Fedders Split System Air Conditioner User Manual

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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