Carrier 48HC User Manual

48HC

Single Package Rooftop Gas Heating/Electric Cooling Unit with Puronr (R---410A) Refrigerant Sizes: 17, 20, 24, 28

Installation Instructions

NOTE: Read the entire instruction manual before starting the installation

TABLE OF CONTENTS

SAFETY CONSIDERATIONS 2....................

INSTALLATION 9...............................

Jobsite Survey 9................................

Step 1 -- Plan for Unit Location 9..................

Roof Mount 9...............................

Step 2 -- Plan for Sequence of Unit Installation 10.....

Curb--Mount Installation 10....................

Pad--Mount Installation 10.....................

Frame--Mount Installation 10...................

Step 3 -- Inspect Unit 10..........................

Step 4 -- Provide Unit Support 10..................

Roof Curb Mount 10.........................

Slab Mount (Horizontal Units Only) 10..........

Alternate Unit Support

(In Lieu of Curb or Slab Mount) 10.............

Step 5 -- Field Fabricate Ductwork 14...............

Step 6 -- Rig and Place Unit 14....................

Positioning on Curb 15.......................

Step 7 -- Horizontal Duct Connection 15............

Step 8 -- Install Outside Air Hood — Factory Option 15.. Step 9 -- Install Flue Hood and Combustion Air Hood 16..

Step 10 -- Install Gas Piping 16....................

Gas Supply Line 16..........................

Factory--Option Thru--Base Connections 18.......

Step 11 -- Install External Condensate Trap and Line 19..

Step 12 -- Make Electrical Connections 19...........

Field Power Supply 19........................

Units without Factory--Installed Disconnect 20....

Units with Factory--Installed Disconnect 20.......

All Units 20................................

Convenience Outlets 20.......................

Factory--Option Thru--Base Connections 22......

Units without Thru--Base Connections 22.........

Field Control Wiring 22.......................

Thermostat 22...............................

Unit without Thru--Base Conversion Kit 22.......

Heat Anticipator Settings 23...................

Transformer Connection

for 208--v Power Supply 23.....................

Humidi--MiZer

Humidi--MiZer -- Space RH Controller 24........

PremierLinkt (Factory Option) 26...............

Supply Air Temperature (SAT) Sensor 29.........

Outdoor Air Temperature (OAT) Sensor 29.......

EconoMi$er2 29.............................

Field Connections 29..........................

Space Sensors 31............................

Connect Thermostat 31.......................

Configure the Unit for Thermostat Mode 31......

Economizer Controls 32........................

Indoor Air Quality (CO

Outdoor Air Quality Sensor 32.................

Space Relative Humidity Sensor or

Humidistat Connections 33....................

Smoke Detector/Fire Shutdown (FSD) 34.........

Filter Status Switch 34........................

Supply Fan Status Switch 34...................

Remote Occupied Switch 34...................

Power Exhaust (output) 34.....................

CCN Communication Bus 35..................

RTU Open Control System 36...................

Supply Air Temperature (SAT) Sensor 39.........

Outdoor Air Temperature (OAT) Sensor 39.......

EconoMi$er2 39.............................

Control Connections 24..........

)Sensor 32.............

Field Connections 39..........................

Space Temperature (SPT) Sensors 40............

Indoor Air Quality (CO

Outdoor Air Quality Sensor 41.................

Space Relative Humidity Sensor or Humidistat 41..

Smoke Detector/Fire Shutdown (FSD) 42.........

Connecting Discrete Inputs 42..................

Communication Wiring -- Protocols 43............

General 43.................................

Local Access 44.............................

RTU Open Troubleshooting 44.................

Outdoor Air Enthalpy Control 45.................

Differential Enthalpy Control 45................

Smoke Detectors 46...........................

48HC

Return Air Sensor Tube Installation 46...........

Smoke Detector Test Magnet 47................

Additional Application Data 47.................

Step 13 -- Adjust Factory--Installed Options 50........

Step 14 -- Install Accessories 50...................

)Sensor 40.............

SAFETY CONSIDERATIONS

WARNING

FIRE, EXPLOSION HAZARD

Failure to follow this warning could result in personal injury or death.

Disconnect gas piping from unit when leak testing at pressure greater than 0.5 psig (3450 Pa). Pressures greater than 0.5 psig (3450 Pa) will cause gas valve damage resulting in hazardous condition. If gas valve is subjected to pressure greater than 0.5 psig (3450 Pa), it must be replaced before use. When pressure testing field--supplied gas piping at pressures of 0.5 psig (3450 Pa) or less, a unit connected to such piping must be isolated by closing the manual gas valve.

WARNING

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could cause personal injury or death.

Before performing service or maintenance operations on unit, always turn off main power switch to unit and install lock(s) and lockout tag(s). Unit may have more than one power switch.

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

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.

. When you see this symbol on the

WARNING

UNIT OPERATION AND SAFETY HAZARD

Failure to follow this warning could cause personal injury, death and/or equipment damage.

Puronr (R--410A) refrigerant systems operate at higher pressures than standard R--22 systems. Do not use R--22 service equipment or components on Puron refrigerant equipment.

WARNING

PERSONAL INJURY AND ENVIRONMENTAL HAZARD

Failure to follow this warning could cause personal injury or death.

Relieve pressure and recover all refrigerant before system repair or final unit disposal.

Ware safety glasses and gloves when handling refrigerants. Keep torches and other ignition sources away from refrigerants and oils.

CAUTION

CUT 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.

48HC

Fig. 1 -- Unit Dimensional Drawing – 17 Size Unit

C10896

48HC

Fig. 1 -- Unit Dimensional Drawing – 17 Size Unit (cont.)

C10897

48HC

Fig. 2 -- Unit Dimensional Drawing – 20 and 24 Size Units

C10892

48HC

Fig. 2 -- Unit Dimensional Drawing – 20 and 24 Size Units (cont.)

C10893

48HC

Fig. 3 -- Unit Dimensional Drawing – 28 Size Unit

C10900

48HC

Fig. 3 -- Unit Dimensional Drawing – 28 Size Unit (cont.)

C10901

INSTALLATION

Jobsite Survey

Complete the following checks before installation.

1. Consult local building codes and the NEC (National Electrical Code) ANSI/NFPA 70 for special installation requirements.

2. Determine unit location (from project plans) or select unit location.

3. Check for possible overhead obstructions which may interfere with unit lifting or rigging.

Step 1 — Plan for Unit Location

Select a location for the unit and its support system (curb or other) that provides for the minimum clearances required for safety. This includes the clearance to combustible surfaces, unit performance and service access below, around and above unit as specified in unit drawings. See Fig. 4.

NOTE: Consider also the effect of adjacent units.

96” (2438)

36” (914)

42” (1067)

Be sure that the unit is installed such that snow will not block the combustion air intake or flute outlet.

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 or other sources of contaminated air. For proper unit operation, adequate combustion and ventilation air must be provided in accordance with Section 5.3 (Air for Combustion and Ventilation) of the National Fuel Gas Code, ANSI Z223.1 (American National Standards Institute) and NFPA (National Fire Protection Association) 54 TIA----54----84----1. In Canada, installation must be in accordance with the CAN1----B149 installation codes for gas burning appliances.

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 products could enter the building, and at least 4 ft (1.2 m) from any adjacent building (or per local code). Locate the flue assembly at least 10 ft (3.05 m) from an adjacent unit’s fresh air intake hood if within 3 ft (0.91 m) of same elevation (or per local code). When unit is located adjacent to public walkways, flue assembly must be at least 7 ft (2.1 m) above grade.

48HC

42” (1067)

36” (914)

Fig. 4 -- Service Clearance Dimensional Drawing

Table 1 – Operating Weights

48HC**

Base Unit 1892 (858) 2102 (954) 2247 (1019) 2292 (1040)

Economizer 245 (111) 245 (111) 245 (111) 245 (111)

Powered Outlet 32 (15) 32 (15) 32 (15) 32 (15)

H u m i d i --- M i Z e rRSystem

Curb

14--- in/356 mm 273 (124) 273 (124) 273 (124) 273 (124)

24--- in/610 mm 350 (159) 350 (159) 350 (159) 350 (159)

17 20 24 28

83 (38) 83 (38) 88 (40) 92 (42)

C10638

Select a unit mounting system that provides adequate height to allow installation of condensate trap per requirements. Refer to Step 11 — Install External Condensate Trap and Line – for required trap dimensions.

Roof Mount —

Check building codes for weight distribution requirements. Unit operating weight is shown in Table 1.

UNIT LB (KG)

Step 2 — Plan for Sequence of Unit Installation

The support method used for this unit will dictate different sequences for the steps of unit installation. For example, on curb--mounted units, some accessories must be installed on the unit before the unit is placed on the curb. Review the following for recommended sequences for installation steps.

Curb--mounted installation —

NOTE: The gasketing of the unit to the roof curb is critical

for a watertight seal. Install gasket supplied with the roof curb as shown in Figs. 6, 7 and 8. Improperly applied gasket can also result in air leaks and poor unit performance.

Curb should be level. This is necessary for unit drain to function properly. Unit leveling tolerances are show in Fig. 9. Refer to Accessory Roof Curb Installation Instructions for additional information as required.

Install curb Install field--fabricated ductwork inside curb Install thru--base service connection fittings (affects

curb and unit) Rig and place unit Remove top skid Install outside air hood Install smoke detector tube Install combustion air hood

48HC

Install flue hood Install gas piping Install condensate line trap and piping Make electrical connections

Install insulation, cant strips, roofing felt, and counter flashing as shown. Ductwork must be attached to curb and

not to the unit. Thru--the--base power connection must be installed before the unit is set on the roof curb. If

field--installed thru--the--roof curb gas connections are desired remove knockout in basepan located in the gas section, see Fig. 5 for location. Gas connections and power connections to the unit must be field installed after the unit is installed on the roof curb.

If electric and control wiring is to be routed through the basepan, remove knockouts in basepan located in control box area of access panel; see Fig. 1, 2, or 3 for basepan knockout locations for location. Attach the service connections to the basepan.

Install other accessories

Hood Carton Location

Pad--mounted installation —

(rear access panel)

Prepare pad and unit supports Rig and place unit Remove duct covers and top skid

Control Box

ccess Panel

Install smoke detector return air sensor tube Install field--fabricated ductwork at unit duct openings Install outside air hood Install combustion air hood Install flue hood Install gas piping Install condensate line trap and piping Make electrical connections Install other accessories

Filter and

Indoor Coil

Access Panel

Indoor Blower Access Panel

Gas Heat

Access Panel

Compressor

(each side)

C11154

Fig. 5 -- Typical Access Panel and Compressor Locations

Frame--mounted installation —

Frame--mounted applications generally follow the sequence for a curb installation. Adapt as required to suit specific installation plan.

Step 3 — Inspect unit

Inspect unit for transportation damage. File any claim with transportation agency.

Slab Mount (Horizontal Units Only) —

Provide a level concrete slab that extends a minimum of 6–in. (150 mm) beyond unit cabinet. Install a gravel apron in front of condenser coil air inlet to prevent grass and foliage from obstructing airflow.

NOTE: Horizontal units may be installed on a roof curb if required.

Confirm before installation of unit that voltage, amperage and circuit protection requirements listed on unit data plate agree with power supply provided.

Locate the carton containing the outside air hood parts; see Figs. 5 and 12. Do not remove carton until unit has been rigged and located in final position.

Step 4 — Provide Unit Support

Roof Curb Mount —

Alternate Unit Support (In Lieu of Curb or Slab Mount) —

A non--combustible sleeper rail can be used in the unit curb support area. If sleeper rails cannot be used, support the long sides of the unit with a minimum of 4 equally spaced 4--in. x 4--in. (102 mm x 102 mm) pads on each side. Locate pads so that they support the rails. Make sure to avoid the fork openings.

Accessory roof curb details and dimensions are shown in Figs. 6, 7 and 8. Assemble and install accessory roof curb in accordance with instructions shipped with the curb.

48HC

Fig. 6 -- Roof Curb Details – 17 Size Unit

C10954

48HC

Fig. 7 -- Roof Curb Details – 20 and 24 Size Units

C10955

48HC

Fig. 8 -- Roof Curb Details – 28 Size Unit

C10956

A minimum clearance is not required around ductwork.

MAXIMUM ALLOWABLE

DIFFERENCE IN. (MM)

A-B

0.25” (6)

B-C

0.5” (12)

Fig. 9 -- Unit Leveling Tolerances

Step 5 — Field Fabricate Ductwork

Cabinet return-air static pressure (a negative condition) shall not exceed 0.5 in. wg (87 Pa) with economizer or without economizer.

For vertical ducted applications, secure all ducts to roof curb

48HC

and building structure. Do not connect ductwork to unit. Fabricate supply ductwork so that the cross sectional

dimensions are equal to or greater than the unit supply duct opening dimensions 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 applicable codes.

Ducts passing through unconditioned spaces must be insulated and covered with a vapor barrier.

A-C

0.5” (12)

C10628

CAUTION

PROPERTY DAMAGE HAZARD

Failure to follow this caution may result in damage to roofing materials.

Membrane roofs can be cut by sharp sheet metal edges. Be careful when placing any sheet metal parts on such roof.

Step 6 — Rig and Place Unit

Keep unit upright and do not drop. Spreader bars are not required if top crating is left on unit. Rollers may be used to move unit across a roof. Level by using unit frame as a reference. See Table 1 (on page 9) and Fig. 10 for additional information.

Lifting holes are provided in base rails as shown in Fig. 10. Refer to rigging instructions on unit.

UNIT DAMAGE HAZARD

Failure to follow this caution may result in equipment damage.

All panels must be in place when rigging. Unit is not designed for handling by fork truck when packaging is removed.

CAUTION

If a plenum return is used on a vertical unit, the return should be ducted through the roof deck to comply with applicable fire codes.

"914-1371"

(36"-54")

"B"

SEE DETAIL A

"C"

"A"

UNIT

48HC**17 2339 1061 127.8 3249 58.7 1491 52.3 1328

48HC**20 2549 1156 141.5 3595 71.5 1816 52.3 1328

48HC**24 2699 1224 141.5 3595 71.5 1816 60.3 1532

48HC**28 2748 1246 157.8 4007 80.3 2040 60.3 1532

NOTES:

1. Dimensions in ( ) are inches.

2. Hook rigging shackles through holes in base rail, as shown in detail “A.” Holes in base rails are centered around the unit center of gravity. Use wooden top to prevent rigging straps from damaging unit.

MAX WEIGHT

LB KG IN MM IN MM IN MM

Fig. 10 -- Rigging Details

Before setting the unit onto the curb, recheck gasketing on curb.

PLACE ALL SEAL STRIP IN PLACE BEFORE PLACING UNIT ON ROOF CURB.

DUCT END

DIMENSIONS

A B C

DETAIL A

C09107

PositioningonCurb—

Position unit on roof curb so that the following clearances are maintained: curb and the base rail inside the right and left,

/4in. (6 mm) clearance between the roof

/2in. (12 mm) clearance between the roof curb and the base rail inside the front and back. This will result in the distance between the roof curb and the base rail inside on the condenser end of the unit being approximately equal to Details A and B in Figs. 6, 7 and 8.

Do not attempt to slide unit on curb after unit is set. Doing so will result in damage to the roof curb seal.

Although unit is weatherproof, guard against water from higher level runoff and overhangs.

Flue vent discharge must have a minimum horizontal clearance of 48 in. (1220 mm) from electric and gas meters, gas regulators, and gas relief equipment. Minimum distance between unit and other electrically live parts is 48 inches (1220 mm).

Flue gas can deteriorate building materials. Orient unit such that flue gas will not affect building materials. Locate mechanical draft system flue assembly at least 48 in. (1220 mm) from an adjacent building or combustible material.

Field--supplied

/4--inch) flanges should be attached to horizontal duct openings (see Fig. 11) 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.

Step 8 — Install Outside Air Hood — Factory Option

The outside air hood for factory--option economizer and two--position damper is shipped in knock--down form and requires field assembly. The panel for the hood top is shipped on the end of the unit (see Fig. 12). The remaining parts for the hood assembly (including side panels, filters and tracks) are shipped in a carton that is secured to the rear of the blower assembly. Access the carton location through rear panel (see Fig. 13).

Hood Top

Shipping Position

48HC

After unit is in position, remove rigging skids and shipping materials.

Step 7 — Horizontal Duct Connection

Refer to Figs. 1, 2 and 3 for locations and sizes of the horizontal duct connections. Note that there are two different return air duct connection locations – one for unit without an economizer (on back side of unit) and a different one for unit equipped with an economizer (on left end, under the economizer hood). The supply air duct connection is on the back side. See Fig. 11 for top view depicting typical horizontal duct arrangements.

C09134

Fig. 12 -- Hood Top – Shipping Position

To remove the hood parts package:

1. Remove the back blower access panel.

2. Locate and cut the strap, being careful to not damage any wiring.

3. Carefully lift the hood package carton through the back blower access opening.

See Fig. 14 for identification of the various parts of the hood assembly.

Hood

Package

Horizontal Supply Air

Supply

Location Back Back Left end

H e ig ht --- I n . ( mm ) 157/8(402) 493/8(1253) 183/8(467)

W i d t h --- i n. ( m m ) 293/4(756) 233/8(593) 615/8(1564)

Return Air Duct

without

Economizer

Return without

Economizer

Return Air Duct

with Economize

C10626

Return with

Economizer

Fig. 11 -- Horizontal Duct Opening Dimensions

C09133

Fig. 13 -- Hood Package – Shipping Location

To assemble the outside air hood:

1. Remove hood top panel from shipping position on unit end.

2. Install four angles to the upper end panel using the screws provided.

The combustion air hood is attached to the back of the burner access panel. Remove the two screws securing the hood to the back of the burner access panel. Using the two screws, re--attach the hood to the front of the burner access panel as shown in Fig. 16.

3. Apply seal strip to mating flanges on the side plates of the hood (see Fig. 14).

Apply Seal Strips to the back of

Apply Seal Strip to the front of

pply Seal Strips to the back of these flanges

Seal Strips

this flange

48HC

these surfaces

Item # Description Qty 1 Angles 4 2 Side Plates 2 3 Hood 1 4 Outdoor Air Screens 4 5 Side Filter Supports 2 6 Side Drip Angles 2 7 Top Diverters 2

Fig. 14 -- Hood Part Identification and Seal Strip

Application Areas

Apply Seal Strip to the back of this flange

Apply Seal Strip to the front of this flange

C09079

Combustion

Air Hood

Flue Hood

C10744

Fig. 16 -- Flue Hood and Combustion Air Hood Details

Step 10 — Install Gas Piping

Installation of the gas piping must be in accordance with local building codes and with applicable national codes.

4. Secure side plates to panel using the screws provided.

5. Apply seal strip to mating flange of the hood (see Fig. 14).

6. Secure top flange using screws provided in kit.

7. Install outdoor air screens by sliding them into the channel formed by the four angles installed in step 2. Make sure that the screens extend across the entire length of the hood.

8. Install side filter supports using the screws provided.

9. Install side drip angles using the screws provided.

10. Run a continuous length of seal strip across the hood covering the engagement holes in the lower hood.

11. Install top diverter using the screws provided.

12. On units with barometric relief, remove screws at bottom of relief damper. Do not discard damper door.

In U.S.A., refer to NFPA 54/ANSI Z223.1 National Fuel Gas Code (NFGC). In Canada, installation must be accordance with the CAN/CSA B149.1 and CAN/CSA B149.2 installation codes for gas burning appliances.

This unit is factory equipped for use with Natural Gas 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 fuel. See accessory kit installation instructions regarding these accessories.

NOTE: Furnace gas input rate on rating plate is for installation up to 2000 ft (610 m) above sea level. In U.S.A. the input rating for altitudes above 2000 ft (610 m) must be derated by 4% for each 1000 ft (305 m) above sea level. In Canada the input rating must be derated by 10% for altitudes of 2000 ft (610 m) to 4500 ft (1372 m) above sea level.

For natural gas applications, gas pressure at unit gas connection must not be less than 5 in. wg (1246 Pa) or greater than 13 in. wg (3240 Pa) while the unit is operating. For liquified petroleum applications, the gas pressure must not be less than 11 in. wg (2740 Pa) or greater than 13 in. wg (3240 Pa) at the unit connection.

C09090

Fig. 15 -- Hood Assembly – Completed

Step 9 — Install Flue Hood and Combustion Air Hood

The flue hood is shipped screwed to the fan deck inside the burner compartment. Remove the burner access panel and then remove the flue hood from its shipping location. Using the screws provided, install flue hood in the

Gas Supply Line —

The gas supply pipe enters the unit adjacent to the burner access panel on the front side of the unit, through the grommeted hole. The gas connection to the unit is made

to the Table 2 lists typical

/4in. FPT gas inlet port on the unit gas valve.

/4inch NPT (National Pipe Thread) field supplied pipe fittings required for Thru--Base gas supply, starting from the unit gas valve (see Fig. 17).

location shown in Fig. 16.

+ 36 hidden pages