CONDENSING UNIT INSTALLATION INSTRUCTIONS
Table of Contents
CONDENSING UNIT SAFETY........................................................ |
1 |
INSTALLATION REQUIREMENTS ................................................ |
2 |
Tools and Parts ............................................................................ |
2 |
System Requirements.................................................................. |
2 |
Location Requirements................................................................ |
2 |
Electrical Requirements ............................................................... |
3 |
INSTALLATION INSTRUCTIONS .................................................. |
4 |
Inspect Shipment ......................................................................... |
4 |
Connect Refrigerant Lines ........................................................... |
4 |
Make Electrical Connections ....................................................... |
5 |
Complete Installation.................................................................... |
8 |
SEQUENCE OF OPERATION ........................................................ |
8 |
SYSTEM MAINTENANCE .............................................................. |
8 |
ASSISTANCE OR SERVICE........................................................... |
8 |
WARRANTY .................................................................................. |
11 |
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.
Whirlpool Gold™ Model W2GC3
48299L005
INSTALLATION REQUIREMENTS
These instructions are intended as a general guide only 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 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.
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
■ Torch |
■ ⁄" nut driver |
■¹⁄" nut driver
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.
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 and on the condensing unit 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 expansion device size and amount of refrigerant charge required.
■This condensing unit has been factory charged with a quantity of refrigerant (R22) sufficient for a matched indoor coil and a maximum 15 ft of refrigerant line.
Indoor System Expansion Device
■Check the indoor coil expansion device to see whether it matches the required expansion device for the indoor coil and condensing unit being installed.
■Refer to the refrigerant charge label located on the inside of the condensing unit access panel for the correct expansion device size required.
■Replace the expansion device with the correct size if this size is not already installed in the indoor coil. Instructions for replacing the expansion device are provided with the indoor coil.
Location Requirements
■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" 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 |
C To |
D |
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Power |
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48" Overhead |
Supply |
To |
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Clearance |
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Indoor |
(Discharge |
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Unit |
Air) |
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12" Clearance |
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To |
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Indoor |
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(Inlet Air) |
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Coil |
E
36" Clearance |
30" Service |
12" Clearance Between |
(Inlet Air) |
Access Clearance |
Unit and Building |
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A. Weatherproof disconnect switch |
D. House thermostat |
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B. NEC class 1 wiring |
E. Seal openings |
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C. NEC class 2 wiring |
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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.
8’
B
A
8’
E
F
A.Floor joist or roof rafter
B.Strapping material (around vapor line only)
C.Wire tie (around vapor line only)
D.Tape or wire tie
E.Metal sleeve
F.Tape or wire tie
C
D
G
G.Strap the vapor line to the floor joist or roof rafter at 8" intervals, then strap the liquid line to the vapor line.
Transition from Horizontal to Vertical
This shows how to make a transition from horizontal to vertical.
A |
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G |
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B |
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B |
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C |
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C |
F |
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F |
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D |
D |
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E |
E |
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A. Anchored heavy |
C. Liquid line |
E. Metal sleeve |
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nylon wire tie |
D. Vapor line— |
F. Wall stud |
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B. Strap liquid line |
wrapped in |
G. Automotive muffler- |
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to vapor line. |
armaflex |
type hanger |
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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.
B
A C D
C
E
A
J
LK
A.Outside wall
B.Refrigerant lines must not contact wall.
C.Vapor line wrapped in armaflex
D.Liquid line
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E |
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F |
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G |
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H |
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E |
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I |
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E |
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G |
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H |
E. Wire tie |
J. Caulk |
F. Inside wall |
K. Fiberglass |
G. Strap |
insulation |
H. Sleeve |
L. PVC pipe |
I.Wood block between studs
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.
Rating Plate Ampacity |
AWG |
Less than 15 |
14 |
16 - 20 |
12 |
21 - 30 |
10 |
31 - 50 |
8 |
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NOTE: All outdoor wiring must be suitable for outdoor use. Use copper conductors only.
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■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 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 unit, because your claim may be denied.
3.Remove valve cores.
4.Wrap the service valves with a wet rag.
5.If 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.
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.
8.Replace valve cores.
9.Pressurize the lines and indoor coil with dry nitrogen not to exceed 20 psi.
10.Leak test the refrigerant lines and indoor coil.
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⁄" 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.
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 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.
■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.
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.
A 
A. Seal openings where refrigerant lines penetrate structure.
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 non system-matched evaporator coils.
■The condensing unit is factory-charged with the proper refrigerant charge amount for a matching evaporator and 15 ft of refrigerant line. Refer to the condensing unit rating plate for the exact amount of this factory charge.
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