Carrier WEATHERMAKER 48AJ Installation Instructions Manual
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Carrier WEATHERMAKER 48AJ Installation Instructions Manual

Carrier WEATHERMAKER 48AJ Installation Instructions Manual

Single package rooftop units electric cooling/gas heating with scroll compressor and comfortlink controls
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See also: Operation & Service Manual
CONTENTS
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . 1
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-36
Step 1 - Provide Unit Support . . . . . . . . . . . . . . . . . . . 1
• ALTERNATE UNIT SUPPORT
Step 2 - Rig and Place Unit . . . . . . . . . . . . . . . . . . . . . 2
• POSITIONING
Step 3 - Field Fabricate Ductwork . . . . . . . . . . . . . . . 2
Step 4 - Make Unit Duct Connections . . . . . . . . . . . 2
Step 5 - Install Flue Hood . . . . . . . . . . . . . . . . . . . . . . 19
Step 6 - Trap Condensate Drain . . . . . . . . . . . . . . . . 19
Step 7 - Install Gas Piping . . . . . . . . . . . . . . . . . . . . . 19
• FIELD CONTROL WIRING
Step 9 - Make Outdoor-Air Inlet
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Relief Damper Hood. . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Step 12 - Install All Accessories . . . . . . . . . . . . . . . 35
Step 13 - Field Modifications. . . . . . . . . . . . . . . . . . . 35

SAFETY CONSIDERATIONS

Installation and servicing of air-conditioning equipment can
be hazardous due to system pressure and electrical compo-
nents. Only trained and qualified service personnel should in-
stall, repair, or service air-conditioning equipment.
Untrained personnel can perform the basic maintenance
functions of cleaning coils and filters and replacing filters. All
other operations should be performed by trained service per-
sonnel. 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. Wear safety glasses and work
gloves. Use quenching cloth for unbrazing operations. Have
fire extinguishers available for all brazing operations.
WARNING
Before performing service or maintenance operations on
unit, turn off main power switch to unit. Electrical shock
could cause personal injury.
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Catalog No. 04-53480067-01
Installation Instructions
Page
Printed in U.S.A.
Single Package Rooftop Units
Electric Cooling/Gas Heating
with Scroll Compressor and
COMFORTLINK™ Controls
1. Improper installation, adjustment, alteration, service,
or maintenance can cause property damage, personal
injury, or loss of life. Refer to the User's Information
Manual provided with this unit for more details.
2. Do not store or use gasoline or other flammable va-
pors and liquids in the vicinity of this or any other
appliance.
What to do if you smell gas:
1. DO NOT try to light any appliance.
2. DO NOT touch any electrical switch, or use any
phone in your building.
3. IMMEDIATELY call your gas supplier from a neigh-
bor's phone. Follow the gas supplier's instructions.
4. If you cannot reach your gas supplier, call the fire
department.
Disconnect gas piping from unit when pressure testing at
pressure greater than 0.5 psig. Pressures greater than
0.5 psig will cause gas valve damage resulting in hazardous
condition. If gas valve is subjected to pressure greater than
0.5 psig, it must be replaced before use. When pressure
testing field-supplied gas piping at pressures of 0.5 psig or
less, a unit connected to such piping must be isolated by
closing the manual gas valve(s).

INSTALLATION

Step 1 - Provide Unit Support

1. All panels must be in place when rigging or damage
to unit may occur.
2. Unit is not designed for handling by fork truck.
Form 48A-7SI
Pg 1
WEATHERMAKER
48AJ,AK,AW,AY020-060
WARNING
WARNING
CAUTION
8-09
Replaces: 48A-5SI
®

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Summary of Contents for Carrier WEATHERMAKER 48AJ

  • Page 1: Table Of Contents

    Installation Instructions CONTENTS SAFETY CONSIDERATIONS ..... . 1 INSTALLATION ....... . 1-36 Step 1 —...

  • Page 2: Installation

    ROOF CURB — For vertical discharge units, assemble or in- stall accessory roof curb in accordance with instructions shipped with this accessory. See Fig. 1-3. Install insulation, cant strips, roofing, and counter flashing as shown. Ductwork can be installed to roof curb before unit is set in place. Curb should be level.
  • Page 3 a48-6715...
  • Page 4 a48-6716...
  • Page 5 a48-6717...
  • Page 6 a48-8235...
  • Page 7 a48-8236...
  • Page 9 A48-8380...
  • Page 10 a48-8239...
  • Page 11 a48-8240...
  • Page 12 a50-8102...
  • Page 13 Table 1 — Physical Data — 48AJ,AK,AW,AY Units UNIT 48AJ,AK,AW,AY NOMINAL CAPACITY (tons) BASE UNIT OPERATING WEIGHT (lb) COMPRESSOR Quantity ... Type (Ckt 1/Ckt 2) 2…SR*782AT/1…SR*782AE Number of Refrigerant Circuits Oil (oz) (Ckt 1, Ckt 2) REFRIGERANT TYPE Operating Charge (lb-oz) Circuit 1 Circuit 2 CONDENSER COIL*...
  • Page 14 Table 1 — Physical Data — 48AJ,AK,AW,AY Units (cont) UNIT 48AJ,AK,AW,AY NOMINAL CAPACITY (tons) BASE UNIT OPERATING WEIGHT (lb) COMPRESSOR 1…SR*812AT, Quantity ... Type (Ckt 1/Ckt 2) 1…SR*942AT/2…SR*942AT Number of Refrigerant Circuits Oil (oz) (Ckt 1, Ckt 2) Precharged REFRIGERANT TYPE Operating Charge (lb-oz) Circuit 1 Circuit 2...
  • Page 15 Table 1 — Physical Data — 48AJ,AK,AW,AY Units (cont) UNIT 48AJ,AK,AW,AY NOMINAL CAPACITY (tons) BASE UNIT OPERATING WEIGHT (lb) COMPRESSOR 2…SM125/1…SM125, Quantity ... Type (Ckt 1/Ckt 2) 1…SM175 Number of Refrigerant Circuits Oil (oz) (Ckt 1, Ckt 2) Precharged REFRIGERANT TYPE Operating Charge (lb-oz) Circuit 1 Circuit 2...
  • Page 16 a48-8246...
  • Page 17 UNIT 48AJ/AK Low Heat 3842 3915 48AJ/AK High Heat 3922 3995 48AW/AY Low Heat 3882 3955 48AW/AY High Heat 3962 4035 OPTION/ ACCESSORY Barometric Relief Power Exhaust Mod. Power Exhaust Cu Tubing/Cu Fin Condenser Coil Outdoor Air Hood Crate and Packaging (Less Hoods' Weight) Outdoor Air Hoods/Filters Hail Guard...
  • Page 18 UNIT MOTOR SIZE MOTOR SHAFT SHAFT DIA. 48AJ,AK, SPEED (in.) AW,AY (rpm) 1.125 1.375 1.625 1096 1.125 1.375 1.625 1106 1.375 1.625 1096 1.625 1187 1.375 1.625 1096 1.625 1187 1.625 1005 1.625 1147 1.875 1247 1.625 1.625 1050 1.875 1182 1.625 1.625...

  • Page 19: Step 5 - Install Flue Hood

    Step 5 — Install Flue Hood 48AJ,AK,AW,AY020-050 UNITS — Flue hood is shipped inside gas section of unit. To install, secure flue hood to access panel. See Fig. 14. 48AJ,AK,AW,AY051 AND 060 UNITS — Flue hood and wind baffle are shipped inside gas section of unit. To install, se- cure flue hood to access panel.

  • Page 20: Field Power Supply

    Fig. 18 — Field Gas Piping IMPORTANT: Natural gas pressure at unit gas connection must not be less than 5 in. wg or greater than 13.5 in. wg. Size gas-supply piping for 0.5-in. wg maximum pressure drop. Do not use supply pipe smaller than unit gas connection. OPTIONAL STAGED GAS UNITS —...
  • Page 21 Table 8A — Electrical Data — 48AJ,AK,AW,AY Units without Convenience Outlet VOLTAGE UNIT VOLTAGE RANGE SIZE Cir A, No. 1 Cir A, No. 2 Cir B, No. 1 Cir B, No. 2 3 PH, 60 Hz Min Max RLA LRA RLA LRA RLA LRA RLA LRA 187 229 207 253 414 508...
  • Page 22 Table 8A — Electrical Data — 48AJ,AK,AW,AY Units without Convenience Outlet (cont) VOLTAGE UNIT VOLTAGE RANGE SIZE Cir A, No. 1 Cir A, No. 2 Cir B, No. 1 Cir B, No. 2 3 PH, 60 Hz Min Max RLA LRA RLA LRA RLA LRA RLA LRA 187 229 207 253 414 508...
  • Page 23 Table 8A — Electrical Data — 48AJ,AK,AW,AY Units without Convenience Outlet (cont) VOLTAGE UNIT VOLTAGE RANGE SIZE Cir A, No. 1 Cir A, No. 2 Cir B, No. 1 Cir B, No. 2 3 PH, 60 Hz Min Max RLA LRA RLA LRA RLA LRA RLA LRA 187 229 25.6 207 253...
  • Page 24 Table 8A — Electrical Data — 48AJ,AK,AW,AY Units without Convenience Outlet (cont) VOLTAGE UNIT VOLTAGE RANGE SIZE Cir A, No. 1 Cir A, No. 2 Cir B, No. 1 Cir B, No. 2 3 PH, 60 Hz Min Max RLA LRA RLA LRA RLA LRA RLA LRA 187 229 34.3 207 253...
  • Page 25 Table 8B — Electrical Data — 48AJ,AK,AW,AY Units with Convenience Outlet VOLTAGE UNIT RANGE VOLTAGE Cir A, No. 1 Cir A, No. 2 Cir B, No. 1 Cir B, No. 2 SIZE 3 PH, 60 Hz Min Max RLA LRA RLA LRA RLA LRA RLA LRA 187 229 207 253 414 508 10.2...
  • Page 26 Table 8B — Electrical Data — 48AJ,AK,AW,AY Units with Convenience Outlet (cont) VOLTAGE UNIT RANGE VOLTAGE Cir A, No. 1 Cir A, No. 2 Cir B, No. 1 Cir B, No. 2 SIZE 3 PH, 60 Hz Min Max RLA LRA RLA LRA RLA LRA RLA LRA 187 229 207 253 414 508 10.2...
  • Page 27 Table 8B — Electrical Data — 48AJ,AK,AW,AY Units with Convenience Outlet (cont) VOLTAGE UNIT RANGE VOLTAGE Cir A, No. 1 Cir A, No. 2 Cir B, No. 1 Cir B, No. 2 SIZE 3 PH, 60 Hz Min Max RLA LRA RLA LRA RLA LRA RLA LRA 187 229 25.6 25.6 207 253 25.6...
  • Page 28 Table 8B — Electrical Data — 48AJ,AK,AW,AY Units with Convenience Outlet (cont) VOLTAGE UNIT RANGE VOLTAGE Cir A, No. 1 Cir A, No. 2 Cir B, No. 1 Cir B, No. 2 SIZE 3 PH, 60 Hz Min Max RLA LRA RLA LRA RLA LRA RLA LRA 187 229 34.3 34.3 207 253 34.3...
  • Page 29 Carrier TEMP system control operation. • Stand-alone with a thermostat (CV) or with a space sen- sor (CV and VAV) • Network application with CCN (Carrier Comfort Network • Demand ventilation with CO • Economizer and economizer with changeover control •...
  • Page 30 Staged Gas Control Option Thermistors — If the unit is equipped with the staged gas heat option, supply-air ther- mistors must be installed. Three supply-air thermistors are shipped with staged gas units and are inside the heating sec- tion. The supply-air thermistors should be located in the supply duct with the following criteria: •...
  • Page 31 11 and 12 on TB6. This will require the use of the optional controls expansion module. Remote IAQ Override — If the control is being used with non Carrier building management system it supports the use of the device or ™...

  • Page 32: Adjustments

    Step 9 — Make Outdoor-Air Inlet Adjustments ECONOMIZER FIXED DAMPER — Hoods are used on all units with economizer or adjustable self-closing fixed outdoor air damper. NOTE: If accessory power exhaust or barometric relief pack- ages are being added to the unit, install power exhaust or baro- metric relief before installing economizer hoods.

  • Page 33: Step 10 - Position Power Exhaust/Barometric

    HOOD SIDE 48-1104 Fig. 26 — Adding Seal Strip to Back of Hood Top Mounting Flange GRAY FOAM STRIP CROSS MEMBER 48-1105 Fig. 27 — Adding Foam Strip to Cross Member BLOCKOFF BAFFLE GRAY FOAM STRIP a48-4328 Fig. 28 — Adding Seal Strip to Block-Off Baffle HOOD TOP Fig.

  • Page 34: Step 11 - Route Vav Static Pressure Sensor

    LOCATION BAROMETRIC RELIEF OR POWER EXHAUST “SIDE #2” 23.28” “END #2” ALTERNATE LOCATION (END) a48-8244 Fig. 31 — Power Exhaust Relocated to Side Return Duct NOTES: 1. Unless otherwise specified, all dimensions are to outside of part. 2. Dimensions are in inches. 3.

  • Page 35: Step 12 - Install All Accessories

    • Return air smoke detector • Controls expansion module (used for interface to build- ing management systems, not typically needed on system with the Carrier Comfort Network tem) • Plugged filter sensor • Motormaster® V low ambient head pressure control...
  • Page 36 31.25” INSIDE a48-8245 Fig. 34 — Side Return Air Conversion Copyright 2009 Carrier Corporation Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 04-53480067-01 Printed in U.S.A.

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