Heatcraft Mohave Advanced Hot Gas Defrost System Installation and Operation Manual

H-IM-HGD0

Replaces June 2017

Mohave Hot Gas Defrost

Installation

& Operation

FEBRUARY 2021 Part Number 25007401

Installation, Start-Up, Operation and

Troubleshooting with Wiring Diagrams

Table of Contents

Controller Quick Reference Guide

.............................................................................3-5

Receiving and Inspection

General Safety Information ...................................................................................... 6

Warranty Statement ............................................................................................... 6

System and Components ....................................................................................... 7

Installation

Unit Cooler Installation ............................................................................................ 8

Placement ............................................................................................... 9

Condensing Unit Installation

Field Piping Guidelines ........................................................................12-24

Operation

Hot Gas Unit Cooler Typical Factory Piping .............................................................. 40

Hot Gas Condensing Unit Typical Factory Piping ....................................................... 41

Refrigeration Operation ...................................................................................42-43

Evacuation & Leak Detection ................................................................................ 48

Check Out & Start-Up .......................................................................................... 49

Monitoring & Reviewing Operation Values ............................................................... 52

Error and Alarm Details......................................................................................... 53

Refrigerant Charging .......................................................................................54-55

Operational Check Out ......................................................................................... 56

Troubleshooting .................................................................................58-60

Preventive Maintenance ..................................................................................61-62

InterLink Service Parts ......................................................................................... 63

Factory Default Settings ...................................................................................65-68

Mohave Control Board Comparison........................................................................ 69

Electronic Pressure Regulator Comparison .............................................................. 70

Modbus Definitions .........................................................................................71-74

© 2021 Heatcraft Refrigeration Products LLC

2


The Mohave ™ Hot Gas Controller is located inside the condensing unit electrical panel. The

Service Switch is adjacent to the controller on the side of the enclosure.

Program

Review Enter

Control Buttons

Monitor

Reset

Time

Program Review : Review or Change the Program Settings

Enter : Accepts changes into memory

Monitor : View Current Operating Conditions of the System

Reset Time : Resets the time clocks of the microprocessor to 0.

Clear/Test : Clear ignores program selections prior to pressing

Enter and terminates Service Mode. Test causes the system to cycle through all of the outputs for troubleshooting.

Select Knob : Used for Cycling through Monitoring and

Programming Parameters.

Force Service : Press this button twice to cause the system to Clear/

Test pump down and remain off until the Clear button is pressed.

Force Defrost : System will pump down and begin a defrost cycle. This will not effect the normally scheduled defrosts.

Selection

Knob

Force

Service

Force

Defrost

Service Switch

This toggle switch may be placed in the “on” position to force the system into Service Mode. The compressor will pump down and shut off. The evaporator fans will de-energize.

The system can be left in service.

Operating Modes

MODE

OFF

COOL

PMPD

SERV

DELY

DEF1

DEF2

DEF3

FREZ

TEST

SERV

EVAC

DESCRIPTION

Compressor Off

Compressor On in Cooling Normal Cooling Operation

System in Pump Down Mode

Service Mode, System is Off

Time Delay

Defrost Stage 1

Pre-Defrost or ByPass Mode

Defrost Stage 2

Defrost Mode

Defrost Stage 3

Post Defrost Equalization or Drain Down Mode

Refreeze Mode

Test Mode

Service Mode

Evacuation Mode

3

4


Program Review Menu

DISPLAY

CLKH

CLKM

°F °C

1224

ALRT

RTDF

DF01

DF02

DF03

DF04

DF05-DF12

APPL

REFR

MODL

XPRT

*

**

DESCRIPTION

Set the Time of Day clock hour value

Set the Time of Day clock minute value

Set Fahrenheit or Celsius temperature units (°F or °C)

Set Time display method (12 hr. or 24 hr.)

Set the Alarm Time (2 to 120 minutes)

(See Program Review Section for additional information)

FACTORY

DEFAULT

None

None

°F

12 hr

20 min

Defrost Schedule based on Compressor Runtime

Set Defrost 1 starting time (12:00 am to 12:00 pm in 30 minute increments)

Set Defrost 2 starting time


OFF

12:00AM

6:00AM

12:00PM


Set Defrost XX starting time

6:00PM

--- ---

Set Application type (Med., Low) Med Temp

Set Refrigerant type (R-22, R-404A, R-507, R-407A, R-407C, R-407F, R-448A and R-449A)” R-404A

Set Model Number 1502

Expert Mode (To Access Additional Program Parameters (On, Off) Off

*Software V1.04 and higher.

**Menu re-ordered Software V2.05 and higher

Monitor Display Menu

DISPLAY

VALP

DESCRIPTION

Defrost Regulator Valve percent of opening (0 to 100%)

SUPH

SucT

SucP

SSuc

LIQP

AMBT

AUXT

E1DT

E2DT

ACIN

TMMS

TMHM

CCYC

RnTM

DFTM

ETLD

RTLD

VERS

Superheat (°F.) measured at inlet of Suction Accumulator

Suction Temperature (°F.) at inlet of Suction Accumulator

Suction Pressure (PSIG/”HG) at inlet of Suction Accumulator

Saturated Suction Temperature (°F.) at inlet of Suction Accumulator

Liquid Pressure (PSIG) measured between Receiver and Condenser

Ambient Air Temperature (°F.) measured entering condenser coil

Auxiliary Probe Temperature (°F.)

Evaporator 1 Defrost Sensor Termination Temp (°F.) at outlet of Evaporator 1

Evaporator 2 Defrost Sensor Termination Temp (°F.) at outlet of Evaporator 2

Control Board voltage (24VAC nominal)

Current time minutes and seconds

Current time hours and minutes

Compressor Cycles since Midnight

Compressor Run Time since Midnight

Duration Time of Last Defrost

Elapsed Time since last Defrost (HH.MM)

Run Time since last Defrost (HH.MM)

Software version


LIQS

EVPH

FAN4

FAN3

FAN2

FAN1

COMP

BYPV

SucS

DEFS

3WAY

ALRM

VALS

EVAC

Forced Output Menu

DISPLAY

EVPF

DESCRIPTION

Evaporator Fan Contactor

Liquid Line Solenoid

Evaporator Pan Heater

Condenser Fan 4 Contactor




Compressor Contactor

Bypass Solenoid

Suction Stop Solenoid

Defrost Solenoid

3-Way Valve Solenoid

Alarm Contacts

Regulator Valve Control

Activate all Solenoids, Open the Pressure Regulator Valve

System Alarms

DISPLAY

Alr1

Alr2

Alr3

Alr4

DESCRIPTION

Persistent input sensor/transducer failure

Combines Err4 and Err8, system off

Repeated Safety Circuit Open condition

Prolonged Cooling Startup Failure

System Errors

DISPLAY

Err1

Err2

Err3

Err4

Err5

Err6

Err7

Err8

Err9

Er10

Er11

Er12

Er13

DESCRIPTION

Suction temperature sensor open or short

Ambient temp sensor open or short

Auxiliary temp sensor open or short

Suction Pressure sensor open or short

Liquid Pressure sensor open or short

Evap 1 defrost temp sensor open or short


Redundant Low Pressure Switch Malfunction detected

Safety Circuit interruption during normal operation

Prolonged Low Suction Pressure during cooling

Low Suction Pressure startup failure

High Suction Pressure startup failure

Post Defrost pump down error

5

6

General Safety Information

1. Installation and maintenance to be performed only by qualified personnel who are familiar with this type of equipment.

2. Some units are pressurized with dry air or inert gas.

All units must be evacuated before charging the system with refrigerant.

3. Make sure that all field wiring conforms to the requirements

of the equipment and all applicable national and local codes.

4. Avoid contact with sharp edges and coil surfaces.

They are a potential injury hazard.

5. Make sure all power sources are disconnected before any service work is done on units.

WARNING:

Refrigerant can be harmful if it is inhaled. Refrigerant must be used and recovered responsibly.

Failure to follow this warning may result in personal injury or death.

Inspection

Responsibility should be assigned to a dependable individual at the job site to receive material. Each shipment should be carefully checked against the bill of lading. The shipping receipt should not be signed until all items listed on the bill of lading have been accounted. Check carefully for concealed damage. Any shortage or damages should be reported to the delivering carrier. Damaged material becomes the delivering carrier’s responsibility, and should not be returned to the manufacturer unless prior approval is given to do so. When uncrating, care should be taken to prevent damage.

Heavy equipment should be left on its shipping base until it has been moved to the final location. Check the serial tag information with invoice. Report any discrepancies to your Heatcraft Refrigeration Products Sales Representative.

the purchaser must submit a proof-of-purchase of a compressor and supply it to

Heatcraft Refrigeration Products Warranty Claims for reimbursement.

Seller makes no express warranties except as noted above. All implied warranties are limited to the duration of the Express Warranty. Liability for incidental and consequential damages is excluded.

The forgoing is in lieu of all other warranties, express or implied, notwithstanding the provisions of the uniform commercial code, the Magnuson-Moss Warranty - Federal

Trade Commission Improvement Act, or any other statutory or common law, federal or state.

Warranty Statement

Seller warrants to its direct purchasers that products, including Service Parts, manufactured by SELLER shall be of a merchantable quality, free of defects in material or workmanship, under normal use and service for a period of one (1) year from date of original installation, or eighteen (18) months from date of shipmen t by SELLER, whichever first occurs. Any product covered by this order found to Seller’s satisfaction to be defective upon examination at Seller’s factory will at

SELLER’s option, be repaired or replaced and returned to Buyer via lowest common carrier, or SELLER may at its option grant Buyer a credit for the purchase price of the defective article. Upon return of a defective product to SELLER’s plant, freight prepaid, by Buyer, correction of such defect by repair or replacement, and return freight via lowest common carrier, shall constitute full performance by SELLER of its obligations hereunder.

SELLER makes no warranty, express or implied, of fitness for any particular purpose, or of any nature whatsoever, with respect to products manufactures or sold by seller hereunder, except as specifically set forth above and on the face hereof. It is expressly understood and agreed that SELLER shall not be liable to buyer, or any customer of buyer, for direct or indirect, special, incidental, consequential or penal damages, or for any expenses incurred by reason of the use or misuse by buyer or third parties of said products. To the extent said products may be considered "consumer products,"

As defined in Sec. 101 of the Magnuson-Moss Warranty - Federal Trade Commission

Improvement Act, SELLER makes no warranty of any kind, express or implied, to

"consumers," except as specifically set forth above and on the face hereof.

SELLER shall have no liability for expenses incurred for repairs made by Buyer except by prior, written authorization. Every claim on account of breach of warranty shall be made to SELLER in writing within the warranty period specified above – otherwise such claim shall be deemed waived. Seller shall have no warranty obligation whatsoever if its products have been subjected to alteration, misuse, negligence, free chemicals in system, corrosive atmosphere, accident, or if operation is contrary to SELLER’s or manufacturer’s recommendations, or if the serial number has been altered, defaced, or removed.

MOTOR COMPRESSORS:

Motor compressors furnished by SELLER are subject to the standard warranty terms set forth above, except that motor compressor replacements or exchanges shall be made through the nearest authorized wholesaler of the motor compressor manufacturer (not at SELLER’s factory) and no freight shall be allowed for transportation of the motor compressor to and from the wholesaler. The replacement motor compressor shall be identical to the model of the motor compressor being replaced. Additional charges which may be incurred throughout the substitution of other than identical replacements are not covered by this warranty. An optional, non assignable, four (4) year extended compressor warranty may be purchased within the boundaries of the United Sates of America, its territories and possessions, and

Canada. With this extended compressor warranty, replacements are administered by an authorized compressor distributor only. Replacements within the first year of the warranty area available through the distributor; the second through fifth years,

The following conditions should be adhered to when installing this unit to maintain the manufacturers warranty:

(a) System piping must be in accordance with good refrigeration practices.

(b) Inert gas must be charged into the piping during brazing.

(c) The power supply to the unit must meet the following conditions:

A. Three phase voltages must be +/-

10% of nameplate ratings. Single phase must be within +10% or

-5% of nameplate ratings.

B. Phase imbalance cannot exceed 2%.

(d) All control and safety switch circuits must be properly connected according to the wiring diagram.

(e) The factory installed wiring must not be changed without written

(f) factory approval.

All equipment is installed in accordance with Heatcraft Refrigeration

Products specified minimum clearances.

(g) Devices not provided by Heatcraft shall not be connected to the

Mohave controller without written factory approval

(h) Refrigerant line runs between condensing unit and evaporator(s) shall not exceed 200 ft without written factory approval

System and Components

Condensing Unit

(Vertical Air Discharge Design)

Standard Features:

• Electronic Hot Gas Defrost Controller includes Defrost Initiation and

Termination Control, Pressure Fan Cycling for Head Pressure Control, Ambient

Fan Cycling Option, Anti-Short Cycling Protection, and Low Pressure Control

• Electronic Pressure Regulator for Defrost Control

• Suction Accumulator

• High Pressure and Redundant Low Pressure Control

• Oil Pressure Safety Control

• High Efficiency Copeland Discus Compressors with POE oil

• Thermally Protected Permanently Lubricated Ball Bearing Condenser Fan

Motors

• Electrical Controls located in easily accessible control box with a hinged cover

• Receivers are sized for sufficient pump down capacity with inlet and outlet service valves

• Cabinet is constructed from painted galvanized steel

• Convenient Access Panels for easy servicing to internal components

• Suction and Discharge Vibration Eliminators

• Separate Sub-cooling Circuit.

• Replaceable Liquid Line Filter Drier

• Replaceable Core Suction Filter

• Sight Glass

• Compressor Head Fan on L6 Models

• MODBUS RS-485 (Inherent on control board)

Optional Features:

• Head Pressure Valves (ORI/ORD)

• Oil Separator

• Insulated and Heated Receiver

• Fused Disconnect Switch

• Non-fused Disconnect Switch

• Coated Condenser Coils for protection against harsh environments (Consult factory)

• Phase Loss Monitor

• Mounted Evaporator Control Contactors

• Remote Monitoring (RRC) Wireless Transmitter

• Variable Frequency Drive Package for Condenser Motors (Consult factory)

• Demand Cooling (Required for R-407A, R-407F, R-448A, and R-449A L6

models)

Evaporators

(Medium Profile & High Profile Unit Coolers)

Standard Features:

• All Components are factory installed and wired

• Power Supply Independent from Condensing Unit

• Mounted Fan Control Contactors and Drain Pan Heater Contactors if specified

• Four or Six Fins Per Inch Models

• Mounted TXV and Distributor Nozzle

• Mounted Check Valves

• Mounted Liquid Line Solenoid

• Suction P-Trap

• Thermally Protected Permanently Lubricated Evaporator Fan Motors

• Mounted Electric Drain Pan Heaters

• Insulated Drain Pan (Low Temperature Systems)

Optional Features:

•

•

Mounted Hot Gas Drain Pan Loop

Evaporator Powered from Condensing Unit

7

8

Unit Cooler Installation

Unit Cooler Installation

Most evaporators can be mounted with rod hangers, lag screws, or bolts. Use 5/16" bolt and washers or rod for up to 250 pounds, 3/8" for up to 600 pounds and

5/8" for over 600 pounds. Care should be taken to mount the units level so that condensate drains properly. Adequate support must be provided to hold the weight of the unit.

When using rod hangers, allow adequate space between the top of the unit and the ceiling for cleaning. To comply with NSF Standard 7, the area above the unit cooler must be sealed or exposed in such a way to facilitate hand cleaning without the use of tools. When lagging or bolting the unit flush to the ceiling, seal the joint between the top and the ceiling with an NSF listed sealant and ends of open hanger channels must be sealed to prevent accumulation of foreign matter.

When locating unit coolers in a cooler or freezer, refer to Figure 1-2 for guidelines.

Figure 1. Large Coolers and Freezers Placement.

NOTE: Always avoid placement of Unit Coolers directly above doors and door openings.

Baffled Unit

Where one wall evaporator mounting is satisfactory.

Cooler or Freezers where one wall will not accommodate all required evaporators or where air throw distance must be considered.

Allow sufficient space between rear of Unit Cooler and wall to permit free return of air.

Baffle

Glass

Display

Door

Elevation view of glass display door cooler or freezer. Be sure air discharge blows above, not directly at doors. Provide baffle if door extends above blower level.

Cooler or Freezer with Glass Display

Doors

Unit Cooler Installation & Condensate Lines

Unit Coolers (continued)

Recommended Unit Cooler Placement

Some general rules for evaporator placement which must be followed are:

1. The air pattern must cover the entire room

2. NEVER locate evaporators over doors

3.

4.

5.

Location of aisles, racks, etc. must be known

Location relative to compressors for minimum pipe runs

Location of condensate drains for minimum run.

The size and shape of the storage will generally determine the type and number of evaporators to be used and their location. The following are some typical examples:

Traps on low temperature units must be outside of refrigerated enclosures. Traps subject to freezing temperatures must be wrapped with heat tape and insulated.

NOTE: Always trap single evaporator system drain lines individually to prevent humidity migration.

Minimum Unit Clearances

Figure 2. Medium Profile and Large Unit Coolers

NOTE:

Two evaporators

Condensate Drain Lines

One evaporator

NOTE: Leave space equal to unit height between bottom of unit and product.

Do not stack product in front of fans.

Condensate Drain Lines

Either copper or steel drain lines should be used and properly protected from freezing. In running drain lines, provide a minimum 4 inches per foot pitch for proper drainage. Drain lines should be at least as large as the evaporator drain connection.

All plumbing connections should be made in accordance with local plumbing codes.

All condensate drain lines must be trapped, and run to an open drain. They must never be connected directly to the sewer system. Traps in the drain line must be located in a warm ambient. We recommend a trap on each evaporator drain line prior to any tee connections. Traps located outside, or extensive outside runs of drain line must be wrapped with a drain line heater. The heater should be connected so that it operates continuously. It is recommended that the drain line be insulated to prevent heat loss. A heat input of 20 watts per linear foot of drain line for 0˚F

(-18˚C) room applications and 30 watts per linear foot for -20˚F (-29˚C) rooms is satisfactory. In freezers, the evaporator drain pan fitting should be included when heating and insulating the drain line.

Inspect drain pan periodically to insure free drainage of condensate. If drain pan contains standing water, check for proper installation. The drain pan should be cleaned regularly with warm soapy water.

- 1/4” / FT

WARNING: All power must be disconnected before cleaning.

Drain pan also serves as cover of hazardous moving parts. Operation of unit without drain pan constitutes a hazard.

9

Condensing Unit Installation

Space & Location Requirements for Air Cooled Condensing Units and Remote Condensers

The most important consideration which must be taken into account when deciding upon the location of air-cooled equipment is the provision for a supply of ambient air to the condenser, and removal of heated air from the condensing unit or remote condenser area. Where this essential requirement is not adhered to, it will result in higher head pressures, which cause poor operation and potential failure of equipment.

Units must not be located in the vicinity of steam, hot air or fume exhausts. Corrosive atmospheres require custom designed condensers.

Another consideration which must be taken is that the unit should be mounted away from noise sensitive spaces and must have adequate support to avoid vibration and noise transmission into the building. Units should be mounted over corridors, utility areas, rest rooms and other auxiliary areas where high levels of sound are not an important factor. Sound and structural consultants should be retained for recommendations.

Space and Location Requirements for Condensing Units and Remote Condensers

Walls or Obstructions

The unit should be located so that air may circulate freely and not be recirculated. For proper air flow and access all sides of the unit should be a minimum of “W” away from any wall or obstruction. It is preferred that this distance be increased whenever possible. Care should be taken to see that ample room is left for maintenance work through access doors and panels.

Overhead obstructions are not permitted. When the unit is in an area where it is enclosed by three walls the unit must be installed as indicated for units in a pit.

Multiple Units

For units placed side by side, the minimum distance between units is the width of the largest unit. If units are placed end to end, the minimum distance between units is 4 feet.

Units in Pits

The top of the unit should be level with the top of the pit, and side distance increased to “2W”.

If the top of the unit is not level with the top of pit, discharge cones or stacks must be used to raise discharge air to the top of the pit. This is a minimum requirement.

Decorative Fences

Fences must have 50% free area, with 1 foot undercut, a “W” minimum clearance, and must not exceed the top of unit. If these requirements are not met, unit must be installed as indicated for “Units in pits”.

Walls or Obstructions for Horizontal Air Flow Multiple Units with Horizontal Air Flow

10

* “W” = Total width of the condensing unit or condenser.

Condensing Unit Installation

Condensing Unit Rigging and Mounting

Rigging holes are provided on all units. Caution should be exercised when moving these units. To prevent damage to the unit housing during rigging, cables or chains used must be held apart by spacer bars. The mounting platform or base should be level and located so as to permit free access of supply air.

Ground Mounting

Concrete slab raised six inches above ground level provides a suitable base. Raising the base above ground level provides some protection from ground water and wind blown matter. Before tightening mounting bolts, recheck level of unit. The unit should in all cases be located with a clear space in all directions that is at a minimum, equal to the height of the unit above the mounting surface. A condensing unit mounted in a corner formed by two walls, may result in discharge air recirculation with resulting loss of capacity.

Spring Mounted Compressor

Compressors are secured rigidly to make sure there is no transit damage. Before operating the unit, it is necessary to follow these steps: a. b. c. d. e.

Remove the upper nuts and washers.

Discard the shipping spacers.

Install the neoprene spacers. (Spacers located in the electrical panel or tied to compressor.)

Replace the upper mounting nuts and washers.

Allow 1/16 inch space between the mounting nut/ washer and the neoprene spacer. See Figure 3 below.

Rigid Mounted Compressor

Some products use rigid mounted compressors. Check the compressor mounting bolts to insure they have not vibrated loose during shipment. See Figure 3 and 5 below.

Roof Mounting

Due to the weight of the units, a structural analysis by a qualified engineer may be required before mounting. Roof mounted units should be installed level on steel channels or an I-beam frame capable of supporting the weight of the unit. Vibration absorbing pads or springs should be installed between the condensing unit legs or frame and the roof mounting assembly.

Access

Provide adequate space at the compressor end of the unit for servicing. Provide adequate space on the connection side to permit service of components.

Figure 3. Spring Mount Figure 4. Solid Mount for Mobile or Deep

Sump Application.

Figure 5. Spring Mount

11

Piping

Recommended Refrigerant Piping Practices

The system as supplied by Heatcraft Refrigeration Products , was thoroughly cleaned and dehydrated at the factory. Foreign matter may enter the system by way of the evaporator to condensing unit piping. Therefore, care must be used during installation of the piping to prevent entrance of foreign matter.

Refrigerant Pipe Support

1. Normally, any straight run of tubing must be supported in at least two locations near each end of the run. Long runs require additional supports. The refrigerant lines should be supported and fastened properly. As a guide, 3/8 to 7/8 should be supported every 5 feet; 1-1/8 and 1-3/8 every 7 feet; and 1-5/8 and 2-1/8 every

9 to 10 feet.

Install all refrigeration system components in accordance with applicable local and national codes and in conformance with good practice required for the proper operation of the system.

The refrigerant pipe size should be selected from the tables on pages 15-21. The interconnecting pipe size is not necessarily the same size as the stub-out on the condensing unit or the evaporator.

The following procedures should be followed:

(a) Do not leave dehydrated compressors or filter driers open to the

(b) atmosphere.

Use only refrigeration grade copper tubing, properly sealed against contamination.

(c)

(d)

(e)

Suction lines should slope 1/4" per 10 feet towards the compressor.

Suitable P-type oil traps should be located at the base of each suction riser to enhance oil return to the compressor.

For desired method of superheat measurement, a pressure tap should be installed in each evaporator suction line in the proximity of the expansion valve bulb.

(f) be passed through the line at low pressure to prevent scaling and oxidation inside the tubing. Dry nitrogen is preferred.

(g)

(h)

(i)

Use only a suitable silver solder alloy on suction and liquid lines.

Limit the soldering paste or flux to the minimum required to prevent contamination of the solder joint internally. Flux only the male portion of the connection, never the female. After brazing, remove excess flux.

If isolation valves are installed at the evaporator,full port ball valves

(j) should be used.

Do not install liquid/suction line heat exchangers.

2. When changing directions in a run of tubing, no corner should be left unsupported. Supports should be placed a maximum of 2 feet in each direction from the corner.

3. Piping attached to a vibrating object (such as a compressor or compressor base) must be supported in such a manner that will not restrict the movement of the vibrating object. Rigid mounting will fatigue the copper tubing.

4. Do not use short radius ells. Short radius elbows have points of excessive stress concentration and are subject to breakage at these points.

5. Thoroughly inspect all piping after the equipment is in operation and add supports wherever line vibration is significantly greater than most of the other piping. Extra supports are relatively inexpensive as compared to refrigerant loss.

Example of Pipe Support Condensing Unit / Compressor to Wall Support.

12

Piping

The following are examples of proper piping layout for typical system configurations

13

14

Piping

Piping

Unit Cooler Piping

Pipe size example:

Given: -10°F Freezer with one system having (2) evaporators

• One condensing unit rated at 24,000 BTUH’s @ -20°F SST R404A refrigerant.

• Two evaporators each rated at 12,000 BTUH’s @ 10°F TD.

• 75 feet of actual line run between condensing unit to first evaporator and 20 feet of actual line run between the first evaporator and the second evaporator (see figure below).

NOTE: This is a line sizing example. Use diagrams on page

13-14 for piping orientation.

How to figure line sizes:

1. Determine equivalent line run = actual run + valves and fitting allowances.

2. Use Line Sizing Tables on pages 16-21 to size lines.

3. Note any special considerations.

Fittings in this system:

• (6) 90° elbows in main line plus a 90° turn through a tee.

• (5) addtional 90° elbows to first evaporator.

• (4) additional 90° elbows to second evaporator.

Evap. 2 Evap. 1

Determine line size 1 (main line from condensing unit):

1. Main line from the condensing unit to be sized for the total capacity (balance) of the whole system of 24,000 BTUH’s (Table 3 and 3A).

2. Refer to 24,000 @75 feet at -20°F SST R404A on the chart.

You will find the suction line to be 1 1/8" and 1/2" liquid line.

3. Refer to Table 5A. For every 1 1/8" 90° elbow you must add 3 equivalent feet of pipe and 2 equivalent feet of pipe for each 1 1/8" tee.

Therefore, total equivalent line run =

Actual line run

+ (6) 1 1/8" elbows @ 3'

+ (1) 1 1/8" tee @ 2'

Total equivalent line run

75 feet

18 feet

2 feet

95 feet

4. Refer to Table 3A. For 95 total equivalent feet, the suction line size should be 1

3/8" and the liquid line stays at 1/2" line.

Note: The gray shaded areas on Table 2. For 24,000 BTUH’s, the maximum suction riser is 1 1/8" to insure proper oil return and pressure drop from the bottom p-trap to the top p-trap.

Determine line size 2 (evaporators):

1. Line sizing to each evaporator is based on 12,000 BTUH’s and equivalent run from condensing unit. First evaporator has an 80 ft. run and the second evaporator has a 95 ft. run.

2. Table 3 indicates 7/8" suction for the first evaporator and Table 3A indicates 1

1/8" suction for the second evaporator.

3. Refer to Table 5A. Each 7/8" 90° elbow adds 2 equivalent feet of pipe. Each

1 1/8" 90° elbow adds 3 equivalent feet and a 90° turn through a 1 1/8" tee adds 6 equivalent feet.

4. Actual line run (evap 1) 80 feet

+ (5) 7/8" elbows @ 2'

+ (1) 90° turn through tee @ 6'


Actual line run (evap 2)

10 feet

6 feet

96 feet

95 feet

+ (4) 1 1/8" elbows @ 3'


12 feet

107 feet

5. Table 3A indicates 1 1/8" suction line and 3/8" liquid line from main line to both evaporators.

15

Line Sizing

Table 1. Recommended Line Sizes for R-407*

System

Capacity

25' 50'

+40 ˚F

Equivalent Lengths

75' 100' 150' 200' 25'

SUCTION LINE SIZE

SUCTION TEMPERATURE

+20 ˚F


50' 75' 100' 150' 200' 25' 50'

+10 ˚F


75' 100' 150' 200'

1,000 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8

3,000 3/8 3/8 3/8 3/8 1/2 1/2 3/8 3/8 3/8 1/2 1/2 1/2 3/8 3/8 1/2 1/2 1/2 1/2

4,000 3/8 3/8 1/2 1/2 1/2 1/2 3/8 1/2 1/2 1/2 5/8 5/8 3/8 1/2 1/2 5/8 5/8 5/8

6,000 3/8 1/2 1/2 1/2 5/8 5/8 1/2 1/2 1/2 5/8 5/8 5/8 1/2 1/2 5/8 5/8 5/8 5/8

9,000 1/2 1/2 5/8 5/8 5/8 5/8 1/2 5/8 5/8 7/8 7/8 7/8 1/2 5/8 5/8 7/8 7/8 7/8

12,000 1/2 5/8 5/8 7/8 7/8 7/8 5/8 5/8 7/8 7/8 7/8 7/8 5/8 7/8 7/8 7/8 7/8 7/8

15,000 5/8 5/8 7/8 7/8 7/8 7/8 5/8 7/8 7/8 7/8 7/8 7/8 5/8 7/8 7/8 7/8 7/8 7/8

18,000 5/8 7/8 7/8 7/8 7/8 7/8 5/8 7/8 7/8 7/8 7/8 7/8 7/8 7/8 7/8 7/8 1 1/8 1 1/8

24,000 5/8 7/8 7/8 7/8 7/8 7/8 7/8 7/8 7/8 7/8 1 1/8 1 1/8 7/8 7/8 7/8 1 1/8 1 1/8 1 1/8

30,000 7/8 7/8 7/8 7/8 1 1/8 1 1/8 7/8 7/8 7/8 1 1/8 1 1/8 1 1/8 7/8 7/8 1 1/8 1 1/8 1 1/8 1 1/8

36,000 7/8 7/8 7/8 1 1/8 1 1/8 1 1/8 7/8 7/8 1 1/8 1 1/8 1 1/8 1 1/8 7/8 1 1/8 1 1/8 1 1/8 1 1/8 1 3/8

42,000 7/8 7/8 1 1/8 1 1/8 1 1/8 1 1/8 7/8 7/8 1 1/8 1 1/8 1 1/8 1 1/8 7/8 1 1/8 1 1/8 1 1/8 1 3/8 1 3/8

48,000 7/8 7/8 1 1/8 1 1/8 1 1/8 1 1/8 7/8 1 1/8 1 1/8 1 1/8 1 3/8 1 3/8 7/8 1 1/8 1 1/8 1 1/8 1 3/8 1 3/8

54,000 7/8 1 1/8 1 1/8 1 1/8 1 1/8 1 3/8 7/8 1 1/8 1 1/8 1 1/8 1 3/8 1 3/8 1 1/8 1 1/8 1 1/8 1 3/8 1 3/8 1 3/8

60,000 7/8 1 1/8 1 1/8 1 1/8 1 3/8 1 3/8 1 1/8 1 1/8 1 1/8 1 3/8 1 3/8 1 3/8 1 1/8 1 1/8 1 1/8 1 3/8 1 3/8 1 3/8

66,000 7/8 1 1/8 1 1/8 1 1/8 1 3/8 1 3/8 1 1/8 1 1/8 1 1/8 1 3/8 1 3/8 1 3/8 1 1/8 1 1/8 1 3/8 1 3/8 1 3/8 1 5/8

72,000 7/8 1 1/8 1 1/8 1 1/8 1 3/8 1 3/8 1 1/8 1 1/8 1 1/8 1 3/8 1 3/8 1 3/8 1 1/8 1 1/8 1 3/8 1 3/8 1 3/8 1 5/8

78,000 7/8 1 1/8 1 1/8 1 3/8 1 3/8 1 3/8 1 1/8 1 1/8 1 1/8 1 3/8 1 3/8 1 5/8 1 1/8 1 1/8 1 3/8 1 3/8 1 5/8 1 5/8

84,000 1 1/8 1 1/8 1 1/8 1 3/8 1 3/8 1 3/8 1 1/8 1 1/8 1 3/8 1 3/8 1 5/8 1 5/8 1 1/8 1 3/8 1 3/8 1 3/8 1 5/8 1 5/8

90,000 1 1/8 1 1/8 1 3/8 1 3/8 1 3/8 1 5/8 1 1/8 1 3/8 1 3/8 1 5/8 1 5/8 1 5/8 1 1/8 1 3/8 1 3/8 1 5/8 1 5/8 1 5/8

120,000 1 1/8 1 3/8 1 3/8 1 5/8 1 5/8 1 5/8 1 3/8 1 3/8 1 5/8 1 5/8 1 5/8 2 1/8 1 3/8 1 5/8 1 5/8 1 5/8 2 1/8 2 1/8

150,000 1 3/8 1 3/8 1 5/8 1 5/8 1 5/8 2 1/8 1 3/8 1 5/8 1 5/8 1 5/8 2 1/8 2 1/8 1 3/8 1 5/8 1 5/8 2 1/8 2 1/8 2 1/8

180,000 1 3/8 1 3/8 1 5/8 1 5/8 2 1/8 2 1/8 1 3/8 1 5/8 1 5/8 2 1/8 2 1/8 2 1/8 1 5/8 2 1/8 2 1/8 2 1/8 2 1/8 2 1/8

210,000 1 3/8 1 5/8 1 5/8 2 1/8 2 1/8 2 1/8 1 5/8 1 5/8 2 1/8 2 1/8 2 1/8 2 1/8 1 5/8 2 1/8 2 1/8 2 1/8 2 1/8 2 5/8

240,000 1 5/8 1 5/8 2 1/8 2 1/8 2 1/8 2 1/8 1 5/8 2 1/8 2 1/8 2 1/8 2 1/8 2 5/8 1 5/8 2 1/8 2 1/8 2 1/8 2 5/8 2 5/8

300,000 1 5/8 2 1/8 2 1/8 2 1/8 2 1/8 2 5/8 1 5/8 2 1/8 2 1/8 2 1/8 2 5/8 2 5/8 2 1/8 2 1/8 2 1/8 2 5/8 2 5/8 2 5/8

360,000 1 5/8 2 1/8 2 1/8 2 1/8 2 5/8 2 5/8 2 1/8 2 1/8 2 1/8 2 5/8 2 5/8 2 5/8 2 1/8 2 1/8 2 5/8 2 5/8 2 5/8 2 5/8

480,000 2 1/8 2 1/8 2 1/8 2 5/8 2 5/8 2 5/8 2 1/8 2 5/8 2 5/8 2 5/8 3 1/8 3 1/8 2 1/8 2 5/8 2 5/8 3 1/8 3 1/8 3 1/8

600,000 2 1/8 2 5/8 2 5/8 2 5/8 3 1/8 3 1/8 2 5/8 2 5/8 2 5/8 3 1/8 3 1/8 3 1/8 2 1/8 2 5/8 3 1/8 3 1/8 3 1/8 3 5/8

* NOTES:

1. Sizes that are highlighted indicate maximum suction line sizes that should be used for risers. Riser size should not exceed horizontal size. Properly placed suction traps must also be used for adequate oil return. All sizes shown are for O.D. Type L copper tubing.

2. Suction line sizes selected at pressure drop equivalent to 2˚F. Reduce estimate of system capacity accordingly.

3. If system load drops below 40% of design, consideration to installing double suction risers should be made.

4. R407A, R407C, R407F

16

Line Sizing

Table 1A. Recommended Line Sizes for R-407 (continued)*

LIQUID LINE SIZE

1/2

1/2

5/8

5/8

1/2

1/2

1/2

1/2

5/8

5/8

5/8

7/8

1/2

1/2

1/2

1/2

3/8

3/8

1/2

1/2

1/2

1/2

5/8

5/8

3/8

3/8

3/8

3/8

Receiver to

Expansion Valve

Expansion Valve

25' 50' 75' 100' 150' 200'

3/8 3/8 3/8 3/8 3/8 3/8

3/8

3/8

3/8

3/8

3/8

3/8

3/8

3/8

3/8

3/8

3/8

3/8

3/8

3/8

3/8

3/8

3/8

3/8

3/8

3/8

3/8

3/8

3/8

3/8

3/8

3/8

3/8

3/8

3/8

3/8

3/8

3/8

3/8

3/8

3/8

3/8

3/8

1/2

3/8

3/8

1/2

3/8

1/2

1/2

1/2

1/2

1/2

1/2

1/2

5/8

1/2

1/2

1/2

1/2

5/8

5/8

5/8

5/8

5/8

5/8

7/8

7/8

1/2

1/2

5/8

5/8

5/8

5/8

5/8

5/8

5/8

7/8

7/8

7/8

5/8

5/8

5/8

5/8

5/8

5/8

5/8

7/8

7/8

7/8

7/8

7/8

7/8

7/8

7/8

7/8

7/8

7/8

7/8

7/8

7/8

7/8

7/8 1 1/8 1 1/8 180,000

7/8 1 1/8 1 1/8 210,000

7/8 1 1/8 1 1/8 1 1/8 240,000

7/8 1 1/8 1 1/8 1 1/8 300,000

7/8 1 1/8 1 1/8 1 1/8 1 1/8 1 3/8 360,000

7/8 1 1/8 1 1/8 1 3/8 1 3/8 1 3/8 480,000

1 1/8 1 1/8 1 3/8 1 3/8 1 3/8 1 3/8 600,000

1,000

3,000

4,000

6,000

9,000

12,000

15,000

18,000

24,000

30,000

5/8

7/8

7/8

7/8

5/8

5/8

5/8

5/8

7/8

7/8

7/8

7/8

36,000

42,000

48,000

54,000

60,000

66,000

72,000

78,000

84,000

90,000

120,000

150,000

NOTES:

1. All sizes shown are for O.D. Type L copper tubing.

2 .R407A, 407C, R407F

17

Line Sizing

Table 2. Recommended Line Sizes for R-448A/R-449A

System

Capacity

BTU/H

25' 50'

+20 ˚F


75' 100' 150' 200' 25'



+10 ˚F


-10 ˚F


50' 75' 100' 150' 200' 25' 50' 75' 100' 150' 200'

1,000 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 1/2 3/8 3/8 3/8 1/2 1/2 1/2

3,000 3/8 3/8 1/2 1/2 1/2 5/8 3/8 1/2 1/2 1/2 5/8 5/8 1/2 1/2 5/8 5/8 5/8 7/8

4,000 3/8 1/2 1/2 1/2 5/8 5/8 1/2 1/2 1/2 5/8 5/8 7/8 1/2 5/8 5/8 5/8 7/8 7/8

6,000 1/2 1/2 5/8 5/8 7/8 7/8 1/2 1/2 5/8 5/8 7/8 7/8 1/2 5/8 5/8 7/8 7/8 7/8

9,000 5/8 5/8 7/8 7/8 7/8 7/8 5/8 5/8 7/8 7/8 7/8 7/8 5/8 7/8 7/8 7/8 7/8 1 1/8

12,000 5/8 7/8 7/8 7/8 7/8 7/8 5/8 7/8 7/8 7/8 7/8 1 1/8 7/8 7/8 7/8 7/8 1 1/8 1 1/8

15,000 5/8 7/8 7/8 7/8 7/8 1 1/8 7/8 7/8 7/8 7/8 1 1/8 1 1/8 7/8 7/8 7/8 1 1/8 1 1/8 1 1/8

18,000 7/8 7/8 7/8 7/8 1 1/8 1 1/8 7/8 7/8 7/8 1 1/8 1 1/8 1 1/8 7/8 7/8 1 1/8 1 1/8 1 1/8 1 3/8

24,000 7/8 7/8 7/8 1 1/8 1 1/8 1 1/8 7/8 1 1/8 1 1/8 1 1/8 1 1/8 1 3/8 7/8 1 1/8 1 1/8 1 1/8 1 3/8 1 3/8

30,000 7/8 7/8 1 1/8 1 1/8 1 1/8 1 3/8 7/8 1 1/8 1 1/8 1 1/8 1 3/8 1 3/8 1 1/8 1 1/8 1 1/8 1 3/8 1 3/8 1 3/8

36,000 7/8 1 1/8 1 1/8 1 1/8 1 3/8 1 3/8 1 1/8 1 1/8 1 1/8 1 3/8 1 3/8 1 3/8 1 1/8 1 1/8 1 3/8 1 3/8 1 3/8 1 5/8

42,000 1 1/8 1 1/8 1 1/8 1 3/8 1 3/8 1 3/8 1 1/8 1 1/8 1 3/8 1 3/8 1 3/8 1 5/8 1 1/8 1 3/8 1 3/8 1 3/8 1 5/8 1 5/8

48,000 1 1/8 1 1/8 1 3/8 1 3/8 1 3/8 1 3/8 1 1/8 1 1/8 1 3/8 1 3/8 1 5/8 1 5/8 1 1/8 1 3/8 1 3/8 1 3/8 1 5/8 1 5/8

54,000 1 1/8 1 1/8 1 3/8 1 3/8 1 3/8 1 5/8 1 1/8 1 3/8 1 3/8 1 3/8 1 5/8 1 5/8 1 3/8 1 3/8 1 3/8 1 5/8 1 5/8 1 5/8

60,000 1 1/8 1 1/8 1 3/8 1 3/8 1 5/8 1 5/8 1 1/8 1 3/8 1 3/8 1 5/8 1 5/8 1 5/8 1 3/8 1 3/8 1 5/8 1 5/8 1 5/8 2 1/8

66,000 1 1/8 1 3/8 1 3/8 1 3/8 1 5/8 1 5/8 1 1/8 1 3/8 1 3/8 1 5/8 1 5/8 1 5/8 1 3/8 1 5/8 1 5/8 1 5/8 1 5/8 1 5/8

72,000 1 1/8 1 3/8 1 3/8 1 5/8 1 5/8 1 5/8 1 1/8 1 3/8 1 5/8 1 5/8 1 5/8 1 5/8 1 3/8 1 5/8 1 5/8 1 5/8 1 5/8 1 5/8

78,000 1 1/8 1 3/8 1 3/8 1 5/8 1 5/8 2 1/8 1 3/8 1 3/8 1 5/8 1 5/8 1 5/8 2 1/8 1 3/8 1 5/8 1 5/8 1 5/8 1 5/8 2 1/8

84,000 1 1/8 1 3/8 1 5/8 1 5/8 1 5/8 2 1/8 1 3/8 1 3/8 1 5/8 1 5/8 2 1/8 2 1/8 1 3/8 1 5/8 1 5/8 1 5/8 2 1/8 2 1/8

90,000 1 3/8 1 3/8 1 5/8 1 5/8 2 1/8 2 1/8 1 3/8 1 5/8 1 5/8 1 5/8 2 1/8 2 1/8 1 5/8 1 5/8 1 5/8 2 1/8 2 1/8 2 5/8

120,000 1 3/8 1 5/8 1 5/8 2 1/8 2 1/8 2 1/8 1 3/8 1 5/8 2 1/8 2 1/8 2 1/8 2 1/8 1 5/8 2 1/8 2 1/8 2 1/8 2 5/8 2 5/8

150,000 1 5/8 1 5/8 2 1/8 2 1/8 2 1/8 2 1/8 1 5/8 2 1/8 2 1/8 2 1/8 2 1/8 2 5/8 2 1/8 2 1/8 2 1/8 2 5/8 2 5/8 2 5/8

180,000 1 5/8 2 1/8 2 1/8 2 1/8 2 1/8 2 5/8 1 5/8 2 1/8 2 1/8 2 1/8 2 5/8 2 5/8 2 1/8 2 1/8 2 5/8 2 5/8 2 5/8 3 1/8

210,000 1 5/8 2 1/8 2 1/8 2 1/8 2 5/8 2 5/8 2 1/8 2 1/8 2 1/8 2 5/8 2 5/8 2 5/8 2 1/8 2 1/8 2 5/8 2 5/8 3 1/8 3 1/8

240,000 1 5/8 2 1/8 2 1/8 2 1/8 2 5/8 2 5/8 2 1/8 2 1/8 2 5/8 2 5/8 2 5/8 2 5/8 2 1/8 2 5/8 2 5/8 2 5/8 3 1/8 3 1/8

300,000 2 1/8 2 1/8 2 5/8 2 5/8 2 5/8 3 1/8 2 1/8 2 5/8 2 5/8 2 5/8 3 1/8 3 1/8 2 5/8 2 5/8 2 5/8 3 1/8 3 1/8 3 5/8

360,000 2 1/8 2 1/8 2 5/8 2 5/8 3 1/8 3 1/8 2 1/8 2 5/8 2 5/8 2 5/8 3 1/8 3 1/8 2 5/8 2 5/8 3 1/8 3 1/8 3 5/8 3 5/8

480,000 2 1/8 2 5/8 2 5/8 3 1/8 3 1/8 3 5/8 2 5/8 2 5/8 2 5/8 2 5/8 3 5/8 3 5/8 2 5/8 3 1/8 3 1/8 3 5/8 3 5/8 4 1/8

600,000 2 5/8 2 5/8 3 1/8 3 1/8 3 5/8 3 5/8 2 5/8 2 5/8 3 1/8 3 1/8 3 5/8 3 5/8 3 1/8 3 1/8 3 1/8 3 5/8 4 1/8 4 1/8

* NOTES:

1. Sizes that are highlighted indicate maximum suction line sizes that should be used for risers. Riser size should not exceed horizontal size. Properly placed suction traps must also be used for adequate oil return. All sizes shown are for O.D. Type L copper tubing.



4. R407A, R407C, R407F

18

Line Sizing

Table 2. Recommended Line Sizes for R-448A/R-449A (continued)*

System

Capacity

BTU/H

25' 50'

-20 ˚F


75' 100' 150' 200' 25' 50'



-30 ˚F


75' 100' 150' 200' 25'

-40 ˚F


50' 75' 100' 150' 200'

1,000 3/8 3/8 1/2 1/2 1/2 1/2 3/8 3/8 1/2 1/2 1/2 5/8 3/8 1/2 1/2 1/2 5/8

3,000 1/2 1/2 5/8 5/8 7/8 7/8 1/2 1/2 5/8 5/8 7/8 7/8 1/2 1/2 5/8 5/8 7/8

5/8

7/8

4,000 1/2 5/8 5/8 7/8 7/8 7/8 5/8 5/8 5/8 7/8 7/8 7/8 1/2 5/8 5/8 7/8 7/8 7/8

6,000 5/8 5/8 7/8 7/8 7/8 7/8 5/8 5/8 7/8 7/8 7/8 7/8 5/8 5/8 7/8 7/8 7/8 1 1/8

9,000 5/8 7/8 7/8 7/8 1 1/8 1 1/8 5/8 7/8 7/8 7/8 1 1/8 1 1/8 5/8 7/8 7/8 7/8 1 1/8 1 1/8

12,000 7/8 7/8 7/8 1 1/8 1 1/8 1 1/8 7/8 7/8 7/8 1 1/8 1 1/8 1 1/8 7/8 7/8 7/8 1 1/8 1 1/8 1 1/8

15,000 7/8 7/8 1 1/8 1 1/8 1 1/8 1 3/8 7/8 7/8 1 1/8 1 1/8 1 1/8 1 3/8 7/8 7/8 1 1/8 1 1/8 1 1/8 1 3/8

18,000 7/8 1 1/8 1 1/8 1 1/8 1 3/8 1 3/8 7/8 1 1/8 1 1/8 1 1/8 1 3/8 1 3/8 7/8 1 1/8 1 1/8 1 1/8 1 3/8 1 3/8

24,000 1 1/8 1 1/8 1 1/8 1 3/8 1 3/8 1 3/8 1 1/8 1 1/8 1 1/8 1 3/8 1 3/8 1 3/8 1 1/8 1 1/8 1 1/8 1 3/8 1 3/8 1 3/8

30,000 1 1/8 1 1/8 1 1/8 1 3/8 1 3/8 1 5/8 1 1/8 1 1/8 1 3/8 1 3/8 1 3/8 1 5/8 1 1/8 1 1/8 1 3/8 1 3/8 1 3/8 1 5/8

36,000 1 1/8 1 1/8 1 3/8 1 3/8 1 3/8 1 5/8 1 1/8 1 3/8 1 3/8 1 3/8 1 3/8 1 5/8 1 1/8 1 3/8 1 3/8 1 3/8 1 5/8 1 5/8

42,000 1 1/8 1 3/8 1 3/8 1 5/8 1 5/8 1 5/8 1 1/8 1 3/8 1 3/8 1 3/8 1 5/8 1 5/8 1 1/8 1 3/8 1 3/8 1 3/8 1 5/8 1 5/8

48,000 1 1/8 1 3/8 1 3/8 1 5/8 1 5/8 1 5/8 1 1/8 1 3/8 1 3/8 1 3/8 1 5/8 1 5/8 1 1/8 1 3/8 1 3/8 1 3/8 1 5/8 1 5/8

54,000 1 3/8 1 3/8 1 5/8 1 5/8 1 5/8 1 5/8 1 3/8 1 3/8 1 3/8 1 5/8 1 5/8 2 1/8 1 3/8 1 3/8 1 3/8 1 5/8 1 5/8 2 1/8

60,000 1 3/8 1 3/8 1 5/8 1 5/8 1 5/8 2 1/8 1 3/8 1 3/8 1 5/8 1 5/8 1 5/8 2 1/8 1 3/8 1 3/8 1 5/8 1 5/8 1 5/8 2 1/8

66,000 1 3/8 1 5/8 1 5/8 1 5/8 1 5/8 2 1/8 1 3/8 1 5/8 1 5/8 1 5/8 1 5/8 2 1/8 1 3/8 1 5/8 1 5/8 1 5/8 1 5/8 2 1/8

72,000 1 3/8 1 5/8 1 5/8 1 5/8 1 5/8 2 1/8 1 3/8 1 5/8 1 5/8 1 5/8 1 5/8 2 1/8 1 3/8 1 5/8 1 5/8 1 5/8 1 5/8 2 1/8

78,000 1 5/8 1 5/8 1 5/8 1 5/8 2 1/8 2 1/8 1 5/8 1 5/8 1 5/8 1 5/8 2 1/8 2 1/8 1 5/8 1 5/8 1 5/8 1 5/8 2 1/8 2 1/8

84,000 1 5/8 1 5/8 1 5/8 2 1/8 2 1/8 2 1/8 1 5/8 1 5/8 1 5/8 2 1/8 2 1/8 2 1/8 1 5/8 1 5/8 1 5/8 2 1/8 2 1/8 2 1/8

90,000 1 5/8 1 5/8 2 1/8 2 1/8 2 1/8 2 5/8 1 5/8 2 1/8 2 1/8 2 1/8 2 1/8 2 5/8 1 5/8 1 5/8 2 1/8 2 1/8 2 1/8 2 5/8

120,000 1 5/8 2 1/8 2 1/8 2 1/8 2 5/8 2 5/8 1 5/8 2 1/8 2 1/8 2 1/8 2 5/8 2 5/8 1 5/8 2 1/8 2 1/8 2 1/8 2 5/8 2 5/8

150,000 2 1/8 2 1/8 2 1/8 2 5/8 2 5/8 2 5/8 2 1/8 2 1/8 2 1/8 2 5/8 2 5/8 2 5/8 2 1/8 2 1/8 2 5/8 2 5/8 2 5/8 2 5/8

180,000 2 1/8 2 1/8 2 5/8 2 5/8 2 5/8 3 1/8 2 1/8 2 1/8 2 5/8 2 5/8 2 5/8 3 1/8 2 1/8 2 1/8 2 5/8 2 5/8 2 5/8 3 1/8

210,000 2 1/8 2 5/8 2 5/8 2 5/8 3 1/8 3 1/8 2 1/8 2 5/8 2 5/8 2 5/8 3 1/8 3 1/8 2 1/8 2 5/8 2 5/8 2 5/8 3 1/8 3 1/8

240,000 2 1/8 2 5/8 2 5/8 2 5/8 3 1/8 3 1/8 2 5/8 2 5/8 2 5/8 3 1/8 3 1/8 3 5/8 2 5/8 2 5/8 2 5/8 3 1/8 3 1/8 3 5/8

300,000 2 5/8 2 5/8 2 5/8 3 1/8 3 5/8 3 5/8 2 5/8 2 5/8 3 1/8 3 1/8 3 5/8 4 1/8 2 5/8 2 5/8 3 1/8 3 5/8 3 5/8 4 1/8

360,000 2 5/8 2 5/8 3 1/8 3 5/8 3 5/8 4 1/8 2 5/8 3 1/8 3 5/8 3 5/8 3 5/8 4 1/8 2 5/8 3 1/8 3 5/8 3 5/8 4 1/8 4 1/8

480,000 2 5/8 3 1/8 3 1/8 3 5/8 3 5/8 4 1/8 3 1/8 3 5/8 3 5/8 4 1/8 4 1/8 4 1/8 3 1/8 3 5/8 3 5/8 4 1/8 4 1/8 4 1/8

600,000 3 1/8 3 1/8 3 1/8 3 5/8 3 5/8 4 1/8 3 1/8 3 5/8 3 5/8 4 1/8 4 1/8 5 1/8 3 1/8 3 5/8 3 5/8 4 1/8 4 1/8 5 1/8

19

Table 2A. Recommended Line Sizes for R-448A/R-449A


3/8

3/8

3/8

3/8

3/8

3/8

3/8

3/8

3/8

3/8

Receiver to

Expansion Valve

Expansion Valve

25' 50' 75' 100' 150' 200'

3/8

3/8

3/8

3/8

3/8

3/8

3/8

3/8

3/8

3/8

3/8

3/8

3/8

3/8

3/8

3/8

3/8

3/8

3/8

3/8

3/8

3/8

3/8

3/8

3/8

3/8

3/8

3/8

3/8

3/8

3/8

3/8

3/8

3/8

3/8

3/8

1/2

1/2

3/8

3/8

1/2

1/2

1/2

1/2

3/8

3/8

1/2

1/2

1/2

1/2

3/8

1/2

1/2

1/2

1/2

1/2

1/2

1/2

1/2

1/2

1/2

5/8

1/2

1/2

5/8

5/8

1/2

1/2

1/2

1/2

5/8

7/8

7/8

1/2

1/2

1/2

1/2

1/2

1/2

1/2

1/2

5/8

5/8

5/8

1/2

1/2

1/2

5/8

5/8

5/8

5/8

5/8

5/8

7/8

7/8

1/2

1/2

5/8

5/8

5/8

5/8

5/8

5/8

7/8

7/8

7/8

5/8

5/8

5/8

7/8

1/2

5/8

5/8

5/8

5/8

5/8

5/8

5/8

5/8

7/8

7/8

7/8

48,000

54,000

60,000

66,000

72,000

78,000

84,000

90,000

7/8

7/8

7/8

7/8

120,000

150,000

7/8 1 1/8 180,000

7/8

7/8

7/8

7/8

7/8

7/8

7/8

7/8

7/8

7/8

1 1/8

1 1/8

7/8

7/8

1 1/8

1 1/8

7/8

1 1/8

1 1/8

1 1/8

1 1/8

1 1/8

1 1/8

1 1/8

210,000

240,000

300,000

360,000

1 1/8 1 1/8 1 1/8 1 1/8 1 3/8 1 3/8 480,000

1 1/8 1 1/8 1 1/8 1 3/8 1 3/8 1 3/8 600,000

1,000

3,000

4,000

6,000

9,000

12,000

15,000

18,000

24,000

30,000

36,000

42,000

Line Sizing

20

Line Sizing

Table 3. Recommended Line Sizes for R-404A and R-507 *

SYSTEM

CAPACITY

BTU/H

+40˚F


+20˚F


+10˚F


0˚F

Equivalent

25' 50' 75' 100' 150' 200' 25' 50' 75' 100' 150' 200' 25' 50' 75' 100' 150' 200' 25' 50' 75'

1,000 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8 1/2 1/2 1/2 3/8 3/8 1/2

3,000 3/8 3/8 1/2 1/2 1/2 5/8 3/8 1/2 1/2 1/2 5/8 5/8 5/8 7/8 1/2 1/2 5/8

4,000 3/8 1/2 1/2 1/2 5/8 5/8 1/2 1/2 1/2 5/8 5/8 5/8 7/8 7/8 1/2 5/8 5/8

6,000 1/2 1/2 5/8 5/8 7/8 7/8 1/2 1/2 1/2 5/8 5/8 7/8 7/8 7/8 5/8 5/8 7/8

9,000 5/8 5/8 7/8 7/8 7/8 7/8 5/8 5/8 7/8 1/8 5/8 7/8 7/8

12,000 5/8 7/8 7/8 7/8 7/8 7/8 5/8 7/8 7/8 7/8 7/8 1 7/8 7/8 7/8 1 1/8 1 1/8 7/8 7/8 7/8

15,000 5/8 7/8 7/8 7/8 7/8 1 7/8 7/8 7/8 7/8 1 1/8 1 1/8 7/8 7/8 7/8 1 1/8 1 1/8 1 1/8 7/8 7/8 1 1/8

18,000 7/8 7/8 7/8 7/8 1 1/8 1 1/8 7/8 7/8 7/8 1 1/8 1 1/8 1 1/8 7/8 7/8 1 1/8 1 1/8 1 1/8 1 3/8 7/8 1 1/8 1 1/8

24,000 7/8 7/8 7/8 1 1/8 1 1/8 1 1/8 7/8 1 1/8 1 1/8 1 1/8 1 1/8 1 3/8 7/8 1 1/8 1 1/8 1 1/8 1 3/8 1 3/8 1 1/8 1 1/8 1 1/8

30,000 7/8 7/8 1 1/8 1 1/8 1 1/8 1 3/8 7/8 1 1/8 1 1/8 1 1/8 1 3/8 1 3/8 1 1/8 1 1/8 1 1/8 1 3/8 1 3/8 1 3/8 1 1/8 1 1/8 1 1/8

36,000 7/8 1 1/8 1 1/8 1 1/8 1 3/8 1 3/8 1 1/8 1 1/8 1 1/8 1 3/8 1 3/8 1 3/8 1 1/8 1 1/8 1 3/8 1 3/8 1 3/8 1 5/8 1 1/8 1 1/8 1 3/8

42,000 1 1 /8 1 1/8 1 1/8 1 3/8 1 3/8 1 3/8 1 1/8 1 1/8 1 3/8 1 3/8 1 3/8 1 5/8 1 1/8 1 3/8 1 3/8 1 3/8 1 5/8 1 5/8 1 1/8 1 3/8 1 3/8

48,000 1 1/8 1 1/8 1 3/8 1 3/8 1 3/8 1 3/8 1 1/8 1 1/8 1 3/8 1 3/8 1 5/8 1 5/8 1 1/8 1 3/8 1 3/8 1 3/8 1 5/8 1 5/8 1 1/8 1 3/8 1 3/8

54,000 1 1/8 1 1/8 1 3/8 1 3/8 1 3/8 1 5/8 1 1/8 1 3/8 1 3/8 1 3/8 1 5/8 1 5/8 1 3/8 1 3/8 1 3/8 1 5/8 1 5/8 1 5/8 1 3/8 1 3/8 1 5/8

60,000 1 1/8 1 1/8 1 3/8 1 3/8 1 5/8 1 5/8 1 1/8 1 3/8 1 3/8 1 5/8 1 5/8 1 5/8 1 3/8 1 3/8 1 5/8 1 5/8 1 5/8 2 1/8 1 3/8 1 3/8 1 5/8

66,000 1 1/8 1 3/8 1 3/8 1 3/8 1 5/8 1 5/8 1 1/8 1 3/8 1 3/8 1 5/8 1 5/8 1 5/8 1 3/8 1 5/8 1 5/8 1 5/8 1 5/8 1 5/8 1 3/8 1 5/8 1 5/8

72,000 1 1/8 1 3/8 1 3/8 1 5/8 1 5/8 1 5/8 1 1/8 1 3/8 1 5/8 1 5/8 1 5/8 1 5/8 1 3/8 1 5/8 1 5/8 1 5/8 1 5/8 1 5/8 1 3/8 1 5/8 1 5/8

78,000 1 1/8 1 3/8 1 3/8 1 5/8 1 5/8 2 1/8 1 3/8 1 3/8 1 5/8 1 5/8 1 5/8 2 1/8 1 3/8 1 5/8 1 5/8 1 5/8 1 5/8 2 1/8 1 5/8 1 5/8 1 5/8

84,000 1 1/8 1 3/8 1 5/8 1 5/8 1 5/8 2 1/8 1 3/8 1 3/8 1 5/8 1 5/8 2 1/8 2 1/8 1 3/8 1 5/8 1 5/8 1 5/8 2 1/8 2 1/8 1 5/8 1 5/8 1 5/8

90,000 1 3/8 1 3/8 1 5/8 1 5/8 2 1/8 2 1/8 1 3/8 1 5/8 1 5/8 1 5/8 2 1/8 2 1/8 1 5/8 1 5/8 1 5/8 2 1/8 2 1/8 2 5/8 1 5/8 1 5/8 2 1/8

120,000 1 3/8 1 5/8 1 5/8 2 1/8 2 1/8 2 1/8 1 3/8 1 5/8 2 1/8 2 1/8 2 1/8 2 1/8 1 5/8 2 1/8 2 1/8 2 1/8 2 5/8 2 5/8 1 5/8 2 1/8 2 1/8

150,000 1 5/8 1 5/8 2 1/8 2 1/8 2 1/8 2 1/8 1 5/8 2 1/8 2 1/8 2 1/8 2 1/8 2 5/8 2 1/8 2 1/8 2 1/8 2 5/8 2 5/8 2 5/8 2 1/8 2 1/8 2 1/8

180,000 1 5/8 2 1/8 2 1/8 2 1/8 2 1/8 2 5/8 1 5/8 2 1/8 2 1/8 2 1/8 2 5/8 2 5/8 2 1/8 2 1/8 2 5/8 2 5/8 2 5/8 3 1/8 2 1/8 2 1/8 2 5/8

210,000 1 5/8 2 1/8 2 1/8 2 1/8 2 5/8 2 5/8 2 1/8 2 1/8 2 1/8 2 5/8 2 5/8 2 5/8 2 1/8 2 1/8 2 5/8 2 5/8 3 1/8 3 1/8 2 1/8 2 5/8 2 5/8

240,000 1 5/8 2 1/8 2 1/8 2 1/8 2 5/8 2 5/8 2 1/8 2 1/8 2 5/8 2 5/8 2 5/8 2 5/8 2 1/8 2 5/8 2 5/8 2 5/8 3 1/8 3 1/8 2 1/8 2 5/8 2 5/8

300,000 2 1/8 2 1/8 2 5/8 2 5/8 2 5/8 3 1/8 2 1/8 2 5/8 2 5/8 2 5/8 3 1/8 3 1/8 2 5/8 2 5/8 2 5/8 3 1/8 3 1/8 3 5/8 2 5/8 2 5/8 2 5/8

360,000 2 1/8 2 1/8 2 5/8 2 5/8 3 1/8 3 1/8 2 1/8 2 5/8 2 5/8 2 5/8 3 1/8 3 1/8 2 5/8 2 5/8 3 1/8 3 1/8 3 5/8 3 5/8 2 5/8 2 5/8 3 1/8

480,000 2 1/8 2 5/8 2 5/8 3 1/8 3 1/8 3 5/8 2 5/8 2 5/8 2 5/8 2 5/8 3 5/8 3 5/8 2 5/8 3 1/8 3 1/8 3 5/8 3 5/8 4 1/8 2 5/8 3 1/8 3 1/8

600,000 2 5/8 2 5/8 3 1/8 3 1/8 3 5/8 3 5/8 2 5/8 2 5/8 3 1/8 3 1/8 3 5/8 3 5/8 3 1/8 3 1/8 3 1/8 3 5/8 4 1/8 4 1/8 3 1/8 3 1/8 3 1/8

* NOTES:

1. Sizes that are highlighted indicate maximum suction line sizes that should be used for risers. Riser size should not exceed horizontal size. Properly placed suction traps must also be used for adequate oil return.

All sizes shown are for O.D. Type L copper tubing.



21

22

Line Sizing

Table 3A. Recommended Line Sizes for R-404A and R-507 (continued) *




Receiver to

-20˚F

Lengths

-30˚F


-40˚F


Expansion Valve


SYSTEM

CAPACITY

100' 150' 200' 25' 50' 75' 100' 150' 200' 25' 50' 75' 100' 150' 200' 25' 50' 75' 100' 150' 200' BTU/H

1/2 1/2 1/2 3/8 3/8 1/2 1/2 1/2 5/8 3/8 1/2 1/2 1/2 5/8 5/8 3/8 3/8 3/8 3/8 3/8 3/8 1,000

5/8 7/8 7/8 1/2 1/2 5/8 5/8 7/8 7/8 1/2 1/2 5/8 5/8 7/8 7/8 3/8 3/8 3/8 3/8 3/8 3/8 3,000

7/8 7/8 7/8 5/8 5/8 5/8 7/8 7/8 7/8 1/2 5/8 5/8 7/8 7/8 7/8 3/8 3/8 3/8 3/8 3/8 3/8 4,000

7/8 7/8 7/8 5/8 5/8 7/8 7/8 7/8 7/8 5/8 5/8 7/8 7/8 7/8 1 6,000

7/8 1 1/8 1 1/8 5/8 7/8 7/8 7/8 1 1/8 1 1/8 5/8 7/8 7/8 7/8 1 1/8 3/8 3/8 3/8 3/8 3/8 3/8 9,000

1 1/8 1 1/8 1 1/8 7/8 7/8 7/8 1 1/8 1 1/8 1 1/8 7/8 7/8 7/8 1 1/8 1 1/8 3/8 3/8 3/8 3/8 3/8 1/2 12,000

1 1/8 1 1/8 1 3/8 7/8 7/8 1 1/8 1 1/8 1 1/8 1 3/8 7/8 7/8 1 1/8 1

1 1/8 1 3/8 1 3/8 7/8 1 1/8 1 1/8 1 1/8 1 3/8 1 3/8 7/8 1 1/8 1 1/8 1 1/8 1 3/8 3/8 3/8 3/8 1/2 1/2 1/2 18,000

1 3/8 1 3/8 1 3/8 1 1/8 1 1/8 1 1/8 1 3/8 1 3/8 1 3/8 1 1/8 1 1/8 1 1/8 1 3/8 1 3/8 3/8 3/8 1/2 1/2 1/2 1/2 24,000

1 3/8 1 3/8 1 5/8 1 1/8 1 1/8 1 3/8 1 3/8 1 3/8 1 5/8 1 1/8 1 1/8 1 3/8 1

1 3/8 1 3/8 1 5/8 1 1/8 1 3/8 1 3/8 1 3/8 1 3/8 1 5/8 1 1/8 1 3/8 1 3/8 1 3/8 1 5/8 1 5/8 1/2 1/2 1/2 1/2 1/2 5/8 36,000

1 5/8 1 5/8 1 5/8 1 1/8 1 3/8 1 3/8 1 3/8 1 5/8 1 5/8 1 1/8 1 3/8 1 3/8 1 3/8 1 5/8 1

1 5/8 1 5/8 1 5/8 1 1/8 1 3/8 1 3/8 1 3/8 1 5/8 1 5/8 1 1/8 1 3/8 1 3/8 1 3/8 1 5/8 1

1 5/8 1 5/8 1 5/8 1 3/8 1 3/8 1 3/8 1 5/8 1 5/8 2 1/8 1 3/8 1 3/8 1 3/8 1 5/8 1 1/8 1/2 1/2 1/2 5/8 5/8 5/8 54,000

1 5/8 1 5/8 2 1/8 1 3/8 1 3/8 1 5/8 1 5/8 1 5/8 2 1/8 1 3/8 1 3/8 1 5/8 1

1 5/8 1 5/8 2 1/8 1 3/8 1 5/8 1 5/8 1 5/8 1 5/8 2 1/8 1 3/8 1 5/8 1 5/8 1 5/8 1 5/8 2 1/8 1/2 1/2 5/8 5/8 5/8 5/8

1 5/8 1 5/8 2 1/8 1 3/8 1 5/8 1 5/8 1 5/8 1 5/8 2 1/8 1 3/8 1 5/8 1 5/8 1 5/8 1 5/8 2 1/8 1/2 5/8 5/8 5/8 5/8 5/8

66,000

72,000

1 5/8 2 1/8 2 1/8 1 5/8 1 5/8 1 5/8 1 5/8 2 1/8 2 1/8 1 5/8 1 5/8 1 5/8 1 5/8 2 1/8 2

2 1/8 2 1/8 2 1/8 1 5/8 1 5/8 1 5/8 2 1/8 2 1/8 2 1/8 1 5/8 1 5/8 1 5/8 2 1/8 2 1/8 5/8 5/8 5/8 5/8 7/8 7/8 84,000

2 1/8 2 1/8 2 5/8 1 5/8 2 1/8 2 1/8 2 1/8 2 1/8 2 5/8 1 5/8 1 5/8 2 1/8 2

2 1/8 2 5/8 2 5/8 1 5/8 2 1/8 2 1/8 2 1/8 2 5/8 2 5/8 1 5/8 2 1/8 2 1/8 2 1/8 2 5/8 2

2 5/8 2 5/8 2 5/8 2 1/8 2 1/8 2 1/8 2 5/8 2 5/8 2 5/8 2 1/8 2 1/8 2 5/8 2 5/8 2

2 5/8 2 5/8 3 1/8 2 1/8 2 1/8 2 5/8 2 5/8 2 5/8 3 1/8 2 1/8 2 1/8 2 5/8 2 5/8 2 5/8 3 1/8 7/8 7/8 7/8 7/8 1 1/8 1 1/8 180,000

2 5/8 3 1/8 3 1/8 2 1/8 2 5/8 2 5/8 2 5/8 3 1/8 3 1/8 2 1/8 2 5/8 2 5/8 2 5/8 3 1/8 3 1/8 7/8 7/8 7/8 1 1/8 1 1/8 1 1/8 210,000

2 5/8 3 1/8 3 1/8 2 5/8 2 5/8 2 5/8 3 1/8 3 1/8 3 5/8 2 5/8 2 5/8 2 5/8 3 1/8 3 1/8 3 5/8 7/8 7/8 1 1/8 1 1/8 1 1/8 1 3/8 240,000

3 1/8 3 5/8 3 5/8 2 5/8 2 5/8 3 1/8 3 1/8 3 5/8 4 1/8 2 5/8 2 5/8 3 1/8 3 5/8 3 5/8 4 1/8 7/8 1 1/8 1 1/8 1 1/8 1 3/8 1 3/8 300,000

3 5/8 3 5/8 4 1/8 2 5/8 3 1/8 3 1/8 3 5/8 3 5/8 4 1/8 2 5/8 3 1/8 3 5/8 3 5/8 4 1/8 4 1/8 1 1/8 1 1/8 1 1/8 1 3/8 1 3/8 1 5/8 360,000

3 5/8 3 5/8 4 1/8 3 1/8 3 5/8 3 5/8 4 1/8 4 1/8 4 1/8 3 1/8 3 5/8 3 5/8 4 1/8 4 1/8 4 1/8 1 1/8 1 1/8 1 3/8 1 3/8 1 5/8 1 5/8 480,000

3 5/8 3 5/8 4 1/8 3 1/8 3 5/8 3 5/8 4 1/8 4 1/8 5 1/8 3 1/8 3 5/8 3 5/8 4 1/8 4 1/8 5 1/8 1 1/8 1 3/8 1 3/8 1 5/8 1 5/8 1 5/8 600,000

* NOTES:

1. Sizes that are highlighted indicate maximum suction line sizes that should be used for risers. Riser size should not exceed horizontal size. Properly placed suction traps must also be used for adequate oil return.

All sizes shown are for O.D. Type L copper tubing.



Line Sizing

Table 4. Weight of Refrigerants in Copper Lines During Operation (Pounds per 100 Lineal feet of type"L" tubing)

Line Size

O.D.

in Inches

3/8

Refrigerant

R-507/R-404A

R-407

R-448A/R-449A

Liquid

Line

3.4

3.8

3.6

-40˚F

.03

.02

.02

-20˚F

Suction Line at Suction Temperature

0˚F +20˚F +40˚F

.04

.03

.03

.06

.04

.04

.09

.06

.06

.13

.09

.09

1/2

5/8

7/8

1 1/8

1 3/8

1 5/8

2 1/8

2 5/8

3 1/8

3 5/8

4 1/8

R-507/R-404A

R-407

R-448A/R-449A

R-507/R-404A

R-407

R-448A/R-449A

R-507/R-404A

R-407

R-448A/R-449A

R-507/R-404A

R-407

R-448A/R-449A

R-507/R-404A

R-407

R-448A/R-449A

R-507/R-404A

R-407

R-448A/R-449A

R-507/R-404A

R-407

R-448A/R-449A

R-507/R-404A

R-407

R-448A/R-449A

R-507/R-404A

R-407

R-448A/R-449A

R-507/R-404A

R-407

R-448A/R-449A

R-507/R-404A

R-407

R-448A/R-449A

.98

.63

.96

1.51

.98

1.37

.40

.26

.36

.56

.36

.62

2.16

1.40

1.86

.07

.05

.10

.15

.10

.17

.04

.03

.03

.07

.05

.05

.26

.17

.25

3.80

2.45

2.40

209

230

220

298

328

314

77.7

85.7

82.1

135

149

143

403

444

425

523

577

552

21.1

23.3

22.3

36.1

39.7

38.1

6.3

7.0

6.7

10.2

11.2

10.8

54.9

60.5

58.0

3.23

2.38

3.65

5.00

3.67

5.20

1.32

.96

1.36

1.86

1.38

.2.36

7.14

5.23

7.04

.15

.18

.37

.51

.37

.63

.16

.11

.11

.25

.18

.18

.86

.63

.96

12.58

17.80

.9.11

4.58

3.49

5.30

7.07

5.39

.7.57

1.87

1.43

1.98

2.64

2.01

3.44

9.95

8.27

10.24

.35

.26

.54

.72

.54

.92

.24

.17

.16

.35

.26

.26

1.24

.93

1.40

13.61

9.23

13.25

3.62

2.46

3.45

5.17

3.50

4.67

9.09

6.17

6.05

.95

.65

.90

1.35

.91

1.57

2.35

1.60

2.42

.17

.12

.25

.37

.25

.42

.13

.08

.07

.17

.12

.12

.63

.43

.64

1.43

1.00

1.56

2.21

1.55

2.22

.58

.41

.58

.82

.57

1.01

3.15

2.23

3.01

.23

.16

.27

.39

.27

.41

5.55

3.92

3.89

.07

.05

.05

.11

.08

.08

.11

.08

.16

23

Line Sizing

Table 5. Pressure Loss of Liquid Refrigerants in Liquid Line Risers (Expressed in Pressure Drop, PSIG, and Subcooling Loss, ˚F).

Liquid Line Rise in Feet

10'

Refrigerant

R-134A

PSIG

4.9

R-507/R-404A 4.1

˚F

2.0

1.1

R-407 4.3

R-448A/R-449A 4.3

1.4

1.1

15'

PSIG

7.4

6.1

˚F

2.9

1.6

6.4

6.5

2.0

1.7

PSIG

9.8

8.2

20' 25' 30' 40' 50' 75' 100'

˚F PSIG ˚F PSIG ˚F PSIG ˚F PSIG ˚F PSIG ˚F PSIG ˚F

4.1

12.3

5.2

14.7

6.3

19.7

8.8

24.6

11.0

36.8

17.0

49.1

23.7

2.1

10.2

2.7

12.2

3.3

16.3

4.1

20.4

5.6

30.6

8.3

40.8

11.8

8.5

8.7

2.7

10.6

3.4

12.8

4.1

17.0

5.4

21.3

6.8

39.1

10.1

42.5

13.5

2.3

10.9

2.8

13.0

3.4

17.4

4.5

21.7

5.6

32.6

8.3

43.5

10.9

Based on 110˚F liquid temperature at bottom of riser.

Table 6. Equivalent Feet of Pipe Due to Valve and Fitting Friction

Copper Tube, O.D., Type “L”

Globe Valve (Open)

Angle Valve (Open)

90˚ Turn Through Tee

Tee (Straight Through) or Sweep Below .75

90˚ Elbow or Reducing Tee (Straight Through) 1

1/2

14

7

3

5/8

16

9

4

1

2

7/8 1 1/8 1 3/8 1 5/8 2 1/8 2 5/8 3 1/8 3 5/8 4 1/8 5 1/8 6 1/8

22

12

5

28

15

6

36

18

8

42

21

9

57

28

12

69

34

14

83

42

17

99

49

20

118

57

22

138

70

28

168

83

34

1.5

2

2

3

2.5

4

3

4

3.5

5

4

7

5

8

6

10

7

12

9

14

11

16

24

Optional Controls

Head Pressure Control

A. Dual Valve System

The system employs an ORI (open on rise of inlet pressure) valve and an ORD ( open on rise of differential pressure) valve.

When operating below the head pressure set point, the ORI valve restricts refrigerant flow. As refrigerant backs up and floods the condenser, the discharge pressure increases. If the refrigerant flow is sufficiently restricted, the ORD valve bypasses refrigerant discharge gas downstream of the ORI. Both valves will modulate to maintain the discharge pressure setting.

This system requires additional refrigerant to flood the condenser during low ambient operation. See the Refrigerant Charging Section for more information.

ORI valve adjustment should be made with a gauge connected to the discharge port of the compressor. Adjustments should be made during mild or low ambient conditions. It may be beneficial to temporarily turn on additional condenser fan(s) to lower the discharge pressure below the desired set point.

Turn the adjustment stem on the ORI with a hex wrench. Clockwise rotation will increase and counterclockwise will decrease the discharge pressure setting.

If adjustments are made during warm ambient conditions, it may not be possible to adjust the ORI valve as low as desired. Readjustment may be necessary once cooler conditions prevail.

Typical ORI discharge pressure settings are 150 to 180 psi. The factory default pressure fan cycle settings (controlled by liquid refrigerant pressure) are appropriate for this range.

If outside of this adjustment range, the condenser fan settings may need to be changed. Note that the liquid pressure will be approximately 20 psi lower than the discharge pressure during low ambient conditions.

If desired, the first fan may be re-programmed to operate with the compressor.

CAUTION: For Ambient Fan Cycling; Under no circumstance should all condenser motors be allowed to cycle off on one control. At least one motor shall be wired to operate at all times. Under most circumstances, the condenser motor nearest the inlet header should remain on whenever the compressor is operating.

Note: Cut-out temperature is ºF below cut-in temperature

C.

Phase Loss Monitor

The combination phase sequence and loss monitor relay protects the system against phase loss (single phasing), phase reversal (improper sequence) and low voltage

(brownout). When phase sequence is correct and full line voltage is present on all three phases, the relay is energized as the normal condition indicator light glows.

Note: If compressor fails to operate and the normal condition indicator light on the phase monitor does not glow, then the supplied electrical current is not in phase with the monitor. This problem is easily corrected by the following steps:

1. Turn power off at disconnect switch

2. Swap any two of the three power input wires

3. Turn power on. Indicator light should glow and compressor should start

4. Observe motors for correct rotation

Figure 6. Dual Valve Piping Arrangement

Table 7. Ambient Fan Cycle Default Thermostat Settings

Thermostat Settings ºF Cut-In

Models

2 Fan Units

3 Fan Units

Fan #1

ON

ON

Fan #2

50

50

Fan #3

–

60

Fan #4

–

–

4 Fan Units ON 50 60 70

D.

Evaporator Powered From Condensing Unit

The system may be optionally ordered with the evaporator control contactors mounted in the condensing unit electrical box instead of the evaporator. This arrangement may be desirable for retrofit installations or applications where evaporator access is limited.

B. Ambient Fan Cycle Control

This is an automatic winter control method which will maintain a condensing pressure within reasonable limits by cycling fan motors in response to outside air temperature.

The thermostat(s) should be field adjusted to shut off the fan when the condensing temperature is reduced to approximately 90 ˚ F. Table 6 lists default settings. These settings are approximate as they do not take into account variations in load.

25

Optional Controls

E. Copeland Demand Cooling for Discus L6 Models

Energy efficiency regulations drive continuous change in the availability of refrigerants to the marketplace. With the introduction of R-22 as a replacement for R-502 compressors began to experience internal discharge temperatures that exceed the safe operational limits for long term stability of refrigerant oil. In response to this

Demand Cooling was developed as a reliable method to keep discharge temperatures reduced to a safe level without inhibiting the operating limits of the compressor. With the phase out of R-22, the following refrigerants have become viable alternatives:

R-407A/C/F and R-448A/449-A. All of these refrigerants require special attention to discharge temperature control. Also forthisreasonsuctiontoliquid heat exchangers are not recommended unless they are necessary to prevent another potential problem.

The Copeland Demand Cooling System

Copeland's demand cooling system uses modern electronics to provide a reliable, cost-effective solution to this problem. It is required for all single stage required for all single stageR-22,R-407A/C/ForR-448A/449-A applications with saturated suction temperatures below 0˚F.

The Demand Cooling module uses the signal of a discharge head temperature sensor to monitor discharge gas temperature. If a critical temperature is reached, the module energizes along life injection valve which meters a controlled amount of saturated refrigerant into the compressor suction cavity to cool the suction gas. Refer to Figure 13.

This process controls the discharge temperature to a safe level. If, for some reason, the discharge temperature rises above a preset maximum level, the Demand Cooling module will turn the compressor off (requiring a manual reset) and actuate its alarm contact. To minimize the amount of refrigerant which must be injected, the suction gas cooling process is performed after the gas has passed around and through the motor.

Operating Range

Demand Cooling is designed to protect the compressor from high discharge temperatures over the evaporating and condensing temperature ranges shown in

Figure 12 at a maximum return gas temperature of 65˚F.

Demand Cooling System Design

When Demand Cooling operates, it “diverts” refrigeration capacity in the form of injected saturated refrigerant from the evaporator to the compressor. The effect of this diversion on evaporator capacity is minimal because the diverted capacity is used to cool the gas entering the compressor. As the gas is cooled, it naturally becomes more dense, increasing the mass flow through the compressor, which partly compensates for the capacity diverted from the evaporator.

1. Compressor Return Gas Temperature: Suction lines should be well

insulated to reduce suction line heat gain. Return gas superheat

should be as low as possible consistent with safe compressor

operation.

2. Condensing Temperatures: It is important when using R-22, R-407

A/C/F or R-448A/449A as a low temperature refrigerant that

condensing temperatures be minimized to reduce compression ratios

and compressor discharge temperature.

3. Suction Pressure: Evaporator design and system control settings

should provide the maximum suction pressure consistent with the

application in order to have as low a compression ratio as possible.

In most cases, with floating head systems where condensing temperatures are low during most of the year, Demand Cooling will operate primarily as a compressor protection control much as the oil failure control protects the compressor during periods of low oil pressure. Demand Cooling will be allowed to operate only during those periods when condensing temperatures and return gas temperatures are high or in periods where a system failure

(such as an ice evaporator, an expansion valve which does not control superheat, blocked condenser, or a failed condenser fan) raises condensing temperatures or return gas temperatures to abnormally high levels or lowers suction pressure to abnormally low levels.

Figure 13. Single Stage Internal Refrigerant Injection

Figure 12. Demand Cooling Injection

26

Wiring Installation

Field Wiring

WARNING: All wiring must be done in accordance with applicable codes and local ordinances.

Wiring Installation

Wiring between the condensing unit and the unit cooler(s) will be as follows (see wiring diagrams):

The field wiring should enter the areas as provided on the unit. The wiring diagram for each unit is located on the inside of the electrical panel door. All field wiring should be done in a professional manner and in accordance with all governing codes. Before operating unit, double check all wiring connections, including the factory terminals.

Factory connections can vibrate loose during shipment.

1. The serial data tag on the unit is marked with the electrical characteristic for wiring the unit

2. Consult the wiring diagram in the unit cooler and in the condensing unit for proper connections

3. Wire type should be of copper conductor only and of the proper size to handle the connected load

4. The unit must be grounded

High voltage – A separate power supply from the condensing unit may be utilized for the evaporator. All appropriate local codes regarding disconnects and fusing must be followed. See the unit cooler spec. plate for ampacity.

Low voltage – 24 VAC control circuit. Each evaporator connects to the condensing unit with the following connections: defrost termination temperature (2 conductors), liquid line solenoid (2 conductors), evaporator fan contactor control (2 conductors).

In addition, some evaporators will require 2 conductors for the pan heater contactor control. Eight-conductor, 18 gauge thermostat wiring is recommended. The thermostat contact connection can be run within this bundle of wires also if there are extra wires available. All 24 volt wiring must be run separate from the line voltage wiring.

Low voltage wiring must be 18 gauge minimum. For low voltage wiring, maximum distance is 500 feet from condensing unit to evaporators.

General Installation

• Refer to wiring schematic shipped on units for unit wiring.

• The hot gas controller is shipped with preset control settings that are typical for the application. Changes should be made according to directions outlined under

Program Settings.

• The condensing unit electrical panel contains the electronic control board. The control board has a terminal block that is labeled to match the low voltage wiring connections going to the evaporator(s). The temperature and pressure sensors located on the condensing unit are pre-connected to the control board at the factory.

Alarm circuit – The onboard alarm is a dry set of contacts (Com, NO, NC) which activates to indicate an alarm. The type and wiring for the alarm is customer specified.

Note that the alarm circuit does not distinguish or indicate what has caused the alarm.

The maximum contact rating is 120V, 0.5A.

Mohave Hot Gas System Controller Battery Back-Up - The control board has a

CR2032 (3V) back-up battery with an expected life of 10 years. In the event of battery failure; the system will lose time during power outages but will otherwise operate normally.

Mohave Modbus RS-485

The "A" and "B" terminal signals should be connected to the PC host, and the

"COM" terminal should be connected to the PC's digital ground.

If the green LED (BUS indicator) is 'ON' when "A" and "B" are connected to the PC, then these terminals should be swapped so the green LED is 'OFF'.

The green LED should flash when the PC host sends a mod-bus message, and the yellow LED (XMIT indicator) should flash when the Mohave board responds to a query.

Communication Settings:

-Baud Rate: 9600

-Parity: Even

-Data Bits: 8

-Stop Bits: 1

27

28

(Field supplied, not used when auxiliary temperature sensor is field installed and activated to control room temperature)

Wiring Diagram

(Standard Independent Evaporator Power Supply)

CONTROL BOARD

(24V)

Wiring Diagram


CONTROL BOARD

(24V)


29

Heatcraft Refrigeration

Products LLC

Wiring Diagram

Typical Evaporator Wiring (Electric Drain Pan Heater)


208-230V / 3 / 60 HZ

-OR-575V / 3 / 60HZ

FOR SINGLE PHASE

SEE NOTE # 2

EVAP FAN

C

CONDENSING UNIT

EVAP

DEFR. HTR.

EVAP

DEFR.TEMP

LIQ. LINE

SOL.

T-STAT

C

24 VAC

18 GA. MIN.

T1 T2 T3

30

HEATER

CONTACTOR

7

8

30 A

1 2 3

FAN

CONTACTOR

*

ROOM

THERMOSTAT

( FIELD SUPPLIED )

3B

4

5

3A

6

N

7

X

9 10 4 5 6

RED

BLACK

BLUE

YELLOW

EVAPORATOR ELECTRICAL END

EVAPORATOR HEADER END H1 H2 H3 F1 F2 F3

4

N

3

X J

DRAIN

PAN

HEATERS

EVAPORATOR

FAN MOTORS

MTR

MTR

MTR

EVAP DEFROST

SUCTION

TEMP

SENSOR

F1 F2

MTR

SINGLE PHASE

DETAIL

MTR

MTR

LIQUID LINE

SOLENOID

MODELS 1860

& 2120 ONLY

Mfg. NOTES:

1. WIRE NUMBERS MATCH WIRE MARKER NUMBERS ON

HARNESS ASSEMBLIES.

2. FOR 208-230/1/60 HZ WIRE TO T1 & T2

FIELD WIRING

** USE COPPER CONDUCTORS ONLY**

PART NO. 29781301

REV D

* NOTE: NOT USED WHEN AUX TEMPERATURE SENSOR IS

FIELD-INSTALLED AND ACTIVATED TO CONTROL ROOM

TEMPERATURE

Heatcraft, Inc.

208-230V / 3 / 60 HZ

460V / 3 / 60HZ

575V / 3 / 60HZ

FOR SINGLE PHASE

SEE NOTE #2

T1 T2 T3

Wiring Diagram

Typical Evaporator Wiring (Hot Gas Drain Pan)


CONDENSING UNIT

EVAP FAN

C

EVAP

DEFR.TEMP

LIQ. LINE

SOL.

T-STAT

C

24 VAC

18 GA. MIN.

1 2 3

ROOM

THERMOSTAT *

( FIELD SUPPLIED )

FAN

CONTACTOR

3B

4

5

3A

6

N

7

X

4 5 6

RED

BLACK

18-2

SOLENOID

HARNESS

H1 H2 H3 F1 F2 F3

SINGLE PHASE

DETAIL

F1 F2

MTR

MTR

MTR


EVAPORATOR HEADER END

4

N

3

X J

EVAPORATOR

FAN MOTORS

3 PHASE

MTR

EVAP DEFROST

SUCTION

TEMP

SENSOR

LIQUID LINE

SOLENOID

MTR

* NOTE: NOT USED WHEN AUX TEMPERATURE SENSOR IS

FIELD-INSTALLED AND ACTIVATED TO CONTROL ROOM

TEMPERATURE

MTR

Mfg. NOTES:

1. WIRE NUMBERS MATCH WIRE MARKER NUMBERS ON

HARNESS ASSEMBLIES.

2. FOR 208-230/1/60 OR 460/1/60 WIRE TO T1 & T2

FIELD WIRING


PART NO. 29781201 REV B

31

Wiring Diagram

Typical Evaporator Wiring (Electric Drain Pan Heater)

(Optional Evaporator Powered Off Condensing Unit)

Heatcraft Refrigeration Products LLC

CONDENSING

UNIT

EVAP FAN

C

EVAP

DEFR. HTR

EVAP

DEFR.TEMP

LIQ. LINE

SOL.

T-STAT

C

24 VAC

18 GA. MIN.

HEATER

CONTACTOR

FAN

CONTACTOR

208-230V / 3 / 60 HZ

-OR-575V / 3 / 60 HZ

FOR SINGLE PHASE

SEE NOTE #1

CONDENSING UNIT

ELECTRIC BOX

EVAPORATOR

ELECTRIC BOX

3B

4

5

3A

6

N

7

X

* ROOM

THERMOSTAT

( FIELD SUPPLIED )

32

Mfg. NOTES:

1.FOR 208-230/1/60 WIRE TO T1 & T2 AND F1 & F2

FIELD WIRING

18-2

SOLENOID

HARNESS

H1 H2 H3 F1 F2 F3

4

N

3

X J

DRAIN

PAN

HEATERS

EVAPORATOR

FAN MOTORS

3 PHASE

MTR

SINGLE PHASE

DETAIL

F1 F2

MTR

MTR

MTR



EVAP DEFROST

SUCTION

TEMP

SENSOR

MTR


MTR


PART NO. 29781801

REV D

LIQUID LINE

SOLENOID

MODELS 1860

& 2120 ONLY

* NOTE: NOT USED WHEN AUX TEMPERATURE SENSOR

IS FIELD-INSTALLED AND ACTIVATED TO CONTROL

ROOM TEMPERATURE

Heatcraft, Inc.

Wiring Diagram

Typical Evaporator Wiring (Hot Gas Drain Pan)

(Optional Evaporator Powered Off Condensing Unit)

FAN

CONTACTOR

EVAP FAN

C

CONDENSING

UNIT

EVAP

DEFR.TEMP

LIQ. LINE

SOL.

T-STAT

C

24 VAC

18 GA. MIN.

208-230V / 3 / 60 HZ

460V / 3 / 60HZ

575V / 3 / 60HZ

FOR SINGLE PHASE

SEE NOTE #1

CONDENSING UNIT

ELECTRIC BOX

EVAPORATOR

ELECTRIC BOX

3B

4

5

3A

6

N

7

X

* ROOM

THERMOSTAT

( FIELD SUPPLIED )

H1 H2 H3 F1 F2 F3

SINGLE PHASE

DETAIL

F1 F2

MTR

MTR

MTR

4

N

3

X J

18-2

SOLENOID

HARNESS

EVAPORATOR

FAN MOTORS

3 PHASE

MTR



MTR EVAP DEFROST

SUCTION

TEMP

SENSOR

LIQUID LINE

SOLENOID

MTR

Mfg. NOTES:

1.FOR 208-230/1/60 OR 460/1/60 WIRE TO T1 & T2 AND F1 & F2

FIELD WIRING


PART NO. 29781701 REV B


* NOTE: NOT USED WHEN AUX TEMPERATURE

SENSOR IS FIELD-INSTALLED AND ACTIVATED TO

CONTROL ROOM TEMPERATURE

33

4

5

6

CONTACTOR C2

T1

T2

T3

L1

L2

L3

FM

1

2

3

COMPRESSOR

CT

T1

T2

T3

L1

L2

L3

CONTACTOR C1

Wiring Diagram


208-230V/60Hz/3Ø - CONDENSING UNIT - UNIT WIRING

F3

POWER

BLOCK

F1 F2

L1

T1

L2

T2

L3

T3

C3

L1

T1

L2

T2

L3

T3

C4

7 8 9 10 11 12

FM1 FM2

TO

SHEET 2

34

LEGEND

C ------- CONTACTOR

CB ------- CIRCUIT BREAKER

CT ------- CURRENT TRANSDUCER (IN CMPR EBOX)

DHC ------- DEFROST HEATER CONTACTOR

EFC ------- EVAPORATOR FAN CONTACTOR

F ------- FUSE

FC ------- FAN CAPACITOR

FM ------- FAN MOTOR

YELLOW

CRANKCASE

HEATER

10

7

R1

8

BLUE

11

C2

C1

14

TDR

L1

LPS

L2

HPS

12 13

2

R1

4

HPS

DT

COMP

OPS

15 16

OPS

240 M L 2

SERVICE MATE

AUX1

LLS

AUX2 CMOD

17

HEADER/COMPRESSOR END

M1

M2

SHEET 1 OF 2

USE COPPER CONDUCTORS ONLY

FACTORY WIRING

FIELD WIRING

Model #:

Unit Serial #:

Customer:

BDV2702L6C test

Rev 3.24

208-230V/60HZ/3Ø - CONDENSING UNIT - CONTROL BOARD WIRING

TO

SHEET 1 c

C1 n/o c

C2 n/o

CU Suct Temp

BLUE

Ambient Temp

WHITE

CU Suct Press

0-300 PSIA

CU Liquid Press

0-500 PSIA

BLUE

RED

SERVICE SW.

SAFETY CKT.

SUCTION TEMP

AMBIENT TEMP

AUX TEMP

SUCTION PRESSURE

LIQUID PRESSURE

Alarm

PRESSURE

REGULATOR

LIQ LINE SOL1 LIQ LINE SOL2

230V

240

24V

C 240 C

C 24V

3-Way Sol.

Defrost Sol

Suction Sol

Bypass Valve

Redundant LPS

3-Way Sol.

30

31

32

33

Defrost Sol

Suction Sol

34

35

36

37

Bypass Valve

Redundant LPS

0

R1

1

COMP

Cond Fan #1

Cond Fan #2

Cond Fan #3

Cond Fan #4

C3

C4

FIELD WIRING

CONNECTIONS

LEGEND

C ------- CONTACTOR


CM ------- COMPRESSOR MODULE

DCM ------- DEMAND COOLING MODULE

F ------- FUSE

FCS ------- FAN CYCLING SWITCH

HPS ------- HIGH PRESSURE SWITCH

LPS ------- LOW PRESSURE SWITCH

LSV ------- LIQUID SOLENOID VALVE

OPS ------- OIL PRESSURE SWITCH

PLM ------- PHASE LOSS MONITOR

R ------- RELAY

Comp Aux -- COMPRESSOR AUXILLARY

CONTACTS (Compressor proof )

TDR ------- TIME DELAY RELAY

WWS ------- WIRE WHEN SUPPLIED

SHEET 2 OF 2


FACTORY WIRING

FIELD WIRING

Model #:

Unit Serial #:

Customer:

BDV2702L6C test

Rev 3.24

4

5

6

CONTACTOR C2

T1

T2

T3

L1

L2

L3

FM

1

2

3

COMPRESSOR

CT

T1

T2

T3

L1

L2

L3

CONTACTOR C1

208-230V/60Hz/3Ø - CONDENSING UNIT - UNIT WIRING

F3

F1 F2

L1

T1

L2

T2

L3

T3

C3

L1

T1

L2

T2

L3

T3

C4

7 8 9 10 11 12

FM1 FM2

POWER

BLOCK

TO

SHEET 2

LEGEND

C ------- CONTACTOR





F ------- FUSE



YELLOW

CRANKCASE

HEATER

10

7

R1

8

BLUE

11

C2

C1

14

TDR

L1

LPS

L2

HPS

12 13

2

R1

4

HPS

DT

COMP

OPS

15 16

OPS

240 M L 2

SERVICE MATE

AUX1

LLS

AUX2 CMOD

17

HEADER/COMPRESSOR END

M1

M2

SHEET 1 OF 2


FACTORY WIRING

FIELD WIRING

Model #:

Unit Serial #:

Customer:

BDV2702L6C test

Rev 3.24

Wiring Diagram


208-230V/60HZ/3Ø - CONDENSING UNIT - CONTROL BOARD WIRING

TO

SHEET 1 c

C1 n/o c

C2 n/o

CU Suct Temp

BLUE

Ambient Temp

WHITE

CU Suct Press

0-300 PSIA

CU Liquid Press

0-500 PSIA

BLUE

RED

SERVICE SW.

SAFETY CKT.

SUCTION TEMP

AMBIENT TEMP

AUX TEMP

SUCTION PRESSURE

LIQUID PRESSURE

Alarm

PRESSURE

REGULATOR


230V

240

24V

C 240 C

C 24V

3-Way Sol.

Defrost Sol

Suction Sol

Bypass Valve

Redundant LPS

3-Way Sol.

30

31

32

33

Defrost Sol

Suction Sol

34

35

36

37

Bypass Valve

Redundant LPS

0

R1

1

COMP

Cond Fan #1

Cond Fan #2

Cond Fan #3

Cond Fan #4

C3

C4

FIELD WIRING

CONNECTIONS

LEGEND

C ------- CONTACTOR




F ------- FUSE







R ------- RELAY





SHEET 2 OF 2


FACTORY WIRING

FIELD WIRING

Model #:

Unit Serial #:

Customer:

BDV2702L6C test

Rev 3.24

35

Wiring Diagram


460V/60Hz/3Ø - CONDENSING UNIT - UNIT WIRING

460V/60HZ/3Ø - CONDENSING UNIT - CONTROL BOARD WIRING

TO

SHEET 1

LEGEND

C ------- CONTACTOR





F ------- FUSE



36

1

2

3

COMPRESSOR

CT

T1

T2

T3

L1

L2

L3

CONTACTOR C1

L1

T1

L2

T2

L3

T3

C3

L1

T1

L2

T2

L3

T3

C4

L1

T1

L2

T2

L3

T3

C5

7 8 9 10 11 12 13 14 15

FM1 FM2 FM3

F3

POWER

BLOCK

F1

H1

X4

F2

460V

H4 TRANSFORMER

X1

230V

TO

SHEET 2 c

C1 n/o

CU Suct Temp

BLUE

Ambient Temp

WHITE

YELLOW

CRANKCASE

HEATER

10

7

R1

8

BLUE

11

CU Suct Press

0-300 PSIA

CU Liquid Press

0-500 PSIA

BLUE

RED

C1

14

TDR

L1

LPS

L2

HPS

12 13

2

R1

4

HPS

DT

COMP

OPS

15 16

OPS

240 M L 2

SERVICE MATE

AUX1

LLS

AUX2 CMOD

17


FACTORY WIRING

FIELD WIRING

Model #:

Unit Serial #:

Customer:

BDV3502M6D

Test

Rev 3.24

LEGEND

C ------- CONTACTOR




F ------- FUSE







R ------- RELAY





SERVICE SW.

SAFETY CKT.

SUCTION TEMP

AMBIENT TEMP

AUX TEMP

SUCTION PRESSURE

LIQUID PRESSURE

Alarm

PRESSURE

REGULATOR


230V

240

24V

C 240 C

C 24V

3-Way Sol.

Defrost Sol

Suction Sol

Bypass Valve

Redundant LPS

3-Way Sol.

30

31

32

33

Defrost Sol

Suction Sol

34

35

36

37

Bypass Valve

Redundant LPS

0

R1

1

COMP

Cond Fan #1

Cond Fan #2

Cond Fan #3

Cond Fan #4

C3

C4

C5

FIELD WIRING

CONNECTIONS

SHEET 2 OF 2


FACTORY WIRING

FIELD WIRING

Model #:

Unit Serial #:

Customer:

BDV3502M6D

Test

Rev 3.24

460V/60Hz/3Ø - CONDENSING UNIT - UNIT WIRING

TO

SHEET 1

1

2

3

COMPRESSOR

CT

T1

T2

T3

L1

L2

L3

CONTACTOR C1

L1

T1

L2

T2

L3

T3

C3

L1

T1

L2

T2

L3

T3

C4

L1

T1

L2

T2

L3

T3

C5

7 8 9 10 11 12 13 14 15

FM1 FM2 FM3

F3

LEGEND

C ------- CONTACTOR





F ------- FUSE



POWER

BLOCK

F1

H1

X4

F2

460V

H4 TRANSFORMER

X1

230V

TO

SHEET 2 c

C1 n/o

CU Suct Temp

BLUE

Ambient Temp

WHITE

YELLOW

CRANKCASE

HEATER

10

7

R1

8

BLUE

11

CU Suct Press

0-300 PSIA

CU Liquid Press

0-500 PSIA

BLUE

RED

C1

14

TDR

L1

LPS

L2

HPS

12 13

2

R1

4

HPS

DT

COMP

OPS

15 16

OPS

240 M L 2

SERVICE MATE

AUX1

LLS

AUX2 CMOD

17

SHEET 1 OF 2


FACTORY WIRING

FIELD WIRING

Model #:

Unit Serial #:

Customer:

BDV3502M6D

Test

Rev 3.24

LEGEND

C ------- CONTACTOR




F ------- FUSE







R ------- RELAY





Wiring Diagram


460V/60HZ/3Ø - CONDENSING UNIT - CONTROL BOARD WIRING

SERVICE SW.

SAFETY CKT.

SUCTION TEMP

AMBIENT TEMP

AUX TEMP

SUCTION PRESSURE

LIQUID PRESSURE

Alarm

PRESSURE

REGULATOR


230V

240

24V

C 240 C

C 24V

3-Way Sol.

Defrost Sol

Suction Sol

Bypass Valve

Redundant LPS

3-Way Sol.

30

31

32

33

Defrost Sol

Suction Sol

34

35

36

37

Bypass Valve

Redundant LPS

0

R1

1

COMP

Cond Fan #1

Cond Fan #2

Cond Fan #3

Cond Fan #4

C3

C4

C5

FIELD WIRING

CONNECTIONS

SHEET 2 OF 2


FACTORY WIRING

FIELD WIRING

Model #:

Unit Serial #:

Customer:

BDV3502M6D

Test

38

Wiring Diagram

(Standard Independent Evaporator Power Supply with VFD Condenser Fans)

Wiring Diagram

(Standard Independent Evaporator Power Supply with VFD Condenser Fans)

39

40

Electrical

Connections

(this side)

Hot Gas Unit Cooler Typical Factory Piping

Note: Control contactors mount under a cover on front of unit (not shown)

Air

Flow

Suction

Connection

Liquid

Connection

Liquid

Solenoid

Valve

Thermostatic

Expansion

Valve

Check

Valves

Check

Valve

Suction

P-Trap

Hot Gas

D rain Pan

Shown

Hot Gas Condensing Unit Typical Factory Piping

COMPRESSOR

SUCTION

ACCUMULATOR

DEFROST

SOLENOID

(NC)

SUCTION PRESSURE

SENSOR LOCATION REDUNDANT

LOW PRESSURE

SWITCH LOCATION

3-WAY VALVE

(NO BLEED

PORT)

LIQUID PRESSURE

SENSOR LOCATION

BASE

VALVE

LIQUID

FILTER

DRIER

CHECK

VALVE

LIQUID

SIGHTGLASS

CHECK

VALVE

ELECTRONIC

PRESSURE

REGULATOR

BY-PASS

SOLENOID

BASE

VALVE

CHECK

VALVE

LIQUID

FILTER

DRIER

SUCTION

SOLENOID

(NC)

SUCTION

FILTER

LIQUID

RECEIVER

PIPINGb.dft

rev.B

41

Refrigeration Operation


The refrigeration operation of the Mohave Hot Gas System is very similar to a standard refrigeration system. An external thermostat is connected to the hot gas control board at the terminal block connections labeled T-Stat and C (for common). When the normally open contact inside the thermostat closes (a call for cooling), the hot gas control board responds by activating a series of solenoids and contactors (described below) in order to initiate and maintain a refrigeration cycle. Later, when the thermostat contact opens, the hot gas control board deactivates the solenoids in a preset manner in order to safely turn off the refrigeration process and maintain an Off condition.

During refrigeration operation, the hot gas controller monitors liquid pressure to determine if each fan should be ON or OFF .

These settings and other fan control options may be modified by turning on the Expert Mode ( XPRT ) in the Program Menu. See Program Review and

Optional Controls for more information.

At initial power up, the system defaults to the OFF mode for a minimum of two minutes. Following the two-minute hold off period, the control circuit examines the state of the thermostat input. If the thermostat input signal is activated (closed between T-Stat and C), the system begins the refrigeration startup process. Full refrigeration mode (or COOL mode) is achieved when the control board has activated the solenoids necessary to provide refrigerant flow between the evaporator(s) and the condensing unit (Suction Solenoid and Liquid Line Solenoid), activated the compressor contactor, deployed the appropriate control over the condenser fans, and turned on the evaporator fans.

Evaporator Fan Control: After initial power-up, the evaporator fans will be turned off. When the system initiates the first cooling cycle, the hot gas controller monitors the temperature value of the evaporator defrost termination sensor mounted on the evaporator suction headers. When the controller determines that the suction header has reached the refreeze setpoint, the evaporator fans will be activated. If there are two evaporators, the fans will be energized by the first sensor to achieve setpoint. Once activated, the evaporator fans will continue to run until either a defrost cycle is initiated, or if the system is placed in SERVICE mode.

Anti Short-Cycle Protection: During cooling mode, the control board is programmed to allow a minimum system ON time of 1 minute and a minimum OFF time of 2 minutes.

Refrigerant Solenoid and Compressor Contactor Control: The Suction

Solenoid is initially activated following the power-up two-minute hold off time.

It is maintained in the ON state until a defrost cycle is initiated. The timing of the liquid line solenoid (LLS) activation is based upon the saturated suction temperature (SST) which is calculated from the suction pressure value. If the

SST is greater than 15ºF, the compressor contactor is activated before the

LLS is activated in order to decrease the suction pressure prior to startup.

When the SST drops to -5ºF, the LLS is activated. If the SST does not fall to -5ºF within 2 minutes, Er12 is activated and the system goes to

OFF mode.

Pump Down

At the end of each cooling cycle, when the box temperature is met, the hot gas control system will pump down and turn off the compressor.

If the SST is 15ºF or less, the LLS is activated immediately. When the

SST rises to -10ºF for medium temperature applications or -20ºF for low temperature applications, the compressor contactor is activated. If the SST fails to rise in 2 minutes, Er11 is activated and the system goes to

OFF mode.

When the thermostat signal is deactivated, the liquid line solenoid is turned off immediately. The compressor contactor will stay activated until the suction pressure falls below the pre-programmed cut out pressure. The compressor contactor and all condenser fan contactors will be deactivated simultaneously.

The evaporator fans will continue running.

Condenser Fan Control: When the Condensing Unit Model is selected in the Program Review Menu; the program automatically activates the default

Head Pressure Control Scheme.

Method: Pressure Fan Cycling ( PRES ) All fans

Minimum condensing temperature: 65ºF.

The default ON and OFF settings are optimized to maximize energy efficiency while still providing adequate pressure for the thermostatic expansion valve(s) to work properly. The parameters are refrigerant specific.

Fans are staged to minimize fluctuations in head pressure during operation.

42


To pump down, the Liquid Line Solenoid(s) is deactivated and the compressor runs until the pressure measured at the suction accumulator falls below the pre-programmed cut out pressure value, or two minutes has elapsed. The compressor is then turned off until the start of the next cooling cycle. During the pump down process, the LED display will show PMPD .

Manual Pump down: A single pole, single throw switch is connected to the Service SW input on the Hot gas control board. Activating this switch

(closing the contact) will cause the system to pump down and shut off. While in Service mode, the evaporator fans will turn off. Note that the system will not restart until the switch contact has been opened. The hot gas controller will display SERV while in Service mode.

The system can also be pumped-down by pressing the SERVICE button twice. To restart the system, press the CLEAR button.

Black = Piping Inactive

Gray = Piping Active

43

Defrost Operation


Defrost Timing/Schedule Programming

The hot gas controller can be programmed with up to 12 defrost start times.

The Program Review menu section describes the process to program or delete a valid start time. Note that clearing a start time by pressing CLEAR and the ENTER will disable all start times following the one being cleared.

There must be 30 minutes of elapsed time following a start of defrost before another defrost can be scheduled. A defrost cycle can be initiated manually at any time.

Force Defrost Manually

To manually force the start of a defrost-cycle, press the FORCE DEFROST button. If the system is in COOL mode, the system will pump down and go to the off mode before the defrost process is started.

Defrost Process

The defrost process has four steps: Pre-defrost ( equalization, Defrost operation ( DEF2 equalization and drain down, and Refreeze (

DEF1

), Post-defrost (

FREZ ).

) pressure

DEF3 ) pressure

The compressor contactor turns on at the same time that the pressure regulator is activated. The ambient temperature is measured, and a determination is made of how many condenser fans should be operating.

The correct number of condenser fans is activated at the same time as the compressor contactor.

Termination of defrost is accomplished by either both evaporators reaching their target termination temps, or the liquid pressure measured between the receiver and the condenser coil reaching its target pressure, or the preprogrammed fail safe time.

When one of the termination factors is realized, the compressor, condenser fan(s), and the defrost solenoid are turned off. The 3-Way valve and the Pan heaters are left on. The pressure regulator is activated to 100% open, and

DEF3 begins.

DEF3 :

Post-defrost has two purposes. The first is the transfer of high pressure refrigerant at the evaporator back to the condenser receiver by way of the pressure regulator. The pressure regulator is open 100% during this step.

The second purpose is drain down time for the warm evaporators. This allows the water that was melted off of the coil to drain out of the evaporator drain pan. The time duration for this step is identical to the DEF1 equalization time.

DEF1 :

Pre-defrost, or defrost step 1, always follows activation of Off mode. If the system is in Cool mode when the defrost cycle is activated, the control will pump down and go to Off mode before activating pre-defrost.

After the completion of the delay time period, the 3-Way valve and the pan heater contactor are turned off. One second later the Suction Solenoid is turned on, and then one second after that the compressor turns on.

The condenser fan control algorithm is also enabled. When the pressure measured at the suction sensor falls below -10°F SST, the liquid line solenoid is activated and the process step changes to Refreeze.

The purpose of DEF1 is to equalize the refrigerant pressures between the condensing unit receiver and the evaporator(s). This is accomplished by first deactivating the evaporator fans, and the suction solenoid. Next the

Bypass Solenoid and the evaporator Pan Heater contactor are activated.The time duration of the pressure equalization is programmed as

PROGRAM REVIEW menu.

EQUT in the

DEF2 :

After the equalization time has elapsed, the Bypass Solenoid is deactivated.

The Defrost Solenoid is activated 1 second later, followed by the 3-Way valve solenoid 1 second after that. Next, the pressure regulator control algorithm is enabled. The initial position is full open, but it quickly makes adjustments in order to stabilize the pressures and temperatures seen at the inlet of the suction accumulator.

FREZ :

The Refreeze step is identical to Cooling mode except that the evaporator fans are turned off. This is to allow the evaporator coils to freeze any remaining water that might be left over from the drain down step so that when the fans turn on, the water will not be sprayed into the refrigerated space. When the evaporator reaches the refreeze set-point, or the refreeze time limit elapses, the fans turn on and the system begins a cooling cycle. If the thermostat is satisfied, or deactivated, the system will run a cooling cycle for two minutes and then pump down and shut off.

After the compressor is energized, the suction stop valve may be pulsed to limit the suction pressure at the compressor.

Through the refreeze period and into cooling mode,the liquid solenoid may energize and de-energize to hold the evaporator below 10 °F SST and allow the expansion valve to better regulate as the system enters cooling mode.

Parameter LLSP controls the duration of this pulsing event.

During the DEF2 operation, the pressure regulator continues to maintain the appropriate volume of refrigerant flow through the system based upon the current ambient conditions, the refrigerant type, and the type of cooling application.

44

Hot Gas Defrost Cycle Diagrams




45

Hot Gas Defrost Cycle Diagrams




46


Defrost Termination Parameters

The hot gas controller uses a combination of temperature, pressure and time values to make the decision to end the defrost cycle. The Defrost Failsafe

Time is used at all times to limit the length of defrost. At cool ambient temperatures, the controller checks both the temperature and pressure of the defrosting evaporator(s) before making a termination decision. In warm ambient temperatures, the Defrost Termination Pressure is used exclusively to insure that the evaporators remain in defrost for a sufficient length of time.

When the controller is programmed, default temperature, pressure and time values are populated into settings. These default values were selected to fit the majority of applications. If necessary, these parameters may be accessed and changed in Expert Mode.

Defrost Skip Parameters

The hot gas controller monitors refrigeration operation for several situations that would indicate that a defrost cycle is unnecessary. In these situations, the controller will skip the next scheduled defrost.

Compressor run time is calculated since the last defrost cycle. If the run time is less that 30 minutes, the next defrost cycle is skipped.

When the measured saturated suction temperature is consistently above

32ºF, the defrost cycle is skipped.

47

Evacuation & Leak Detection

Evacuation & Leak Detection

Due to the smaller molecule size of HFC’s, they will tend to leak more readily than

CFC’s. Consequently, it is of the utmost importance that proper system evacuation and leak detection procedures be employed.

Copeland recommends a minimum evacuation to 500 microns. In addition, a vacuum decay test is strongly recommended to assure there is not a large pressure differential between the system and vacuum pump. Good evacuation processes include frequent vacuum pump oil changes and large diameter, short hose connections to both high and low sides of the system preferably using bronze braided hose.

Leak detection can be carried out in the conventional manner.

If HCFC or CFC tracer gas is used, care must be taken to completely remove all traces of the gas prior to introducing HFC’s.

Electronic leak detectors are now available that will sense HFC’s. This is considered preferable since it removes the possibility of chlorine remaining in the system after leak testing with HCFC’s and/or CFC’s. There is a view that even small quantities of chlorine may act as a catalyst encouraging copper plating and/or corrosion and should therefore be avoided.

Leak Testing

After all lines are connected, the entire system must be leak tested. The complete system should be pressurized to not more than 150 psig with refrigerant and dry nitrogen (or dry CO

2

). The use of an electronic type leak detector is highly recommended because of its greater sensitivity to small leaks. As a further check it is recommended that this pressure be held for a minimum of 12 hours and then rechecked. For a satisfactory installation, the system must be leak tight.

Line Insulation

After the final leak test, refrigerant lines exposed to high ambient conditions should be insulated to reduce heat pickup and prevent the formation of flash gas in the liquid lines. Suction lines must always be insulated with 3/4" wall Armstrong “Armaflex” or equal. When required, Liquid lines should be insulated with 1/2 inch wall insulation or better. The insulation located in outdoor environments should be protected from UV exposure to prevent deterioration of insulating value.

Evacuation

Within the last several years, manufacturers have developed fluorescent dye leak detection systems for use with refrigerants. These dyes mix with the lubricant and, when exposed to an ultraviolet light “fluoresce,” indicates the location of leaks.

Copeland has tested and approved the Rigid “System Safe” dye and found it to be compatible with the compressor materials in systems.

NOTE: The Hot Gas Control Board may be powered up and set on“EVAC” Mode during Evacuation. In this mode, all of the system valves are energized. See Page 47.

CAUTION: Do not use the refrigeration compressor to evacuate the system. Do not start the compressor while it is in a vacuum.

A good, deep vacuum pump should be connected to both the low and high side evacuation valves with copper tube or high vacuum hoses (1/4" ID minimum). If the compressor has service valves, they should remain closed. A deep vacuum gauge capable of registering pressure in microns should be attached to the system for pressure readings.

A shut off valve between the gauge connection and vacuum pump should be provided to allow the system pressure to be checked after evacuation. Do not turn off vacuum pump when connected to an evacuated system before closing shut off valve.

The vacuum pump should be operated until a pressure of 1,500 microns absolute pressure is reached — at which time the vacuum should be broken with the refrigerant to be used in the system through a drier until the system pressure rises above “0” psig.

NOTE: Refrigerant used during evacuation cannot be vented.

Reclaim all used refrigerant. EPA regulations are constantly being updated to ensure your procedure follows correct regulations.

Repeat this operation a second time.

Open the compressor service valves and evacuate the entire system to 500 microns absolute pressure. Raise the pressure to 2 psig with the refrigerant and remove the vacuum pump.

48

Start-Up Operation and Program Review

Check Out and Start Up

After the installation has been completed, the following points should be covered before the system is placed in operation:

(a) Check all electrical and refrigerant connections.

Be sure they are all tight.

(b) Observe compressor oil level before start-up. The oil level should be at or slightly above the 3/4 level of the sight glass. Refer to Table 7 on page 52 for proper compressor oil.

(c) Remove upper mounting nuts on the compressor feet. Remove the shipping spacers. Install the neoprene washers onto the compressor feet.

Replace the upper mounting nuts and washers,allowing 1/16" space between the mounting nut and the neoprene spacer.

(d) Check high and low pressure controls, oil pressure safety controls, and all other safety controls, and adjust if necessary.

(e) Check the room thermostat for normal operation and adjust.

(f) Wiring diagrams, instruction bulletins, etc. attached to the condensing units should be read and filed for future reference.

(g) All fan motors on air cooled condensers,evaporators, etc. should be checked for proper rotation. Fan motor mounts should be carefully checked for tightness and proper alignment.

(h) Observe system pressures during charging and initial operation. Do not add oil while the system is short of refrigerant unless oil level is dangerously low.

(i) Continue charging until system has sufficient refrigerant for proper operation. Do not overcharge. Remember that bubbles in a sight glass may be caused by a restriction as well as a shortage of refrigerant.

(j) Do not leave unit unattended until the system has reached normal operating conditions and the oil charge has been properly adjusted to maintain the oil level between 1/2 and 1/4 of the sight glass.

(k) Make sure all Schrader valve caps are in place and tight

Start-Up Operation - Initial Power On

At the initial application of power to the system, the compressor and the evaporator fans will be in a 2-minute hold-off cycle and will not start immediately. The 4-digit

LED indicator located on the control board will display OFF . If the room thermostat setting is below the current room temperature, the contact inside the thermostat will be closed, and the associated T-Stat LED on the controller circuit board will be lit. Under these conditions, the system will begin a cooling cycle.

Operating Mode Display

OFF Off Mode

COOL Cooling Mode

PMPD Pump Down

SERV Service Mode

DELY Delay Mode

DEF1 Pre-Defrost, or Bypass Mode

DEF2 Defrost Mode

DEF3 Post-Defrost Equalization, or Drain Mode

TEST Test Mode

Programming and Reviewing Settings and Changes

The Program Review button is used to program, review and change all program settings for the system.

Press PROGRAM REVIEW button. The Setpoint item will appear on the LED. After a few seconds delay the Setpoint value will display. Each time the button is pressed a different item is displayed.

Next, use the SELECT knob to change value of Setpoint item.

Next, when the desired value is selected, press the ENTER button to place it in program memory. If the ENTER button is not pressed the value will not be stored in memory and thus will not be changed.

CAUTION: Extreme care must be taken in starting compressors for the first time after system charging. At this time, all of the oil and most of the refrigerant might be in the compressor creating a condition which could cause compressor damage due to slugging.

Activating the crankcase heater for 24 hours prior to start-up is required. If no crankcase heater is present, then directing a 500 watt heat lamp or other safe heat source on the lower shell of the compressor for approximately thirty minutes will be beneficial in eliminating this condition which might never reoccur.

There are two levels of menu setting programs: Normal and Expert. The Expert settings are visible when the XPRT menu item is changed from Off to On.

Program Review

(Items Available when in Normal Mode)

CLKH ....... Set the Time of Day clock hour value

CLKM ....... Set the Time of Day clock minute value

°F°C ....... Set Fahrenheit/Celsius temperature units (°F/°C)

1224 ....... Set Time display method (12HR / 24HR)

ALRT ....... Set the Alarm Time (2 to 120 minutes)

RDTf ....... Defrost schedule based upon compressor runtime (OFF or Defrost based upon compressor runtime in 30 minute increments) Note that the time based menu choices below are diabled when RTDF is activated.

DF01 ....... Set Defrost #1 starting time (12:00 to 12:00 in 30 minute increments)

DF02 ....... Set Defrost #2 starting time




APPL ....... Set Application type (MED, LOW)

REFR ....... Set Refrigerant type (R-22, R-404A, R-507, R-407A, R-407C,

......................

R-407F, R-448A and R-449A )

MODL ....... Set Condensing Unit Model Number

XPRT ....... Activate expert menu items (Off, On)

49

Program Review

Program Review

(Items Available when in Expert Mode)

CLKH ....... Set the Time of Day clock hour value

CLKM ...... Set the Time of Day clock minute value

°F°C ...... Set Fahrenheit/Celsius temperature units (°F/°C)

1224 ...... Set Time display method (12HR. / 24HR)

ALRT ...... Set the Alarm Time (2 to 120 minutes)

RDTF * . ...Defrost time based upon compressor runtime (OFF or Defrost based

....................

upon compressor runtime in 30 minute increments) Note that the time

....................

based menu choices below are disabled when RDTF is activated.

DF01 ...... Set Defrost #1 starting time (12:00 to 12:00. in 30 minute increments)

DF02 ...... Set Defrost #2 starting time




APPL *** . Set Application type (MED, LOW)

REFR ...... Set Refrigerant type R-22, R-404A, R-507, R-407A, R407C,R407F)

MODL ...... Set Condensing Unit Model Number

XPRT ...... Activate expert menu items (Off, On)

FAN1 ...... Set Fan #1 operation type (OFF, ON, PRES, AMBT)




F1ON ...... Set Fan #1 turn-on parameter (Only used if PRES or AMBT selected.

PRES range is 110 psig to 300 psig, AMBT range is 30°F to 90°F).

F2ON ...... Set Fan #2 turn-on parameter



F1OF ...... Set Fan #1 turn-off parameter (Only used if PRES or AMBT selected.

PRES range is 110 psig to 300 psig, AMBT range is 30°F to 90°F).

F2OF ...... Set Fan #2 turn-off parameter



DFT1 ...... Set Evaporator #1 termination temperature ( 50°F to 100°F)

DFT2 ...... Set Evaporator #2 termination temperature ( 50°F to 100°F)

DEFP ...... Set Defrost termination pressure (160 psig to 300 psig)

DEFT ...... Set Defrost fail-safe time (5 minutes to 30 minutes)

EQUT ...... Set defrost process equalizing time (1 to 10 minutes)

LPSH ...... Set value of LPS cut-in value (0 psig to 30 psig)

LPSL ...... Set value of LPS cut-out value (0 psig to 30 psig)

FZET ...... Evaporator refreeze temperature (20ºF to 40ºF)

FZTM ...... Evaporator refreeze maximum time (0 to 10 minutes)

VALM ** .. Electronic pressure regulator manufacturer (Carel or Alco)

PRFS ...... Electronic pressure regulator full scale

PRUI ...... Electronic pressure regulator update rate (seconds)

DFIO . .. .Electronic pressure regulator initial position (percent)

LLSP . .. Liquid solenoid post defrost pulse period ( 0 to 15 minutes)

EVPF * . .. Evaporator fans running during refrigeration off-cycle (OFF or ON)

ALRH ...... Alarm room high temperature threshold in degrees

ALRL ...... Alarm room low temperature threshold in degrees

AUXT ...... Enable thermostat functionality via the auxiliary temperature sensor

(ON/OFF)

BOXT ...... Box set point when using the thermostat functionality from parameter

AUXT (only appears when AUXT = ON)

MBAd ...... Modbus address

Use the Program Review button to select these items:

Clock Hour setting – CLKH – Selection is made of the current hour. If 12 hour mode is selected, these values are displayed as 12:XX to 11:XX for the AM hours.

The PM hours will be displayed with a decimal point following the minutes (12:XX.). If

24 hour mode is selected, the hours will run from 00:XX to 23:XX.

Clock Minute setting – CLKM – Selection is made of the current minute. The currently programmed time is displayed in the standard HH:MM format. Turning the potentiometer will cause the minute value to change between 00 and 59 minutes.

Degrees F/C setting – °F°C – Select units to display temperature. Fahrenheit or

Celsius. Default: Fahrenheit.

Clock Time display setting – 12 24 – Selection is made of time display method.

Use of 12-Hour technique is implemented by activating the last decimal place of the

4-character display when the time is indicating PM instead of AM values. Default:

12-Hour mode.

Alarm Time – ALRT – Time which the alarm elements conditions must exceed before alarm is triggered. Default: 20 minutes.

Defrost schedule method 1 - RDTF - Defrost may be schedules based upon clock time or compressor run time. For clock time, select OFF and schedule the desired defrost start times (from 0 to 12 defrosts per day). For compressor run time, select the amount of compressor run time (in refrigeration mode) to occur between defrost periods (from 30 minutes to 12 hours). Default: OFF

Defrost #1 Start Time – DF01 – Programmed start time for defrost #1. Time value is displayed in HH.MM format. This time follows the 12/24 selection format.

To disable the start time, press the CLEAR/TEST button and then press ENTER .

All start times following the cleared time will become disabled. Default: 12.00

Defrost #2 Start Time – DF02 - Programmed start time for defrost #2. Time value is displayed in HH.MM format. This time follows the 12/24 selection format.

Default: 6.00

Defrost #3 Start Time – DF03 - Programmed start time for defrost #3. Time value is displayed in HH.MM format. This time follows the 12/24 selection format. Default: 12.00.

Defrost #4 Start Time – DF04 - Programmed start time for defrost #4. Time value is displayed in HH.MM format. This time follows the 12/24 selection format. Default: 6.00.

Defrost #5 to #12 Time – DFXX – These start times are preset to --.— values and are disabled. To enable the start time, turn the blue knob to the desired time value and press the

ENTER button.

Application Type – APPL – Selection is made for Medium Temp application or Low Temp application. Default: Medium Temp.

Refrigerant Type – REFR – Selection for type of refrigerant – R-22, R-404A, R-507,

R-407A, R-407C, R-407F, R-448 and R-449A . Default is R-404A

Application Model Number – MODL – Selection is made to indicate which condensing unit model the circuit board is installed onto. The four digit number associated with the system capacity in BTU’s is used. For example, a BDV1502M6 would have a numeric indication of

‘1502’. Turning the blue knob increments the choices available, pressing enter selects the currently displayed value. Default: 1502.

Expert Mode Menu Activation – XPRT – Selection is made to turn on or off the ability to view and modify specific menu items. Default: Off.

50

Program Review

Note: all items listed below are only viewable when the Expert Mode option is turned on.

Condenser Fan #x Operation Method – FANX – Note that x represents a value between

1 and 4, and is selected in descending order following #1. Selection is made for type of fan operation control. Choices are: OFF, ON, PRES, and AMBT. The selection made will determine the parameter type of the operation ranges. Default: PRES.

Condenser Fan #x ON operation value – FXON – Note that x represents a value between

1 and 4, and is selected in descending order following #1. This setting chooses the on value for the fan selected. When ON or OFF is chosen for a particular fan operation, this step will not be displayed. If AMBT was chosen, the value displayed is a temperature in °F. The temperature selection range is 30°F to 90°F. If PRES was selected, the value displayed represents a pressure in ‘psig’. The pressure selection range is 110 psig to 300 psig.

Condenser Fan #x OFF operation value – FxOF – Note that x represents a value between 1 and 4, and is selected in descending order following #1. This setting chooses the off value for the fan selected. When ON or OFF is chosen for a particular fan operation, this step will not be displayed. If AMBT was chosen, the value displayed is a temperature in °F. The temperature selection range is 30°F to 90°F. If PRES was selected, the value displayed represents a pressure in ‘psig’. The pressure selection range is 110 psig to 300 psig.

Defrost Termination Temp for Evaporator #1 – DFT1 – This is the temperature as sensed from the evaporator suction line that is used to determine when the defrost cycle is complete.

The value is displayed as a temperature.

Default: 75°F (Low Temperature) 85°F (Medium Temperature)

Defrost Termination Temp for Evaporator #2 – DFT2 – This is the temperature as sensed from the evaporator suction line that is used to determine when the defrost cycle is complete.

The value is displayed as a temperature. Note: when two evaporators are used, both evaporator temperatures must reach their set point to terminate defrost. Default: Same as DFT1 .

Defrost Termination Pressure – DEFP – Selection is made of the pressure value that will signify a complete defrost process. This decision is made in an ‘OR’ manner with the defrost termination temperature and the defrost failsafe time. That is, if any one of the defrost termination parameters is satisfied, the defrost will terminate. The value displayed is a pressure in ‘psig’ format. Default: 210 PSIG.

Defrost Failsafe Time – DEFT – This is the maximum time allowed for a coil to remain in defrost. Defrost will be terminated if the defrost end temperature measured at the evaporator(s)

(both must be at temp if two evaporators) or the defrost end pressure is not attained when this time has expired. Default: 25 minutes.

Equalizing Time – EQUT – This is the duration time of the ‘pre-defrost’ pressure equalization process and the ‘post-defrost’ drain time. The selection range is 1 minute to 10 minutes. Default: 2 minutes.

Evaporator Refreeze Temperature – FZET – This is the evaporator temperature at which the fans energize after the refreeze (fan delay) period unless the maximum refreeze time is reached. The selection range is 20F to 40F.

Evaporator Refreeze Maximum Time - FZTM - This is the maximum time for the refreeze

(fan delay) period. The selection range is 0 to 10 minutes.

Low Pressure Switch simulation ‘Cut-In’ value – LPSH – Selection is made of the ‘cut-in’ pressure value normally made on the mechanical low-pressure control switch. The value displayed is a pressure in ‘psig’ format.

The pressure range is 0 psig to 30 psig.

Low Pressure Switch simulation Cut-Out value – LPSL – Selection is made of the ‘cutout’ pressure value normally made on the mechanical low-pressure control switch. The value displayed is a pressure in ‘psig’ format. The pressure range is 0 psig to 30 psig.

Electronic Pressure Regulator Manufacturer 1 VALM - This parameter controls the Electronic

Pressure Regulator Settings that are loaded for each corresponding application to match the installed valve (Carel or Alco). Default: Carel (CARL).

Electronic Pressure Regulator - PRFS, PRUI, DFIO - These parameters control the operation of the pressure regulator during the defrost period and the default selections are tuned to specific condensing unit models. Field modification is not recommended.

Default: See table of factory default settings.

Liquid solenoid pulse feature LLSP - In the period immediately after defrost, the evaporator fans will energize and the liquid solenoid valve may be pulsed to reduce the evaporating temperature and give the warm thermostatic expansion valve additional time to close. This feature will function primarily on medium temperature systems and is adjustable from

0 to 15 minutes. Default: 5 minutes.

Evaporator fan run operation 1 - EVPF - This parameter controls the status of the evaporator fans during the refrigeration off-cycle when the thermostat is satisfied. (On or OFF) Default: On.

High auxiliary temperature alarm – ALHR – This parameter is the temperature set point that when measured above by the auxiliary temperature sensor will cause an ALR5 alarm after the alarm time has been exceeded. Default: OFF.

Low auxiliary temperature alarm – ALRL – This parameter is the temperature set point that when measured below by the auxiliary temperature sensor will cause an ALR6 alarm after the alarm time has been exceeded. Default: OFF.

Auxiliary temperature sensor thermostat control – AUXT – This parameter will allow the auxiliary temperature sensor to be used as a box thermostat control. Auxiliary temperature sensor can be extended up to 500ft using 18 gauge wire. There is no alarm provision for an auxiliary sensor failure and an external box temperature alarm is recommended if this functionality is desired. When used for box thermostat functionality setting the low and high temperature alarms (parameters ALRL, ALRH) is recommended. The recommended location of the auxiliary temperature sensor for box thermostat control is on the inlet air side of the evaporator. Default: OFF.

Box thermostat set point – BOXT – This parameter is the box temperature, or room temperature, set point that the Mohave board will control to using the auxiliary temperature sensor if parameter AUXT is enabled. There is a non-changeable 1 degree differential around this set point for refrigeration operation. This parameter will only appear in the menu if

AUXT is enabled. Default 35 degrees Fahrenheit. The box thermostat set-point range is

-25°F to 50°F.

Modbus address - MBAd - multiple Mohave control boards may be connected via Modbus

RS-485, which allows monitor menu functions and system status to be viewed. This setting allows each board to be addressed uniquely (1 to 50). Default: 1. Consult Heatcraft application engineering for further support.

Note: *Available on Software version V1.04 and higher

**Available on Software version V1.06 and higher

***Menu Re-Ordered on Software version V2.05 and higher

51

Monitoring and Reviewing Operation Values

Reviewing Operation Values

The Monitor button is used to examine and review the current operating conditions of the system.

Forced Output Items

These items are displayed as the blue knob is turned in a clockwise direction. Turning the knob counter clockwise reverses the order. Pressing ENTER will activate the displayed item.

Press MONITOR button. A descriptive abbreviation of the item will appear on the LED. After a few seconds delay the current value of the item will display. Each time the button is pressed a different item is displayed.

Monitor Button Items

VALP . . . ..Defrost Regulator Valve percent of opening (0 to 100%)

SUPH . . . ..Superheat (°F) measured at inlet of Suction Accumulator

SucT . . . ..Suction Temperature (°F) at inlet of Suction Accumulator

SucP . . . ..Suction Pressure (PSIG/HG) at inlet of Suction Accumulator

SSuc . . . ..Saturated Suction Temperature (°F)

LIQP . . . ..Liquid Pressure measured between CU Receiver and Condenser

AMBT . . . ..Ambient Temperature (°F) measured at condenser coil

AUXT . . . ..Auxiliary Temperature (°F)

E1DT . . . ..Evaporator #1 Defrost Termination Temp (°F)

E2DT . . . ..Evaporator #2 Defrost Termination Temp (°F)

ACIN . . . ..Control Board voltage (24VAC nominal)

TMMS . . . ..Current time minutes-seconds

TMHM . . . ..Current time hours-minutes

CCYC . . . ..Compressor cycles since midnight

RnTM . . . ..Compressor run time since midnight

DFTM . . . ..Duration of last defrost

ETLD . . . ..Elapsed time since last defrost

RTLD . . . ..Run time since last defrost

VERS . . . ..Software version

Force Defrost

To force a ‘defrost’, press the FORCE DEFROST button. The system will pump-down and shut off the compressor. The system will activate the solenoids required for the ‘pre-defrost’ bypass operation, and a defrost will commence as described in a later section. The display will show

DEF1 .

EVPF ...... Evaporator Fan Contactor

LIQS ...... Liquid Line Solenoid

EVPH ...... Evaporator Pan Heater

FAN4 ...... Condenser Fan #4 Contactor




COMP ...... Compressor Contactor

BYPV ...... Bypass Solenoid

SucS ...... Suction Stop Solenoid

DEFS ...... Defrost Solenoid

3WAY ...... 3-Way Valve Solenoid

ALRM ...... Alarm Contacts

VALS ...... Regulator Valve control

EVAC ...... Evacuate System Mode

Pressing ENTER when VALS is selected causes the number 0 to be displayed. This represents the percentage of regulator valve opening. Turning the blue knob will increase or decrease this number until a desired setting is made. Press the ENTER button to force the regulator to change to the desired setting.

CLEAR/TEST Button

Pressing this button ONCE will return the LED display to the default display. With the system in the OFF mode, pressing this button will activate the TEST mode. In the TEST mode, the controller will activate the outputs one at a time starting with the evaporator fans for

4 seconds per output. The sequencing will continue until the CLEAR button is pressed again.

Status Indicator Led

A red, four digit, alphanumeric LED on the hot gas control board indicates status, alarms, and error codes.

Reset Time

Pressing this button will reset the time clock in the microprocessor to zero. At initial power up, pressing this button will bypass the two minute hold off and the system will start immediately after a valid ‘T-stat’ signal is recognized. The display will show DELY.

Force Service

Pressing this button TWICE will cause the system to pump down and the compressor to shut off.

The system will remain off until the CLEAR button is pressed. When the system is initially placed into FORCE SERVICE mode, the display will show SERV .

While in ‘Service mode’, individual outputs may be activated by selecting the desired output circuit and pressing the ENTER button. The output circuit is selected by turning the blue knob.

Turning the blue knob completely counter-clockwise selects EVPF or evaporator fans.

LED Display

OFF

COOL

DELY

PMPD

DEF1

DEF2

DEF3

FREZ

TEST

SERV

Mode

Off

Cooling

Delay

Pump Down

Pre-Defrost Bypass

Defrost

Drain down

Refreeze

Test

Service

52

Error and Alarm Details

Alarms

Alr1

Alr2

Alr3

Alr4

Alr5

Alr6

Mode

Persistent input sensor/transducer failure

Combined Err4 and Err8, system off

Repeated Safety Circuit Open condition

Prolonged cooling startup failure

High auxiliary temperature sensor alarm

Low auxiliary temperature sensor alarm.

Safety Circuit Interruption - Alr3

If the safety circuit input signal is broken during normal refrigeration or defrost,

Err9 is displayed. This failure is caused when one of the components connected to the Service Mate TM such as the oil pressure switch or the high pressure switch opens unexpectedly.

NOTE: An Alarm Activation turns on the Alarm Relay and LED

Errors

Err1

Err2

Err3

Err4

Err5

Err6

Err7

Err8

Err9

Er10

Er11

Er12

Er13

Mode

Suction temperature sensor open or short

Ambient temp sensor open or short

Auxiliary temp sensor open or short

Suction Pressure sensor open or short

Liquid Pressure sensor open or short



Redundant low pressure switch open or short

Safety Circuit interruption during normal operation

Prolonged Low Suction Pressure during cooling

Low Suction Pressure startup failure

High Suction Pressure startup failure

Post Defrost pump down error

Component Errors - Alr1

During operation, the hot gas control board examines each input device to determine if its signal falls within a preset operational window. When the input device fails, the control board identifies the member by flashing an error code on the LED display. If the signal is restored to normal parameters, the error code is immediately removed.

If the error persists for the amount of time programmed in step ALRT of the

Program Review menu, Alarm #1 will activate. Alarm 1 causes the Alarm Relay and the alarm LED to turn on, it does not shut the system down .

When one of the input sensors fail, the hot gas controller will adjust its decision making process to accomodate the loss. These adjustments are referred to as contingencies and are stop-gap measures to keep the system running until the failed component can be replaced.

Shut down Error - Alr2

If the suction pressure sensor fails ( Err4 , Alr1 ), the redundant low pressure switch is used to operate the system during refrigeration until the pressure sensor can be replaced. If the redundant low pressure switch also fails ( Err8 ), the system will stop operating and display Alr2.

If the pressure sensor is replaced, the system will begin operating again normally.

If the pressure switch is replaced, the system will operate under the Err4 ,

Alr1 constraints.

The hot gas controller will wait 4 minutes and attempt to restart the interrupted process. If successful, the error is cleared. If unsuccessful, the system will shutdown again and try to restart later. If the problem persists, Alr3 will be activated.

Failure to Start Errors - Alr4

Normal start up processes for cooling mode requires a specific pressure range to be present at the suction pressure sensor. If the measured pressure is too high or too low, steps are taken to cause the pressure to adjust before full cooling mode can be achieved. If these methods are not successful within 2 minutes, Er11 (for a pressure too low) or Er12 (for a pressure too high) is displayed. The system will continue trying to start every four minutes. If the error persists for the amount of time programmed in step ALRT , Alr4 will be activated.

Box Thermostat (Feature Enabled) Limits Exceeded -

Alr5, Alr6

High auxiliary temperature sensor alarm - ALR5 . This alarm energizes the alarm relay output if the measure auxiliary temperature sensor value is above the ALRH set point for a length of the ALRT time, and de-energizes the alarm relay output immediately when the temperature is no longer above the ALRH set point.

Low auxiliary temperature sensor alarm – ALR6 . This alarm energizes the alarm relay output if the measured auxiliary temperature sensor value is below the

ALRL set point for a length of the ALRT time, and de-energizes the alarm relay output immediately when the temperature is no longer below the ALRL set point.

Persistant Low Suction Pressure - Er10

When the measured suction pressure falls to 0 psig or less, the system will shut down and display Er10 . The duration of time that is allowed is dependent on the measured ambient temperature. If the ambient temperature is above 20ºF, the shut down is immediate. If the ambient is 20ºF or less, the low pressure condition must persist for 15 seconds before the error is identified.

Suction Pressure Fails to Drop Following Defrost or

Cooling, ER12, ER13

If the suction pressure does not drop after 4 minutes of operation following the defrost 3 period, Er13 is displayed. This will not cause an alarm condition because the system will begin attempting to start a cooling cycle 4 minutes later, and the high pressure start-up fault ( Er12 ) will take over.

Component Errors - Alarm 1 - Contingency Chart

Component

Suction Temperature Sensor Open or Short

Ambient Temperature Sensor Open or Short

Suction Pressure Sensor Open or Short

Error #

Err1

Err2

Err4

Liquid Pressure Sensor Open or Short

Evap 1 Defrost Temperature Sensor Open or Short

Evap 2 Defrost Temperature Sensor Open or Short

Redundant Low Pressure Switch Malfunction Detected

Err5

Err6

Err7

Err8

Contingency

Regulator control during defrost will be by pressure only

Condenser fans configured for ambient control will cycle with compressor

Medium temperature systems will air defrost*, low temperature systems will refrigerate as long as possible without defrost. Redundant low pressure switch used to control refrigeration

Condenser fans configured for pressure control will cycle with the compressor; defrosts will terminate by evap temperature

Two evap systems will use other evap sensor or system will pressure terminate defrost, refreeze will be time value

Two evap systems will use other evap sensor or system will pressure terminate defrost, refreeze will be time value

System will operate normally, this is a back-up device

*DEFA Displayed in this Mode

53

MODEL/ REFRIG

M6 (R404A/R507)

M6 (R404A/R507)

M6 (R404A/R507)

M6 (R404A/R507)

M6 (R404A/R507)

M6 (R404A/R507)

M6 (R404A/R507)

M6 (R404A/R507)

M6 (R407A,C,F)

M6 (R407A,C,F)

M6 (R407A,C,F)

M6 (R407A,C,F)

M6 (R407A,C,F)

M6 (R407A,C,F)

M6 (R407A,C,F)

M6 (R407A,C,F)

M6 (R448A/449A)

M6 (R448A/449A)

M6 (R448A/449A)

M6 (R448A/449A)

M6 (R448A/449A)

M6 (R448A/449A)

M6 (R448A/449A)

Refrigerant Charging

Refrigerant Charging Instructions

1. Install a liquid line drier in the refrigerant supply line between the service gauge and the liquid service port of the receiver. This extra drier will insure that all refrigerant supplied to the system is clean and dry.

2. When initially charging a system that is in a vacuum, liquid refrigerant can be added directly into the receiver tank.

3. Check serial data tag attached to the unit for refrigerant capacity (if special application). Maximum system refrigerant capacity is 90% of receiver capacity. Do not add more refrigerant than the data tag indicates, unless the line run exceeds 25ft. Then, additional refrigerant may be added as per the chart on page 20. Weigh the refrigerant drum before charging so an accurate record can be kept of the weight of refrigerant put in the system.

See adjacent table for Standard Receiver Capacities.

4. Start the system and finish charging until the sight glass indicates a full charge and the proper amount has been weighed in. If the refrigerant must be added to the system through the suction side of the compressor, charge in vapor form only. Liquid charging must be done in the high side only or with liquid metering devices to protect the compressor.

Charge Quantity and Condenser Fan Control

The method of head pressure control affects refrigerant charge and the staging of the condenser fans. The system should have the minimum charge necessary to allow for proper operation at all expected conditions. Condenser fan control settings should balance system efficiency with fan motor power consumption. Stable pressures during refrigeration are another important consideration. The following guidelines are intended to support these goals.

Receiver Capacities and Head Pressure Valve Flooding Charges

Additional Refrigerant Charge (Lbs) Required for Various Evaporating Temperatures (SST)

752, 762

802

1002, 1202

1502, 2002

2502

3002

3502

4002

752, 762

802

1002, 1202

1502, 2002

2502

3002

3502

SIZE

752, 762

802

1002, 1202

1502, 2002

2502

3002

3502

4002

(90%) RECEIVER

CAPACITY Lbs

135

205

205

205

88

88

88

135

123

188

188

188

81

81

81

123

85

85

85

131

131

199

199

20F SST

-20F AMB

73

73

98

92

17

22

30

49

67

67

89

84

15

20

27

45

71

71

95

16

21

29

47

Condenser Flooding Charge, Lbs

10F SST

-20F AMB

78

78

104

98

18

23

31

52

71

71

95

90

16

21

29

47

76

76

101

17

22

31

50

20F SST

20F AMB

64

64

86

81

15

19

26

43

59

59

78

74

13

17

24

39

63

63

83

14

19

25

42

10F SST

20F AMB

69

69

92

87

16

20

28

46

63

63

84

79

14

19

25

42

67

67

89

15

20

27

45

54

MODEL/ REFRIG

L6 (R404A/R507)

L6 (R404A/R507)

L6 (R404A/R507)

L6 (R404A/R507)

L6 (R404A/R507)

L6 (R407A,F)

L6 (R407A,F)

L6 (R407A,F)

L6 (R407A,F)

L6 (R407A,F)

L6 (R448A/449A)

L6 (R448A/449A)

L6 (R448A/449A)

L6 (R448A/449A)

L6 (R448A/449A)

Refrigerant Charging

SIZE

0602, 0752

0902, 1002, 1202

1502

2202

2702, 3002

0602, 0752

0902, 1002, 1202

1502

2202

2702, 3002

0602, 0752

0902, 1002, 1202

1502

2202

2702, 3002

(90%) RECEIVER

CAPACITY Lbs

123

88

88

88

135

135

81

81

81

123

85

85

85

131

131

-5F SST

-20F AMB

65

17

23

31

51

71

16

21

28

47

17

22

30

50

69

Condenser Flooding Charge, Lbs

-25F SST

-20F AMB

69

18

24

33

54

75

17

22

30

50

18

23

32

53

73

-5F SST

20F AMB

59

16

21

28

46

65

14

19

26

42

15

20

27

45

63

-25F SST

20F AMB

65

17

23

31

51

71

16

21

28

47

17

22

30

50

69

Systems with Pressure Fan Cycling for Head Pressure

Control (Standard)

For these systems the general recommendation is to use a clear sight glass as an indication of proper refrigerant charge, then add another 10% to compensate for liquid pressure changes during fan cycling. During cooler ambient temperatures the fan cycle settings should be temporarily changed to yield a 105 ° F minimum condensing temperature during the charging process. An alternate method is to temporarily block a portion of the entering air condenser surface to restrict airflow.

In these cases, the settings should be maintained until the evaporator superheat has been checked and adjusted.

The default pressure fan cycling settings are optimized to maintain a minimum 65 ° F condensing temperature. These settings may be changed if desired.

Systems with Floating (Low) Head Pressure

For these systems the general recommendation is to use a clear sight glass as an indication of proper refrigerant charge. During cooler ambient temperatures the fan cycle settings should be temporarily changed to yield a 105 ° F minimum condensing temperature during the charging process. An alternate method is to temporarily block a portion of the entering air condenser surface to restrict airflow. In these cases, the settings should be maintained until the evaporator superheat has been checked and adjusted.

There are a number of different fan cycling possibilities for floating head systems.

Generally, fans are turned off with decreasing ambient temperature to save energy.

The first (header) fan is run continuously with the compressor and other fans are controlled by pressure or ambient temperature.

Please note that special expansion valve and nozzle selections are often required for floating head pressure applications.

Systems with Head Pressure Valves (ORI/ORD)

For these systems the general recommendation is to use a clear sight glass as an indication of proper refrigerant charge, then add an additional amount for condenser flooding (See Table on Pages 52-53). During cooler ambient temperatures the fan cycle settings should be temporarily changed to yield a 105 ° F minimum condensing temperature during the charging process. An alternate method is to temporarily block a portion of the entering air condenser surface to restrict airflow.

In these cases, the settings should be maintained until the evaporator superheat has been checked and adjusted.

The default pressure fan cycling settings should be appropriate for a 150-180 psi discharge pressure setting on the ORI valve. If other settings are desired, the fan cycling settings may need to be changed.

55

Operational Check Out

Operational Check Out

After the system has been charged and has operated for at least two hours at normal operating conditions without any indication of malfunction, it should be allowed to operate overnight on automatic controls. Then a thorough recheck of the entire

(h)

(i)

(j)

(k) system operation should be made as follows:

(a) Check compressor discharge and suction pressures.

If not within system design limits, determine why and take corrective action.

(b) Check liquid line sight glass and expansion valve operation. If there are indications that more refrigerant is required, leak test all connections and

(c)

(d) system components and repair any leaks before adding refrigerant.

Observe oil level in compressor crankcase sight glass. Add oil as necessary to bring level to bottom 1/4 of the sight glass.

Thermostatic expansion valves must be checked for proper superheat settings. Valves set at high superheat will lower refrigeration capacity. Low

(e)

(f) superheat promotes liquid slugging and compressor bearing washout.

Using suitable instruments, carefully check line voltage and amperage at the compressor terminals. Voltage must be within 10% of that indicated on the condensing unit nameplate. If high or low voltage is indicated, notify the power company. If amperage draw is excessive, immediately determine the cause and take corrective action. On three phase motor compressors, check to see that a balanced load is drawn by each phase.

The maximum approved settings for high pressure controls on our air cooled condensing equipment is 425 psig. On air cooled systems, check as follows: Disconnect the fan motors or block the condenser inlet air. Watch

(g) high pressure gauge for cutout point. Recheck all safety and operating controls for proper operation and adjust if necessary.

Once the room is near design temperature, observe a defrost cycle. The defrost sequence may be manually started by pressing the force defrost button

Check drain pan for proper drainage.

Check head pressure controls for pressure setting.

Check crankcase heater operation.

Install instruction card and control system diagram for use of building manager or owner.

Suction superheat should be checked at the compressor as follows:

1. Measure the suction pressure at the suction service valve of the compressor and determine the saturation temperature corresponding to this pressure from a “Temperature-Pressure”

2.

3. chart.

Measure the suction temperature of the suction line about one foot back from the compressor using an accurate thermometer.

Subtract the saturated temperature from the actual suction line temperature.

The difference is superheat.

Too low a suction superheat can result in liquid being returned to the compressor.

This will cause dilution of the oil and eventual failure of the bearings and rings or in the extreme case, valve failure.

Too high a suction superheat will result in excessive discharge temperatures which cause a break down of the oil and results in piston ring wear, piston and cylinder wall damage.

It should also be remembered that the system capacity decreases as the suction superheat increases. For maximum system capacity, suction superheat should be kept as low as is practical. Copeland mandates a minimum superheat of 20˚F at the compressor . We recommend that the superheat at the compressor be between

20˚F and 30˚F.

If adjustments to the suction superheat need to be made, the expansion valve at the evaporator should be adjusted.

Evaporator Superheat

Check Your Superheat. After the box temperature has reached or is close to reaching the desired temperature, the evaporator superheat should be checked and adjustments made if necessary. Generally, systems with a design TD of 10 ˚ F should have a superheat value of 6 ˚ to 10 ˚ F for maximum efficiency. For systems operating at higher TD’s, the superheat can be adjusted to 12 ˚ to 15 ˚ ˚F as required.

NOTE: Minimum compressor suction superheat of 20˚F may override these recommendations on some systems with short line runs.

System Balancing - Compressor Superheat

To properly determine the superheat of the evaporator, the following procedure is the method Heatcraft recommends:

IMPORTANT: In order to obtain the maximum capacity from a system, and to ensure trouble-free operation, it is necessary to balance each and every system.

This is extremely important with any refrigeration system.

The critical value which must be checked is suction superheat.

1. Measure the temperature of the suction line at the point the bulb is clamped.

2. Obtain the suction pressure that exists in the suction line at the bulb location using a gauge in the external equalized line will gauge directly in the suction line near the evaporator or directly in the suction header of the evaporator.

3. Convert the pressure obtained above to saturated evaporator temperature by using a temperature-pressure chart.

4. Subtract the saturated temperature from the actual suction line temperature.

The difference is superheat.

5. For refrigerants with glide use dew point saturation values.

56

Refrigeration Oils

Polyol Ester Lubricants

Hygroscopicity

Ester lubricants (POE) have the characteristic of quickly absorbing moisture from the ambient surroundings. This is shown graphically in Figure 7 where it can be seen that such lubricants absorb moisture faster and in greater quantity than conventional mineral oils. Since moisture levels greater than 100 ppm will results in system corrosion and ultimate failure, it is imperative that compressors, components, containers and the entire system be kept sealed as much as possible. Lubricants will be packaged in specially designed, sealed containers. After opening, all the lubricant in a container should be used at once since it will readily absorb moisture if left exposed to the ambient. Any unused lubricant should be properly disposed of. Similarly, work on systems and compressors must be carried out with the open time as short as possible. Leaving the system or compressor open during breaks or overnight MUST

BE AVOIDED!

Polyol Ester Lubricants

The Mobil EAL ARCTIC 22 CC is the preferred Polyol ester due to unique additives included in this lubricant. ICI Emkarate RL 32S is an acceptable Polyol ester lubricant approved for use when Mobil is not available. These POE’s must be used if HFC refrigerants are used in the system. They are also acceptable for use with any of the traditional refrigerants or interim blends and are compatible with mineral oils. They can therefore be mixed with mineral oils when used in systems with CFC or HCFC refrigerants. These lubricants are compatible with one another and can be mixed.

Table 7. Refrigeration Oils

Traditional Refrigerants and Refrigeration Oils

POE's

Mobil EAL ARCTIC 22 CC

ICI (Virginia KMP) EMKARATE RL 32CF

P = Preferred Lubricant Choice A = Acceptable Alternative

*(Reprinted by permission from Copeland Corporation)

HFC's R-404A, R-507, R-407A, R-407C, R-407F

HFO Blends R-448A, R-449A

P

P

Figure 7.

Color

As received, the POE lubricant will be clear or straw colored. After use, it may acquire a darker color. This does not indicate a problem as the darker color merely reflects the activity of the lubricant's protective additive.

Oil Level

During Copeland's testing of Polyol ester oil, it was found that this lubricant exhibits a greater tendency to introduce oil into the cylinder during flooded start conditions. If allowed to continue, this condition will cause mechanical failure of the compressor.

A crankcase heater is required with condensing units and it must be turned on several hours before start-up.

Oil level should not exceed 1/2 sight glass during operation.

57

Hot Gas Controller Troubleshooting Chart

Troubleshooting

58

Troubleshooting

General Evaporator Troubleshooting Chart

SYMPTOMS

Fan(s) will not operate

Room temperature too high

Ice accumulating on ceiling

around evaporator and/or on

fan guards venturi or blades

Coil not clearing of frost during

defrost cycle

Ice accumulating in drain pan

POSSIBLE CAUSES

1. Main switch open

2. Blown fuses

3. Defective motor

4. Defective timer or defrost thermostat

5. Unit in defrost cycle

1. Room thermostat set too high

2. Superheat too high

3. System low on refrigerant

4. Coil iced-up

5. Unit cooler located too close to doors

6. Heavy air infiltration

1. Defrost duration is too long

2. Defective defrost thermostat or timer

3. Too many defrosts

1. Coil temperature not getting above freezing point during defrost

2. Not enough defrost cycles per day

3. Defrost cycle too short

4. Defective timer or defrost thermostat

1. Defective heater

2. Unit not pitched properly

3. Drain line plugged

4. Defective drain line heater

5. Defective timer or thermostat

Uneven coil frosting 1. Located too close to door or opening

2. Defrost termination set too low

3. Incorrect or missing distributor nozzle

POSSIBLE CORRECTIVE STEPS

1. Close switch

2. Replace fuses. Check for short circuits or overload conditions

3. Replace motor

4. Replace defective component

5. Wait for completion of cycle

1. Adjust thermostat

2. Adjust thermal expansion valve

3. Add refrigerant

4. Manually defrost coil. Check defrost controls for malfunction

5. Relocate unit cooler or add strip curtain to door opening

6. Seal unwanted openings in room

1. Adjust defrost termination settings


3. Reduce number of defrosts

1. Check heater operation

2. Adjust controller for more defrost cycles

3. Adjust defrost settings for longer cycle


1. Replace heater

2. Check and adjust if necessary

3. Clean drain line

4. Replace heater


1. Relocate evaporator

2. Adjust defrost termination setting

higher.

3. Add or replace nozzle with appropriately sized orifice for conditions.

59

Troubleshooting

General System Troubleshooting Chart

PROBLEM POSSIBLE CAUSES POSSIBLE CORRECTIVE STEPS

Compressor will not run 1. Main switch open.

2. Fuse blown.

1. Close switch.

2. Check electrical circuits and motor winding for shorts or

grounds Investigate for possible overloading. Replace fuse

after fault is corrected.

3. Thermal overloads tripped.

4. Defective contactor or coil.

5. System shut down by safety devices.

3. Overloads are automatically reset. Check unit closely when unit comes back on line.

4. Repair or replace.

5. Determine type and cause of shutdown and correct it before resetting safety switch.

6. No cooling required.

7. Liquid line solenoid will not open.

8. Motor electrical trouble.

9. Loose wiring.

10. Phase loss monitor inoperative.

6. None. Wait until calls for cooling.

7. Repair or replace coil.

8. Check motor for open windings, short circuit

or burn out.

9. Check all wire junctions. Tighten all

terminal screws.

10. Refer to page 24.

1. Check setting of expansion valves.

2. Relocate, add or remove hangers.

3. Replace.

Compressor noisy or vibrating

High discharge pressure

Low discharge pressure

1. Flooding of refrigerant into crankcase.

2. Improper piping support on suction or

liquid line.

3. Worn compressor.

.

1. Non-condensables in system.

2. System overcharges with refrigerant.

3. Discharge shutoff valve partially closed.

4. Fan not running.

5. Head pressure control setting.

6. Dirty condenser coil.

1. Faulty condenser temperature regulation.

2. Suction shutoff valve partially closed.

3. Insufficient refrigerant in system.

4. Low suction pressure.

5. Variable head pressure valve.

1. Remove the non-condensables.

2. Remove excess.

3. Open valve.

4. Check electrical circuit.

5. Adjust.

6. Clean.

1. Check condenser control operation.

2. Open valve.

3. Check for leaks. Repair and add charge.

4. See corrective steps for low suction pressure.

5. Check valve setting.

High suction pressure

Low suction pressure

Little or no oil pressure

1. Excessive load.

2. Expansion valve overfeeding.

1. Lack of refrigerant.

2. Evaporator dirty or iced.

3. Clogged liquid line filter drier.

4. Clogged suction line or compressor

suction gas strainers.

5. Expansion valve malfunctioning.

6. Condensing temperature too low.

7. Improper TXV.

1. Clogged suction oil strainer.

2. Excessive liquid in crankcase.

3. Low oil pressure safety switch defective.

4. Worn oil pump.

5. Oil pump reversing gear stuck in wrong

position.

6. Worn bearings.

7. Low oil level.

8. Loose fitting on oil lines.

9. Pump housing gasket leaks.

1. Reduce load or add additional equipment.

2. Check remote bulb. Regulate superheat.

1. Check for leaks. Repair and add charge.

2. Clean.

3. Replace cartridge(s).

4. Clean strainers.

5. Check and reset for proper superheat.

6. Check means for regulating condensing temperature.

7. Check for proper sizing.

1. Clean.

2. Check crankcase heater. Reset expansion valve for higher superheat. Check liquid line solenoid valve operation.

3. Replace.

4. Replace.

5. Reverse direction of compressor rotation.

6. Replace compressor.

7. Add oil and/or through defrost.

8. Check and tighten system.

9. Replace gasket.

Compressor loses oil

Compressor thermal protector switch open

60

1. Lack of refrigerant.

2. Excessive compression ring blow by.

3. Refrigerant flood back.

4. Improper piping or traps.

1. Operating beyond design conditions.

2. Discharge valve partially shut.

3. Blown valve plate gasket.

4. Dirty condenser coil.

5. Overcharged system.

1. Check for leaks and repair. Add refrigerant.

2. Replace compressor.

3. Maintain proper superheat at

compressor.

4. Correct piping.

1. Add components to bring conditions within acceptable limits (Consult Heatcraft)

2. Open valve.

3. Replace gasket.

4. Clean coil.

5. Reduce charge.

Preventive Maintenance

Unit Coolers

At every six month interval, or sooner if local conditions cause clogging or fouling of air passages through the finned surface, the following items should be checked.

1) Visually inspect unit

• Look for signs of corrosion on fins, cabinet, copper tubing and solder joints.

• Look for excessive or unusual vibration for fan blades or sheet metal panels when in operation. Identify fan cell(s) causing vibration and check motor and blade carefully.

• Look for oil stains on headers, return bends, and coil fins. Check any suspect areas with an electronic leak detector.

• Check drain pan to insure that drain is clear of debris, obstructions or ice buildup and is free draining.

2) Clean evaporator coil and blades

• Periodic cleaning can be accomplished by using a brush, pressurized water or a commercially available evaporator

coil cleaner or mild detergent. Never use an acid

based cleaner. Follow label directions for appropriate

use. Be sure the product you use is approved for use in

your particular application.

• Flush and rinse coil until no residue remains.

• Pay close attention to drain pan, drain line and trap.

3) Check the operation of all fans and ensure airflow is unobstructed

• Check that each fan rotates freely and quietly. Replace

any fan motor that does not rotate smoothly or makes an

unusual noise.

• Check all fan set screws and tighten if needed.

• Check all fan blades for signs of stress or wear.

Replace any blades that are worn, cracked or bent.

• Verify that all fan motors are securely fastened to the

motor rail.

• Lubricate motors if applicable.

4) Inspect electrical wiring and components

• Visually inspect all wiring for wear, kinks, bare areas and

discoloration. Replace any wiring found to be damaged.

• Verify that all electrical and ground connections are secure, tighten if necessary.

• Check operation/calibration of all fan cycle and defrost controls when used.

• Look for abnormal accumulation of ice patterns and adj ust defrost cycles accordingly

• Compare actual defrost heater amp draw against unit data plate.

• Check drain line heat tape for proper operation

(supplied and installed by others).

5) Refrigeration Cycle

• Check unit cooler superheat and compare reading for your specific application

• Visually inspect coil for even distribution

Air Cooled Condensing Units

Quarterly

1) Visually inspect unit

• Look for signs of oil stains on interconnection piping and condenser coil. Pay close attention to areas around

solder joints, building penetrations and pipe clamps.

Check any suspect areas with an electronic leak detector.

Repair any leaks found and add refrigerant as needed.

• Check condition of moisture indicator/sightglass in the sight glass if so equipped. Replace liquid line drier if there is indication of slight presence of moisture. Replace

refrigerant, oil and drier if moisture concentration is indicated to be high.

• Check moisture indicator/sightglass for flash gas. If found

check entire system for refrigerant leaks and add

refrigerant as needed after repairing any leaks.

• Check compressor sightglass (if equipped) for

proper oil level.

• Check condition of condenser. Look for accumulation

of dirt and debris (clean as required).

• Check for unusual noise or vibration. Take corrective

action as required.

• Inspect wiring for signs of wear or discoloration and

repair if needed.

• Check and tighten all flare connections.

Semi-Annually

2) Repeat all quarterly inspection items.

3) Clean condenser coil and blades

• Periodic cleaning can be accomplished by using a brush,

pressurized water and a commercially available foam coil

cleaner. If foam cleaner is used, it should not be an acid

based cleaner. Follow label directions for appropriate use.

• Rinse until no residue remains.

4) Check operation of condenser fans

• Check that each fan rotates freely and quietly.

Replace any fan motor that does not rotate smoothly

or makes excessive noise.

• Check all fan blade set screws and tighten as required.

• Check all fan blades for signs of cracks, wear or stress.

Pay close attention to the hub and spider. Replace blades

as required.

• Verify that all motors are mounted securely.

• Lubricate motors if applicable. Do not lubricate

permanently sealed, ball bearing motors.

61

Semi-Annually (cont.)

5) Inspect electrical wiring and components

• Verify that all electrical and ground connections are secure, tighten as required.

• Check condition of compressor and heater contactors.

Look for discoloration and pitting. Replace as required.

• Check operation and calibration of all timers, relays pressure controls and safety controls.

• Clean electrical cabinet. Look for signs of moisture, dirt, debris, insects and wildlife. Take corrective action as required.

• Verify operation of crankcase heater by measuring amp draw.

6) Check refrigeration cycle

• Check suction, discharge and net oil pressure readings.

If abnormal take appropriate action.

• Check pressure drop across all filters and driers.

Replace as required.

• Verify that superheat at the compressor conforms to

specification. (See page 54)

• Check pressure and safety control settings and verify proper operation.

Preventive Maintenance

Annually

7) In addition to quarterly and semiannual maintenance

checks, submit an oil sample for analysis

• Look for high concentrations of acid or moisture. Change

oil and driers until test results read normal.

• Investigate source of high metal concentrations, which

normally are due to abnormal bearing wear. Look for

liquid refrigerant in the crankcase, low oil pressure or low

superheat as a possible source.

8) Inspect suction accumulator (if equipped)

• If the accumulator is insulated remove insulation and inspect for leaks and corrosion.

• Pay close attention to all copper to steel brazed connections

• Wire brush all corroded areas and peeling paint.

• Apply an anticorrosion primer and paint as required.

Re-insulate if applicable.

• Check accuracy of the suction line temperature and pressure sensors before the suction accumulator by comparing the controller reading in the monitor mode to a thermometer and pressure gauge of known accuracy

62

InterLink Service Parts

Hot Gas Defrost System Service Parts

Whenever possible, replacement parts are to be obtained from a local wholesaler authorized to sell one of Heatcraft Refrigeration Products’ brands.

Replacement parts which are covered under the terms of the warranty statement on page 6 of this manual, will be reimbursed for total part cost only. The original invoice from the parts supplier must accompany all warranty claims for replacement part reimbursement. Heatcraft Refrigeration Products reserves the right to adjust the compensation amount paid on any parts submitted for warranty reimbursement when a parts supplier’s original invoice is not provided with a claim. You may obtain information regarding local authorized wholesalers by calling the InterLink Service Parts Center at 1-800-686-7278 between the hours of 7:30 AM to 4:30 PM Central Time.

ELECTRICAL PARTS

Description

Hot Gas Control Board

Transformer 100VA 24V - 208/230V

Part Number

28910302

22555601

Electronic Pressure Regulator +

Pressure Regulator Harness +

29326701

22592201

Suction Pressure Transducer (0-300 PSIA) 28911202

Suction Transducer Harness (Blue)

Liquid Pressure Transducer (0-500 PSIA)

Liquid Transducer Harness (Black)

Suction Temp Sensor (Blue)

Ambient /Room Temp Sensor (White 93" leads)

High Pressure Switch

Evaporator Sensor

Evaporator Contactor 30A

Evaporator Contactor 40A

Evap Liquid Solenoid 1/2” conn



Low Pressure Switch (Redundant)

Coil (Parker SC) 24V

22515102

28911203

22515103

28900310

28900311

28913201

28900108

2252430

2252440

29324201

29324301

29324401

2890099

22593201

Condensing

Unit Model

1502 M6

2002 M6

2502 M6

3002 M6

3502 M6

4002 M6

0752 M2

0762 M2

0802 M2

1002 M2

1202 M2

1502 M2

2002 M2

2502 M2

3002 M2

3502 M2

4002 M2

0602L6

0752L6

0902L6

01002L6

01202L6

01502L6

2202L6

2702L6

3002L6

0752 M6

0762 M6

0802 M6

1002 M6

1202 M6

CONDENSING UNIT PIPING COMPONENTS

3-Way

Valve

Suction

Stop

Solenoid

Valve

Defrost

Solenoid

Valve

Bypass

Solenoid

Valve

29323601

29323601

29330301

29330301

29321701

29321701

29324201

29324201

29323701

29323701

29323701

29323701

29323701

29323801

29323801

29323701

29323701

29323701

29323701

29323701

29323801

29323801

29323801

29330401

29330401

29330401

29330402

29330402

29330403

29330403

29330301

29330301

29330401

29330401

29330402

29330402

29330402

29330403

29323801 29330403 29330402

29323801 29330402 (2) 29330403

29323801 29330402 (2) 29330403

29323701 29330301 29321701

29323701 29330301 29321701

29323701

29323701

29323701

29330401

29330401

29330402

29321801

29321801

29321901

29323801

29323801

29323801

29330402

29330402

29330403

29321901

29321901

29330402

29323801 29330403 29330402

29323801 29330402 (2) 29330403

29323801 29330402 (2) 29330403

29321801

29321801

29321901

29321901

29330402

29330402

29330402

29321701

29321701

29321801

29321801

29321901

29321901

29321901

29330402

29324401

29324401

29324401

29324201

29324201

29324201

29324201

29324301

29324301

29324301

29324401

29324401

29324401

29324401

29324201

29324201

29324201

29324301

29324301

29324301

29324301

29324201

29324201

29324201

29324201

29324301

29324301

29324301

29324401

Aeroquip

Hose

28991009

28991002

28991001

28991001

28991001

28991001

28991003

28991003

28991002

28991002

28991002

28991009

28991002

28991001

28991001

28991001

28991001

28991004

28991004

28991002

28991002

28991002

28991002

28991001

28991009

28991009

28991003

28991003

28991002

28991002

28991002

*Effective 2/15/12, production and service parts will use the 28910302 control board with V1.06 software which is backwards compatible with all previous versions. See Pages 65 for installation and wiring differences.

+ Effective 11/1/11, production and service parts will use the 29326701 Carel pressure regulator and 22592201 harness. See Page 66 for valve identification and Page 63-64 for regulator program settings. V1.06 software is programmed for the Carel valve. Alco may be selected in Expert mode or the parameters may be programmed manually on the previous 28910301 control board.

NOTE: for suction stop and defrost values use the following valve seal kits:

Valve: HRP # 29330301 use Parker #204671

Valve: HRP# 29330401,02,03 use Parker #204670

63

64

Service Record

A permanent data sheet should be prepared on each refrigeration system at an installation, with a copy for the owner and the original for the installing contractor's files.

If another firm is to handle service and maintenance, additional copies should be prepared as necessary.

System Reference Data

The following information should be filled out and signed by Refrigeration Installation Contractor at time of start-up.

Date System Installed: _____________________________________________________

Installer and Address: _____________________________________________________

_____________________________________________________

_____________________________________________________

Condensing Unit

Unit Model#: ________________________________________

Compressor Model #: ____________________ Compressor Model #: _________________

Compressor Serial #: ____________________ Compressor Serial #: __________________

Electrical _________________ Volts __________________ Phase_______

Voltage at Compressor

Amperage at Compressor

L1__________ L2 ___________

L1__________ L2 ___________

Evaporator(s)

Quantity

L3 ___________

L3 ___________

Evaporator Model #: ____________________ Evaporator Model #: __________________

Evaporator Serial #: ____________________ Evaporator Serial #: __________________

Electrical _________________ Volts __________________ Phase _______

Expansion Valve Manufacturer/Model ____________________ _______________________

Ambient at Start-Up _____________________________˚F

Design Box Temperature ______________________˚F _________________________˚F

Operating Box Temperature ______________________˚F

Thermostat Setting ____________________________˚F

Defrost Setting _____ / day

__________________________˚F

__________________________˚F

______ minutes fail-safe ______/day ______minutes fail-safe

Compressor Discharge Pressure _____________________PSIG ____________________PSIG

Compressor Suction Pressure _____________________PSIG ____________________PSIG

Suction Line Temperature @ Comp. ______________________˚F ______________________˚F

Discharge Line Temperature @ Comp. ____________________˚F ______________________˚F

Superheat at Compressor _____________________˚F ______________________˚F

Suction Line Temperature @ Evaporator ___________________˚F ______________________˚F

Superheat at Evaporator _____________________˚F ______________________˚F

Evacuation: # times _______ Final Micron_______ # Times ________ Final Micron_______

Evaporator Drain Line Trapped Outside of Box: yes no

65

Factory Default Settings

M6

M6

M6

M6

M6

M6

M6

M6

M6

MODEL REFRIG

M2

M2

M2

M2

M2

M2

M2

M2

M2

M2

M6

M6

M6

M6

M6

M6

M6

M6

M6

M6

M6

R22

R22

R22

R22

R22

R22

R22

R22

R22

R22

R404A

R404A 802 190

R404A 1002 190

R404A 1202 190

R404A 1502 190

R404A 2002 190

R404A 2502 190

R404A 3002 190

R404A 3502 190

R404A 4002 190

R507

752,

762

195

SIZE

752,

762

155

802 155

1002 155

1202 155

Fan Cycle Settings (Liquid Pressure, PRES), psig DFT 1

Fan 1 Fan 2 Fan 3 Fan 4 Fan 1 Fan 2 Fan 3 Fan 4 DFT 2 DEFP

ON ON ON ON OFF OFF OFF OFF °F psig

170

170

170

170

---

---

---

---

---

---

---

---

110

110

110

110

145

145

145

145

---

---

---

---

---

---

---

---

85

85

85

85

210

210

210

210

1502 155

2002 155

2502 155

3002 155

3502 155

4002 155

752,

762

190

170

170

170

170

170

170

205

---

---

180

180

180

180

---

---

---

---

---

---

195

---

110

110

110

110

110

110

135

145

145

145

145

145

145

175

---

---

155

155

155

155

---

---

---

---

---

170

---

85

85

85

85

85

85

85

210

210

210

210

210

210

210

205

205

205

205

205

205

205

205

205

210

---

---

---

---

---

220

220

220

220

---

---

---

---

---

---

---

---

---

235

---

135

135

135

135

135

135

135

135

135

140

175

175

175

175

175

175

175

175

175

180

---

---

---

---

---

190

190

190

190

---

---

---

---

---

---

---

---

---

205

--85 210

85

85

85

85

85

85

85

85

85

210

210

210

210

210

210

210

210

210

M6

M6

M6

M6

M6

M6

M6

M6

M6

R507 802 195

R507 1002 195

R507 1202 195

R507 1502 195

R507 2002 195

R507

R507

R507

2502

3002

3502

195

195

195

R507 4002 195

R407A

R407A

752,

762

802

190

190

R407A

R407A

R407A

1002

1202

1502

190

190

190

R407A 2002 190

R407A 2502 190

R407A 3002 190

R407A 3502 190

210

210

210

210

210

210

210

210

210

205

205

205

205

205

205

205

205

205

---

---

---

---

---

225

225

225

225

---

---

220

220

220

---

---

---

---

---

---

---

---

---

---

---

---

245

---

---

---

---

---

---

---

---

---

140

140

140

140

140

140

140

140

140

135

135

135

135

135

135

135

135

135

180

180

180

180

180

180

180

180

180

175

175

175

175

175

175

175

175

175

---

---

---

---

---

195

195

195

195

---

---

190

190

190

---

---

---

---

---

---

---

---

---

---

---

---

210

---

---

---

---

---

---

---

---

---

85

85

85

85

85

85

85

85

85

210

210

210

210

210

210

210

210

210

85

85

85

85

85

85

85

85

85

210

210

210

210

210

210

210

210

210

DEFT

Min.

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

EQUT

Min.

2

LPSH LPSL psig psig

16 6

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

24

24

24

24

24

24

24

24

24

26

16

16

16

16

16

16

16

16

16

24

10

10

10

10

10

10

10

10

10

11

6

6

6

6

6

6

6

6

6

10

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

26

26

26

26

26

26

26

26

26

15

15

15

15

15

15

15

15

15

11

11

11

11

11

11

11

11

11

3

3

3

3

3

3

3

3

3

35

35

35

35

35

35

35

35

35

35

35

35

35

35

35

35

35

35

35

35

35

35

35

35

35

35

35

35

35

35

35

35

35

35

35

35

35

35

FZET FZTM

°F Min.

35 4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

CAREL ALCO

PRFS

320

PRFS PRUI

300 15

410

470

510

550

320

350

380

570

590

320

410

470

510

550

320

350

380

570

590

320

380

440

520

600

300

320

340

700

780

300

380

440

520

600

300

320

340

700

780

300

15

15

17

20

23

25

15

15

15

15

15

15

17

20

23

25

15

15

15

15

410

470

510

320

350

380

550

570

590

320

470

510

550

570

320

350

380

410

380

440

520

300

320

340

600

700

780

300

440

520

600

700

300

320

340

380

15

15

17

15

15

15

20

23

25

15

15

17

20

23

15

15

15

15

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

DFIO

100

100

100

100

100

100

100

100

100

100

100

66


M6

M6

M6

M6

M6

M6

M6

M6

M6

L6

L6

L6

L6

L6

L6

L6

L6

L6

L6

L6

L6

L6

L6

M6

L6

L6

L6

L6

M6

M6

M6

M6

M6

M6

M6

M6

MODEL REFRIG

M6

SIZE

Fan Cycle Settings (Liquid Pressure, PRES) , psig DFT 1


ON

R407A 4002 190

ON

205

ON

220

ON

235

OFF

135

OFF

175

OFF

190

OFF

205

°F

85 psig

210

M6

M6

R507

R507

R507

R507

R507

R407C

752,

762

180

R407C 802 180

R407C 1002 180

R407C 1202 180

R407C 1502 180

R407C 2002 180

R407C

R407C

R407C

R407C

R407F

R407F 802 200

R407F 1002 200

R407F 1202 200

R407F

R407F

R407F

R407F

R407F

R407F 4002 200

R404A 602 190

R404A 752

R404A 902

190

190

R404A 1002 190

R404A

R404A

R404A

R404A

R404A

R507

R507

R507

R507

2502

3002

3502

4002

752,

762

1502

2002

2502

3002

3502

1202

1502

2202

2702

3002

602

752

902

1002

1202

1502

2202

2703

3002

180

180

180

180

200

200

200

200

200

200

190

190

190

190

190

195

195

195

195

195

195

195

195

195

195

195

195

195

195

195

195

195

195

195

215

210

210

210

210

210

210

210

210

210

205

205

205

205

205

215

205

205

205

205

215

215

215

215

215

215

215

215

---

---

---

---

---

---

210

210

210

210

---

---

---

---

---

---

230

230

230

230

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

225

---

---

---

---

---

---

---

---

---

250

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

130

130

130

130

130

130

130

130

130

130

145

145

145

145

145

145

145

145

145

145

135

135

135

135

135

135

135

135

135

140

140

140

140

140

140

140

140

140

165

165

165

165

165

165

165

165

165

165

185

185

185

185

185

185

185

185

185

185

175

175

175

175

175

175

175

175

175

180

180

180

180

180

180

180

180

180

---

---

---

---

---

---

180

180

180

180

---

---

---

---

---

---

200

200

200

200

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

195

---

---

---

---

---

---

---

---

215

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

85

75

75

75

75

75

85

75

75

75

75

180

180

180

180

180

215

180

180

180

180

85

85

85

85

85

85

85

85

215

215

215

215

215

215

215

215

85

85

85

85

85

85

85

85

85

85

210

210

210

210

210

210

210

210

210

210

215

75

75

75

75

75

75

75

75

75

180

180

180

180

180

180

180

180

180

DEFT EQUT

Min.

Min.

25 2

25 2

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

25

25

25

25

25

25

25

25

25

25

2

2

2

2

2

2

2

2

2

2


15 3

12 1

FZET

°F

35

35

12

12

12

12

12

12

12

12

12

16

10

10

10

10

10

16

10

10

10

10

16

16

16

16

16

16

16

16

11

11

11

11

11

11

11

11

11

1

1

1

1

1

1

1

1

1

4

2

2

2

2

2

2

2

2

2

2

4

2

2

4

4

4

4

4

4

4

4

2

2

2

2

2

2

35

35

35

35

35

35

35

35

35

35

30

30

30

30

30

30

30

30

35

30

30

30

30

35

35

35

35

35

35

35

35

30

30

30

30

30

30

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

CAREL ALCO

FZTM

Min.

4

4

PRFS

590

320

PRFS PRUI

780 25

300 15

510

550

570

590

320

350

380

410

470

320

450

480

540

560

580

320

350

400

590

320

350

400

410

410

470

510

550

570

320

350

380

410

450

480

540

560

580

520

600

700

780

300

320

340

380

440

300

420

460

580

660

720

300

320

360

780

300

320

360

380

380

440

520

600

700

300

320

340

380

420

460

580

660

720

17

20

23

25

15

15

15

15

15

15

15

16

19

22

23

15

15

15

25

15

15

15

15

15

15

17

20

23

15

15

15

15

15

16

19

22

23

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

DFIO

100

100


M6

L6

L6

L6

L6

L6

L6

L6

L6

L6

L6

M6

M6

M6

L6

L6

M6

M6

M6

M6

M6

L6

L6

L6

L6

L6

L6

L6

L6

L6

M6

M6

M6

M6

M6

M6

M6

M6

M6

M6

MODEL REFRIG

M6 R448A

SIZE




752,

762

195 210 ----140 180 ----85 215

CAREL ALCO

DEFT EQUT

Min.

Min.


FZET

°F

FZTM

Min.

PRFS PRFS PRUI DFIO

25 2 26 10 35 4 320 300 15 100

R448A 802 195

R448A 1002 195

R448A 1202 195

R448A 1502 195

R448A 2002 195

R448A 2502 195

R448A 3002 195

R448A 3502 195

R448A 4002 195

R449A

752

762

195

R449A 802 195

R449A 1002 195

R449A 1202 195

R449A 1502 195

R449A 2002 195

R449A 2502 195

R449A 3002 195

R449A 3502 195

R449A 4002 195

R448A 602 195

R448A 752 195

R448A 902 195

R448A 1002 195

R448A 1202 195

R448A 1502 195

R448A 2202 195

R448A 2702 195

R448A 3002 195

R449A 602

R449A 752

R449A 902

195

195

195

R449A 1002 195

R449A 1202 195

R449A 1502 195

R449A 2202 195

R449A 2702 195

R449A 3002 195

R407A 602 190

R407A 752

R407A 902

190

190

210

210

210

210

210

210

210

210

210

210

---

225

225

225

---

---

---

---

225

---

---

---

---

---

---

---

---

---

---

---

---

225

225

225

---

---

---

---

---

---

225

---

---

---

---

---

---

---

---

---

210

210

210

210

210

210

210

210

210

210

210

210

210

210

210

210

210

210

210

210

210

210

205

205

205

210

210

210

210

210

---

---

---

240

---

---

---

---

---

---

140

140

140

140

140

140

140

140

140

140

140

140

140

140

140

140

140

140

140

140

140

140

140

140

140

140

140

140

140

140

140

140

135

135

135

140

140

140

140

140

---

---

---

---

---

---

---

---

---

---

---

---

---

240

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

195

195

195

---

---

---

---

195

---

180

180

180

180

180

180

180

180

180

180

---

---

---

---

---

---

---

---

---

---

---

195

195

195

---

---

---

---

---

---

195

---

---

---

---

---

---

---

---

---

180

180

180

180

180

180

180

180

180

180

180

180

180

180

180

180

180

180

180

180

180

180

175

175

175

180

180

180

180

180

---

---

---

---

---

---

---

---

---

---

---

---

---

210

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

210

---

---

---

---

---

---

215 25 2 26

10

10

10

10

10

10

10

10

10

10

26

26

26

26

10

26

26

26

26

26

7

7

10

7

10

10

10

10

10

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

215

215

215

215

215

215

215

215

215

215

215

215

215

215

215

215

215

215

215

215

215

210

210

210

215

215

215

215

215

85

85

85

85

85

85

85

85

85

85

85

75

75

75

75

75

75

75

75

75

75

85

85

85

75

75

85

85

85

85

85

75

75

75

75

75

75

75

75

75

215

215

215

215

215

215

215

215

215

215

25

25

25

25

25

25

25

25

25

25

2

2

2

2

2

2

2

2

2

2

26

26

26

26

26

26

26

26

26

26

10

10

10

10

10

10

10

10

10

10

10 35

30

30

30

30

30

30

30

30

30

30

35

35

35

30

30

35

35

35

35

35

30

30

30

30

30

30

30

30

30

2

2

2

2

2

2

2

2

2

2

10

10

10

2

2

10

10

10

10

10

2

0

2

2

0

0

2

2

2

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

35

35

35

35

35

35

35

35

35

35

4

4

4

4

4

4

4

4

4

4

320

510

550

570

320

350

380

410

470

590

300

520

600

700

300

320

340

380

440

780

15

22

23

15

15

15

15

15

15

16

19

20

23

25

15

15

15

15

15

15

17

19

22

23

15

15

15

15

15

16

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

15

20

23

25

15

15

15

15

17

15

100

100

100

100

100

100

100

100

100

100

300

580

660

720

300

320

320

360

380

420

460

520

600

700

780

300

300

320

340

380

440

460

580

660

720

360

380

420

300

320

320

540

560

580

320

350

350

400

410

450

480

510

550

570

590

320

320

350

380

410

470

480

540

560

580

400

410

450

320

350

67


L6

L6

L6

L6

L6

L6

L6

L6

L6

L6

L6

L6

L6

L6

L6

L6

L6

L6

L6

L6

L6

L6

L6

MODEL REFRIG

L6

SIZE




R407A 1002 190 205 ----135 175 ----75 210

R407A 1202 190

R407A 1502 190

R407A 2202 190

R407A 2702 190

R407A 3002 190

R407C 602 180

R407C 752 180

R407C 902 180

R407C 1002 180

R407C 1202 180

R407C 1502 180

R407C 2202 180

R407C 2702 180

R407C 3002 180

R407F 602 200

R407F 752 200

R407F 902 200

R407F 1002 200

R407F 1202 200

R407F 1502 200

R407F 2202 200

R407F 2702 200

R407F 3002 200

195

195

215

215

215

215

215

195

195

195

215

215

215

215

205

205

195

195

205

205

205

195

195

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

130

130

145

145

145

145

145

130

130

130

145

145

145

145

135

135

130

130

135

135

135

130

130

165

165

185

185

185

185

185

165

165

165

185

185

185

185

175

175

165

165

175

175

175

165

165

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

---

75

75

75

75

75

75

75

75

75

75

75

75

75

75

75

75

75

75

75

75

75

75

75

210

210

215

215

215

215

215

210

210

210

215

215

215

215

210

210

210

210

210

210

210

210

210

7

7

7

7

7

7

7

7

7

7

7

7

7

7

7

7

7

7

7

7

7

7

7


7 0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

DEFT EQUT

Min.

Min.

25 2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

CAREL ALCO

FZTM

Min.

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

FZET

°F

30

30

30

30

30

30

30

30

30

30

30

30

30

30

30

30

30

30

30

30

30

30

30

30

PRFS PRUI

380 15

420

460

360

380

420

460

580

580

660

720

300

320

660

720

420

720

300

320

460

580

660

360

380

15

16

15

15

15

16

19

19

22

23

15

15

22

23

15

23

15

15

16

19

22

15

15

PRFS

410

450

480

400

410

450

480

540

540

560

580

320

350

560

580

450

580

320

350

480

540

560

400

410

DFIO

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

100

DEFP- Defrost Termination Pressure

DEFT- Defrost Failsafe Time

EQUT- Equalizing Time

LPSH- LPS Cut In

LPSL- LPS Cut Out

FZET- Evap. Refreeze Temp

FZTM- Evap. Refreeze Max. Time

**Drawing 29326701 indicates, " Valve has been qualified by Heatcraft for a minimum room temperature of -30C (-22F) and a minimum refrigerant temperature of -35C (-31F)

***Suction Pressure Transducer, 28911202, (0-300 psia)

68

Mohave Control Board Comparison

FIRST GENERATION HRP# 28910301 SECOND GENERATION HRP# 28910302

No Terminal Block

Note: Screws must be tight to provide grounding.

Redundant Low Pressure Switch Terminals ( REMOTE DEFR & C )

Redundant Low Pressure Switch Terminals ( SEPARATE TERMINAL BLOCK )

Service Part Note: Review wiring and mounting differences when replacing a First Gen Board with a Second Gen Board.

69

Electronic Pressure Regulator Comparison

70

SEE PAGE 39 OF INSTALLATION MANUAL FOR LOCATION OF PRESSURE

REGULATOR IN CONDENSING UNIT. DETERMINE THE MANUFACTURER

BASED UPON THIS PICTORIAL

Heatcraft Mohave Control Modbus Definitions

Heatcraft Mohave Control

ModBus Definitions

Rev. 17

10/4/2016

NOTE: For this device, ModBus message frames must be no larger that 256 bytes

NOTE: For ModBus commands, temperatures are always degrees F, pressures are always psia, and times are always 24-hour HHMM

Discrete Inputs -

CMD 0x02 (Read)

"Enter" pushbutton

"Clear/Test" pushbutton

"Program Review" pushbutton

"Force Service" pushbutton

"Monitor" pushbutton

"Force Defrost" pushbutton

"Reset Time" pushbutton

Service Switch contacts

Safety Switch contacts

CU Suction Pressure switch contacts

T-Stat contacts

BeaconII I/F current sense

Remote Defrost switch contacts

Coils -

CMD 0x01 (Read), CMD 0x05 (Single Write)

CMD 0x0F (Multiple Write)

Beacon "Low Pressure Switch" output

Evaporator Heater relay

Liquid Line Solenoids relay

Evaporator Fan relay

Condenser Fan 4 relay




Alarm relay

Compressor relay

Bypass Valve relay

Suction Solenoid relay

Defrost Solenoid relay

3-Way Valve relay

Input Address Byte Addr.

9

10

7

8

11

12

2

3

0

1

4

5

6

1

1

0

1

1

1

0

0

0

0

0

0

0

Bit Addr.

1

2

7

0

3

4

2

3

0

1

4

5

6

Coil Address Byte Addr.

Bit Addr.

3

4

5

6

7

8

0

1

2

9

10

11

12

13

0

0

0

0

0

1

0

0

0

1

1

1

1

1

3

4

5

6

7

0

0

1

2

3

4

1

2

5

Input Registers -

CMD 0x04 (Read)

Suction Temperature (-55 to +125 degrees F)

Ambient Temperature (-55 to +125 degrees F)

Auxilliary Temperature (-55 to +125 degrees F)

Data Type

Word, signed

Word, signed

Word, signed

Word Addr.

0

1

2

Label

SucT

AMBT

AUXT

71

72

Mohave Hot Gas Control Modbus Definitions

Suction Pressure (0 to 300 psia), displayed as 30" Hg to 285 psig

Liquid Pressure (0 to 500 psia), displayed as 30" Hg to 485 psig

Evap 1 Defrost Temp (-55 to +125 degrees F)

Evap 2 Defrost Temp (-55 to +125 degrees F)

Saturated Suction Temp (-55 to +125 degrees F)

Suction Superheat (-128 to +127 degrees F)

Regulator Valve position (0 to 820 steps)

AC input voltage (0 to 315 volts*10), e.g. 243 = 24.3 Vac

SELECT control position (0=full CCW to 255=full CW)

Errors (bit-packed):

0x0001 CU Suction Temperature sensor error

0x0002 CU Ambient Temperature sensor error

0x0004 CU Aux Temperature sensor error

0x0008 CU Suction Pressure sensor error

0x0010 CU Liquid Pressure sensor error

0x0020 Evaporator #1 Defrost Temperature sensor error

0x0040 Evaporator #2 Defrost Temperature sensor error

0x0080 CU Suction Pressure switch error

0x0100 Safety Circuit shut-down error

0x0200 Prolonged low suction pressure shut-down error

0x0400 Low-pressure start-up error

0x0800 High-pressure start-up error

0x1000 Defrost pump-down error

(0x2000 to 0x8000 not used)

Alarms (bit-packed):

0x0001 Persistent input sensor failure alarm

0x0002 CU Suction Pressure sensor & switch failure alarm

0x0004 repeated safety circuit open condition alarm

0x0008 Persistent low- or high-pressure startup failure alarm

0x0010 High CU Aux (Room) Temperature alarm

0x0020 Low CU Aux (Room) Temperature alarm

(0x0040 to 0x8000 not used)

Software Version (RRrr - MAJOR.minor revision); e.g. 107 = 1.07

Operating Mode (0=Off, 1=Delay, 2=Cooling, 3=Pump-Down, 4=Defrost1,

5=Defrost2, 6=Defrost3, 7=DefrostA, 8=Re-Freeze, 9=Test, 10=Service)

Status/Configuration (bit-packed):

0x0001 Displayed temperature units (0=degrees F, 1=degrees C)

0x0002 Displayed time mode (0=12 hour, 1=24 hour)

0x0004 Application Type (0=Low temp, 1=Medium temp)

0x0008 Evaporator fan mode if not cooling (0=off, 1=on)

0x0010 Expert mode (0=off, 1=on)

0x0020 Parameter lock mode (0=unlocked, 1=locked)

0x0040 Service mode configured (0=off, 1=on)

0x0080 CU Aux Room Temperature control (0=off, 1=on)

0x0100 CU Aux Temperature sensor attached (0=no, 1=yes)

0x0200 Evaporator #2 temperature sensor attached (0=no, 1=yes)

0x1000 Remote control (0=off, 1=on)

0x2000 Error status (0=no errors, 1=one or more errors detected)

0x4000 Alarm status (0=no alarms, 1=one or more alarms detected)

(0x0400, 0x0800, 0x8000 not used)

Word

Word

Word, signed

Word, signed

Word, signed

Word, signed 8

Word 9

Word 10

Word 11

Word 12

5

6

3

4

7

Word

Word

Word

Word

SucP

LIQP

E1DT

E2DT

SSuc

SUPH

VALP

ACIN

13

Alr1

Alr2

Alr3

Alr4

Alr5

Alr6

14

15

VERS

OFF DELY

COOL PUMP

DEF1 DEF2

DEF3 DEFA

FREZ TEST

SERV

16

Err1

Err2

Err3

Err4

Err5

Err6

Err7

Err8

Err9

Er10

Er11

Er12

Er13

XPRT

Heatcraft Mohave Control Modbus Definitions

Last elapsed defrost time (minutes)

Compressor cycles since midnight (0 to 255)

Run time since midnight (0000 to 2359 HHMM)

Elapsed time since last defrost (00000 to 25559 HHHMM)

Run time since last defrost (00000 to 25559 HHHMM)

Word

Word

Word

Word

Word

17

18

19

20

21

DFTM

CCYC

RnTM

ETLD

RTLD

Holding Registers -

CMD 0x03 (Read), CMD 0x06 (Single Write)

CMD 0x10 (Multiple Write)

Data Type revised

Display Right char. (7-bit ASCII + 0x80 DP)

Display Ctr-Right char. (7-bit ASCII + 0x80 DP)

Display Ctr-Left char. (7-bit ASCII + 0x80 DP)

Display Left char. (7-bit ASCII + 0x80 DP)

Word

Word

Word

Word

Time of Day (0000 to 2359 HHMM) Word

Pressure Regulator setpoint (0 to 820 steps) Word

Refrigerant Type (0=R-22, 1=R-404A, 2=R-507, 3=R-407A, 4=R-407C,

5=R-407F, 6=R-448A, 7=R-449A)

Word

Application Type (0=Low temp, 1=Medium temp)

Model Number (500 to 5000)

Displayed temperature units (0=degrees F, 1=degrees C)

Displayed time mode (0=12 hour, 1=24 hour)

Evaporator fan mode if not cooling (0=off, 1=on)

Parameter lock mode (0=unlocked, 1=locked)

Number of evaporators (1 or 2)

Evaporator #1 defrost termination temp (+50 to +100 degrees F)

Evaporator #2 defrost termination temp (+50 to +100 degrees F)

Defrost termination pressure (175 to 315 psia), displayed as 160 to 300 psig

Defrost override time limit (5 to 30 minutes)

Alarm condition duration (2 to 120 minutes)

Pressure Regulator full scale (100 to 820 steps)

Equalization time (1 to 10 minutes)

Low Pressure Switch high limit (15 to 45 psia), displayed as 0 to 30 psig

Low Pressure Switch low limit (15 to 45 psia), displayed as 0 to 30 psig

Evaporator re-freeze temperature threshold (+20 to +40 degrees F)

Normal valve update interval (10 to 30 seconds)

Initial defrost Pressure Regulator opening (50 to 100%)

Evaporator re-freeze time limit (0 to 10 minutes)

Cooling mode LLS Pulsing time limit (0 to 15 minutes)

ESV/PR valve manufacturer (0=Carel or 1=Alco)

CU Aux Room Temperature control (0=off, 1=on)

CU Aux Room Temperature setpoint (-25 to +50 degrees F)

High CU Aux Temp Alarm threshold (-35 to +100 degrees F), +127 if disabled

Low CU Aux Temp Alarm threshold (-35 to +100 degrees F), -128 if disabled

Run-time defrost interval (0030 to 1200 HHMM), 0000 if disabled

Defrost #1 start time (0000 to 2330 HHMM), 2530 if not used







Word

Word

Word

Word

Word

Word

Word

Word, signed

Word, signed

Word

Word

Word

Word

Word

Word

Word

Word, signed

Word

Word

Word

Word

Word

Word

Word, signed

Word, signed

Word, signed

Word

Word

Word

Word

Word

Word

Word

Word

Word Addr.

Label

22

23

24

25

26

27

28

29

30

31

32

11

12

13

14

15

16

9

10

7

8

17

18

19

20

21

33

34

35

36

37

38

39

40

2

3

0

1

4 CLKH CLKM

5

6

REFR

APPL

MODL

øFøC

1224

EVPF

LPSL

FZET

PRUI

DFIO

FZTM

LLSP

VALM

AUXT

BOXT

ALRH

ALRL

RTDF

DFT1

DFT2

DEFP

DEFT

ALRT

PRFS

EQUT

LPSH

DF01

DF02

DF03

DF04

DF05

DF06

DF07

73

74

Mohave Hot Gas Control Modbus Definitions






Number of CU fans (1 to 4)

CU Fan #1 mode (0=off, 1=on, 2=press. ctl., 3=temp. ctl.)




CU Fan #1 On pressure (125 to 315 psia), displayed as 110 to 300 psig




CU Fan #1 Off pressure (125 to 315 psia), displayed as 110 to 300 psig




CU Fan #1 On temperature (+30 to +90 degrees F)




CU Fan #1 Off temperature (+30 to +90 degrees F)




(not used)

Remote Control (0xAA55=activate, 0xFF00=deactivate)

NOTE: The Write Remote Control command with a data value of 'activate'

is ignored unless the Mohave Control is in "Off" or "Service" modes

Word

Word

Word

Word

Word

Word

Word

Word

Word

Word

Word

Word

Word

Word

Word

Word

Word

Word

Word, signed

Word, signed

Word, signed

Word, signed

Word, signed

Word, signed

Word, signed

Word, signed

---

Word

64

65

66

67 to 7999

8000

60

61

62

63

49

50

51

52

53

54

55

56

57

58

59

44

45

46

47

48

41

42

43

DF08

DF09

DF10

DF11

DF12

F1OF

F2OF

F3OF

F4OF

F1ON

F2ON

F3ON

F4ON

F1OF

F2OF

F3OF

F4OF

FAN1

FAN2

FAN3

FAN4

F1ON

F2ON

F3ON

F4ON

Diagnostic -

CMD 0x08 (Read/Write)

Restart communications

Clear Counters and Diagnostic Register

Read Bus Message Counter

Read Bus Communication Error Counter

Read Bus Exception Error Counter

Read Slave Message Counter

Read Slave No Response Counter

Read Slave NAK Counter

Read Slave Busy Counter

Read Bus Character Overrun Counter

Clear Overrun Counter and Flag

Activate Remote Control mode

Deactivate Remote Control mode

NOTE: The Activate Remote Control command is ignored

unless the Mohave Control is in "Off" or "Service" modes

Sub-Function

0x01

0x0A

0x0B

0x0C

0x0D

0x0E

0x0F

0x10

0x11

0x12

0x14

0xAA55

0xFF00

Notes

75

Since product improvement is a continuing effort, we reserve the right to make changes in specifications without notice.

Heatcraft Refrigeration Products LLC

2175 West Park Place Blvd. • Stone Mountain, GA 30087

770-465-5600 • Fax: 770-465-5990 • www.heatcraftrpd.com

H-IM-HGD0221 | Version 002

Heatcraft Mohave Advanced Hot Gas Defrost System Installation and Operation Manual 76 Pages

Heatcraft Mohave Advanced Hot Gas Defrost System Installation and Operation Manual

Mohave Hot Gas Defrost

Installation

& Operation

Installation, Start-Up, Operation and

Troubleshooting with Wiring Diagrams

Controller Quick Reference Guide

Receiving and Inspection

Installation

Operation

Control Buttons

Service Switch

Operating Modes

MODE

DESCRIPTION

Compressor Off

Compressor On in Cooling Normal Cooling Operation

System in Pump Down Mode

Service Mode, System is Off

Time Delay

Defrost Stage 1

Pre-Defrost or ByPass Mode

Defrost Stage 2

Defrost Mode

Defrost Stage 3

Post Defrost Equalization or Drain Down Mode

Refreeze Mode

Test Mode

Service Mode

Evacuation Mode

Program Review Menu

DISPLAY

*

**

DESCRIPTION

Set the Time of Day clock hour value

Set the Time of Day clock minute value

Set Fahrenheit or Celsius temperature units (°F or °C)

Set Time display method (12 hr. or 24 hr.)

Set the Alarm Time (2 to 120 minutes)

FACTORY

DEFAULT

None

None

°F

12 hr

20 min

Defrost Schedule based on Compressor Runtime

Set Defrost 1 starting time (12:00 am to 12:00 pm in 30 minute increments)

Set Defrost 2 starting time

Set Defrost 3 starting time

OFF

12:00AM

6:00AM

12:00PM

Set Defrost 4 starting time

Set Defrost XX starting time

6:00PM

--- ---

Set Application type (Med., Low) Med Temp

Set Refrigerant type (R-22, R-404A, R-507, R-407A, R-407C, R-407F, R-448A and R-449A)” R-404A

Set Model Number 1502

Expert Mode (To Access Additional Program Parameters (On, Off) Off

Monitor Display Menu

DISPLAY

DESCRIPTION

Defrost Regulator Valve percent of opening (0 to 100%)

Superheat (°F.) measured at inlet of Suction Accumulator

Suction Temperature (°F.) at inlet of Suction Accumulator

Suction Pressure (PSIG/”HG) at inlet of Suction Accumulator

Saturated Suction Temperature (°F.) at inlet of Suction Accumulator

Liquid Pressure (PSIG) measured between Receiver and Condenser

Ambient Air Temperature (°F.) measured entering condenser coil

Auxiliary Probe Temperature (°F.)

Evaporator 1 Defrost Sensor Termination Temp (°F.) at outlet of Evaporator 1

Evaporator 2 Defrost Sensor Termination Temp (°F.) at outlet of Evaporator 2

Control Board voltage (24VAC nominal)

Current time minutes and seconds

Current time hours and minutes