Heatcraft Mohave Installation & Operation Manual Download

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H-IM-HGD0

FEBRUARY 2021

Part Number 25007401

Installation, Start-Up, Operation and
Troubleshooting with Wiring Diagrams

Mohave Hot Gas Defrost

Installation

& Operation

Replaces June 2017

Summary of Contents for Mohave

Page 1: ...H IM HGD0 FEBRUARY 2021 Part Number 25007401 Installation Start Up Operation and Troubleshooting with Wiring Diagrams Mohave Hot Gas Defrost Installation Operation Replaces June 2017...

Page 2: ...sing 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...

Page 3: ...h 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 se...

Page 4: ...lator 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 S...

Page 5: ...nd Err8 system off Alr3 Repeated Safety Circuit Open condition Alr4 Prolonged Cooling Startup Failure DISPLAY DESCRIPTION Err1 Suction temperature sensor open or short Err2 Ambient temp sensor open or...

Page 6: ...the standard warranty terms set forth above except that motor compressor replacements or exchanges shall be made through the nearest authorized wholesaler of the motor compressor manufacturer not at...

Page 7: ...tion Filter Sight Glass Compressor Head Fan on L6 Models MODBUS RS 485 Inherent on control board Optional Features Head Pressure Valves ORI ORD Oil Separator Insulated and Heated Receiver Fused Discon...

Page 8: ...h 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...

Page 9: ...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 lo...

Page 10: ...of the unit is not level with the top of pit discharge cones or stacks must be used to raise discharge air to the top of the pit This is a minimum requirement Decorative Fences Fences must have 50 fre...

Page 11: ...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 su...

Page 12: ...n 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...

Page 13: ...13 Piping The following are examples of proper piping layout for typical system configurations...

Page 14: ...14 Piping...

Page 15: ...ore total equivalent line run Actual line run 75 feet 6 1 1 8 elbows 3 18 feet 1 1 1 8 tee 2 2 feet Total equivalent line run 95 feet 4 Refer to Table 3A For 95 total equivalent feet the suction line...

Page 16: ...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...

Page 17: ...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...

Page 18: ...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...

Page 19: ...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...

Page 20: ...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...

Page 21: ...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...

Page 22: ...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...

Page 23: ...10 17 23 16 27 37 25 42 51 37 63 72 54 92 1 3 8 R 507 R 404A R 407 R 448A R 449A 54 9 60 5 58 0 26 17 25 39 27 41 63 43 64 86 63 96 1 24 93 1 40 1 5 8 R 507 R 404A R 407 R 448A R 449A 77 7 85 7 82 1...

Page 24: ...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 5 Pressure Loss of Liquid Refrigerants in Liquid Line Risers Expressed...

Page 25: ...ethod 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...

Page 26: ...d through the motor Operating Range Demand Cooling is designed to protect the compressor from high discharge temperatures over the evaporating and condensing temperature ranges shown in Figure 12 at a...

Page 27: ...codes regarding disconnects and fusing must be followed See the unit cooler spec plate for ampacity Low voltage 24 VAC control circuit Each evaporator connects to the condensing unit with the followi...

Page 28: ...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...

Page 29: ...29 24V Wiring Diagram Standard Independent Evaporator Power Supply CONTROL BOARD Field supplied not used when auxiliary temperature sensor is field installed and activated to control room temperature...

Page 30: ...SEE NOTE 2 DRAIN PAN HEATERS EVAPORATOR FAN MOTORS 7 FAN CONTACTOR HEATER CONTACTOR 8 1 2 3 2 FOR 208 230 1 60 HZ WIRE TO T1 T2 CONDENSING UNIT MTR MTR MTR F1 F2 SINGLE PHASE DETAIL EVAP FAN C EVAP D...

Page 31: ...NOID 208 230V 3 60 HZ 460V 3 60HZ 575V 3 60HZ FOR SINGLE PHASE SEE NOTE 2 EVAPORATOR FAN MOTORS 3 PHASE FAN CONTACTOR 18 2 SOLENOID HARNESS Mfg NOTES 1 WIRE NUMBERS MATCH WIRE MARKER NUMBERS ON HARNES...

Page 32: ...NDENSING UNIT 24 VAC 18 GA MIN EVAP DEFROST SUCTION TEMP SENSOR LIQUID LINE SOLENOID 208 230V 3 60 HZ OR 575V 3 60 HZ FOR SINGLE PHASE SEE NOTE 1 EVAPORATOR FAN MOTORS 3 PHASE FAN CONTACTOR 18 2 SOLEN...

Page 33: ...4 H1 H2 H3 F1 F2 F3 CONDENSING UNIT 24 VAC 18 GA MIN EVAP DEFROST SUCTION TEMP SENSOR LIQUID LINE SOLENOID 208 230V 3 60 HZ 460V 3 60HZ 575V 3 60HZ FOR SINGLE PHASE SEE NOTE 1 EVAPORATOR FAN MOTORS 3...

Page 34: ...IRING USE COPPER CONDUCTORS ONLY SHEET 1 OF 2 BLUE YELLOW 8 COMP BLUE 2 TDR L1 HPS 4 R1 12 13 L2 HPS LPS DT YELLOW 11 CRANKCASE HEATER R1 7 10 C1 AUX2 SERVICE MATE OPS AUX1 LLS CMOD 3 CONTACTOR C1 L2...

Page 35: ...BLUE Evap 1 Def Temp Beaco n Comp ressor Evap 2 Def Temp CONNECTIONS FIELD WIRING Remot e Defr T STAT Evap Fan C SUCTION PRESSURE LIQUID PRESSURE Cond Fan 4 LIQ LINE SOL2 LIQ LINE SOL1 C EVAP PAN HTR...

Page 36: ...8 COMP BLUE 2 TDR L1 HPS 4 R1 12 13 L2 HPS LPS DT YELLOW 11 CRANKCASE HEATER R1 7 10 C1 AUX2 SERVICE MATE OPS AUX1 LLS CMOD 3 CONTACTOR C1 L2 L3 L1 T1 T2 T3 2 1 COMPRESSOR BLOCK POWER C C 230V 460V SH...

Page 37: ...0 500 PSIA RED BLUE Evap 1 Def Temp Beaco n Comp ressor Evap 2 Def Temp CONNECTIONS FIELD WIRING Remo te Defr T STAT Evap Fan C SUCTION PRESSURE LIQUID PRESSURE Cond Fan 4 LIQ LINE SOL2 LIQ LINE SOL1...

Page 38: ...38 Standard Independent Evaporator Power Supply with VFD Condenser Fans Wiring Diagram...

Page 39: ...39 Standard Independent Evaporator Power Supply with VFD Condenser Fans Wiring Diagram...

Page 40: ...Connections this side Note Control contactors mount under a cover on front of unit not shown Suction Connection Liquid Connection Liquid Solenoid Valve Thermostatic Expansion Valve Check Valves Check...

Page 41: ...FILTER DRIER BASE VALVE BASE VALVE BY PASS SOLENOID DEFROST SOLENOID NC CHECK VALVE LIQUID FILTER DRIER CHECK VALVE ELECTRONIC PRESSURE REGULATOR COMPRESSOR CHECK VALVE PIPINGb dft rev B REDUNDANT LO...

Page 42: ...to 10 F for medium temperature applications or 20 F 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 t...

Page 43: ...w 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 dow...

Page 44: ...s 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 Termination of defrost is...

Page 45: ...45 Defrost Operation Black Piping Inactive Gray Piping Active Hot Gas Defrost Cycle Diagrams...

Page 46: ...46 Defrost Operation Black Piping Inactive Gray Piping Active Hot Gas Defrost Cycle Diagrams...

Page 47: ...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 applicati...

Page 48: ...psig NOTE Refrigerant used during evacuation cannot be vented Reclaim all used refrigerant EPA regulations are constantly being updated to ensure your procedure follows correct regulations Repeat thi...

Page 49: ...nd R 449A MODL Set Condensing Unit Model Number XPRT Activate expert menu items Off On Start Up Operation and Program Review Check Out and Start Up After the installation has been completed the follow...

Page 50: ...our mode is selected these values are displayed as 12 XX to 11 XX for the AM hours The PM hours will be displayed with a decimal point following the minutes 12 XX If 24 hour mode is selected the hours...

Page 51: ...ersion V1 04 and higher Available on Software version V1 06 and higher Menu Re Ordered on Software version V2 05 and higher Low Pressure Switch simulation Cut In value LPSH Selection is made of the cu...

Page 52: ...se the system to pump down and the compressor to shut off The system will remain off until the CLEAR button is pressed When the system is initially placed into FORCE SERVICE mode the display will show...

Page 53: ...r 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 Re...

Page 54: ...l affects refrigerant charge and the staging of the condenser fans The system should have the minimum charge necessary to allow for proper operation at all expected conditions Condenser fan control se...

Page 55: ...etting on the ORI valve If other settings are desired the fan cycling settings may need to be changed Systems with Floating Low Head Pressure For these systems the general recommendation is to use a c...

Page 56: ...ressure at the suction service valve of the compressor and determine the saturation temperature corresponding to this pressure from a Temperature Pressure chart 2 Measure the suction temperature of th...

Page 57: ...sealed containers After opening all the lubricant in a container should be used at once since it will readily absorb moisture if left exposed to the ambient Any unused lubricant should be properly di...

Page 58: ...viceMate Reference Guide Go to next step Follow General System Troubleshooting Chart LPS Function is on the Control Board 2 Check Compressor Contactor s and Auxiliary Switch es for Proper Operation Re...

Page 59: ...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 temperat...

Page 60: ...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 o...

Page 61: ...actual defrost heater amp draw against unit data plate Check drain line heat tape for proper operation supplied and installed by others 5 Refrigeration Cycle Check unit cooler superheat and compare r...

Page 62: ...nd safety control settings and verify proper operation Preventive Maintenance Annually 7 In addition to quarterly and semiannual maintenance checks submit an oil sample for analysis Look for high conc...

Page 63: ...9324401 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 2933040...

Page 64: ...____________________ _______________________ Ambient at Start Up _____________________________ F Design Box Temperature ______________________ F _________________________ F Operating Box Temperature _...

Page 65: ...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...

Page 66: ...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...

Page 67: ...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...

Page 68: ...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 1...

Page 69: ...ing 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 Firs...

Page 70: ...70 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...

Page 71: ...witch 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 M...

Page 72: ...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 r...

Page 73: ...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 1...

Page 74: ...5 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 3...

Page 75: ...75 Notes...

Page 76: ...West Park Place Blvd Stone Mountain GA 30087 770 465 5600 Fax 770 465 5990 www heatcraftrpd com Since product improvement is a continuing effort we reserve the right to make changes in specifications...

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