Carrier WeatherMaker Puron 48FC 04 Series Installation Instructions Manual
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Carrier WeatherMaker Puron 48FC 04 Series Installation Instructions Manual

Single package rooftop gas heating/electric cooling unit with r-410a refrigerant
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CONTENTS
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . 1
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 (When Required). . . . . . . . . . . . . . . . . . 10
Step 8 - Install Outside Air Hood . . . . . . . . . . . . . . 11
Step 10 - Install Flue Hood . . . . . . . . . . . . . . . . . . . 12
Integrated Gas Controller . . . . . . . . . . . . . . . . . . . . . 25
EconoMi$er® X (Factory Option) . . . . . . . . . . . . . . . 26
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Catalog No. 04-53480245-01
Single Package Rooftop Gas Heating/Electric Cooling Unit
Installation Instructions
Printed in U.S.A.
Form 48FC-4-7-02SI
with Puron
®
RTU Open Controller (Factory Option) . . . . . . . . . . .40
Controller Options . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Smoke Detectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
• ECONOMI$ER® IV OCCUPANCY SWITCH
Step 15 - Install Accessories . . . . . . . . . . . . . . . . . .41
Step 16 - Fan Speed Set Up . . . . . . . . . . . . . . . . . . .42
START-UP CHECKLIST . . . . . . . . . . . . . . . . . . . . .CL-1

SAFETY CONSIDERATIONS

Improper
installation,
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 agency,
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 thoroughly 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 requirements.
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
WeatherMaker
48FC04-07
(R-410A) Refrigerant
adjustment,
alteration,
words
DANGER, WARNING,
2-19
Replaces: 48FC-4-7-01SI
®
service,

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Summary of Contents for Carrier WeatherMaker Puron 48FC 04 Series

  • Page 1: Table Of Contents

    ® WeatherMaker 48FC04-07 Single Package Rooftop Gas Heating/Electric Cooling Unit with Puron ® (R-410A) Refrigerant Installation Instructions • OUTPUTS CONTENTS • ENVIRONMENTAL SAFETY CONSIDERATIONS ....1 •...
  • Page 2 WARNING WARNING ELECTRICAL SHOCK HAZARD CARBON-MONOXIDE POISONING HAZARD Failure to follow this warning could cause personal injury Failure to follow instructions could result in severe personal or death. injury or death due to carbon-monoxide poisoning, if com- bustion products infiltrate into the building. Before performing service or maintenance operations on unit, turn off main power switch to unit and install lock(s) Check that all openings in the outside wall around the vent...

  • Page 3: Model Number Nomenclature And Dimensions

    MODEL NUMBER NOMENCLATURE AND Table 1 — Rated Indoor Airflow DIMENSIONS MODEL NUMBER RATED INDOOR AIRFLOW (CFM) See Fig. 1 for 48FC model number nomenclature. See Fig. 2 48FC*A/B04 1050 for unit dimensional drawings. Figure 2 also shows service 48FC*A/B05 1500 clearance dimensions.
  • Page 4 Fig. 2 — Unit Dimensional Drawing...
  • Page 5 Fig. 2 — Unit Dimensional Drawing (cont)
  • Page 6 Fig. 2 — Unit Dimensional Drawing (cont)

  • Page 7: 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 8 Fig. 3 — Roof Curb Details...

  • Page 9: 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. Step 6 — Rig and Place Unit CAUTION PROPERTY DAMAGE HAZARD Failure to follow this caution may result in damage to roofing...

  • Page 10: Step 7 - Convert To Horizontal And Connect Ductwork (When Required)

    "B" DETAIL "A" 36"- 54" 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 out- 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 con- tinue at Step 10 below. PANEL Relocate latch shipped inside the compressor compartment be- hind the hinged compressor door to location shown in Fig. 14 INDOOR COIL ACCESS PANEL after unit installation.

  • Page 13: Factory-Option Thru-Base Connections (Gas Connections)

    Table 3 — Natural Gas Supply Line Pressure Ranges 9” MINIMUM CLEARANCE FOR PANEL REMOVAL UNIT MODEL UNIT SIZE MIN. MAX. 4.0 in. wg 13.0 in. wg REGULATOR 48FCD/E/S/R 04, 05, 06, 07 MANUAL GAS (996 Pa) (3240 Pa) SHUTOFF VALVE 48FCF/T 5.0 in.
  • Page 14 9” (229mm) MIN BURNER ACCESS PANEL UNION THRU-CURB ADAPTER UNIT BASE RAIL DRIP BRASS FITTING SUPPORT EMBOSSMENT SHUT OFF FOR GAS PIPING BRACKET VALVE Fig. 18 — Gas Line Piping for 3 to 6 Ton Units Fig. 20 — Gas Piping, Typical Curb Sidewall Piping Other hardware required to complete the installation of the gas (Example 2) supply line includes a manual shutoff valve, a sediment trap...

  • Page 15: Step 12 - Install External Condensate Trap And Line

    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). Pres- sure test the gas supply piping system at pressures equal to or less than 0.5 psig (3450 Pa).

  • Page 16: Units With Factory-Installed Non-Fused Disconnect

    operation of the convenience outlet is desired, connect the source leads to the load side of the unit disconnect. On a unit without a unit-mounted disconnect, connect the source leads to compressor contactor C and indoor fan contactor IFC pressure lugs with unit field power leads.

  • 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. % VOLTAGE IMBALANCE: max voltage deviation from average voltage = 100 x...
  • Page 18 GFCI (ground-fault circuit interrupter) duplex receptacle rated at 15A behind a hinged waterproof access cover, located on the end panel of the unit. See Fig. 29. Figure 30 shows the Convenience Outlet Utilization label, which is located below the convenience outlet. CONVENIENCE OUTLET GFCI PWD-CO FUSE...

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

    THERMOSTAT VOLTAGE CONNECTIONS TERMINALS L1: RED + YEL H1 + H3 Install a Carrier-approved accessory thermostat according to 208, 230 L2: BLU + GRA H2 + H4 installation instructions included with the accessory. For com- L1: RED plete economizer function, select a two-stage cooling thermo-...

  • 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 combi- Connections Board nation thermostat-humidistat control device such as Carrier’s Edge ® Pro Thermidistat™ device with isolated contact set for dehumidification control.

  • Page 21: Typical Unit Wiring Diagrams

    Connecting the Carrier Humidistat (HL38MG029) Connecting the Thermidistat device (33CS2PPRH-01) Route the humidistat 2-conductor cable (field-supplied) Route the Thermidistat multi-conductor thermostat cable through the hole provided in the unit corner post. (field-supplied) through the hole provided in the unit cor- Feed wires through the raceway built into the corner post ner post.
  • 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 on Integrated Gas Controller the Integrated Gas Controller (IGC) board. An LED (light This unit contains an Integrated Gas Controller (IGC) board. emitting diode) on the IGC board turns on and remains on The IGC control board uses a flue gas pressure switch that during normal operation.

  • Page 26: Economi$Er X (Factory Option)

    UNIT CONTROL BOARD Fig. 45 — Typical IGC Control Wiring Diagram Economizer Module ® EconoMi$er X (Factory Option) The module is the core of the EconoMi$er X system. The The EconoMi$er X system is an expandable economizer con- module is mounted in the unit’s control box, and includes the trol system, which includes a W7220 economizer module (con- user interface for the system.

  • Page 27: Inputs

    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 Return Air (RA) bus sensor can be added to the system for dif- AUX2- ferential enthalpy or dry bulb changeover.

  • Page 28: Interface Overview

    Table 8 — Economizer Module Table 9 — HH57AC081 Sensor Wiring Terminations (Right Hand 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 29: Setup And Configuration

    To use the keypad when working with menus: NOTE: When values are displayed, pressing and holding the ▲ or ▼ button causes the display to automatically increment or • Press the ▲ (Up arrow) button to move to the previous decrement.
  • Page 30 Table 11 — W7220 Menu Structure* PARAMETER PARAMETER EXPANDED PARAMETER NAME MENU PARAMETER DEFAULT RANGE AND Notes VALUE INCREMENT † FIRST STAGE COOLING DEMAND (Y1–IN) ECON 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...
  • Page 31 Table 11 — W7220 Menu Structure* (cont) PARAMETER PARAMETER EXPANDED PARAMETER NAME MENU PARAMETER DEFAULT RANGE AND Notes VALUE INCREMENT † EXHAUST STAGE 2 RELAY OUTPUT Output of AUX1 O terminal Displays ON when damper position reaches programmed EXH2 OUT ON/OFF percentage set point.
  • Page 32 Table 11 — W7220 Menu Structure* (cont) PARAMETER PARAMETER EXPANDED PARAMETER NAME MENU PARAMETER DEFAULT RANGE AND Notes VALUE INCREMENT † EXHAUST FAN STAGE 1 SETPOINT Set point for OA damper position when exhaust fan 1 is powered 0 to 100%; by the economizer.
  • Page 33 Table 11 — W7220 Menu Structure* (cont) PARAMETER PARAMETER EXPANDED PARAMETER NAME MENU PARAMETER DEFAULT RANGE AND Notes VALUE INCREMENT † NONE Used for alarm for when the DA air temperature is too high. Sets 70°F to 180°F DA HI ALM 80°F (27°C) upper range of alarm;...
  • Page 34 Table 11 — W7220 Menu Structure* (cont) PARAMETER PARAMETER EXPANDED PARAMETER NAME MENU PARAMETER DEFAULT RANGE AND Notes VALUE INCREMENT † Check if outdoor temperature is below the LOW Temp Lockout on set point menu. Check if Mixed air temperature on STATUS FREEZE ALARM menu is below the Lo Set point on Advanced menu.
  • Page 35 Table 13 — Dry Bulb Operation without DCV (CO Sensor) — 1 Speed Fan DEMAND OUTSIDE AIR CONTROLLED GOOD TO Y1-I Y2-I FAN SPEED Y1-O Y2-O OCCUPIED UNOCCUPIED VENTILATION (DCV) ECONOMIZE High 0-v/Off 0-v/Off MIN POS Closed High 24-v/On 0-v/Off MIN POS Closed High...
  • Page 36 Table 16 — Enthalpy Operation with DCV (CO Sensor) — 1 Speed Fan DEMAND OUTSIDE AIR CONTROLLED GOOD TO Y1-I Y2-I FAN SPEED Y1-O Y2-O OCCUPIED UNOCCUPIED VENTILATION (DCV) ECONOMIZE High 0-v/Off 0-v/Off Closed VENTMIN High 24-v/On 0-v/Off Closed VENTMIN High 24-v/On 24-v/On...
  • Page 37 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 38: Enthalpy Settings

    Table 20 — Enthalpy 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 0v/Off...

  • Page 39: Checkout

    ECONOMIZING DUAL ENTHALPY AVAILABLE HIGH LIMIT NOT AVAILABLE SINGLE ENTHALPY P2 (T,RH) (T,RH) TEMPERATURE Fig. 51 — Single Enthalpy Curve Boundaries Table 22 — Single Enthalpy and Dual Enthalpy High Limit Curves POINT P1 POINT P2 ENTHALPY TEMP. DRY TEMP. ENTHALPY HUMIDITY HUMIDITY...

  • Page 40: Rtu Open Controller (Factory Option)

    You can also navigate to the Alarms menu at any time. unit terminal board may be necessary to complete the unit and smoke detector configuration to meet project requirements. Clearing Alarms Units equipped with factory-optional return-air smoke detec- Once the alarm has been identified and the cause has been re- tors require a relocation of the sensor module at unit moved (e.g.

  • 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 roof curb) SMOKE DETECTORS • LP conversion kit Smoke detector(s) will be connected at the Unit Control Board • Flue discharge deflector (UCB), at terminals marked “Smoke Shutdown.”...

  • Page 42: 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 for the location on 3 phase voltage units or Fig. 56 for the location on single phase voltage units.

  • Page 43: Units With Systemvu™ Controls

    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 44 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 2019 Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 04-53480245-01 Printed in U.S.A. Form 48FC-4-7-02SI Pg 46 2-19 Replaces: 48FC-4-7-01SI...
  • Page 47 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 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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