lower than the range specified in the Section 19, “Manifold Pressure Adjustment” is considered to be an improper procedure. Above 6,000' elevation orifice changes are required, and capacity reductions are a function of altitude impact and orifice change. Pressure switch change is required above 6,000' elevation. For natural gas, see Altitude Table 10 below and Orifice Tables 11A and 11B on following pages.

TABLE 11A Natural Gas Orifice Tables for Models W24G, W30G and W36G All other orifice sizes shown are available as individual field-supplied items. See orifice tables below for specifications and number required. Factory Standard Input Gas Heat* Value BTU/Cu. Ft. Up to 6,000' No Changes Except for BTU Content 6,001' to 8,000' Requires Pressure Switch Change and Orifice Change Based on BTU Content 8,001' to 10,000' Requires Pressure Switch Change and Orifice Change Based on BTU Content 25000 BTU Per Burner 700-749 2.75 2.70 2.60 750-799 2.70 2.60 2.50 800-849 2.60 2.50 2.45 850-899 2.50 2.45 2.35 900-949 2.45 2.35 (2.30) 950-999 2.35 (2.30) 2.25 1000-1049** (2.30) 2.25 [2.20] 1050-1100 2.25 [2.20] 2.15 Pressure Switch Standard (.55) Order 8620-189 High Altitude Pressure Switch Kit (.42) (2.30) is the standard factory-installed orifice size [2.20] orifices are shipped with the unit for field-installed optional 10% derate Optional 10% Field- Converted Derate Gas Heat* Value BTU/Cu. Ft. Up to 6,000’ No Changes Except for BTU Content 6,001’ to 8,000’ Requires Pressure Switch Change and Orifice Change Based on BTU Content 8,001’ to 10,000’ Requires Pressure Switch Change and Orifice Change Based on BTU Content 22250 BTU Per Burner 700-749 2.60 2.50 2.45 750-799 2.50 2.45 2.40 800-849 2.45 2.40 (2.30) 850-899 2.40 (2.30) 2.25 900-949 (2.30) 2.25 [2.20] 950-999 2.25 [2.20] 2.15 1000-1049** [2.20] 2.15 2.10 1050-1100 2.15 2.15 2.10 Pressure Switch Standard (.55) Order 8620-189 High Altitude Pressure Switch Kit (.42) [2.20] orifices are shipped with the unit for field-installed optional 10% input rate (2.30) is the factory-installed orifice size for full rated input At standard conditions: 30.00 inches Mercury, 60F, saturated, .60 specific gravity. All Natural Gas factory orifice sizing and standard input ratings based on nominal 1025 BTU/cu. ft. gas and sea level conditions * ** Orifice Size (mm) Orifice Diameter 2.10 0.0826 2.15 0.0846 2.20 0.0866 2.25 0.0885 2.30 0.0905 2.35 0.0925 2.40 0.0945 No. of Orifices Required Based on Unit Input Rating 41,000 (2) 45,000 (2) 61,000 (3) 68,000 (3) 75,000 (3) 81,000 (4) 90,000 (4) 100,000 (4) 113,000 (5) 125,000 (5) Orifice Size (mm) Orifice Diameter 2.45 0.0964 2.50 0.0984 2.60 0.1024 2.70 0.1063 2.75 0.1082 2.80 0.1102 2.90 0.1142

All other orifice sizes shown are available as individual items. See orifice tables on page 32 for part numbers and number required. TABLE 11B Natural Gas Orifice Tables for Models W42G, W48G and W60G Factory Standard Input Gas Heat* Value BTU/Cu. Ft. Up to 6,000’ No Changes Except for BTU Content 6,001’ to 8,000’ Requires Pressure Switch Change and Orifice Change Based on BTU Content 8,001’ to 10,000’ Requires Pressure Switch Change and Orifice Change Based on BTU Content 25000 BTU Per Burner 700-749 2.90 2.80 2.70 750-799 2.80 2.70 2.60 800-849 2.70 2.60 2.50 850-899 2.60 2.50 2.45 900-949 2.50 2.45 (2.40) 950-999 2.45 (2.40) 2.35 1000-1049** (2.40) 2.35 [2.30] 1050-1100 [2.30] 2.25 2.20 Pressure Switch Standard (.55) Order 8620-189 High Altitude Pressure Switch Kit (.42) (2.40) is the standard factory-installed orifice size [2.30] orifices are shipped with the unit for field-installed optional 10% derate Optional 10% Field Converted Derate Gas Heat* Value BTU/Cu. Ft. Up to 6,000’ No Changes Except for BTU Content 6,001’ to 8,000’ Requires Pressure Switch Change and Orifice Change Based on BTU Content 8,001’ to 10,000’ Requires Pressure Switch Change and Orifice Change Based on BTU Content 22250 BTU Per Burner 700-749 2.75 2.70 2.60 750-799 2.70 2.60 2.50 800-849 2.60 2.50 850-899 2.50 2.45 (2.40) 900-949 (2.40) 2.35 [2.30] 950-999 2.35 [2.30] 2.25 1000-1049** [2.30] 2.25 2.20 1050-1100 2.25 2.25 2.20 Pressure Switch Standard (.55) Order 8620-189 High Altitude Pressure Switch Kit (.42) [2.30] orifices are shipped with the unit for field-installed optional 10% input rate (2.40) is the factory-installed orifice size for full rated input At standard conditions: 30.00 inches Mercury, 60F, saturated, .60 specific gravity. All Natural Gas factory orifice sizing and standard input ratings based on nominal 1025 BTU/cu. ft. gas and sea level conditions * **

23. MEASURING AIR TEMPERATURE RISE Air temperature rise (supply air temperature minus return air temperature) must be within allowable air temperature rise range specified on furnace rating plate. Two thermometers with 1° resolution capable of reading up to 200° F will be needed. Check thermometers to make sure they agree, or compensate accordingly. Follow this procedure: 1. Open supply air registers and return air grilles. Make sure the registers and grilles are free of obstruction from rugs, carpets, drapes or furniture. 2. Set balancing dampers in supply duct system. 3. Check duct work for obstructions or leaks. 22. CONVERSION OF GAS INPUT BTUH FROM HIGH TO LOW RATING All the derated WG series units are produced with maximum BTUH input orifices installed. To field convert input, a change to main burner orifices is required. NOTE: No change to air orifices is necessary. A set of low input orifices is shipped with every unit. They will be found packaged in a bag behind the burner door. Refer to the unit rating plate to confirm the proper orifice size. Proper installation of the orifices is detailed as follows: 1. Shut off electrical supply to the unit. 2. Shut off gas supply to the unit. 3. Remove burner access panel. 4. Disconnect gas valve from gas supply piping. 5. Disconnect the two wires from the gas valve. 6. Remove the manifold assembly so that orifices are now accessible and remove orifices. 7. Apply a modest amount of pipe compound to the new orifices and screw them into the manifold. 8. To assemble burner, reverse Steps 1 through 7. 4. Make sure filters are clean and in place. 5. Place one thermometer in supply air plenum approximately 2' from furnace. Locate thermometer tip in center of plenum to ensure proper temperature measurement. 6. Place second thermometer in return air duct approximately 2' from furnace. Locate thermometer tip in center of duct to ensure proper temperature measurement. 7. Set room thermostat on highest temperature setting. Operate furnace 10 minutes. Record supply air and return air temperatures. 8. Calculate air temperature rise by subtracting return air temperature from supply air temperature. • If air temperature rise is above the temperature rise range on rating plate, furnace is overfired or has insufficient airflow. Check gas input following the instructions in Section 20, “Checking Gas Input Rate”. If air temperature rise is still above temperature rise range specified, more heating airflow is needed. Check duct work and grilles to make sure all are properly sized. • If air temperature rise is below the temperature rise range on rating plate, furnace is underfired or has too much airflow. Check gas input following the instructions in Section 20, “Checking Gas Input Rate”. If air temperature rise is still below temperature rise range specified, less heating airflow is needed. Adjust dampers or grilles as needed. • After making adjustments, check air temperature rise to verify that resulting air temperature rise is within allowable range. If air temperature rise is still outside the temperature rise range specified on rating plate, check duct system design with a qualified heating engineer. It may be necessary to re-size the duct work. Recheck air temperature rise after revising duct systems. 9. Set room thermostat to desired setting. 10. Remove thermometers and seal duct work holes. NOTE: Failure to seal holes could result in reduced system performance. 24. FILTERS A 2" thick throwaway filter is supplied with each unit. This filter is installed by opening the filter service door (see Figure 16). Replacement filters are available through the dealer. WARNING Failure to follow these instructions could create a hazard resulting in property damage, bodily injury, or death.

25. COMPRESSOR CONTROL MODULE The compressor control module is standard on models covered by this manual. Features Delay-on-Make Timer Short Cycle Protection/Delay-on-Break High Pressure Detection HPC Status LED Test Mode Brownout Protection with Adjustment Delay-on-Make Timer A delay-on-make timer is included to be able to delay startup of the compressor. This is desired when more than one unit is on a structure so that all of the units do not start at the same time which could happen after a power loss or building shutdown. The delay- on-make time period is 2 minutes plus 10% of the delay-on-break time period. To ensure that all of the units do not start at the same time, adjust the delay- on-break timer on each unit to a slightly different delay time. Short Cycle Protection/Delay-on-Break An anti-short cycle timer is included to prevent short cycling the compressor. This is adjustable from 30 seconds to 5 minutes via the adjustment knob. Once FIGURE 16 Access Internal Filter Through Upper Service Door a compressor call is lost, the time period must expire before a new call will be initiated. High Pressure Detection High pressure switch monitoring allows for a lockout condition in a situation where the switch is open. If the high pressure switch opens, the CCM will de- energize the compressor. If the switch closes again, it will then restart the compressor after the delay- on-break setting has expired on the device. If the switch trips again during the same thermostat call, the compressor will be de-energized and the alarm terminal will be energized indicating an alarm. The red LED will light and stay on until power is cycled to the control or a loss of voltage is present at Y terminal for more than ½ second. Test Mode By rapidly rotating the potentiometer (POT) clockwise (see Figure 17 on page 36), all timing functions will be removed for testing. The conditions needed for the unit to enter test mode are as follows: POT must start at a time less than or equal to the 40 second mark. The POT must then be rapidly rotated to a position greater than or equal to the 280 second mark in less than ¼ second. Normal operation will resume after power is reset or after the unit has been in test mode for at least 5 minutes. MIS-3237 FILTER FILTER SERVICE DOOR

Brownout Protection with Adjustment Brownout protection may be necessary if the utility power or generator power has inadequate power to prevent the voltage from dropping when the compressor starts. This is rare but can happen if the generator is undersized at the site or if the site is in a remote location far from the main power grid. Under normal circumstances, allowing the brownout to be ignored for a time period should not be needed. The 8201-169 is shipped in “0” do not ignore position, with all the DIP switches off (see Figure 17). If ignoring the brownout is needed because of the above conditions, three preset timers can be set by DIP switches in order to delay signaling a power brownout for a specific length of time after compressor contactor is energized. This allows the compressor a time period to start even if the voltage has dropped and allows the voltage to recover. This delay only happens when the CC terminal energizes. The delay can be set to 1 second (A DIP switch), 5 seconds (B DIP switch) or 10 seconds (C DIP switch); time is not cumulative—only the longest setting will apply. If the voltage recovers during the brownout delay period, the compressor will start. If a brownout condition is detected by the 8201-169, the troubleshooting light will flash blue. The light will continue to flash until the cooling call is satisfied or power is removed from the Y terminal. This condition does not prevent operation, it only indicates that a brownout condition was present at some point during the cooling call. If a brownout condition is detected, CC will be de-energized and will retry after the delay- on-make timer is satisfied; this process will continue until call is satisfied. If user chooses the “0” do not ignore position when the site has inadequate utility or generator power, this could lead to the compressor never starting. The control will see the brownout immediately and not start. A common scenario and one that has been seen in the field is when a unit or units switches from utility power to generator power. With slower transfer switches, the time delay between the utility power and generator power didn’t cause a problem. The units lost power, shut off and came back on line normally. With the introduction of almost instantaneous transfer switches, the millisecond long power glitch can be enough that the compressor will start to run backwards. In this scenario, the CCM will catch this and restart the units normally. FIGURE 17 8201-169 COMPRESSOR CONTROL MODULE High Pressure Switch Compressor Contactor Output Alarm Output Common Delay-on-Break Time Adjustment Potentiometer Brownout Ignore Time DIP Switches* 18-30 VAC Input Y Input from Thermostat and High Pressure Switch Troubleshooting Light * Turn on only one switch for that specific ignore time setting. 10 seconds is the maximum brownout ignore time. Jumper

27. LIGHTING AND SHUTDOWN INSTRUCTIONS FIGURE 18 Lighting and Shutdown Instruction Label  BEND & PEEL “HERE” TO REMOVE LABEL LINER  A. This appliance does not have a pilot. It is equipped with an ignition device which automatically lights the burner. Do NOT try to light the burner by hand. B. BEFORE OPERATING smell all around the appliance area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor. WHAT TO DO IF YOU SMELL GAS * Do not try to light any appliance. * Do not touch any electric switch; do not use any phone in your building. * Immediately call your supplier from a neighbor’s phone. Follow the gas supplier’s instructions. * If you cannot reach your gas supplier; call the fire department. C. Use only your hand to push in or move the gas control lever. Never use tools. If the lever will not push in or turn by hand, don’t try to repair it, call a qualified ser- vice technician. Force or attempted repair may result in a fire or explosion. D. Do not use this appliance if any part has been under water. Immediately call a qualified service technician to inspect the appliance and to replace any part of the control sys- tem and any gas control which has been under water. WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. 1. Set the thermostat to lowest setting. 2. Turn off all electric power to the appliance if service is to be performed. 3. Remove control access panel. 4. Push in gas control lever slightly and move to “OFF”. Do not force. 5. Replace control access panel. 7961-509 TO TURN OFF GAS TO APPLIANCE FOR YOUR SAFETY READ BEFORE OPERATING OPERATING INSTRUCTIONS 1. STOP! Read the safety information above on this label. 2. Set the thermostat to lowest setting 3. Turn off all electric power to the appliance. 4. This appliance is equipped with an ignition device which automatically lights the burner. Do NOT try to light the burner by hand. 5. Remove control access panel. 6. Push in gas control knob slightly and turn clockwise to “OFF”. NOTE: Knob cannot be turned to “OFF” unless knob is pushed in slightly. Do not force. 7. Wait five (5) minutes to clear out any gas. Then smell for gas, including near the floor. If you smell gas, STOP! Follow “B” in the safety information above on this label. If you don’t smell gas, go to the next step. 8. Turn gas control knob counterclockwise to “ON”. 9. Replace control access panel. 10. Turn on all electric power to the appliance. 11. Set thermostat to desired setting. 12. If the appliance will not operate, follow the instructions “To Turn Off Gas To Appliance” and call your service technician or gas supplier. GAS CONTROL KNOB SHOWN IN “OFF” POSITION GAS INLET 26. 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 “Y” 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. If a fault condition occurs, reverse two of the supply leads to the unit. Do not reverse any of the unit factory wires as damage may occur.

28. SERVICE AGENCY PROCEDURES Main Burner Observe the main burners in operation. The flame should be mostly “blue” with possibly a little orange (not yellow) at the tips of the flame. The flames should be in the center of the heat exchanger tubes and not impinging on the heat exchanger surfaces themselves. Observe the fire until the blower starts (there is a normal delay period until the heat exchanger warms up). There should be no change in the size or shape of the flame. If there is any wavering or blowing of the flame on blower start-up, it is an indication of a possible leak in the heat exchanger. Burners/Heat Exchanger/Flue Gas Passage Ways The burners, heat exchanger and interior flue gas passages may be inspected using a light on small mirror or an extension handle. Remove the screws securing the inducer and collector box. Now inspect the upper tubes of the heat exchanger. Check the exterior of the heat exchanger and the interior flue gas passages for any evidence of deterioration due to corrosion, cracking or other causes. If signs of sooting exist, remove the burners and clean the heat exchanger, as required. 29. MAINTAINING UNIT IN GOOD WORKING ORDER The unit should be inspected annually by a qualified service agency. MIS-165 FIGURE 19 Top View of Gas Control CAUTION Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing. WARNING Follow these procedures before inspecting furnace. • Turn room thermostat to its lowest or off setting. • Turn off manual gas shut-off valve. • Wait at least 5 minutes for furnace to cool if it was recently operating. • Turn off furnace electrical power; failure to do so could result in injury or death. WARNING Use replacement parts listed in the Replacement Parts list only. The use of incorrect parts could cause improper unit operation, resulting in damage, injury or death.

Routine Maintenance 1. Air Filters – Check the condition at least monthly when the unit is in use, and replace as necessary. 2. Lubrication Requirements – The indoor circulating air blower motor and outdoor circulating air fan motor are permanently lubricated and requires no re-oiling. The combustion air blower motor requires no re-oiling. Routine Inspection 1. Inspect the physical support of the unit annually to make sure it is securely fastened to the building. Also look for any obvious signs of deterioration. 2. Inspect the main burners at the beginning of each heating season and clean as necessary. 3. Inspect the vent terminal and combustion air intake hood for any obvious deterioration, to make sure it is free and clear of any obstructions. 30. TROUBLESHOOTING NIDEC SELECTECH SERIES ECM MOTORS If the Motor Is Running 1. It is normal for the motor to rock back and forth on start up. Do not replace the motor if this is the only problem identified. 2. If the system is excessively noisy, does not appear to change speeds in response to a demand (Heat, Cool, Other) or is having symptoms during the cycle such as tripping limit or freezing coil, check the following: A. Wait for programmed delays to time out. B. Ensure that the motors control inputs are wired as shown in the factory-supplied wiring diagram to ensure motor is getting proper control signals and sequencing. C. Remove the filter and check that all dampers, registers and grilles are open and free flowing. If removing the filters corrects the problem, clean or replace with a less restrictive filter. Also check and clean the blower wheel or coil as necessary. Annual Maintenance Routine inspection and maintenance procedures are the responsibility of the user and are outlined below. 1. Before inspecting unit: A. Turn room thermostat to lowest or off setting. B. Turn off equipment gas shut-off valve. C. Wait for unit to cool if it was recently operating. D. Turn off electrical power to unit. 2. Inspect the following: A. Vent terminal and combustion air intake terminal. Make sure both are free from obstructions. B. Vertical vent applications – Inspect venting system. Make sure system has no holes, is physically sound and free from obstructions. C. Make sure the supply and return air flange sleeves or duct work are securely fastened to unit and physically sound. D. Supply and return grilles must be open and free from obstructions. E. Inspect to make sure the unit is securely fastened to the wall. Seal any possible leaks between unit and wall with appropriate exterior sealing material. F. Inspect burners, heat exchanger, induced draft blower and induced draft blower collector box. There must be no obvious signs of deterioration. G. Inspect all electrical connections and wiring. H. Check all gas piping for leaks with soap solution used to detect leaks. I. Inspect, clean and repair as needed the entire blower assembly, air filters, draft inducer, cooling coils and vent options (if installed). WARNING Disconnect electrical power before servicing unit. Failure to do so could result in electrical shock or death. WARNING Turn off electrical power supply to prevent injury from moving parts or electric shock.

D. Check the external static pressure (total of both supply and return) to ensure it is within the range as listed on the unit serial plate. If higher than allowed, additional duct work is needed. E. If the motor does not shut off at the end of the cycle, wait for any programmed delays to time out (no more than 90 seconds). Also make sure that there is no call for “Continuous Fan” on the G terminal. F. If the above diagnostics do not solve the problem, confirm the voltage checks in the next section below, then continue with the Model SelecTech Communication Diagnostics. If the Motor Is Not Running 1. Check for proper high voltage and ground at the L/ L1, G, N/L2 connections at the motor (see Figure 20). Correct any voltage issues before proceeding to the next step. The SelecTech motor is voltage specific. Only the correct voltage should be applied to the proper motor. Input voltage within plus or minus 10% of the nominal line power VAC is acceptable. 2. If the motor has proper high voltage and ground at the L/L1, G, N/L2 connections, then continue with the Model SelecTech Communication Diagnostics. Model SelecTech Communication Diagnostics The SelecTech motor is communicated through 24 VAC low voltage (thermostat control circuit wiring). 1. Start with unit wiring diagram to confirm proper connections and voltage (see Figure 21). 2. Initiate a demand from the thermostat and check the voltage between the common and the appropriate motor terminal (1-5). (G input is typically on terminal #1, but always refer to wiring diagram.) A. If the low voltage communication is not present, check the demand from the thermostat. Also check the output terminal and wire(s) from the terminal strip or control relay(s) to the motor. B. If the motor has proper high voltage (verified in Step 1 of If the Motor Is Not Running), proper low voltage to a programmed terminal and is not operating, the motor is failed and will require replacement. FIGURE 20 Motor Connections Manual 2100-467H Page 22 of 23 FIGURE 10 ↓ ↓ NOTE: Bard Models PA13242; PA13302; PA13362-A, -B; PA13422-A, -B, -C; PA13482-A, -B, -C; PA13602-A, -B, -C contain the X13-Series Motors. TROUBLESHOOTING GE X13-SERIES ECM2.3™ MOTORS If the Motor is Running 1. It is normal for the motor to rock back and forth on start up. Do not replace the motor if this is the only problem identified. 2. If the system is excessively noisy, does not appear to change speeds in response to a demand (Heat, Cool, Other), or is having symptoms during the cycle such as tripping limit or freezing coil, check the following: a.Wait for programmed delays to time out. b.Ensure that the motors control inputs are wired to the factory supplied wiring diagram to insure motor is getting proper control signals and sequencing. c.Remove the filter and check that all dampers, registers, and grilles are open and free flowing. If removing the filters corrects the problem, clean or replace with a less restrictive filter. Also check and clean the blower wheel or coil as necessary. d.Check the external static pressure (total of both supply and return) to insure that you are within the ranges as listed on the unit serial plate. If higher than allowed, additional duct work is needed. e.If the motor does not shut off at the end of the cycle, wait for any programmed delays to time out (no more than 90 seconds). Also make sure that there is no call for “Continuous Fan” on the "G" terminal. f. If the above diagnostics do not solve the problem, confirm the voltage checks in the next section below, then continue with the “Model X13 Communication Diagnostics”. If the Motor is Not Running 1. Check for proper high voltage and ground at the (L/L1) (G) (N/ L2) connections at the motor (see Figure 10). Correct any voltage issues before proceeding to the next step. The X13 Motor is voltage specific. Only the correct voltage should be applied to the proper motor. Input voltage within plus or minus 10% of the nominal 230 VAC is acceptable. 2. If the motor has proper high voltage and ground at the (L/L1) (G) (N/L2) connections, then continue with the “Model X13 Communication Diagnostics”. L2 LINE POWER EARTH GROUND L1 LINE POWER NOTE: MOTOR IS CONSTANTLY POWERED BY LINE VOLTAGE LINE POWER LINE POWER GROUND

31. REPLACEMENT PARTS Replacement parts for the gas/electric units are available through local distributors. A replacement parts list manual is supplied with each unit. When ordering parts or making inquires pertaining to any of the units covered by these WARNING Use replacement parts listed in Replacement Parts list. Failure to do so could cause improper furnace operation, resulting in property damage, personal injury or death. FIGURE 21 Motor Connections Manual 2100-467H Page 23 of 23 FIGURE 11 24VAC "R" Signal through thermostat output. 24VAC Common 24VAC Common 24VAC "R" Signal through thermostat output. Speed Tap 1: Balanced Climate Speed Speed Tap 2: Cool Speed Speed Tap 3: Cool High Speed Speed Tap 4: Heat Speed Speed Tap 5: Heat High Speed instructions, it is very important to always supply the complete model number and serial number of the unit. This is necessary to assure that the correct parts (or an approved alternate part) are issued to the service agency.

32. SEQUENCE OF OPERATION – HEATING On a call for heat from the thermostat, the induced draft blower is energized. Once sufficient draft is established, the pressure switch contacts close and the ignition system is energized. The direct spark igniter will be energized allowing gas to flow. At the same time the main valve is energized, a 30-second blower delay timer is activated. After this delay, the heating speed blower relay energizes. The blower will begin operating and remain in operation until the set delay time after the call for heat has been satisfied. This timing sequence guarantees blower on, blower off operation. This unit is equipped with a flame roll-out switch, which is wired in series with the control circuit. This is a manual reset switch and is used for the purpose of preventing possible fire hazard in the event of a system malfunction. If this switch has opened the control circuit, there could be a possible system malfunction. Some of the conditions that might cause a roll-out to occur are blockage or sooting of primary heat exchanger, overfiring of furnace due to improper main burner orifices or incorrect manifold pressure, insufficient combustion air or installation deficiencies with respect to return air duct design or sizing. FIGURE 22 Sequence of Operation Electronic Blower Control Action System Response Thermostat calls for heat (W terminal is energized). • Combustion air blower is energized. • Air proving switch makes. Airflow is established. • Ignition system is energized. • Gas valve opens and main burner lights. • Heat fan on delay timing begins. When timing is complete, the circulating fan is energized at heat speed. Thermostat ends call for heat. • Ignition system is de-energized and gas valve closes. • Combustion air blower is de-energized after postpurge timing. • Heat fan off delay timing begins. When timing is complete, the circulating fan is de-energized. Thermostat begins call for cool (G and Y terminals re-energized). • Cooling contactor is energized. • Circulating fan is energized on cool speed after cool fan on delay timing. Thermostat begins call for fan (G terminal is de-energized). • Circulating fan is de-energized Limit (flame rollout) opens. • Thermostat and ignition system are de-energized and gas valve closes. • Combustion air blower and circulating fan heat speed are energized. Limit (auto reset) or flame rollout (manual reset) circuit closed. • Combustion air blower remains energized for postpurge timing. • The circulation fan remains energized for the selected delay off timing. • Normal operation resumes. Once the problem has been resolved, reset the switch by pressing down on the reset button on top of the switch. See Figure 22 for additional information. 33. SEQUENCE OF OPERATION – COOLING On a call for cooling from the room thermostat, the blower relay will be energized as well as the compressor contactor. Following termination of the cooling cycle, the blower motor will continue to run for one minute. See Figure 22 for additional information. The unit may be equipped with a low ambient control for lower outdoor temperature operation in the cooling mode. If equipped with this optional control, the condenser fan will not operate immediately upon compressor start-up, and will cycle on and off until the condensing pressure remains above 180 PSIG. Low ambient control energizes the fan motor at 280 PSIG, de-energizes at 180 PSIG.

34. SETTING UNIT AIRFLOW All models have multiple speed direct drive blower motors. If supply and return ducts are connected to the unit, the ducts must be of adequate size. Refer to the appropriate blower tables. See Tables 12, 13, 14, 15, 16 and 17 for maximum static pressures acceptable. Note the minimum CFM for Heating and Cooling operation. The unit is set from the factory at the default speed. W**G units have three (3) selectable speeds for cooling and two (2) selectable speeds for heating. First set the airflow for heating. For high static applications the speed should be set to high. When in doubt, note the allowable air temperature rise listed on the name plate and using the procedure listed in Section 23, "Measuring Air Temperature Rise", measure the air temperature rise. If the temperature rise is above allowable range, the heating airflow must be increased. To increase the heating airflow speed: • First disconnect power to the unit. • Open the control panel and find the furnace control board (see Figure 23). • Remove the black wire from the unused terminal and then remove the red wire from the heat terminal. • Install the red wire on the unused terminal and the black wire on the heat terminal. • Close the control panel and repeat the air temperature rise test. • To reduce the heating airflow speed from high to standard, move the black wire from the heat terminal to the unused terminal and the red wire from the unused terminal to the heat terminal. The default speed for cooling is the rated cooling speed that is listed in Tables 12, 13, 14, 15, 16 and 17. The higher cooling speed tap can be used for higher duct static applications or to increase the sensible cooling capacity. The higher speeds can also be used when higher sensible cooling is desired. To increase the cooling airflow speed: • First disconnect power to the unit. • Open the control panel and find the terminal block above the blower relay (see Figure 24 on page 44). MIS-4138 RED BLACK FURNACE CONTROL BOARD BLACK RED STANDARD TO HIGH BLACK RED STANDARD HEATING AIRFLOW RED BLACK HIGH HEATING AIRFLOW MIS-4138 FIGURE 23 Increasing Heating Speed

• Locate the orange and blue wires on the terminal block below the furnace control board. • Switch the terminal landings on the terminal block. • Close the control panel. • To reduce the cooling airflow speed from high to rated, reverse the blue and orange wires on the terminal block below the furnace control board. NOTE: Be sure to adjust the system static or blower speed to maintain airflows above the minimum recommendations to prevent freeze up conditions if Balanced Climate mode is activated. Do not operate the unit in Balanced Climate mode if running high static applications as indicated in the blower performance table. If Balanced Climate mode is activated as described on page 22, the unit will run in this mode at all times unless there is a call for ventilation, electric heat or 2nd stage cooling from a 2-stage thermostat. At that time, the unit will automatically activate a higher speed tap. Blower Speeds Five factory programmed speed taps (torque settings) are available for the motor, and are selected through different unit modes of operation. These modes are energized by 24VAC signals from the low voltage terminal block located inside the control panel by a thermostat or other controlling device. Each speed tap is programmed by Bard at the factory to different motor torque settings (see Figure 25). Multiple motor speed taps may be energized simultaneously by 24VAC power during different modes of operation. The highest number speed tap energized takes priority with 5 being the highest and 1 being the lowest. FIGURE 25 Speed Taps Speed Tap 1: Balanced Climate Speed Speed Tap 2: Cool Speed Speed Tap 3: Cool High Speed Speed Tap 4: Heat Speed Speed Tap 5: Heat High Speed Manual 2100-467H Page 23 of 23 FIGURE 11 TROUBLESHOOTING GE X13-SERIES ECM2.3™ MOTORS CONT’D. Model X13 Communication Diagnostics The X13 motor is communicated through 24 VAC low voltage (Thermostat Control Circuit Wiring). 1. Start with unit wiring diagram to confirm proper connections and voltage (see Figure 11). 2. Initiate a demand from the thermostat and check the voltage between the common and the appropriate motor terminal (1-5). ("G" input is typically on terminal #1, but refer to wiring diagram!) a. If the low voltage communication is not present, check the demand from the thermostat. Also check the output terminal and wire(s) from the terminal strip or control relay(s) to the motor. b. If the motor has proper high voltage as identified above (Motor not Running #1), and proper low voltage to a programmed terminal, and is not operating, the motor is failed, and will require replacement. 24VAC "R" Signal through thermostat output. 24VAC Common 24VAC Common 24VAC "R" Signal through thermostat output. 24VAC Common 24VAC "R" signal through thermostat output FIGURE 24 Increasing Cooling Speed TERMINAL BLOCK TERMINAL BLOCK BLUE ORANGE/BLACK ORANGE TERMINAL BLOCK BLUE ORANGE ORANGE/BLACK TERMINAL BLOCK BLUE ORANGE ORANGE/BLACK MIS-4139 PURPLE BLOWER RELAY BLACK/WHITE BLUE YELLOW/WHITE ORANGE/BLACK BLACK/WHITE WIRE ORANGE/BLACK TERMINAL BLOCK IN REFERENCE TO LOCATION OF BLUE : WIRE LOCATIONS ON ORANGE & PLEASE NOTE . HIGH AIRFLOW BLUE ORANGE B ORANGE/BLACK STANDARD RATED COOLING AIRFLOW TO CHANGE FROM RATED TO HIGH A PINK OPTIONAL NOTE A RATED AIRFLOW B HIGH COOLING AIRFLOW

TABLE 12 W24G4 Indoor Blower Performance @ 230 and 460 VOLTS Recommended W24G cooling airflow range at rated 800 CFM @ 0.10 ESP (WC) is 700 - 910 CFM Factory set on Rated speed for cooling and Medium speed for heating. SG-3, RG-3, non-ducted application adjustment – Reduce airflow by 100 CFM for SG-3 and RG-3 installations ESP Inches H2O COOLING MODE MANUAL FAN and HEATING MODE Wet Coil 90,000 BTU Input 81,000 BTU Input Balanced Rated High Medium High Medium High 0 670 928 1213 0.1 598 851 1141 1361 0.2 511 760 1055 1288 1373 1288 0.3 417 662 962 1214 1324 1214 0.4 323 564 870 1143 1278 1143 0.5 235 473 784 1077 1237 1077 1237 ESP Inches H2O COOLING MODE MANUAL FAN and HEATING MODE Wet Coil 68,000 BTU Input 61,000 BTU Input Balanced Rated High Medium High Medium High 0 670 928 1213 0.1 598 851 1141 0.2 511 760 1055 1288 0.3 417 662 962 1214 0.4 323 564 870 1143 1278 1143 0.5 235 473 784 1077 1237 1077 ESP Inches H2O COOLING MODE MANUAL FAN and HEATING MODE Wet Coil 45,000 BTU Input 41,000 BTU Input Balanced Rated High Medium High Medium High 0 670 928 1213 0.1 598 851 1141 1361 0.2 511 760 1055 1288 0.3 417 662 962 1214 1324 0.4 323 564 870 1143 1278 1143 0.5 235 473 784 1077 1237 1077

TABLE 13 W30G4 Indoor Blower Performance @ 230 AND 460 VOLTS Recommended W30G cooling airflow range at rated 900 CFM @ 0.15 ESP (WC) is 750 - 1150 CFM Factory set on Rated speed for cooling and Medium speed for heating. Dehumidification coil adjustment – Reduce airflow by 35 CFM for dehumidification coil installed SG-3, RG-3, non-ducted application adjustment – Reduce airflow by 100 CFM for SG-3 and RG-3 installations ESP Inches H2O COOLING MODE MANUAL FAN and HEATING MODE Wet Coil 90,000 BTU Input 81,000 BTU Input Balanced Rated High Medium High Medium High 0 850 1022 1157 1281 0.1 769 953 1098 1237 1375 1237 0.2 688 883 1038 1188 1329 1188 0.3 606 812 975 1134 1279 1134 0.4 523 739 910 1075 1225 1075 1225 0.5 439 664 843 1011 1168 1011 1168 ESP Inches H2O COOLING MODE MANUAL FAN and HEATING MODE Wet Coil 68,000 BTU Input 61,000 BTU Input Balanced Rated High Medium High Medium High 0 850 1022 1157 1281 0.1 769 953 1098 1237 0.2 688 883 1038 1188 0.3 606 812 975 1134 1279 1134 0.4 523 739 910 1075 1225 1075 0.5 439 664 843 1011 1168 1011 ESP Inches H2O COOLING MODE MANUAL FAN and HEATING MODE Wet Coil 45,000 BTU Input 41,000 BTU Input Balanced Rated High Medium High Medium High 0 850 1022 1157 1281 0.1 769 953 1098 1237 0.2 688 883 1038 1188 1329 1188 0.3 606 812 975 1134 1279 1134 0.4 523 739 910 1075 1225 1075 0.5 439 664 843 1011 1168 1011 1168

TABLE 14 W36G4 Indoor Blower Performance @ 230 AND 460 VOLTS Recommended W36G cooling airflow range at rated 1100 CFM @ 0.10 ESP (WC) is 940 - 1250 CFM Factory set on Rated speed for cooling and Medium speed for heating. SG-3, RG-3, non-ducted application adjustment – Reduce airflow by 100 CFM for SG-3 and RG-3 installations ESP Inches H2O COOLING MODE MANUAL FAN and HEATING MODE Wet Coil 90,000 BTU Input 81,000 BTU Input Balanced Rated High Medium High Medium High 0 932 1202 1281 1281 0.1 855 1148 1238 1237 1375 1237 0.2 776 1091 1190 1188 1329 1188 0.3 695 1030 1139 1134 1279 1134 0.4 614 966 1083 1075 1225 1075 1225 0.5 530 898 1022 1011 1168 1011 1168 ESP Inches H2O COOLING MODE MANUAL FAN and HEATING MODE Wet Coil 68,000 BTU Input 61,000 BTU Input Balanced Rated High Medium High Medium High 0 932 1202 1281 1281 0.1 855 1148 1238 1237 0.2 776 1091 1190 1188 0.3 695 1030 1139 1134 1279 1134 0.4 614 966 1083 1075 1225 1075 0.5 530 898 1022 1011 1168 1011 ESP Inches H2O COOLING MODE MANUAL FAN and HEATING MODE Wet Coil 45,000 BTU Input 41,000 BTU Input Balanced Rated High Medium High Medium High 0 932 1202 1281 1281 0.1 855 1148 1238 1237 0.2 776 1091 1190 1188 1329 1188 0.3 695 1030 1139 1134 1279 1134 0.4 614 966 1083 1075 1225 1075 0.5 530 898 1022 1011 1168 1011 1168

TABLE 15 W42G4 Indoor Blower Performance @ 230 AND 460 VOLTS Recommended W42G cooling airflow range at rated 1300 CFM @ .15 ESP (WC) is 1030 - 1480 CFM Factory set on Rated speed for cooling and Medium speed for heating. SG-5, RG-5, non-ducted application adjustment – Reduce airflow by 170 CFM for SG-5 and RG-5 installations ESP Inches H2O COOLING MODE MANUAL FAN and HEATING MODE Wet Coil 125,000 BTU Input 113,000 BTU Input Balanced Rated High Medium High Medium High 0 1084 1394 1552 1788 0.1 1011 1335 1498 1734 0.2 930 1270 1439 1678 1678 0.3 840 1198 1374 1618 1618 0.4 741 1119 1305 1557 1811 1557 0.5 633 1034 1230 1492 1754 1492 ESP Inches H2O COOLING MODE MANUAL FAN and HEATING MODE Wet Coil 100,000 BTU Input 90,000 BTU Input Balanced Rated High Medium High Medium High 0 1084 1394 1552 1788 0.1 1011 1335 1498 1734 1734 0.2 930 1270 1439 1678 1678 0.3 840 1198 1374 1618 1870 1618 0.4 741 1119 1305 1557 1811 1557 0.5 633 1034 1230 1492 1754 1492 ESP Inches H2O COOLING MODE MANUAL FAN and HEATING MODE Wet Coil 75,000 BTU Input 68,000 BTU Input Balanced Rated High Medium High Medium High 0 1084 1394 1552 1788 0.1 1011 1335 1498 1734 0.2 930 1270 1439 1678 1678 0.3 840 1198 1374 1618 1870 1618 0.4 741 1119 1305 1557 1811 1557 0.5 633 1034 1230 1492 1754 1492

TABLE 16 W48G4 Indoor Blower Performance @ 230 AND 460 VOLTS Recommended W48G cooling airflow range at rated 1450 CFM @ .20 ESP (WC) is 1150 - 1680 CFM Factory set on Rated speed for cooling and Medium speed for heating. SG-5, RG-5, non-ducted application adjustment – Reduce airflow by 170 CFM for SG-5 and RG-5 installations ESP Inches H2O COOLING MODE MANUAL FAN and HEATING MODE Wet Coil 125,000 BTU Input 113,000 BTU Input Balanced Rated High Medium High Medium High 0 1185 1501 1668 1788 0.1 1118 1445 1616 1734 0.2 1042 1384 1560 1678 1678 0.3 958 1317 1500 1618 1618 0.4 866 1245 1436 1557 1811 1557 0.5 766 1167 1368 1492 1754 1492 ESP Inches H2O COOLING MODE MANUAL FAN and HEATING MODE Wet Coil 100,000 BTU Input 90,000 BTU Input Balanced Rated High Medium High Medium High 0 1185 1501 1668 1788 0.1 1118 1445 1616 1734 1734 0.2 1042 1384 1560 1678 1678 0.3 958 1317 1500 1618 1870 1618 0.4 866 1245 1436 1557 1811 1557 0.5 766 1167 1368 1492 1754 1492 ESP Inches H2O COOLING MODE MANUAL FAN and HEATING MODE Wet Coil 75,000 BTU Input 68,000 BTU Input Balanced Rated High Medium High Medium High 0 1185 1501 1668 1788 0.1 1118 1445 1616 1734 0.2 1042 1384 1560 1678 1678 0.3 958 1317 1500 1618 1870 1618 0.4 866 1245 1436 1557 1811 1557 0.5 766 1167 1368 1492 1754 1492

TABLE 17 W60G4 Indoor Blower Performance @ 230 AND 460 VOLTS Recommended W60G cooling airflow range at rated 1650 CFM @ .20 ESP (WC) is 1360 - 1850 CFM Factory set on Rated speed for cooling and Medium speed for heating. SG-5, RG-5, non-ducted application adjustment – Reduce airflow by 170 CFM for SG-5 and RG-5 installations ESP Inches H2O COOLING MODE MANUAL FAN and HEATING MODE Wet Coil 125,000 BTU Input 113,000 BTU Input Balanced Rated High Medium High Medium High 0 1347 1771 1881 1743 0.1 1272 1708 1823 1682 0.2 1199 1646 1766 1619 1843 1619 0.3 1128 1584 1709 1554 1783 1554 0.4 1060 1523 1652 1486 1721 1486 0.5 994 1462 1596 1417 1657 1417 1657 ESP Inches H2O COOLING MODE MANUAL FAN and HEATING MODE Wet Coil 100,000 BTU Input 90,000 BTU Input Balanced Rated High Medium High Medium High 0 1347 1771 1881 1743 0.1 1272 1708 1823 1682 1682 0.2 1199 1646 1766 1619 1843 1619 0.3 1128 1584 1709 1554 1783 1554 0.4 1060 1523 1652 1486 1721 1486 1721 0.5 994 1462 1596 1417 1657 1417 1657 ESP Inches H2O COOLING MODE MANUAL FAN and HEATING MODE Wet Coil 75,000 BTU Input 68,000 BTU Input Balanced Rated High Medium High Medium High 0 1347 1771 1881 1743 0.1 1272 1708 1823 1682 1682 0.2 1199 1646 1766 1619 1843 1619 0.3 1128 1584 1709 1554 1783 1554 0.4 1060 1523 1652 1486 1721 1486 1721 0.5 994 1462 1596 1417 1657 1417 1657

TABLE 18 Integrated Furnace and Blower Control Operation IGNITION SEQUENCE CONTROL Ignition Source 24 VAC DSI Flame Sensing Remote Timings - Prepurge - Postpurge - Inter-trial purge - Pressure switch proving period - Trials for ignition - Trial for ignition - Ignition sequence lockout - Heat blower on - delay - Heat blower off - delay - Cool blower on - delay - Cool blower off - delay - Manual fan operations - High limit control operation - Flame rollout switch operation 15 seconds 30 seconds (0 if cycle terminated before valve “on”) 15 seconds 60 seconds 3 per ignition sequence 7 seconds total time to prove flame 60 minutes (after 3 trials for ignition), auto reset - can be reset during the 60-minute lockout period by opening thermostat circuit for 3 seconds or more 30 seconds (timing starts when ignitor cycles off) 90, 120, 150 seconds selectable; factory set at 120 7 seconds 60 seconds Operates on selected heating speed and cycles off during ignition or burner start-up sequence. Automatic reset, ignition sequence restart. See Note 1. Manual reset, igniton sequence initiated after switch is manually reset. See Note 1. NOTE 1: After the fourth limit trip on a given call for heat, there will be a 1-hour delay before the ignition sequence will restart. After either high limit switch or flame rollout switch actuation, the inducer will operate for the 30-second postpurge and the comfort air blower will operate for the selected off delay. If on Manual Fan operation, the comfort air blower will continue to operate. SAFETY UNITS High limit/Rollout Pressure switch SPST in 24 Volt SPST, safe start check COMFORT FAN CONTROL Heating Speed Fan Normal operation - ON delay - OFF delay Limit Operation Flame Sense 30 seconds fixed. Timing starts when igniter de-energized. 3 selectable timings – 120 seconds standard can be changed to 90 or 150 seconds. ON when limit OPEN OFF after OFF delay when limit CLOSES ON if flame is sensed and there is no call for heat. Cooling Speed Fan - ON delay - OFF delay 7 seconds 60 seconds Manual Fan ON continuously on HEATING speed. When call for cool, the fan switches to COOLING speed. Then when thermostat satisfied, the fan switches back to HEATING speed after COOLING OFF delay. DIAGNOSTIC INDICATOR A red LED is provided to indicate system faults as follows: Steady ON - Control okay in standby, call for heat, cool or fan modes Steady OFF - Internal control fault or no power. Also check 3A fuse on control. 1 flash - Lockout due to failed ignition or flame dropouts 2 flashes - Pressure switch open with inducer on 3 flashes - Pressure switch is closed with inducer off 4 flashes - Limit switch is open 5 flashes - Flame detected with gas valve closed 6 flashes - Compressor output delayed from short cycle/staging timer The flash rate is 0.25 seconds on, 0.25 seconds off with 2.0 seconds pause between flash codes.

35. PRESSURE SERVICE PORTS High and low pressure service ports are installed on all units so that the system operating pressures can be observed. Table 19 outlines expected pressures at various indoor and outdoor temperatures. This unit employs high-flow Coremax valves instead of the typical Shrader type valves. TABLE 19 Cooling Pressure Table Model Return Air Temperature Pressure 75° 80° 85° 90° 95° 100° 105° 110° 115° 120° 125° W24G4 75° DB 62° WB Low Side High Side 119.7 298.0 122.6 318.5 125.3 340.2 127.9 363.0 130.3 386.9 132.8 411.8 135.0 438.0 137.2 465.3 139.1 493.6 141.0 523.2 142.8 553.8 80° DB 67° WB Low Side High Side 128.0 305.6 131.1 326.7 134.0 348.9 136.8 372.3 139.4 396.8 142.0 422.4 144.4 449.2 146.7 477.2 148.8 506.3 150.8 536.6 152.7 568.0 85° DB 72° WB Low Side High Side 132.5 316.3 135.7 338.1 138.7 361.1 141.6 385.3 144.3 410.7 147.0 437.2 149.5 464.9 151.8 493.9 154.0 524.0 156.1 555.4 158.0 587.9 W30G4 75° DB 62° WB Low Side High Side 120.1 297.7 122.7 318.0 125.2 339.5 127.6 362.0 130.0 385.5 132.3 410.0 134.5 435.5 136.8 462.2 138.9 489.7 141.0 518.4 143.1 548.1 80° DB 67° WB Low Side High Side 128.5 305.3 131.2 326.2 133.9 348.2 136.5 371.3 139.0 395.4 141.5 420.5 143.9 446.7 146.3 474.0 148.6 502.3 150.8 531.7 153.0 562.2 85° DB 72° WB Low Side High Side 133.0 316.0 135.8 337.6 138.6 360.4 141.3 384.3 143.9 409.2 146.5 435.2 148.9 462.3 151.4 490.6 153.8 519.9 156.1 550.3 158.4 581.9 W36G4 75° DB 62° WB Low Side High Side 124.4 312.6 126.8 334.9 129.1 357.9 131.3 381.6 133.4 405.9 135.4 431.0 137.4 456.7 139.1 483.1 140.9 510.2 142.6 538.0 144.2 566.5 80° DB 67° WB Low Side High Side 133.1 320.6 135.6 343.5 138.1 367.1 140.4 391.4 142.7 416.3 144.8 442.0 146.9 468.4 148.8 495.5 150.7 523.3 152.5 551.8 154.2 581.0 85° DB 72° WB Low Side High Side 137.8 331.8 140.3 355.5 142.9 379.9 145.3 405.1 147.7 430.9 149.9 457.5 152.0 484.9 154.0 512.8 156.0 541.6 157.8 571.1 159.6 601.3 W42G4 75° DB 62° WB Low Side High Side 124.7 328.7 127.4 350.3 130.0 373.0 132.3 396.7 134.6 421.4 136.7 447.1 138.8 473.8 140.6 501.4 142.3 530.1 143.9 559.7 145.4 590.4 80° DB 67° WB Low Side High Side 133.4 337.1 136.3 359.3 139.0 382.6 141.5 406.9 144.0 432.2 146.2 458.6 148.4 485.9 150.4 514.3 152.2 543.7 153.9 574.1 155.5 605.5 85° DB 72° WB Low Side High Side 138.1 348.9 141.1 371.9 143.9 396.0 146.5 421.1 149.0 447.3 151.3 474.7 153.6 502.9 155.7 532.3 157.5 562.7 159.3 594.2 W48G4 75° DB 62° WB Low Side High Side 124.9 325.9 126.8 347.5 128.7 369.8 130.4 392.9 132.2 416.9 134.0 441.7 135.8 467.2 137.5 493.6 139.3 520.8 141.0 548.9 142.7 577.8 80° DB 67° WB Low Side High Side 133.6 334.3 135.6 356.4 137.6 379.3 139.5 403.0 141.4 427.6 143.3 453.0 145.2 479.2 147.1 506.3 149.0 534.2 150.8 563.0 152.6 592.6 85° DB 72° WB Low Side High Side 138.3 346.0 140.3 368.9 142.4 392.6 144.4 417.1 146.3 442.6 148.3 468.9 150.3 496.0 152.2 524.0 154.2 552.9 156.1 582.7 157.9 613.3 W60G4 75° DB 62° WB Low Side High Side 123.3 309.0 125.1 329.6 127.0 351.4 128.8 374.2 130.6 398.2 132.5 423.3 134.3 449.6 136.1 477.0 137.9 505.5 139.8 535.2 141.6 566.0 80° DB 67° WB Low Side High Side 131.9 316.9 133.8 338.1 135.8 360.4 137.8 383.8 139.7 408.4 141.7 434.2 143.6 461.1 145.6 489.2 147.5 518.5 149.5 548.9 151.4 580.5 85° DB 72° WB Low Side High Side 136.5 328.0 138.5 349.9 140.6 373.0 142.6 397.2 144.6 422.7 146.7 449.4 148.6 477.2 150.7 506.3 152.7 536.6 154.7 568.1 156.7 600.8 WARNING! Do NOT use a Schrader valve core removal tool with these valves. Use of such a tool could result in eye injuries or refrigerant burns! To change a Coremax valve without first removing the refrigerant, a special tool is required which can be obtained at www.fastestinc.com/en/SCCA07H. See the replacement parts manual for replacement core part numbers. Low side pressure ± 4 PSIG High side pressure ±10 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, and the system evacuated and recharged to serial plate instruction.

"A" AIRFLOW MIS-1724 TABLE 20 Fan Blade Dimension FIGURE 26 Fan Blade 38. LOW-NOX BURNER ASSEMBLY “N” SUFFIX MODELS ONLY – U.S. INSTALLATIONS ONLY Natural Gas Models Only Model numbers designated with an “N” are designed for low NOx emissions which comply with all California Air Quality Management District regulations for nitrogen oxide emission levels. Refer to Figure 27 for NOx insert information. * * IMPORTANT * * For propane (LP) conversions, the NOx reduction screen inserts shown below must be removed. This is accomplished by removing the burner box assembly and removing the NOx screens. Reassemble unit properly before firing. Failure to remove the NOx screens can result in improper operation and malfunction of the burner system. FIGURE 27 Low NOx Insert 36. R-410A REFRIGERANT CHARGE This unit was charged at the factory with the quantity of refrigerant listed on the serial plate. AHRI capacity and efficiency ratings were determined by testing with this refrigerant charge quantity. Table 19 shows nominal pressures for the units. Since many installation specific situations can affect the pressure readings, this information should only be used by certified technicians as a guide for evaluating proper system performance. They shall not be used to adjust charge. If charge is in doubt, reclaim, evacuate and recharge the unit to the serial plate charge. 37. FAN BLADE SETTING DIMENSIONS The correct fan blade setting dimension for proper air delivery across the outdoor coil is shown in Figure 26. Model Dimension A W24G 1.25 W30G 1.25 W36G 1.25 W42G 1.75 W48G 1.75 W60G 1.75

INDEX Wiring Diagrams Unit Model No. Basic Wiring Diagram W24G4-A 4085-177 W24G4-B 4085-277 W24G4-C 4085-400 W30G4-A 4085-177 W30G4-B 4085-277 W30G4-C 4085-400 W36G4-A 4085-177 W36G4-B 4085-277 W36G4-C 4085-400 W42G4-A 4085-177 W42G4-B 4085-277 W42G4-C 4085-400 W48G4-A 4085-177 W48G4-B 4085-277 W48G4-C 4085-400 W60G4-A 4085-175 W60G4-B 4085-275 W60G4-C 4085-398