Whirlpool Heat Pump W4GH6 User Manual

HEAT PUMP INSTALLATION INSTRUCTIONS  
Table of Contents  
HEAT PUMP SAFETY.....................................................................1  
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  
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  
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:  
You can be killed or seriously injured if you don't immediately  
follow instructions.  
DANGER  
You can be killed or seriously injured if you don't  
instructions.  
follow  
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.  
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  
I
The heat pump is designed and approved for outdoor use  
only.  
I
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 GoldModel W4GH6  
48488A006  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Minimum Clearances  
Transition from Horizontal to Vertical  
This shows how to make a transition from horizontal to vertical.  
A B  
C
D
To  
Power  
Supply  
Style 1  
Style 2  
48" Overhead  
Clearance  
(Discharge  
Air)  
To  
A
G
Indoor  
Unit  
To  
12" Clearance  
(Inlet Air)  
Indoor  
Coil  
B
C
B
C
E
F
F
D
D
E
E
30" Service  
12" Clearance Between  
Unit and Building  
36" Clearance  
A. Style 1—anchored  
heavy nylon wire tie  
B. Strap liquid line to  
vapor line.  
C. Liquid line  
E. Metal sleeve  
F. Wall stud  
G. Style 2—automotive  
muffler-type hanger  
Access Clearance  
(Inlet Air)  
D. Vapor line—  
wrapped in  
armaflex  
A. Weatherproof disconnect switch  
B. NEC class 1 wiring  
D. House thermostat  
E. Seal openings  
C. NEC class 2 wiring  
Installing Vertical Runs (new construction shown)  
This shows how to install line sets on vertical runs.  
Line Set Isolation  
NOTE: Similar installation practices should be used if line set is  
to be installed on exterior of outside wall.  
The following illustrations demonstrate procedures which ensure  
proper refrigerant line set isolation.  
IMPORTANT: Refrigerant lines must not contact structure.  
B
Installing Horizontal Runs  
This shows how to install line sets on horizontal runs.  
A
C
C
D
H
NOTE: To hang line set from joist or rafter, use either metal  
strapping material or anchored heavy nylon wire ties.  
E
F
D
C
G
C
8'  
G
H
E
B
D
A
I
8'  
E
G
G
E
D
J
A
K
L
H
F
A. Metal strapping material  
(around vapor line only)  
B. Floor joist or roof rafter  
C. Anchored heavy nylon wire tie G. Strap the vapor line to the floor  
(around vapor line only)  
D. Tape or wire tie  
E. Metal sleeve  
F. Tape or anchored heavy nylon  
wire tie  
A. Outside wall  
D. Liquid line  
E. Anchored heavy nylon  
wire tie  
F. Inside wall  
G. Metal strapping material  
H. Metal sleeve  
I. Wood block  
between studs  
J. Caulk  
K. Fiberglass  
insulation  
L. PVC pipe  
B. Refrigerant lines  
must not contact  
wall.  
C. Vapor line wrapped  
in armaflex  
joist or roof rafter at 8" intervals,  
then strap the liquid line to the  
vapor line.  
3
Download from Www.Somanuals.com. All Manuals Search And Download.  
Electrical Requirements  
Inspect Shipment  
WARNING  
Excessive Weight Hazard  
WARNING  
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.  
Electrically ground condensing unit or heat pump.  
Connect ground wire to ground lug.  
1. Check the heat pump rating plate to confirm specifications  
Use copper wire for supply connection.  
Correct wire gauge is shown in the chart below.  
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.  
Failure to follow these instructions can result in  
death or electrical shock.  
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.  
Rating Plate Ampacity  
Less than 15  
16 - 20  
AWG  
14  
NOTE: If any damages are discovered and reported to the carrier,  
do not install the heat pump because your claim may be denied.  
12  
Flush Refrigerant Lines  
21 - 30  
10  
Refrigerant lines must be flushed by a licensed, EPA certified  
refrigerant technician in accordance with established procedures.  
31 - 50  
8
NOTES:  
I
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.  
NOTE: All outdoor wiring must be suitable for outdoor use. Use  
copper conductors only.  
I
All field wiring must be done in accordance with National  
Electrical Code requirements, applicable requirements of UL,  
or local codes, where applicable.  
I
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.”  
I
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  
High  
Pressure  
Pressure  
Outdoor  
System  
Gauge Manifold  
Closed  
Vapor Line  
Existing Vapor Line  
Existing Liquid Line  
Service Valve  
Existing  
Indoor Coil  
Opened  
Liquid Line  
Service Valve  
NOTE: The inverted R-22 cylinder must contain at least  
the same amount of refrigerant as was recovered from  
the existing system.  
Tank Return  
Inlet  
Discharge  
Recovery Machine  
Recovery Cylinder  
4
Download from Www.Somanuals.com. All Manuals Search And Download.  
1. Disconnect power.  
8. Remove the valve cores.  
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.  
A
B
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. 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.  
A
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.  
A. Thermal expansion valve  
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.  
Orifice  
A
C
D
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.  
E
F
B
G
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.  
A. Distributor fitting  
B. Mounting flange  
C. Piston orifice  
E. Orifice extension stub  
F. 0.812" brass hex nut  
G. Brass hex fitting  
D. Ring seal (supplied)  
7. Remove the caps from the suction and liquid pressure taps.  
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
Download from Www.Somanuals.com. All Manuals Search And Download.  
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.  
A
B
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.  
Thermal Expansion Valve Installation  
A
IMPORTANT:  
B
I
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.  
C
F
I
I
I
Avoid sharp bends or possible kinking in the refrigerant lines  
during installation as this may cause a reduction in  
performance.  
E
D
Use care with the refrigerant lines during the installation  
process. Sharp bends or possible kinking in the lines will  
cause a reduction in performance.  
A. Distributor  
D. Liquid line stub  
E. Strainer  
B. Teflon® seal  
C. Thermal expansion valve  
F. Teflon® seal  
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.  
To install the thermal expansion valve:  
1. Separate the distributor assembly.  
Install Thermal Expansion Valve  
2. If a piston orifice is installed, remove the piston orifice and old  
Teflon® seal and discard.  
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.  
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  
Thermal expansion valves equipped with Chatleff-type fittings are  
available from the manufacturer. See Thermal Expansion Valve  
Kits chart in “System Requirements.”  
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
Download from Www.Somanuals.com. All Manuals Search And Download.  
6. Tighten to 20 to 30 ft lbs. Use backup wrench on all wrench  
6. Make sure indoor coil has been put in place according to the  
Installation Instructions and is connected to the refrigerant  
lines.  
flats.  
NOTE: Overtightening may crush the Teflon® seal and cause  
a leak.  
7. Replace valve cores.  
8. Pressurize the lines and indoor coil with a pressure not to  
7. Connect the external equalizer line to the equalizer port on  
exceed 20 psig.  
the suction line.  
9. Leak test the lines with a pressure not to exceed 20 psig.  
8. Tighten to 8 ft lbs.  
10. Evacuate the indoor coil and lines to a minimum of  
500 microns to remove contamination and moisture, then  
disconnect the vacuum pump.  
9. Attach the superheat sensing bulb to the suction header with  
the strap provided with the thermal expansion valve.  
B
A
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.  
F
E
13. Pack insulating material around refrigerant lines where they  
penetrate the structure to protect the lines and to minimize  
vibration transmission.  
C
Refrigerant Charge  
Refrigerant lines must be connected by a licensed, EPA certified  
refrigerant technician in accordance with established procedures.  
D
IMPORTANT:  
I
Refrigerant charge adjustment will be required for line set  
lengths greater than 15 ft and for evaporator coils not  
matched to the systems.  
I
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.  
A. Equalizer port  
D. Liquid line  
B. Superheat sensing bulb  
C. Thermal expansion valve  
E. Suction line  
F. Equalizer line  
I
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.  
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.  
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.  
I
I
If necessary, adjust the refrigerant charge for compatibility  
with the evaporator coil.  
Connect Liquid and Suction Lines  
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.  
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.  
Check Charge Using Normal Operating Pressures  
Use Normal Operating Pressures chart to perform maintenance  
checks.  
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.  
NOTES:  
I
I
I
The Normal Operating Pressures chart is not a procedure for  
charging the system.  
3. Remove valve cores.  
4. Wrap the service valves with a wet rag.  
Minor variations in these pressures may be due to differences  
in installations.  
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.  
Significant deviations could mean that the system is not  
properly charged or that a problem exists with some  
component in the system.  
NOTE: Do not use soft solder.  
7
Download from Www.Somanuals.com. All Manuals Search And Download.  
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  
-24  
-36  
-48  
-60  
Temperature of the Air  
Entering the Outdoor Coil  
Liquid  
Suction  
Liquid  
Suction  
Liquid  
Suction  
Liquid  
Suction  
Cooling—1st Stage (Low Capacity)  
65ºF  
75ºF  
85ºF  
95ºF  
105ºF  
115ºF  
232  
264  
307  
353  
403  
460  
146  
148  
149  
151  
153  
155  
225  
261  
302  
349  
397  
461  
144  
147  
149  
151  
153  
157  
235  
268  
310  
356  
407  
466  
144  
145  
147  
148  
150  
152  
225  
264  
305  
352  
405  
459  
138  
141  
142  
146  
148  
150  
Cooling—2nd Stage (High Capacity)  
65ºF  
75ºF  
85ºF  
95ºF  
105ºF  
115ºF  
240  
279  
322  
371  
423  
485  
143  
145  
147  
149  
151  
154  
239  
278  
322  
367  
426  
489  
139  
141  
143  
146  
148  
151  
244  
283  
326  
374  
427  
491  
140  
141  
144  
147  
148  
151  
241  
280  
324  
373  
425  
486  
134  
136  
137  
138  
142  
146  
Heating—1st Stage (Low Capacity)  
40ºF  
50ºF  
337  
322  
93  
328  
333  
98  
369  
366  
75  
351  
335  
63  
92  
117  
118  
114  
Heating—2nd Stage (High Capacity)  
20º  
279  
288  
302  
306  
62  
296  
309  
322  
336  
62  
311  
334  
354  
381  
58  
308  
323  
318  
329  
59  
70  
69  
82  
30ºF  
40ºF  
50ºF  
76  
75  
72  
93  
92  
89  
112  
113  
108  
8
Download from Www.Somanuals.com. All Manuals Search And Download.  
Suction Line Sizes  
Installations exceeding 100 ft are not recommended.  
Liquid Line Sizes  
Installations exceeding 100 ft are not recommended.  
Btu/h  
Line Set Size (in. OD)  
Btu/h  
Line Set Size (in. OD)  
24,000  
³⁄₄  
³⁄₄  
³⁄₄  
24,000  
³⁄₈  
³⁄₈  
³⁄₈  
³⁄₈  
³⁄₈  
³⁄₈  
³⁄₈  
³⁄₈  
³⁄₈  
36,000  
⁷⁄₈  
⁷⁄₈  
⁷⁄₈  
36,000  
³⁄₈  
48,000  
⁷⁄₈  
⁷⁄₈  
⁷⁄₈  
48,000  
³⁄₈  
60,000  
1¹⁄₈  
1¹⁄₈  
25 ft  
1¹⁄₈  
60,000  
³⁄₈  
Line Set Length  
Less than  
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  
Make Electrical Connections  
I
Install an adequately-sized branch circuit disconnect,  
according to the NEC, within sight of and readily accessible  
from heat pump.  
WARNING  
I
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.  
Connect ground wire to ground lug.  
WARNING  
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  
Disconnect power before servicing.  
Rating Plate Ampacity  
Less than 15  
16 - 20  
AWG  
14  
Replace all parts and panels before operating.  
Failure to do so can result in death or electrical shock.  
12  
21 - 30  
10  
1. Disconnect power.  
2. Remove control box cover.  
31 - 50  
8
3. Connect the field supply wires L1 and L2 to contactor  
terminals L1 and L2.  
IMPORTANT:  
I
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
Download from Www.Somanuals.com. All Manuals Search And Download.  
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  
Outdoor Unit  
Power  
Power  
A
B
R
C
R
C
R
C
L2  
L1  
Common  
1st Stage  
Aux. Heat  
1st Stage  
Aux. Heat  
W1  
W1  
W2  
W3  
W1  
Indoor Blower  
If Applicable  
G
O
G
A
B
Reversing Valve  
L2  
L1  
O
Y1  
Y2  
Y1  
Y2  
Y1  
Y2  
Compressor  
C
A. Ground lug  
B. Field supply ground wire  
C. 208/230 volt field supply wires  
With Auxiliary Heat  
Indoor Unit  
Thermostat  
Outdoor Unit  
Power  
Power  
A
B
R
C
R
C
R
C
Common  
Emergency  
Heat Relay  
Emergency Heat  
E
Outdoor  
1st Stage  
Aux. Heat  
Thermostat  
W1  
W2  
W3  
W1  
W1  
1st Stage Aux. Heat  
Indoor Blower  
G
O
G
If Applicable  
Reversing Valve  
O
Y1  
Y1  
Y1  
Y2  
Compressor  
Y2  
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  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Outdoor Unit Typical Wiring Diagram  
LT BU  
R
Outdoor  
Fan  
Dual Capacitor  
PR  
F
C
H
Thermostat  
Y1 Y2  
W1  
BK  
C
R
O
Fan  
BK  
OR  
W1  
O-OUT  
LO-PS  
W1  
C
L
Y
C
L
BU  
L
24V  
R
O
R
O
Y1  
DF  
Common  
BK  
R
C
S
Y1 OUT  
Y1  
HI-PS  
Compressor  
Crankcase Heater  
Diagnostic  
Module  
Defrost  
Control  
Y
L2  
L1  
208-230/60/1  
Ground  
Lug  
Ground  
Crankcase  
Thermostat  
Thermostat  
Defrost Control  
Fan  
Reversing Valve  
C
R
W1  
O
Y1 Y2  
Defrost  
Thermostat  
L1  
O-OUT  
LO-PS  
W1  
C
Low Pressure  
Switch  
L
24V  
Compressor  
L
R
O
Defrost Switch  
BU  
DF  
Common  
BK  
L1  
C
S
R
Compressor  
Contactor  
Y1  
Y1 OUT  
HI-PS  
Compressor  
Contactor  
Diagnostic  
Module  
Y2  
R
L
Y1  
C
208-230/60/1  
High Pressure  
Y
R
Switch  
R
Y
L2  
LT BU  
OR  
Crankcaser  
Heater  
Fan  
BK  
Defrost Control  
F
HI-PS  
LO-PS  
Crankcase  
Thermostat  
H
C
Dual  
Equipment  
Ground  
Outdoor Fan  
Motor  
Low Pressure  
Switch  
High Pressure  
Switch  
Capacitor  
PR  
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  
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.  
allow for pressures and temperatures to stabilize.  
11  
Download from Www.Somanuals.com. All Manuals Search And Download.  
SEQUENCE OF OPERATION  
Defrost Control  
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.  
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.  
Heating Cycle  
Defrost Control Timing Pins  
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.  
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.  
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.  
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.  
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.  
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.  
Defrost Thermostat  
NOTE: The 30-second “off” cycle is not functional when  
jumpering the TEST pins.  
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.  
12  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Time Delay  
Adjust Defrost System  
Defrost Control Board  
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.  
Optional high pressure switch connections  
NOTE: To add the pressure switch, remove the factory-installed  
jumper.  
Pressure Switch Circuit  
P1  
FAN  
30  
60  
90  
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.  
A
B
C2  
K1 Relay  
TEST  
DS1  
DS2  
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.  
H
P5  
U2  
K2 Relay  
C
D
U1  
O-OUT  
P2  
W1  
C
L
LO-PS  
DF  
24V  
L
I
E
F
R
NOTE: The defrost control board ignores input from the low  
pressure switch terminals during:  
C5  
O
Y1-OUT  
HI-PS  
Y1  
I
I
I
I
TEST mode  
K3 Relay  
Defrost cycle  
G
90-second start-up period  
P6  
Y1  
TST PS DF  
C
R
O
First 90 seconds after the reversing valve switches heat/cool  
modes  
A. Defrost time setting pins  
B. Test pins  
C. Compressor delay pins  
D. Reversing valve  
F. Defrost thermostat  
G. High pressure switch (optional)  
H. Diagnostic LEDs  
I. Low voltage terminal strip  
connections  
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.  
E. Low pressure switch (optional)  
Defrost Control Board Diagnostic LEDs  
Green  
LED (DS2)  
Red LED  
(DS1)  
Adjust Time Between Defrost Cycles  
Mode  
No Power to Board  
Off  
Off  
WARNING  
Normal Operation/Power to Board Simultaneous Slow Flash  
Short Cycle Lockout  
Alternating Slow Flash  
Low Pressure Switch Fault  
Low Pressure Switch Lockout  
High Pressure Switch Fault  
High Pressure Switch Lockout  
Off  
Off  
Slow Flash  
On  
Electrical Shock Hazard  
Slow Flash Off  
On Off  
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  
Download from Www.Somanuals.com. All Manuals Search And Download.  
2. Remove the heater compartment access panel.  
3. Connect the test pins on the defrost control using a test  
jumper wire.  
3. Adjust the time period between defrost cycles by placing the  
defrost time plug in the proper position. See “Defrost Control  
Board.”  
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.  
I
I
I
For 30-minute intervals between defrost cycles, connect  
the Defrost Time Setting Plug to the pins corresponding  
to 30.  
4. Replace control box cover.  
5. Reconnect power.  
6. Start system in heating operation.  
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).  
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.  
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.  
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.”  
Troubleshoot the Defrost System  
WARNING  
Defrost Control Setting  
T1 - 30 minutes  
Defrost Test Cycle Time  
7 seconds  
T2 - 60 minutes  
14 seconds  
Electrical Shock Hazard  
T3 - 90 minutes  
21 seconds  
Disconnect power before servicing.  
8. If an adjustment is required, see “Adjust Time Between  
Replace all parts and panels before operating.  
Failure to do so can result in death or electrical shock.  
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  
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.  
sensor terminals, if used.  
12. Replace control box cover.  
13. Reconnect power.  
1. Disconnect power.  
2. Remove control box cover.  
14  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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.  
WARNING  
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.  
Electrical Shock Hazard  
Disconnect power before servicing.  
Diagnostic LEDs Interpretation  
Replace all parts and panels before operating.  
Failure to do so can result in death or electrical shock.  
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.  
System Diagnostic Module  
W4GH6 heat pumps contain a diagnostic module for  
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.  
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  
Power (Green)  
Trip (Red)  
Fault Description  
Troubleshooting Information  
Module has power.  
I
Supply voltage is present at module terminals.  
Thermostat demand signal Y1  
is present, but the  
compressor is not running.  
I
I
I
I
I
I
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  
Alert (Yellow) Flash Code 2  
Long Run Time: Compressor  
is running extremely long run  
cycles.  
NOTE: Not applicable on heat  
pump models.  
System Pressure Trip:  
Discharge or suction pressure  
out of limits or compressor is  
overloaded.  
I
I
High head pressure.  
Condenser coil has poor air circulation (dirty, blocked,  
damaged).  
I
I
I
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  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Flash Codes  
LED Status  
Fault Description  
Troubleshooting Information  
Alert (Yellow) Flash Code 3  
Short Cycling: Compressor is  
running only briefly.  
I
I
I
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.  
I
If low pressure switch is present, go to Flash Code  
1 information.  
Alert (Yellow) Flash Code 4  
Alert (Yellow) Flash Code 5  
Locked Rotor  
Open circuit  
I
I
I
I
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.  
I
I
I
I
I
I
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.  
I
Compressor windings are damaged.  
Alert (Yellow) Flash Code 6  
Alert (Yellow) Flash Code 7  
Open Start Circuit: Current  
only in run circuit.  
I
I
I
Run capacitor has failed.  
Open circuit in the compressor start wiring or connections.  
Compressor start winding is damaged.  
Open Run Circuit: Current  
only in start circuit  
I
I
Open circuit in the compressor run wiring or connections.  
Compressor run winding is damaged.  
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.  
Alert (Yellow) Flash Code 8  
Welded Contactor:  
Compressor always runs.  
I
I
Compressor contactor has failed to close.  
Thermostat demand signal not connected to the module.  
Alert (Yellow) Flash Code 9  
Low Voltage: Control circuit  
less than 17 VAC  
I
I
Control circuit transformer is overloaded.  
Low line voltage (contact utility if voltage at disconnect is low).  
24 VAC Power Wiring  
Thermostat Demand 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.  
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.  
16  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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  
ASSISTANCE OR SERVICE  
I
I
I
Leaves and other large obstructions should be removed from  
the heat pump surfaces without damaging the fin surface of  
the coil.  
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  
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.  
Please include a daytime phone number in your correspondence.  
An annual inspection by a qualified person should be  
performed to ensure continued quality performance.  
Accessories  
To order accessories contact your Whirlpool® Home Cooling and  
Heating dealer.  
17  
Download from Www.Somanuals.com. All Manuals Search And Download.  
18  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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  
Download from Www.Somanuals.com. All Manuals Search And Download.  
48488A006  
®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.  
© 2006. All rights reserved.  
Download from Www.Somanuals.com. All Manuals Search And Download.  

Weed Eater Tiller WER500D User Manual
Weslo Treadmill 83129502 User Manual
Westinghouse Flat Panel Television SK 26H240S User Manual
Westinghouse Indoor Furnishings 82011 User Manual
Whynter Automobile Parts ARC 14FIL3M User Manual
Woods Equipment TV Mount BH6500 User Manual
Woodstock Sander W1740 User Manual
XM Satellite Radio Satellite Radio SRXM 001 User Manual
Yamaha Music Mixer DM1000 VCM User Manual
Zanussi Refrigerator ZT 51 2 R User Manual