Fedders AC1A024A, AC1A036A, AC1A030A, AC1A042A, AC1A060A Installation, Operation And Maintenance Manual

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Installation, Operation and Maintenance
Cased Evaporator Coils
Upflow/Downflow
TABLE OF CONTENTS
RECOGNIZE SAFETY SYMBOLS, WORDS AND LABELS ................2
NOTES TO INSTALLER ....................................................................2
INTRODUCTION ..............................................................................3
INSTALLATION
Codes..................................................................................2
Installation of Evaporator Coils........................................3
Connect Refrigerant Piping ..............................................3
Factory and Field Installed Expansion Valves..................3
Condensate Drain Plumbing ............................................4
Heater Exchange Clearance..............................................4
CHECK AND ADJUST AIRFLOW ....................................................5
Static Pressure Drop Chart................................................5
Adjusting Airflow..............................................................5
COIL NOMENCLATURE ..................................................................6
SPECIFICATIONS..............................................................................6
DIMENSIONS ..................................................................................6
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.
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RECOGNIZE SAFETY SYMBOLS, WORDS AND LABELS
hat You Need To Know About Safety Instructions
W
Warning and Important Safety Instructions appearing in this manual are not meant to cover all possible conditions and situations that may occur. Common sense, caution and care must be exercised when operating or cleaning tools and equipment.
lways contact your dealer, distributor, service agent or
A manufacturer about problems or conditions you do not understand.
This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.
DANGER
DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
WARNING
WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION
CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.
CAUTION
CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in property damage.
WARNING
MPROPER INSTALLATION, ADJUSTMENT,
I ALTERATION, SERVICE OR MAINTENANCE CAN CAUSE INJURY, PROPERTY DAMAGE OR LOSS OF LIFE. READ THIS MANUAL COMPLETELY BEFORE BEGINNING ANY WORK AND FOLLOW ALL SAFETY PRECAUTIONS.
A QUALIFIED INSTALLER MUST PERFORM INSTALLATION AND SERVICE.
DO NOT DESTROY THIS MANUAL. PLEASE READ CAREFULLY AND KEEP IN A SAFE PLACE FOR FUTURE REFERENCE BY A SERVICE TECHNICIAN.
THESE INSTRUCTIONS ARE INTENDED AS AN AID TO QUALIFIED SERVICE PERSONNEL FOR PROPER INSTALLATION, ADJUSTMENT AND OPERATION OF THIS COMPONENT. READ THESE INSTRUCTIONS THOROUGHLY BEFORE ATTEMPTING INSTALLATION OR OPERATION. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN IMPROPER INSTALLATION, ADJUSTMENT, SERVICE OR MAINTENANCE, POSSIBLY RESULTING IN FIRE, ELECTRICAL SHOCK, PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.
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, DAMAGE TO EQUIPMENT, OR DEATH.
DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS AND LIQUIDS, OR OTHER COMBUSTIBLE MATERIALS IN THE VICINITY OF THIS COIL OR ANY OF ITS MATCHING SYSTEM COMPONENTS (CONDENSING UNIT, HEAT PUMP, OR FURNACE).
NOTES TO INSTALLER
The words “SHALL” and “MUST” indicate a requirement which is essential to satisfactory and safe product performance. The words “SHOULD” and “MAY” indicate a recommendation or advice which is not essential and not required but which may be useful or helpful.
Installation and service personnel are required by some locales to be licensed. Persons not qualified SHALL NOT install this equipment nor interpret these instructions.
This installation and maintenance manual is provided to ensure the proper installation and the most satisfactory performance of the equipment. The instructions contained herein SHALL NOT be deemed to extend, modify, alter or expand any of the representations contained in the limited warranty.
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INTRODUCTION
Return
R
eturn
Supply
Supply
Downflow F
urnace
Evaporator Coil
Evaporator C
oil
Upflow Furnace
8 o’cl
4 o’clock8 o’clock
his manual is intended as an aid to qualified HVAC installers
T
uring the installation of Fedders Cased Coils on upflow or
d downflow furnaces. Do not install coil in horizontal position (see illustration below).
INSPECTION AND UNPACKING
A thorough inspection of the shipping container should be made immediately upon receiving your unit. Look for any punctures or openings, and if it appears damage has occurred, it should be noted on the freight bill before signing. The delivering carrier should be contacted immediately to inspect damage, and no installation work should begin until this inspection is completed.
nstallation of Evaporator Coils
I
he cased coil is designed to fit Fedders furnaces the same
T width.
1. Set coil on upflow furnace discharge air opening.
2. Ensure coil is level for proper condensate drainage. o not tip coil toward condensate drain.
D
3. When installing wider coil on narrow furnace, use a
field supplied adapter.
4. When installing narrow coil on wide furnace, create
ield fabricated adapter. Consult your dealer for
f
lternate installation instructions.
a
NOTE: In downflow position installation with Fedders furnace, break off perforated duct flange on coil/furnace.
Connect Refrigerant Piping
Use field supplied tubing of refrigerant grade. Suction tube must be insulated. Do not use damaged, dirty, or contaminated tubing because it may plug refrigerant flow control device. ALWAYS evacuate the coil and field supplied tubing before opening outdoor unit service valves.
Factory and Field-Installed Expansion Valves
1. The bulb and capillary tubing should be routed outside
of the case. Make sure the capillary tube will not contact any sharp edges of the case. On factory installed expansion valves, the adjustable sensing bulb is not permanently installed onto the coils’ vapor line in order to allow easy removal during installation.
Sensing bulb attached with clamps
INSTALLATION
Codes
The installer codes and/or regulations pertaining to this type of equipment and its installation. Such codes and/or regulations should take precedence over any recommendations contained herein. Installations SHALL be made in accordance with the National Electrical Code, local codes and recommendations made by the National Board of Fire Underwriters. Consult local building codes and National Electrical Code (NEC) for special requirements.
EXTERIOR SURFACE COIL HOUSING MAY SWEAT WHEN UNIT IS INST AS AN ATTIC OR GARAGE. THE INSTALLER MUST INSULATE THE CABINET WITH 1” FIBERGLASS INSULA
SHALL comply with all local, state, and federal
CAUTION
ALLED IN NON-CONDITIONED SPACE SUCH
TION.
Vapor line
Attach bulb to vapor line at four or eight o’clock position
CAUTION
THE TXV SENSING BULB CAN BE DAMAGED BY EXTREME HEAT FROM BRAZING. THE BULB SHOULD BE REMOVED BEFORE PERFORMING ANY BRAZING PROCEDURE AND NOT INSTALLED UNTIL AFTER THE VAPOR AND LIQUID LINES ARE BRAZED AND LEAK CHECKED.
CAUTION
THE TXV VALVE CAN BE DAMAGED BY EXTREME HEAT. PROPER PRECAUTIONS SHOULD BE TAKEN TO AVOID OVERHEATING THE TXV VALVE AND CAUSING DAMAGE TO THE INTERNAL COMPONENTS.
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Factory and Field-Installed Expansion Valves (cont.)
U
NIT
F
LEXIBLE
T
UBING-HOSE
O
R PIPE
DRAIN
CONNECTION
A POSITIVE LIQUID SEAL IS REQUIRED
2” MINIMUM
3” MINIMUM
2. To assure accurate sensing and the best performance, the bulb should be placed on the upper half of the vapor line at the four or eight o’clock position and at least 6” from the coil manifold.
ARNING
W
LWAYS HAVE A FIRE EXTINGUISHER AVAILABLE
A
HEN WORKING WITH AN OPEN FLAME.
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ALWAYS USE SAFETY GLASSES, PROTECTIVE CLOTHING, AND WORK GLOVES.
ondensate Drain Plumbing
C
Coils are provided with two 3/4” female pipe drain fittings, and an emergency drain fitting. Do not over tighten these fittings; it could result in damage to the drain pan.
WARNING
For downflow, or any installation where condensate overflow could create a hazard or water damage, the emergency drain fitting MUST be used. The emergency drain MUST be left open. If the emergency drain has to be piped away from the air handler, its outlet MUST be installed in a location that would allow any drainage to be immediately noticed.
Install condensate drain trap as close to the coil as possible. Use drain connection size or larger. Do not operate unit without trap (see illustration below). Unit must be level or slightly inclined toward drain.
Condensate drain trap
TXV valve can be accessed through the valve cover-plate on the front of the casing.
3. Attach the bulb securely with the copper strap provided.
4. Insulate the bulb thoroughly with a suitable insulation material such as cork tape.
5. Coils with TXVs should be charged 10-12 degrees (+ or – one degree) of sub-cooling. This supercedes any subcooling value listed with condensing unit’s literature.
For the majority of installations no adjustment to the TXV setting is required. However
, if the measured superheat 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.
NOTE: When r
eclaim pr
r
ocedures.
emoving r
efrigerant, always use standar
d
Heat Exchanger Clearance
For gas furnace applications, refer to furnace installation instructions for proper heat exchanger clearance.
CAUTION
1. Do not connect the drain line to a closed sewer.
2. Never terminate an open sewer or drain connection within the return air duct, platform, or return plenum.
3. Pitch the drain line at least 1/4” per foot away from the drain pan.
4. If condensate drain connection is on the negative side of the blower, a trap must be installed to ensure positive drainage.
Condensate drain lines should not be reduced in size
5. from the connection size supplied.
The drain line should be insulated where necessary
6. prevent sweating and damage due to condensate forming on the outside surface of the line.
est condensate drain line with water before operating
7. T system.
8. If unit is located in or above a living space where damage may result from condensate overflow, a field supplied, external condensate pan should be installed under the entire unit, and a secondary condensate line (with appropriate trap) should be run from the unit into the pan. Any condensate in this external condensate pan should be drained to a noticeable place. As an alternative to using an external condensate pan, some localities may allow the running of a separate 3/4 inch condensate line (with appropriate trap) per local code to a place where the condensate will be noticeable.
, to
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CHECK AND ADJUST AIRFLOW
Check that the correct amount of air is flowing through the
oil by measuring the pressure drop using an air flow gauge.
c
hecking Static Drop Across Coil
C
. The coil should be dry and clean. The air filter must be
1
lean and all registers open. Do not run the condensing
c unit when checking air flow.
2. Run the Blower on cooling speed.
3. Set the blower motor speed-belt drive or direct drive to the nominal CFM required across coil and the dry coil static reading. See chart below.
MODEL
INDOOR
CASED COILS
600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900
AC1A024A .10 .11 .12 .13
AC1A030A .15 .17 .19 .21
AC1A036A .19 .20 .22 .23 .24
AC1A042A .15 .17 .18 .21
AC1A060A .21 .23 .23
Adjusting Air Flow
If gauge reading is below the required pressure, increase blower speed until reading is the same or slightly above the required pressure.
If the gauge reading is above required pressure, decrease the blower speed.
Refer to instructions included with your furnace or blower for directions on changing blower speed.
NOTE: You may not be able to obtain a gauge reading exactly the same as the required pressure due to variations in duct systems and blower speeds.
A slightly high reading is acceptable.
A low reading will indicate conditions that could cause a freeze up. This will shorten compressor life. Too much air will result in poor humidity control and overheating of the compressor. It may cause tripping of the compressor overload.
If you are using a belt driven blower, use an ammeter to check the motor current draw motor name plate amps, replace the motor with one with greater horsepower
. If the current draw is higher than the
.
THROUGH DRY COIL* & HOUSING (INCHES WATER COLUMN / CFM)
STATIC PRESSURE DROP
* Dry coil static shown. Increase static by 20% for wet coil static.
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14 = 14.5” Casing Width 1
6 = 16” Casing Width 17 = 17.5” Casing Width 20 = 20.5” Casing Width 22 = 22” Casing Width
C
A = First Revision
Major Revision
024 = 18,000/24000 BTU/H [5.28/7.03 kW] 030 = 30,000 BTU/H [8.79 kW] 036 = 36,000 BTU/H [10.55 kW] 042 = 42,000 BTU/H [12.31 kW] 060 = 60,000 BTU/H [17.5 kW]
Nominal Capacity
C = Cased Coil S = Slab Coil
Case Designation
1 = Upflow/Downflow
Position
A = A Series
Design Series
A C1 A 036 A 14
A = Fedders Coil
Brand Coil
14 = 14.5” Casing Width 16 = 16” Casing Width 17 = 17.5” Casing Width 20 = 20.5” Casing Width 22 = 22” Casing Width
Casing Width
A = First Revision
Major Revision
024 = 18,000/24,000 BTU/H [5.28/7.03 kW] 0
30 = 30,000 BTU/H [8.79 kW] 036 = 36,000 BTU/H [10.55 kW] 042 = 42,000 BTU/H [12.31 kW] 060 = 60,000 BTU/H [17.5 kW]
Nominal Capacity
C = Cased Coil
Case Designation
1 = Upflow/Downflow
Position
A = A Series
Design Series
COIL NOMENCLATURE
SPECIFICATIONS
MODEL
INDOOR
CASED COILS
AC1A024A 14.5, 16 600 - 900 3/8 3/4
AC1A030A 14.5, 16, 17.5, 20.5 800 - 1,250 3/8 7/8
AC1A036A 14.5, 16, 17.5, 20.5 1,000 - 1,400 3/8 7/8
AC1A042A 17.5, 20.5 1,300 - 1,500 3/8 7/8
AC1A060A 20.5, 22 1,400 - 1,900 3/8 7/8
CASED COIL DIMENSIONS
Model Number Width Height Depth
AC1A024A14 14.5” 20.0” 21” AC1A030A14 AC1A036A14 14.5” 20.5” 21” AC1A024A16 16” 18.5” 21” AC1A030A16 16” AC1A036A16 16” 18.5” 21” AC1A030A17 17.5” 18.5” 21” AC1A036A17 17.5” AC1A042A17 17.5” 23.5” 21” AC1A060A17 17.5” 22.5” 24” AC1A030A20 20.5” AC1A036A20 20.5” 18.5” 21” AC1A042A20 20.5” 22.5” 21” AC1A060A20 AC1A060A22 22” 22.5” 24”
FLUSH FIT TO
FURNACE WIDTH
14.5” 20.0” 21”
18.5” 21”
18.5” 21”
18.5” 21”
20.5”
22.5” 24”
DESIGN CFM
RANGE
LINE CONNECTIONS O.D.
LIQUID LINE
SUCTION
LINE
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LIMITED WARRANTY
LIMITED FIVE YEAR WARRANTY:
Fedders will provide a replacement part or component that proves to be defective in material or workmanship.
ARRANTY LIMITATIONS:
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• Limited Warranty does not include allowances for labor r travel expense connected with the installation of
o
arts, so furnished in this Limited Warranty or for field
p
epair, or servicing of the equipment, nor for
r refrigerant used
• 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
• Replacement parts are warranted only for the balance
of the original warranty period
• 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
THIS WARRANTY DOES NOT COVER DAMAGE CAUSED BY:
Improper installation
• Misuse of equipment
• Negligent servicing
• Improper applications
• Preventative maintenance
• Unauthorized modifications Improper electrical supply
• Failure to follow manufacturer’s instructions and rating plate
nformation
i
• Accidents or other events beyond Fedders’ control
ENTIRE WARRANTY:
THE ABOVE CONTAINS THE SOLE AND EXCLUSIVE STATEMENT OF THE EXPRESS WARRANTIES AND ASSOCIATED REMEDIES AVAILABLE WITH THE 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.
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The information in this manual supersedes and replaces the previous instruction/operation manual with regards to Air Handler products. 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. 3/07 23-23-0451N-004
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