INSTALLATION INSTRUCTIONS FOR PACKAGE HEAT PUMP OR PACKAGE COOLING UNIT Table of Contents HEAT PUMP/ELECTRIC COOLING SAFETY...............................1 INSTALLATION REQUIREMENTS ................................................2 Tools and Parts ............................................................................2 Location Requirements ................................................................2 Ductwork Requirements ..............................................................4 Electrical Requirements ...............................................................4 INSTALLATION INSTRUCTIONS ..................................................4 Inspect Shipment .........................................................................4 Place Heat Pump or Air Conditioning Unit in Final Location.......5 Connect Condensate Drain .........................................................5 Install Ductwork............................................................................5 Filters ............................................................................................5 Electric Heat Installation and Adjustment....................................6 Make Electrical Connections .......................................................6 Complete Installation ...................................................................7 SEQUENCE OF OPERATION ........................................................7 Start-up Procedure—Cooling Cycle ............................................7 Start-up Procedure—Heat Pump ................................................8 Final System Checks....................................................................8 Explanation and Guidance—Heat Pump.....................................8 Defrost Cycle................................................................................9 System Troubleshooting ............................................................10 Circulating Air Blower.................................................................11 Blower Performance Data ..........................................................12 CHARGE VERIFICATION .............................................................14 SYSTEM MAINTENANCE ............................................................16 TROUBLESHOOTING ..................................................................17 ASSISTANCE OR SERVICE .........................................................20 Accessories ................................................................................20 HEAT PUMP/ELECTRIC COOLING SAFETY Recognize this symbol as a safety precaution. Please adhere to the following warnings and cautions when installing, adjusting, altering, servicing or operating this unit. ATTENTION INSTALLATION PERSONNEL Prior to installation, thoroughly familiarize yourself with this installation manual. Observe all safety warnings. During installation or repair, caution is to be observed. It is your responsibility to install the product safely and to educate the customer on its safe use. Recognize Safety Symbols, Words and Labels The following symbols and labels are used throughout this manual to indicate immediate or potential hazards.It is the owner’s responsibility to read and comply with all safety information and instructions accompanying these symbols. Failure to heed safety information increases the risk of serious personal injury or death, property damage and/or product damage. WARNING Hazards or unsafe practices could result in property damage, product damage, severe personal injury or death. Goodman 1 CAUTION Hazards or unsafe practices may result in property damage, product damage, personal injury or death. Placeho for Ba Code Whirlpool Gold® Models WGPH45**AM, WPC45**AM WPIO-362 CAUTION Goodman 9 Hazards or unsafe practices may result in property or product damage. Tradewinds Distributing Company, LLC 14610 Breakers Drive Jacksonville, FL 32258 WARNING WARNING HIGH VOLTAGE! Goodman 6 Installation and repair of this unit should be performed ONLY by individuals meeting the requirements of an “Entry Level Technician” as specified by the Air-Conditioning, Heating and Refrigeration Institute (AHRI). Attempting to install or repair this unit without such background may result in product damage, personal injury or death. Goodman 7 WARNING Do not connect to or use any device Goodman 36that is not design- certified for use with this unit. Serious property damage, personal injury, reduced unit performance and/or hazardous conditions may result from the use of such non-approved devices. WARNING Goodman 98 Connecting unit ductwork to unauthorized heat producing devices such as a fireplace insert, stove, etc., may result in property damage, fire, carbon monoxide poisoning, explosion, personal injury or death. WARNING This product contains or produces a chemical or chemicals whichGoodman may cause serious45 illness or death and which are known to the State of California to cause cancer, birth defects or other reproductive harm. Disconnect ALL power before servicing. Multiple power sources may be present. Failure to do so may cause property damage, personal injury or death. WARNING This unit must not be used as a “construction heater” Goodman 79 during the finishing phases of construction on a new structure. This type of use may result in premature failure of the unit due to extremely low return air temperatures and exposure to corrosive or very dirty atmospheres. WARNING Goodman 37 To prevent the risk of property damage, personal injury, or death, do not store combustible materials or use gasoline or other flammable liquids or vapors in the vicinity of this unit. IMPORTANT: The United States Environmental Protection Agency (EPA) has issued various regulations regarding the introduction and disposal of refrigerants in this unit. Failure to follow these regulations may harm the environment and can lead to the imposition of substantial fines. These regulations may vary by jurisdiction. A certified technician must perform the installation and service of this product. Should questions arise, contact your local EPA office. This product is designed and manufactured to permit installation in accordance with national codes. It is the installer’s responsibility to install this unit in accordance with national codes and/or prevailing local codes and regulations. INSTALLATION REQUIREMENTS These instructions are intended as a general guide only for use by qualified persons and do not supersede any national or local codes in any way. Compliance with all local, state, or national codes pertaining to this type of equipment should be determined prior to installation. Read this entire instruction manual, as well as the instructions supplied in separate equipment, before starting the installation. The installation of the heat pump or air conditioning unit, wiring, warm air ducts, venting, etc., must conform to the requirements of the National Fire Protection Association; the National Electrical Code, ANSI/NFPA No. 70 (latest edition) in the United States, and any state laws, local ordinances (including plumbing or wastewater codes). Local authorities having jurisdiction should be consulted before installation is made. Such applicable regulations or requirements take precedence over the general instructions in this manual. Tools and Parts Gather the required tools before starting installation. Read and follow the instructions provided with any tools listed here. 2 Tools needed ■ ■ ⁵⁄₁₆" nut driver Screwdriver ■ Tape measure Parts needed Check local codes and existing electrical supply. Read “Electrical Requirements” and “Ductwork Requirements” before purchasing parts. Location Requirements Consider the effect of the outdoor fan noise on conditioned space and any adjacent occupied space. It is recommended that the unit be placed so that the condenser air discharge does not blow toward windows less than 25 ft (7.6 m) away. Heat pumps require special location consideration in areas of heavy snow accumulation and/or areas with prolonged continuous subfreezing temperatures. Heat pump unit bases have holes under the outdoor coil to permit drainage of defrost water accumulation. The unit must be situated to allow free unobstructed drainage of the defrost water and ice. A minimum 2" (5.1 cm) clearance under the outdoor coil is required in milder climates. ■ Ground Level Preinstallation Details The ductwork must be placed into the roof curb before mounting the package unit. The unit should be set on a solid, level foundation, preferably a concrete slab at least 4" (10.2 cm) thick. The slab should be above ground level and surrounded by a graveled area for good drainage. Any slab used as a unit’s foundation should not adjoin the building, since it is possible that sound and vibration may be transmitted to the structure. Rooftop Preinstallation Details Roof Curb G 2009 ENV3 Check that the roof is weathertight and allows proper drainage of condensation. Use steel or treated wood beams as unit support for load distribution. NOTE: To ensure proper condensate drainage, the unit must be installed in a level position. ■ To avoid possible property damage or personal injury, the roof must have sufficient structural strength to carry the weight of the unit(s) and snow or water loads as required by local codes. Consult a structural engineer to determine the weight capabilities of the roof. ■ The unit may be installed directly on wood floors or on Class A, Class B, or Class C roof covering material. ■ To avoid possible personal injury, a safe, flat surface for service personnel should be provided. Rooftop Installation Minimum Clearances Roof Curb Installations Only NOTES: ■ Sufficient structural support must be determined prior to locating and mounting the curb and package unit. ■ Curb insulation, cant strips, flashing and general roofing material are furnished by the contractor. ■ Curbing must be installed in compliance with the National Roofing Contractors Association Manual. ■ Construct ductwork using current industry guidelines. The unit is designed to be located outside the building with an unobstructed condenser air inlet and discharge. Additionally, the unit must be situated to permit access for service and installation. Condenser air enters from 3 sides. Air discharges upward from the top of the unit. Refrigerant gauge connections are made on the right-hand side of the unit as you face the compressor compartment. Electrical connections can be made on the right-hand side of the unit. The best and most common application is for the unit to be located 10" (25.4 cm) from the wall (4" [10.2 cm] minimum) with the connection side facing the wall. This close-to-the-wall application minimizes exposed wiring. Close-to-the-wall application assures free, unobstructed air to the other 2 sides. In more confined application spaces, such as corners, provide a minimum 10" (25.4 cm) clearance on all air inlet sides. Allow 18" (45.7 cm) minimum for service access to the compressor compartment and controls. The top of the unit should be completely unobstructed. If the unit is to be located under an overhang, there should be a minimum of 36" (91.4 cm) clearance and provisions made to deflect the warm discharge air out from under the overhang. 3 Down Discharge Applications Minimum Clearances 10" (25.4 cm) A Cut insulation around bottom openings and remove panels from the bottom of the unit, saving the screws holding the panels in place. NOTE: Single phase models require installation of horizontal duct kit #20464501PDGK (medium chassis) and #20464502PDGK (large chassis). Panel Removal 36" (91.4 cm) B C 36" (91.4 cm) 36" (91.4 cm) A. Wall B. Unit C. Curb B A A. Supply air panel B. Return air panel Ductwork Requirements ■ ■ ■ ■ Install all conditioned air plenums, ducts and air filters in accordance with NFPA 90B Standard for the Installation of Warm Air Heating and Air-Conditioning Systems (latest edition). The heat pump or air conditioning unit is provided with flanges for the connection of the plenum and ducts. All air filters must be listed as Class 2 air filters. All ductwork must be made of materials and insulated to meet local, state and national codes. Ductwork installed outdoors must be sealed, weatherproof and sheltered against physical damage. Caulking, flashing or other means of adequately providing a permanent weather seal should be used where duct penetrates a building or structure opening. Airflow Conversion Units can easily be converted from horizontal to downflow airflow delivery. In downflow or high static installations, the installer should measure the total external static and review the blower performance charts before performing the installation. In some installations it will be necessary to change the blower speed to provide proper airflow. Horizontal Airflow Single phase models are shipped without horizontal duct covers. If needed, these kits may be ordered through your local supplier. Electrical Requirements WARNING HIGH VOLTAGE! Disconnect ALL power before servicing. 6 be present. Multiple powerGoodman sources may Failure to do so may cause property damage, personal injury or death. NOTE: All outdoor wiring must be suitable for outdoor use. Use copper conductors only. ■ All field wiring must be done in accordance with National Electrical Code requirements, applicable requirements of UL, or local codes, where applicable. ■ 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 service ampacity, and operating voltage. See the wiring connection diagrams in “Troubleshooting.” ■ This heat pump or air conditioning unit must be electrically grounded in accordance with National Electric Code (ANSI/ NFPA 70) requirements, applicable requirements of UL, or local codes, where applicable. INSTALLATION INSTRUCTIONS Be sure to examine the heat pump or air conditioning unit inside the carton if the carton is damaged. Inspect Shipment This heat pump or air conditioning unit is shipped in one package, completely assembled and wired. The indoor thermostat and accessories are shipped in a separate carton when ordered. ■ Check the heat pump or air conditioning unit rating plate to confirm specifications are as ordered. ■ Upon receipt of heat pump or air conditioning unit, inspect it for possible shipping damage. 4 ■ 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 or air conditioning unit, since your claim may be denied. A Place Heat Pump or Air Conditioning Unit in Final Location F WARNING Goodman 109 To prevent property damage, the unit should remain in an upright position during all rigging and moving operations. To facilitate lifting and moving when a crane is used, place the unit in an adequate cable sling. WARNING To prevent property damage, personal injury or death, ensure the roof has sufficient structural Goodman 110 strength to carry the weight of the unit(s), roof curb, snow loads and water loads as required by local codes. Consult a structural engineer to determine the weight capabilities of the roof. CAUTION Goodman To avoid possible personal injury, 111 a safe, flat surface for service personnel should be provided. IMPORTANT: If you are using a bottom discharge with the roof curb, the ductwork should be attached to the curb prior to the installation of the unit. Lower the unit carefully onto the roof mounting curb. While you are rigging the unit, the center of gravity will cause the condenser end of the unit to be lower than the supply air end. Rigging B E C D A. Drain connection B. 2" (5.1 cm) minimum C. 3" (7.6 cm) minimum D. Positive liquid seal (required) E. Flexible tubing, hose or pipe F. Unit Install Ductwork IMPORTANT: ■ Install ductwork in accordance with NFPA 90B and any local codes. ■ When the unit is installed so that the supply ducts carry air circulated by the unit to areas outside the space containing the unit, the return air shall be handled by a duct or ducts sealed to the unit casing and terminated outsides the space containing the unit. ■ If there is no complete return air duct system, the return air connection must be sealed to the unit casing and run full size to a location outside the utility room or space housing the unit to avoid a negative pressure on the venting system. Filters Filters are not provided with unit, and must be supplied and installed in the return duct system by the installer. A field installed filter grille is recommended for easy and convenient access to the filters for periodic inspection and cleaning. Filters must have adequate face area for the rated quantity of the unit. See the Air Delivery Table for the recommended filter size. Air Delivery Table Nominal Filter Area sq ft (cm2) Placeholder for Rigging art 7 (6,503) 6 (5,574) 5 (4,645) 4 (3,716) 3 (2,787) 2 (1,858) 500 Connect Condensate Drain The condensate drain connection of the evaporator is a half coupling of ³⁄₄" N.P.T. A ³⁄₄" drain line with trap must be installed on all applications to avoid accumulation of condensate. Condensate Drain Connection ■ ■ ■ Install the condensate drain trap as shown. Use a ³⁄₄" (1.9 cm) NPT drain connection size or larger. An external trap must be installed for proper condensate drainage. Unit must be level or slightly inclined toward drain. Dis p bl osa eF ilte r ilter ent F an Perm 1,000 1,500 2,000 2,500 Airflow - SCFM 3,000 3,500 Minimum Filter Size Nominal Size—in. (cm) Nominal Area—sq ft (cm2) 10 x 20 (25.4 x 50.8) 1.4 (1,301) 14 x 20 (35.6 x 50.8) 1.9 (1,765) 14 x 25 (35.6 x 63.5) 2.4 (2,230) 15 x 20 (38.1 x 50.8) 2.1 (1,951) 16 x 20 (40.6 x 50.8) 2.2 (2,044) 16 x 25 (40.6 x 63.5) 2.8 (2,601) 20 x 20 (50.8 x 50.8) 2.8 (2,601) 20 x 25 (50.8 x 63.5) 3.5 (3,252) 25 x 25 (63.5 x 63.5) 4.3 (3,995) 5 Electric Heat Installation and Adjustment Make Electrical Connections Wiring WARNING Goodman 6 HIGH VOLTAGE! WARNING Disconnect ALL power before servicing. Goodman 6HIGH VOLTAGE! Multiple power sources may be present. Disconnect ALL power before servicing. Failure to do so may cause property damage, personal injury or death. Multiple power sources may be present. This series of electric cooling and heat pump package equipment is designed to accept a field installed electric heat kit. The unit is equipped to easily install the HKR Series Electric Heat Kit. Full installation instructions are included in this kit. Please use this document for guidance in field equipping the package unit with electric heat. Choose the heat kit that fits the application for the specific installation. Permanently mark the unit’s nameplate with the model being installed. High and low voltage connections are detailed in the heat kit instructions. Indoor blower motor speed tap selection may need to be modified to accommodate normal continuous operation to prevent a nuisance trip. See the following charts. WPC45(24-48) Models Electric Heat KW Unit Model Number 5 8 10 15 20 WPC4524AM41 3 3 3 x x WPC4530AM41 3 3 3 3 x WPC4536AM41 3 3 3 3 x WPC4542AM41 3 3 3 3 x WPC4548AM41 3 3 3 3 3 All models are factory-shipped at T3 speed. WGPH45(24-60) Models Electric Heat KW Unit Model Number 5 8 10 15 20 WGPH4524AM41 x x x WGPH4530AM41 x x x x WGPH4536AM41 x x x x WGPH4543AM41 x x x x WGPH4549AM41 x x x x x WGPH4560AM41 x x x x x Failure to do so may cause property damage, personal injury or death. All wiring should be made in accordance with the National Electrical Code (N.E.C). The local power company should be consulted to determine the availability of sufficient power to operate the unit. The voltage, frequency and phase at the power supply should be checked to make sure it corresponds to the unit’s rated voltage requirement. Install a branch circuit fused disconnect near the unit, in accordance with the N.E.C. or local codes. Wire sizes and overcurrent protection should be determined from the unit nameplate ampacity and in accordance with Branch Circuit Ampacity chart or the N.E.C. Under no circumstances should wiring be sized smaller than is recommended by either of these 2 sources. Branch Circuit Ampacity Supply Wire Length—ft (m) 15 20 25 30 35 40 45 50 200 (61) 6 4 4 4 3 3 2 2 150 (45.7) 8 6 6 4 4 4 3 3 100 (30.5) 10 8 8 6 6 6 4 4 50 (15.2) 14 12 10 10 8 8 6 6 Fuses smaller than that recommended on the wiring diagrams could result in unnecessary fuse failure or service calls. The use of protective devices of larger size than indicated could result in extensive damage to the equipment. The manufacturer bears no responsibility for damage caused to equipment as result of the use of larger than is recommended size protective devices. All units have undergone a run test prior to packaging for shipment. This equipment has been started at minimum rated voltage and checked for satisfactory operation. Do not attempt to operate this unit if the voltage is not within the minimum and maximum voltages shown on nameplate. All exterior wiring must be within approved weatherproof conduit. The unit must be permanently grounded in accordance with local codes, or in absence of local codes, with N.E.C. ANSI/ NFPA No. 70-1984 or latest edition by using ground lug in the control box. Fuses or HACR type circuit breakers may be used where codes permit. High Voltage Wiring Single Phase—Connect the 2 leads to terminals L1 and L2 in the electrical control section, using wire sizes specified in the wiring table. 6 Low Voltage Wiring Internal Wiring ■ A diagram detailing the internal wiring of this unit is located on the electrical box cover. If any of the original wire supplied with the appliance must be replaced, the wire gauge and insulation must be the same as the original wiring. Transformer is wired for 230 volts on the 208/230 models. See the wiring diagram for 208-volt wiring. 1. Disconnect power. 2. Remove the control access panel. 3. Route the field supply wires through the line voltage conduit opening to the electrical connection area, providing sufficient length to connect to the pigtail leads. Heat pumps—Connect 24V wires from the thermostat to the corresponding wires in the control box using 18 AWG as follows: WPC45 Terminal 24-60 Thermostat Red R (24V) Green G (Fan) White W1 (Heat)* Brown W2 (Heat)* Yellow Y (Cool) Blue C (24V Common) WGPH45 Terminal 24-43 Thermostat 49-60 Thermostat Red R (24V) R (24V) Green G (Fan) G (Fan) Orange O (Rev. Valve) Single Phase Units ■ Connect the field supply wires (L1, L2) to the 2 black pigtail leads using UL-Listed wire connectors. O (Rev. Valve) nd White W1 (Heat, 2 )* W1 (Heat, 2nd)* Brown W2 (Heat, 3rd)* W2 (Heat, 3rd)* Purple Not used Y1 (Low Cool) Yellow Y1 (Cool) Y2 (High Cool) Blue C (24V Common) C (24V Common *Optional field installed heat connections NOTES: ■ Thermostats must be set to energize “G” during cooling. This is default on most all thermostats. ■ WGPH4549 and WGPH4560 have 2-stage cooling and require 2-stage heat/cool with optional 3rd-stage electric heat thermostat. Complete Installation IMPORTANT: Do not use this heat pump or condensing unit if any part has been under water. Immediately call a qualified person to inspect the heat pump or condensing unit and to replace any part of the control system which has been under water. 1. Check that you have all of your tools. 2. Dispose of/recycle all packaging materials. 3. Check the heat pump or condensing unit in its final location. SEQUENCE OF OPERATION Start-up Procedure—Cooling Cycle WARNING Goodman HIGH6 VOLTAGE! Disconnect ALL power before servicing. Multiple power sources may be present. Failure to do so may cause property damage, personal injury or death. 1. Disconnect power. 2. Turn the thermostat switch to “Cool” and the fan switch to “Auto.” 3. Set the temperature setting to the highest setting. 4. Verify that all of the registers are set to the normal open position. 5. Turn on the electrical supply at the disconnect. 6. Turn the fan switch to the “ON” position. The blower should operate after a 7-second delay. 7. Turn the fan switch to the “Auto” position. The blower should stop after an approximate 60-second delay. 8. Slowly lower the cooling temperature until the unit starts. The compressor, blower and fan should now be operating. 9. Allow the unit to run for 10 minutes. Check that cool air is being supplied by the unit. 10. Turn the temperature setting to the highest position, stopping the unit. The indoor blower will continue to run for approximately 60 seconds. 11. Turn the thermostat switch to “OFF” and disconnect all power when servicing the unit. 7 Start-up Procedure—Heat Pump WARNING Goodman HIGH6 VOLTAGE! Disconnect ALL power before servicing. Multiple power sources may be present. Failure to do so may cause property damage, personal injury or death. 1. Check that the cooling mode for the heat pump is working properly according to the procedure listed in the “Start-up Procedure—Cooling Cycle” section. ■ The reversing valve is energized when the thermostat is placed in the cooling position. ■ A clicking sound should be noticeable from the reversing valve. ■ By lowering the temperature setting to call for cooling, the contactor is energized. ■ The compressor, blower and fan should then be running. 2. After the cooling mode is checked out, turn the thermostat system switch to “OFF.” 3. Turn the thermostat switch to “HEAT” and the fan switch to “AUTO.” 4. Slowly raise the heating temperature setting. When the heating 1st stage makes contact, stop raising the temperature setting. The compressor, blower and fan should now be running with the reversing valve in the deenergized (heating) position. 5. After giving the unit time to settle out, check that the unit is supplying heated air. 6. If the outdoor ambient is above 80°F (26.7ºC), the unit may trip on its high pressure cutout when on heating. The compressor should stop. 7. The heating cycle must be thoroughly checked, so postpone the test to another day when conditions are more suitable. IMPORTANT: Be sure to test the unit. 8. If the outdoor ambient is low and the unit operates properly on the heating cycle, you may check the pressure cutout operation by blocking off the indoor return air until the unit trips. 9. If the unit operates properly in the heating cycle, raise the temperature setting until the heating 2nd stage makes contact. Supplemental resistance heat, if installed, should now turn on. Check that the supplemental resistant heat operates properly. NOTES: ■ WGPH4549-60 has 2 stages of compressor heat. During the resistance heat test, increase the temperature setting until the 3rd-stage heat is energized. ■ If outdoor thermostats are installed, the outdoor ambient temperature must be below the set point of these thermostats for the heaters to operate. It may be necessary to jumper these thermostats to check heater operation if outdoor ambient temperature is mild. 10. For thermostats with an emergency heat switch, raise the temperature setting until the heating 2nd stage makes contact. NOTE: The emergency heat switch is located at the bottom of the thermostat. Move the switch to emergency heat. The heat pump will stop, the blower will continue to run, all heaters will come on, and the thermostat emergency heat light will turn on. 8 11. If the unit is being checked in the wintertime when the outdoor coil is cold enough to activate the defrost control, observe at least one defrost cycle to make sure the unit defrosts completely. Final System Checks 1. Check that all supply and return air grilles are adjusted and the air distribution system is balanced for the best compromise between heating and cooling. 2. Check for air leaks in the ductwork. See “Airflow Measurement and Adjustment” and “Checking Charge.” 3. Check that the unit is free of “rattles,” and the tubing in the unit is free from excessive vibration. 4. Check that the tubes and lines are not rubbing against each other or against the sheet metal surfaces or edges. If contact is found, correct the problem. 5. Set the thermostat at the appropriate setting for cooling and heating or automatic changeover for normal use. 6. Check that the owner is instructed on the unit operation, filter, servicing, correct thermostat operation, etc. 7. The previous sections are recommended to serve as an indication that the unit will operate normally. Explanation and Guidance—Heat Pump When the heat pump is in the cooling cycle, the heat pump operates exactly as an air conditioning unit. The heat pump operates in the heating cycle by redirecting refrigerant flow through the refrigerant circuit external to the compressor. This is accomplished through the reversing valve. Hot discharge vapor from the compressor is directed to the indoor coil (evaporator on the cooling cycle) where the heat is removed, and the vapor condenses to a liquid. It then goes through the expansion device to the outdoor coil (condenser on the cooling cycle) where the liquid is evaporated, and the vapor goes to the compressor. When the solenoid valve coil is operated either from heating to cooling or cooling to heating, the piston in the reversing valve to the low pressure (high pressure) reverses position in the reversing valve. The following illustrations show a schematic of a heat pump on the cooling cycle and the heating cycle. In addition to a reversing valve, a heat pump is equipped with an expansion device and check valve for the indoor coil, and similar equipment for the outdoor coil. It is also provided with a defrost control system. The expansion devices are flowrator distributors and perform the same function on the heating cycle as on the cooling cycle. The flowrator distributors also act as check valves to allow for the reverse of refrigerant flow. When the heat pump is on the heating cycle, the outdoor coil is functioning as an evaporator. The temperature of the refrigerant in the outdoor coil must be below the temperature of the outdoor air in order to extract heat from the air. Thus, the greater the difference in the outdoor temperature and the outdoor coil temperature, the greater the heating capacity of the heat pump. This phenomenon is a characteristic of a heat pump. It is a good practice to provide supplementary heat for all heat pump installations in areas where the temperature drops below 45°F (7.2ºC). It is also a good practice to provide sufficient supplementary heat to handle the entire heating requirement should there be a component failure of the heat pump, such as a compressor, refrigerant leak, etc. Since the temperature of the refrigerant in the outdoor coil on the heating cycle is generally below the freezing point, frost forms on the surfaces of the outdoor coil under certain weather conditions. Therefore, it is necessary to reverse the flow of the refrigerant to provide hot gas in the outdoor coil to melt the frost accumulation. This is accomplished by reversing the heat pump to the cooling cycle. At the same time, the outdoor fan stops to hasten the temperature rise of the outdoor coil and lessen the time required for defrosting. The indoor blower continues to run, and the supplementary heaters are energized. Cooling Cycle C D B A E F C G H H C J I J B A. Evaporator B. Service valves C. Service ports D. Reversing valve E. Condenser F. Accumulator G. Compressor H. Distributors K I. Indoor coil J. Check valve orifices K. Outdoor coil 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 Control During operation, the power to the circuit board is controlled by a temperature sensor, which is clamped to a feeder tube entering the outdoor coil. Defrost timing periods of 30, 60 and 90 minutes may be selected by connecting the circuit board jumper to 30, 60 and 90, respectively. Accumulation of time for the timing period selected starts when the sensor closes (approximately 34°F [1ºC]), and when the wall thermostat calls for heat. At the end of the timing period, the unit’s defrost cycle will be initiated provided the sensor remains closed. When the sensor opens (approximately 60°F [16ºC]), the defrost cycle is terminated and the timing period is reset. If the defrost cycle is not terminated due to the sensor temperature, a 10-minute override interrupts the unit’s defrost period. Circuit Board DF2 TEST Heating Cycle Jumper Wire C D B A E 90 A 60 30 DF1 C Y W2 R R DFT F Suggested Field Testing/Troubleshooting 1. Run the unit in the heating mode (room thermostat calling for heat). 2. Check the unit for proper charge. NOTE: Bands of frost on the condenser coil indicate low refrigerant charge. G H H C I J A. Condenser B. Service valves C. Service ports D. Reversing valve J B E. Evaporator F. Accumulator G. Compressor H. Distributors K I. Indoor coil J. Check valve orifices K. Outdoor coil Defrost Cycle 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. 3. Turn off power to the unit. 4. Disconnect the outdoor fan by removing the purple lead from “DF2” on the defrost control. 5. Restart the unit and allow frost to accumulate. 6. After a few minutes of operation, the defrost thermostat should close. To verify this, check for 24 volts between “DFT” and “C” on the control board. If the temperature at the thermostat is less than 28°F (-2ºC) and the thermostat is open, replace the defrost thermostat, since it is defective. 7. When the defrost thermostat has closed, short the test pins on the circuit board until the reversing valve shifts, indicating defrost. This should take up to 21 seconds depending on what timing period the control is set. NOTE: After defrost initiation, the short must instantly be removed, or the unit’s defrost period will last only 2.3 seconds. 8. After the defrost thermostat has terminated, check the defrost thermostat for 24 volts between “DFT” and “C.” The reading should indicate 0 volts (open sensor). 9. Turn off power to the unit. 10. Replace the outdoor fan motor lead to terminal “DF2” on the circuit board and turn on power. 9 System Troubleshooting Symptom Possible Cause Remedy High head—low suction ■ Restriction in liquid line or flowrator ■ Remove or replace with proper size flowrator. High head—high or normal suction ■ Dirty condenser coil Overcharged Condenser fan not running ■ Clean coil. Correct system charge. Repair or replace condenser fan. Incorrect flowrator Defective compressor valves Flowrator not seating properly ■ Power off or loose electrical connection Thermostat out of calibration; set too high Defective contactor Blown fuses or tripped circuit breaker Transformer defective High or low pressure control (optional) open Compressor overload contacts open ■ ■ ■ Low head—high suction ■ ■ ■ Unit will not run. ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ Replace with correct flowrator. Replace compressor. Check for debris under flowrator or deformed flowrator. Remove debris or replace flowrator. Check for unit voltage at contactor in unit. Reset thermostat. Check for 24 volts at contactor coil. Replace if contacts are open. Replace fuse or reset circuit breaker. Check wiring. Replace transformer. Reset high pressure control or check unit charge. High pressure control opens at 610 psig, and low pressure control opens at 22 psig. ■ Replace compressor. NOTE: Wait at least 2 hours for overload to reset. ■ ■ Loose connection Compressor stuck Grounded or open winding Open internal overload Low voltage connection Capacitor weak, open or shorted Check for unit voltage at compressor. Check and tighten all connections. Wait at least 2 hours for overload to reset. If still open, replace the compressor. At compressor terminals, voltage must be within 10% of nameplate volts when unit is operating. Check capacitor. Replace if defective. Low suction—Cool compressor, iced evaporator coil ■ Low indoor airflow ■ Compressor short cycles ■ Condenser fan runs; compressor does not run. ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ Defective overload protector Unit cycling on low pressure control High pressure switch cuts out ■ Low airflow ■ ■ Registers sweat ■ ■ ■ ■ High suction pressure ■ ■ ■ Insufficient cooling ■ ■ ■ ■ Excessive load Defective compressor Reversing valve not seating properly. ■ Improperly sized unit Improper airflow Incorrect refrigerant charge. Incorrect voltage ■ ■ ■ ■ ■ ■ Evaporator coil freezing or frosting ■ ■ ■ 10 Low airflow Low refrigerant charge Operating unit in cooling mode below 65ºF (18ºC) outdoor temperature ■ ■ ■ Increase speed of blower or reduce restriction. Replace air filters. Replace overload protector. Check for correct voltage. Check refrigerant charge and/or airflow. Check airflow (indoor and outdoor) Increase speed of blower or reduce restriction. Replace air filters. Recheck load calculation Replace compressor. Replace reversing valve. Recalculate load. Check airflow—should be approximately 400 CFM per ton. Charge per procedure attached to unit service panel. At compressor terminals, voltage must be within 10% of nameplate volts when unit is operating. Check airflow—should be approximately 400 CFM per ton. Properly charge unit. Install or check low ambient control—should be open below 65ºF (18ºC) outdoor temperature. Circulating Air Blower WARNING HIGH VOLTAGE! 6 Disconnect ALLGoodman power before servicing. Multiple power sources may be present. Failure to do so may cause property damage, personal injury or death. Airflow Measurement and Adjustment Please review the ductwork section before proceeding with the airflow measurements and adjustments in this section. The unit blower curves (see Specification Sheets) are based on the external static pressure (ESP per in./W.C.). The duct openings on the unit are considered internal static pressure. As long as ESP is maintained, the unit will deliver the proper air up to the maximum static pressure listed for the CFM required by the application (for example, home, building, etc.). In general, 400 CFM per ton of cooling capacity is a rule of thumb. Some applications depending on the sensible and latent capacity requirements may need only 350 CFM or up to 425 CFM per ton. Check condition space load requirements (from load calculations) and equipment expanded ratings data to match CFM and capacity. After the unit is set and the ductwork completed, verify the ESP with a 1" (2.5 cm) inclined manometer with pitot tubes or a Magnahelic gauge and confirm CFM to blower curves in the Specification Sheets. All units have 3-speed blower motors. If the low speed is not utilized, the speed tap can be changed to medium or high speed. NOTE: Never run CFM below 350 CFM per ton. Evaporator freezing or poor unit performance is possible. Adjusting Speed Tap for Indoor Blower Motor X-13 Motor Adjust the CFM by changing the 24V low voltage lead at the speed terminal block on the motor. (T1—Low Speed, T2 and T3—Medium Speed, T4 and T5—High Speed). NOTE: Factory set T1 (G, Fan), T2 (Cool/High cool), T3 (W2 Electric Heat), T4 and T5 reserved for high static (Cool/High Cool) and W2. ECM Motor Speed Adjustment Each ECM blower motor has been preprogrammed for operation at 4 distinct airflow levels when operating in Cooling/ Heat Pump mode or Electric Heat mode. These 4 distinct levels may also be adjusted slightly lower or higher if desired. The adjustment between levels and the trim adjustments are made by changing the DIP switch(s) either to an OFF or ON position. See Blower Performance Data charts. WGPH45 DIP Switch Functions The ECM motor has an electronic control that contains 8 2-position DIP switches. The function of these DIP switches is shown in the following chart. DIP Switch Number Function 1 2 Electric Heat 3 N/A 4 Indoor Thermostat 5 Cooling and Heat Pump CFM 6 7 CFM Trim Adjust 8 For WGPH4524-43 models, DIP Switch 4 must be set to ON. DIP Switch 4 must be set to OFF for 2-stage compressor models WGPH4549-60. DIP Switch 4 ON energizes Y1 signal to the ECM motor anytime Y/Y2 is energized. The indoor motor will not operate properly if switch is not set correctly for the model. WGPH CFM Delivery and Adjustments See “Circulating Air Blower” for CFM output, adjustments and DIP switch settings. WGPH Thermostat Fan Only Mode During Fan Only operations, the CFM output is 50% of the high-stage cooling setting. WGPH Humidity Control When using a Humidistat (normally closed), cut jumper PJ6 on the control board. The Humidistat will affect both low-stage and high-stage cooling airflow by adjusting the airflow to 85%. ECM Motor The ECM control board is factory-set with the DIP Switch 4 in the “ON” position for single stage units and to the "OFF" position for the 2-stage units. All other DIP switches are factory-set in the “OFF” position. For most applications, the settings are to be changed according to the electric heat size. The ECM motor provides many features not available on the traditional PSC motor. These features include: ■ Improved Efficiency ■ Constant CFM ■ Soft Start and Stop ■ Improved Humidity Control WGPH 2-Stage Heating When using staged electric heat, cut jumper PJ4 on the control board. WGPH Thermostat Wiring Use the thermostat wiring diagrams provided with the thermostat when making these connections. 11 Blower Performance Data E.S.P. (In. of H2O) Model Speed Volts—230 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 WPC4524AM T1 (G) CFM 882 808 727 649 545 - - - Watts 82 86 92 102 108 - - - T2/T3 T4/T5 WPC4530AM T1 (G) T2/T3 T4/T5 WPC4536AM T1 (G) T2/T3 T4/T5 WPC4542AM T1 T2/T3 T4/T5 WPC4548AM T1 T2/T3 T4/T5 CFM 933 873 810 733 637 584 - - Watts 93 103 109 120 126 135 - - CFM 1,058 1,012 945 896 816 723 672 - Watts 124 136 142 153 168 172 179 - CFM 893 824 752 665 575 - - - Watts 87 95 101 111 115 - - - CFM 1,132 1,070 1,011 959 889 827 733 669 Watts 153 162 168 179 184 195 206 208 CFM 1,287 1,236 1,165 1,123 1,066 1,012 958 857 Watts 211 217 228 239 244 255 265 272 CFM 852 764 711 592 545 - - - Watts 80 82 86 95 99 - - - CFM 1,232 1,190 1,131 1,082 1,023 996 889 819 Watts 202 214 221 229 235 246 258 264 CFM 1,267 1,213 1,162 1,120 1,058 1,009 932 841 Watts 218 226 236 245 247 260 272 275 CFM 1,123 1,070 1,025 984 942 894 839 774 Watts 162 170 182 193 204 216 229 242 CFM 1,437 1,390 1,354 1,318 1,281 1,243 1,204 1,165 Watts 310 317 331 342 355 366 377 389 CFM 1,528 1,490 1,450 1,410 1,383 1,348 1,312 1,267 Watts 372 379 391 403 416 427 439 451 CFM 1,199 1,138 1,085 1,017 957 889 820 755 Watts 162 173 185 193 211 219 232 245 CFM 1,799 1,745 1,698 1,658 1,610 1,560 1,522 1,450 Watts 480 493 508 521 531 545 550 547 CFM 1,921 1,865 1,818 1,780 1,719 1,667 1,579 1,183 Watts 582 585 602 625 627 621 595 569 NOTES: ■ Data shown is dry coil. Wet coil pressure drop is approximately 0.2" H20, for 3-row indoor coil; and 0.3" H20, for 4-row indoor coil. ■ Data shown does not include filter pressure drop, approximately 0.08" H2O. ■ All models should run no less than 350 CFM/Ton. ■ Reduce airflow by 2% for 208-volt operation. WGPH4524AM Cooling/HP Adjust Speed Tap CFM* Electric Heat Adjust Tap CFM* D Minus 630 D Minus 630 D Normal 700 D Normal 700 D Plus 770 D Plus 770 WGPH4524AM Cooling/HP Adjust Speed Tap CFM* Electric Heat Adjust Tap CFM* C Minus 743 C Minus 743 C Normal 825 C Normal 825 C Plus 908 C Plus 908 B Minus 855 B Minus 855 B Normal 950 B Normal 950 B Plus 1,045 B Plus 1,045 A Minus 945 A Minus 945 A Normal 1,050 A Normal 1,050 A Plus 1,155 A Plus 1,155 *At 0.1 to 0.5 ESP 12 WGPH4530AM, WGPH4536AM WGPH4560AM Cooling/HP Adjust Speed Tap CFM* Electric Heat Adjust Tap CFM* Cooling/HP Adjust Speed Tap CFM* Electric Heat Adjust Tap CFM* D Minus 720 D Minus 720 D Minus 1,260 D Minus 1,260 D Normal 800 D Normal 800 D Normal 1,400 D Normal 1,400 D Plus 880 D Plus 880 D Plus 1,540 D Plus 1,540 C Minus 900 C Minus 900 C Minus 1,440 C Minus 1,440 C Normal 1,000 C Normal 1,000 C Normal 1,600 C Normal 1,600 C Plus 1,100 C Plus 1,100 C Plus 1,760 C Plus 1,760 B Minus 990 B Minus 990 B Minus 1,620 B Minus 1,620 B Normal 1,100 B Normal 1,100 B Normal 1,800 B Normal 1,800 B Plus 1,210 B Plus 1,210 B Plus 1,980 B Plus 1,980 A Minus 1,125 A Minus 1,125 A Minus 1,800 A Minus 1,800 A Normal 1,250 A Normal 1,250 A Normal 2,000 A Normal 2,000 A Plus 1,375 A Plus 1,375 A Plus 2,200 A Plus 2,200 *At 0.1 to 0.5 ESP *At 0.1 to 0.5 ESP WGPH4543AM, WGPH4549AM CFM Output for DIP Switch Combinations 1 and 2— Electric Heat Cooling/HP Adjust Speed Tap CFM* Electric Heat Adjust Tap CFM* D Minus 1,103 D Minus 1,103 D Normal 1,225 D Normal 1,225 D Plus*** 1,348 D Plus 1,348 C Minus** 1,260 C Minus** 1,260 C Normal 1,400 C Normal 1,400 C Plus 1,540 C Plus 1,540 B Minus 1,530 B Minus 1,530 B Normal 1,700 B Normal 1,700 B Plus 1,870 B Plus 1,870 A Minus 1,620 A Minus 1,620 A Normal 1,800 A Normal 1,800 A Plus 1,980 A Plus*** 1,980 *At 0.1 to 0.5 ESP **Denotes factory setting for WGPH4543AM ***Denotes factory setting for WGPH4549AM Model Speed Tap Switch 1 Switch 2 Electric Heat—CFM WGPH4524 A Off Off 1,050(F) B 1,400 Off 950 WGPH4530 WGPH4536 WGPH4543 WGPH4549 WGPH4560 (F) C Off On 825 D On On 700 A Off Off 1,250(F) B On Off 1,100 C Off On 1,000 D On On 800 A Off Off 1,250(F) B On Off 1,100 C Off On 1,000 D On On 800 A Off Off 1,800 B On Off 1,700 C Off On 1,400(F) D On On 1,225 A Off Off 1,800 B On Off 1,700 C Off On 1,400 D On On 1,225(F) A Off Off 2,000(F) B On Off 1,800 C Off On 1,600 D On On 1,400 Factory setting 13 CFM Output for DIP Switch Combinations 5 and 6— Cooling/Heating CFM Output for DIP Switch Combinations 5 and 6— Cooling/Heating Model Speed Tap Switch 5 Switch 6 Cooling/ HP—CFM Model Speed Tap Switch 5 Switch 6 Cooling/ HP—CFM WGPH4524 A Off Off 1,050(F) WGPH4543 A Off Off 1,800 B 1,400 Off 950 B On Off 1,700 C Off On 825 C Off On 1,400(F) WGPH4530 WGPH4536 D On On 1,225 A Off Off 1,800 1,100 B On Off 1,700 On 1,000 C Off On 1,400 On On 800 D On On 1,225(F) A Off Off 1,250(F) A Off Off 2,000(F) B On Off 1,100 B On Off 1,800 C Off On 1,000 C Off On 1,600 D On On 800 D On On 1,400 D On On 700 A Off Off 1,250(F) B On Off C Off D WGPH4549 WGPH4560 (F) Factory setting DIP Switch Settings for Single- and 2-Stage Thermostats Model Switch 3 Switch 4 Thermostat WGPH45** N/A On Single-Stage N/A Off 2-Stage Adjustments Through DIP Switch Combinations 7 and 8 CFM Switch 7 Switch 8 +10% On Off Normal Off Off -10% Off On CHARGE VERIFICATION Determine Superheat 1. Read suction pressure. 3. Read suction line temperature. 2. Determine Saturated Suction Temperature from tables or 4. Use the following formula to determine Superheat. pressure gauge saturated temperature scale (R-410A). Superheat = Suction Line Temperature - Saturated Suction Temperature Saturated Suction Pressure Temperature Suction Pressure Saturated Suction Temperature ºF Suction Pressure Saturated Suction Temperature ºF PSIG R-410A PSIG R-410A 50 1 78 20 52 3 80 21 54 4 85 24 56 6 90 26 58 7 95 29 60 8 100 31 62 10 110 36 64 11 120 41 66 13 130 45 68 14 140 49 14 Saturated Suction Pressure Temperature Suction Pressure Saturated Suction Temperature ºF Suction Pressure Saturated Suction Temperature ºF PSIG R-410A PSIG R-410A 70 15 150 53 72 16 160 56 74 17 170 60 76 19 Subcooling = Saturated Line Temperature - Liquid Line Temperature Saturated Liquid Pressure Temperature Liquid Pressure Saturated Liquid Temperature ºF Liquid Pressure Saturated Liquid Temperature ºF PSIG R-410A PSIG R-410A 200 70 375 112 210 73 405 118 220 76 415 119 225 78 425 121 235 80 435 123 245 83 445 125 255 85 475 130 265 88 500 134 275 90 525 138 285 92 550 142 295 95 575 145 305 97 600 149 325 101 625 152 355 108 Single Speed Application—WPC45 1. Purge the gauge lines. 2. Connect the service gauge manifold to the access fittings. Run the system for at least 10 minutes to allow the pressure to stabilize. 3. Temporarily install a thermometer on the liquid (small) line near the liquid line access fitting with adequate contact and insulate for best possible reading. 4. Check subcooling and superheat. Systems with TXV application should have a subcooling of 10 + 2°F and superheat of 15ºF to 18ºF. a) If subcooling and superheat are low, adjust TXV to 15ºF to 18ºF, and then check subcooling. b) If subcooling is low and superheat is high, add charge to raise subcooling to 10ºF ± 2ºF then check superheat. c) If subcooling and superheat are high, adjust TXV valve to 15ºF to 18ºF, and then check subcooling. d) If subcooling is high and superheat is low, adjust TXV valve to 15ºG to 18ºF superheat and remove charge to lower the subcooling to 10ºF ± 2ºF. NOTES: ■ The TXV should not be adjusted at light load conditions of 55ºF (13ºC) to 60ºF (16ºC). Under such conditions, only the subcooling can be evaluated. This is because the suction pressure is dependent upon the indoor airflow and the wet bulb temperature. ■ Do not adjust the charge based on the suction pressure unless there is a gross undercharge. 5. Disconnect the manifold set. Installation is complete. 2-Speed Application—WGPH45 Run the unit on low-stage cooling for 10 minutes until the refrigerant pressures stabilize. Follow the guidelines and methods below to check the unit operation and ensure that the refrigerant charge is within limits. Charge the unit on low stage. 1. Purge the gauge lines. 2. Connect the service gauge manifold to the access fittings. Run the system for at least 10 minutes to allow the pressure to stabilize. 3. Temporarily install a thermometer on the liquid (small) line near the liquid line access fitting with adequate contact and insulate for best possible reading. 4. Check subcooling and superheat. The 2-stage systems running on low stage with TXV application should have a subcooling of 5ºF to 7ºF and superheat of 15ºF to 18ºF. a) If subcooling and superheat are low, adjust TXV to 15ºF to 18ºF superheat, then check subcooling. NOTE: To adjust superheat, turn the valve stem clockwise to increase and counterclockwise to decrease. b) If subcooling is low and superheat is high, add charge to raise subcooling to 5ºF to 7ºF, and then check superheat. c) If subcooling and superheat are high, adjust TXV valve to 15ºF to 18ºF superheat, and then check subcooling. d) If subcooling is high and superheat is low, adjust TXV valve to 15ºF to 18ºF superheat and remove charge to lower the subcooling to 5ºF to 7ºF. NOTE: Do not adjust the charge based on the suction pressure unless there is a gross undercharge. 5. Disconnect the manifold set. Installation is complete. 15 Refrigerant Charge Check—Units with Fixed Orifice Devices After completing the airflow measurements and adjustments, the unit’s refrigerant charge must be checked. The unit comes factory-charged, but this charge is based on 325 CFM per ton and a minimum ESP per ARI test conditions (generally between 0.15 to 0.25 ESP). When air quantity or ESP is different than above, the refrigerant charge must be adjusted to the proper amount. All package units with fixed orifice devices are charged using the superheat method at the compressor suction line. For charging in the warmer months, 8ºF ± 3ºF superheat at the compressor is required at conditions 95ºF (35ºC) outdoor ambient (dry bulb) temperature, 80ºF (27ºC) dry bulb/67ºF (19ºC) wet bulb indoor ambient, approximately 50% humidity. This superheat varies when conditions vary from the conditions described. After superheat is adjusted, it is recommended that the subcooling be checked at the condenser coil liquid line out. In most operating conditions, 10ºF to 15ºF of sub-cooling is adequate. SYSTEM MAINTENANCE WARNING ■ Outside Air Into Return Duct Do not introduce cold outside air into the return duct of a heat pump installation. Do not allow air entering the indoor coil to drop below 65°F (18ºC). Air below this temperature will cause low discharge pressure, thus low suction pressure, and excessive defrost cycling resulting in low heating output. It may also cause false defrosting. ■ Undercharge An undercharged heat pump on the heating cycle will cause low discharge pressure resulting in low suction pressure and frost accumulation on the outdoor coil. ■ Poor “Terminating” Sensor Contact The defrost terminating sensor must make good thermal contact with the outdoor coil tubing. Poor contact may not terminate the defrost cycle quickly enough to prevent the unit from cutting out on high discharge pressure. ■ Malfunctioning Reversing Valve This may be due to: HIGH VOLTAGE! Disconnect ALL power before servicing. Goodman 6 Multiple power sources may be present. Failure to do so may cause property damage, personal injury or death. The self-contained package air conditioner or heat pump should operate for many years without excessive service calls if the unit is installed properly. However, it is recommended that the homeowner inspect the unit before a seasonal start-up. The coils should be free of debris, so adequate airflow is achieved. The return and supply registers should be free of any obstructions. The filters should be cleaned or replaced. These few steps will help to keep the product up time to a maximum. The System Troubleshooting chart should help in identifying problems if the unit does not operate properly. Service NOTE: The following information is for use by qualified service agency only. Others should not attempt to service this equipment. Common Causes of Unsatisfactory Operation of Heat Pump on the Heating Cycle. ■ 16 Inadequate Air Volume Through Indoor Coil When a heat pump is in the heating cycle, the indoor coil is functioning as a condenser. The return air filter must always be clean, and sufficient air volume must pass through the indoor coil to prevent excessive discharge pressure, and high pressure cutout. 1. Solenoid not energized—In order to determine if the solenoid is energized, touch the nut that holds the solenoid cover in place with a screwdriver. If the nut magnetically holds the screwdriver, the solenoid is energized and the unit is in the cooling cycle. 2. No voltage at the solenoid—Check unit voltage. If no voltage, check wiring circuit. 3. Valve will not shift—If the unit is undercharged, check for leaks. If valve body damaged, replace valve. If unit is properly charged, and it is on the heating cycle, raise the discharge pressure by restricting airflow through the indoor coil. If the valve does not shift, tap it lightly on both ends with a screwdriver handle. NOTE: Do not tap the valve body. If the unit is on the cooling cycle, raise the discharge pressure by restricting airflow through the outdoor coil. If the valve does not shift after the above attempts, turn off the unit and wait until the discharge and suction pressure equalize, and repeat above steps. If the valve does not shift, replace it. TROUBLESHOOTING Wiring Diagram—WGPH45(24-43)AM WARNING Goodman 6 Long HIGH VOLTAGE! Disconnect ALL power before servicing. Multiple power sources may be present. Failure to do so may cause property damage, personal injury or death. NOTE: Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring. NOTE #2 R BK PR PR 1 2 3 C 208 TR 240 BU BK BU 24V R T2 Y BU BU C BK BK 2 0 8 2 4 0 / 1 / L2 R T1 See NOTE 4 L1 BK BU Y GND R 60 C OR LVJB OR Y See NOTE 5 R O BK Y R Y BR W LVDR W W2 W 2 4 VAC 3 6 9 2 5 8 1 4 7 H EATER F W1 W2 C R Y1 C R THER MO STAT RCCF Y R R HUMIDISTAT Y1/Y2 HUM R BR W BR OR BU E/W1W/W2O OTCOT1OT2 C R Y1 G DF1 DF2 HEATPUMP H DFT D IP S W IT C H PLF BK R HVDR 1 2 3 4 5 6 7 8 BU ON R V S TB O FF R W1 W2 O C R OU TDO OR O BU COND EN SER Y R R R YCON COMO W2 ED DC G Y1 R G PR Y ++ T h e r m o s t a t SA (If Used See NOTE 3 BR PR R R R BU BK BK Y Y Y BU Control Box S C R VSM 16-Pin Plug DFT CM BK BK LPS HPS COMP RVC L1 R R C N 4 5 6 PLF Factory Wiring Placeholder for Wiring Diagram Component Legend T1 C G G C COM 3 C T2 RCCF F NOTE #3 H L DFT 208-240 2 24V Supply Voltage 208-240/1/60 Y1 R Y1 COMP Y2 YCON S W1 S.A. W1 NOTE #2 O Thermostat O O W2 W2 O R W2 If Used VSM DFT NOTE #2 G LVDR VSTB R DF1 C CM Y RVC HVDR (High Volt) TR 1 DC C DF2 C LPS C Line Voltage Low Voltage CM Optional High Voltage COMP DC Field Wiring DFT High Voltage GND Low Voltage HPS Symbol Color HVDR LPS Black BK LVDR Blue BU LVJB Brown BR PLF Green G RVC Orange OR RCCF Purple PR SA Red R TR White W VSM Yellow Y VSTB Contactor Condenser Motor Compressor Defrost Control Defrost Thermostat Equipment Ground High Pressure Switch High Voltage Defrost Relay Low Pressure Switch Low Voltage Defrost Relay Low Voltage Junction Box Female Plug Connector Reversing Valve Coil Run Capacitor for Compressor and Fan Start Assist Transformer Variable Speed Motor Variable Speed Terminal Block L2 HPS NOTES: 1. Replacement wire must be the same size and the same type insulation as original (at least 105ºC). Use copper conductor only. 2. To change the evaporator motor speed, move the white and yellow leads from the EM “2” and “3” to “4” and “5.” If both leads are energized, the higher speed setting is used. 3. For 208-volt transformer operation, move the purple wires from Terminal 3 to Terminal 2 on the transformer. 4. Start assist factor equipped, when required. 5. Use copper conductors only. ++ Use N.E.C. Class 2 wire. 17 Wiring Diagram—WGPH45(49-60)AM WARNING Goodman 6 Long HIGH VOLTAGE! Disconnect ALL power before servicing. Multiple power sources may be present. Failure to do so may cause property damage, personal injury or death. NOTE: Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring. NOTE #2 R BK PR PR 1 2 3 C 208 TR 240 BU BU 24V BK BU R T2 Y BU BU C BK BK 2 0 8 2 4 0 / 1 / L2 R T1 See NOTE 4 L1 BK BU Y Y R GND 60 C OR OR Y R O Y BK Y R BR W W W2 W 2 4 VAC 3 6 9 2 5 8 1 4 7 W1 W2 C R Y1 F R THER MO STAT RCCF Y R R HUMIDISTAT Y1/Y2 HUM R BR W BR OR BU E/W1W/W2O OTCOT1OT2 C R Y1 G DF1 DF2 C HEATPUMP H DFT D IP S W IT C H PLF BK R HVDR 1 2 3 4 5 6 7 8 BU ON R V S TB O FF R H EATER LVDR OU TDO OR O LVJB See NOTES 5&6 BU COND ENSER Y R R R YCON COMO W2 ED DC R PR G PR Y W1 W2 O C R Y1 G Y2 ++ T h e r m o s t a t SA (If Used) See NOTE 3 BR PR R R R BK BK VSM DFT CM BK BK Y BU HPS LPS COMP BU RVC Control Box S C R Y 16-Pin Plug BU Y Y SOL L1 R R C N 4 5 6 PLF Factory Wiring Placeholder for Wiring Diagram Component Legend T1 C G C COM 3 C F T2 RCCF NOTE #3 H L DF1 C TR 1 CM Y RVC DC C S0L HVDR (High Voltage) DFT 208-240 2 24V Thermostat Supply Voltage 208-240/1/60 G R Y1 COMP Y1 S Y2 YCON S.A. W1 NOTE #2 W1 O O W2 W2 O O R W2 If Used VSM DFT NOTE #2 G LVDR VSTB R DF2 C LPS C Line Voltage Low Voltage CM Optional High Voltage COMP DC Field Wiring DFT High Voltage GND Low Voltage HPS HVDR Symbol Color LPS Black BK LVDR Blue BU LVJB Brown BR PLF Green G RVC Orange OR RCCF Purple PR SA Red R TR White W VSM Yellow Y VSTB Contactor Condenser Motor Compressor Defrost Control Defrost Thermostat Equipment Ground High Pressure Switch High Voltage Defrost Relay Low Pressure Switch Low Voltage Defrost Relay Low Voltage Junction Box Female Plug Connector Reversing Valve Coil Run Capacitor for Compressor and Fan Start Assist Transformer Variable Speed Motor Variable Speed Terminal Block L2 HPS NOTES: 1. Replacement wire must be the same size and the same type insulation as original (at least 105ºC). Use copper conductor only. 2. For 208-volt transformer operation, move the purple wires from Terminal 3 to Terminal 2 on the transformer. 18 3. 4. ++ 5. 6. Start assist factor equipped, when required. Use copper conductors only. Use N.E.C. Class 2 wire. Set DIP Switch 4 on VSTB to Off position. Refer to installation instructions for fan speed settings. Wiring Diagram—WPC45**AM WARNING Goodman 6 Long HIGH VOLTAGE! Disconnect ALL power before servicing. Multiple power sources may be present. Failure to do so may cause property damage, personal injury or death. NOTE: Wiring is subject to change. Always refer to the wiring diagram on the unit for the most up-to-date wiring. NOTE #3 PR BK PR 1 2 3 C 208 TR 240 PR BU BK BU 24V R T2 BU C BK BK 2 0 8 2 4 0 / 1 / L2 R T1 See NOTE 5 L1 Y R BK GND G G 60 R R PR R Y LVJB BR W BU Y BU H G F C RCCF Y R G W PLF 3 6 9 2 5 8 1 4 7 BR Y R G W Y R G W1 BR BU W2 C ++ BR SA (If Used) See NOTE 4 BK PR R PR BR BK G C L G N 1 2 3 4 5 T h e r m o s t a t BK BU/PK BU/PK Control Box Y S C R HPS CM EM COMP See NOTE 2 L1 C N 4 5 6 PLF Factory Wiring Placeholder for Wiring Diagram 1 T1 C 3 3 C F T2 RCCF NOTE #4 H L 208-240 2 24V W1 Y Thermostat W2 Supply Voltage 208-240/1/60 R S 2 COMP S.A. If Used EM NOTE #2 G NOTE #3 R C TR 1 2 CM C 3 1 EM C HPS G C Contactor Condenser Motor Compressor Defrost Control Defrost Thermostat Equipment Ground High Pressure Switch High Voltage Defrost Relay Low Pressure Switch Low Voltage Defrost Relay Low Voltage Junction Box Female Plug Connector Reversing Valve Coil Run Capacitor for Compressor and Fan Start Assist Transformer Variable Speed Motor Variable Speed Terminal Block L2 See NOTE #2 NOTES: 1. Replacement wire must be the same size and the same type insulation as original (at least 105ºC). Use copper conductor only. 2. To change the evaporator motor speed, move the white and yellow leads from the EM “2” and “3” to “4” and “5.” If both leads are energized, the higher speed setting is used. Component Legend C Line Voltage Low Voltage CM Optional High Voltage COMP DC Field Wiring DFT High Voltage GND Low Voltage HPS Symbol Color HVDR LPS Black BK LVDR Blue BU LVJB Brown BR PLF Green G RVC Orange OR RCCF Purple PR SA Red R TR White W VSM Yellow Y VSTB BU/PK Blue/Pink 3. For 208-volt transformer operation, move the purple wires from Terminal 3 to Terminal 2 on the transformer. 4. Start assist factor equipped, when required. 5. Use copper conductors only. ++ Use N.E.C. Class 2 wire 19 ASSISTANCE OR SERVICE If you need further assistance, you can write to the below address with any questions or concerns: Tradewinds Distributing Company, LLC 14610 Breakers Drive Jacksonville, FL 32258 Accessories To order accessories, contact your Whirlpool® Home Cooling and Heating dealer. Please include a daytime phone number in your correspondence. WPIO-362 © 2010. All rights reserved. ®Registered Trademark/TM Trademark of Whirlpool, U.S.A., Manufactured under license by Tradewinds Distributing Company, LLC, Jacksonville, Florida. Warranty provided by manufacturer. All other trademarks are owned by their respective companies. 2/10 Printed in U.S.A.