Page 1: Table Of Contents
48JC04-06 Single Package Rooftop Gas Heat/Electric Cooling Unit with Puron ® (R-410A) Refrigerant 3 to 5 Nominal Tons Service and Maintenance Instructions Remote Test/Reset Station Dirty Sensor Test ..22 SAFETY CONSIDERATIONS ....2 Dirty Sensor Test Using an SD-TRK4 .
Page 2: Safety Considerations
APPENDIX B — PHYSICAL DATA....48 APPENDIX C — FAN PERFORMANCE ... 50 WARNING APPENDIX D — WIRING DIAGRAMS ... . 63 START-UP CHECKLIST .
Page 3: Unit Arrangement And Access
Heating UNIT ARRANGEMENT AND ACCESS • Heat exchanger flue passageways cleanliness General • Gas burner condition Figures 1 and 2 show general unit arrangement and access • Gas manifold pressure locations. • Heating temperature rise Economizer or Outside Air Damper FILTER ACCESS PANEL •...
Page 4: Supply Fan (Blower) Section
Supply Fan (Direct-Drive) All JC units have the EcoBlue™ direct drive vane axial fan 17 1/4” system. The fan is driven by an ECM motor with speed that is user set through the SystemVu™ controller. Speeds are fully configurable from 40% to 100% of motor’s maximum speed. See Fig.
Page 5 5. Using the UP and DOWN arrow keys highlight SET- set the values. Press ENTER after setting each value to con- TINGS and then press ENTER. tinue to the next selection. 6. Use the DOWN arrow key highlight the UNIT CONFIG- •...
Page 6 TROUBLESHOOTING THE ECM MOTOR EcoBlue™ motors are designed with several built-in protections included in the motor software. If the motor detects a fault it will safely shut down. For temperature related faults the motor re- quires a line voltage reset to continue operation. For all others, the motor will resume operation automatically as soon as the fault condition is cleared.
Page 7 Fig. 11 — Fan System Re-Assembly 6. Install four #10-32 x 1/2-in. hex head machine screws (P/N: AD07AB126) to connect aluminum stator to motor. Tighten to 23 in.-lb (2.6 Nm). 7. Fit grommet on motor wire harness into keyhole feature on the side of the stator and pull wire harness out through Fig.
Page 8: Cooling
Reinstalling Motor and Fan Assembly provided in this unit). The coil may be one-row or composite-type two-row. Composite two-row coils are two single-row coils fabri- See Fig. 12. cated with a single return bend end tubesheet. 1. Align motor harness/grommet at ~7 o’clock (facing Condenser Coil Maintenance and Cleaning installer) and align the bottom flats on right and left sides Recommendation...
Page 9 TOP PANEL COIL CLIPS REMOVE REMOVE SCREWS SCREWS FROM ALL SIDES OF TOP PANEL CONDENSER CENTER POST COMPRESSOR ACCESS PANEL CONDENSER Fig. 15 — Condenser Coil Clips COIL CONDENSER COIL CORNER POST Fig. 13 — Location of Screws and Coil Corner Post TOP VIEW Lift and rotate the top panel at the condenser fan end and rotate the panel 90 degrees.
Page 10: Evaporator Coil
6. Reconnect wiring. 7. Replace access panels. CAUTION THERMOSTATIC EXPANSION VALVE (TXV) UNIT DAMAGE HAZARD Failure to follow this caution may result in accelerated All 48JC units have a factory-installed nonadjustable thermo- corrosion of unit parts. static expansion valve (TXV). The TXV is a bi-flow, bleed port expansion valve with an external equalizer.
Page 11: Refrigerant System Pressure Access Ports
Refrigerant System Pressure Access Ports There are two access ports in the system: on the suction tube near the compressor and on the discharge tube near the com- pressor. These are brass fittings with black plastic caps. The hose connection fittings are standard 1/4-in. SAE male flare couplings.
Page 12: Puron (R-410A) Refrigerant
15.6 Refrigerant Charge Amount of refrigerant charge is listed on the unit’s nameplate. Refer to Carrier GTAC2-5 Charging, Recovery, Recycling and Remove Charge if Below the Reclamation training manual and the following procedures. Curve Unit panels must be in place when unit is operating during the charging procedure.
Page 13 5 Ton JC 4 Ton JC R410A Refrigerant Charging Chart R410A Refrigerant Charging Chart (Unit must be put in Test Mode and set the Cooling test compressor (Unit must be put in Test Mode and set the Cooling test compressor speed to 4100) speed to 4500) 60.0...
Page 14: Compressor
COMPRESSOR Compressor Rotation Lubrication CAUTION The compressor is charged with the correct amount of oil at the factory. EQUIPMENT DAMAGE HAZARD Failure to follow this caution can result in premature wear and damage to equipment. CAUTION Scroll compressors can only compress refrigerant if UNIT DAMAGE HAZARD rotating in the right direction.
Page 15 NO SCREW (Blank Tab) Fig. 26 — Condenser-Fan Assembly — Screw Pattern Sequence...
Page 16: Troubleshooting Cooling System
Troubleshooting Cooling System Refer to Table 2 for additional troubleshooting topics. Table 2 — Troubleshooting SYMPTOM CAUSE SOLUTION Power failure. Call power company. Fuse blown or circuit breaker tripped. Replace fuse or reset circuit breaker. Determine root cause. Defective thermostat, contactor, transformer. Replacement component.
Page 17: Convenience Outlets
3. Press the gasket over the screw heads. Slip the backing CONVENIENCE OUTLETS plate over the screw heads at the keyhole slots and align with the gasket; tighten the two screws until snug (do not over-tighten). WARNING 4. Mount the weatherproof cover to the backing plate as ELECTRICAL OPERATION HAZARD shown in Fig.
Page 18: Duty Cycle
unit is factory-configured for immediate smoke detector shut- down operation; additional wiring or modifications to unit termi- nal board may be necessary to complete the unit and smoke de- tector configuration to meet project requirements. System The smoke detector system consists of a four-wire controller and one or two sensors.
Page 19: Smoke Detector Locations
appropriate action to shut down fans and blowers, change over air handling systems, notify the fire alarm control panel, etc. The sensor uses a process called differential sensing to prevent SUPPLY AIR gradual environmental changes from triggering false alarms. A SMOKE DETECTOR rapid change in environmental conditions, such as smoke from a fire, causes the sensor to signal an alarm state but dust and...
Page 20: Completing Installation Of Return Air Smoke
RETURN AIR SMOKE DETECTOR SENSOR WITH 2. Remove the return air smoke sensor module and its detec- ECONOMIZER tor plate. 3. Rotate the detector plate so the sensor is facing outwards The sampling tube is inserted through the side plates of the and the sampling tube connection is on the bottom.
Page 21: Sensor And Controller Tests
Fig. 37 — Typical Smoke Detector System Wiring ADDITIONAL APPLICATION DATA IMPORTANT: Failure to follow this ALERT can result Refer to the application data document “Factory Installed Smoke in an unnecessary evacuation of the facility. Detectors for Small and Medium Rooftop Units 2 to 25 Tons” for This test places the duct detector into the alarm state.
Page 22: Changing The Dirt Sensor Test
Table 3 — Dirty LED Test FLASHES DESCRIPTION 0-25% dirty. (Typical of a newly installed detector) SMOKE DETECTOR 25-50% dirty CONTROLLER 51-75% dirty 76-99% dirty − AUXILIARY EQUIPMENT DIRTY SENSOR TEST PROCEDURE 1. Hold the test magnet where indicated on the side of the sensor housing for two seconds.
Page 23: Indicators
Table 4 — Detector Indicators CONTROL OR DESCRIPTION HVAC DUCT SAMPLING INDICATOR TUBE SENSOR Resets the sensor when it is in the alarm or trouble Magnetic test/ HOUSING state. Activates or tests the sensor when it is in the reset switch normal state.
Page 24: Protective Devices
2. Check the wiring between the sensor and the controller. If Relief Device wiring is loose or missing, repair or replace as required. A soft solder joint at the suction service access port provides pressure relief under abnormal temperature and pressure condi- CONTROLLER’S POWER LED IS OFF tions (i.e., fire in building).
Page 25: Fuel Types And Pressures
SUPPLY PRESSURE SWITCH Fuel Types and Pressures The LP conversion kit includes a supply low pressure switch. NATURAL GAS The switch contacts (from terminal C to terminal NO) will The 48JC unit is factory-equipped for use with natural gas open the gas valve power whenever the supply line pressure (NG) fuel at elevation under 2000 ft (610 m).
Page 26: Burners And Igniters
HEATER TUBE ASSEMBLY SEAL STRIPS, SPONGE RUBBER REGULATOR GASKET REGULATOR BAFFLE ASSEMBLY (LOW NO x ONLY) RETAINER FLUE COVER ASSEMBLY PRESSURE SWITCH HOSE CONNECTION VESTIBULE PLATE FLUE BAFFLE (LOW NO x ONLY) INDUCER FAN-MOTOR ASSEMBLY BURNER ASSEMBLY Fig. 45 — Heat Exchanger Assembly To inspect blower wheel, shine a flashlight into draft hood Orifice projection opening.
Page 27 HEAT EXCHANGER SUPPORT RACK LIMIT SWITCH HEAT EXCHANGER COVER PANEL UNIT BURNER CENTER PARTITION POST PANEL Fig. 47 — Heat Exchanger Access - Internal Panels, Center Post and HX Rack Locations CLEANING AND ADJUSTMENT 1. Remove burner rack from unit as described in “Removal and Replacement of Gas Train”...
Page 28 7. Disconnect the igniter wires and sensor wires at the inte- 11. Remove the screws around the vestibule plate. grated gas controller (IGC). 12. Remove the nuts holding the heat exchanger support rack 8. Disconnect a gas pipe union and remove the gas manifold to the fan deck.
Page 29: Burner Ignition
GAS VALVE control box (see Fig. 49). The IGC contains a self-diagnostic LED (light-emitting diode). A single LED (see Fig. 52) on the All models (except Low NOx) are equipped with 2-stage gas IGC provides a visual display of operational or sequential prob- valves.
Page 30 RED LED - STATUS Fig. 52 — Integrated Gas Controller (IGC) Board...
Page 31: Troubleshooting Heating System
MINIMUM HEATING ENTERING AIR TEMPERATURE may be compromised when heating is initiated using low enter- ing air temperatures with insufficient heating temperature rise. When operating on first stage heating, the minimum tempera- ture of air entering the dimpled heat exchanger is 50°F continu- ous and 45°F intermittent for standard heat exchangers and Thermostat 40°F continuous and 35°F intermittent for stainless steel heat...
Page 32 Table 11 — IGC Board LED Alarm Codes ACTION TAKEN BY FLASH DESCRIPTION RESET METHOD PROBABLE CAUSE CONTROL CODE Normal Operation — — — Loss of power to the IGC. Check 5 amp fuse Hardware Failure No gas heating. — on IGC, power to unit, 24V circuit breaker, transformer, and wiring to the IGC.
Page 33: Systemvu Control System
The user can The SystemVu control system is fully communicating and access a built-in test routine that can be used at start-up com- cable-ready for connection to the Carrier Comfort Network missioning and troubleshooting. ®...
Page 34 OUTDOOR AIR DETAIL "A" TEMPERATURE (OAT) SENSOR RETURN AIR TEMPERATURE (RAT) SENSOR DETAIL "A" SUPPLY AIR TEMPERATURE (SAT) SENSOR Fig. 55 — Locations of Air Temperature Sensors...
Page 35: Compressor Vfd
speed ramp protections, however these are smaller than what the COMPRESSOR VFD SystemVu controller uses. Review the Compressor Control sec- The 48/50JC units are equipped with a variable speed compressor. tion for SystemVu controller start and ramp functions found in the To control this compressor a Variable Frequency Drive (VFD) is 48/50JC 04-06 Ultra High Efficiency Single Package Rooftop required.
Page 36: Converter Board
SENSOR DC- OUT RS485 DC- IN Fig. 57 — Drive Board Table 12 — Drive Board Inputs/Outputs TERMINAL LABEL DESCRIPTION TYPE CONNECTOR High Pressure switch input 3.3vdc 2 Pins SENSOR DLT sensor input 10k thermistor Pins 1 and 2 (inner 2 pins) Modbus communication with the RS485 RS485 Communication...
Page 37 Switch 1 Switch 2 Switch 3 Switch 4 Fig. 58 — Converter Board Table 13 — Converter Board Inputs/Outputs REFERENCE DESCRIPTION TYPE CONNECTOR NUMBER Not used — — Not used — — Modbus communication with the drive board RS485 Communication Pins 1,2, and 3 Input control from SystemVu PWM signal...
Page 38 Table 16 — Converter Board Error Codes ERROR CODE FAULT DESCRIPTION DRIVE MODBUS REGISTER ACTION/CAUSE E-01 Compressor Phase Over Current Reg.78|80 Bit0 1. Check the U/V/W connections on the drive side. 2. Check the compressor motor windings. 3. Check the compressor is operating within specified limits.
Page 39 Table 16 — Converter Board Error Codes (cont) ERROR CODE FAULT DESCRIPTION DRIVE MODBUS REGISTER ACTION/CAUSE E-19 Compressor Phase Current Reg.79|81 Bit2 Check if the compressor is operating outside the Foldback Timeout specified speed range. E-20 Compress Power Module Reg.79|81 Bit3 Compressor phase current ...
Page 40 Table 16 — Converter Board Error Codes (cont) ERROR CODE FAULT DESCRIPTION DRIVE MODBUS REGISTER ACTION/CAUSE E-54 Power Module Temperature Sensor Reg.83|85 Bit5 1. Verify proper airflow over the heatsink of the drive. Open/Short Fault Remove any obstructions. 2. Check that the compressor is operating within specified limits.
Page 41: Filter Board
Filter Board The Filter board is a support board that helps filter out noise and spikes on the voltage supplied to the Drive board. For trouble- shooting, make sure the AC voltage is the same going into the board and coming out of the board. See Fig. 59 and Table 17 for more details on the filter board.
Page 42: Capacitor Board
troubleshooting. See Fig. 60 and Table 18 below for more details Capacitor Board on the capacitor board. LINE REACTOR WARNING The line reactor is only used on 575 volt units. It is mounted and ELECTRICAL SHOCK HAZARD used in place of the filter board and capacitor board. The line reac- tor protects the drive board from noise and spikes on the supply Failure to follow this warning could result in personal injury, or voltage.
Page 43: Economizer System
ECONOMIZER SYSTEM OUTSIDE AIR EconoMi$er2 TEMPERATURE SENSOR The unit may be equipped with a factory-installed or accessory ECONOMI$ER2 PLUG (field-installed) EconoMi$er2 system. See Fig. 61 for compo- nent locations. Economizers use direct-drive damper actuators. IMPORTANT: Any economizer that meets the econo- mizer requirements as laid out in California’s Title 24 mandatory section 120.2 (fault detection and diagnostics) and/or prescriptive section 140.4 (life-cycle tests, damper...
Page 44: Pre-Start-Up/Start-Up
c. Inspect all field-wiring and factory-wiring connections. PRE-START-UP/START-UP Be sure that connections are completed and tight. Be sure that wires are not in contact with refrigerant tubing or sharp edges. WARNING d. Inspect coil fins. If damaged during shipping and han- PERSONAL INJURY HAZARD dling, carefully straighten fins with a fin comb.
Page 45: Return-Air Filters
Compressor Rotation WARNING CAUTION If the information in this manual is not followed exactly, a fire or explosion may result causing property damage, per- EQUIPMENT DAMAGE HAZARD sonal injury or loss of life. Failure to follow this caution can result in premature wear and Do not store or use gasoline or other flammable vapors and damage to equipment.
Page 46: Ventilation (Continuous Fan)
2. Turn on electrical supply and manual gas valve. To restore the original default value, reset the power to the unit. 3. Set system switch selector at HEAT position and fan To shut off unit, set system selector switch at OFF position. switch at AUTO.
Page 47: Nomenclature
APPENDIX A — MODEL NUMBER NOMENCLATURE Position: 9 10 11 12 13 14 15 16 17 18 – Example: Unit Heat Type Factory Assigned 48 - Gas Heat Packaged Rooftop 0 = Standard 1 = LTL Model Series - WeatherMaster ®...
Page 48 APPENDIX B — PHYSICAL DATA 48JC 3 TO 5 TON — COOLING 48JC UNIT 48JC*V04 48JC*W04 48JC*V05 48JC*W05 48JC*V06 48JC*W06 NOMINAL TONS BASE UNIT OPERATING WT (lb) 48JC* REFRIGERATION SYSTEM No. Circuits/No. Compressors/Type 1 / 1 / Variable Speed Scroll 1 / 1 / Variable Speed Scroll 1 / 1 / Variable Speed Scroll Puron...
Page 49 APPENDIX B — PHYSICAL DATA 48JC 3 TO 5 TON GAS HEAT DATA 48JC UNIT 48JC**04 48JC**05 48JC**06 GAS CONNECTION No. of Gas Valves Natural Gas Supply Line Pressure (in. wg)/(psig) 4-13 / 0.18-0.47 4-13 / 0.18-0.47 4-13 / 0.18-0.47 Liquid Propane Supply Line Pressure (in.
Page 50 APPENDIX C — FAN PERFORMANCE GENERAL FAN PERFORMANCE NOTES 1. Interpolation is permissible. Do not extrapolate. 5. The Fan Performance tables offer motor/drive recommen- dations. In cases when two motor/drive combinations 2. External static pressure is the static pressure difference would work, the lower horsepower option is recom- between the return duct and the supply duct plus the static mended.
Page 51 APPENDIX C — FAN PERFORMANCE 48JC**04 THREE PHASE — 3 TON VERTICAL SUPPLY (RPM - BHP) AVAILABLE EXTERNAL STATIC PRESSURE (in. wg) 1092 0.09 1317 0.16 1503 0.24 1666 0.32 1812 0.41 1140 0.10 1361 0.18 1543 0.26 1703 0.34 1847 0.44 1050...
Page 52 APPENDIX C — FAN PERFORMANCE 48JC**04 THREE PHASE – MEDIUM STATIC — 3 TON VERTICAL SUPPLY (RPM - VDC) AVAILABLE EXTERNAL STATIC PRESSURE (in. wg) 1092 1317 1503 1666 1812 1140 1361 1543 1703 1847 1050 1190 1405 1584 1741 1884 1125 1241...
Page 53 APPENDIX C — FAN PERFORMANCE 48JC**05 THREE PHASE — 4 TON VERTICAL SUPPLY (RPM - BHP) AVAILABLE EXTERNAL STATIC PRESSURE (in. wg) 1200 1190 0.18 1383 0.28 1544 0.39 1685 0.51 1814 0.63 1300 1255 0.21 1441 0.32 1599 0.43 1737 0.55 1863...
Page 54 APPENDIX C — FAN PERFORMANCE 48JC**05 THREE PHASE – MEDIUM STATIC — 4 TON VERTICAL SUPPLY (RPM - VDC) AVAILABLE EXTERNAL STATIC PRESSURE (in. wg) 1200 1190 1383 1544 1685 1814 1300 1255 1441 1599 1737 1863 1400 1320 1500 1654 1791 1914...
Page 55 APPENDIX C — FAN PERFORMANCE 48JC**06 THREE PHASE — 5 TON VERTICAL SUPPLY (RPM - BHP) AVAILABLE EXTERNAL STATIC PRESSURE (in. wg) 1500 1387 0.28 1561 0.40 1711 0.53 1845 0.66 1967 0.80 1625 1473 0.34 1638 0.46 1784 0.60 1914 0.74 2034...
Page 56 APPENDIX C — FAN PERFORMANCE 48JC**06 THREE PHASE – MEDIUM STATIC — 5 TON VERTICAL SUPPLY (RPM - VDC) AVAILABLE EXTERNAL STATIC PRESSURE (in. wg) 1500 1387 1561 1711 1845 1967 1625 1473 1638 1784 1914 2034 1750 1561 1718 1859 1987 2103...
Page 57 APPENDIX C — FAN PERFORMANCE 48JC**04 THREE PHASE — 3 TON HORIZONTAL SUPPLY (RPM - BHP) AVAILABLE EXTERNAL STATIC PRESSURE (in. wg) 1060 0.08 1292 0.15 1483 0.23 1650 0.31 1798 0.40 1106 0.09 1331 0.16 1519 0.24 1683 0.33 1831 0.43 1050...
Page 58 APPENDIX C — FAN PERFORMANCE 48JC**04 THREE PHASE – MEDIUM STATIC — 3 TON HORIZONTAL SUPPLY (RPM - VDC) AVAILABLE EXTERNAL STATIC PRESSURE (in. wg) 1060 1292 1483 1650 1798 1106 1331 1519 1683 1831 1050 1154 1371 1556 1718 1864 1125 1204...
Page 59 APPENDIX C — FAN PERFORMANCE 48JC**05 THREE PHASE — 4 TON HORIZONTAL SUPPLY (RPM - BHP) AVAILABLE EXTERNAL STATIC PRESSURE (in. wg) 1200 1148 0.16 1343 0.26 1507 0.37 1651 0.48 1781 0.60 1300 1209 0.19 1397 0.29 1557 0.40 1698 0.52 1826...
Page 60 APPENDIX C — FAN PERFORMANCE 48JC**05 THREE PHASE – MEDIUM STATIC — 4 TON HORIZONTAL SUPPLY (RPM - VDC) AVAILABLE EXTERNAL STATIC PRESSURE (in. wg) 1200 1148 1343 1507 1651 1781 1300 1209 1397 1557 1698 1826 1400 1271 1452 1608 1747 1873...
Page 61 APPENDIX C — FAN PERFORMANCE 48JC**06 THREE PHASE — 5 TON HORIZONTAL SUPPLY (RPM - BHP) AVAILABLE EXTERNAL STATIC PRESSURE (in. wg) 1500 1335 0.25 1507 0.36 1660 0.49 1797 0.62 1921 0.75 1625 1418 0.30 1580 0.42 1727 0.55 1861 0.68 1983...
Page 62 APPENDIX C — FAN PERFORMANCE 48JC**06 THREE PHASE – MEDIUM STATIC — 5 TON HORIZONTAL SUPPLY (RPM - VDC) AVAILABLE EXTERNAL STATIC PRESSURE (in. wg) 1500 1335 1507 1660 1797 1921 1625 1418 1580 1727 1861 1983 1750 1502 1655 1796 1926 2046...
Page 63 APPENDIX D — WIRING DIAGRAMS WIRING DIAGRAMS 48JC**04-06 UNITS SIZE VOLTAGE CONTROL PAGE POWER PAGE 208/230-3-60 48TC003234 48TC003238 04-06 Controller 460-3-60 48TC003234 48TC003238 (SystemVu™ – Standard) 575-3-60 48TC003234 48TC003239...
Page 64 APPENDIX D — WIRING DIAGRAMS Fig. B — 48JC**04-06 Control Wiring Diagram...
Page 65 APPENDIX D — WIRING DIAGRAMS Fig. C — 48JC**04-06 Power Wiring Diagram — 208/230, 460-3-60...
Page 66 APPENDIX D — WIRING DIAGRAMS Fig. D — 48JC**04-06 Power Wiring Diagram — 575-3-60 © 2021 Carrier Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 04-53480283-01 Printed in U.S.A.
Page 67 START-UP CHECKLIST 48JC04-06 SINGLE PACKAGE ROOFTOP GAS HEAT/ELECTRIC COOLING UNIT (REMOVE AND USE FOR JOB FILE) NOTE: To avoid injury to personnel and damage to equipment or property when completing the procedures listed in this start-up checklist, use good judgment, follow safe practices, and adhere to the safety considerations/information as outlined in the preceding sections of this Service and Maintenance Instructions document.
Page 68 6. Switch unit to OFF by turning Humidimizer test to OFF under the COOL TEST menu Compressor and outdoor fan stop, CLV and RDV solenoids de-energzed (Y/N) ______ © 2021 Carrier Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.

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