Mohave Hot Gas Defrost

Installation
& Operation
H-IM-HGD0 FEBRUARY 2021 Part Number 25007401
Replaces June 2017

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
Condensate Lines.................................................................................... 10
Condensing Unit Installation
Rigging ............................................................................................... 11
Field Piping Guidelines.........................................................................12-24
Optional Controls................................................................................25-26
System Wiring....................................................................................27-39
Operation
Hot Gas Unit Cooler Typical Factory Piping............................................................... 40
Hot Gas Condensing Unit Typical Factory Piping........................................................ 41
Refrigeration Operation....................................................................................42-43
Defrost Operation...............................................................................44-47
Evacuation & Leak Detection................................................................................. 48
Check Out & Start-Up........................................................................................... 49
Program Review.................................................................................50-51
Monitoring & Reviewing Operation Values................................................................ 52
Error and Alarm Details......................................................................................... 53
Refrigerant Charging........................................................................................54-55
Operational Check Out.......................................................................................... 56
Refrigeration Oils..................................................................................... 57
Troubleshooting..................................................................................58-60
Preventive Maintenance...................................................................................61-62
InterLink Service Parts.......................................................................................... 63
Service Record....................................................................................... 64
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
 Controller Quick Reference Guide
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 Reset
Review Enter Monitor Time
Control Buttons

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/ Selection Force Force
Test Knob Service Defrost
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.

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 DESCRIPTION
OFF Compressor Off
COOL Compressor On in Cooling Normal Cooling Operation
PMPD System in Pump Down Mode
SERV Service Mode, System is Off
DELY Time Delay
DEF1 Defrost Stage 1
Pre-Defrost or ByPass Mode
DEF2 Defrost Stage 2
Defrost Mode
DEF3 Defrost Stage 3
Post Defrost Equalization or Drain Down Mode
FREZ Refreeze Mode
TEST Test Mode
SERV Service Mode
EVAC Evacuation Mode

3
 Controller Quick Reference Guide
Program Review Menu

DISPLAY DESCRIPTION FACTORY

DEFAULT
CLKH Set the Time of Day clock hour value None
CLKM Set the Time of Day clock minute value None
°F °C Set Fahrenheit or Celsius temperature units (°F or °C) °F
1224 Set Time display method (12 hr. or 24 hr.) 12 hr
ALRT Set the Alarm Time (2 to 120 minutes) 20 min
RTDF* Defrost Schedule based on Compressor Runtime OFF
DF01 Set Defrost 1 starting time (12:00 am to 12:00 pm in 30 minute increments) 12:00AM
DF02 Set Defrost 2 starting time 6:00AM
DF03 Set Defrost 3 starting time 12:00PM
DF04 Set Defrost 4 starting time 6:00PM
DF05-DF12 Set Defrost XX starting time --- ---
APPL** Set Application type (Med., Low) Med Temp
REFR Set Refrigerant type (R-22, R-404A, R-507, R-407A, R-407C, R-407F, R-448A and R-449A)” R-404A
MODL Set Model Number 1502
XPRT Expert Mode (To Access Additional Program Parameters (On, Off) Off
(See Program Review Section for additional information) *Software V1.04 and higher.
**Menu re-ordered Software V2.05 and higher

Monitor Display Menu

DISPLAY DESCRIPTION
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.) at inlet of Suction Accumulator
LIQP Liquid Pressure (PSIG) measured between Receiver and Condenser
AMBT Ambient Air Temperature (°F.) measured entering condenser coil
AUXT Auxiliary Probe Temperature (°F.)
E1DT Evaporator 1 Defrost Sensor Termination Temp (°F.) at outlet of Evaporator 1
E2DT Evaporator 2 Defrost Sensor Termination Temp (°F.) at outlet of Evaporator 2
ACIN Control Board voltage (24VAC nominal)
TMMS Current time minutes and seconds
TMHM Current time hours and minutes
CCYC Compressor Cycles since Midnight
RnTM Compressor Run Time since Midnight
DFTM Duration Time of Last Defrost
ETLD Elapsed Time since last Defrost (HH.MM)
RTLD Run Time since last Defrost (HH.MM)
VERS Software version
4
 Controller Quick Reference Guide
Forced Output Menu
DISPLAY DESCRIPTION
EVPF Evaporator Fan Contactor
LIQS Liquid Line Solenoid
EVPH Evaporator Pan Heater
FAN4 Condenser Fan 4 Contactor
FAN3 Condenser Fan 3 Contactor
FAN2 Condenser Fan 2 Contactor
FAN1 Condenser Fan 1 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 Activate all Solenoids, Open the Pressure Regulator Valve

System Alarms

DISPLAY DESCRIPTION
Alr1 Persistent input sensor/transducer failure
Alr2 Combines Err4 and Err8, system off
Alr3 Repeated Safety Circuit Open condition
Alr4 Prolonged Cooling Startup Failure

System Errors
DISPLAY DESCRIPTION
Err1 Suction temperature sensor open or short
Err2 Ambient temp sensor open or short
Err3 Auxiliary temp sensor open or short
Err4 Suction Pressure sensor open or short
Err5 Liquid Pressure sensor open or short
Err6 Evap 1 defrost temp sensor open or short
Err7 Evap 2 defrost temp sensor open or short
Err8 Redundant Low Pressure Switch Malfunction detected
Err9 Safety Circuit interruption during normal operation
Er10 Prolonged Low Suction Pressure during cooling
Er11 Low Suction Pressure startup failure
Er12 High Suction Pressure startup failure
Er13 Post Defrost pump down error
5
 General Safety Information
1. Installation and maintenance to be performed only by 3. Make sure that all field wiring conforms to the requirements
qualified personnel who are familiar with this type of of the equipment and all applicable national and local codes.
equipment.
4. Avoid contact with sharp edges and coil surfaces.
2. Some units are pressurized with dry air or inert gas. They are a potential injury hazard.
All units must be evacuated before charging the system
with refrigerant. 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 the purchaser must submit a proof-of-purchase of a compressor and supply it to
material. Each shipment should be carefully checked against the bill of lading. The Heatcraft Refrigeration Products Warranty Claims for reimbursement.
shipping receipt should not be signed until all items listed on the bill of lading have Seller makes no express warranties except as noted above. All implied warranties
been accounted. Check carefully for concealed damage. Any shortage or damages are limited to the duration of the Express Warranty. Liability for incidental and
should be reported to the delivering carrier. Damaged material becomes the delivering consequential damages is excluded.
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. The forgoing is in lieu of all other warranties, express or implied, notwithstanding the
Heavy equipment should be left on its shipping base until it has been moved to the provisions of the uniform commercial code, the Magnuson-Moss Warranty - Federal
final location. Check the serial tag information with invoice. Report any discrepancies Trade Commission Improvement Act, or any other statutory or common law, federal
to your Heatcraft Refrigeration Products Sales Representative. or state.

SELLER makes no warranty, express or implied, of fitness for any particular purpose,
Warranty Statement or of any nature whatsoever, with respect to products manufactures or sold by seller
Seller warrants to its direct purchasers that products, including Service Parts, hereunder, except as specifically set forth above and on the face hereof. It is expressly
manufactured by SELLER shall be of a merchantable quality, free of defects in understood and agreed that SELLER shall not be liable to buyer, or any customer of
material or workmanship, under normal use and service for a period of one (1) year buyer, for direct or indirect, special, incidental, consequential or penal damages, or
from date of original installation, or eighteen (18) months from date for any expenses incurred by reason of the use or misuse by buyer or third parties of
of shipment by SELLER, whichever first occurs. Any product covered by this order said products. To the extent said products may be considered "consumer products,"
found to Seller’s satisfaction to be defective upon examination at Seller’s factory will at As defined in Sec. 101 of the Magnuson-Moss Warranty - Federal Trade Commission
SELLER’s option, be repaired or replaced and returned to Buyer via lowest common Improvement Act, SELLER makes no warranty of any kind, express or implied, to
carrier, or SELLER may at its option grant Buyer a credit for the purchase price of the "consumers," except as specifically set forth above and on the face hereof.
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 The following conditions should be adhered to when installing this unit to maintain the
hereunder. manufacturers warranty:
(a) System piping must be in accordance with good
SELLER shall have no liability for expenses incurred for repairs made by Buyer refrigeration practices.
except by prior, written authorization. Every claim on account of breach of warranty (b) Inert gas must be charged into the piping during brazing.
shall be made to SELLER in writing within the warranty period specified above – (c) The power supply to the unit must meet the following conditions:
otherwise such claim shall be deemed waived. Seller shall have no warranty obligation A. Three phase voltages must be +/-
whatsoever if its products have been subjected to alteration, misuse, negligence, 10% of nameplate ratings. Single
free chemicals in system, corrosive atmosphere, accident, or if operation is contrary phase must be within +10% or
to SELLER’s or manufacturer’s recommendations, or if the serial number has been -5% of nameplate ratings.
altered, defaced, or removed. B. Phase imbalance cannot exceed 2%.
(d) All control and safety switch circuits must be properly connected
MOTOR COMPRESSORS: according to the wiring diagram.
Motor compressors furnished by SELLER are subject to the standard warranty (e) The factory installed wiring must not be changed without written
terms set forth above, except that motor compressor replacements or exchanges factory approval.
shall be made through the nearest authorized wholesaler of the motor compressor (f) All equipment is installed in accordance with Heatcraft Refrigeration
manufacturer (not at SELLER’s factory) and no freight shall be allowed for Products specified minimum clearances.
transportation of the motor compressor to and from the wholesaler. The replacement (g) Devices not provided by Heatcraft shall not be connected to the
motor compressor shall be identical to the model of the motor compressor being Mohave controller without written factory approval
replaced. Additional charges which may be incurred throughout the substitution of (h)  Refrigerant line runs between condensing unit and evaporator(s) shall
other than identical replacements are not covered by this warranty. An optional, non not exceed 200 ft without written factory approval
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,

6
 System and Components
Condensing Unit
(Vertical Air Discharge Design)

Standard Features:
• Electronic Hot Gas Defrost Controller includes Defrost Initiation and Evaporators
Termination Control, Pressure Fan Cycling for Head Pressure Control, Ambient (Medium Profile & High Profile Unit Coolers)
Fan Cycling Option, Anti-Short Cycling Protection, and Low Pressure Control
• Electronic Pressure Regulator for Defrost Control Standard Features:
• Suction Accumulator • All Components are factory installed and wired
• High Pressure and Redundant Low Pressure Control • Power Supply Independent from Condensing Unit
• Oil Pressure Safety Control • Mounted Fan Control Contactors and Drain Pan Heater Contactors if specified
• High Efficiency Copeland Discus Compressors with POE oil • Four or Six Fins Per Inch Models
• Thermally Protected Permanently Lubricated Ball Bearing Condenser Fan • Mounted TXV and Distributor Nozzle
Motors • Mounted Check Valves
• Electrical Controls located in easily accessible control box with a hinged cover • Mounted Liquid Line Solenoid
• Receivers are sized for sufficient pump down capacity with inlet and outlet • Suction P-Trap
service valves • Thermally Protected Permanently Lubricated Evaporator Fan Motors
• Cabinet is constructed from painted galvanized steel • Mounted Electric Drain Pan Heaters
• Convenient Access Panels for easy servicing to internal components • Insulated Drain Pan (Low Temperature Systems)
• Suction and Discharge Vibration Eliminators
• Separate Sub-cooling Circuit. Optional Features:
• Replaceable Liquid Line Filter Drier • Mounted Hot Gas Drain Pan Loop
• Replaceable Core Suction Filter • Evaporator Powered from Condensing Unit
• 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)

7
 Unit Cooler Installation
Unit Cooler Installation
Most evaporators can be mounted with rod hangers, lag screws, or bolts. Use 5/16" top and the ceiling with an NSF listed sealant and ends of open hanger channels must
bolt and washers or rod for up to 250 pounds, 3/8" for up to 600 pounds and be sealed to prevent accumulation of foreign matter.
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 When locating unit coolers in a cooler or freezer, refer to Figure 1-2 for guidelines.
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

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 Cooler or Freezers where one wall will not Allow sufficient space between rear
satisfactory. accommodate all required evaporators of Unit Cooler and wall to permit free
or where air throw distance must be return of air.
considered.

Elevation view of glass display door cooler or

Baffle freezer. Be sure air discharge blows above, not
directly at doors. Provide baffle if door extends
Glass above blower level.
Display
Door
Cooler or Freezer with Glass Display
Doors

8
 Unit Cooler Installation & Condensate Lines
Unit Coolers (continued)

Recommended Unit Cooler Placement

Some general rules for evaporator placement which must be followed are: Traps on low temperature units must be outside of refrigerated enclosures. Traps
1. The air pattern must cover the entire room subject to freezing temperatures must be wrapped with heat tape and insulated.
2. NEVER locate evaporators over doors
3. Location of aisles, racks, etc. must be known
4. Location relative to compressors for minimum pipe runs NOTE: Always trap single evaporator system drain
5. Location of condensate drains for minimum run. lines individually to prevent humidity migration.

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:

Minimum Unit Clearances

Figure 2. Medium Profile and Large Unit Coolers

NOTE:
W = Total width
of evaporator Two evaporators
coil surface.

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 - 1/4” / FT
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.

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 Another consideration which must be taken is that the unit should be mounted away
upon the location of air-cooled equipment is the provision for a supply of ambient from noise sensitive spaces and must have adequate support to avoid vibration
air to the condenser, and removal of heated air from the condensing unit or remote and noise transmission into the building. Units should be mounted over corridors,
condenser area. Where this essential requirement is not adhered to, it will result in utility areas, rest rooms and other auxiliary areas where high levels of sound are
higher head pressures, which cause poor operation and potential failure of equipment. not an important factor. Sound and structural consultants should be retained for
Units must not be located in the vicinity of steam, hot air or fume exhausts. Corrosive recommendations.
atmospheres require custom designed condensers.

Space and Location Requirements for Condensing Units and Remote Condensers
Walls or Obstructions Multiple Units
The unit should be located so that air may circulate freely and not be For units placed side by side, the minimum distance between units is
recirculated. For proper air flow and access all sides of the unit should be a the width of the largest unit. If units are placed end to end, the minimum
minimum of “W” away from any wall or obstruction. It is preferred that this distance between units is 4 feet.
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.

Units in Pits Decorative Fences

The top of the unit should be level with the top of the pit, and side distance Fences must have 50% free area, with 1 foot undercut, a “W” minimum
increased to “2W”. 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”.
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.

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

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

10
 Condensing Unit Installation
Condensing Unit Rigging and Mounting
Rigging holes are provided on all units. Caution should be exercised when moving Spring Mounted Compressor
these units. To prevent damage to the unit housing during rigging, cables or chains
Compressors are secured rigidly to make sure there is no transit damage. Before
used must be held apart by spacer bars. The mounting platform or base should be
operating the unit, it is necessary to follow these steps:
level and located so as to permit free access of supply air.
a. Remove the upper nuts and washers.
b. Discard the shipping spacers.
Ground Mounting c. Install the neoprene spacers. (Spacers located in the electrical panel or
Concrete slab raised six inches above ground level provides a suitable base. Raising tied to compressor.)
the base above ground level provides some protection from ground water and wind d. Replace the upper mounting nuts and washers.
blown matter. Before tightening mounting bolts, recheck level of unit. The unit should e. Allow 1/16 inch space between the mounting nut/
in all cases be located with a clear space in all directions that is at a minimum, equal washer and the neoprene spacer. See Figure 3 below.
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 Rigid Mounted Compressor
loss of capacity. 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 Refrigerant Pipe Support
The system as supplied by Heatcraft Refrigeration Products, was 1. Normally, any straight run of tubing must be supported in at least two locations
thoroughly cleaned and dehydrated at the factory. Foreign matter may enter the near each end of the run. Long runs require additional supports. The refrigerant
system by way of the evaporator to condensing unit piping. Therefore, care must lines should be supported and fastened properly. As a guide, 3/8 to 7/8 should be
be used during installation of the piping to prevent entrance of foreign matter. 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 2. When changing directions in a run of tubing, no corner should be left
operation of the system. unsupported. Supports should be placed a maximum of 2 feet in each direction
from the corner.
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 3. Piping attached to a vibrating object (such as a compressor or compressor base)
condensing unit or the evaporator. must be supported in such a manner that will not restrict the movement of the
vibrating object. Rigid mounting will fatigue the copper tubing.
The following procedures should be followed:
(a) Do not leave dehydrated compressors or filter driers open to the 4. Do not use short radius ells. Short radius elbows have points of excessive stress
atmosphere. concentration and are subject to breakage at these points.
(b) Use only refrigeration grade copper tubing, properly sealed against 5. Thoroughly inspect all piping after the equipment is in operation and add
contamination. supports wherever line vibration is significantly greater than most of the other
(c) Suction lines should slope 1/4" per 10 feet towards the compressor. piping. Extra supports are relatively inexpensive as compared to refrigerant loss.
(d) Suitable P-type oil traps should be located at the base of each
suction riser to enhance oil return to the compressor.
(e) 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)  When brazing refrigerant lines, an inert gas should
be passed through the line at low pressure to prevent
scaling and oxidation inside the tubing. Dry nitrogen is
preferred.
(g) Use only a suitable silver solder alloy on suction and liquid lines.
(h) 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.
(i) If isolation valves are installed at the evaporator,full port ball valves
should be used.
(j) Do not install liquid/suction line heat exchangers.

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
 Piping

14
 Piping
Unit Cooler Piping
Pipe size example:
Given: -10°F Freezer with one system having (2) evaporators NOTE: This is a line sizing example. Use diagrams on page
13-14 for piping orientation.
• 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).

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): Determine line size 2 (evaporators):
1. Main line from the condensing unit to be sized for the total c apacity (balance) of 1. Line sizing to each evaporator is based on 12,000 BTUH’s and equivalent
the whole system of 24,000 BTUH’s (Table 3 and 3A). run from condensing unit. First evaporator has an 80 ft. run and the second
evaporator has a 95 ft. run.
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. 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. 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. 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
Therefore, total equivalent line run =
adds 6 equivalent feet.
Actual line run 75 feet
4. Actual line run (evap 1) 80 feet
+ (6) 1 1/8" elbows @ 3' 18 feet
+ (5) 7/8" elbows @ 2' 10 feet
+ (1) 1 1/8" tee @ 2' 2 feet
+ (1) 90° turn through tee @ 6' 6 feet
Total equivalent line run 95 feet
Total equivalent line run 96 feet
4. Refer to Table 3A. For 95 total equivalent feet, the suction line size should be 1 Actual line run (evap 2) 95 feet
3/8" and the liquid line stays at 1/2" line.
+ (4) 1 1/8" elbows @ 3' 12 feet
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 Total equivalent line run 107 feet
to the top p-trap.
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*
SUCTION LINE SIZE
SUCTION TEMPERATURE
+40 ˚F +20 ˚F +10 ˚F
System Equivalent Lengths Equivalent Lengths Equivalent Lengths
Capacity
25' 50' 75' 100' 150' 200' 25' 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 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 p laced 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

Receiver to
Expansion Valve
Expansion Valve
25' 50' 75' 100' 150' 200'
3/8 3/8 3/8 3/8 3/8 3/8 1,000
3/8 3/8 3/8 3/8 3/8 3/8 3,000
3/8 3/8 3/8 3/8 3/8 3/8 4,000
3/8 3/8 3/8 3/8 3/8 3/8 6,000
3/8 3/8 3/8 3/8 3/8 3/8 9,000
3/8 3/8 3/8 3/8 3/8 3/8 12,000
3/8 3/8 3/8 3/8 3/8 3/8 15,000
3/8 3/8 3/8 3/8 1/2 1/2 18,000
3/8 3/8 3/8 1/2 1/2 1/2 24,000
3/8 1/2 1/2 1/2 1/2 5/8 30,000
3/8 1/2 1/2 1/2 5/8 5/8 36,000
3/8 1/2 1/2 1/2 5/8 5/8 42,000
1/2 1/2 1/2 5/8 5/8 5/8 48,000
1/2 1/2 1/2 5/8 5/8 5/8 54,000
1/2 1/2 5/8 5/8 5/8 5/8 60,000
1/2 1/2 5/8 5/8 5/8 7/8 66,000
1/2 5/8 5/8 5/8 5/8 7/8 72,000
1/2 5/8 5/8 5/8 7/8 7/8 78,000
1/2 5/8 5/8 5/8 7/8 7/8 84,000
1/2 5/8 5/8 7/8 7/8 7/8 90,000
5/8 5/8 7/8 7/8 7/8 7/8 120,000
5/8 7/8 7/8 7/8 7/8 7/8 150,000
7/8 7/8 7/8 7/8 1 1/8 1 1/8 180,000
7/8 7/8 7/8 7/8 1 1/8 1 1/8 210,000
7/8 7/8 7/8 1 1/8 1 1/8 1 1/8 240,000
7/8 7/8 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

* 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
SUCTION LINE SIZE
SUCTION TEMPERATURE
System
Capacity +20 ˚F +10 ˚F -10 ˚F
BTU/H Equivalent Lengths Equivalent Lengths Equivalent Lengths

25' 50' 75' 100' 150' 200' 25' 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 p laced 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
18
 Line Sizing
Table 2. Recommended Line Sizes for R-448A/R-449A (continued)*

SUCTION LINE SIZE

SUCTION TEMPERATURE
System
Capacity -20 ˚F -30 ˚F -40 ˚F
BTU/H Equivalent Lengths Equivalent Lengths Equivalent Lengths

25' 50' 75' 100' 150' 200' 25' 50' 75' 100' 150' 200' 25' 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 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 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
 Line Sizing
Table 2A. Recommended Line Sizes for R-448A/R-449A
LIQUID LINE SIZE

Receiver to
Expansion Valve
Expansion Valve
25' 50' 75' 100' 150' 200'
3/8 3/8 3/8 3/8 3/8 3/8 1,000
3/8 3/8 3/8 3/8 3/8 3/8 3,000
3/8 3/8 3/8 3/8 3/8 3/8 4,000
3/8 3/8 3/8 3/8 3/8 3/8 6,000
3/8 3/8 3/8 3/8 3/8 3/8 9,000
3/8 3/8 3/8 3/8 3/8 3/8 12,000
3/8 3/8 3/8 3/8 3/8 1/2 15,000
3/8 3/8 3/8 3/8 1/2 1/2 18,000
3/8 3/8 1/2 1/2 1/2 1/2 24,000
3/8 3/8 1/2 1/2 1/2 1/2 30,000
3/8 1/2 1/2 1/2 1/2 1/2 36,000
3/8 1/2 1/2 1/2 1/2 5/8 42,000
1/2 1/2 1/2 1/2 1/2 5/8 48,000
1/2 1/2 1/2 1/2 5/8 5/8 54,000
1/2 1/2 1/2 5/8 5/8 5/8 60,000
1/2 1/2 5/8 5/8 5/8 5/8 66,000
1/2 1/2 5/8 5/8 5/8 5/8 72,000
1/2 1/2 5/8 5/8 5/8 7/8 78,000
1/2 5/8 5/8 5/8 5/8 7/8 84,000
1/2 5/8 5/8 5/8 7/8 7/8 90,000
5/8 5/8 5/8 7/8 7/8 7/8 120,000
5/8 7/8 7/8 7/8 7/8 7/8 150,000
5/8 7/8 7/8 7/8 7/8 1 1/8 180,000
7/8 7/8 7/8 7/8 7/8 1 1/8 210,000
7/8 7/8 7/8 7/8 1 1/8 1 1/8 240,000
7/8 7/8 1 1/8 1 1/8 1 1/8 1 1/8 300,000
7/8 7/8 1 1/8 1 1/8 1 1/8 1 1/8 360,000
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

20
 Line Sizing
Table 3. Recommended Line Sizes for R-404A and R-507 *
SUCTION LINE SIZE
SYSTEM
SUCTION TEMPERATURE
CAPACITY
+40˚F +20˚F +10˚F 0˚F
BTU/H
Equivalent Lengths Equivalent Lengths Equivalent Lengths 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 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 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 7/8 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 5/8 5/8 7/8 7/8 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 7/8 7/8 7/8 5/8 7/8 7/8 7/8 7/8 1 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 1/8 7/8 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 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 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.
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.

21
 Line Sizing
Table 3A. Recommended Line Sizes for R-404A and R-507 (continued) *

SUCTION LINE SIZE LIQUID LINE SIZE
SUCTION TEMPERATURE Receiver to
-20˚F -30˚F -40˚F Expansion Valve SYSTEM
Lengths Equivalent Lengths Equivalent Lengths Equivalent Lengths 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 1/8 3/8 3/8 3/8 3/8 3/8 3/8 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 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 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 1/8 1 1/8 1 3/8 3/8 3/8 3/8 3/8 1/2 1/2 15,000

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 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 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 3/8 1 3/8 1 5/8 3/8 1/2 1/2 1/2 1/2 1/2 30,000

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 5/8 1/2 1/2 1/2 1/2 5/8 5/8 42,000

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 5/8 1/2 1/2 1/2 5/8 5/8 5/8 48,000

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

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 66,000

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

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 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 1/8 2 1/8 2 5/8 5/8 5/8 5/8 7/8 7/8 7/8 90,000

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 5/8 5/8 7/8 7/8 7/8 7/8 120,000

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 5/8 7/8 7/8 7/8 7/8 1 1/8 150,000

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.
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.

22
 Line Sizing
Table 4. Weight of Refrigerants in Copper Lines During Operation (Pounds per 100 Lineal feet of type"L" tubing)

Line Size Suction Line at Suction Temperature

O.D. Liquid
in Inches Refrigerant Line -40˚F -20˚F 0˚F +20˚F +40˚F

R-507/R-404A 3.4 .03 .04 .06 .09 .13

3/8 R-407 3.8 .02 .03 .04 .06 .09
R-448A/R-449A 3.6 .02 .03 .04 .06 .09

R-507/R-404A 6.3 .04 .07 .13 .16 .24

1/2 R-407 7.0 .03 .05 .08 .11 .17
R-448A/R-449A 6.7 .03 .05 .07 .11 .16

R-507/R-404A 10.2 .07 .11 .17 .25 .35

5/8 R-407 11.2 .05 .08 .12 .18 .26
R-448A/R-449A 10.8 .05 .08 .12 .18 .26

R-507/R-404A 21.1 .07 .11 .17 .15 .35

7/8 R-407 23.3 .05 .08 .12 .18 .26
R-448A/R-449A 22.3 .10 .16 .25 .37 .54

R-507/R-404A 36.1 .15 .23 .37 .51 .72

1 1/8 R-407 39.7 .10 .16 .25 .37 .54
R-448A/R-449A 38.1 .17 .27 .42 .63 .92

R-507/R-404A 54.9 .26 .39 .63 .86 1.24

1 3/8 R-407 60.5 .17 .27 .43 .63 .93
R-448A/R-449A 58.0 .25 .41 .64 .96 1.40

R-507/R-404A 77.7 .40 .58 .95 1.32 1.87

1 5/8 R-407 85.7 .26 .41 .65 .96 1.43
R-448A/R-449A 82.1 .36 .58 .90 1.36 1.98

R-507/R-404A 135 .56 .82 1.35 1.86 2.64

2 1/8 R-407 149 .36 .57 .91 1.38 2.01
R-448A/R-449A 143 .62 1.01 1.57 .2.36 3.44

R-507/R-404A 209 .98 1.43 2.35 3.23 4.58

2 5/8 R-407 230 .63 1.00 1.60 2.38 3.49
R-448A/R-449A 220 .96 1.56 2.42 3.65 5.30

R-507/R-404A 298 1.51 2.21 3.62 5.00 7.07

3 1/8 R-407 328 .98 1.55 2.46 3.67 5.39
R-448A/R-449A 314 1.37 2.22 3.45 5.20 .7.57

R-507/R-404A 403 2.16 3.15 5.17 7.14 9.95

3 5/8 R-407 444 1.40 2.23 3.50 5.23 8.27
R-448A/R-449A 425 1.86 3.01 4.67 7.04 10.24

R-507/R-404A 523 3.80 5.55 9.09 12.58 13.61

4 1/8 R-407 577 2.45 3.92 6.17 17.80 9.23
R-448A/R-449A 552 2.40 3.89 6.05 .9.11 13.25

23
 Line Sizing
Table 5. Pressure Loss of Liquid Refrigerants in Liquid Line Risers (Expressed in Pressure Drop, PSIG, a nd Subcooling Loss, ˚F).
Liquid Line Rise in Feet

10' 15' 20' 25' 30' 40' 50' 75' 100'

Refrigerant PSIG ˚F PSIG ˚F PSIG ˚F PSIG ˚F PSIG ˚F PSIG ˚F PSIG ˚F PSIG ˚F PSIG ˚F

R-134A 4.9 2.0 7.4 2.9 9.8 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

R-507/R-404A 4.1 1.1 6.1 1.6 8.2 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

R-407 4.3 1.4 6.4 2.0 8.5 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

R-448A/R-449A 4.3 1.1 6.5 1.7 8.7 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” 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 5 1/8 6 1/8

Globe Valve (Open) 14 16 22 28 36 42 57 69 83 99 118 138 168

Angle Valve (Open) 7 9 12 15 18 21 28 34 42 49 57 70 83

90˚ Turn Through Tee 3 4 5 6 8 9 12 14 17 20 22 28 34

Tee (Straight Through) or Sweep Below .75 1 1.5 2 2.5 3 3.5 4 5 6 7 9 11

90˚ Elbow or Reducing Tee (Straight Through) 1 2 2 3 4 4 5 7 8 10 12 14 16

24
 Optional Controls
Head Pressure Control
CAUTION: F or Ambient Fan Cycling; Under no circumstance
A. Dual Valve System should all condenser motors be allowed to cycle off
on one control. At least one motor shall be wired to
The system employs an ORI (open on rise of inlet pressure) valve and an ORD ( open operate at all times. Under most circumstances, the
on rise of differential pressure) valve. condenser motor nearest the inlet header should
remain on whenever the compressor is operating.
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. Table 7. Ambient Fan Cycle Default Thermostat Settings

This system requires additional refrigerant to flood the condenser during low ambient Thermostat Settings ºF Cut-In
operation. See the Refrigerant Charging Section for more information. Models Fan #1 Fan #2 Fan #3 Fan #4

ORI valve adjustment should be made with a gauge connected to the discharge 2 Fan Units ON 50 – –
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 3 Fan Units ON 50 60 –
lower the discharge pressure below the desired set point.
4 Fan Units ON 50 60 70
Turn the adjustment stem on the ORI with a hex wrench. Clockwise rotation will
increase and counterclockwise will decrease the discharge pressure setting. Note: Cut-out temperature is ºF below cut-in temperature

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
C. Phase Loss Monitor
conditions prevail.
The combination phase sequence and loss monitor relay protects the system against
Typical ORI discharge pressure settings are 150 to 180 psi. The factory default phase loss (single phasing), phase reversal (improper sequence) and low voltage
pressure fan cycle settings (controlled by liquid refrigerant pressure) are appropriate (brownout). When phase sequence is correct and full line voltage is present on all
for this range. three phases, the relay is energized as the normal condition indicator light glows.
If outside of this adjustment range, the condenser fan settings may need to be Note: If compressor fails to operate and the normal condition indicator light on the
changed. Note that the liquid pressure will be approximately 20 psi lower than the phase monitor does not glow, then the supplied electrical current is not in phase with
discharge pressure during low ambient conditions. the monitor. This problem is easily corrected by the following steps:
If desired, the first fan may be re-programmed to operate with the compressor. 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

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 Demand Cooling System Design
Energy efficiency regulations drive continuous change in the availability of refrigerants When Demand Cooling operates, it “diverts” refrigeration capacity in the form of
to the marketplace. With the introduction of R-22 as a replacement for R-502 injected saturated refrigerant from the evaporator to the compressor. The effect of this
compressors began to experience internal discharge temperatures that exceed the diversion on evaporator capacity is minimal because the diverted capacity is used to
safe operational limits for long term stability of refrigerant oil. In response to this cool the gas entering the compressor. As the gas is cooled, it naturally becomes more
Demand Cooling was developed as a reliable method to keep discharge temperatures dense, increasing the mass flow through the compressor, which partly compensates
reduced to a safe level without inhibiting the operating limits of the compressor. With for the capacity diverted from the evaporator.
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 1. Compressor Return Gas Temperature: Suction lines should be well
discharge temperature control. Also forthisreasonsuctiontoliquid heat exchangers are insulated to reduce suction line heat gain. Return gas superheat
not recommended unless they are necessary to prevent another potential problem. should be as low as possible consistent with safe compressor
operation.
The Copeland Demand Cooling System 2. Condensing Temperatures: It is important when using R-22, R-407
Copeland's demand cooling system uses modern electronics to provide a A/C/F or R-448A/449A as a low temperature refrigerant that
reliable, cost-effective solution to this problem. It is required for all single condensing temperatures be minimized to reduce compression ratios
stage required for all single stageR-22,R-407A/C/ForR-448A/449-A applications and compressor discharge temperature.
with saturated suction temperatures below 0˚F.
3. Suction Pressure: Evaporator design and system control settings
The Demand Cooling module uses the signal of a discharge head temperature should provide the maximum suction pressure consistent with the
sensor to monitor discharge gas temperature. If a critical temperature is reached, application in order to have as low a compression ratio as possible.
the module energizes along life injection valve which meters a controlled amount of
saturated refrigerant into the compressor suction In most cases, with floating head systems where condensing temperatures
cavity to cool the suction gas. Refer to Figure 13. 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
This process controls the discharge temperature to a safe level. If, for some compressor during periods of low oil pressure. Demand Cooling will be
allowed to operate only during those periods when condensing temperatures
reason, the discharge temperature rises above a preset maximum level, and return gas temperatures are high or in periods where a system failure
the Demand Cooling module will turn the compressor off (requiring a manual reset) (such as an ice evaporator, an expansion valve which does not control superheat,
and actuate its alarm contact. To minimize the amount of refrigerant which must blocked condenser, or a failed condenser fan) raises condensing temperatures or
be injected, the suction gas cooling process is performed after the gas has passed return gas temperatures to abnormally high levels or lowers suction pressure to
around and through the motor. abnormally low levels.

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.

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 Wiring Installation

applicable codes and local ordinances. 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
High voltage – A separate power supply from the condensing unit may be utilized for
each unit is located on the inside of the electrical panel door. All field wiring should be
the evaporator. All appropriate local codes regarding disconnects and fusing must be
done in a professional manner and in accordance with all governing codes. Before
followed. See the unit cooler spec. plate for ampacity.
operating unit, double check all wiring connections, including the factory terminals.
Factory connections can vibrate loose during shipment.
Low voltage – 24 VAC control circuit. Each evaporator connects to the condensing
1. The serial data tag on the unit is marked with the electrical characteristic for unit with the following connections: defrost termination temperature (2 conductors),
wiring the unit liquid line solenoid (2 conductors), evaporator fan contactor control (2 conductors).
2. Consult the wiring diagram in the unit cooler and in the condensing unit for In addition, some evaporators will require 2 conductors for the pan heater contactor
proper connections control. Eight-conductor, 18 gauge thermostat wiring is recommended. The
3. Wire type should be of copper conductor only and of the proper size to handle thermostat contact connection can be run within this bundle of wires also if there are
the connected load extra wires available. All 24 volt wiring must be run separate from the line voltage
4. The unit must be grounded wiring.

Low voltage wiring must be 18 gauge minimum. For low voltage wiring, maximum
General Installation distance is 500 feet from condensing unit to evaporators.
• Refer to wiring schematic shipped on units for unit wiring.
• The hot gas controller is shipped with preset control settings that are typical for Alarm circuit – The onboard alarm is a dry set of contacts (Com, NO, NC) which
the application. Changes should be made according to directions outlined under activates to indicate an alarm. The type and wiring for the alarm is customer specified.
Program Settings. Note that the alarm circuit does not distinguish or indicate what has caused the alarm.
• The condensing unit electrical panel contains the electronic control board. The The maximum contact rating is 120V, 0.5A.
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 Mohave Hot Gas System Controller Battery Back-Up - The control board has a
located on the condensing unit are pre-connected to the control board at the factory. 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
 Wiring Diagram

(24V)

(Standard Independent Evaporator Power Supply)

CONTROL BOARD

(Field supplied, not used when

auxiliary temperature sensor is field
installed and activated to control
room temperature)

28
 Wiring Diagram
(24V)

(Standard Independent Evaporator Power Supply)

CONTROL BOARD

(Field supplied, not used when auxiliary

temperature sensor is field installed and
activated to control room temperature)

29
 Wiring Diagram
Typical Evaporator Wiring (Electric Drain Pan Heater)
(Standard Independent Evaporator Power Supply)

208-230V / 3 / 60 HZ
Heatcraft Refrigeration -OR-575V / 3 / 60HZ
Products LLC FOR SINGLE PHASE
EVAP FAN EVAP EVAP
SEE NOTE # 2 LIQ. LINE T-STAT
C DEFR. HTR. DEFR.TEMP SOL. C
24 VAC
CONDENSING UNIT 18 GA. MIN.

T1 T2 T3

* ROOM
1 2 3 THERMOSTAT
( FIELD SUPPLIED )
7
8
HEATER
CONTACTOR

FAN
30 A CONTACTOR 3B 5 6 7
4 3A N X

RED

BLACK

9 10 4 5 6 BLUE

YELLOW

EVAPORATOR ELECTRICAL END

H1 H2 H3 F1 F2 F3 EVAPORATOR HEADER END

4 3
N X J

EVAP DEFROST
SUCTION
TEMP
SENSOR

EVAPORATOR
FAN MOTORS
LIQUID LINE
SOLENOID

MTR F1 F2
DRAIN
PAN
HEATERS

MTR
SINGLE PHASE
MTR DETAIL

MTR
MTR

MTR MODELS 1860

& 2120 ONLY

Mfg. NOTES: ** USE COPPER CONDUCTORS ONLY**

1. WIRE NUMBERS MATCH WIRE MARKER NUMBERS ON
HARNESS ASSEMBLIES. PART NO. 29781301 * NOTE: NOT USED WHEN AUX TEMPERATURE SENSOR IS
FIELD-INSTALLED AND ACTIVATED TO CONTROL ROOM
2. FOR 208-230/1/60 HZ WIRE TO T1 & T2
REV D TEMPERATURE
FIELD WIRING

30
 Wiring Diagram
Typical Evaporator Wiring (Hot Gas Drain Pan)
(Standard Independent Evaporator Power Supply)

208-230V / 3 / 60 HZ
Heatcraft, Inc. 460V / 3 / 60HZ
575V / 3 / 60HZ
FOR SINGLE PHASE
SEE NOTE #2

T1 T2 T3 EVAP FAN EVAP LIQ. LINE T-STAT

C DEFR.TEMP SOL. C

CONDENSING UNIT 24 VAC

18 GA. MIN.

1 2 3

ROOM
THERMOSTAT *
( FIELD SUPPLIED )

FAN
CONTACTOR 3B 5 6 7
4 3A N X

RED

BLACK 18-2
SOLENOID
HARNESS
4 5 6

EVAPORATOR ELECTRICAL END

H1 H2 H3 F1 F2 F3 EVAPORATOR HEADER END

4 3
N X J

EVAP DEFROST
EVAPORATOR SUCTION
FAN MOTORS TEMP
3 PHASE SENSOR
LIQUID LINE
SOLENOID

MTR

SINGLE PHASE
DETAIL
MTR
F1 F2 * NOTE: NOT USED WHEN AUX TEMPERATURE SENSOR IS
FIELD-INSTALLED AND ACTIVATED TO CONTROL ROOM
TEMPERATURE

MTR MTR
Mfg. NOTES:
1. WIRE NUMBERS MATCH WIRE MARKER NUMBERS ON
HARNESS ASSEMBLIES.

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

FIELD WIRING

** USE COPPER CONDUCTORS ONLY**

MTR
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 EVAP EVAP LIQ. LINE T-STAT

C DEFR. HTR DEFR.TEMP SOL. C
24 VAC
18 GA. MIN.

HEATER FAN
CONTACTOR CONTACTOR

* ROOM
THERMOSTAT
( FIELD SUPPLIED )

CONDENSING UNIT
ELECTRIC BOX
EVAPORATOR
ELECTRIC BOX

208-230V / 3 / 60 HZ
-OR-575V / 3 / 60 HZ
FOR SINGLE PHASE
SEE NOTE #1
3B 5 6 7
4 3A N X

18-2
SOLENOID
HARNESS
H1 H2 H3 F1 F2 F3
4 3
N X J

EVAPORATOR ELECTRICAL END

EVAPORATOR HEADER END

EVAPORATOR
FAN MOTORS
3 PHASE SINGLE PHASE
DETAIL

MTR F1 F2
DRAIN
PAN
HEATERS
EVAP DEFROST
SUCTION
MTR TEMP
MTR SENSOR LIQUID LINE
SOLENOID

MTR
MTR

(Field supplied, not used when auxiliary temperature

MTR
sensor is field installed and activated to control room MODELS 1860
& 2120 ONLY
temperature)

** USE COPPER CONDUCTORS ONLY**

Mfg. NOTES:
1.FOR 208-230/1/60 WIRE TO T1 & T2 AND F1 & F2 PART NO. 29781801 * NOTE: NOT USED WHEN AUX TEMPERATURE SENSOR

FIELD WIRING
REV D IS FIELD-INSTALLED AND ACTIVATED TO CONTROL
ROOM TEMPERATURE

32
 Wiring Diagram
Typical Evaporator Wiring (Hot Gas Drain Pan)

(Optional Evaporator Powered Off Condensing Unit)

Heatcraft, Inc.

EVAP FAN EVAP LIQ. LINE T-STAT

C DEFR.TEMP SOL. C
CONDENSING 24 VAC
FAN UNIT
18 GA. MIN.
CONTACTOR

* ROOM
THERMOSTAT
( FIELD SUPPLIED )

CONDENSING UNIT
ELECTRIC BOX
EVAPORATOR
ELECTRIC BOX

208-230V / 3 / 60 HZ
460V / 3 / 60HZ
575V / 3 / 60HZ
FOR SINGLE PHASE
SEE NOTE #1

3B 5 6 7
4 3A N X

H1 H2 H3 F1 F2 F3 18-2
SOLENOID
4 3 HARNESS
N X J

EVAPORATOR ELECTRICAL END

EVAPORATOR EVAPORATOR HEADER END

FAN MOTORS
3 PHASE

MTR

SINGLE PHASE MTR EVAP DEFROST

SUCTION
DETAIL TEMP
SENSOR
LIQUID LINE
F1 F2 SOLENOID

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

MTR FIELD WIRING

** USE COPPER CONDUCTORS ONLY**

PART NO. 29781701 REV B * NOTE: NOT USED WHEN AUX TEMPERATURE
MTR SENSOR IS FIELD-INSTALLED AND ACTIVATED TO
(Field supplied, not used when auxiliary temperature sensor is field installed andCONTROL ROOM TEMPERATURE
activated to control room temperature)

33
 Wiring Diagram
(Standard Independent Evaporator Power Supply)

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

CONTACTOR C2

T1 L1
4
T2 L2
5
T3 L3
6

FM

COMPRESSOR

CT POWER
BLOCK
T1 L1
1
T2 L2
2
T3 L3
3

CONTACTOR C1
F3

F1 F2

C3 C4

L1 L2 L3 L1 L2 L3

T1 T2 T3 T1 T2 T3

TO
SHEET 2
7 8 9 10 11 12

FM1 FM2

YELLOW BLUE

CRANKCASE
HEATER 7 R1
8
10
YELLOW

11

C2
BLUE

C1
SERVICE MATE

L1 L2 COMP LLS

TDR
LPS HPS DT OPS AUX1 AUX2 CMOD

12 13 15 16

2 4
R1
HPS OPS

14 17
240 M L 2
HEADER/COMPRESSOR END

M1

M2

LEGEND
C ------- CONTACTOR
CB ------- CIRCUIT BREAKER SHEET 1 OF 2 Model #: BDV2702L6C
CT ------- CURRENT TRANSDUCER (IN CMPR EBOX)
DHC ------- DEFROST HEATER CONTACTOR
EFC ------- EVAPORATOR FAN CONTACTOR
Unit Serial #: test
USE COPPER CONDUCTORS ONLY
F ------- FUSE
FC ------- FAN CAPACITOR FACTORY WIRING Customer:
FM ------- FAN MOTOR FIELD WIRING Rev 3.24

34
 Wiring Diagram
(Standard Independent Evaporator Power Supply)

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

TO
SHEET 1

230V

240 C 240 C

24V

PRESSURE
C 24V
REGULATOR

Alarm 3-Way Sol.

30
3-Way Sol.
SERVICE SW.
31

Defrost Sol
C1 C2 32
c n/o c n/o Defrost Sol
33
SAFETY CKT.
Suction Sol
34
Suction Sol
35

BLUE Bypass Valve

CU Suct Temp SUCTION TEMP 36
Bypass Valve
37

Redundant LPS
WHITE
Ambient Temp AMBIENT TEMP
Redundant LPS

0 1
R1
AUX TEMP
COMP

CU Suct Press
BLUE SUCTION PRESSURE
0-300 PSIA
C3
Cond Fan #1

CU Liquid Press
RED
0-500 PSIA LIQUID PRESSURE C4
Cond Fan #2

Cond Fan #3

Cond Fan #4
Beacon Compressor

Evap #1 Def Temp

Evap #2 Def Temp

EVAP PAN HTR

LIQ LINE SOL1

LIQ LINE SOL2

Remote Defr

Evap Fan
T-STAT

FIELD WIRING
CONNECTIONS

LEGEND
C ------- CONTACTOR
CB ------- CIRCUIT BREAKER
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 SHEET 2 OF 2 Model #: BDV2702L6C
OPS ------- OIL PRESSURE SWITCH
PLM ------- PHASE LOSS MONITOR
R ------- RELAY
Unit Serial #: test
Comp Aux -- COMPRESSOR AUXILLARY USE COPPER CONDUCTORS ONLY
CONTACTS (Compressor proof ) FACTORY WIRING Customer:
TDR ------- TIME DELAY RELAY FIELD WIRING Rev 3.24
WWS ------- WIRE WHEN SUPPLIED

35
 Wiring Diagram
(Standard Independent Evaporator Power Supply)
460V/60Hz/3Ø - CONDENSING UNIT - UNIT WIRING

COMPRESSOR

CT POWER
BLOCK
T1 L1
1
T2 L2
2
T3 L3
3

CONTACTOR C1
F3

F1 F2

460V
H1 H4 TRANSFORMER
C3 C4 C5
X4 X1

L1 L2 L3 L1 L2 L3 L1 L2 L3 230V

T1 T2 T3 T1 T2 T3 T1 T2 T3

TO
SHEET 2
7 8 9 10 11 12 13 14 15

FM1 FM2 FM3

YELLOW BLUE

C
CRANKCASE
HEATER 7 R1
8
10

C
YELLOW

11
BLUE

C1
SERVICE MATE

L1 L2 COMP LLS

TDR
LPS HPS DT OPS AUX1 AUX2 CMOD

12 13 15 16

2 4
R1
HPS OPS

14 17
240 M L 2
HEADER/COMPRESSOR END

M1 C ------
CB -----
M2
CM ----
M3
DCM ---
F -------
FCS ----
LEGEND
HPS ----
C ------- CONTACTOR
SHEET 10F2
SHEET 1 OF 2
LPS -----
CB ------- CIRCUIT BREAKER Model #: BDV3502M6D LSV -----
CT ------- CURRENT TRANSDUCER (IN CMPR EBOX) OPS ----
DHC ------- DEFROST HEATER CONTACTOR
EFC ------- EVAPORATOR FAN CONTACTOR
Unit Serial #: Test PLM ----
R ------
USE COPPER CONDUCTORS ONLY Comp A
F ------- FUSE
FC ------- FAN CAPACITOR FACTORY WIRING Customer: CON
FM ------- FAN MOTOR FIELD WIRING TDR ----
WWS --

Rev 3.24
36
 Wiring Diagram
(Standard Independent Evaporator Power Supply)
460V/60HZ/3Ø - CONDENSING UNIT - CONTROL BOARD WIRING

TO
SHEET 1

230V

240 C 240 C

24V

PRESSURE
C 24V
REGULATOR

Alarm 3-Way Sol.

30
3-Way Sol.
SERVICE SW.
31

Defrost Sol
C1 32
c n/o Defrost Sol
33
SAFETY CKT.
Suction Sol
34
Suction Sol
35

BLUE Bypass Valve

CU Suct Temp SUCTION TEMP 36
Bypass Valve
37

Redundant LPS
WHITE
Ambient Temp AMBIENT TEMP
Redundant LPS

0 1
R1
AUX TEMP
COMP

CU Suct Press
BLUE SUCTION PRESSURE
0-300 PSIA
C3
Cond Fan #1

CU Liquid Press
RED
0-500 PSIA LIQUID PRESSURE C4
Cond Fan #2

C5
Cond Fan #3

Cond Fan #4
Beacon Compressor

Evap #1 Def Temp

Evap #2 Def Temp

EVAP PAN HTR

LIQ LINE SOL1

LIQ LINE SOL2

Remote Defr

Evap Fan
T-STAT

FIELD WIRING
CONNECTIONS

LEGEND
C ------- CONTACTOR
CB ------- CIRCUIT BREAKER
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 SHEET 2 OF 2 Model #: BDV3502M6D
OPS ------- OIL PRESSURE SWITCH
PLM ------- PHASE LOSS MONITOR
R ------- RELAY
Unit Serial #: Test
Comp Aux -- COMPRESSOR AUXILLARY USE COPPER CONDUCTORS ONLY
CONTACTS (Compressor proof ) FACTORY WIRING Customer:
TDR ------- TIME DELAY RELAY FIELD WIRING
WWS ------- WIRE WHEN SUPPLIED

Rev 3.24
Rev 3.24
37
 Wiring Diagram
(Standard Independent Evaporator Power Supply with VFD Condenser Fans)

38
 Wiring Diagram
(Standard Independent Evaporator Power Supply with VFD Condenser Fans)

39
 Hot Gas Unit Cooler Typical Factory Piping

Note: Control contactors

mount under a cover
Electrical on front of unit (not shown)
Connections
(this side)

Air
Flow
Suction
Connection

Liquid
Connection

Liquid
Solenoid
Valve

Thermostatic
Expansion
Valve

Check
Valves

Check
Valve

Hot Gas
Suction Drain Pan
P-Trap Shown

40
 Hot Gas Condensing Unit Typical Factory Piping

COMPRESSOR SUCTION
ACCUMULATOR

DEFROST
SOLENOID VALVE
(NC)
(NC)

SUCTION PRESSURE
REDUNDANT SENSOR LOCATION
LOW PRESSURE
SWITCH LOCATION

3-WAY VALVE
(NO BLEED
PORT)
LIQUID PRESSURE
SENSOR LOCATION
BASE SUCTION
SUCTION STOP
VALVE SOLENOID VALVE
(NC)
(NC)
LIQUID CHECK
FILTER VALVE
DRIER
LIQUID SUCTION
LIQUID FILTER FILTER
SIGHTGLASS DRIER
CHECK
VALVE

ELECTRONIC
PRESSURE
REGULATOR LIQUID
RECEIVER
BY-PASS
BY-PASS
SOLENOID BASE
VALVE
VALVE
CHECK PIPINGb.dft
VALVE rev.B

41
 Refrigeration Operation
Refrigeration Operation
The refrigeration operation of the Mohave Hot Gas System is very similar to a During refrigeration operation, the hot gas controller monitors liquid pressure
standard refrigeration system. An external thermostat is connected to the hot to determine if each fan should be ON or OFF.
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 These settings and other fan control options may be modified by turning on
call for cooling), the hot gas control board responds by activating a series of the Expert Mode (XPRT) in the Program Menu. See Program Review and
solenoids and contactors (described below) in order to initiate and maintain Optional Controls for more information.
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 Evaporator Fan Control: After initial power-up, the evaporator fans
turn off the refrigeration process and maintain an Off condition. will be turned off. When the system initiates the first cooling cycle, the hot
gas controller monitors the temperature value of the evaporator defrost
At initial power up, the system defaults to the OFFmode for a minimum termination sensor mounted on the evaporator suction headers. When the
of two minutes. Following the two-minute hold off period, the control circuit controller determines that the suction header has reached the refreeze
examines the state of the thermostat input. If the thermostat input signal is setpoint, the evaporator fans will be activated. If there are two evaporators,
activated (closed between T-Stat and C), the system begins the refrigeration the fans will be energized by the first sensor to achieve setpoint. Once
startup process. Full refrigeration mode (or COOLmode) is achieved when activated, the evaporator fans will continue to run until either a defrost cycle
the control board has activated the solenoids necessary to provide refrigerant is initiated, or if the system is placed in SERVICE mode.
flow between the evaporator(s) and the condensing unit (Suction Solenoid
and Liquid Line Solenoid), activated the compressor contactor, deployed the Anti Short-Cycle Protection: During cooling mode, the control board
appropriate control over the condenser fans, and turned on is programmed to allow a minimum system ON time of 1 minute and a
the evaporator fans. minimum OFF time of 2 minutes.

Refrigerant Solenoid and Compressor Contactor Control: The Suction Pump Down
Solenoid is initially activated following the power-up two-minute hold off time. At the end of each cooling cycle, when the box temperature is met, the hot
It is maintained in the ON state until a defrost cycle is initiated. The timing of gas control system will pump down and turn off the compressor.
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.

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
 Refrigeration Operation

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 Operation

Defrost Timing/Schedule Programming

The hot gas controller can be programmed with up to 12 defrost start times. Termination of defrost is accomplished by either both evaporators reaching
The Program Review menu section describes the process to program or their target termination temps, or the liquid pressure measured between the
delete a valid start time. Note that clearing a start time by pressing CLEAR receiver and the condenser coil reaching its target pressure, or the pre-
and the ENTER will disable all start times following the one being cleared. programmed fail safe time.
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 When one of the termination factors is realized, the compressor, condenser
at any time. 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
Force Defrost Manually DEF3 begins.
To manually force the start of a defrost-cycle, press the FORCE DEFROST
button. If the system is in COOLmode, the system will pump down and go DEF3:
to the off mode before the defrost process is started. 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
Defrost Process pressure regulator. The pressure regulator is open 100% during this step.
The second purpose is drain down time for the warm evaporators. This
The defrost process has four steps: Pre-defrost (DEF1) pressure allows the water that was melted off of the coil to drain out of the evaporator
equalization, Defrost operation (DEF2), Post-defrost (DEF3) pressure drain pan. The time duration for this step is identical to the DEF1
equalization and drain down, and Refreeze (FREZ). equalization time.

DEF1: After the completion of the delay time period, the 3-Way valve and the
Pre-defrost, or defrost step 1, always follows activation of Off mode. If the pan heater contactor are turned off. One second later the Suction Solenoid
system is in Cool mode when the defrost cycle is activated, the control will is turned on, and then one second after that the compressor turns on.
pump down and go to Off mode before activating pre-defrost. The condenser fan control algorithm is also enabled. When the pressure
measured at the suction sensor falls below -10°F SST, the liquid line
The purpose of DEF1 is to equalize the refrigerant pressures between solenoid is activated and the process step changes to Refreeze.
the condensing unit receiver and the evaporator(s). This is accomplished
by first deactivating the evaporator fans, and the suction solenoid. Next the FREZ:
Bypass Solenoid and the evaporator Pan Heater contactor are activated.The The Refreeze step is identical to Cooling mode except that the evaporator
time duration of the pressure equalization is programmed as EQUT in the fans are turned off. This is to allow the evaporator coils to freeze any
PROGRAM REVIEW menu. 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
DEF2: space. When the evaporator reaches the refreeze set-point, or the refreeze
After the equalization time has elapsed, the Bypass Solenoid is deactivated. time limit elapses, the fans turn on and the system begins a cooling cycle. If
The Defrost Solenoid is activated 1 second later, followed by the 3-Way valve the thermostat is satisfied, or deactivated, the system will run a cooling cycle
solenoid 1 second after that. Next, the pressure regulator control algorithm for two minutes and then pump down and shut off.
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 After the compressor is energized, the suction stop valve may be pulsed to
suction accumulator. limit the suction pressure at the compressor.

The compressor contactor turns on at the same time that the pressure Through the refreeze period and into cooling mode,the liquid solenoid may
regulator is activated. The ambient temperature is measured, and a energize and de-energize to hold the evaporator below 10 °F SST and allow
determination is made of how many condenser fans should be operating. the expansion valve to better regulate as the system enters cooling mode.
The correct number of condenser fans is activated at the same time as the
Parameter LLSP controls the duration of this pulsing event.
compressor contactor.

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
 Defrost Operation
Hot Gas Defrost Cycle Diagrams
Black = Piping Inactive
Gray = Piping Active

45
 Defrost Operation
Hot Gas Defrost Cycle Diagrams Black = Piping Inactive
Gray = Piping Active

46
 Defrost Operation
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 Leak Testing
Due to the smaller molecule size of HFC’s, they will tend to leak more readily than After all lines are connected, the entire system must be leak tested. The complete
CFC’s. Consequently, it is of the utmost importance that proper system evacuation system should be pressurized to not more than 150 psig with refrigerant and
and leak detection procedures be employed. dry nitrogen (or dry CO2). The use of an electronic type leak detector is highly
recommended because of its greater sensitivity to small leaks. As a further check
Copeland recommends a minimum evacuation to 500 microns. In addition, a vacuum it is recommended that this pressure be held for a minimum of 12 hours and then
decay test is strongly recommended to assure there is not a large pressure differential rechecked. For a satisfactory installation, the system must be leak tight.
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. Line Insulation
Leak detection can be carried out in the conventional manner. After the final leak test, refrigerant lines exposed to high ambient conditions should
If HCFC or CFC tracer gas is used, care must be taken to completely remove all be insulated to reduce heat pickup and prevent the formation of flash gas in the liquid
traces of the gas prior to introducing HFC’s. 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
Electronic leak detectors are now available that will sense HFC’s. This is considered better. The insulation located in outdoor environments should be protected from UV
preferable since it removes the possibility of chlorine remaining in the system after exposure to prevent deterioration of insulating value.
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. 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, CAUTION: Do not use the refrigeration compressor
when exposed to an ultraviolet light “fluoresce,” indicates the location of leaks. to evacuate the system. Do not start the
Copeland has tested and approved the Rigid “System Safe” dye and found it to be compressor while it is in a vacuum.
compatible with the compressor materials in systems.
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
NOTE: The Hot Gas Control Board may be powered up and set compressor has service valves, they should remain closed. A deep vacuum gauge
on“EVAC” Mode during Evacuation. In this mode, all of the capable of registering pressure in microns should be attached to the system for
system valves are energized. See Page 47. 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: R
 efrigerant 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 Start-Up Operation - Initial Power On
After the installation has been completed, the following points should be covered before At the initial application of power to the system, the compressor and the evaporator
the system is placed in operation: fans will be in a 2-minute hold-off cycle and will not start immediately. The 4-digit
(a) Check all electrical and refrigerant connections. LED indicator located on the control board will display OFF. If the room thermostat
Be sure they are all tight. setting is below the current room temperature, the contact inside the thermostat will be
(b) Observe compressor oil level before start-up. The oil level should be closed, and the associated T-Stat LED on the controller circuit board will be lit. Under
at or slightly above the 3/4 level of the sight glass. Refer to Table 7 on these conditions, the system will begin a cooling cycle.
page 52 for proper compressor oil.
(c) Remove upper mounting nuts on the compressor feet. Remove the Operating Mode Display
shipping spacers. Install the neoprene washers onto the compressor feet. OFF Off Mode
Replace the upper mounting nuts and washers,allowing 1/16" space COOL Cooling Mode
between the mounting nut and the neoprene spacer. PMPD Pump Down
(d) Check high and low pressure controls, oil pressure safety controls, and SERV Service Mode
all other safety controls, and adjust if necessary.
DELY Delay Mode
(e) Check the room thermostat for normal operation and adjust.
(f) Wiring diagrams, instruction bulletins, etc. attached to the condensing DEF1 Pre-Defrost, or Bypass Mode
units should be read and filed for future reference. DEF2 Defrost Mode
(g) All fan motors on air cooled condensers,evaporators, etc. should be DEF3 Post-Defrost Equalization, or Drain Mode
checked for proper rotation. Fan motor mounts should be carefully TEST Test Mode
checked for tightness and proper alignment.
(h) Observe system pressures during charging and initial operation. Do Programming and Reviewing Settings and Changes
not add oil while the system is short of refrigerant unless oil level is
The Program Review button is used to program, review and change all program
dangerously low.
settings for the system.
(i) Continue charging until system has sufficient refrigerant for proper
operation. Do not overcharge. Remember that bubbles in a sight glass
Press PROGRAM REVIEW button. The Setpoint item will appear on the LED. After a
may be caused by a restriction as well as a shortage of refrigerant.
few seconds delay the Setpoint value will display. Each time the button is pressed a
(j) Do not leave unit unattended until the system has reached normal
different item is displayed.
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 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 There are two levels of menu setting programs: Normal and Expert. The Expert settings
most of the refrigerant might be in the compressor creating a are visible when the XPRT menu item is changed from Off to On.
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 Program Review (Items Available when in Normal Mode)
watt heat lamp or other safe heat source on the lower shell of the
compressor for approximately thirty minutes will be beneficial in CLKH........ Set the Time of Day clock hour value
eliminating this condition which might never reoccur. 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
DF03........ Set Defrost #3 starting time
DF04........ Set Defrost #4 starting time
DF12........ Set Defrost #12 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) Use the Program Review button to select these
CLKH........ Set the Time of Day clock hour value items:
CLKM....... Set the Time of Day clock minute value
°F°C....... Set Fahrenheit/Celsius temperature units (°F/°C) Clock Hour setting – CLKH – Selection is made of the current hour. If 12 hour
1224....... Set Time display method (12HR. / 24HR) mode is selected, these values are displayed as 12:XX to 11:XX for the AM hours.
ALRT....... Set the Alarm Time (2 to 120 minutes) The PM hours will be displayed with a decimal point following the minutes (12:XX.). If
RDTF* . ...Defrost time based upon compressor runtime (OFF or Defrost based 24 hour mode is selected, the hours will run from 00:XX to 23:XX.
.................... upon compressor runtime in 30 minute increments) Note that the time
.................... based menu choices below are disabled when RDTF is activated. Clock Minute setting – CLKM – Selection is made of the current minute. The
DF01....... Set Defrost #1 starting time (12:00 to 12:00. in 30 minute increments) currently programmed time is displayed in the standard HH:MM format. Turning the
DF02....... Set Defrost #2 starting time potentiometer will cause the minute value to change between 00 and 59 minutes.
DF03....... Set Defrost #3 starting time
DF04....... Set Defrost #4 starting time Degrees F/C setting – °F°C– Select units to display temperature. Fahrenheit or
DF12....... Set Defrost #12 starting time Celsius. Default: Fahrenheit.
APPL***.. Set Application type (MED, LOW)
REFR....... Set Refrigerant type R-22, R-404A, R-507, R-407A, R407C,R407F) Clock Time display setting – 12 24– Selection is made of time display method.
MODL....... Set Condensing Unit Model Number Use of 12-Hour technique is implemented by activating the last decimal place of the
XPRT....... Activate expert menu items (Off, On) 4-character display when the time is indicating PM instead of AM values. Default:
FAN1....... Set Fan #1 operation type (OFF, ON, PRES, AMBT) 12-Hour mode.
FAN2....... Set Fan #2 operation type (OFF, ON, PRES, AMBT)
FAN3....... Set Fan #3 operation type (OFF, ON, PRES, AMBT) Alarm Time – ALRT – Time which the alarm elements conditions must exceed
FAN4....... Set Fan #4 operation type (OFF, ON, PRES, AMBT) before alarm is triggered. Default: 20 minutes.
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). Defrost schedule method1 - RDTF - Defrost may be schedules based upon clock
F2ON....... Set Fan #2 turn-on parameter time or compressor run time. For clock time, select OFF and schedule the desired
F3ON....... Set Fan #3 turn-on parameter defrost start times (from 0 to 12 defrosts per day). For compressor run time, select
F4ON....... Set Fan #4 turn-on parameter the amount of compressor run time (in refrigeration mode) to occur between defrost
F1OF....... Set Fan #1 turn-off parameter (Only used if PRES or AMBT selected. periods (from 30 minutes to 12 hours). Default: OFF
PRES range is 110 psig to 300 psig, AMBT range is 30°F to 90°F).
F2OF....... Set Fan #2 turn-off parameter Defrost #1 Start Time – DF01 – Programmed start time for defrost #1. Time
F3OF....... Set Fan #3 turn-off parameter value is displayed in HH.MM format. This time follows the 12/24 selection format.
F4OF....... Set Fan #4 turn-off parameter To disable the start time, press the CLEAR/TEST button and then press ENTER.
DFT1....... Set Evaporator #1 termination temperature ( 50°F to 100°F) All start times following the cleared time will become disabled. Default: 12.00
DFT2....... Set Evaporator #2 termination temperature ( 50°F to 100°F)
DEFP....... Set Defrost termination pressure (160 psig to 300 psig) Defrost #2 Start Time – DF02 - Programmed start time for defrost #2. Time
DEFT....... Set Defrost fail-safe time (5 minutes to 30 minutes) value is displayed in HH.MM format. This time follows the 12/24 selection format.
EQUT....... Set defrost process equalizing time (1 to 10 minutes) Default: 6.00
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) Defrost #3 Start Time – DF03 - Programmed start time for defrost #3. Time value is
FZET....... Evaporator refreeze temperature (20ºF to 40ºF) displayed in HH.MM format. This time follows the 12/24 selection format. Default: 12.00.
FZTM....... Evaporator refreeze maximum time (0 to 10 minutes)
VALM**... Electronic pressure regulator manufacturer (Carel or Alco) Defrost #4 Start Time – DF04 - Programmed start time for defrost #4. Time value is
PRFS....... Electronic pressure regulator full scale displayed in HH.MM format. This time follows the 12/24 selection format. Default: 6.00.
PRUI....... Electronic pressure regulator update rate (seconds)
DFIO . .. .Electronic pressure regulator initial position (percent) 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
LLSP . .. .Liquid solenoid post defrost pulse period ( 0 to 15 minutes)
ENTER button.
EVPF* . .. Evaporator fans running during refrigeration off-cycle (OFF or ON)
ALRH....... Alarm room high temperature threshold in degrees Application Type – APPL– Selection is made for Medium Temp application or Low Temp
ALRL....... Alarm room low temperature threshold in degrees application. Default: Medium Temp.
AUXT....... Enable thermostat functionality via the auxiliary temperature sensor
(ON/OFF) Refrigerant Type – REFR – Selection for type of refrigerant – R-22, R-404A, R-507,
BOXT....... Box set point when using the thermostat functionality from parameter R-407A, R-407C, R-407F, R-448 and R-449A . Default is R-404A
AUXT (only appears when AUXT = ON)
MBAd....... Modbus address 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. 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
Condenser Fan #x Operation Method – FANX– Note that x represents a value between displayed is a pressure in ‘psig’ format.
1 and 4, and is selected in descending order following #1. Selection is made for type of fan The pressure range is 0 psig to 30 psig.
operation control. Choices are: OFF, ON, PRES, and AMBT. The selection made will determine
the parameter type of the operation ranges. Default: PRES. Low Pressure Switch simulation Cut-Out value – LPSL– Selection is made of the ‘cut-
out’ pressure value normally made on the mechanical low-pressure control switch. The value
Condenser Fan #x ON operation value –FXON– Note that x represents a value between displayed is a pressure in ‘psig’ format. The pressure range is 0 psig to 30 psig.
1 and 4, and is selected in descending order following #1. This setting chooses the on value Electronic Pressure Regulator Manufacturer1- VALM- This parameter controls the Electronic
for the fan selected. When ON or OFF is chosen for a particular fan operation, this step will Pressure Regulator Settings that are loaded for each corresponding application to match the
not be displayed. If AMBTwas chosen, the value displayed is a temperature in °F. The installed valve (Carel or Alco). Default: Carel (CARL).
temperature selection range is 30°F to 90°F. If PRESwas selected, the value displayed
represents a pressure in ‘psig’. The pressure selection range is 110 psig to 300 psig. Electronic Pressure Regulator - PRFS, PRUI, DFIO- These parameters
control the operation of the pressure regulator during the defrost period and the default
Condenser Fan #x OFF operation value – FxOF – Note that x represents a value between 1 selections are tuned to specific condensing unit models. Field modification is not recommended.
and 4, and is selected in descending order following #1. This setting chooses the off value Default: See table of factory default settings.
for the fan selected. When ON or OFF is chosen for a particular fan operation, this step will
not be displayed. If AMBTwas chosen, the value displayed is a temperature in °F. The Liquid solenoid pulse feature - LLSP- In the period immediately after defrost, the
temperature selection range is 30°F to 90°F. If PRESwas selected, the value displayed evaporator fans will energize and the liquid solenoid valve may be pulsed to reduce the
represents a pressure in ‘psig’. The pressure selection range is 110 psig to 300 psig. 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
Defrost Termination Temp for Evaporator #1 – DFT1 – This is the temperature as sensed 0 to 15 minutes. Default: 5 minutes.
from the evaporator suction line that is used to determine when the defrost cycle is complete.
The value is displayed as a temperature. Evaporator fan run operation1 - EVPF- This parameter controls the status of the evaporator
Default: 75°F (Low Temperature) 85°F (Medium Temperature) fans during the refrigeration off-cycle when the thermostat is satisfied. (On or OFF) Default: On.

Defrost Termination Temp for Evaporator #2 – DFT2 – This is the temperature as sensed High auxiliary temperature alarm – ALHR– This parameter is the temperature set point that
from the evaporator suction line that is used to determine when the defrost cycle is complete. when measured above by the auxiliary temperature sensor will cause an ALR5 alarm after the
The value is displayed as a temperature. Note: when two evaporators are used, both evaporator alarm time has been exceeded. Default: OFF.
temperatures must reach their set point to terminate defrost. Default: Same as DFT1.
Low auxiliary temperature alarm – ALRL– This parameter is the temperature set point that
Defrost Termination Pressure – DEFP– Selection is made of the pressure value that when measured below by the auxiliary temperature sensor will cause an ALR6 alarm after the
will signify a complete defrost process. This decision is made in an ‘OR’ manner with the alarm time has been exceeded. Default: OFF.
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 Auxiliary temperature sensor thermostat control – AUXT– This parameter will allow the
in ‘psig’ format. Default: 210 PSIG. 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
Defrost Failsafe Time – DEFT – This is the maximum time allowed for a coil to remain in auxiliary sensor failure and an external box temperature alarm is recommended if this
defrost. Defrost will be terminated if the defrost end temperature measured at the evaporator(s) functionality is desired. When used for box thermostat functionality setting the low and high
(both must be at temp if two evaporators) or the defrost end pressure is not attained when this temperature alarms (parameters ALRL, ALRH) is recommended. The recommended location
time has expired. Default: 25 minutes. of the auxiliary temperature sensor for box thermostat control is on the inlet air side of the
evaporator. Default: OFF.
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 Box thermostat set point – BOXT– This parameter is the box temperature, or room
minutes. Default: 2 minutes. 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
Evaporator Refreeze Temperature – FZET– This is the evaporator temperature at which this set point for refrigeration operation. This parameter will only appear in the menu if
the fans energize after the refreeze (fan delay) period unless the maximum refreeze time is AUXT is enabled. Default 35 degrees Fahrenheit. The box thermostat set-point range is
reached. The selection range is 20F to 40F. -25°F to 50°F.

Evaporator Refreeze Maximum Time - FZTM- This is the maximum time for the refreeze Modbus address - MBAd- multiple Mohave control boards may be connected via Modbus
(fan delay) period. The selection range is 0 to 10 minutes. 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 Forced Output Items
The Monitor button is used to examine and review the current operating conditions of the These items are displayed as the blue knob is turned in a clockwise direction. Turning the knob
system. 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 EVPF....... Evaporator Fan Contactor
few seconds delay the current value of the item will display. Each time the button is pressed a LIQS....... Liquid Line Solenoid
different item is displayed. EVPH....... Evaporator Pan Heater
FAN4....... Condenser Fan #4 Contactor
Monitor Button Items FAN3....... Condenser Fan #3 Contactor
VALP. . . . . Defrost Regulator Valve percent of opening (0 to 100%) FAN2....... Condenser Fan #2 Contactor
SUPH. . . . . Superheat (°F) measured at inlet of Suction Accumulator FAN1....... Condenser Fan #1 Contactor
SucT. . . . . Suction Temperature (°F) at inlet of Suction Accumulator COMP....... Compressor Contactor
SucP. . . . . Suction Pressure (PSIG/HG) at inlet of Suction Accumulator BYPV....... Bypass Solenoid
SSuc. . . . . Saturated Suction Temperature (°F) SucS....... Suction Stop Solenoid
LIQP. . . . . Liquid Pressure measured between CU Receiver and Condenser DEFS....... Defrost Solenoid
AMBT. . . . . Ambient Temperature (°F) measured at condenser coil 3WAY....... 3-Way Valve Solenoid
AUXT. . . . . Auxiliary Temperature (°F) ALRM....... Alarm Contacts
E1DT. . . . . Evaporator #1 Defrost Termination Temp (°F) VALS....... Regulator Valve control
E2DT. . . . . Evaporator #2 Defrost Termination Temp (°F) EVAC....... Evacuate System Mode
ACIN. . . . . Control Board voltage (24VAC nominal)
TMMS. . . . . Current time minutes-seconds Pressing ENTER when VALS is selected causes the number 0 to be displayed. This
TMHM. . . . . Current time hours-minutes represents the percentage of regulator valve opening. Turning the blue knob will increase or
CCYC. . . . . Compressor cycles since midnight decrease this number until a desired setting is made. Press the ENTER button to force the
RnTM. . . . . Compressor run time since midnight regulator to change to the desired setting.
DFTM. . . . . Duration of last defrost
ETLD. . . . . Elapsed time since last defrost CLEAR/TEST Button
RTLD. . . . . Run time since last defrost Pressing this button ONCE will return the LED display to the default display. With the system
VERS. . . . . Software version in the OFF mode, pressing this button will activate the TESTmode. 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.
Force Defrost
To force a ‘defrost’, press the FORCE DEFROST button. The system will pump-down and shut Status Indicator Led
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
A red, four digit, alphanumeric LED on the hot gas control board indicates status,
DEF1. alarms, and error codes.

LED Display Mode

Reset Time OFF Off
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
COOL Cooling
after a valid ‘T-stat’ signal is recognized. The display will show DELY.
DELY Delay
PMPD Pump Down
DEF1 Pre-Defrost Bypass
Force Service DEF2 Defrost
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
DEF3 Drain down
into FORCE SERVICE mode, the display will show SERV.
FREZ Refreeze
TEST Test
While in ‘Service mode’, individual outputs may be activated by selecting the desired output SERV Service
circuit and pressing the ENTER button. The output circuit is selected by turning the blue knob.
Turning the blue knob completely counter-clockwise selects EVPFor evaporator fans.

52
 Error and Alarm Details
Alarms Mode Safety Circuit Interruption - Alr3
Alr1 Persistent input sensor/transducer failure If the safety circuit input signal is broken during normal refrigeration or defrost,
Alr2 Combined Err4 and Err8, system off Err9 is displayed. This failure is caused when one of the components connected
Alr3 Repeated Safety Circuit Open condition to the Service MateTM such as the oil pressure switch or the high pressure switch
Alr4 Prolonged cooling startup failure opens unexpectedly.
Alr5 High auxiliary temperature sensor alarm
The hot gas controller will wait 4 minutes and attempt to restart the interrupted
Alr6 Low auxiliary temperature sensor alarm.
process. If successful, the error is cleared. If unsuccessful, the system will shutdown
NOTE: An Alarm Activation turns on the Alarm Relay and LED again and try to restart later. If the problem persists, Alr3 will be activated.

Errors Mode Failure to Start Errors - Alr4

Err1 Suction temperature sensor open or short Normal start up processes for cooling mode requires a specific pressure range to be
Err2 present at the suction pressure sensor. If the measured pressure is too high or too
Ambient temp sensor open or short
low, steps are taken to cause the pressure to adjust before full cooling mode can
Err3 Auxiliary temp sensor open or short
be achieved. If these methods are not successful within 2 minutes, Er11 (for a
Err4 Suction Pressure sensor open or short pressure too low) or Er12 (for a pressure too high) is displayed. The system will
Err5 Liquid Pressure sensor open or short continue trying to start every four minutes. If the error persists for the amount of time
Err6 Evap 1 defrost temp sensor open or short programmed in step ALRT, Alr4 will be activated.
Err7 Evap 2 defrost temp sensor open or short
Err8 Redundant low pressure switch open or short Box Thermostat (Feature Enabled) Limits Exceeded -
Err9 Safety Circuit interruption during normal operation Alr5, Alr6
Er10 Prolonged Low Suction Pressure during cooling High auxiliary temperature sensor alarm - ALR5. This alarm energizes the alarm
Er11 Low Suction Pressure startup failure relay output if the measure auxiliary temperature sensor value is above the ALRH
Er12 High Suction Pressure startup failure set point for a length of the ALRT time, and de-energizes the alarm relay output
Er13 Post Defrost pump down error immediately when the temperature is no longer above the ALRH set point.

Component Errors - Alr1 Low auxiliary temperature sensor alarm – ALR6. This alarm energizes the
During operation, the hot gas control board examines each input device to determine alarm relay output if the measured auxiliary temperature sensor value is below the
if its signal falls within a preset operational window. When the input device fails, the ALRL set point for a length of the ALRT time, and de-energizes the alarm
control board identifies the member by flashing an error code on the LED display. If relay output immediately when the temperature is no longer below the ALRLset
the signal is restored to normal parameters, the error code is immediately removed. point.
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 Persistant Low Suction Pressure - Er10
the alarm LED to turn on, it does not shut the system down. When the measured suction pressure falls to 0 psig or less, the system will shut
When one of the input sensors fail, the hot gas controller will adjust its decision down and display Er10. The duration of time that is allowed is dependent on the
making process to accomodate the loss. These adjustments are referred to as measured ambient temperature. If the ambient temperature is above 20ºF, the shut
contingencies and are stop-gap measures to keep the system running until the failed down is immediate. If the ambient is 20ºF or less, the low pressure condition must
component can be replaced. persist for 15 seconds before the error is identified.

Shut down Error - Alr2 Suction Pressure Fails to Drop Following Defrost or
If the suction pressure sensor fails (Err4, Alr1), the redundant low Cooling, ER12, ER13
pressure switch is used to operate the system during refrigeration until the pressure If the suction pressure does not drop after 4 minutes of operation following the
sensor can be replaced. If the redundant low pressure switch also fails (Err8), defrost 3 period, Er13 is displayed. This will not cause an alarm condition
the system will stop operating and display Alr2.
because the system will begin attempting to start a cooling cycle 4 minutes later,
If the pressure sensor is replaced, the system will begin operating again normally. and the high pressure start-up fault (Er12) will take over.
If the pressure switch is replaced, the system will operate under the Err4,
Alr1 constraints.

Component Errors - Alarm 1 - Contingency Chart

Component Error # Contingency
Suction Temperature Sensor Open or Short Err1 Regulator control during defrost will be by pressure only
Ambient Temperature Sensor Open or Short Err2 Condenser fans configured for ambient control will cycle with compressor
Suction Pressure Sensor Open or Short Err4 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
Liquid Pressure Sensor Open or Short Err5 Condenser fans configured for pressure control will cycle with the compressor; defrosts will terminate by evap
temperature
Evap 1 Defrost Temperature Sensor Open or Short Err6 Two evap systems will use other evap sensor or system will pressure terminate defrost, refreeze will be time value
Evap 2 Defrost Temperature Sensor Open or Short Err7 Two evap systems will use other evap sensor or system will pressure terminate defrost, refreeze will be time value
Redundant Low Pressure Switch Malfunction Detected Err8 System will operate normally, this is a back-up device
*DEFA Displayed in this Mode

53
 Refrigerant Charging
Refrigerant Charging Instructions Charge Quantity and Condenser Fan Control
1. Install a liquid line drier in the refrigerant supply line between the service The method of head pressure control affects refrigerant charge and the staging of
gauge and the liquid service port of the receiver. This extra drier will insure the condenser fans. The system should have the minimum charge necessary to allow
that all refrigerant supplied to the system is clean and dry. for proper operation at all expected conditions. Condenser fan control settings should
balance system efficiency with fan motor power consumption. Stable pressures
2. When initially charging a system that is in a vacuum, liquid refrigerant can during refrigeration are another important consideration. The following guidelines are
be added directly into the receiver tank. intended to support these goals.

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.

Receiver Capacities and Head Pressure Valve Flooding Charges

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

Condenser Flooding Charge, Lbs

(90%) RECEIVER 20F SST 10F SST 20F SST 10F SST
MODEL/ REFRIG SIZE CAPACITY Lbs -20F AMB -20F AMB 20F AMB 20F AMB

M6 (R404A/R507) 752, 762 81 15 16 13 14

M6 (R404A/R507) 802 81 20 21 17 19
M6 (R404A/R507) 1002, 1202 81 27 29 24 25
M6 (R404A/R507) 1502, 2002 123 45 47 39 42
M6 (R404A/R507) 2502 123 67 71 59 63
M6 (R404A/R507) 3002 188 67 71 59 63
M6 (R404A/R507) 3502 188 89 95 78 84
M6 (R404A/R507) 4002 188 84 90 74 79
M6 (R407A,C,F) 752, 762 88 17 18 15 16
M6 (R407A,C,F) 802 88 22 23 19 20
M6 (R407A,C,F) 1002, 1202 88 30 31 26 28
M6 (R407A,C,F) 1502, 2002 135 49 52 43 46
M6 (R407A,C,F) 2502 135 73 78 64 69
M6 (R407A,C,F) 3002 205 73 78 64 69
M6 (R407A,C,F) 3502 205 98 104 86 92
M6 (R407A,C,F) 4002 205 92 98 81 87
M6 (R448A/449A) 752, 762 85 16 17 14 15
M6 (R448A/449A) 802 85 21 22 19 20
M6 (R448A/449A) 1002, 1202 85 29 31 25 27
M6 (R448A/449A) 1502, 2002 131 47 50 42 45
M6 (R448A/449A) 2502 131 71 76 63 67
M6 (R448A/449A) 3002 199 71 76 63 67
M6 (R448A/449A) 3502 199 95 101 83 89

54
 Refrigerant Charging
Condenser Flooding Charge, Lbs

(90%) RECEIVER -5F SST -25F SST -5F SST -25F SST
MODEL/ REFRIG SIZE CAPACITY Lbs -20F AMB -20F AMB 20F AMB 20F AMB

L6 (R404A/R507) 0602, 0752 81 16 17 14 16

L6 (R404A/R507) 0902, 1002, 1202 81 21 22 19 21
L6 (R404A/R507) 1502 81 28 30 26 28
L6 (R404A/R507) 2202 123 47 50 42 47
L6 (R404A/R507) 2702, 3002 123 65 69 59 65
L6 (R407A,F) 0602, 0752 88 17 18 16 17
L6 (R407A,F) 0902, 1002, 1202 88 23 24 21 23
L6 (R407A,F) 1502 88 31 33 28 31
L6 (R407A,F) 2202 135 51 54 46 51
L6 (R407A,F) 2702, 3002 135 71 75 65 71
L6 (R448A/449A) 0602, 0752 85 17 18 15 17
L6 (R448A/449A) 0902, 1002, 1202 85 22 23 20 22
L6 (R448A/449A) 1502 85 30 32 27 30
L6 (R448A/449A) 2202 131 50 53 45 50
L6 (R448A/449A) 2702, 3002 131 69 73 63 69

Systems with Pressure Fan Cycling for Head Pressure Systems with Floating (Low) Head Pressure
Control (Standard) For these systems the general recommendation is to use a clear sight glass as an
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
indication of proper refrigerant charge, then add another 10% to compensate for cycle settings should be temporarily changed to yield a 105°F minimum condensing
liquid pressure changes during fan cycling. During cooler ambient temperatures temperature during the charging process. An alternate method is to temporarily block
the fan cycle settings should be temporarily changed to yield a 105°F minimum a portion of the entering air condenser surface to restrict airflow. In these cases, the
condensing temperature during the charging process. An alternate method is to settings should be maintained until the evaporator superheat has been checked and
temporarily block a portion of the entering air condenser surface to restrict airflow. adjusted.
In these cases, the settings should be maintained until the evaporator superheat has There are a number of different fan cycling possibilities for floating head systems.
been checked and adjusted. Generally, fans are turned off with decreasing ambient temperature to save energy.
The default pressure fan cycling settings are optimized to maintain a minimum 65°F The first (header) fan is run continuously with the compressor and other fans are
condensing temperature. These settings may be changed if desired. 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 Suction superheat should be checked at the compressor as follows:
After the system has been charged and has operated for at least two hours at normal 1. Measure the suction pressure at the suction service
operating conditions without any indication of malfunction, it should be allowed to valve of the compressor and determine the saturation
operate overnight on automatic controls. Then a thorough recheck of the entire temperature corresponding to this pressure from a “Temperature-Pressure”
system operation should be made as follows: chart.
(a) Check compressor discharge and suction pressures. 2. Measure the suction temperature of the suction line about one foot back
If not within system design limits, determine why and take corrective action. from the compressor using an accurate thermometer.
(b) Check liquid line sight glass and expansion valve operation. If there are 3. Subtract the saturated temperature from the actual suction line temperature.
indications that more refrigerant is required, leak test all connections and The difference is superheat.
system components and repair any leaks before adding refrigerant.
(c) Observe oil level in compressor crankcase sight glass. Add oil as necessary Too low a suction superheat can result in liquid being returned to the compressor.
to bring level to bottom 1/4 of the sight glass. This will cause dilution of the oil and eventual failure of the bearings and rings or in
(d) Thermostatic expansion valves must be checked for proper superheat the extreme case, valve failure.
settings. Valves set at high superheat will lower refrigeration capacity. Low Too high a suction superheat will result in excessive discharge temperatures which
superheat promotes liquid slugging and compressor bearing washout. cause a break down of the oil and results in piston ring wear, piston and cylinder wall
(e) Using suitable instruments, carefully check line voltage and amperage at damage.
the compressor terminals. Voltage must be within 10% of that indicated It should also be remembered that the system capacity decreases as the suction
on the condensing unit nameplate. If high or low voltage is indicated, superheat increases. For maximum system capacity, suction superheat should be kept
notify the power company. If amperage draw is excessive, immediately as low as is practical. Copeland mandates a minimum superheat of 20˚F at the
determine the cause and take corrective action. On three phase motor compressor. We recommend that the superheat at the compressor be between
compressors, check to see that a balanced load is drawn by each phase. 20˚F and 30˚F.
(f) The maximum approved settings for high pressure controls on our air If adjustments to the suction superheat need to be made, the expansion valve at the
cooled condensing equipment is 425 psig. On air cooled systems, check as evaporator should be adjusted.
follows: Disconnect the fan motors or block the condenser inlet air. Watch
high pressure gauge for cutout point. Recheck all safety and operating Evaporator Superheat
controls for proper operation and adjust if necessary. Check Your Superheat. After the box temperature has reached or is close to
(g) Once the room is near design temperature, observe a defrost cycle. The reaching the desired temperature, the evaporator superheat should be checked and
defrost sequence may be manually started by pressing the force defrost adjustments made if necessary. Generally, systems with a design TD of 10˚F should
button have a superheat value of 6˚ to 10˚F for maximum efficiency. For systems operating at
(h) Check drain pan for proper drainage. higher TD’s, the superheat can be adjusted to 12˚ to 15˚ ˚F as required.
(i) Check head pressure controls for pressure setting.
(j) Check crankcase heater operation. NOTE: M
 inimum compressor suction superheat
(k) Install instruction card and control system diagram for use of building of 20˚F may override these recommendations
manager or owner. 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 1. Measure the temperature of the suction line at the
necessary to balance each and every system. point the bulb is clamped.

This is extremely important with any refrigeration system. 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
The critical value which must be checked is suction superheat.
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 Polyol Ester Lubricants

Ester lubricants (POE) have the characteristic of quickly absorbing moisture from
The Mobil EAL ARCTIC 22 CC is the preferred Polyol ester due to unique additives
the ambient surroundings. This is shown graphically in Figure 7 where it can be
included in this lubricant. ICI Emkarate RL 32S is an acceptable Polyol ester lubricant
seen that such lubricants absorb moisture faster and in greater quantity than
approved for use when Mobil is not available. These POE’s must be used if HFC
conventional mineral oils. Since moisture levels greater than 100 ppm will results in
refrigerants are used in the system. They are also acceptable for use with any of the
system corrosion and ultimate failure, it is imperative that compressors, components,
traditional refrigerants or interim blends and are compatible with mineral oils. They
containers and the entire system be kept sealed as much as possible. Lubricants will
can therefore be mixed with mineral oils when used in systems with CFC or HCFC
be packaged in specially designed, sealed containers. After opening, all the lubricant in
refrigerants. These lubricants are compatible with one another and can be mixed.
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!

Table 7. Refrigeration Oils

HFC's R-404A, R-507, R-407A, R-407C, R-407F
Traditional Refrigerants and Refrigeration Oils
HFO Blends R-448A, R-449A
Mobil EAL ARCTIC 22 CC P
POE's
ICI (Virginia KMP) EMKARATE RL 32CF P
P = Preferred Lubricant Choice A = Acceptable Alternative
*(Reprinted by permission from Copeland Corporation)

Color Figure 7.
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
58
Problem Step Action Item If OK If Not OK
1 Check Primary Power Supply Disconnect Check fuses and/or circuit breakers

Input Power LED on Controller Board 2 Check Voltage to 24V transformers in Condensing Unit Electrical Box Go to Re-set circuit breaker(s) on transformers
is not lit 3 Check Transformer Secondary Output Volts next Replace transformers if necessary, if voltage is low, check tap position on primary
4 Check Voltage to Controller Board step Check factory Wiring and Connections
5 Replace Board
Go to
Controller Board has Input Power,
1 Verify that Black Jumper Is Installed on “Pic Pwr” Pins to the Right of the Backup Battery Power Supply next Install Jumper if Missing
Display is Blank
step
Go to
Board Loses Time of Day Settings
1 Replace Battery on Controller Board next
when Power Interrupted
step
1 Check that the Sensor Connections are Secure at Board; Check Field Wiring if Evap Defrost Temp Sensor Secure, Correct the Wiring if Loose, Incorrect or Shorted
Err1, Err2, Err6, Err7 (with or without 2 Ohm the Sensor to Detect Open or Short Condition Replace Sensor if Open or Shorted
Go to
Alr1) Displaying on Controller Sensor
3 Check the Sensor Positions for Correct Placement next Place Sensor in Correct Position+
Open or Shorted-and-Temp Sensor
4 Compare Displayed Value (Use Monitor Function) to Thermometer at Sensor Location step Replace Sensor if Readings do not agree
General Troubleshooting
5 Compare Displayed Value (Use Monitor Function) to Reference Temp on Ohm Table++ Replace Board if Readings do not agree
Hot Gas Controller Troubleshooting Chart

1 Check that the Sensor Connections are Secure at Board and at the Sensor Secure, Correct the Wiring if Loose, Incorrect or Shorted
2 Ohm the Sensor to Detect Open or Short Condition Replace Sensor if Open or Shorted
Err4, Err5 (with or without Alr1)
3 Check Controller Board for Shorted Components if Sensor was Shorted Go to Replace Board if Damaged
Displaying on Controller Sensor
next
Open or Shorted-and-Pressure 4 Check Refrigerant Type In Program Menu Change Refrigerant Type Selected to Actual Refrigerant Used
step
Sensor General Troubleshooting
5 Check the Sensor Positions for Correct Placement Place Sensor in Correct Position (see Piping Diagram in Manual)
6 Compare Displayed Value (Use Monitor Function) to Gauge at Sensor Location Replace Sensor if Readings do not agree
1 Check ServiceMate Status and ServiceMate Reference Guide Go to Follow General System Troubleshooting Chart, LPS Function is on the Control Board
Err9 (with or without Alr3) (Safety
2 Check Compressor Contactor(s) and Auxiliary Switch(es) for Proper Operation next Replace contactor(s) or Auxiliary Switch(es)
Circuit Opening)
3 Check Relay 1 for Proper Wiring and Operation step Replace Relay 1 or Correct Wiring
1 View Displayed Value (Use Monitor Function) for the Suction Pressure Sensor Go to Follow General System Troubleshooting Chart for Low Suction Pressure
Er10 (Prolonged Low Suction
next
Pressure) 2 Compare Displayed Value (Use Monitor Function) to Gauge at Suction Pressure Sensor Location Go To Pressure Sensor Troubleshooting
step
1 View Displayed Value (Use Monitor Function) for the Suction Pressure Sensor Go to Follow General System Troubleshooting Chart for Low Suction Pressure
Er 11 (Low Suction Pressure at
2 Compare Displayed Value (Use Monitor Function) to Gauge at Suction Pressure Sensor Location next Go To Pressure Sensor Troubleshooting
Startup) (with or without Alr4)
3 Check the Liquid Solenoid Valve for Proper Wiring and Operation step Replace valve or correct wiring
Troubleshooting

1 View Displayed Value (Use Monitor Function) for the Suction Pressure Sensor Follow General System Troubleshooting Chart for High Suction Pressure
2 Compare Displayed Value (Use Monitor Function) to Gauge at Suction Pressure Sensor Location Go to Go To Pressure Sensor Troubleshooting
Er12 (High Suction Pressure at
3 Check Bypass Valve for Proper Wiring and Operation next Replace valve or correct wiring
Startup) (with or without Alr4)
4 Check Defrost Valve for Proper Wiring and Operation step Replace valve or correct wiring , make sure manual lift feature is disabled if present
5 Check compressor for problems (valve or running gear issues) Replace or repair compressor
1 Check Bypass Valve for Proper Wiring and Operation Replace valve or correct wiring
2 Check Defrost Valve for Proper Wiring and Operation Go to Replace valve or correct wiring , make sure manual lift feature is disabled if present
Er13 (Post Defrost Pumpdown Error) next
3 Check the Liquid Solenoid Valve for Proper Wiring and Operation step Replace valve or correct wiring
4 Check compressor for problems (valve or running gear issues) Replace or repair compressor
+ Temperature Sensor Positions:
Ambient Sensor is Secured on the Condenser Side Panel to Measure Air Temperature Entering #1 Condenser Cell
Suction and Defrost Temperature Sensors are Secured in Copper Sensor Well on the Side of the Suction Line
++ Temperature Sensor Ohm Range
TEMP ºF OHMS TEMP ºF OHMS
104 5320 32 32650
86 8060 23 42330
77 10000 14 55330
68 12490 5 72950
59 15710 -4 97070
50 19900 -13 130410
41 25400 -22 176960
 Troubleshooting
General Evaporator Troubleshooting Chart

SYMPTOMS POSSIBLE CAUSES POSSIBLE CORRECTIVE STEPS

Fan(s) will not operate 1. Main switch open 1. Close switch
2. Blown fuses 2. Replace fuses. Check for short
circuits or overload conditions
3. Defective motor 3. Replace motor
4. Defective timer or defrost thermostat 4. Replace defective component
5. Unit in defrost cycle 5. Wait for completion of cycle

Room temperature too high 1. Room thermostat set too high 1. Adjust thermostat
2. Superheat too high 2. Adjust thermal expansion valve
3. System low on refrigerant 3. Add refrigerant
4. Coil iced-up 4. Manually defrost coil. Check defrost
controls for malfunction
5. Unit cooler located too close to doors 5. Relocate unit cooler or add strip curtain
to door opening
6. Heavy air infiltration 6. Seal unwanted openings in room

Ice accumulating on ceiling 1. Defrost duration is too long 1. Adjust defrost termination settings
around evaporator and/or on 2. Defective defrost thermostat or timer 2. Replace defective component
fan guards venturi or blades 3. Too many defrosts 3. Reduce number of defrosts


Coil not clearing of frost during 1. Coil temperature not getting above 1. Check heater operation
defrost cycle freezing point during defrost
2. Not enough defrost cycles per day 2. Adjust controller for more defrost cycles
3. Defrost cycle too short 3. Adjust defrost settings for longer cycle
4. Defective timer or defrost thermostat 4. Replace defective component

Ice accumulating in drain pan 1. Defective heater 1. Replace heater

2. Unit not pitched properly 2. Check and adjust if necessary
3. Drain line plugged 3. Clean drain line
4. Defective drain line heater 4. Replace heater
5. Defective timer or thermostat 5. Replace defective component

Uneven coil frosting 1. Located too close to door or opening 1. Relocate evaporator
2. Defrost termination set too low 2. Adjust defrost termination setting
higher.
3. Incorrect or missing distributor nozzle 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. 1. Close switch.
2. Fuse blown. 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. 3. Overloads are automatically reset. Check unit closely when
unit comes back on line.
4. Defective contactor or coil. 4. Repair or replace.
5. System shut down by safety devices. 5. Determine type and cause of shutdown and correct it before
resetting safety switch.

6. No cooling required. 6. None. Wait until calls for cooling.
7. Liquid line solenoid will not open. 7. Repair or replace coil.
8. Motor electrical trouble. 8. Check motor for open windings, short circuit
or burn out.
9. Loose wiring. 9. Check all wire junctions. Tighten all
terminal screws.
10. Phase loss monitor inoperative. 10. Refer to page 24.

Compressor noisy or vibrating 1. Flooding of refrigerant into crankcase. 1. Check setting of expansion valves.
2. Improper piping support on suction or 2. Relocate, add or remove hangers.
liquid line.
3. Worn compressor. 3. Replace.
.

High discharge pressure 1. Non-condensables in system. 1. Remove the non-condensables.

2. System overcharges with refrigerant. 2. Remove excess.
3. Discharge shutoff valve partially closed. 3. Open valve.
4. Fan not running. 4. Check electrical circuit.
5. Head pressure control setting. 5. Adjust.
6. Dirty condenser coil. 6. Clean.

Low discharge pressure 1. Faulty condenser temperature regulation. 1. Check condenser control operation.
2. Suction shutoff valve partially closed. 2. Open valve.
3. Insufficient refrigerant in system. 3. Check for leaks. Repair and add charge.
4. Low suction pressure. 4. See corrective steps for low suction pressure.
5. Variable head pressure valve. 5. Check valve setting.

High suction pressure 1. Excessive load. 1. Reduce load or add additional equipment.
2. Expansion valve overfeeding. 2. Check remote bulb. Regulate superheat.

Low suction pressure 1. Lack of refrigerant. 1. Check for leaks. Repair and add charge.
2. Evaporator dirty or iced. 2. Clean.
3. Clogged liquid line filter drier. 3. Replace cartridge(s).
4. Clogged suction line or compressor 4. Clean strainers.
suction gas strainers.
5. Expansion valve malfunctioning. 5. Check and reset for proper superheat.
6. Condensing temperature too low. 6. Check means for regulating condensing temperature.
7. Improper TXV. 7. Check for proper sizing.

Little or no oil pressure 1. Clogged suction oil strainer. 1. Clean.
2. Excessive liquid in crankcase. 2. Check crankcase heater. Reset expansion valve for higher
superheat. Check liquid line solenoid valve operation.
3. Low oil pressure safety switch defective. 3. Replace.
4. Worn oil pump. 4. Replace.
5. Oil pump reversing gear stuck in wrong 5. Reverse direction of compressor rotation.
position.
6. Worn bearings. 6. Replace compressor.
7. Low oil level. 7. Add oil and/or through defrost.
8. Loose fitting on oil lines. 8. Check and tighten system.
9. Pump housing gasket leaks. 9. Replace gasket.

Compressor loses oil 1. Lack of refrigerant. 1. Check for leaks and repair. Add refrigerant.
2. Excessive compression ring blow by. 2. Replace compressor.
3. Refrigerant flood back. 3. Maintain proper superheat at
compressor.
4. Improper piping or traps. 4. Correct piping.

Compressor thermal protector switch open 1. Operating beyond design conditions. 1. Add components to bring conditions
within acceptable limits (Consult Heatcraft)
2. Discharge valve partially shut. 2. Open valve.
3. Blown valve plate gasket. 3. Replace gasket.
4. Dirty condenser coil. 4. Clean coil.
5. Overcharged system. 5. Reduce charge.

60
 Preventive Maintenance
Unit Coolers Air Cooled Condensing Units
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.
Quarterly
1) Visually inspect unit
• Look for signs of corrosion on fins, cabinet, copper tubing and solder joints. 1) Visually inspect unit
• Look for signs of oil stains on interconnection piping and
• Look for excessive or unusual vibration for fan blades
or sheet metal panels when in operation. Identify fan condenser coil. Pay close attention to areas around
cell(s) causing vibration and check motor and blade solder joints, building penetrations and pipe clamps.
carefully. Check any suspect areas with an electronic leak detector.
Repair any leaks found and add refrigerant as needed.
• Look for oil stains on headers, return bends, and coil
fins. Check any suspect areas with an electronic leak
detector. • Check condition of moisture indicator/sightglass in the
sight glass if so equipped. Replace liquid line drier if there
• Check drain pan to insure that drain is clear of debris, is indication of slight presence of moisture. Replace
obstructions or ice buildup and is free draining. refrigerant, oil and drier if moisture concentration is
2) Clean evaporator coil and blades indicated to be high.

• Periodic cleaning can be accomplished by using a brush, • Check moisture indicator/sightglass for flash gas. If found
pressurized water or a commercially available evaporator
coil cleaner or mild detergent. Never use an acid check entire system for refrigerant leaks and add
based cleaner. Follow label directions for appropriate refrigerant as needed after repairing any leaks.
use. Be sure the product you use is approved for use in
your particular application. • Check compressor sightglass (if equipped) for
• Flush and rinse coil until no residue remains. proper oil level.

• Pay close attention to drain pan, drain line and trap. • Check condition of condenser. Look for accumulation
of dirt and debris (clean as required).
3) Check the operation of all fans and ensure airflow is
unobstructed
• Check for unusual noise or vibration. Take corrective
• Check that each fan rotates freely and quietly. Replace action as required.
any fan motor that does not rotate smoothly or makes an
unusual noise.
• Inspect wiring for signs of wear or discoloration and
• Check all fan set screws and tighten if needed. repair if needed.

• Check all fan blades for signs of stress or wear. • Check and tighten all flare connections.
Replace any blades that are worn, cracked or bent.
• Verify that all fan motors are securely fastened to the Semi-Annually
motor rail.
2) Repeat all quarterly inspection items.
• Lubricate motors if applicable.
3) Clean condenser coil and blades
4) Inspect electrical wiring and components
• Periodic cleaning can be accomplished by using a brush,
• Visually inspect all wiring for wear, kinks, bare areas and pressurized water and a commercially available foam coil
discoloration. Replace any wiring found to be damaged. cleaner. If foam cleaner is used, it should not be an acid
based cleaner. Follow label directions for appropriate use.
• Verify that all electrical and ground connections are
secure, tighten if necessary. • Rinse until no residue remains.
• Check operation/calibration of all fan cycle and
defrost controls when used. 4) Check operation of condenser fans
• Check that each fan rotates freely and quietly.
• Look for abnormal accumulation of ice patterns and Replace any fan motor that does not rotate smoothly
adjust defrost cycles accordingly or makes excessive noise.
• Compare actual defrost heater amp draw against unit • Check all fan blade set screws and tighten as required.
data plate.
• Check drain line heat tape for proper operation • Check all fan blades for signs of cracks, wear or stress.
(supplied and installed by others). Pay close attention to the hub and spider. Replace blades
as required.
5) Refrigeration Cycle
• Check unit cooler superheat and compare reading for • Verify that all motors are mounted securely.
your specific application
• Lubricate motors if applicable. Do not lubricate
• Visually inspect coil for even distribution permanently sealed, ball bearing motors.

61
 Preventive Maintenance
Semi-Annually (cont.) Annually

5) Inspect electrical wiring and components 7) In addition to quarterly and semiannual maintenance
checks, submit an oil sample for analysis
• Verify that all electrical and ground connections are
secure, tighten as required. • Look for high concentrations of acid or moisture. Change
oil and driers until test results read normal.
• Check condition of compressor and heater contactors.
Look for discoloration and pitting. Replace as required. • Investigate source of high metal concentrations, which
normally are due to abnormal bearing wear. Look for
• Check operation and calibration of all timers, relays liquid refrigerant in the crankcase, low oil pressure or low
pressure controls and safety controls. superheat as a possible source.

• Clean electrical cabinet. Look for signs of moisture, dirt, 8) Inspect suction accumulator (if equipped)
debris, insects and wildlife. Take corrective action as required.
• If the accumulator is insulated remove insulation and
inspect for leaks and corrosion.
• Verify operation of crankcase heater by measuring amp draw.
• Pay close attention to all copper to steel brazed connections
6) Check refrigeration cycle
• Check suction, discharge and net oil pressure readings. • Wire brush all corroded areas and peeling paint.
If abnormal take appropriate action.
• Apply an anticorrosion primer and paint as required.
• Check pressure drop across all filters and driers. Re-insulate if applicable.
Replace as required.
• Check accuracy of the suction line temperature and pressure
• Verify that superheat at the compressor conforms to sensors before the suction accumulator by comparing the controller
specification. (See page 54) reading in the monitor mode to a thermometer and pressure gauge
of known accuracy
• Check pressure and safety control settings and verify
proper operation.

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 CONDENSING UNIT PIPING COMPONENTS
Part Num- Suction
Defrost Bypass
Description ber Condensing 3-Way Stop Aeroquip
Solenoid Solenoid
Hot Gas Control Board 28910302 Unit Model Valve Solenoid Hose
Valve Valve
Valve
Transformer 100VA 24V - 208/230V 22555601
0602L6 29323601 29330301 29321701 29324201 28991004
Electronic Pressure Regulator +
29326701
0752L6 29323601 29330301 29321701 29324201 28991004
Pressure Regulator Harness+ 22592201
0902L6 29323701 29330401 29321801 29324201 28991002
Suction Pressure Transducer (0-300 PSIA) 28911202
01002L6 29323701 29330401 29321801 29324201 28991002
Suction Transducer Harness (Blue) 22515102
01202L6 29323701 29330401 29321901 29324201 28991002
Liquid Pressure Transducer (0-500 PSIA) 28911203
01502L6 29323701 29330402 29321901 29324301 28991002
Liquid Transducer Harness (Black) 22515103
2202L6 29323701 29330402 29330402 29324301 28991001
Suction Temp Sensor (Blue) 28900310
2702L6 29323801 29330403 29330402 29324301 28991009
Ambient /Room Temp Sensor (White 93"
28900311 3002L6 29323801 29330403 29330402 29324301 28991009
leads)
High Pressure Switch 28913201 0752 M6 29323701 29330301 29321701 29324201 28991003

Evaporator Sensor 28900108 0762 M6 29323701 29330301 29321701 29324201 28991003

Evaporator Contactor 30A 2252430 0802 M6 29323701 29330401 29321801 29324201 28991002

Evaporator Contactor 40A 2252440 1002 M6 29323701 29330401 29321801 29324201 28991002

Evap Liquid Solenoid 1/2” conn 29324201 1202 M6 29323701 29330402 29321901 29324301 28991002

Evap Liquid Solenoid 5/8” conn 29324301 1502 M6 29323801 29330402 29321901 29324301 28991009
2002 M6 29323801 29330402 29321901 29324301 28991002
Evap Liquid Solenoid 7/8” conn 29324401
2502 M6 29323801 29330403 29330402 29324401 28991001
Low Pressure Switch (Redundant) 2890099
3002 M6 29323801 29330403 29330402 29324401 28991001
Coil (Parker SC) 24V 22593201
3502 M6 29323801 29330402 (2) 29330403 29324401 28991001
4002 M6 29323801 29330402 (2) 29330403 29324401 28991001
0752 M2 29323701 29330301 29321701 29324201 28991003
0762 M2 29323701 29330301 29321701 29324201 28991003
0802 M2 29323701 29330401 29321801 29324201 28991002
1002 M2 29323701 29330401 29321801 29324201 28991002
1202 M2 29323701 29330402 29321901 29324301 28991002
1502 M2 29323801 29330402 29321901 29324301 28991009
2002 M2 29323801 29330402 29321901 29324301 28991002
2502 M2 29323801 29330403 29330402 29324401 28991001
3002 M2 29323801 29330403 29330402 29324401 28991001
3502 M2 29323801 29330402 (2) 29330403 29324401 28991001
4002 M2 29323801 29330402 (2) 29330403 29324401 28991001

*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
 Service Record
A permanent data sheet should be prepared on each refrigeration system at an If another firm is to handle service and maintenance, additional copies should be
installation, with a copy for the owner and the original for the installing contractor's files. 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#: ________________________________________
Unit Serial #: ________________________________________
Compressor Model #: ____________________ Compressor Model #: _________________
Compressor Serial #: ____________________ Compressor Serial #: __________________

Electrical _________________ Volts __________________ Phase_______
Voltage at Compressor L1__________ L2 ___________ L3 ___________
Amperage at Compressor L1__________ L2 ___________ L3 ___________
Evaporator(s) Quantity
________________________________________
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 __________________________˚F
Thermostat Setting ____________________________˚F __________________________˚F
Defrost Setting _____ / day ______ 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

64
 Factory Default Settings
Fan Cycle Settings (Liquid Pressure, PRES), psig DFT 1 CAREL ALCO

MODEL REFRIG SIZE Fan 1 Fan 2 Fan 3 Fan 4 Fan 1 Fan 2 Fan 3 Fan 4 DFT 2 DEFP DEFT EQUT LPSH LPSL FZET FZTM

ON ON ON ON OFF OFF OFF OFF °F psig Min. Min. psig psig °F Min. PRFS PRFS PRUI DFIO

752,
M2 R22 155 170 --- --- 110 145 --- --- 85 210 25 2 16 6 35 4 320 300 15 100
762

M2 R22 802 155 170 --- --- 110 145 --- --- 85 210 25 2 16 6 35 4 320 300 15 100

M2 R22 1002 155 170 --- --- 110 145 --- --- 85 210 25 2 16 6 35 4 350 320 15 100

M2 R22 1202 155 170 --- --- 110 145 --- --- 85 210 25 2 16 6 35 4 380 340 15 100

M2 R22 1502 155 170 --- --- 110 145 --- --- 85 210 25 2 16 6 35 4 410 380 15 100

M2 R22 2002 155 170 --- --- 110 145 --- --- 85 210 25 2 16 6 35 4 470 440 15 100

M2 R22 2502 155 170 180 --- 110 145 155 --- 85 210 25 2 16 6 35 4 510 520 17 100

M2 R22 3002 155 170 180 --- 110 145 155 --- 85 210 25 2 16 6 35 4 550 600 20 100

M2 R22 3502 155 170 180 --- 110 145 155 85 210 25 2 16 6 35 4 570 700 23 100

M2 R22 4002 155 170 180 195 110 145 155 170 85 210 25 2 16 6 35 4 590 780 25 100

752,
M6 R404A 190 205 --- --- 135 175 --- --- 85 210 25 2 24 10 35 4 320 300 15 100
762

M6 R404A 802 190 205 --- --- 135 175 --- --- 85 210 25 2 24 10 35 4 320 300 15 100

M6 R404A 1002 190 205 --- --- 135 175 --- --- 85 210 25 2 24 10 35 4 350 320 15 100

M6 R404A 1202 190 205 --- --- 135 175 --- --- 85 210 25 2 24 10 35 4 380 340 15 100

M6 R404A 1502 190 205 --- --- 135 175 --- --- 85 210 25 2 24 10 35 4 410 380 15 100

M6 R404A 2002 190 205 --- --- 135 175 --- --- 85 210 25 2 24 10 35 4 470 440 15 100

M6 R404A 2502 190 205 220 --- 135 175 190 --- 85 210 25 2 24 10 35 4 510 520 17 100

M6 R404A 3002 190 205 220 --- 135 175 190 --- 85 210 25 2 24 10 35 4 550 600 20 100

M6 R404A 3502 190 205 220 --- 135 175 190 --- 85 210 25 2 24 10 35 4 570 700 23 100

M6 R404A 4002 190 205 220 235 135 175 190 205 85 210 25 2 24 10 35 4 590 780 25 100

752,
M6 R507 195 210 --- --- 140 180 --- --- 85 210 25 2 26 11 35 4 320 300 15 100
762

M6 R507 802 195 210 --- --- 140 180 --- --- 85 210 25 2 26 11 35 4 320 300 15 100

M6 R507 1002 195 210 --- --- 140 180 --- --- 85 210 25 2 26 11 35 4 350 320 15 100

M6 R507 1202 195 210 --- --- 140 180 --- --- 85 210 25 2 26 11 35 4 380 340 15 100

M6 R507 1502 195 210 --- --- 140 180 --- --- 85 210 25 2 26 11 35 4 410 380 15 100

M6 R507 2002 195 210 --- --- 140 180 --- --- 85 210 25 2 26 11 35 4 470 440 15 100

M6 R507 2502 195 210 225 --- 140 180 195 --- 85 210 25 2 26 11 35 4 510 520 17 100

M6 R507 3002 195 210 225 --- 140 180 195 --- 85 210 25 2 26 11 35 4 550 600 20 100

M6 R507 3502 195 210 225 --- 140 180 195 --- 85 210 25 2 26 11 35 4 570 700 23 100

M6 R507 4002 195 210 225 245 140 180 195 210 85 210 25 2 26 11 35 4 590 780 25 100

752,
M6 R407A 190 205 --- --- 135 175 --- --- 85 210 25 2 15 3 35 4 320 300 15 100
762

M6 R407A 802 190 205 --- --- 135 175 --- --- 85 210 25 2 15 3 35 4 320 300 15 100

M6 R407A 1002 190 205 --- --- 135 175 --- --- 85 210 25 2 15 3 35 4 350 320 15 100

M6 R407A 1202 190 205 --- --- 135 175 --- --- 85 210 25 2 15 3 35 4 380 340 15 100

M6 R407A 1502 190 205 --- --- 135 175 --- --- 85 210 25 2 15 3 35 4 410 380 15 100

M6 R407A 2002 190 205 --- --- 135 175 --- --- 85 210 25 2 15 3 35 4 470 440 15 100

M6 R407A 2502 190 205 220 --- 135 175 190 --- 85 210 25 2 15 3 35 4 510 520 17 100

M6 R407A 3002 190 205 220 --- 135 175 190 --- 85 210 25 2 15 3 35 4 550 600 20 100

M6 R407A 3502 190 205 220 --- 135 175 190 --- 85 210 25 2 15 3 35 4 570 700 23 100

65
 Factory Default Settings
Fan Cycle Settings (Liquid Pressure, PRES) , psig DFT 1 CAREL ALCO

MODEL REFRIG SIZE Fan 1 Fan 2 Fan 3 Fan 4 Fan 1 Fan 2 Fan 3 Fan 4 DFT 2 DEFP DEFT EQUT LPSH LPSL FZET FZTM

ON ON ON ON OFF OFF OFF OFF °F psig Min. Min. psig psig °F Min. PRFS PRFS PRUI DFIO

M6 R407A 4002 190 205 220 235 135 175 190 205 85 210 25 2 15 3 35 4 590 780 25 100

752,
M6 R407C 180 195 --- --- 130 165 --- --- 85 210 25 2 12 1 35 4 320 300 15 100
762

M6 R407C 802 180 195 --- --- 130 165 --- --- 85 210 25 2 12 1 35 4 320 300 15 100

M6 R407C 1002 180 195 --- --- 130 165 --- --- 85 210 25 2 12 1 35 4 350 320 15 100

M6 R407C 1202 180 195 --- --- 130 165 --- --- 85 210 25 2 12 1 35 4 380 340 15 100

M6 R407C 1502 180 195 --- --- 130 165 --- --- 85 210 25 2 12 1 35 4 410 380 15 100

M6 R407C 2002 180 195 --- --- 130 165 --- --- 85 210 25 2 12 1 35 4 470 440 15 100

M6 R407C 2502 180 195 210 --- 130 165 180 --- 85 210 25 2 12 1 35 4 510 520 17 100

M6 R407C 3002 180 195 210 --- 130 165 180 --- 85 210 25 2 12 1 35 4 550 600 20 100

M6 R407C 3502 180 195 210 --- 130 165 180 --- 85 210 25 2 12 1 35 4 570 700 23 100

M6 R407C 4002 180 195 210 225 130 165 180 195 85 210 25 2 12 1 35 4 590 780 25 100

752,
M6 R407F 200 215 --- --- 145 185 --- --- 85 215 25 2 16 4 35 4 320 300 15 100
762

M6 R407F 802 200 215 --- --- 145 185 --- 85 215 25 2 16 4 35 4 320 300 15 100

M6 R407F 1002 200 215 --- --- 145 185 --- --- 85 215 25 2 16 4 35 4 350 320 15 100

M6 R407F 1202 200 215 --- --- 145 185 --- --- 85 215 25 2 16 4 35 4 380 340 15 100

M6 R407F 1502 200 215 --- --- 145 185 --- --- 85 215 25 2 16 4 35 4 410 380 15 100

M6 R407F 2002 200 215 --- --- 145 185 --- --- 85 215 25 2 16 4 35 4 470 440 15 100

M6 R407F 2502 200 215 230 --- 145 185 200 --- 85 215 25 2 16 4 35 4 510 520 17 100

M6 R407F 3002 200 215 230 --- 145 185 200 --- 85 215 25 2 16 4 35 4 550 600 20 100

M6 R407F 3502 200 215 230 --- 145 185 200 --- 85 215 25 2 16 4 35 4 570 700 23 100

M6 R407F 4002 200 215 230 250 145 185 200 215 85 215 25 2 16 4 35 4 590 780 25 100

L6 R404A 602 190 205 --- --- 135 175 --- --- 75 180 25 2 10 2 30 4 320 300 15 100

L6 R404A 752 190 205 --- --- 135 175 --- --- 75 180 25 2 10 2 30 4 350 320 15 100

L6 R404A 902 190 205 --- --- 135 175 --- --- 75 180 25 2 10 2 30 4 400 360 15 100

L6 R404A 1002 190 205 --- --- 135 175 --- --- 75 180 25 2 10 2 30 4 410 380 15 100

L6 R404A 1202 190 205 --- --- 135 175 --- --- 75 180 25 2 10 2 30 4 450 420 15 100

L6 R404A 1502 190 205 --- --- 135 175 --- --- 75 180 25 2 10 2 30 4 480 460 16 100

L6 R404A 2202 190 205 --- --- 135 175 --- --- 75 180 25 2 10 2 30 4 540 580 19 100

L6 R404A 2702 190 205 --- --- 135 175 --- --- 75 180 25 2 10 2 30 4 560 660 22 100

L6 R404A 3002 190 205 --- --- 135 175 --- --- 75 180 25 2 10 2 30 4 580 720 23 100

L6 R507 602 195 210 --- --- 140 180 --- --- 75 180 25 2 11 2 30 4 320 300 15 100

L6 R507 752 195 210 --- --- 140 180 --- --- 75 180 25 2 11 2 30 4 350 320 15 100

L6 R507 902 195 210 --- --- 140 180 --- --- 75 180 25 2 11 2 30 4 400 360 15 100

L6 R507 1002 195 210 --- --- 140 180 --- --- 75 180 25 2 11 2 30 4 410 380 15 100

L6 R507 1202 195 210 --- --- 140 180 --- --- 75 180 25 2 11 2 30 4 450 420 15 100

L6 R507 1502 195 210 --- --- 140 180 --- --- 75 180 25 2 11 2 30 4 480 460 16 100

L6 R507 2202 195 210 --- --- 140 180 --- --- 75 180 25 2 11 2 30 4 540 580 19 100

L6 R507 2703 195 210 --- --- 140 180 --- --- 75 180 25 2 11 2 30 4 560 660 22 100

L6 R507 3002 195 210 --- --- 140 180 --- --- 75 180 25 2 11 2 30 4 580 720 23 100

66
 Factory Default Settings
Fan Cycle Settings (Liquid Pressure, PRES) , psig DFT 1 CAREL ALCO

MODEL REFRIG SIZE Fan 1 Fan 2 Fan 3 Fan 4 Fan 1 Fan 2 Fan 3 Fan 4 DFT 2 DEFP DEFT EQUT LPSH LPSL FZET FZTM

ON ON ON ON OFF OFF OFF OFF °F psig Min. Min. psig psig °F Min. PRFS PRFS PRUI DFIO

752,
M6 R448A 195 210 --- --- 140 180 --- --- 85 215 25 2 26 10 35 4 320 300 15 100
762

M6 R448A 802 195 210 --- --- 140 180 --- --- 85 215 25 2 26 10 35 4 320 300 15 100

M6 R448A 1002 195 210 --- --- 140 180 --- --- 85 215 25 2 26 10 35 4 320 300 15 100

M6 R448A 1202 195 210 --- --- 140 180 --- --- 85 215 25 2 26 10 35 4 350 320 15 100

M6 R448A 1502 195 210 --- --- 140 180 --- --- 85 215 25 2 26 10 35 4 380 340 15 100

M6 R448A 2002 195 210 --- --- 140 180 --- --- 85 215 25 2 26 10 35 4 410 380 15 100

M6 R448A 2502 195 210 225 --- 140 180 195 --- 85 215 25 2 26 10 35 4 470 440 17 100

M6 R448A 3002 195 210 225 --- 140 180 195 --- 85 215 25 2 26 10 35 4 510 520 20 100

M6 R448A 3502 195 210 225 --- 140 180 195 --- 85 215 25 2 26 10 35 4 550 600 23 100

M6 R448A 4002 195 210 225 240 140 180 195 210 85 215 25 2 26 10 35 4 570 700 25 100

752
M6 R449A 195 210 --- --- 140 180 --- --- 85 215 25 2 26 10 35 4 590 780 15 100
762

M6 R449A 802 195 210 --- --- 140 180 --- --- 85 215 25 2 26 10 35 4 320 300 15 100

M6 R449A 1002 195 210 --- --- 140 180 --- 85 215 25 2 26 10 35 4 320 300 15 100

M6 R449A 1202 195 210 --- --- 140 180 --- --- 85 215 25 2 26 10 35 4 350 320 15 100

M6 R449A 1502 195 210 --- --- 140 180 --- --- 85 215 25 2 26 10 35 4 380 340 15 100

M6 R449A 2002 195 210 --- --- 140 180 --- --- 85 215 25 2 26 10 35 4 410 380 15 100

M6 R449A 2502 195 210 225 --- 140 180 195 --- 85 215 25 2 26 10 35 4 470 440 17 100

M6 R449A 3002 195 210 225 --- 140 180 195 --- 85 215 25 2 26 10 35 4 510 520 20 100

M6 R449A 3502 195 210 225 --- 140 180 195 --- 85 215 25 2 26 10 35 4 550 600 23 100

M6 R449A 4002 195 210 225 240 140 180 195 210 85 215 25 2 26 10 35 4 570 700 25 100

L6 R448A 602 195 210 --- --- 140 180 --- --- 75 215 25 2 26 2 30 4 590 780 15 100

L6 R448A 752 195 210 --- --- 140 180 --- --- 75 215 25 2 10 2 30 4 320 300 15 100

L6 R448A 902 195 210 --- --- 140 180 --- --- 75 215 25 2 10 2 30 4 350 320 15 100

L6 R448A 1002 195 210 --- --- 140 180 --- --- 75 215 25 2 10 2 30 4 400 360 15 100

L6 R448A 1202 195 210 --- --- 140 180 --- --- 75 215 25 2 10 2 30 4 410 380 15 100

L6 R448A 1502 195 210 --- --- 140 180 --- --- 75 215 25 2 10 2 30 4 450 420 16 100

L6 R448A 2202 195 210 --- --- 140 180 --- --- 75 215 25 2 10 2 30 4 480 460 19 100

L6 R448A 2702 195 210 --- --- 140 180 --- --- 75 215 25 2 10 2 30 4 540 580 22 100

L6 R448A 3002 195 210 --- --- 140 180 --- --- 75 215 25 2 10 2 30 4 560 660 23 100

L6 R449A 602 195 210 --- --- 140 180 --- --- 75 215 25 2 10 2 30 4 580 720 15 100

L6 R449A 752 195 210 --- --- 140 180 --- --- 75 215 25 2 10 2 30 4 320 300 15 100

L6 R449A 902 195 210 --- --- 140 180 --- --- 75 215 25 2 10 2 30 4 350 320 15 100

L6 R449A 1002 195 210 --- --- 140 180 --- --- 75 215 25 2 10 2 30 4 400 360 15 100

L6 R449A 1202 195 210 --- --- 140 180 --- --- 75 215 25 2 10 2 30 4 410 380 15 100

L6 R449A 1502 195 210 --- --- 140 180 --- --- 75 215 25 2 10 2 30 4 450 420 16 100

L6 R449A 2202 195 210 --- --- 140 180 --- --- 75 215 25 2 10 2 30 4 480 460 19 100

L6 R449A 2702 195 210 --- --- 140 180 --- --- 75 215 25 2 10 2 30 4 540 580 22 100

L6 R449A 3002 195 210 --- --- 140 180 --- --- 75 215 25 2 10 2 30 4 560 660 23 100

L6 R407A 602 190 205 --- --- 135 175 --- --- 75 210 25 2 7 0 30 4 580 720 15 100

L6 R407A 752 190 205 --- --- 135 175 --- --- 75 210 25 2 7 0 30 4 320 300 15 100

L6 R407A 902 190 205 --- --- 135 175 --- --- 75 210 25 2 7 0 30 4 350 320 15 100

67
 Factory Default Settings
Fan Cycle Settings (Liquid Pressure, PRES) , psig DFT 1 CAREL ALCO

MODEL REFRIG SIZE Fan 1 Fan 2 Fan 3 Fan 4 Fan 1 Fan 2 Fan 3 Fan 4 DFT 2 DEFP DEFT EQUT LPSH LPSL FZET FZTM

ON ON ON ON OFF OFF OFF OFF °F psig Min. Min. psig psig °F Min. PRFS PRFS PRUI DFIO

L6 R407A 1002 190 205 --- --- 135 175 --- --- 75 210 25 2 7 0 30 4 410 380 15 100

L6 R407A 1202 190 205 --- --- 135 175 --- --- 75 210 25 2 7 0 30 4 450 420 15 100

L6 R407A 1502 190 205 --- --- 135 175 --- --- 75 210 25 2 7 0 30 4 480 460 16 100

L6 R407A 2202 190 205 --- --- 135 175 --- --- 75 210 25 2 7 0 30 4 540 580 19 100

L6 R407A 2702 190 205 --- --- 135 175 --- --- 75 210 25 2 7 0 30 4 560 660 22 100

L6 R407A 3002 190 205 --- --- 135 175 --- --- 75 210 25 2 7 0 30 4 580 720 23 100

L6 R407C 602 180 195 --- --- 130 165 --- --- 75 210 25 2 7 0 30 4 320 300 15 100

L6 R407C 752 180 195 --- --- 130 165 --- --- 75 210 25 2 7 0 30 4 350 320 15 100

L6 R407C 902 180 195 --- --- 130 165 --- --- 75 210 25 2 7 0 30 4 400 360 15 100

L6 R407C 1002 180 195 --- --- 130 165 --- --- 75 210 25 2 7 0 30 4 410 380 15 100

L6 R407C 1202 180 195 --- --- 130 165 --- --- 75 210 25 2 7 0 30 4 450 420 15 100

L6 R407C 1502 180 195 --- --- 130 165 --- --- 75 210 25 2 7 0 30 4 480 460 16 100

L6 R407C 2202 180 195 --- --- 130 165 --- --- 75 210 25 2 7 0 30 4 540 580 19 100

L6 R407C 2702 180 195 --- --- 130 165 --- --- 75 210 25 2 7 0 30 4 560 660 22 100

L6 R407C 3002 180 195 --- --- 130 165 --- --- 75 210 25 2 7 0 30 4 580 720 23 100

L6 R407F 602 200 215 --- --- 145 185 --- --- 75 215 25 2 7 0 30 4 320 300 15 100

L6 R407F 752 200 215 --- --- 145 185 --- --- 75 215 25 2 7 0 30 4 350 320 15 100

L6 R407F 902 200 215 --- --- 145 185 --- --- 75 215 25 2 7 0 30 4 400 360 15 100

L6 R407F 1002 200 215 --- --- 145 185 --- --- 75 215 25 2 7 0 30 4 410 380 15 100

L6 R407F 1202 200 215 --- --- 145 185 --- --- 75 215 25 2 7 0 30 4 450 420 15 100

L6 R407F 1502 200 215 --- --- 145 185 --- --- 75 215 25 2 7 0 30 4 480 460 16 100

L6 R407F 2202 200 215 --- --- 145 185 --- --- 75 215 25 2 7 0 30 4 540 580 19 100

L6 R407F 2702 200 215 --- --- 145 185 --- --- 75 215 25 2 7 0 30 4 560 660 22 100

L6 R407F 3002 200 215 --- --- 145 185 --- --- 75 215 25 2 7 0 30 4 580 720 23 100

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

SEE PAGE 39 OF INSTALLATION MANUAL FOR LOCATION OF PRESSURE

REGULATOR IN CONDENSING UNIT. DETERMINE THE MANUFACTURER
BASED UPON THIS PICTORIAL

70
 Heatcraft Mohave Control Modbus Definitions
Heatcraft Mohave Control Rev. 17 10/4/2016
ModBus Definitions

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) Input Address Byte Addr. Bit Addr.

"Enter" pushbutton 0 0 0
"Clear/Test" pushbutton 1 0 1
"Program Review" pushbutton 2 0 2
"Force Service" pushbutton 3 0 3
"Monitor" pushbutton 4 0 4
"Force Defrost" pushbutton 5 0 5
"Reset Time" pushbutton 6 0 6
Service Switch contacts 7 0 7
Safety Switch contacts 8 1 0
CU Suction Pressure switch contacts 9 1 1
T-Stat contacts 10 1 2
BeaconII I/F current sense 11 1 3
Remote Defrost switch contacts 12 1 4

Coils -
CMD 0x01 (Read), CMD 0x05 (Single Write) Coil Address Byte Addr. Bit Addr.
CMD 0x0F (Multiple Write)

Beacon "Low Pressure Switch" output 0 0 0

Evaporator Heater relay 1 0 1
Liquid Line Solenoids relay 2 0 2
Evaporator Fan relay 3 0 3
Condenser Fan 4 relay 4 0 4
Condenser Fan 3 relay 5 0 5
Condenser Fan 2 relay 6 0 6
Condenser Fan 1 relay 7 0 7
Alarm relay 8 1 0
Compressor relay 9 1 1
Bypass Valve relay 10 1 2
Suction Solenoid relay 11 1 3
Defrost Solenoid relay 12 1 4
3-Way Valve relay 13 1 5

Input Registers -
CMD 0x04 (Read) Data Type Word Addr. Label

Suction Temperature (-55 to +125 degrees F) Word, signed 0 SucT

Ambient Temperature (-55 to +125 degrees F) Word, signed 1 AMBT
Auxilliary Temperature (-55 to +125 degrees F) Word, signed 2 AUXT

71
 Mohave Hot Gas Control Modbus Definitions

Suction Pressure (0 to 300 psia), displayed as 30" Hg to 285 psig Word 3 SucP
Liquid Pressure (0 to 500 psia), displayed as 30" Hg to 485 psig Word 4 LIQP
Evap 1 Defrost Temp (-55 to +125 degrees F) Word, signed 5 E1DT
Evap 2 Defrost Temp (-55 to +125 degrees F) Word, signed 6 E2DT
Saturated Suction Temp (-55 to +125 degrees F) Word, signed 7 SSuc
Suction Superheat (-128 to +127 degrees F) Word, signed 8 SUPH
Regulator Valve position (0 to 820 steps) Word 9 VALP
AC input voltage (0 to 315 volts*10), e.g. 243 = 24.3 Vac Word 10 ACIN
SELECT control position (0=full CCW to 255=full CW) Word 11
Errors (bit-packed): Word 12
0x0001 CU Suction Temperature sensor error Err1
0x0002 CU Ambient Temperature sensor error Err2
0x0004 CU Aux Temperature sensor error Err3
0x0008 CU Suction Pressure sensor error Err4
0x0010 CU Liquid Pressure sensor error Err5
0x0020 Evaporator #1 Defrost Temperature sensor error Err6
0x0040 Evaporator #2 Defrost Temperature sensor error Err7
0x0080 CU Suction Pressure switch error Err8
0x0100 Safety Circuit shut-down error Err9
0x0200 Prolonged low suction pressure shut-down error Er10
0x0400 Low-pressure start-up error Er11
0x0800 High-pressure start-up error Er12
0x1000 Defrost pump-down error Er13
(0x2000 to 0x8000 not used)
Alarms (bit-packed): Word 13
0x0001 Persistent input sensor failure alarm Alr1
0x0002 CU Suction Pressure sensor & switch failure alarm Alr2
0x0004 repeated safety circuit open condition alarm Alr3
0x0008 Persistent low- or high-pressure startup failure alarm Alr4
0x0010 High CU Aux (Room) Temperature alarm Alr5
0x0020 Low CU Aux (Room) Temperature alarm Alr6
(0x0040 to 0x8000 not used)
Software Version (RRrr - MAJOR.minor revision); e.g. 107 = 1.07 Word 14 VERS
OFF DELY
COOL PUMP
Operating Mode (0=Off, 1=Delay, 2=Cooling, 3=Pump-Down, 4=Defrost1,
Word 15 DEF1 DEF2
5=Defrost2, 6=Defrost3, 7=DefrostA, 8=Re-Freeze, 9=Test, 10=Service) DEF3 DEFA
FREZ TEST
SERV
Status/Configuration (bit-packed): Word 16
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) XPRT
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)

72
 Heatcraft Mohave Control Modbus Definitions
Last elapsed defrost time (minutes) Word 17 DFTM
Compressor cycles since midnight (0 to 255) Word 18 CCYC
Run time since midnight (0000 to 2359 HHMM) Word 19 RnTM
Elapsed time since last defrost (00000 to 25559 HHHMM) Word 20 ETLD
Run time since last defrost (00000 to 25559 HHHMM) Word 21 RTLD

Holding Registers -
CMD 0x03 (Read), CMD 0x06 (Single Write) Data Type Word Addr. Label
CMD 0x10 (Multiple Write)

Display Right char. (7-bit ASCII + 0x80 DP) Word 0

Display Ctr-Right char. (7-bit ASCII + 0x80 DP) Word 1
Display Ctr-Left char. (7-bit ASCII + 0x80 DP) Word 2
Display Left char. (7-bit ASCII + 0x80 DP) Word 3
Time of Day (0000 to 2359 HHMM) Word 4 CLKH CLKM
Pressure Regulator setpoint (0 to 820 steps) Word 5
Refrigerant Type (0=R-22, 1=R-404A, 2=R-507, 3=R-407A, 4=R-407C,
revised Word 6
5=R-407F, 6=R-448A, 7=R-449A) REFR
Application Type (0=Low temp, 1=Medium temp) Word 7 APPL
Model Number (500 to 5000) Word 8 MODL
Displayed temperature units (0=degrees F, 1=degrees C) Word 9 øFøC
Displayed time mode (0=12 hour, 1=24 hour) Word 10 1224
Evaporator fan mode if not cooling (0=off, 1=on) Word 11 EVPF
Parameter lock mode (0=unlocked, 1=locked) Word 12
Number of evaporators (1 or 2) Word 13
Evaporator #1 defrost termination temp (+50 to +100 degrees F) Word, signed 14 DFT1
Evaporator #2 defrost termination temp (+50 to +100 degrees F) Word, signed 15 DFT2
Defrost termination pressure (175 to 315 psia), displayed as 160 to 300 psig Word 16 DEFP
Defrost override time limit (5 to 30 minutes) Word 17 DEFT
Alarm condition duration (2 to 120 minutes) Word 18 ALRT
Pressure Regulator full scale (100 to 820 steps) Word 19 PRFS
Equalization time (1 to 10 minutes) Word 20 EQUT
Low Pressure Switch high limit (15 to 45 psia), displayed as 0 to 30 psig Word 21 LPSH
Low Pressure Switch low limit (15 to 45 psia), displayed as 0 to 30 psig Word 22 LPSL
Evaporator re-freeze temperature threshold (+20 to +40 degrees F) Word, signed 23 FZET
Normal valve update interval (10 to 30 seconds) Word 24 PRUI
Initial defrost Pressure Regulator opening (50 to 100%) Word 25 DFIO
Evaporator re-freeze time limit (0 to 10 minutes) Word 26 FZTM
Cooling mode LLS Pulsing time limit (0 to 15 minutes) Word 27 LLSP
ESV/PR valve manufacturer (0=Carel or 1=Alco) Word 28 VALM
CU Aux Room Temperature control (0=off, 1=on) Word 29 AUXT
CU Aux Room Temperature setpoint (-25 to +50 degrees F) Word, signed 30 BOXT
High CU Aux Temp Alarm threshold (-35 to +100 degrees F), +127 if disabled Word, signed 31 ALRH
Low CU Aux Temp Alarm threshold (-35 to +100 degrees F), -128 if disabled Word, signed 32 ALRL
Run-time defrost interval (0030 to 1200 HHMM), 0000 if disabled Word 33 RTDF
Defrost #1 start time (0000 to 2330 HHMM), 2530 if not used Word 34 DF01
Defrost #2 start time (0000 to 2330 HHMM), 2530 if not used Word 35 DF02
Defrost #3 start time (0000 to 2330 HHMM), 2530 if not used Word 36 DF03
Defrost #4 start time (0000 to 2330 HHMM), 2530 if not used Word 37 DF04
Defrost #5 start time (0000 to 2330 HHMM), 2530 if not used Word 38 DF05
Defrost #6 start time (0000 to 2330 HHMM), 2530 if not used Word 39 DF06
Defrost #7 start time (0000 to 2330 HHMM), 2530 if not used Word 40 DF07

73
 Mohave Hot Gas Control Modbus Definitions
Defrost #8 start time (0000 to 2330 HHMM), 2530 if not used Word 41 DF08
Defrost #9 start time (0000 to 2330 HHMM), 2530 if not used Word 42 DF09
Defrost #10 start time (0000 to 2330 HHMM), 2530 if not used Word 43 DF10
Defrost #11 start time (0000 to 2330 HHMM), 2530 if not used Word 44 DF11
Defrost #12 start time (0000 to 2330 HHMM), 2530 if not used Word 45 DF12
Number of CU fans (1 to 4) Word 46
CU Fan #1 mode (0=off, 1=on, 2=press. ctl., 3=temp. ctl.) Word 47 FAN1
CU Fan #2 mode (0=off, 1=on, 2=press. ctl., 3=temp. ctl.) Word 48 FAN2
CU Fan #3 mode (0=off, 1=on, 2=press. ctl., 3=temp. ctl.) Word 49 FAN3
CU Fan #4 mode (0=off, 1=on, 2=press. ctl., 3=temp. ctl.) Word 50 FAN4
CU Fan #1 On pressure (125 to 315 psia), displayed as 110 to 300 psig Word 51 F1ON
CU Fan #2 On pressure (125 to 315 psia), displayed as 110 to 300 psig Word 52 F2ON
CU Fan #3 On pressure (125 to 315 psia), displayed as 110 to 300 psig Word 53 F3ON
CU Fan #4 On pressure (125 to 315 psia), displayed as 110 to 300 psig Word 54 F4ON
CU Fan #1 Off pressure (125 to 315 psia), displayed as 110 to 300 psig Word 55 F1OF
CU Fan #2 Off pressure (125 to 315 psia), displayed as 110 to 300 psig Word 56 F2OF
CU Fan #3 Off pressure (125 to 315 psia), displayed as 110 to 300 psig Word 57 F3OF
CU Fan #4 Off pressure (125 to 315 psia), displayed as 110 to 300 psig Word 58 F4OF
CU Fan #1 On temperature (+30 to +90 degrees F) Word, signed 59 F1ON
CU Fan #2 On temperature (+30 to +90 degrees F) Word, signed 60 F2ON
CU Fan #3 On temperature (+30 to +90 degrees F) Word, signed 61 F3ON
CU Fan #4 On temperature (+30 to +90 degrees F) Word, signed 62 F4ON
CU Fan #1 Off temperature (+30 to +90 degrees F) Word, signed 63 F1OF
CU Fan #2 Off temperature (+30 to +90 degrees F) Word, signed 64 F2OF
CU Fan #3 Off temperature (+30 to +90 degrees F) Word, signed 65 F3OF
CU Fan #4 Off temperature (+30 to +90 degrees F) Word, signed 66 F4OF
(not used) --- 67 to 7999
Remote Control (0xAA55=activate, 0xFF00=deactivate) Word 8000

NOTE: The Write Remote Control command with a data value of 'activate'
is ignored unless the Mohave Control is in "Off" or "Service" modes

Diagnostic -
CMD 0x08 (Read/Write) Sub-Function

Restart communications 0x01

Clear Counters and Diagnostic Register 0x0A
Read Bus Message Counter 0x0B
Read Bus Communication Error Counter 0x0C
Read Bus Exception Error Counter 0x0D
Read Slave Message Counter 0x0E
Read Slave No Response Counter 0x0F
Read Slave NAK Counter 0x10
Read Slave Busy Counter 0x11
Read Bus Character Overrun Counter 0x12
Clear Overrun Counter and Flag 0x14
Activate Remote Control mode 0xAA55
Deactivate Remote Control mode 0xFF00

NOTE: The Activate Remote Control command is ignored

unless the Mohave Control is in "Off" or "Service" modes

74
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