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38AK,38AKS,38AQS008-012 48/50H J,48/50TJ,50LJQ008-014 Accessory Low Ambient Operation Motormaster® III Control Package 50/60 Hz
Installation Instructions
Part Numbers: CAMOTOR3001AOO, CAMOTOR3002A00
CONTENTS |
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Page |
SAFETY CONSIDERATIONS................................... |
1 |
GENERAL .............................................................. |
1,2 |
INSTALLATION...................................................... |
2-16 |
Step 1 — Install Motor ............................................. |
2 |
Step 2 — Install Motormaster III |
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Controller .............................................................. |
3 |
Step 3 — Install Sensor ........................................... |
3 |
Step 4 — Make Electrical Connections ................. |
6 |
Step 5 — Install Field-Fabricated |
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Wind Baffies and Brackets.................................. |
6 |
Step 6 — Restore Power to Unit.............................. |
6 |
TROUBLESHOOTING .......................................... |
17 |
SAFETY CONSIDERATIONS |
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Installation, start-up, and servicing of this |
equipment |
can be hazardous due to system pressures, electrical com |
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ponents, and equipment location (roofs, elevated struc |
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tures, etc.)- |
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Only trained, qualified installers and service technicians |
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should install, start up, and service this equipment. |
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When working on this equipment, observe precautions in |
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the literature and on tags, stickers, and labels attached to |
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the equipment and any other safety precautions that may |
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apply. |
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The Motormaster III device is a motor speed control de vice which adjusts condenser fan motor speed in response to declining liquid temperatures. A properly applied Motormaster III control extends the operating range of air condi tioning systems and permits operation at lower outdoor am bient temperatures.
Table 1 shows the ambient temperature in cooling at which each unit will operate without modification.
Table 1 — Unit Ambient Temperature Operation
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COMPRESSOR |
CONDENSER |
MINIMUM |
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UNIT |
TEMP |
OUTDOOR |
|||
CAPACITY |
TEMP |
||||
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F(C) |
||||
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F(C) |
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Small Rooftop Units |
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All |
100% |
90 (32) |
25 |
(--1) |
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Split System Units |
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38AQS008 (60 Hz) |
100% |
90 (32) |
55 |
(13) |
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38AK/AKS008 |
100% |
90 (32) |
60 |
(15) |
|
(50/60 Hz) |
|||||
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|
|
|
||
38AKS009 (60 Hz) |
100% |
90 (32) |
53 |
(12) |
|
38AKS009 (50 Hz) |
100% |
90 (32) |
57 |
(14) |
|
38AKS012* |
100% |
90 (32) |
48 |
(9) |
|
(50/60 Hz) |
67% |
80 (27) |
52 |
(11) |
|
38AK012 |
100% |
90 (32) |
52 |
(11) |
|
(50/60 Hz) |
|||||
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* Unit has one step of unloading.
A WARNING
Open all remote disconnects before servicing this equip ment. Electrical shock could result in personal injury.
GENERAL
This book contains instructions for the installation, start-up, and service of the Motormaster III control on 38AKS008-012, 38AQS008, 38AK008-012, 48/50TJ008014, 48/50HJ008-014, and 50LJQ008,012 units. The Motormaster III control is not used on 50-Hz versions of the 50HJ008-014 and 50LJQ008,012 units.
NOTE: The Motormaster III control is not used on 48/50HJ and 48/50TJ units with 2 condenser fans. The control is used on single condensing fan units only.
The Motormaster III accessory is UL (Underwriters’ Lab oratories) and CSA (Canadian Standards Association) approved on all split system and small rooftop electric cool ing and gas heating/electric cooling units.
To operate the units below the ambient temperatures in Table 1, wind baffles and the Motormaster III control pack age must be added. The Motormaster III control permits operation of the unit to an ambient temperature of -20 F (-29 C) for small rooftop units, and 0 F (-18 C) for split system units.
The Motormaster III regulates the speed of 3-phase fan motors which are compatible with the control. These motors are included in the package. See Tables 2 and 3 for the contents of the Motormaster III accessory packages. The CAMOTOR3001A00 package contains a motor for 208/230 volt, 60 Hz and 220 volt, 50 Hz applications. The CAMOTOR3002A00 package contains a motor for 460 and 575 volt, 60 Hz and 400 volt, 50 Hz applications. See Fig. 1.
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obiigations.
Book|1 |1 |1 |1 |4 |4 |4 |4 |
PC 111 Catalog No 533-803 Printed in U S A. Form 38/48/50-4SI Pg 1 |
1-95 Replaces: New |
Tab la 1b 3a 5a 2a 5a 6a 6b |
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|
Table 2 - Motormaster® III Control Package CAMOTOR3001A00, 208/230 v, 60 Hz and 220 v, 50 Hz Applications
QUANTITY |
ITEM |
PART NO. |
1 |
Motormaster III Control |
HR46GN001 |
1 |
Sensor |
30GT412176 |
1 |
Motor |
HD52GK208 |
8 |
Screw (5/16-In.) |
AL81AS216 |
1 |
Relay |
HN61KZ024 |
2 |
Screw (no. 6 — 20 X 3/4-ln ) |
AL56AU128 |
1 |
Bracket |
50DK507132 |
1 |
Socket |
HY07RB030 |
Table 3 — Motormaster III Control Package CAMOTOR3002A00, 460 and 575 v, 60 Hz and 400 V, 50 Hz Applications
QUANTITY |
ITEM |
PART NO. |
1 |
Motormaster III Control |
HR46GN001 |
1 |
Sensor |
30GT412176 |
1 |
Motor |
HD52GK460 |
8 |
Screw (5/16-in ) |
AL81AS216 |
1 |
Relay |
HN61KZ024 |
2 |
Screw (no. 6 — 20 X 3/4-in.) |
AL56AU128 |
1 |
Bracket |
50DK507132 |
1 |
Socket |
HY07RB030 |
Before Installing — inspect the contents of the acces sory package before installing. File a claim with the ship per if shipping damage is found. Contact the Carrier dis tributor if a part is missing.
3 1/4 IN.
(83 mm)
16 IN
(406 mm)
MOUNTING BASE
/
INSTALLATION
Step 1 — Install Motor
A WARNING
To avoid the possibility of electrical shock, open all disconnects before installing or servicing this accessory.
1.Shut off unit power supply.
2.Remove unit access panel and control box cover.
3.Disconnect fan motor connection in control box and remove motor leads from control box.
4.Remove condenser fan assembly (grille, motor, motor cover, and fan) by removing the 6 grille holddown screws.
5.Loosen fan hub set screws and remove condenser fan from motor shaft.
6.Carefully lift off motor cover.
7.Remove the 4 holddown nuts that attach the motor to the grille. Pull the motor wires through the grille conduit.
8.Cut back the steel conduit on the grille (one grille wire width) to allow adequate space for new fan motor.
9.Feed the Motormaster III motor wires through the con duit and install motor from accessory kit onto grille us ing nuts from Step 7.
10.Replace the motor cover on the grille using the square cutouts.
11.Replace condenser fan on motor shaft.
12.Adjust fan height as shown in Fig. 2.
13. Tighten set screws on fan hub to 7 ft-lbs (9.52 N-m [newton-meters]) ± 1 ft-lb (1.5 N-m).
NOTE: On 48HJ009 and 48HJ/TJ014 units, perform Step 2
— Install the Motormaster III Controller through Step 4 — Make Electrical Connections, before reinstalling the con denser fan. Motormaster III installation is done through the condenser fan opening with the fan and motor removed.
14. Reinstall condenser fan assembly onto unit using screws from Step 4. Torque to 20 in.-lbs (2260 mN-m)
±2 in.-lbs (226 mN-m).
15.Pull motor wires completely through conduit.
MOTOR COVER |
OUTLET GRILLE |
Fig. 2 — Condenser Fan Height Adjustment
Fig. 1 — Motormaster III Control
Step 2 — Install Motormaster® III Controller
1. Configure the control signal selection switch. Remove the cover of the Motormaster III control. Set the switch on the Motormaster III control board (underneath cover) to accept the thermistor (sensor) input signal. Set the frequency switch to match the unit power supply (50 Hz or 60 Hz). See Fig. 3 for switch locations and proper position. Replace the cover.
2. 38AK008.012; 38AKS008-012; 48HJ008,012; 48TJ008012; 50HJ/TJ008-014; AND 50UQ008,012; UNITS WITH SINGLE POINT BOX: Mount the Motormaster III con troller on the unit in the location specified in Fig. 4-6. The controller must be mounted vertically with the leads at the bottom. Using the template provided on the last page of the book, mark the 4 mounting hole locations. Mount the controller using the Yie-in. self-drilling screws provided.
A CAUTION
To avoid damaging components and wiring, use ex treme care when drilling screw holes and screwing in fasteners.
50HJ/TJ008-014 AND 50LJQ008,012 UNITS WITH OUT SINGLE POINT BOX; 48HJ009 (208/230 AND 460 V); AND 48HJ/TJ014 UNITS: Mount the Motormaster III controller on the unit in the location spec ified in Pig. 7 and 8. The controller must be mounted vertically with the leads at the bottom. Using the tem plate supplied on the last page of the manual, mark the 4 mounting locations. Mount the controller using the yi6-in. self-drilling screws provided. To prevent any water leakage though the bulkhead (the partition sepa rating the indoor and outdoor sections), an electric
component compatible, general purpose silicon rubber sealant must be used along the 4 edges of the controller and at the 4 mounting-screw locations.
38AQS008 AND 48HJ009 (575 V) UNITS: The Motormaster III controller must be mounted on a sheet metal bracket provided. Mount the bracket on the unit in the location specified in Fig. 9 and 10 using four yi6-in. self-drilling screws provided. If needed, a bracket mounting template is provided on page 21. The control ler must be mounted vertically, with the leads at the bottom. Mount the controller on the bracket using the remaining four 5/16-in. self-drilling screws. See Fig. 11 for controller mounting details.
Step 3 — Install Sensor
38AK008,012; 38AKS008-012 AND 48/50HJ,TJ008-014 UNITS — Install the sensor for thermistor input control on the header tube designated in Fig. 12. Connect the sensor leads to the violet and gray control signal leads on the Motormaster III controller. Wrap and tie excess sensor wir ing. Refer to Step 4 — Make Electrical Connections and the unit wiring diagram for more information on wiring the sensor.
A CAUTION
I Sensor assembly is delicate. Handle with care. |
38AQS008 AND 50LJQ008,012 UNITS - Wiring is fieldsupplied. Wiring must be 16 AWG (American Wire Gage) (1.5 mm^), appliance wiring material, rated 75 C or its equiv alent, with %4-in. (.8 mm) minimum insulation thickness. All wiring must comply with NEC (National Electrical Code) and applicable local codes.
50 HZ |
PHASE SEQUENCE |
,(o^ |
INDICATOR |
ADJUST SWITCH |
|
|
TO MATCH LINE |
60 HZ |
FREQUENCY |
|
ADJUST SWITCH TO \ MATCH INPUT
k CONTROL SIGNAL
CONTROL INPUT
___ CE]__________
(SENSOR) THERMISTOR* 4 - 20 mA
LEGEND
GND — Ground
*For thermistor (sensor) signal, move switch to the left.
NOTE: Thermistor is designated in text as “sensor.”
□
LHizzi
□
LEADS TO POWER
SOURCE
BLACK LI
BLUEL3 -
YELL2
LEADS TO
MOTOR
GRN (GND) CONTROL SIGNAL LEADS
+VIO -GRAY
3 HOLES 0 88 DIA (FOR 1/2 IN CONDUIT)-
Fig. 3 — Motormaster III Control Signal Selection Switch
TOP VIEW
UJ |
|
z |
|
< |
Lil |
a. |
Z |
-CO |
< |
CO |
0. |
LU |
CO |
o |
-CO |
o |
iii |
< |
o |
|
o |
|
< |
Fig. 5 — Motormaster III Controller Location
50HJ,50LJQ,50TJ008-014
(With Single Point Box)
K
Fig. 7 - Motormaster III Controller Location - 50HJ, 50LJQ, 50TJ008-014 (Without Single Point Box)
TOP VIEW
Fig. 8 — Motormaster® III Controller Location — |
Fig. 10 — Motormaster III Controller Location — |
48HJJJ014, All Voltages; 48HJ009, 208/230, |
|
460-3-60 Only |
38AQS008 |
TOP VIEW |
|
SIDE VIEW |
FRONT VIEW |
Fig. 9 — Motormaster III Controller Location |
|
48HJ009 (575 V) |
Fig. 11 — Motormaster Hi Controller Mounting |
Install the sensor for thermistor input control on the header tube designated in Fig. 13 and 14. Insert relay into socket. Install the Motormaster® III relay in the unit control box, in the location specified in Fig. 15 and 16. Use the two no. 6-20 X 3/4-in. screws provided.
Connect one sensor lead to the violet control signal lead on the Motormaster III controller and to a field-supplied 16 AWG wire with a wirenut. Connect the remaining sensor lead to the gray control sensor lead on the Motormaster III controller and to another field-supplied 16 AWG wire with a wirenut.
Route both field-supplied wires through a factorypunched access hole under the control box. Attach the wires to screw terminals 1 and 9 on the Motormaster III relay in the control box. Wrap and tie excess sensor wiring. Wrap wirenuts with waterproof tape to prevent them from loos ening and to ensure watertightness. Refer to Step 4 - Make Electrical Connections and the unit wiring diagram for more information on wiring the sensor.
A CAUTION
Sensor assembly is delicate. Handle with care.
Step 4 — Make Electrical Connections
A WARNING
To avoid possibility of electrical shock and personal injury, turn off all power to unit before making elec trical connections. Tag all disconnects to alert others not to turn on power until work is completed.
The wires necessary for wiring the Motormaster III con trol to the unit must be field-supplied. Use 16 AWG (Amer ican Wire Gage) (1.5 mm^) appliance material wire, with 2/64-in. (.8 mm) minimum insulation thickness. Use 75 C type or equivalent. All wiring must comply with NEC (National Electrical Code) and applicable local codes.
38AK008,012 AND 38AKS008-012 UNITS - Power wir ing must comply with all local and national electrical code (NEC) requirements. Refer to Eig. 17-19 for power wiring connections. Utilize field-supplied wirenuts and 'A in. insulated female quick-connects for making power wiring connections. Wrap wirenuts with waterproof tape to pre vent them from loosening and ensure watertightness.
NOTES;
1.On 50 Hz units, disconnect the yellow wire connected to terminal 22 of the compressor contactor (C).
2.See wiring diagram on unit for more details.
48/50HJ008-014 AND 48/50TJ008-014 UNITS - Power wiring must comply with all local and National Electrical Code (NEC) requirements. Refer to Fig. 20-25 for power wiring connections. Utilize field-supplied wirenuts and V4-in. insulated female quick-connects for making power wiring connections. Wrap wirenuts with waterproof tape to prevent them from loosening and ensure watertightness.
NOTES;
1On 220 V, 50 Hz units, disconnect the black wire con nected to capacitor 1. On 400 v, 50 Hz units, disconnect blue wire connected to capacitor 1. Cap wire with a wire nut (50TJ008-014 only).
2. See wiring diagram on unit for more details.
38AQS008 AND 50LJQ008,012 UNITS - Power wiring must comply with all local and National Electrical Code (NEC) requirements. Refer to Fig. 26-28 for power wiring connections. Utilize field-supplied wirenuts and 'A-in. in sulated female quick-connects for making power wiring con nections. Wrap wirenuts with waterproof tape to prevent them from loosening and ensure watertightness. See wiring diagram on unit for more details.
Step 5 — Install Field-Fabricated Wind Baffles
and Brackets
A WARNING
To avoid the possibility of electrical shock, open all disconnects before installing or servicing this accessory.
Wind baffles must be field-fabricated for all units to en sure proper cooling cycle operation at low-ambient temper atures with Motormaster III controls. See Fig. 29 and 30 for number and sizes of baffles required and for baffle de tails. Use 20-gage (1 mm) galvanized sheet metal or similar corrosion-resistant material for the baffles. Use fieldsupplied screws to attach baffles to unit. Screws should be 'A-in. (6.3 mm) diameter or larger. Drill required screws holes for mounting the baffles.
A CAUTION
To avoid damage to refrigerant coils and electrical com ponents, use extreme care when drilling screw holes and screwing in fasteners.
Step 6 — Restore Power To Unit - When all elec trical connections have been made, ensure they are tight
and correct.
1.Restore power to the unit.
2.Check the phase sequence indicator on the Motormaster III control. It should not be lit. If lit, turn off power and reverse LI (black) and L2 (yellow) power leads. See
Fig. 3.
3. With |
phasing |
on |
Motormaster |
III |
control |
correct, |
make |
sure that |
the |
fan motors |
are |
rotating |
in the |
proper direction. If fan rotation is backwards, shut off power. Reverse the supply power leads between the Motormaster III control and the condenser fan motor to correct rotation.
4.Reinstall control box cover.
5.Reinstall unit access panel.
oo
$
QO
\
Oj
RETURN BEND END 48/50TJ008
OD
QO
e
i
V QO
QO
RETURN BEND END |
_.,r. |
38AK008.012, 38AKS008,009,012; 48/50HJ009 |
48/50TJ009 |
i
Fig. 12 — Motormaster® III Sensor Locations — 38AK, AKS; 48/50HJ,TJ Units
RETURN BEND END
48/50HJ012 RETURN BEND END 48/50TJ012
+
RETURN BEND END 48/50HJJJ014
Fig. 12 - Motormaster® III Sensor Locations — 38AK, AKS and 48/50HJ,TJ UNITS (cont)
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