Whirlpool GOLD W4GH6 Unit installation

CONDENSING UNIT INSTALLATION INSTRUCTIONS
Table of Contents
CONDENSING UNIT SAFETY........................................................1
INSTALLATION REQUIREMENTS ................................................1
Tools and Parts ............................................................................2
System Requirements..................................................................2
Location Requirements ................................................................2
Electrical Requirements ...............................................................3
INSTALLATION INSTRUCTIONS ..................................................4
Inspect Shipment .........................................................................4
Flush Refrigerant Lines ................................................................4
Connect Refrigerant Lines ...........................................................6
Charge Refrigerant Lines .............................................................8
Make Electrical Connections .....................................................10
Complete Installation..................................................................12
SEQUENCE OF OPERATION ......................................................12
TROUBLESHOOTING ..................................................................12
System Diagnostic Module ........................................................12
SYSTEM MAINTENANCE ............................................................14
ASSISTANCE OR SERVICE .........................................................14
Accessories ................................................................................14
WARRANTY ..................................................................................15
CONDENSING UNIT 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:
DANGER
WARNING
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.
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. The installation must comply with all state and
local codes as well as the National Electrical Code.
Whirlpool Gold® Model W4GC6
48487D008
■
■
The condensing unit is designed and approved for outdoor
use only.
The condensing unit must be installed with no ductwork in
the airstream. The outdoor fan is not designed to operate
against any additional static pressure.
Indoor System Thermal Expansion Valve
Tools and Parts
Gather the required tools and parts before starting installation.
Read and follow the instructions provided with any tools listed
here.
Tools Needed
■
■
■
■
■
W4GC6 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
Torch
¹⁄₄" nut driver
⁵⁄₁₆" nut driver
Adjustable wrench
■
■
■
Gauge set for R-410A
refrigerant
Service wrench with hexhead extension
Torque wrench
Model
Part Number
W4GC624
A4TXV01
W4GC636
A4TXV02
W4GC648, W4GC660
H4TXV03
Parts Needed
Check local codes and HVAC supplier. Check existing electrical
supply, and read “Electrical Requirements,” “Location
Requirements,” “System Requirements” and “Connect
Refrigerant Lines.”
NOTE: Some condensing units do not contain a factory-installed
filter dryer. With those units, a properly sized filter dryer must be
field installed in the liquid (high pressure) line set between the
outdoor condensing unit and indoor evaporator unit.
Location Requirements
■
■
System Requirements
Condensing unit 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.
■ The designed system matches are listed in the condensing
unit specification sheets. Refrigerant charging instructions
are located on the back of the service access panel.
■ This condensing unit has been factory charged with a
quantity of refrigerant (R-410A) sufficient for a matched
indoor coil and a maximum 15 ft (4.6 m) of refrigerant line.
■ In order to maintain the SEER rating, this condensing unit
must be matched to an indoor section containing a variable
speed blower.
■ Refer to the Thermal Expansion Valve Kits chart to determine
the correct size thermal expansion valve required.
■ This product has been designed and manufactured to meet
ENERGY STAR® 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.
■ A filter dryer approved for use with R-410A refrigerant is
installed in the condensing unit.
■ If this condensing unit is equipped with a crankcase heater, it
should be energized 24 hours before the condensing unit is
started to avoid compressor damage as a result of slugging.
■ Use only polyol ester oils if oil must be added to the system.
Mineral oil is not compatible with refrigerant.
■
■
■
This condensing unit is designed to be located outdoors with
sufficient clearance for free entrance to the inlet and
discharge air openings. The location must also allow for
adequate service access. See “Minimum Clearances.”
Where possible, select a location for the condensing unit
which is shaded from the direct rays of the sun most of the
time. North or east locations are usually most desirable.
Position the condensing unit to avoid direct contact with
water, snow or ice from a roofline overhead.
The condensing unit 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 condensing unit into the conditioned
space.
The condensing unit foundation should be raised to a
minimum of 3" (7.6 cm) above finish grade. In areas which
have prolonged periods of temperatures below freezing, and/
or snowfall, the condensing unit should be elevated above
the average snow line.
Avoid placing the condensing unit near areas such as
sleeping quarters or study rooms. Normal operating sound
levels may be objectionable if the condensing unit is placed
near certain rooms.
Minimum Clearances
A B
48" (121.9 cm)
Overhead Clearance
(Discharge Air)
)
m )
c
5
ir
.
30 t A
" ( le
12 e (In
nc
ra
ea
Cl
E
D
F
G
H
Cl 36
ea "
ra (91
nc .4
e ( cm
Inl )
et
Ai
r)
ice
erv ce
S
)
n
cm ra
.2 lea
76 ss C
(
"
30 cce
A
A. Weatherproof disconnect switch
B. NEC class 1 wiring
C. NEC class 2 wiring
D. To power supply
2
C
12" (30.5 cm) Clearance
Between Unit and Building
E. House thermostat
F. To indoor unit
G. To indoor coil
H. Seal openings
Line Set Isolation
The following illustrations demonstrate procedures which ensure
proper refrigerant line set isolation.
IMPORTANT: Refrigerant lines must not contact structure.
B
Installing Horizontal Runs
A
C
This shows how to install line sets on horizontal runs.
NOTES:
■ To hang line set from joist or rafter, use either metal strapping
material or anchored heavy nylon wire ties.
■ Strap the vapor line to the floor joist or roof rafter at 8 ft
(2.4 m) intervals, then strap the liquid line to the vapor line.
C
D
H
E
F
G
H
E
D
G
C
A
8'
A
B
I
C
J
8'
L
D
E
A
C
A. Metal strapping material (around D. Metal strapping material (around
vapor line only)
vapor line only) and tape or heavy
nylon wire tie (around vapor and
B. Floor joist or roof rafter
liquid lines)
C. Tape or heavy nylon wire tie
E. Metal sleeve
(around vapor and liquid lines)
E
G
D
K
H
A. Outside wall
B. Space between wall and refrigerant
lines
C. Vapor line wrapped in armaflex
D. Liquid line
E. Anchored heavy nylon wire tie
F. Inside wall
G. Metal strapping material
H. Metal sleeve
I. Wood block between studs
J. Caulk
K. Fiberglass insulation
L. PVC pipe
Electrical Requirements
Transition from Horizontal to Vertical
This shows how to make a transition from horizontal to vertical.
Style 1
WARNING
Style 2
A
G
B
B
C
C
Electrical Shock Hazard
Electrically ground condensing unit or heat pump.
F
E
D
A. Style 1—anchored heavy nylon wire tie
B. Tape or heavy nylon wire tie holding
liquid line to vapor line.
C. Liquid line
D. Vapor line—wrapped in armaflex
F
E
D
E. Metal sleeve
F. Wall stud
G. Style 2—automotive
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.
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
AWG
Less than 15
14
16 - 20
12
21 - 30
10
31 - 50
8
NOTE: All outdoor wiring must be suitable for outdoor use. Use
copper conductors only.
3
■
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 circuit ampacity, and operating voltage. See the
wiring diagrams in “Make Electrical Connections.”
INSTALLATION INSTRUCTIONS
Inspect Shipment
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 condensing unit is shipped in one package, completely
assembled and wired. The thermostat is shipped in a separate
carton when ordered.
1. Check the condensing unit rating plate to confirm
specifications are as ordered.
2. Upon receipt of equipment, inspect it for possible shipping
damage. Examine the condensing unit 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 condensing unit, because your claim may be
denied.
Flush Refrigerant Lines
Refrigerant lines must be flushed by a licensed, EPA certified
refrigerant technician in accordance with established procedures.
NOTES:
■ R-410A outdoor systems are not recommended for use with
indoor systems that have used R-22 as the refrigerant.
However, if this unit is 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 1999, the R-22 coil and line set
must be flushed prior to installation.
■ Check the refrigerant lines for size and length. See “Connect
Refrigerant Lines.”
■
■
Polyol ester (POE) oils are used in Whirlpool units charged
with R-410A refrigerant. Residual mineral oil from the R-22
system can act as an insulator, inhibiting proper heat transfer.
It can also clog the thermal expansion valve, reducing system
performance and capacity.
Failure to properly flush the system according to the following
instructions will void the warranty.
Tools and Parts
2 clean R-22 recovery
cylinders
Oilless recovery machine
with a “pump down” feature
■
■
■
■
Gauge set for R-22
refrigerant
Gauge set for R-410A
refrigerant
Flushing Connections
NOTE: The inverted R-22 cylinder must contain at least the same amount of refrigerant as was recovered from the existing system.
C
F
A
S
R
Q
B
D
L
K
G
H
E
J
I
M
N
O
P
A. Existing indoor coil
F. Low pressure
B. Existing vapor line
G. High pressure
C. Inverted R-22 cylinder (contains clean R-22 to be used for flushing) H. Gauge manifold
D. Vapor line service valve
I. Closed
E. Outdoor system
J. Opened
4
K. Liquid line service valve
L. Existing liquid line
M. Tank return
N. Inlet
O. Discharge
P. Recovery machine
Q. Recovery cylinder
R. Vapor
S. Liquid
1. Disconnect power.
2. Remove the refrigerant from the existing system according to
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 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.
8. Remove the valve cores.
A
B
Thermal Expansion Valve
A. Suction pressure tap
B. Liquid pressure tap
A
A. Thermal expansion valve
Orifice
A
B
C
D
G
F
A. Distributor fitting
B. Piston orifice
C. Ring seal (supplied)
D. Orifice extension stub
E
E. 0.812" Brass hex nut
F. Brass hex fitting
G. Mounting flange
7. Remove the caps from the suction and liquid pressure taps.
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 in
accordance with the manufacturer’s instructions provided
with the recovery system being used.
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 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 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 maxumum
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.
5
17. Install the valve cores.
18. Install the R-410A thermal expansion valve specified for this
system in the indoor coil. See “Install Thermal Expansion
Valve” in the “Connect Refrigerant Lines” section.
NOTE: R-410A systems use only thermal expansion valves.
19. Pressurize the lines and indoor coil with a pressure not to
exceed 20 psig.
20. Leak test the lines with a pressure not to exceed 20 psig.
21. Evacuate the indoor coil and lines to a minimum of
500 microns to remove contamination and moisture, then
disconnect the vacuum pump.
22. Open the suction and liquid service valves fully.
23. Insulate the suction line with refrigerant line insulation
material of ¹⁄₄" (6.4 mm) or more wall thickness.
24. Pack insulating material around refrigerant lines where they
penetrate the structure to protect the lines and to minimize
vibration transmission.
A
B
A. Suction pressure tap
B. Liquid pressure tap
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. Condensing units should be
installed only with specified line sizes for approved system
combinations with elevation differences up to 15 ft (4.6 m)
and total length of up to 50 ft (15.2 m). 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.
■ 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
Thermal expansion valves equipped with Chatleff-type fittings are
available from the manufacturer. See Thermal Expansion Valve
Kits chart in “System Requirements.”
To install the thermal expansion valve:
1. Separate the distributor assembly.
2. If a piston orifice is installed, remove the piston orifice and old
Teflon® seal and discard.
3. Insert nozzle end of the thermal expansion valve along with a
new Teflon® seal into the distributor.
4. 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.
5. Attach liquid line portion of distributor assembly along with
new Teflon® seal to the inlet of the thermal expansion valve.
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/lbs.
Thermal Expansion Valve Installation
A
B
C
F
E
D
A. Distributor
B. Teflon seal
C. Thermal expansion valve
D. Liquid line stub
E. Strainer
F. Teflon® seal
®Teflon is a registered trademark of E.I. Dupont de Nemours and
Company.
6
9. Attach the superheat sensing bulb to the suction header with
the strap provided with the thermal expansion valve.
A B
F
C
E
8. Replace valve cores.
9. Pressurize the lines and indoor coil with a pressure not to
exceed 20 psig.
10. Leak test the lines with a pressure not to exceed 20 psig.
11. Evacuate the indoor coil and lines to a minimum of
500 microns to remove contamination and moisture, then
disconnect the vacuum pump.
12. Open the suction and liquid service valves fully.
13. Insulate the suction line with refrigerant line insulation
material of ¹⁄₄" (6.4 mm) or more wall thickness.
14. Pack insulating material around refrigerant lines where they
penetrate the structure to protect the lines and to minimize
vibration transmission.
D
A
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
1. Route the suction and liquid lines from the fittings on the
indoor coil to the fittings on the condensing unit. 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.
4. Wrap the service valves with a wet rag.
5. If a filter dryer is not provided, install a filter dryer in the liquid
line between the outdoor condensing unit and the indoor
evaporator coil.
6. 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 (593ºC).
NOTE: Do not use soft solder.
7. Make sure indoor coil has been put in place according to the
Installation Instructions and is connected to the refrigerant
lines.
A. Insulating material around refrigerant lines
Suction Line Sizes
Installations exceeding 100 ft (30.5 m) are not recommended.
Btu/h
Line Set Size—in. (cm) OD
24,000
³⁄₄ (1.9)
³⁄₄ (1.9)
³⁄₄ (1.9)
36,000
⁷⁄₈ (2.2)
⁷⁄₈ (2.2)
⁷⁄₈ (2.2)
48,000
⁷⁄₈ (2.2)
⁷⁄₈ (2.2)
⁷⁄₈ (2.2)
60,000
1¹⁄₈ (2.9)
1¹⁄₈ (2.9)
1¹⁄₈ (2.9)
Line Set
Length
Less than
25 ft (7.6 m)
25 ft (7.6 m)
Over 25 ft (7.6 m) and
up to 50 ft (15.2 m)
Liquid Line Sizes
Installations exceeding 100 ft (30.5 m) are not recommended.
Btu/h
Line Set Size—in. (cm) OD
24,000
³⁄₈ (1)
³⁄₈ (1)
³⁄₈ (1)
36,000
³⁄₈ (1)
³⁄₈ (1)
³⁄₈ (1)
48,000
³⁄₈ (1)
³⁄₈ (1)
³⁄₈ (1)
60,000
³⁄₈ (1)
³⁄₈ (1)
³⁄₈ (1)
Line Set
Length
Less than
25 ft (7.6 m) Over 25 ft (7.6 m) and up
25 ft (7.6 m)
to 50 ft (15.2 m)
7
Charge Refrigerant Lines
NOTE: Refrigerant lines must be charged by a licensed, EPA
certified refrigeration technician in accordance with established
procedures.
The outdoor condensing unit should be charged during warm
weather. However, applications arise in which charging must
occur in the colder months. The method of charging is
determined by the system’s refrigerant expansion device and the
outdoor ambient temperature. Choose one of the following
charge methods based on the system’s refrigerant expansion
device and the outdoor ambient temperature.
Measure the Liquid Line Temperature and the Outdoor
Ambient Temperature
1. Connect the manifold gauge set to the service valve ports as
follows:
■ Low pressure gauge to suction line service valve
■
High pressure gauge to liquid line service valve
2. Close manifold gauge set valves.
3. Connect the center manifold hose to an upright cylinder of
refrigerant (R410A).
4. If room temperature is below 70°F (21ºC), set the room
thermostat to call for heat. This will create the necessary load
for properly charging the system in the cooling cycle.
5. When the heating demand has been satisfied, switch the
thermostat to cooling mode with a set point of 68°F.
6. When pressures have stabilized, use a digital thermometer to
record the liquid and suction line temperatures.
7. Use a digital thermometer to record the outdoor ambient
temperature.
NOTE: The outdoor temperature will determine which charging
method to use.
Charge Using Weigh-In Method (Thermal Expansion
Valve Systems)
Use this method if the system is void of refrigerant, or if the
outdoor ambient temperature is cool.
1. Locate and repair any leaks.
2. If necessary, recover the refrigerant from the condensing unit.
3. Conduct a leak check, then evacuate as previously outlined.
4. Weigh in the charge according to the total amount shown on
the condensing unit nameplate.
NOTE: If weighing facilities are not available or if the condensing
unit is being charged during warm weather, follow one of the
other charging methods.
IMPORTANT:
■ Refrigerant charge adjustment will be required for line set
lengths greater than 15 ft (4.6 m) and for non systemmatched evaporator coils.
■ The condensing unit is factory-charged with the proper
refrigerant charge amount for a matching evaporator and
15 ft (4.6 m) of refrigerant line. Refer to the condensing unit
rating plate for the exact amount of this factory charge.
8
■
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 (4.6 m), add refrigerant
by weighing in 0.60 oz per ft of ³⁄₈" (1 cm) O.D. liquid line.
■
If necessary, adjust the refrigerant charge for compatibility
with the evaporator coil.
Charge Using Sub-cooling Method (Thermal Expansion
Valve Systems)—Outdoor Temperatures 65°F (18ºC) or
Above
Use this method if charging a Thermal Expansion Valve system
when the outdoor ambient temperature is 65°F (18ºC) or above.
1. Attach the manifold gauge hose to the liquid service port.
2. If the condensing unit pressures are stable, use a digital
thermometer to record the liquid line temperature.
3. Record the liquid line pressure reading.
4. Use a temperature/pressure chart for refrigerant (R410A) to
determine the saturation temperature for the liquid line
pressure reading.
5. Subtract the liquid line temperature from the saturation
temperature to determine sub-cooling. See Sub-cooling
Values chart.
_____ ° (Saturation Temperature °F) - _____ ° (Liquid Line
Temperature °F) = _____ ° (Sub-cooling Value °F)
6. Compare the sub-cooling value with those shown in Subcooling Values chart.
■ If sub-cooling is greater than shown, recover some
refrigerant.
■
If sub-cooling is less than shown, add some refrigerant.
Sub-cooling Values
Model
W4GC624A
W4GC636A
Temperature ºF
5
6
Model
W4GC648A
W4GC660A
Temperature ºF
6
9
Charge Using Approach Method (Thermal Expansion
Valve Systems)—Outdoor Temperatures 65°F (18ºC) or
Above
Use this method if charging a Thermal Expansion Valve system
when the outdoor ambient temperature is 65ºF (18ºC) or above.
NOTES:
■ The following procedure is intended as a general guide.
■ Use on Thermal Expansion Valve systems only.
■ For best results, indoor temperature should be 70°F (21ºC) to
80°F (27ºC).
■ Monitor system pressures while charging.
1. Record outdoor ambient temperature using a digital
thermometer.
2. Attach high pressure gauge set.
3. Operate condensing unit for several minutes to allow system
pressures to stabilize.
4. Compare stabilized pressures with those provided in the
Normal Operating Pressures chart.
NOTES:
■
Minor variations in these pressures may be expected due
to differences in installations.
■
Significant differences could mean that the system is not
properly charged or that a problem exists with some
component in the system.
■
Pressures higher than those listed indicate that the
system is overcharged.
■
Pressures lower than those listed indicate that the system
is undercharged.
■
Verify adjusted charge using the approach method.
5. Use the same digital thermometer to check liquid line
temperature.
6. Subtract the outdoor ambient temperature from the liquid line
temperature to determine the approach temperature.
_____ ° (Liquid Line Temperature °F) - _____ ° (Outdoor
Ambient Temperature °F) = _____ ° (Approach
Temperature °F)
7. Compare the approach value with those shown in the
Approach Values for Thermal Expansion Valve Systems
charts.
■ If the approach values are too high, add refrigerant to
lower the approach temperature
■
If the approach values are too low, recover refrigerant
from the system to increase the approach temperature.
Approach Values for Thermal Expansion Valve Systems
Model
W4GC624A
W4GC636A
Temperature ºF
8
10
Model
W4GC648A
W4GC660A
Temperature ºF
8
4
Approach value is the liquid line temperature minus the
outdoor ambient temperature (∆°F).
NOTE: For best results, use the same digital thermometer to
check both outdoor ambient and liquid temperatures.
■
Check Charge Using Normal Operating Pressures
Use the Normal Operating Pressures chart to perform
maintenance checks.
NOTES:
■ This chart is not a procedure for charging the system.
Minor variations in these pressures may be due to differences
in installations.
Significant deviations could mean that the system is not
properly charged or that a problem exists with some
component in the system.
■
■
Normal Operating Pressures
W4GC624A
W4GC636A
W4GC648A
W4GC660A
Liquid
Suction
Liquid
Suction
Liquid
Suction
Liquid
Suction
65 (18)
244
136
238
133
247
130
250
125
75 (23.9)
283
138
278
135
281
134
291
127
85 (29.4)
326
141
324
137
325
137
334
130
95 (35)
376
142
374
139
336
139
383
133
105 (40.6)
428
144
429
142
428
141
434
136
115 (46.1)
486
146
500
144
485
144
489
139
65 (18)
249
126
251
129
249
123
243
117
75 (23.9)
288
133
291
135
286
129
285
123
85 (29.4)
331
138
334
139
328
133
329
129
95 (35)
379
143
383
143
372
137
376
134
105 (40.6)
325
147
435
147
419
141
427
137
115 (46.1)
481
150
490
150
475
145
485
141
Temperature of the Air
Entering the Outdoor Coil
1st Stage (Low Capacity)
2nd Stage (High Capacity)
NOTE: Values provided are typical pressures. Indoor unit match-up, indoor air quality and indoor load will cause pressures to vary.
9
Make Electrical Connections
2. Remove control box cover.
3. Connect the field supply wires L1 and L2 to contactor
terminals L1 and L2.
4. Connect ground wire to ground lug.
WARNING
T2
T1
L2
L1
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
AWG
Less than 15
14
16 - 20
12
21 - 30
10
31 - 50
8
IMPORTANT:
■ 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 voltage. See the
wiring diagrams later in this section.
■ Install an adequately-sized branch circuit disconnect,
according to the NEC, within sight of and readily accessible
from the condensing unit.
■ The cable or conduit and fittings connected from the
disconnect to the condensing unit shall be rated for outdoor
use.
A
L2
B
C
A. Ground lug
B. Field supply ground wire
C. 208/230 volt field supply wires
5. Connect low voltage circuit.
Typical Wiring Connection (low voltage circuit)
See wiring diagrams for power supply connections. If the indoor
unit is not equipped with a blower relay, one must be field
supplied and installed.
Thermostat
R
W1
Single Phase Electrical Connections
Indoor Unit
Outdoor Unit
R
R
W
W
Y
Y
Y2
Y2
G
G
C
C
Power
Heat
Y
Cooling
Refer to “Wiring Connection Diagram—Single Phase 208/230
Volt” later in this section.
Y2
G
WARNING
L1
A
Indoor Blower
C
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.
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.
10
6. Replace control box cover.
7. Reconnect power.
B
Wiring Connection Diagram—Single Phase 208/230 Volt
LT BU
R
Y
BU
Outdoor
Fan
Motor
Dual
Capacitor
BK
G
SOLE
S
C
BK
To 24 VAC
Power Source
20 VA Minimum
NEC Class 2
R
R
BU
R
C
L
Y1
Compressor
H
C
Y1
Y2
Compressor
Contactor
R
C
R
Y2
Y
R
R
R
F
Y
A132
Crankcase Heater
(if used)
L2
L1
Ground
Lug
208-230/60/1
GRD
Compressor
S
C
R
BK
L1
Compressor
Contactor
L Y2 R Y1 C
208-230/60/1
High Pressure
Switch
Diagnostic
Module
Loss of Charge
Switch
Y
Fan
H
Equipment
Ground
C
BK
Defrost
Control
OR
R
Compressor
Heater
PR
Outdoor
Fan
Motor
Dual
Capacitor
Line Voltage Factory Installed
BK
Black
Line Voltage Field Installed
R
Red
24-Volt Factory Installed
Y
Yellow
Class II Voltage Field Installed
BU
Blue
LT BU
Light Blue
G
Green
PR
Purple
Compressor
Contactor
R
L2
High
Pressure
Switch
Loss of
Charge
Switch
R
Y2
Y1
C
To 24 VAC
Power Source
20 VA Minimum
NEC Class 2
11
Complete Installation
1. Operate the condensing unit for a period of at least
15 minutes to allow for pressures and temperatures to
stabilize.
2. If condensing unit does not appear to be functioning
correctly, have condensing unit checked by a person certified
by the EPA to handle refrigerant.
SEQUENCE OF OPERATION
Upon cooling demand, the thermostat closes circuit R to Y. Closing R
to Y energizes the condenser for cooling operation and closes the unit
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.
TROUBLESHOOTING
Condensing Unit Fails to Operate Properly
LED Description
Review “Sequence of Operation” and visually inspect the
condensing unit before troubleshooting:
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.
WARNING
Electrical Shock Hazard
Disconnect power before servicing.
Diagnostic LEDs Interpretation
Replace all parts and panels before operating.
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.
Failure to do so can result in death or electrical shock.
System Diagnostic Module
W4GC6 condensing units contain a diagnostic module for
troubleshooting air conditioning 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.
Flash Codes
LED Status
Fault Description
Troubleshooting Information
Power (Green)
Module has power.
■
Supply voltage is present at module terminals.
Trip (Red)
Thermostat demand signal Y1 is
present, but the compressor is
not running.
■
Compressor protector is open.
Outdoor unit power disconnect is open.
Compressor circuit breaker or fuse(s) is open.
Broken wire or connector is not making contact.
Low pressure switch is open, if present in system.
Compressor contactor has failed to open.
■
■
■
■
■
12
Flash Codes
LED Status
Fault Description
Troubleshooting Information
Alert (Yellow) Flash Code 1
Long Run Time: Compressor is
running extremely long run
cycles.
■
■
■
■
■
■
■
Alert (Yellow) Flash Code 2
System Pressure Trip: Discharge
or suction pressure out of limits
or compressor is overloaded.
■
■
■
■
■
Alert (Yellow) Flash Code 3
Short Cycling: Compressor is
running only briefly.
■
■
■
■
Alert (Yellow) Flash Code 4
Locked Rotor
■
■
■
■
Alert (Yellow) Flash Code 5
Open circuit
■
■
■
■
■
■
■
Alert (Yellow) Flash Code 6
Open Start Circuit: Current only
in run circuit.
■
■
■
Alert (Yellow) Flash Code 7
Alert (Yellow) Flash Code 8
Alert (Yellow) Flash Code 9
Open Run Circuit: Current only
in start circuit
■
Welded Contactor: Compressor
always runs.
■
Low Voltage: Control circuit less
than 17 VAC
■
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.
■
■
■
Low refrigerant charge.
Evaporator blower is not running.
Evaporator coil is frozen.
Faulty expansion valve.
Condenser coil is dirty.
Liquid line restriction (filter dryer blocked, if present in the system)
Thermostat is malfunctioning.
High head pressure.
Condenser coil has poor air circulation (dirty, blocked, damaged).
Condenser fan is not running.
Return air duct has substantial leakage.
If low pressure switch is present in the system, go to Flash Code 1
information.
Thermostat demand signal is intermittent.
Time delay relay or control board is defective.
If high pressure switch is present, go to Flash Code 2 information.
If low pressure switch is present, go to Flash Code 1 information.
Run capacitor has failed.
Low line voltage (contact utility if voltage at disconnect is low).
Excessive liquid refrigerant in the compressor.
Compressor bearings are seized.
Outdoor unit power disconnect is open.
Compressor circuit breaker or fuse(s) is open.
Compressor contactor has failed to open.
High pressure switch is open and requires manual reset.
Open circuit in the compressor supply wiring or connections.
Unusually long compressor protector reset time due to the
extreme ambient temperature.
Compressor windings are damaged.
Run capacitor has failed.
Open circuit in the compressor start wiring or connections.
Compressor start winding is damaged.
Open circuit in the compressor run wiring or connections.
Compressor run winding is damaged.
Compressor contactor has failed to close.
Thermostat demand signal not connected to the module.
Control circuit transformer is overloaded.
Low line voltage (contact utility if voltage at disconnect is low).
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 less than 0.5 VAC.
13
Incorrectly Wired Module Codes
Depending on the system configuration, some Alert flash codes
may not be active. The presence of safety switches affects how
the system alerts are displayed by the module.
Incorrectly wiring the diagnostic module will cause false LED
codes. The Incorrectly Wired Module Troubleshooting chart
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
Recommended Troubleshooting Action
Green LED is not on, module does not
power up.
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 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
■
Leaves and other large obstructions should be removed from
the condensing unit surfaces without damaging the fin
surface of the coil.
■
■
Routinely clean or change the indoor air filter. Should the
indoor coil become dirty, thus restricting airflow, call a
qualified service person to clean the coil surface.
An annual inspection by a qualified person should be
performed to ensure continued high-quality performance.
ASSISTANCE OR SERVICE
If you need further assistance, you can write to the below
address with any questions or concerns:
Whirlpool® Home Cooling and Heating
14610 Breakers Drive
Jacksonville, FL 32258
14
Please include a daytime phone number in your correspondence.
Accessories
To order accessories contact your Whirlpool® Home Cooling and
Heating dealer.
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 Owner
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.
15
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
48487D008
© 2008. All rights reserved.
®Registered Trademark/TM Trademark of Whirlpool, U.S.A.,
Manufactured under license by Tradewinds Distributing Company, LLC., Coconut Grove, Florida
5/08
Printed in U.S.A.