Carrier WeatherMaker 48FC04-07 Installation Instructions Manual Download

Page: 1 / 48

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

Catalog No. 04-53480209-01

Printed in U.S.A.

Form 48FC-4-7-01SI

Pg 1

1018

8-18

Replaces: NEW

Installation Instructions

CONTENTS

Page

SAFETY CONSIDERATIONS

. . . . . . . . . . . . . . . . . . . . . .1

MODEL NUMBER NOMENCLATURE AND
DIMENSIONS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Rated Indoor Airflow

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Jobsite Survey

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Step 1 — Plan for Unit Location

. . . . . . . . . . . . . . . . . . .7

• ROOF MOUNT

Step 2 — Plan for Sequence of Unit Installation

. . .7

• CURB-MOUNTED INSTALLATION

• PAD-MOUNTED INSTALLATION

• FRAME-MOUNTED INSTALLATION

Step 3 — Inspect Unit

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Step 4 — Provide Unit Support

. . . . . . . . . . . . . . . . . . .7

• ROOF CURB MOUNT

• SLAB MOUNT (HORIZONTAL UNITS ONLY)

• ALTERNATE UNIT SUPPORT (IN LIEU OF CURB

OR SLAB MOUNT)

Step 5 — Field Fabricate Ductwork

. . . . . . . . . . . . . . .9

Step 6 — Rig and Place Unit

. . . . . . . . . . . . . . . . . . . . . .9

• POSITIONING ON CURB

Step 7 — Convert to Horizontal and Connect
Ductwork

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Step 8 — Install Outside Air Hood

. . . . . . . . . . . . . . .11

• ECONOMIZER AND TWO-POSITION DAMPER

HOOD PACKAGE REMOVAL AND SETUP

(FACTORY OPTION)

• ECONOMIZER AND TWO-POSITION HOOD

Step 9 — Units with Hinged Panels Only

. . . . . . . . .12

Step 10 — Install Flue Hood

. . . . . . . . . . . . . . . . . . . . .12

Step 11 — Install Gas Piping

. . . . . . . . . . . . . . . . . . . . .13

• FACTORY-OPTION THRU-BASE CONNECTIONS

(GAS CONNECTIONS)

Step 12 — Install External Condensate Trap
and Line

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Step 13 — Make Electrical Connections

. . . . . . . . 16

• FIELD POWER SUPPLY

• UNITS WITH FACTORY-INSTALLED NON-FUSED

DISCONNECT

• UNITS WITHOUT FACTORY-INSTALLED

NON-FUSED DISCONNECT

• ALL UNITS

• CONVENIENCE OUTLETS

• FACTORY-OPTION THRU-BASE CONNECTIONS

(ELECTRICAL CONNECTIONS)

• UNITS WITHOUT THRU-BASE CONNECTIONS

(ELECTRICAL CONNECTIONS)

• FIELD CONTROL WIRING

• THERMOSTAT

• HEAT ANTICIPATOR SETTINGS

• HUMIDI-MIZER

CONTROL CONNECTIONS

• TYPICAL UNIT WIRING DIAGRAMS

Integrated Gas Controller

. . . . . . . . . . . . . . . . . . . . . . .25

EconoMi$er

X (Factory Option)

. . . . . . . . . . . . . . . . .27

Page

RTU Open Controller (Factory Option)

. . . . . . . . . . . 41

SystemVu™ Controller (Factory Option)

. . . . . . . . 41

Controller Options

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

• LOW AMBIENT

Smoke Detectors

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Step 14 — Adjust Factory-Installed Options

. . . . . 42

Step 15 — Install Accessories

. . . . . . . . . . . . . . . . . . . 42

Step 16 — Fan Speed Set Up

. . . . . . . . . . . . . . . . . . . . 43

START-UP CHECKLIST

. . . . . . . . . . . . . . . . . . . . . . . .CL-1

SAFETY CONSIDERATIONS

Improper installation, adjustment, alteration, service,

maintenance, or use can cause explosion, fire, electrical

shock or other conditions which may cause personal injury or

property damage. Consult a qualified installer, service agen-

cy, or your distributor or branch for information or assistance.

The qualified installer or agency must use factory-authorized

kits or accessories when modifying this product. Refer to the

individual instructions packaged with the kits or accessories

when installing.

Follow all safety codes. Wear safety glasses and work

gloves. Use quenching cloths for brazing operations and have

a fire extinguisher available. Read these instructions thor-

oughly and follow all warnings or cautions attached to the

unit. Consult local building codes and appropriate national

electrical codes (in USA, ANSI/NFPA70, National Electrical

Code (NEC); in Canada, CSA C22.1) for special require-

ments.

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 injury or product and property damage. NOTE

is used to highlight suggestions which will result in enhanced in-

stallation, reliability, or operation.

WARNING

Electrical shock can cause personal injury and death. Shut

off all power to this equipment during installation and ser-

vice. There may be more than one disconnect switch. Tag

all disconnect locations to alert others not to restore power

until work is completed.

WeatherMaker

48FC04-07 Single Package Rooftop

Gas Heating/Electric Cooling Unit

with Puron

(R-410A) Refrigerant

Summary of Contents for WeatherMaker 48FC04-07

Page 1: ... 42 Step 15 Install Accessories 42 Step 16 Fan Speed Set Up 43 START UP CHECKLIST CL 1 SAFETY CONSIDERATIONS Improper installation adjustment alteration service maintenance or use can cause explosion fire electrical shock or other conditions which may cause personal injury or property damage Consult a qualified installer service agen cy or your distributor or branch for information or assistance T...

Page 2: ...g parts and servicing air conditioning equipment WARNING CARBON MONOXIDE POISONING HAZARD Failure to follow instructions could result in severe person al injury or death due to carbon monoxide poisoning if combustion products infiltrate into the building Check that all openings in the outside wall around the vent and air intake pipe s are sealed to prevent infiltration of combustion products into ...

Page 3: ...Cu Al Cu D E coat Al Cu E coat Al Cu E Cu Cu Al Cu F Cu Cu Cu Cu M Al Cu Al Cu Louvered Hail Guard N Precoat Al Cu Al Cu Louvered Hail Guard P E coat Al Cu Al Cu Louvered Hail Guard Q E coat Al Cu E coat Al Cu Louvered Hail Guard R Cu Cu Al Cu Louvered Hail Guard S Cu Cu Cu Cu Louvered Hail Guard Design Revision Factory Design Revision Base Unit Controls 0 Electro mechanical Controls can be used w...

Page 4: ...4 Fig 2 Unit Dimensional Drawing 1018 ...

Page 5: ...5 Fig 2 Unit Dimensional Drawing cont 1018 ...

Page 6: ...6 Fig 2 Unit Dimensional Drawing cont 1018 ...

Page 7: ...accessories must be installed on the unit before the unit is placed on the curb Review the fol lowing for recommended sequences for installation steps CURB MOUNTED INSTALLATION 1 Install curb 2 Install field fabricated ductwork inside curb 3 Install accessory thru base service connection package affects curb and unit refer to accessory installation instructions for details 4 Prepare bottom condens...

Page 8: ...INSULATED PANELS 25 4 1 THK POLYURETHANE FOAM 44 5 1 3 4 DENSITY 3 DIMENSIONS IN ARE IN MILLIMETERS 4 ROOFCURB 18 GAGE STEEL 5 ATTACH DUCTWORK TO CURB FLANGES OF DUCT REST ON CURB 6 SERVICE CLEARANCE 4 FEET ON EACH SIDE 7 DIRECTION OF AIR FLOW 8 CONNECTOR PACKAGE CRBTMPWR001A01 IS FOR THRU THE CURB GAS TYPE PACKAGE CRBTMPWR003A01 IS FOR THRU THE BOTTOM TYPE GAS CONNECTIONS TYPICAL 4 SIDES SUPPLY A...

Page 9: ...unit upright and do not drop Spreader bars are re quired Rollers may be used to move unit across a roof Rig ging materials under unit cardboard or wood must be re moved PRIOR to placing the unit on the roof curb Level by using unit frame as a reference See Table 2 and Fig 5 for ad ditional information Lifting holes are provided in base rails as shown in Fig 5 Refer to rigging instructions on unit ...

Page 10: ...round duct openings must be tight Secure with screws as shown in Fig 8 Cover seams with foil duct tape Field supplied flanges should be attached to horizontal duct openings and all ductwork should be secured to the flanges Insulate and weatherproof all external ductwork joints and roof or building openings with counter flashing and mastic in accordance with applicable codes Do not cover or obscure...

Page 11: ... to not damage any wiring or cut tie wraps secur ing any wiring Fig 10 Economizer and Two Position Damper Hood Parts Location 3 Carefully lift the hood assembly with metal tray through the filter access opening and assemble per the steps outlined in the Economizer Hood and Two Position Hood section below ECONOMIZER AND TWO POSITION HOOD NOTE If the power exhaust accessory is to be installed on the...

Page 12: ...place the filter access panel Fig 13 Economizer Filter Installation Step 9 Units with Hinged Panels Only If the unit does not have hinged panels skip this step and continue at Step 10 below Relocate latch shipped inside the compressor compartment behind the hinged compressor door to location shown in Fig 14 after unit installation Fig 14 Compressor Door Latch Location Step 10 Install Flue Hood Flu...

Page 13: ...use a pipe size smaller than 1 2 inch Size the gas supply line to allow for a maximum pressure drop of 0 5 in wg 124 Pa between gas regulator source and unit gas valve connection when unit is operating at high fire flow rate The gas supply line can approach the unit in three ways horizontally from outside the unit across the roof thru curb under unit basepan accessory kit required or through unit ...

Page 14: ...located at least 9 in 230 mm away from the access panel to permit the panel to be removed for service If a regulator valve is installed it must be located a minimum of 4 ft 1220 mm away from the unit s flue outlet Some municipal codes require that the man ual shutoff valve be located upstream of the sediment trap See Fig 19 and 20 for typical piping arrangements for gas piping that has been routed...

Page 15: ...lled and factory in stalled gas lines after all piping connections have been com pleted Use soap and water solution or method specified by local codes and or regulations NOTE If orifice hole appears damaged or it is suspected to have been redrilled check orifice hole with a numbered drill bit of correct size Never redrill an orifice A burr free and squarely aligned orifice hole is essential for pr...

Page 16: ...connection points on contactor C or optional dis connect switch These leads are for factory run test purposes on ly remove and discard before connecting field power wires to unit connection points Make field power connections directly to line connection pressure lugs only Fig 25 Power Wiring Connections Fig 26 Disconnect Switch and Unit UNITS WITH FACTORY INSTALLED NON FUSED DIS CONNECT The factor...

Page 17: ...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 25 and unit label diagram for field power wiring connections Provide a ground fault and short circuit over current pro tection device fuse or breaker per NEC Article 440 or local codes Refer to unit informative data plate for MOCP Maxi mum Over Cur...

Page 18: ...ory Installed DDC 1 Remove the blank cover plate at the convenience outlet discard the blank cover 2 Loosen the two screws at the GFCI duplex outlet until approximately 1 2 in 13 mm under screw heads is exposed Press the gasket over the screw heads 3 Slip the backing plate over the screw heads at the key hole slots and align with the gasket tighten the two screws until snug do not over tighten 4 M...

Page 19: ...ector lock nuts before connecting electrical conduits Field supplied and field installed liquid tight conduit con nectors and conduit may be attached to the connectors on the basepan Pull correctly rated high voltage and low voltage through appropriate conduits Connect the power conduit to the internal disconnect if unit is so equipped or to the exter nal disconnect through unit side panel A hole ...

Page 20: ...lable for single phase 3 volt age code models The Humidi MiZer dehumidification system requires a field supplied and field installed space relative humidity con trol device This device may be a separate humidistat control contact closes on rise in space RH above control setpoint or a combination thermostat humidistat control device such as Carrier s Edge Pro Thermidistat device with isolated con t...

Page 21: ...ilt into the corner post see Fig 35 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 The Thermidistat has dry contacts at terminals D1 and D2 for dehumidification operation see Fig 39 Connect D1 to the R terminal on the UCB Connect D2 to the HUM terminal on the UCB Refer to the installation ...

Page 22: ...22 Fig 40 Typical Control Wiring Diagram Electro Mechanical with W7212 48FC 04 06 208 230 3 60 Unit Shown ...

Page 23: ...23 Fig 41 Typical Electro Mechanical with W7220 Control Wiring Diagram 48FC 07 208 230 3 60 Unit Shown ...

Page 24: ...24 T Fig 42 Typical 48FC 04 07 Power Wiring Diagram 208 230V Unit Shown ...

Page 25: ...mum position If the over temperature limit opens prior to the start of the indoor fan blower the IGC will shut down the burners and the control will shorten the 45 second delay to 5 seconds less than the time to trip the limit For example if the limit trips at 37 seconds the control will change the fan on delay from 45 seconds to 32 sec onds Once the fan on delay has been modified it will not chan...

Page 26: ...26 Fig 45 Typical IGC Control Wiring Diagram UNIT CONTROL BOARD ...

Page 27: ...other options are available with bus sen sors User Interface Provides status for normal operation setup parameters checkout tests and alarm and error conditions with a 2 line 16 character LCD display and four button keypad Electrical Rated Voltage 20 to 30 Vac RMS 50 60 Hz Transformer 100 va maximum system input Nominal Power Consumption at 24 Vac 60 Hz 11 5 VA without sensors or actuators Relay D...

Page 28: ...e Sensor Polarity Insensitive Connection S BUS S BUS S BUS Sylk Bus Sylk is a trademark of Honeywell International Inc Enthalpy Control Sensor Polarity Insensitive Connection Bottom Left Terminal Block IAQ 2 10 2 10 vdc Air Quality Sensor Input e g CO2 sensor IAQ COM COM Air Quality Sensor Common IAQ 24V 24 vac Air Quality Sensor 24 vac Source ACT 2 10 2 10 vdc Damper Actuator Output 2 10 vdc ACT ...

Page 29: ...e for Keypad and menu navigation Settings and parameter changes Menu structure and selection User Interface The user interface consists of a 2 line LCD display and a 4 button keypad on the front of the economizer controller Keypad Use the four navigation buttons see Fig 50 to scroll through the menus and menu items select menu items and to change parameter and configuration settings To use the key...

Page 30: ...coil This unit application has the control sensor lo cated after the cooling coil in the fan section where it is desig nated as Cooling Supply Air Temperature or SAT sensor Setup and Configuration Before being placed into service the W7220 Economizer module must be set up and configured for the installed system The setup process uses a hierarchical menu structure that is easy to use Press the and ...

Page 31: ... air temperature Displays _ _ _F if sensor sends invalid value short or out of range OA HUM _ _ 0 to 100 OUTSIDE AIR RELATIVE HUMIDITY Displays measured value of outdoor humidity from OA sensor Displays _ _ if not connected short or out of range RA TEMP _ _ _ F 0 to 140 F RETURN AIR TEMPERATURE Displays measured value of return air temperature from RAT sensor Displays _ _ _ F if sensor sends inval...

Page 32: ...with 1 heat and 2 cool IF using 2 speed with 1 heat and 1 cool then set for HEATING ventilation If using 3 speed with 1 heat and 2 cool then set for LOW SPEED COOLING VENTMAX M 5 4 V 2 to 10 Vdc DCV MAXIMUM DAMPER POSITION AT MEDIUM SPEED Only displays if unit is set for 3 speed with 1 heat and 2 cool Set for HEATING ventilation VENTMAX H 4 4 V 2 to 10 Vdc DCV MAXIMUM DAMPER POSITION AT HIGH SPEED...

Page 33: ...2 SPAN 2000ppm 1000 to 3000 ppm Increment by 10 CO2 ppm span to match CO2 sensor STG3 DLY 2 0h 0 min 5 min 15 min then 15 min intervals Up to 4 hrs or OFF COOLING STAGE 3 DELAY Delay after stage 2 cool has been active Turns on second stage of cooling when economizer is first stage and mechanical cooling is second stage Allows three stages of cooling 1 economizer and 2 mechanical OFF no Stage 3 coo...

Page 34: ... ERR N A N A DISCHARGE AIR S BUS SENSOR ERROR Discharge air sensor has failed or become disconnected check wiring then replace sensor if the alarm continues OA SENS T ERR N A N A OUTSIDE AIR TEMPERATURE SENSOR ERROR Outdoor air temperature sensor has failed or become disconnected check wiring then replace if the alarm continues ACT ERROR N A N A ACTUATOR ERROR Actuator has failed or become disconn...

Page 35: ...put terminal An external timeclock or relay is required to implement an Occu pancy schedule on the economizer damper position 2 STATUS MA TEMP SETPOINTS MAT SET The W7220 menu parameters and labels include designations MA MAT and Mixed Air for the economizer cooling control sensor On these roof top units the economizer control sensor is located downstream of the evaporator indoor coil in the suppl...

Page 36: ...oundary the conditions are not good to economize and the mode is set to NO Figure 51 shows the 5 current boundaries There is also a high limit boundary for differential enthalpy The high limit boundary is ES1 when there are no stages of mechanical cooling energized and HL high limit when a compressor stage is energized Fig 51 Single Enthalpy Curve Boundaries Table 12 Single Enthalpy and Dual Entha...

Page 37: ...N ON HIGH MIN POS Closed YES N A OFF OFF OFF OFF HIGH MIN POS Closed N A ON OFF OFF OFF HIGH MIN POS to Full Open Closed to Full Open N A ON ON ON OFF HIGH MIN POS to Full Open Closed to Full Open Below CO2 Set NO N A OFF OFF OFF OFF HIGH VENTMIN Closed N A ON OFF ON OFF HIGH VENTMIN Closed N A ON ON ON ON HIGH VENTMIN Closed YES N A OFF OFF OFF OFF HIGH VENTMIN Closed N A ON OFF OFF OFF HIGH VENT...

Page 38: ...y STG3 DLY in Advanced setup COOL Y2 OUT will be turned ON after the delay time specified N A Not applicable STATE FAN SPEED OCC Low Y1 Low Y2 High W High INPUTS OUTPUTS DEMAND CONTROLLED VENTILATION DCV OUTSIDE AIR GOOD TO ECONOMIZE W HEAT ON COOL Y1 IN COOL Y2 IN COOL Y1 OUT COOL Y2 OUT FAN SPEED reference only DAMPER POSITION OCCUPIED UNOCCUPIED NONE NO ON N A N A OFF OFF HIGH MIN POS H Closed ...

Page 39: ...GOOD TO ECONOMIZE W HEAT ON COOL Y1 IN COOL Y2 IN COOL Y1 OUT COOL Y2 OUT FAN SPEED reference only DAMPER POSITION OCCUPIED UNOCCUPIED NONE NO ON N A N A OFF OFF LOW MIN POS L Closed OFF OFF OFF OFF OFF LOW MIN POS L Closed OFF ON OFF ON OFF HIGH MIN POS H Closed OFF ON ON ON ON HIGH MIN POS H Closed YES ON N A N A OFF OFF LOW MIN POS L Closed OFF OFF OFF OFF OFF LOW MIN POS L Closed OFF ON OFF OF...

Page 40: ... time of in stallation or at any time during the operation of the system as a test that the system is operable Troubleshooting Alarms The economizer module provides alarm messages that dis play on the 2 line LCD NOTE Upon power up the module waits 60 minutes before checking for alarms This allows time for all the configured de vices e g sensors actuator to become operational The excep tion is the ...

Page 41: ... only All components necessary for operation are facto ry provided and mounted The unit is factory configured for immediate smoke detector shutdown operation additional wiring or modifications to unit terminal board may be neces sary to complete the unit and smoke detector configuration to meet project requirements Units equipped with factory optional Return Air smoke detectors require a relocatio...

Page 42: ...ence at terminals marked OCCU PANCY Detach the jumper covering the Occupancy termi nals on the UCB and then attach the required connections Step 15 Install Accessories Available accessories include Roof curb Thru base connection kit must be installed before unit is set on roof curb LP conversion kit Flue discharge deflector Manual outside air damper Two position motorized outside air damper EconoM...

Page 43: ...he High Voltage cover in the Control Box 3 Connect a multimeter to the Vdc terminals on the UCB 4 Set the Range Switch to either A B or C per the Switch Range table 5 Using a straight blade screwdriver turn the Vdc control dial to fine tune the Vdc reading 6 Record the reading in the Field Setting field Fig 55 UCB Fan Speed Controls 3 Phase Units Fig 56 UCB Fan Speed Controls Single Phase Units NO...

Page 44: ...NDOOR FAN and then press ENTER 8 Refer to the job specifications to set the following deter mining the values per the RPM Calculator label see Fig 59 Use the UP and DOWN arrow keys and the BACK key to set the values Press ENTER after setting each value to continue to the next selection IDF VENT SPD IDF HEAT SPD IDF LOW COOL SPD IDF HIGH SPD IDF FREE COOL SPD For further details see the FC GC Serie...

Page 45: ...512 1601 1692 1784 1878 1973 2069 2166 1500 1625 1750 1875 2000 2125 2250 2375 65 0 4 1609 1688 1768 1850 1933 2018 2104 2192 2282 65 0 6 1764 1839 1916 1994 2073 2153 2235 2317 0 8 1902 1974 2047 2123 2200 2277 2356 65 1 0 2028 2097 2168 2241 2316 65 1 2 2147 2212 2280 2351 65 1 4 2260 2322 2387 65 1 6 1 8 2 0 2367 65 65 UNIT MODEL NUMBER ...

Page 46: ...ht to discontinue or change at any time specifications or designs without notice and without incurring obligations Catalog No 04 53480209 01 Printed in U S A Form 48FC 4 7 01SI Pg 46 1018 8 18 Replaces NEW Carrier Corporation 2018 ...

Page 47: ... Verify gas pressure to unit gas valve is within specified range Y N _____ Check gas piping for leaks Y N _____ Check that indoor air filters are clean and in place Y N _____ Check that outdoor air inlet screens are in place Y N _____ Verify that unit is level Y N _____ Verify that fan assembly is free of obstructions and rotor spins freely Y N _____ Verify that scroll compressors are rotating in ...

Page 48: ...B Discharge pressure _______________ PSIG C Entering air temperature _______________ F D Liquid line temperature at outlet or reheat coil _______________ F E Confirm correct rotation for compressor Y N _____ F Check for correct ramp up of outdoor fan motor as condenser coil warms Y N _____ 4 Switch unit to high latent mode sub cooler by closing humidistat with Y1 closed Y N _____ 5 Check unit char...

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Carrier WeatherMaker 48FC04-07, Installation Instructions Manual

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