HEAT PUMP INSTALLATION INSTRUCTIONS
Table of Contents
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
???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.
Whirlpool Gold??? Model W4GH6
48488A006
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
Parts Needed
Check local codes and HVAC supplier. Check existing electrical supply, and read ???Electrical Requirements,??? ???Location Requirements,??? ???System Requirements??? and ???Connect Refrigerant Lines.???
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.
???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
???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
???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.
Indoor System Thermal Expansion Valve
???W4GH6 units are designed for use with thermal expansion valve systems only. The thermal expansion valve must be ordered separately from the manufacturer.
Thermal Expansion Valve Kits
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.
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Minimum Clearances
E
Line Set Isolation
The following illustrations demonstrate procedures which ensure proper refrigerant line set isolation.
Installing Horizontal Runs
This shows how to install line sets on horizontal runs.
NOTE: To hang line set from joist or rafter, use either metal strapping material or anchored heavy nylon wire ties.
Transition from Horizontal to Vertical
This shows how to make a transition from horizontal to vertical.
Installing Vertical Runs (new construction shown)
This shows how to install line sets on vertical runs.
NOTE: Similar installation practices should be used if line set is to be installed on exterior of outside wall.
IMPORTANT: Refrigerant lines must not contact structure.
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Electrical Requirements
WARNING
Electrical Shock Hazard Electrically ground condensing unit or heat pump. Connect ground wire to ground lug.
Use copper wire for supply connection. Correct wire gauge is shown in the chart below.
Failure to follow these instructions can result in death or electrical shock.
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
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 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.
Flush Refrigerant Lines
Refrigerant lines must be flushed by a licensed, EPA certified refrigerant technician in accordance with established procedures.
NOTES:
???
???Check the refrigerant lines for size and length. See ???Connect Refrigerant Lines.???
Flushing Connections
Existing
Indoor Coil
Inverted
Existing Vapor Line
Existing Liquid Line
Vapor
Liquid
Recovery Cylinder
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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
3.Disconnect the liquid and vapor lines from the existing outdoor unit.
4.Remove the existing outdoor unit.
5.Set the new
6.Remove the existing
Thermal Expansion Valve
A
D.Ring seal (supplied)
7.Remove the caps from the suction and liquid pressure taps.
8. Remove the valve cores.
A
B
A.Suction pressure tap
B.Liquid pressure tap
9.Connect an
10.Connect the
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
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
16.Remove the recovery machine, gauges,
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17. Install the valve cores.
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,
???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
Thermal expansion valves equipped with
Thermal Expansion Valve Installation
A
B
C
F
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.
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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
D
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 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.
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 ????????" 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
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 ????????" O.D. liquid line.
???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.
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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.
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Suction Line Sizes
Installations exceeding 100 ft are not recommended.
Liquid Line Sizes
Installations exceeding 100 ft are not recommended.
Make Electrical Connections
WARNING
Electrical Shock Hazard Electrically ground condensing unit or heat pump. Connect ground wire to ground lug.
Use copper wire for supply connection. Correct wire gauge is shown in the chart below.
Failure to follow these instructions can result in death or electrical shock.
IMPORTANT:
???Electrical wiring, disconnect means and
???Install an
???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
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.
2.Remove control box cover.
3.Connect the field supply wires L1 and L2 to contactor terminals L1 and L2.
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4. Connect ground wire to ground lug.
T2 T1
L2 L1
A
L2 L1
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)
NOTE: Some connections may not apply.
Refer to specific thermostat and indoor unit.
Without Auxiliary Heat
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.
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Outdoor Unit Typical Wiring Diagram
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.
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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
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
Defrost Thermostat
The defrost thermostat is located on the liquid line between the check/expansion valve and the distributor. When defrost thermostat senses 42??F or cooler, the thermostat contacts close and send a signal to the defrost control board to start the defrost timing. It also terminates defrost when the liquid line warms up to 70??F.
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
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
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
Compressor Delay
The defrost board has a
NOTE: The
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Time Delay
The time delay is 5 minutes long. The delay helps to protect the compressor from short cycling in case the power to the heat pump is interrupted or a pressure switch opens. The delay is bypassed by placing the timer select jumper across the TEST pins for 0.5 seconds.
Pressure Switch Circuit
The defrost control includes
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
NOTE: The defrost control board ignores input from the low pressure switch terminals during:
???TEST mode
???Defrost cycle
???
???First 90 seconds after the reversing valve switches heat/cool modes
NOTE: If the TEST pins are jumpered and the
Defrost Control Board Diagnostic LEDs
Adjust Defrost System
Defrost Control Board
Optional high pressure switch connections
NOTE: To add the pressure switch, remove the
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.
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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
???For
???For
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.
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.Replace control box cover.
5.Reconnect power.
6.Start system in heating operation.
7.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.???
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.
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TROUBLESHOOTING
Review ???Sequence of Operation??? and visually inspect the heat pump before troubleshooting:
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.
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.
Power LED (Green) indicates voltage is present at the power connection of the module.
Alert LED (Yellow) communicates an abnormal system condition through a unique flash code. The Alert LED will flash a number of times consecutively, pause, and then repeat the process. The number of consecutive flashes correlates to a particular abnormal condition.
Trip LED (Red) indicates there is a demand signal from the thermostat but no current to the compressor is detected by the module. The Trip LED typically indicates the compressor protector is open or may indicate missing supply power to the compressor.
Diagnostic LEDs Interpretation
When an abnormal system condition occurs, the diagnostic module displays the appropriate Alert and/or Trip LED. The yellow Alert LED will flash a number of times consecutively, pause, and then repeat the process. To identify a flash code number, count the number of consecutive flashes. Refer to the Flash Codes chart for information on the flash codes.
Every time the module powers up, the last Alert LED flash code that occurred prior to shutdown is displayed for 60 seconds. The module will continue to display the previous flash code until the condition returns to normal or 24 VAC is removed from the module. Trip and Alert LED???s flashing at the same time means control circuit voltage is too low for operation.
Flash Codes
???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.
??? Return air duct has substantial leakage.
??? If low pressure switch is present in the system, go to Flash Code 1 information.
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Flash Codes
??? Compressor start winding is damaged.
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.
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.
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.
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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
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.
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Keep this book and your sales slip together for future reference. You must provide proof of purchase or installation date for
Write down the following information about your Split System Heat
Dealer name____________________________________________________
Address ________________________________________________________
Phone number __________________________________________________
Model number __________________________________________________
Serial number __________________________________________________
Installation date ________________________________________________
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