Gas Heater User Manual

ManualsBrandsCarrier ManualsGas HeaterSINGLE PACKAGE ROOFTOP 48HC

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

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

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

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

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

Summary of content (52 pages)

PAGE 1
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 Units without Thru-- Base Connections . . . . . . . . . 22 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Field Control Wiring . . . . . . . . . . . . . . . . . . . . . . .
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Field Connections . . . . . . . . . . . . . . . . . . . . . . . . . . 39 ! Space Temperature (SPT) Sensors . . . . . . . . . . . . 40 Indoor Air Quality (CO2) Sensor . . . . . . . . . . . . . 40 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.
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48HC Fig.
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8HC Fig. 1 - Unit Dimensional Drawing – 17 Size Unit (cont.
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48HC Fig.
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48HC Fig. 2 - Unit Dimensional Drawing – 20 and 24 Size Units (cont.
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48HC Fig.
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48HC Fig. 3 - Unit Dimensional Drawing – 28 Size Unit (cont.
PAGE 9
INSTALLATION Jobsite Survey Be sure that the unit is installed such that snow will not block the combustion air intake or flute outlet. 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.
PAGE 10
Step 2 — Plan for Sequence of Unit Installation 48HC 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.
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48HC Fig.
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48HC Fig.
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48HC Fig.
PAGE 14
A minimum clearance is not required around ductwork. CAUTION ! C 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. MAXIMUM ALLOWABLE DIFFERENCE IN. (MM) A B A-B 0.25” (6) B-C 0.5” (12) A-C 0.5” (12) C10628 Fig.
PAGE 15
Position unit on roof curb so that the following clearances are maintained: 1/4 in. (6 mm) clearance between the roof curb and the base rail inside the right and left, 1/2 in. (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.
PAGE 16
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. 3. Apply seal strip to mating flanges on the side plates of the hood (see Fig. 14). Apply Seal Strips to the back of these surfaces 3 Apply Seal Strip to the front of this flange Apply Seal Strips to the back of these flanges The combustion air hood is attached to the back of the burner access panel.
PAGE 17
Table 2 – Typical 3/4- in NPT Field Supplied Piping Parts 4 5 3 6 Item Qty CPN Description 1 1 CA15RA201 90 Deg Street Elbow 2 1 CA01CA226 5 Inch Long Nipple 3 1 CA85RA201 Ground --- Joint Union 4 1 CA01CA218 3 Inch Long Nipple 5 1 CA05RA201 90 Deg Elbow 6 1 CA01CA250 12 Inch Long Nipple 7 1 CA05RA201 90 Deg Elbow 8 1 CA01CA218 3 Inch Long Nipple 9 1 CA20RA201 TEE 10 1 CA01CN222 4 Inch Long Nipple (Sediment Trap) 11 1 CA38RA201 Cap 12 1 CA01CA220 3 1/2
PAGE 18
Factory-- Option Thru-- Base Connections — 48HC Electrical Connections: Knockouts are located in the control box area. Remove the appropriate size knockout for high voltage connection. Use the field supplied connector depending on wiring or conduit being utilized. Remove the 7/8 - in (22mm) knockout and appropriate connector for low voltage wiring. If non-- unit powered convenience outlet is being utilized, remove the 7/8 - in (22mm) knockout and utilize appropriate connector for 115 volt line.
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Step 12 — Make Electrical Connections ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death. Do not use gas piping as an electrical ground. Unit cabinet must have an uninterrupted, unbroken electrical ground to minimize the possibility of personal injury if an electrical fault should occur.
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! WARNING ! CAUTION UNIT DAMAGE HAZARD Failure to follow this caution may result in equipment damage. Operation on improper line voltage or excessive phase imbalance constitutes abuse and may cause damage to electrical components. Such operation would invalidate any applicable Carrier warranty. FIRE HAZARD Failure to follow this warning could result in intermittent operation or unsatisfactory performance. Do not connect aluminum wire between disconnect switch and air conditioning unit.
PAGE 21
Two types of convenience outlets are offered on 48HC models: Non--unit powered and unit--powered. Both types provide a 125--volt GFCI (ground--fault circuit--interrupter) duplex receptacle rated at 15--A behind a hinged access cover, located on the corner panel of the unit. See Fig. 26. Control Box Access Panel Non-- unit powered type: This type requires the field installation of a general-- purpose 125-- volt 15-- A circuit powered from a source elsewhere in the building.
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Field Control Wiring — NOTICE/AVIS Convenience Outlet Utilization Maximum Intermittent Use 15 - Amps Maximum Continuous Use 8 - Amps Observe a 50% limit on the circuit Loading above 8 - Amps Utilisation de la prise utilitaire Usage intermittent maximum 15 - Amps Usage continu maximum 8 - Amps Observez une limite de 50% sur le circuit Chargement au-dessus de 8 - Amps 50HE501288 2.0 C10077 48HC Fig.
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Central Terminal Board Typical Thermostat Corrections X X C C G G W2 W2 W2 W1 W1 W1 O/B/Y2 Y2 Y2 Y1 Y1 Y1 R R R C See Caution G Rubber Grommet Corner Post Wire Ties 48HC (see Note) T–STAT Note: Typical multi-function marking. Follow manufacturer’s configuration instructions to select Y2. Field Wiring ! CAUTION Thru the Base Connection UNIT DAMAGE HAZARD Failure to follow this caution may cause a short circuit.
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Humidi--MiZerR Control Connections 48HC Humidi-- MiZer – Space RH Controller — NOTE: The Humidi-- MiZer is a factory installed option. The Humidi-- MiZer dehumidification system requires a field-- supplied and - installed space relative humidity control device.
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48HC Fig. 34 - Typical Humidi-- MiZerR Adaptive Dehumidification System Humidistat Wiring EDGE Pro THERMIDISTAT C11139 Unit CTB THERMOSTAT X* Rc Rh W1 G Y2 C O/W2/B Y1 C G W2 W1 Y2 Y1 OAT RRS SRTN HUM D1 D2 V+ Vg R Humidi-MiZer™ FIOP *Connection not required. Fig.
PAGE 26
48HC PremierLinkt (Factory--Option) Fig. 36 - PremierLink Controller C08199 The PremierLink controller (see Fig. 36) is compatible with Carrier Comfort Networkr (CCN) devices. This control is designed to allow users the access and ability to change factory-- defined settings, thus expanding the function of the standard unit control board. CCN service access tools include System Pilott, Touch Pilott and Service Tool.
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48HC Fig.
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48HC Fig.
PAGE 29
Supply Air Temperature (SAT) Sensor — NOTE: The sensor must be mounted in the discharge airstream downstream of the cooling coil and any heating devices. Be sure the probe tip does not come in contact with any of the unit’s heater surfaces. On FIOP-- equipped 48HC 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 thermistor.
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48HC Table 5 – Space Sensor Mode TB3 TERMINAL 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 LEGEND: T55 T56 CCN CMPSAFE FILTER FSD IAQ OAQ RH SFS --------------------- FIELD CONNECTION T55---SEN/T56---SEN RMTOCC T55---SEN/T56---SEN CMPSAFE T56---SET FSD LOOP---PWR SPS IAQ ---SEN FILTER IAQ ---COM/OAQ ---COM/RH ---COM CCN + (RED) OAQ ---SEN/RH ---SEN CCN Gnd (WHT) AUX OUT(Power Exhaust) CCN --- (BLK) INPUT SIGNAL Analog (10k thermistor) Discrete, 24VAC Analog (10k thermistor) Discrete, 24VAC Analog (10k thermis
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Space Sensors — SEN The PremierLink controller is factory-- shipped configured for Space Sensor Mode. A Carrier T-- 55 or T-- 56 space sensor must be used. T-- 55 space temperature sensor provides a signal of space temperature to the PremierLink control. T-- 56 provides same space temperature signal plus it allows for adjustment of space temperature setpoints from the face of the sensor by the occupants. SEN TB3 PL 1 J6-7 TB3 3 PL J6-6 5 J6-5 Jumper SET SET C10022 Fig.
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Economizer Controls Indoor Air Quality (CO2) Sensor — The indoor air quality sensor accessory monitors space carbon dioxide (CO2) levels. This information is used to monitor IAQ levels. Several types of sensors are available, for wall mounting in the space or in return duct, with and without LCD display, and in combination with space temperature sensors. Sensors use infrared technology to measure the levels of CO2 present in the space air.
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TB3 13 PL J5-2 SIG COM TB3 11 J5-3 24 VAC Fig. 49 - Outdoor CO2 Sensor Connections C11157 Space Relative Humidity Sensor or Humidistat Connections — Space Relative Humidity Sensor connections: The accessory space relative humidity sensor (33ZCSENSRH-01) is installed on an interior wall to measure the relative humidity of the air within the occupied space. The use of a standard 2 X 4 inch electrical box to accommodate the wiring is recommended for installation.
PAGE 34
Smoke Detector/Fire Shutdown (FSD) — This function is available only when PremierLink is configured for (Space) Sensor Mode. The unit is factory-- wired for PremierLink FSD operation when PremierLink is factory-- installed. Connect one side of the switch’s NO contact set to CTB’s THERMOSTAT-- R terminal. Connect the other side of the NO contact set to TB3-- 8. Setpoint for Supply Fan Status is set at the switch. See Fig. 53.
PAGE 35
The PremierLink controller connects to the bus in a daisy chain arrangement. Negative pins on each component must be connected to respective negative pins, and likewise, positive pins on each component must be connected to respective positive pins. The controller signal pins must be wired to the signal ground pins. Wiring connections for CCN must be made at the 3-- pin plug. At any baud (9600, 19200, 38400 baud), the number of controllers is limited to 239 devices maximum.
PAGE 36
RTU Open Control System Refer to Table 9, RTU Open Controller Inputs and Outputs for locations of all connections to the RTU Open board. 48HC The RTU Open control is factory-- mounted in the 48HC unit’s main control box, to the right of the CTB. See Fig. 37. Factory wiring is completed through harnesses connected to the CTB. Field connections for RTU Open sensors will be made at the Phoenix connectors on the RTU Open board.
PAGE 37
48HC Fig.
PAGE 38
48HC Fig.
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Table 9 – RTU Open Controller Inputs and Outputs Space Temp / Zone Temp Supply Air Temperature Outdoor Air Temperature Space Temperature Offset Pot Safety Chain Feedback Compressor Safety Status Fire Shutdown Status Enthalpy Status Humidistat Input Status Indoor Air CO2 Outdoor Air CO2 Space Relative Humidity Supply Fan Status* Filter Status* Door Contact Input* Occupancy Contact* BACnet OBJECT NAME TYPE OF I/O DEDICATED INPUTS zone_temp AI (10K Thermistor) sa_temp AI (10K Thermistor) oa_temp AI (10K Th
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to the RTU Open. Connect to the wires to the removable Phoenix connectors and then reconnect the connectors to the board. 48HC Space Temperature (SPT) Sensors — There are two types of SPT sensors available from Carrier, resistive input non-communicating (T55, T56, and T59) and Rnet communicating (SPS, SPPL, SPP, and SPPF) sensors. Each type has a variety of options consisting of: timed override button, set point adjustment, a LCD screen, and communication tie in.
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To connect the sensor to the control, identify the positive (4 to 20 mA) and ground (SIG COM) terminals on the sensor. See Fig. 46. Connect the 4-- 20 mA terminal to RTU Open terminal J4-- 2 and connect the SIG COM terminal to RTU Open terminal J4-- 3. See Fig. 63. IAQ Sensor 4-20mA J4-2 SIG COM J4-3 24 VAC Fig.
PAGE 42
J4-1 or J4-4 + 24 VDC Supply Voltage J4-2 or J4-5 (-) 4 to 20 mA Current Loop Output to RTU-OPEN Relative Humidity Sensor (Polarized Male Connector) SPAN ZERO 48HC 4-20 VAC GND 0-5V mA or or VDC 0-10V Fig. 66 - Duct Relative Humidity Sensor Typical Wiring Humidistat: The accessory humidistat provides the RTU Open insight to the relative humidity in the space. The humidistat reads the RH level in the space and compares it to its setpoint to operate a dry contact.
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Communication Wiring -- Protocols General — Protocols are the communication languages spoken by control devices. The main purpose of a protocol is to communicate information in the most efficient method possible. Different protocols exist to provide different kinds of information for different applications. In the BAS application, many different protocols are used, depending on manufacturer. Protocols do not change the function of a controller; just make the front end user different.
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Local Access — Virtual BACview: Virtual BACview is a freeware computer BACview6 Handheld: The BACview6 is a keypad/display interface used to connect to the RTU Open to access the control information, read sensor values, and test the RTU, see Fig. 70. This is an accessory interface that does not come with the RTU Open controller and can only be used at the unit. Connect the BACview6 to the RTU Open J12 local access port. There are 2 password protected levels in the display (User and Admin).
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Table 10 – LEDs The LEDs on the RTU Open Control Board (see Fig. 57) show the status of certain functions: If this LED is on... Status is... Power RTU Open has power Rx RTU Open is receiving data from the network segment Tx RTU Open is transmitting data over the network segment DO# The digital output is active The Run and Error LEDs indicate control module and network status And Error LED shows... Status is...
PAGE 46
24V RED PL6-1 (24-V) – 4-20 Main GND BLK PL6-4 (COM) + VDC Out LOW GRA 7 CTB ECON (P’LINK: to J4-2) or (RTU Open: to J2-6) R O TA TIO N Outside Air Enthalpy Switch Return Air Sampling Tube (Shipping Location) + 24-36 VDC In – 4-20 Main Out Return Air Enthalpy Sensor C11161 C09102 48HC Fig. 72 - Outside and Return Air Enthalpy Sensor Wiring Fig. 73 - Typical Supply Air Smoke Detector Sensor Location To wire the return air enthalpy sensor, perform the following: 1.
PAGE 47
To install the return air sensor sampling tube: Smoke Detector Test Magnet — 1. Remove the tube from its shipping location. 2. Open the unit end to access the return air sensor (located on right-- hand partition) 3. Orient the tube’s sampling holes into the return air flow direction. For vertical application, position the sampling holes on the bottom of the tube, facing into the bottom return duct opening.
PAGE 48
UNIT Table 11 - Unit Wire/Fuse or HACR Breaker Sizing Data (cont) NOM. V--- Ph--- Hz IFM TYPE COMBUSTION FAN MOTOR FLA LRA 398 84.9 100.0 90 418 415 87.6 100.0 93 435 85 424 92.4 100.0 99 444 45.0 39 236 43.3 50.0 46 248 50.0 41 245 44.7 50.0 48 257 41.1 50.0 44 249 47.3 60.0 51 261 27.9 35.0 29 186 32.7 40.0 35 194 27.9 35.0 29 186 32.7 40.0 35 194 HIGH 30.7 40.0 33 200 35.5 45.0 38 208 STD 80.5 100 85 445 92.
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Legend and Notes for Table 11 % Voltage Imbalance = 100 x max voltage deviation from average voltage average voltage Example: Supply voltage is 230-3-60 AB = 224 v BC = 231 v AC = 226 v Average Voltage = = (224 + 231 + 226) 3 = 681 3 227 Determine maximum deviation from average voltage. (AB) 227 – 224 = 3 v (BC) 231 – 227 = 4 v (AC) 227 – 226 = 1 v Maximum deviation is 4 v. Determine percent of voltage imbalance. % Voltage Imbalance = 100 x 4 227 = 1.
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48HC Economizer 2 Position Damper Fig.
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48HC
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48HC Copyright 2011 Carrier Corp. D 7310 W. Morris St. D Indianapolis, IN 46231 Printed in U.S.A. Edition Date: 04/11 Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.