United Technologies Carrier WeatherMaker 48TC 18 Series Installation Instructions Manual

Single package rooftop with gas heat/electric cooling horizontal air flow unit with puron r-410a refrigerant

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48TC units for installation in the United States contain use of Carrier's Staged Air Volume (SAV™) 2-speed

indoor fan control system. This complies with the U.S. Department of Energy (DOE) efficiency standard of

2018.

48TC units for installation outside the United States may or may not contain use of the SAV 2-speed indoor fan

control system as they are not required to comply with the U.S. Department of Energy (DOE) efficiency

standard of 2018.

For specific details on operation of the Carrier SAV 2-speed indoor fan system, refer to the Variable Frequency

Drive (VFD) Factory-Installed Option 2-Speed Motor Control Installation, Setup, and Troubleshooting manual.

CONTENTS

SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . 1

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Rated Indoor Airflow (cfm) . . . . . . . . . . . . . . . . . . . . . 3

INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Job-Site Survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Step 1 — Plan for Unit Location . . . . . . . . . . . . . . . . 17

• ROOF MOUNT

Step 2 — Plan for Sequence of Unit Installation . . . 17

• ROOF CURB MOUNT

• PAD-MOUNTED INSTALLATION

• FRAME-MOUNTED INSTALLATION

Step 3 — Inspect Unit . . . . . . . . . . . . . . . . . . . . . . . . 18

Step 4 — Provide Unit Support . . . . . . . . . . . . . . . . . 18

• SLAB MOUNT

• ROOF CURB MOUNT

• ALTERNATE UNIT SUPPORT (IN LIEU OF SLAB OR

CURB MOUNT)

Step 5 — Rig and Place Unit . . . . . . . . . . . . . . . . . . . 18

• POSITIONING ON CURB

Step 6 — Field Fabricate Ductwork . . . . . . . . . . . . . 23

Step 7 — Horizontal Duct Connection . . . . . . . . . . . 23

Step 8 — Install Outside Air Hood (Factory-

Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Step 9 — Install Flue Hood and Combustion Air

Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Step 10 — Install Gas Piping. . . . . . . . . . . . . . . . . . . 24

• GAS SUPPLY LINE

• FACTORY-OPTION THRU-BASE CONNECTIONS

Step 11 — Install External Condensate Trap and

Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Step 12 — Make Electrical Connections . . . . . . . . . 27

• FIELD POWER SUPPLY

• UNITS WITHOUT FACTORY-INSTALLED NON-

FUSED DISCONNECT

• UNITS WITH FACTORY-INSTALLED NON-FUSED

DISCONNECT

• TO FIELD INSTALL THE NFD SHAFT AND HANDLE

• ALL UNITS

• CONVENIENCE OUTLETS

• FACTORY-OPTION THRU-BASE CONNECTIONS

Humidi-MiZer® Control Connections . . . . . . . . . . . . 31

• HUMIDI-MIZER – SPACE RH CONTROLLER

Staged Air Volume (SAV™) with Variable Frequency

Drive (Factory-Installed Option) . . . . . . . . . . . . . . 34

EconoMi$er® X (Factory-Installed Option) . . . . . . . 34

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.

Catalog No. 04-53480269-01

Single Package Rooftop with Gas Heat/Electric Cooling

Horizontal Air Flow Unit with Puron

Installation Instructions

Printed in U.S.A.

Form 48TC-18-29-H-04SI

• PRODUCT DESCRIPTION

• SYSTEM COMPONENTS

• SPECIFICATIONS

• INPUTS

• OUTPUTS

• ENVIRONMENTAL

• ECONOMIZER MODULE WIRING DETAILS

• S-BUS SENSOR WIRING

• CO2 SENSOR WIRING

• INTERFACE OVERVIEW

• USER INTERFACE

• KEYPAD

• MENU STRUCTURE

• SETUP AND CONFIGURATION

• TIME-OUT AND SCREENSAVER

• ENTHALPY SETTINGS

• TWO-SPEED FAN OPERATION

• CHECKOUT

• TROUBLESHOOTING

PremierLink™ Control . . . . . . . . . . . . . . . . . . . . . . . 47

RTU Open Control System. . . . . . . . . . . . . . . . . . . . 47

Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Smoke Detectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

• RETURN AIR SENSOR TUBE INSTALLATION

• SMOKE DETECTOR TEST MAGNET

• ADDITIONAL APPLICATION DATA

Step 13 — Adjust Factory-Installed Options . . . . . 61

• ECONOMI$ER IV OCCUPANCY SWITCH

Step 14 — Install Accessories . . . . . . . . . . . . . . . . . 61

Step 15 — Check Belt Tension . . . . . . . . . . . . . . . . 61

• BELT FORCE — DEFLECTION METHOD

• BELT TENSION METHOD

Pre-Start and Start-Up . . . . . . . . . . . . . . . . . . . . . . . 62

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 litera-

ture, tags and labels attached to the unit, and other safety precau-

tions that may apply.

Follow all safety codes, including ANSI (American National Stan-

dards Institute) Z223.1. Wear safety glasses and work gloves. Use

Pg 1

8-19

WeatherMaker

48TC 18-29

(R-410A) Refrigerant

Replaces: 48TC-18-29-H-03SI

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Summary of Contents for United Technologies Carrier WeatherMaker 48TC 18 Series

Page 1 ® WeatherMaker 48TC 18-29 Single Package Rooftop with Gas Heat/Electric Cooling ® Horizontal Air Flow Unit with Puron (R-410A) Refrigerant Installation Instructions 48TC units for installation in the United States contain use of Carrier's Staged Air Volume (SAV™) 2-speed indoor fan control system. This complies with the U.S. Department of Energy (DOE) efficiency standard of 2018.
Page 2 quenching cloth for unbrazing operations. Have fire extinguisher available for all brazing operations. CAUTION It is important to recognize safety information. This is the safety- CUT HAZARD alert symbol . When you see this symbol on the unit and in in- Failure to follow this caution may result in personal injury.
Page 3 GENERAL AVERTISSEMENT These installation instructions cover the 48TC units with gas heat RISQUE D’INTOXICATION AU MONOXYDE and electric cooling. Units are pre-wired and pre-charged with en- CARBONE vironmentally sound Puron (R-410A) refrigerant at the factory. ® Si ces directives ne sont pas suivies, cela peut entraîner des See Fig.
Page 4 Position: 9 10 11 12 13 14 15 16 17 18 Example: Unit Heat Type Packaging 48 - Gas Heat Packaged Rooftop 0 = Standard ® Model Series - WeatherMaker Electrical Options TC - Standard Efficiency A = Non-USA models - No (SAV) included C = Non-Fused Disconnect G = Standard USA models - (SAV) included Heat Options...
Page 5 Fig. 2 — 48TC**18 Horizontal Airflow...
Page 6 Fig. 3 — 48TC**18 Back View and Condensate Drain Location...
Page 7 Fig. 4 — 48TC**18 Corner Weights and Clearances...
Page 8 Fig. 5 — 48TC**18 Bottom View...
Page 9 Fig. 6 — 48TC**21, 25 Horizontal Airflow...
Page 10 Fig. 7 — 48TC**21, 25 Back View and Condensate Drain Location...
Page 11 Fig. 8 — 48TC**21, 25 Corner Weights and Clearances...
Page 12 Fig. 9 — 48TC**21, 25 Bottom View...
Page 13 Fig. 10 — 48TC**29 Horizontal Airflow...
Page 14 Fig. 11 — 48TC**29 Back View and Condensate Drain Location...
Page 15 Fig. 12 — 48TC**29 Corner Weights and Clearances...
Page 16 Fig. 13 — 48TC**29 Bottom View...
Page 17 ROOF MOUNT INSTALLATION Check building codes for weight distribution requirements. Unit Job-Site Survey operating weight is shown in Table 2. Complete the following checks before installation. Step 2 — Plan for Sequence of Unit Installation Consult local building codes and the NEC (National Elec- trical Code) ANSI/NFPA 70 for special installation The support method used for this unit will dictate different se- requirements.
Page 18 Step 3 — Inspect Unit HOOD CARTON LOCATION Inspect unit for transportation damage. File any claim with trans- (REAR ACCESS PANEL) portation agency. Confirm before installation of unit that voltage, amperage and cir- cuit protection requirements listed on unit data plate agree with CONTROL BOX power supply provided.
Page 19 DETAIL A (914-1371) 36"-54" DUCT END "B" SEE DETAIL A "C" "A" DIMENSIONS MAX WEIGHT UNIT 48TC**18 2339 1061 127.8 3249 58.7 1491 52.3 1328 48TC**21 2549 1156 141.5 3595 71.5 1816 52.3 1328 48TC**25 2699 1224 141.5 3595 71.5 1816 60.3 1532...
Page 20 Fig. 17 — Roof Curb Details — 18 Size Unit...
Page 21 Fig. 18 — Roof Curb Details — 21 and 25 Size Units...
Page 22 Fig. 19 — Roof Curb Details — 29 Size Units...
Page 23 Step 6 — Field Fabricate Ductwork Cabinet return-air static pressure (a negative condition) shall not exceed 0.5 in. wg (87 Pa) with economizer or without economizer. HOOD TOP SHIPPING Fabricate supply ductwork so that the cross sectional dimensions POSITION are equal to or greater than the unit supply duct opening dimen- sions for the first 18-in.
Page 24 retainers. To do so, first insert the air screens into pocket cre- ated at the end of hood (item #3), then fully put the air screen into place, and then slide them back into pocket created in the filter support (item #1). Repeat this for each air screen (see Fig.
Page 25 Manifold pressure is factory-adjusted for NG fuel use. Adjust as CAUTION required to obtain best flame characteristics. See Tables 5 and 6 for ranges. EQUIPMENT DAMAGE Failure to follow this caution may result in equipment damage. Table 3 — Natural Gas Supply Line Pressure When connecting the gas line to the unit gas valve, the installer UNIT MODEL UNIT SIZE...
Page 26 Density type and is labeled for use on gas lines. Apply tape per manufacturer’s instructions. 9” MINIMUM CLEARANCE Pressure-test all gas piping in accordance with local and FOR PANEL REMOVAL FROM national plumbing and gas codes before connecting piping to REGULATOR MANUAL GAS METER...
Page 27 NOTE: Field-supplied wiring shall conform with the limitations of minimum 63°F (33°C) rise. FIELD POWER SUPPLY If equipped with optional powered convenience outlet: the power source leads to the convenience outlet’s transformer primary are not factory connected. Installer must connect these leads accord- ing to required operation of the convenience outlet.
Page 28 UNITS WITHOUT FACTORY-INSTALLED NON-FUSED Measure the tip of the shaft to the outside surface of the cor- DISCONNECT ner post to be 0.88-in. When installing units, provide a disconnect switch per NEC (Na- Tighten the locking screw to secure the shaft to the NFD. tional Electrical Code) of adequate size.
Page 29 Loosen the two screws at the GFCI duplex outlet, until approxi- mately -in. (13 mm) under screw heads are exposed. Press the UNITS WITHOUT DISCONNECT OPTION UNITS WITH DISCONNECT OPTION gasket over the screw heads. Slip the backing plate over the screw EQUIP FACTORY EQUIP...
Page 30 The electrical entrance is located in the control box area and can be accessed through the control box access panel. An embossed area is provided with three knock outs. High voltage is brought through the multi knock out by removing the appropriate size for the size of the fitting required.
Page 31 ® Humidi-MiZer Control Connections CENTRAL HUMIDI-MIZER – SPACE RH CONTROLLER TERMINAL TYPICAL NOTE: The Humidi-MiZer system is a factory installed option. BOARD THERMOSTAT The Humidi-MiZer dehumidification system requires a field-sup- CORRECTIONS plied and installed space relative humidity control device. This de- vice may be a separate humidistat control (contact closes on rise in space RH above control setpoint) (see Fig.
Page 32 To Connect the Carrier Humidistat (HL38MG029): Route the humidistat 2-conductor cable (field-supplied) through the hole provided in the unit corner post. RUBBER Feed wires through the raceway built into the corner post (see GROMMET Fig. 44) to the 24-v barrier located on the left side of the con- trol box.
Page 33 ® Fig. 45 — Typical Humidi-MiZer Adaptive Dehumidification System Humidistat Wiring EDGE Pro THERMIDISTAT Unit CTB THERMOSTAT O/W2/B SRTN ® Humidi-MiZer FIOP *Connection not required. ® Fig. 46 — Typical Rooftop Unit with Humidi-MiZer Adaptive Dehumidification System ® with Edge Pro Thermidistat Device...
Page 34 Mixed Air sensor, and an outdoor dry bulb sensor. Enthalpy and Staged Air Volume (SAV™) with Variable Fre- other options are available with bus sensors. quency Drive (Factory-Installed Option) User Interface For details on operating 48TC 2 stage cooling units equipped with the factory installed Stage Air Volume option, refer to the Variable Provides status for normal operation, setup parameters, checkout Frequency Drive (VFD) Installation, Setup, and Troubleshooting...
Page 35 Storage Temperature: Table 8 — Economizer Module - Left Hand Terminal Blocks –40°F to 150°F (–40°C to 65°C) LABEL TYPE DESCRIPTION Shipping Temperature: Top Left Terminal Block –40°F to 150°F (–40°C to 65°C) 20k NTC Mixed Air Temperature Sensor (Polarity Relative Humidity: and COM Insensitive Connection)
Page 36 SENSOR (HOT) BLACK YELLOW ANALOG BROWN – ORANGE GREEN SWITCH LABEL POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED. Fig. 50 — CO Sensor Wiring SWITCHES INTERFACE OVERVIEW This section describes how to use the economizer’s user interface for: •...
Page 37 Press the (Enter) button to display the value of the cur- rently displayed item. Table 12 illustrates the complete hierarchy. Your menu parame- ters may be different depending on your configuration. Press the ▲ button to increase (change) the displayed param- eter value.
Page 38 Table 12 — 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 YES = outside air being used for 1 stage cooling...
Page 39 Table 12 — Menu Structure (cont) PARAMETER PARAMETER MENU PARAMETER DEFAULT RANGE AND NOTES VALUE INCREMENT EXHAUST STAGE 2 RELAY OUTPUT EXH2 OUT ON/OFF Output of AUX terminal; displays only if AUX = EXH2 ENERGY RECOVERY VENTILATOR ON/OFF Output of AUX terminal; displays only if AUX = ERV MECH COOL ON Displays stage of mechanical cooling that is active.
Page 40 Table 12 — Menu Structure (cont) PARAMETER PARAMETER MENU PARAMETER DEFAULT RANGE AND NOTES VALUE INCREMENT Display order = MM/DD/YY INSTALL 01/01/10 Setting order = DD, MM, then YY. UNITS DEG F or C Sets economizer controller in degrees Fahrenheit or Celsius CONV = conventional;...
Page 41 Table 12 — Menu Structure (cont) PARAMETER PARAMETER MENU PARAMETER DEFAULT RANGE AND NOTES VALUE INCREMENT SUPPLY AIR TEMPERATURE CALIBRATION MAT T CAL 0.0°F ±2.5°F Allows for the operator to adjust for an out of calibration temperature sensor. OUTSIDE AIR TEMPERATURE CALIBRATION OAS T CAL 0.0°F ±2.5°F...
Page 42 Table 12 — Menu Structure (cont) PARAMETER PARAMETER MENU PARAMETER DEFAULT RANGE AND NOTES VALUE INCREMENT Check if outdoor temperature is below the LOW Temp Lockout on setpoint menu. Check if Mixed air temperature on STATUS FREEZE ALARM menu is below the Lo Setpoint on Advanced menu. When conditions are back in normal range then the alarm will go away.
Page 43 Table 14 — Dry Bulb Operation without 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 0v/Off 0v/Off MIN POS Closed NONE HIGH 24v/On 0v/Off MIN POS Closed HIGH...
Page 44 Table 17 — 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 0v/Off 0v/Off VENTMIN Closed HIGH 24v/On 0v/Off VENTMIN Closed HIGH 24v/On 24v/On VENTMIN...
Page 45 Table 20 — Enthalpy Operation without DCV (CO Sensor) — 2 Speed Fan DEMAND OUTSIDE AIR CONTROLLED GOOD TO Y1-I Y2-I Y1-O Y2-O OCCUPIED UNOCCUPIED SPEED VENTILATION (DCV) ECONOMIZE 0v/Off 0v/Off MIN POS Closed 24v/On 0v/Off MIN POS Closed HIGH 24v/On 24v/On MIN POS...
Page 46 ECONOMIZING DUAL ENTHALPY AVAILABLE HIGH LIMIT NOT AVAILABLE SINGLE ENTHALPY P2 (T,RH) (T,RH) TEMPERATURE Fig. 52 — Single Enthalpy Curve Boundaries Table 22 — Single Enthalpy and Dual Enthalpy High Limit Curves POINT P1 POINT P2 ENTHALPY TEMP. DRY TEMP. ENTHALPY HUMIDITY HUMIDITY...
Page 47 TROUBLESHOOTING WARNING Alarms The economizer module provides alarm messages that display on ELECTRICAL SHOCK HAZARD the 2-line LCD. Failure to follow this warning could result in personal injury, NOTE: Upon power up, the module waits 60 minutes before property damage, or death. checking for alarms.
Page 48 Fig. 53 — PremierLink™ Wiring Diagram...
Page 49 Fig. 54 — PremierLink Wiring Diagram with Humidi-MiZer ® System...
Page 50 Fig. 55 — Typical RTU Open System Control Wiring Diagram...
Page 51 Fig. 56 — Typical RTU Open System Control Wiring Diagram with Humidi-MiZer ® System...
Page 52 Fig. 57 — 48TC**18-29 Control Wiring Diagram...
Page 53 Fig. 58 — 48TC**18-29 Power Wiring Diagram, 208/230-3-60...
Page 54 Fig. 59 — 48TC**18-29 Power Wiring Diagram, 460-3-60...
Page 55 Fig. 60 — 48TC**18-29 Power Wiring Diagram, 575-3-60...
Page 56 ® Fig. 61 — 48TC**18-29 Control Wiring Diagram with Humidi-MiZer System...
Page 57 ® Fig. 62 — 48TC**18-29 Power Wiring Diagram with Humidi-MiZer System (208/230-3-60)
Page 58 ® Fig. 63 — 48TC**18-29 Power Wiring Diagram with Humidi-MiZer System (460-3-60)
Page 59 ® Fig. 64 — 48TC**18-29 Power Wiring Diagram with Humidi-MiZer System (575-3-60)
Page 60 Smoke Detectors Smoke detectors are available as factory-installed options on 48TC models. Smoke detectors may be specified for supply air only, for return air without or with economizer, or in combina- tion of supply air and return air. The unit is factory-configured for immediate smoke detector shutdown operation;...
Page 61 Unit Without Economizer or Economizer 2 Position Damper 2 Position Damper Fig. 68 — EconoMi$er ® IV Wiring • DDC interface (PremierLink) Step 13 — Adjust Factory-Installed Options • Louvered hail guard ECONOMI$ER IV OCCUPANCY SWITCH • Phase monitor control Refer to Fig.
Page 62 BLOWER PULLEY V-BELT MOTOR PULLEY MOTOR Table 1 BELT DEFLECTION FORCE (LBS) BELT SMALLEST MOUNTING UNNOTCHED CROSS SHEAVE NOTCHED BELTS BELTS MOTOR MOUNTING BOLTS (4) SECTION DIAMETER USED USED PLATE 3.0-3.6 Fig. 70 — Belt Drive Motor Mounting A, AX 3.8-4.8 Pre-Start and Start-Up 5.0-7.0...
Page 63 START-UP CHECKLIST — 48TC 17-30 SINGLE PACKAGE ROOFTOP WITH ® HEAT/ELECTRIC COOLING WITH PURON (R-410A) REFRIGERANT 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 64 PRESSURES (COOLING MODE) REFRIGERANT SUCTION CIRCUIT 1 _____________ PSIG _____________ °F CIRCUIT 2 _____________ PSIG _____________ °F REFRIGERANT DISCHARGE CIRCUIT 1 _____________ PSIG _____________ °F CIRCUIT 2 _____________ PSIG _____________ °F Verify that 3-phase fan motor and blower are rotating in correct direction (Y/N) _____ Verify that 3-phase scroll compressor is rotating in the correct direction (Y/N) _____ VERIFY REFRIGERANT CHARGE USING CHARGING CHARTS (Y/N) _____ GENERAL...

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