Whirlpool GOLD W4GH6 User's Manual

HEAT PUMP INSTALLATION INSTRUCTIONS
Table of Contents
HEAT PUMP SAFETY.....................................................................1
INSTALLATION REQUIREMENTS ................................................1
Tools and Parts ............................................................................2
System Requirements..................................................................2
Location Requirements ................................................................2
Electrical Requirements ...............................................................4
Inspect Shipment .........................................................................4
Flush Refrigerant Lines ................................................................4
Connect Refrigerant Lines ...........................................................6
Make Electrical Connections .......................................................9
Complete Installation .................................................................11
SEQUENCE OF OPERATION ......................................................12
Cooling Cycle .............................................................................12
Heating Cycle .............................................................................12
Defrost Cycle..............................................................................12
Adjust Defrost System ...............................................................13
Troubleshoot the Defrost System ..............................................14
TROUBLESHOOTING ..................................................................15
System Diagnostic Module ........................................................15
SYSTEM MAINTENANCE ............................................................17
ASSISTANCE OR SERVICE .........................................................17
Accessories ................................................................................17
WARRANTY ..................................................................................18
HEAT PUMP SAFETY
Your safety and the safety of others are very important.
We have provided many important safety messages in this manual and on your appliance. Always read and obey all safety
messages.
This is the safety alert symbol.
This symbol alerts you to potential hazards that can kill or hurt you and others.
All safety messages will follow the safety alert symbol and either the word “DANGER” or “WARNING.”
These words mean:
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 W4GH6
48488A006
■
The heat pump is designed and approved for outdoor use
only.
■
The heat pump 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
■
■
■
■
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
Parts Needed
Check local codes and HVAC supplier. Check existing electrical
supply, and read “Electrical Requirements,” “Location
Requirements,” “System Requirements” and “Connect
Refrigerant Lines.”
Refrigerant charging instructions include a list of matching
indoor equipment with the proper thermal expansion valve
size and amount of refrigerant charge required.
■
This heat pump has been factory charged with a quantity of
refrigerant (R-410A) sufficient for a matched indoor coil and a
maximum 15 ft of refrigerant line.
■
In order to maintain the 16 SEER rating, this heat pump must
be matched with an indoor section containing a variable
speed blower.
■
Refer to the refrigerant charge label located on the inside of
the heat pump access panel for the correct thermal
expansion valve size 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 drier approved for use with R-410A refrigerant is
installed in the heat pump.
■
If this condensing unit is equipped with a crankcase heater, it
should be energized 24 hours before the condensing unit is
started to prevent compressor damage as a result of
slugging.
■
Use only polyol ester oils if oil must be added to the system.
Mineral oil is not compatible with refrigerant.
2
Model
Part Number
W4GH624
H4TXV01
W4GH636
H4TXV02
W4GH648, 60
H4TXV03
Location Requirements
■
This heat pump 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 heat pump which is
shaded from the direct rays of the sun most of the time. North
or east locations are usually most desirable. Position the heat
pump to avoid direct contact with water, snow or ice from a
roofline overhead.
■
The heat pump must be installed on a solid, level mounting
pad that will not settle or shift. Isolate the pad from the
building structure to avoid possible transmission of sound or
vibration from the heat pump into the conditioned space.
■
The heat pump foundation should be raised to a minimum of
3" above finish grade. In areas which have prolonged periods
of temperatures below freezing, and/or snowfall, the heat
pump should be elevated above the average snow line. If
heat pump is to be installed on a flat roof, it should be on a
platform or other support which will raise the inlet air opening
12" minimum above the surface of the flat roof.
■
Care should be taken to ensure free drainage of condensate
from defrost cycles. This will prevent ice accumulation. The
heat pump should be located away from walkways to prevent
possible icing from defrost condensate.
■
Avoid placing the heat pump near areas such as sleeping
quarters or study rooms. Normal operating sound levels may
be objectionable if the heat pump is placed near certain
rooms. A shift in sound type does occur during the defrost
mode. The defrost mode generally lasts no longer than
10 minutes.
System Requirements
Heat pump system matches are derived from actual laboratory
testing of matched systems. It is recommended that only
matching equipment be used to ensure proper operation and
efficient performance.
■ The designed system matches are listed in the heat pump
unit specification sheets and on the heat pump refrigerant
charging instructions located on the back of the service
access panel.
■
W4GH6 units are designed for use with thermal expansion
valve systems only. The thermal expansion valve must be
ordered separately from the manufacturer.
Transition from Horizontal to Vertical
Minimum Clearances
A B
C To
This shows how to make a transition from horizontal to vertical.
D
Power
Supply
48" Overhead
Clearance
(Discharge
Air)
Style 1
To
Indoor
Unit
Style 2
A
G
To
Indoor
Coil
12" Clearance
(Inlet Air)
B
B
C
C
E
F
36" Clearance
(Inlet Air)
30" Service
Access Clearance
A. Weatherproof disconnect switch
B. NEC class 1 wiring
C. NEC class 2 wiring
12" Clearance Between
Unit and Building
D. House thermostat
E. Seal openings
F
D
E
A. Style 1—anchored
heavy nylon wire tie
B. Strap liquid line to
vapor line.
C. Liquid line
D. Vapor line—
wrapped in
armaflex
E. Metal sleeve
F. Wall stud
G. Style 2—automotive
muffler-type hanger
Installing Vertical Runs (new construction shown)
Line Set Isolation
The following illustrations demonstrate procedures which ensure
proper refrigerant line set isolation.
This shows how to install line sets on vertical runs.
NOTE: Similar installation practices should be used if line set is
to be installed on exterior of outside wall.
IMPORTANT: Refrigerant lines must not contact structure.
B
Installing Horizontal Runs
A
C
This shows how to install line sets on horizontal runs.
NOTE: To hang line set from joist or rafter, use either metal
strapping material or anchored heavy nylon wire ties.
D
D
G
8'
C
B
D
8'
C
H
C
E
D
E
A
E
F
G
H
E
I
G
J
D
E
G
A
L
F
A. Metal strapping material
(around vapor line only)
B. Floor joist or roof rafter
C. Anchored heavy nylon wire tie
(around vapor line only)
D. Tape or wire tie
E. Metal sleeve
F. Tape or anchored heavy nylon
wire tie
G. Strap the vapor line to the floor
joist or roof rafter at 8" intervals,
then strap the liquid line to the
vapor line.
K
A. Outside wall
B. Refrigerant lines
must not contact
wall.
C. Vapor line wrapped
in armaflex
H
D. Liquid line
I. Wood block
between studs
E. Anchored heavy nylon
wire tie
J. Caulk
F. Inside wall
K. Fiberglass
insulation
G. Metal strapping material
L. PVC pipe
H. Metal sleeve
3
Electrical Requirements
Inspect Shipment
WARNING
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.
Electrical Shock Hazard
This heat pump is shipped in one package, completely
assembled and wired. The thermostat is shipped in a separate
carton when ordered.
1. Check the heat pump rating plate to confirm specifications
are as ordered.
2. Upon receipt of equipment, carefully inspect it for possible
shipping damage. Take special care to examine the heat
pump inside the carton if the carton is damaged.
If damage is found, it should be noted on the carrier’s freight bill.
Damage claims should be filed with the carrier immediately.
Claims of shortages should be filed with the seller within 5 days.
NOTE: If any damages are discovered and reported to the carrier,
do not install the heat pump because your claim may be denied.
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
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 of 1999, the R-22 coil and line
set must be flushed prior to installation.
8
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 circuit ampacity, and operating voltage. See the
wiring diagrams in “Make Electrical Connections.”
■
Check the refrigerant lines for size and length. See “Connect
Refrigerant Lines.”
Flushing Connections
Inverted R-22 Cylinder
(Contains clean R-22 to
be used for flushing)
Low
Pressure
Existing
Indoor Coil
Existing Vapor Line
Vapor Line
Service Valve
Existing Liquid Line
Liquid Line
Service Valve
Liquid
Vapor
Tank Return
Inlet
Discharge
Recovery Cylinder
4
Recovery Machine
Outdoor
System
High
Pressure
Gauge Manifold
Opened
Closed
NOTE: The inverted R-22 cylinder must contain at least
the same amount of refrigerant as was recovered from
the existing system.
1. Disconnect power.
2. Remove the refrigerant from the existing system per the
manufacturer’s instructions provided with the recovery
system being used. Connect the R-22 gauge set is
connected to both sides of the refrigerant system (as shown),
and verify that the entire system is void of refrigerant in
accordance with the manufacturer’s instructions provided
with the recovery system being used.
3. Disconnect the liquid and vapor lines from the existing
outdoor unit.
4. Remove the existing outdoor unit.
5. Set the new R-410A outdoor unit and connect the refrigerant
lines. See “Connect 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
C
D
E
B
F
G
A. Distributor fitting
B. Mounting flange
C. Piston orifice
D. Ring seal (supplied)
E. Orifice extension stub
F. 0.812" brass hex nut
G. Brass hex fitting
7. Remove the caps from the suction and liquid pressure taps.
9. Connect an R-22 cylinder with clean refrigerant to the suction
pressure tap.
10. Connect the R-22 gauge set to the liquid line service valve
and connect a recovery machine with an empty recovery tank
to the gauge set.
11. Set the recovery machine for liquid recovery and start the
recovery machine in accordance with the manufacturer’s
instructions provided with the recovery system being used.
12. Open the gauge set valves to allow the recovery machine to
run until a vacuum level less than 0" Hg (gauge pressure) is
established in the existing system line set and indoor coil.
13. Invert the cylinder of clean R-22 and open its valve to allow
liquid refrigerant to flow into the system through the vapor
line valve.
14. After all of the liquid refrigerant has been recovered, switch
the recovery machine to vapor recovery 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 maximum
amount of oil is removed.
15. Close the valves on the inverted R-22 cylinder and gauge set.
16. Remove the recovery machine, gauges, R-22 cylinder and the
field provided fitting installed in Step 6.
5
17. Install the valve cores.
18. Install the R-410A thermal expansion valve specified for this
system in the indoor coil.
NOTE: R-410A systems use only thermal expansion valves.
A
B
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. Open the suction and liquid service valves fully.
22. Insulate the suction line with refrigerant line insulation
material of ¹⁄₄" or more wall thickness.
23. Pack insulating material around refrigerant lines where they
penetrate the structure to protect the lines and to minimize
vibration transmission.
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. Heat pumps should be
installed only with specified line sizes for approved system
combinations with elevation differences up to 15 ft and total
length of up to 50 ft. See the Suction Line Sizes and Liquid
Line Sizes charts later in this section.
■ Avoid sharp bends or possible kinking in the refrigerant lines
during installation as this may cause a reduction in
performance.
■ Use care with the refrigerant lines during the installation
process. Sharp bends or possible kinking in the lines will
cause a reduction in performance.
■ To avoid contamination of the refrigerant system, do not
remove the caps from the lines or system connection points
until connections are ready to be completed.
Install Thermal Expansion Valve
W4GH6 heat pumps are designed for use with thermal expansion
valve systems only. An R-410A system will not operate properly
with an R-22 thermal expansion valve.
Thermal expansion valves equipped with Chatleff-type fittings are
available from the manufacturer. See Thermal Expansion Valve
Kits chart in “System Requirements.”
Thermal Expansion Valve Installation
A
B
C
F
E
D
A. Distributor
B. Teflon® seal
C. Thermal expansion valve
D. Liquid line stub
E. Strainer
F. Teflon® seal
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.
®Teflon is a registered trademark of E.I. Dupont de Nemours and
Company.
6
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.
9. Attach the superheat sensing bulb to the suction header with
the strap provided with the thermal expansion valve.
A B
F
C
E
6. Make sure indoor coil has been put in place according to the
Installation Instructions and is connected to the refrigerant
lines.
7. Replace valve cores.
8. Pressurize the lines and indoor coil with a pressure not to
exceed 20 psig.
9. Leak test the lines with a pressure not to exceed 20 psig.
10. Evacuate the indoor coil and lines to a minimum of
500 microns to remove contamination and moisture, then
disconnect the vacuum pump.
11. Open the suction and liquid service valves fully.
12. Insulate the suction line with refrigerant line insulation
material of ¹⁄₄" or more wall thickness.
13. Pack insulating material around refrigerant lines where they
penetrate the structure to protect the lines and to minimize
vibration transmission.
Refrigerant Charge
D
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.
Refrigerant lines must be connected by a licensed, EPA certified
refrigerant technician in accordance with established procedures.
IMPORTANT:
■ Refrigerant charge adjustment will be required for line set
lengths greater than 15 ft and for evaporator coils not
matched to the systems.
■ The heat pump is factory charged with the proper refrigerant
charge amount for a matching evaporator and 15 ft of
refrigerant line. Refer to the heat pump rating plate for the
exact amount of this factory charge.
■ Adjustment of the refrigerant charge will be necessary based
on the system combination and line length. To adjust the
refrigerant size for increased line lengths, add the following
amount of refrigerant.
For line set lengths greater than 15 ft, add refrigerant by
weighing in 0.60 oz per ft of ³⁄₈" O.D. liquid line.
■
Connect Liquid and Suction Lines
■
1. Route the suction and liquid lines from the fittings on the
indoor coil to the fittings on the heat pump. Run the lines in
as direct a path as possible, avoiding unnecessary turns and
bends.
2. For product efficiency, be sure that the suction line is
insulated over the entire exposed length and that both
suction and liquid lines are not in direct contact with floors,
walls, ductwork, floor joists, or other piping.
3. Remove valve cores.
4. Wrap the service valves with a wet rag.
5. Connect the suction and liquid lines, using a brazing
compound. Braze with an alloy of silver or copper and
phosphorus with a melting point above 1,100°F.
NOTE: Do not use soft solder.
If necessary, adjust the refrigerant charge for compatibility
with the evaporator coil.
In heat pump systems, horizontal suction lines should be
slightly sloped toward the heat pump. Piping must avoid dips
or low spots, which can collect oil.
Check Charge Using Normal Operating Pressures
Use Normal Operating Pressures chart to perform maintenance
checks.
NOTES:
■ The Normal Operating Pressures 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.
7
Normal Operating Pressures
NOTE: Values provided in chart are typical pressures. Indoor unit matchup, indoor air quality and indoor load will cause pressures to
vary.
Model
Temperature of the Air
Entering the Outdoor Coil
-24
Liquid
-36
-48
-60
Suction
Liquid
Suction
Liquid
Suction
Liquid
Suction
Cooling—1st Stage (Low Capacity)
65ºF
232
146
225
144
235
144
225
138
75ºF
264
148
261
147
268
145
264
141
85ºF
307
149
302
149
310
147
305
142
95ºF
353
151
349
151
356
148
352
146
105ºF
403
153
397
153
407
150
405
148
115ºF
460
155
461
157
466
152
459
150
Cooling—2nd Stage (High Capacity)
65ºF
240
143
239
139
244
140
241
134
75ºF
279
145
278
141
283
141
280
136
85ºF
322
147
322
143
326
144
324
137
95ºF
371
149
367
146
374
147
373
138
105ºF
423
151
426
148
427
148
425
142
115ºF
485
154
489
151
491
151
486
146
Heating—1st Stage (Low Capacity)
40ºF
337
93
328
98
369
75
351
63
50ºF
322
117
333
118
366
114
335
92
Heating—2nd Stage (High Capacity)
8
20º
279
62
296
62
311
58
308
59
30ºF
288
76
309
75
334
72
323
70
40ºF
302
93
322
92
354
89
318
69
50ºF
306
112
336
113
381
108
329
82
Suction Line Sizes
Liquid Line Sizes
Installations exceeding 100 ft are not recommended.
Installations exceeding 100 ft are not recommended.
Btu/h
Line Set Size (in. OD)
³⁄₄
24,000
³⁄₈
³⁄₈
³⁄₈
⁷⁄₈
⁷⁄₈
36,000
³⁄₈
³⁄₈
³⁄₈
⁷⁄₈
⁷⁄₈
⁷⁄₈
48,000
³⁄₈
³⁄₈
³⁄₈
60,000
1¹⁄₈
1¹⁄₈
1¹⁄₈
60,000
³⁄₈
³⁄₈
³⁄₈
Line Set Length
Less than
25 ft
25 ft
Over 25 ft and
up to 50 ft
Line Set Length
Less than
25 ft
25 ft
Over 25 ft and
up to 50 ft
Btu/h
Line Set Size (in. OD)
24,000
³⁄₄
³⁄₄
36,000
⁷⁄₈
48,000
Make Electrical Connections
■
WARNING
■
Install an adequately-sized branch circuit disconnect,
according to the NEC, within sight of and readily accessible
from heat pump.
The cable or conduit and fittings connected from the
disconnect to the heat pump shall be rated for outdoor use.
Single Phase Electrical Connections
Refer to “Wiring Diagram—Single Phase 208/230 Volt.”
Electrical Shock Hazard
Electrically ground condensing unit or heat pump.
WARNING
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.
Electrical Shock Hazard
Rating Plate Ampacity
AWG
Less than 15
14
16 - 20
12
21 - 30
10
31 - 50
8
Disconnect power before servicing.
Replace all parts and panels before operating.
Failure to do so can result in death or electrical shock.
1. Disconnect power.
2. Remove control box cover.
3. Connect the field supply wires L1 and L2 to contactor
terminals L1 and L2.
IMPORTANT:
■ 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 wiring
diagrams later in this section.
9
4. Connect ground wire to ground lug.
5. Connect low voltage circuit.
Typical Wiring Connection (low voltage circuit)
T2
T1
NOTE: Some connections may not apply.
Refer to specific thermostat and indoor unit.
Without Auxiliary Heat
Indoor Unit
Thermostat
A
L2
L1
Power
R
R
C
W1
R
Common
C
1st Stage
Aux. Heat
Outdoor Unit
Power
C
1st Stage
Aux. Heat
W1
B
W1
W2
W3
G
A
L2
L1
O
B
Indoor Blower
G
If Applicable
Reversing Valve
Y1
O
Y1
Y1
Y2
Y2
Compressor
Y2
C
A. Ground lug
B. Field supply ground wire
C. 208/230 volt field supply wires
With Auxiliary Heat
Indoor Unit
Thermostat
A
R
Power
C
E
W1
R
C
Common
R
C
Emergency
Heat Relay
Emergency Heat
1st Stage
Aux. Heat
Outdoor Unit
Power
W1
W2
Outdoor
Thermostat
W1
1st Stage Aux. Heat
W3
G
O
Indoor Blower
G
Reversing Valve
Y1
If Applicable
O
Y1
Y1
Y2
Y2
Compressor
Y2
A. Do not connect C (common) connection between indoor unit and
thermostat except when required by the indoor thermostat. Refer
to the thermostat installation instructions.
B. C (common) connection between indoor unit and outdoor unit
required for proper operation.
6. Replace control box cover.
7. Reconnect power.
10
B
Outdoor Unit Typical Wiring Diagram
LT BU
R
Outdoor
Fan
Dual Capacitor
PR
F C H
Thermostat
BK
BK
C R
Fan
W1
O
Y1 Y2
OR
Y2
R
O-OUT
C
BK
R
C
Compressor
Contactor
S
BU
Y1 L
R
Sole
R
Y
Compressor Diagnostic
Crankcase Heater Module
W1
W1
C
LO-PS
24V L
R
DF
Common
O
Y1 OUT
Y1
C
L
R
O
L
Y1
HI-PS
Defrost
Control
Y
L2
Ground
Lug
Ground
Crankcase
Thermostat
Defrost
Thermostat
Defrost Control
Reversing Valve
L1
BK
C
S
R
Compressor
Contactor
BU
Diagnostic
Module
208-230/60/1
L Y2 Y1 R
Y
W1
L
24V
DF
C
L
R
Common
Y1 OUT
O
Y1
HI-PS
Y
LT BU
OR
Crankcaser
Heater
Fan
R
Equipment
Ground
Compressor
Contactor
High Pressure
Switch
R W1 O Y1 Y2
R
R
L2
C
O-OUT
LO-PS
Thermostat
C
Fan
Low Pressure
Switch
Defrost Switch
Compressor
L1
208-230/60/1
L1
Defrost Control BK
Crankcase H
C
F
Thermostat
Dual
Capacitor
LO-PS
PR
Outdoor Fan
Motor
Low Pressure
Switch
HI-PS
High Pressure
Switch
Line Voltage Factory Installed
Line Voltage Field Installed
24 Volt Factory Installed
Class II Voltage Field Installed
Complete Installation
1. Operate the heat pump for a period of at least 15 minutes to
allow for pressures and temperatures to stabilize.
2. If heat pump does not appear to be functioning correctly,
have heat pump checked by a person certified by the EPA to
handle refrigerant.
11
SEQUENCE OF OPERATION
Cooling Cycle
Upon cooling demand, the thermostat closes circuit R to O and Y.
Closing R to O and Y energizes the reversing valve for cooling
operation and closes the heat pump contactor, starting the
compressor and outdoor fan. The thermostat automatically
closes R to G circuit, which also brings on the indoor fan at the
same time. Upon satisfying cooling demand, the thermostat will
open the above circuits and open the main contactor, stopping
the compressor and outdoor fan. If the indoor unit is equipped
with a delay timer, the blower will continue to operate for 60 to
90 seconds, which improves system efficiency.
Heating Cycle
Upon heating demand, the thermostat closes circuit R to Y, which
closes the heat pump contactor, starting the compressor and
outdoor fan. The reversing valve is not energized in the heating
mode. The thermostat again automatically brings on the indoor
fan at the same time. Upon satisfying heating demand, the
thermostat opens the above circuits and stops heat pump
operation.
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. To adjust the time period between defrost cycles,
see “Adjust Time Between Defrost Cycles.”
The defrost control will initiate a defrost cycle when the selected
time period has elapsed and the defrost sensor sees a
temperature below freezing. At the start of a defrost cycle, the
defrost control will energize the reversing valve solenoid, shifting
the reversing valve and de-energizing the outdoor fan. The
defrost relay will also close, energizing temporary heat for
increased comfort during defrost (if the indoor unit is so
equipped). The heat pump will remain in defrost until the defrost
sensor has determined that the frost has been removed from the
coil or a 10-minute period has elapsed, whichever comes first.
Defrost Thermostat
The defrost thermostat is located on the liquid line between the
check/expansion valve and the distributor. When defrost
thermostat senses 42ºF or cooler, the thermostat contacts close
and send a signal to the defrost control board to start the defrost
timing. It also terminates defrost when the liquid line warms up to
70ºF.
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Defrost Control
The defrost control board includes the combined functions of the
time/temperature defrost control, defrost relay, diagnostic LEDs
and terminal strip for field wiring connections. See “Defrost
Control Board” in the “Adjust Defrost System” section.
The control provides automatic switching from normal heating
operation to defrost mode and back. During compressor cycle
(call for defrost), the control accumulates compressor run times
at 30, 60 or 90 minute field-adjustable intervals. If the defrost
thermostat is closed when the selected compressor run time
interval ends, the defrost relay is energized and defrost begins.
Defrost Control Timing Pins
Each timing pin selection provides a different accumulated
compressor run time period during one thermostat run cycle. This
time period must occur before a defrost cycle is initiated. The
defrost interval can be adjusted to 30 (T1), 60 (T2) or 90 (T3)
minutes. See “Defrost Control Board” in the “Adjust Defrost
System” section. The defrost timing jumper is factory-installed to
provide a 60-minute defrost interval. If the timing selector jumper
is not in place, the control defaults to a 90-minute defrost
interval. The maximum defrost period is 14 minutes and cannot
be adjusted.
A test option is provided for troubleshooting. The test mode may
be started any time the unit is in the heating mode and the
defrost thermostat is closed or jumpered. If the jumper is in the
test position at power-up, the control will ignore the test pins.
When the jumper is placed across the Test pins for 2 seconds,
the control will enter the defrost mode. If the jumper is removed
before an additional 5-second period has elapsed (7 seconds
total), the unit will remain in defrost mode until the defrost
thermostat opens or 14 minutes have passed. If the jumper is not
removed until after the additional 5-second period has elapsed,
the defrost will terminate and the test option will not function
again until the jumper is removed and re-applied.
Compressor Delay
The defrost board has a field-selectable function to reduce
occasional sounds that may occur while the heat pump is cycling
in and out of the defrost mode. The compressor will be cycled off
for 30 seconds while going in and out of the defrost mode when
the compressor delay jumper is removed.
NOTE: The 30-second “off” cycle is not functional when
jumpering the TEST pins.
Time Delay
Adjust Defrost System
The time delay is 5 minutes long. The delay helps to protect the
compressor from short cycling in case the power to the heat
pump is interrupted or a pressure switch opens. The delay is
bypassed by placing the timer select jumper across the TEST
pins for 0.5 seconds.
Defrost Control Board
Optional high pressure switch connections
NOTE: To add the pressure switch, remove the factory-installed
jumper.
Pressure Switch Circuit
P1
The defrost control includes LO-PS terminals to connect an
optional low pressure (loss of charge pressure) switch. A high
pressure switch (optional) can be connected to the HI PS
terminals. See “Defrost Control Board” in the “Adjust Defrost
System” section.
During a single demand cycle, the defrost control will lock out
the heat pump after the fifth time that the circuit is interrupted by
any pressure switch wired to the control board. In addition,
the diagnostic LEDs will indicate a locked-out pressure switch
after the fifth occurrence of an open pressure switch. See
Defrost Control Board Diagnostic LEDs chart later in this section.
The heat pump will remain locked out until power to the board is
interrupted, then re-established, or until the jumper is applied to
the TEST pins for 0.5 seconds.
NOTE: The defrost control board ignores input from the low
pressure switch terminals during:
■ TEST mode
■ Defrost cycle
■ 90-second start-up period
■ First 90 seconds after the reversing valve switches heat/cool
modes
NOTE: If the TEST pins are jumpered and the 5-minute delay is
being bypassed, the LO PS terminal signal is not ignored during
the 90-second start-up period.
Defrost Control Board Diagnostic LEDs
Mode
Green
LED (DS2)
Red LED
(DS1)
No Power to Board
Off
Off
Normal Operation/Power to Board
Simultaneous Slow Flash
Short Cycle Lockout
Alternating Slow Flash
Low Pressure Switch Fault
Off
Slow Flash
Low Pressure Switch Lockout
Off
On
High Pressure Switch Fault
Slow Flash
Off
High Pressure Switch Lockout
On
Off
FAN
30
60
90
A
C2
K1 Relay
TEST
B
DS1
DS2
C
D
P5
U1
U2
K2 Relay
O-OUT
P2
W1
L
C
LO-PS
24V
E
H
L
DF
F
I
R
C5
O
Y1-OUT
Y1
HI-PS K3 Relay
G
P6
TST PS DF C
A. Defrost time setting pins
B. Test pins
C. Compressor delay pins
D. Reversing valve
E. Low pressure switch (optional)
R
O Y1
F. Defrost thermostat
G. High pressure switch (optional)
H. Diagnostic LEDs
I. Low voltage terminal strip
connections
Adjust Time Between Defrost Cycles
WARNING
Electrical Shock Hazard
Disconnect power before servicing.
Replace all parts and panels before operating.
Failure to do so can result in death or electrical shock.
1. Disconnect power.
13
2. Remove the heater compartment access panel.
3. Adjust the time period between defrost cycles by placing the
defrost time plug in the proper position. See “Defrost Control
Board.”
■ For 30-minute intervals between defrost cycles, connect
the Defrost Time Setting Plug to the pins corresponding
to 30.
■
For 60-minute intervals between defrost cycles, connect
the Defrost Time Setting Plug to the pins corresponding
to 60 (this setting is the factory preset setting).
■
For 90-minute intervals between defrost cycles, connect
the Defrost Time Setting Plug to the pins corresponding
to 90.
4. Replace the heater compartment access panel.
5. Reconnect power.
Troubleshoot the Defrost System
WARNING
Electrical Shock Hazard
Disconnect power before servicing.
Replace all parts and panels before operating.
Failure to do so can result in death or electrical shock.
The defrost control is equipped with a set of pins (labeled TEST
on control circuit board) to aid in troubleshooting the defrost
system. Connecting the test pins speeds up the defrost cycle
time by a factor of 256.
1. Disconnect power.
2. Remove control box cover.
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3. Connect the test pins on the defrost control using a test
jumper wire.
NOTE: If the outdoor temperature is above 32°F, connect the
defrost sensor terminals using a test jumper wire. See
“Defrost Control Board” in the “Adjust Defrost System”
section.
4.
5.
6.
7.
Replace control box cover.
Reconnect power.
Start system in heating operation.
Time the defrost test cycle as determined by the chart. After
the corresponding defrost cycle time from the chart below
has elapsed, the reversing valve should shift to defrost mode
and the outdoor fan should stop. After 2 seconds of defrost
operation, the reversing valve should shift back to heating
operation and the outdoor fan should start.
NOTE: If this procedure is not observed, check the reversing
valve solenoid for correct operation by measuring
temperatures and pressures under heating and cooling
modes. If the reversing valve solenoid operates correctly then
replace the defrost control board. See “Sequence of
Operation.”
Defrost Control Setting
Defrost Test Cycle Time
T1 - 30 minutes
7 seconds
T2 - 60 minutes
14 seconds
T3 - 90 minutes
21 seconds
8. If an adjustment is required, see “Adjust Time Between
Defrost Cycles” in the “Adjust Defrost System” section.
9. Disconnect power.
10. Remove control box cover.
11. Remove jumper from test pins and jumper from defrost
sensor terminals, if used.
12. Replace control box cover.
13. Reconnect power.
TROUBLESHOOTING
Heat Pump Fails to Operate Properly
LED Description
Review “Sequence of Operation” and visually inspect the heat
pump 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
W4GH6 heat pumps contain a diagnostic module for
troubleshooting heat pump system failures. By monitoring and
analyzing data from the compressor and thermostat demand, the
module can accurately detect the cause of electrical and system
related failure without any sensors. If a system problem occurs, a
flashing LED indicator communicates the failure code.
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.
■
■
■
■
■
Alert (Yellow) Flash Code 1
Long Run Time: Compressor
is running extremely long run
cycles.
NOTE: Not applicable on heat
pump models.
Alert (Yellow) Flash Code 2
System Pressure Trip:
Discharge or suction pressure
out of limits or compressor is
overloaded.
■
■
■
■
■
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.
15
Flash Codes
LED Status
Fault Description
Troubleshooting Information
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
NOTE: This code will
flash within 5 minutes of
power interruption until the
5 minute short cycle timer
has elapsed. Allow at least
5 minutes of run time before
confirming this code.
Open Run Circuit: Current
only in start circuit
■
Alert (Yellow) Flash Code 8
Welded Contactor:
Compressor always runs.
■
Low Voltage: Control circuit
less than 17 VAC
■
Alert (Yellow) Flash Code 9
24 VAC Power Wiring
The diagnostic module requires a constant nominal 24 VAC
power supply. The wiring to the module’s R and C terminals must
be directly from the indoor unit or thermostat. The module cannot
be powered by R and C terminals on the defrost board without
experiencing nuisance alerts.
16
■
■
■
Thermostat demand 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.
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 heat pump 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 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
Please include a daytime phone number in your correspondence.
Accessories
To order accessories contact your Whirlpool® Home Cooling and
Heating dealer.
17
18
Keep this book and your sales slip together for future
reference. You must provide proof of purchase or installation
date for in-warranty service.
Write down the following information about your Split System
Heat Pump—Outdoor Section to better help you obtain
assistance or service if you ever need it.
Dealer name____________________________________________________
Address ________________________________________________________
Phone number __________________________________________________
Model number __________________________________________________
Serial number __________________________________________________
Installation date ________________________________________________
19
48488A006
© 2006. All rights reserved.
®Registered Trademark/TM Trademark of Whirlpool, U.S.A.,
Manufactured under license by Tradewinds Distributing Company, LLC., Coconut Grove, Florida
6/06
Printed in U.S.A.