CONDENSING UNIT INSTALLATION INSTRUCTIONS
CONDENSING UNIT INSTALLATION INSTRUCTIONSTable of ContentsCONDENSING UNIT SAFETY.1INSTALLATION REQUIREMENTS .2Tools and Parts .2System Requirements.3Location Requirements .3Electrical Requirements .4INSTALLATION INSTRUCTIONS .4Inspect Shipment .4Flush Refrigerant Lines .4System Installation .4Connect Refrigerant Lines .5Make Electrical Connections .7Charge Refrigerant Lines .8Complete Installation.12TROUBLESHOOTING .12SYSTEM MAINTENANCE .15ASSISTANCE OR SERVICE .15Accessories .15CONDENSING UNIT SAFETYRecognize this symbol as a safety precaution.Recognize Safety Symbols, Words and LabelsCAUTIONGoodman 9Hazards or unsafe practices may result in propertyor product damage.The following symbols and labels are used throughout thismanual to indicate immediate or potential hazards.It is theowner’s responsibility to read and comply with all safetyinformation and instructions accompanying these symbols.Failure to heed safety information increases the risk of seriouspersonal injury or death, property damage and/or productdamage.WARNINGHazards or unsafe practices could result in propertydamage, product damage, severe personal injury or death.Goodman 1CAUTIONHazards or unsafe practices may result in propertydamage, product damage, personal injury or death.WARNINGInstallation and repair of this unit shouldbe performed ONLY by individuals meetingthe requirements of an “Entry Level Technician”as specified by the Air-Conditioning, Heating andRefrigeration Institute (AHRI). Attempting toinstall or repair this unit without such background mayresult in product damage, personal injury or death.Goodman 7WARNINGHIGH VOLTAGE!Goodman 6Disconnect ALL power before servicing.Multiple power sources may be present.Failure to do so may cause property damage,personal injury or death.Whirlpool and Whirlpool Gold Models WAC43, WAC44, WGAC43, WGAC44, WGAC46, WGAC48 R-410 Condensing UnitsWPIO-258F
INSTALLATION REQUIREMENTSThese instructions are intended as a general guide only for use byqualified persons and do not supersede any national or localcodes in any way. The installation must comply with all state andlocal codes as well as the National Electrical Code. The condensing unit is designed and approved for outdooruse only. The condensing unit must be installed with no ductwork inthe airstream. The outdoor fan is not designed to operateagainst any additional static pressure.WARNINGGoodman12To avoid possible injury, explosion or death, practice safehandling of refrigerants.WARNINGRefrigerants areheavier than air. TheyGoodman13can "push out"the oxygen in your lungs or in any enclosed space. Toavoid possible difficulty in breathing or death: Never purge refrigerant into an enclosed room orspace. By law, all refrigerants must be reclaimed. If an indoor leak is suspected, throughly ventilate thearea before beginning work. Liquid refrigerant can be very cold. To avoid possiblefrostbite or blindness, avoid contact and wear glovesand goggles. If liquid refrigerant does contact yourskin or eyes, seek medical help immediately. Always follow EPA regulations. Never burn refrigerant,as poisonous gas will be produced.WARNINGGoodman 15To avoid possible explosion, use only returnable (notdisposable) service cylinders when removing refrigerantfrom a system. Ensure the cylinder is free of damage which could leadto a leak or explosion. Ensure the hydrostatic test date does not exceed 5 years. Ensure the pressure rating meets or exceeds 400 lbs.When in doubt, do not use cylinder.IMPORTANT: The United States Environmental ProtectionAgency (EPA) has issued various regulations regarding theintroduction and disposal of refrigerants in this unit. Failure tofollow these regulations may harm the environment and can leadto the imposition of substantial fines. These regulations may varyby jurisdiction. A certified technician must perform the installationand service of this product. Should questions arise, contact yourlocal EPA office.This product is designed and manufactured to permit installationin accordance with national codes. It is the installer’sresponsibility to install this unit in accordance with national codesand/or prevailing local codes and regulations.Tools and PartsGather the required tools and parts before starting installation.Read and follow the instructions provided with any tools listedhere.Tools Needed WARNINGGoodman14To avoid possibleexplosion: Never apply flame or steam to a refrigerant cylinder. Ifyou must heat a cylinder for faster charging, partiallyimmerse it in warm water. Never fill a cylinder more than 80% full of liquidrefrigerant. Never add anything other than R-22 to an R-22 cylinderor R-410A to an R-410A cylinder. The serviceequipment used must be listed or certified for the typeof refrigerant used. Store cylinders in a cool, dry place. Never use a cylinderas a platform or a roller.2 Torch¹ ₄" (6.4 mm) nut driverVacuum pumpMicron gauge ⁵ ₁₆" (7.6 mm) nut driverGauge set for R-410ArefrigerantNitrogen systemParts NeededCheck local codes and HVAC supplier. Check existing electricalsupply, and read “Electrical Requirements,” “LocationRequirements,” “System Requirements” and “ConnectRefrigerant Lines.”NOTE: Some condensing units do not contain a factory-installedfilter dryer. With those units, a properly sized filter dryer must befield installed in the liquid (high pressure) line set between theoutdoor condensing unit and indoor evaporator unit.
System RequirementsCondensing unit system matches are derived from actuallaboratory testing of matched systems. It is recommended thatonly matching equipment be used to ensure proper operationand efficient performance. The designed system matches are listed in the condensingunit specification sheets and on the condensing unitrefrigerant charging instructions located on the back of theservice access panel. In order to maintain the SEER rating,this condensing unit must be matched to the correct indoorsection. Refrigerant charging instructions include a list of matchingindoor equipment with the proper thermal expansion devicesize and amount of refrigerant charge required. This condensing unit has been factory charged with aquantity of refrigerant (R-410A) sufficient for a matchedindoor coil and a maximum 15 ft (4.6 m) of refrigerant line. This condensing unit has been designed and manufacturedto meet criteria for energy efficiency when matched withappropriate coil components. However, proper refrigerantcharge and proper airflow are critical to achieve ratedcapacity and efficiency. Installation of this product shouldfollow the manufacturer’s refrigerant charging and airflowinstructions. Failure to confirm proper charge and airflow mayreduce energy efficiency and shorten equipment life. A filter dryer approved for use with R-410A refrigerant isinstalled in the condensing unit. If this condensing unit is equipped with a crankcase heater, itshould be energized 24 hours before the condensing unit isstarted to avoid 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. The condensing unit must be installed on a solid, levelmounting pad that will not settle or shift. Isolate the pad fromthe building structure to avoid possible transmission of soundor vibration from the condensing unit into the conditionedspace.The condensing unit foundation should be raised to aminimum of 3" (7.6 cm) above finish grade. In areas whichhave prolonged periods of temperatures below freezing, and/or snowfall, the condensing unit should be elevated abovethe average snow line.Avoid placing the condensing unit near areas such assleeping quarters or study rooms. Normal operating soundlevels may be objectionable if the condensing unit is placednear certain rooms.Where possible, the top of the condensing unit should becompletely unobstructed.If vertical conditions require placement beneath anobstruction, there should be a minimum of 5 ft (1.5 m)between the top of the condensing unit and the obstruction.NOTE: The specified dimensions meet requirements for aircirculation only. Consult all appropriate regulatory codes priorto determining final clearances.Avoid corner installations if possible.Either side adjacent to the valves can be placed toward thestructure provided the side away from the structure maintainsminimum service clearance.Installation Clearances—Single or Multiple Unit InstallationAIndoor System Thermal Expansion Device Check the indoor coil thermal expansion device to seewhether it matches the required expanison device for theindoor coil and condensing unit being installed. Use only anthermal expansion device that is manufactured to operatewith R-410A refrigerant.Refer to the refrigerant charge label located on the inside ofthe condensing unit access panel for the correct thermalexpansion device size required.Replace the thermal expansion device with the correct one ifit is not already installed in the indoor coil. Instructions forreplacing the thermal expansion device are provided with theindoor coil.BBBBBBDDCDCCOK!DDCDCOK!COK!DCLocation Requirements This condensing unit is designed to be located outdoors withsufficient clearance for free entrance to the inlet anddischarge air openings. The location must also allow foradequate service access. See “Installation Clearances.”Where possible, select a location for the condensing unitwhich is shaded from the direct rays of the sun most of thetime. North or east locations are usually most desirable.Position the condensing unit to avoid direct contact withwater, snow or ice from a roofline overhead.A. Not recommendedB. 10" (25.4 cm)C. 18" (45.7 cm)D. 20" (50.8 cm)3
Rooftop Installation Check that the roof structure can support the weight of thecondensing unit.Keep the weather-tight integrity of the roof during and afterinstallation.Vibration-absorbing pads or springs can be installed betweenthe condensing unit legs or frame and the roof mountingassembly to reduce noise vibration.Electrical RequirementsWARNING31or death, theTo avoid the risk ofGoodmaninjury, electrical shockfurnace must be electrically grounded in accordance withlocal codes or, in their absence, with the latest edition of theNational Electric Code (NEC).Failure to follow these regulations may harm the environment andcan lead to the imposition of substantial fines. These regulationsmay vary by jurisdiction. A certified technician must perform theinstallation and service of this product. Should questions arise,contact your local EPA office.This product is designed and manufactured to permit installationin accordance with national codes. It is the installer’sresponsibility to install this unit in accordance with national codesand/or prevailing local codes and regulations.NOTE: All outdoor wiring must be suitable for outdoor use. Usecopper conductors only. All field wiring must be done in accordance with NationalElectrical Code requirements, applicable requirements of UL,or local codes, where applicable. Electrical wiring, disconnect means and over-currentprotection are to be supplied by the installer. Refer to therating plate for the maximum over-current protection,minimum circuit ampacity, and operating voltage. See thewiring diagrams in “Make Electrical Connections.”IMPORTANT: The United States Environmental ProtectionAgency (EPA) has issued various regulations regarding theintroduction and disposal of refrigerants in this unit.INSTALLATION INSTRUCTIONS Inspect ShipmentThis condensing unit is shipped in one package, completelyassembled and wired. The thermostat is shipped in a separatecarton when ordered. Check the condensing unit rating plate to confirmspecifications are as ordered. Upon receipt of equipment, inspect it for possible shippingdamage. Examine the condensing unit inside the carton if thecarton is damaged. If damage is found, it should be noted on the carrier’s freightbill. Damage claims should be filed with the carrierimmediately. Claims of shortages should be filed with theseller within 5 days.NOTE: If any damages are discovered and reported to the carrier,do not install the condensing unit, because your claim may bedenied. Polyol ester (POE) oils are used in Whirlpool units chargedwith R-410A refrigerant. Residual mineral oil from the R-22system can act as an insulator, inhibiting proper heat transfer.It can also clog the thermal expansion device, reducingsystem performance and capacity.Where possible, drain as much residual compressor oil fromthe existing systems, lines, and traps. Pay close attention tolow areas where oil may collect.System InstallationMounting Evaporator Coil Above Condensing UnitWhen mounting the evaporator coil above the condensing unit,an inverted loop in the suction line adjacent or near theconnection to the evaporator coil is required. The top of the loopmust be slightly higher than the top of the evaporator coil.CFlush Refrigerant LinesRefrigerant lines must be flushed by a licensed, EPA certifiedrefrigerant technician in accordance with established procedures.NOTES: R-410A outdoor systems are not recommended for use withindoor systems that have used R-22 as the refrigerant.However, if this condensing unit is being matched with anapproved line set which was previously charged with R-22refrigerant, the line set must be flushed prior to installation.See your local distributor for an appropriate flushing kit. Check the refrigerant lines for size and length. See “ConnectRefrigerant Lines.”4ABDA. Condensing unitB. Suction lineC. Evaporator coilD. Liquid line
Mounting Condensing Unit Below Evaporator CoilWhen mounting the condensing unit above the evaporator coil,oil traps are required at equal intervals along the suction line. Install 1 oil trap for a height difference of 15 ft to 25 ft (4.6 mto 7.6 m) between indoor and outdoor units. Install 2 oil traps for a height difference of 26 ft to 50 ft (7.9 mto 15.2 m) between indoor and outdoor units. Install 3 oil traps for a height difference of 51 ft to 100 ft(15.5 m to 30.5 m) between indoor and outdoor units. Install 4 oil traps for a height difference of 101 ft to 150 ft(30.8 m to 45.7 m) between indoor and outdoor units.AGoodman16CAUTIONThe compressor POE oil for R-410A units is extremelysusceptible to moisture absorption and could causecompressor failure. Do not leave system open toatmosphere any longer than necessary for installation.Goodman17WARNINGTo avoid the risk of fire or explosion, never use oxygen,high pressure air or flammable gases for leak testing of arefrigeration system.CDWARNINGGoodman18To avoid possible explosion, the line from the nitrogencylinder must include a pressure regulator and a pressurerelief valve. The pressure relief valve must be set to open atno more than 150 psig.BA. Condensing unitB. Liquid lineConnect Liquid and Suction LinesC. Suction lineD. Evaporator coilInsulation is necessary to avoid condensation from forming anddropping from the suction line. Armflex (or satisfactoryequivalent) with ³ ₈" (1 cm) minimum wall thickness isrecommended. In severe conditions (hot, high humidity areas),¹ ₂" (1.3 cm) insulation may be required. Insulation must beinstalled in a manner which keeps tubing from damage andcontamination.Connect Refrigerant LinesRefrigerant lines must be connected by a licensed, EPA certifiedrefrigerant technician in accordance with established procedures.IMPORTANT: Connecting refrigerant lines must be clean, dehydrated,refrigerant-grade copper lines. Condensing units should beinstalled only with specified line sizes for approved systemcombinations with elevation differences up to 15 ft (4.6 m)and total length of up to 50 ft (15.2 m). See the Suction LineSizes and Liquid Line Sizes charts later in this section. Avoid sharp bends or possible kinking in the refrigerant linesduring installation as this may cause a reduction inperformance. To avoid contamination of the refrigerant system, do notremove the caps from the lines or system connection pointsuntil connections are ready to be completed. In condensing unit systems, horizontal suction lines shouldbe slightly sloped toward the condensing unit. Piping mustavoid dips or low spots, which can collect oil.1. Route the suction and liquid lines from the fittings on theindoor coil to the fittings on the condensing unit. Run thelines in as direct a path as possible, avoiding unnecessaryturns and bends.2. For product efficiency, be sure that the suction line isinsulated over the entire exposed length and that bothsuction and liquid lines are not in direct contact with floors,walls, ductwork, floor joists, or other piping.3. Remove valve cores.4. Wrap the service valves with a wet rag or an approvedthermal trap.5. If a filter dryer is not provided, install a filter dryer in the liquidline between the outdoor condensing unit and the indoorevaporator coil.NOTE: To reduce oxidation from forming and contaminatingthe system, purge the line set/coil with nitrogen (1 to 2 psig)during the brazing process.6. Connect the suction and liquid lines, using a brazingcompound. Braze with an alloy of silver or copper andphosphorus with a melting point above 1,100 F (593ºC).NOTE: Do not use soft solder.7. Make sure indoor coil has been put in place according to theInstallation Instructions and is connected to the refrigerantlines.8. Replace valve cores.9. Pressurize the lines and indoor coil with a pressure not toexceed 20 psig.10. Leak test the lines with a pressure not to exceed 20 psig.11. Connect the vacuum pump with 250 micron capability to theservice valves.5
12. Evacuate the system to 250 microns or less using the suctionand liquid service valves.NOTE: Using both valves is necessary since somecompressors create a mechanical seal separating the sides ofthe system.Suction Line SizesCondensingUnit TonsLine Set Size—inches (cm) OD13. Close the pump valve and hold the vacuum for 10 minutes.Typically the pressure will rise during this period.1.5⁵ ₈ (1.6)³ ₄ (1.9)³ ₄ (1.9)2⁵ ₈ (1.6)³ ₄ (1.9)³ ₄ (1.9)2.5⁵ ₈ (1.6)³ ₄ (1.9)⁷ ₈ (2.2)3³ ₄ (1.9)⁷ ₈ (2.2)1¹ ₈ (2.9)3.5⁷ ₈ (2.2)1¹ ₈ (2.9)1¹ ₈ (2.9)4⁷ ₈ (2.2)1¹ ₈ (2.9)1¹ ₈ (2.9)5⁷ ₈ (2.2)1¹ ₈ (2.9)1¹ ₈ (2.9)Line SetLengthLess than25 ft (7.6 m) to25 ft (7.6 m) 49 ft (14.9 m)Vacuum in 02,000Condensibles orsmall leak present1,5001,000No leaksNo condensibles500012345 6Minutes78910If the pressure rises to 1,000 microns or less and remainssteady, the system is considered leak-free; proceed tostart-up. If the pressure rises above 1,000 microns but holdssteady below 2,000 microns, moisture and/or noncondensables may be present or the system may have asmall leak. Return to Step 12. If the same result isencountered, check for leaks as previously indicated andrepair as necessary. Repeat the evacuation.If the pressure rises
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
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AGMA American Gear Manufacturers Association AIA American Institute of Architects. AISI American Iron and Steel Institute ANSI American National Standards Institute, Inc. AREA American Railway Engineering Association ASCE American Society of Civil Engineers ASME American Society of Mechanical Engineers ASTM American Society for Testing and .
