Carrier WeatherMaker 48FC04-07 Installation Instructions Manual
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Carrier WeatherMaker 48FC04-07 Installation Instructions Manual

Single package rooftop gas heating/electric cooling unit with puron r-410a refrigerant
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CONTENTS
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . .1
DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Step 8 - Install Outside Air Hood . . . . . . . . . . . . . . .11
HOOD PACKAGE REMOVAL AND SETUP
(FACTORY OPTION)
Step 10 - Install Flue Hood . . . . . . . . . . . . . . . . . . . . .12
Step 11 - Install Gas Piping. . . . . . . . . . . . . . . . . . . . .13
and Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
®
Integrated Gas Controller . . . . . . . . . . . . . . . . . . . . . . .25
X (Factory Option) . . . . . . . . . . . . . . . . .27
®
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Catalog No. 04-53480209-01
Installation Instructions
Page
Printed in U.S.A.
Form 48FC-4-7-01SI
48FC04-07 Single Package Rooftop
Gas Heating/Electric Cooling Unit
®
with Puron
RTU Open Controller (Factory Option). . . . . . . . . . . 41
Controller Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Smoke Detectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Step 15 - Install Accessories . . . . . . . . . . . . . . . . . . . 42
Step 16 - Fan Speed Set Up . . . . . . . . . . . . . . . . . . . . 43
START-UP CHECKLIST. . . . . . . . . . . . . . . . . . . . . . . .CL-1

SAFETY CONSIDERATIONS

Improper installation, adjustment, alteration, service,
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 agen-
cy, 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 thor-
oughly 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 require-
ments.
It is important to recognize safety information. This is the
safety-alert symbol
unit and in instructions or manuals, be alert to the potential
for personal injury.
Understand the signal words DANGER, WARNING,
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 which will result in enhanced in-
stallation, reliability, or operation.
Electrical shock can cause personal injury and death. Shut
off all power to this equipment during installation and ser-
vice. There may be more than one disconnect switch. Tag
all disconnect locations to alert others not to restore power
until work is completed.
Pg 1
1018
WeatherMaker
(R-410A) Refrigerant
. When you see this symbol on the
WARNING
8-18
Replaces: NEW
®
Page

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Summary of Contents for Carrier WeatherMaker 48FC04-07

  • Page 1: Table Of Contents

    ® WeatherMaker 48FC04-07 Single Package Rooftop Gas Heating/Electric Cooling Unit ® with Puron (R-410A) Refrigerant Installation Instructions CONTENTS Page Page SAFETY CONSIDERATIONS ..... .1 RTU Open Controller (Factory Option).

  • Page 2: Model Number Nomenclature And

    WARNING AVERTISSEMENT Failure to follow this warning could result in personal RISQUE D’INTOXICATION AU MONOXYDE DE injury or death. CARBONE Disconnect gas piping from unit when leak testing at pres- Si ces directives ne sont pas suivies, cela peut entraîner des sure greater than 0.5 psig (3450 Pa).

  • Page 3: Rated Indoor Airflow

    Rated Indoor Airflow Table 1 — Rated Indoor Airflow Table 1 lists the rated indoor airflow used for the AHRI MODEL NUMBER RATED INDOOR AIRFLOW (CFM) efficiency rating for the units covered in this document. 48FC*A/B04 1050 48FC*A/B05 1500 48FC*A/B06 2000 48FC*M/N07 2400...
  • Page 4  Fig. 2 — Unit Dimensional Drawing 1018...
  • Page 5  Fig. 2 — Unit Dimensional Drawing (cont) 1018...
  • Page 6  Fig. 2 — Unit Dimensional Drawing (cont) 1018...

  • Page 7: Installation

    INSTALLATION Step 2 — Plan for Sequence of Unit Installation The support method used for this unit will dictate different Jobsite Survey sequences for the steps of unit installation. For example, on Complete the following checks before installation. curb-mounted units, some accessories must be installed on Consult local building codes and the NEC (National the unit before the unit is placed on the curb.
  • Page 8 Fig. 3 — Roof Curb Details...

  • Page 9: Slab Mount (Horizontal Units Only)

    A minimum clearance is not required around ductwork. Step 6 — Rig and Place Unit CAUTION Failure to follow this caution may result in damage to roof- ing materials. Membrane roofs can be cut by sharp sheet metal edges. Be careful when placing any sheet metal parts on such roof.

  • Page 10: Step 7 - Convert To Horizontal And Connect

    "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 UNIT MAX WEIGHT 48FC**04 74.5 1890 37.6 33.5 48FC**05 74.5 1890 36.5 33.5 48FC**06...

  • Page 11: Step 8 - Install Outside Air Hood

    SCREWS HOOD PARTS PLASTIC TIE WRAP QTY (2) DUCT COVERS SHEET METAL FACE UP SCREWS FOR METAL TRAY QTY (2) BASEPAN Fig. 10 — Economizer and Two-Position Damper Hood Parts Location Carefully lift the hood assembly (with metal tray) through the filter access opening and assemble per the steps outlined in the Economizer Hood and Two-Position Fig.

  • Page 12: Step 9 - Units With Hinged Panels Only

    Step 9 — Units with Hinged Panels Only If the unit does not have hinged panels, skip this step and continue at Step 10 below. PANEL Relocate latch shipped inside the compressor compartment behind the hinged compressor door to location shown in INDOOR COIL Fig.

  • Page 13: Step 11 - Install Gas Piping

    Step 11 — Install Gas Piping Table 6 — Liquid Propane Manifold Pressure Ranges Installation of the gas piping must be accordance with lo- cal building codes and with applicable national codes. In UNIT MODEL UNIT SIZE HIGH FIRE LOW FIRE U.S.A., refer to NFPA 54/ANSI Z223.1 National Fuel Gas 10 in.
  • Page 14 HIGH VOLTAGE BRASS FITTING FOR CONDUIT 3 TO 6 TON UNITS CONNECTOR 9” (229mm) min Thru-Curb Adapter Union AUXILIARY POWER Unit Base Rail SUPPLY (OPTIONAL) LOW VOLTAGE CONDUIT Shut Off CONNECTOR Valve Fig. 17 — Thru-Base Gas Connection Fittings The thru-base gas connector has male and female threads. The male threads protrude above the basepan of the unit;...

  • Page 15: Step 12 - Install External Condensate Trap

    When installing the gas supply line, observe local codes pertaining to gas pipe installations. Refer to the NFPA 54/ ANSI Z223.1 NFGC latest edition (in Canada, CAN/CSA B149.1). In the absence of local building codes, adhere to the following pertinent recommendations: •...

  • Page 16: Step 13 - Make Electrical Connections

    NOTE: Unit may be equipped with short test leads (pigtails) on the field line connection points on contactor C or optional dis- connect switch. These leads are for factory-run test purposes on- MINIMUM PITCH ly; remove and discard before connecting field power wires to 1˝...

  • Page 17: Units Without Factory-Installed Non-Fused Disconnect

    Operation on improper line voltage or excessive phase imbal- ance constitutes abuse and may cause damage to electrical components. Such operation would invalidate any applicable Carrier warranty. Example: Supply voltage is 230-3-60 AB = 224 v BC = 231 v...

  • Page 18: Convenience Outlets

    CONVENIENCE OUTLETS WARNING WARNING Failure to follow this caution could result in personal injury or death. Failure to follow this caution could result in personal injury Disconnect all power to unit and convenience outlet. Lock- or death. out and tag-out all power prior to installation. Units with convenience outlet circuits may use multiple dis- connects.

  • Page 19: Factory-Option Thru-Base Connections (Electrical Connections)

    The 48FC unit requires an external temperature control de- vice. This device can be a thermostat (field-supplied) or a SystemVu™ controller (available as factory-installed option for use on a Carrier Comfort Network ® or as a stand alone control) or the RTU Open Controller for Building Manage- ment Systems using non-CCN protocols (RTU Open control- ler is available as a factory-installed option only).

  • Page 20: Heat Anticipator Settings

    This device may be a separate humidistat control (contact closes on rise in space RH above control setpoint) or a combination thermostat-humidistat control device such as Carrier’s Edge ® Pro Thermidistat™ device with isolated con- tact set for dehumidification control. See Fig. 36 and Fig. 37.

  • Page 21: Typical Unit Wiring Diagrams

    D2 for dehumidification operation (see Fig. 39). Connect Fig. 38. D1 to the R terminal on the UCB. Connect D2 to the HUM terminal on the UCB. Refer to the installation instructions included with the Carrier Edge Pro Ther- ® UNIT CONTROL midistat device for more information.
  • Page 22 Fig. 40 — Typical Control Wiring Diagram Electro-Mechanical with W7212 (48FC 04-06 208-230/3/60 Unit Shown)
  • Page 23 Fig. 41 — Typical Electro-Mechanical with W7220 Control Wiring Diagram (48FC 07 208-230/3/60 Unit Shown)
  • Page 24 Fig. 42 — Typical 48FC 04-07 Power Wiring Diagram, 208-230V Unit Shown...

  • Page 25: Integrated Gas Controller

    When the thermostat calls for heating, power is sent to W Integrated Gas Controller on the Integrated Gas Controller (IGC) board. An LED (light This unit contains an Integrated Gas Controller (IGC) emitting diode) on the IGC board turns on and remains on board.
  • Page 26 UNIT CONTROL BOARD Fig. 45 — Typical IGC Control Wiring Diagram...

  • Page 27: Economi$Er X (Factory Option)

    User Interface ® EconoMi$er X (Factory Option) Provides status for normal operation, setup parameters, The EconoMi$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.
  • Page 28 Storage Temperature Table 7 — Economizer Module - Left Hand Terminal Blocks –40 to 150°F (–40 to 65°C) LABEL TYPE DESCRIPTION Shipping Temperature Top Left Terminal Block –40 to 150°F (–40 to 65°C) 20k NTC Mixed Air Temperature Sensor (Polarity Relative Humidity and COM Insensitive Connection)
  • Page 29 S-Bus Sensor Wiring to power the CO sensor OR make sure the ground for the power supplies are common. See Fig. 49 for CO sensor The labels on the sensors and controller are color coded wiring. for ease of installation. Orange labeled sensors can only be wired to orange terminals on the controller.
  • Page 30 Press the (Enter) button to display the value of the IMPORTANT: Table 11 illustrates the complete hierar- currently displayed item. chy. Your menu parameters may be different depending Press the ▲ button to increase (change) the displayed on your configuration. parameter value.
  • Page 31 Table 11 — W7220 Menu Structure* PARAMETER PARAMETER MENU PARAMETER DEFAULT RANGE AND NOTES † VALUE INCREMENT ECONO AVAIL YES/NO FIRST STAGE COOLING DEMAND (Y1–IN) YES = economizing available; the system can use outside air for free cooling when required ECONOMIZING YES/NO FIRST STAGE COOLING RELAY OUTPUT...
  • Page 32 Table 11 — W7220 Menu Structure*(cont) PARAMETER PARAMETER MENU PARAMETER DEFAULT RANGE AND NOTES † VALUE INCREMENT MAT SET 53°F 38 to 70°F; MIXED AIR SETPOINT Setpoint determines where the economizer will mod- increment by 1 ulate the OA damper to maintain the mixed air temperature. LOW T LOCK 32°F -45 to 80°F...
  • Page 33 Table 11 — W7220 Menu Structure*(cont) PARAMETER PARAMETER MENU PARAMETER DEFAULT RANGE AND NOTES † VALUE INCREMENT INSTALL 01/01/17 Display order = MM/DD/YY Setting order = DD, MM, then YY. UNITS DEG F or C Sets economizer controller in degrees Fahrenheit or Celsius EQUIPMENT CONV Conventional or HP...
  • Page 34 Table 11 — W7220 Menu Structure*(cont) PARAMETER PARAMETER MENU PARAMETER DEFAULT RANGE AND NOTES † VALUE INCREMENT DAMPER MINIMUM The checkout for the damper minimum position is based on the system. POSITION DAMPER OPEN Position damper to the full open position. Exhaust fan contacts enable during the DAMPER OPEN test.
  • Page 35 LEGEND AND NOTES FOR TABLE 11 LEGEND NOTES: STATUS  OCCUPIED — The factory-standard Occupancy CLO — Compressor Lockout signal originates with a thermostat or other controller call for ERV — Energy Recovery Ventilator indoor fan operation at UCB terminal G. This signal passes through the Unit Control Board’s OCCUPANCY jumper to the LCD —...
  • Page 36 Enthalpy Settings OA dew point are all below the selected boundary, the econo- mizer sets the economizing mode to YES, economizing is When the OA temperature, enthalpy and dew point are be- available. low the respective setpoints, the Outdoor Air can be used for economizing.
  • Page 37 Standard or Single Speed Fan Operation The W7220 controller will control a standard 1 speed unit when configured for FAN TYPE = 1 SPEED. Refer to Table 13 for economizer operation. Table 13 — Economizer Operation - FAN TYPE = 1SPEED INPUTS OUTPUTS DEMAND...
  • Page 38 2 Speed Fan Operation The W (heating mode) is not controlled by the W7220 but it requires the status to know where to position the OA damp- NOTE: 2 Speed Fan operation applies to 48FC**07 models er for minimum position for the fan speed. only.
  • Page 39 2SP H/C (2 Speed Heat/Cool) Fan Operation (single phase economizer FAN TYPE must be set to keep the appropriate units only) outside air intake. The W7220 controller does not actually control the fan On single phase 48FC 3 to 5 ton units, if reduced the heat- speed or the heat output of the unit, and only uses this infor- ing fan speed is lower than the cooling speed and the econo- mation to help determine the damper position.
  • Page 40 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 ▲ and ▼ buttons. diagrams. For checkout, review the Status of each configured Press the (Enter) button to select the item.

  • Page 41: Rtu Open Controller (Factory Option)

    Completing Return Air Smoke Sensor Installation RTU Open Controller (Factory Option) Unscrew the two screws holding the Return Air Smoke For details on operating 48FC**04-07 units equipped with the Detector assembly. See Fig. 53, Step 1. Save the screws. factory-installed RTU Open controller option refer to the Turn the assembly 90 degrees and then rotate end to end.

  • Page 42: Step 14 - Adjust Factory-Installed Options

    Step 14 — Adjust Factory-Installed Options Step 15 — Install Accessories Available accessories include: SMOKE DETECTORS • Roof curb Smoke detector(s) will be connected at the Unit Control Board • Thru-base connection kit (must be installed before unit is (UCB), at terminals marked “Smoke Shutdown.” Detach the set on roof curb) jumper covering the Smoke Shutdown terminals on the UCB and then attach the wiring harness from the smoke detector.

  • Page 43: Step 16 - Fan Speed Set Up

    Step 16 — Fan Speed Set Up UNITS WITH ELECTRO-MECHANICAL CONTROLS The Fan Speed set up controls are located on the lower section of the Unit Control Board (UCB). See Fig. 55 loca- tion on 3 phase voltage units or Fig. 56 for location on single phase voltage units.
  • Page 44 ESP in. wg Factory Setting: Calculator 7.8 V 1500 Field Setting: 1625 Record field setting here 10.0 1750 1875 2000 Switch Range: 2125 2250 4.1 - 7.5 2375 6.9 - 8.7 2500 7.7 - 10.0 Field Accessories: Economizer * Overlap in A, B, C switch range designed for maximum field adjustment potential.
  • Page 45 ESP in. wg Calculator 1425 1609 1764 1902 2028 2147 2260 2367 1500 1512 1688 1839 1974 2097 2212 2322 1625 1601 1768 1916 2047 2168 2280 2387 1750 1692 1850 1994 2123 2241 2351 1875 1784 1933 2073 2200 2316 2000 1878...
  • Page 46 © 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. 04-53480209-01 Printed in U.S.A. Form 48FC-4-7-01SI Pg 46 1018 8-18 Replaces:NEW...

  • Page 47: Start-Up Checklist

    START-UP CHECKLIST FOR 48FC04-07 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 48 9. Open humidistat input compressor and outdoor fan stop; LSV and DSV solenoids de-energized (Y/N) _____ 10. Restore setpoints 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.

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