Carrier 48-50P2, 48-50P4, 48-50P3, 48-50P5030-100 User Manual

Installation Instructions

Part Numbers: CRLOWAMB033A00 THROUGH CRLOWAMB038A00

CONTENTS

Page

SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . 1

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Pre-Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Step 1 — Install Field-Fabricated Wind Baffles . . . 3 Step 2 — Mounting and Electrical Connections

for Motormaster

Step 3 — Configure Motormaster V Control . . . . . 11

Step 4 — Test Motormaster V Control . . . . . . . . . . . 11

START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-13

TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . 13-15

SAFETY CONSIDERATIONS

Installation, start-up, and servicing of this equipment can be hazardous due to system pressures, electrical components, and equipment location (roofs, elevated structures, etc.).

Only trained, qualified installers and service technicians should install, start up, and service this equipment.

When working on this equipment, observe precautions in the literature and on tags, stickers, and labels attached to the equipment and any other safety precautions that may apply.

V Control . . . . . . . . . . . . . . . . . . . . 5

48/50P2,P3,P4,P5030-100

Low Ambient Operation

MOTORMASTER® V Control Accessory

50/60 Hz

WARNING

Open all remote disconnects before servicing this equipment. Electrical shock could result in personal injury.

GENERAL

This book contains instructions for the installation, start-up, and service of the Motormaster V (MMV) control on 48/50P030-100 units.

The Motormaster V control is a motor speed control device which adjusts condenser fan motor speed in response to varying liquid refrigerant pressure. A properly applied Motormaster V control extends the operating range of air-conditioning systems and permits operation at lower outdoor ambient temperatures.

To operate these units at very low ambient temperatures, Motormaster V controls (Fig. 1) must be added. Field-fabricated and installed wind baffles are also required for units in areas with prevailing winds of more than 5 mph (8 kph) and where temperatures drop below 32 F (0° C). The Motormaster V control permits operation of the unit to an ambient temperature of –20 F (–29 C). The control regulates the speed of one or two 3-phase fan motors depending on unit size. Replacement of the fan motor on most units is not necessary since the control is compatible with the factory-installed fan motors. To verify that unit fan motors are compatible with the control see Table 1.

See Tables 2-4 for the Motormaster V control accessory package usage and contents. Field wiring of control is required.

Table 1 — Replacement Motor Part Numbers

48/50P2,P3,P4,P5 UNIT SIZE VOLTAGE ACCESSORY PART NUMBER

208/230-3-60 Not Required, Std Unit Motor

035

030, 040-060

070

075-100

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.

Catalog No. 04-53480070-01 Printed in U.S.A. Form 48/50P-2SI Pg 1 9-09 Replaces: New

400-3-50, 460-3-60 Not Required, Std Unit Motor

575-3-60 Not Required, Std Unit Motor

380-3-60 HD56AK380

208/230-3-60 HD52AK002

400-3-50, 460-3-60 HD52AK002

575-3-60 Not Required, Std Unit Motor

380-3-60 Not Required, Std Unit Motor

208/230-3-60 HD52AK002 (2 Required)

400-3-50, 460-3-60 HD52AK002 (2 Required)

575-3-60 Not Required, Std Unit Motor

380-3-60 Not Required, Std Unit Motor

208/230-3-60 Not Available

400-3-50, 460-3-60 HD52AK002 (2 Required)

575-3-60 Not Required, Std Unit Motor

380-3-60 Not Available

Table 2 — Motormaster® V Control Package Contents — 48/50P030-060 Units

256

12 13A

13B

13C

TO MOTOR(S)

BLK

YEL

BLU

FROM FUSE BLOCK

TO PRESSURE TRANSDUCER

12561

2 14 13A 13B 13C 15 25 2 30 31 TXA

TXB

COM

+5V

TERMINAL

BLOCK

B-

B+

PRESSURE

TRANSDUCER

Fig. 1 — Motormaster® V Control

NOTE: Wire colors for MMPT:

2 — BLACK (A) 5 — GREEN (C) 6 — RED (B)

ITEM CRLOWAMB033A00 CRLOWAMB034A00 CRLOWAMB035A00 Connector ( Connector (1-in.) HW60HH006 Controller, 230 V 2 Hp HR46TN001 — — Controller, 460 V 2 Hp — HR46TN002 — Controller, 575 V 2 Hp — — HR46TN003 Enclosure 30RA500381 Enclosure Cover 30RA500519 Enclosure Mounting Bracket 50EJ500656 Fan Relay HN61KK055 Relay Base HN79KK035 Fuse Block HY11UT035 Fuse 15A, KTK-R, Class CC — HY10KB151 (3) HY10KB151 (3) Fuse 20A, KTK-R, Class CC HY10KB200 (3) — — Harness Assembly 48ZZ401971 Harness Assembly 48EJ402454 Harness Assembly 48ZZ402001 Label 48ZZ502002 Transducer HK05ZZ001 Transducer Harness 48EJ403240 Varnish Cloth (Large) 48DA510141 Varnish Cloth (Small) 38C24601 Wire Tie HY76TB123 (12) Wire Tie HY76TB045 (5) Wire, 16 Gage 72 in. Long WHT (1), GRY (1)

/2-in.) HW60EA001

Table 3 — Motormaster V Control Package Contents — 48/50P070-100 Units

ITEM CRLOWAMB036A00 CRLOWAMB037A00 CRLOWAMB038A00

Connector ( Connector (1-in.) HW60HH006 (2) Controller, 230 V 2 Hp HR46TN001 (2) — — Controller, 460 V 2 Hp — HR46TN002 (2) — Controller, 575 V 2 Hp — — HR46TN003 (2) Enclosure 30RA500381 (2) Enclosure Cover 30RA500519 (2) Enclosure Mounting Bracket 50EJ500656 (2) Fan Relay HN61KK055 (2) Relay Base HN79KK035 (2) Fuse Block HY11UT035 (2) Fuse 15A, KTK-R, Class CC — HY10KB151 (6) HY10KB151 (6) Fuse 20A, KTK-R, Class CC HY10KB200 (6) — — Harness Assembly 48ZZ401971 (2) Harness Assembly 48EJ402454 (2) Harness Assembly 48ZZ402001 (2) Label 48ZZ502002 Transducer HK05ZZ001 (2) Transducer Harness 48EJ403240 (2) Varnish Cloth (Large) 48DA510141 (2) Varnish Cloth (Small) 38C24601 (2) Wire Tie HY76TB123 (6) Wire Tie HY76TB045 (2) Wire, 16 Gage 72 in. Long WHT (2), GRY (2)

/2-in.) HW60EA001 (2)

Table 4 — Motormaster V Control Package Usage

UNIT VOLTAGE ITEM DESCRIPTION

48/50P030-060

48/50P070-100

INSTALLATION

Pre-Installation —

package before installing. File a claim with the shipper if there is shipping damage or if a part is missing.

Inspect the contents of this accessory

Step 1 — Install Field-Fabricated Wind Baffles

WARNING

To avoid the possibility of electrical shock, open all disconnects before installing or servicing this accessory.

On size 040-060 units, in areas with prevailing winds of more than 5 mph (8 kph) and where temperatures drop below 32 F (0° C), wind baffles must be field fabricated to ensure

208/230 CRLOWAMB033A00

380, 400, 460 CRLOWAMB034A00

575 CRLOWAMB035A00

208/230 CRLOWAMB036A00

380, 400, 460 CRLOWAMB037A00

575 CRLOWAMB038A00

proper cooling cycle operation at low-ambient temperatures with Motormaster V controls. Wind baffles are not needed on size 030, 035, and 070-100 units. See Fig. 2 for baffle details. Use 20-gage (1 mm) galvanized sheet metal, or similar corrosion-resistant material for the baffles. Use field-supplied screws to attach baffles to unit. Screws should be eter or larger. Screws should not be more than

/4-in. (6.3 mm) diam-

/2-inch in length.

Drill required screw holes for mounting baffles.

CAUTION

To avoid damage to refrigerant coils, electrical components, and wiring use extreme care when drilling screw holes and screwing in fasteners.

WIND BAFFLE

Fig. 2 — Wind Baffle Details

NOTE: 48/50P030, 035, and 070-100 units do not require baffles.

UNIT SIZE QUANTITY

DIMENSION “A”

in. mm 030,035 Not Used — — 040-060 2 78.125 ± 0.125 1984 ± 3 070-100 Not Used — —

BAFFLE INSTALLATION LOCATION (SIZES 050 AND 060 SHOWN)

a48-8561

a48-8560

Step 2 — Mounting and Electrical Connections for Motormaster® V Control

WARNING

To avoid possibility of electric shock and personal injury, open and tag all electrical disconnects before installing or servicing unit.

WARNING

Hazard of electric shock. Wait three minutes after disconnecting incoming power before servicing drive. Capacitors retain charge after power is removed.

CAUTION

To avoid damage to the small terminals on the Motormaster V control, use care when tightening the compression terminals and use the proper size screwdriver.

CAUTION

DO NOT connect incoming AC power to Motormaster V output terminals T1, T2, and T3. Severe damage to the control will result.

48/50P030-060 UNITS — For 48/50P030-035 units, the Motormaster controlled outdoor-fan motor (OFM) is the no. 1 OFM (see Fig. 3). The no. 2 OFM is controlled by the Com- fortlink head pressure control routine.

For 48/50P040 units, the Motormaster controlled outdoorfan motor (OFM) is the no. 3 OFM (see Fig. 3). The no. 1 and 2 OFMs are controlled by the Comfortlink head pressure control routine.

For 48/50P050-060 units, the Motormaster controlled outdoor-fan motor (OFM) is the no. 1 OFM (see Fig. 3). The no. 2, 3, and 4 OFMs are controlled by the Comfortlink head pressure control routine.

Use the following procedure to mount and connect the MMV controllers to these units:

1. Disconnect power to the unit. Lockout and tag power disconnect.

2. Remove control box covers.

3. For size 030-035 units, remove panel from condenser section on OFM 1 side of the unit in order to gain access to the outdoor fan section. See Fig. 4. For size 040-060 units, remove panel above control box as shown in Fig. 5 and 6.

4. Mount accessory fuse block HY11UT035 and fan relay base HN79KK035 inside control box as shown in Fig. 7. Secure components with ½-in. sheet metal screws.

a. Insert fuses into fuse blocks and relays into relay

bases.

b. Install harness 48EJ402454 from load side of CCB

(control circuit breaker terminals 21, 22, 23) to line side of MMF (Motormaster V fuse block) as shown in Fig. 8. Note that it may be easier to pick up the load side of CCB from the ¼-in. male quick connect terminals on the line side (terminals 11, 12, 13) of the OFC contactors (see power schematic on control box door).

c. Connect FR (fan relay) coil to OFC1 coil using the

72-in. long 16 gage white and gray wires (stripped end goes to FR) as shown in Fig. 8.

5. Mount the MMV controller enclosure 30RA500381 on the bulkhead of the unit inside the outdoor fan section, as shown in Fig. 4-6, using the mounting brackets 50EJ500656 installed on the enclosure. Remove the enclosure cover and install the ½-in. HW60EA001 and 1-in. HW60HH006 connectors in the holes in the lower right hand side of the enclosure.

6. Connect transducer HK05ZZ001 to the liquid line service Schrader port of refrigerant Circuit A. Plug transducer cable 48EJ403240 into transducer. Run cable to the MMV enclosure, as shown in Fig. 4-6.

Run MMPT (Motormaster V pressure transducer) cable through ½-in. connector of MMV enclosure (do not tighten connector screws at this time). Connect red, green, and black wires to MMV terminals 6, 5, and 2 as shown in Fig. 8. Terminate drain wire of transducer cables under one of the lower MMV mounting screws.

7. Make remaining electrical connections to MMV (see Fig. 8).

a. In main control box, disconnect black, red, blue,

and green wires from load side (terminals 21, 22,

23) of OFC1 (sizes 030-035, 050-060) contactor or OFC 3 (size 040) (label cable from OFC1 or OFC3 (size 040) as OFM1 or OFM3 (size 040). Pull wires out through the hole in the bottom of the control box and run them up the corner post to the opening of the cable tray on the side of the control box, as shown in Fig. 4-6. Run the cable through the wire tray to the MMV enclosures.

b. Run the OFM1/OFC3 (040) cable through the 1-in.

connector of the MMV enclosure (do not tighten connector screws at this time). Remove ring terminals from black, red, and blue wires and strip insulation back 3/8-in. Connect black, red, and blue wires to MMV terminals T1, T2, and T3. Connect green ground wire to MMV ground screw.

c. In the main control box connect Motormaster VFD

(variable frequency drive) harness 48ZZ401971 to the load side of the MMF (label the opposite end of this harness as MMF). Run the harness along the bottom of the control box and out through the hole that the OFM harness was in. Pull the harness out through the hole in the bottom of the control box and run it through the opening of the cable tray (in the same manner as the OFM harnesses).

d. Run the MMF cable through 1-in. connector of the

MMV enclosure (do not tighten connector screws at this time). Connect L1, L2, and L3 wires to MMV terminals L1, L2, and L3. Connect green ground wire to MMV ground screw. Place 1 large varnish cloth 48DA510141 around both cables at the point they enter the 1-in. connector. Tighten down connector screws being careful not to damage the cables.

e. In the main control box connect one Motormaster

VFD harness 48ZZ402001 to the NO (normally open) contact of the FR (see Fig. 8). Run the harnesses along the bottom of the control box and out through the hole that the OFM harness was in. Pull the harness out through the hole in the bottom of the control box and run it through the opening of the cable (in the same manner as the OFM harness).

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