Whirlpool W2GC3 Installation Instructions

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Page 1

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

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:

Connect Refrigerant Lines ...........................................................4

Make Electrical Connections .......................................................5

Complete Installation....................................................................8

SEQUENCE OF OPERATION ........................................................8

SYSTEM MAINTENANCE ..............................................................8

ASSISTANCE OR SERVICE...........................................................8

WARRANTY ..................................................................................11

You can be killed or seriously injured if you don't immediately

DANGER

WARNING

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

follow instructions.

can be killed or seriously injured if you don't

You instructions.

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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

■ To rc h

■ ¹⁄₄" 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

■ ⁵⁄₁₆" nut driver

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

AB C D

48" Overhead

Clearance

(Discharge

Air)

12" Clearance (Inlet Air)

36" Clearance (Inlet Air)

A. Weatherproof disconnect switch B. NEC class 1 wiring C. NEC class 2 wiring

30" Service

Access Clearance

Power

Supply

Indoor

12" Clearance Between Unit and Building

D. House thermostat

E. Seal openings

Unit

Indoor

Coil

■ 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.

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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.

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.

8’

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. Ta p e o r w ire

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.

Transition from Horizontal to Vertical

This shows how to make a transition from horizontal to vertical.

A. Outside wall B. Refrigerant lines must

not contact wall.

C. Vapor line wrapped in

armaflex

D. Liquid line

Electrical Requirements

E. Wire tie

F. Inside wall G. Strap H. Sleeve

I. Wood block

between studs

WARNING

F G

H E

I E

J. Caulk K. Fiberglass

insulation

L. PVC pipe

A. 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. W a l l s t ud

G. Automotive muffler-

type hanger

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

Less than 15

16 - 20 21 - 30 31 - 50

AWG

12 10

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.

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.

■ 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.”

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 ¹⁄₄" 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. 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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■ 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:

1. Add refrigerant by weighing in 0.60 oz per ft of ³⁄₈" O.D.

liquid line.

2. Add refrigerant by weighing in 1.2 oz per ft of ¹⁄₂" O.D.

liquid line.

■ If necessary, adjust the refrigerant charge for compatibility

with the evaporator coil.

■ In condensing unit systems, horizontal suction lines should

be slightly sloped toward the condensing unit. Piping must avoid dips or low spots, which can collect oil.

Suction Line Sizes

Installations exceeding 100 ft are not recommended.

BTU/HR Line Set Size (in. OD)

18,000 ³⁄₄ ³⁄₄ ³⁄₄

24,000 ³⁄₄ ³⁄₄ ³⁄₄

30,000 ³⁄₄ ³⁄₄ ³⁄₄

36,000 ⁷⁄₈ ⁷⁄₈ ⁷⁄₈

42,000 ⁷⁄₈ ⁷⁄₈ ⁷⁄₈

48,000 ⁷⁄₈ ⁷⁄₈ ⁷⁄₈

Make Electrical Connections

WARNING

death or electrical shock.

Rating Plate Ampacity

Less than 15

16 - 20 21 - 30 31 - 50

AWG

12 10

60,000 1¹⁄₈ 1¹⁄₈ 1¹⁄₈

Line Set Length Less than

25 ft

25 ft Over 25 ft

Liquid Line Sizes

Installations exceeding 100 ft are not recommended.

BTU/HR Line Set Size (in. OD)

18,000 ³⁄₈ ³⁄₈ ³⁄₈

24,000 ³⁄₈ ³⁄₈ ³⁄₈

30,000 ³⁄₈ ³⁄₈ ³⁄₈

36,000 ³⁄₈ ³⁄₈ ³⁄₈

42,000 ³⁄₈ ³⁄₈ ³⁄₈

48,000 ³⁄₈ ³⁄₈ ³⁄₈

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

IMPORTANT:

■ Electrical wiring, disconnect means and over-current

■ 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.

Page 6

Single Phase Electrical Connections

Refer to Wiring Connection Diagram—Single Phase 208/230 Volt later in this section.

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.

Typical Wiring Connection (low voltage circuit)

Thermostat

R C

Indoor Unit

R C

24V Control Wiring (NEC Class 2)

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.

Outdoor Unit

R C

1. Disconnect power.

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.

T1T2

L1L2

Typical Wiring Connection (low voltage circuit)

Thermostat

24V Control Wiring (NEC Class 2)

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.

8. Replace control box cover.

9. Reconnect power.

Indoor Unit

Outdoor Unit

R C

A. Ground lug B. Field supply ground wire C. 208/230 volt field supply wires

5. Connect low voltage circuit.

Page 7

Wiring Connection Diagram—Single Phase 208/230 Volt

Comfort Alert (When Used)

Discharge

Thermostat

(When Used)

High Pressure Switch

Schematic of Power Circuit

Fan

Comp

(When Used)

R C Y

S C R

Crankcase Heater

(When Used)

Fan

Contactor

T1 L1

Connect to "C," "Y" and "R" terminals of indoor control circuit having minimum 40 VA, 24 volt NEC Class II transformer.

Outdoor Power Supply

Com

Herm

Comp

Run Cap

(When Used)

Crankcase

Heater

Ground

Wire

Line Voltage - Factor y Line Voltage - Factor y When Used Line Voltage - Field Low Voltage - Factor y Low Voltage - Factor y When Used Low Voltage - Field

To single phase power supply per rating plate with minimum 167ºF copper wire only. Circuit protection per rating plate.

NOTE: If the original wire is replaced, the same size and type wire must be used.

Alt.

Contactor

Ground

Wire

Contactor

Typical Schematic of Control Circuit

Compressor

Motor

Discharge Thermostat

(When Used)

Dual

Capacitor

High Pressure Switch

(When Used)

Compressor

Contactor Coil

Fan

Motor

L2T2

Thermostat Terminals

Page 8

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 - 90 seconds, which improves system efficiency.

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 14610 Breakers Drive Jacksonville, FL 32258

Please include a daytime phone number in your correspondence.

Home Cooling and Heating

Page 9

Notes

Page 10

Notes

Page 11

Page 12

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 Condensing Unit to better help you obtain assistance or service if you ever need it.

Dealer name____________________________________________________

Address ________________________________________________________

Phone number __________________________________________________

Model number __________________________________________________

Serial number __________________________________________________

Installation date ________________________________________________

48299L005

Manufactured under license by Tradewinds Distributing Company, LLC., Coconut Grove, Florida

®Registered Trademark/TM Trademark of Whirlpool, U.S.A.,

Printed in U.S.A.

11/05