Bohn BDV-0602L6 Service Manual
Technical Guide
BNHGDTB
March 2011
Replaces BN-HGDTB, July 2009
L
U
®
C
US
Table of Contents
Overview ......................................................................................2
System Features .........................................................................3
Condensing Unit ................................................................. 4-13
Mohave Hot Gas Defrost Quick Reference .......................5
Mohave Hot Gas Unit Cooler Typical Factory Piping . 14
Medium Prole Evaporator ...........................................15-17
Large Unit Cooler .............................................................18-23
Hot Gas Defrost Systems ...............................................24-28
Refrigeration and Defrost Operation ........................ 29-31
Mohave Hot Gas Defrost Cycle Diagrams ............... 32, 33
Overview
The Mohave™ advanced hot gas defrost refrigeration system
with controller utilizes hot gas to greatly reduce defrost
times and operates in all outdoor ambient temperatures.*
This leads to increased energy eciency and product
integrity in a refrigeration system that can be used in a
greater variety of environmental conditions. This system
utilizes a state-of-the-art electronic defrost controller with
a proprietary control scheme that allows the system to
continually operate at its most optimal level.
*Tested to -20°F ambient.
Hot Gas Control Board Features & Benets
• The Mohave controller completely manages timing and sequence of defrost
• Point to point wiring to all control components
• Automatically compensates for changes in outdoor temperatures
• Quick and easy troubleshooting
• Monitors all pressures, temperatures, and setpoints in real time.
• Easily programmable through a menu driven interface
• The control board with conformal coating will handle the toughest conditions
• LED indicators on the board clearly show system status
• Remote alarm notication
• Signicant energy savings over electric defrost systems
E Solutions™ branded products and options are designed to exceed current energy and environmental
standards. We have made a conscious commitment to developing environmentally innovative products
that allow our customers to make energy ecient, eco-conscious choices. Products included in the
E Solutions portfolio reduce costs, improve bottom lines, and enhance both equipment performance and
service life. The Mohave™ Advanced Hot Gas Defrost System contains a sophisticated controller with sensors
that gather information and assess the condition of the system to defrost more eciently, resulting in energy
savings. To further increase energy savings, EC motors are available for some evaporator models.
2
Main System Features
Condensing Unit
• Integral condenser sub-cooling circuit in condenser for added capacity and vapor free liquid
• Floating Tube™ condenser coil design
• Electronic defrost controller
• Pressure or ambient fan cycling for head pressure control
• Electronic pressure regulator for defrost control
• Anti-short cycling protection
• High pressure and low pressure controls
• Oil pressure safety control
• Easily accessible control box
• High eciency Copeland Discus® compressors with poe oil
• Thermally protected permanently lubricated ball bearing condenser fan
motor(s)
• Receivers are sized for sucient pumpdown capacity with inlet and outlet service valves
• Cabinet is constructed from painted galvanized steel
• Replaceable core liquid line lter drier
• Replaceable core suction lter
Evaporators
• All components are factory installed and wired
• Independent or single point power supply from condensing unit
• 4 and 6 FPI medium and large unit coolers
Features:
• Mounted TXV and distributor nozzle
• Mounted check valves
• Mounted liquid line solenoid
• Mounted suction “P” trap
• Electric drain pan heater standard (mounted hot gas drain loop optional)
• Mounted and wired control contactors
Electric Vs. Hot Gas Drain Pan
Electric Drain Pan Heater (Std) Advantages
• In this option, the drain pan surface is heated with low
wattage electric heater(s)
• The electrical power requirements to the evaporator are
unchanged
Hot Gas Drain Pan Loop Advantages
• In this option, hot refrigerant gas passes through a loop
of copper tubing that heats the drain pan surface before it
defrosts the evaporator coil
• Lower cost solution
• Defrost is even quicker because more hot gas is available to
defrost the evaporator coil
• In applications where there is limited evaporator accessibility (ex:
controlled atmosphere rooms)
3
Vertical Air Discharge Condensing Unit
The BDV Outdoor Discus Condensing Unit features a leak
resistant design which includes:
• The Floating Tube™ condenser coil design. Refrigerant
carrying copper tubes do not contact any metal support
sheets; instead, the coil is constructed with expanded
anchor tubes which support the coil construction and
do not carry refrigerant. The coil design eliminates one
of the major causes of leaks in refrigeration systems
• Limited ve year warranty against condenser tube sheet
and center support leaks
• Designed for use with R-404A, R-507, R-22
• Polyol Ester Oil charge on all units
• Pre-bent copper tubes minimize braze joints on
internal piping
• Encapsulated high pressure switch eliminates
capillary tubes
• Sentronic oil safety control
• ServiceMate™ diagnostic module
• Electronic defrost controller
Other Standard Features
• High eciency Copeland Discus® compressors
• Thermally protected, permanently lubricated ball
bearing condenser fan motors
• Electrical controls including compressor contactor,
relays, and electronic controls are located in easily
accessible control box with a hinged cover
• Receivers sized for sucient pump down capacity with
inlet and outlet service valves
• Cabinet constructed from pre-painted steel
• Convenient access panels for easy servicing to internal
components
• Suction and discharge vibration eliminators
• Separate subcooling circuit in condenser for added
capacity and vapor free liquid
• Replaceable core liquid line lter drier and sight glass
• Replaceable core suction lter
• Anti-short cycle timer
• Suction accumulator
• Condenser fan cycling (pressure or temperature)
• Pressure relief valve on receiver
• Crankcase heater
Optional Features
• Oil separator
• Fused disconnect switch
• Non-fused disconnect switch
• Coated condenser coils for protection
against metal erosion in harsh environments
• Manual reset high pressure switch
• Low ambient kit with insulated, heated receiver
• Phase loss protection
• Adjustable head pressure control valves
• Evaporator control contactors mounted in condensing unit
Nomenclature
BDV 150 2 L 6 C
BDV – Vertical Air Discharge
Nominal Horsepower
060 – 6 HP
075 – 7.5 HP
076 – 7.5 HP
080 – 8 HP
090 – 9 HP
100 – 10 HP
120 – 12 HP
150 – 15 HP
200 – 20 HP
250 – 25 HP
300 – 30 HP
350 – 35 HP
400 – 40 HP
Hot Gas Defrost – 2
Refrigerant
6 – R-404A or R-507 or R-22
Application (SST)
L – Low (0°F to -40°F)
M – Medium (30°F to -10°F)
4
Electrical Characteristics
C – 208-230/3/60
D – 460/3/60
K – 230/3/60
E – 575/3/60
The Mohave Controller
• Fast, dependable, and ecient positive defrost of
evaporators
• Five to ten minute defrost times in most applications
• Will operate eciently in all outdoor ambient
conditions*
• Signicant energy savings over electric defrost systems
• Highest levels of product integrity through more stable
box temperatures
*Tested to -20°F ambient.
Mohave Hot Gas Defrost Controller
Quick Reference Guide
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
Program
Review
Clear/
Test
Enter
Selection
Knob
Monitor
Force
Service
Reset
Time
Force
Defrost
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 pump down and remain o until the Clear button is pressed
Force Defrost: System will pump down and begin a defrost cycle. This will not aect 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 o. The evaporator fans will de-energize. The system can be left in service mode for seasonal “OFF” situations.
Operating Modes
Mode Description
OFF Compressor O
COOL Compressor On in Cooling Normal Cooling Operation
PMPD System in Pump Down Mode
SERV Service Mode, System is O
DELY Timed 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
5
Electrical Box Features
Condenser Fan
Contactors
Compressor Contactor
Control Circuit
Transformers
Electrical Service
Knockouts
Typical Internal Piping
Control Circuit Fuses
& Service Switch
All Service Controls are located
in a separate electrical panel
allowing eld adjustments
without disconnecting power to
the unit
Oil
Pressure Switch
ServiceMate™ Diagnostic
Module
Mohave Hot Gas System
Controller
Main Power Block
Replaceable Core Liquid
Filter Drier
3-Way Valve
Electronic Pressure
Regulator
Pre-bent Internal Piping
Prevents Braze Joints
Defrost
Solenoid
Replaceable Core
Suction Filter
Bypass
Solenoid
Suction Stop
Solenoid
Liquid Receiver with Service Valves Allow Charge Isolation
Easily Accessible
Discus Compressor
Galvanized Steel
Base with Rigging Points
Suction Accumulator
6
Performance Data • Model BDV • Medium Temperature
Saturated Suction Temperature °F
R-404A or R-507
Model BDV
0752M6
0762M6
0802M6
1002M6
1202M6
1502M6
2002M6
2502M6
3002M6
3502M6
4002M6
Ambient
Temp. °F
90 70,900 64,300 57,900 51,700 45,900
95 67,600 61,300 55,300 49,400 43,800
100 64,500 58,500 52,800 47,100 41,600
110 58,300 53,000 47,700 42,400 37,400
90 80,300 73,400 66,600 60,000 53,600
95 76,800 70,100 63,500 57,300 51,000
100 73,100 66,800 60,700 54,600 48,700
110 66,200 60,600 54,900 49,200 43,700
90 94,300 86,000 77,900 70,200 62,700
95 90,500 82,600 74,900 67,500 60,000
100 86,800 79,200 71,800 64,400 57,500
110 79,000 72,400 65,700 59,000 52,500
90 114,800 104,900 95,100 85,800 76,800
95 110,100 100,600 91,300 82,200 73,400
100 105,300 96,200 87,400 78,600 70,000
110 95,700 87,500 79,300 71,200 63,200
90 138,300 126,500 115,100 103,800 92,800
95 132,500 121,200 110,300 99,400 88,800
100 126,600 116,100 105,400 95,000 84,800
110 115,100 105,400 95,700 86,200 76,600
90 153,300 140,300 127,600 115,000 102,900
95 146,800 134,300 122,200 110,200 98,500
100 140,300 128,700 116,900 105,300 94,000
110 127,500 116,800 106,100 95,600 85,100
90 162,500 147,300 132,900 119,300 106,000
95 154,200 140,100 126,500 113,200 100,400
100 146,400 133,100 119,900 107,100 94,800
110 131,000 118,600 106,500 94,700 83,300
90 212,900 193,000 174,000 156,200 139,400
95 203,800 184,600 166,500 149,000 132,800
100 194,700 176,100 158,600 141,800 126,200
110 176,800 159,600 143,100 127,400 112,600
90 249,200 227,500 206,500 185,600 165,500
95 238,100 217,300 197,200 177,100 157,800
100 226,900 207,400 187,900 168,600 150,000
110 205,000 186,900 169,100 151,500 134,500
90 312,300 285,400 259,300 234,400 209,600
95 297,800 272,700 248,300 223,600 200,000
100 284,000 260,400 236,600 212,900 189,800
110 256,900 235,000 213,200 191,400 169,900
90 359,700 329,700 300,600 272,000 244,200
95 345,100 315,900 287,400 259,800 232,900
100 329,600 301,500 274,300 247,500 221,600
110 298,200 272,700 247,400 222,600 198,600
25°F
BTUH
20°F
BTUH
15°F
BTUH
10°F
BTUH
5°F
BTUH
7
Performance Data • Model BDV • Medium Temperature
Saturated Suction Temperature °F
R-22
Model BDV
0752M6
0762M6
0802M6
1002M6
1202M6
1502M6
2002M6
2502M6
3002M6
3502M6
4002M6
Ambient
Temp. °F
90 68,500 61,900 55,600
95 66,100 59,700 53,600
100 63,700 57,400 51,500
110 58,900 53,000 47,300
90 76,600 69,400 62,600
95 73,700 66,800 60,300
100 71,100 64,300 57,900
110 65,600 59,200 53,200
90 93,000 84,200 75,900
95 89,900 81,300 73,200
100 86,800 78,400 70,400
110 80,600 72,600 65,000
90 111,900 101,500 91,400
95 108,200 98,000 88,100
100 104,600 94,500 84,800
110 97,100 87,500 78,200
90 125,800 113,600 102,000
95 121,700 109,700 98,300
100 117,500 105,700 94,700
110 109,000 97,900 87,400
90 142,400 128,000 114,600
95 137,600 123,700 110,500
100 132,800 119,300 106,500
110 123,500 110,600 98,500
90 157,500 143,000 129,100
95 151,800 137,500 123,900
100 146,200 132,100 118,700
110 135,000 121,400 108,400
90 205,000 186,900 169,600
95 198,100 180,100 163,200
100 191,000 173,300 156,800
110 176,700 159,900 144,000
90 241,500 219,600 198,300
95 233,500 211,800 190,900
100 225,200 203,900 183,500
110 208,500 188,200 168,800
90 295,100 268,700 243,200
95 285,300 259,000 234,100
100 274,900 249,400 225,000
110 254,200 230,100 207,100
90 342,300 312,700 284,600
95 331,200 302,100 274,700
100 320,100 291,600 264,800
110 297,900 270,800 244,900
25°F
BTUH
20°F
BTUH
15°F
BTUH
8
Performance Data • Model BDV • Low Temperature
Saturated Suction Temperature °F
R-404A or R-507
Model BDV
Ambient
Temp. °F
90 55,500 44,800 39,800 35,100 26,900 20,400
0°F
BTUH
-10°F
BTUH
-15°F
BTUH
-20°F
BTUH
-30°F
BTUH
-40°F
BTUH
0602L6
0752L6
0902L6
1002L6
1202L6
95 53,000 42,700 37,900 33,400 25,400 19,000
100 50,500 40,600 36,000 31,600 23,900 17,600
110 45,400 36,500 32,200 28,200 20,900 14,900
90 64,200 52,000 46,300 40,900 31,400 23,900
95 61,300 49,700 44,100 38,900 29,700 22,300
100 58,400 47,300 42,000 37,000 28,000 20,700
110 52,600 42,600 37,700 33,100 24,600 17,400
90 78,600 63,600 56,600 50,000 38,400 29,200
95 75,200 60,800 54,000 47,700 36,300 27,400
100 71,900 58,000 51,400 45,300 34,300 25,500
110 65,100 52,400 46,300 40,500 30,300 21,800
90 86,000 70,400 62,700 55,700 43,000 32,800
95 82,300 67,100 59,800 53,000 40,700 30,600
100 78,700 64,000 57,000 50,300 38,300 28,500
110 71,600 57,800 51,300 45,000 33,700 24,200
90 89,100 73,000 64,900 57,400 43,900 32,900
95 84,900 69,400 61,800 54,500 41,300 30,300
100 80,800 66,000 58,800 51,700 38,700 27,800
1502L6
2202L6
2702L6
3002L6
110 72,400 59,300 52,600 46,100 33,600 22,400
90 117,500 96,600 86,700 77,300 60,000 45,500
95 112,100 92,100 82,500 73,400 56,700 42,600
100 106,800 87,600 78,300 69,600 53,500 39,800
110 95,900 78,500 70,100 61,900 47,100 34,100
90 139,400 115,800 103,700 92,400 71,500 52,400
95 132,200 109,500 98,300 87,400 67,100 49,500
100 125,000 103,500 92,800 82,400 62,800 45,600
110 110,500 91,500 81,900 72,400 54,200 37,800
90 175,500 144,100 128,300 113,700 87,400 65,500
95 167,400 136,800 122,100 107,900 82,300 60,900
100 159,900 130,000 115,900 102,200 77,300 56,200
110 143,500 116,300 103,300 90,700 67,200 47,100
90 192,900 158,100 141,400 125,300 96,700 73,600
95 183,400 150,200 134,100 118,700 90,800 68,200
100 173,900 142,300 126,900 112,200 84,900 62,600
110 154,700 126,300 112,300 98,500 73,400 51,800
9
Specications and Dimensions • Model BDV
Model
BDV Compressor
0752M6
0762M6
0802M6
1002M6
1202M6
1502M6
2002M6
2502M6
3DA3A075E 2 24” 5/8 1-5/8 93 / 81 A 1650
3DB3A100E 2 26” 5/8 1-5/8 93 / 81 B 1725
3DF3A120E 2 26” 7/8 2-1/8 93 / 81 B 1750
3DS3A150E 2 30” 7/8 2-1/8 142 / 123 C 1780
4DA3A200E 2 30” 7/8 2-1/8 142 / 123 C 1860
4DH3A250E 3 30” 1-1/8 2-1/8 142 / 123 D 1950
Condenser
Fan Data Connections
No.
Fans Dia. Liquid Suction
2DL3-075E 2 24” 5/8 1-3/8 93 / 81 A 1550
2DA3-075E 2 24” 5/8 1-3/8 93 / 81 A 1550
Receiver
(90% Full)
R-22/R404A
Lbs.
Dim. Info.
See Figure
Approx.
Net
Weight
Lbs.
3002M6
3502M6
4002M6
0602L6
0752L6
0902L6
1002L6
1202L6
1502L6
2202L6
4DJ3A300E 3 30” 1-1/8 2-1/8 216 / 188 D 1950
6DH3A350E 3 30” 1-1/8 2-1/8 216 / 188 D 2800
6DJ3A400E 4 30” 1-1/8 2-1/8 216 / 188 E 3000
3DA3A060E 2 24” 5/8 1-3/8 81 A 1600
3DB3A075E 2 24” 5/8 1-3/8 81 A 1600
3DF3A090E 2 24” 5/8 1-5/8 81 A 1650
3DS3A100E 2 24” 5/8 1-5/8 81 A 1650
4DA3A101E 2 24” 5/8 1-5/8 81 A 1700
4DL3A150E 2 26” 7/8 2-1/8 81 B 1850
4DT3A220E 2 30” 7/8 2-1/8 81 C 2120
2702L6
3002L6
10
6DL3A270E 2 30” 1-1/8 2-1/8 123 C 2180
6DT3A300E 2 30” 1-1/8 2-1/8 123 C 2200
Dimensions (Inches) • Model BDV
A
B
C
1.76
FRAME C/L
55.5
55.5
55.5
1.76
FRAME C/L
O 2.50 K.O.
O 2.50 K.O.
44.5
44.50
6.66
6.64
O 1.38 X 1.75 K.O.
10.14
8.4 6
4.03
O 1.38 X 1.75 K.O.
O 1.38 X 1.75 K.O.
10.14
8.46
4.02
11.58
11.58
15.00
15.00
O 3.00
O 3.00
99.3 4
LIQUID
109.48
SUCTION
99.2 2
LIQUID
109.57
SUCTION
120
144.00
15.00
15.00
6.56
LIQUID
7.4 1
LIQUID
9.27
SUCTION
9.70
SUCTION
D
E
57.5
55.5
1.76
FRAME C/L
O 2.50 K.O.
1.76
FRAME C/L
O 2.50 K.O.
1.76
FRAME C/L
O 2.50 K.O.
44.7
44.5
44.5
10.46
6.73
6.66
8.46
6.66
O 1.38 X 1.7 5 K.O.
13.58
12.14
4.10
10.14
8.4 6
4.03
O 1.38 X 1.75 K.O.
11.58
10.14
4.03
15.00
11.58
O 3.00
15.00
99.50
LIQUID
125.00
15.00
O 3.00
142.73
SUCTION
99.50
LIQUID
O 3.00
142.75
SUCTION
99.34
LIQUID
142.74
SUCTION
280.0 5
225.67
170.68
9.41
LIQUID
11.70
LIQUID
15.00
LIQUID
15.00
7.4 1
9.70
SUCTION
7.41
LIQUID
15.00
11
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