Page 1: Table Of Contents
Puron (R-410A) Refrigerant Installation Instructions 48HC 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 It is important to recognize safety information. This is the safety- alert symbol . When you see this symbol on the unit and in WARNING instructions or manuals, be alert to the potential for personal injury. CARBON-MONOXIDE POISONING HAZARD Understand the signal words DANGER, WARNING, CAUTION, Failure to follow instructions could result in severe personal and NOTE.
Page 3 WARNING WARNING ELECTRICAL SHOCK HAZARD FIRE HAZARD Failure to follow this warning could cause personal injury Failure to follow this warning could result in personal inju- or death. ry, death, and/or property damage. Before performing service or maintenance operations on Manifold pressure tap set screw must be tightened and -in.
Page 4: Model Number Nomenclature And
MODEL NUMBER NOMENCLATURE AND Pre-Installation DIMENSIONS Complete the following checks before installation. Consult local building codes and the NEC (National Elec- See Fig. 1 for 48HC model number nomenclature. See Figures 2 and 3 for unit dimensional drawings. Figure 4 shows trical Code) ANSI/NFPA 70 for special installation service clearance dimensions.
Page 5 Position: 10 11 12 13 14 15 16 17 18 Example: Unit Heat Type Factory Assigned 48 - Gas Heat Packaged Rooftop 0 = Standard 1 = LTL Model Series - WeatherMaster ® HC - High Efficiency Electrical Options A = None B = HACR Breaker Heat Options C = Non-Fused Disconnect...
Page 6 Fig. 2 — Unit Dimensional Drawing — Sizes 07-09...
Page 7 Fig. 2 — Unit Dimensional Drawing — Sizes 07-09 (cont)
Page 8 Fig. 3 — Unit Dimensional Drawing — Sizes 11 and 12...
Page 9 Fig. 3 — Unit Dimensional Drawing — Sizes 11 and 12 (cont)
Page 10: 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 42-in. (1067 mm) Surface behind servicer is grounded (e.g., metal, masonry wall) 36-in.
Page 11: Roof Mount
Although unit is weatherproof, avoid locations that permit wa- PAD-MOUNTED INSTALLATION ter from higher level runoff and overhangs to fall onto the unit. Prepare pad and unit supports Locate mechanical draft system flue assembly at least 4 ft Check and tighten the bottom condensate drain connection (1.2 m) from any opening through which combustion products plug could enter the building, and at least 4 ft (1.2 m) from any adja-...
Page 12 Fig. 5 — Roof Curb Details — Sizes 07-12...
Page 13: Slab Mount (Horizontal Units Only)
If a plenum return is used on a vertical unit, the return should be ducted through the roof deck to comply with applicable fire codes. A minimum clearance is not required around ductwork. CAUTION PROPERTY DAMAGE HAZARD Failure to follow this caution may result in damage to roofing materials.
Page 14: Positioning On Curb
DIMENSIONS MAX WEIGHT UNIT 48HC*(A,B,D,E)07 1200 88.0 2235 44.0 1120 41.5 1055 48HC*(D,E)08 1420 88.0 2235 44.0 1120 49.5 1255 48HC*(D,E)09 1420 88.0 2235 44.0 1120 49.5 1255 48HC*(D,E)11/12 1665 88.0 2235 32.0 49.5 1255 NOTES: 1. SPREADER BARS REQUIRED — Top damage will occur if spreader bars are not used. 2.
Page 15: Step 7 - Convert To Horizontal And Connect Ductwork (When Required)
Step 7 — Convert to Horizontal and Connect SCREWS Ductwork (when required) Unit is shipped in the vertical duct configuration. Unit without factory-installed economizer or return-air smoke detector op- tion may be field-converted to horizontal ducted configuration. To convert to horizontal configuration, remove screws from side duct opening covers (see Fig.
Page 16 Insert the hood divider between the hood sides. See Fig. 15 and 16. Secure hood divider with 2 screws on each hood side. The hood divider is also used as the bottom fil- ter rack for the aluminum filter. Open the filter clips which are located underneath the hood top.
Page 17: Step 9 - Install Flue Hood
Step 9 — Install Flue Hood Table 5 — Natural Gas Manifold Pressure Ranges Flue hood is shipped screwed to the basepan beside the burner UNIT MODEL UNIT SIZE HIGH FIRE LOW FIRE compartment access panel. Remove from shipping location and 07, 08, 09, 11, 3.5 in.
Page 18: Factory Option Thru-Base Connections (Gas Connections)
FACTORY OPTION THRU-BASE CONNECTIONS (GAS piping does not block access to the unit’s main control box or limit the required working space in front of the control box. CONNECTIONS) This service connection kit consists of a NPT gas adapter fit- ting, an electrical bulkhead connector and a -in.
Page 19: Step 11 - Install External Condensate Trap
When installing the gas supply line, observe local codes per- taining 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: Avoid low spots in long runs of pipe.
Page 20: Step 12 - Make Electrical Connections
Units Without Disconnect or HACR Option MINIMUM PITCH Equip 1˝ (25 mm) PER BASE RAIL GR Lug 10´ (3 m) OF LINE 3˝ (76 mm) OPEN VENT Disconnect TO ROOF SEE NOTE DRAIN ROOF Ground CURB (GR) DRAIN PLUG 208/230-3-60 460-3-60 575-3-60 NOTE: Trap should be deep enough to offset maximum unit static...
Page 21: Units With Factory-Installed Non-Fused Disconnect Or Hacr
11. Engaging the shaft into the handle socket, re-install (3) hex screws on the NFD enclosure. 12. Re-install the unit front panel. ELECTRIC DISCONNECT SWITCH COPPER WIRE ONLY ALUMINUM WIRE Fig. 28 — 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 located...
Page 22: Electrical Connections
10%. Use the formula shown below to determine the percent of voltage imbalance. Operation on im- proper line voltage or excessive phase imbalance constitutes abuse and may cause damage to electrical components. Such operation would invalidate any applicable Carrier warranty.
Page 23 Non-powered type PWRD-CO This type requires the field installation of a general-purpose TRANSFORMER 125-volt 15-A circuit powered from a source elsewhere in the CONVENIENCE building. Observe national and local codes when selecting wire OUTLET size, fuse or breaker requirements and disconnect switch size GFCI and location.
Page 24: Units Without Thru-Base Connections
HACR CIRCUIT BREAKER Link™ controller (available as factory-installed option or as The amp rating of the HACR factory-installed option is based field-installed accessory, for use on a Carrier Comfort Net- on the size, voltage, indoor motor and other electrical options work ®...
Page 25: Humidi-Mizer ® System Control Connections
This device may be a separate humidistat control (contact clos- es on rise in space RH above control setpoint) or a combination ® thermostat-humidistat control device such as Carrier’s Edge Pro Thermidistat with isolated contact set for dehumidification control. The humidistat is normally used in applications where ®...
Page 26 Fig. 41 — Typical Humidi-MiZer ® Adaptive Dehumidification System Humidistat Wiring...
Page 27: Typical Control Wiring Diagrams
Edge Programable Thermostat Unit CTB THERMOSTAT O/W2/B SRTN Humidi-MiZer™ FIOP *Connection not required. Fig. 42 — Typical Rooftop Unit with Humidi-MiZer Adaptive Dehumidification System with ® Edge Pro Thermidistat Device TYPICAL CONTROL WIRING DIAGRAMS See Fig. 43-50.
Page 28 Fig. 43 — Electro-Mechanical Control Wiring Diagram...
Page 29 ® Fig. 44 — Electro-Mechanical Control Wiring Diagram with Humidi-MiZer System...
Page 30 Fig. 45 — Typical ComfortLink Control Wiring Diagram (48HC*08/09 shown)
Page 31 Fig. 46 — Typical 48HC ComfortLink Control Power Wiring Diagram with Optional Humidi-MiZer System (208/230V, 460V - 3 Ph - 60 Hz shown)
Page 32 Fig. 47 — Typical PremierLink™ Control Wiring Diagram...
Page 33 ® Fig. 48 — Typical PremierLink Control Wiring Diagram with Humidi-MiZer System Option...
Page 34 Fig. 49 — Typical RTU Open Controller Wiring Diagram...
Page 35 Fig. 50 — Typical RTU Open Controller Wiring Diagram with Humidi-MiZer ® System Option...
Page 36: Economi$Er ® X (Factory Option)
ECONOMI$ER X (FACTORY OPTION) User Interface ® The interface provides status for normal operation, setup pa- The EconoMi$er X system is an expandable economizer rameters, checkout tests, and alarm and error conditions with a control system, which includes a W7220 economizer mod- 2-line 16 character LCD display and four button keypad.
Page 37 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 Relative Humidity and COM (Polarity Insensitive Connection) 5% to 95% RH non-condensing...
Page 38 S-Bus Sensor Wiring Sensor Wiring The labels on the sensors and controller are color coded for When using a CO sensor the black and brown common wires ease of installation. Orange labeled sensors can only be wired are internally connected and only one is connected to “IAQ to orange terminals on the controller.
Page 39 To use the keypad when working with Setpoints, System and Advanced Settings, Checkout tests and Alarms: IMPORTANT: Table 11 illustrates the complete hierar- Navigate to the desired menu. chy. Your menu parameters may be different depending Press the (Enter) button to display the first item in the on your configuration.
Page 40 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 41 Table 11 — Menu Structure* (cont) PARAMETER PARAMETER MENU PARAMETER DEFAULT RANGE AND NOTES VALUE INCREMENT ACT COUNT 1 to 65535 Displays number of times actuator has cycled. 1 cycles equals 180 deg. of actuator movement in any direction. ACTUATOR OK/Alarm (on Alarm Displays ERROR if voltage or torque is below actuator range.
Page 42 Table 11 — Menu Structure* (cont) PARAMETER PARAMETER MENU PARAMETER DEFAULT RANGE AND NOTES VALUE INCREMENT INSTALL 01/01/10 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 43 Table 11 — 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 44 Table 11 — 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 AUX2 IN 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 45 Table 13 — Dry Bulb 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...
Page 46 Table 16 — Enthalpy Operation with 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 VENTMIN Closed HIGH 24v/On 0v/Off VENTMIN Closed HIGH 24v/On 24v/On VENTMIN...
Page 47 Table 18 — Dry Bulb Operation with 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 VENTMIN Closed 24v/On 0v/Off VENTMIN Closed HIGH 24v/On 24v/On VENTMIN Closed...
Page 48 ECONOMIZING DUAL ENTHALPY AVAILABLE HIGH LIMIT NOT AVAILABLE SINGLE ENTHALPY P2 (T,RH) (T,RH) TEMPERATURE Fig. 56 — Single Enthalpy Curve Boundaries Table 21 — Single Enthalpy and Dual Enthalpy High Limit Curves POINT P1 POINT P2 ENTHALPY TEMP. DRY TEMP. ENTHALPY HUMIDITY HUMIDITY...
Page 49: Smoke Detectors
Troubleshooting WARNING Alarms Failure to follow this warning could result in personal inju- The economizer module provides alarm messages that display ry, property damage, or death. on the 2-line LCD. Before performing service or maintenance operations on NOTE: Upon power up, the module waits 60 minutes before unit, always turn off main power switch to unit and install checking for alarms.
Page 50: Additional Application Data
Staged Air Volume (SAV™) with Variable Fre- quency Drive (Factory Option) RETURN AIR For details on operating 48HC 2 stage cooling units equipped SMOKE DETECTOR with the factory-installed Staged Air Volume option, refer to (AS SHIPPED) the Variable Frequency Drive (VFD) Installation, Setup and Troubleshooting Supplement.
Page 51: Step 13 - Adjust Factory-Installed Options
Unit Without Economizer or Economizer 2 Position Damper 2 Position Damper ® Fig. 59 — EconoMi$er IV Wiring • Louvered hail guard Step 13 — Adjust Factory-Installed Options • Motormaster ® head pressure controls SMOKE DETECTORS • Phase monitor control Smoke detector(s) will be connected at the Controls Connec- •...
Page 52: Pre-Start And Start-Up
BELT TENSION METHOD — Requires belt tension gauge that measures tension in belt in units of lbs force. BLOWER PULLEY V-BELT MOTOR PULLEY MOTOR BELT DEFLECTION FORCE (LBS) BELT SMALLEST UNNOTCHED CROSS SHEAVE NOTCHED BELTS BELTS SECTION DIAMETER USED USED MOUNTING 3.0-3.6 MOTOR MOUNTING...
Page 54 © Carrier Corporation 2019 Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 04-53480221-01 Printed in U.S.A. Form 48HC-7-12-06SI Pg 54 1-19 Replaces: 48HC-7-12-05SI...
Page 55: Start-Up Checklist
START-UP CHECKLIST (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 preceding sec- tions of this Installation Instructions.
Page 56 10. Restore set-points for thermostat and humidistat (Y/N) _____ REPEAT PROCESS FOR 2 COMPRESSOR SYSTEMS. © Carrier Corporation 2019 Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 04-53480221-01 Printed in U.S.A.

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