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Heatcraft BOHN MAC Series, Installation And Operation Manual

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Installation and Operation Manual

MAC

 Series

Condensing Units

Replaces H-IM-67H (01/18)

T

ABLE of 

C

ONTENTS

General safety and inspection

Condensing unit specifications ............................... 2

Evaporator unit specifications ................................. 3

Evaporator placement ............................................. 4

Condensing Unit placement.....................................5

Refrigerant piping and line sizes ..........................6-8

Leak detection and evacuation ................................ 9

Field wiring ........................................................... 10

Beacon II Controller

   Installation .......................................................... 11

   Refrigerant line brazing

   Power supply

   Wiring ................................................................ 12

   Box temp control settings

   Refrigerant charging

   Start-up operation ............................................... 13

   Initial power on

   Operating mode display ..................................... 14

   Program & review settings/changes ..............15-18

   Low ambient operation

   Pumpdown ....................................................19-20

   Defrost ................................................................ 20

   Alarms and error indicator LED ........................ 21

   Evaporator fans shut down by operators

   Power failure

   Space sensor terminal

   Checking sensors ............................................... 22

   System defaults

   Control sensor and piping .................................. 23

   Checking operation of exp. valve

   Exp. valve motor winding resistance ................. 24

   Smart Controller ............................................25-36

   Operational checkout ......................................... 37

   Preventive maintenance ................................38-40

Diagnostics .......................................................41-44

Beacon II parts lists ..........................................45-46

Startup Checklist ..............................................47-48

Wiring diagrams ...............................................49-51

Warranty information ............................................ 52

  H-IM-67H 

March 2018 

Part #25006401

Summary of Contents for BOHN MAC Series

Page 1: ...ngs Refrigerant charging Start up operation 13 Initial power on Operating mode display 14 Program review settings changes 15 18 Low ambient operation Pumpdown 19 20 Defrost 20 Alarms and error indicator LED 21 Evaporator fans shut down by operators Power failure Space sensor terminal Checking sensors 22 System defaults Control sensor and piping 23 Checking operation of exp valve Exp valve motor wi...

Page 2: ...sonal injury or death 3 Avoid contact with sharp edges and coil surfaces they are a potential injury hazard 4 Make sure all power sources are disconnected before any service work is done on units carrier Damaged material becomes the delivering carrier s responsibility and should not be returned to the manufacturer unless prior approval is given to do so When uncrating care should be taken to preve...

Page 3: ...0 400 2 45 5 33 25 7 8 1 2 1 0 49 LET120BEB2N6MK Freezer 12 000 3 61 5 49 25 7 8 1 2 1 5 11 7 60 LET160BEB2N6MK Freezer 16 000 4 77 5 65 25 1 1 8 1 2 2 0 15 7 81 MAC8X ADT104BEB2N6MK Cooler 10 400 2 45 5 33 25 7 8 1 2 1 0 49 LET160BEB2N6MK Freezer 16 000 4 77 5 65 25 1 1 8 1 2 2 0 15 7 81 LET180BEB2N6MK Freezer 18 000 4 77 5 65 25 1 1 8 1 2 2 0 15 7 84 ...

Page 4: ...Top View H Total Height of Unit s Coil Surface Side View 1 1 2 H 2 H H 1 2 W 1 2 W W Cooler Freezer Loading Door Note Whenever possible always try to position the evaporator to blow towards the walk in door Never position the evaporator over or adjacent to a door opening Freezer Cooler Loading Door Evaporator Placement ...

Page 5: ...m hot air or fume exhausts Cor rosive atmospheres require custom designed condensers Another consideration which must be taken is that the 3 Feet from Building Wall 3 Feet minimum Clearance 3 Feet minimum Clearance to an Open Block Wall or Shrubs 3 Feet minimum Clearance for Contractor to Service Unit Figure 4 unit should be mounted away from noise sensitive spaces and must have adequate support t...

Page 6: ... 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 Remove temperature sensor attached to suction line on Beacon II systems before brazing of the solder joint internally Flux only the male portion of the connection never the female After brazing remove excess flux j Wrap expansion valves with wet ...

Page 7: ...vide a minimum of 1 4 inch per foot pitch for proper drainage Drain lines should be at least as large as the evaporator drain connec tion All plumbing connections should be made in ac cordance 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 systems Traps in the drain line must be located in a warm ambi...

Page 8: ...brating object such as a compressor or compressor base must be supported in such a manner that will not restrict the movement of the vibrating object Rigid mounting will fatigue the copper tubing 4 Do not use short radius ells Short radius elbows have points of excessive stress concentration and are subject to breakage at these points 5 Thoroughly inspect all piping after the equipment is in opera...

Page 9: ...ween 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 A good deep vacuum pump should be connected to both the low and high side evacuation valves with copper tube or high vacuum hoses 1 4 ID minimum If the compressor has service valves...

Page 10: ...e inside of the electrical panel door All field wiring should be done in a professional manner and in accordance with all governing codes Before operating the unit double check all wiring connections including the factory terminals Factory connections can vibrate loose during shipment 1 The nameplate on the unit is marked with the electrical Figure 9 Beacon II Board characteristic for wiring the u...

Page 11: ...E button twice To start the system cooling press the CLEAR button Room sensors must be left connected on ALL evaporators A pressure transducer is installed on the evaporator Do not leak test system above 150 PSI or damage to transducer could occur Refer to the Beacon II Smart Controller Installation Manual shipped with the Beacon II Smart Controller for installation programming and monitoring info...

Page 12: ... be as follows see attached wiring diagrams High voltage There may be high voltage on the defrost heater relay and the fan relay See unit cooler spec plate for ampacity Low voltage 24V Class II control circuit A total of five low voltage leads are required to connect the condensing unit to the evaporator see wiring diagram Two of these leads are for connecting the outdoor temperature sensor The ot...

Page 13: ...un in the cooling mode a minimum of 2 minutes even if the setpoint temperature is met In applications where the system is grossly oversized the box tem perature could go below the differential tem perature before the system cycles off In the OFF cycle the system will be off for a minimum of 4 minutes even if the box tempera ture goes above the differential temperature before cooling will be restar...

Page 14: ...s will continue to run The LED will alternately display oFF and BOX TEMPERATURE When the room sensor detects a rise in temperature of approximately 2 F and the compressor has been off for at least 4 minutes the EEV will open to its last position then the compressor will start The valve is then adjusted as necessary to obtain the setpoint superheat setting During this time the compressor will run f...

Page 15: ...e setpoint item will appear on the LED After a few seconds delay the Setpoint value will display Each time the button is pressed a different setpoint item is displayed Next use the SELECT knob to change value of setpoint item Next when the desired value is selected press the ENTER button to place it in program memory If the ENTER button is not pressed the value will not be stored in the memory and...

Page 16: ...ts electric defrost off and air defrost off 12 Programming Reviewing Programming And Reviewing Settings Changes cont d Use the PROGRAM REVIEW button to select these items Defrost Type A E Selection is made for air defrost or electric defrost coil This will automatically set the system factory defaults for air defrost and electric defrost See default settings Refrigerant Type rEF Selection for type...

Page 17: ...button to FORCE DEFROST To force a defrost press the FORCE DEFROST button The system will pumpdown The heaters are then turned on The display will show dEF and room temp Use this button to RESET TIME Pressing this button will reset the time clock in the microprocessor to zero At initial power up pressing this button will bypass the four minute hold off and the system will start immediately after t...

Page 18: ...x Temp A2 Low Box Temp A3 System has failed to start the compressor on 4 consecutive attempts A4 Input Fault Box Temp Suction Temp Pressure Transducer open or not installed Use this button to CLEAR TEST Pressing this button ONCE will return the LED display to the default display With the system in the OFF mode pressing and holding this button will start the TEST mode In the TEST mode it will cycle...

Page 19: ...ressure switch opens or 2 minutes has elapsed The compressor is then off and remains off until the start of the next cooling cycle While in the off cycle the system will initiate a short pumpdown at 4 minute intervals only if the Low Pressure Switch closes to ensure that any refrigerant leakage will not cause a problem For Manual Pumpdown a single pole single throw switch can be used to connect SE...

Page 20: ...efrost will now occur at 10 00 AM and then a defrost will occur every 6 hours thereafter TIME REMAINING UNTIL NEXT DEFROST To find out how much time is left until the next defrost is scheduled use the MONITOR button to scroll to dFS The time displayed will be how much time until the next scheduled defrost DEFROST SCHEDULE IN MEMORY Beacon II does not have a real time clock but it keeps track of th...

Page 21: ...installed The system will pumpdown cycle off and try to restart for these faults Each try will be after the 4 minutes Hold Off period for the following fault conditions E7 High pressure or low pressure cutout E6 Low superheat After the fourth try the Alarm contacts will be closed and an alarm message displayed on the LED To clear the error for E2 Defrost Temp Sensor Open Short and E5 Outdoor Temp ...

Page 22: ...nsor Terminals Beacon II provides a set of input terminals for customers who may want to monitor an additional temperature or items such as Product Temperature This input terminal requires a signal from a thermistor which meets the temperature resistance values in Table 5 below If a product temperature simulator is used it must meet the resistance temperature specification listed in Table 5 The te...

Page 23: ...efrost Fail Safe Times DEFSAF 40 min 60 min Defrost End Temperature DEFTMP 45F 55F Alarm High Temperature ALR HI 50F 5F Alarm Low Temperature ALR LO 30F 15F Alarm Time ALRMIN 60 min 60 min Temperature Units F C F F Clock Setting 12 24H 12 H 12H Fan Cycling FNSTIR Off Off Test Mode TEST Off Off Service Mode SERVIC Off Off Beacon II Controller System Defaults Figure 11 Control Sensor And Piping Tabl...

Page 24: ...the valve is closed and at 5 Volts the valve is fully open At values between 0 and 5 Volts the valve will be opened proportionately 3 Use the MONITOR button to display SCP Evaporator Suction Pressure Record the pressure displayed Start the system and observe the pressure displayed If the pressure does not increase the expansion valve could be defective 4 If the system is running use the MONITOR bu...

Page 25: ...t going to the cooler or freezer The Smart Controller with LCD display will also alert you to any alarm conditions in your refrigeration system The Smart Controller will display the problem in addition to letting you know when to call for service See pages 49 51 for proper wiring instructions Refer to the installation and operation manual that ships with each Smart Controller for complete instruct...

Page 26: ...Has buzzer to signal alarms f Locking keypad Beacon II Smart Controller allows complete programming and monitoring of the system The Controller display has the following buttons COOLING DEFROST PROG REVIEW MONITOR ENTER CLEAR SETPOINT AND TIME The normal LCD display will show the Programmed Box Set point temperature Actual Box Temperature the Current Time of day and the Mode i e COOL DEFROST or OF...

Page 27: ...rost to save energy on defrost Sounds a buzzer to indicate an Alarm condition System Number Box Set point Temperature Time of Day Set point Slide Bar Operating Mode Box Temperature System Selection Bar Can be mounted up to 1000 ft away from the system being controlled Each Beacon II Smart Controller can control four independent systems with up to 4 evaporators on each system A Backup battery will ...

Page 28: ...mart Controller II should not be mounted where it will experience temperatures below 40 ºF or above 100 ºF Installation Beacon II Smart Controller Base A terminal strip for wiring connections is located on the base of the Smart Controller To access this terminal strip pull both halves of the Smart Controller housing apart Mounting holes are located in the plastic base Terminal Strip RS232 Connecto...

Page 29: ... this first system DO NOT disconnect the Room sensor from any of the Evaporators See typical wiring diagram at the back of these instructions A minimum 18 gauge wire should be used All low voltage wiring must be run separate from high voltage wiring Power Supply The Beacon II Smart Controller gets its 24 VAC power supply from an evaporator When controlling multiple systems the Beacon II Smart Cont...

Page 30: ...n 2 seconds The Smart Controller LCD screen will display WAIT Initialization of Beacon II Smart Controller INITIALIZATION of BEACON II SMART CONTROLLER After WAIT is displayed it may take up to 2 minutes for the initialization to be completed and the normal LCD screen is displayed If unsuccessful NOCHG will appear CLOCK This is used to set the time of day on the display Depress the button to move ...

Page 31: ...bar to select first defrost time then press ENTER Use button to scroll to next defrost period dF 2 use TIME slide bar to select second defrost time and press ENTER Repeat steps for each required defrost period If defrost times are not programmed the system will use the defaults Electric Defrost four per day at 4 00 AM 10 00 PM 4 00 PM 10 00 AM Air Defrost two per day at 9 00 AM 9 00 PM DEFSAF Defr...

Page 32: ...Evaporator Determined by Suction Transducer SUCPRE Evaporator Suction Pressure Measured by Suction Transducer OD TMP Actual outdoor ambient temperature Measured at the Condensing Unit DEFTMP Evaporator coil temperature Used to terminate defrost DEFTIM Defrost Time Length of last defrost CMPCYC Comp Cycles No of Compressor Cycles since 12 00 midnight CMPRUN Comp run time Measured since 12 00 midnig...

Page 33: ...horted open or not installed STSEN Suction Temperature sensor shorted open or not installed SPSEN Suction pressure transducer shorted open or not installed ODSEN Outdoor temperature sensor shorted SUPLO Superheat too low SHTDN Compressor shutdown High or low refrigerant pressure or low oil pressure The error code will flash alternately with the normal display information When the error condition i...

Page 34: ...t is cleared for the following conditions Suction sensor shorted open or not installed Room temperature sensor shorted open or not installed Pressure Transducer open or not installed The system will pumpdown cycle off and try to restart for three consecutive times Each try will be after the 4 minutes Hold Off period for the following fault conditions Oil pressure High pressure or low pressure cuto...

Page 35: ...rost times Hence we recommend that a minimum of 8 defrost periods be programmed when Smart Defrost is turned on The system will not defrost eight times per day but with this many defrost periods it will have better options to keep the coil clear To activate Smart Defrost press the PROG REVIEW button until SMTDFT is displayed Move the SETPOINT slide bar to ON then press ENTER Press CLEAR to return ...

Page 36: ... chassis ground or earth ground for best noise immunity Beacon II Board All four corner brass spacers on the Beacon II board should have sheet metal screws and they should all be screwed in Smart Controller Run a 20 AWG or larger wire from TB11 of the Smart Control SUB BASE to ground the sub base terminal block connectors are numbered from TB1 on the left to TB13 on the right ...

Page 37: ...time delay relay for low pressure switch in condensing unit It should be set at one minute the second marker d Check high and low pressure controls pressure regulating valves oil pressure safety controls and all other safety controls and adjust them if necessary e On freezers only check the low pressure switch setting It must be set to 0 PSIG cut out 10 PSIG cut in to allow start and operation esp...

Page 38: ...ing potentially costly repairs of a premature failure due to equipment neglect The following is Bohn Heatcraft s minimum recommendations Preventive Maintenance for regularly scheduled preventive maintenance of your McDonald s refrigeration system Quali fied and licensed refrigeration companies only should perform all preventive and corrective maintenance on refrigeration equipment While we cannot ...

Page 39: ...fan blades for signs of cracks wear or stress Pay close attention to the hub and spider Replace blades as required 4 4 Verify that all motors are mounted securely 4 Inspect electrical wiring and components 4 1 Verify that all electrical and ground connections are secure tighten as required 4 2 Check condition of compressor defrost heater and condenser fan contactors Look for discoloration and pitt...

Page 40: ...4 4 Verify that all fan motors are securely fastened 4 Inspect electrical wiring and components 4 1 Visually inspect all wiring for wear kinks bare areas and discoloration Replace any wiring found to be damaged 4 2 Verify that all electrical and ground connections are secure tighten if necessary 4 3 Check operation calibration of all fan cycle and defrost controls when used 4 4 Look for abnormal a...

Page 41: ...s needed E2 Defrost Sensor Check Sensor and Board Connection Replace as needed E3 Suction Sensor Check Sensor and Board Connection Replace as needed E4 Suction Transducer Check Transducer and Board Connection Replace as needed E5 Outdoor Sensor Check Sensor wiring and Board Connection Replace or remove 1 Check Refrigerant Type 1 Compare board setpoint and refrigerant 2 Check coil for ice 2 Defrost...

Page 42: ... line sizing Correct line sizing Check for liquid line restrictions Repair line or remove restrictions Check operation of HPS Replace HPS if necessary E7 Compressor 4 Oil Pressure Safety OPS Tripped Shutdown Check oil level in compressor Add oil to crankcase to minimum level Check oil sump screen pickup Clean or replace pickup screen Check oil pump pressure Replace compressor oil pump Check for pr...

Page 43: ...unding of board 2 Check Voltage to Evaporator Transformer 1 Check field wiring for breaks or shorts power is below 18V and 3 Check Transformer Secondary Output Volts Go to 2 Replace if necessary appears at initial power 4 Check Voltage at Control Board 24 and C next step 3 Check factory wiring and connections 5 Check Voltage at SMART Controller II 4 Check field wiring from board 1 Check grounding ...

Page 44: ...aporator coil 13 Defrost coil and check defrost cycle see E2 settings setpoints and defrost sensor 14 Check defrost parameters 14 Correct defrost setpoints in program frequency and termination of defrosts 15 Check superheat setpoint too high 15 Correct setpoint for more cooling surface 16 Check display values F or C 16 Correct setpoint for proper display values Placing system into SERVICE MODE Ter...

Page 45: ...rts Table 7 Condensing Unit Parts List PART DESCRIPTION PART NUMBER EVAPORATORS PART DESCRIPTION CONDENSING UNITS MAC5X Compressor Freezer ZF15K4EZF13K4E ZF15K4E Compressor Cooler RST43C1EZS13KAE ZS13KAE Disconnect Fuses 2251011322510112 22510113 Start Relay Cooler 1007647 N A Start Capacitor Cooler 7076959 N A Run Capacitor Cooler 7076950 70757856 Compressor Contactor Cooler 2254304 Compressor Co...

Page 46: ...o 30 VAC Controlling Box Temp Range 30 F to 70 F Box Temp Dead Band 1 F Cold Ambient Limits Start and operate to 20 F Table 10 Beacon II Operational Limits Table 9 Beacon II Smart Controller Parts List PART PART DESCRIPTION NUMBER Beacon II Smart Controller 89704302 ...

Page 47: ...8 F No of Defrost Day 4 Defrost End Temp 65 F COOLER Refrigerant Type R448A Box Setpoint Temp 35 F Superheat 8 F No of Defrost Day 2 Defrost End Temp 50 F SYSTEM CHECKS Check compressor superheat for the COOLER Should be between 20 F 30 F YES NO Check compressor superheat for the FREEZER Should be between 20 F 30 F YES NO Force unit into a defrost check heater amps Should match nameplate amps YES ...

Page 48: ...Cooler suction pressure ______PSIG Freezer suction pressure ______PSIG Cooler suction temperature ______ F Freezer suction temperature ______ F Cooler refrigerant charge ______lbs Freezer refrigerant charge ______lbs Cooler compressor superheat ______ F Freezer compressor superheat ______ F Cooler evaporator superheat ______ F Freezer evaporator superheat ______ F Cooler discharge temperature ____...

Page 49: ...49 Wiring Diagrams Diagram 1 Low Profile Evaporator Wiring ...

Page 50: ...50 Diagram 2 MAC Unit Wiring Wiring Diagrams ...

Page 51: ...51 COOLER FREEZER Diagram 3 24 Volt Connection Wiring With Smart Controller Diagram 3 24 Volt Connection Wiring with Smart Controller Wiring Diagrams ...

Page 52: ... Day 7 Days a Week Call Toll Free 877 HTCRAFT 877 482 7238 Warranty Coverage Standard Parts Labor 2 Years Beacon Parts TXV Sensors Board Smart Controller 3 Years Compressor Part 5 Years A Brand of Heatcraft Refrigeration Products LLC 2175 West Park Place Blvd Stone Mountain GA 30087 770 465 5600 Fax 770 465 5990 www heatcraftrpd com ...

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