International comfort products R2A3 GKR Series User manual

These instructions must be read and understood completely before attempting installation.
DANGER, WARNING, CAUTION, and
NOTE
The signal words DANGER, WARNING,
CAUTION, and NOTE are used to identify levels of
hazard seriousness. The signal word DANGER is
only used on product labels to signify an immediate
hazard. The signal words WARNING, CAUTION,
and NOTE will be used on product labels and
throughout this manual and other manuals that may
apply to the product.
DANGER - Immediate hazards which will result in
severe personal injury or death.
WARNING - Hazards or unsafe practices which
could result in severe personal injury or death.
CAUTION - Hazards or unsafe practices which
may result in minor personal injury or product or
property damage.
NOTE - Used to highlight suggestions which will
result in enhanced installation, reliability, or operation.
Safety Labeling and Signal Words
Signal Words in Manuals
The signal word WARNING is used throughout this
manual in the following manner:
4& WARNING
The signal word CAUTION is used throughout this
manual in the following manner:
4& CAUTION
Signal Words on Product Labeling
Signal words are used in combination with colors
and/or pictures on product labels.
TABLE OF CONTENTS
Inspect New Unit .......... 0.0.0... eee ee eee 2
Safety Considerations .......... 0. ccc eee een eee 2
Location... tte enes 2
Clearances 22... ces 2-3
Unit Supporto... 0. eee ees 4
Refrigeration System ........ cece eee ees 5-9
Electrical Wiring ........... 0.0.0... e ee eee 10-12
Start-up Procedure 2... 0... cece eee ees 12
Refrigerant Charge ......... cee cee eee eee 13-16
Sequence of Operation......... 0... c eee ee ees 16
Maintenance .. 0... 0.6 eee 16
7 aa NS) te
DEATH, PERSONAL INJURY, AND/OR PROPERTY
DAMAGE HAZARD
Failure to carefully read and follow this warning
could result in equipment malfunction, property
damage, personal injury and/or death.
Installation or repairs made by unqualified per-
sons could result in equipment malfunction, prop-
erty damage, personal injury and/or death.
The information contained in this manual is in-
tended for use by a qualified service technician fa-
miliar with safety procedures and equipped with
the proper tools and test instruments.
Installation must conform with local building
codes and with the National Electrical Code
NFPA70 current edition or Canadian Electrical
Code Part 1 CSA C.22.1.
421 01 6400 00 Nov 2010

INSPECT NEW UNIT
After uncrating unit, inspect thoroughly for hidden
damage. If damage is found, notify the transportation
SAFETY CONSIDERATIONS
company immediately and file a concealed damage
claim.
Consult a qualified installer, service agency, or the
dealer/distributor for information and assistance. The
qualified installer must use factory authorized kits and
accessories when modifying this product. Refer to the
individual instructions packaged with the kit or accessory
when installing.
The weight of the product requires careful and proper
handling procedures when lifting or moving to avoid
personal injury. Use care to avoid contact with sharp or
pointed edges.
Follow all safety codes. Wear safety glasses, protective
clothing, and work gloves. Use a heat sinking material —
such as a wet rag - during brazing operations. Keep a fire
extinguisher available. Consult local codes and the
National Electric Code (NEC) for special requirements.
Improper installation, adjustment, alteration, service or
maintenance can void the warranty.
LOCATION
4& WARNING
ELECTRICAL SHOCK HAZARD
Failure to turn off the main (remote) electrical dis-
connect device could result in personal injury or
death.
Before installing, modifying or servicing system,
turn OFF the main (remote) electrical disconnect
device. There may be more than one disconnect
device.
Check local codes for regulations concerning zoning,
noise, platforms, and other issues.
Locate unit away from fresh air intakes, vents, or
bedroom windows. Noise may carry into the openings
and disturb people inside.
Locate unit in a well drained area, or support unit high
enough so that water runoff will not enter the unit.
Locate unit away from areas where heat, lint, or exhaust
fumes will be discharged onto unit (as from dryer vents).
CLEARANCES
Locate unit away from recessed or confined areas where
recirculation of discharge air may occur (refer to
CLEARANCES section of this document).
Roof-top installation is acceptable providing the roof will
support the unit and provisions are made for water
drainage and noise/vibration dampening.
NOTE: Roof mounted units exposed to wind may require
wind baffles. Consult the manufacturer for additional
information.
Nominal minimum clearances are 48 inches (1.2m)
above unit for discharge air and 18 inches (457mm) on
each side of the coil for intake air. Clearance on any one
side of the coil (normally between unit and structure) may
be reduced to 6 inches (152mm). Nominal minimum
clearances are based on a solid parallel object such as a
wall or roof overhang.
The clearance may be reduced for a single object with
small surface area, such as the end of a wall, outside
corner of a wall, fence section, post, etc. As a general
rule, the minimum clearance from the unit should equal
the width of the object. For example, a 6 inch (152mm)
fence post should be a minimum of 6 inches (152mm)
from the unit.
Do not install unit under roof overhangs unless gutters are
present. A minimum vertical clearance of 48 inches
(1.2m) is required to the overhang.
Inside corner locations on single story structures require
evaluation. Large overhanging soffits may cause air
recirculation in a corner area even though recommended
minimum clearances are maintained. As a guide, locate
the unit far enough out so that half of the discharge grille is
out from under the soffit.
When placing two or more units side-by-side, provide a
minimum of 18 inches (457mm) between units.
Provide minimum service clearance of 24 inches
(610mm) from control box corner and side service panel.
Refer to Figure 1.
421 01 6400 00

Figure 1 Clearances (various examples)
24”
(610mm)
Service
24”
(610mm)
Service
1 8”
(457mm)
1 8”
(457mm)
6”
(152mm)
24”
24”
18”
(61
Omm)
(610mm)
(457mm)
Service
Service
4”
(102mm)
wide fence
24”
(610mm)
Service
24”
(610mm)
Service
24”
(610mm)
Service
1 8”
(457mm)
1 8”
(457mm)
1 8”
(457mm)
421 01 6400 00 3

UNIT SUPPORT
NOTE: Unit must be level + 2 degrees {3/8 inch rise or fall
per foot of run (10mm rise or fall per 305 mm of run) } or
compressor may not function properly.
A. GROUND LEVEL INSTALLATION
The unit must be level and supported above grade by
beams, platform, or a pad. Platform or pad can be of open
or solid construction but should be of permanent
materials such as concrete, bricks, blocks, steel, or
pressure- treated timbers approved for ground contact.
Soil conditions must be considered so that the platform or
pad does not shift or settle and leave the unit partially
supported. Minimum pad dimensions are shown in Figure
If beams or an open platform are used for support, it is
recommended that the soil be treated or area be graveled
to reduce the growth of grasses and weeds.
To minimize vibration or noise transmission, it is
recommended that supports not be in contact with the
building structure. However, slabs on grade constructions
with an extended pad are normally acceptable.
B. ROOF TOP INSTALLATION
This type of installation is not recommended on wood
frame structures where low noise levels are required.
Supporting structure or platform for the unit must be level.
If installation is on a flat roof, locate unit minimum 6 inches
(152mm) above roof level.
Place the unit over one or more load bearing walls. If there
are several units, mount them on platforms that are
self-supporting and span several load bearing walls.
These suggestions are to minimize noise and vibration
transmission through the structure. If the structure is a
home or apartment, avoid locating the unit over
bedrooms or study.
NOTE: When unit is to be installed on a bonded
guaranteed roof, a release must be obtained from the
building owner to free the installer from all liabilities.
C. FASTENING UNIT DOWN
If conditions or local codes require the unit be attached in
place, remove the knockouts in the base pan and install
tie down bolts through the holes (refer to Figure 2).
Contact local distributor for hurricane hold-down details
and the P.E. (Professional Engineer) certification, when
required.
A
CAUTION
PROPERTY DAMAGE HAZARD
Failure to follow this caution may result in proper-
ty damage.
Inadequate unit support may cause excessive
vibration, noise, and/or stress on the refrigerant
lines, leading to refrigerant line failure.
Figure 2 Tie Down Knockouts
3/8” (10mm) dia. Tie Down Knockouts
In Base Pan (2 places)
View From Top
Base Pan Width
Inches (mm)
Base Pan Tie Down Minimum
Width x Knockouts Mounting Pad
Depth A B Cc Dimensions
23x 28 7-34 [47716] 16 23x28
(684 x 584) (97) | (113) | (457) (684 x 584)
Oe tite | Scie | 4-76 | 21-1/4 26 x 26
(652 x 652) (230) | (113) | (640) (680 x 660)
Bexar |oane| ete | 2458 | siexalte
(791 x 791) (230) | (165) | (625) (800 x 800)
421 01 6400 00

REFRIGERATION SYSTEM
A. COMPONENT MATCHES
Check to see that the proper system componenis are in
place, especially the indoor coil.
R-22 outdoor units can only be used with R-22 specific
indoor coils. If there is a refrigerant mis-match, consult
the indoor coil manufacturer to determine if a refrigerant
conversion kit is available for the indoor coil.
This outdoor unit is designed for use only with indoor coils that
utilize a TXV refrigerant metering device or Piston metering
device. If any other type of metering device is installed on the
indoor coil, consult the indoor coil manufacturer to determine if
a TXV conversion kit is available.
CAUTION
UNIT OPERATION HAZARD
This unit utilizes R-22 refrigerant. Use only R-22
refrigerant when servicing this unit.
DO NOT under any circumstances use R-410A
refrigerant in this system.
A
Installing with TXV
When installing a TXV on an indoor coil, follow the
instructions provided with the new TXV.
A typical TXV installation is shown in Figure 3.
Figure 3 Typical TXV Installation
INDOOR
COIL
EQUALIZER |
TUBE
SENSING | SUCTION
BULB TUBE
~~ LIQUID
TUBE
TXV
SENSING BULB
(EITHER SIDE) STRAP
SUCTION
8 O'CLOCK 4 O'CLOCK
Installing with Indoor Piston - cooling operation
Check piston size shipped with indoor unit to see if it
matches required indoor piston size.
If it does not match, replace indoor piston with correct
piston size.
B. REFRIGERANT LINE SETS
The refrigerant line set must be properly sized to assure
maximum efficiency and proper oil circulation.
Refer to Product Specifications and Long Line
Applications Guideline for line set sizing.
NOTE: Total line set length must not exceed 200 feet
(61m).
A crankcase heater must be used when the refrigerant
line length exceeds 80 feet (24.4m).
If outdoor unit is more than 10 feet (8m) higher than the
indoor coil, refer to the Long Line Applications Guideline
manual for instructions.
When the outdoor unit is higher than the indoor coil, the
vertical separation must not exceed 100 feet (80m).
When the outdoor unit is lower than the indoor coil, the
vertical separation must not exceed 50 feet (15.2m).
If it is necessary to add refrigerant line in the field, use
dehydrated or dry, sealed, deoxidized, copper
refrigeration tubing. Do not use copper water pipe.
Do not remove rubber plugs or caps from copper tubing
until connections are ready to be made.
Be extra careful when bending refrigeration tubing.
Tubing can “kink” easily, and if this occurs, the entire
length of tubing must be replaced.
7 aN Le
PERSONAL INJURY HAZARD
Failure to relieve system pressure could result in
personal injury and/or death.
Relieve pressure and recover all refrigerant before
servicing existing equipment, and before final unit
disposal. Use all service ports and open all flow-
control devices, including solenoid valves.
A
CAUTION
UNIT OPERATION HAZARD
Failure to follow this caution may result in improp-
er product operation.
Do not leave system open to atmosphere any lon-
ger than absolutely required for installation. Inter-
nal system components - especially refrigerant
oils - are extremely susceptible to moisture con-
tamination. Keep ends of tubing sealed during
installation until the last possible moment.
421 01 6400 00

C. ROUTING AND SUSPENDING REFRIGERANT
LINES
Run refrigerant lines as straight and direct as possible,
avoiding unnecessary bends and turns. Always insulate
the entire suction line. Both lines should be insulated
when routed through an attic or when routed through an
underground raceway.
When routing refrigerant lines through a foundation or
wall, do not allow refrigerant lines to come in direct
contact with the building structure.
Make openings large enough so that lines can be
wrapped with extra insulation. Fill all gaps with RTV caulk.
This will prevent noise transmission between the tubing
and the foundation or wall.
Along floor or ceiling joists, suspend refrigerant lines so
that they do not contact the building structure, water
pipes, or ductwork. Use insulated or suspension type
hangers. Metal straps must be at least 1” (25mm) wide to
avoid cutting into the tube insulation. Keep the liquid and
suction lines separate. Refer to Figure 4.
Figure 4 Routing and Suspending Refrigerant Lines
JOIST
OUTDOOR WALL INDOOR WALL a
HANGER STRAP
CAULK (AROUND SUCTION
~—_¢ LIQUID TUBE TUBE ONLY) WY) INSULATION
SUCTION TUBE
O
oO
t 0
SUCTION TUBE
INSULATION
1” (25mm) MIN —| be
LIQUID TUBE
THROUGH THE WALL SUSPENSION
A CAUTION
UNIT OPERATION HAZARD
Failure to follow this caution may result in improp-
er product operation.
Do not bury more than 36” (1m) of line set under-
ground. Refrigerant may migrate to cooler buried
section during extended periods of unit shut-
down, causing refrigerant slugging and possible
compressor damage at start-up.
If ANY section of the line set is buried under-
ground, provide a minimum 6” (152mm) vertical
rise at the service valve.
D. OUTDOOR UNIT HIGHER THAN INDOOR UNIT
Proper oil return to the compressor should be maintained
with suction gas velocity. If velocities drop below 1500
fom (feet per minute), oil return will be decreased. To
maintain suction gas velocity, do not upsize vertical
suction risers.
421 01 6400 00

E. LIQUID LINE FILTER-DRIER
NOTE: lt is recommended that an appropriate filter—drier
be installed in the liquid line.
Leave the plugs in the tube ends until the filter—drier is
installed. The optimal location for the filter—drier is close
to the indoor coil. Install the filter-drier with the arrow
pointing towards the indoor coil. Refer to Figure 5.
Liquid Line Filter—-Drier
Figure
5
Installed
at
Indoor
Coil
Filter-Drier
(arrow points towards indoor coil)
38-11-84
F. SERVICE VALVES
Service valves are closed and tube stubs are plugged
from the factory. Outdoor units are shipped with a dry
nitrogen holding charge sealed in the unit. Leave the
service valves closed until all other refrigerant system
work is complete or the charge will be lost. Leave the
plugs in place until line set tubing is ready to be inserted.
Service valve bodies are brass and tube stubs are
copper.
Service Valve Figure 6
VALVE CORE
G. BRAZING CONNECTIONS
NOTE: Remove valve core from schrader port on both
Service Valves BEFORE brazing. This helps prevent
overheating and damage to valve seals (refer to Figure 6).
Replace valve core when brazing is completed.
7 aN Le
FIRE HAZARD
Failure to remove refrigerant and oil charge before
brazing could result in personal injury, death, and/
or property damage.
Refrigerant and oil mixture could ignite and burn
as it escapes and contacts brazing torch. Make
sure the refrigerant charge is properly removed
from both the high and low sides of the system be-
fore brazing any component or lines.
Clean line set tube ends with emery cloth or steel brush.
Remove any grit or debris.
Insert line set tube ends into service valve tube stubs.
Apply heat absorbing paste or heat sink product between
service valve and joint. Wrap service valves with a heat
sinking material such as a wet cloth.
Braze joints using a Sil-Fos or Phos-copper alloy.
A CAUTION
PRODUCT DAMAGE HAZARD
Failure to follow this caution may result in product
damage.
Braze with Sil-Fos or Phos-copper alloy on cop-
per—-to-copper joints and wrap a wet cloth around
rear of fitting to prevent damage to TXV.
421 01 6400 00

H. OPENING SERVICE VALVES
Outdoor units are shipped with a dry nitrogen holding
charge sealed in the unit. Opening the service valves
releases this charge into the system.
NOTE: Open the Suction service valve first. If the Liquid
service valve is opened first, oil from the compressor may
be drawn into the indoor coil TXV, restricting refrigerant
flow and affecting operation of the system.
Remove Suction service valve cap and insert a hex
wrench into the valve stem. Hold the valve body steady
with an end-wrench and back out the stem by turning the
hex wrench counterclockwise. Turn the stem until it just
contacts the rolled lip of the valve body.
After the nitrogen charge has bled into the system, open
the Liquid service valve.
NOTE: These are not back-seating valves. It is not
necessary to force the stem tightly against the rolled lip.
The service valve cap is a primary seal for the valve and
must be properly tightened to prevent leaks. Make sure
cap is clean and apply refrigerant oil to threads and
sealing surface on inside of cap.
Tighten cap finger tight and then tighten additional 1/6 of a
turn (1 wrench flat) to properly seat the sealing surfaces.
NOTE: Using the service ports (or gauge set), release the
nitrogen pressure from the system before attaching
vacuum pump.
I. EVACUATING CONDENSER, LINE SET, AND
INDOOR COIL
A CAUTION
PRODUCT DAMAGE HAZARD
Failure to follow this caution may result in product
damage.
Never use the outdoor unit compressor as a vacu-
um pump. Doing so may damage the compressor.
Condenser, line set, and indoor coil should be evacuated
using the recommended deep vacuum method of 500
microns. lf deep vacuum equipment is not available, the
alternate triple evacuation method may be used by
following the specified procedure.
If vacuum must be interrupted during the evacuation
procedure, always break vacuum with dry nitrogen.
A
CAUTION
UNIT OPERATION HAZARD
This unit is filled with a Nitrogen charge. Prior to
starting this unit, evacuate to 500 microns and
charge with refrigerant listed on rating label.
Deep Vacuum Method
The deep vacuum method requires a vacuum pump
capable of pulling a vacuum to 500 microns and a vacuum
gauge capable of accurately measuring this vacuum
level. The deep vacuum method is the most positive way
of assuring a system is free of air and water.
Watch the vacuum gauge as the system is pulling down.
The response of the gauge is an indicator of the condition
of the system (refer to Figure 7).
With no leaks in the system, allow the vacuum pump to
run for 30 minutes minimum at the deep vacuum level.
Fiqure 7 Deep Vacuum Gauge Response
g and System Conditions
5000 +
4500 4
4000 - a
LEAK IN
8500 — SYSTEM
8 3000 4
2500 4
9
= 2000 - DE
VACUUM TIGHT
1800 TOO WET
4000 -
TIGHT
$00 DRY SYSTEM
' ' ' ' ' ' ' '
oO 1 2 3 4 5 6 7
MINUTES
421 01 6400 00

Triple Evacuation Method
The triple evacuation method should only be used when
system does not contain any water in liquid form and
vacuum pump is only capable of pulling down to 28 inches
of mercury (711mm Hg). Refer to Fig. 8 and proceed is as
follows:
1. Pull system down to 28 inches of mercury (711mm
Hg) and allow pump to continue operating for an
additional 15 minutes.
2, Close manifold valves or valve at vacuum pump
and shut off vacuum pump.
3. Connect a nitrogen cylinder and regulator to
system and fill with nitrogen until system pressure
is 2 psig.
4. Close nitrogen valve and allow system to stand for
1 hour. During this time, dry nitrogen will diffuse
throughout the system absorbing moisture.
Repeat this procedure as indicated in Figure 8.
6. After the final evacuate sequence, confirm there
are no leaks in the system. If a leak is found, repeat
the entire process after repair is made.
Figure 8 Triple Evacuation Sequence
EVACUATE
:
BREAK VACUUM WITH DRY NITROGEN
WAIT
EVACUATE
BREAK VACUUM WITH DRY NITROGEN
v
WAIT
v
EVACUATE
v
CHECK FOR TIGHT, DRY SYSTEM
(IF IT HOLDS DEEP VACUUM)
v
CHARGE SYSTEM
:
th
J. GAUGE PORTS
Check for leaks at the schrader ports and tighten valve
cores if necessary. Install plastic caps finger tight.
421 01 6400 00

ELECTRICAL WIRING
4& WARNING
ELECTRICAL SHOCK HAZARD
Failure to turn off the main (remote) electrical discon-
nect device could result in personal injury or death.
Before installing, modifying or servicing system, turn
OFF the main (remote) electrical disconnect device.
There may be more than one disconnect device.
Single phase supply voltage must be 208/230 volts (197
volt minimum to 253 volts maximum) 60 Hz.
Outdoor units are approved for use with copper
conductors only. Do not use aluminum wire.
Refer to unit rating plate for minimum circuit ampacity and
circuit protection requirements.
For 3-phase units, refer to unit rating plate for the
required supply voltage. Depending on the model,
required supply voltage will be:
208/230 V, 3-phase, 60 Hz
or
460 V, 3-phase, 60 Hz
Grounding
Permanently ground unit in accordance with the National
Electrical Code and local codes or ordinances. Use a
copper conductor of the correct size from the grounding
lug in control box to a grounded connection in the service
panel or a properly driven and electrically grounded
ground rod.
Wiring Connections
Make all outdoor electrical supply (Line Voltage)
connections with raintight conduit and fittings. Most
codes require a disconnect switch outdoors within sight of
the unit. Consult local codes for special requirements.
Route electrical supply (Line Voltage) wiring through
knockout hole in bottom of Control Box. Connect wires to
Contactor and Ground Lug according to Wiring Diagram
on unit. Also refer to Figure 9.
For 3-phase 208/230V and 460V - Connect two power
wires to Contactor and one power wire to Blue lead wire
(use wire nut). Connect ground wire to Ground Lug. Refer
to Wiring Diagram on unit and Figure 10.
Thermostat Wiring Connections
Route thermostat wiring through rubber grommet in
bottom of Control Box. Low voltage lead wires are
provided in the control box for connection to thermostat
wires (use wire nuts). Refer to Wiring Diagram on unit and
Figure 11 for low voltage wiring examples.
NOTE: Use No. 18 AWG (American Wire Gage)
color-coded, insulated (35 °C minimum) wire. [ff
thermostat is located more than 100 feet (81m) from unit
as measured along the control voltage wires, use No. 16
AWG color-coded wires to avoid excessive voltage drop.
Figure 9 Electrical Supply (Line Voltage) Connections
DISCONNECT
PER NEC AND/OR
LOCAL CODES
TCS CONTACTOR
“4 11 0
“FELDPOWER fo 8
WIRING
L2
weet steer eee TB eee eee OD ®
23 or 13
FIELD GROUND
inne oe ©
GROUND
LUG
Figure 10 3-Phase 208/230V and 460V Electrical Supply (Line Voltage) Connections
DISCONNECT
PER NEC AND/OR
LOCAL CODES
SY CONTACTOR
11.0
wee eee ee eee eee LI ---L® &
FIELD POWER L3
veeeec reese AB eee eee OD ®
WIRING 13
eee eee eee eee l2__
\ ] BLUE LEAD WIRE
FIELD GROUND
Wining PTT @
GROUND
LUG
10 421 01 6400 00

Figure 11 Typical Thermostat Connections
THERMOSTAT FURNACE AIR CONDITIONER
24 VAC HOT [pf 4
24 VAC COM q
HEAT STAGE 1 WM 1
COOL STAGE 1 YN2
INDOOR FAN 4
ae
t
[=]
[=]
[E]
7
,
THERMOSTAT FAN COIL AIR CONDITIONER
24 VAC HOT [Ff 4
24 VAC COM q
HEAT STAGE 1 WM 1
COOL STAGE 1 YN2
INDOOR FAN 4
]
1 '
[=]
[=]
i
v
©
i
-]}- - + 4
421 01 6400 00 11

Phase Monitor Relay Board
Some 208/230 V and 460 V units are factory equipped
with a phase monitor relay board.
The Phase Monitor Board detects the sequence of the
three phase electrical system, and a relay breaks the Y
(call for cooling) control signal if the phasing is incorrect.
Additionally, the board will detect the loss of voltage on
any of the three phase inputs and break the Y signal in the
same way.
An LED on the board displays the following status:
Red LED ON - Normal function, relay contact closed.
Red LED Blinking - Abnormal function, relay contact open.
Red LED OFF - No 24 VAC control power present at board.
NOTE: If phase monitor is activated, correct the phase
problem, and then follow these steps to reset the phase
monitor:
1. Ensure line voltage is ON to the unit.
2. Disconnect 24 volts to outdoor unit.
3. Re-apply 24 volts to the outdoor unit.
This will reset the phase monitor.
START-UP PROCEDURE
Figure 12 Phase Monitor Relay Board
CONTAC TOR z2avac com 3, 3
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Re
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To f Nea
2 <> 4s a
[ » Se -~C_)- ro NY
Riz 2 T+ +
<> | C- ”
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8 ft e|.| 1
ag -C> w= A
o> ts re RS
oT <> —_
Bo Ra 2avan oO
<> natibiaee PROBLEN RIS. Oo
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a plz BLUE
oe Rid %
=
@ ' *@
cepLizosaa-o1 b>" VEL LI-BLK
1. Set indoor thermostat selector switch to OFF.
2. Turn ON all electrical disconnect devices.
3. If unit has a crankcase heater, energize the heater
and wait 24 hours before proceeding.
4. Set indoor thermostat at desired temperature. Be
sure setpoint is below indoor ambient temperature or
thermostat will not call for cooling.
5. Set indoor thermostat selector switch to COOL.
Operate unit for minimum 15 minutes, then check
system refrigerant charge.
Check For Proper Phasing
3-phase 208/230 V and 460 V models.
Observe the LED on the Phase Monitor Relay Board. If
the LED is blinking, turn off power to the unit and swap any
two of the supply voltage wires. Turn power back on and
repeat the start-up procedure.
12 421 01 6400 00

REFRIGERANT CHARGE
Figure 13 shows the suggested refrigerant charge
quantities for a 15 foot (4.6m) lineset. If shorter or longer
refrigerant lines or a different indoor coil are used, the
charge will have to be adjusted.
Figure 13 Suggested Refrigerant Charge
Quantity for 15 foot (4.6m) Lineset
Model Number Ibs. (kg)
R2A318GKR 3.56 (1.62)
R2A324GKR 4.08 (1.85)
R2A330GKR 4.11 (1.87)
R2A336GKR 5.35 (2.43)
R2A342GKR 7.01 (3.19)
R2A348GKR 8.88 (4.04)
R2A360GKR 10.52 (4.79)
Suggested charge amount and desired subcooling are
shown on unit rating plate. Charging method is shown on
information plate inside unit.
For TXV, use subcooling method.
For Piston, use superheat method.
To properly check or adjust charge, conditions must be
favorable for subcooling or superheat charging.
Favorable conditions exist when the outdoor temperature
is between 70°F and 100°F (21°C and 38°C), and the
indoor temperature is between 70°F and 80°F (21°C and
27°C). Follow the procedure below.
Weigh in charge according to suggested quantities
shown in Figure 13. Adjust charge by adding or removing
0.6 oz/ft (17 g/mm) of 3/8 liquid line above or below 15 feet
(4.6 m) respectively.
For standard refrigerant line lengths 80 feet (24.4m) or
less, allow system to operate in cooling mode at least 15
minutes. If conditions are favorable, check system
charge by super heat method for fixed metering device
and subcooling method for TXV. If any adjustment is
necessary, adjust charge slowly and allow system to
operate for 15 minutes to stabilize before declaring a
properly charged system.
If the indoor temperature is above 80°F (27°C), and the
outdoor temperature is in the favorable range, adjust
system charge by weight based on line length and allow
the indoor temperature to drop to 80°F (27°C) before
attempting to check system charge by subcooling method
as described above.
If the indoor temperature is below 70°F (21°C), or the
outdoor temperature is not in the favorable range, adjust
charge for line set length above or below 15 feet (4.6m)
only. Charge level should then be appropriate for the
system to achieve rated capacity. The charge level could
then be checked at another time when the both indoor and
outdoor temperatures are in a more favorable range.
NOTE: If line length is beyond 80 feet (24.4m) or greater
than 20 feet (6.1m) vertical separation, See Long Line
Guideline for special charging requirements.
421 01 6400 00 13

A. UNITS WITH COOLING MODE TXV
Units installed with cooling mode TXV require charging by
the subcooling method.
1.
2.
Operate unit a minimum of 15 minutes before
checking charge.
Measure liquid service valve pressure by attaching
an accurate gage to service port.
Measure liquid line temperature by attaching an
accurate thermistor type or — electronic
thermometer to liquid line near outdoor coil.
Refer to unit rating plate for required subcooling
temperature.
Refer to Figure 16. Find the point where required
subcooling temperature intersects measured
liquid service valve pressure.
To obtain required subcooling temperature at a
specific liquid line pressure, add refrigerant if liquid
line temperature is higher than indicated or reclaim
refrigerant if temperature is lower. Allow a
tolerance of +3°F (+1.7°C).
B. UNITS WITH INDOOR PISTON
Units installed with indoor pistons require charging by the
superheat method.
The following procedure is valid when indoor airflow is
within +21 percent of its rated CFM.
1.
2.
10.
11.
12.
Operate unit a minimum of 15 minutes before
checking charge.
Measure suction pressure by attaching an
accurate gage to suction valve service port.
Measure suction temperature by attaching an
accurate thermistor type or — electronic
thermometer to suction line at service valve.
Measure outdoor air dry-bulb temperature with
thermometer.
Measure indoor air (entering indoor coil} wet-bulb
temperature with a sling psychrometer.
Refer to Figure 14. Find outdoor temperature and
evaporator entering air wet-bulb temperature. At
this intersection, note superheat. Where a dash
(--) appears on the table, do not attempt to charge
system under these conditions or refrigerant
slugging may occur. Charge must be weighted in,
adding or removing 0.6 o2/ft of 3/8 liquid line above
or below 15 feet (4.6m) respectively.
Refer to Figure 15. Find superheat temperature
(from #6 above) and suction pressure. At this
intersection, note suction line temperature.
If unit has a higher suction line temperature than
charted temperature, add refrigerant until charted
temperature is reached.
If unit has a lower suction line temperature than
charted temperature, reclaim refrigerant until
charted temperature is reached.
When adding refrigerant, charge in liquid form into
suction service port using a_ flow-restricting
device.
If outdoor air temperature or pressure at suction
valve changes, charge to new suction line
temperature indicated on chart.
Optimum performance will be achieved when
the operating charge produces 10°F suction
superheat at suction service valve with 95°F
(35°C) outdoor ambient and 80°F (27°C) dry
bulb 67°F (19°C) wet bulb indoor temperature
(DOE “A” test conditions) at rated airflow.
14 421 01 6400 00

Figure 14 Superheat Charging
EVAPORATOR ENTERING AIR TEMPERATURE (°F WB)
OUTDOOR TEMP (°F)
50 52 54 56 58 60 62 64 67 68 70 72 74 76
55 9 12 14 17 20 23 26 29 32 35 37 40 42 45
60 7 10 12 15 18 2 24 27 30 33 35 38 40 43
65 — 6 10 13 16 19 4 24 27 30 33 36 38 af
70 — | — 7 10 13 16 19 4 24 27 30 33 36 39
75 — | — | — 6 9 12 15 18 4 24 28 34 34 37
80 — |_— |— | — 5 8 12 15 18 4 25 28 34 35
85 — | — | — | — | — | — 8 14 15 19 22 26 30 33
90 — | — | — | — | — | — 5 9 13 16 20 24 27 34
95 — |— > — | — | — | — | — 6 10 14 18 22 25 29
100 — |— | — |— | — |— |— J — 8 12 15 20 23 27
105 — |— | — |— | — |— |— J — 5 9 13 17 22 26
110 — |— f— |— |— | — |— | — J — 6 14 15 20 25
115 — |_— f— |— |— |— |— J— J — J — 8 14 18 23
*Optimum performance point, 95°F (35°C) outdoor ambient and (80°F / 27°C dry bulb), (67°F / 19°C wet bulb) indoor conditions. (DOE A Test Conditions)
Where a dash (——) appears do not attempt to charge system under these conditions or refrigerant slugging may occur. Charge must be weighed in.
Note: Superheat °F is at low—sicde service port, Allow a tolerance of + 3°F (+ 1.7°C)
Note: Indoor dry bulb between 70°F and 80°F (21°C and 27°C)
Figure 15
SUPERHEAT TEMP (°F)
Required Suction-Line Temperature
SUCTION PRESSURE AT SERVICE PORT (PSIG)
67.1 70.0 73.0 76.0 79.2
421 01 6400 00 15

Figure 16 Rating Plate (required) Subcooling Temperature °F (°C)
°F
Measured Liquid 10
Pressure (psig)
oF oF
15 20
R-22 Required Liquid Line Temperature °F (°C)
163 83 78
171 86 81
179 89 84
187 92 87
196 95 90
205 98 93
214 101 96
223 104 99
233 107
243 110
253 113
264 116
274 119
285 122
297 125
309 128
SEQUENCE OF OPERATION
73 68
76 71
79 74
82 77
85 80
88 83
91 86
94 89
97 92
95
98
With power supplied to indoor and outdoor units,
transformer is energized.
On a cali for cooling, the thermostat makes circuits R-Y
and R-G, Circuit R-Y energizes contactor, starting
outdoor fan motor and compressor. Circuit R-G
energizes indoor unit blower relay, starting indoor blower
motor.
MAINTENANCE
When thermostat is satisfied, its contacts open,
de-energizing contactor and blower relay. Compressor
and motors stop.
NOTE: If indoor unit is equipped with a time-delay relay
circuit, the blower runs an additional length of time to
increase system efficiency.
Condensate Drain
During the cooling season, check monthly for free flow of
drainage and clean if necessary.
Cleanliness
These tips will help keep the air conditioner looking better
and working more efficiently:
1. Free flow of air is essential. Keep fences, shrubs,
trash cans, and other obstructions at least 18
inches (0.5m) from all coil inlets.
2. Keep the coil free of grass clippings, leaves,
weeds, and other debris.
NOTE: Coil may occasionally require cleaning with
a liquid solution. The coil must be cold when
cleaning. Use an alkaline based cleaner only.
Cleaning a hot coil or using an acid based cleaner
will remove the paint from the fins and may clog the
coil.
3. Never use a weather cover over the outdoor unit
unless it is a ventilated type or made of breathable
fabric that will allow moisture to evaporate rapidly.
A cover that holds moisture in the unit will cause
more rust build-up and damage than normal
exposure to weather.
International Comfort Products, LLC
16 Lewisburg, TN 37091 USA
421 01 6400 00