Page 1: Table Of Contents
® WeatherMaster 48HC**04-06 Single Package Rooftop Gas Heating/Electric Cooling Unit ® with Puron (R-410A) Refrigerant Installation Instructions CONTENTS Economi$er® X (Factory Option) ....41 • SYSTEM COMPONENTS SAFETY CONSIDERATIONS .
Page 2 WARNING WARNING Electrical shock can cause personal injury and death. Shut off CARBON-MONOXIDE POISONING HAZARD all power to this equipment during installation. There may be Failure to follow instructions could result in severe personal more than one disconnect switch. Tag all disconnect locations injury or death due to carbon-monoxide poisoning, if combus- to alert others not to restore power until work is completed.
Page 3: Model Number Nomenclature And Dimensions
MODEL NUMBER NOMENCLATURE AND WARNING DIMENSIONS FIRE HAZARD See Fig. 1 for 48HC model number nomenclature. See Fig. 2-6 Failure to follow this warning could result in severe personal for unit dimensional drawings. Figure 4 shows service clear- injury and/or property damage. ance dimensions.
Page 4 Position: 9 10 11 12 13 14 15 16 17 18 Example: Unit Heat Type Factory Assigned 48 - Gas Heat Packaged Rooftop 0 = Standard 1 = LTL Model Series - WeatherMaster ® Electrical Options HC - High Efficiency A = None B = HACR Breaker Heat Options...
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Page 10: 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 be- Consult local building codes and the NEC (National Elec- fore the unit is placed on the curb.
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Page 12: Slab Mount (Horizontal Units Only)
The gasketing of the unit to the roof curb is critical for a watertight Step 5 — Field Fabricate Ductwork seal. Install gasket supplied with the roof curb as shown in Fig. 4. Cabinet return-air static pressure (a negative condition) shall not Improperly applied gasket can also result in air leaks and poor unit exceed 0.35 in.
Page 13: Positioning On Curb
"B" 36"- 54" DETAIL "A" 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 48HC-A04 74.5 1890 38.0 33.5 48HC-A05 74.5 1890 38.0 41.5 1055...
Page 14: Step 8 - Install Outside Air Hood
Step 8 — Install Outside Air Hood REMOVABLE HORIZONTAL RETURN DUCT OPENING COVER ECONOMIZER AND TWO POSITION DAMPER HOOD PACKAGE REMOVAL AND SETUP (FACTORY OPTION) NOTE: Economizer and two position damper are not available as factory-installed options for single phase (-3 voltage code) models.
Page 15: Economizer And Two-Position Hood
ECONOMIZER AND TWO-POSITION HOOD NOTE: If the power exhaust accessory is to be installed on the unit, the hood shipped with the unit will not be used and must be discarded. Save the aluminum filter for use in the power exhaust hood assembly.
Page 16: Step 11 - Install Gas Piping
Step 11 — Install Gas Piping Installation of the gas piping must be accordance with local CAUTION building codes and with applicable national codes. In U.S.A., re- fer to NFPA 54/ANSI Z223.1 National Fuel Gas Code (NFGC). EQUIPMENT DAMAGE In Canada, installation must be accordance with the CAN/CSA Failure to follow this caution may result in equipment damage.
Page 17 HIGH VOLTAGE BRASS FITTING FOR CONDUIT 3 TO 6 TON UNITS CONNECTOR AUXILIARY POWER SUPPLY (OPTIONAL) LOW VOLTAGE CONDUIT CONNECTOR Fig. 23 — Thru-Base Connection Fittings (Units Built On and After 4/15/2019) Remove the “L” bracket assembly from the unit. Remove connector plate assembly from the “L”...
Page 18 piping that has been routed through the sidewall of the curb. See When installing the gas supply line, observe local codes pertaining Fig. 27 for typical piping arrangement when thru-base is used. En- to gas pipe installations. Refer to the NFPA 54/ANSI Z223.1 sure that all piping does not block access to the unit’s main control NFGC latest edition (in Canada, CAN/CSA B149.1).
Page 19: Step 12 - Install External Condensate Trap And Line
MINIMUM PITCH 1˝ (25 mm) PER BASE RAIL 10´ (3 m) OF LINE 3˝ (76 mm) OPEN VENT TO ROOF SEE NOTE DRAIN BURNER ROOF CURB ORIFICE DRAIN PLUG NOTE: Trap should be deep enough to offset maximum unit static difference.
Page 20: Units With Factory-Installed Non-Fused Disconnect Or Hacr
Make sure the NFD shipped from the factory is at OFF position (the arrow on the black handle knob is at OFF). WARNING Insert the shaft with the cross pin on the top of the shaft in the horizontal position. See Fig. 34. FIRE HAZARD Measure from the tip of the shaft to the top surface of the Failure to follow this warning could result in personal injury,...
Page 21: Units Without Factory-Installed Non-Fused Disconnect Or Hacr
Tighten the locking screw to secure the shaft to the HACR. Provide a ground fault and short circuit over-current protection de- vice (fuse or breaker) per NEC Article 440 (or local codes). Refer Turn the handle to the OFF position with red arrow point- to unit informative data plate for MOCP (Maximum Over-Current ing at OFF.
Page 22 The weatherproof cover kit is shipped in the unit’s control box. The kit includes the hinged cover, a backing plate, and gasket. WARNING Electrical shock can cause personal injury and death. Shut off all power to this equipment during installation. There may be more than one disconnect switch.
Page 23: Factory-Option Thru-Base Connections (Electrical Connections)
-in. electrical bulkhead connector, and a Link™ controller (available as factory-installed option or as field- -in. electrical bulkhead connector, all factory-installed in the installed accessory, for use on a Carrier Comfort Network ® or as a embossed (raised) section of the unit basepan in the condenser stand alone control) or the RTU Open Controller for Building section.
Page 24 RH above control setpoint) or a combination ther- For wire runs up to 50 ft. (15 m), use no. 18 AWG (American mostat-humidistat control device such as Carrier’s Edge ® Wire Gage) insulated wire [95°F (35°C) minimum]. For 50 to 75 Thermidistat™...
Page 25 CTB terminal R and the PINK lead to Fig. 45 — Edge Pro Thermidistat the LTLO switch with field-supplied wire nuts. Refer to the installation instructions included with the Carrier Edge Pro Thermidistat device for more information. Fig. 46 — Typical Humidi-MiZer Adaptive Dehumidification System Humidistat Wiring Downloaded from ManualsNet.com...
Page 26 EDGE Pro THERMIDISTAT Unit CTB THERMOSTAT O/W2/B SRTN Humidi-MiZer™ FIOP *Connection not required. Fig. 47 — Typical Rooftop Unit with Humidi-MiZer Adaptive Dehumidification System and Edge Pro Thermidistat Device LOW AMBIENT CONTROL (FACTORY OPTION) When the thermostat calls for heating, power is sent to W on the Integrated Gas Controller (IGC) board.
Page 27 COMFORTLINK (FACTORY OPTION) Table 7 — IGC Board Faults For details on operating 48HC units equipped with the factory in- stalled ComfortLink option, refer to “Controls, Start-Up, Opera- LED INDICATION ERROR MODE tion and Troubleshooting for 48/50HC 04-28 Single Package Normal operation Rooftop Unit with ComfortLink Controls.”...
Page 28 STATUS LOCKING TAB CONNECTOR OVERCURRENT FUSE PROTECTION LOCKING REDUNDANT GAS TAB CONNECTOR VALVE RELAY SPADE CONNECT IGNITOR Fig. 49 — IGC Board Component Layout Fig. 50 — Typical IGC Control Wiring Diagram Fig. 51 — 48HC Control Box Component Locations with ComfortLink Controls Downloaded from ManualsNet.com search engine...
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Page 34 Fig. 57 — 48HC**04-06 Electromechanical Power Wiring Diagram (208/230-1-60 Units) Downloaded from ManualsNet.com search engine...
Page 35 Fig. 58 — 48HC**04-06 Power Wiring Diagram (208/230-3-60, 460-3-60 Units) Downloaded from ManualsNet.com search engine...
Page 36 Fig. 59 — 48HC**04-06 Power Wiring Diagram (575-3-60 Units) Downloaded from ManualsNet.com search engine...
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Page 38 Fig. 61 — 48HC**04-06 Electromechanical Power Wiring Diagram with Humidi-MiZer System (208/230-1-60 Units) Downloaded from ManualsNet.com search engine...
Page 39 Fig. 62 — 48HC**04-06 Power Wiring Diagram with Humidi-MiZer System (208/230-3-60, 460-3-60 Units) Downloaded from ManualsNet.com search engine...
Page 40 Fig. 63 — 48HC**04-06 Power Wiring Diagram with Humidi-MiZer System (575-3-60 Units) Downloaded from ManualsNet.com search engine...
Page 41: Economi$Er® X (Factory Option)
Electrical ® Economi$er X (Factory Option) • Rated Voltage — 20 to 30 vac RMS, 50/60 Hz The EconoMi$er X system is an expandable economizer control system, which includes a W7220 economizer module (controller) • Transformer — 100 va maximum system input with an LCD and keypad (see Fig.
Page 42: Economizer Module Wiring Details
Relative Humidity Table 10 — Economizer Module - Right Hand 5% to 95% RH non-condensing Terminal Blocks ECONOMIZER MODULE WIRING DETAILS LABEL TYPE DESCRIPTION Use Fig. 65 and Tables 9 and 10 to locate the wiring terminals for Top Right Terminal Blocks the Economizer module.
Page 43: Interface Overview
To use the keypad when working with menus: Table 11 — HH57AC081 Sensor Wiring Terminations • Press the ▲ (Up arrow) button to move to the previous menu. TERMINAL TYPE DESCRIPTION • Press the ▼ (Down arrow) button to move to the next NUMBER LABEL menu.
Page 44: Setup And Configuration
the cooling coil. This unit application has the control sensor locat- The setup process uses a hierarchical menu structure that is easy to ed after the cooling coil, in the fan section, where it is designated use. Press the ▲ and ▼ arrow buttons to move forward and back- as (Cooling) Supply Air Temperature or SAT sensor.
Page 45 Table 13 — W7220 Menu Structure* (cont) PARAMETER PARAMETER EXPANDED PARAMETER NAME MENU PARAMETER DEFAULT RANGE AND Notes VALUE INCREMENT † DAMPER OUT 2.0v 2.0 to 10.0v Displays voltage output to the damper actuator.*** ACT POS 0 to 100% Displays actual position of actuator Displays number of times actuator has cycled.
Page 46 Table 13 — W7220 Menu Structure* (cont) PARAMETER PARAMETER EXPANDED PARAMETER NAME MENU PARAMETER DEFAULT RANGE AND Notes VALUE INCREMENT † DCV MINIMUM DAMPER POSITION 2 to 10 vdc or 100 Displays only if a CO sensor is connected. Used for Va to 9990 cfm (ventilation min cfm) set point.
Page 47 Table 13 — 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 low. Set 35°F to 65°F DA LO ALM 45°F (7°C) lower range of alarm, below this temperature the alarm will show (2°C to 18°C);...
Page 48 Table 13 — W7220 Menu Structure* (cont) PARAMETER PARAMETER EXPANDED PARAMETER NAME MENU PARAMETER DEFAULT RANGE AND Notes VALUE INCREMENT † ACTUATOR ERROR Actuator has failed or become disconnected - check for stall, ACT ERROR over voltage, under voltage and actuator count. Replace actuator if damper is movable and supply voltage is between 21.6 V and 26.4 V.
Page 49 Table 15 — 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 50 Table 18 — Enthalpy Operation with 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 0-v/Off 0-v/Off Closed VENTMIN High 24-v/On 0-v/Off Closed VENTMIN High 24-v/On 24-v/On Closed...
Page 51: Enthalpy Settings
ENTHALPY SETTINGS When the OA temperature, enthalpy and dew point are below the CAUTION respective set points, the Outdoor Air can be used for economiz- ing. Figure 69 shows the new single enthalpy boundaries in the EQUIPMENT DAMAGE HAZARD W7220. There are 5 boundaries (set points ES1 through ES5), Failure to follow this caution may result in equipment damage.
Page 52: Additional Application Data
Turn the assembly 90 degrees and then rotate end to end. RETURN AIR Make sure that the elbow fitting is pointing down. See SMOKE DETECTOR Fig. 71, Step 2. (AS SHIPPED) Screw the sensor and detector plate into its operating position using screws from Step 1.
Page 53: Step 14 - Adjust Factory-Installed Options
Fig. 72 — EconoMi$er IV Wiring • Differential enthalpy sensor Step 14 — Adjust Factory-Installed Options • sensor SMOKE DETECTORS • DDC interface (PremierLink™ Controls) Smoke detector(s) will be connected at the Controls Connections • Louvered hail guard Board, at terminals marked “Smoke Shutdown.” Cut jumper JMP 3 when ready to energize unit.
Page 54: Belt Tension Method
TENSION FORCE IN BELT (LBS) (www.hvacpartners.com). Used Fig. 73 — V-Belt Force Label © 2020 Carrier Corporation Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 04-53480254-01 Printed in U.S.A.
Page 55: Start-Up Checklist
START-UP CHECKLIST FOR 48HC 04-06 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 56 9. Open humidistat input compressor and outdoor fan stop; LSV and DSV solenoids de-energized (Y/N) _____ 10. Restore set-points for thermostat and humidistat (Y/N) _____ © 2020 Carrier Corporation Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.

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