Page 1: Table Of Contents
® WeatherMaker 48KC04-06 Single Package Rooftop Gas Heating/Electric Cooling Unit ® with Puron (R-410A) Refrigerant Installation Instructions Page CONTENTS Outdoor Air Enthalpy Control ....40 Page Smoke Detectors .
Page 2: Model Number Nomenclature And
WARNING AVERTISSEMENT RISQUE D’INTOXICATION AU MONOXYDE DE Failure to follow this warning could result in personal injury CARBONE or death. Disconnect gas piping from unit when leak testing at pressure Si ces directives ne sont pas suivies, cela peut entraîner des greater than 0.5 psig (3450 Pa).
Page 3 Rated Indoor Airflow Table 1 — Rated Indoor Airflow Table 1 lists the rated indoor airflow used for the AHRI ef- MODEL NUMBER FULL LOAD AIRFLOW (CFM) ficiency rating for the units covered in this document. 48KC*A/B04 1050 48KC*A/B05 1400 48KC*A/B06 1750 Position:...
Page 4 Fig. 2 — Unit Dimensional Drawing...
Page 5 Fig. 2 — Unit Dimensional Drawing (cont)
Page 6: Installation
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. (1067 mm) Surface behind servicer is grounded (e.g., metal, masonry wall) 36 in.
Page 7: Roof Mount
ROOF MOUNT PAD-MOUNTED INSTALLATION Check building codes for weight distribution require- Prepare pad and unit supports ments. Unit operating weights are shown in Table 2. Check and tighten the bottom condensate drain connec- tion plug Table 2 — Operating Weights Rig and place unit Convert unit to side duct connection arrangement UNIT LB (KG)
Page 8 Fig. 4 — Roof Curb Details...
Page 9: Slab Mount (Horizontal Units Only)
Fabricate supply ductwork so that the cross sectional di- mensions are equal to or greater than the unit supply duct opening dimensions for the first 18 in. (458 mm) of duct length from the unit basepan. Insulate and weatherproof all external ductwork, joints, and roof openings with counter flashing and mastic in accor- dance with applicable codes.
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 48KC-A04 74.5 1890 33.5 48KC-A05 74.5 1890 33.5 48KC-A06 1020 74.5...
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
Carefully lift the hood assembly (with metal tray) Remove the shipping tape holding the economizer baro- through the filter access opening and assemble per the metric relief damper in place (economizer only). steps outlined in the Economizer Hood and Two-Position Insert the hood divider between the hood sides.
Page 13: Step 11 - Install Gas Piping
The gas supply pipe enters the unit at the burner access panel on the front side of the unit, through the long slot at the bottom of the access panel. The gas connection to the unit is made to the -in.
Page 14: Factory-Option Thru-Base Connections (Gas Connections)
9” MINIMUM CLEARANCE FOR PANEL REMOVAL REGULATOR MANUAL GAS SHUTOFF VALVE BASE UNIT 48” MINIMUM DRIP LEG PER NFGC BASE RAIL BRASS FITTING SUPPORT FIELD-FABRICATED EMBOSSMENT ROOF FOR 3-6 TON UNITS BRACKET SUPPORT CURB FROM Fig. 19 — Gas Line Piping for 3 to 5 Ton Units Only METER Other hardware required to complete the installation of the LEGEND...
Page 15: Step 12 - Install External Condensate Trap
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). 9”...
Page 16: Step 13 - Make Electrical Connections
The piping for the condensate drain and external trap can convenience outlet. If an always-energized convenience be completed after the unit is in place. See Fig. 25. outlet operation is desired, connect the source leads to the line side of the unit-mounted disconnect. (Check with local codes to ensure this method is acceptable in your area.) If a de- energize via unit disconnect switch operation of the convenience outlet is desired, connect the source leads to the...
Page 17: Units With Factory-Installed Non-Fused Disconnect Or Hacr
ELECTRIC DISCONNECT SWITCH COPPER WIRE ONLY ALUMINUM WIRE Fig. 27 — Disconnect Switch and Unit UNITS WITH FACTORY-INSTALLED NON-FUSED DIS- CONNECT OR HACR The factory-installed option non-fused disconnect (NFD) or HACR switch is located in a weatherproof enclosure locat- ed under the main control box. The manual switch handle and Fig.
Page 18: Units Without Factory-Installed Non-Fused Disconnect Or Hacr
Field-Install the HACR Shaft and Handle UNITS WITHOUT FACTORY-INSTALLED NON-FUSED DISCONNECT OR HACR Remove unit front panel (see Fig. 2). Remove (3) hex screws on the HACR enclosure — (2) When installing units, provide a disconnect switch per on the face of the cover and (1) on the left side cover. See NEC (National Electrical Code) of adequate size.
Page 19 GFCI RECEPTACLE PWD-CO TRANSFORMER NOT INCLUDED COVER - WHILE-IN-USE CONVENIENCE WEATHERPROOF OUTLET GFCI GASKET PWD-CO FUSE SWITCH BASEPLATE FOR GFCI RECEPTACLE CONTROL BOX Fig. 33 — Weatherproof Cover Installation ACCESS PANEL Non-Powered Convenience Outlet Fig. 32 — Convenience Outlet Location This type requires the field installation of a general-pur- Installing Weatherproof Cover pose 125v 15A circuit powered from a source elsewhere in...
Page 20: 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 accessories 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 21: Units Without Thru-Base Connections (Electrical Connections)
PremierLink™ controller (available as factory-installed op- larger than no. 18 AWG cannot be directly connected to the tion or as field-installed accessory, for use on a Carrier Com- thermostat and will require a junction box and splice at the fort Network ®...
Page 22: Heat Anticipator Settings
Fig. 40 — Edge Pro Thermidistat Set heat anticipator settings at 0.14 amp for the first stage and 0.14 amp for second-stage heating, when available. Connecting the Carrier Humidistat (HL38MG029) HUMIDI-MIZER ® CONTROL CONNECTIONS Route the humidistat 2-conductor cable (field-supplied) through the hole provided in the unit corner post.
Page 23 ® Fig. 41 — Typical Humidi-MiZer Adaptive Dehumidification System Humidistat Wiring...
Page 24 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...
Page 25 Fig. 43 — Typical Control Wiring Diagram Electro-Mechanical with W7212...
Page 26 Fig. 44 — Typical 48KC 04-06 Power Wiring Diagram, 208-230/3/60 Unit Shown...
Page 27: Low Ambient Control (Factory Option)
When the thermostat calls for heating, power is sent to W Low Ambient Control (Factory Option) on the Integrated Gas Controller (IGC) board. An LED (light If the unit comes with Electro-Mechanical (EM) control, emitting diode) on the IGC board turns on and remains on then no adjustment is necessary.
Page 28 Locking Tab Connector Overcurrent Fuse Protection Locking Redundant Gas Tab Connector Valve Relay Spade Connect Ignitor Fig. 46 — IGC Board Component Layout Fig. 47 — Typical IGC Control Wiring Diagram...
Page 29: Economi$Er (Factory Option)
User Interface ® Economi$er (Factory Option) Provides status for normal operation, setup parameters, The EconoMi$er X system is an expandable economizer checkout tests, and alarm and error conditions with a 2-line control system, which includes a W7220 economizer module 16 character LCD display and four button keypad. (controller) with an LCD and keypad (See Fig.
Page 30 Shipping Temperature Table 7 — Economizer Module - Left Hand Terminal Blocks -40 to 150°F (-40 to 65°C) LABEL TYPE DESCRIPTION Relative Humidity Top Left Terminal Block 5% to 95% RH non-condensing 20k NTC Mixed Air Temperature Sensor Economizer Module Wiring Details and COM (Polarity Insensitive Connection) Use Fig.
Page 31 S-Bus Sensor Wiring to power the CO sensor OR make sure the ground for the power supplies are common. See Fig. 51 for CO sensor wir- The labels on the sensors and controller are color coded ing. for ease of installation. Orange labeled sensors can only be wired to orange terminals on the controller.
Page 32 Use the ▲ and ▼ buttons to scroll to the desired param- eter. IMPORTANT: Table 11 illustrates the complete hierar- Press the (Enter) button to display the value of the chy. Your menu parameters may be different depending currently displayed item. on your configuration.
Page 33 Table 11 — 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 34 Table 11 — Menu Structure* (cont) PARAMETER PARAMETER MENU PARAMETER DEFAULT RANGE AND NOTES † VALUE INCREMENT SUPPLY AIR SETPOINT 38 to 65 F; increment MAT SET Setpoint determines where the economizer will modulate the OA damper to by 1 maintain the mixed air temperature.
Page 35 Table 11 — Menu Structure* (cont) PARAMETER PARAMETER MENU PARAMETER DEFAULT RANGE AND NOTES † VALUE INCREMENT INPUT INPUT or ALWAYS OCCUPIED MODE BY EXTERNAL SIGNAL When using a setback thermostat with occupancy out (24 vac), the 24 vac is input “INPUT”...
Page 36 Table 11 — Menu Structure* (cont) PARAMETER PARAMETER MENU PARAMETER DEFAULT RANGE AND NOTES † VALUE INCREMENT Alarms display only when they are active. The menu title “ALARMS(#)” includes the number of active alarms in parenthesis ( ). When using SYLK bus sensors, “SYLK”...
Page 37 Table 12 — Damper Minimum Position Settings and Readings on Checkout Menu DEMAND CONTROLLED VENTILATION SETPOINTS FAN SPEED 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 38 Table 15 — 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 39 ECONOMIZING DUAL ENTHALPY AVAILABLE HIGH LIMIT NOT AVAILABLE SINGLE ENTHALPY P2 (T,RH) (T,RH) TEMPERATURE Fig. 53 — Single Enthalpy Curve Boundaries Checkout To perform a Checkout test: Inspect all wiring connections at the economizer module’s Scroll to the desired test in the Checkout menu using the terminals, and verify compliance with the installation wiring ▲...
Page 40: Outdoor Air Enthalpy Control
Outdoor Air Enthalpy Control Smoke Detectors (P/N 33CSENTHSW) Smoke detectors are available as factory-installed options on 48KC models. Smoke detectors may be specified for Sup- The enthalpy control (33CSENTHSW) is available as a ply Air only or for Return Air without or with economizer, or field-installed accessory to be used with the EconoMi$er ®...
Page 41: Step 14 - Adjust Factory-Installed Options
• Thru-base connection kit (must be installed before unit is Step 14 — Adjust Factory-Installed Options set on curb) SMOKE DETECTORS • LP conversion kit • Flue discharge deflector Smoke detector(s) will be connected at the Controls Connec- • Manual outside air damper tions Board, at terminals marked “Smoke Shutdown.”...
Page 42: Step 16 - Check Belt Tension
TENSION FORCE IN BELT (LBS) Used Table 2 Fig. 59 — 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. 04-53480188-01 Printed in U.S.A.
Page 43: Start-Up Checklist
START-UP CHECKLIST FOR 48KC04-06 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 2018 Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.

Carrier WeatherMaker 48KC Series Installation Instructions Manual

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