Whirlpool W4GH6 User 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

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:

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

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.

follow instructions.

can be killed or seriously injured if you don't

You instructions.

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.

Tools and Parts

Gather the required tools and parts before starting installation. Read and follow the instructions provided with any tools listed here.

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.

Tools Needed

■ To rc h

■ ¹⁄₄" nut driver

■ ⁵⁄₁₆" nut driver

■ Adjustable wrench

■ Gauge set for R-410A

refrigerant

■ Service wrench with hex-

head 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.”

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 (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 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.

criteria for energy efficiency when matched

Thermal Expansion Valve Kits

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.

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

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.

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.

Transition from Horizontal to Vertical

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

Style 1

Style 2

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)

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.

F G

H E

I E

I. Wood block

between studs

J. Caulk

K. Fiberglass

insulation

L. PVC pipe

A. Outside wall B. Refrigerant lines

must not contact wall.

C. Vapor line wrapped

in armaflex

D. Liquid line

E. Anchored heavy nylon

wire tie

F. Inside wall G. Metal strapping material H. Metal sleeve

Electrical Requirements

Inspect Shipment

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

Less than 15

16 - 20 21 - 30 31 - 50

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.”

AWG

12 10

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:

■ 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.

■ Check the refrigerant lines for size and length. See “Connect

Refrigerant Lines.”

Flushing Connections

Existing

Indoor Coil

Liquid

Recovery Cylinder

Vapor

Inverted R-22 Cylinder (Contains clean R-22 to be used for flushing)

Existing Vapor Line

Existing Liquid Line

Vapor Line

Service Valve

Liquid Line

Service Valve

Tank Return

Inlet

Discharge

Recovery Machine

Low

Pressure

Outdoor

System

NOTE: The inverted R-22 cylinder must contain at least the same amount of refrigerant as was recovered from the existing system.

Gauge Manifold

Opened

High

Pressure

Closed

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.

Thermal Expansion Valve

A. Thermal expansion valve

Orifice

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.

8. Remove the valve cores.

A. Suction pressure tap B. Liquid pressure tap

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.

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.

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. Distributor B. Teflon

C. Thermal expansion valve

seal

D. Liquid line stub

E. Strainer F. Te f l on

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

3. Insert nozzle end of the thermal expansion valve along with a

4. Tighten to 20 to 30 ft lbs. Use backup wrench on all wrench

5. Attach liquid line portion of distributor assembly along with

seal and discard.

Te fl on

new Teflon

seal into the distributor.

flats. NOTE: Overtightening may crush the Teflon

a leak.

new Teflon

seal to the inlet of the thermal expansion valve.

seal and cause

®Teflon is a registered trademark of E.I. Dupont de Nemours and

Company.

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