Carrier WeatherExpert 48N2 Installation Instructions Manual
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Carrier WeatherExpert 48N2 Installation Instructions Manual

Carrier WeatherExpert 48N2 Installation Instructions Manual

Packaged rooftop cooling units with gas heat and comfortlink controls
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CONTENTS
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . 1
ACOUSTICAL CONSIDERATIONS . . . . . . . . . . . . . . . 3
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Ductwork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Acoustic Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Step 1 - Perform Jobsite Survey . . . . . . . . . . . . . . . 4
Step 2 - Place Unit . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Step 3 - Roof Mount Unit . . . . . . . . . . . . . . . . . . . . . 4
Step 4 - Slab Mount Unit . . . . . . . . . . . . . . . . . . . . . 4
Step 5 - Install Curb Gasketing . . . . . . . . . . . . . . . 18
Step 7 - Rig Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Step 8 - Connect Condensate Drain . . . . . . . . . . . 27
Step 9 - Install Outdoor Air Hoods . . . . . . . . . . . . 28
Step 10 - Route Field Wiring . . . . . . . . . . . . . . . . . 29
Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Step 16 - Connect Gas Piping . . . . . . . . . . . . . . . . 34
Step 18 - Install Flue/Inlet Hoods . . . . . . . . . . . . . 34
Gas Units Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Step 20 - Install Unit Accessories . . . . . . . . . . . . . 36
CONTROLS INSTALLATION . . . . . . . . . . . . . . . . . . . 41
Variable Air Volume Units . . . . . . . . . . . . . . . . . . . . 41
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Catalog No. 04-53480164-01
Packaged Rooftop Cooling Units with Gas Heat
Installation Instructions
PAGE
Printed in U.S.A.
Form 48N-11SI
48N2,N3,N4,N5,N6,N7,N8,N9
and ComfortLink Controls
Option and Accessory Control Wiring . . . . . . . . . . .42
Optional UPC Open Installation . . . . . . . . . . . . . . . .48
Smoke Control Modes . . . . . . . . . . . . . . . . . . . . . . . .49
• FIRE SHUTDOWN
• PRESSURIZATION
• EVACUATION
• SMOKE PURGE
• SMOKE CONTROL INSTALLATION

GENERAL

This installation instruction contains basic unit installation infor-
mation, installation of thermostats, and installation of remote tem-
perature sensors. For additional information and service instruc-
tions, refer to the Controls, Start-Up, Operation, Service and Trou-
bleshooting literature.

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 words DANGER, WARNING, 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
WeatherExpert
1-2021
Replaces: 48N-10SI
®

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  • Page 1: Table Of Contents

    CONTENTS Option and Accessory Control Wiring ...42 Carrier Comfort Network® (CCN) Interface ..47 PAGE Optional UPC Open Installation ....48 GENERAL .
  • Page 2 DANGER AVERTISSEMENT DO NOT USE TORCH to remove any component. System RISQUE D´INCENDIE OU D´EXPLOSION contains oil and refrigerant under pressure. Si les consignes de sécurité ne sont pas suivies à la lettre, cela To remove a component, wear protective gloves and goggles peut entraîner la mort, de graves blessures ou des dommages and proceed as follows: matériels.

  • Page 3: Acoustical Considerations

    ACOUSTICAL CONSIDERATIONS AVERTISSEMENT In order to minimize sound transmitted to the space, please con- form to the following recommendations (see Fig. 1): RISQUE D’INTOXICATION AU MONOXYDE DE CARBONE Location Si ces directives ne sont pas suivies, cela peut entraîner des •...

  • Page 4: Installation

    FLEXIBLE CONNECTORS SUPPLY AND RETURN INTAKE SUPPLY DISCHARGE PLENUM PLENUM COMPRESSOR/ CONDENSING SECTION ALL ROOF VIBRATION PENETRATIONS ISOLATORS SHOULD BE IN ROOF SEALED CURB AIR TIGHT SUPPLY AND RETURN DUCTS LINED WITH ACOUSTICAL DUCT LINER ROUND DUCT CONTROLS RUMBLE BEST Fig.
  • Page 5 MINIMUM SPACING (ft) UNIT Series Series Fig. 2 — Multiple Unit Minimum Separation...
  • Page 6 Table 1 — Physical Data 48N — 75-150 Tons Nominal Capacity BASE UNIT (Model Number - Pos.6) * † NOMINAL CAPACITY (tons) WEIGHT (lb) Base Unit * 12,000 12,455 12,455 16,170 16,860 17,040 Split Unit - Main Section 9,110 9,565 9,565 12,880 13,570...
  • Page 7 Table 1 — Physical Data 48N — 75-150 Tons Nominal Capacity (cont) BASE UNIT (Model Number - Pos. 6) * † NOMINAL CAPACITY (tons) HUMIDI-MIZER COIL ® Type MCHX Material Aluminum Quantity Surface E-Coated Total Face Area (sq ft) 34.5 STANDARD AND HIGH CAPACITY HOT WATER COILS Type RTPF...
  • Page 8 Table 1 — Physical Data 48N — 75-150 Tons Nominal Capacity (cont) BASE UNIT (Model Number - Pos. 6) * † NOMINAL CAPACITY (tons) OPTIONAL POWER EXHAUST Power Exhaust Diameter (in.) Wheel and Blade Type DWDI Forward Curve Maximum Allowable Cfm 42,000 60,000 Maximum Allowable Speed (rpm)
  • Page 9 Table 1 — Physical Data 48N — 75-150 Tons Nominal Capacity (cont) BASE UNIT (Model Number - Pos. 6) *† NOMINAL CAPACITY (tons) MERV 8 MERV 8 Type (Standard) (Optional) Outside Air Filters MERV 14 MERV 14 Size (in.)…. Qty 16 x 20 x 2……….16 16 x 20 x 2……….16 MERV 8...
  • Page 10 Table 2 — Operating Weights of Options and Accessories (lb) 48N UNIT SIZE (TON NOMINAL CAPACITY) (for MODEL NUMBER Pos. 6)* OPTION OR ACCESSORY (75) (90) (105) (120) (130) (150) Economizer Filters 2 in. MERV 7 4 in. MERV 8 4 in.
  • Page 11 Table 2 — Operating Weights of Options and Accessories (lb) (cont) 48N UNIT SIZE (TON NOMINAL CAPACITY) (for MODEL NUMBER Pos. 6)* OPTION OR ACCESSORY (75) (90) (105) (120) (130) (150) Supply/PE/Return Motor Includes VFD - 460 Volt TEFC 5 Hp 7.5 Hp 10 Hp 15 Hp...
  • Page 12 Table 3 — Supply Fan and Drive Data MOTOR DRIVE DRIVEN MOTOR MOTOR BUSHING BUSHING QTY OF SHAFT SHAFT SHEAVE SHEAVE BELTS SPEED TYPE TYPE BELTS SIZE (in.) SIZE (in.) BROWNING BROWNING (rpm) 1770 2.125 1800 4B5V70 B 2 1/8 4B5V68 B 2 1/4 5VX530...
  • Page 13 Table 5 — Return Fan Drive Data MOTOR DRIVE DRIVEN MOTOR MOTOR FAN SHAFT BUSHING BUSHING QTY OF FAN SPEED SHAFT SHEAVE SHEAVE BELTS SIZE (in.) TYPE TYPE BELTS (rpm) SIZE (in.) BROWNING BROWNING 1770 2.125 1236 4B5V70 B 2 1/8 4R5V103 R1 2 1/2 5VX1000...
  • Page 14 DIMENSIONS ARE SHOWN IN INCHES. DIMENSIONS IN [ ] ARE IN MILLIMETERS. “G” SUPPORT TO END OF PEDESTAL SEE CONDENSER SECTION SEE CONDENSER SECTION Fig. 3 — Roof Curb Units...
  • Page 15 48N Roof Curb Sizes N, P, Q 48N Roof Curb Sizes R, S, T (75-105 Ton Nominal Capacity) (120-150 Ton Nominal Capacity) DIMENSION DIMENSION DIMENSION DIMENSION DIMENSION DIMENSION PART NUMBER* PART NUMBER* A (in.) B (in.) C (in.) A (in.) B (in.) C (in.) CRRFCURB225A00...
  • Page 16 DIMENSIONS ARE SHOWN IN INCHES. DIMENSIONS IN [ ] ARE IN MILLIMETERS. Roof Curb Condenser Support UNIT SIZE DIM. DIM. DIM. DIM. COND COILS 2V COND COIL 3V NOMINAL TONS 75 ALL — 129.50 10.98 131.75±0.75 133.50 90 STD EFFICIENCY —...
  • Page 17 Table 6 — Refrigerant Charge CHARGE (LB) CHARGE (LB) UNIT SIZE UNIT CONFIGURATION UNITS WITHOUT HUMIDI-MIZER ® SYSTEM UNITS WITH HUMIDI-MIZER ® SYSTEM (NOMINAL CAPACITY, TONS) Circuit A Circuit B Circuit A Circuit B Standard Capacity Standard Efficiency 46.5 52.6 46.5 69.6 High Capacity Standard Efficiency...

  • Page 18: Step 5 - Install Curb Gasketing

    Step 5 — Install Curb Gasketing Field-fabricated ductwork for vertical supply/vertical return units must be attached to the roof curb, or to the support steel, prior to After ductwork has been connected to the roof curb, apply gasket the final rigging and installation of the unit. Supply and return duct material ( -in.
  • Page 19 Econ, Bar Rel, Standard filters, High Cap Evap, High Efficiency, High Static Supply Fan w/ largest motor, High Static PE w/ largest motor, No Heat, No Post section, No Humidimizer, No Extended Chassis, No Split, No Field Filter Section Econ, Bar Rel, Standard filters, High Cap Evap, High Efficiency, High Static Supply Fan w/ largest motor,...
  • Page 20 Econ, Bar Rel, Cartridge filters, Hi Cap Evap, High Efficiency, High Static Supply Fan w/ largest motor, Hi Static Return Fan w/ largest motor, High Electric Heat, 8' Blank section w/ post filters, Extended chassis w/ humidimizer, Split, No Field filter section Econ, Bar Rel, Cartridge filters, Hi Cap Evap, High Efficiency, High Static Supply Fan w/ largest motor,...
  • Page 21 High Efficiency, High Static Supply Fan w/ largest motor, Hi Static Return Fan w/ largest motor, High Electric Heat, 8' Blank section w/ post filters, Extended chassis w/ humidimizer, Split, No Field filter section Econ, Bar Rel, Cartridge filters, Hi Cap Evap, High Efficiency, High Static Supply Fan w/ largest motor,Hi Static Return Fan w/ largest motor, High gas heat, 8' Blank...
  • Page 22 Cond End Return End CENTER OF NOMINAL CORNER WEIGHTS (lb) GRAVITY CAPACITY TOTAL (lb) (tons) A (in.) B (in.) 4,129 4,047 4,892 4,796 17,864 275.9 67.2 4,396 4,310 5,359 5,254 19,319 308.1 67.2 4,478 4,390 5,526 5,417 19,810 309.8 67.2 48 Series Non-Split 5,455 5,347...
  • Page 23 Fig. 11 — 48N Unit Sizes N, P, Q (75-105 Ton Nominal Capacity)
  • Page 24 FIELD NOMINAL EXTENDED SUPPLY BLANK 2-PIECE CAPACITY/ COND CHASSIS FILTER SECTION UNIT (in.) (in.) (in.) (in.) (in.) (in.) (in.) (in.) (in.) (in.) EFFICIENCY SECTION 498.11 314.42 177.02 266.07 499.35 202.75 119.76 — 313.36 4 FT 564.61 380.92 195.27 284.32 565.85 221.00 119.76 —...
  • Page 25 139.88 BASE FRAME Fig. 12 — 48N Unit Sizes R, S, T (120-150 Ton Nominal Capacity)
  • Page 26 FIELD NOMINAL HIGH EXTENDED BLANK CAPACITY/ PIECE COND CHASSIS FILTER SECTION (in.) (in.) (in.) (in.) (in.) (in.) (in.) (in.) (in.) (in.) EFFICIENCY HEAT* UNIT (in.) SECTION (in.) 523.04 339.35 48 186.86 291.00 524.28 227.68 119.76 — 338.29 4 FT 589.54 405.85 48 205.11 309.25 590.78 245.93 119.76 —...

  • Page 27: Step 8 - Connect Condensate Drain

    With field-supplied fittings and pipe sections, plumb the primary Step 8 — Connect Condensate Drain condensate drain to the 2-in. FPT connector on the base rail. Use a The drain is a 2-in. FPT pipe connection located on the right-hand trap height of at least 7 inches.

  • Page 28: Step 9 - Install Outdoor Air Hoods

    Assemble hoods (see Fig. 19). Step 9 — Install Outdoor Air Hoods Unit sizes 75 to 105 nominal tons have three hoods on both sides. a. Attach hood sides (Items 1 and 2) to the hood top (Item Unit sizes 120 to 150 nominal tons have four hoods on both sides. 3).

  • Page 29: Step 10 - Route Field Wiring

    RECOMMENDED FIELD-SUPPLIED CAUTION DISCONNECT Use care when drilling into corner post to avoid damage to LOCATION condenser coil. Fig. 20 — Disconnect Location control box door. The disconnect is located in the power box be- Step 10 — Route Field Wiring hind the power box door for all units.
  • Page 30 106.0 95.4 LEGEND NOTE: Extensive motor and electrical testing on the Carrier units has ensured that the full horsepower range of the motor can be utilized with Bhp — Brake Horsepower confidence. Using fan motors up to the horsepower ratings shown in the BkW —...

  • Page 31: Step 12 - Connect Air Pressure Tubing

    POWER EXHAUST Step 12 — Connect Air Pressure Tubing Before options such as the variable frequency drive (VFD) and/or The tubing for the building pressure (BP) control (achieved via the modulating power exhaust (PE) can operate properly, the pneu- modulating power exhaust option) should sample building pres- matic tubing for pressure sensing must be installed.
  • Page 32 LEGEND ACC FSS — Accessory Fan Status Switch — Ground — Air Pressure Switch — Low Volume Terminal — Circuit Breaker — Main Base Board PPSS — Controls Expansion Module — Plenum Pressure Safety Switch RACFM — Compressor Modulation Relay —...

  • Page 33: Step 13 - Remove Supply-Fan Shipping Bracket

    Remove screws holding shipping bracket to spring support. NOTE: It is not necessary to remove the shipping bracket, only remove the screws. After removing all shipping bracket screws, level fan sled using the adjusting screws. RETURN FAN SHIPPING BRACKET BOLTS Fig.

  • Page 34: Step 16 - Connect Gas Piping

    Remove shipping block-offs and shipping tape from all open- Step 16 — Connect Gas Piping ings in the access panel. Unit is equipped for use with natural gas only. Installation must Attach flue outlet hoods (see Fig. 29) to access panel using conform with local building codes, or in the absence of local codes, with the National Fuel Gas Code (NFGC), ANSI Z223.1.
  • Page 35 Table 8 — Flue Hood and Inlet Hood Usage QUANTITY USED HOOD TYPE PART LIST Sizes 75-105 Size 75 Sizes 90, 105 Sizes 90, 105 Sizes 120-150 Sizes 120-150 Sizes 120-150 (Low Heat) (High Heat) (Medium Heat) (High Heat) (Low Heat) (Medium Heat) (High Heat) Top (6-in.)

  • Page 36: Step 19 - Install Supply-Air Thermistors

    7. Remove the roof cap, top cover and L brackets from the fil- Step 19 — Install Supply-Air Thermistors (Modu- ter end of the return section. Save these parts for later instal- lating Gas Units Only) lation. See Fig. 36 and 37. Supply-air thermistors are a field-installed, factory-provided com- 8.
  • Page 37 Table 10 — 75-105 Nominal Ton Units Parts List ITEM COMPONENT NUMBER QUANTITY COMPONENT NAME COMPONENT QUALIFIER 48NG501939 RAIL,MOUNTING SPLIT,BASE,GUIDE 48NG501935 ROD,THREADED -10 UNC 2A 30-in. L 48NG501937 WASHER,PLATE -in. LRT SPLIT AU02AB361 WASHER,FLAT AT11AB361 NUT,HEAVY HEX 48NG501938 BRACKET,TIE LRT SPLIT TOP AL48AM307 SCREW,HEXHD SR 48NG501936...
  • Page 38 ROOF COVER TOP RAIL GUIDES BASE RAIL GUIDES Fig. 36 — Roof Cap and Top Cover Removal Fig. 33 — Base and Top Rail Guide Locations L BRACKETS BASE RAIL GUIDE Fig. 34 — Base Rail Guide Fig. 37 — L Bracket Removal TOP RAIL GUIDE INSTALL TAR TAPE ON...
  • Page 39 L BRACKETS Fig. 39 — Secure Base Rails Fig. 42 — L Bracket Installation TOP CAPS END CAPS COVER Fig. 40 — Top Rail Brackets Fig. 43 — Main Unit and Return Section Top Cover Assemblies BASEPAN JOINT/COVER Fig. 41 — Basepan Joint/Cover...
  • Page 40 DETAIL A RUN VFD POWER WIRES THROUGH THIS BUSHING, SEPARATE FROM CONTROL WIRES SEE DETAIL A Fig. 44 — Wire Routing VFD WITH BYPASS DETAIL NN VFD WITHOUT BYPASS SEE DETAIL NN DETAIL NN VFD DETAILS Fig. 45 — Return Section Component Locations...

  • Page 41: Controls Installation

    CONTROL WIRING Quabik 6130 — The unit can be controlled with a Carrier-approved accessory elec- SENSORS tro-mechanical or electronic thermostat that has two stages of cooling, two stages of heating control, and an output for fan con- Sensors should be wired using single twisted pairs of 20 AWG trol.

  • Page 42: Space Temperature Sensor (T-55)

    NOTE: When enabling these options in the control make sure the CEM or other required board were shipped in the unit. Otherwise NOTE: Only Carrier sensors may be used for standard T-55 space the sensor will not function and communications errors to non ex- averaging.
  • Page 43 TB201 SENSOR 1 SENSOR 4 SENSOR 3 SENSOR 2 SPACE TEMPERATURE AVERAGING (4 SENSOR APPLICATION) TB201 SENSOR 1 SENSOR 2 SENSOR 3 SENSOR 6 SENSOR 5 SENSOR 4 NOTE: Use T-55 sensor only. SENSOR 9 SENSOR 8 SENSOR 7 SPACE TEMPERATURE AVERAGING (9 SENSOR APPLICATION) Fig.
  • Page 44 FIELD INSTALLED (FIELD SUPPLIED) JUMPER WHEN ENTHALPY SWITCH NOT USED Fig. 51 — Outdoor Air Enthalpy Switch Wiring TB201 Fig. 52 — CO Space Sensor Wiring FILTER STATUS - RETURN SWITCH 180 OHM AN 5 FILTER PRESSURE RETURN FILTER STATUS - POST FILTER 180 OHM AN 6 FILTER PRESSURE - POST FILTER...
  • Page 45 TB203 MIXED AIR HUMIDITY 4 - 20 ma ACCSY PL29-1 OA HUMIDITY 24VDC 4 - 20 ma PL29-2 ACCSY TB202 24VDC SPACE HUMIDITY 4 - 20 ma ACCSY PL37-5 RETURN HUMIDITY 24VDC 4 - 20 ma AN10 PL37-6 ACCSY Fig. 55 — Space and Return Air Humidity Sensor Wiring Fig.
  • Page 46 TB201 TB201 PL45-1 PL45-2 PL45-3 PL45-6 PL45-5 PL45-4 Fig. 57 — Return Air Smoke Detector Wiring FIRE SHUTDOWN TB201 Fig. 58 — Fire Shutdown Wiring TB 202 RCB J4 Fig. 59 — Purge, Evacuation, and Pressurization Wiring...

  • Page 47: Carrier Comfort Network® (Ccn) Interface

    TB201 Fig. 60 — CCN Connections The following color code is recommended: Carrier Comfort Network (CCN) Interface ® The 48N Series units can be connected to the CCN system if de- sired. The communication bus wiring is supplied and installed in...

  • Page 48: Optional Upc Open Installation

    To wire the UPC Open controller to the BAS network: IMPORTANT: A shorted CCN bus cable will prevent some Pull the screw terminal connector from the controller's BAS routines from running and may prevent unit from starting. If Port. abnormal conditions occur, unplug the connector. If conditions Check the communications wiring for shorts and grounds.

  • Page 49: Ms/Tp Wiring Recommendations

    Fig. 62 — Open System Network Wiring PRESSURIZATION Pressurization mode is intended to keep smoke out of a zone. The factory-installed optional economizer is required for this function. Pressurization is accomplished by the following: • opening the economizer (option) • running the supply fan (optional inlet guide vanes open or optional VFD at normal duct static pressure set point) •...
  • Page 50 Table 14 — MS/TP Wiring Recommendations SPECIFICATION RECOMMENDATION Cable Single twisted pair, low capacitance, CL2P, 22 AWG (7x30), TC foam FEP, plenum rated cable Conductor 22 or 24 AWG stranded copper (tin plated) Insulation Foamed FEP 0.015 in. (0.381 mm) wall 0.060 in. (1.524 mm) O.D. Color Code Black/White Twist Lay...
  • Page 52 © 2021 Carrier Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 04-53480164-01 Printed in U.S.A. Form 48N-11SI Pg 52 1-2021 Replaces: 48N-10SI...

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