Carrier WeatherMaker 48TC 06 Installation Instructions Manual
Carrier WeatherMaker 48TC 06 Installation Instructions Manual

Carrier WeatherMaker 48TC 06 Installation Instructions Manual

Single package rooftop with gas heat/electric cooling

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48TC 07 units for installation in the United States contain use of Carrier's Staged Air Volume (SAV™)
2-speed indoor fan control system. This complies with the U.S. Department of Energy (DOE) efficiency
standard of 2018.
48TC 07 units for installation outside the United States may or may not contain use of the SAV 2-speed
indoor fan control system as they are not required to comply with the U.S. Department of Energy (DOE)
efficiency standard of 2018.
For specific details on operation of the Carrier SAV 2-speed indoor fan system refer to the Variable
Frequency Drive (VFD) Factory-Installed Option 2-Speed Motor Control Installation, Setup, and
Troubleshooting manual.
CONTENTS
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . 1
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Job-Site Survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Step 1 - Plan for Unit Location. . . . . . . . . . . . . . . . . 6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Step 3 - Inspect Unit . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Step 4 - Provide Unit Support . . . . . . . . . . . . . . . . . 7
OR SLAB MOUNT)
Step 5 - Field Fabricate Ductwork. . . . . . . . . . . . . . 9
Step 6 - Rig and Place Unit . . . . . . . . . . . . . . . . . . . . 9
Ductwork (When Required) . . . . . . . . . . . . . . . . . 10
Step 8 - Install Outside Air Hood. . . . . . . . . . . . . . 10
HOOD PACKAGE REMOVAL AND SETUP - FAC-
TORY OPTION
Step 9 - Install Flue Hood . . . . . . . . . . . . . . . . . . . . 11
Step 10 - Install Gas Piping . . . . . . . . . . . . . . . . . . 11
(GAS CONNECTIONS)
Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
(ELECTRICAL CONNECTIONS)
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Catalog No. 04-53480180-01
Installation Instructions
Page
Printed in U.S.A.
Single Package Rooftop with
Gas Heat/Electric Cooling
• ECONOMI$ER X (FACTORY-INSTALLED OPTION)
• ECONOMIZER MODULE WIRING DETAILS
• INTERFACE OVERVIEW
• PREMIERLINK
• PREMIERLINK FIELD CONNECTIONS
• ECONOMIZER CONTROLS
• RTU OPEN CONTROL SYSTEM
• RTU OPEN CONTROL SYSTEM FIELD
CONNECTIONS
• SMOKE DETECTORS
• ECONOMI$ER IV OCCUPANCY SWITCH
Step 14 - Install Accessories . . . . . . . . . . . . . . . . . 57
Step 15 - Check Belt Tension . . . . . . . . . . . . . . . . 57
• BELT TENSION METHOD
Pre-Start and Start-Up . . . . . . . . . . . . . . . . . . . . . . . . 58
START-UP CHECKLIST . . . . . . . . . . . . . . . . . . . . . CL-1
These installation instructions cover the 48TC units with
gas heat and electric cooling. Units are pre-wired and pre-
charged with environmentally sound Puron
refrigerant at the factory. See Fig. 1 for model number nomen-
clature. See Fig. 2 for unit dimensions. See Fig. 3 for service
clearances.

SAFETY CONSIDERATIONS

Improper installation, adjustment, alteration, service, main-
tenance, 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 quali-
fied installer or agency must use factory-authorized kits or ac-
cessories 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
Form 48TC-4-7-04SI
Pg 1
WeatherMaker
48TC 04-07
®
CONTROL CONNECTION
(FACTORY-OPTION)

GENERAL

4-18
Replaces: 48TC-4-7-03SI
®
®
(R-410A)

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Summary of Contents for Carrier WeatherMaker 48TC 06

  • Page 1: Table Of Contents

    Gas Heat/Electric Cooling Installation Instructions 48TC 07 units for installation in the United States contain use of Carrier's Staged Air Volume (SAV™) 2-speed indoor fan control system. This complies with the U.S. Department of Energy (DOE) efficiency standard of 2018.
  • Page 2 fire extinguisher available. Read these instructions thoroughly and follow all warnings or cautions attached to the unit. WARNING Consult local building codes and appropriate national electrical codes (in USA, ANSI/NFPA70, National Electrical Code CARBON-MONOXIDE POISONING HAZARD (NEC); in Canada, CSA C22.1) for special requirements. Failure to follow instructions could result in severe person- It is important to recognize safety information.
  • Page 3 Position: 9 10 11 12 13 14 15 16 17 18 Example: Unit Heat Type Packaging & Seismic Complience 48 - Gas Heat Packaged Rooftop 0 = Standard 1 = LTL 3 = California Seismic Compliant Label Model Series - WeatherMaker ®...
  • Page 4 Fig. 2 — Unit Dimensional Drawing...
  • Page 5 Fig. 2 — Unit Dimensional Drawing (cont)
  • Page 6: Installation

    DIMENSION LOCATION CONDITION in. (mm) 48 (1219) Unit disconnect is mounted on panel. 18 (457) No disconnect, convenience outlet option. 18 (457) Recommended service clearance. 12 (305) Minimum clearance. 42 (1067) Surface behind servicer is grounded (e.g., metal, masonry wall). 36 (914) Surface behind servicer is electrically non-conductive (e.g., wood, fiberglass).
  • Page 7: Step 2 - Plan For Sequence Of Unit

    When unit is located adjacent to public walkways, flue assem- Confirm before installation of unit that voltage, amperage and bly must be at least 7 ft (2.1 m) above grade. circuit protection requirements listed on unit data plate agree with power supply provided. Select a unit mounting system that provides adequate height to allow installation of condensate trap per requirements.
  • Page 8 Fig. 5 — Roof Curb Details...
  • Page 9: Step 5 - Field Fabricate Ductwork

    For further details see Step 11 — Install External Condensate Cabinet Step 5 — Field Fabricate Ductwork — Trap and Line on page 14. return-air static pressure (a negative condition) shall not exceed 0.35 in. wg (87 Pa) with economizer or 0.45 in. wg (112 Pa) Before setting the unit onto the curb, recheck gasketing on without economizer.
  • Page 10: Step 7 - Convert To Horizontal And Connect Ductwork (When Required)

    Step 7 — Convert to Horizontal and Connect Unit is shipped in the Ductwork (When Required) — FILTER ACCESS PANEL vertical duct configuration. Unit without factory-installed economizer or return air smoke detector option may be field- converted to horizontal ducted configuration. To convert to horizontal configuration, remove screws from side duct open- ing covers and remove covers.
  • Page 11: Step 9 - Install Flue Hood

    1. The indoor coil access panel will be used as the top of 7. Replace the filter access panel. the hood. Remove the screws along the sides and bot- tom of the indoor coil access panel. See Fig. 10. DIVIDER PANEL OUTSIDE HOOD...
  • Page 12: Factory-Option Thru-Base Connections

    Table 3 — Natural Gas Supply Line Pressure Ranges 9” MINIMUM CLEARANCE UNIT MODEL UNIT SIZE MIN. MAX. FOR PANEL REMOVAL 4.0 in. wg 13.0 in. wg 48TCD/E/F 04, 05, 06, 07 REGULATOR (996 Pa) (3240 Pa) MANUAL GAS SHUTOFF VALVE Table 4 —...
  • Page 13 (406 mm) (field-supplied) to the street elbow and extend it through the access panel at the gas support bracket. See Fig. 16. 9” (229 mm) MIN. BURNER ACCESS PANEL UNION THRU-CURB ADAPTER BRASS FITTING SUPPORT EMBOSSMENT FOR 3-6 TON UNITS BRACKET UNIT BASE RAIL Fig.
  • Page 14: Step 11 - Install External Condensate Trap And Line

    4. Pressure-test all gas piping in accordance with local and socket drive extension) and install it in the side drain connec- national plumbing and gas codes before connecting pip- tion. ing to unit. NOTE: Pressure test the gas supply system after the gas supply piping is connected to the gas valve.
  • Page 15: Field Power Supply

    FIELD POWER SUPPLY — If equipped with optional Assemble the shaft and handle to the switch at this point. Dis- Powered Convenience Outlet: The power source leads to the card the factory test leads (see Fig. 24). convenience outlet’s transformer primary are not factory con- Connect field power supply conductors to LINE side termi- nected.
  • Page 16: Disconnect

    (fuse or breaker) per NEC Article 440 (or local damage to electrical components. Such operation would invali- codes). Refer to unit informative data plate for MOCP (Maxi- date any applicable Carrier warranty. mum Over-current Protection) device size. NOTE: Check all factory and field electrical connections for tightness.
  • Page 17 Table 8 — Unit Wire/Fuse or HACR Breaker Sizing Data — Single Speed Indoor Fan Motor NO C.O. OR UNPWR C.O. WITH PWRD C.O. WITH P.E. (POWERED WITH P.E. (POWERED NO P.E. NO P.E. FROM UNIT) FROM UNIT) UNIT NOM. V-PH-HZ TYPE FUSE DISC.
  • Page 18: Convenience Outlets

    CONVENIENCE OUTLETS RTU Open) the weatherproof cover kit is secured to the base- pan underneath the control box, see Fig. 28. WARNING IMPORTANT: DISCONNECT ALL POWER TO Failure to follow this warning could result in personal UNIT AND CONVENIENCE OUTLET. LOCK-OUT injury or death.
  • Page 19: Factory-Option Thru-Base Connections

    Fig. 30 — Powered Convenience Outlet Wiring factory-installed option only). Test the GFCI receptacle by pressing the TEST button on Thermostat — Install a Carrier-approved accessory 2-stage the face of the receptacle to trip and open the receptacle. Check thermostat according to installation instructions included with for proper grounding wires and power line phasing if the GFCI the accessory.
  • Page 20 This device may be a separate humidistat control (contact closes on rise in space RH above control setpoint) or a combi- nation thermostat-humidistat control device such as Carrier’s EDGE Pro Thermidistat with isolated contact set for dehu- ®...
  • Page 21 Fig. 34 — 48TC*B07 (Unit with Humidi-MiZer ® Adaptive Dehumidification System) Humidistat Wiring...
  • Page 22 ® Fig. 35 — Edge ® Pro Thermidistat EDGE Pro THERMIDISTAT Unit CTB THERMOSTAT O/W2/B SRTN ® Humidi-MiZer FIOP *Connection not required. Fig. 36 — 48TC*B07 (Unit with Humidi-MiZer Adaptive Dehumidification System...
  • Page 23 ECONOMI$ER X (FACTORY-INSTALLED OPTION) Relay Digital Output Rating at 30 Vac (maximum power ® from Class 2 input only) — 1.5A run: Product Description — The EconoMi$er X system is an ex- 3.5A inrush at 0.45PF (200,000 cycles) or pandable economizer control system, which includes a W7220 7.5A inrush at 0.45PF (100,000 cycles) economizer module (controller) with an LCD and keypad (see Fig.
  • Page 24 ECONOMIZER MODULE WIRING DETAILS — Use Table 10 — Economizer Module - Right Hand Fig. 38 and Tables 9 and 10 to locate the wiring terminals for Terminal Blocks the Economizer module. LABEL TYPE DESCRIPTION NOTE: The four terminal blocks are removable. Slide out each Top Right Terminal Blocks terminal block, wire it, and then slide it back into place.
  • Page 25: Disconnect

    Keypad — The four navigation buttons (see Fig. 41) are used Table 11 — HH57AC081 Sensor Wiring to scroll through the menus and menu items, select menu items, Terminations and to change parameter and configuration settings. TERMINAL TYPE DESCRIPTION NUMBER LABEL S-BUS Communications...
  • Page 26 Setup and Configuration — Before being placed into service, the W7220 Economizer module must be setup and configured IMPORTANT: Table 13 illustrates the complete hierar- for the installed system. chy. Your menu parameters may be different depending on your configuration. IMPORTANT: During setup, the Economizer module is For example if you do not have a DCV (CO ) sensor,...
  • Page 27 Table 13 — Menu Structure PARAMETER PARAMETER MENU PARAMETER DEFAULT RANGE AND NOTES VALUE INCREMENT FIRST STAGE COOLING DEMAND (Y1-IN) ECONO AVAIL YES/NO YES = economizing available; the system can use outside air for free cooling when required FIRST STAGE COOLING RELAY OUTPUT ECONOMIZING YES/NO YES = outside air being used for 1 stage cooling...
  • Page 28 Table 13 — Menu Structure (cont) PARAMETER PARAMETER MENU PARAMETER DEFAULT RANGE AND NOTES VALUE INCREMENT Displays number of times actuator has cycled. ACT COUNT 1 to 65535 1 cycles equals 180 deg. of actuator movement in any direction. OK/Alarm (on Alarm ACTUATOR Displays ERROR if voltage or torque is below actuator range.
  • Page 29 Table 13 — Menu Structure (cont) PARAMETER PARAMETER MENU PARAMETER DEFAULT RANGE AND NOTES VALUE INCREMENT Display order = MM/DD/YY INSTALL 01/01/10 Setting order = DD, MM, then YY. UNITS DEG F or C Sets economizer controller in degrees Fahrenheit or Celsius CONV = conventional;...
  • Page 30: Disconnect

    Table 13 — Menu Structure (cont) PARAMETER PARAMETER MENU PARAMETER DEFAULT RANGE AND NOTES VALUE INCREMENT MAT T CAL 0.0°F ±2.5°F SUPPLY AIR TEMPERATURE CALIBRATION Allows for the operator to adjust for an out of calibration temperature sensor. OAS T CAL 0.0°F ±2.5°F OUTSIDE AIR TEMPERATURE CALIBRATION...
  • Page 31 Table 13 — Menu Structure (cont) PARAMETER PARAMETER MENU PARAMETER DEFAULT RANGE AND NOTES VALUE INCREMENT SHUTDOWN ACTIVE AUX2 IN is programmed for SHUTDOWN and 24 V has been applied to AUX 2IN terminal. DMP CAL RUNNING DAMPER CALIBRATION ROUTINE RUNNING If DCV Auto enable has been programmed, when the W7220 is complet- ing a calibration on the dampers, this alarm will display.
  • Page 32 Table 14 — Damper Minimum Position Settings and Readings on Checkout Menu DEMAND CONTROLLED FAN SPEED VENTILATION SETPOINTS CHECKOUT SENSOR) MIN POS VMAX–HS MIN POS H VMAX–HS MIN POS L VMAX–LS VENT MIN VMAX–HS VENT MAX VMAX–HS VENT MIN H VMAX–HS VENT MAX H VMAX–LS...
  • Page 33 Table 17 — Enthalpy Operation No 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 0v/Off 0v/Off MIN POS Closed NONE HIGH 24v/On 0v/Off MIN POS Closed HIGH 24v/On...
  • Page 34 Table 19 — Dry Bulb Operation No DCV (CO Sensor) — 2 Speed Fan DEMAND OUTSIDE AIR CONTROLLED GOOD TO Y1-I Y2-I Y1-O Y2-O OCCUPIED UNOCCUPIED SPEED VENTILATION (DCV) ECONOMIZE 0v/Off 0v/Off MIN POS Closed NONE 24v/On 0v/Off MIN POS Closed HIGH 24v/On...
  • Page 35 Table 21 — Enthalpy Operation No DCV (CO Sensor) — 2 Speed Fan DEMAND OUTSIDE AIR CONTROLLED GOOD TO Y1-I Y2-I Y1-O Y2-O OCCUPIED UNOCCUPIED SPEED VENTILATION (DCV) ECONOMIZE 0v/Off 0v/Off MIN POS Closed 24v/On 0v/Off MIN POS Closed HIGH 24v/On 24v/On MIN POS...
  • Page 36 ECONOMIZING DUAL ENTHALPY AVAILABLE HIGH LIMIT NOT AVAILABLE SINGLE ENTHALPY P2 (T,RH) (T,RH) TEMPERATURE Fig. 42 — Single Enthalpy Curve Boundaries Table 23 — Single Enthalpy and Dual Enthalpy High Limit Curves POINT P1 POINT P2 ENTHALPY TEMP. DRY TEMP. ENTHALPY HUMIDITY HUMIDITY...
  • Page 37 Checkout To perform a Checkout test: Inspect all wiring connections at the Economizer module’s 1. Scroll to the desired test in the Checkout menu using terminals, and verify compliance with the installation wiring the ▲ and ▼ buttons. diagrams. 2. Press the button to select the item.
  • Page 38 PREMIERLINK™ (FACTORY-OPTION) — The Premier- includes the supply-air temperature (SAT) sensor. The outdoor Link controller (see Fig. 43) is compatible with Carrier Com- air temperature (OAT) sensor is included in the FIOP/accesso- fort Network (CCN) devices. This control is designed to al- ry EconoMi$er2 package.
  • Page 39 Fig. 45 — PremierLink Wiring Schematic...
  • Page 40 Fig. 46 — PremierLink Wiring Schematic with Humidi-MiZer ® System...
  • Page 41 Supply Air Temperature (SAT) Sensor — FIOP- information. Have a copy of this manual available at unit equipped 48TC unit, the unit is supplied with a supply-air tem- start-up. perature (SAT) sensor (33ZCSENSAT). This sensor is a tubu- NOTE: The sensor must be mounted in the discharge air- lar probe type, approx 6-inches (152 mm) in length.
  • Page 42 CCN - (BLK) Digital, 5VDC LEGEND — Space Temperature Sensor — Fire Shutdown — Space Temperature Sensor — Indoor Air Quality (CO — Carrier Comfort Network ® (communication bus) — Outdoor Air Quality (CO CMPSAFE — Compressor Safety — Relative Humidity FILTER —...
  • Page 43 Space Sensors — The PremierLink controller is factory- shipped configured for Space Sensor Mode. A Carrier T-55 or T-56 space sensor must be used. T-55 space temperature sensor provides a signal of space temperature to the PremierLink con- trol. T-56 provides same space temperature signal plus it allows for adjustment of space temperature setpoints from the face of the sensor by the occupants, see Fig.
  • Page 44 If the 48TC unit has an economizer system and Wiring the Indoor Air Quality Sensor — For each sensor, use free-cooling operation is required, a sensor representing Return two 2-conductor 18 AWG (American Wire Gage) twisted-pair Air Temperature must also be connected (field-supplied and in- cables (unshielded) to connect the separate isolated 24 vac stalled).
  • Page 45 PremierLink control can monitor return filter status in two The sensor must be mounted vertically on the wall. The ways: By monitoring a field-supplied/installed filter pressure Carrier logo should be orientated correctly when the sensor is switch or via supply fan runtime hours. properly mounted.
  • Page 46 1000 ft. sure rises indicating fan operation. NOTE: Carrier device default is 9600 band. Connect one side of the switch’s NO contact set to CTB’s Communications Bus Wire Specifications — The CCN THERMOSTAT-R terminal.
  • Page 47 The RTU Open controller is an integrated component of the (typically WHT) to the unit’s TB1-14 terminal. Connect the Carrier rooftop unit. Its internal application programming pro- CCN (-) lead (typically BLK) to the unit’s TB1-16 terminal. vides optimum performance and energy efficiency. RTU Open See Fig.
  • Page 48 Fig. 65 — Typical RTU Open System Control Wiring Diagram...
  • Page 49 ® Fig. 66 — Typical RTU Open System Control Wiring Diagram with Humidi-MiZer System...
  • Page 50 Table 30 — RTU Open Controller Inputs and Outputs BACNET OBJECT CONNECTION POINT NAME TYPE OF I/O CHANNEL DESIGNATION NAME PIN NUMBER (S) DEDICATED INPUTS Space Temp / Zone Temp zone_temp AI (10K Thermistor) J20–1 & 2 Analog Input 10 Supply Air Temperature sa_temp AI (10K Thermistor)
  • Page 51 BLU (SPT) Space Temperature (SPT) Sensors — There are two types of J20-1 SPT sensors available from Carrier, resistive input non-com- municating (T55, T56, and T59) and Rnet communicating (SPS, SPPL, SPP, and SPPF) sensors. Each type has a variety of options consisting of: timed override button, set-point ad- justment, a LCD screen, and communication tie in.
  • Page 52: Humidi-Mizer

    To accurately monitor the quality of the air in the condi- Humidi-MiZer ® Control Wiring — In units equipped with tioned air space, locate the sensor near a return-air grille (if the Humidi-MiZer option there are two pink (PNK) wires loose present) so it senses the concentration of CO leaving the in the control box used to control the dehumidification function...
  • Page 53: Rtu Open Communication Wiring Protocols

    or 9 to Fan Status and normally open (N/O) or normally closed J4-1 or J4-4 + 24 VDC (N/C). Input 8 or 9 is recommended for easy of installation. Re- SUPPLY VOLTAGE fer to Fig. 64 and Fig. 65 or 66 for wire terminations at J5. J4-2 or J4-5 (-)4 to 20 mA Current Remote Occupancy —...
  • Page 54: Local Access

    LOCAL ACCESS Wall Mounted Equipment Touch — The Equipment Touch is a wall mounted interface used to connect to the RTU Open to access the control information, read sensor values, and mainte- nance. This is an accessory interface that does not come with the RTU Open controller.
  • Page 55: Outdoor Air Enthalpy Control

    Table 31 — LEDs (The LEDs on the RTU Open show the status of certain functions) IF THIS LED IS ON... THE STATUS IS... Power RTU Open has power RTU Open is receiving data from the network segment RTU Open is transmitting data over the network segment The digital output is active The Run and Error LEDs indicate control module and network status 2 Flashes Per Second...
  • Page 56 Completing Installation of Return Air Smoke Sensor 1. Unscrew the two screws holding the Return Air Smoke RETURN AIR Detector assembly. See Fig. 81, Step 1. Save the SMOKE DETECTOR screws. (AS SHIPPED) 2. Turn the assembly 90 and then rotate end to end. Make sure that the elbow fitting is pointing down.
  • Page 57: Smoke Detectors

    Fig. 82 — EconoMi$er IV Wiring • Power Exhaust Step 13 — Adjust Factory-Installed Options • Differential dry-bulb sensor (EconoMi$er IV) SMOKE DETECTORS — Smoke detector(s) will be con- • Outdoor enthalpy sensor nected at the Controls Connections Board, at terminals marked •...
  • Page 58: Pre-Start And Start-Up

    TENSION FORCE IN BELT (LBS) Used Table 2 Fig. 83 — V-Belt Force Label © Carrier Corporation 2018 Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 04-53480180-01 Printed in U.S.A.
  • Page 59 START-UP CHECKLIST — 48TC PACKAGED ROOFTOP UNITS WITH GAS HEAT AND ELECTRIC COOLING 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 preceding sections of this Installation Instruction document.
  • Page 60 (Y/N) _____ 10. Restore set-points for thermostat and humidistat (Y/N) _____ © Carrier Corporation 2018 Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 04-53480180-01 Printed in U.S.A.

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