Carrier WeatherExpert 48JC04 Installation Instructions Manual
Carrier WeatherExpert 48JC04 Installation Instructions Manual

Carrier WeatherExpert 48JC04 Installation Instructions Manual

Ultra high efficiency single package rooftop gas heating/electric cooling unit with puron (r-410a) refrigerant

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CONTENTS
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . 1
DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Rated Indoor Airflow . . . . . . . . . . . . . . . . . . . . . . . . . . 3
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Jobsite Survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Step 1 - Plan for Unit Location . . . . . . . . . . . . . . . . . 7
Step 3 - Inspect Unit . . . . . . . . . . . . . . . . . . . . . . . . . 7
Step 4 - Provide Unit Support . . . . . . . . . . . . . . . . . . 7
• ALTERNATE UNIT SUPPORT (IN LIEU OF CURB OR
Step 5 - Field Fabricate Ductwork . . . . . . . . . . . . . . 9
Step 6 - Rig and Place Unit . . . . . . . . . . . . . . . . . . . . 9
Ductwork (When Required). . . . . . . . . . . . . . . . . . 10
Step 8 - Install Outside Air Hood . . . . . . . . . . . . . . 11
• ECONOMIZER HOOD PACKAGE REMOVAL AND
Step 10 - Install Flue Hood . . . . . . . . . . . . . . . . . . . 12
Step 11 - Install Gas Piping. . . . . . . . . . . . . . . . . . . 12
(GAS CONNECTIONS)
Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
• ALL UNITS
• HACR AMP RATING
• UNITS WITHOUT THRU-BASE CONNECTIONS
(ELECTRICAL CONNECTIONS)
• FIELD CONTROL WIRING
• SPACE TEMPERATURE SENSOR (SPT)
• THERMOSTAT
• HEAT ANTICIPATOR SETTINGS
• HUMIDI-MIZER® CONTROL CONNECTIONS
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Catalog No. 04-53480282-01
Single Package Rooftop Gas Heating/Electric Cooling Unit
Installation Instructions
Printed in U.S.A.
Form 48JC-4-6-01SI
48JC04-06 Ultra High Efficiency
with Puron
®
Integrated Gas Controller. . . . . . . . . . . . . . . . . . . . . .27
Controller Options . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Smoke Detectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Step 15 - Install Accessories . . . . . . . . . . . . . . . . . .30
Step 16 - Fan Speed Set Up . . . . . . . . . . . . . . . . . . .30
START-UP CHECKLIST . . . . . . . . . . . . . . . . . . . . .CL-1

SAFETY CONSIDERATIONS

Improper
installation,
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
. When you see this symbol on the 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.
WARNING
Electrical shock can cause personal injury and death. Shut
off all power to this equipment during installation. There
may be more than one disconnect switch. Tag all disconnect
locations to alert others not to restore power until work is
completed.
Pg 1
WeatherExpert
(R-410A) Refrigerant
adjustment,
alteration,
5-2020
Replaces: New
®
service,

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  • Page 1: Table Of Contents

    WeatherExpert ® 48JC04-06 Ultra High Efficiency Single Package Rooftop Gas Heating/Electric Cooling Unit with Puron (R-410A) Refrigerant ® Installation Instructions • TYPICAL UNIT WIRING DIAGRAMS CONTENTS Integrated Gas Controller..... .27 SAFETY CONSIDERATIONS .
  • Page 2: Model Number Nomenclature And

    AVERTISSEMENT WARNING RISQUE D’INTOXICATION AU MONOXYDE DE FIRE, EXPLOSION HAZARD CARBONE Failure to follow this warning could result in death, serious Si ces directives ne sont pas suivies, cela peut entraîner des personal injury and/or property damage. blessures graves ou une intoxication au monoxyde de car- bone pouvant causer la mort, si des produits de combustion Disconnect gas piping from unit when pressure testing at s’infiltrent dans le bâtiment.
  • Page 3: Rated Indoor Airflow

    Rated Indoor Airflow Table 1 — Rated Indoor Airflow Table 1 lists the rated indoor airflow used for the AHRI effi- MODEL NUMBER RATED INDOOR AIRFLOW (CFM) ciency rating for the units covered in this document. 48JC**04 1125 48JC**05 1430 48JC**06 2000 Position:...
  • Page 4 Fig. 2 — Unit Dimensional Drawing...
  • Page 5 Fig. 2 — Unit Dimensional Drawing (cont)
  • Page 6 Fig. 2 — Unit Dimensional Drawing (cont)
  • Page 7: Installation

    INSTALLATION Step 2 — Plan for Sequence of Unit Installation The support method used for this unit will dictate different se- Jobsite Survey quences for the steps of unit installation. For example, on curb- Complete the following checks before installation. mounted units, some accessories must be installed on the unit 1.
  • Page 8 ROOF CURB NOTES: POWER WIRING CONTROL WIRING ACCESSORY CONVENIENCE CONNECTOR PKG. ACC. GAS CONNECTION TYPE GAS FITTING ACCESSORY # 1. ROOFCURB ACCESSORY IS SHIPPED DISASSEMBLED. FITTING FITTING OUTLET WIRING CONNECTOR 2. INSULATED PANELS: 25.4 [1"] THK. POLYURETHANE FOAM, 44.5 [1-3/4] # DENSITY. 14"...
  • Page 9: Slab Mount (Horizontal Units Only)

    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. A minimum clearance is not required around ductwork. Step 6 — Rig and Place Unit CAUTION PROPERTY DAMAGE HAZARD Failure to follow this caution may result in damage to roof-...
  • Page 10: Step 7 - Convert To Horizontal And Connect

    "B" 36"- 54" DETAIL "A" PLACE ALL SEAL STRIP IN PLACE REQUIRED (914-1371) BEFORE PLACING UNIT ON ROOF CURB. SPREADER BARS DUCT END "C" "A" SEE DETAIL "A" DIMENSIONS MAX WEIGHT UNIT 48JC**04 74.5 1890 35.8 41.5 1055 48JC**05 1018 74.5 1890 35.8...
  • Page 11: Step 8 - Install Outside Air Hood

    SCREWS HOOD PARTS PLASTIC TIE WRAP QTY (2) DUCT COVERS SHEET METAL FACE UP SCREWS FOR METAL TRAY QTY (2) BASEPAN Fig. 10 — Economizer Hood Parts Location 3. Carefully lift the hood assembly (with metal tray) through the filter access opening and assemble per the steps out- lined in the following section (Economizer Hood).
  • Page 12: Step 9 - Units With Hinged Panels Only

    Step 9 — Units with Hinged Panels Only If the unit does not have hinged panels, skip this step and con- tinue at Step 10 below. PANEL Relocate latch shipped inside the compressor compartment be- hind the hinged compressor door to location shown in Fig. 14 INDOOR COIL ACCESS PANEL after unit installation.
  • Page 13: Factory Option Thru-Base Connections

    0.5 in. wg (124 Pa) between gas regulator source and unit gas Table 3 — Natural Gas Supply Line Pressure Ranges valve connection when unit is operating at high-fire flow rate. The gas supply line can approach the unit in three ways: hori- UNIT MODEL UNIT SIZE MIN.
  • Page 14 Check tightness of connector lock nuts before connecting gas piping. Install a -in. NPT street elbow on the thru-base gas fitting. Attach a -in. pipe nipple with minimum length of 16-in. (406 mm) (field-supplied) to the street elbow and extend it through the access panel at the gas support bracket.
  • Page 15: Step 12 - Install External Condensate Trap And

    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- 9”...
  • Page 16: Step 13 - Make Electrical Connections

    FIELD POWER SUPPLY If equipped with optional Powered Convenience Outlet, the power source leads to the convenience outlet’s transformer pri- mary are not factory connected. Installer must connect these leads according to required operation of the convenience outlet. If an always-energized convenience outlet operation is desired, connect the source leads to the line side of the unit-mounted dis- connect.
  • Page 17: Units With Factory-Installed Non-Fused Disconnect Or Hacr

    Units Without Non-Fused Disconnect or HACR Option Equip GR Lug Disconnect Disconnect 208/230-1-60 Ground (GR) 208/230-3-60 460-3-60 575-3-60 Units With Non-Fused Disconnect or HACR Option Fig. 28 — NFD Enclosure Location Optional Disconnect 3 Phase Only Switch 3 Phase Only Factory Wiring Ground...
  • Page 18: Units Without Factory-Installed Non-Fused Disconnect Or Hacr

    by moving the black wire with the -in. female spade connector from the 230v connection and moving it to the 200v -in. male terminal on the primary side of the transformer. Refer to unit label diagram for additional information. Field power wires will be connected at line-side pressure lugs on the power terminal block or at factory-installed option non-fused disconnect.
  • Page 19 The weatherproof cover kit is secured to the basepan under- neath the control box (see Fig. 34). GFCI RECEPTACLE COVER - WHILE-IN-USE NOT INCLUDED WEATHERPROOF GASKET BASEPLATE FOR GFCI RECEPTACLE Fig. 35 — Weatherproof Cover Installation Non-Powered Convenience Outlet This type requires the field installation of a general-purpose 125-v 15A circuit powered from a source elsewhere in the WEATHERPROOF building.
  • Page 20: Factory-Option Thru-Base Connections (Electrical Connections)

    L1: RED abuse and may cause damage to electrical components. Such L2: GRA operation would invalidate any applicable Carrier warranty. Fig. 36 — Powered Convenience Outlet Wiring max voltage deviation from average voltage % Voltage...
  • Page 21 Fig. 38 shows the wiring connections from the accessory space Space Temperature Sensor (T-56) temperature sensors to the SystemVu MBB. The T-56 space temperature sensor (part no. 33ZCT56SPT) is a field-installed accessory. This sensor includes a sliding scale on the front cover that permits an occupant to adjust the space SYSTEMVU MBB temperature set point remotely.
  • Page 22 Thermostat Wiring, Units Without Thru-Base Connection Kit THERMOSTAT Pass the thermostat control wires through the hole provided in Install a Carrier-approved accessory thermostat according to the corner post; then feed the wires through the raceway built installation instructions included with the accessory. For com- into the corner post to the control box.
  • Page 23: Typical Unit Wiring Diagrams

    Main Base Board Fig. 44 — Accessory Field-Installed Humidistat TYPICAL UNIT WIRING DIAGRAMS Connecting the Carrier Humidistat (HL38MG029) 1. Route the humidistat 2-conductor cable (field-supplied) See Fig. 46-48 for examples of typical unit control and power wiring diagrams. These wiring diagrams are mounted on the through the hole provided in the unit corner post.
  • Page 24 Fig. 46 — 48JC 04-06 Control Wiring Diagram...
  • Page 25 Fig. 47 — 48JC 04-06 Power Wiring Diagram, 208/230, 460V Unit Shown...
  • Page 26 Fig. 48 — 48JC 04-06 Power Wiring Diagram, 575V Unit Shown...
  • Page 27: Integrated Gas Controller

    When the thermostat calls for heating, power is sent to W on Integrated Gas Controller the Integrated Gas Controller (IGC) board. An LED (light This unit contains an Integrated Gas Controller (IGC) board. emitting diode) on the IGC board turns on and remains on The IGC control board uses a flue gas pressure switch that during normal operation.
  • Page 28 Table 7 — IGC Board LED Alarm Codes ACTION TAKEN BY FLASH DESCRIPTION RESET METHOD PROBABLE CAUSE CONTROL CODE Normal Operation — — — Hardware Failure No gas heating. — Loss of power to the IGC. Check 5 amp fuse on IGC, power to unit, 24V circuit breaker, transformer, and wiring to the IGC.
  • Page 29: Controller Options

    Controller Options LOW AMBIENT RETURN AIR Refer to the 48/58JC 04-06 Single Package Rooftop Units with SMOKE DETECTOR (AS SHIPPED) SystemVu Controller Controls, Start-up, Operation and Trou- bleshooting manual for details on adjusting “Cooling Lock- Out” setting and configure for the specific job requirements. Smoke Detectors Smoke detectors are available as factory-installed options on 48JC models.
  • Page 30: Step 14 - Adjust Factory-Installed Options

    Step 14 — Adjust Factory-Installed Options Step 16 — Fan Speed Set Up SMOKE DETECTORS SYSTEMVU™ CONTROLS Smoke detector(s) will be connected to the SystemVu Main The fan speed settings are accessed through the SystemVu Base Board at J5. interface. 1.
  • Page 31 ESP in. wg Calculator 1425 1609 1764 1902 2028 2147 2260 2367 1500 1512 1688 1839 1974 2097 2212 2322 1625 1601 1768 1916 2047 2168 2280 2387 1750 1692 1850 1994 2123 2241 2351 1875 1784 1933 2073 2200 2316 2000 1878...
  • Page 34 © 2020 Carrier Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Catalog No. 04-53480282-01 Printed in U.S.A. Form 48JC-4-6-01SI Pg 34 5-2020 Replaces: New...
  • Page 35: Start-Up Checklist

    START-UP CHECKLIST FOR 48JC**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 Installation Instruction document.
  • Page 36 8. Open humidistat input compressor and outdoor fan stop; LSV and DSV solenoids de-energized (Y/N) _____ 9. Restore set points for thermostat and humidistat (Y/N) _____ © 2020 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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