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48HC

Single Package Rooftop

Gas Heating/Electric Cooling Unit

with Puron

r

(R---410A) Refrigerant

Sizes: 04, 05, 06

Installation Instructions

NOTE

: Read the entire instruction manual before starting

the installation

TABLE OF CONTENTS

SAFETY CONSIDERATIONS

2

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INSTALLATION

6

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Jobsite Survey

6

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Step 1 -- Plan for Unit Location

6

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Roof Mount

6

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Step 2 -- Plan for Sequence of Unit Installation

7

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Curb--Mount Installation

7

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Pad--Mount Installation

7

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Frame--Mount Installation

7

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Step 3 -- Inspect Unit

7

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Step 4 -- Provide Unit Support

7

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Roof Curb Mount

7

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Slab Mount (Horizontal Units Only)

7

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Alternate Unit Support

(In Lieu of Curb or Slab Mount)

7

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Step 5 -- Field Fabricate Ductwork

9

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Step 6 -- Rig and Place Unit

9

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Positioning on Curb

10

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Step 7 -- Convert to Horizontal & Connect Ductwork

10

.

Step 8 -- Install Outside Air Hood

10

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Economizer and Two Position Damper Hood

Package Removal and Setup — Factory Option

10

. .

Economizer Hood and Two--Position Hood

11

. . . . .

Step 9 -- Units with Hinged Panels Only

11

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Step 10 -- Install Flue Hood

12

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Step 11 -- Install Gas Piping

12

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Factory--Option Thru--Base Connections

(Gas Connections)

13

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Step 12 -- Install External Condensate Trap and Line

15

. .

Step 13 -- Make Electrical Connections

15

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Field Power Supply

15

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Units with Factory--Installed

Non--Fused Disconnect or HACR

16

. . . . . . . . . . . . .

Units without Factory--Installed

Non--Fused Disconnect or HACR

17

. . . . . . . . . . . . .

All Units

17

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Convenience Outlets

18

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HACR

19

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Factory--Option Thru--Base Connections

(Electrical Connections)

19

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Units without Thru--Base Connections

20

. . . . . . . . .

Field Control Wiring

20

. . . . . . . . . . . . . . . . . . . . . . .

Thermostat

20

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Unit without Thru--Base Connection Kit

20

. . . . . . .

Heat Anticipator Settings

20

. . . . . . . . . . . . . . . . . . .

Humidi--MiZer

R

Control Connections

21

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Humidi--MiZer -- Space RH Controller

21

. . . . . . . .

Low Ambient Control (Factory Option

23

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Comfort

Link Control

23

. . . . . . . . . . . . . . . . . . . . . . . .

PremierLink

t

(Factory Option)

28

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Supply Air Temperature (SAT) Sensor

31

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Outdoor Air Temperature (OAT) Sensor

31

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EconoMi$er2

31

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Field Connections

31

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Space Sensors

33

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Connect Thermostat

33

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Configure the Unit for Thermostat Mode

33

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Economizer Controls

34

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Indoor Air Quality (CO

2

sensor)

34

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Outdoor Air Quality Sensor

34

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Space Relative Humidity Sensor or

Humidistat Connections

35

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Smoke Detector/Fire Shutdown (FSD)

35

. . . . . . . . .

Filter Status Switch

36

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Supply Fan Status Switch

36

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Remote Occupied Switch

36

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Power Exhaust (output)

36

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CCN Communication Bus

36

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RTU Open Control System

38

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Supply Air Temperature (SAT) Sensor

41

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Summary of Contents for 48HC Series

Page 1: ... Gas Connections 13 Step 12 Install External Condensate Trap and Line 15 Step 13 Make Electrical Connections 15 Field Power Supply 15 Units with Factory Installed Non Fused Disconnect or HACR 16 Units without Factory Installed Non Fused Disconnect or HACR 17 All Units 17 Convenience Outlets 18 HACR 19 Factory Option Thru Base Connections Electrical Connections 19 Units without Thru Base Connection...

Page 2: ...rsonal 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 injury or product and property damage NOTE is used to highlight suggestions which will result in enhanced installation reliability or operation FIRE EXPLOSION HAZARD Failure to follow this warning could result in personal in...

Page 3: ...vision A Factory Design Revision Base Unit Controls 0 Base Electromechanical Controls 1 PremierLink Controller 2 RTU Open Multi Protocol Controller D ComfortLink Controls Intake Exhaust Options A None B Temperature Economizer w Barometric Relief F Enthalpy Economizer w Barometric Relief K 2 Position Damper Service Options 0 None 1 Unpowered Convenience Outlet 2 Powered Convenience Outlet 3 Hinged ...

Page 4: ...4 Horizontal Connections Economizer Vertical Connections Economizer C12227 Fig 2 Unit Dimensional Drawing 48HC ...

Page 5: ...it fresh air intake hood C 36 in 914 mm 18 in 457 mm Side condensate drain is used Minimum clearance D 48 in 1219 mm 42 in 1067 mm 36 in 914 mm Special No flue discharge accessory installed surface is combustible material Surface behind servicer is grounded e g metal masonry wall another unit Surface behind servicer is electrically non conductive e g wood fiberglass Check for adjacent units or bui...

Page 6: ...23 1 American National Standards Institute and NFPA National Fire Protection Association 54 TIA 54 84 1 In Canada installation must be in accordance with the CAN1 B149 installation codes for gas burning appliances Although unit is weatherproof avoid locations that permit water from higher level runoff and overhangs to fall onto the unit Locate mechanical draft system flue assembly at least 4 ft 1 ...

Page 7: ...e carton until unit has been rigged and located in final position Step 4 Provide Unit Support Roof Curb Mount Accessory roof curb details and dimensions are shown in Fig 4 Assemble and install accessory roof curb in accordance with instructions shipped with the curb NOTE The gasketing of the unit to the roof curb is critical for a watertight seal Install gasket supplied with the roof curb as shown...

Page 8: ...FCURB001A01 1 2 356 2 0 610 48HC 04 06 NOTES 1 Roof curb accessory is shipped disassembled 2 Insulated panels 3 Dimensions in are in millimeters 4 Roof curb galvanized steel 5 Attach ductwork to curb flanges of duct rest on curb 6 Service clearance 4 ft on each side 7 Direction of airflow 8 Connector package CRBTMPWR001A01 is for thru the curb type gas CRBTMPWR003A01 is for thru the base type gas ...

Page 9: ...Place Unit Keep unit upright and do not drop Spreader bars are required Rollers may be used to move unit across a roof Level by using unit frame as a reference See Table 1 and Fig 6 for additional information Lifting holes are provided in base rails as shown in Fig 6 Refer to rigging instructions on unit Before setting the unit onto the curb recheck gasketing on curb UNIT DAMAGE HAZARD Failure to ...

Page 10: ...to horizontal ducted configuration To convert to horizontal configuration remove screws from side duct opening covers and remove covers Using the same screws install covers on vertical duct openings with the insulation side down Seals around duct openings must be tight See Fig 7 Field supplied flanges should be attached to horizontal duct openings and all ductwork should be secured to the flanges ...

Page 11: ...des to the unit See Fig 11 B TOP PANEL INDOOR COIL ACCESS PANEL 19 1 16 SCREW HOOD DIVIDER LEFT HOOD SIDE 33 3 8 848mm 483mm C06026 Fig 11 Economizer Hood Construction 3 Remove the shipping tape holding the economizer barometric relief damper in place economizer only 4 Insert the hood divider between the hood sides See Fig 11 and 12 Secure hood divider with 2 screws on each hood side The hood divi...

Page 12: ...its the gas pressure at unit gas connection must not be less than 5 in wg 1245 Pa or greater than 13 in wg 3240 Pa while the unit is operating For liquified petroleum applications the gas pressure must not be less than 11 in wg 2740 Pa or greater than 13 6 in wg 3390 Pa at the unit connection The gas supply pipe enters the unit at the burner access panel on the front side of the unit through the l...

Page 13: ...n pipe nipple with minimum length of 16 in 406 mm field supplied to the street elbow and extend it through the access panel at the gas support bracket See Fig 17 EMBOSSMENT BRASS FITTING FOR 3 6 TON UNITS SUPPORT BRACKET C08016 Fig 17 Gas Line Piping for 3 to 6 Ton Units Only Other hardware required to complete the installation of the gas supply line will include a manual shutoff valve a sediment ...

Page 14: ...and gas codes before connect ing piping to unit 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 Pressure test the gas supply piping system at pressures equal to or less than 0 5 psig 3450 Pa The uni...

Page 15: ...al fault should occur This ground may consist of electrical wire connected to unit ground lug in control compartment or conduit approved for electrical ground when installed in accordance with NEC National Electrical Code ANSI NFPA 70 latest edition in Canada Canadian Electrical Code CSA Canadian Standards Association C22 1 and local electrical codes WARNING NOTE Field supplied wiring shall confor...

Page 16: ...mble the shaft and handle to the switch at this point Discard the factory test leads see Fig 24 Connect field power supply conductors to LINE side terminals when the switch enclosure cover is removed to attach the handle C12278 Fig 26 Location of Non Fused Disconnect Enclosure To field install the NFD shaft and handle 1 Remove the unit front pane see Fig 2 2 Remove 3 hex screws on the NFD enclosur...

Page 17: ...disconnect on the unit cabinet All Units All field wiring must comply with NEC and all local codes Size wire based on MCA Minimum Circuit Amps on the unit informative plate See Fig 24 and the unit label diagram for power wiring connections to the unit power terminal blocks and equipment ground Maximum wire size is 2ga AWG copper only per pole on contactors See Fig 24 and unit label diagram for fie...

Page 18: ... weatherproof cover to the backing plate as shown in Fig 31 Remove two slot fillers in the bottom of the cover to permit service tool cords to exit the cover Check for full closing and latching RECEPTACLE NOT INCLUDED COVER WHILE IN USE WEATHERPROOF BASE PLATE FOR GFCI RECEPTACLE C09022 Fig 31 Weatherproof Cover Installation Non powered type This type requires the field installation of a general p...

Page 19: ...he factory If field installed accessories are added or changed in the field i e power exhaust ERV the HACR may no longer be of the proper amp rating and therefore will need to be removed from the unit See unit nameplate and label on factory installed HACR for the amp rating of the HACR that was shipped with the unit from the factory See unit nameplates for the proper fuse HACR or maximum over curr...

Page 20: ...cable or equivalent single leads of different colors with minimum of seven leads If the thermostat does not require a 24 v source no C connection required use a thermostat cable or equivalent with minimum of six leads Check the thermostat installation instructions for additional features which might require additional conductors in the cable For wire runs up to 50 ft 15 m use no 18 AWG American Wi...

Page 21: ...to the corner post see Fig 36 to the 24 v barrier located on the left side of the control box The raceway provides the UL required clearance between high voltage and low voltage wiring 3 Use wire nuts to connect humidistat cable to two PINK leads in the low voltage wiring as shown in Fig 39 To connect the Thermidistat device 33CS2PPRH 01 1 Route the Thermidistat multi conductor thermostat cable fi...

Page 22: ...tat Wiring Rc Rh W1 G Y2 C O W2 B Y1 OAT RRS SRTN HUM D1 D2 V Vg X C G W2 W1 Y2 Y1 R EDGE Pro THERMIDISTAT Unit CTB THERMOSTAT Connection not required Humidi MiZer FIOP C09298 Fig 40 Typical Rooftop Unit with Humidi MiZer Adaptive Dehumidification System with EDGE Pro Thermidistat Device 48HC ...

Page 23: ...ls on adjusting Cooling Lock Out setting and configure for your specific job requirements ComfortLink Factory Option For details on operating 48HC units equipped with the factory installed ComfortLink option refer to Controls Start Up Operation and Troubleshooting for 48 50HC 04 28 Single Package Rooftop Unit with ComfortLink Controls Catalog No 48 50HC C02T or later C12250 Fig 41 48HC Control Box...

Page 24: ...24 C12251 Fig 42 ComfortLink Control Wiring Diagram 48HC 3 5 Ton Units 48HC ...

Page 25: ...25 C12252 Fig 43 48HC ComfortLink with Humidi MiZer Power Wiring Diagram 208 230V 1 Ph 60 Hz 48HC ...

Page 26: ...26 C12253 Fig 44 48HC ComfortLink with Humidi MiZer Power Wiring Diagram 208 230V 460V 3Ph 60 Hz 48HC ...

Page 27: ...27 C12254 Fig 45 48HC ComfortLink with Humidi MiZer Power Wiring Diagram 575V 3 Ph 60 Hz 48HC ...

Page 28: ... through harnesses connected to the CTB thermostat Field connections are made at a 16 pole terminal block TB1 located on the bottom shelf of the unit control box in front of the PremierLink controller The factory installed PremierLink control includes the supply air temperature SAT sensor The outdoor air temperature OAT sensor is included in the FIOP accessory EconoMi ert2 package The PremierLink ...

Page 29: ...29 C101145 Fig 48 PremierLink Wiring Schematic 48HC ...

Page 30: ...30 C101146 Fig 49 PremierLink Wiring Schematic with Humidi MiZerR 48HC ...

Page 31: ...ice Outdoor air management functions can be enhanced with field installation of these accessory control devices Enthalpy control outdoor air or differential sensors Space CO2 sensor Outdoor air CO2 sensor Refer to Table 3 for accessory part numbers Field Connections Field connections for accessory sensor and input devices are made at the 16 pole terminal block TB1 located on the control box bottom...

Page 32: ...ion bus OAQ Outdoor Air Quality CO2 CMPSAFE Compressor Safety RH Relative Humidity FILTER Dirty Filter Switch SFS Supply Fan Status Table 5 Thermostat Mode TB1 TERMINAL FIELD CONNECTION INPUT SIGNAL 1 RAT SEN Analog 10k thermistor 2 G Discrete 24VAC 3 RAT SEN Analog 10k thermistor 4 Y1 Discrete 24VAC 5 6 Y2 Discrete 24VAC 7 LOOP PWR Analog 24VDC 8 W1 Discrete 24VAC 9 IAQ SEN Analog 4 20mA 10 W2 Di...

Page 33: ...s on the CTB s THERMOSTAT connection strip for these Connect the thermostat s Y1 Y2 W1 W2 and G terminals to PremierLink TB1 as shown in Fig 55 If the 48HC unit is equipped with factory installed smoke detector s disconnect the factory BLU lead at TB1 6 Y2 before connecting the thermostat Identify the BLU lead originating at CTB DDC 1 disconnect at TB1 6 and tape off Confirm that the second BLU le...

Page 34: ...e Indoor Air Quality Sensor For each sensor use two 2 conductor 18 AWG American Wire Gage twisted pair cables unshielded to connect the separate isolated 24 vac power source to the sensor and to connect the sensor to the control board terminals To connect the sensor to the control identify the positive 4 to 20 mA and ground SIG COM terminals on the sensor See Fig 56 Connect the 4 20 mA terminal to...

Page 35: ... least 4 ft between the sensor and any corner Airflow near corners tends to be reduced resulting in erratic sensor readings The sensor should be vertically mounted approximately 5 ft up from the floor beside the space temperature sensor For wiring distances up to 500 feet use a 3 conductor 18 or 20 AWG cable ACCN communication cable can be used although the shield is not required The shield must b...

Page 36: ...to TB1 8 Setpoint for Supply Fan Status is set at the switch See Fig 63 R 8 TB1 J4 6 PL Fan Pressure Switch NO close on rise in pressure CTB Thermostat C08118 Fig 63 PremierLink Wiring Fan Pressure Switch Connection Remote Occupied Switch The PremierLink control permits a remote timeclock to override the control s on board occupancy schedule and place the unit into Occupied mode This function may ...

Page 37: ... The communication bus shields must be tied together at each system element If the communication bus is entirely within one building the resulting continuous shield must be connected to ground at only one single point If the communication bus cable exits from one building and enters another building the shields must be connected to the grounds at a lightning suppressor in each building one point o...

Page 38: ...oller is an integrated component of the Carrier rooftop unit Its internal application programming provides optimum performance and energy efficiency RTU Open enables the unit to run in 100 stand alone control mode Carrier s I Vu Open network or a Third Party Building Automation System BAS On board DIP switches allow you to select your protocol and baud rate of choice among the four most popular pr...

Page 39: ...39 C101147 Fig 69 RTU Open System Control Wiring Diagram 48HC ...

Page 40: ...40 C101148 Fig 70 RTU Open System Control Wiring Diagram with Humidi MiZerR 48HC ...

Page 41: ...O Analog Output DI Discrete Input DO Discrete Output These inputs if installed take the place of the default input on the specific channel according to schematic Parallel pins J5 1 J2 6 J5 3 J1 10 J5 5 J1 2 are used for field installation The RTU Open controller requires the use of a Carrier space sensor A standard thermostat cannot be used with the RTU Open system Supply Air Temperature SAT Senso...

Page 42: ...shielded 18 or 20 gauge two conductor twisted pair cable may be used Connect T 55 See Fig 51 for typical T 55 internal connections Connect the T 55 SEN terminals to RTU Open J20 1 and J20 2 See Fig 71 SEN SEN J20 1 J20 2 C08460 Fig 71 RTU Open T 55 Sensor Connections Connect T 56 See Fig 53 for T 56 internal connections Install a jumper between SEN and SET terminals as illustrated Connect T 56 ter...

Page 43: ...t the SIG COM terminal to RTU Open J4 6 See Fig 75 SEN COM J4 5 J4 6 OAQ Sensor 24 VAC C11086 Fig 75 RTU Open Outdoor CO2 Sensor 33ZCSENCO2 Connections Space Relative Humidity Sensor or Humidistat NOTE The accessory space relative humidity sensor and humidistat are not available for single phase 3 voltage code models Humidi MiZerR Control Wiring In units equipped with the Humidi MiZer option there...

Page 44: ...accessory the unit must be configured for filter status by setting MENU Config Inputs input 3 5 8 or 9 to Filter Status and normally open N O or normally closed N C Input 8 or 9 is recommended for easy of installation Refer to Fig 67 and Fig 69 or Fig 70 for wire terminations at J5 Fan Status The fan status accessory is a field installed accessory This accessory detects when the indoor fan is blow...

Page 45: ...s See Fig 78 and 79 for protocol switch settings and address switches The 3rd party connection to the RTU Open is through plug J19 See Fig 80 for wiring NOTE Power must be cycled after changing the SW1 3 switch settings Refer to the RTU Open Controller Integration Guide Catalog No 11 808 428 01 for more detailed information on protocols 3rd party wiring and networking SW3 Protocol Selection PROTOC...

Page 46: ...Handheld The USB Link interface USB L is required to connect a computer to the RTU Open board The link cable connects a USB port to the J12 local access port This program functions and operates identical to the handheld RTU Open Troubleshooting Communication LEDs The LEDs indicate if the controller is speaking to the devices on the network The LEDs should reflect communication traffic based on the...

Page 47: ...as a field installed accessory to be used with the EconoMi er2 damper system The outdoor air enthalpy sensor is part of the enthalpy control The separate field installed accessory return air enthalpy sensor 33CSENTSEN is required for differential enthalpy control See Fig 82 Locate the enthalpy control in the economizer next to the Actuator Motor Locate two GRA leads in the factory harness and conn...

Page 48: ...modifications to unit terminal 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 require a relocation of the sensor module at unit installation See Fig 84 for the as shipped location Completing Installation of Return Air Smoke Sensor 1 Unscrew the two screws holding the Return Ai...

Page 49: ...D STD 8 15 7 43 10 15 9 45 9 15 9 45 11 15 11 47 MED 8 15 7 43 10 15 9 45 9 15 9 45 11 15 11 47 HIGH 8 15 7 49 10 15 9 51 9 15 9 51 11 15 11 53 48HC A B F05 208 230 1 60 DD STD 37 50 35 127 38 50 37 129 41 60 41 132 43 60 43 134 BD STD 34 50 32 132 36 50 35 134 39 60 38 137 41 60 40 139 MED 34 50 32 132 36 50 35 134 39 60 38 137 41 60 40 139 208 230 3 60 DD STD 26 30 26 93 28 40 28 95 31 40 31 98 ...

Page 50: ... 26 125 29 40 28 127 31 45 31 130 33 45 33 132 MED 27 40 26 143 29 40 28 145 32 45 31 148 34 45 34 150 HIGH 29 40 29 169 31 45 31 171 34 45 34 174 36 50 36 176 460 3 60 DD STD 14 20 14 58 15 20 15 59 16 20 16 60 17 20 17 61 BD STD 12 15 12 60 13 15 13 61 14 20 14 62 15 20 15 63 MED 13 15 12 69 14 20 13 70 15 20 15 71 16 20 16 72 HIGH 14 20 13 82 15 20 14 83 16 20 16 84 17 20 17 85 575 3 60 DD STD ...

Page 51: ... 11 15 12 44 13 15 14 46 STD 8 15 7 43 10 15 9 45 9 15 9 45 11 15 11 47 MED 8 15 7 43 10 15 9 45 9 15 9 45 11 15 11 47 HIGH 8 15 7 49 10 15 9 51 9 15 9 51 11 15 11 53 48HC A B F05 208 230 1 60 DD STD 37 50 35 127 38 50 37 129 41 60 41 132 43 60 43 134 STD 34 50 32 132 36 50 35 134 39 60 38 137 41 60 40 139 MED 34 50 32 132 36 50 35 134 39 60 38 137 41 60 40 139 208 230 3 60 DD STD 26 30 26 93 28 4...

Page 52: ... 36 50 36 127 STD 27 40 26 125 29 40 28 127 31 45 31 130 33 45 33 132 MED 27 40 26 143 29 40 28 145 32 45 31 148 34 45 34 150 HIGH 29 40 29 169 31 45 31 171 34 45 34 174 36 50 36 176 460 3 60 DD STD 14 20 14 58 15 20 15 59 16 20 16 60 17 20 17 61 STD 12 15 12 60 13 15 13 61 14 20 14 62 15 20 15 63 MED 13 15 12 69 14 20 13 70 15 20 15 71 16 20 16 72 HIGH 14 20 13 82 15 20 14 83 16 20 16 84 17 20 17...

Page 53: ...breaker 2 Unbalanced 3 Phase Supply Voltage Never operate a motor where a phase imbalance in supply voltage is greater than 2 Use the following formula to de termine the percentage of voltage imbalance Voltage Imbalance 100 x max voltage deviation from average voltage average voltage Example Supply voltage is 230 3 60 AB 224 v BC 231 v AC 226 v Average Voltage 224 231 226 681 3 3 227 Determine max...

Page 54: ...sion kit Flue discharge deflector Manual outside air damper Two Position motorized outside air damper EconoMi er IV with control EconoMi er2 without control for external signal Power Exhaust Differential dry bulb sensor EconoMi er IV Outdoor enthalpy sensor Differential enthalpy sensor CO2 sensor DDC interface PremierLink Louvered hail guard Motormaster head pressure controls Phase monitor control...

Page 55: ...SS j CHECK THAT RETURN INDOOR AIR FILTERS ARE CLEAN AND IN PLACE j VERIFY THAT UNIT INSTALLATION IS LEVEL j CHECK FAN WHEELS AND PROPELLER FOR LOCATION IN HOUSING ORIFICE AND SETSCREW TIGHTNESS j CHECK TO ENSURE THAT ELECTRICAL WIRING IS NOT IN CONTACT WITH REFRIGERANT LINES OR SHARP METAL EDGES j CHECK PULLEY ALIGNMENT AND BELT TENSION PER INSTALLATION INSTRUCTIONS III START UP REFER TO UNIT SERV...

Page 56: ...ARGE USING CHARGING CHARTS GENERAL j SET ECONOMIZER MINIMUM VENT AND CHANGEOVER SETTINGS TO MATCH JOB REQUIREMENTS IF EQUIPPED Copyright 2012 Carrier Corp D 7310 W Morris St D Indianapolis IN 46231 Edition Date 04 12 Manufacturer reserves the right to change at any time specifications and designs without notice and without obligations Catalog No 48HC 15SI Replaces 48HC 14SI 48HC ...

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