Page 1: Table Of Contents
48JC(G/H)*04-06 Single Package Rooftop Ultra Low NOx (14 ng /J) Gas Heat / Electric Cooling Unit with Puron ® (R-410A) Refrigerant 3 to 5 Nominal Tons Service and Maintenance Instructions CONTENTS Changing the Dirt Sensor Test ....21 Remote Station Test .
Page 2: Safety Considerations
APPENDIX A — MODEL NUMBER  NOMENCLATURE......46 WARNING APPENDIX B — PHYSICAL DATA ....47 APPENDIX C —...
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 Filter Access Panel Economizer or Outside Air Damper •...
Page 4: Supply Fan (Blower) Section
SUPPLY FAN (BLOWER) SECTION 17-1/4" WARNING ELECTRICAL OPERATION HAZARD Failure to follow this warning could result in personal injury or death. Before performing service or maintenance operations on unit, LOCKOUT/TAGOUT the main power switch to unit. Divider Electrical shock and rotating equipment could cause severe Outside injury.
Page 5 EVALUATING MOTOR SPEED If installing any accessories listed at the bottom of the Set Up Label, add accessory RPM to base unit RPM in upper portion The direct drive ECM blower motor uses a constant speed design. of the label. Motor speed is controlled by a 0-10 vdc signal, where 10 vdc is NOTE: The Fan Speed Set Up labels are located on the High equal to motor’s maximum RPM.
Page 6 TROUBLESHOOTING THE ECM MOTOR Removing the Motor and Fan Assembly NOTE: Due to press fit design of composite Rotor on Motor, it is EcoBlue™ motors are designed with several built-in protections highly recommended that any time a motor is replaced the fan included in the motor software.
Page 7 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). Fit grommet on motor wire harness into keyhole feature on the side of the stator and pull wire harness out through grommet.
Page 8: Cooling
Reinstalling Motor and Fan Assembly Condenser Coil See Fig. 12. The condenser coil is fabricated with round tube copper hairpins and plate fins of various materials and/or coatings (see Model Align motor harness/grommet at ~7 o’clock (facing installer) Number Nomenclature in Appendix A to identify the materials and align the bottom flats on right and left sides of fan stator provided in this unit).
Page 9 Two-Row Condenser Coils Clean coil as follows: Coil Clips Turn off unit power, tag disconnect. Remove all screws from the top panel except the screws securing the condenser fan to the top panel (see Fig. 13). Top Panel Remove Remove screws Screws from all sides of top panel...
Page 10: Evaporator Coil
Evaporator Coil CLEANING THE EVAPORATOR COIL CAUTION Turn unit power off. Install lockout tag. Remove evapora- UNIT DAMAGE HAZARD tor coil access panel. Failure to follow this caution may result in reduced unit If economizer or two-position damper is installed, remove performance or unit shutdown.
Page 11: Replacing Txv
Replacing TXV Recover refrigerant. Remove TXV support clamp using a 5/l6-in. nut driver. Remove TXV using a wrench and an additional wrench on connections to prevent damage to tubing. Remove equalizer tube from suction line of coil. Use file or tubing cutter to cut brazed equalizer line approximately 2 inches above suction tube.
Page 12: Puron (R-410A) Refrigerant
Puron (R-410A) refrigerant from the cylinder as a vapor. 15.6 Refrigerant Charge Amount of refrigerant charge is listed on the unit’s nameplate. Re- fer to Carrier GTAC2-5 Charging, Recovery, Recycling and Rec- Remove Charge if Below the lamation 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 R-410A Refrigerant Charging Chart R-410A 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 The compressor is charged with the correct amount of oil at the CAUTION factory. EQUIPMENT DAMAGE HAZARD Failure to follow this caution can result in premature wear and CAUTION damage to equipment. 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
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 Mount the weatherproof cover to the backing plate as ELECTRICAL OPERATION HAZARD shown in Fig.
Page 18: Duty Cycle
SMOKE DETECTORS Smoke detectors are available as factory-installed options on 48JC(G/H) models. Smoke detectors may be specified for sup- ply air only, for return air without or with economizer, or in com- bination of supply air and return air. Return air smoke detectors are arranged for vertical return configurations only.
Page 19: Smoke Detector Locations
Air is introduced to the duct smoke detector sensor’s sensing chamber through a sampling tube that extends into the HVAC duct and is directed back into the ventilation system through a (shorter) Supply Air exhaust tube. Smoke Detector The difference in air pressure between the two tubes pulls the sam- pled air through the sensing chamber.
Page 20: Completing Installation Of Return Air Smoke
RETURN AIR SMOKE DETECTOR SENSOR WITH Return Air Smoke Detector ECONOMIZER (Operating Position Shown) The sampling tube is inserted through the side plates of the econo- mizer housing, placing it across the return air opening on the unit basepan (see Fig. 34). The holes in the sampling tube face down- ward, into the return air stream.
Page 21: Sensor And Controller Tests
ADDITIONAL APPLICATION DATA Dirty Sensor Test Refer to the application data document “Factory Installed Smoke The dirty sensor test provides an indication of the sensor’s ability Detectors for Small and Medium Rooftop Units 2 to 25 Tons” to compensate for gradual environmental changes. A sensor that for discussions on additional control features of these smoke de- can no longer compensate for environmental changes is consid- tectors including multiple unit coordination.
Page 22: Sd-Trk4 Remote Alarm Test Procedure
SD-TRK4 Remote Alarm Test Procedure Detector Cleaning Turn the key switch to the RESET/TEST position for CLEANING THE SMOKE DETECTOR seven seconds. Clean the duct smoke sensor when the Dirty LED is flashing con- Verify that the test/reset station’s Alarm LED turns on. tinuously or sooner, if conditions warrant.
Page 23: Troubleshooting
The SuperDuct™ duct smoke detector enters the trouble state Troubleshooting under the following conditions: CONTROLLER’S TROUBLE LED IS ON • A sensor’s cover is removed and 20 minutes pass before it Check the Trouble LED on each sensor connected to the is properly secured.
Page 24: Protective Devices
PROTECTIVE DEVICES GAS HEATING SYSTEM Compressor Protection General The heat exchanger system consists of a gas valve feeding multi- OVERCURRENT ple in-shot burners off a manifold. The burners fire into matching The compressor has internal line-break motor protection. primary tubes. The primary tubes discharge into combustion ple- num where gas flow converges into secondary tubes.
Page 25: Fuel Types And Pressures
Fuel Types and Pressures Combustion-Air Blower Clean periodically to assure proper airflow and heating efficiency. NATURAL GAS Inspect blower wheel every fall and periodically during heating The 48JC unit is factory-equipped for use with natural gas (NG) season. For the first heating season, inspect blower wheel every fuel at elevation under 2000 ft (610 m).
Page 26: Burners And Igniters
CLEANING AND ADJUSTMENT Burners and Igniters Remove gas valve assembly from unit as described in “Removal and Replacement of Gas Train” on page 26. CAUTION If factory orifice has been removed, check that each orifice is tight at its threads into the manifold pipe, and that orifice pro- EQUIPMENT DAMAGE HAZARD jection does not exceed maximum value (see Fig.
Page 27 Heat Exchanger Support Rack Limit Switch Heat Exchanger Cover Panel Unit Center Burner Post Partition Panel Fig. 46 — Heat Exchanger Access - Internal Panels, Center Post and HX Rack Locations GAS VALVE All Ultra-Low NOx models are equipped with a single-stage gas valve.
Page 28: Burner Ignition
CHECK UNIT OPERATION AND MAKE NECESSARY Table 7 — LED Error Code Descriptions ADJUSTMENTS NOTE: Gas supply pressure at gas valve inlet must be within LED INDICATION ERROR CODE DESCRIPTION specified ranges for fuel type and unit size (see Tables 5 and 6). Normal Operation Slide out burner partition panel.
Page 29 Spade Connect Ignitor Redundant Gas Valve Relay Status LED Overcurrent Fuse Protection Fig. 49 — Integrated Gas Control (IGC) Board MINIMUM HEATING ENTERING AIR TEMPERATURE Thermostat When operating on first stage heating, the minimum temperature of air entering the dimpled heat exchanger is 50°F continuous and 45°F intermittent for standard heat exchangers and 40°F continuous and 35°F intermittent for stainless steel heat ex- OALT...
Page 30: Troubleshooting Heating System
Troubleshooting Heating System Refer to Tables 8 and 9 for additional troubleshooting topics. Table 8 — Heating Service Troubleshooting PROBLEM CAUSE REMEDY Misaligned spark electrodes. Check flame ignition and sensor electrode positioning. Adjust as needed. Check gas line for air, purge as necessary. After purging gas line of air, allow gas to dissipate for at least 5 minutes before attempting to relight No gas at main burners.
Page 31 Table 9 — IGC Board LED Alarm Codes FLASH SYMPTOM CAUSE REMEDY CODE Normal Operation — — No Power or Hardware Failure Loss of power to control module Check 5-amp fuse on the IGC, power to unit, 24V circuit breaker, (IGC) and transformer.
Page 32: Systemvu Control System
The user can access a The SystemVu control system is fully communicating and cable- built-in test routine that can be used at start-up commissioning ready for connection to the Carrier Comfort Network (CCN), and troubleshooting.
Page 33 Outdoor Air Detail “A” Temperature (OAT) Sensor Return Air Temperature (RAT) Sensor Detail “A” Supply Air Temperature (SAT) Sensor Fig. 52 — Locations of Air Temperature Sensors...
Page 34: Compressor Vfd
speed ramp protections, however these are smaller than what the COMPRESSOR VFD SystemVu controller uses. Review the Compressor Control sec- The 48JC units are equipped with a variable speed compressor. To tion for SystemVu controller start and ramp functions found in the control this compressor a Variable Frequency Drive (VFD) is re- 48/50JC 04-06 Ultra High Efficiency Single Package Rooftop quired.
Page 35 SENSOR DC- OUT RS485 DC- IN Fig. 54 — Drive Board Table 10 — Drive Board Inputs/Outputs TERMINAL LABEL DESCRIPTION TYPE CONNECTOR High Pressure switch input 3.3 vdc 2 Pins SENSOR DLT sensor input 10k thermistor Pins 1 and 2 (inner 2 pins) Modbus communication with the RS485 RS485 Communication...
Page 36: Converter Board
The converter board has a four-digit display to provide feedback Converter Board for troubleshooting. It will read “IDLE” when in standby waiting The converter board is the primary interface for troubleshooting as for a signal, and the software version “S##.#” will alternate with well as SystemVu’s interface to the VFD.
Page 37 Table 14 — 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 38 Table 14 — Converter Board Error Codes (cont) ERROR CODE FAULT DESCRIPTION DRIVE MODBUS REGISTER ACTION/CAUSE Compressor phase current  foldback protection E-20 Compress Power Module Reg.79|81 Bit3 Temperature Foldback Timeout value (for 30 seconds). Check if the compressor is operating outside the specified speed range.
Page 39 Table 14 — Converter Board Error Codes (cont) ERROR CODE FAULT DESCRIPTION DRIVE MODBUS REGISTER ACTION/CAUSE E-62 Stator Heater Overcurrent Reg.83|85 Bit13 Compress windings are drawing more current than expected in stator heater mode. If problem persist contact application engineer. E-64 Fault Limit Lockout Reg.83|85 Bit15...
Page 40: 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. 56 and Table 15 for more details on the filter board.
Page 41: Capacitor Board
LINE REACTOR Capacitor Board The line reactor is only used on 575 volt units. It is mounted and used in place of the filter board and capacitor board. The line reac- WARNING tor protects the drive board from noise and spikes on the supply voltage.
Page 42: Economizer Systems
ECONOMIZER SYSTEMS Outside Air The unit may be equipped with a factory-installed or accessory Temperature Sensor (field-installed) economizer system without a control system EconoMi$er2 Plug (EconoMi$er2). See Fig. 58 for component locations. Economizers use direct-drive damper actuators. IMPORTANT: Any economizer that meets the economizer requirements as laid out in California’s Title 24 mandatory section 120.2 (fault detection and diagnostics) and/or pre- scriptive section 140.4 (life-cycle tests, damper leakage, 5...
Page 43: 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 44: Return-Air Filters
Refrigerant Service Ports Each unit system has two 1/4-in. SAE flare (with check valves) WARNING service ports: one on the suction line, and one on the compressor discharge line. Be sure that caps on the ports are tight. If the information in this manual is not followed exactly, a fire or explosion may result causing property damage, personal in- Compressor Rotation jury or loss of life.
Page 45: Heating
The evaporator-fan off delay can also be modified. Once the call Heating for heating has ended, there is a 10-minute period during which Purge gas supply line of air by opening union ahead of the the modification can occur. If the limit switch trips during this pe- gas valve.
Page 46 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 - WeatherExpert JC - Ultra High Efficiency Electrical Options A = None...
Page 47 APPENDIX B — PHYSICAL DATA 48JC(G/H) 3 Ton Physical Data 48JC(G/H) UNIT 48JC(G/H)V04 48JC(G/H)W04 NOMINAL TONS BASE UNIT OPERATING WT (lb) REFRIGERATION SYSTEM No. Circuits/No. Compressors/Type 1 / 1 / Variable Speed Scroll 1 / 1 / Variable Speed Scroll Puron (R-410A) Charge A/B (lb-oz) 12-0...
Page 48 APPENDIX B — PHYSICAL DATA (cont) 48JC(G/H) 4 Ton Physical Data 48JC(G/H) UNIT 48JC(G/H)V05 48JC(G/H)W05 NOMINAL TONS BASE UNIT OPERATING WT (lb) REFRIGERATION SYSTEM No. Circuits/No. Compressors/Type 1 / 1 / Variable Speed Scroll 1 / 1 / Variable Speed Scroll Puron ®...
Page 49 APPENDIX B — PHYSICAL DATA (cont) 48JC(G/H) 5 Ton Physical Data 48JC(G/H) UNIT 48JC(G/H)V06 48JC(G/H)W06 NOMINAL TONS BASE UNIT OPERATING WT (lb) REFRIGERATION SYSTEM No. Circuits/No. Compressors/Type 1 / 1 / Variable Speed Scroll 1 / 1 / Variable Speed Scroll Puron ®...
Page 50 APPENDIX B — PHYSICAL DATA (cont) 48JC(G/H) 3 to 5 Ton Gas Heat Data 48JC(G/H) UNIT 48JC(G/H)*04 48JC(G/H)*05 48JC(G/H)*06 GAS CONNECTION No. of Gas Valves Natural Gas Supply Line Pressure  5-13 [0.18-0.47] 5-13 [0.18-0.47] 5-13 [0.18-0.47] (in. wg [psig]) HEAT ANTICIPATOR SETTING (AMPS) First Stage 0.14...
Page 51 Data book. External static pressure is the static pressure difference For more information on the performance limits of Carrier between the return duct and the supply duct plus the static motors, see the Application Data section of the Product pressure caused by any FIOPs or accessories.
Page 52 APPENDIX C — FAN PERFORMANCE (cont) 48JC(G/H)*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...
Page 53 APPENDIX C — FAN PERFORMANCE (cont) 48JC(G/H)*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...
Page 54 APPENDIX C — FAN PERFORMANCE (cont) 48JC(G/H)*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...
Page 55 APPENDIX C — FAN PERFORMANCE (cont) 48JC(G/H)*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...
Page 56 APPENDIX C — FAN PERFORMANCE (cont) 48JC(G/H)*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...
Page 57 APPENDIX C — FAN PERFORMANCE (cont) 48JC(G/H)*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...
Page 58 APPENDIX C — FAN PERFORMANCE (cont) 48JC(G/H)*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...
Page 59 APPENDIX C — FAN PERFORMANCE (cont) 48JC(G/H)*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...
Page 60 APPENDIX C — FAN PERFORMANCE (cont) 48JC(G/H)*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...
Page 61 APPENDIX C — FAN PERFORMANCE (cont) 48JC(G/H)*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...
Page 62 APPENDIX C — FAN PERFORMANCE (cont) 48JC(G/H)*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...
Page 63 APPENDIX C — FAN PERFORMANCE (cont) 48JC(G/H)*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...
Page 64 APPENDIX D — WIRING DIAGRAMS 48JC(G/H)*04-06 Units — Wiring Diagrams CONTROL WIRING POWER WIRING CONTROLLER VOLTAGE PAGE PAGE DIAGRAM DIAGRAM 208/230-3-60 48TC004529 48JC(G/H)*04-06 with 48TC004528 SystemVu Controller 460-3-60 48TC004530...
Page 65 APPENDIX D — WIRING DIAGRAMS (cont) Fig. B — 48JC(G/H)*04-06 — Control Wiring Diagram — 208/230, 460-3-60 — Ultra Low NOx Unit with SystemVu Controller...
Page 66 APPENDIX D — WIRING DIAGRAMS (cont) Fig. C — 48JC(G/H)*04-06 — Power Wiring Diagram — 208/230-3-60 — Ultra Low NOx Unit with SystemVu Controller...
Page 67 APPENDIX D — WIRING DIAGRAMS (cont) Fig. D — 48JC(G/H)*04-06 — Power Wiring Diagram — 460-3-60 — Ultra Low NOx Unit with SystemVu Controller...
Page 70 © 2023 Carrier Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 04-53480306-01 Printed in U.S.A. Form 48JCG-4-6-01SM Pg 70 11-23 Replaces: NEW...
Page 71 START-UP CHECKLIST 48JC(G/H)*04-06 SINGLE PACKAGE ROOFTOP GAS HEATING/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 preceding sec- tions of this Service and Maintenance Instruction document.
Page 72 (Y/N) _____ 10. Restore set points for thermostat and humidistat (Y/N) _____ © 2023 Carrier Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 04-53480306-01 Printed in U.S.A.

This manual is also suitable for:

48jcg 04-06 series

Carrier 48JCH 04-06 Series Service And Maintenance Instructions

Quick Links

Troubleshooting

Related Manuals for Carrier 48JCH 04-06 Series

Summary of Contents for Carrier 48JCH 04-06 Series

This manual is also suitable for:

Table of Contents