Carrier WeatherMaker 48TC**16 Installation Instructions Manual Download

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48TC**16

Single Package Rooftop

Gas Heating/Electric Cooling Unit

with Puron

(R---410A) Refrigerant

Size 16

Installation Instructions

NOTE

: Read the entire instruction manual before starting

the installation

TABLE OF CONTENTS

SAFETY CONSIDERATIONS

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

INSTALLATION

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

Jobsite Survey

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

Step 1 -- Plan for Unit Location

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

Roof Mount

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

Step 2 -- Plan for Sequence of Unit Installation

. . . . . .

Curb--Mount Installation

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

Pad--Mount Installation

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

Frame--Mount Installation

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

Step 3 -- Inspect Unit

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

Step 4 -- Provide Unit Support

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

Roof Curb Mount

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

Slab Mount (Horizontal Units Only)

. . . . . . . . . . .

Alternate Unit Support

(In Lieu of Curb or Slab Mount)

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

Step 5 -- Field Fabricate Ductwork

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

Step 6 -- Rig and Place Unit

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

Positioning on Curb

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

Step 7 -- Convert to Horizontal and Connect Ductwork

. . .

Step 8 -- Install Outside Air Hood

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

Economizer Hood Removal and Setup —

Factory Option

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

Two Position Damper Hood Removal and Setup —

Factory Option

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

Economizer Hood and Two--Position Hood

. . . . .

Step 9 -- Install Flue Hood

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

Step 10 -- Install Gas Piping

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

Factory--Option Thru--Base Connections

(Gas Connections)

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

Step 11 -- Install External Condensate Trap and Line

. .

Step 12 -- Make Electrical Connections

. . . . . . . . . . .

Field Power Supply

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

All Units

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

Units without Factory--Installed Disconnect

. . . .

Units with Factory--Installed Disconnect

. . . . . . .

Convenience Outlets

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

Factory--Option Thru--Base Connections

(Electrical Connections)

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

Units without Thru--Base Connections

. . . . . . . . .

Field Control Wiring

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

Thermostat

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

Unit without Thru--Base Connection Kit

. . . . . . .

Heat Anticipator Settings

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

Humidi--MiZer

Control Connections

. . . . . . . . . .

Humidi--MiZer -- Space RH Controller

. . . . . . . .

PremierLink

(Factory Option)

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

Supply Air Temperature (SAT) Sensor

. . . . . . . . .

Outdoor Air Temperature (OAT) Sensor

. . . . . . .

EconoMi$er2

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

Field Connections

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

Space Sensors

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

Connect Thermostat

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

Configure the Unit for Thermostat Mode

. . . . . .

Economizer Controls

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

Indoor Air Quality (CO

sensor)

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

Outdoor Air Quality Sensor

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

Space Relative Humidity Sensor or

Humidistat Connections

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

Smoke Detector/Fire Shutdown (FSD)

. . . . . . . . .

Filter Status Switch

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

Supply Fan Status Switch

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

Remote Occupied Switch

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

Power Exhaust (output)

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

CCN Communication Bus

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

RTU Open Control System

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

Supply Air Temperature (SAT) Sensor

. . . . . . . . .

Outdoor Air Temperature (OAT) Sensor

. . . . . . .

EconoMi$er2

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

Field Connections

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

Space Temperature (SPT) Sensors

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

Indoor Air Quality (CO

) Sensor

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

Summary of Contents for WeatherMaker 48TC**16

Page 1: ...1 Install External Condensate Trap and Line 13 Step 12 Make Electrical Connections 14 Field Power Supply 14 All Units 15 Units without Factory Installed Disconnect 15 Units with Factory Installed Disconnect 15 Convenience Outlets 16 Factory Option Thru Base Connections Electrical Connections 18 Units without Thru Base Connections 18 Field Control Wiring 18 Thermostat 18 Unit without Thru Base Conn...

Page 2: ... 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 injury o...

Page 3: ...3 Horizontal Connections Economizer Vertical Connections Economizer C10864A Fig 1 Unit Dimensional Drawing 16 Size Unit 48TC 16 ...

Page 4: ...ngs See Fig 2 NOTE Consider also the effect of adjacent units Unit may be installed directly on wood flooring or on Class A B or C roof covering material when roof curb is used Do not install unit in an indoor location Do not locate air inlets near exhaust vents relief valves or other sources of contaminated air 18 457 42 1067 Required bottom condensate drain connection Otherwise 36 914mm for cond...

Page 5: ...requirements listed on unit data plate agree with power supply provided Step 4 Provide Unit Support Roof Curb Mount Accessory roof curb details and dimensions are shown in Fig 3 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...

Page 6: ...6 C10772 Fig 3 Roof Curb Details 48TC 16 ...

Page 7: ...AUTION Step 6 Rig and Place Unit When the unit is ready to be rigged and no longer will be lifted by a fork truck the wood protector under the basepan must be removed Remove 4 screws from each base rail Wood protector will drop to the ground See instructions on the unit base rails Keep unit upright and do not drop Spreader bars are required Rollers may be used to move unit across a roof Level by u...

Page 8: ...ctions on page 17 NOTE If gas and or electrical connections are not going to occur at this time tape or otherwise cover the fittings so that moisture does not get into the building or conduit in the interim Remove all shipping materials and top skid Remove extra center post from the condenser end of the unit so that the condenser end of the unit matches Figs 26 and 27 Recycle or dispose of all shi...

Page 9: ...ped in knock down form and assembled to a metal support tray using plastic stretch wrap Located in the return air compartment the assembly s metal tray is attached to the basepan and also attached to the damper using two plastic tie wraps 2 To gain access to the hood remove the filter access panel See Fig 9 3 Locate the 2 screws holding the metal tray to the basepan and remove In order to remove t...

Page 10: ...er in place 4 Insert the hood divider between the hood sides See Figs 13 and 14 Secure hood divider with 3 screws on each hood side The hood divider is also used as the bottom filter rack for the aluminum filter 5 Attach the post that separates the filters with the screws provided 6 Open the filter clips which are located underneath the hood top Insert the aluminum filters into the bottom filter r...

Page 11: ...ata 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 basepan factory option or accessor...

Page 12: ...ap drip leg and a ground joint union A pressure regulator valve may also be required to convert gas pressure from pounds to inches of pressure 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 i...

Page 13: ...nd joint union Check for gas leaks at the field installed and factory installed gas lines after all piping connections have been completed Use soap and water solution or method specified by local codes and or regulations FIRE OR EXPLOSION HAZARD Failure to follow this warning could result in personal injury death and or property damage S Connect gas pipe to unit using a backup wrench to avoid dama...

Page 14: ...ith 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 conform with the limitations of minimum 63_F 33_C rise Field Power Supply For those units without through the curb power conduit must be used to route the main power from the condenser end via th...

Page 15: ...indicated on unit nameplate See Table 10 On 3 phase units voltages between phases must be balanced within 2 and the current within 10 Use the formula shown in the legend for Table 10 see Note 2 on page 45 to determine the percent of voltage imbalance All units except 208 230 v units are factory wired for the voltage shown on the nameplate If the 208 230 v unit is to be connected to a 208 v power s...

Page 16: ...ehind the convenience outlet access is through the panel beneath the control box See Fig 32 The primary leads to the convenience outlet transformer are not factory connected Selection of primary power source is a customer option If local codes permit the transformer primary leads can be connected at the line side terminals on the unit mounted non fused disconnect this will provide service power to...

Page 17: ...anch Circuits for use of convenience outlets WARNING Installing Weatherproof Cover A weatherproof while in use cover for the factory installed convenience outlets is now required by UL standards This cover cannot be factory mounted due its depth it must be installed at unit installation For shipment the convenience outlet is covered with a blank cover plate The weatherproof cover kit is shipped in...

Page 18: ...nit side panel A hole must be field cut in the main control box bottom on the left side so the 24 v control connections can be made Connect the control power conduit to the unit control box at this hole Units without Thru Base Connections 1 Install power wiring conduit through side panel open ings Install conduit between disconnect and control box 2 Install power lines to terminal connections as s...

Page 19: ...ntrol box after removing one of the two knockouts in the corner of the box Use a connector at the control box to protect the wire as it passes into the control box Pull the wires over to the terminal strip at the upper left corner of the Central Terminal Board CTB Use the connector at the control box and the wire tie to take up any slack in the thermostat wire to ensure that it will not be damaged...

Page 20: ... slack in the humidistat cable to ensure that it will not be damaged by contact with the condenser coil see Fig 39 5 Use wire nuts to connect humidistat cable to two PINK leads in the low voltage wiring as shown in Fig 42 To connect the Thermidistat device 33CS2PPRH 01 1 Route the Thermidistat multi conductor thermostat cable field supplied through the bushing the unit s louvered end panel see Fig...

Page 21: ...t 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 43 Typical Rooftop Unit with Humidi MiZer Adaptive Dehumidification System with EDGE Pro Thermidistat Device 48TC 16 ...

Page 22: ...tral Terminal Board CTB see Fig 45 Factory wiring is completed through harnesses connected to the CTB Field connections are made at a 16 pole terminal block TB3 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 F...

Page 23: ...23 C11202 Fig 46 PremierLink Wiring Schematic 48TC 16 ...

Page 24: ...24 C11203 Fig 47 PremierLink Wiring Schematic with Humidi MiZerR 48TC 16 ...

Page 25: ...2 has no internal logic device 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 TB3 locate...

Page 26: ...n bus OAQ Outdoor Air Quality CO2 CMPSAFE Compressor Safety RH Relative Humidity FILTER Dirty Filter Switch SFS Supply Fan Status Table 5 Thermostat Mode TB3 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 Disc...

Page 27: ...the CTB s THERMOSTAT connection strip for these Connect the thermostat s Y1 Y2 W1 W2 and G terminals to PremierLink TB3 as shown in Fig 53 If the 48TC 16 unit is equipped with factory installed smoke detector s disconnect the factory BLU lead at TB3 6 Y2 before connecting the thermostat Identify the BLU lead originating at CTB DDC 1 disconnect at TB3 6 and tape off Confirm that the second BLU lead...

Page 28: ...Sensor 33ZCSENCO2 Typical Wiring Diagram Wiring the 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...

Page 29: ...hen the sensor is properly mounted Avoid corner locations Allow at 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...

Page 30: ...figuration screens and on unit alarm sequence Supply Fan Status Switch The PremierLink control can monitor supply fan operation through a field supplied installed differential pressure switch This sequence will prevent or interrupt operation of unit cooling heating and economizer functions until the pressure switch contacts are closed indicating proper supply fan operation Install the differential...

Page 31: ...dividual conductors must be insulated with PVC PVC nylon vinyl Teflon or polyethylene An aluminum polyester 100 foil shield and an outer jacket of PVC PVC nylon chrome vinyl or Teflon with a minimum operating temperature range of 20_C to 60_C is required Do not run communication wire in the same conduit as or next to any AC voltage wiring The communication bus shields must be tied together at each...

Page 32: ... controller 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 popu...

Page 33: ...33 C11204 Fig 67 RTU Open System Control Wiring Diagram 48TC 16 ...

Page 34: ...34 C11205 Fig 68 RTU Open System Control Wiring Diagram with Humidi MiZerR 48TC 16 ...

Page 35: ...re 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 Sensor On FIOP equipped 48TC 16 unit the unit is supplied with a supply air temperature SAT sensor 33ZCSENSAT This sensor is a tubular probe type approx 6 inches 12 7 mm in length It is a nominal 10 k ohm thermist...

Page 36: ...mper J20 3 SET C08461 Fig 70 RTU Open T 56 Sensor Connections Connect T 59 The T 59 space sensor requires a separate isolated power supply of 24 VAC See Fig 71 for internal connections at the T 59 Connect the SEN terminal BLU to RTU Open J20 1 Connect the COM terminal BRN to J20 2 Connect the SET terminal STO or BLK to J20 3 OR SET SEN OPB COM PWR BLU SPT BLK STO 24 VAC SENSOR WIRING POWER WIRING ...

Page 37: ...ons Space Relative Humidity Sensor or Humidistat Humidi MiZerR Control Wiring In units equipped with the Humidi MiZer option there are two pink PNK wires loose in the control box used to control the dehumidification function of the unit These pink wires are meant to be tied to a space humidistat or thermidistat on an electromechanical unit On RTU Open equipped units these pink wires must be connec...

Page 38: ... 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 65 and Fig 67 or Fig 68 for wire terminations at J5 Fan Status The fan status accessory is a field installed accessory This accessory detects when the indoor fan is blowing air W...

Page 39: ...See Fig 76 and 77 for protocol switch settings and address switches The 3rd party connection to the RTU Open is through plug J19 See Fig 78 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 PROTOCOL...

Page 40: ...See Form 48 50HCTQ 01T Appendix A for navigation and screen content Virtual BACview Virtual BACview is a freeware computer program that functions as the BACview6 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 identically to the handheld RTU Open Trouble...

Page 41: ...roller Integration Guide Catalog No 11 808 428 01 for details on configuration and troubleshooting of connected networks Have a copy of these manuals available at unit start up Outdoor Air Enthalpy Control PNO 33CSENTHSW The enthalpy control 33CSENTHSW is available as a field installed accessory to be used with the EconoMi er2 damper system The outdoor air enthalpy sensor is part of the enthalpy c...

Page 42: ...udes a controller housing a printed circuit board and a clear plastic cover The controller can be connected to one or two compatible duct smoke sensors The clear plastic cover is secured to the housing with a single captive screw for easy access to the wiring terminals The controller has three LEDs for Power Trouble and Alarm and a manual test reset button all located on the cover face Sensor Modu...

Page 43: ... The controller is located on a bracket to the right of the return filter accessed through the lift off filter panel Smoke Detector Sensor C08245 Fig 83 Typical Supply Air Smoke Detector Sensor Location Return Air without Economizer The sampling tube is located across the return air opening on the unit basepan See Fig 86 The holes in the sampling tube face downward into the return air stream The s...

Page 44: ...perating position using screws from Step 1 Make sure the sampling tube connection is on the bottom and the ex haust tube is on the top See Fig 86 5 Connect the flexible tube on the sampling inlet to the sampling tube on the basepan Controller Screws Flexible Exhaust Tubes Sampling Tube C10331 Fig 85 Return Air Detector Shipping Position Sampling Tube C10332 Fig 86 Return Air Sensor Operating Posit...

Page 45: ...190 MED 28 2 35 30 186 32 40 34 190 HIGH 34 4 40 37 198 38 2 45 41 202 Legend and Notes for Table 10 LEGEND BRKR Circuit breaker CO Convenience outlet DISC Disconnect FLA Full load amps IFM Indoor fan motor LRA Locked rotor amps MCA Minimum circuit amps P E Power exhaust PWRD CO Powered convenient outlet UNPWR CO Unpowered convenient outlet NOTES 1 In compliance with NEC requirements for multimoto...

Page 46: ...t be installed before unit Thru base connection kit must be installed before unit is set on curb Manual outside air damper Two Position motorized outside air damper EconoMi er IV with control and integrated barometric relief EconoMi er2 without control for external signal and integrated barometric relief Barometric relief Power Exhaust Differential dry bulb sensor EconoMi er IV Outdoor enthalpy se...

Page 47: ...47 48TC 16 ...

Page 48: ...W Morris St D Indianapolis IN 46231 Printed in U S A Edition Date 05 11 Manufacturer reserves the right to change at any time specifications and designs without notice and without obligations Catalog No 48TC 14SI Replaces 48TC 11SI 48TC 16 ...

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