Carrier WeatherMaker 48KC Series Installation Instructions Manual Download

Page: 1 / 44

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

Catalog No. 04-53480188-01

Printed in U.S.A.

Form 48KC-4-6-03SI

Pg 1

11-18

Replaces: 48KC-4-6-02SI

Installation Instructions

CONTENTS

Page

SAFETY CONSIDERATIONS

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

MODEL NUMBER NOMENCLATURE AND
DIMENSIONS

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

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Jobsite Survey

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Step 1 — Plan for Unit Location

. . . . . . . . . . . . . . . . . . .6

• 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 OR HACR

• UNITS WITHOUT FACTORY-INSTALLED NON-

FUSED DISCONNECT OR HACR

• ALL UNITS

• CONVENIENCE OUTLETS

• HACR AMP RATING

• 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

Low Ambient Control (Factory Option)

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

Integrated Gas Controller

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

Economi$er

(Factory Option)

. . . . . . . . . . . . . . . . . . .29

Page

Outdoor Air Enthalpy Control

. . . . . . . . . . . . . . . . . . . 40

Smoke Detectors

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Premierlink™ (Factory Option)

. . . . . . . . . . . . . . . . . . 40

RTU Open Control System

. . . . . . . . . . . . . . . . . . . . . . 40

Step 14 — Adjust Factory-Installed Options

. . . . . 41

Step 15 — Install Accessories

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

Step 16 — Check Belt Tension

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

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

agency, 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 thoroughly

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

requirements.
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 installation,

reliability, or operation.

WARNING

Electrical shock can cause personal injury and death. Shut off

all power to this equipment during installation and service.

There may be more than one disconnect switch. Tag all dis-

connect locations to alert others not to restore power until

work is completed.

WeatherMaker

48KC04-06 Single Package Rooftop

Gas Heating/Electric Cooling Unit

with Puron

(R-410A) Refrigerant

Summary of Contents for WeatherMaker 48KC Series

Page 1: ...nstalled Options 41 Step 15 Install Accessories 41 Step 16 Check Belt Tension 42 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 agency or your distributor or branch for informatio...

Page 2: ... parts and servicing air conditioning equipment WARNING CARBON MONOXIDE POISONING HAZARD Failure to follow instructions could result in severe personal injury or death due to carbon monoxide poisoning if combus tion 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 t...

Page 3: ...Guard R Cu Cu Al Cu Louvered Hail Guard S Cu Cu Cu Cu Louvered Hail Guard Voltage 1 575 3 60 3 208 230 1 60 5 208 230 3 60 6 460 3 60 Design Revision Factory Design Revision Base Unit Controls 0 Electro mechanical Controls can be used with W7212 EconoMi er IV Non Fault Detection and Diagnostic 1 PremierLink Controller 2 RTU Open Multi Protocol Controller 6 Electro mechanical with W7220 Economizer ...

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

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

Page 6: ...iances 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 2 m from any opening through which combustion prod ucts could enter the building and at least 4 ft 1 2 m from any adjacent building or per local code Locate the flue as sembly at least 10 ft 3 05 m from an a...

Page 7: ...cal connections 11 Install other accessories FRAME MOUNTED INSTALLATION Frame mounted applications generally follow the se quence for a curb installation Adapt the sequence as required to suit specific installation plan Step 3 Inspect Unit Inspect unit for transportation damage File any claim with transportation agency Confirm before installation of unit that voltage amperage and circuit protectio...

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: ...m the unit basepan Insulate and weatherproof all external ductwork joints and roof openings with counter flashing and mastic in accor dance with applicable codes Ducts passing through unconditioned spaces must be insu lated and covered with a vapor barrier If a plenum return is used on a vertical unit the return should be ducted through the roof deck to comply with appli cable fire codes A minimum...

Page 10: ...de duct opening covers see Fig 7 and remove cov ers Use the screws to install the covers on vertical duct open ings with the insulation side down The panels must be insert ed into the notches on the basepan to properly seal The notches are covered by the tape used to secure the insulation to the basepan and are not easily seen See Fig 8 for position of the notches in the basepan Seals around duct ...

Page 11: ...cess panel The hood assembly s metal tray is attached to the basepan and also attached to the damper using two plastic tie wraps 1 To gain access to the hood remove the filter access panel See Fig 10 Fig 10 Typical Access Panel Locations 2 Locate the 2 screws holding the metal tray to the base pan and remove Locate and cut the 2 plastic tie wraps securing the assembly to the damper See Fig 11 Be c...

Page 12: ...d divider is also used as the bot tom filter rack for the aluminum filter 5 Open the filter clips which are located underneath the hood top Insert the aluminum filter into the bottom filter rack hood divider Push the filter into position past the open filter clips Close the filter clips to lock the filter into place See Fig 14 6 Caulk the ends of the joint between the unit top panel and the hood t...

Page 13: ...Natural Gas Manifold Pressure Ranges Manifold pressure for LP fuel use must be adjusted to speci fied range Follow instructions in the accessory kit to make ini tial readjustment see Table 6 Table 6 Liquid Propane Manifold Pressure Ranges Install a gas supply line that runs to the unit heating sec tion Refer to the NFPA 54 NFGC or equivalent code for gas pipe sizing data Do not use a pipe size sma...

Page 14: ...ure The manual shutoff valve must be located within 6 ft 1 83 m of the unit The union located in the final leg entering the unit must be 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 shu...

Page 15: ...sing the external main manual shutoff valve and slightly opening the ground joint union Check for gas leaks at the field installed 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...

Page 16: ... optional disconnect or HACR See Fig 26 and unit label diagram for field power wiring connections NOTE Unit may be equipped with short test leads pigtails on the field line 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 d...

Page 17: ...Remove the front cover of the NFD enclosure 4 Make sure the NFD shipped from the factory is at OFF position the arrow on the black handle knob is at OFF 5 Insert the shaft with the cross pin on the top of the shaft in the horizontal position See Fig 29 6 Measure from the tip of the shaft to the top surface of the black pointer the measurement should be 3 75 to 3 88 in 95 to 99 mm 7 Tighten the loc...

Page 18: ...it 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 Current Protection device size NOTE Units ordered with factory installed HACR do not need an additional ground fault and short circuit over current protec tive devi...

Page 19: ...en selecting wire size fuse or breaker requirements and disconnect switch size and location Route 125v power supply conduc tors into the bottom of the utility box containing the duplex receptacle 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 receptacle This option also includes a manual s...

Page 20: ...ed in the field for example 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 name plate and label on factory installed HACR for the amp rating of the HACR that was shipped with the unit from the factory Fig 36 See unit nameplates for the proper fuse HACR or maximum over current protection device required on the unit w...

Page 21: ...h the thermostat installation instructions Typical low voltage connections are shown in Fig 37 Fig 37 Low Voltage Thermostat Connections If the thermostat contains a logic circuit requiring 24v power use a thermostat cable or equivalent single leads of different colors with minimum of seven leads If the thermo stat does not require a 24v source no C connection re quired use a thermostat cable or e...

Page 22: ...d through the hole provided in the unit corner post 2 Feed wires through the raceway built into the corner post see Fig 38 to the 24v 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 41 Connecting the T...

Page 23: ...23 Fig 41 Typical Humidi MiZer Adaptive Dehumidification System Humidistat Wiring ...

Page 24: ... Humidi MiZer Adaptive Dehumidification System and Edge Pro Thermidistat Device 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 ...

Page 25: ...25 Fig 43 Typical Control Wiring Diagram Electro Mechanical with W7212 ...

Page 26: ...26 Fig 44 Typical 48KC 04 06 Power Wiring Diagram 208 230 3 60 Unit Shown ...

Page 27: ...hes the pressure switch and the flame sensor Assuming the unit is controlled through a room ther mostat set for fan auto 45 seconds after ignition occurs the indoor fan motor will energize and the outdoor air dampers will open to their minimum 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...

Page 28: ...28 Fig 46 IGC Board Component Layout Fig 47 Typical IGC Control Wiring Diagram Locking Tab Connector Overcurrent Fuse Protection Redundant Gas Valve Relay Locking Tab Connector Spade Connect Ignitor ...

Page 29: ...are available with bus sensors 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 Digital Output R...

Page 30: ...ensitive 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 COM COM Damper Actuat...

Page 31: ... the EconoMi er user interface 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 52 to scroll through the menus and menu items select menu items and to change parameter and configur...

Page 32: ... location before the cooling 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 sys tem The setup process uses a hierarchical menu structure that...

Page 33: ...r 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 invalid ...

Page 34: ...ors are connected and DCV CAL ENABLE is set to AUTO mode the OA dampers are controlled by CFM and displays from 100 to 9990 CFM 2 to 10 Vdc With 2 speed fan units VENTMIN L low speed fan and MIN POS H high speed fan settings are required Default for VENTMIN L is 3 2V and VENT MIN H is 2 8V ERV OAT SP 32 F 0 to 50 F increment by 1 ENERGY RECOVERY VENTILATOR UNIT OUTDOOR AIR TEMPERA TURE SETPOINT On...

Page 35: ...per range of alarm above this temperature the alarm will show on the display DCVCAL ENA MAN MAN manual AUTO Turns on the DCV automatic control of the dampers Resets ventilation based on the RA OA and MA sensor conditions Requires all 3 RA OA and MA sensors MAT T CAL 0 0 F 2 5 F SUPPLY AIR TEMPERATURE CALIBRATION Allows for the operator to adjust for an out of calibration temperature sensor OAS T C...

Page 36: ... continues OA SYLK T ERR N A N A OUTSIDE AIR S BUS SENSOR ERROR Outdoor air enthalpy sensor has failed or become disconnected check wir ing then replace sensor if the alarm continues OA SYLK H ERR N A N A RA SYLK T ERR N A N A RETURN AIR S BUS SENSOR ERROR Return air enthalpy sensor has failed or become disconnected check wiring then replace sensor if the alarm continues RA SYLK H ERR N A N A DA S...

Page 37: ...D NONE NO OFF OFF HIGH 0v Off 0v Off MIN POS Closed ON OFF HIGH 24v On 0v Off MIN POS Closed ON ON HIGH 24v On 24v On MIN POS Closed NONE YES OFF OFF HIGH 0v Off 0v Off MIN POS Closed ON OFF HIGH 0v Off 0v Off MIN POS to Full Open Closed to Full Open ON ON HIGH 24v On 0v Off MIN POS to Full Open Closed to Full Open DEMAND CONTROLLED VENTILATION DCV OUTSIDE AIR GOOD TO ECONOMIZE Y1 I Y2 I FAN SPEED...

Page 38: ...there are no stages of mechanical cooling energized and HL high limit when a compressor stage is energized DEMAND CONTROLLED VENTILATION DCV OUTSIDE AIR GOOD TO ECONOMIZE Y1 I Y2 I FAN SPEED Y1 O Y2 O OCCUPIED UNOCCUPIED NONE NO OFF OFF HIGH 0v Off 0v Off MIN POS Closed ON OFF HIGH 24v On 0v Off MIN POS Closed ON ON HIGH 24v On 24v On MIN POS Closed NONE YES OFF OFF HIGH 0v Off 0v Off MIN POS Clos...

Page 39: ...m 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 SAT sensor which will alarm immediately If one or more alarms are prese...

Page 40: ...ranged for vertical return configura tions 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 Retu...

Page 41: ...mplete the installation Step 15 Install Accessories Available accessories include Curb Thru base connection kit must be installed before unit is set on curb LP conversion 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 ...

Page 42: ... ring at that point 3 Press the tension checker downward on the belt until the large O ring is at the bottom of the straightedge 4 Adjust the belt tension as needed Adjust belt tension by loosing the motor mounting plate front bolts and rear bolt see Fig 60 and slide the plate towards the fan to reduce tension or away from the fan to increase ten sion Ensure the blower shaft and motor shaft are pa...

Page 43: ...n 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 _____ Check fan wheels and propeller for location in housing orifice and verify setscrew is tight Y N _____ Verify that fan sheaves are aligned and belts are properly tensioned Y N _...

Page 44: ...ir 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 Check unit charge per charging chart Y N _____ Jumper 32L Motormaster temperature sensor during this check Remove jumper when complete 5 Switch unit to high late...

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Carrier WeatherMaker 48KC Series, Installation Instructions Manual

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