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Carrier WeatherMaster 48HC Series, Installation Instructions Manual

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Carrier WeatherMaster 48HC Series Installation Instructions Manual Download Page 32

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Summary of Contents for WeatherMaster 48HC Series

Page 1: ...ON ENTHALPY SETTINGS CHECKOUT TROUBLESHOOTING PremierLink Factory Option 51 RTU Open Controller Factory Installed Option 51 Smoke Detectors 51 COMPLETING RETURN AIR SMOKE SENSOR INSTALLATION ADDITIONAL APPLICATION DATA Step 14 Adjust Factory Installed Options 53 SMOKE DETECTORS ECONOMI ER IV OCCUPANCY SWITCH Step 15 Install Accessories 53 Step 16 Check Belt Tension 53 BELT FORCE DEFLECTION METHOD ...

Page 2: ...SONAL 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 CARBON MONOXIDE POISONING HAZARD Failure to follow instructions could result in severe personal injury or death due to carbon ...

Page 3: ...he units covered in this document WARNING FIRE HAZARD Failure to follow this warning could result in severe personal injury and or property damage Manifold pressure tap set screw must be tightened and 1 8 in NPT pipe plug must be installed to prevent gas leaks MANIFOLD GAS VALVE MANIFOLD PRESSURE TAP SET SCREW Table 1 Rated Indoor Airflow CFM MODEL NUMBER FULL LOAD AIRFLOW CFM 48HC A B F04 1050 48...

Page 4: ...trols 0 Base Electromechanical Controls 1 PremierLinkTM 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 Access Panels 4 Hinged Access Panels and Unp...

Page 5: ...5 Fig 2 48HC 04 06 Units Built On and After 4 15 2019 Downloaded from ManualsNet com search engine ...

Page 6: ...6 Fig 3 48HC 04 06 Units Built Prior to 4 15 2019 Downloaded from ManualsNet com search engine ...

Page 7: ...7 Fig 4 48HC 04 06 Corner Weights and Clearances Downloaded from ManualsNet com search engine ...

Page 8: ...8 Fig 5 48HC 04 06 Base Rail Details Downloaded from ManualsNet com search engine ...

Page 9: ...9 Fig 6 48HC 04 06 Thru the Base Charts Downloaded from ManualsNet com search engine ...

Page 10: ... are shown in Table 2 Step 2 Plan for Sequence of Unit Installation The support method used for this unit will dictate different se quences for the steps of unit installation For example on curb mounted units some accessories must be installed on the unit be fore the unit is placed on the curb Review the following for rec ommended sequences for installation steps CURB MOUNTED INSTALLATION 1 Instal...

Page 11: ...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 AIR RETURN AIR ROOFING ...

Page 12: ...rk to unit Fabricate supply ductwork so that the cross sectional dimensions are equal to or greater than the unit supply duct opening dimen sions for the first 18 in 458 mm of duct length from the unit basepan Insulate and weatherproof all external ductwork joints and roof openings with counter flashing and mastic in accordance with ap plicable codes Ducts passing through unconditioned spaces must...

Page 13: ...t without factory installed economizer or return air smoke detector option may be field converted to horizontal ducted configuration To convert to horizontal configuration remove screws from side duct opening covers see Fig 10 and remove covers Use the screws to install the covers on vertical duct openings with the insulation side down The panels must be inserted into the notches on the basepan to...

Page 14: ... two plastic tie wraps 2 To gain access to the hood remove the filter access panel See Fig 13 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 14 Be careful to not damage any wiring or cut tie wraps securing any wiring 4 Carefully lift the hood assembly with metal tray through the filter access...

Page 15: ...er into position past the open filter clips Close the filter clips to lock the filter into place See Fig 17 6 Caulk the ends of the joint between the unit top panel and the hood top 7 Replace the filter access panel Fig 15 Indoor Coil Access Panel Relocation Fig 16 Economizer Hood Construction Fig 17 Economizer Filter Installation Step 9 Units with Hinged Panels Only Relocate latch shipped inside ...

Page 16: ...t gas valve connection when unit is operating at high fire flow rate The gas supply line can approach the unit in three ways horizon tally from outside the unit across the roof through curb under unit basepan accessory kit required or through unit basepan factory option or accessory kit required Consult accessory kit installation instructions for details on these installation methods Observe clear...

Page 17: ...h of 16 in 406 mm field supplied to the street elbow and extend it through the ac cess panel at the gas support bracket See Fig 24 Fig 24 Gas Line Piping for 3 to 5 Ton Units Only Other hardware required to complete the installation of the gas supply line includes a manual shutoff valve a sediment trap drip leg and a ground joint union A pressure regulator valve may also be required to convert gas...

Page 18: ...ith local and national plumbing and gas codes before connecting 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 Pres sure test the gas supply piping system at pressures equal to or le...

Page 19: ...eration of the convenience outlet is desired connect the source leads to the load side of the unit disconnect On a unit without a unit mounted disconnect connect the source leads to compressor contactor C and indoor fan contactor IFC pressure lugs with unit field power leads See Convenience Outlets on page 21 for power transformer connections The field power wires are connected to the unit at line...

Page 20: ...painted cover horizontally with the red arrow pointing to the left 10 Secure the handle to the painted cover with 2 screws and lock washers supplied 11 Engaging the shaft into the handle socket re install 3 hex screws on the NFD enclosure 12 Re install the unit front panel Fig 33 NFD Enclosure Location Fig 34 NFD Handle and Shaft Assembly Field Install the HACR Shaft and Handle 1 Remove unit front...

Page 21: ...ss required by local codes All field wiring must comply with the NEC and local requirements All units except 208 230v units are factory wired for the voltage shown on the nameplate If the 208 230v unit is to be connected to a 208v power supply the control transformer must be rewired by moving the black wire with the 1 4 in female spade connector from the 230v connection and moving it to the 200v 1...

Page 22: ...thods will result in the conve nience outlet circuit being de energized when the unit disconnect or HACR switch is open See Fig 39 Fig 39 Powered Convenience Outlet Wiring Using Unit Mounted Convenience Outlets Units with unit mounted convenience outlet circuits will often re quire that two disconnects be opened to de energize all power to the unit Treat all units as electrically energized until t...

Page 23: ...unit control box at this hole UNITS WITHOUT THRU BASE CONNECTIONS ELEC TRICAL CONNECTIONS 1 Install power wiring conduit through side panel openings Install conduit between disconnect and control box 2 Install power lines to terminal connections as shown in Fig 31 on page 20 Voltage to compressor terminals during operation must be within voltage range indicated on unit nameplate On 3 phase units v...

Page 24: ...routing power and control wiring Fig 43 Field Control Wiring Raceway HEAT ANTICIPATOR SETTINGS Set heat anticipator settings at 0 14 amp for the first stage and 0 14 amp for second stage heating when available HUMIDI MIZER CONTROL CONNECTIONS Humidi MiZer Space RH Controller NOTE The Humidi MiZer system is a factory installed option which is only available for units equipped with belt drive motors...

Page 25: ...at multi conductor thermostat cable field supplied through the hole provided in the unit corner post 2 Feed wires through the raceway built into the corner post see Fig 43 to the 24 v barrier located on the left side of the con trol 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 dehumidif...

Page 26: ...rough a room thermostat set for fan auto 45 seconds after ignition occurs the indoor fan mo tor 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 45 second delay to 5 seconds less than the time to tip the limit For example i...

Page 27: ...h Fault Gas valve and igniter Off Indoor fan and inducer On Limit switch closed or heat call W Off High temperature limit switch is open Check the operation of the indoor evaporator fan motor Ensure that the supply air temperature rise is within the range on the unit nameplate Check wiring and limit switch operation 3 Flashes Flame Sense Fault Indoor fan and inducer On Flame sense normal Power res...

Page 28: ...ol Wiring Diagram Fig 51 48HC Control Box Component Locations with ComfortLink Controls LOCKING TAB CONNECTOR OVERCURRENT FUSE PROTECTION REDUNDANT GAS VALVE RELAY LOCKING TAB CONNECTOR SPADE CONNECT IGNITOR STATUS LED Downloaded from ManualsNet com search engine ...

Page 29: ...29 Fig 52 48HC 04 06 ComfortLink Control Wiring Diagram Downloaded from ManualsNet com search engine ...

Page 30: ...30 Fig 53 48HC 04 06 ComfortLink Power Wiring Diagram with Humidi MiZer System 208 230 1 60 Downloaded from ManualsNet com search engine ...

Page 31: ...31 Fig 54 48HC 04 06 ComfortLink Power Wiring Diagram with Humidi MiZer 208 230 3 60 460 3 60 Downloaded from ManualsNet com search engine ...

Page 32: ...32 Fig 55 48HC 04 06 ComfortLink Power Wiring Diagram with Humidi MiZer 575 3 60 Downloaded from ManualsNet com search engine ...

Page 33: ...33 Fig 56 48HC 04 06 Control Wiring Diagram Downloaded from ManualsNet com search engine ...

Page 34: ...34 Fig 57 48HC 04 06 Electromechanical Power Wiring Diagram 208 230 1 60 Units Downloaded from ManualsNet com search engine ...

Page 35: ...35 Fig 58 48HC 04 06 Power Wiring Diagram 208 230 3 60 460 3 60 Units Downloaded from ManualsNet com search engine ...

Page 36: ...36 Fig 59 48HC 04 06 Power Wiring Diagram 575 3 60 Units Downloaded from ManualsNet com search engine ...

Page 37: ...37 Fig 60 48HC 04 06 Control Wiring Diagram with Humidi MiZer System Downloaded from ManualsNet com search engine ...

Page 38: ...38 Fig 61 48HC 04 06 Electromechanical Power Wiring Diagram with Humidi MiZer System 208 230 1 60 Units Downloaded from ManualsNet com search engine ...

Page 39: ...39 Fig 62 48HC 04 06 Power Wiring Diagram with Humidi MiZer System 208 230 3 60 460 3 60 Units Downloaded from ManualsNet com search engine ...

Page 40: ...40 Fig 63 48HC 04 06 Power Wiring Diagram with Humidi MiZer System 575 3 60 Units Downloaded from ManualsNet com search engine ...

Page 41: ...al 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 Rating at 30 vac maximum power from Class 2 input only 1 5A run 3 5A in...

Page 42: ...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 Actuator Output Common ACT 24v 24 vac Damper Actuator 24 vac Source NA AUX2 OCC E GND EXH1 AUX1 O Y2 Y1 Y2 O Y1 O C R 50048848 002 Rev A NA A2 OCC EX A1 Y2I Y2O Y1I Y1O C R MAT MAT OAT OAT S BUS S BUS IAQ 2 10 IAQCOM IAQ 24V ACT 2 10 ACT ...

Page 43: ...on Buttons To use the keypad when working with Setpoints System and Ad vanced Settings Checkout tests and Alarms 1 Navigate to the desired menu 2 Press the Enter button to display the first item in the currently displayed menu 3 Use the and buttons to scroll to the desired parameter 4 Press the Enter button to display the value of the cur rently displayed item 5 Press the button to increase change...

Page 44: ...IN OFF ON OFF SECOND STAGE COOLING DEMAND Y2 IN Y2 I signal from space thermostat or unitary controller for second stage cooling ON 24 vac on terminal Y2 I OFF 0 vac on terminal Y2 I COOL Y2 OUT OFF ON OFF SECOND STAGE COOLING RELAY OUTPUT Cool Stage 2 Relay Output to mechanical cooling Y2 OUT terminal MA TEMP _ _ _ F or _ _ _ C 40 F to 150 F 40 C to 66 C SUPPLY AIR TEMPERATURE Cooling Mode Displa...

Page 45: ...ckout At or below the set point the Y1 O and Y2 O will not be energized on the controller DRYBLB SET 63 F 17 C 48 F to 80 F 9 C to 27 C increment by 1 degree OA DRY BULB TEMPERATURE CHANGEOVER SETPOINT Dry bulb set point will only appear if using dry bulb changeover Set point determines where the economizer will assume outdoor air temperature is good for free cooling e g at 63 F unit will economiz...

Page 46: ... The value is found on the nameplate label for the specific unit AUX1 OUT NONE NONE ERV EXH2 SYS Select OUTPUT for AUX1 O relay NONE not configured output is not used ERV Energy Recovery Ventilator EXH2 second damper position 24 vac out for second exhaust fan SYS use output as an alarm signal OCC INPUT INPUT or ALWAYS OCCUPIED MODE BY EXTERNAL SIGNAL When using a setback thermostat with occupancy ...

Page 47: ...pen position Exhaust fan contacts enable during the DAMPER OPEN test Make sure to pause in the mode to allow exhaust contacts to energize due to the delay in the system DAMPER CLOSE N A N A Positions damper to the fully closed position CONNECT Y1 O N A N A Closes the Y1 O relay Y1 O CONNECT Y2 O N A N A Closes the Y2 O relay Y2 O CONNECT AUX1 O N A N A Energizes the AUX output If Aux setting is NO...

Page 48: ...R Actuator has failed or become disconnected check for stall over voltage under voltage and actuator count Replace actuator if damper is movable and supply voltage is between 21 6 V and 26 4 V Check actuator count on STATUS menu FREEZE ALARM N A N A Check if outdoor temperature is below the LOW Temp Lockout on set point menu Check if Mixed air temperature on STATUS menu is below the Lo Set point o...

Page 49: ... AIR GOOD TO ECONOMIZE Y1 I Y2 I FAN SPEED Y1 O Y2 O OCCUPIED UNOCCUPIED Below CO2 set No Off Off High 0 v Off 0 v Off VENTMIN Closed On Off High 24 v On 0 v Off VENTMIN Closed On On High 24 v On 24 v On VENTMIN Closed Yes Off Off High 0 v Off 0 v Off VENTMIN Closed On Off High 0 v Off 0 v Off VENTMIN to Full Open Closed to Full Open On On High 24 v On 0 v Off VENTMIN to Full Open Closed to Full O...

Page 50: ...TMIN to Full Open Closed to Full Open On On High 24 v On 0 v Off VENTMIN to Full Open Closed to Full Open Above CO2 set No Off Off High 0 v Off 0 v Off VENTMIN to VENTMAX Closed On Off High 24 v On 0 v Off VENTMIN L to VENTMAX Closed On On High 24 v On 24 v On VENTMIN H to VENTMAX Closed Yes Off Off High 0 v Off 0 v Off VENTMIN L to VENTMAX Closed On Off High 0 v Off 0 v Off VENTMIN to Full Open C...

Page 51: ...ests 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 oper...

Page 52: ...am pling tube on the basepan ADDITIONAL APPLICATION DATA Refer to the application data document Factory Installed Smoke Detectors for Small and Medium Rooftop Units 2 to 25 Tons for discussions on additional control features of these smoke detectors including multiple unit coordination Fig 70 Return Air Smoke Detector Shipping Position Fig 71 Completing Installation of Return Air Smoke Sensor RETU...

Page 53: ...Link Controls Louvered hail guard Motormaster head pressure controls Phase monitor control Refer to separate installation instructions for information on in stalling these accessories Step 16 Check Belt Tension Measure the belt span length as shown in Fig 73 Calculate the re quired deflection by multiplying the belt span length by 1 64 For example if the belt span length is 32 inches 32 x 1 64 1 2...

Page 54: ...nual for detailed Pre Start and Start Up instruc tions Download the latest versions from HVAC Partners www hvacpartners com 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...

Page 55: ... _____ 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 _____ Verify that scro...

Page 56: ...________ 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 ...

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