Installation, Operation and Maintenance
1.5 Through 5 Ton
Split System Air Conditioner
TABLE OF CONTENTS
INTRODUCTION..............................................................................1
NOTES TO INSTALLER ....................................................................1
RECOGNIZE SAFETY SYMBOLS, WORDS AND LABELS ................1
CODES ............................................................................................1
INSPECTION AND UNPACKING......................................................1
INSTALLATION
Clearances..........................................................................2
Support ..............................................................................2
Exposure ............................................................................2
Proximity to Evaporator....................................................2
ELECTRICAL CONNECTIONS ..........................................................2
SERVICE VALVE CONNECTIONS
Braze Joints ..............................................................................3
Evacuation ................................................................................3
Opening the Service Valve (Step Valve) ................................3
CONNECT REFRIGERANT PIPING ..................................................4
Precautions................................................................................4
Liquid Line Sizes........................................................................4
Suction Line Sizes......................................................................4
SUBCOOLING CHARGING ............................................................5
OPERATION INSTRUCTIONS ..........................................................5
MAINTENANCE INSTRUCTIONS ....................................................5
CONDENSING UNIT NOMENCLATURE ..........................................6
LIMITED WARRANTY ....................................................................7
NOTE:
THESE INSTRUCTIONS ARE INTENDED AS AN AID TO QUALIFIED
SERVICE PERSONNEL FOR PROPER INSTALLATION, ADJUSTMENT
AND OPERATION OF THIS EQUIPMENT. READ THE ENTIRE
INSTRUCTION MANUAL THOROUGHLY BEFORE ATTEMPTING
INSTALLATION OR OPERATION.
Proximity to Evaporator
INSTALLATION
Locating the condenser as close as possible to the
evaporator will increase the system capacities by reducing
the line set refrigerant pressure drop, and will make the
system less susceptible to liquid migrations due to less
refrigerant charge.
Condensing Unit Location
The condensing unit should be located outdoors as close as
possible to the evaporator. Consider the following factors:
Clearances
Electrical Connections
The air inlet should be located at least 12" from a wall or
other obstruction for unrestricted air flow.
DANGER
The air outlet should be located so as to direct discharged
air away from the building. Three feet of clearance around
the unit and a minimum of six feet clearance above the
unit is required to avoid recirculation of condenser
discharge air on vertical discharge models. Avoid locating
unit under low overhanging roofs.
BEFORE PERFORMING ANY WORK ON THIS EQUIPMENT,
POWER SUPPLY MUST BE TURNED OFF AT THE HOUSEHOLD
SERVICE BOX TO AVOID THE POSSIBILITY OF SHOCK,
INJURY, DEATH OR DAMAGE TO EQUIPMENT.
Support
Mount the unit on a sturdy base approximately four to six
inches above the ground. In areas known for snow
accumulation, the unit should be elevated at least 18"
above the ground. A concrete slab is recommended.
Concrete slab should not contact the building foundation
to prevent possible sound or vibration transmission.
Rooftop installation is acceptable in areas of low snow
accumulations, provided the roof will support the unit and
provisions are made for water drainage and the noise or
vibration through the structure.
WARNING
ELECTRICAL EQUIPMENT SHOULD BE INSTALLED BY A
QUALIFIED,
LICENSED
ELECTRICIAN.
IMPROPER
ELECTRICAL HOOK-UP MAY DAMAGE EQUIPMENT, CAN
CREATE A HAZARD, CAUSE PERSONAL INJURY OR
DEATH, AND WILL VOID THE WARRANTY.
1. The installer shall check available power to make certain it
matches the unit rating plate (located inside control box
cover) and that constant voltage can be maintained to the
unit. Unsatisfactory performance would otherwise result.
The local power company should be contacted regarding
any problems or questions concerning power supply.
Exposure
Placement of the unit should be in a well-drained area, or
the unit must be supported high enough so run-off will not
enter the unit.
Avoid installations under roof overhangs without
guttering. Water draining from the roof onto the unit
could produce excessive noise and may cause ice to build
up on the coil or fan during cold weather.
Locate unit away from windows, patios, decks, etc. where
unit operation sound may disturb customer.
2
Control box cover
Opening for line
voltage conduit or cable
Do not locate where heat, lint or exhaust fumes will be
discharged on the unit (as from dryer or furnace vent).
Opening for
low-voltage wiring
3
Wiring diagram and rating
plate are located inside
control box cover
1
2. Install a line service disconnect switch within sight of the
condensing unit. The line voltage service wiring for the
condensing unit should include a fused disconnect switch.
Rain Gutters
Six feet
clearance
above the
unit
3. Use correct wire size and fuse size. To ensure that adequate
voltage will be available at the condensing unit, the line
voltage service wiring must be of adequate size. Minimum
recommended wire ampacities and maximum fuse sizes are
listed on the unit name plate.
4. Two holes are provided in the control box.
Three feet
clearance
a. One is for the connection of the line voltage conduit or
cable. The hole is sized for 3/4" conduit.
Three feet
clearance
b.One is for low-voltage wiring. (Refer to the wiring
diagram attached to electrical box cover for connection.)
5. Be sure to ground the condensing unit by securing the
ground wire to the grounding lug inside the control box.
Concrete slab
or preformed pad
6. Be sure to follow National Electrical Code and all local
codes.
2
Evacuation
Electrical Connections (cont.)
The outdoor unit is factory charged. Evacuation is necessary
on the uncharged portions of the total system. Purge the
system with dry nitrogen. Then connect a vacuum pump and
a vacuum gage capable of accurately measuring below
1,000 microns vacuum depth. The deep vacuum method is
the most positive way of assuring a system is free of air and
liquid water.
Connect Control Wiring
1. Route 24 volt control wires through control wiring
grommet and connect leads to control wiring.
2. Use No. 18 AWG color coded, insulated wire. If thermostat
is located more than 100 ft. from unit, as measured along
the control voltage wires, use No. 16 AWG wire to avoid
excessive voltage drop.
3. All wiring must be NEC Class 1 and must be separated from
incoming power leads. Use furnace transformer, fan coil
transformer, or accessory transformer for control power.
WARNING
Note: Use of available 24 volt accessories may exceed the
minimum power requirement. Determine total transformer
load and increase the transformer capacity or split the load
with an accessory transformer as required.
IF THE INSTALLER IS MAKING UP HIS OWN LINE SETS,
HE MUST MAKE SURE THE TUBING IS CLEAN OF ANY
IMPURITIES OR MOISTURE.
Final wiring check
Check factory wiring and field wire connections to ensure
terminations are secured properly. Check wire routing to
ensure wires are not in contact with tubing, sheet metal,
etc.
Opening the Service Valve (Step Valve)
NOTE: This is not a back-seating valve.
1. Remove the valve cap using an adjustable wrench.
2. Open the valve by inserting a hex wrench (3/16" for the
liquid line, 5/16" for the vapor line) into the stem and back
out counter-clockwise until the valve stem just touches the
retaining ring. Do not over tighten.
SERVICE VALVE CONNECTIONS
Braze joints
1. Remove the valve core from the schrader port. Wrap a
quenching cloth around the service valve. Clean and flux
the joint and braze with brazing rod containing at least
10% silver (such as silphos type brazing rod). DO NOT USE
SOFT SOLDER. Replace the schrader valve core after
brazing has cooled.
3. Replace the valve cap finger-tight, then tighten an
additional 1/12 turn or 1/2 hex flat. A metal-to-metal seal is
now complete.
5
2. Leak-check all braze joints at approximately 80 psi
pressure, purge, and evacuate the lines.
Schrader
valve port
WARNING
DO NOT USE AIR TO LEAK-CHECK BRAZE JOINTS.
DRY NITROGEN SHOULD BE USED TO LEAK-CHECK.
4
Torch
Service
valve
Remove cap
Open valve
Replace cap
Opening the Service Valve (Straight Valve)
NOTE: This is not a back-seating valve.
Brazing rod
Open the valve by using an adjustable wrench to turn the
adjusting flange 1/4 turn counter-clockwise. The flange will
come to a stop and the seal is now complete.
Quenching Cloth
WARNING
6
ALWAYS HAVE A FIRE EXTINGUISHER AVAILABLE
WHEN WORKING WITH AN OPEN FLAME.
Adjusting
flange
ALWAYS USE SAFETY GLASSES, PROTECTIVE
CLOTHING, AND WORK GLOVES.
Open valve
3
Precautions
CONNECT REFRIGERANT PIPING
Refer to the chart below for the minimum recommended tube
outside diameter sizes on liquid and suction lines. Ensure that
vapor and liquid tube diameters are appropriate for unit
capacity. Run refrigerant tubes as directly as possible by
avoiding unnecessary turns and bends.
The following guidelines should be followed when installing
refrigerant piping. Comply with all local, state, and federal
codes and/or regulations pertaining to this type of
equipment and its installation.
1. Run the tubing by the most direct route and support
every few feet. Do not run the lines underground unless
they are in a chase. Leave enough material between
structure and unit to absorb vibration.
Undersized line sets will increase the refrigerant pressure drop
between the indoor evaporator and outdoor unit, resulting in
a decrease in system capacity. Oversizing the line sets may result
in excessive refrigerant charge, thereby making the system
more susceptible to liquid migration.
2. Insulate the vapor line to prevent sweating and line loss.
In underground chases, the vapor line should be
insulated to provide vibration isolation between the
vapor and liquid line. A minimum of 3/8” insulation is
recommended in conditioned space and 1/2” to 3/4” in
unconditioned space. Ensure that tubing insulation is
pliable and completely surrounds vapor tube.
When passing refrigerant tubes through the wall, seal opening
with RTV or other pliable silicon based caulk.
Avoid direct tubing contact with water pipes, duct work, floor
joists, wall studs, floors, and walls.
Do not suspend refrigerant tubing from joists and studs with a
rigid wire or strap which comes in direct contact with tubing.
3. In general, the piping should be sloped toward the
outdoor unit to prevent oil trapping. Where vertical
risers occur, a suction line trap should be located at the
base of the riser to assure proper oil return.
When necessary, use hanger straps which are 1 in. wide and
conform to shape of tubing insulation.
Isolate hanger straps from insulation by using metal sleeves
bent to conform to shape of insulation.
WARNING
Condensing units are available with pre-charged, sweat-type
copper connecting fittings.
REFRIGERANT LINE LENGTH MUST NOT EXCEED 75’ ON
HORIZONTAL RUNS AND 40’ ON VERTICAL RISERS.
Units are factory charged for 15’ of line set tubing.
•
•
•
•
Adjust charge 0.65 oz per foot of variation from chart for
1/4" and 5/8" line set.
Adjust charge 0.66 oz per foot of variation from chart for
3/8” and 3/4” line set.
Adjust charge 0.67 oz per foot of variation from chart for
3/8" and 7/8" line set.
Adjust charge 0.72 oz per foot of variation from chart for
1/2" and 1 1/8" line set.
7
OUTDOOR
SECTION
LIQUID
LINE
LIQUID LINE SIZES
LINE SET LENGTH AND SIZE
CONDENSER
Can only be
20’
MODEL
15 FT
25 FT
50 FT
75 FT*
20’ vertical
NUMBER
LINE SET LINE SET LINE SET LINE SET
separation
without
additional
accessories.
INDOOR
COIL
C18ABD1
C24ABD1
C30ABD1
C36ACD1
C42ACD1
C48ACD1
C60ACD1
3/8”
3/8”
3/8”
3/8”
3/8”
3/8”
1/2”
3/8”
3/8”
3/8”
3/8”
3/8”
3/8”
1/2”
3/8”
3/8”
3/8”
3/8”
3/8”
3/8”
1/2”
3/8”
3/8”
3/8”
3/8”
3/8”
3/8”
1/2”
SUCTION
LINE
WARNING
IF THE INSTALLER IS MAKING UP HIS OWN LINE SETS, HE
MUST MAKE SURE THE TUBING IS CLEAN OF ANY
IMPURITIES OR MOISTURE. USE ONLY CLEAN AIR
CONDITIONING AND REFRIGERATION GRADE SEAMLESS
COPPER TUBING. PLUMBING GRADE COPPER IS
INADEQUATE. TO ENSURE A CLEAN SYSTEM FREE OF ANY
CONTAMINANTS, PURGING WITH DRY NITROGEN AND A
DEEP VACUUM IS NECESSARY ON ALL SWEAT-TYPE
MODELS AND ON THE UNCHARGED PORTIONS OF ALL
MODELS NOT INCORPORATING PRECHARGED LINES. IT IS
DESIRABLE TO PULL A VACUUM TO 1,000 MICRONS (29.96”
HG) TO ENSURE TROUBLE FREE OPERATION.
SUCTION LINE SIZES
LINE SET LENGTH AND SIZE
CONDENSER
MODEL
NUMBER
15 FT
25 FT 50 FT
75 FT*
LINE SET LINE SET LINE SET LINE SET
C18ABD1
C24ABD1
C30ABD1
C36ACD1
C42ACD1
C48ACD1
3/4”
3/4”
7/8”
7/8”
7/8”
7/8”
3/4”
3/4”
7/8”
7/8”
7/8”
7/8”
1 1/8”
3/4”
3/4”
7/8”
7/8”
7/8”
7/8”
1 1/8”
3/4”
3/4”
7/8”
7/8”
1 1/8”
1 1/8”
1 1/8”
C60ACD1 1 1/8”
* DO NOT EXCEED 75 FT MAX LINE SET LENGTH
4
SUB-COOLING CHARGING
OPERATION INSTRUCTIONS
Coils with TXVs should be charged 10-12 degrees (+ or – one
degree) of sub-cooling. For proper sub-cooling readings, a
standard high side gauge is required for pressure readings.
1. If the furnace and air conditioner are on separate
thermostats, turn the furnace thermostat off during the
cooling season to prevent simultaneous operation of the
heating and cooling systems. Reverse the procedure during
the heating season.
Use the chart below to determine the required sub-cooling value.
INSTRUCTIONS
1. Measure the outdoor air temperature. (T1)
2. Measure the liquid line pressure at the outdoor unit and
determine condenser refrigerant temperature by the scale on
the high side pressure gauge. (T2)
3. Measure the liquid line temperature on the liquid line at the
outdoor unit. (T3)
4. Subtract T3 from T2. (T2 – T3) This is the subcooling value.
Compare this value and the outdoor temperature (T1), to the
charts below. If the value is below the line, add refrigerant. If
the value is above the line, remove refrigerant charge.
Adjust thermostat temperature and fan settings according
to the thermostat manufacturer’s recommendations. It is not
recommended to vary the temperature settings more than 5
degrees. Varying the temperature more than 5 degrees or
turning the thermostat off for periods less than 12 hours can
actually cost you more in energy consumption than keeping
the temperature constant. Consider indoor plants and pets
when varying the temperature from the normal comfort
level.
NOTE: For the majority of installations no adjustment to the
TXV setting is required. However, if the measured superheat
at the evaporator is less than 4° or greater than 8° an
adjustment is required. The adjustment stem is at the base of
the valve under the flare nut. To increase superheat tighten
the stem clockwise and to decrease superheat back-out the
stem counter-clockwise. Use a 1/4” refrigeration service
wrench for this function.
2. IMPORTANT: Wait at least 3 minutes after turning the air
conditioner off before trying to restart. If an attempt is
made to start the compressor before the refrigerant
pressures are equalized, the compressor motor may trip on
its overload. An additional waiting period will be required
before restarting.
NOTE: When removing refrigerant, always use standard reclaim
procedures.
MAINTENANCE INSTRUCTIONS
For continuing high performance and to minimize possible
equipment failure, periodic maintenance must be performed on
this equipment. Frequency of maintenance may vary depending
upon geographic areas, such as costal applications.
SUB-COOLING CHART FOR UNITS WITH TXV
WARNING
BE SURE THE UNIT DISCONNECT IS IN THE “OFF”
POSITION AND THAT ALL ELECTRICAL POWER TO THE
UNIT IS TURNED “OFF” BEFORE CLEANING THE SYSTEM.
1. Keep the condenser (outdoor coil) clean. Wash it down with
a garden hose if necessary.
WARNING
SERIOUS PERSONAL INJURY OR DEATH MAY RESULT IF
WATER SPRAY IS DIRECTED TOWARD LIVE ELECTRICAL
CONNECTIONS OR POWER SOURCES.
2. Remove any loose grass, leaves, papers, etc., from the area
around the condenser coil. These could reduce the air supply
through the coil and reduce the amount of cooling.
°F
°F
°F
°F
°F
°F
3. Always install and keep system filters clean. Consult your
licensed Contractor for filter replacement schedules and
instructions.
FINAL CHECKS FOR INSTALLER
1. Ensure that all wiring is routed away from tubing and sheet
metal edges to prevent rub-through or wire pinching.
2. Ensure that all wiring and tubing is secure in unit before
adding panels and covers.
3. Tighten service valve stem caps to 1/12 turn past finger tight.
4. Leave Owner’s Manual with owner. Explain system operation
and periodic maintenance requirements outlined in manual.
5
CONDENSING UNIT
NOMENCLATURE
A B D
C 24
1
V F
Poduct Type
Brand
C = Air Conditoner
F= Fedders
CH = Heat Pump
Fitting Type
V = Sweat
Nominal Capacity
18 = 18000 BTU/H [5.28 kW]
24 = 24000 BTU/H [7.03 kW]
30 = 30000 BTU/H [8.79 kW]
36 = 36000 BTU/H [10.55 kW]
42 = 42000 BTU/H [12.31 kW]
48 = 48000 BTU/H [14.07 kW]
60 = 60000 BTU/H [17.5 kW]
Electrical Designation
1 = 208/230 Volts, 1 Phase, 60 Hz
2 = 230 Volts, 1 Phase, 50 Hz
3 = 208/230 Volts, 3 Phase, 60 Hz
4 = 460 Volts, 3 Phase, 60 Hz
5 = 230 Volts, 3 Phase, 50 Hz
6 = 380 Volts, 3 Phase, 50 Hz
Series
A
Variations
D = R-22 Refrigerant
Z = R-410A Refrigerant
Chassis Size
B = 21 1/2” W x 21 1/2” D x H
C = 29 1/2” W x 29 1/2” D x H
6
LIMITED WARRANTY
LIMITED FIVE YEAR WARRANTY:
Fedders will provide a replacement part or component
that proves to be defective in material or workmanship.
THIS WARRANTY DOES NOT COVER DAMAGE CAUSED BY:
• Improper installation
• Misuse of equipment
WARRANTY LIMITATIONS:
• Negligent servicing
• Limited Warranty does not include allowances for labor
or travel expense connected with the installation of
parts, so furnished in this Limited Warranty or for field
repair, or servicing of the equipment, nor for
refrigerant used
• Improper applications
• Preventative maintenance
• Unauthorized modifications
• Improper electrical supply
• Failure to follow manufacturer’s instructions and rating plate
information
• Accidents or other events beyond FEDDERS’ control
ENTIRE WARRANTY:
• For warranty purposes the purchase date is established
by a proof of purchase. If a proof of purchase can not
be verified, then warranty period will be measured
from the date of manufacture plus 6 months.
• Cost of repair or replacement of consumable parts is
not covered under the terms of this warranty
THE ABOVE CONTAINS THE SOLE AND EXCLUSIVE
STATEMENT OF THE EXPRESS WARRANTIES AND
ASSOCIATED REMEDIES AVAILABLE WITH THE
• Replacement parts are warranted only for the balance
of the original warranty period
PRODUCTS
DESCRIBED.
NO
OTHER
EXPRESS
WARRANTIES ARE MADE. ALL IMPLIED WARRANTIES,
INCLUDING BUT NOT LIMITED TO ANY IMPLIED
WARRANTY OF MERCHANTABILITY OR FITNESS FOR A
PARTICULAR PURPOSE, OR IMPLIED WARRANTIES
OTHERWISE ARISING FROM COURSE OF DEALING OR
USAGE OF TRADE ARE LIMITED IN DURATION TO ONE
YEAR FROM THE DATE OF ORIGINAL PURCHASE. IN NO
EVENT SHALL FEDDERS BE LIABLE FOR ANY INDIRECT,
INCIDENTAL OR CONSEQUENTIAL DAMAGES, EVEN IF
ADVISED IN ADVANCE OF THE POSSIBILITY OF SUCH
DAMAGES. NO WARRANTIES, EXPRESS OR IMPLIED,
ARE MADE TO ANY BUYER UPON RESALE.
SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG
AN IMPLIED WARRANTY LASTS OR DO NOT ALLOW THE
EXCLUSION OR LIMITATION OF INCIDENTAL OR
CONSEQUENTIAL DAMAGES, SO THE ABOVE LIMITATIONS
MAY NOT APPLY TO YOU. THIS WARRANTY GIVES YOU
SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER
RIGHTS, WHICH MAY VARY FROM STATE TO STATE. NO
WARRANTIES ARE MADE FOR UNITS SOLD OUTSIDE THE
ABOVE STATED AREAS. YOUR DISTRIBUTOR OR FINAL
SELLER MAY PROVIDE A WARRANTY ON UNITS SOLD
OUTSIDE OF THESE AREAS.
• Applies only to original installation and normal use and
service within the 48 contiguous United States, District
of Columbia and Canada
• Applies to service performed by an authorized servicer.
WARRANTY IS VOID IF:
• Serial plate is defaced
• Product has defect or damage due to product
alteration, connection to an improper electrical supply,
shipping and handling, fire, flood, lightning or other
conditions beyond the control of Fedders
• Product is not installed according to Fedders’
instructions and specifications
• Product is operated in a corrosive environment
containing concentrations of corrosive agents causing
deterioration of components
• Product is operated with indoor unit or refrigerant
control device that does not meet Fedders’
specifications
• Product is moved from original installation site
OWNER’S RESPONSIBILITIES:
• Provide proof of purchase (sales receipt)
• Provide normal care and maintenance as outlined in
installation and operation manual
• Make product reasonably accessible for service
• Pay for freight, labor and travel expenses
• Pay for premium service costs for service outside
servicer’s normal business hours
• Pay for service calls related to product installation and
maintenance
The information in this manual supersedes and replaces the previous instruction/operation manual. Illustrations cover the general
appearance of the units at the time of publication and the manufacturer reserves the right to make changes in design and
construction at any time without notice.
For replacement parts please, consult the installing dealer or contractor.
Fedders Corporation
505 Martinsville Rd.
Liberty Corner, NJ 07938
REV. 8/06
23-23-0418N-013
7
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