Installation Instructions

Transcription

1 PART NUMBER: 001A00 002A00 SMALL PACKAGED PRODUCTS 1---1/2 to 5 TONS (50/60 Hz) MOTORMASTER II HEAD PRESSURE CONTROLLER Installation Instructions NOTE: Read the entire instruction manual before starting the installation. SAFETY CONSIDERATIONS Installation and servicing of this equipment can be hazardous due to mechanical and electrical components. Only trained and qualified personnel should install, repair, or service this equipment. Untrained personnel can perform basic maintenance functions such as cleaning and replacing air filters. All other operations must be performed by trained service personnel. When working on this equipment, observe precautions in the literature, on tags, and on labels attached to or shipped with the unit and other safety precautions that may apply. Follow all safety codes. Installation must be in compliance with local and national building codes. Wear safety glasses, protective clothing, and work gloves. Have fire extinguisher available. Read these instructions thoroughly and follow all warnings or cautions included in literature and attached to the unit. Recognize safety information. This is the safety -alert symbol. When you seethissymbolon theunitand in instructions ormanuals, be alert to the potential for personal injury. Understand these 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 hazards which could resultin personalinjury 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. Follow all safety codes. Wear safety glasses and work gloves. Have a fire extinguisher available.! WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could cause personal injury or death. Before performing service or maintenance operations on unit, turn off main power switch to unit and install lockout tag. Ensure electrical service to rooftop unit agrees with voltage and amperage listed on the unit rating plate. INTRODUCTION These instructions cover the installation of the Motormaster II Controller head pressure control device. Refer to the Installation section for directions. Louvered panels are required for this installation; see Item 9 in the Installation section of this document and Tables 1 and 2 for more information. Table 1 Add Louvered Panels to These Units 48ES 574D 48GS 582A PY1P --- B 48GX 583A PY2P --- B 48SD 574A 48SZ 674A 50ES 704D 50GS 701A PA1P --- B 50GX 702A PA2P --- B 50JS 601A PH1P --- B 50JX 602A PH2P --- B 50SD 704A 50SZ 604A Table2 DoNOTAddLouveredPanelstoTheseUnits 48VL 577C 50SX 557A 50HX 657A 50VL 707C 50ZP 564A PA1Z 50ZH 664A PH1Z 50ZHA 664B PH3Z 50ZPA 564B PA3Z 50JZ* 602B* 48GP* 583B* 48CE* 574C 48DT* 677B 48DU* 577B 48JZ* 583B* 48XP* 574B* 48XZ* 674B 50CE* 704C* 50CR* 604C* 50DT* 607B* 50DU* 707B* 50GL* 702B* 50XP* 704B* 50XZ* 604B* *Louvered panels are standard on these units. 1

2 3. Disconnect outdoor-fan motor (OFM). (See Wiring Schematic, Fig. 8 or 9.) 4. Remove OFM wires from unit control box. 5. Mount Motormaster II Controller on unit. Refer to Fig The controller must be mounted vertically with the leads at the bottom. Using the Mounting Template (Fig. 10) as a guide, drill mounting holes. To ensure electrical ground, insert star washers (supplied with the controller) under the heads of mounting screws. NOTE: Field -supplied conduit must be used between controller and access panel (or wire into unit entrance). 6. Determine sensor location by referring to Fig Route sensor wire through bottom of Motormaster II Controller (Fig. 1) to sensor location specified. Prior to installation, apply conductive grease supplied with accessory to contact surface of sensor.! CAUTION COMPONENT DAMAGE HAZARD Failure to follow this caution may result in component damage. Sensor assembly is delicate. Handle with care. Motormaster II Controller Interior Fig. 1 - Controller Interior INTEGRAL WIRE TIE C Attach sensor to top half of header tube as shown in Fig. 2. Installed sensor must be left uninsulated. 8. Power wiring must comply with all local and National Electrical Code (NEC) and International Electric Code (IEC) requirements. Refer to Fig. 8 and 9 for power wiring connections. Coil up all excess wire and secure. (Yellow and blue wires, from controller, must run to unit contactor and connect on the load side.)! CAUTION 3/8" HEADER TUBE CONDUCTIVE GREASE NOTE: INSTALLED MUST BE UNINSULATED. Sensor Connection Details Fig. 2 - Sensor Connection Details DESCRIPTION AND USAGE C00103 The Motormaster II head pressure controller is a cycle control device activated by a temperature sensor mounted on a header tube of the outdoor coil (see Fig. 1). It is designed to cycle the outdoor-fan motors to maintain the saturated condensing temperature within normal operating limits of approximately 130 to 110_F high (54_C to 43_C), 70 to 50_F low (21 to 10_C). The controller maintains working head pressure at low ambient temperatures down to -20_F (-29_C) when properly installed. INSTALLATION 1. Disconnect power to unit. Install lockout tag. 2. Remove unit access panel. UNIT OPERATION AND COMPONENT DAMAGE HAZARD Failure to follow this caution may result in improper unit operation or component damage. All wires must be secured so that they are not in contact with unit tubing. 9. To prevent wind cross-currents form causing abnormally low condensing temperatures, louvered panels are required on some models. See Table 1 and 2 for models requiring/not requiring louvered panels. 10. Reconnect power to the unit. The Motormaster II head pressure controller is equipped with an alternate operating mode. When this mode is selected, the controller shifts the fan cycle sequence to effectively raise the average condensing temperature approximately 20_F higher than the standard operating mode. In this alternate mode, the outdoor fan begins cycling at higher outdoor ambient temperatures. This mode should only be used if the evaporator coil shows signs of frosting at low outdoor ambient temperatures. To select the alternate operating mode, move the jumper wire on the Motormaster II control board from reset T1 to T2. Refer to Fig. 7 for thermistor resistance vs. temperature. 2

3 MOTORMASTER II WIRE LEADS BULKHEAD COMPRESSOR CONDENSER COIL SLICE PLASTIC SERVICE CAP DN UNIT AND FEED LEADS MOTORMASTER II 50ZP, ZH, 564A/664A, PA1Z/PH1Z UNITS Fig. 3 - Mounting Locations C00108 MOTORMASTER II CONTROLLER 1 3/8 MOTORMASTER II CONTROLLER EVAP COIL ACCESS PANEL CONDUIT 6 FROM BOTTOM OF UNIT CONDUIT HOLE FOR CONDUIT CONNECTION 50SX/ 557A 50HX/ 657A Fig. 4 - Mounting Locations BULKHEAD C00141 MOTORMASTER II MOTORMASTER II WIRE LEADS SLICE PLASTIC SERVICE CAP ON UNIT AND FEED LEADS COMPRESSOR 48/50GS, GX, JS, JX, GP, GL, JZ UNITS 582A/701A, 583A/702A, 601A, 602A, 583B, 702B, 602B,683B PY1P-B/PA1P-B, PY2P-B/PA2P-B, PH1P-B, PH2P-B SMALL CABINET Fig. 5 - Mounting Locations-Small Cabinet C00109 BULKHEAD MOTORMASTER II MOTORMASTER II WIRE LEADS SLICE PLASTIC SERVICE CAP ON UNIT AND FEED LEADS COMPRESSOR 48/50GS, GX, JS, JX, GP, GL, JZ UNITS 582A/701A, 583A/702A, 601A, 602A, 583B, 702B, 602B, 683B PY1P-B/PA1P-B, PY2P-B/PA2P-B, PH1P-B, PH2P-B LARGE CABINET Fig. 6 - Mounting Locations-Large Cabinet 3 C00110

4 Table 3 Sensor Location Index MODEL NUMBER FIGURE NUMBER 50JX/602A/PH2P---B Fig JX/602/PH2P---B 060 AND 50JS/601A/PH1P---B Fig JS/601A/PH1P---B Fig GS/582A/PY1P---B/50GS/701A/PA1P---B AND 48GX/583A/PY2P---B/50GX/702A/PA2P---B Fig GS/582A/PY1P---B/50GS/701A/PA1P---B AND 48GX/583A/PY2P---B/50GX/702A/PA2P---B Fig GP/50GL/583B/702B AND 50GL Fig GP/50GL/583B/702B 060 Fig /50JZ/683B/602B Fig ZP/564A/PA1Z Fig ZP/564A/PA1Z Fig ZH/664A/PH1Z Fig ZH/664A/PH1Z Fig SZ/557A Fig HX/657A Fig HX/657A Fig ES/50ES/574D/704D Fig XP/50XP/48CE/50CE/577B/574C/704B/704C Fig DT/50DT/607B/677B Fig DU/50DU/48BL/50VL/577B/707B/577C/707C Fig SD/50SD/574A/704A/PY3P/PA3P Series 301 AND A Fig SD/50SD/574A/704A/PA3P/PY3P Series 311 AND B Fig DT/50DT/677B/607B Fig DU/50DU/577B/707B AND 48VL/50VL/577C/707C Fig SZ/50SZ/674A/604A Fig VL/50VL/577C/707C AND 060 Fig XZ/50XZ/50CR/674B/604B AND 604C Fig ZHA/50ZPA/564B/664B/PA3Z/PH3Z Fig ZHA/50ZPA/564B/664B/PA3Z AND PH3Z048 AND PH3P 060 Fig ,000 40,000 RESISTANCE (OHMS) 30,000 20,000 10, TEMPERATURE (F) Thermistor Resistance vs Temperature Fig. 7 - Thermistor Resistance vs. Temperature Chart C

5 OUTDOOR-FAN MOTOR SINGLE-PHASE UNITS UNIT CONTROL BOX L1 L UNITS C T1 21 T2 23 BLK 3-PHASE UNITS UNIT CONTROL BOX C C BLK BLK BRN THIS WIRE RELOCATED FROM BASE UNIT CONTACTOR VIEW A BLU BLK VIEW A 208/230-V UNITS ONLY OF1 DR OF2 MOTORMASTER II CONTROL BOX ORANGE BLK RED C OFC L2 T2 OFC L1 T1 BLK O C LOW VOLTAGE CONTROL BOX* BLK BLU 460-V UNITS ONLY OFR 1 3 BLU TRAN (SEE NOTE #1) A C 24 RED BRN R C LOGIC BOARD W1 T2 T1 S2 S1 GRN- C1 ORG OFC C2 BRN 3 COIL 1 (SEE NOTE #2) 4 5 Field supplied relay for all Heat pumps should be located in the control box of the unit. C DR OFC OFR TRAN LEGEND Contactor Defrost Relay Outdoor-Fan Contactor Outdoor-Fan Relay Transformer Field Wiring RELOCATE JUMPER TO TERMINAL T2 FOR ALTERNATE OPERATION. *In low voltage control box, O is orange and C is Brown (common). NOTES: 1. Motomaster II transformer is wired for 460-v supply; it must be rewired for 208/230-v application. Be sure to insulate unused tap. 2. Relay, part no. HN61KB324, is field supplied and normally closed A00 transformer only contains a 400-v. supply. CONTROL THERMISTOR Fig. 8 - Wiring Schematic Heat Pumps C

6 SINGLE-PHASE UNITS UNIT CONTROL BOX C L1 T1 L2 T2 BLU 3-PHASE UNITS UNIT CONTROL BOX C 21 C 23 BLU BLK OUTDOOR-FAN MOTOR THIS WIRE RELOCATED FROM BASE UNIT CONTACTOR MOTOMASTER CONTROL BOX BLK SEE NOTE C ORANGE RED OFC L2 T2 OFC L1 T1 BLK A C 24 RED BRN R C LOGIC BOARD GRN- C1 ORG OFC C2 BRN W1 T2 T1 S2 S1 RELOCATE JUMPER TO TERMINAL T2 FOR ALTERNATE OPERATION LEGEND C - Contractor OFC - Outdoor- Fan Contactor TRAN - Transformer NOTE: 1. Motormaster II is wired for 460-v supply; it must be rewired for 208/230-v application. Be sure to insulate unused tap A00 Transformer only contains a 400V supply. CONTROL THERMISTOR Fig. 9 - Wiring Schematic, AC and Gas PACs C

7 MOUNTING TEMPLATE 5-3/8-in. REF [136.5] TOP CUT ALONG SOLID BORDER LINES TO REMOVE TEMPLATE DRILL 9/64-in. [3.6] DIAMETER HOLE TEMPLATE FOR MOTORMASTER II 001A00 NOTE: Dimensions in [ ] are in millimeters 5-in. [127] 9-in. REF [228.6] DRILL 9/64-in. [3.6] DIAMETER HOLE 2-3/8-in. REF [60.3] 1-1/8-in. REF [28.6] Fig Controller Mounting Template C00105V2 7

8 50 JX, 602A, PH2P-B 024 Left Back 50 JX, 602A, PH2P-B 042 Left Back 50JS.601A.PHIP-B 036 BACK 50JS.601A.PHIP-B 048 BACK 50 JX, 602A, PH2P-B 030/036 Left Back 50 JX, 602A, PH2P-B 048 Left Back Fig Sensor Mounting Location A JS.601A.PHIP-B JS.601A.PHIP-B 060 BACK BACK Fig Sensor Mounting Location A JX, 602A,PH2P-B 060 BACK 50JS, 601A,PH1P-B 024 BACK RETURN BEND END 48GS, 582A, PY1P-B, 50GS, 701A, PA1P-B, 018, 024, 030 & GX, 583A, PY2P-B, 024, 50GX, 702A, PA2P-B, 024 BACK 50JS, 601A,PH1P-B 018 BACK 50JS, 601A,PH1P-B 030 BACK Fig Sensor Mounting Location A07441 RETURN BEND END 50/48GX030, 702A/583A030, PA2P/PY2P 030 (B SERIES) BACK Fig Sensor Mounting Location A

9 RETURN BEND END 48GS.582A,PY1PB042 50GS,701A,PY2PB042 48GX,583A,PY2P-B GX,702A,PA2P-B 036 BACK RETURN BEND END 50/48GS A/582A048 PA1P/PY1P048 (B SERIES) BACK 48GP024/50GL B024/702B024 BACK 48GP030/50GL B030/702B030 BACK RETURN BEND END 50/48GS/ A/582A060 PA1P/PY1P060 48/50GX042& A/702A042&048 PY2P/PA2P042&048 (B SERIES) BACK RETURN BEND END 48/50GX A/582A/583A060 PA2P/PY1P/PY2P060 (B SERIES) BACK Fig Sensor Mounting Location A GP036/50GL B036/702B036 BACK 48GP042, 048/50GL042, B042, 048/702B042, 048 BACK A07445 Fig Sensor Mounting Location 9

10 48/50JZ B/602B024 BACK 48/50JZ030, B/602B030, 036 BACK 48GP060/50GL B060/702B060 BACK Fig Sensor Mounting Location A /50JZ042, B/602B042, 048 BACK 48/50JZ B/602B060 BACK Fig Sensor Mounting Location A

11 50ZP, 564A, PA1Z024 50ZP, 564A, PA1Z030 50ZP/564A/PA1Z048 50ZP/564A/PA1Z060 Fig Sensor Mounting Location A ZP, 564A, PA1Z036 50ZP, 564A, PA1Z042 Fig Sensor Mounting Location A

12 50ZH/664A/PH1Z024 50ZH/664A/PH1Z030 50ZH/664A/PH1Z060 50ZH/664A/PH1Z048 Fig Sensor Mounting Location A ZH/664A/PH1Z036 50ZH/664A/PH1Z042 Fig Sensor Mounting Location A

13 50SX/557A SX/557A 030/036 50HX/657A/048 Sensor Location 50HX/657A/060 Fig Sensor Mounting Location Sensor Location A SX/557A 042/048 50SX/557A 060 Fig Sensor Mounting Location A

14 Sensor Location Sensor Location 50HX/657A024 50HX/657A030 Sensor Location Sensor Location 50HX/657A036 50HX/657A042 Fig Sensor Mounting Location A

15 48ES DNW018 50ES DNX018 BACK 48ES DNW024 50ES DNX024 BACK 48ES DNW030 50ES DPW DNX DPX030 BACK 48ES DNW036 50ES DPW DEW DNX DPX DEX036 BACK 48ES ES-048 BACK 574DNW DPW DEW DNX DPX DEX048 48ES ES DNW DPW DEW DNX DPX DEX060 BACK Fig Sensor Mounting Location A

16 16 48XP BNW024 48XP BNW030 50XP BNX024 50XP BNX030 48CE CNW024 48CE CNW030 50CE CNX024 50CE CNX030 48XP BNW036 50XP BPW036 48CE BNX036 50CE BPX036 48XP BNW042 50XP BPW042 48CE BNX042 50CE BPX042 48ES CNW042 50ES CPW CNX CPX DNW DPW DEW DNX DPX DEX042 48XP BNW048 50XP BPW048 48CE BNX048 50CE BPX CNW CPW CNX CPX048 48XP BNW060 50XP BPW060 48CE BNX060 50CE BPX CNW CPW CNX CPX060 A07404 Fig Sensor Mounting Location

17 48DT DT BNW BNX024 48DT DT BNW BNX030 48DT DT BNW BNX036 48DT DT BNW BNX042 Fig Sensor Mounting Location A

18 48DU DU DU DU VL VL BNW BNW BNX BNX CNW CNX048 Fig Sensor Mounting Location 48DU DU BNW BNX060 A

19 48SD ANW024 50SD ANX024 PY3P024 PA3P and A Series 48SD ANW030 50SD APW ANX APX030 PY3P024 PA3P and A Series 48SD ANW036 50SD APW AEW ANX APX AEX036 PY3P036 PA3P and A Series 48SD ANW042 50SD APW AEW ANX APX AEX042 PY3P042 PA3P and A Series 48SD SD ANW APW AEW ANX APX AEX048 PY3P048 PA3P , 311, A and B Series 48SD ANW060 50SD APW AEW ANX APX AEX060 PY3P060 PA3P , 311, A and B Series Fig Sensor Mounting Location A

20 48SD ANW024 50SD ANX024 PA3P024 PY3P and B Series 48SD ANW030 50SD APW ANX APX030 PY3P030 PA3P and B Series 48SD ANW036 50SD APW AEW ANX APX AEX036 PY3P036 PA3P and B Series Fig Sensor Mounting Location 48SD ANW042 50SD APW AEW ANX APX AEX042 PY3P042 PA3P and B Series A

21 48DT DT BNW BNX048 48DT DT BNW BNX060 Fig Sensor Mounting Location A DU DU BNW BNX024 48DU DU VL VL VL VL BNW BNX CNW CNW CNX CNX042 48DU DU BNW BNX036 Fig Sensor Mounting Location A

22 22 48SZ ANW024 50SZ ANX024 48SZ ANW030 50SZ APW ANX APX030 48SZ ANW036 50SZ APW ANX APX036 48SZ ANW042 50SZ APW ANX APX042 48SZ ANW048 50SZ APW ANX APX048 48SZ ANW060 50SZ APW ANX APX060 A07411 Fig Sensor Mounting Location

23 48VL VL CNW CNX018 48VL VL VL VL CNW CNW CPW CNX CNX CPX030 48VL VL CNW CPW CEW CNX CPX CEX060 Fig Sensor Mounting Location A

24 24 48XZ BNW036 50XZ BPW036 50CR BNX BPX CNX CPX036 48XZ BNW048 50XZ BPW048 50CR BNX BPX CNX CPX048 48XZ BNW060 50XZ BPW060 50CR BNX BPX CNX CPX060 48XZ BNW042 50XZ BPW042 50CR BNX BPX CNX CPX042 48XZ BNW024 48XZ BNW030 50XZ BPW030 50XZ BNX024 50CR BNX030 50CR BPX CNX CPX030 A07413 Fig Sensor Mounting Location

25 50ZHA024 50ZPA BNW BNX024 PA3Z024 PH3Z024 50ZHA030 50ZPA BNW BPW BNX BPX030 PA3Z030 PH3Z030 Fig Sensor Mounting Location 50ZHA036 50ZPA BNW BPW BNX BPX036 PA3Z036 PH3Z036 A

26 50ZHA042 50ZPA BNW BPW BNX BPX042 PA3Z042 PH3Z042 50ZPA048 50ZHA BNW BPW BNX BPX048 PA3Z048 PH3Z048 Fig Sensor Mounting Location 50ZHA060 50ZPA BNW BPW BNX BPX060 PA3Z060 PH3P060 A07416 Copyright 2007 CAC / BDP D 7310 W. Morris St. D Indianapolis, IN Printed in U.S.A. Edition Date: 06/07 Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations. 26 Catalog No: IIK---01 Replaces: IIK 555A