Carrier WeatherMaker 48TC A/B07 Series Installation Instructions Manual Download Page 56

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Fig. 81 —

V-Belt Force Label

BELT TENSION METHOD
Requires belt tension gage that measures tension in belt in units of

lbs force.

Fig. 82 —

Belt Drive Motor Mounting

Pre-Start and Start-Up

This completes the mechanical installation of the unit. Refer to the

unit’s Service Manual for detailed Pre-Start and Start-Up instruc

tions. Download the latest versions from HVAC Partners

(www.hvacpartners.com).

Troubleshooting the Ultra Tech™ Compressor

The Ultra Tech

compressor’s molded plug should be used at all

times. The maximum power is 5A.
MODULATION CONTROL INPUT SPECIFICATIONS
The compressor will modulate from part load to full load when the

voltage supplied to the molded plug is 18 to 28vdc or 18 to 28 vac

rectified to vdc. The compressor will modulate from full load to

part load when the current in the circuit drops below 0.9 MA. See

Table 24 and Fig. 83 for details.

TORQUE ALL SHEAVE SET SCREWS TO 110-130 in. lbs

SET
SCREW

STRAIGHT
EDGE

BELT SPAN

BELT DEFLECTION FORCE - SEE TABLE 1

DEFLECTION = BELT SPAN

Table 1

Table 2

BELT

CROSS

SECTION

SMALLEST

SHEAVE

DIAMETER

BELT DEFLECTION FORCE (LBS)

UNNOTCHED

BELTS

NOTCHED BELTS

USED

NEW

USED

NEW

A, AX

3.0-3.6

3.7

5.5

4.1

6.1

3.8-4.8

4.5

6.8

5.0

7.4

5.0-7.0

5.4

8.0

5.7

8.4

B, BX

3.4-4.2

—

4.9

7.2

4.4-5.6

5.3

7.9

7.1

10.5

5.8-8.6

6.3

9.4

8.5

12.6

BELT CONDITION

TENSION FORCE IN BELT (LBS)

New

100

Used

1. UltraTech™ is a trademark of Emerson Climate Technologies, Inc.

BLOWER PULLEY

V-BELT

MOTOR
PULLEY

MOTOR

MOTOR MOUNTING

PLATE

MOUNTING

BOLTS (4)

Table 24 —

Troubleshooting Ultra Tech Compressor

STAGE

CAPACITY

METERING

LIQUID LINE

SOLENOID

COMPRESSOR

UNLOADER

FOR ULTRA TECH

COMPRESSOR

TROUBLESHOOTING

(COMPRESSOR CURRENT)

FOR LIQUID LINE SOLENOID

VALVE TROUBLESHOOTING

(TOP EVAPORATOR COIL

TEMPERATURE)

Part Load

(66%)

TXV

Closed (De-

energized)

De-energized

Approx. 80% or less

Top section of the evaporator coil

will not be cold (U-bend tubes)

Y1+Y2

Full Load

(100%)

TXV+Fixed Open (Energized)

Energized

100%

Top section of the evaporator coil

will be cold (U-bend tubes)

Summary of Contents for WeatherMaker 48TC A/B07 Series

Page 1: ...VENIENCE OUTLETS ALL UNITS FACTORY OPTION THRU BASE CONNECTIONS ELECTRICAL CONNECTIONS SIZE 07 14 FACTORY OPTION THRU BASE CONNECTIONS ELECTRICAL CONNECTIONS SIZE 16 HUMIDI MIZER CONTROL CONNECTIONS EconoMi er X Factory Installed Option 41 PRODUCT DESCRIPTION SYSTEM COMPONENTS SPECIFICATIONS INPUTS OUTPUTS ENVIRONMENTAL ECONOMIZER MODULE WIRING DETAILS S BUS SENSOR WIRING CO2 SENSOR WIRING INTERFA...

Page 2: ... to pressure greater than 0 5 psig it must be replaced before use When pressure testing field supplied gas piping at pressures of 0 5 psig or less a unit connected to such piping must be isolated by closing the man ual gas valve s DANGER ELECTRICAL SHOCK HAZARD Failure to follow this warning will result in personal injury or death Before performing service or maintenance operations on unit turn of...

Page 3: ...tened and 1 8 in NPT pipe plug must be installed to prevent gas leaks CAUTION PERSONAL INJURY HAZARD Failure to follow this caution may result in personal injury Sheet metal parts may have sharp edges or burrs Use care and wear appropriate protective clothing safety glasses and gloves when handling parts and servicing air conditioning equipment WARNING FIRE OR EXPLOSION HAZARD Failure to follow th...

Page 4: ...l Al Cu Cu J Al Al E coat Al Cu K E coat Al Al Al Cu L E coat Al Al E coatAl Cu T Al Al Al Cu Louvered Hail Guard U Al Al Cu Cu Louvered Hail Guard V Al Al E coat Al Cu Louvered Hail Guard W E coat Al Al Al Cu Louvered Hail Guard X E coat Al Al E coat Al Cu Louvered Hail Guard Voltage 1 575 3 60 3 208 230 1 60 5 208 230 3 6 460 3 60 Design Revision Factory Design Revision Base Unit Controls 0 Elec...

Page 5: ...5 Fig 2 Dimensional Drawing for Units Built On and After 4 15 19 Size 07 ...

Page 6: ...6 Fig 3 Dimensional Drawing for Units Built Prior To 4 15 19 Size 07 ...

Page 7: ...7 Fig 4 Unit Corner Weights and Clearances Size 07 ...

Page 8: ...8 Fig 5 Base Rail Details Size 07 ...

Page 9: ...9 Fig 6 Thru the Base Charts Size 07 ...

Page 10: ...10 Fig 7 Unit Dimensional Drawing Size 08 09 12 ...

Page 11: ...11 Fig 7 Unit Dimensional Drawing Size 08 09 12 ...

Page 12: ...12 Fig 8 Unit Dimensional Drawing Size 14 ...

Page 13: ...13 Fig 8 Unit Dimensional Drawing Size 14 cont ...

Page 14: ...14 Fig 9 Unit Dimensional Drawing Size 16 ...

Page 15: ...15 Fig 9 Unit Dimensional Drawing Size 16 cont ...

Page 16: ...es 07 14 only locate mechanical draft system flue assem bly at least 4 ft 1 2 m from any opening through which combus tion products 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 adjacent unit s fresh air in take hood if within 3 ft 0 91 m of same elevation or per local code When unit is located ...

Page 17: ...nsions are shown in Fig 12 14 Assemble and install accessory roof curb in accordance with instructions shipped with the curb Curb should be level This is necessary for unit drain to function properly Unit leveling toler ances are shown in Fig 11 Refer to Accessory Roof Curb Instal lation Instructions for additional information as required Fig 11 Unit Leveling Tolerances NOTE The gasketing of the u...

Page 18: ...UTHORIZATION OF CARRIER CORPORATION 1 DEC 2 DEC 3 DEC ANG MATERIAL AUTHORIZATION NUMBER TITLE 1041738 CURB ASY ROOF ENGINEERING 004 007 ENGINEERING REQUIREMENTS SIZE DRAWING NUMBER REV T 005 Y 002 DRAFTER CHECKER D 48TC400427 B WEIGHT MMC 06 17 11 SHEET 5 OF 5 SURFACE FINISH MFG PURCH MODEL INTERNAL USE ONLY NEXT DRAWING SCALE DISTRIBUTION PURCH N A MMC NOTES 1 ROOFCURB ACCESSORY IS SHIPPED DISASS...

Page 19: ...RT WITHOUT THE WRITTEN AUTHORIZATION OF CARRIER CORPORATION 1 DEC 2 DEC 3 DEC ANG MATERIAL AUTHORIZATION NUMBER TITLE 1029120 CURB ASY ROOF ENGINEERING MANUFACTURING ENGINEERING REQUIREMENTS SIZE DRAWING NUMBER REV T 005 Y 002 DRAFTER CHECKER D 50HJ405012 C WEIGHT MMC 12 16 09 SHEET 5 OF 5 SURFACE FINISH MFG PURCH MODEL INTERNAL USE ONLY NEXT DRAWING SCALE DISTRIBUTION PURCH N A NOTES 1 ROOFCURB A...

Page 20: ...20 Fig 14 48TC 16 Roof Curb Details ...

Page 21: ... size units size 16 units do not require spreader bars Rollers may be used to move unit across a roof Level by using unit frame as a reference See Table 2 and Fig 15 for additional information Lifting holes are provided in base rails as shown in Fig 15 Refer to rigging instructions on unit Rigging materials under unit cardboard or wood to prevent base pan damage must be removed PRIOR to placing th...

Page 22: ...e po sitioned as shown in Fig 16 Maintain the 151 2 in 394 mm and 85 8 in 220 mm clearances and allow the 225 16 in 567 mm di mension to float if necessary Fig 16 Retrofit Installation Dimensions Size 16 Shown If the alternative condensate drain location through the bottom of the unit is used in conjunction with a retrofit curb the hole in the curb must be moved 12 5 in 320 mm towards the duct end...

Page 23: ...o the flanges Insulate and weatherproof all external ductwork joints and roof or build ing openings with counter flashing and mastic in accordance with applicable codes Do not cover or obscure visibility to the unit s informative data plate when insulating horizontal ductwork Fig 18 Horizontal Conversion Panels Fig 19 Location of Notches Fig 20 Horizontal Duct Panels In Place IMPORTANT If the unit...

Page 24: ...hed to the damper using two plastic tie wraps 2 To gain access to the hood remove the filter access panel See Fig 21 3 Locate the 2 screws holding the metal tray to the basepan and remove Locate and cut the 2 plastic tie wraps securing the assembly to the damper see Fig 22 Be careful to not damage any wiring or cut tie wraps securing any wiring The indoor coil access panel will be used as the top ...

Page 25: ...ch hood side The hood divider is also used as the bottom 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 fil ter clips Close the filter clips to lock the filter into place See Fig 26 Fig 24 Indoor Coil Access Panel Relocation Size 07 ...

Page 26: ...for gas burning appliances This unit is factory equipped for use with natural gas NG fuel at elevations up to 2000 ft 610 m above sea level Unit may be field converted for operation at elevations above 2000 ft 610 m and or for use with liquefied petroleum LP fuel See ac cessory kit installation instructions regarding these accessories NOTE Furnace gas input rate on rating plate is for installation...

Page 27: ...uctions for details on these installation methods Observe clearance to gas line components per Fig 32 Fig 32 Gas Piping Guide with Accessory Thru the Curb Service Connections FACTORY OPTION THRU BASE CONNECTIONS GAS CONNECTIONS SIZES 07 14 This service connection kit consists of a 1 2 in NPT gas adapter fitting brass a 1 2 in electrical bulkhead connector and a 3 4 in electrical bulkhead connector...

Page 28: ...nd discard the wire tie on the gas fitting Hand tighten the fitting if it has loosened in transit 3 Remove connector plate assembly from the L bracket and discard the L bracket but retain the washer head screws and the gasket located between the L bracket and the connector plate assembly NOTE Take care not to damage the gasket as it is reused in the following step 4 Place the gasket over the embos...

Page 29: ...oes not block access to the unit s main control box or limit the required working space in front of the control box Fig 40 Gas Piping with Thru Curb Accessory Fig 41 Gas Piping with Thru Curb Accessory Alternate Layout Fig 42 Gas Piping Thru Base Connections When installing the gas supply line observe local codes pertaining to gas pipe installations Refer to the NFPA 54 ANSI Z223 1 NFGC latest edi...

Page 30: ...a trap at least 4 in 102 mm deep and protect against freeze up If drain line is installed downstream from the external trap pitch the line away from the unit at 1 in per 10 ft 25 mm in 3 m of run Do not use a pipe size smaller than the unit connection 3 4 in Step 12 Make Electrical Connections NOTE Field supplied wiring shall conform with the limitations of minimum 63 F 33 C rise FIELD POWER SUPPL...

Page 31: ...is provided wrapped around compressor A second conduit is provided with factory installed powered conve nience outlet For those units that require conduit larger than 1 in it must be field supplied Fig 48 and 49 show the wire routings If the field disconnect is larger than 100A it must be attached to the unit using accessory CRDISBKT001A00 disconnect switch bracket see Fig 50 Follow the instructio...

Page 32: ...n necting field power wires to unit connection points Make field power connections directly to line connection pressure lugs only Fig 52 Disconnect Switch and Unit UNITS WITH FACTORY INSTALLED NON FUSED DIS CONNECT The factory installed optional non fused disconnect NFD switch is located in a weatherproof enclosure located under the main con trol box The manual switch handle and shaft are shipped ...

Page 33: ...aft into the handle socket re install 3 hex screws on the NFD enclosure 12 Re install the unit front panel Fig 55 Handle and Shaft Assembly for NFD Sizes 07 14 Fig 56 Handle and Shaft Assembly for NFD Size 16 UNITS WITHOUT FACTORY INSTALLED NON FUSED DISCONNECT When installing units provide a disconnect switch per NEC Na tional Electrical Code of adequate size Disconnect sizing data is provided on...

Page 34: ...ro mechanical controls the weatherproof cover kit is shipped in the unit s control box The kit includes the hinged cover a backing plate and gasket On units with a factory installed direct digital controller PremierLink or RTU Open the weath erproof cover kit is secured to the basepan underneath the control box See Fig 59 Disconnect All Power To Unit and Convenience Outlet Lock Out and Tag Out All...

Page 35: ... the bottom of the disconnect box For the load side wiring to the factory option disconnect route the wires through the hole on the right side of the disconnect Be sure to create a drip loop at least 6 inches long ALL UNITS Test the GFCI receptacle by pressing the TEST button on the face of the receptacle to trip and open the receptacle Check for proper grounding wires and power line phasing if th...

Page 36: ...quivalent single leads of different colors with minimum of seven leads see Fig 62 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 addi tional features which might require additional conductors in the cable For wire runs up to 50 ft 15 m use no 18 AWG Ameri can...

Page 37: ...e Cooling Heating ther mostat according to installation instructions included with the ac cessory If using an electronic thermostat configure it for non heat pump operation Locate the thermostat accessory on a solid wall in the conditioned space to sense average temperature in ac cordance with the thermostat installation instructions If the thermostat contains a logic circuit requiring 24 v power ...

Page 38: ...vice 33CS2PPRH 01 for Size 07 14 1 Route the Thermidistat multi conductor thermostat cable field supplied through the hole provided in the unit cor ner post 2 Feed wires through the raceway built into the corner post see Fig 63 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 Thermidista...

Page 39: ...39 Fig 69 48TC 07 14 Typical Humidi MiZer Adaptive Dehumidification System Humidistat Wiring ...

Page 40: ...40 Fig 70 48TC 16 Typical Humidi MiZer Adaptive Dehumidification System Humidistat Wiring ...

Page 41: ...and either a 20k outdoor air temperature sensor or S Bus enthalpy sensors Economizer Module The module is the core of the EconoMi er X system The module is mounted in the unit s control box and includes the user inter face for the system The W7220 economizer module provides the basic inputs and outputs to provide simple economizer control When used with the optional sensors the economizer module p...

Page 42: ...hree 3 S Bus sensors may be connected to the W7220 economizer module For outdoor air OA return air RA and discharge supply air DA 4 Binary Inputs 1 wire 24 vac common GND see page 44 for wiring details 24 vac power supply 20 to 30 vac 50 60Hz 100 VAClass 2 transformer OUTPUTS Actuator Signal 2 10 vdc minimum actuator impedance is 2k ohm bus two wire output for bus communicating actuators Exhaust f...

Page 43: ...AT 20k NTC and COM Mixed Air Temperature Sensor Polarity Insensitive Connection OAT OAT 20k NTC and COM Outdoor Air Temperature Sensor Polarity Insensitive Connection S BUS S BUS S BUS Sylk Bus 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 ...

Page 44: ...o return to the current menu parameter 10 Press the Menu Up Exit button to return to the previ ous menu MENU STRUCTURE Table 12 illustrates the complete hierarchy of menus and parame ters for the EconoMi er X system The Menus in display order are STATUS SET POINTS SYSTEM SETUP ADVANCED SETUP CHECKOUT ALARMS NOTE Some parameters in the menus use the letters MA or MAT indicating a mixed air temperat...

Page 45: ... of outdoor 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 F to 140 F 18 C to 60 C RETURN AIR TEMPERATURE Displays measured value of return air temperature from RAT sensor Displays _ _...

Page 46: ... dampers controlled by CFM 100 to 9990 cfm increment by 10 If OA MA RA and CO2 sensors 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 VENTMIN H is 2 8V ERV OAT SP 32 F 0 F to 50 F...

Page 47: ...nsor OA H CAL 0 RH 10 RH OUTSIDE AIR HUMIDITY CALIBRATION Allows for operator to adjust for an out of calibration humidity sensor RA T CAL 0 0 F 2 5 F RETURN AIR TEMPERATURE CALIBRATION Allows for the operator to adjust for an out of calibration temperature sensor RA H CAL 0 RH 10 RH RETURN AIR HUMIDITY CALIBRATION Allows for operator to adjust for an out of calibration humidity sensor DA T CAL 0 ...

Page 48: ...led or become disconnected check wiring then replace sensor if the alarm continues RA SYLK H ERR N A N A DA SYLK T 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...

Page 49: ...CUPIED 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 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 50: ...IGH 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 Y1 O Y2 O OCCUPIED UNOCCUPIED Below CO2 Set No OFF OFF HIGH 0v Off 0v Off VENTMIN Closed ON OFF HIGH 24v On 0v Off VENTMIN Closed ON ON HIGH 24v On 24v On VENTMIN Closed Yes OFF OFF HIGH 0v Off 0v Off VENTMIN Closed ON OFF HIGH 0v Off 0v Off VENTMIN to Full...

Page 51: ...ON ON HIGH 24v On 24v On VENTMIN to VENTMAX Closed Yes OFF OFF LOW 0v Off 0v Off VENTMIN to VENTMAX Closed ON OFF LOW 0v Off 0v Off VENTMIN to Full Open Closed to Full Open ON ON HIGH 24v On 0v Off VENTMIN to Full Open Closed to Full Open DEMAND CONTROLLED VENTILATION DCV OUTSIDE AIR GOOD TO ECONOMIZE Y1 I Y2 I FAN SPEED Y1 O Y2 O OCCUPIED UNOCCUPIED NO CO2 SENSOR NO OFF OFF LOW 0v Off 0v Off MIN ...

Page 52: ...W7220 does not control the supply directly but uses the following input status to determine the speed of the supply fan and controls the OAdamper to the required posi tion see Table 23 Table 23 Fan Speed The W heating mode is not controlled by the W7220 but it re quires the status to know where to position the OA damper for minimum position for the fan speed The 2 speed fan delay is available when...

Page 53: ...can all be performed at the time of installation 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 display 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 devic es e g sensors actuator to become operation...

Page 54: ...rn air smoke detectors require a relocation of the sensor module at unit installation See Fig 78 for the as shipped location COMPLETING INSTALLATION OF RETURN AIR SMOKE SENSOR 1 Unscrew the two screws holding the return air smoke detector assembly See Fig 79 Step 1 2 Save the screws 3 Turn the assembly 90 degrees and then rotate end to end Make sure that the elbow fitting is pointing down See Fig ...

Page 55: ...nsor DDC interface PremierLink controller Louvered hail guard Motormaster head pressure controls Phase monitor control Refer to separate installation instructions for information on in stalling these accessories Step 15 Check Belt Tension Measure the belt span length as shown in Fig 81 Calculate the re quired deflection by multiplying the belt span length by 1 64 For example if the belt span lengt...

Page 56: ...130 in lbs SET SCREW SET SCREW STRAIGHT EDGE BELT SPAN BELT DEFLECTION FORCE SEE TABLE 1 DEFLECTION BELT SPAN 64 Table 1 Table 2 BELT CROSS SECTION SMALLEST SHEAVE DIAMETER BELT DEFLECTION FORCE LBS UNNOTCHED BELTS NOTCHED BELTS USED NEW USED NEW A AX 3 0 3 6 3 7 5 5 4 1 6 1 3 8 4 8 4 5 6 8 5 0 7 4 5 0 7 0 5 4 8 0 5 7 8 4 B BX 3 4 4 2 4 9 7 2 4 4 5 6 5 3 7 9 7 1 10 5 5 8 8 6 6 3 9 4 8 5 12 6 BELT ...

Page 57: ...57 Fig 83 Ultra Tech Scroll Compressor Diagram ...

Page 58: ...ight to discontinue or change at any time specifications or designs without notice and without incurring obligations Catalog No 04 53480257 01 Printed in U S A Form 48TC 7 16 02SI Pg 58 5 2020 Replaces 48TC 7 16 01SI 2020 Carrier ...

Page 59: ...eck 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 _____ Verify that scroll compre...

Page 60: ..._____ 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 latent mode sub cooler by clo...

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