Carrier WEATHERMASTER Z6 User Manual

Single package gas heating and electric cooling units with direct spark ignition and comfortlink controls

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User's information manual (8 pages)

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GENERAL

This installation instruction contains basic unit installation

information, including installation of thermostats and remote

temperature sensors.

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.

Catalog No. 04-53480060-01

Single Package Gas Heating and Electric Cooling Units

with Direct Spark Ignition and COMFORTLINK™ Controls

Installation Instructions

Page

(CCN) Interface. . . . . . . 60

Printed in U.S.A.

For additional information and service instructions, refer to

the Controls and Troubleshooting literature also enclosed in

this literature packet.

The 48ZT,ZW units are equipped with standard integral

economizer and high-capacity power exhaust.

The 48Z6,Z8 units are equipped with factory-installed

return/exhaust fans.

The staged gas control (SGC) option adds the capability to

control the rooftop unit's gas heating system to a specified sup-

ply air temperature set point for purposes of tempering a cool

mixed-air condition.

SAFETY CONSIDERATIONS

Installation and servicing of air-conditioning equipment can

be hazardous due to system pressure and electrical compo-

nents. Only trained and qualified service personnel should

install, repair, or service air-conditioning equipment.

Untrained personnel can perform basic maintenance func-

tions of cleaning coils and filters and replacing filters. All

other operations should be performed by trained service per-

sonnel. When working on air-conditioning equipment, observe

precautions in the literature, tags and labels attached to the unit,

and other safety precautions that may apply.

Follow all safety codes, including ANSI (American Nation-

al Standards Institute) Z223.1. Wear safety glasses and work

gloves. Use quenching cloth for unbrazing operations. Have

fire extinguisher available for all brazing operations.

WARNING

Before performing service or maintenance operations on

unit, turn off main power switch to unit. Electrical shock

could cause personal injury.

FOR YOUR SAFETY

WHAT TO DO IF YOU SMELL GAS

Do not try to light any appliance. Do not touch any electri-

cal switch; do not use any phone in your building. Immedi-

ately call your gas supplier from a neighbor's phone.

Follow the gas supplier's instructions. If you cannot reach

your gas supplier, call the fire department.

FOR YOUR SAFETY

Do not store or use gasoline or other flammable vapors and

liquids in the vicinity of this or any other appliance.

WARNING

Improper installation, adjustment, alteration, service, or

maintenance can cause injury or property damage. Refer to

this manual. For assistance or additional information, con-

sult a qualified installer, service agency, or the gas supplier.

Form 48Z-8SI

Pg 1

WEATHERMASTER

48ZG,ZN030-105

48ZT,ZW,Z6,Z8075-105

4-09

Replaces: 48Z-7SI

Table of Contents

Summary of Contents for Carrier WEATHERMASTER Z6

Page 1: Table Of Contents
The 48Z6,Z8 units are equipped with factory-installed return/exhaust fans. The staged gas control (SGC) option adds the capability to control the rooftop unit’s gas heating system to a specified sup- ply air temperature set point for purposes of tempering a cool mixed-air condition.
Page 2: Installation
CAUTION Disconnect gas piping from units when leak testing at pres- sures greater than 0.5 psig. Pressures greater than 0.5 psig will cause gas valve damage resulting in a hazardous condition. If gas valve is subjected to pressure greater than 0.5 psig, it must be replaced.
Page 3 BASE UNIT NOMINAL CAPACITY (tons) OPERATING WEIGHT (lb) Base Unit Low Heat High Heat With Economizer Low Heat High Heat COMPRESSORS Quantity...Type Oil Charge (pints) Capacity Steps (%) Number of Refrigerant Circuits REFRIGERANT Operating Charge (lb), Ckt 1/Ckt 2 Standard Evaporator Coil Standard Evaporator with HGBP Alternate High-Capacity Evaporator Coil Alternate High-Capacity Evaporator with HGBP...
Page 4 Table 1A — Physical Data (48ZG,ZN030-050) (cont) BASE UNIT NOMINAL CAPACITY (tons) OPERATING WEIGHT (lb) Base Unit Low Heat High Heat With Economizer Low Heat High Heat COMPRESSORS Quantity...Type Oil Charge (pints) Capacity Steps (%) Number of Refrigerant Circuits REFRIGERANT Operating Charge (lb), Ckt 1/Ckt 2 Standard Evaporator Coil Standard Evaporator with HGBP...
Page 5 BASE UNIT NOMINAL CAPACITY (tons) OPERATING WEIGHT (lb) Base Unit Low Heat High Heat With Economizer Low Heat High Heat COMPRESSORS Quantity...Type Oil Charge (Pints) Capacity Steps (%) Number of Refrigerant Circuits REFRIGERANT Operating Charge (lb), Ckt 1/Ckt 2 Standard Evaporator Coil Standard Evaporator with HGBP Alternate High-Capacity Evaporator Coil Alternate High-Capacity Evaporator...
Page 6 Table 1C — Physical Data (48ZG,ZN075-105) BASE UNIT NOMINAL CAPACITY (tons) OPERATING WEIGHT (lb) Base Unit without Economizer Low Heat/High Heat With Economizer Low Heat/High Heat COMPRESSOR Number Circuit (No. Cyl) Model 06E Oil Charge (pints) Capacity Steps (%) Number of Refrigerant Circuits REFRIGERANT Operating Charge (lb), Ckt 1/Ckt 2 Standard Evaporator Coil...
Page 7 Table 1C — Physical Data (48ZG,ZN075-105) (cont) BASE UNIT OPTIONAL POWER EXHAUST Quantity...Motor Hp Motor Frame Size Efficiency at Full Load (%) High Efficiency Premium Efficiency Fan Pulley Pitch Diameter (in.) Motor Pulley Pitch Diameter (in.) Shaft Diameter at Pulley (in.) Resulting Fan Rpm Maximum Allowable Rpm FILTERS...
Page 8 BASE UNIT NOMINAL CAPACITY (tons) OPERATING WEIGHT (lb) Base Unit without Economizer Low Heat/High Heat With Economizer Low Heat/High Heat COMPRESSOR Number Circuit (No. Cyl) Model 06E Oil Charge (pints) Capacity Steps (%) Number of Refrigerant Circuits REFRIGERANT Operating Charge (lb), Ckt 1/Ckt 2 Standard Evaporator Coil Standard Evaporator with HGBP Alternate High-Capacity Evaporator Coil...
Page 9 Table 1D — Physical Data (48Z6,Z8075-105) (cont) BASE UNIT RETURN/EXHAUST FAN Quantity...Motor Hp Motor Frame Size Efficiency at Full Load (%) High/Premium Fan Pulley Pitch Diameter (in.) Motor Pulley Pitch Diameter (in.) Shaft Diameter at Pulley (in.) Resulting Fan Rpm Maximum Allowable Rpm FILTERS Standard Efficiency Throwaway (Standard)
Page 10 Table 1E — Physical Data (48ZT,ZW075-105) BASE UNIT NOMINAL CAPACITY (tons) OPERATING WEIGHT (lb) Base Unit without Economizer Low Heat/High Heat COMPRESSOR Number Circuit (No. Cyl) Model 06E Oil Charge (pints) Capacity Steps (%) Number of Refrigerant Circuits REFRIGERANT Operating Charge (lb), Ckt 1/Ckt 2 Standard Evaporator Coil Standard Evaporator with HGBP Alternate High-Capacity Evaporator Coil...
Page 11 Table 1E — Physical Data (48ZT,ZW075-105) (cont) BASE UNIT POWER EXHAUST Total Hp Quantity...Motor Hp Motor Frame Size Efficiency at Full Load (%) High Efficiency Premium Efficiency Fan Sheave Pitch Diameter (in.) Motor Sheave Pitch Diameter (in.) Resulting Fan Rpm Maximum Allowable Rpm Belts —...
Page 12 SHAFT SPEED DIA (in.) (rpm) Sizes 030-050 Sizes 055-070 Sizes 075-105 (Forward Curved Fan) Sizes 075-105 (Airfoil Fan) 1353 1493 1593 1711 1799 *Sizes 040,050 only. MOTOR TOTAL MOTOR SHAFT SPEED QTY...HP DIA (in.) Sizes 030-050 2...3 6† 2...3 10** 2...5 15** 2...7.5...
Page 18 Fig. 6 — Gasket Location on Roof Curb (48ZG,ZN055-105 and 48Z6,Z8075-105 Units) Fig. 7 — Gasket Location — Condenser Section Roof Curb (Size 055-105 Units) "X" CONDENSER END SUPPORT 4 REF. 9 3/4" "X"- NO GASKET DETAIL A-A...
Page 19 Fig. 8 — Gasket Location on Roof Curb (48ZT,ZW075-105 Units) 1. ALL PANELS MUST BE IN PLACE WHEN RIGGING. 2. DO NOT ATTEMPT TO FORK THESE UNITS. WEIGHT UNIT 48Z030 5770 2623 48Z035 5895 2679 48Z040 6670 3032 48Z050 6710 3050 Fig.
Page 20 1. ALL PANELS MUST BE IN PLACE WHEN RIGGING. 2. DO NOT ATTEMPT TO FORK THESE UNITS. WEIGHT UNIT 48Z055 8,820 48Z060 9,120 48Z070 9,550 48ZG,ZN075 10,445 48ZG,ZN090 10,655 48ZG,ZN105 11,385 48Z6,Z8075 11,915 48Z6,Z8090 12,125 48Z6,Z8105 12,855 Fig. 10 — Rigging Label — Size 055-105 Units (Standard Chassis) 1.
Page 21 1. ALL PANELS MUST BE IN PLACE WHEN RIGGING. 2. DO NOT ATTEMPT TO FORK THESE UNITS. WEIGHT UNIT 48Z055 9548 4330 48Z060 9668 4385 Fig. 12 — Rigging Label — Size 055,060 Units (Extended Chassis) 1. ALL PANELS MUST BE IN PLACE WHEN RIGGING. 2.
Page 22 UNITS 48ZG,ZN VERTICAL SUPPLY AND RETURN/ LOW GAS HEAT VERTICAL SUPPLY AND RETURN/ HIGH GAS HEAT VERTICAL SUPPLY AND RETURN/ EXTENDED CHASSIS/LOW GAS HEAT VERTICAL SUPPLY AND RETURN/ EXTENDED CHASSIS/HIGH GAS HEAT UNITS 48ZT,ZW WITH HIGH-CAPACITY POWER EXHAUST VERTICAL SUPPLY AND RETURN/ LOW GAS HEAT, HIGH-CAPACITY POWER EXHAUST VERTICAL SUPPLY AND RETURN/...
Page 23: Condensate Drain Connections
Condensate Drain Connections — tal of five drain connections required on each unit: one primary drain (on right-hand side of the unit) and four secondary drains (two on each side of unit). PRIMARY DRAIN — The primary drain is a 2-in. NPT pipe connection located on the right-hand side of the unit looking at the unit from the return air end.
Page 27 a48-8451...
Page 30 a48-8452...
Page 31 a48-8453...
Page 32 a48-8454...
Page 33: Install Outdoor Hoods
Fig. 24 — Primary Drain Connection A = 4-in. (102 mm) min — Sizes 030-070 7-in. (178 mm) min — Sizes 075-105 Fig. 25 — Slab-Mounted Condensate Drain Piping Details Fig. 26 — Secondary Condensate Drain Location Fig. 27 — Secondary Drain Seal Plate Location A = 4-in.
Page 34 OUTDOOR AIR HOOD Fig. 29 — Outdoor Air Hood Installation (Sizes 030-050) OUTDOOR-AIR HOOD (ALL HOODS) Fig. 30 — Outdoor-Air and Economizer Hood SIDE HOOD (ROTATE OPEN) END HOOD (FIXED) Fig. 31 — Economizer Outdoor-Air Hood Installation (Sizes 030-050) SIDE HOOD (ROTATE OPEN) END HOOD...
Page 35: Install Economizer Hoods (48Zt,Zw Units)
Install Economizer Hoods (48ZT,ZW Units) — The economizer uses a total of 4 outdoor intake hoods, 2 on each side of the unit. See Fig. 37. Two small hoods (one per side) are factory-installed and are pivoted inside the unit chas- sis for shipment.
Page 36: Field Wire Routing
SEE DETAIL Z DETAIL Z SCALE 3:4 Field Wire Routing UNIT SIZES 030-050 — Field wiring can be brought into the unit through the basepan and roof curb or through the corner post in the side of the unit next to the control box. -in.
Page 37 Units with Factory-Installed Disconnect — The factory- installed disconnect is an interlocking, door-type. The discon- nect handle locks the door when it is in the ON position. The disconnect handle must be in the OFF position to open the con- trol box door.
Page 38 Use care when drilling into corner post to avoid damage to con- denser coil. Fig. 40 — Disconnect Location — 48ZG,ZN055-105 and 48Z6,Z8075-105 Units Use care when drilling into corner post to avoid damage to con- denser coil. Fig. 41 — Disconnect Location — 48ZT,ZW075-105 Units CAUTION CAUTION...
Page 39 DISCONNECT PER NEC EQUIP GND LEGEND EQUIP — Equipment — Ground — National Electrical Code — Terminal Block Fig. 42 — Field Power Wiring Connections Fig. 43 — Factory-Installed Disconnect Location FACTORY WIRE DISCONNECT EQUIP PER NEC FIELD WIRE Fig. 44 — Field Power Wiring Connections for Factory-Installed Disconnect LEGEND EQUIP —...
Page 40 COMPRESSOR NOMINAL VOLTAGE No. 1 VOLTAGE RANGE (3 Ph 60 Hz) 208/230 187-254 53.2 414-508 28.8 518-632 23.1 LEGEND — Full Load Amps — Nominal Horsepower — Indoor (Supply) Fan Motor — Locked Rotor Amps — Minimum Circuit Amps (for wire sizing) MOCP —...
Page 41 COMPRESSOR NOMINAL VOLTAGE No. 1 VOLTAGE RANGE (3 Ph 60 Hz) 208/230 187-254 53.2 414-508 28.8 518-632 23.1 LEGEND — Full Load Amps — Nominal Horsepower — Indoor (Supply) Fan Motor — Locked Rotor Amps — Minimum Circuit Amps (for wire sizing) MOCP —...
Page 42 COMPRESSOR NOMINAL VOLTAGE No. 1 VOLTAGE RANGE (3 Ph 60 Hz) 208/230 187-254 69.2 414-508 34.6 518-632 26.7 LEGEND — Full Load Amps — Nominal Horsepower — Indoor (Supply) Fan Motor — Locked Rotor Amps — Minimum Circuit Amps (for wire sizing) MOCP —...
Page 43 Table 10 — Electrical Data, 48ZG,ZN050 Units COMPRESSOR NOMINAL VOLTAGE No. 1 VOLTAGE RANGE (3 Ph 60 Hz) 208/230 187-254 89.7 414-508 43.6 518-632 36.5 LEGEND — Full Load Amps — Nominal Horsepower — Indoor (Supply) Fan Motor — Locked Rotor Amps —...
Page 44 Table 11 — Electrical Data, 48ZG,ZN055 Units COMPR NOMINAL NO. 1 VOLTAGE VOLTAGE RANGE (3 Ph 60 Hz) RLA LRA RLA LRA 208/230 187-254 414-508 50.6 518-632 39.1 LEGEND — Full Load Amps — Nominal Horsepower — Indoor (Supply) Fan Motor —...
Page 45 Table 12 — Electrical Data, 48ZG,ZN060 Units COMPR NOMINAL NO. 1 VOLTAGE VOLTAGE RANGE (3 Ph 60 Hz) RLA LRA RLA LRA 208/230 187-254 414-508 50.6 518-632 39.1 LEGEND — Full Load Amps — Nominal Horsepower — Indoor (Supply) Fan Motor —...
Page 46 Table 13 — Electrical Data, 48ZG,ZN070 Units COMPR NOMINAL NO. 1 VOLTAGE VOLTAGE RANGE (3 Ph 60 Hz) RLA LRA RLA LRA 208/230 187-254 414-508 50.6 65.4 518-632 39.1 52.6 LEGEND — Full Load Amps — Nominal Horsepower — Indoor (Supply) Fan Motor —...
Page 47 Table 14 — Electrical Data — 48ZG,ZN075-105 Units NOMINAL UNIT VOLTAGE VOLTAGE No. 1 SIZE (3 Ph RANGE 60 Hz) 414-508 50.6 414-508 65.4 414-508 50.6 LEGEND — Full Load Amps — Nominal Horsepower — Indoor (Supply) Fan Motor — Locked Rotor Amps —...
Page 48 Table 15 — Electrical Data — 48Z6,Z8075-105 Units VOLTAGE RANGE UNIT VOLTAGE No. 1 SIZE (3 Ph, 60 Hz) 50.6 65.4 50.6 LEGEND — Full Load Amps — Nominal Horsepower — Locked Rotor Amps — Minimum Circuit Amps (for wire sizing) MOCP —...
Page 49 Table 16 — Electrical Data — 48ZT,ZW075-105 Units VOLTAGE UNIT VOLTAGE No. 1 3 PH, SIZE RANGE 60 Hz 414-508 50.6 518-632 39.1 414-508 65.4 COMPRESSOR No. 2 No. 3 No. 4 Total 65.4 — — — — 16.5 52.6 —...
Page 50 Table 16 — Electrical Data — 48ZT,ZW075-105 Units (cont) VOLTAGE UNIT VOLTAGE No. 1 3 PH, SIZE RANGE 60 Hz 518-632 52.6 414-508 50.6 518-632 39.1 LEGEND — Full Load Amps — Nominal Horsepower — Indoor (Evaporator) Fan Motor — Locked Rotor Amps —...
Page 51: Air Pressure Tubing
Before options such as inlet Air Pressure Tubing — guide vanes (IGV), variable frequency drive (VFD), and/or modulating power exhaust can operate properly, the pneumatic tubing for pressure sensing must be installed. Use fire-retardant plenum tubing (field-supplied). All control devices use tubing.
Page 52 Fig. 46 — Auxiliary Control Box Location (Sizes 055-105) OACFM TRANSDUCER LEGEND — Building Pressure Transducer — Duct Pressure Transducer — Filter Switch OACFM — Outdoor Air Cfm Sensor Transducer Fig. 47 — Auxiliary Control Box Details (Sizes 030-050) — Building Pressure Transducer —...
Page 53: Supply-Fan Shipping Brackets
OACFM TRANSDUCER LEGEND BP — Building Pressure OACFM — Outdoor Air Cfm Transducer Sensor Transducer DP — Duct Pressure PPSS — Plenum Pressure Transducer Safety Switch FS — Filter Switch RFCFM — Return Fan Cfm Sensor Transducer Fig. 49 — Auxiliary Control Box Details (Size 075-105 Units with Return Fan) Supply-Fan Shipping Brackets —...
Page 54: Remove Txv Shipping Blocks
Fig. 52 — Shipping Brackets (Sizes 075-105) Shipping blocks Remove TXV Shipping Blocks — for the TXV bracket are used on size 030-075 units with high capacity coils and all 075-105 size units. Remove the foam shipping block before starting unit. See Fig. 54. SHIPPING BLOCK NOTE: All dimensions are in inches.
Page 55: Compressor Mounting
Compressor Mounting SIZES 030-090 — Each compressor 4 springs. The springs are compressed for shipment. After the unit is installed, the holddown nuts need to be loosened for nor- mal operation. See Fig. 55 for compressor mounting details. Loosen each bolt using nut indicated until the flatwasher -in.) can be moved with finger pressure.
Page 56: Installing Flue/Inlet Hoods
*NPT plug is field supplied. NOTE: Follow all local codes. Fig. 58 — Gas Piping Details Installing Flue/Inlet Hoods — hoods are shipped in a package taped to the basepan in the fan section. The flue (outlet) hoods are pre-assembled. The flue de- flector and inlet hoods require assembly.
Page 57 Fig. 59 — Flue/Inlet Hood Locations, 030-060 Units FLUE AND FLUE DEFLECTOR HOOD LARGE INLET HOOD SMALL INLET HOOD LARGE INLET HOOD LOCATION HIGH-HEAT ONLY) Fig. 60 — Flue/Inlet Hood Locations, 055-105 Units Fig. 61 — Flue Outlet Hood PUSH BAFFLE DOWN SO THESE 2...
Page 58 ACCESS PANEL OPENING SIDE (TYP BOTH SIDES) Fig. 65 — Inlet Hood Assembly HOOD TYPE PARTS LIST FIG. NO. Top (14-in.) Side (Left) Side (Right) Large Inlet Screen 65,66 (14-in.) Cover Speed Clips Screws Top (6-in.) Side (Left) Side (Right) Small Inlet Screen (6-in.)
Page 59: Install Unit Accessories
• Navigator™ hand-held display CONTROL WIRING — The unit can be controlled with a Carrier-approved accessory electro-mechanical or electronic thermostat that has two stages of cooling, two stages of heating control, and an output for fan control. The thermostat may also include time of day scheduling or use scheduling routines built into the ComfortLink™...
Page 60: Optional And Accessory Control Wiring
4 or 9 sensors as shown in Fig. 69. NOTE: Only Carrier sensors may be used for standard T-55 space averaging. Sensors must be used in multiples of 1, 4, and 9 only, with total sensors wiring not to exceed 1000 ft.
Page 61: Smoke Control Modes
d. Secure shield wire to CCN screw terminal SHIELD on the COMM board. IMPORTANT: A shorted CCN bus cable will prevent some routines from running and may prevent unit from starting. If abnormal conditions occur, unplug the connec- tor. If conditions return to normal, check CCN connector, and run new cable if necessary.
Page 62 TB202 SENSOR 1 SENSOR 4 SENSOR 3 SENSOR 2 SPACE TEMPERATURE AVERAGING (4 SENSOR APPLICATION) TB202 SENSOR 1 SENSOR 2 SENSOR 3 SENSOR 6 SENSOR 5 SENSOR 4 SENSOR 9 SENSOR 8 SENSOR 7 SPACE TEMPERATURE AVERAGING (9 SENSOR APPLICATION) NOTE: Use T55 sensor only.
Page 63 Fig. 70 — Heat Interlock Relay Wiring FIELD INSTALLED (FIELD SUPPLIED) JUMPER WHEN ENTHALPY SWITCH NOT USED Fig. 71 — Outdoor Air Enthalpy Switch Wiring Fig. 72 — CO Space Sensor Wiring FILTER STATUS Fig. 73 — Filter Status Wiring...
Page 64 Fig. 74 — Fan Status Switch Wiring Fig. 75 — Space and Return Air Humidity Sensor Wiring Fig. 76 — Return Air CO Sensor Wiring...
Page 65 Fig. 77 — Return Air Smoke Detector Wiring Fig. 78 — Fire Shutdown Wiring RCB J4 Fig. 79 — Purge, Evacuation, and Pressurization Wiring...
Page 66 COMM BOARD Fig. 80 — CCN Connections...
Page 68 Copyright 2009 Carrier Corporation Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 04-53480060-01 Printed in U.S.A. Form 48Z-8SI Pg 68 4-09 Replaces: 48Z-7SI...

This manual is also suitable for:

Weathermaster 48zg Weathermaster 48zt Weathermaster zw Weathermaster z8075-105 Weathermaster zn030-105 Weathermaster 48zg030 ... Show all

Carrier WEATHERMASTER Z6 User Manual

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GENERAL

Installation Instructions

SAFETY CONSIDERATIONS

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