Whirlpool GOLD W4GH6 Instruction manual

MULTIPOSITIONAL CASED EVAPORATOR COIL
INSTALLATION INSTRUCTIONS
Table of Contents
EVAPORATOR COIL SAFETY .......................................................1
INSTALLATION REQUIREMENTS ................................................2
Tools and Parts ............................................................................2
System Requirements..................................................................2
Location Requirements ................................................................2
Drain Requirements .....................................................................2
INSTALLATION INSTRUCTIONS ..................................................2
Inspect Shipment .........................................................................2
Prepare Evaporator Coils.............................................................3
Verify Orifice Size .........................................................................3
Assemble Distributor/Orifice ........................................................3
Install Evaporator Coil ..................................................................3
Field Conversion for Horizontal Airflow........................................5
Install Auxiliary Drain Pan (If required) .........................................5
Install Condensate Drains ............................................................6
Connect Refrigerant Lines ...........................................................6
ASSISTANCE OR SERVICE ...........................................................6
WARRANTY ....................................................................................7
EVAPORATOR COIL 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 follow instructions.
You can be killed or seriously injured if you don't
follow 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.
The California Safe Drinking Water and Toxic Enforcement Act requires the Governor of California to publish a list of substances
known to the State of California to cause cancer, birth defects, or other reproductive harm, and requires businesses to warn of
potential exposure to such substances.
WARNING: This product contains a chemical known to the State of California to cause cancer, birth defects, or other
reproductive harm.
This appliance can cause low-level exposure to one of the substances listed: formaldehyde.
065715702
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.
All models are designed for indoor installation only.
Install the conditioned air plenum, ducts and air filters (not
provided) in accordance with NFPA 90B Standard for the
Installation of Warm Air Heating and Air-Conditioning Systems
(latest edition).
Air filters (not provided) must be listed as Class 2 furnace air
filters.
Tools and Parts
Gather the required tools and parts before starting installation.
Read and follow the instructions provided with any tools listed
here.
■
■
■
Airflow greater than 450 CFM per 12,000 Btu/h as noted
above can cause water spray to blow into air duct.
All air passing over the evaporator coil must be filtered.
Evaporator coils are matched to specific outdoor units to
obtain an ARI rating. The orifice installed on each evaporator
coil is chosen for the Btu/h capacity of the coil. The factoryinstalled orifice size is stamped on the orifice body, and is
identified with a label on the orifice extension stub. The orifice
size must match the size called for on the refrigerant charging
table found on the outdoor unit. A selection of replacement
orifices is available from the distributor.
Location Requirements
When the horizontal evaporator coil is installed in an attic, above
a finished ceiling, or in any location where condensate overflow
would result in property damage, the installer must provide an
auxiliary drain pan in addition to the primary and secondary
drains. The auxiliary drain pan must be connected to a drainage
system separate from the primary condensate drain.
Tools Needed
■
■
■
■
Torch
Tape measure
Flat-blade screwdriver
¹⁄₄" nut driver
■
■
■
■
¹³⁄₁₆" open end wrench
Level
Drill
¹⁄₈" drill bit
Drain Requirements
■
■
Parts Needed
Check local codes. Check the existing drain configuration before
purchasing parts.
■
■
Field-fabricated auxiliary drain pan (in some installations)
Sheet metal screws (4)
Parts Supplied
■
Evaporator coil may be provided as a separate coil or
mounted in a duct extension.
■
■
All vertical mount models come from the factory with right
and left front drain connections.
Multiposition models come from the factory with right and left
front drain connections for vertical and horizontal
installations.
Minimum ¾" (1.9 cm) copper or PVC drain lines are
recommended.
NOTE: Check local codes before connecting drain lines to an
existing drainage system.
A field-fabricated auxiliary drain pan, with a drainpipe to the
outside of the building, is required in all installations over a
finished living space or in any area that may be damaged by
overflow from the main drain pan. In some localities, local
codes may require an auxiliary drain pan for any horizontal
installation.
System Requirements
IMPORTANT:
■ The blower and duct system must be properly sized in order to
provide adequate cooling and heating performance. For proper
cooling operation, the airflow through the indoor coil should be
350 to 450 CFM per ton of cooling capacity (or 350 to 450 CFM
per 12,000 Btu/h) based on the rating of the outdoor unit.
INSTALLATION INSTRUCTIONS
Inspect Shipment
WARNING
Excessive Weight Hazard
Use two or more people to move and install
evaporator coil.
Failure to do so can result in back or other injury.
1. Check the evaporator coil rating plate to confirm
specifications are as ordered.
2
2. Upon receipt of evaporator coil, inspect it for possible
shipping damage. Examine the evaporator coil 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 evaporator coil, because your claim may be
denied.
Orifice Extension Stub—After Removal of Shipping Strap
Prepare Evaporator Coils
A
IMPORTANT:
■ This evaporator coil was manufactured containing a dry air
precharge of 10 psi. Slowly remove the rubber line seal plugs
to relieve the dry air precharge pressure.
■ Before installation, wash the coil finned areas with a mild
soap solution to remove shipping and handling
contamination.
B
A. Orifice extension stub
B. Ring seal
5. Slide the brass hex nut over the orifice extension stub.
A
B
C
D
A
G
B
C
A. Evaporator coil inside housing
B. Left horizontal drain connections
C. Right horizontal drain connections
Verify Orifice Size
IMPORTANT: The proper orifice size is dependent on indoor coil/
outdoor unit combination and application. Consult the outdoor
unit information to determine if the indoor unit has the correct
orifice installed.
Assemble Distributor/Orifice
1. Remove the brass hex nut from distributor/orifice assembly.
2. Remove the line seal plug from the orrifice assembly.
3. Unscrew and remove the shipping strap from the orifice
extension stub. Remove the orifice extension stub from the
panel.
4. Relocate the ring seal to the stub end of the orifice extension
stub as shown.
Orifice Extension Stub—Before Removal of Shipping Strap
A
B
E
F
A. Distributor fitting
D. Orifice extension stub
B. Piston orifice
E. 0.812" Brass hex nut
C. Ring seal (supplied)
F. Brass hex fitting
G. Mounting flange
6. If a change in orifice is required, remove the factory-installed
orifice with an orifice extractor tool.
7. Insert the proper orifice into the fitting, seal end first. Make
sure the orifice is free to move in the fitting.
8. Assemble the brass hex nut and orifice extension stub onto
the distributor/orifice assembly as shown.
NOTE: Overtightening the brass hex nut will crush the gasket
and might result in a system leak or stuck piston.
9. Dispose of/recycle all packaging and unused parts.
Install Evaporator Coil
IMPORTANT:
■ The evaporator coil must be installed in the discharge
(supply) air of a gas or oil furnace. Do not install an
evaporator coil in the return air, or excessive condensation
will occur within the furnace.
■ Install the evaporator coil level with the drain connection to
ensure proper drainage.
■ To avoid damage to the plastic drain pan, minimum spacing
is required between the drain pan and a furnace heat
exchanger. A minimum spacing of 2" (5.1 cm) is required for a
gas furnace. A minimum spacing of 4" (10.2 cm) is required
for an oil-fired furnace. See “Evaporator Coil Drain Pan
Clearances.”
Evaporator Coil Drain Pan Clearances
C
A. Orifice extension stub
B. Shipping strap
A
C. Ring seal
B
C
A. Furnace heat exchanger
B. Gas—2" (5.1 cm) minimum; Oil-fired—4" (10.2 cm) minimum
C. Plastic drain pan
3
Install Splash Shield—Horizontal Installation
Vertical Installations
1. Insert lip of splash shield behind drain pan edge.
2. Align splash shield so that it slopes toward the horizontal
drain pan.
A
A
B
B
C
A. Splash shield
B. Slope of splash shield
Position the evaporator coil on the outlet of the furnace using
sheet metal screws.
The evaporator coil should be level, or pitched slightly toward
the drain connection.
Airflow should be set to 350 CFM per ton.
Install splash shield (provided) on the evaporator coil outlet.
The bottom flange of the splash shield should rest on the
horizontal drain pan. The sides of the splash shield should be
attached to the duct flanges with sheet metal screws (not
provided). See “Install Splash Shield—Horizontal
Installation.”
■
■
■
A
C. Water trough
D. Horizontal drain pan
3. Using holes in splash shield as a guide, drill four ¹⁄₈" (3.2 mm)
holes into coil duct mounting flange.
Horizontal Installations
■
C
D
A. Evaporator coil—inside housing
B. Left horizontal drain connections
C. Right horizontal drain connections
B
B
A
C
A. Holes for mounting splash shield to duct flanges when horizontal
drain pain is flush with top of housing
B. Holes for mounting splash shield to duct flanges when horizontal
drain pan is 2" (5.1 cm) shorter than top of housing.
C. Do not use these holes.
C
4. Fasten the splash shield to the duct mounting flange with
4 sheet metal screws (field supplied).
A
C
E
D
B
F
A. Splash shield
B. Evaporator coil—standard
horizontal application—
left-hand installation shown,
right-hand installation typical
C. Furnace
D. Evaporator coil—counterflow
horizontal application—
right-hand installation shown,
left-hand installation typical
E. Transition
F. 12" (30.5 cm) minimum
NOTE: All horizontal applications must have splash shield
attached to coil case.
C
A
A. Duct flange
B. Sheet metal screws
4
C. Splash shield
Upflow Position—Coil Inside Housing
Field Conversion for Horizontal Airflow
1. Remove the front panels from the unit.
2. Pull the coil assembly from the housing.
3. Remove the horizontal drain pan and reinstall it to the
opposite side of the coil.
NOTE: The horizontal drain pan must have the drain plugs
closed in the rear of the unit.
4. Remove the top cap.
5. Remove the water diverter, and reinstall it to the opposite
slab.
6. Replace the top cap.
7. Apply sealant to seal any air gaps.
Upflow Position—Before Conversion
A
A. Front flange—cut and folded back
Upflow Position—Panel Installed
NOTE: It may be necessary to notch out a hole in the access
panel to allow access to the suction header.
A
B
C
Upflow Position—After Conversion
A. Suction header
B. Old drain connection—sealed
C. Horizontal drain connections
Install Auxiliary Drain Pan
(if required)
■
■
■
8. Cut the front flange on the housing and fold it back to allow
access to the horizontal drain connections.
9. Slide the coil assembly back into the housing.
NOTE: If the unit is equipped with a sheet metal housing
adapter, it will have to be moved to the opposite side of the
housing.
10. Reinstall the piping panel to the housing.
11. Cut a hole in the access panel to allow access to the
horizontal drain connections.
12. Reinstall the access panel to the housing.
13. Seal old drain connection hole in the piping panel to avoid air
leakage.
■
See “Location Requirements” for furnace installation
configurations that require an auxiliary drain pan.
Counterflow installations located directly over objects that
can be damaged by condensate, such as in an installation on
a second floor over a finished ceiling, require an auxiliary
drain pan.
The auxiliary drain pan should be installed below the supply
plenum. It should be at least 2" (5.2 cm) deep and at least 2"
(5.2 cm) larger in all directions than the supply plenum. A
separate drain line from the auxiliary drain pan to an open
drain should be provided.
The open drain should be visible so that any water coming
from the auxiliary drain can be seen as an indicator that the
primary drain is plugged, which should be investigated and
corrected.
5
Install Condensate Drains
The evaporator coil is provided with ³⁄₄" (1.9 cm) NPT condensate
drain connections. The vertical drain connections are visible and
the horizontal drain locations are covered by factory-installed
knockouts. Select the drain location appropriate for the
application. Remove the appropriate knockout for horizontal
applications.
Make sure the evaporator coil is level with the drain opening so
that the drain pan will empty completely without leaving water
standing in the pan.
1. Connect primary drain line connection to the drain pan
(large hole).
2. Connect secondary drain line connection to the drain pan
(small hole). Route the secondary drain to empty at a location
easily seen, so that any drainage coming from that line would
be noticed. If there is drainage from the secondary drain line,
a problem exists with the primary drain system, which should
be investigated and corrected.
NOTE: Use thread sealant on drain pan fittings. Install drain
lines hand tight. Do not overtighten.
3. Install a 3" (7.6 cm) trap in both the primary and secondary
drain lines as close to the the evaporator coil as practical.
Make sure the top of the trap is below the connection to the
drain pan to allow complete drainage of the pan.
NOTE: Horizontal runs must also have an anti-siphon air vent
(standpipe) installed ahead of the horizontal run. See “Typical
Condensate Drain Connection.” An extremely long horizontal
run may require an oversized drain line to eliminate air
trapping.
Typical Condensate Drain Connection
(secondary drain not shown)
B
A
C
G
D
E
F
H
A. Evaporator coil
B. Drain connection
C. Drain line
D. 1" (2.5 cm) minimum
E. 12" (30.5 cm) maximum
F. 3" (7.6 cm) minimum
G. Anti-siphon air vent for horizontal runs
H. Drain trap
NOTE: Do not install the evaporator coil without a drain trap. The
condensate drain is on the negative pressure side of the blower;
therefore, air being pulled through the condensate line will inhibit
positive drainage without a proper trap.
4. Route the drain line to the outside or to an appropriate drain.
Drain lines must be installed so they do not block service
access to the front of the evaporator coil. A 24" (61 cm)
clearance is required for filter, coil, or blower removal and
service access.
NOTE: Check local codes before connecting the drain line to
an existing drainage system.
5. Insulate the drain lines where sweating could cause water
damage.
Test condensate drain pan and drain line after installation
1. Pour several quarts of water into drain pan, enough to fill
drain trap and line.
2. Check that the drain pan is draining completely, no leaks are
found in drain line fittings, and water is draining from the end
of the primary drain line.
3. Correct any leaks found.
Connect Refrigerant Lines
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. Evaporator coils should be
installed only with specified line sizes for approved system
combinations.
Use care with the refrigerant lines during the installation process.
Sharp bends or possible kinking in the lines will cause a
restriction.
Do not remove the caps from the lines or system connection
points until connections are ready to be completed.
1. Route the suction and liquid lines from the fittings on the
indoor coil to the fittings on the outdoor unit. Run the lines in
as direct a path as possible, avoiding unnecessary turns and
bends.
2. Ensure 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. Connect the suction and liquid lines to the evaporator coil.
4. To avoid damaging the rubber grommets in the cabinet while
brazing, slide the rubber grommets over the refrigerant lines
until they are away from the heat source.
5. Braze with an alloy of silver or copper and phosphorus with a
melting point above 1,100°F (593ºC).
NOTE: Do not use soft solder.
6. Reinstall the rubber grommets after brazing is finished.
7. Make sure outdoor unit has been put in place according to
the Installation Instructions and is connected to the
refrigerant lines.
ASSISTANCE OR SERVICE
If you need further assistance, you can write to the below
address with any questions or concerns:
6
Whirlpool® Home Cooling and Heating
14610 Breakers Drive
Jacksonville, FL 32258
Please include a daytime phone number in your correspondence.
LIMITED WARRANTY
Applies in U.S.A. and Canada Only
FAILURE TO MAINTAIN YOUR EQUIPMENT WILL VOID THIS WARRANTY
COVERED EQUIPMENT
The following Whirlpool® and Whirlpool Gold® (G) cooling and heating equipment is covered by the Limited Warranty:
Condensing Units: W2C3, W2C4, W2GC3, W4GC3, W4GC4, W4GC6, W4GC8
Heat Pumps: W2H3, W2H4, W2GH3, W4GH3, W4GH4, W4GH6, W4GH8
Gas Furnaces: WFAT, WFAR, WFCT, WFCC, WGFA, WGFB, WFAU, WGFD, WGFE
Air Handlers: WAHMS, WAHMV
Electric Furnaces: WMB
Evaporator Coils: WEC1P, WEM1P, WEU1P, WEH1P
Package Equipment: W2PG3, W2PH3, W2PC3, W4PG4, W4PH4
FIVE (5) YEAR COVERAGE—RESIDENTIAL APPLICATIONS
The covered equipment and covered component are warranted by Whirlpool® Home Cooling and Heating for a period of five (5) years
from the date of the original installation, when installed in a residental application (single-family dwelling which includes homes,
duplexes, apartments and condominiums). If, during this period, a covered component fails because of a manufacturing defect,
Whirlpool® Home Cooling and Heating will provide a free replacement part to the owner through a licensed service contractor. You must
pay shipping charges and all other costs of warranty service. Whirlpool® Home Cooling and Heating will not pay labor involved in
diagnostic calls or in removing, repairing, servicing or replacing parts. Such cost may be covered by a separate warranty provided by
the installer.
ONE (1) YEAR COVERAGE—NON-RESIDENTIAL APPLICATIONS
The covered equipment and covered component are warranted by Whirlpool® Home Cooling and Heating for a period of one (1) year
from the date of the original installation, when installed in non-residential applications. If, during this period, a covered component fails
because of a manufacturing defect, Whirlpool® Home Cooling and Heating will provide a free replacement part to the owner through a
licensed service contactor. You must pay shipping charges and all other costs of warranty service, Whirlpool® Home Cooling and
Heating will not pay labor involved in diagnostic calls or in removing, repairing, servicing or replacing parts. Such costs may be covered
by a separate warranty provided by the installer.
EXTENDED COVERAGE
Your Whirlpool® Home Cooling and Heating limited warranty provides extended coverage on the components outlined below. The
extended coverage begins with the date of the original unit installation and represents the total warranty period for the specific
component.
Heat Exchangers:
WFAT, WFAR, WGFA, WGFB, W2PG3—Twenty (20) Years—Residential Applications
WFAT, WFAR, WGFA, WGFB, W2PG3—Ten (10) Years—Non-Residential Applications or Subsequent Owners
Non-Direct Vent Applications:
WFCT, WFCC, WFB—Twenty (20) Years—Residential Applications
WFCT, WFCC, WFB—Ten (10) Years—Non-Residential Applications or Subsequent Owners
Direct Vent Applications:
WFAU, WFCT, WFCC, WGFD, WGFE—Limited Lifetime—Residential Applications
WFAU, WFCT, WFCC, WGFD, WGFE—Twenty (20) Years—Non-Residential Applications or Subsequent Owners
For those models for which the limited lifetime heat exchanger warranty is offered, it will apply only to those Residential Applications
Where the original purchaser of the equipment owns and occupies the residence where the equipment is located at the time of the
warranty claim. When a warranty claim is made under the limited lifetime heat exchanger warranty for a Residential application and a
subsequent owner or a non-owner occupies the residence where the equipment is located, then coverage under the limited lifetime
heat exchanger warranty is limited to twenty (20) years. Lifetime coverage under the limited lifetime heat exchanger warranty is subject
to proof of purchase and is not transferable. All terms of this warranty must be followed.
Heat Exchanger Availability: If a replacement heat exchanger is no longer available for a unit covered by this warranty, Whirlpool® Home
Cooling and Heating will allow a credit toward the purchase of an equivalent furnace (at the current suggested distributor’s cost).
Compressors:
W2C3, W2H3, W2C4, W2H4, W2PG3, W2PH3, W2PC3—Five (5) Years
W2GC3, W4GC3, W4GC6, W2GH3, W4GH3, W4GH6—Ten (10) Years
Extended warranty coverage on compressors applies to the original equipment purchaser, subject to proof of purchase, and is not
transferable. Compressor warranty is five (5) years in all non-residential applications and for subsequent owners in residential
applications.
NOTE: If the date of original installation cannot be verified, the warranty period will be deemed to begin six (6) months after the
date of manufacture.
7
EXCLUDED COMPONENTS
The following components are not covered by this warranty: cabinets, cabinet pieces, air filters, dryers, refrigerant, refrigerant line sets,
belts, wiring, fuses, oil nozzles and unit accessories.
REPAIRS
All repairs of covered components must be made with authorized service parts by a licensed service dealer or contractor. Labor
charges are not covered by this warranty. Such costs may be covered by a separate warranty provided by the installer.
CARE OF EQUIPMENT
Your new unit must be properly installed, operated and maintained in accordance with the unit installation, operation and maintenance
instructions provided with each unit. Failure to provide maintenance according to Whirlpool® Home Cooling and Heating instructions
will void this warranty. You may be asked to provide written documentation of annual and other periodic preventive maintenance.
WARRANTY PROCEDURE
When warranty parts are required:
1. Be prepared to furnish the following information:
a) Complete model and serial number
b) Proof of required periodic maintenance, installation date and location
c) An accurate description of the problem
2. Call your local licensed service dealer or contractor
3. If the installing dealer is unable to provide warranty parts, check the yellow pages for another licensed service dealer or contractor
in your area or contact:
Whirlpool Home Cooling and Heating
14610 Breakers Drive
Jacksonville, FL 32258
WARRANTY LIMITATIONS
1. This warranty is void if the covered equipment is removed from the original installation site.
2. This warranty does not cover damage or defect resulting from:
a) Flood, wind, fire, lightning, mold, or installation and operation in a corrosive atmosphere, or otherwise in contact with corrosive
materials (chlorine, fluorine, salt, recycled waste water, urine, fertilizers, or other damaging substances or chemicals)
b) Accident, or neglect or unreasonable use or operation of the equipment including operation of electrical equipment at voltages
other than the range specified on the unit nameplate (includes damages caused by brownouts)
c) Modification, change or alteration of the equipment, except as directed in writing by Whirlpool® Home Cooling and Heating
d) Operation with system components (indoor unit, outdoor unit and refrigerant control devices) which do not match or meet the
specifications recommended by Whirlpool® Home Cooling and Heating
e) Operation of furnaces with return air temperatures of less than 60°F (16°C) or operation of a furnace field installed downstream
from a cooling coil
f ) Use of contaminated or alternate refrigerant
3. The installation of replacement parts under the terms of this warranty does not extend the original warranty period.
Whirlpool® Home Cooling and Heating makes no express warranties other than the warranty specified above. All implied
warranties, including the implied warranties of merchantability and fitness for a particular purpose, are excluded to the extent
to a period legally permissible. Should such exclusion or limitation of the warranty be unenforceable, such implied warranties
are in any event limited to a period of one (1) year. Liability for incidental and consequential damages is excluded. Some states
do not allow limitation of incidental damages, so the limitations or exclusions may not apply to you.
Whirlpool® Home Cooling and Heating will not pay electricity or fuel costs, or increases in electricity or fuel costs, for any
reason whatsoever, including additional or unusual use of supplemental electric heat. This warranty does not cover lodging
expenses or labor charges.
Whirlpool® Home Cooling and Heating shall not be liable for any default or delay in performance under this warranty caused by
any contingency beyond its control.
This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.
Keep this warranty 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 furnace to better
help you obtain assistance or service if you ever need it. You will
need to know the complete model and serial number. You can
find this information located on the rating plate on the inside
panel for all models except for model WFCH, which is located on
the outside of the product.
Unit Model Number _____________________________________________
Serial Number __________________________________________________
Installation Date ________________________________________________
Installing Contractor ____________________________________________
Phone__________________________________________________________
4/01/2008
065715702
© 2008. All rights reserved.
®Registered Trademark/TM Trademark of Whirlpool, U.S.A.,
Manufactured under license by Tradewinds Distributing Company, LLC., Coconut Grove, Florida
6/08
Printed in U.S.A.