Carrier WeatherMaster 48HC04 Series Installation Instructions Manual
Single package rooftop
gas heating/electric cooling unit with puron (r-410a) refrigerant
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Also See for WeatherMaster 48HC04 Series:
- Service and maintenance instructions (148 pages)
Table of Contents
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CONTENTS
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . 1
Rated Indoor Airflow . . . . . . . . . . . . . . . . . . . . . . . . . . 3
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Jobsite Survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Step 1 - Plan for Unit Location . . . . . . . . . . . . . . . . . 7
Step 3 - Inspect Unit . . . . . . . . . . . . . . . . . . . . . . . . . 7
Step 4 - Provide Unit Support . . . . . . . . . . . . . . . . . . 7
Step 5 - Field Fabricate Ductwork . . . . . . . . . . . . . . 9
Step 6 - Rig and Place Unit . . . . . . . . . . . . . . . . . . . . 9
Ductwork (When Required). . . . . . . . . . . . . . . . . . 10
Step 8 - Install Outside Air Hood . . . . . . . . . . . . . . 11
Step 9 - Units with Hinged Panels Only . . . . . . . . . 12
Step 10 - Install Flue Hood . . . . . . . . . . . . . . . . . . . 12
Step 11 - Install Gas Piping. . . . . . . . . . . . . . . . . . . 13
Step 13 - Make Electrical Connections . . . . . . . . . 15
Economi$er® X (Factory Option) . . . . . . . . . . . . . . . 29
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Catalog No. 04-53480191-01
Installation Instructions
Printed in U.S.A.
Form 48HC-4-6-02SI
48HC04-06 Single Package Rooftop
Gas Heating/Electric Cooling Unit
with Puron
®
PremierLink™ (Factory Option). . . . . . . . . . . . . . . . .39
Smoke Detectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Step 14 - Adjust Factory-Installed Options . . . . . .41
Step 15 - Install Accessories . . . . . . . . . . . . . . . . . .41
Step 16 - Check Belt Tension . . . . . . . . . . . . . . . . .41
Pre-Start and Start-Up . . . . . . . . . . . . . . . . . . . . . . . .42
START-UP CHECKLIST . . . . . . . . . . . . . . . . . . . . .CL-1
SAFETY CONSIDERATIONS
Improper
installation,
maintenance, or use can cause explosion, fire, electrical shock
or other conditions which may cause personal injury or
property damage. Consult a qualified installer, service agency,
or your distributor or branch for information or assistance. The
qualified installer or agency must use factory-authorized kits or
accessories when modifying this product. Refer to the
individual instructions packaged with the kits or accessories
when installing.
Follow all safety codes. Wear safety glasses and work gloves.
Use quenching cloths for brazing operations and have a fire
extinguisher available. Read these instructions thoroughly and
follow all warnings or cautions attached to the unit. Consult
local building codes and appropriate national electrical codes
(in USA, ANSI/NFPA70, National Electrical Code (NEC); in
Canada, CSA C22.1) for special requirements.
It is important to recognize safety information. This is the
safety-alert symbol
. When you see this symbol on the unit
and in instructions or manuals, be alert to the potential for
personal injury.
Understand the signal
CAUTION, and NOTE. These words are used with the safety-
alert symbol. DANGER identifies the most serious hazards
which will result in severe personal injury or death.
WARNING signifies hazards which could result in personal
injury or death. CAUTION is used to identify unsafe practices,
which may result in minor personal injury or product and
property damage. NOTE is used to highlight suggestions
Pg 1
1-19
WeatherMaster
(R-410A) Refrigerant
adjustment,
alteration,
words
DANGER, WARNING,
Replaces: 48HC-4-6-01SI
®
service,
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Table of Contents
Related Manuals for Carrier WeatherMaster 48HC04 Series
Summary of Contents for Carrier WeatherMaster 48HC04 Series
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Page 1: Table Of Contents
® WeatherMaster 48HC04-06 Single Package Rooftop Gas Heating/Electric Cooling Unit with Puron ® (R-410A) Refrigerant Installation Instructions • SYSTEM COMPONENTS CONTENTS • SPECIFICATIONS SAFETY CONSIDERATIONS ....1 •... - Page 2 which will result in enhanced installation, reliability, or AVERTISSEMENT operation. RISQUE D’INTOXICATION AU MONOXYDE DE WARNING CARBONE Si ces directives ne sont pas suivies, cela peut entraîner des Electrical shock can cause personal injury and death. Shut off blessures graves ou une intoxication au monoxyde de all power to this equipment during installation.
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Page 3: Model Number Nomenclature And Dimensions
MODEL NUMBER NOMENCLATURE AND DIMENSIONS See Fig. 1 for 48HC model number nomenclature. See Fig. 2 for unit dimensional drawings. Figure 3 shows service clear- ance dimensions. Rated Indoor Airflow Table 1 lists the rated indoor airflow used for the AHRI effi- ciency rating for the units covered in this document. - Page 4 Position: 9 10 11 12 13 14 15 16 17 18 Example: Unit Heat Type Factory Assigned 48 - Gas Heat Packaged Rooftop 0 = Standard 1 = LTL Model Series - WeatherMaster ® Electrical Options HC - High Efficiency A = None B = HACR Breaker Heat Options...
- Page 5 Vertical Connections / Economizer Horizontal Connections / Economizer Fig. 2 — 48HC 04-06 Unit Dimensional Drawing...
- Page 6 Fig. 2 — 48HC 04-06 Unit Dimensional Drawing (cont) LOCATION DIMENSION CONDITION 48 in. (1219 mm) Unit disconnect is mounted on panel 18 in. (457 mm) No disconnect, convenience outlet option 18 in. (457 mm) Recommended service clearance 12 in. (305 mm) Minimum clearance 40 in.
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Page 7: Installation
INSTALLATION Step 2 — Plan for Sequence of Unit Installation The support method used for this unit will dictate different se- Jobsite Survey quences for the steps of unit installation. For example, on curb- Complete the following checks before installation. mounted units, some accessories must be installed on the unit Consult local building codes and the NEC (National Elec- before the unit is placed on the curb. - Page 8 Fig. 4 — Roof Curb Details...
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Page 9: Slab Mount (Horizontal Units Only)
Curb should be level. This is necessary for unit drain to function Step 5 — Field Fabricate Ductwork properly. Unit leveling tolerances are shown in Fig. 5. Refer to Cabinet return-air static pressure (a negative condition) shall Accessory Roof Curb Installation Instructions for additional in- not exceed 0.35 in. -
Page 10: Positioning On Curb
"B" 36"- 54" DETAIL "A" PLACE ALL SEAL STRIP IN PLACE REQUIRED (914-1371) BEFORE PLACING UNIT ON ROOF CURB. SPREADER BARS DUCT END "C" "A" SEE DETAIL "A" DIMENSIONS MAX WEIGHT UNIT 48HC-A04 74.5 1890 38.0 33.5 48HC-A05 74.5 1890 38.0 41.5 1055... -
Page 11: Step 8 - Install Outside Air Hood
Step 8 — Install Outside Air Hood REMOVABLE HORIZONTAL RETURN DUCT OPENING COVER ECONOMIZER AND TWO POSITION DAMPER HOOD PACKAGE REMOVAL AND SETUP (FACTORY OPTION) NOTE: Economizer and two position damper are not available as factory-installed options for single phase (-3 voltage code) models. -
Page 12: Economizer And Two-Position Hood
ECONOMIZER AND TWO-POSITION HOOD NOTE: If the power exhaust accessory is to be installed on the unit, the hood shipped with the unit will not be used and must be discarded. Save the aluminum filter for use in the power exhaust hood assembly. -
Page 13: Step 11 - Install Gas Piping
kit installation instructions for details on these installation Step 11 — Install Gas Piping methods. Observe clearance to gas line components per Installation of the gas piping must be accordance with local Fig. 17. building codes and with applicable national codes. In U.S.A., refer to NFPA 54/ANSI Z223.1 National Fuel Gas Code (NF- GC). - Page 14 9” (229mm) MIN BURNER ACCESS PANEL UNION THRU-CURB ADAPTER BRASS FITTING SUPPORT EMBOSSMENT FOR 3-6 TON UNITS BRACKET Fig. 19 — Gas Line Piping for 3 to 5 Ton Units Only UNIT BASE RAIL Other hardware required to complete the installation of the gas supply line includes a manual shutoff valve, a sediment trap (drip leg) and a ground-joint union.
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Page 15: Step 12 - Install External Condensate Trap And Line
NOTE: Pressure test the gas supply system after the gas supply piping is connected to the gas valve. The supply piping must be disconnected from the gas valve during the testing of the piping systems when test pressure is in excess of 0.5 psig (3450 Pa). Pres- sure test the gas supply piping system at pressures equal to or less than 0.5 psig (3450 Pa). -
Page 16: Units With Factory-Installed Non-Fused Disconnect Or Hacr
your area.) If a de-energize via unit disconnect switch operation of the convenience outlet is desired, connect the source leads to the load side of the unit disconnect. On a unit without a unit- mounted disconnect, connect the source leads to compressor ELECTRIC contactor C and indoor fan contactor IFC pressure lugs with unit DISCONNECT... -
Page 17: Units Without Factory-Installed Non-Fused Disconnect Or Hacr
Fig. 31 — HACR Handle and Shaft Assembly Fig. 29 — NFD Handle and Shaft Assembly UNITS WITHOUT FACTORY-INSTALLED NON-FUSED Field-Install the HACR Shaft and Handle DISCONNECT OR HACR Remove unit front panel (see Fig. 2). When installing units, provide a disconnect switch per NEC Remove (3) hex screws on the HACR enclosure - (2) on (National Electrical Code) of adequate size. -
Page 18: Convenience Outlets
CONVENIENCE OUTLETS Loosen the two screws at the GFCI duplex outlet, until approximately -in. (13 mm) under screw heads is exposed. Press the gasket over the screw heads. WARNING Slip the backing plate over the screw heads at the keyhole ELECTRICAL OPERATION HAZARD slots and align with the gasket;... -
Page 19: Hacr Amp Rating
Fig. 35 — Convenience Outlet Utilization Notice Label HACR AMP RATING The amp rating of the HACR factory-installed option is based on the size, voltage, indoor motor and other electrical options of the unit as shipped from the factory. If field-installed acces- sories are added or changed in the field (for example, power exhaust, ERV), the HACR may no longer be of the proper amp rating and therefore will need to be removed from the unit. -
Page 20: Units Without Thru-Base Connections (Electrical Connections)
Pull the wires over to Link™ controller (available as factory-installed option or as the terminal strip on the upper-left corner of the Controls Con- field-installed accessory, for use on a Carrier Comfort Net- nection Board. See Fig. 38. work or as a stand alone control) or the RTU Open Controller ®... -
Page 21: Heat Anticipator Settings
This device may be a separate humidistat control (contact Route the Thermidistat multi-conductor thermostat cable closes on rise in space RH above control setpoint) or a combi- (field-supplied) through the hole provided in the unit cor- nation thermostat-humidistat control device such as Carrier’s ner post. Edge ®... - Page 22 ® Fig. 41 — Typical Humidi-MiZer Adaptive Dehumidification System Humidistat Wiring EDGE Pro THERMIDISTAT Unit CTB THERMOSTAT O/W2/B SRTN Humidi-MiZer™ FIOP *Connection not required. Fig. 42 — Typical Rooftop Unit with Humidi-MiZer Adaptive Dehumidification System ® and Edge Pro Thermidistat Device...
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Page 23: Low Ambient Control (Factory Option)
LOW AMBIENT CONTROL (FACTORY OPTION) the unit is controlled through a room thermostat set for “fan au- to,” 45 seconds after ignition occurs, the indoor fan motor will If the unit comes with Electro-Mechanical (EM) control, then energize, and the outdoor air dampers will open to their mini- no adjustment is necessary. - Page 24 LOCKING TAB CONNECTOR OVERCURRENT FUSE PROTECTION LOCKING REDUNDANT GAS TAB CONNECTOR VALVE RELAY SPADE CONNECT IGNITOR Fig. 44 — IGC Board Component Layout Fig. 45 — Typical IGC Control Wiring Diagram Fig. 46 — 48HC Control Box Component Locations with ComfortLink Controls...
- Page 25 Fig. 47 — ComfortLink Control Wiring Diagram (48HC 3-5 Ton Units)
- Page 26 ® Fig. 48 — 48HC ComfortLink with Humidi-MiZer — Power Wiring Diagram, 208/230-1-60...
- Page 27 ® Fig. 49 — 48HC ComfortLink with Humidi-MiZer — Power Wiring Diagram, 208/230, 460-3-60...
- Page 28 Fig. 50 — 48HC ComfortLink with Humidi-MiZer ® — Power Wiring Diagram, 575-3-60...
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Page 29: Economi$Er X (Factory Option)
User Interface ® Economi$er X (Factory Option) Provides status for normal operation, setup parameters, check- The EconoMi$er X system is an expandable economizer con- out tests, and alarm and error conditions with a 2-line 16 char- trol system, which includes a W7220 economizer module (con- acter LCD display and four button keypad. -
Page 30: Economizer Module Wiring Details
Storage Temperature Table 6 — Economizer Module - Left Hand Terminal –40°F to 150°F (–40°C to 65°C) Blocks Shipping Temperature LABEL TYPE DESCRIPTION –40°F to 150°F (–40°C to 65°C) Top Left Terminal Block Relative Humidity 20k NTC Mixed Air Temperature Sensor (Polarity 5% to 95% RH non-condensing and COM Insensitive Connection) -
Page 31: Interface Overview
SENSOR (HOT) BLACK YELLOW ANALOG BROWN – ORANGE GREEN SWITCH POWER SUPPLY. PROVIDE DISCONNECT LABEL MEANS AND OVERLOAD PROTECTION AS REQUIRED. Fig. 54 — CO Sensor Wiring SWITCHES INTERFACE OVERVIEW This section describes how to use the EconoMi$er ® user inter- face for: •... -
Page 32: Setup And Configuration
Press the (Enter) button to display the value of the • CHECKOUT currently displayed item. • ALARMS Press the ▲ button to increase (change) the displayed NOTE: Some parameters in the menus use the letters MA or parameter value. MAT, indicating a mixed air temperature sensor location before Press the ▼... - Page 33 Table 10 — W7220 Menu Structure* (cont) PARAMETER PARAMETER EXPANDED PARAMETER NAME MENU PARAMETER DEFAULT RANGE AND Notes VALUE INCREMENT † OUTSIDE AIR RELATIVE HUMIDITY Displays measured value of outdoor humidity from OA Sylk Bus OA HUM _ _ % 0 to 100% sensor.
- Page 34 Table 10 — W7220 Menu Structure* (cont) PARAMETER PARAMETER EXPANDED PARAMETER NAME MENU PARAMETER DEFAULT RANGE AND Notes VALUE INCREMENT † VENTILATION MINIMUM POSITION MIN POS 2.8 V 2 to 10 vdc Displays ONLY if a CO sensor is NOT connected. DCV MAXIMUM DAMPER POSITION Displays only if a CO sensor is connected.
- Page 35 Table 10 — W7220 Menu Structure* (cont) PARAMETER PARAMETER EXPANDED PARAMETER NAME MENU PARAMETER DEFAULT RANGE AND Notes VALUE INCREMENT † 1000 to 3000 ppm; ppm span to match CO sensor; e.g.: 500-1500 sensor CO2 SPAN 2000ppm Increment by 50 output would be 500 CO zero and 1000 CO span.
- Page 36 Table 10 — W7220 Menu Structure* (cont) PARAMETER PARAMETER EXPANDED PARAMETER NAME MENU PARAMETER DEFAULT RANGE AND Notes VALUE INCREMENT † OA SYLK T ERR OUTSIDE AIR S-BUS SENSOR ERROR Outdoor air enthalpy sensor has failed or become disconnected - OA SYLK H ERR check wiring, then replace sensor if the alarm continues.
- Page 37 Table 11 — Damper Minimum Position Settings and Readings on Checkout Menu DEMAND CONTROLLED VENTILATION FAN SPEED SETPOINTS CHECKOUT SENSOR) MIN POS VMAX–HS VENT MIN VMAX–HS VENT MAX VMAX–HS Table 12 — Dry Bulb Operation without DCV (CO Sensor) — 1 Speed Fan DEMAND OUTSIDE AIR CONTROLLED...
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Page 38: Enthalpy Settings
Table 15 — Enthalpy Operation with DCV (CO Sensor) — 1 Speed Fan DEMAND OUTSIDE AIR CONTROLLED GOOD TO Y1-I Y2-I Y1-O Y2-O OCCUPIED UNOCCUPIED SPEED VENTILATION (DCV) ECONOMIZE High 0-v/Off 0-v/Off Closed VENTMIN High 24-v/On 0-v/Off Closed VENTMIN High 24-v/On 24-v/On Closed... -
Page 39: Checkout
Table 16 — Single Enthalpy and Dual Enthalpy High Limit Curves POINT P1 POINT P2 ENTHALPY TEMP. DRY TEMP. ENTHALPY HUMIDITY HUMIDITY CURVE BULB (F) DEWPOINT (F) (btu/lb/da) TEMP. (F) TEMP. (F) (%RH) (%RH) 28.0 36.8 66.3 80.1 26.0 39.6 63.3 80.0 24.0... -
Page 40: Completing Return Air Smoke Sensor Installation
COMPLETING RETURN SMOKE SENSOR RETURN AIR INSTALLATION SMOKE DETECTOR Unscrew the two screws holding the Return Air Smoke (AS SHIPPED) Detector assembly. See Fig. 58, Step 1. Save the screws. Turn the assembly 90 degrees and then rotate end to end. Make sure that the elbow fitting is pointing down. -
Page 41: Step 14 - Adjust Factory-Installed Options
Fig. 59 — EconoMi$er IV Wiring • Differential enthalpy sensor Step 14 — Adjust Factory-Installed Options • sensor SMOKE DETECTORS • DDC interface (PremierLink™ Controls) Smoke detector(s) will be connected at the Controls Connec- • Louvered hail guard tions Board, at terminals marked “Smoke Shutdown.” Cut jumper JMP 3 when ready to energize unit. -
Page 42: Belt Tension Method
(www.hvacpartners.com). Table 2 Fig. 60 — V-Belt Force Label © Carrier Corporation 2019 Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 04-53480191-01 Printed in U.S.A. -
Page 43: Start-Up Checklist
START-UP CHECKLIST FOR 48HC04-06 SINGLE PACKAGE ROOFTOP GAS HEATING/ELECTRIC COOLING UNIT (REMOVE AND USE FOR JOB FILE) NOTE: To avoid injury to personnel and damage to equipment or property when completing the procedures listed in this start-up checklist, use good judgment, follow safe practices, and adhere to the safety considerations/information as outlined in preced- ing sections of this Installation Instruction document. - Page 44 9. Open humidistat input compressor and outdoor fan stop; LSV and DSV solenoids de-energized (Y/N) _____ 10. Restore set-points for thermostat and humidistat (Y/N) _____ © Carrier Corporation 2019 Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.