Carrier WeatherExpert 48N2 Installation Instructions Manual
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Carrier WeatherExpert 48N2 Installation Instructions Manual

Carrier WeatherExpert 48N2 Installation Instructions Manual

Packaged rooftop cooling units with gas heat and comfortlink controls
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CONTENTS
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SAFETY CONSIDERATIONS. . . . . . . . . . . . . . . . . . . . .1,2
ACOUSTICAL CONSIDERATIONS . . . . . . . . . . . . . . .2,3
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Ductwork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Acoustic Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
Step 1 - Perform Jobsite Survey . . . . . . . . . . . . . . . . 3
Step 2 - Place Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Step 3 - Roof Mount Unit. . . . . . . . . . . . . . . . . . . . . . . . 3
Step 4 - Slab Mount Unit . . . . . . . . . . . . . . . . . . . . . . . . 3
Step 5 - Install Curb Gasketing . . . . . . . . . . . . . . . . 15
Step 7 - Rig Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Step 8 - Connect Condensate Drain. . . . . . . . . . . . 15
Step 9 - Install Outdoor Hoods . . . . . . . . . . . . . . . . . 24
Step 10 - Route Field Wiring . . . . . . . . . . . . . . . . . . . 25
Bracket Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Step 14 - Remove Power Exhaust Shipping
Bracket Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Shipping Brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Step 16 - Connect Gas Piping. . . . . . . . . . . . . . . . . . 30
Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Step 18 - Install Flue/Inlet Hoods . . . . . . . . . . . . . . 31
Step 20 - Install Unit Accessories . . . . . . . . . . . . . . 32
Two-Piece Unit Fit Up . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
CONTROLS INSTALLATION. . . . . . . . . . . . . . . . . . 37-49
(SAV) Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Variable Air Volume (VAV) Units . . . . . . . . . . . . . . . . 38
Option and Accessory Control Wiring. . . . . . . . . . . 38
Optional UPC Open Installation . . . . . . . . . . . . . . . . . 44
Smoke Control Modes . . . . . . . . . . . . . . . . . . . . . . . . . . 46

GENERAL

This installation instruction contains basic unit installation
information, including installation of thermostats and remote
temperature sensors.
For additional information and service instructions, refer to
the Controls, Start-Up, Operation, Service and Troubleshooting
literature.
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Catalog No. 04-53480121-01
Packaged Rooftop Cooling Units with Gas Heat and

Installation Instructions

Page
(CCN) Interface . . . . . . 44
®
Printed in U.S.A.
48N2,N3,N4,N5,N6,N7,N8,N9

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.
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 electrical
switch; do not use any phone in your building. Immediately
call your gas supplier from a neighbor's phone. Follow the
gas supplier's instructions. If you cannot reach your gas sup-
plier, 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.
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.
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. When pressure testing field-
supplied gas piping at pressures of 0.5 psig or less, the unit
connected to such piping must be isolated by manually
closing the gas valve.
Form 48N-8SI
Pg 1
WeatherExpert

ComfortLink Controls

WARNING
WARNING
CAUTION
10-16
Replaces: 48N-7SI
®

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Summary of Contents for Carrier WeatherExpert 48N2

  • Page 1: Table Of Contents

    Option and Accessory Control Wiring... 38 (CCN) Interface ..44 Carrier Comfort Network ® CAUTION Optional UPC Open Installation .

  • Page 2: Acoustical Considerations

    • Avoid mounting the unit in the middle of large roof expanses between vertical supports. This will minimize WARNING the phenomenon known as roof bounce. • Install the units close to vertical roof supports (columns DO NOT USE TORCH to remove any component. System or load bearing walls).

  • Page 3: Installation

    Flexible Connectors Supply and Return Intake Supply Discharge Plenum Plenum Compressor/ Condensing Section All Roof Vibration Penetrations Isolators Should Be in Roof Sealed Curb Air Tight Supply and Return Ducts Lined with Acoustical Duct Liner Round Duct Controls Rumble Best Fig.
  • Page 4 MINIMUM SPACING (ft) UNIT Series Series a48-8682 Fig. 2 — Multiple Unit Minimum Separation...
  • Page 5 Table 1 — Physical Data 48N Sizes N-T (75-150 Tons Nominal Capacity) BASE UNIT NOMINAL CAPACITY (tons) WEIGHT (lb) Base Unit* 12,000 12,455 12,455 16,170 16,860 17,040 Split Unit - Main Section 9,110 9,565 9,565 12,880 13,570 13,750 Split Unit - Return Section 2,890 2,890 2,890...
  • Page 6 Table 1 — Physical Data 48N Sizes N-T (75-150 Tons Nominal Capacity) (cont) BASE UNIT NOMINAL CAPACITY (tons) ® HUMIDI-MIZER COIL Type MCHX Material Aluminum Quantity Surface E-Coated Total Face Area (sq ft) 34.5 STANDARD AND HIGH CAPACITY HOT WATER COILS Type RTPF Material...
  • Page 7 Table 1 — Physical Data 48N Sizes N-T (75-150 Tons Nominal Capacity) (cont) BASE UNIT NOMINAL CAPACITY (tons) OPTIONAL POWER EXHAUST Power Exhaust Diameter (in.) Wheel and Blade Type DWDI Forward Curve 60,000 Maximum Allowable Cfm 42,000 Maximum Allowable Speed (rpm) 1,200 1,200 Shaft Diameter at Pulley (in.)
  • Page 8 Table 2 — Operating Weights of Options and Accessories (lb) 48N UNIT SIZE (TON NOMINAL CAPACITY) OPTION OR ACCESSORY (75) (90) (105) (120) (130) (150) Economizer Filters 2 in. MERV 7 4 in. MERV 8 4 in. MERV 14 12 in. MERV 14 Bag with 2 in. Pre-Filter 12 in.
  • Page 9 Table 2 — Operating Weights of Options and Accessories (lb) (cont) 48N UNIT SIZE (TON NOMINAL CAPACITY) OPTION OR ACCESSORY (75) (90) (105) (120) (130) (150) Supply/PE/Return Motor Includes VFD 460 Volt TEFC 7.5 Hp 10 Hp 15 Hp 20 Hp 25 Hp 30 Hp 40 Hp...
  • Page 10 Table 3 — Supply Fan and Drive Data MOTOR DRIVE DRIVEN MOTOR MOTOR SHAFT SHAFT SHEAVE BUSHING SHEAVE BUSHING QTY OF SPEED SIZE (in.) SIZE (in.) BROWNING TYPE BROWNING TYPE BELTS BELTS (rpm) 1770 2.125 1800 4B5V70 B 2 1/8 4B5V68 B 2 1/4 5VX530...
  • Page 11 Table 5 — Return Fan Drive Data MOTOR DRIVE DRIVEN MOTOR MOTOR SHAFT SHAFT SHEAVE BUSHING SHEAVE BUSHING QTY OF FAN SPEED SIZE (in.) SIZE (in.) BROWNING TYPE BROWNING TYPE BELTS BELTS (rpm) 1770 2.125 1236 4B5V70 B 2 1/8 4R5V103 R1 2 1/2 5VX1000...
  • Page 13 48N Roof Curb Sizes N, P, Q 48N Roof Curb Sizes R, S, T (75-105 Ton Nominal Capacity) (120-150 Ton Nominal Capacity) DIMENSION DIMENSION DIMENSION DIMENSION DIMENSION DIMENSION PART NUMBER* PART NUMBER* A (in.) B (in.) C (in.) A (in.) B (in.) C (in.) CRRFCURB225A00...

  • Page 15: Step 5 - Install Curb Gasketing

    To attach ductwork to roof curb, insert duct approximately After ductwork Step 5 — Install Curb Gasketing — 10 to 11 in. up into roof curb. Connect ductwork to 14-gage has been connected to the roof curb, apply gasket material roof curb material with sheet metal screws driven from inside -in.
  • Page 16 Econ, Bar Rel, Standard filters, High Cap Evap, High Efficiency, High Static Supply Fan w/ largest motor, High Static PE w/ largest motor, No Heat, No Post section, No Humidimizer, No Extended Chassis, No Split, No Field Filter Section Econ, Bar Rel, Standard filters, High Cap Evap, High Efficiency, High Static Supply Fan w/ largest motor,...
  • Page 17 Econ, Bar Rel, Cartridge filters, Hi Cap Evap, High Efficiency, High Static Supply Fan w/ largest motor, Hi Static Return Fan w/ largest motor, High Electric Heat, 8' Blank section w/ post filters, Extended chassis w/ humidimizer, Split, No Field filter section Econ, Bar Rel, Cartridge filters, Hi Cap Evap, High Efficiency, High Static Supply Fan w/ largest motor,...
  • Page 18 High Efficiency, High Static Supply Fan w/ largest motor, Hi Static Return Fan w/ largest motor, High Electric Heat, 8' Blank section w/ post filters, Extended chassis w/ humidimizer, Split, No Field filter section Econ, Bar Rel, Cartridge filters, Hi Cap Evap, High Efficiency, High Static Supply Fan w/ largest motor,Hi Static Return Fan w/ largest motor, High gas heat, 8' Blank...
  • Page 19 Cond End Return End a48-8793 CENTER OF NOMINAL CORNER WEIGHTS (lb) GRAVITY CAPACITY TOTAL (lb) (tons) A (in.) B (in.) 4,129 4,047 4,892 4,796 17,864 275.9 67.2 4,396 4,310 5,359 5,254 19,319 308.1 67.2 4,478 4,390 5,526 5,417 19,810 309.8 67.2 48 Series Non-Split 5,455...
  • Page 21 FIELD NOMINAL EXTENDED SUPPLY BLANK 2-PIECE CAPACITY/ COND CHASSIS FILTER SECTION UNIT EFFICIENCY SECTION 498.11 314.42 48 177.02 266.07 499.35 202.75 119.76 — 313.36 4 FT 564.61 380.92 48 195.27 284.32 565.85 221.00 119.76 — 379.86 8 FT 612.86 429.17 48 195.27 284.32 614.10 221.00 119.76 —...
  • Page 22 A48-...
  • Page 23 FIELD NOMINAL HIGH EXTENDED BLANK CAPACITY/ PIECE COND CHASSIS FILTER SECTION EFFICIENCY HEAT* UNIT SECTION 523.04 339.35 48 186.86 291.00 524.28 227.68 119.76 — 338.29 2 4 FT 589.54 405.85 48 205.11 309.25 590.78 245.93 119.76 — 404.79 2 8 FT 637.79 454.10 48 205.11 309.25 639.03 245.93 119.76 —...

  • Page 24: Step 9 - Install Outdoor Hoods

    "J" AUXILIARY COIL LOCATION Auxiliary Coil Location — in. UNIT HEIGHT B DISTANCE J SIZES 48N (TONS) N, P, Q (75-105) 12.85 See dimension J on certified drawings, pages 21-24 R, S, T (120-150) 12.85 Fig. 13 — Units with Optional Extended Chassis — Location of Coil Tracks Unit sizes 75 Step 9 —...

  • Page 25: Step 10 - Route Field Wiring

    a48-8725 SHIPPING SUPPORT SEAL STRIP STRAPS FILTERS OUTDOOR HOODS (BOTH SIDES) PACKAGING SEAL STRIP Fig. 16 — Packaging Locations a48-8727 a48-8726 Fig. 18 — Seal Strips a48-8728 HOOD SUPPORTS (BOTH SIDES) Fig. 19 — Hood Assembly Fig. 17 — Hood Supports Field power wir- Step 10 —...

  • Page 26: Step 11 - Make Field Electrical Connections

    RECOMMENDED a48-8729 FIELD-SUPPLIED DISCONNECT LOCATION CAUTION Use care when drilling into corner post to avoid damage to con- denser coil. Fig. 20 — Disconnect Location Voltages between phases must be balanced within 2%, and Step 11 — Make Field Electrical Connections the current must be balanced within 10%.
  • Page 27 Bhp — Brake Horsepower BkW — Brake Kilowatts NOTE: Extensive motor and electrical testing on the Carrier units has ensured that the full horsepower range of the motor can be uti- lized with confidence. Using fan motors up to the horsepower ratings shown in the Motor Limitations table will not result in nuisance trip- ping or premature motor failure.

  • Page 28: Step 12 - Connect Air Pressure Tubing

    adjusting BP control set points, refer to the Controls, Start- Step 12 — Connect Air Pressure Tubing — Up, Operation, Service, and Troubleshooting book. fore options such as the variable frequency drive (VFD) and/or modulating power exhaust can operate properly, the pneumatic Step 13 —...
  • Page 29 a48-8731 Fig. 24 — Control Box Component Arrangement...

  • Page 30: Step 16 - Connect Gas Piping

    SPRING SUPPORT a48-8732 SHIPPING BRACKET SCREWS (4) EACH SPRING Fig. 25 — Supply Fan and Power Exhaust Fan Shipping Bracket Bolts Unit is equipped Step 16 — Connect Gas Piping — for use with natural gas only. Installation must conform with local building codes, or in the absence of local codes, with the a48-8733 National Fuel Gas Code (NFGC), ANSI Z223.1.

  • Page 31: Step 18 - Install Flue/Inlet Hoods

    a48-8734 OUTLET FLUE HOOD INLET HOOD *NPT plug is field supplied. NOTE: Follow all local codes. Step 18 — Install Flue/Inlet Hoods — flue/inlet hoods are shipped in a package taped to the basepan in the fan section. The flue (outlet) hoods are pre-assembled. The inlet hoods require assembly.

  • Page 32: Step 19 - Install Supply-Air Thermistors

    ACCESS PANEL COVER VIEW PORT OPENING (14-IN. HOOD ONLY) COVER HOOD Fig. 31 — Inlet Hood View Port Cover SIDE (TYP BOTH SIDES) Installation (14-in.) SCREEN For appli- Step 20 — Install Unit Accessories — cations requiring accessories, the following packages are available: All units: SPEED CLIP...

  • Page 33: Two-Piece Unit Fit Up

    Two-Piece Unit Fit Up 1. Locate and remove split parts package from return sec- tion of unit. Open package and remove split unit parts. See Tables 10 and 11 for parts list. 2. Rig main unit section and return section separately. 3.
  • Page 34 Table 10 — 75-105 Nominal Ton Units Parts List ITEM COMPONENT NUMBER QUANTITY COMPONENT NAME COMPONENT QUALIFIER 48NG501939 RAIL,MOUNTING SPLIT,BASE,GUIDE 48NG501935 ROD,THREADED -10 UNC 2A 30-in. L 48NG501937 WASHER,PLATE -in. LRT SPLIT AU02AB361 WASHER,FLAT AT11AB361 NUT,HEAVY HEX 48NG501938 BRACKET,TIE LRT SPLIT TOP AL48AM307 SCREW,HEXHD SR 48NG501936...
  • Page 35 ROOF COVER a50-8880 a50-8883 Fig. 35 — Roof Cap and Top Cover Removal Fig. 38 — Secure Base Rails L BRACKETS a50-8884 Fig. 39 — Top Rail Brackets a50-8881 a50-8885 Fig. 36 — L Bracket Removal A50-8882 INSTALL TAR TAPE ON ENTIRE BASE RAIL EDGE BASEPAN JOINT/COVER Fig.
  • Page 36 TOP CAPS L BRACKETS END CAPS COVER A50-8886 a50-8887 Fig. 42 — Main Unit and Return Section Fig. 41 — L Bracket Installation Top Cover Assemblies DETAIL A RUN VFD POWER WIRES THROUGH THIS BUSHING, SEE DETAIL A SEPARATE FROM CONTROL WIRES Fig.

  • Page 37: Controls Installation

    CONTROL WIRING — The unit can be controlled with a PANEL A50-8890 Carrier-approved accessory electro-mechanical or electronic BRACKETS thermostat that has two stages of cooling, two stages of heating control, and an output for fan control. The thermostat may also Fig.

  • Page 38: Variable Air Volume (Vav) Units

    18 AWG cannot be directly connected at the thermostat and will require a junction box and splice at the thermostat. NOTE: Only Carrier sensors may be used for standard T-55 space averaging. Sensors must be used in multiples of 1, 4, and FIELD SUPPLIED THERMOSTAT 9 only, with total sensors wiring not to exceed 1000 ft.
  • Page 39 TB201 SENSOR 4 SENSOR 1 SENSOR 3 SENSOR 2 a48-8737 SPACE TEMPERATURE AVERAGING (4 SENSOR APPLICATION) TB201 SENSOR 1 SENSOR 2 SENSOR 3 SENSOR 6 SENSOR 5 SENSOR 4 NOTE: Use T-55 sensor only. SENSOR 9 SENSOR 8 SENSOR 7 SPACE TEMPERATURE AVERAGING (9 SENSOR APPLICATION) Fig.
  • Page 40 FIELD INSTALLED (FIELD SUPPLIED) JUMPER WHEN ENTHALPY SWITCH NOT USED a48-8478 Fig. 50 — Outdoor Air Enthalpy Switch Wiring TB201 a48-8479 Fig. 51 — CO Space Sensor Wiring FILTER STATUS - RETURN SWITCH 180 OHM AN 5 FILTER PRESSURE RETURN a48-8738 FILTER STATUS - POST FILTER AN 6...
  • Page 41 a48-8741 Fig. 53 — Fan Status Switch Wiring a48-8740 TB203 MIXED AIR HUMIDITY 4 - 20 ma ACCSY PL29-1 OA HUMIDITY 24VDC 4 - 20 ma PL29-2 ACCSY TB202 24VDC SPACE HUMIDITY 4 - 20 ma ACCSY PL37-5 RETURN HUMIDITY 24VDC 4 - 20 ma AN10...
  • Page 42 a48-8483 Fig. 55 — Return Air CO Sensor Wiring TB201 TB201 PL45-1 a48-8739 PL45-2 PL45-3 PL45-6 PL45-5 PL45-4 Fig. 56 — Return Air Smoke Detector Wiring FIRE SHUTDOWN TB201 a48-8485 Fig. 57 — Fire Shutdown Wiring...
  • Page 43 TB 202 RCB J4 a48-8486 Fig. 58 — Purge, Evacuation, and Pressurization Wiring a48-8487 TB201 Fig. 59 — CCN Connections...

  • Page 44: Carrier Comfort Network

    3. Wire the CCN to the screw terminals on the COMM ® Carrier Comfort Network (CCN) Interface — board as follows: The 48N Series units can be connected to the CCN system if desired. The communication bus wiring is supplied and a.
  • Page 45 BT485 TERMINATOR BACNET CONNECTION POWER LED Tx1 LED Rx1 LED BACNET Tx2 LED BAUD RATE DIP SWITCHES Rx2 LED ADDRESS ROTARY SWITCHES RUN LED ERROR LED Fig. 60 — UPC Open Controller Fig. 61 — Open System Network Wiring...

  • Page 46: Smoke Control Modes

    MS/TP WIRING RECOMMENDATIONS — Recom- mendations are shown in Tables 14 and 15. The wire jacket and UL temperature rating specifications list two acceptable alternatives. The Halar* specification has a higher tempera- ture rating and a tougher outer jacket than the SmokeGard† specification, and it is appropriate for use in applications where the user is concerned about abrasion.
  • Page 47 PRESSURIZATION — Pressurization mode is intended to • opening the economizer (option required) keep smoke out of a zone. The factory-installed optional • running the exhaust fans (option or accessory required) economizer is required for this function. Pressurization is ac- •...
  • Page 48 © Carrier Corporation 2016 Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 04-53480121-01 Printed in U.S.A. Form 48N-8SI Pg 48 10-16 Replaces: 48N-7SI...

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