Carrier WeatherMaker 48TC Series Installation Instructions Manual
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Carrier WeatherMaker 48TC Series Installation Instructions Manual

Single package rooftop with gas heat/electric cooling
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48TC*D/E 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.
48TC*D/E units for installation outside the United States may or may not contain Carrier's Staged Air Volume
(SAV) 2-speed indoor fan control system as they are not required to comply with the U.S. Department of
Energy (DOE) 2018 mandatory efficiency standard.
48TC*M units for installation inside or outside the United States do not contain use of Carrier's Staged Air
Volume (SAV) 2-speed indoor fan motor control system as they comply with the U.S. Department of Energy
(DOE) 2018 mandatory efficiency standard without their use.
For specific details on operation of the Carrier SAV 2-speed indoor fan system refer to the Variable Frequency
Drive (VFD) Factory-Installed Option 2-Speed Motor Control Installation, Setup, and Troubleshooting manual.
CONTENTS
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . 2
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Rated Indoor Airflow (cfm) . . . . . . . . . . . . . . . . . . . . . 3
Pre-Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Step 1 - Plan for Unit Location . . . . . . . . . . . . . . . 16
Step 3 - Inspect Unit . . . . . . . . . . . . . . . . . . . . . . . . 17
Step 4 - Provide Unit Support . . . . . . . . . . . . . . . . 17
• ALTERNATE UNIT SUPPORT (IN LIEU OF CURB OR
Step 5 - Field Fabricate Ductwork . . . . . . . . . . . . . 21
Step 6 - Rig and Place Unit . . . . . . . . . . . . . . . . . . 21
Ductwork (When Required) . . . . . . . . . . . . . . . . . 23
• SIZES 07-14
Step 8 - Install Outside Air Hood . . . . . . . . . . . . . . 24
14)
Step 9 - Install Flue Hood . . . . . . . . . . . . . . . . . . . . 26
Step 10 - Install Gas Piping . . . . . . . . . . . . . . . . . . 26
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Catalog No. 04-53480257-01
Installation Instructions
Page
Printed in U.S.A.
Form 48TC-7-16-02SI
Single Package Rooftop with
Gas Heat/Electric Cooling
Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
• CO2 SENSOR WIRING
PremierLink™ Control . . . . . . . . . . . . . . . . . . . . . . . .54
RTU Open Control System . . . . . . . . . . . . . . . . . . . .54
Pg 1
WeatherMaker
48TC 07-16
5-2020
Replaces: 48TC-7-16-01SI
®

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Summary of Contents for Carrier WeatherMaker 48TC Series

  • Page 1: Table Of Contents

    Energy (DOE) 2018 mandatory efficiency standard. 48TC*M units for installation inside or outside the United States do not contain use of Carrier’s Staged Air Volume (SAV) 2-speed indoor fan motor control system as they comply with the U.S. Department of Energy (DOE) 2018 mandatory efficiency standard without their use.

  • Page 2: Safety Considerations

    • ECONOMI$ER IV OCCUPANCY SWITCH Step 14 — Install Accessories ....55 WARNING Step 15 — Check Belt Tension ....55 •...

  • Page 3: General

    WARNING AVERTISSEMENT FIRE HAZARD RISQUE D'INCENDIE OU D'EXPLOSION Failure to follow this warning could result in severe personal Si les consignes de sécurité ne sont pas suivies à la lettre, cela injury and/or property damage. peut entraîner la mort, de graves blessures ou des dommages matériels.
  • Page 4 2. Determine unit location (from project plans) or select unit 3. Check for possible overhead obstructions which may location. interfere with unit lifting or rigging. Position: 9 10 11 12 13 14 15 16 17 18 Example: Unit Heat Type Packaging Compliance 48 - Gas Heat Packaged Rooftop 0 = Standard...
  • Page 5 Fig. 2 — Dimensional Drawing for Units Built On and After 4/15/19 (Size 07)
  • Page 6 Fig. 3 — Dimensional Drawing for Units Built Prior To 4/15/19 (Size 07)
  • Page 7 Fig. 4 — Unit Corner Weights and Clearances (Size 07)
  • Page 8 Fig. 5 — Base Rail Details (Size 07)
  • Page 9 Fig. 6 — Thru-the-Base Charts (Size 07)
  • Page 10 Fig. 7 — Unit Dimensional Drawing (Size 08, 09, 12)
  • Page 11 Fig. 7 — Unit Dimensional Drawing (Size 08, 09, 12)
  • Page 12 Fig. 8 — Unit Dimensional Drawing (Size 14)
  • Page 13 Fig. 8 — Unit Dimensional Drawing (Size 14) (cont)
  • Page 14 Fig. 9 — Unit Dimensional Drawing Size 16...
  • Page 15 Fig. 9 — Unit Dimensional Drawing Size 16 (cont)

  • Page 16: Installation

    DIMENSION LOCATION CONDITION in. (mm) 48 (1219) Unit disconnect is mounted on panel. 18 (457) No disconnect, convenience outlet option. 18 (457) Recommended service clearance. 12 (305) Minimum clearance. 42 (1067) Surface behind servicer is grounded (e.g., metal, masonry wall). 36 (914) Surface behind servicer is electrically non-conductive (e.g., wood, fiberglass).

  • Page 17: Step 2 - Plan For Sequence Of Unit Installation

    instructions shipped with the curb. Curb should be level. This is Step 2 — Plan for Sequence of Unit Installation necessary for unit drain to function properly. Unit leveling toler- The support method used for this unit will dictate different se- ances are shown in Fig.
  • Page 18 Fig. 12 — 48TC**07 Roof Curb Details...
  • Page 19 Fig. 13 — 48TC**08-14 Roof Curb Details...
  • Page 20 Fig. 14 — 48TC**16 Roof Curb Details...

  • Page 21: Slab Mount (Horizontal Units Only)

    Table 2 — Operating Weights UNITS — lb (kg) 48TC 48TC*A 652 (296) 48TC*M 777 (353) 805 (365) 850 (386) 48TC*D 900 (408) 970 (440) 980 (444) 1075 (487) 1305 (592) Economizer Vertical 50 (23) 75 (34) 75 (34) 75 (34) 75 (34) 130 (47) Horizontal...

  • Page 22: Positioning On Curb

    POSITION ALL SEAL STRIPS IN PLACE “B” BEFORE INSTALLING UNIT ON ROOF CURB 36”-54” DETAIL “A” AS CLOSE TO THIS END AS POSSIBLE (914-1371) DUCT END SEE DETAIL “A” “C” “A” DIMENSIONS MAX WEIGHT UNIT 48TC 07 1075 74.5 1890 39.0 41.5 1055...

  • Page 23: Step 7 - Convert To Horizontal And Connect

    REMOVABLE HORIZONTAL ORIGINAL NEW POSITION RETURN DUCT OPENING COVER POSITION (MOVED 12.5 in.) Fig. 17 — Alternative Condensate Drain Hole REMOVABLE HORIZONTAL SUPPLY DUCT OPENING COVER Positions Fig. 18 — Horizontal Conversion Panels IMPORTANT: If the unit has the factory-installed thru- the-base option, make sure to complete installation of the NOTCHES NOTCHES...

  • Page 24: Size 16

    SIZE 16 Unit is shipped in the vertical duct configuration. Unit without fac- tory-installed economizer or return air smoke detector option may be field-converted to horizontal ducted configuration using acces- sory CRDUCTCV002A00. To convert to horizontal configura- tion, remove screws from side duct opening covers and remove covers.

  • Page 25: Two-Position Damper Hood Removal (Factory Option Size 16)

    TWO-POSITION DAMPER HOOD REMOVAL (FACTORY 6. Caulk the end of the joint between the unit top panel and the hood top. OPTION SIZE 16) 7. Replace the filter access panel. 1. The hood is shipped in knock-down form and assembled to a metal support tray using plastic stretch wrap.

  • Page 26: Step 9 - Install Flue Hood

    (hood divider). Push the filter into position past the open fil- Step 9 — Install Flue Hood ter clips. Close the filter clips to lock the filter into place. See Flue hood is shipped screwed to the basepan beside the burner Fig.

  • Page 27: Factory-Option Thru-Base Connections (Gas Connections) (Sizes 07-14)

    For natural gas applications, gas pressure at unit gas connection must not be less than 4 in. wg (996 Pa) or greater than 13 in. wg (3240 Pa) while the unit is operating for sizes 07 to 14 and less 9”...

  • Page 28: Factory-Option Thru-Base Gas Connections (Size 16)

    FACTORY-OPTION THRU-BASE GAS CONNECTIONS HIGH VOLTAGE (SIZE 16) BRASS FITTING FOR CONDUIT 3 TO 6 TON UNITS CONNECTOR This service connection kit consists of a -in. NPT gas adapter fitting (stainless steel), a -in. electrical bulkhead connector and a -in. electrical bulkhead connector, connected to an “L” bracket covering the embossed (raised) section of the unit basepan in the condenser section.

  • Page 29: All Units

    The thru-base gas connector has male and female threads. The male threads protrude above the basepan of the unit; the female threads protrude below the basepan. Check tightness of connector lock nuts before connecting gas pip- 9” (229 mm) MIN. ing.

  • Page 30: Step 11 - Install External Condensate Trap And

    4. Pressure-test all gas piping in accordance with local and national plumbing and gas codes before connecting piping to unit. 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).

  • Page 31: Field Power Supply (Size 16)

    your area.) If a de-energize via unit disconnect switch operation of Field power wires are connected to the unit at line-side pressure the convenience outlet is desired, connect the source leads to the lugs on compressor contactor C and indoor fan contactor IFC (see load side of the unit disconnect.

  • Page 32: All Units

    WARNING FIRE HAZARD Failure to follow this warning could result in personal injury, 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. 50 — Mounting Position for Field Disconnects ALUMINUM (over 100A) (Size 16) WIRE...

  • Page 33: Units Without Factory-Installed Non-Fused Disconnect

    Fig. 55 — Handle and Shaft Assembly for NFD (Sizes 07-14) Fig. 54 — Location of Non-Fused Disconnect Enclosure (Size 16) To field install the NFD shaft and handle (see Fig. 55 or 56): 1. Remove the unit front panel (see Fig. 2-9). 2.

  • Page 34: Convenience Outlets

    Operation on improper line voltage or ex- FUSE SWITCH cessive phase imbalance constitutes abuse and may cause damage to electrical components. Such operation would invalidate any ap- plicable Carrier warranty. max voltage deviation from average voltage % Voltage = 100 x Imbalance...

  • Page 35: All Units

    Unit-mounted convenience outlets GFCI RECEPTACLE Outlets will often require that two disconnects be opened to de-en- COVER - WHILE-IN-USE NOT INCLUDED WEATHERPROOF ergize all power to the unit. Treat all units as electrically energized until the convenience outlet power is also checked and de-energi- zation is confirmed.

  • Page 36: Factory-Option Thru-Base Connections (Electrical Connections) (Size 16)

    (available as factory-installed option or as field-installed 1. Typical multi-function marking. Follow manufacturer’s configuration instructions to select Y2. Do not configure for O output. accessory, for use on a Carrier Comfort Network or as a stand- ® 2. Y2 to Y2 connection required on single-stage cooling units when alone control) or the RTU Open Controller for Building Manage- integrated economizer function is desired.
  • Page 37 BULKHEAD CONNECTOR This device can be a thermostat (field-supplied) or a PremierLink™ controller (available as factory-installed option or as field-installed accessory, for use on a Carrier Comfort Network or as a stand-alone control) or the RTU Open Controller ® for Building Management Systems using non-CCN protocols (RTU Open is available as a factory-installed option only).

  • Page 38: Humidi-Mizer® Control Connections

    RH above control set point) or a combina- Refer to the installation instructions included with the Car- tion thermostat-humidistat control device such as Carrier’s rier Edge Thermidistat device for more information. Edge® Pro Thermidistat with isolated contact set for dehumidi- fication control (see Fig.
  • Page 39 Fig. 69 — 48TC**07-14, Typical Humidi-MiZer ® Adaptive Dehumidification System Humidistat Wiring...
  • Page 40 Fig. 70 — 48TC**16, Typical Humidi-MiZer ® Adaptive Dehumidification System Humidistat Wiring...

  • Page 41: Economi$Er® X (Factory-Installed Option)

    EDGE Pro THERMIDISTAT Unit CTB THERMOSTAT O/W2/B SRTN ® Humidi-MiZer FIOP *Connection not required. Fig. 71 — 48TC**07-16 Unit with Humidi-MiZer Adaptive Dehumidification System with Edge ® Pro Thermidistat Device The W7220 economizer module automatically detects sensors by EconoMi$er ® X (Factory-Installed Option) polling to determine which sensors are present.

  • Page 42: Inputs

    Electrical Relative Humidity: Rated Voltage — 20 to 30 vac RMS, 50/60 Hz 5% to 95% RH non-condensing Transformer — 100 va maximum system input ECONOMIZER MODULE WIRING DETAILS Nominal Power Consumption (at 24 vac, 60 Hz) — 11.5 VA with- Use Fig.

  • Page 43: S-Bus Sensor Wiring

    Table 8 — Economizer Module - Left Hand Terminal Blocks LABEL TYPE DESCRIPTION Top Left Terminal Block 20k NTC Mixed Air Temperature Sensor (Polarity and COM Insensitive Connection) 20k NTC Outdoor Air Temperature Sensor and COM (Polarity Insensitive Connection) S-BUS S-BUS Enthalpy Control Sensor S-BUS...

  • Page 44: Interface Overview

    5. Press the ▲ button to increase (change) the displayed SENSOR parameter value. 6. Press the ▼ button to decrease (change) the displayed (HOT) BLACK parameter value. NOTE: When values are displayed, pressing and holding the ▲ or YELLOW ▼ button causes the display to automatically increment. ANALOG BROWN –...
  • Page 45 Table 12 — 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 cool- ing when required FIRST STAGE COOLING RELAY OUTPUT ECONOMIZING YES/NO...
  • Page 46 Table 12 — Menu Structure* (cont) PARAMETER PARAMETER MENU PARAMETER DEFAULT RANGE AND NOTES † VALUE INCREMENT 38°F to 65°F SUPPLY AIR set point MAT SET (3°C to 18°C); Set point determines where the economizer will modulate the OA damper increment by 1°F to maintain the mixed air temperature.
  • Page 47 Table 12 — Menu Structure* (cont) PARAMETER PARAMETER MENU PARAMETER DEFAULT RANGE AND NOTES † VALUE INCREMENT FACTORY DEFAULT NO or YES Resets all set points to factory defaults when set to YES. LCD will briefly SYSTEM flash YES and change to NO but all parameters will change to the factory SETUP (cont) default values.
  • Page 48 Table 12 — Menu Structure* (cont) PARAMETER PARAMETER MENU PARAMETER DEFAULT RANGE AND NOTES † VALUE INCREMENT RA SYLK T ERR RETURN AIR S-BUS SENSOR ERROR Return air enthalpy sensor has failed or become disconnected - check RA SYLK H ERR wiring, then replace sensor if the alarm continues.
  • Page 49 Table 13 — Damper Minimum Position Settings and Readings on Checkout Menu DEMAND CONTROLLED VENTILATION SET POINTS FAN SPEED CHECKOUT SENSOR) MIN POS VMAX–HS MIN POS H VMAX–HS MIN POS L VMAX–LS VENT MIN VMAX–HS VENT MAX VMAX–HS VENT MIN H VMAX–HS VENT MAX H VMAX–LS...
  • Page 50 Table 16 — Enthalpy Operation without 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 HIGH 24v/On 0v/Off MIN POS Closed HIGH 24v/On...
  • Page 51 Table 19 — 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 52: Enthalpy Settings

    Table 22 — Single Enthalpy and Dual Enthalpy High Limit Curves POINT P1 POINT P2 ENTHALPY TEMP. DRY TEMP. ENTHALPY HUMIDITY HUMIDITY CURVE BULB ( DEWPOINT ( (btu/lb/da) ° ° TEMP. ( TEMP. ( ° ° (%RH) (%RH) 28.0 36.8 66.3 80.1 26.0...

  • Page 53: Checkout

    ECONOMIZING DUAL ENTHALPY AVAILABLE HIGH LIMIT NOT AVAILABLE SINGLE ENTHALPY P2 (T,RH) (T,RH) TEMPERATURE Fig. 77 — Single Enthalpy Curve Boundaries CHECKOUT NOTE: For information about menu navigation and use of the keypad, see Interface Overview on page 44. Inspect all wiring connections at the economizer module’s termi- To perform a Checkout test: nals, and verify compliance with the installation wiring diagrams.

  • Page 54: Premierlink™ Control

    COMPLETING INSTALLATION RETURN-AIR SMOKE SENSOR CAUTION 1. Unscrew the two screws holding the return-air smoke EQUIPMENT DAMAGE HAZARD detector assembly. See Fig. 79, Step 1. 2. Save the screws. Failure to follow this caution may result in equipment damage. 3. Turn the assembly 90 degrees and then rotate end to end. Be sure to allow enough time for compressor start-up and shut- Make sure that the elbow fitting is pointing down.

  • Page 55: Step 13 - Adjust Factory-Installed Options

    Fig. 80 — EconoMi$er IV Wiring ® • Phase monitor control Step 13 — Adjust Factory-Installed Options Refer to separate installation instructions for information on in- SMOKE DETECTORS stalling these accessories. Smoke detector(s) will be connected at the Controls Connections Step 15 —...

  • Page 56: Belt Tension Method

    BLOWER PULLEY BELT DEFLECTION FORCE - SEE TABLE 1 V-BELT DEFLECTION = BELT SPAN MOTOR STRAIGHT PULLEY EDGE SCREW SCREW MOTOR TORQUE ALL SHEAVE SET SCREWS TO 110-130 in. lbs BELT DEFLECTION FORCE (LBS) BELT SMALLEST UNNOTCHED CROSS SHEAVE NOTCHED BELTS BELTS SECTION DIAMETER...
  • Page 57 Fig. 83 — Ultra Tech Scroll Compressor Diagram...
  • Page 58 © 2020 Carrier Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 04-53480257-01 Printed in U.S.A. Form 48TC-7-16-02SI Pg 58 5-2020 Replaces: 48TC-7-16-01SI...

  • Page 59: Start-Up Checklist

    START-UP CHECKLIST — 48TC PACKAGED ROOFTOP UNITS WITH GAS HEAT AND ELECTRIC COOLING 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 Installation Instruction document.
  • Page 60 10. Restore set-points for thermostat and humidistat (Y/N) _____ REPEAT PROCESS FOR 2 COMPRESSOR SYSTEMS © 2020 Carrier Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 04-53480257-01 Printed in U.S.A.

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