Carrier WeatherMaker 48GC Series Installation Instructions Manual
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Carrier WeatherMaker 48GC Series Installation Instructions Manual

Single package rooftop with gas heat/electric cooling and ecoblue fan technology
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CONTENTS
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . 1
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Rated Indoor Airflow (cfm) . . . . . . . . . . . . . . . . . . . . . 3
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Jobsite Survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Step 1 - Plan for Unit Location . . . . . . . . . . . . . . . 20
Step 3 - Inspect Unit . . . . . . . . . . . . . . . . . . . . . . . . 21
Step 4 - Provide Unit Support . . . . . . . . . . . . . . . . 21
Step 5 - Field Fabricate Ductwork . . . . . . . . . . . . . 25
Step 6 - Rig and Place Unit . . . . . . . . . . . . . . . . . . 25
Step 9 - Assemble Barometric Hood . . . . . . . . . . . 27
Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Step 11 - Install Gas Piping . . . . . . . . . . . . . . . . . . 29
• CONVENIENCE OUTLETS
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Catalog No. 04-53480479-01
Installation Instructions
Page
Printed in U.S.A.
Form No. 48GC-17-28-02SI Rev. B
WeatherMaker
Single Package Rooftop
with Gas Heat/Electric Cooling
and EcoBlue™ Fan Technology
• HUMIDI-MIZER
®
SYSTEM CONTROL CONNECTIONS
Integrated Gas Controller . . . . . . . . . . . . . . . . . . . . .44
(Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
EconomizerONE (Factory Option) . . . . . . . . . . . . . .49
Smoke Detectors . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
EconomizerONE Occupancy Switch . . . . . . . . . . . .70
Step 14 - Install Accessories . . . . . . . . . . . . . . . . .70
Step 15 - Fan Speed Set Up . . . . . . . . . . . . . . . . . .70
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
®
48GC**17-28
3-24
Replaces: 48GC-17-28-01SI

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  • Page 1: Table Of Contents

    ® WeatherMaker 48GC**17-28 Single Package Rooftop with Gas Heat/Electric Cooling and EcoBlue™ Fan Technology Installation Instructions • HUMIDI-MIZER ® SYSTEM CONTROL CONNECTIONS CONTENTS • TYPICAL UNIT WIRING DIAGRAMS Page Integrated Gas Controller .....44 SAFETY CONSIDERATIONS .

  • Page 2: Electrical Shock Hazard

    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 Failure to follow instructions could result in severe personal WARNING injury or death due to carbon-monoxide poisoning, if FIRE, EXPLOSION HAZARD combustion products infiltrate into the building.

  • Page 3: General

    GENERAL See Fig. 1-16 for unit options and dimensions. WARNING Rated Indoor Airflow (cfm) FIRE HAZARD Table 1 lists the rated indoor airflow used for the AHRI efficiency Failure to follow this warning could result in severe personal rating for the units covered in this document. injury and/or property damage.
  • Page 4 Position: 9 10 11 12 13 14 15 16 17 18 Example: Unit Type Packaging Compliance 48 - Gas Heat/Electric Cooling Unit 0 = Standard ® Model Series - WeatherMaster Electrical Options GC - High Efficiency Packaged RTU A = None with EcoBlue™...
  • Page 5 Fig. 2 — 48GC**17 Vertical Airflow...
  • Page 6 Fig. 3 — 48GC**17 Horizontal Airflow...
  • Page 7 Fig. 4 — 48GC**17 Back View and Condensate Drain Location...
  • Page 8 Fig. 5 — 48GC**17 Corner Weights and Clearances...
  • Page 9 Fig. 6 — 48GC**17 Bottom View...
  • Page 10 Fig. 7 — 48GC**20, 24 Vertical Airflow...
  • Page 11 Fig. 8 — 48GC**20, 24 Horizontal Airflow...
  • Page 12 Fig. 9 — 48GC**20, 24 Back View and Condensate Drain Location...
  • Page 13 Fig. 10 — 48GC**20, 24 Corner Weights and Clearances...
  • Page 14 Fig. 11 — 48GC**20, 24 Bottom View...
  • Page 15 Fig. 12 — 48GC**28 Vertical Airflow...
  • Page 16 Fig. 13 — 48GC**28 Horizontal Airflow...
  • Page 17 Fig. 14 — 48GC**28 Back View and Condensate Drain Location...
  • Page 18 Fig. 15 — 48GC**28 Corner Weights and Clearances...
  • Page 19 Fig. 16 — 48GC**28 Bottom View...

  • Page 20: Installation

    INSTALLATION Step 2 — Plan for Sequence of Unit Installation The support method used for this unit will dictate different Jobsite Survey sequences for the steps of unit installation. For example, on Complete the following checks before installation. curb-mounted units, some accessories must be installed on the Consult local building codes and the NEC (National unit before the unit is placed on the curb.

  • Page 21: Step 3 - Inspect Unit

    Thru-the-base power connection must be installed before the unit Step 3 — Inspect Unit is set on the roof curb. If field-installed thru-the-roof curb gas con- Inspect unit for transportation damage. File any claim with trans- nections are desired remove knockout in basepan located in the portation agency.
  • Page 22 Fig. 19 — Roof Curb Details — Size 17 Unit...
  • Page 23 Fig. 20 — Roof Curb Details — Size 20 and 24 Units...
  • Page 24 Fig. 21 — Roof Curb Details — Size 28 Unit...

  • Page 25: Step 5 - Field Fabricate Ductwork

    Step 5 — Field Fabricate Ductwork Step 6 — Rig and Place Unit Cabinet return-air static pressure (a negative condition) shall not Keep unit upright and do not drop. Spreader bars are not required exceed 0.5 in. wg (87 Pa) with or without economizer. if top crating is left on unit.

  • Page 26: Positioning On Curb

    POSITIONING ON CURB Step 8 — Install Outside Air Hood - Factory Option Position unit on roof curb so that the following clearances are The outside air hood for factory-option economizer and 2-position maintained: 1/4 in. (6 mm) clearance between the roof curb and damper is shipped in knock-down form and requires field assem- the base rail inside the right and left, 1/2 in.

  • Page 27: Step 9 - Assemble Barometric Hood

    Secure side retainers (Item 6) to side panels (Items 4 and 5) using the screws provided, screwing from outside of the hood. Secure each central retainer (Item 2) to the hood top (Item 3). Then align central retainers to holes located on filter support (Item 1), so central retainer is perpendicular to hood and each filter support.

  • Page 28: Barometric Hood (Horizontal Configuration)

    Install parts as shown in the following exploded view (see On the field installed economizer (CRECOMZR0**A00), a Fig. 32) using the seal strip and screws provided in the parts birdscreen or hardware cloth is shipped attached to the box. bottom panel used for vertical applications. NOTE: This panel is not used for horizontal return applications.

  • Page 29: Step 11 - Install Gas Piping

    Table 5 — Natural Gas Manifold Pressure Ranges UNIT MODEL UNIT SIZE HIGH FIRE LOW FIRE 3.0 in. wg 2.0 in. wg 48GC** 17, 20, 24, 28 (748 Pa) (498 Pa) Manifold pressure for LP fuel use must be adjusted to specified range (see Table 6).

  • Page 30: Factory Option Thru-Base Connections

    FACTORY OPTION THRU-BASE CONNECTIONS Electrical Connections Knockouts are located in the control box area. Remove the appro- priate size knockout for high voltage connection. Use the field supplied connector depending on wiring or conduit being utilized. Remove the 7/8 in. (22 mm) knockout and appropriate connector for low voltage wiring.

  • Page 31: Step 12 - Install External Condensate Trap And Line

    WARNING Minimum Pitch Failure to follow this warning could result in personal injury, 1 in. (25 mm) Per Base Rail death and/or property damage. 10 ft (3 m) of Line • Connect gas pipe to unit using a backup wrench to 3 in.

  • Page 32: Fire Hazard

    handle and shaft are shipped in the control box and must be mounted on the corner post adjacent to the control box (see Fig. 46 or 47). Note that the tape covering the hole for the shaft in the corner post must be removed prior to handle and shaft installation. To field install the NFD shaft and handle: Load Open the control box panel.

  • Page 33: All Units

    To field install the HACR shaft and handle: Units Without Disconnect Option Open the control box panel. Make sure the HACR shipped from the factory is at OFF Equip GR Lug position (the white arrow pointing at OFF). Insert the shaft all the way with the cross pin on the top of the shaft in the horizontal position.

  • Page 34: Convenience Outlets

    Not Included Weatherproof 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. CONVENIENCE OUTLETS WARNING ELECTRICAL OPERATION HAZARD Gasket Failure to follow this warning could result in personal injury or death.

  • Page 35: Units Without Thru-Base Connections

    FIELD CONTROL WIRING The 48GC unit requires an external temperature control device. This device can be a thermostat (field-supplied) or a SystemVu™ controller (available as factory-installed option for use on a Carrier Comfort Network ® or as a stand-alone control).

  • Page 36: Heat Anticipator Settings

    (contact closes on rise UNIT DAMAGE HAZARD in space RH above control setpoint, see Fig. 55) or a combination thermostat-humidistat control device such as Carrier’s Edge ® Failure to follow this caution may cause a short circuit.

  • Page 37: Typical Unit Wiring Diagrams

    (see Fig. 58). Connect D1 to the R terminal on the UCB. Connect D2 to the HUM termi- nal on the UCB. Refer to the installation instructions included with the Carrier Edge ® Pro Thermidistat device for more information.
  • Page 38 Fig. 59 — Typical 48GC**17-28 Control Wiring Diagram, Electro-Mechanical with POL224 Controller...
  • Page 39 Fig. 60 — Typical 48GC**17-24 Power Wiring Diagram, Electro-Mechanical Controller...
  • Page 40 Fig. 61 — Typical 48GC**28 Power Wiring Diagram, Electro-Mechanical Controller...
  • Page 41 Fig. 62 — Typical 48GC**17-28 Control Wiring Diagram, SystemVu™ Controller...
  • Page 42 Fig. 63 — Typical 48GC**17-24 Power Wiring Diagram, SystemVu™ Controller...
  • Page 43 Fig. 64 — 48GC**28 Power Wiring Diagram, SystemVu™ Controller...

  • Page 44: Integrated Gas Controller

    to 5 seconds less than the time to trip the limit. For example, if the Integrated Gas Controller limit trips at 37 seconds, the control will change the “fan on delay” This unit contains an Integrated Gas Controller (IGC) board. The from 45 seconds to 32 seconds.
  • Page 45 Status Locking Tab Connector Overcurrent Fuse Protection Locking Redundant Gas Tab Connector Valve Relay Spade Connect Ignitor Fig. 66 — IGC Board Component Layout UNIT CONTROL BOARD Fig. 67 — Typical IGC Control Wiring Diagram...
  • Page 46 Table 8 — IGC Board LED Alarm Codes a, b, c, d ACTION TAKEN BY FLASH DESCRIPTION RESET METHOD PROBABLE CAUSE CONTROL CODE Normal Operation — — — Hardware Failure No gas heating. Loss of power to the IGC. Check 5 amp fuse —...

  • Page 47: Humidi-Mizer Dehumidification System

    Humidi-MiZer Dehumidification System  DEHUM/MECH COOLING (SUBCOOLING) MODE (Optional) This mode increases the latent heat removal and decreases sen- sible cooling compared to normal cooling. This occurs when Units with the factory-installed Humidi-MiZer system option there is a cooling and dehumidification demands. are capable of providing multiple modes of improved dehu- midification as a variation of the normal cooling cycle.
  • Page 48 Indoor Supply Valve 3-Wway Valve Condenser Coil Hot Gas Reheat Coil Outdoor Air Expansion Valve (TXV) Compressor Evaporator Coil = Closed Valve = Open Valve Indoor Return Air = 3-Way Valve Fig. 69 — Subcooling Mode – Humidi-MiZer System for 48GC 17-28 Indoor Supply Valve 3-Way...

  • Page 49: Economizerone (Factory Option)

    LED Indication EconomizerONE (Factory Option) NOTE: If different faulty events occur at the same time, the ECONOMIZER SETTINGS sensor/DAC LED lights up following this priority: Red  Interface Overview Yellow  Off. For example, if there is a humidity sensor error and air temperature failure at the same time, the sensor LED EconomizerONE turns red rather than yellow.
  • Page 50 Table 10 — LED Indication FREE SENSOR Power STATUS COOLING DAC LED Yellow Yellow Yellow Commissioning mode Blinking Blinking Blinking Power start-up Yellow On Yellow On Yellow On Free cooling is running Green On — — Free cooling is available Green —...
  • Page 51 Table 11 — Free Cooling Functions CONTROL MODE SENSORS USED ENABLE FREE COOLING? The outside air dry bulb temperature is compared with the set temperature OA (Outside Air) temperature sensor Control Mode 1 shutoff set point. • Fixed Dry Bulb If the outside air dry bulb temperature is below the temperature shutoff set MA (Mixed Air) temperature sensor point, then the outside air is used to meet all or part of the cooling demand.
  • Page 52 Table 12 — 1 and 2-Stage Cooling Stage I/O Logic Table 15 — Different Fan Speeds with Different Configured Outputs ECONOMIZER COOLING COOLING CONDITION MET STAGE 1 STAGE 2 FAN TYPE 1-SPEED COOLING 2-STAGE COOLING • Spd H (regardless of •...
  • Page 53 Table 17 — Different Damper Position Setting with Different Configured Outputs (DCV is Enabled) FAN TYPE 1-STAGE COOLING 2-STAGE COOLING • 2VENTMIN H to 2VENTMAX H (regardless of • 2VENTMIN H to 2VENTMAX H (regardless of 1-SPEED FAN cooling demand, OCC=Yes) cooling demand, OCC=Yes) 2VENTMIN L to 2VENTMAXL ...
  • Page 54 • If Exhaust Fan 2 is connected and configured, then Fault Detection and Diagnostics Exhaust Fan 2 parameter group (L, M, and H) is available, The economizer controller can detect and diagnose free cool- depending on fan configuration. ing faults, sensor operation faults, and damper modulating •...

  • Page 55: Wiring

    WIRING WARNING Failure to follow this caution may result in damage to equipment. Be sure to allow enough time for compressor startup and shutdown between checkout tests so that the compressors do not short-cycle.  Mounting Devices Connected to the Economizer Controller Devices like damper actuators, sensors (temperature sensor, hu- midity sensor, combination temperature and humidity sensor, CO...
  • Page 56 Table 19 — Economizer Control Wiring Settings LABEL TYPE DESCRIPTION RS485 Modbus A Line A RS485 Modbus B Line B ¬ GND_ISO Earth Ground Type II NTC 10K or 0-10 vdc Mixed or Discharge Air Temperature Sensor Mixed or Discharge Air Temperature Sensor Common Type II NTC 10K or 0-10 vdc Outside Air Temperature Sensor 0-10 vdc or 4-20mA...
  • Page 57 Connecting Peripheral Devices to the Economizer Controller See Fig. 78-82 for wiring details. • Outside Air: Connect to the Mixed or Discharge Air Temperature Sensor OAT and COM terminals of the Outside Air Temperature Sensor device. • Return Air (Differential): Return Air Temperature Sensor Connect to the RAT and S-COM...
  • Page 58 • Outside Combination Temperature/ Humidity: Connect Combo Temperature and Humidity Sensor to the OAT, COM, and OAH terminals of the device. • Combo Temperature and Humidity Sensor Return Combination Temperature/ Humidity: Connect to the RAT, S-COM, and RAH terminals of the device. Fig.

  • Page 59: Setup And Configuration

    SETUP AND CONFIGURATION NOTE: Parameters and display menus may display differently/ dynamically if different applications are configured. See Tables 20-27. IMPORTANT: Before setup and configuration, it is recom- mended to obtain some location-based values, such as shutoff points, or utilize the location services in the Climatix ™...
  • Page 60 Table 20 — Status Display PARAMETER DESCRIPTION VALUE 1FREECOOL Indicates if the system can use outdoor air for free cooling. 1ECON ENAB Indicates if outdoor air is being used for the first stage of cooling. Indicates if the space is occupied. If users choose ALWAYS for 6OCC when configuring I/ Os, the parameter value is YES;...
  • Page 61 Table 21 — Parameter Settings — Basic PARAMETER DESCRIPTION RANGE DEFAULT Temperature shutoff set point can be obtained automatically if a smartphone or tablet is connected to the network provided by a Wi-Fi/WLAN stick 2 TEMP OFF plugged into the Economizer Controller and the mobile application is 48...80°F;...
  • Page 62 Table 22 — Parameter Settings — Advanced PARAMETER DESCRIPTION VALUE/RANGE DEFAULT 3FREEZE POS Anti-freeze protection damper position (closed or minimum). 3SD ACT POS Damper position during shutdown (open or closed). MAT sensor location: • Choose MAT if the sensor is installed before the DX (Direct Expansion) coil. 3DIF T LOC •...
  • Page 63 Table 23 — Parameter Settings — I/O Configurations (cont) PARAMETER DESCRIPTION VALUE DEFAULT Choose ACT FB if feedback signal is available from the connected damper ACT FB 6AUX-AI2 ACT FB actuator. Otherwise, choose NONE. NONE Choose “COOL 2” if Cooling Stage 2 is available (another compressor is COOL 2 6Y2O COOL 2...

  • Page 64: Installing Optional Hh57Lw001 Single Outside Air Enthalpy Sensor

    Table 26 — Enter Running State PARAMETER DESCRIPTION 8RUN STATE Change to Running State. Press Enter to confirm the change. 8ENTER RUN? Confirm the change to Running State. Perform factory reset. Press Enter to confirm the reset. (This action resets the controller 8FACTORY DEF password to default: OneBT.) 8DEF CONFIRM?
  • Page 65 Fig. 83 — HH57LW001 Dimensional, Connection and Switching Information Fig. 84 — HH79NZ039 Dry Bulb and Mixed Air Sensor Wiring Economizer Actuator Outside Air (This End) Damper Wiring Harness Return Air Damper Fig. 85 — EconomizerONE System Component Locations Fig. 86 — California Title 24 Zones...
  • Page 66 U.S. and Canada I-Codes / ASHRAE Zones Climate Zone 1 Climate Zone 5 and Marine Climate Zone 2 Climate Zone 6 Climate Zone 3 Climate Zone 7 and 8 Climate Zone 4 (Except Marine) Fig. 87 — U.S. and Canada Climate Zones Table 28 —...
  • Page 67 Economizers are shipped standard with an HH79NZ039 outside Table 29 — California Title 24 Regional High Limit air dry bulb sensor (refer to Fig. 84). System default setting (high Dry Bulb Temperature Settings temp limit) is 63°F (17°C) and has a range of 48°F to 80°F (9°C to REQUIRED HIGH LIMIT 27°C).

  • Page 68: Checkout

    CHECKOUT NOTE: All settings are stored in non-volatile flash memory. Status Inspect all wiring connections at the economizer module’s termi- nals, and verify compliance with the installation wiring diagrams. Use the Status menu (refer to Table 20) to check the parameter For checkout, review the Status of each configured parameter and values for the various devices and sensors configured.

  • Page 69: Troubleshooting

    TROUBLESHOOTING For EconomizerONE troubleshooting issues, see Table 31. Table 31 — Operating Issues and Concerns SYMPTOM REASON SOLUTION An alarm is displayed on the Sensor, damper, or the whole working Check sensor, damper, or the whole working system following the detailed alarm information. system may not work properly DAC LED is blinking RED Damper slippage...

  • Page 70: Systemvu™ Controller (Factory Option)

    detected. See Typical Wiring Diagram (Fig. 59) for the red wires SystemVu™ Controller (Factory Option) in the Indoor fan plug. For details on operating 48GC**17-28 units equipped with the Units with two fan motors are wired to connect the motor protec- factory-installed SystemVu controller option, refer to the FC/GC tion relays in series.

  • Page 71: Units With Systemvu™ Controls

    ESP in. wg Factory Setting: Calculator 9.0 V 6000 Field Setting: 6500 Record field setting here 7000 7500 8000 Switch Range: 8500 9000 4.1 - 7.5 9500 10.0 6.9 - 8.7 10000 7.7 - 10.0 Field Accessories: Economizer * Overlap in A, B, C switch range designed for maximum field adjustment potential.
  • Page 72 ESP in. wg Calculator 1250 1348 1441 1528 1610 1688 1762 1832 1899 1963 6000 1336 1428 1515 1598 1677 1753 1824 1893 1959 2021 6500 1423 1509 1591 1670 1746 1819 1888 1955 2020 2081 7000 1510 1591 1669 1744 1817 1887...
  • Page 74 © 2024 Carrier Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 04-53480479-01 Printed in U.S.A. Form No. 48GC-17-28-02SI Rev. B Pg 74 3-24 Replaces: 48GC-17-28-01SI...

  • Page 75: Start-Up Checklist

    START-UP CHECKLIST FOR 48GC**17-28 SINGLE PACKAGE ROOFTOP GAS HEATING/ELECTRIC COOLING UNITS (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 sections of this Installation Instruction document.
  • Page 76 (Y/N) _____ 10. Restore set-points for thermostat and humidistat (Y/N) _____ © 2024 Carrier Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 04-53480479-01 Printed in U.S.A.

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