Carrier WeatherExpert 48LC 04 Series Installation Instructions Manual
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Carrier WeatherExpert 48LC 04 Series Installation Instructions Manual

Carrier WeatherExpert 48LC 04 Series Installation Instructions Manual

Single package rooftop gas heating/electric cooling unit with puron (r-410a) refrigerant
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NOTE: Read the entire instruction manual before starting the
installation.
CONTENTS
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . 1
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Rated Indoor Airflow (cfm) . . . . . . . . . . . . . . . . . . . . . 3
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Jobsite Survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Step 1 - Plan for Unit Location . . . . . . . . . . . . . . . . . 9
Step 3 - Inspect Unit . . . . . . . . . . . . . . . . . . . . . . . . . 9
Step 4 - Provide Unit Support . . . . . . . . . . . . . . . . . . 9
Step 5 - Field Fabricate Ductwork . . . . . . . . . . . . . 10
Step 6 - Rig and Place Unit . . . . . . . . . . . . . . . . . . . 10
Ductwork (when required). . . . . . . . . . . . . . . . . . . 12
Step 8 - Install Outside Air Hood . . . . . . . . . . . . . . 13
Step 10 - Install Flue Hood . . . . . . . . . . . . . . . . . . . 14
Step 11 - Install Gas Piping. . . . . . . . . . . . . . . . . . . 14
• UNITS WITHOUT FACTORY-INSTALLED NON-
FUSED DISCONNECT OR HACR
• CONVENIENCE OUTLETS
• FACTORY-OPTION THRU-BASE CONNECTIONS
(ELECTRICAL CONNECTIONS)
• FIELD CONTROL WIRING
• UNIT WITHOUT THRU-BASE CONNECTION KIT
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Catalog No. 04-53480187-01

Installation Instructions

Printed in U.S.A.
Form 48LC-4-6-04SI
WeatherExpert
Single Package Rooftop
Gas Heating/Electric Cooling Unit
with Puron
Humidi-MiZer® Control Connections . . . . . . . . . . . .27
RTU Open Control System. . . . . . . . . . . . . . . . . . . . .30
Smoke Detectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Step 15 - Install Accessories . . . . . . . . . . . . . . . . . .34
Step 16 - Check Belt Tension . . . . . . . . . . . . . . . . .34
Pre-Start and Start-Up . . . . . . . . . . . . . . . . . . . . . . . .34
• STANDARD DISPLAY MODE
• PARAMETERS MODE
• CHANGED PARAMETERS MODE
• DRIVE PARAMETER BACKUP MODE
• CLOCK SET MODE
• I/O SETTINGS MODE
KEYPAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
START-UP CHECKLIST . . . . . . . . . . . . . . . . . . . . .CL-1

SAFETY CONSIDERATIONS

Installation and servicing of air-conditioning equipment can be
hazardous due to system pressure and electrical components.
Only trained and qualified service personnel should install,
repair, or service air-conditioning equipment.
Untrained personnel can perform basic maintenance functions
of cleaning coils and filters and replacing filters. All other
operations should be performed by trained service personnel.
When working on air-conditioning equipment, observe
precautions in the literature, tags and labels attached to the
unit, and other safety precautions that may apply.
Follow all safety codes, including ANSI (American National
Standards Institute) Z223.1. Wear safety glasses and work
gloves. Use quenching cloth for unbrazing operations. Have
fire extinguisher available for all brazing operations.
It is important to recognize safety information. This is the
safety-alert symbol
. When you see this symbol on the unit
and in instructions or manuals, be alert to the potential for
personal injury.
Understand the signal
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 installation, reliability, or
operation.
Pg 1
®
48LC 04-06
®
(R-410A) Refrigerant
words
DANGER, WARNING,
6-19
Replaces: 48LC-4-6-03SI

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Summary of Contents for Carrier WeatherExpert 48LC 04 Series

  • Page 1: Table Of Contents

    WeatherExpert ® 48LC 04-06 Single Package Rooftop Gas Heating/Electric Cooling Unit with Puron ® (R-410A) Refrigerant Installation Instructions NOTE: Read the entire instruction manual before starting the Humidi-MiZer® Control Connections ... .27 installation.

  • Page 2: General

    AVERTISSEMENT WARNING RISQUE D’INTOXICATION AU MONOXYDE DE FIRE, EXPLOSION HAZARD CARBONE Failure to follow this warning could result in death, serious Si ces directives ne sont pas suivies, cela peut entraîner des personal injury and/or property damage. blessures graves ou une intoxication au monoxyde de car- bone pouvant causer la mort, si des produits de combustion Disconnect gas piping from unit when pressure testing at s’infiltrent dans le bâtiment.

  • Page 3: Rated Indoor Airflow (Cfm)

    Rated Indoor Airflow (cfm) Table 1 — Rated Indoor Airflow (cfm) Table 1 lists the rated indoor airflow used for the AHRI effi- ciency rating for the units covered in this document. FULL LOAD AIRFLOW MODEL NUMBER (CFM) 48LC**04 1050 48LC**05 1400 48LC**06...
  • Page 4 Fig. 2 — Dimensional Drawing of Units Built on and After 4/15/19...
  • Page 5 Fig. 3 — Dimensional Drawing for Units Built On and Prior to 4/14/19...
  • Page 6 Fig. 4 — Corner Weights and Clearances...
  • Page 7 Fig. 5 — Base Rail Details...
  • Page 8 Fig. 6 — Thru-the-Base Charts...

  • Page 9: Installation

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

  • Page 10: Slab Mount (Horizontal Units Only)

    CAUTION PROPERTY DAMAGE HAZARD 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. MAXIMUM ALLOWABLE DIFFERENCE –...
  • Page 11 Fig. 8 — Roof Curb Details...

  • Page 12: Step 7 - Convert To Horizontal And Connect Ductwork (When Required)

    CAUTION - NOTICE TO RIGGERS: AVERTISSEMENT - REMARQUE À L’ATTENTION DES MONTEURS ALL PANELS MUST BE IN PLACE WHEN RIGGING. TOUS LES CAPOTS DOIVENT ÊTRE EN PLACE AVANT LE LEVAGE • Hook rigging shackles through holes in base rail, as shown in Detail “A”. •...

  • Page 13: Step 8 - Install Outside Air Hood

    packaged together, attached to a metal support tray using REMOVABLE HORIZONTAL plastic stretch wrap, and shipped in the return-air compart- RETURN DUCT OPENING COVER ment behind the indoor coil access panel. The hood assem- bly’s metal tray is attached to the basepan and also attached to the damper using two plastic tie-wraps.

  • Page 14: Step 9 - Units With Hinged Panels Only

    PANEL DIVIDER OUTSIDE HOOD CLEANABLE ALUMINUM FILTER FILTER PANEL CAULK HERE BAROMETRIC INDOOR INDOOR RELIEF COIL COIL FILTER ACCESS ACCESS CLIP PANEL PANEL Fig. 17 — Economizer Filter Installation Fig. 15 — Indoor Coil Access Panel Relocation Step 9 — Units with Hinged Panels Only Swing out indoor coil access panel and insert the hood Relocate latch shipped inside the hinged compressor door to sides under the panel (hood top).

  • Page 15: Factory-Option Thru-Base Connections (Gas Connections)

    This unit is factory-equipped for use with natural gas (NG) fuel at elevations up to 2000 ft (610 m) above sea level. Unit may CAUTION be field converted for operation at elevations above 2000 ft EQUIPMENT DAMAGE (610 m) and/or for use with liquefied petroleum fuel. See ac- cessory kit installation instructions regarding these accessories.
  • Page 16 does not block access to the unit’s main control box or limit the required working space in front of the control box. HIGH VOLTAGE BRASS FITTING FOR CONDUIT 3 TO 6 TON UNITS CONNECTOR 9” (229mm) MIN THRU-CURB ADAPTER UNION AUXILIARY POWER SUPPLY...

  • Page 17: Step 12 - Install External Condensate Trap And Line

    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 18: Step 13 - Make Electrical Connections

    All units must have an external trap for condensate drainage. Units Without Disconnect or HACR Option Install a trap at least 4-in. (102 mm) deep and protect against freeze-up. If drain line is installed downstream from the exter- nal trap, pitch the line away from the unit at 1-in. per 10 ft Equip (25 mm in 3 m) of run.
  • Page 19 Fig. 30 — 48LC Control Wiring Diagram...
  • Page 20 Fig. 31 — 48LC Control Wiring Diagram with Humidi-MiZer ® System...
  • Page 21 Fig. 32 — 48LC Power Wiring Diagram, 208/230-v, 460-v 3 Phase...
  • Page 22 Fig. 33 — 48LC Power Wiring Diagram, 575-v 3 Phase...

  • Page 23: Units With Factory-Installed Non-Fused Disconnect Or Hacr

    WARNING FIRE HAZARD Failure to follow this warning could result in personal inju- ry, death, or property damage. Do not connect aluminum wire between disconnect switch and unit. Use only copper wire. ELECTRIC DISCONNECT SWITCH COPPER WIRE ONLY Fig. 35 — Location of Non-Fused Disconnect Enclosure ALUMINUM WIRE...

  • Page 24: All Units

    ALL UNITS All field wiring must comply with NEC and all local codes. Size wire based on MCA (Minimum Circuit Amps) on the unit informative plate. See Fig. 29 and the unit label diagram for power wiring connections to the unit power terminal blocks and equipment ground.
  • Page 25 Installing Weatherproof Cover: A weatherproof while-in-use cover for the factory-installed convenience outlets is now required by UL standards. This cover cannot be factory-mounted due to its depth; it must be in- stalled at unit installation. For shipment, the convenience outlet is covered with a blank cover plate.

  • Page 26: Hacr

    HACR abuse and may cause damage to electrical components. Such The amp rating of the HACR factory-installed option is based operation would invalidate any applicable Carrier warranty. on the size, voltage, indoor motor, and other electrical options % Voltage Imbalance: of the unit as shipped from the factory.

  • Page 27: Heat Anticipator Settings

    This device may be a separate humidistat control (contact closes on rise in space RH above control setpoint) or a combi- (Note 1) (Note 2) nation thermostat-humidistat control device such as Carrier’s Edge ® Pro Thermidistat with isolated contact set for dehumidi- fication control.
  • Page 28 % RELATIVE HUMIDITY Fig. 46 — Accessory Field-Installed Humidistat ® ® Fig. 47 — Edge Pro Thermidistat ® Fig. 48 — Typical Humidi-MiZer Adaptive Dehumidification System Humidistat Wiring Table 7 — Control Modes with Humidi-MiZer System Output and Valve States versus Circuit Mode DEMAND AND MODE OUTPUTS 48LC 04-06 VALVES...

  • Page 29: Reheat Modes

    REHEAT MODES to the expansion device. Reheat Liquid Valve (RLV) and Re- heat Discharge Valve (RDV) are closed. (See Fig. 49.) Dehumidification (reheat) is a cooling mode function. Refer to Reheat 1 (Subcooling Mode) Cooling Operation for cooling mode control. With Humidi- MiZer units, there are three additional HVAC Mode (HVAC) This mode increases latent cooling and decreases sensible expanded texts available for the user: Reheat1, Reheat2, and...

  • Page 30: Economi$Er® X (Factory-Installed Option)

    INDOOR SUPPLY VALVE CONDENSER COIL HUMIDI-MIZER COIL VALVE OUTDOOR AIR EXPANSION VALVE VALVE (TXV) COMPRESSOR EVAPORATOR COIL = CLOSED VALVE = OPEN VALVE INDOOR RETURN Fig. 51 — Hot Gas Reheat Mode (Reheat 2) — Humidi-MiZer System Edge Programable Thermostat Unit CTB THERMOSTAT O/W2/B...
  • Page 31 Fig. 53 — RTU Open System Control Wiring Diagram...
  • Page 32 Fig. 54 — RTU Open System Control Wiring Diagram with Humidi-MiZer ® System...

  • Page 33: Smoke Detectors

    RETURN AIR Smoke Detectors SMOKE DETECTOR Smoke detectors are available as factory-installed options on (AS SHIPPED) 48LC models. Smoke detectors may be specified for supply-air only, for return-air without or with economizer, or in combina- tion of supply-air and return-air. All components necessary for operation are factory-provided and mounted.

  • Page 34: Step 14 - Adjust Factory-Installed Options

    Step 14 — Adjust Factory-Installed Options SMOKE DETECTORS Smoke detector(s) will be connected at the Central Terminal Board (CTB), at terminals marked “Smoke Shutdown”. Re- move jumper JMP 3 when ready to energize unit. Step 15 — Install Accessories Available accessories include: •...

  • Page 35: Start Up With Assistant

    APPENDIX A — VFD OPERATION WITH REMOTE KEYPAD All 48LC size 04-06 units are equipped with a VFD (Variable Frequency Drive) to automatically adjust the indoor-fan motor speed in sequence with the unit’s ventilation, cooling and heat- ing operation. The VFD keypad is included as standard on electromechanical and RTU Open models.
  • Page 36 RJ-45 (CAT5) Cable ABB VFD (Bundled with Control Harness) w/ Remote Keypad Fig. B — Location of VFD in 48LC 04-06 Units Start Up by Changing Parameters Individually VFD Modes Initial start-up is performed at the factory. To start up the VFD The VFD has several different modes for configuring, operat- by changing individual parameters, perform the following pro- ing, and diagnosing the VFD.
  • Page 37 DOWN keys simultaneously. To restore the default factory set- The display will then return to the PAR BACKUP menu. tings, select the Carrier application macro. Select EXIT (SOFT KEY 1) to return to the main menu.
  • Page 38 The control panel can now be disconnected from the drive. change the hours and minutes. Press OK (SOFT KEY 2) to save the configuration and return to the Clock Set menu. Download Application Parameters Use the UP or DOWN keys to highlight TIME FORMAT To download application parameters only to the control panel and press SEL (SOFT KEY 2).
  • Page 39 Table A — 48LC 04 VFD Parameters (cont) UNIT SIZE 48LC 04 Motor Description 1.7 HP 575v 1.7 HP 208-230v 1.7 HP 460v 2.4 HP 575v 2.4 HP 208-230v Drive/Motor Voltage 575v 208-230v 460v 575v 208-230v Motor Part Number HD56FR579 HD56FR233 HD56FR463 HD56FE577...
  • Page 40 Table B — 48LC 04-06 VFD Parameters UNIT SIZE 48LC 04 48LC 05 48LC 06 Motor 2.4 HP 460v 1.7 HP 575v 1.7 HP 208-230v 1.7 HP 460v 2.4 HP 575v Description Drive/motor 460v 575v 208-230v 460v 575v Voltage Motor Part HD56FE653 HD56FR579 HD56FR233...
  • Page 41 Table B — 48LC 04-06 VFD Parameters (cont) UNIT SIZE 48LC 04 48LC 05 48LC 06 Motor 2.4 HP 460v 1.7 HP 575v 1.7 HP 208-230v 1.7 HP 460v 2.4 HP 575v Description Drive/motor 460v 575v 208-230v 460v 575v Voltage Motor Part HD56FE653 HD56FR579...
  • Page 42 Table C — 48LC 05-06 VFD Parameters (cont) UNIT SIZE 48LC 06 48LC 05/06 2.4 HP 208- 2.9 HP 208- Motor Description 2.4 HP 460v 2.9 HP 460v 3.7 HP 575v 230v 230v Drive/Motor Voltage 208-230v 460v 208-230v 460v 575v Motor Part Number HD56FE653 HD56FE653...
  • Page 43 Internal fault. A communication-related problem has been detected between the OMIO and OINT OPEX LINK boards. Contact Carrier. OPEX PWR Internal fault. Low voltage condition detected on the OINT board. Contact Carrier. CURR MEAS Internal fault. Current measurement is out of range. Contact Carrier. SUPPLY PHASE Ripple voltage in the DC link is too high.
  • Page 44 Error in power wiring suspected. Check that input power is wired to drive output. Check for ground OUTP WIRING faults. SYSTEM ERROR Error internal to the drive. Contact Carrier and report the error number. 101-105 SYSTEM ERROR Error internal to the drive. Contact Carrier and report the error number.
  • Page 45 Table E — ALARM CODES ALARM CODE ALARM NAME IN PANEL DESCRIPTION AND RECOMMENDED CORRECTIVE ACTION Reserved 2001 Reserved 2002 Reserved 2003 The change in direction being attempted is not allowed. Do not attempt to change the direction of DIR LOCK motor rotation, or change parameter 1003 DIRECTION to allow direction change (if reverse operation 2004 is safe).
  • Page 46 © 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. 04-53480187-01 Printed in U.S.A. Form 48LC-4-6-04SI Pg 46 6-19 Replaces: 48LC-4-6-03SI...
  • Page 47 START-UP CHECKLIST FOR 48LC SINGLE PACKAGE ROOFTOP COOLING ONLY (REMOVE AND STORE IN 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 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. 04-53480187-01 Printed in U.S.A.

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