Carrier 48LC Series Service And Maintenance Instructions
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Carrier 48LC Series Service And Maintenance Instructions

Nominal 3 to 5 tons single package rooftop gas heating/electric cooling unit with puron (r-410a) refrigerant
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48LC*04---06
Nominal 3 to 5 Tons
Single Package Rooftop
Gas Heating/Electric Cooling Unit
with Puronr (R---410A) Refrigerant
Service and Maintenance Instructions

TABLE OF CONTENTS

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SAFETY CONSIDERATIONS

1
Installation and servicing of air-conditioning equipment
can be hazardous due to system pressure and electrical
2
components. Only trained and qualified service personnel
should
install,
repair,
4
equipment. Untrained personnel can perform the basic
6
maintenance functions of replacing filters. Trained service
personnel should perform all other operations.
8
When working on air-conditioning equipment, observe
9
precautions in the literature, tags and labels attached to
the unit, and other safety precautions that may apply.
Follow all safety codes. Wear safety glasses and work
gloves. Use quenching cloth for unbrazing operations.
Have fire extinguishers available for all brazing
operations.
Follow all safety codes. Wear safety glasses and work
gloves. Use quenching cloth for brazing operations. Have
fire extinguisher available. Read these instructions
thoroughly and follow all warnings or cautions attached to
the unit. Consult local building codes and National
Electrical Code (NEC) for special requirements.
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, and
CAUTION. 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 a hazard 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.
or
service
air-conditioning

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  • Page 1: Table Of Contents

    48LC*04---06 Nominal 3 to 5 Tons Single Package Rooftop Gas Heating/Electric Cooling Unit with Puronr (R---410A) Refrigerant Service and Maintenance Instructions TABLE OF CONTENTS SAFETY CONSIDERATIONS SAFETY CONSIDERATIONS ....Installation and servicing of air-conditioning equipment can be hazardous due to system pressure and electrical UNIT ARRANGEMENT AND ACCESS...

  • Page 2: Unit Arrangement And Access

    WARNING WARNING FIRE, EXPLOSION HAZARD FIRE, EXPLOSION HAZARD Failure to follow this warning could result in personal Failure to follow this warning could result in injury or death. personal injury, death and/or property damage. Disconnect gas piping from unit when pressure testing Refer to the User’s Information Manual provided at pressure greater than 0.5 psig.
  • Page 3 Quarterly Inspection (and 30 days after initial start) Return Air Filters S Return air filter replacement Return air filters are disposable fiberglass media type. Access to the filters is through the small lift- - out panel S Outdoor hood inlet filters cleaned located on the rear side of the unit, above the S Belt tension checked evaporator/return air access panel.

  • Page 4: Supply Fan (Blower) Section

    Belt Manual Outside Air Hood Screen This inlet screen is secured by a retainer angle across the Check the belt condition and tension quarterly. Inspect the top edge of the hood. (See Fig. 4.) belt for signs of cracking, fraying or glazing along the inside surfaces.
  • Page 5 Check the condition of the motor pulley for signs of wear. Glazing of the belt contact surfaces and erosion on these surfaces are signs of improper belt tension and/or belt slippage. Pulley replacement may be necessary. To change fan speed: 1.

  • Page 6: Cooling

    This cleaner available from Carrier Replacement UNIT OPERATION AND SAFETY HAZARD Components Division as part number P902- - 0301 for a one Failure to follow this warning could cause personal gallon container, and part number P902- - 0305 for a 5 injury, death and/or equipment damage.
  • Page 7 CAUTION UNIT DAMAGE HAZARD Failure to follow this caution may result in accelerated corrosion of unit parts. Harsh chemicals, household bleach or acid or basic cleaners should not be used to clean outdoor or indoor coils of any kind. These cleaners can be very difficult to rinse out of the coil and can accelerate corrosion at the fin/tube interface where dissimilar materials are in C08206...

  • Page 8: Puronr (R- -410A) Refrigerant

    Amount of refrigerant charge is listed on the unit’s Service requires replacing the entire liquid header nameplate. Refer Carrier GTAC2- - 5 Charging, assembly. Recovery, Recycling and Reclamation training manual To check for possible blockage of one or more of these and the following procedures.

  • Page 9: Thermostatic Expansion Valve (Txv)

    SEAT CORE (Part No. EC39EZ067) 1/2-20 UNF RH 0.596 WASHER DEPRESSOR PER ARI 720 O-RING +.01/-.035 1/2" HEX FROM FACE OF BODY 5/8” HEX 7/16-20 UNF RH This surface provides a metal to metal seal when torqued into the seat. Appropriate handling is required to not scratch or dent the surface.

  • Page 10: Cooling Charging Charts

    COOLING CHARGING CHARTS C14037 Fig. 13 - - Cooling Charging Charts - - 3 Ton...
  • Page 11 COOLING CHARGING CHARTS (cont.) C14038 Fig. 14 - - Cooling Charging Charts - - 4 Ton...
  • Page 12 COOLING CHARGING CHARTS (cont.) C14039 Fig. 15 - - Cooling Charging Charts - - 5 Ton...
  • Page 13 Table 1 – Cooling Service Analysis PROBLEM CAUSE REMEDY Power failure. Call power company. Fuse blown or circuit breaker tripped. Replace fuse or reset circuit breaker. Defective thermostat, contactor, transformer, Replace component. Compressor and Condenser or control relay. Fan Will Not Start. Insufficient line voltage.

  • Page 14: Convenience Outlets

    Compressor Filter Drier Replace whenever refrigerant system is exposed to Lubrication atmosphere. Only use factory specified liquid- - line filter driers with working pressures no less than 650 psig. Do The compressor is charged with the correct amount of oil not install a suction- - line filter drier in liquid line.

  • Page 15: Smoke Detectors

    UNIT CONNECT PRIMARY TRANSFORMER Pwd-CO Transformer VOLTAGE CONNECTIONS TERMINALS Conv Outlet 208, L1: RED +YEL H1 + H3 GFCI L2: BLU + GRA H2 + H4 L1: RED Pwd-CO Splice BLU + YEL H2 + H3 Fuse L2: GRA Switch L1: RED L2: GRA Duty Cycle: The unit- - powered convenience outlet has a...
  • Page 16 Controller The difference in air pressure between the two tubes pulls the sampled air through the sensing chamber. When a The controller (see Fig. 19) includes a controller housing, sufficient amount of smoke is detected in the sensing a printed circuit board, and a clear plastic cover. The chamber, the sensor signals an alarm state and the controller can be connected to one or two compatible duct controller automatically takes the appropriate action to...
  • Page 17 Smoke Detector Sensor Return Air Sampling Tube C08245 C08129 Fig. 21 - - Typical Supply Air Smoke Detector Sensor Fig. 23 - - Return Air Sampling Tube Location Location Completing Installation of Return Air Smoke Return Air without Economizer — The sampling tube is Sensor: located across the return air opening on the unit basepan.
  • Page 18 FIOP Smoke Detector Wiring and Response FIOP/ PL19- POWER ACCESSORY 24 VAC RETURN SMOKE RJ-45 SENSOR SUPPLY FROM POWER SCHEMATIC RJ-45 SMOKE TRAN SENSOR TROUBLE 3.2 AMPS GRN/YEL ALARM CONTROL BD SMOKE CONTROL MODULE FIOP/ACCESSORY TRAN LCTB-C COFS(FIOP) COFS FIOP/ACCY CCHTS CCHR CONT...
  • Page 19 Sensor Alarm Test Procedure A sensor that can no longer compensate for environmental changes is considered 100% dirty and requires cleaning or 1. Hold the test magnet where indicated on the side of replacing. You must use a field provided SD- - MAG test the sensor housing for seven seconds.
  • Page 20 on and its Dirty LED flashes twice (approximately 60 CAUTION seconds). 2. Reset the sensor by removing the test magnet then OPERATIONAL TEST HAZARD holding it against the sensor housing again until the sensor’s Alarm LED turns off (approximately 2 Failure to follow this caution may result in personnel seconds).
  • Page 21 1. Disconnect power from the duct detector then remove LED turn on. the sensor’s cover. (See Fig. 28.) S The contacts on the controller’s two auxiliary relays switch positions. HVAC duct Sampling S The contacts on the controller’s alarm initiation relay tube Sensor close.

  • Page 22: Protective Devices

    Resetting Alarm and Trouble Condition Trips: Remote Test/Reset Station’s Trouble LED Does Not flash When Performing a Dirty Test, But the Manual reset is required to restore smoke detector systems Controller’s Trouble LED Does to Normal operation. For installations using two sensors, the duct smoke detector does not differentiate which 1.

  • Page 23: Gas Heating System

    The standard supply fan motor is equipped with internal overcurrent and overtemperature protection. Protection Limit Switch devices reset automatically. and Shield The High Static option supply fan motor is equipped with a pilot- - circuit Thermix combination overtemperature/ overcurrent protection device.
  • Page 24 Table 6 – Liquid Propane Supply Line Pressure Ranges This switch also prevents operation when the propane tank level is low which can result in gas with a high UNIT MODEL UNIT SIZE concentration of impurities, additives, and residues that 11.0 in.
  • Page 25 Regulator Heater Tube Gasket Seal Strips, Sponge Rubber Regulator Assembly Baffle Assembly (Low NOx only) Retainer Support Insulation Assembly Wind Cap Assembly (shown inverted, as shipped) Flue Baffle (Low NOx only) Inducer Fan-Motor Assembly Burner Assembly C08227 Fig. 34 - - Heat Exchanger Assembly...
  • Page 26 Burners and Igniters 6. Remove igniter wires and sensor wires at the Integ- rated Gas Unit Controller (IGC). (See Fig. 37.) CAUTION 7. Remove the 2 screws that attach the burner rack to the vestibule plate (Fig. 34). 8. Slide the burner tray out of the unit (Fig. 36). EQUIPMENT DAMAGE HAZARD 9.
  • Page 27 Check Unit Operation and Make Necessary they are blue in appearance, and that the flames are Adjustments approximately the same for each burner. 10. Turn off unit, remove pressure manometer and re- NOTE: Gas supply pressure at gas valve inlet must be place the 1/8 in.
  • Page 28 Hardware Failure indicates orifice reference size). When replacing unit 1 Flash{ Evaporator Fan On/Off Delay Modified orifices, order the necessary parts via Carrier RCD. See 2 Flashes Limit Switch Fault Table 10 for available orifice sizes. See Table 11 and...
  • Page 29 Red LED-Status C08452 Fig. 40 - - Integrated Gas Control (IGC) Board Table 9 – IGC Connections CONNECTION TERMINAL LABEL POINT DESCRIPTION SENSOR LOCATION TYPE OF I/O PIN NUMBER INPUTS RT, C Input power from TRAN 1 control box 24 VAC —...
  • Page 30 Table 10 – Orifice Sizes ORIFICE CARRIER DRILL DRILL SIZE PART NUMBER DIA. (in.) LH32RF129 0.1285 LH32RF125 0.1250 LH32RF120 0.1200 LH32RF116 0.1160 LH32RF113 0.1130 LH32RF111 0.1110 LH32RF110 0.1100 LH32RF105 0.1065 LH32RF104 0.1040 LH32RF102 0.1015 LH32RF103 0.0995 LH32RF098 0.0980 LH32RF096 0.0960 LH32RF094 0.0935...
  • Page 31 Table 12 – Altitude Compensation (48LCL/M/N*04- - 06) - - Low NO Units 60,000, 90,000 120,000 ELEVATION BTUH Nominal BTUH Nominal ft (m) NG Orifice Size NG Orifice Size 0 --- 2000 (610) 2000 (610) 3000 (914) †40 4000 (1219) †41 5000 (1524) †41...
  • Page 32 Table 13 – Heating Service Analysis PROBLEM CAUSE REMEDY Check flame ignition and sensor electrode positioning. Misaligned spark electrodes. 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 No gas at main burners.
  • Page 33 Table 14 – 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 on IGC, power to unit, 24V circuit Hardware Failure No gas heating.

  • Page 34: Economizer Systems

    ECONOMIZER SYSTEMS OUTDOOR AIR HOOD The 48LC 04- - 06 units may be equipped with a factory- - installed or accessory (field- - installed) economizer ECONOMI$ER2 HOOD PLUG system. Two types are available: with a logic control SHIPPING BRACKET system (EconoMi$er X) and without a control system (EconoMi$er2, for use with external control systems such as RTU Open).

  • Page 35: Wiring Diagrams

    WIRING DIAGRAMS C14043 Fig. 44 - - Unit Wiring Diagram - - Power (208/230V, 460V 3 Phase)
  • Page 36 C14044 Fig. 45 - - Unit Wiring Diagram - - Power (575V 3 Phase)
  • Page 37 C14045 Fig. 46 - - Unit Wiring Diagram - - Control...

  • Page 38: Pre- -Start- -Up

    PRE- -START- -UP WARNING WARNING PERSONAL INJURY AND ENVIRONMENTAL HAZARD PERSONAL INJURY HAZARD Failure to follow this warning could result in personal Failure to follow this warning could result in personal injury or death. injury or death. Relieve pressure and recover all refrigerant before 1.
  • Page 39 NOTE: When the compressor is rotating in the wrong WARNING direction, the unit will make an elevated level of noise and will not provide cooling. UNIT OPERATION AND SAFETY HAZARD Cooling Failure to follow this warning could result in personal Set space thermostat to OFF position.

  • Page 40: Fastener Torque Values

    Ventilation (Continuous Fan) the on delay can be reduced to 0 seconds and the off delay can be extended to 180 seconds. Set fan and system selector switches at ON and OFF If the limit switch trips at the start of the heating cycle positions, respectively.

  • Page 41: Appendix I. Model Number Significance

    APPENDIX I. MODEL NUMBER SIGNIFICANCE Model Number Nomenclature 10 11 12 13 14 15 16 17 18 4 8 L C D 0 0 6 A 0 A 5 -- 0 A 0 A 0 ____ ____ ____ Unit Type Brand / Packaging 48 = Gas Heat Packaged 0 = Standard...

  • Page 42: Appendix Ii. Physical Data

    APPENDIX II. PHYSICAL DATA PHYSICAL DATA (COOLING) 3 - - 6 TONS 48LC*004 48LC*005 48LC*006 Refrigeration System # Stages/ # Comp. / Type 2 / 1 / Scroll 2 / 1 / Scroll 2 / 1 / Scroll R--- 410A charge A/B (lbs --- oz) 9 --- 2 9 --- 0 11 --- 0...
  • Page 43 APPENDIX II. PHYSICAL DATA (cont.) PHYSICAL DATA (HEATING) 3 - - 6 TONS 48LC**04 48LC**05 48LC**06 Gas Connection # of Gas Valves Nat. gas supply line press (in. w.g.)/(PSIG) 4 --- 13 / 0.18 --- 0.47 4 --- 13 / 0.18 --- 0.47 4 --- 13 / 0.18 --- 0.47 Propane supply line press (in.

  • Page 44: Appendix Iii Fan Performance

    APPENDIX III FAN PERFORMANCE Table 16 – 48LC*004, 3 phase, 3 ton vertical supply Available External Static Pressure (in. wg) 0.14 0.25 0.38 0.53 0.69 0.17 0.28 0.41 0.56 1016 0.72 1050 0.19 0.30 0.44 0.59 1036 0.76 0.22 1125 0.33 0.47 0.63...
  • Page 45 APPENDIX III FAN PERFORMANCE cont. Table 18 – 48LC*005, 3 phase, 4 ton vertical supply Available External Static Pressure (in. wg) 0.25 0.37 0.51 1200 0.67 1077 0.84 1300 0.30 0.42 0.57 1028 0.73 1105 0.90 1400 0.35 0.48 0.63 1058 0.79 1134...
  • Page 46 APPENDIX III FAN PERFORMANCE cont. Table 20 – 48LC*006, 3 phase, 5 ton vertical supply Available External Static Pressure (in. wg) 0.41 1500 0.55 1067 0.68 1158 0.81 1240 0.93 1625 0.50 1010 0.65 1109 0.79 1198 0.93 1278 1.07 1750 0.59 1056...
  • Page 48 Catalog No: 48LC ---04---06---01SM Copyright 2014 Carrier Corp. D 7310 W. Morris St. D Indianapolis, IN 46231 Edition Date: 01/14 Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations. Replaces: New...

  • Page 49: Unit Start-Up Checklist

    UNIT START-UP CHECKLIST I. PRELIMINARY INFORMATION MODEL NO.: SERIAL NO.: DATE: TECHNICIAN: II. PRE-START-UP (insert checkmark in box as each item is completed) j VERIFY THAT JOBSITE VOLTAGE AGREES WITH VOLTAGE LISTED ON RATING PLATE j VERIFY THAT ALL PACKAGING MATERIALS HAVE BEEN REMOVED FROM UNIT j REMOVE ALL SHIPPING HOLD DOWN BOLTS AND BRACKETS PER INSTALLATION INSTRUCTIONS j VERIFY THAT CONDENSATE CONNECTION IS INSTALLED PER INSTALLATION INSTRUCTIONS j VERIFY THAT FLUE HOOD IS INSTALLED...
  • Page 50 SET ECONOMIZER MINIMUM VENT AND CHANGEOVER SETTINGS TO MATCH JOB REQUIREMENTS (IF EQUIPPED) Catalog No: 48LC ---04---06---01SM Copyright 2014 Carrier Corp. D 7310 W. Morris St. D Indianapolis, IN 46231 Edition Date: 01/14 Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.

This manual is also suitable for:

48lc 04 series48lc 05 series48lc 06 series48lcd006a0a5-0a0a0

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