Whirlpool GOLD W4GH6 User's Manual
Contents
1. oz O HI PS Compressor Diagnostic r Crankcase Heater Module Defrost 7 oM _ l l Control m m 4 i 7 p 12 l Ol Ground r L AEE E EA SEEE E 208 230 60 1 l glua l jl Ground LAR Ae R 4 l I O 0 Crankcase Thermostat a an Defrost Control Thermostat Defrost eversing Valve Conour Thermostat tow A uo _ a Hi Compressor Low ene Tey p 4F o Ae E a BK o Defrost Switch 4 0S L4 x at eee ompressor neon lve our Olei l Contactor j A Ahoia Compressor 208 230 60 1 OU High Pressure HI PS Y Switch R a L2 4 ji LT BU ose a eas OR Crankcaser Heater ES Fan x o Equipment Crankcase GH Thermostat Dual Ground Capacitor PR Line Voltage Factory Installed Line Voltage Field Installed 24 Volt Factory Installed Class II Voltage Field Installed Si LO PS Low Pressure Switch HI PS High Pressure Switch 1 Operate the heat pump for a period of at least 15 minutes to 2 allow for pressures and temperatures to stabilize If heat pump does not appear to be functioning correctly have heat pump checked by a person certified by the EPA to handle refrigerant 11 SEQUENCE OF OPERATION Upon cooling demand the thermos2. HEAT PUMP INSTALLATION INSTRUCTIONS Table of Contents HEAT PUMP SAFETYV csssccsseessssecsseeesseeensecenseeenseeensaeensenensees 1 SEQUENCE OF OPERATION c s ccssscssssesseeesseessseeenseesssenens 12 INSTALLATION REQUIREMENTS ccssscssssssccssssessesssssccssssessseees 1 Cooling iGyCle a ive sei tec ihec he dctieiin hight atenaiatiainiionia 12 TOoIS and Parts natane a arirmlce de teats 2 Heating Cycle ee eeeeeseeteeeeeeeeeteeeeeeenteneaseneaseneaeeeneneeeneees 12 System RequireMent ccccccccscscssesssssssssscsesscsessesessesesecsesesases 2 Defrost CY ClO et ieS aad aes etree ee 12 Location Requirements ccccccesssssessseseessssescsesesssseseseseessessesens 2 Adjust Defrost System ss eeseseieeeeseeeeteeneeneeeneienteneaeeneateneaeas 13 Electrical Requirements c ccsescesesssesessesesetsesetsessstseseeseseeeeeees 4 Troubleshoot the Defrost System cesses 14 Inspect Shipment aranana eaa rarata rare rare raaa a aaa cheeses nel 4 TROUBLESHOOTING 2 ssccessseceseeesseeenseeesseeesseesnseeenseeesseenss 15 Flush Refrigerant Lines c ccccsesteetesscssscsesseeseeeeseeetevsngediesesneses 4 System Diagnostic Module c ccsescsesesereeseseseeeseessrsseeerserees 15 Connect Refrigerant Lines ee eeceeeeeeseeeeeeeeeeeeeeeteeeeeeeeeeeeaees 6 SYSTEM MAINTENANCE qncccccocecocccceccccocecececcecececserececeerececeerereceee 17 Make Electrical Connections Poths MA Vee bed A EE TAEA 9 ASSIST
3. see Adjust Time Between Defrost Cycles The defrost control will initiate a defrost cycle when the selected time period has elapsed and the defrost sensor sees a temperature below freezing At the start of a defrost cycle the defrost control will energize the reversing valve solenoid shifting the reversing valve and de energizing the outdoor fan The defrost relay will also close energizing temporary heat for increased comfort during defrost if the indoor unit is so equipped The heat pump will remain in defrost until the defrost sensor has determined that the frost has been removed from the coil or a 10 minute period has elapsed whichever comes first Defrost Thermostat The defrost thermostat is located on the liquid line between the check expansion valve and the distributor When defrost thermostat senses 42 F or cooler the thermostat contacts close and send a signal to the defrost control board to start the defrost timing It also terminates defrost when the liquid line warms up to 70 F 12 Defrost Control The defrost control board includes the combined functions of the time temperature defrost control defrost relay diagnostic LEDs and terminal strip for field wiring connections See Defrost Control Board in the Adjust Defrost System section The control provides automatic switching from normal heating operation to defrost mode and back During compressor cycle call for defrost the control accumulat
4. 1 Route the suction and liquid lines from the fittings on the indoor coil to the fittings on the heat pump Run the lines in as direct a path as possible avoiding unnecessary turns and bends 2 For product efficiency be sure that the suction line is insulated over the entire exposed length and that both suction and liquid lines are not in direct contact with floors walls ductwork floor joists or other piping 3 Remove valve cores Wrap the service valves with a wet rag 5 Connect the suction and liquid lines using a brazing compound Braze with an alloy of silver or copper and phosphorus with a melting point above 1 100 F NOTE Do not use soft solder gt 6 Make sure indoor coil has been put in place according to the Installation Instructions and is connected to the refrigerant lines Replace valve cores 8 Pressurize the lines and indoor coil with a pressure not to exceed 20 psig 9 Leak test the lines with a pressure not to exceed 20 psig 10 Evacuate the indoor coil and lines to a minimum of 500 microns to remove contamination and moisture then disconnect the vacuum pump 11 Open the suction and liquid service valves fully 12 Insulate the suction line with refrigerant line insulation material of 1 4 or more wall thickness 13 Pack insulating material around refrigerant lines where they penetrate the structure to protect the lines and to minimize vibration transmission y Refrigerant Charg
5. Vapor line F Wall stud B Strap liquid line to wrapped in G Style 2 automotive vapor line armaflex muffler type hanger Installing Vertical Runs new construction shown This shows how to install line sets on vertical runs NOTE Similar installation practices should be used if line set is to be installed on exterior of outside wall IMPORTANT Refrigerant lines must not contact structure C D ETT E N F G N H N E N N iN I N E KI J G N N N H N A Outside wall D Liquid line Wood block B Refrigerant lines E Anchored heavy nylon between studs must not contact wire tie J Caulk wall F Inside wall K Fiberglass C Vapor line wrapped G Metal strapping material insulation in armaflex H Metal sleeve L PVC pipe A WARNING Electrical Shock Hazard Electrically ground condensing unit or heat pump Connect ground wire to ground lug Use copper wire for supply connection Correct wire gauge is shown in the chart below Failure to follow these instructions can result in death or electrical shock Rating Plate Ampacity Less than 15 NOTE All outdoor wiring must be suitable for outdoor use Use copper conductors only m All field wiring must be done in accordance with National Electrical Code requirements applicable requirements of UL or local codes where applicable m Electrical wiring disconnect means and over current protection are to be suppli
6. When an abnormal system condition occurs the diagnostic module displays the appropriate Alert and or Trip LED The yellow Alert LED will flash a number of times consecutively pause and then repeat the process To identify a flash code number count the number of consecutive flashes Refer to the Flash Codes chart for information on the flash codes Every time the module powers up the last Alert LED flash code that occurred prior to shutdown is displayed for 60 seconds The module will continue to display the previous flash code until the condition returns to normal or 24 VAC is removed from the module Trip and Alert LED s flashing at the same time means control circuit voltage is too low for operation Flash Codes LED Status Fault Description Troubleshooting Information Power Green Module has power m Supply voltage is present at module terminals Trip Red Thermostat demand signal Y1 mm Compressor protector is open is present but the m Outdoor unit power disconnect is open compressor is not running i m Compressor circuit breaker or fuse s is open m Broken wire or connector is not making contact m Low pressure switch is open if present in system m Compressor contactor has failed to open Alert Yellow Flash Code 1 Long Run Time Compressor is running extremely long run cycles NOTE Not applicable on heat pump models Alert Yellow Flash Code 2 System Pressure Trip m High head pressure Discharge or sucti
7. the defrost will terminate and the test option will not function again until the jumper is removed and re applied Compressor Delay The defrost board has a field selectable function to reduce occasional sounds that may occur while the heat pump is cycling in and out of the defrost mode The compressor will be cycled off for 30 seconds while going in and out of the defrost mode when the compressor delay jumper is removed NOTE The 30 second off cycle is not functional when jumpering the TEST pins Time Delay The time delay is 5 minutes long The delay helps to protect the compressor from short cycling in case the power to the heat pump is interrupted or a pressure switch opens The delay is bypassed by placing the timer select jumper across the TEST pins for 0 5 seconds Pressure Switch Circuit The defrost control includes LO PS terminals to connect an optional low pressure loss of charge pressure switch A high pressure switch optional can be connected to the HI PS terminals See Defrost Control Board in the Adjust Defrost System section During a single demand cycle the defrost control will lock out the heat pump after the fifth time that the circuit is interrupted by any pressure switch wired to the control board In addition the diagnostic LEDs will indicate a locked out pressure switch after the fifth occurrence of an open pressure switch See Defrost Control Board Diagnostic LEDs chart later in this s
8. or 7 Open Circuit Open Start Circuit or Open Run Circuit are displayed incorrectly Check that the compressor run and start wires are through the module s current sensing holes Verify that the Y terminal is connected to the 24 VAC at the contactor coil Alert Flash Code 6 Open Start Circuit is displayed for Code 7 Open Run Circuit or vice versa Check that the compressor run and start wires are routed through the correct module sensing holes Alert Flash Code 8 Welded Contactor is displayed incorrectly Determine if the module s Y terminal is connected Verify that the Y terminal is connected to the 24 VAC at the contactor coil SYSTEM MAINTENANCE ASSISTANCE OR SERVICE m Leaves and other large obstructions should be removed from If you need further assistance you can write to the below the heat pump surfaces without damaging the fin surface of address with any questions or concerns the coil Whirlpool Home Cooling and Heating m Routinely clean or change the indoor air filter Should the 14610 Breakers Drive indoor coil become dirty thus restricting airflow call a Jacksonville FL 32258 qualified service person to clean the coil surface m An annual inspection by a qualified person should be Please include a daytime phone number in your correspondence performed to ensure continued quality performance To order accessories contact your Whirlpool Home Cooling and Heating dealer 17 Limited Wa
9. ANCE OR SERVICE cecossosseccccomsecccccccsccccccceccecccccccecccccseeeec 17 Complete Installation c ccceccececeeeeeeeeeeeeeeeeeeeaeeseneeeeneesneeeeee 11 ACCESSONIES E E T E 17 WARRANTY scssse0cet oie Sek ok ie nnmnnn nnnm nnmnnn nnana nnan 18 HEAT PUMP SAFETY Your safety and the safety of others are very important We have provided many important safety messages in this manual and on your appliance Always read and obey all safety messages This is the safety alert symbol This symbol alerts you to potential hazards that can kill or hurt you and others All safety messages will follow the safety alert symbol and either the word DANGER or WARNING These words mean You can be killed or seriously injured if you don t immediately A DANGER follow instructions You can be killed or seriously injured if you don t follow A WARN l N G instructions All safety messages will tell you what the potential hazard is tell you how to reduce the chance of injury and tell you what can happen if the instructions are not followed INSTALLATION REQUIREMENTS These instructions are intended as a general guide only for use by m The heat pump is designed and approved for outdoor use qualified persons and do not supersede any national or local only codes in any way The installation must comply with all state and local codes aswellas the National Electrical Code m The heat pump must be installed with no ductwork in the air
10. Refrigerant Lines steps 1 through 5 Do not evacuate the lines 6 Remove the existing R 22 refrigerant flow control orifice or thermal expansion valve on the indoor coil and use a field provided fitting to reconnect the lines Thermal Expansion Valve i 6 Are A Distributor fitting B Mounting flange C Piston orifice D Ring seal supplied E Orifice extension stub F 0 812 brass hex nut G Brass hex fitting 7 Remove the caps from the suction and liquid pressure taps 8 Remove the valve cores A Suction pressure tap B Liquid pressure tap 9 Connect an R 22 cylinder with clean refrigerant to the suction pressure tap 10 Connect the R 22 gauge set to the liquid line service valve and connect a recovery machine with an empty recovery tank to the gauge set 11 Set the recovery machine for liquid recovery and start the recovery machine in accordance with the manufacturer s instructions provided with the recovery system being used 12 Open the gauge set valves to allow the recovery machine to run until a vacuum level less than 0 Hg gauge pressure is established in the existing system line set and indoor coil 13 Invert the cylinder of clean R 22 and open its valve to allow liquid refrigerant to flow into the system through the vapor line valve 14 After all of the liquid refrigerant has been recovered switch the recovery machine to vapor recovery t
11. achment of accessory products not integral to our product including without limitation humidifier air cleaner vent damper thermostat or other mechanical devices not manufactured by the warrantor Products that have been operated in a corrosive atmosphere or otherwise in contact with corrosive materials where a concentration of acids halogenated hydrocarbons or other corrosive elements such as urine salt etc cause deterioration to metal surfaces or integral components NOTE Operation in a corrosive atmosphere is considered misuse and voids this warranty Products that have NOT been installed used and maintained in accordance with our published installation instructions applicable local state provincial or national codes and or ACCA published standards Products that have NOT been installed by competent qualified installers Products that have been moved from their original place of installation Warranty on Replacement Components Any replacement product or component furnished by us will assume the remaining unused portion of the Limited Warranty Consequential Damages The warrantor shall not be responsible for any accidental consequential damages caused by any defect in the product Some states provinces do not allow the exclusion or limitations of incidental or consequential damages so the above limitation or exclusion may not apply to you This product must be installed used and cared for in accordance with the instruction man
12. compressor start wiring or connections m Compressor start winding is damaged Alert Yellow Flash Code 7 Open Run Circuit Current m Open circuit in the compressor run wiring or connections NOTE This code will only in start circuit m Compressor run winding is damaged flash within 5 minutes of power interruption until the 5 minute short cycle timer has elapsed Allow at least 5 minutes of run time before confirming this code Alert Yellow Flash Code 8 Welded Contactor m Compressor contactor has failed to close Compressor always runs m Thermostat demand signal not connected to the module Alert Yellow Flash Code 9 Low Voltage Control circuit Control circuit transformer is overloaded less than 17 VAC m Low line voltage contact utility if voltage at disconnect is low 24 VAC Power Wiring The diagnostic module requires a constant nominal 24 VAC power supply The wiring to the module s R and C terminals must be directly from the indoor unit or thermostat The module cannot be powered by R and C terminals on the defrost board without experiencing nuisance alerts 16 Thermostat Demand Wiring The diagnostic module requires a thermostat demand signal to operate properly The thermostat demand signal input labeled Y on the module should always be connected to the compressor contactor coil so that when the coil is energized the demand signal input is 24 VAC When the coil is not energized the demand signal input should be le
13. d with an indoor section containing a variable speed blower m Refer to the refrigerant charge label located on the inside of the heat pump access panel for the correct thermal expansion valve size required m This product has been designed and manufactured to meet ENERGY STAP criteria for energy efficiency when matched with appropriate coil components However proper refrigerant charge and proper airflow are critical to achieve rated capacity and efficiency Installation of this product should follow the manufacturer s refrigerant charging and airflow instructions Failure to confirm proper charge and airflow may reduce energy efficiency and shorten equipment life m A filter drier approved for use with R 410A refrigerant is installed in the heat pump m If this condensing unit is equipped with a crankcase heater it should be energized 24 hours before the condensing unit is started to prevent compressor damage as a result of slugging m Use only polyol ester oils if oil must be added to the system Mineral oil is not compatible with refrigerant Indoor System Thermal Expansion Valve m W4GH6 units are designed for use with thermal expansion valve systems only The thermal expansion valve must be ordered separately from the manufacturer Thermal Expansion Valve Kits Model Part Number W4GH624 H4TXV01 W4GH636 H4TXV02 W4GH648 60 H4TXV03 m This heat pump is designed to be located outdoors with sufficient cleara
14. e Refrigerant lines must be connected by a licensed EPA certified refrigerant technician in accordance with established procedures IMPORTANT m Refrigerant charge adjustment will be required for line set lengths greater than 15 ft and for evaporator coils not matched to the systems m The heat pump is factory charged with the proper refrigerant charge amount for a matching evaporator and 15 ft of refrigerant line Refer to the heat pump rating plate for the exact amount of this factory charge m Adjustment of the refrigerant charge will be necessary based on the system combination and line length To adjust the refrigerant size for increased line lengths add the following amount of refrigerant For line set lengths greater than 15 ft add refrigerant by weighing in 0 60 oz per ft of 3 O D liquid line m f necessary adjust the refrigerant charge for compatibility with the evaporator coil m In heat pump systems horizontal suction lines should be slightly sloped toward the heat pump Piping must avoid dips or low spots which can collect oil Check Charge Using Normal Operating Pressures Use Normal Operating Pressures chart to perform maintenance checks NOTES m The Normal Operating Pressures chart is not a procedure for charging the system m Minor variations in these pressures may be due to differences in installations m Significant deviations could mean that the system is not properly charged or that a proble
15. ecting the test pins speeds up the defrost cycle time by a factor of 256 1 2 14 Disconnect power Remove control box cover NOME Defrost Control Setting Connect the test pins on the defrost control using a test jumper wire NOTE If the outdoor temperature is above 32 F connect the defrost sensor terminals using a test jumper wire See Defrost Control Board in the Adjust Defrost System section Replace control box cover Reconnect power Start system in heating operation Time the defrost test cycle as determined by the chart After the corresponding defrost cycle time from the chart below has elapsed the reversing valve should shift to defrost mode and the outdoor fan should stop After 2 seconds of defrost operation the reversing valve should shift back to heating operation and the outdoor fan should start NOTE If this procedure is not observed check the reversing valve solenoid for correct operation by measuring temperatures and pressures under heating and cooling modes If the reversing valve solenoid operates correctly then replace the defrost control board See Sequence of Operation Defrost Test Cycle Time T1 30 minutes 7 seconds T2 60 minutes 14 seconds T3 90 minutes 21 seconds If an adjustment is required see Adjust Time Between Defrost Cycles in the Adjust Defrost System section Disconnect power Remove control box cover Remove jumper from te
16. ection The heat pump will remain locked out until power to the board is interrupted then re established or until the jumper is applied to the TEST pins for 0 5 seconds NOTE The defrost control board ignores input from the low pressure switch terminals during m TEST mode m Defrost cycle m 90 second start up period E First 90 seconds after the reversing valve switches heat cool modes NOTE If the TEST pins are jumpered and the 5 minute delay is being bypassed the LO PS terminal signal is not ignored during the 90 second start up period Defrost Control Board Diagnostic LEDs Green Red LED Mode LED DS2 DS1 No Power to Board Off Off Normal Operation Power to Board Simultaneous Slow Flash Short Cycle Lockout Alternating Slow Flash Low Pressure Switch Fault Off Slow Flash Low Pressure Switch Lockout Off On High Pressure Switch Fault Slow Flash Off High Pressure Switch Lockout On Off Defrost Control Board Optional high pressure switch connections NOTE To add the pressure switch remove the factory installed jumper P1 EAN e so A Meo O 0 90 frest K1 Relay B Obps1 H Obpse2 P5 Cc a ui Y2 K2 Relay D O QUT p20 L w LO PS lc 2 E _ BIL l DF DF R F e jo Y1 OUT lyi HI PS K3 Relay G Q PELRREE PO F Defrost thermostat G High pr
17. ed by the installer Refer to the rating plate for the maximum over current protection minimum circuit ampacity and operating voltage See the wiring diagrams in Make Electrical Connections Flushing Connections Inverted R 22 Cylinder Contains clean R 22 to be used for flushing A WARNING Excessive Weight Hazard Use two or more people to move and install condensing unit or heat pump Failure to do so can result in back or other injury This heat pump is shipped in one package completely assembled and wired The thermostat is shipped in a separate carton when ordered 1 Check the heat pump rating plate to confirm specifications are as ordered 2 Upon receipt of equipment carefully inspect it for possible shipping damage Take special care to examine the heat pump inside the carton if the carton is damaged If damage is found it should be noted on the carrier s freight bill Damage claims should be filed with the carrier immediately Claims of shortages should be filed with the seller within 5 days NOTE If any damages are discovered and reported to the carrier do not install the heat pump because your claim may be denied Refrigerant lines must be flushed by a licensed EPA certified refrigerant technician in accordance with established procedures NOTES m R 410A outdoor systems are not recommended for use with indoor systems that have used R 22 as the refrigerant However if this unit i
18. es compressor run times at 30 60 or 90 minute field adjustable intervals If the defrost thermostat is closed when the selected compressor run time interval ends the defrost relay is energized and defrost begins Defrost Control Timing Pins Each timing pin selection provides a different accumulated compressor run time period during one thermostat run cycle This time period must occur before a defrost cycle is initiated The defrost interval can be adjusted to 30 T1 60 T2 or 90 T3 minutes See Defrost Control Board in the Adjust Defrost System section The defrost timing jumper is factory installed to provide a 60 minute defrost interval If the timing selector jumper is not in place the control defaults to a 90 minute defrost interval The maximum defrost period is 14 minutes and cannot be adjusted A test option is provided for troubleshooting The test mode may be started any time the unit is in the heating mode and the defrost thermostat is closed or jumpered If the jumper is in the test position at power up the control will ignore the test pins When the jumper is placed across the Test pins for 2 seconds the control will enter the defrost mode If the jumper is removed before an additional 5 second period has elapsed 7 seconds total the unit will remain in defrost mode until the defrost thermostat opens or 14 minutes have passed If the jumper is not removed until after the additional 5 second period has elapsed
19. essure switch optional H Diagnostic LEDs Low voltage terminal strip connections A Defrost time setting pins B Test pins C Compressor delay pins D Reversing valve E Low pressure switch optional Adjust Time Between Defrost Cycles AWARNING y Electrical Shock Hazard Disconnect power before servicing Replace all parts and panels before operating Failure to do so can result in death or electrical shock 1 Disconnect power 13 Remove the heater compartment access panel Adjust the time period between defrost cycles by placing the defrost time plug in the proper position See Defrost Control Board m For 30 minute intervals between defrost cycles connect the Defrost Time Setting Plug to the pins corresponding to 30 m For 60 minute intervals between defrost cycles connect the Defrost Time Setting Plug to the pins corresponding to 60 this setting is the factory preset setting m For 90 minute intervals between defrost cycles connect the Defrost Time Setting Plug to the pins corresponding to 90 Replace the heater compartment access panel Reconnect power AWARNING Electrical Shock Hazard Disconnect power before servicing Replace all parts and panels before operating Failure to do so can result in death or electrical shock The defrost control is equipped with a set of pins labeled TEST on control circuit board to aid in troubleshooting the defrost system Conn
20. m exists with some component in the system Normal Operating Pressures NOTE Values provided in chart are typical pressures Indoor unit matchup indoor air quality and indoor load will cause pressures to vary Model Temperature of the Air 24 36 48 60 Entering the Outdoor Coil Liquid Suction Liquid Suction Liquid Suction Liquid Suction Cooling 1st Stage Low Capacity 65 F 232 146 225 144 235 144 225 138 75 F 264 148 261 147 268 145 264 141 85 F 307 149 302 149 310 147 305 142 95 F 353 151 349 151 356 148 352 146 105 F 403 153 397 153 407 150 405 148 115 F 460 155 461 157 466 152 459 150 Cooling 2nd Stage High Capacity 65 F 240 143 239 139 244 140 241 134 75 F 279 145 278 141 283 141 280 136 85 F 322 147 322 143 326 144 324 137 95 F 371 149 367 146 374 147 373 138 105 F 423 151 426 148 427 148 425 142 115 F 485 154 489 151 491 151 486 146 Heating 1st Stage Low Capacity 40 F 337 93 328 98 369 75 351 63 50 F 322 117 333 118 366 114 335 92 Heating 2nd Stage High Capacity 20 279 62 296 62 311 58 308 59 30 F 288 76 309 75 334 72 323 70 40 F 302 93 322 92 354 89 318 69 50 F 306 112 336 113 381 108 329 82 Suction Line Sizes Liquid Line Sizes Installations exceeding 100 ft are not recommended Installations exceeding 100 ft are not recommended Btu h Line Set Size in OD Btu h Line Set Si
21. nce for free entrance to the inlet and discharge air openings The location must also allow for adequate service access See Minimum Clearances m Where possible select a location for the heat pump which is shaded from the direct rays of the sun most of the time North or east locations are usually most desirable Position the heat pump to avoid direct contact with water snow or ice from a roofline overhead m The heat pump must be installed on a solid level mounting pad that will not settle or shift Isolate the pad from the building structure to avoid possible transmission of sound or vibration from the heat pump into the conditioned space m The heat pump foundation should be raised to a minimum of 3 above finish grade In areas which have prolonged periods of temperatures below freezing and or snowfall the heat pump should be elevated above the average snow line If heat pump is to be installed on a flat roof it should be ona platform or other support which will raise the inlet air opening 12 minimum above the surface of the flat roof m Care should be taken to ensure free drainage of condensate from defrost cycles This will prevent ice accumulation The heat pump should be located away from walkways to prevent possible icing from defrost condensate m Avoid placing the heat pump near areas such as sleeping quarters or study rooms Normal operating sound levels may be objectionable if the heat pump is placed near certain
22. nstall the thermal expansion valve 1 2 3 Separate the distributor assembly If a piston orifice is installed remove the piston orifice and old Teflon seal and discard Insert nozzle end of the thermal expansion valve along with a new Teflon seal into the distributor Tighten to 20 to 30 ft Ibs Use backup wrench on all wrench flats NOTE Overtightening may crush the Teflon seal and cause a leak Attach liquid line portion of distributor assembly along with new Teflon seal to the inlet of the thermal expansion valve Teflon is a registered trademark of E l Dupont de Nemours and Company 6 Tighten to 20 to 30 ft lbs Use backup wrench on all wrench flats NOTE Overtightening may crush the Teflon seal and cause a leak 7 Connect the external equalizer line to the equalizer port on the suction line 8 Tighten to 8 ft Ibs 9 Attach the superheat sensing bulb to the suction header with the strap provided with the thermal expansion valve A Equalizer port B Superheat sensing bulb C Thermal expansion valve D Liquid line E Suction line F Equalizer line NOTE If installing a thermal expansion valve on an indoor coil that previously used a fixed orifice be sure to remove the existing fixed orifice Failure to remove a fixed orifice when installing a thermal expansion valve to the indoor coil may result in improper operation and damage to the system Connect Liquid and Suction Lines
23. o allow the recovery machine to run until a vacuum level less than 0 Hg gauge pressure is established in the existing system line set and indoor coil in accordance with the manufacturer s instructions provided with the recovery system being used NOTE A single system flush should remove all of the mineral oil from the existing refrigerant lines and indoor coil A second flushing may be done using clean refrigerant if insufficient amounts of mineral oil were removed during the first flush A second flushing may be required to ensure that the maximum amount of oil is removed 15 Close the valves on the inverted R 22 cylinder and gauge set 16 Remove the recovery machine gauges R 22 cylinder and the field provided fitting installed in Step 6 17 Install the valve cores A Suction pressure tap B Liquid pressure tap 18 19 20 21 22 23 Install the R 410A thermal expansion valve specified for this system in the indoor coil NOTE R 410A systems use only thermal expansion valves Pressurize the lines and indoor coil with a pressure not to exceed 20 psig Leak test the lines with a pressure not to exceed 20 psig Open the suction and liquid service valves fully Insulate the suction line with refrigerant line insulation material of 1 4 or more wall thickness Pack insulating material around refrigerant lines where they penetrate the structure to protect the lines and to minimize vibration transmissi
24. on Refrigerant lines must be connected by a licensed EPA certified refrigerant technician in accordance with established procedures IMPORTANT Connecting refrigerant lines must be clean dehydrated refrigerant grade copper lines Heat pumps should be installed only with specified line sizes for approved system combinations with elevation differences up to 15 ft and total length of up to 50 ft See the Suction Line Sizes and Liquid Line Sizes charts later in this section Avoid sharp bends or possible kinking in the refrigerant lines during installation as this may cause a reduction in performance Use care with the refrigerant lines during the installation process Sharp bends or possible kinking in the lines will cause a reduction in performance To avoid contamination of the refrigerant system do not remove the caps from the lines or system connection points until connections are ready to be completed Install Thermal Expansion Valve W4GH6 heat pumps are designed for use with thermal expansion valve systems only An R 410A system will not operate properly with an R 22 thermal expansion valve Thermal expansion valves equipped with Chatleff type fittings are available from the manufacturer See Thermal Expansion Valve Kits chart in System Requirements Thermal Expansion Valve Installation A Distributor B Teflon seal C Thermal expansion valve D Liquid line stub E Strainer F Teflon seal To i
25. on pressure Condenser coil has poor air circulation dirty blocked out of limits or compressor is damaged overloaded z m Condenser fan is not running m Return air duct has substantial leakage m If low pressure switch is present in the system go to Flash Code 1 information 15 Flash Codes LED Status Fault Description Troubleshooting Information Alert Yellow Flash Code 3 Short Cycling Compressor is m Thermostat demand signal is intermittent running only briefly m Time delay relay or control board is defective m If high pressure switch is present go to Flash Code 2 information m If low pressure switch is present go to Flash Code 1 information Alert Yellow Flash Code 4 Locked Rotor m Run capacitor has failed m Low line voltage contact utility if voltage at disconnect is low m Excessive liquid refrigerant in the compressor m Compressor bearings are seized Alert Yellow Flash Code 5 Open circuit m Outdoor unit power disconnect is open m Compressor circuit breaker or fuse s is open m Compressor contactor has failed to open m High pressure switch is open and requires manual reset m Open circuit in the compressor supply wiring or connections m Unusually long compressor protector reset time due to the extreme ambient temperature m Compressor windings are damaged Alert Yellow Flash Code 6 Open Start Circuit Current m Run capacitor has failed only in run circuit m Open circuit in the
26. rooms A shift in sound type does occur during the defrost mode The defrost mode generally lasts no longer than 10 minutes Minimum Clearances ABC To OD Power Supply To Ee Indoor Unit To Indoor Coil 48 Overhead Clearance Discharge A Air a 12 Clearance we DN a Access Clearance NC Inlet Air A Weatherproof disconnect switch B NEC class 1 wiring C NEC class 2 wiring 12 Clearance Between Unit and Building D House thermostat E Seal openings Line Set Isolation The following illustrations demonstrate procedures which ensure proper refrigerant line set isolation Installing Horizontal Runs This shows how to install line sets on horizontal runs NOTE To hang line set from joist or rafter use either metal strapping material or anchored heavy nylon wire ties E Metal sleeve A Metal strapping material around vapor line only F Tape or anchored heavy nylon B Floor joist or roof rafter wire tie C Anchored heavy nylon wire tie G Strap the vapor line to the floor around vapor line only joist or roof rafter at 8 intervals D Tape or wire tie then strap the liquid line to the vapor line Transition from Horizontal to Vertical This shows how to make a transition from horizontal to vertical Style 1 Style 2 A Style 1 anchored C Liquid line E Metal sleeve heavy nylon wire tie D
27. rranty September 2002 This warranty gives you specific legal rights and you may have other rights which vary from state province to state province This warranty applies to U S and Canada only Warrantor Allied Air Enterprises Inc 355 Millennium Dr Orangeburg SC 29115 Products are available under the following brand names Whirlpool Whirlpool Gold IF SOMETHING GOES WRONG CONTACT THE WHIRLPOOL HOME COOLING amp HEATING DEALER FROM WHOM YOU PURCHASED 18 YOUR EQUIPMENT IN MOST CASES YOUR DEALER WILL BE ABLE TO CORRECT THE PROBLEM BUT IF HE SHE IS NOT ABLE TO DO SO YOU SHOULD CONTACT TRADEWINDS DISTRIBUTING DIRECTLY IN WRITING AT THE FOLLOWING ADDRESS Whirlpool Home Cooling and Heating 14610 Breakers Drive Jacksonville FL 32258 General Warranty Subject to the limitations stated in this warranty we warrant the covered equipment for residential use when installed operated and maintained according to the manufacturer s instructions to be free of defects in workmanship or materials for a period of 5 years 1 year for commercial use from the time of initial installation We will replace any defective component without cost or expense to you except for the costs of diagnosis delivery and labor for removing servicing and or replacing the parts or unit WH1 series heat pumps carry a 5 year compressor warranty WH2 and WGH series heat pumps carry a 10 year compressor warranty Warranty Begins The warranty period begins
28. s being matched with an approved line set or indoor coil which was previously charged with R 22 refrigerant or if it is being matched with a coil which was manufactured before January of 1999 the R 22 coil and line set must be flushed prior to installation m Check the refrigerant lines for size and length See Connect Refrigerant Lines Low High Pressure Pressure Outdoor UI I Vapor Line System Gauge Manifold H icti Existing Vapor Line Service Valve g OU Pasting Opened Closed Indoor Coil Existing Liquid Line Liquid Line Service Valve O Inlet Recovery Cylinder O Tank Return Discharge NOTE The inverted R 22 cylinder must contain at least the same amount of refrigerant as was recovered from the existing system Recovery Machine 1 Disconnect power 2 Remove the refrigerant from the existing system per the manufacturer s instructions provided with the recovery system being used Connect the R 22 gauge set is connected to both sides of the refrigerant system as shown and verify that the entire system is void of refrigerant in accordance with the manufacturer s instructions provided with the recovery system being used 3 Disconnect the liquid and vapor lines from the existing outdoor unit 4 Remove the existing outdoor unit 5 Set the new R 410A outdoor unit and connect the refrigerant lines See Connect
29. ss than 0 5 VAC Incorrectly Wired Module Codes Depending on the system configuration some Alert flash codes Incorrectly wiring the diagnostic module will cause false LED may not be active The presence of safety switches affects how codes The Incorrectly Wired Module Troubleshooting chart the system alerts are displayed by the module describes LED operation when the module is incorrectly wired and what troubleshooting action is required to correct the problem Incorrectly Wired Module Troubleshooting Incorrectly Wired Module Indication Green LED is not on module does not power up Recommended Troubleshooting Action Determine if both R and C module terminals are connected See 24 VAC Power Wiring section for R and C wiring Green LED intermittent module powers up only when the compressor runs Determine if R and Y terminals are wired in reverse See 24 VAC Power Wiring earlier in this section for R and C wiring Trip LED is on but the system and the compressor check OK Verify that the Y terminal is connected to the 24 VAC at the contactor coil Trip LED and Alert LED are flashing together Verify that the R and C terminals are connected See 24 VAC Power Wiring earlier in this section for R and C wiring Alert Flash Code 3 Compressor Short Cycling is displayed incorrectly Verify that the Y terminal is connect to the 24 VAC at the contactor coil Alert Flash Codes 5 6
30. st pins and jumper from defrost sensor terminals if used Replace control box cover Reconnect power TROUBLESHOOTING Heat Pump Fails to Operate Properly Review Sequence of Operation and visually inspect the heat pump before troubleshooting AWARNING Electrical Shock Hazard Disconnect power before servicing Replace all parts and panels before operating Failure to do so can result in death or electrical shock W4GH6 heat pumps contain a diagnostic module for troubleshooting heat pump system failures By monitoring and analyzing data from the compressor and thermostat demand the module can accurately detect the cause of electrical and system related failure without any sensors If a system problem occurs a flashing LED indicator communicates the failure code LED Description Power LED Green indicates voltage is present at the power connection of the module Alert LED Yellow communicates an abnormal system condition through a unique flash code The Alert LED will flash a number of times consecutively pause and then repeat the process The number of consecutive flashes correlates to a particular abnormal condition Trip LED Red indicates there is a demand signal from the thermostat but no current to the compressor is detected by the module The Trip LED typically indicates the compressor protector is open or may indicate missing supply power to the compressor Diagnostic LEDs Interpretation
31. stream The outdoor fan is not designed to operate against any additional static pressure Whirlpool Gold Model W4GH6 48488A006 Gather the required tools and parts before starting installation Read and follow the instructions provided with any tools listed here Tools Needed m Torch m Gauge set for R 410A m nut driver refrigerant m 546 nut driver m Service wrench with hex m Adjustable wrench Head extension m Torque wrench Parts Needed Check local codes and HVAC supplier Check existing electrical supply and read Electrical Requirements Location Requirements System Requirements and Connect Refrigerant Lines Heat pump system matches are derived from actual laboratory testing of matched systems It is recommended that only matching equipment be used to ensure proper operation and efficient performance m The designed system matches are listed in the heat pump unit specification sheets and on the heat pump refrigerant charging instructions located on the back of the service access panel m Refrigerant charging instructions include a list of matching indoor equipment with the proper thermal expansion valve size and amount of refrigerant charge required m This heat pump has been factory charged with a quantity of refrigerant R 410A sufficient for a matched indoor coil and a maximum 15 ft of refrigerant line m In order to maintain the 16 SEER rating this heat pump must be matche
32. tat closes circuit R to O and Y Closing R to O and Y energizes the reversing valve for cooling operation and closes the heat pump contactor starting the compressor and outdoor fan The thermostat automatically closes R to G circuit which also brings on the indoor fan at the same time Upon satisfying cooling demand the thermostat will open the above circuits and open the main contactor stopping the compressor and outdoor fan If the indoor unit is equipped with a delay timer the blower will continue to operate for 60 to 90 seconds which improves system efficiency Upon heating demand the thermostat closes circuit R to Y which closes the heat pump contactor starting the compressor and outdoor fan The reversing valve is not energized in the heating mode The thermostat again automatically brings on the indoor fan at the same time Upon satisfying heating demand the thermostat opens the above circuits and stops heat pump operation If the outdoor ambient conditions are such that frost forms on the outdoor coil the defrost control monitors a defrost cycle It then runs the defrost cycle as ambient temperatures require The defrost control is time temperature initiated and temperature terminated with a maximum defrost time time out of 10 minutes The time between defrost cycles is preset at 60 minute intervals at the factory but can be field adjusted between 30 60 or 90 minutes To adjust the time period between defrost cycles
33. ual You are responsible for required periodic maintenance or service such as changing or cleaning of air filters and lubrication or cleaning of components Failure to properly install operate or maintain your unit voids this warranty Keep this book and your sales slip together for future reference You must provide proof of purchase or installation date for in warranty service Write down the following information about your Split System Heat Pump Outdoor Section to better help you obtain assistance or service if you ever need it Dealer name Address Phone number Model number Serial number Installation date 19 48488A006 Registered Trademark TM Trademark of Whirlpool U S A 6 06 2006 All rights reserved Manufactured under license by Tradewinds Distributing Company LLC Coconut Grove Florida Printed in U S A
34. voltage See wiring diagrams later in this section 4 Connect ground wire to ground lug 10 A Ground lug B Field supply ground wire C 208 230 volt field supply wires 1st Stage O g 5 Connect low voltage circuit B Ls ieee ad n A Do not connect C common connection between indoor unit and thermostat except when required by the indoor thermostat Refer to the thermostat installation instructions B C common connection between indoor unit and outdoor unit required for proper operation 6 Replace control box cover 7 Reconnect power Typical Wiring Connection low voltage circuit NOTE Some connections may not apply Refer to specific thermostat and indoor unit Emergency S Heat Relay z Outdoor Thermostat St Stage Aux Heat If Applicable Without Auxiliary Heat Thermostat Indoor Unit Outdoor Unit Pomet Power Ce ay 1st Stage i 4st Stage D Aux Heat H no Aux Heat w Cele If Applicable eee Nabe os fue tec ea be eel Compressor G Oee g With Auxiliary Heat Thermostat Indoor Unit Outdoor Unit O E Power A O B B Outdoor Unit Typical Wiring Diagram LT BU R Outdoor Fan Dual Capacitor Thermostat REPES Compressor Contactor
35. when the installation is complete and the product is ready to operate You must be able to verify this date whenever a warranty claim is made Original bill of sale installer s invoice or other similar document will suffice If the beginning date cannot be verified we will consider warranty coverage to begin 6 months after the date the product was shipped from our factory Limitations on Implied Warranties Implied warranties of merchantability or to the extent applicable fitness for a particular purpose are excluded to the extent legally permissible and are in any event limited to 5 years or the shortest period allowed by law Some states provinces do not allow limitations or exclusions on how long an implied warranty of merchantability or fitness lasts so the above limitations or exclusions may not apply to you Only Warranty This written Limited Warranty is the only warranty made by the warrantor this warranty is in lieu of and excludes all other warranties by the warrantor express or implied The warrantor does not authorize any person to provide on it s behalf any other warranty or to assume for it any further obligation in connection with the warranted product What is NOT Covered by Any Warranty Cabinets or cabinet pieces Normal maintenance items such as filters fan belts fuses or other consumable items Damage caused by misuse failure to maintain properly accidents or acts of God External wiring piping venting or att
36. ze in OD 24 000 K Ya Ys 24 000 36 000 36 000 W 48 000 48 000 60 000 1 1 1 60 000 Line Set Length Less than 25 ft Over 25 ft and Line Set Length Less than 25 ft Over 25 ft and 25 ft up to 50 ft 25 ft up to 50 ft m Install an adequately sized branch circuit disconnect A WARN N G E a NEC within sight of and readily accessible m The cable or conduit and fittings connected from the wh disconnect to the heat pump shall be rated for outdoor use 4 Single Phase Electrical Connections Refer to Wiring Diagram Single Phase 208 230 Volt Electrical Shock Hazard AWARNING y Electrically ground condensing unit or heat pump Connect ground wire to ground lug Use copper wire for supply connection Correct wire gauge is shown in the chart below Failure to follow these instructions can result in death or electrical shock Rating Plate Ampacity Less than 15 Electrical Shock Hazard Disconnect power before servicing Replace all parts and panels before operating Failure to do so can result in death or electrical shock 1 Disconnect power 2 Remove control box cover 3 Connect the field supply wires L1 and L2 to contactor terminals L1 and L2 IMPORTANT m Electrical wiring disconnect means and over current protection are to be supplied by the installer Refer to the rating plate for the maximum over current protection minimum circuit ampacity and operating
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