Carrier 48GC04 Service And Maintenance Instructions
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Carrier 48GC04 Service And Maintenance Instructions

Single package rooftop gas heat/electric cooling unit with puron (r-410a) refrigerant 3 to 5 nominal tons
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Service and Maintenance Instructions
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . 2
UNIT ARRANGEMENT AND ACCESS . . . . . . . . . . . . 3
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 3
Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SUPPLY FAN (BLOWER) SECTION . . . . . . . . . . . . . . 4
Supply Fan (Direct-Drive) . . . . . . . . . . . . . . . . . . . . . . 4
Staged Air Volume . . . . . . . . . . . . . . . . . . . . . . . . . . 11
COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Condenser Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Recommendation . . . . . . . . . . . . . . . . . . . . . . . . . 11
Evaporator Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
TXV Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Replacing TXV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
PURON (R-410A) REFRIGERANT . . . . . . . . . . . . . . 15
Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . . . . . 15
COOLING CHARGING CHARTS . . . . . . . . . . . . . . . . 15
COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Replacing Compressor . . . . . . . . . . . . . . . . . . . . . . . 17
Compressor Rotation . . . . . . . . . . . . . . . . . . . . . . . . 17
Filter Drier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Condenser-Fan Adjustment . . . . . . . . . . . . . . . . . . . 17
Troubleshooting Cooling System . . . . . . . . . . . . . . 19
CONVENIENCE OUTLETS . . . . . . . . . . . . . . . . . . . . 20
Convenience Outlets . . . . . . . . . . . . . . . . . . . . . . . . 20
Installing Weatherproof Cover . . . . . . . . . . . . . . . . . 20
Non-Powered Type . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Unit-Powered Type . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Fuse on Powered Type . . . . . . . . . . . . . . . . . . . . . . . 21
SMOKE DETECTORS . . . . . . . . . . . . . . . . . . . . . . . . 21
System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Smoke Detector Sensor . . . . . . . . . . . . . . . . . . . . . . 21
Smoke Detector Locations . . . . . . . . . . . . . . . . . . . . 22
Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
SENSOR AND CONTROLLER TESTS . . . . . . . . . . . 24
Sensor Alarm Test . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Controller Alarm Test . . . . . . . . . . . . . . . . . . . . . . . . 24
Dirty Controller Test . . . . . . . . . . . . . . . . . . . . . . . . . 24
Dirty Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Changing the Dirt Sensor Test . . . . . . . . . . . . . . . . 25
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Catalog No. 04-53480212-01
Single Package Rooftop Gas Heat/Electric Cooling Unit
Printed in U.S.A.
®
with Puron
Remote Station Test . . . . . . . . . . . . . . . . . . . . . . . . .25
Dirty Sensor Test Using an SD-TRK4 . . . . . . . . . . .25
Detector Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
PROTECTIVE DEVICES . . . . . . . . . . . . . . . . . . . . . . .27
Compressor Protection . . . . . . . . . . . . . . . . . . . . . . .27
Relief Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Control Circuit, 24-V . . . . . . . . . . . . . . . . . . . . . . . . .27
GAS HEATING SYSTEM . . . . . . . . . . . . . . . . . . . . . .27
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Fuel Types and Pressures . . . . . . . . . . . . . . . . . . . .28
Flue Gas Passageways . . . . . . . . . . . . . . . . . . . . . . .28
Combustion-Air Blower . . . . . . . . . . . . . . . . . . . . . . .28
Burners and Igniters . . . . . . . . . . . . . . . . . . . . . . . . .29
Burner Ignition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Orifice Replacement . . . . . . . . . . . . . . . . . . . . . . . . .32
Troubleshooting Heating System . . . . . . . . . . . . . . .34
SYSTEMVU CONTROL SYSTEM . . . . . . . . . . . . . . . .36
SystemVu Interface . . . . . . . . . . . . . . . . . . . . . . . . . .36
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . .36
RTU OPEN CONTROL SYSTEM . . . . . . . . . . . . . . . .37
Sensory/Accessory Installation . . . . . . . . . . . . . . . .37
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . .38
ECONOMIZER SYSTEMS . . . . . . . . . . . . . . . . . . . . .38
EconoMi$er2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Economi$er X (Factory Option) . . . . . . . . . . . . . . . .47
PRE-START-UP/START-UP . . . . . . . . . . . . . . . . . . . .60
START-UP, GENERAL . . . . . . . . . . . . . . . . . . . . . . . .60
Unit Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
Additional Installation/Inspection . . . . . . . . . . . . . .60
Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
Return-Air Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
Outdoor-Air Inlet Screens . . . . . . . . . . . . . . . . . . . . .61
Compressor Mounting . . . . . . . . . . . . . . . . . . . . . . . .61
Internal Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
Refrigerant Service Ports . . . . . . . . . . . . . . . . . . . . .61
Compressor Rotation . . . . . . . . . . . . . . . . . . . . . . . .61
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
Main Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
Ventilation (Continuous Fan) . . . . . . . . . . . . . . . . . .62
FASTENER TORQUE VALUES . . . . . . . . . . . . . . . . .62
START-UP, RTU OPEN CONTROLS . . . . . . . . . . . . .62
START-UP, SYSTEMVU CONTROLS . . . . . . . . . . . .62
48GC04-06
(R-410A) Refrigerant
3 to 5 Nominal Tons
8-19

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Summary of Contents for Carrier 48GC04

  • Page 1: Table Of Contents

    48GC04-06 Single Package Rooftop Gas Heat/Electric Cooling Unit ® with Puron (R-410A) Refrigerant 3 to 5 Nominal Tons Service and Maintenance Instructions Remote Station Test ......25 SAFETY CONSIDERATIONS .

  • Page 2: Safety Considerations

    APPENDIX A — MODEL NUMBER WARNING NOMENCLATURE......63 APPENDIX B — PHYSICAL DATA....64 FIRE, EXPLOSION HAZARD APPENDIX C —...

  • Page 3: Unit Arrangement And Access

    Heating UNIT ARRANGEMENT AND ACCESS • Heat exchanger flue passageways cleanliness General • Gas burner condition Figures 1 and 2 show general unit arrangement and access • Gas manifold pressure locations. • Heating temperature rise FILTER ACCESS PANEL Economizer or Outside Air Damper •...

  • Page 4: Supply Fan (Blower) Section

    Supply Fan (Direct-Drive) All GC units have the EcoBlue™ direct drive vane axial fan 17 1/4” system. The fan is driven by an ECM motor with speed that is user set through the Unit Control Board (UCB). Speeds are ful- ly configurable from 40% to 100% of motor’s maximum speed.
  • Page 5 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. 7 for location on 3 phase voltage units or Fig. 8 for location on single phase volt- age units.
  • Page 6 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 7 Low Speed Fan Adjustment (Single Phase and 3-Phase units) Units with SystemVu™ controls 2-Pin DIP Switch On units equipped with the factory-installed SystemVu con- troller the Fan Speed settings are accessed through the The 2-pin DIP switch is common to both the single and 3 phase SystemVu interface.
  • Page 8 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 9 Removing the Motor and Fan Assembly NOTE: Due to press fit design of composite Rotor on Motor, it is highly recommended that any time a motor is replaced the fan rotor is replaced as well. The rest of the assembly may be reused.
  • Page 10 Install four #10-32 x -in. hex head machine screws (P/N: AD07AB126) to connect aluminum stator to motor. Tighten to 23 in.-lb (2.6 Nm). Fit grommet on motor wire harness into keyhole feature on the side of the stator and pull wire harness out through grommet.

  • Page 11: Staged Air Volume

    Reinstalling Motor and Fan Assembly COOLING See Fig. 17. WARNING Align motor harness/grommet at ~7 o’clock (facing installer) and align the bottom flats on right and left sides UNIT OPERATION AND SAFETY HAZARD of fan stator with fan deck ribs. Drop fan assembly down Failure to follow this warning could cause personal injury, into fan deck opening and slide back until aluminum stator death and/or equipment damage.
  • Page 12 Totaline environmentally balanced coil cleaner is nonflamma- ble, hypo-allergenic, non-bacterial, and a USDA accepted bio- COIL CLIPS degradable agent that will not harm the coil or surrounding components such as electrical wiring, painted metal surfaces, or insulation. Use of non-recommended coil cleaners is strong- ly discouraged since coil and unit durability could be affected.

  • Page 13: Evaporator Coil

    If economizer or two-position damper is installed, remove economizer by disconnecting Molex plug and removing CAUTION mounting screws. UNIT DAMAGE HAZARD Slide filters out of unit. Failure to follow this caution may result in reduced unit Clean coil using a commercial coil cleaner or dishwasher performance or unit shutdown.

  • Page 14: Refrigerant System Pressure Access Ports

    remove the mechanical flare nut from the equalizer line. Then use a new coupling to braze the equalizer line to the stub (previous equalizer line) in suction line. Attach TXV bulb in the same location where the original (in the sensing bulb indent) was when it was removed, using the supplied bulb clamps.

  • Page 15: Puron (R-410A) Refrigerant

    Refrigerant Charge Amount of refrigerant charge is listed on the unit’s nameplate. Refer to Carrier GTAC2-5 Charging, Recovery, Recycling and Reclamation training manual and the following procedures. Unit panels must be in place when unit is operating during the -6.7...
  • Page 16 5 Ton Mid-Tier CHARGING CHART 4 Ton Mid-Tier CHARGING CHART (Unit must run on high stage compressors and (Unit must run on high stage compressors and outdoor fan on high speed) outdoor fan on high speed) °C °F °C °F 59.9 59.9 Add charge if Above Curve...

  • Page 17: Compressor

    COMPRESSOR Compressor Rotation Lubrication CAUTION The compressor is charged with the correct amount of oil at the EQUIPMENT DAMAGE HAZARD factory. Failure to follow this caution can result in premature wear and damage to equipment. CAUTION Scroll compressors can only compress refrigerant if rotat- UNIT DAMAGE HAZARD ing in the right direction.
  • Page 18 NO SCREW (Blank Tab) Fig. 31 — Condenser-Fan Assembly — Screw Pattern Sequence...

  • Page 19: Troubleshooting Cooling System

    Troubleshooting Cooling System Refer to Table 4 for additional troubleshooting topics. Table 4 — Troubleshooting SYMPTOM CAUSE SOLUTION Power failure. Call power company. Fuse blown or circuit breaker tripped. Replace fuse or reset circuit breaker. Determine root cause. Defective thermostat, contactor, transformer. Replacement component.

  • Page 20: Convenience Outlets

    Press the gasket over the screw heads. Slip the backing CONVENIENCE OUTLETS plate over the screw heads at the keyhole slots and align with the gasket; tighten the two screws until snug (do not WARNING over-tighten). Mount the weatherproof cover to the backing plate as ELECTRICAL OPERATION HAZARD shown in Fig.

  • Page 21: Duty Cycle

    unit is factory-configured for immediate smoke detector shut- down operation; additional wiring or modifications to unit termi- nal board may be necessary to complete the unit and smoke de- tector configuration to meet project requirements. System The smoke detector system consists of a four-wire controller and one or two sensors.

  • Page 22: Smoke Detector Locations

    appropriate action to shut down fans and blowers, change over air handling systems, notify the fire alarm control panel, etc. The sensor uses a process called differential sensing to prevent SUPPLY AIR gradual environmental changes from triggering false alarms. A SMOKE DETECTOR rapid change in environmental conditions, such as smoke from a fire, causes the sensor to signal an alarm state but dust and...

  • Page 23: Completing Installation Of Return Air Smoke

    RETURN AIR SMOKE DETECTOR SENSOR WITH Rotate the detector plate so the sensor is facing outwards ECONOMIZER and the sampling tube connection is on the bottom. See Fig. 41. The sampling tube is inserted through the side plates of the economizer housing, placing it across the return air opening on RETURN AIR SMOKE DETECTOR the unit basepan.

  • Page 24: Sensor And Controller Tests

    Fig. 42 — Typical Smoke Detector System Wiring ADDITIONAL APPLICATION DATA IMPORTANT: Failure to follow this ALERT can result Refer to the application data document “Factory Installed Smoke in an unnecessary evacuation of the facility. Detectors for Small and Medium Rooftop Units 2 to 25 Tons” for This test places the duct detector into the alarm state.

  • Page 25: Changing The Dirt Sensor Test

    Table 5 — Dirty LED Test FLASHES DESCRIPTION 0-25% dirty. (Typical of a newly installed detector) SMOKE DETECTOR 25-50% dirty CONTROLLER 51-75% dirty − 76-99% dirty AUXILIARY EQUIPMENT DIRTY SENSOR TEST PROCEDURE Hold the test magnet where indicated on the side of the sensor housing for two seconds.

  • Page 26: Indicators

    Table 6 — Detector Indicators CONTROL OR DESCRIPTION HVAC DUCT SAMPLING INDICATOR TUBE SENSOR Resets the sensor when it is in the alarm or trouble Magnetic test/ HOUSING state. Activates or tests the sensor when it is in the reset switch normal state.

  • Page 27: Protective Devices

    Check the wiring between the sensor and the controller. If Relief Device wiring is loose or missing, repair or replace as required. A soft solder joint at the suction service access port provides pressure relief under abnormal temperature and pressure condi- CONTROLLER’S POWER LED IS OFF tions (i.e., fire in building).

  • Page 28: Fuel Types And Pressures

    SUPPLY PRESSURE SWITCH Fuel Types and Pressures The LP conversion kit includes a supply low pressure switch. NATURAL GAS The switch contacts (from terminal C to terminal NO) will The 48GC unit is factory-equipped for use with natural gas open the gas valve power whenever the supply line pressure (NG) fuel at elevation under 2000 ft (610 m).

  • Page 29: Burners And Igniters

    HEATER TUBE ASSEMBLY SEAL STRIPS, SPONGE RUBBER REGULATOR GASKET REGULATOR BAFFLE ASSEMBLY (LOW NO x ONLY) RETAINER FLUE COVER ASSEMBLY PRESSURE SWITCH HOSE CONNECTION VESTIBULE PLATE FLUE BAFFLE (LOW NO x ONLY) INDUCER FAN-MOTOR ASSEMBLY BURNER ASSEMBLY Fig. 50 — Heat Exchanger Assembly To inspect blower wheel, shine a flashlight into draft hood Orifice projection opening.
  • Page 30 HEAT EXCHANGER SUPPORT RACK LIMIT SWITCH HEAT EXCHANGER COVER PANEL UNIT BURNER CENTER PARTITION POST PANEL Fig. 52 — Heat Exchanger Access - Internal Panels, Center Post and HX Rack Locations CLEANING AND ADJUSTMENT Remove burner rack from unit as described in “Removal and Replacement of Gas Train”...
  • Page 31 Disconnect the igniter wires and sensor wires at the inte- 11. Remove the screws around the vestibule plate. grated gas controller (IGC). 12. Remove the nuts holding the heat exchanger support rack Disconnect a gas pipe union and remove the gas manifold to the fan deck.

  • Page 32: Burner Ignition

    GAS VALVE control box (see Fig. 54). The IGC contains a self-diagnostic LED (light-emitting diode). A single LED (see Fig. 57) on the All three-phase models (except Low NOx) are equipped with 2- IGC provides a visual display of operational or sequential prob- stage gas valves.
  • Page 33 RED LED - STATUS Fig. 57 — Integrated Gas Control (IGC) Board...

  • Page 34: Troubleshooting Heating System

    MINIMUM HEATING ENTERING AIR TEMPERATURE Thermostat When operating on first stage heating, the minimum tempera- ture of air entering the dimpled heat exchanger is 50°F continu- ous and 45°F intermittent for standard heat exchangers and 40°F continuous and 35°F intermittent for stainless steel heat OALT exchangers.
  • Page 35 Table 13 — IGC Board LED Alarm Codes ACTION TAKEN BY FLASH DESCRIPTION RESET METHOD PROBABLE CAUSE CONTROL CODE Normal Operation — — — Loss of power to the IGC. Check 5 amp fuse Hardware Failure No gas heating. — on IGC, power to unit, 24V circuit breaker, transformer, and wiring to the IGC.

  • Page 36: Systemvu Control System

    Through the SystemVu interface, the user can access all of the The SystemVu control system is fully communicating and inputs and outputs to check on their values and status, config- cable-ready for connection to the Carrier Comfort Network ® ure operating parameters, and evaluate the current decision sta- (CCN), Carrier i-Vu ®...

  • Page 37: Rtu Open Control System

    The RTU Open controller is an integrated component of the RTU Open. Some of these can be factory or field installed, Carrier rooftop unit. Its internal application programming pro- while others are only field installable. The RTU Open control- vides optimum performance and energy efficiency. RTU Open...

  • Page 38: Additional Rtu Open Installation And Troubleshooting

    OUTSIDE AIR WARNING TEMPERATURE SENSOR ECONOMI$ER X ELECTRICAL SHOCK HAZARD HARNESS Failure to follow this warning could result in personal inju- ry, death and/or equipment damage. Disconnect and lockout/tagout electrical power before wir- ing the RTU Open controller. Additional RTU Open Installation and Trouble- shooting Additional installation, wiring and troubleshooting information for the RTU Open Controller can be found in the following...

  • Page 39: Economi$Er2

    EconoMi$er2 IMPORTANT: The optional EconoMi$er ® 2 does not include a controller. The EconoMi$er2 is operated by a 4 to 20 mA signal from an existing field-supplied control- ler. See Fig. 64 for wiring information. BLACK TRANSFORMER GROUND BLUE 500 OHM RESISTOR VIOLET PINK...

  • Page 40: Economi$Er Iv (Field-Installed Accessory)

    EconoMi$er IV (Field-Installed Accessory) IMPORTANT: For GC rooftop units EconoMi$er IV is only available as a field-installed accessory. ECONOMI$ER IV STANDARD SENSORS Troubleshooting instructions are enclosed. A functional view of the EconoMi$er ® is shown in Fig. 65. Typical settings, sen- sor ranges, and jumper positions are also shown.
  • Page 41 Table 14 — EconoMi$er IV Input/Output Logic INPUTS OUTPUTS Demand Enthalpy* Compressor N Terminal† Controlled Ventilation Outdoor Return Stage 1 Stage 2 Occupied Unoccupied (DCV) High (Free Cooling Minimum position Closed LED Off) Below set (DCV LED Off) Modulating** (between Modulating** (between min.
  • Page 42 DIP SWITCH CHANGEOVER Table 15 — Supply Air Sensor Temperature/Resistance Values POSITION TEMPERATURE TEMPERATURE (F) RESISTANCE (ohms) 48°F 220,250 100,000 1 2 3 53,010 53°F 29,091 16,500 1 2 3 9,795 55°F 5,970 3,747 1 2 3 3,000 58°F 2,416 1,597 1 2 3 1,080...
  • Page 43 HORIZONTAL ECONOMIZER BAROMETRIC RELIEF FLOW VERTICAL ECONOMIZER BAROMETRIC RELIEF FLOW 2500 2500 Horizontal Economizers Vertical Economizers 2000 2000 1500 1500 3-5 Ton 3-5 Ton 1000 1000 0.05 0.15 0.25 0.05 0.15 0.25 RETURN DUCT STATIC PRESSURE (in. wg) RETURN DUCT STATIC PRESSURE (in. wg) HORIZONTAL ECONOMIZER RETURN AIR PRESSURE DROP VERTICAL ECONOMIZER RETURN AIR PRESSURE DROP 6000...
  • Page 44 Exhaust Set Point Adjustment (29) (32) (35) (38) (41) (43) The exhaust set point will determine when the exhaust fan runs based on damper position (if accessory power exhaust is in- CONTROL CONTROL POINT CURVE APPROX. deg. F (deg. C) stalled).
  • Page 45 EconoMi$er IV control will be in occu- Use setting 1 or 2 for Carrier equipment. pied mode. When the timeclock contacts are open (removing Press Clear and Mode buttons. Hold at least 5 seconds the 24-v signal from terminal N), the EconoMi$er IV will be in until the sensor enters the Edit mode.
  • Page 46 If connected, remove sensor from terminals SO and +. DCV MINIMUM AND MAXIMUM POSITION Connect 1.2 kilo-ohm 4074EJM checkout resistor across To check the DCV minimum and maximum position: terminals SO and +. Make sure EconoMi$er IV preparation procedure has been Put 620-ohm resistor across terminals SR and +.

  • Page 47: Economi$Er X (Factory Option)

    Economizer Module Economi$er X (Factory Option) The module is the core of the EconoMi$er X system. The mod- The EconoMi$er X system is an expandable economizer con- ® ule is mounted in the unit’s control box, and includes the user trol system, which includes a W7220 economizer module (con- interface for the system.
  • Page 48 INPUTS Sensors NOTE: A Mixed Air (MA) analog sensor is required on all W7220 units; either an Outdoor Air (OA) sensor for dry bulb change over or an OA bus sensor for outdoor enthalpy change over is required in addition to the MA sensor. An additional Re- turn Air (RA) bus sensor can be added to the system for differen- tial enthalpy or dry bulb changeover.
  • Page 49 Table 17 — Economizer Module - Right Hand Table 18 — HH57AC081 Sensor Wiring Terminations Terminal Blocks TERMINAL TYPE DESCRIPTION LABEL TYPE DESCRIPTION NUMBER LABEL Top Right Terminal Blocks S-BUS Communications AUX2 I 24 vac IN The first terminal is not used. S-BUS S-BUS (Enthalpy Control...
  • Page 50 • Press the ▼ (Down arrow) button to move to the next Press the (Enter) button to accept the displayed value menu. and store it in nonvolatile RAM. “CHANGE STORED” displays. • Press the (Enter) button to display the first item in the currently displayed menu.
  • Page 51 Table 20 — 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 52 Table 20 — W7220 Menu Structure* (cont) PARAMETER PARAMETER MENU PARAMETER DEFAULT RANGE AND NOTES VALUE INCREMENT † MECH COOL ON 0, 1, or 2 Displays stage of mechanical cooling that is active. HEAT STAGES ON Displays the stage of heat pump heating that is active. STATUS FAN SPEED LOW or HIGH...
  • Page 53 Table 20 — W7220 Menu Structure* (cont) PARAMETER PARAMETER MENU PARAMETER DEFAULT RANGE AND NOTES VALUE INCREMENT † ERV OAT SP 32°F 0 to 50°F ENERGY RECOVERY VENTILATOR UNIT OUTDOOR AIR †† increment by 1 TEMPERATURE SETPOINT Only displayed when AUX1 O = ERV EXH1 SET 0 to 100% Exhaust fan set point for single speed units.
  • Page 54 Table 20 — W7220 Menu Structure* (cont) PARAMETER PARAMETER MENU PARAMETER DEFAULT RANGE AND NOTES VALUE INCREMENT † STG3 DLY 2.0h 0 min, 5 min, COOLING STAGE 3 DELAY 15 min, then Delay after stage 2 cool has been active. Turns on second stage of 15 min intervals.
  • Page 55 Table 20 — W7220 Menu Structure* (cont) PARAMETER PARAMETER MENU PARAMETER DEFAULT RANGE AND NOTES VALUE INCREMENT † DA SYLK T ERR DISCHARGE AIR S-BUS SENSOR ERROR Discharge air sensor has failed or become disconnected - check wiring then replace sensor if the alarm continues. OA SENS T ERR OUTSIDE AIR TEMPERATURE SENSOR ERROR Outdoor air temperature sensor has failed or become disconnected -...
  • Page 56 Enthalpy Settings point are all below the selected boundary, the economizer sets the economizing mode to YES, economizing is available. When the OA temperature, enthalpy and dew point are below the respective setpoints, the Outdoor Air can be used for econ- When all of the OA conditions are above the selected bound- omizing.
  • Page 57 Standard or Single Speed Fan Operation The W (heating mode) is not controlled by the W7220 but it re- quires the status to know where to position the OA damper for FAN TYPE = 1SPEED is not used on 48GC units. minimum position for the fan speed.
  • Page 58 2SP H/C (2 Speed Heat/Cool) Fan Operation this reduction in fan speed during heat, the economizer FAN TYPE must be set to keep the appropriate outside air intake. FAN TYPE = 2SP H/C is not used on 48GC units. On single phase 48GC 3 to 5 ton units, if reduced the heating 3 Speed Fan Operation (single phase units only) fan speed is lower than the high cooling speed and higher than The W7220 controller does not actually control the fan speed...
  • Page 59 CHECKOUT To perform a Checkout test: Scroll to the desired test in the Checkout menu using the Inspect all wiring connections at the economizer module’s ter- minals, and verify compliance with the installation wiring dia- ▲ and ▼ buttons. grams. For checkout, review the Status of each configured pa- Press the (Enter) button to select the item.

  • Page 60: Pre-Start-Up/Start-Up

    c. Inspect all field-wiring and factory-wiring connec- PRE-START-UP/START-UP tions. Be sure that connections are completed and tight. Be sure that wires are not in contact with refrig- WARNING erant tubing or sharp edges. d. Inspect coil fins. If damaged during shipping and han- PERSONAL INJURY HAZARD dling, carefully straighten fins with a fin comb.

  • Page 61: Return-Air Filters

    Compressor Rotation WARNING If the information in this manual is not followed exactly, a CAUTION fire or explosion may result causing property damage, per- EQUIPMENT DAMAGE HAZARD sonal injury or loss of life. Failure to follow this caution can result in premature wear Do not store or use gasoline or other flammable vapors and and damage to equipment.

  • Page 62: Ventilation (Continuous Fan)

    Turn on electrical supply and manual gas valve. Ventilation (Continuous Fan) Set system switch selector at HEAT position and fan Set fan and system selector switches at ON and OFF positions, switch at AUTO. or ON position. Set heating temperature respectively.
  • Page 63 APPENDIX A — MODEL NUMBER NOMENCLATURE Position: 9 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 ®...
  • Page 64 APPENDIX B — PHYSICAL DATA 48GC 3 TO 5 TON — COOLING 48GC UNIT 48GC*M04 48GC*N04 48GC*M05 48GC*N05 48GC*M06 48GC*N06 NOMINAL TONS BASE UNIT OPERATING WT (lb) 48GC* 513/468 555/510 600/555 REFRIGERATION SYSTEM No. Circuits/No. Compressors/Type 1 / 1/ 2-Stage Scroll Puron ®...
  • Page 65 APPENDIX B — PHYSICAL DATA 48GC 3 TO 5 TON GAS HEAT DATA — 1 PHASE UNITS 48GC UNIT 48GC**04 48GC**05 48GC**06 GAS CONNECTION No. of Gas Valves Natural Gas Supply Line Pressure (in. wg)/(psig) 4-13 / 0.18-0.47 Liquid Propane Supply Line Pressure (in. wg)/(psig) 11-13 / 0.40-0.47 HEAT ANTICIPATOR SETTING (AMPS) First Stage...
  • Page 66 APPENDIX B — PHYSICAL DATA 48GC 3 TO 5 TON GAS HEAT DATA — 3 PHASE UNITS 48GC UNIT 48GC**04 48GC**05 48GC**06 GAS CONNECTION No. of Gas Valves Natural Gas Supply Line Pressure (in. wg)/(psig) 4-13 / 0.18-0.47 Liquid Propane Supply Line Pressure (in. wg)/(psig) 11-13 / 0.40-0.47 HEAT ANTICIPATOR SETTING (AMPS) First Stage...
  • Page 67 APPENDIX C — FAN PERFORMANCE GENERAL FAN PERFORMANCE NOTES 1. Interpolation is permissible. Do not extrapolate. 2. External static pressure is the static pressure difference between the return duct and the supply duct plus the static pressure caused by any FIOPs or accessories. 3.
  • Page 68 APPENDIX C — FAN PERFORMANCE 48GC**04 SINGLE PHASE — 3 TON VERTICAL SUPPLY (RPM - BHP) AVAILABLE EXTERNAL STATIC PRESSURE (in. wg) 1129 0.10 1356 0.17 1544 0.26 1708 0.35 1857 0.45 1182 0.11 1402 0.19 1586 0.28 1748 0.37 1894 0.47 1050...
  • Page 69 APPENDIX C — FAN PERFORMANCE 48GC**04 SINGLE PHASE – MEDIUM STATIC — 3 TON VERTICAL SUPPLY (RPM - VDC) AVAILABLE EXTERNAL STATIC PRESSURE (in. wg) 1129 1356 1544 1708 1857 1182 1402 1586 1748 1894 1050 1236 1449 1630 1789 1933 1125 1290...
  • Page 70 APPENDIX C — FAN PERFORMANCE 48GC**04 THREE PHASE — 3 TON VERTICAL SUPPLY (RPM - BHP) AVAILABLE EXTERNAL STATIC PRESSURE (in. wg) 1129 0.10 1356 0.17 1544 0.26 1708 0.35 1857 0.45 1182 0.11 1402 0.19 1586 0.28 1748 0.37 1894 0.47 1050...
  • Page 71 APPENDIX C — FAN PERFORMANCE 48GC**04 THREE PHASE – MEDIUM STATIC — 3 TON VERTICAL SUPPLY (RPM - VDC) AVAILABLE EXTERNAL STATIC PRESSURE (in. wg) 1129 1356 1544 1708 1857 1182 1402 1586 1748 1894 1050 1236 1449 1630 1789 1933 1125 1290...
  • Page 72 APPENDIX C — FAN PERFORMANCE 48GC**05 SINGLE PHASE — 4 TON VERTICAL SUPPLY (RPM - BHP) AVAILABLE EXTERNAL STATIC PRESSURE (in. wg) 1200 1262 0.21 1453 0.33 1614 0.45 1757 0.58 1888 0.72 1300 1333 0.25 1517 0.37 1674 0.50 1813 0.63 1942...
  • Page 73 APPENDIX C — FAN PERFORMANCE 48GC**05 SINGLE PHASE – MEDIUM STATIC — 4 TON VERTICAL SUPPLY (RPM - VDC) AVAILABLE EXTERNAL STATIC PRESSURE (in. wg) 1200 1262 1453 1614 1757 1888 1300 1333 1517 1674 1813 1942 1400 1405 1583 1735 1872 1997...
  • Page 74 APPENDIX C — FAN PERFORMANCE 48GC**05 THREE PHASE — 4 TON VERTICAL SUPPLY (RPM - BHP) AVAILABLE EXTERNAL STATIC PRESSURE (in. wg) 1200 1262 0.21 1452 0.33 1614 0.45 1757 0.58 1888 0.72 1300 1333 0.25 1516 0.37 1674 0.50 1813 0.63 1942...
  • Page 75 APPENDIX C — FAN PERFORMANCE 48GC**05 THREE PHASE – MEDIUM STATIC — 4 TON VERTICAL SUPPLY (RPM - VDC) AVAILABLE EXTERNAL STATIC PRESSURE (in. wg) 1200 1262 1453 1614 1757 1888 1300 1333 1517 1674 1813 1942 1400 1405 1583 1735 1872 1997...
  • Page 76 APPENDIX C — FAN PERFORMANCE 48GC**06 SINGLE PHASE — 5 TON VERTICAL SUPPLY (RPM - BHP) AVAILABLE EXTERNAL STATIC PRESSURE (in. wg) 1500 1387 0.28 1561 0.40 1711 0.53 1845 0.66 1966 0.80 1625 1473 0.34 1638 0.46 1784 0.60 1914 0.74 2034...
  • Page 77 APPENDIX C — FAN PERFORMANCE 48GC**06 SINGLE PHASE – MEDIUM STATIC — 5 TON VERTICAL SUPPLY (RPM - VDC) AVAILABLE EXTERNAL STATIC PRESSURE (in. wg) 1500 1387 1561 1711 1845 1966 1625 1473 1638 1784 1914 2034 1750 1560 1717 1859 1986 2103...
  • Page 78 APPENDIX C — FAN PERFORMANCE 48GC**06 THREE PHASE — 5 TON VERTICAL SUPPLY (RPM - BHP) AVAILABLE EXTERNAL STATIC PRESSURE (in. wg) 1500 1387 0.28 1560 0.40 1711 0.53 1845 0.66 1966 0.80 1625 1473 0.34 1638 0.46 1784 0.60 1915 0.74 2034...
  • Page 79 APPENDIX C — FAN PERFORMANCE 48GC**06 THREE PHASE – MEDIUM STATIC — 5 TON VERTICAL SUPPLY (RPM - VDC) AVAILABLE EXTERNAL STATIC PRESSURE (in. wg) 1500 1387 1560 1711 1845 1966 1473 1638 1784 1915 2034 1625 1750 1561 1717 1858 1986 2103...
  • Page 80 APPENDIX C — FAN PERFORMANCE 48GC**04 SINGLE PHASE — 3 TON HORIZONTAL SUPPLY (RPM - BHP) AVAILABLE EXTERNAL STATIC PRESSURE (in. wg) 1097 0.09 1331 0.16 1524 0.25 1692 0.34 1842 0.44 1146 0.10 1373 0.18 1562 0.27 1728 0.36 1877 0.46 1050...
  • Page 81 APPENDIX C — FAN PERFORMANCE 48GC**04 SINGLE PHASE – MEDIUM STATIC — 3 TON HORIZONTAL SUPPLY (RPM - VDC) AVAILABLE EXTERNAL STATIC PRESSURE (in. wg) 1097 1331 1524 1692 1842 1146 1373 1562 1728 1877 1050 1197 1416 1601 1765 1912 1125 1249...
  • Page 82 APPENDIX C — FAN PERFORMANCE 48GC**04 THREE PHASE — 3 TON HORIZONTAL SUPPLY (RPM - BHP) AVAILABLE EXTERNAL STATIC PRESSURE (in. wg) 1097 0.09 1331 0.16 1524 0.25 1692 0.34 1842 0.44 1146 0.10 1373 0.18 1562 0.27 1728 0.36 1877 0.46 1050...
  • Page 83 APPENDIX C — FAN PERFORMANCE 48GC**04 THREE PHASE – MEDIUM STATIC — 3 TON HORIZONTAL SUPPLY (RPM - VDC) AVAILABLE EXTERNAL STATIC PRESSURE (in. wg) 1097 1331 1524 1692 1842 1146 1373 1562 1728 1877 1050 1197 1416 1601 1765 1912 1125 1249...
  • Page 84 APPENDIX C — FAN PERFORMANCE 48GC**05 SINGLE PHASE — 4 TON HORIZONTAL SUPPLY (RPM - BHP) AVAILABLE EXTERNAL STATIC PRESSURE (in. wg) 1200 1217 0.19 1411 0.30 1576 0.42 1722 0.55 1855 0.68 1300 1283 0.23 1470 0.34 1631 0.46 1774 0.60 1904...
  • Page 85 APPENDIX C — FAN PERFORMANCE 48GC**05 SINGLE PHASE – MEDIUM STATIC — 4 TON HORIZONTAL SUPPLY (RPM - VDC) AVAILABLE EXTERNAL STATIC PRESSURE (in. wg) 1200 1217 1411 1576 1722 1855 1300 1283 1470 1631 1774 1904 1400 1351 1531 1688 1827 1955...
  • Page 86 APPENDIX C — FAN PERFORMANCE 48GC**05 THREE PHASE — 4 TON HORIZONTAL SUPPLY (RPM - BHP) AVAILABLE EXTERNAL STATIC PRESSURE (in. wg) 1200 1216 0.19 1411 0.30 1576 0.42 1722 0.55 1855 0.68 1300 1283 0.23 1470 0.34 1631 0.46 1774 0.60 1904...
  • Page 87 APPENDIX C — FAN PERFORMANCE 48GC**05 THREE PHASE – MEDIUM STATIC — 4 TON HORIZONTAL SUPPLY (RPM - VDC) AVAILABLE EXTERNAL STATIC PRESSURE (in. wg) 1200 1216 1411 1576 1722 1855 1300 1283 1470 1631 1774 1904 1400 1351 1531 1687 1827 1955...
  • Page 88 APPENDIX C — FAN PERFORMANCE 48GC**06 SINGLE PHASE — 5 TON HORIZONTAL SUPPLY (RPM - BHP) AVAILABLE EXTERNAL STATIC PRESSURE (in. wg) 1500 1335 0.25 1507 0.36 1660 0.49 1796 0.61 1921 0.75 1625 1417 0.30 1580 0.42 1727 0.55 1860 0.68 1982...
  • Page 89 APPENDIX C — FAN PERFORMANCE 48GC**06 SINGLE PHASE – MEDIUM STATIC — 5 TON HORIZONTAL SUPPLY (RPM - VDC) AVAILABLE EXTERNAL STATIC PRESSURE (in. wg) 1500 1335 1507 1660 1796 1921 1625 1417 1580 1727 1860 1982 1750 1502 1654 1796 1926 2046...
  • Page 90 APPENDIX C — FAN PERFORMANCE 48GC**06 THREE PHASE — 5 TON HORIZONTAL SUPPLY (RPM - BHP) AVAILABLE EXTERNAL STATIC PRESSURE (in. wg) 1500 1335 0.25 1507 0.36 1660 0.49 1796 0.61 1921 0.75 1625 1418 0.30 1579 0.42 1727 0.55 1860 0.68 1982...
  • Page 91 APPENDIX C — FAN PERFORMANCE 48GC**06 THREE PHASE – MEDIUM STATIC — 5 TON HORIZONTAL SUPPLY (RPM - VDC) AVAILABLE EXTERNAL STATIC PRESSURE (in. wg) 1500 1335 1507 1660 1796 1921 1625 1418 1579 1727 1860 1982 1750 1502 1654 1797 1927 2046...
  • Page 92 APPENDIX D — WIRING DIAGRAMS WIRING DIAGRAMS 48GC**04-06 UNITS SIZE VOLTAGE CONTROL (OVERLAY) PAGE POWER PAGE 208/230-1-60 48TC002961 48TC002955 04-06 Electro-Mechanical 208/230-3-60 48TC002340 48TC002791 W7220 Standard Controller 460/575-3-60 48TC002959 48TC002956 208/230-1-60 48TC002961 (48TM002983) 48TC002955 04-06 RTU Open Controller 208/230-3-60 48TC002340 (48TM002983) 48TC002791 (Factory Option) 460/575-3-60...
  • Page 93 APPENDIX D — WIRING DIAGRAMS Fig. B — 48GC**04-06 Electro-Mechanical Control Wiring Diagram — 208/230-1-60 (with W7220 Control)
  • Page 94 APPENDIX D — WIRING DIAGRAMS Fig. C — 48GC**04-06 Electro-Mechanical Control Wiring Diagram — 208/230-3-60 (with W7220 Control)
  • Page 95 APPENDIX D — WIRING DIAGRAMS Fig. D — 48GC**04-06 Electro-Mechanical Control Wiring Diagram — 460/575-3-60 (with W7220 Control)
  • Page 96 APPENDIX D — WIRING DIAGRAMS Fig. E — 48GC**04-06 208/230-1-60 Unit with RTU Open Controller...
  • Page 97 APPENDIX D — WIRING DIAGRAMS Fig. F — 48GC**04-06 208/230-3-60 Unit with RTU Open Controller...
  • Page 98 APPENDIX D — WIRING DIAGRAMS Fig. G — 48GC**04-06 460/575-3-60 Unit with RTU Open Controller...
  • Page 99 APPENDIX D — WIRING DIAGRAMS Fig. H — 48GC**04-06 Power Wiring Diagram — 208/230-1-60...
  • Page 100 APPENDIX D — WIRING DIAGRAMS Fig. I — 48GC**04-06 Power Wiring Diagram — 208/230-3-60...
  • Page 101 APPENDIX D — WIRING DIAGRAMS Fig. J — 48GC**04-06 Power Wiring Diagram — 460/575-3-60...
  • Page 102 APPENDIX D — WIRING DIAGRAMS Fig. K — 48GC**04-06 SystemVu™ Control Wiring Diagram (All Voltages)
  • Page 103 APPENDIX D — WIRING DIAGRAMS Fig. L — 48GC**04-06 SystemVu™ Power Wiring Diagram — 208/230-1-60...
  • Page 104 APPENDIX D — WIRING DIAGRAMS Fig. M — 48GC**04-06 SystemVu™ Power Wiring Diagram — 208/230-3-60...
  • Page 105 APPENDIX D — WIRING DIAGRAMS Fig. N — 48GC**04-06 SystemVu™ Power Wiring Diagram — 460/575-3-60...

  • Page 106: Form 48Gc-4-6-01Sm Rev. A

    Fig. Q — 48GC**06 Outdoor Circuiting SENSOR LOCATION Fig. P — 48GC**05 Outdoor Circuiting © 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. 04-53480212-01 Printed in U.S.A.
  • Page 107 START-UP CHECKLIST 48GC04-06 SINGLE PACKAGE ROOFTOP GAS HEAT/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 preceding sections of this Service and Maintenance Instruction document.
  • Page 108 5. Turn off heating, cooling, and reheat, restore set points for thermostat and humidistat (Y/N) _____ © Carrier Corporation 2019 Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.

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