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

Carrier WeatherMaker 48FC Series Installation Instructions Manual

Single package rooftop gas heating/electric cooling unit with puron (r-410a) refrigerant
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CONTENTS
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . 1
Rated Indoor Airflow . . . . . . . . . . . . . . . . . . . . . . . . . . 3
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Jobsite Survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Step 1 - Plan for Unit Location . . . . . . . . . . . . . . . . 8
Step 3 - Inspect Unit . . . . . . . . . . . . . . . . . . . . . . . . . 8
Step 4 - Provide Unit Support . . . . . . . . . . . . . . . . . 8
• ALTERNATE UNIT SUPPORT (IN LIEU OF CURB OR
Step 5 - Field Fabricate Ductwork . . . . . . . . . . . . . 10
Step 6 - Rig and Place Unit . . . . . . . . . . . . . . . . . . 10
Ductwork (When Required) . . . . . . . . . . . . . . . . . 11
Step 8 - Install Outside Air Hood . . . . . . . . . . . . . . 12
Step 10 - Install Flue Hood . . . . . . . . . . . . . . . . . . . 13
Step 11 - Install Gas Piping . . . . . . . . . . . . . . . . . . 13
(GAS CONNECTIONS)
Integrated Gas Controller . . . . . . . . . . . . . . . . . . . . . 27
EconoMi$er® X (Factory Option) . . . . . . . . . . . . . . . 29
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Catalog No. 04-53480272-01
Installation Instructions
Page
Printed in U.S.A.
Form 48FC-4-7-03SI
WeatherMaker
Single Package Rooftop
Gas Heating/Electric Cooling Unit
with Puron
®
• ECONOMIZER MODULE WIRING DETAILS
Controller Options . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Smoke Detectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
• ECONOMI$ER® IV OCCUPANCY SWITCH
Step 15 - Install Accessories . . . . . . . . . . . . . . . . .44
Step 16 - Fan Speed Set Up . . . . . . . . . . . . . . . . . .45
START-UP CHECKLIST . . . . . . . . . . . . . . . . . . . . CL-1

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
Pg 1
48FC**04-07
®
(R-410A) Refrigerant
2-2020
Replaces: 48FC-4-7-02SI

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Summary of Contents for Carrier WeatherMaker 48FC Series

  • Page 1: Table Of Contents

    WeatherMaker 48FC**04-07 ® Single Package Rooftop Gas Heating/Electric Cooling Unit with Puron (R-410A) Refrigerant ® Installation Instructions • SPECIFICATIONS CONTENTS • INPUTS Page • OUTPUTS • ENVIRONMENTAL SAFETY CONSIDERATIONS ....1 •...
  • Page 2 injury or product and property damage. NOTE is used to highlight suggestions which will result in enhanced installation, reliability, WARNING or operation. CARBON-MONOXIDE POISONING HAZARD DANGER Failure to follow instructions could result in severe personal injury or death due to carbon-monoxide poisoning, if combus- ELECTRICAL SHOCK HAZARD tion products infiltrate into the building.

  • Page 3: Model Number Nomenclature And Dimensions

    MODEL NUMBER NOMENCLATURE AND WARNING DIMENSIONS FIRE HAZARD See Fig. 1 for 48FC model number nomenclature. See Fig. 2 for Failure to follow this warning could result in severe personal unit dimensional drawings. Figure 2 also shows service clearance injury and/or property damage. dimensions.
  • Page 4 Position: 9 10 11 12 13 14 15 16 17 18 Example: Unit Heat Type Packaging & Seismic Compliance 48 – Gas Heat Packaged Rooftop 0 = Standard 1 = LTL Model Series - WeatherMaker ® FC – 14.0 SEER Standard Efficiency, sizes 04-06 Electrical Options 15.0 IEER Standard Efficiency, size 07 A = None...
  • Page 5 Fig. 2 — Unit Dimensional Drawing...
  • Page 6 Fig. 2 — Unit Dimensional Drawing (cont)
  • Page 7 Fig. 2 — Unit Dimensional Drawing (cont)

  • Page 8: 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- 1.
  • Page 9 ROOF CURB NOTES: POWER WIRING CONTROL WIRING ACCESSORY CONVENIENCE CONNECTOR PKG. ACC. GAS CONNECTION TYPE GAS FITTING ACCESSORY # 1. ROOFCURB ACCESSORY IS SHIPPED DISASSEMBLED. FITTING FITTING OUTLET WIRING CONNECTOR 2. INSULATED PANELS: 25.4 [1"] THK. POLYURETHANE FOAM, 44.5 [1-3/4] # DENSITY. 14"...

  • Page 10: Slab Mount (Horizontal Units Only)

    NOTE: The gasketing of the unit to the roof curb is critical for a Insulate and weatherproof all external ductwork, joints, and roof watertight seal. Install gasket supplied with the roof curb as shown openings with counter flashing and mastic in accordance with ap- in Fig.

  • Page 11: Step 7 - Convert To Horizontal And Connect

    "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 MAX WEIGHT UNIT 48FC**04 74.5 1890 37.6 33.5 48FC**05 74.5 1890 36.5 33.5 48FC**06...

  • Page 12: 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 ECONOMIZER AND TWO-POSITION HOOD NOTE: If the power exhaust accessory is to be installed on the Fig.

  • Page 13: Step 9 - Units With Hinged Panels Only

    COMPRESSOR DOOR OUTDOOR COIL PANEL LATCH PANEL Fig. 14 — Compressor Door Latch Location CAULK HERE Step 10 — Install Flue Hood INDOOR INDOOR COIL COIL Flue hood is shipped screwed to the basepan beside the burner ACCESS ACCESS compartment access panel. Remove from shipping location and PANEL PANEL using screws provided, install flue hood and screen in location...

  • Page 14: Factory Option Thru-Base Connections

    Table 4 — Liquid Propane Supply Line Pressure Ranges 9” MINIMUM CLEARANCE FOR PANEL REMOVAL UNIT MODEL UNIT SIZE MIN. MAX. REGULATOR 11.0 in. wg 13.0 in. wg MANUAL GAS 48FCD/E/S/R 04, 05, 06, 07 SHUTOFF VALVE (2740 Pa) (3240 Pa) BASE UNIT 48FCF/T 11.0 in.
  • Page 15 Check tightness of connector lock nuts before connecting gas piping. Install a -in. NPT street elbow on the thru-base gas fitting. At- tach a -in. pipe nipple with minimum length of 16-in. (406 mm) (field-supplied) to the street elbow and extend it through the ac- cess panel at the gas support bracket.

  • Page 16: 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- 9”...

  • Page 17: Step 13 - Make Electrical Connections

    All units must have an external trap for condensate drainage. In- not factory connected. Installer must connect these leads accord- stall a trap at least 4-in. (102 mm) deep and protect against ing to required operation of the convenience outlet. If an always- freeze-up.

  • Page 18: Units With Factory-Installed Non-Fused Disconnect

    ELECTRIC DISCONNECT SWITCH COPPER WIRE ONLY ALUMINUM WIRE Fig. 27 — Disconnect Switch and Unit UNITS WITH FACTORY-INSTALLED NON-FUSED DISCONNECT The factory-installed option non-fused disconnect (NFD) switch is located in a weatherproof enclosure located under the main con- Fig. 28 — NFD Enclosure Location trol box.

  • Page 19: Convenience Outlets

    Operation on improper line voltage or excessive phase imbalance constitutes abuse and may cause damage to electrical components. Such operation would invalidate any applicable Carrier warranty. max voltage deviation from average voltage % Voltage...
  • Page 20 Unit-Powered Convenience Outlet A unit-mounted transformer is factory-installed to step down the main power supply voltage to the unit to 115v at the duplex recep- tacle. This option also includes a manual switch with fuse, located in a utility box and mounted on a bracket behind the convenience outlet;...

  • Page 21: Factory-Option Thru-Base Connections (Electrical Connections)

    Pull the wires over to the terminal This device can be a thermostat (field-supplied) or a SystemVu™ strip on the upper-left corner of the Unit Control Board. See controller (available as factory-installed option for use on a Carrier Fig. 36. Comfort Network or as a stand alone control) or the RTU Open ®...

  • Page 22: Heat Anticipator Settings

    UNIT CONTROL on rise in space RH above control setpoint) or a combination ther- BOARD mostat-humidistat control device such as Carrier’s Edge ® Thermidistat™ device with isolated contact set for dehumidifica- tion control. See Fig. 37 and Fig. 38. The humidistat is normally used in applications where a temperature control is already provid- ed (units with SystemVu™...
  • Page 23 PROGRAMMABLE THERMOSTAT UNIT CONTROL BOARD THERMOSTAT CONNECTIONS O/W2/B SRTN Fig. 40 — Typical Rooftop Unit with Humidi-MiZer Adaptive Dehumidification System and Edge ® Pro Thermidistat Device...
  • Page 24 Fig. 41 — Typical Control Wiring Diagram Electro-Mechanical with W7212 (48FC 04-06 208-230/3/60 Unit Shown)
  • Page 25 Fig. 42 — Typical Electro-Mechanical with W7220 Control Wiring Diagram (48FC 07 208-230/3/60 Unit Shown)
  • Page 26 Fig. 43 — Typical 48FC 04-07 Power Wiring Diagram, 208-230V Unit Shown...

  • Page 27: Integrated Gas Controller

    When the thermostat calls for heating, power is sent to W on the Integrated Gas Controller Integrated Gas Controller (IGC) board. An LED (light emitting di- This unit contains an Integrated Gas Controller (IGC) board. The ode) on the IGC board turns on and remains on during normal op- IGC control board uses a flue gas pressure switch that senses pres- eration.
  • Page 28 UNIT CONTROL BOARD Fig. 46 — Typical IGC Control Wiring Diagram Table 7 — IGC Board LED Alarm Codes ACTION TAKEN BY FLASH DESCRIPTION RESET METHOD PROBABLE CAUSE CONTROL CODE Normal Operation — — — Hardware Failure No gas heating. Loss of power to the IGC.

  • Page 29: 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 30: S-Bus Sensor Wiring

    Relative Humidity Table 9 — Economizer Module - Right Hand Terminal 5% to 95% RH non-condensing Blocks ECONOMIZER MODULE WIRING DETAILS LABEL TYPE DESCRIPTION Use Fig. 48 and Tables 8 and 9 to locate the wiring terminals for Top Right Terminal Blocks the Economizer module.

  • Page 31: Co2 Sensor Wiring

    To use the keypad when working with menus: Table 10 — 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 32: Setup And Configuration

    SETUP AND CONFIGURATION IMPORTANT: Table 12 illustrates the complete hierarchy. Before being placed into service, the W7220 Economizer module Your menu parameters may be different depending on your must be set up and configured for the installed system. configuration. For example, if you do not have a DCV (CO ) sensor, then none IMPORTANT: During setup, the economizer module is of the DCV parameters appear and only MIN POS will display.
  • Page 33 Table 12 — W7220 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 cooling when required FIRST STAGE COOLING RELAY OUTPUT ECONOMIZING YES/NO...
  • Page 34 Table 12 — W7220 Menu Structure* (cont) PARAMETER PARAMETER MENU PARAMETER DEFAULT RANGE AND NOTES VALUE INCREMENT † MECH COOL ON Displays stage of mechanical cooling that is active. 0, 1, or 2 HEAT STAGES ON Displays the stage of heat pump heating that is active. STATUS SUPPLY FAN SPEED (cont)
  • Page 35 Table 12 — W7220 Menu Structure* (cont) PARAMETER PARAMETER MENU PARAMETER DEFAULT RANGE AND NOTES VALUE INCREMENT † 0°F to 50°F ENERGY RECOVERY VENTILATOR UNIT OUTDOOR AIR ERV OAT SP 32°F (–18°C to 10°C); TEMPERATURE SETPOINT †† increment by 1°F Only displayed when AUX1 O = ERV Exhaust fan set point for single speed units.
  • Page 36 Table 12 — W7220 Menu Structure* (cont) PARAMETER PARAMETER MENU PARAMETER DEFAULT RANGE AND NOTES VALUE INCREMENT † COOLING STAGE 3 DELAY 0 min, 5 min, Delay after stage 2 cool has been active. Turns on second stage of 15 min, then cooling when economizer is first stage and mechanical cooling is STG3 DLY 2.0h...
  • Page 37 Table 12 — W7220 Menu Structure* (cont) PARAMETER PARAMETER MENU PARAMETER DEFAULT RANGE AND NOTES VALUE INCREMENT † DISCHARGE AIR S-BUS SENSOR ERROR DA SYLK T ERR Discharge air sensor has failed or become disconnected - check wiring then replace sensor if the alarm continues. OUTSIDE AIR TEMPERATURE SENSOR ERROR OA SENS T ERR Outdoor air temperature sensor has failed or become disconnected...

  • Page 38: Enthalpy Settings

    ENTHALPY SETTINGS all below the selected boundary, the economizer sets the econo- mizing mode to YES, economizing is available. When the OA temperature, enthalpy and dew point are below the When all of the OA conditions are above the selected boundary, respective setpoints, the Outdoor Air can be used for economiz- the conditions are not good to economize and the mode is set to ing.

  • Page 39: Standard Or Single Speed Fan Operation

    STANDARD OR SINGLE SPEED FAN OPERATION The W7220 controller will control a standard 1 speed unit when configured for FAN TYPE = 1 SPEED. Refer to Table 14 for economizer operation. Table 14 — Economizer Operation - FAN TYPE = 1SPEED INPUTS OUTPUTS DEMAND...

  • Page 40: Speed Fan Operation

    2 SPEED FAN OPERATION The 2 speed fan delay is available when the system is programmed for 2 speed fan (in the System Setup menu item). The 2 speed fan NOTE: 2 Speed Fan operation applies to 48FC**07 models only. delay is defaulted to 5 minutes and can be changed in the Ad- The W7220 controller has the capability to work with a system us- vanced Setup menu item.

  • Page 41: 2Sp H/C (2 Speed Heat/Cool) Fan Operation (Single Phase Units Only)

    2SP H/C (2 SPEED HEAT/COOL) FAN OPERATION (SIN- On single phase 48FC 3 to 5 ton units, if reduced the heating fan speed is lower than the cooling speed and the economizer FAN GLE PHASE UNITS ONLY) TYPE needs to be set to 2SP H/C (2 speed Heat/Cool). This indi- The W7220 controller does not actually control the fan speed or cates that the heating and vent mode fan speed is less than then the heat output of the unit, and only uses this information to help...

  • Page 42: Checkout

    CHECKOUT Inspect all wiring connections at the economizer module’s termi- CAUTION nals, and verify compliance with the installation wiring diagrams. For checkout, review the Status of each configured parameter and EQUIPMENT DAMAGE HAZARD perform the Checkout tests. Failure to follow this caution may result in equipment damage. NOTE: For information about menu navigation and use of the Be sure to allow enough time for compressor start-up and shut- keypad see Interface Overview on page 31.
  • Page 43 board may be necessary to complete the unit and smoke detector configuration to meet project requirements. Units equipped with factory-optional return-air smoke detectors RETURN AIR require a relocation of the sensor module at unit installation. See SMOKE DETECTOR (AS SHIPPED) Fig.

  • Page 44: Step 14 - Adjust Factory-Installed Options

    • LP conversion kit Step 14 — Adjust Factory-Installed Options • Flue discharge deflector SMOKE DETECTORS • Manual outside air damper Smoke detector(s) will be connected at the Unit Control Board • Two-position motorized outside air damper (UCB), at terminals marked “Smoke Shutdown.” Detach the jumper covering the Smoke Shutdown terminals on the UCB and •...

  • Page 45: 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. 56 for the location on 3 phase voltage units or Fig. 57 for the location on single phase volt- age units.

  • Page 46: 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 47 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 2073 2200 2316 1784 1933 2000 1878...
  • Page 50 © 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. 04-53480272-01 Printed in U.S.A. Form 48FC-4-7-03SI Pg 50 2-2020 Replaces: 48FC-4-7-02SI...

  • Page 51: Start-Up Checklist

    START-UP CHECKLIST FOR 48FC 04-07 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 preceding sec- tions of this Installation Instruction document.
  • Page 52 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) _____ © 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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