CARRIER Controls And HVAC Accessories Manual L0604623

User Manual: CARRIER CARRIER Controls and HVAC Accessories Manual CARRIER Controls and HVAC Accessories Owner's Manual, CARRIER Controls and HVAC Accessories installation guides

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Installation Instructions

Fig. 1-MotorMastel _ Low Ambient Controller

A93157

NOTE: Read the entire instruction manual before starting the

installation.

SAFETY CONSIDERATIONS

Improper installation, adjustment, alteration, service,

maintenance, or use can cause explosion, fire, electrical shock, or

other conditions which may cause death, 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, protective clothing,

and work gloves. Use quenching cloth for brazing operations.

Have fire extinguisher available. Read these instructions

thoroughly and follow all warnings or cautions included in

literature and 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

z_. 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 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.

ELECTRICAL OPERATION HAZARD

Failure to follow this warning could result in personal

injury or death.

Before installing, modifying, or servicing system, main

electrical disconnect switch must be in the OFF position.

There may be more than one disconnect switch. Lock out

and tag switch with a suitable warning label.

INTRODUCTION

These instructions cover installation of MotorMaster@ Part No.

KSALA0601AAA and KSALA0701AAA on all residential

single-speed air conditioners and heat pumps. The device is

designed to control outdoor fan motor speed under low outdoor

temperature conditions. A fan motor with ball bearings is

required. The control is available in two models. Part No.

KSALA0601AAA is rated for 208/230-1-60. and Part No.

KSALA0701AAA is rated for 460-1-60. Other accessories may

be required. Refer to the Required Unit Changes section of this

document for details.

DESCRIPTIONANDUSAGE

TheMotorMaster_isafanspeedcontroldeviceactivatedbya

temperaturesensor.It is specificallydesignedto control

condenserfanmotorspeedin responseto thesaturated

condensingtemperatureduringoperationincoolingmodeonly.

For outdoortemperaturesdownto -20_'F.it maintains

condensingtemperatureat100"F-+10°F.(SeeFig.1.)

Themountingcontrolconsistsofasolid-statecircuitonaprinted

circuitboardinanaluminumextrusion,andasensorassemblyto

bemountedtoareturnbendontheunit'scondensercoil.Awire

fromthesensorisconnectedtothecircuitboardinthecontrol

box.

Partsnecessaryformountingcontrolandsensorassemblyare

includedin the kit. Eitherassemblycanbe replaced

independentlyoftheother.If anydamagetotheprintedcircuit

boardor componentsis observedwhenunpackingcontrol

assembly,returnforreplacement.

TheMotorMaster®maintainspropercondensingtemperatureat

anyambienttemperaturedownto-20_'F.Nofieldadjustmentsor

calibrationsarerequired.

Thefollowingmustbeobserved:

• Ifspecialfanmotorsorotheraccessoriesarerequired,

installwherenecessary.

• Measureunitpowersupplyvoltage.Itmustmeet

minimumvoltagespecifiedonunitratingplateand

matchvoltageratingofMotorMaster®.

• Makesureallunitsaremodifiedforwinterstartcontrol

whenneeded.

• Checkthatcontrollocationisasspecified.

• Checkthatsensorlocationisasspecified.

• Makesurethatsensorwiringroutingisasspecified.

• Makesurewindbafflesareinstalledonlyif required.

• Forheatpumpunits,makesureisolationrelayis

available.

INSTALLATION

UNITDAMAGEHAZARD

Failuretofollowthiscautionmayresultinunitdamage.

Exerciseextremecautionwhendrillingholes.Donot

puncturecoiland/ortubing.

PROCEDURE 1 -- MOUNTING CONTROL ASSEMBLY

1. Make sure all power to unit is turned off

ELECTRICAL OPERATION HAZARD

Failure to follow this warning could result in personal

injury or death.

Before installing or servicing system, always turn off main

power to system. There may be more than one disconnect

switch.

2. Determine location for control assembly. (See Fig. 2.

Remove template from back of this instruction and tape to

panel. Drill pilot holes as indicated. When mounting to

service panel, drill two holes. 5/32-in. (0.156 in.)

diameter. 1 in. away from panel edge as shown. (See Fig.

2.)

3. To ensure electrical ground with condensing unit. insert

star lockwashers under head of screws. Fasten control

assembly to unit with four No. 10 sheet metal screws

provided. If wind baffles are used. ensure control has a

continuous ground path to equipment ground. If control

is mounted independent of unit. ensure an adequate

ground path is maintained. All wiring must conform to

NEC and/or local code.

NOTE: When properly positioned (mounted vertically with

leads protruding from bottom of control), control is weather tight.

PROCEDURE 2 -- MOUNTING SENSOR

Mount sensor on a specified condenser coil return bend as shown

in Fig. 3.

IMPORTANT: The sensor assembly is delicate. Handle with

care.

4. Route sensor wire through bottom knockout on service

panel and over to outside row of coil (left side), taking

care not to disturb tubing.

5. Secure sensor on coil return bend with the No. 4-40 screw

and nut supplied with kit as shown in Fig. 4.

6. Bind unused wire and secure it near sensor or next to

control.

7. Protect sensor wire from physical damage or wind

movement where necessary.

Bryant - Legacy - RNC /Legacy Models Bryant - Legacy - RNC /Legacy Models

Carrier - Base /Comfort Series Models

Fig. 2-Control Mounting

Carrier - Base /Comfort Series Models

A06439

TOP OF COIL

j---- 0

,4

-VAPORIN

"_SENSOR LOCATION

LIQUID OUT OR

JUMPER TUBE

TOP OF COIL

0

_SENSOR LOCATION

VAPOR IN

-,,911_--

LIQUID OUT

TOP OF COIL

o o

_°

TOP OF COIL

LIQUID__...._OUT

SENSORLOCATION

VAPOR IN

_SENSOR LOCATION

VAPOR IN

--.,,91--

LIQUID OUT

--I1,,,--

TOP OF COIL

LIQ_UIDOUT TOP OF COIL

i i "--SENSORLOCATION

_VAP°R 2

TOP OF COIL

-C_ VAPOR IN

0 ..t.

0

_ SENSOR LOCATION

O

LIQUID OUT

VAPOR IN

SENSOR LOCATION

--lID--

LIQUID OUT

OR

JUMPERTUBE

Fig. 3- Sensor Location on Return End of Coil

No. 4-40

Screw

Coil Return

Bend

Sensor

I Ctinch Nut

@\ No. 4-40 Nut

Fig. 4 - MotorMaster ® Sensor

A93163

REQUIRED [NIT CHANGES

This section explains the changes required to equipment when

MeterMaster( a_,is applied. Use this section in conjunction with

appropriate wind baffle figures and tables at rear of instruction. A

ball bearing fan motor is required with this control.

PROCEDURE 1-- CONDENSING UNITS

A. Outdoor Fan Motor

Consult presale literature for outdoor fan motor change.

B. Crankcase Heater

Required on all applications where MoterMaster s_ is used. If not

already installed, consult presale literature for required crankcase

heater kit.

C. Hard Start Assist Kit (Capacitor and Relay)

Required on all single-phase applications where MoterMaster%

is used. If net already installed, consult presale literature fer

required start kit.

D. Winter Start Control

Must be used where low evaporator temperatures or nuisance

tripping of low-pressure switch may be encountered. Winter start

control Part No. KAAWS0101AAA must be wired in parallel

with low-pressure switch. (See Fig. 5.) This allows a delay of

approximately 3 minutes before low-pressure switch becomes a

part of control circuit.

NOTE: It is REQUIRED that evaporator freeze thermostat Part

No. KAAFT0101AAA be attached to vapor tube near evaporator

coil to prevent coil freezing. Wire thermostat in series with 24-v

contactor coil. (See Fig. 6.)

E. Wind Baffles

Use only in installations where high winds are prevalent to

prevent cross currents from causing abnormal control operation.

For construction, refer to appropriate wind baffle figures and

tables at rear of this instruction.

NOTE: When wind baffles are used. raising unit off of mounting

pad with 4-in. support feet or unit risers is REQUIRED. This

provides better airflow for moderate and high ambient

temperatures.

F. WMng

MotorMasterdS'_ must be wired in series with fan motor. (See Fig.

7.) Power wiring must comply with all local codes and NEC

requirements.

TDR

---2---

LPS

LPS LOW-PRESSURE SWITCH

C CONTACTOR COIL

TDR TIME DELAY RELAY

T TIME DELAY RELAY COIL

-- FACTORY WIRING

- - - FIELD WIRING

Fig. 5- Winter Start Control

A93165

INDOOR

THERMOSTAT

EVAPORATOR OUTDOOR

FREEZE THERMOSTAT CONTACTO R

Fig. 6 - Evaporator Freeze Thermostat Wiring

A97511

FROM--

CONTACTOR_ _BLK\ /BLK_.. _[/

MOTOR

SUITABLE FOR

USE WITH

MOTOR MASTER

CONTROLLER

SENSOR

A03225

Fig. 7 - Power Wiring for 208-v, 230-v, and 460-v

Condensing Units

PRO('EDURE2-- HEATPUMPS

A. Outdoor Fan Motor

Consult presale literature for outdoor fan motor change.

B. ('rankcase Heater

Required on all applications where MotorMaster'7_; is used. If not

already installed, consult presale literature for required crankcase

heater.

('. Hard Start Assist Kit (Capacitor and Relay)

Required on all single-phase applications where MotorMaster_:_;

is used. If not already installed, consult presale literature for

required accessory start kit.

NOTE: It is REQUIRED that evaporator freeze thermostat Part

No. KAAFT0101AAA be applied to the evaporator coil to

prevent coil freezing.

Wire thermostat in series with 24-v contactor coil. (See Fig. 6.)

D. Wind Baffles

Use only in installations where high winds are prevalent to

prevent cross currents from causing abnormal control operation.

For construction, refer to appropriate wind baffle figures and

tables at rear of instruction

NOTE: When wind baffles are used, raising unit off of mounting

pad with 4-in. support feet or unit risers is REQUIRED. This

provides better airflow for moderate and high ambient

temperatures.

E. Isolation Relay (Heat Pump ONLY)

Mount isolation relay in unit control box and wire into power and

control circuits. This relay switches MotorMaster® out of

outdoor fan motor circuit when heat pump switches to heating

cycle. Relay Part No. KHAIR0101AAA is REQUIRED for use

with 208/230-v and 460-v systems. Note the following:

1. Normally closed relay contacts must be in parallel with

MotorMaster® as shown in Fig. 8.

2. Normally open relay contacts must be in series with

MotorMaster® as shown in Fig. 8.

3. Isolation relay coil must be connected across circuits O

and C on defrost board.

F. Wiring

MotorMaster_ must be wired in series with fan motor. (See Fig.

8.) Power wiring must comply with all local codes and NEC

requirements.

CONTACTOR

OF4

_._, oS,_L_ _SEN SO R

A93168

208/230-v

CONTACTOR

- L_OFR_BL K LYEL _ Bt_IN

DEF _!N__ .F_c.S_._LT'_R_SENSOR

A93156

460-v

Fig. 8 - Power Wiring for 208/230-v and 460-v Heat Pump Units

START-UP

TostartupunitsequippedwithaccessoryMotorMaster®:

1.Turnunitpoweron.

2.Setthermostatbelowroomtemperature.

3.Waitatleast5minutesif unitisequippedwithadelay

circuit.Fanmotorstarts15secbeforecompressorwhen

standarddelaycircuitsareusedandmay:

a.Notoperatewhenambientisbelow50°F.

b.Runatslowspeedwhenambientisbetween70°Fand

80°F.

c.Run at or near full speed when ambient is above 80°F.

4. When compressor starts, fan speed modulates smoothly to

proper controlled speed based on saturated condensing

temperature. After system has run and settled out,

saturation temperature is approximately 100°F -+ 10°K if

the outdoor ambient is below 60°F.

10,000

9000

8000

Or) 7000

"1-

O

Z6000

W

0

Z

Or) 5000

t./)

I.,1..I

4000

3000

2000

lOOO

SERVICE

No field repairs are to be made on this kit. If either the sensor or

the control fails, it should be replaced.

If fan motor does not turn, check control as follows:

1. Check power to condensing unit.

2. Check for voltage across fan motor relay contacts.

3. Check for loose sensor wire connections in MotorMaster®

splice compartment.

4. Bypass MotorMaster® by connecting black wire from

unit contactor directly to black fan motor lead. (See Fig. 7

or 8 and unit wiring label.)

a. If fan does not turn, make sure motor is wired into

circuit properly and run capacitor is not defective.

Replace motor or capacitor if defective.

b. If fan motor runs, make sure that motor was wired in

series with MotorMaster®.

5. If motor runs when connected to single-phase voltage

supply, but does not run when connected in series with

MotorMaster®, check sensor as follows:

a. Check temperature of return bend near sensor with an

electronic thermometer.

b. Disconnect both sensor leads.

c. Check sensor resistance with an ohmmeter and compare

resistance/temperature readings to those in Fig. 9.

d. If sensor is within tolerance shown in Fig. 9, replace

MotorMaster®. If sensor is NOT within tolerance shown

in Fig. 9, replace sensor.

\\

'\ '\

\, \

\ \ \

k \'

\ ,,,\,, \1

\\, N

\1 ,\

\

\- \

\ \

\

\

\

\\

\

%

\

%

\

+ lO%

NOMINAL

- lO%

~ •

50 60 70 80 90 100

TEMPERATURE IN °F

Fig. 9 - Sensor Resistance/Temperature Chart

11o 120 130

A93173

15/16"

8" C-1

AT'L :SU%P%RAT STEEL

--'4 2-s,8"

6 REO'D TYP

1_2" TYP

1-9/16"

TYP

6" TYP

51/4" HOLE

14 REQ'D

- 9/16"

TYP

/4" TYP

D

4 REQ'D

OUTDOOR

UNIT

44 REQ'D

_! 16=1/2" TYP

BAFFLE

MAT'L: 20 GA STEEL

1/4" X 7/16" SLOT_

6 REO'D _._

t

AA

-BAFFLE

3 RE©'D

4---9/16" TYP

7

_" TYP

BAFFLE ASSEMBLY

Fig. 10 -Base /Mid-Tier Baffle Assembly

Table 2--Wind Baffle Dimensions for Entry and Mid-Tier Units (in.)

UNIT SIZE AA C11 C-2 C13 D

Small

Medium

25-3/4

31-1/4

35

Large

UNIT HEIGHT

25

28- 7/16

31-13/16

35-1/4

38- 5/8

42

45- 7/16

25-1/2

28-15/16

32-5/16

35 - 3/4

39-1/8

42-1/2

45-15/16

25-1/2

28-15/16

32-5/16

35 - 3/4

39-1/8

42-1/2

45-15/16

A

20-3/8

23-13/16

27-3/16

30- 5/8

34

37-3/8

40-13/16

20-3/8

23-13/16

27-3/16

30- 5/8

34

37-3/8

40-13/16

20-3/8

23-13/16

27-3/16

30- 5/8

34

37-3/8

40-13/16

B

10-I/16

11-3/4

13-1/2

15-3/16

16- 7/8

18-9/16

20-1/4

10-I/16

11-3/4

13-1/2

15-3/16

16- 7/8

18-9/16

20-1/4

10-I/16

11-3/4

13-1/2

15-3/16

16- 7/8

18-9/16

20-1/4

3-15/16

9- 3/8

13-3/16

1O- 7/8

16-5/16

20-1/8

6-1/8

11-9/16

15-3/8

A06450

41-7/8

47- 3/8

51-1/8

Copyright 2006 CAC' BDP • 73t0 W Mo::is St • Indianapolis, IN 46_31 P:_:_ted in USA

Ma mlfae_ul'er rese_'es the tlght to change, at any time. speeiliea tions and designs without notice and wit hou_ obligations.

10

Edition Date: 04_06 Catalo_ No: AG-KSAL&-01

Replaces: AG SALA 06