WOLSELEY Beermaster Plus Series User manual

wolseley.co.uk/climate
Beermaster Plus Cooling Range
Installation and
maintenance instructions

Cooling
2
Installation and maintenance
instructions
1. Introduction: Page 3
• Glossary Of Terms
• Health And Safety
• Before Installation
• During Installation & Maintenance
• Interconnecting Pipework
• Refrigerant
2. Planning The Installation: Page 4
• Positioning The Condensing Unit
• How To Gain Access To The Condensing Units
• Positioning The Evaporator
• How To Gain Access To The Evaporators
3. Installing The Units: Page 8
• Mounting The Condensing Unit On A Wall Bracket
• Mounting The Evaporator Unit On A Wall Bracket
4. Pipe Sizing: Page 9
• Using Interconnecting Pipe Sizing Charts
• Cellar Temperature 8°C
• Cellar Temperature 10°C
• Cellar Temperature 12°C
5. Pipework Installation - Supports And Routing: Page 10
6. Brazing: Page 11
7. Expansion Valve Phial Location: Page 11
8. Drainage: Page 11
9. Electrical Supply & Function: Page 12
• Cable Sizing
• Cable Connection / Termination
10. Power Entry To The Condensing Units: Page 12
11. Power Entry To The Evaporators: Page 13
12. Pressure Testing: Page 14
• Pressure Leak Test
13. Evacuation: Page 14
14. Refrigerant Charging: Page 14
15. Approximate Refrigeration Charge: Page 15
16. Commissioning: Page 16
• Final Checks
• Compressor Rotation
17. BMOP Functions: Page 16
18. BMIEP Functions: Page 19
19. Maintenance: Page 23
20. Standards Applied To The Product Range: Page 24
21. Noise Levels: Page 24
• BMOP
• BMEIP
22. Weights: Page 25
23. Sales Outlines: Page 26
24. Electrical: Page 31
25. Guarantee: Page 35

3
Cooling
1.Introduction
Glossary of terms
The following abbreviations and terms are used thorough the document and refer to the following:
BFC Beermaster Free Cooler
BMIEP Beermaster Indoor Evaporator Plus (also referred to as the evaporator)
BMOP Beermaster Outdoor Plus (also referred to as the Condensing Unit
FLC Full Load Current
HP High Pressure
LP Low Pressure
LRA Locked Rotor Amps
MCB Motor Circuit Breaker
PCB Printed Circuit Board
PPE Personal Protective Equipment
PRV Pressure Relief Valve
SWA Steel Wire Armoured (used to refer to steel wire armored cable)
TD Temperature Difference
TEV Thermal Expansion Valve
Health and safety
This document has been designed to help you and make the installation easier. Please read the points below to be familiar
with the units and the installation. This manual contains information on hazards that may be encountered when installing and
maintaining the equipment. It is therefore important that these instructions are followed. Upon receipt, the units should be
visually inspected, and the supplier notified of any damage or shortages within seven days from receipt of the unit. Care must
be taken when removing the packaging and during installation, to prevent the finished surfaces being damaged. Units are not
portable and are only for permanent installation.
CAUTION
All work on the unit must be carried out by qualified personnel only. The installation and maintenance manual
must always be kept with the unit. Ensure that the instruction manual is understood before installation. Ensure
working environment is suitable and any additional hazards caused or increased by the environment are given
appropriate consideration.
Use suitable PPE as per site regulations and as appropriate for the task. It is the responsibility of the person performing the task
and their employer to ensure that all necessary PPE is provided and worn. Detailed below is some of the suggested PPE that may
be required during installation and commissioning of the unit.
Head protection Foot protection Hand protection Eye protection
Before installation
Ensure that:
1. The voltage, working fluid and the maximum working pressures stated on the product nameplates are suitable for the
proposed working environment.
2. The units are to be operated solely for cellar type cooling applications and will be put into operation as per this manual.
3. The proposed method of mounting is adequate to support the total operational weight of the unit (including refrigerant
charge), which can be found on the unit nameplate.
4. The working environment is safe and suitable for the work required to install the product.

Cooling
4
700 mm
500 mm
500 mm
150 mm
1000 mm
During installation & maintenance
Ensure that:
1. The units are installed and maintained by qualified personnel only.
2. The electrical supply is isolated and secured from accidental re-connection whilst work is carried out on the equipment.
3. Electrical connections to the unit should be made in accordance with IET regulations as well as local laws and legislation.
Interconnecting pipework
Interconnecting refrigerant lines installed between the condensing unit and evaporator must be purged through with oxygen-free
nitrogen to remove any particles of dirt, debris or moisture, in accordance with good refrigeration practice. Failure to do so could
cause clogging or damage to the solenoid valve and expansion valve during operation.
Care should be taken when completing this to avoid any personal injury. Please note that Nitrogen is an asphyxiant and should
only be used in well-ventilated areas with appropriate procedures and mitigation measures in place to prevent harm.
Refrigerant
The system has been designed and certified when charged with R448a. Charging with R449a is also acceptable. Do not mix these
refrigerants in the same system.
2. Planning the installation
Positioning the condensing unit
To ensure optimum performance, the condensing unit should be situated to give uniform air distribution across the coil.
• Obstructions to airflow should be minimized.
• Coils should ideally be shaded from the sun.
• Consideration should also be given to servicing and airflow. Please see the diagram below.
• If units are roof mounted it is recommended that isolation material is used between the feet of the unit and the roof itself.
The unit should also be installed level and on a firm platform that is able to support the full weight of the unit, including
refrigerant.
• The location of the unit should take into account the minimum clearances, as detailed below.
A Clearance from the top of the unit
B Clearance from the back of the unit to the wall
C Clearance from the RHS of the unit to the wall
D Clearance from the LHS of the unit to the wall
E Clearance from the front of the unit to any other object

5
Cooling
How to gain access to the condensing units
Loosen and remove all screws on the roof of the unit. Remove
and put aside the roof panel.
Loosen and remove all screws on the front two access panels.
Remove the front panel.
Rotate and slide the two side covers off the unit. The covers
will slide out of the from latches on the side of the unit and can
then be set to one side
CAUTION
The discharge line will be hot when the unit has
been running. This is indicated by a label. The
unit should be allowed to cool before accessing.
Possible Hot Discharge Pipe

Cooling
6
Positioning the evaporator
The evaporator has a “draw-through” airflow direction and is designed for either ceiling mounting or wall mounting.
For wall mounting, the wall mounting kit (optional) must be used and is supplied as a separate order.
Locate the evaporator in accordance with the minimum clearances as detailed below:
A Air Clearance
B Rear Clearance
C Left Hand Clearance
D Right Hand Clearance
2000 mm 275 mm
150 mm 150 mm

7
Cooling
How to gain access to the condensing units
To gain access to the solenoid, filter and TEV, the end covers
will need to be removed. This can be done by loosening and
removing the screws. The end covers then slide out from unit.
To gain access to the controls and enable the installation
of the mains cable. The front controls facia will need to be
removed.
CAUTION
The plastic drain tray will need to be removed
before any brazing is carried out the pipework.
This can be done by removing the rear screws
and sliding the drain tray off the unit.
Once all panels have been removed, the following items:
1. TEV
2. Solenoid
3. Filter Drier
Can be accessed for servicing, maintenance and
superheat adjustment.
With the controls cover removed, the PCB board can
be accessed.

Cooling
8
Mounting the condensing unit on a
wall bracket
(Wolseley pt. no. 684222)
Assemble the angle brackets to the uprights using the M8
fixings provided and fix securely to the wall using suitable
wall fixings. (b) Lift the unit into position and fix at all 4 feet
positions with M8 fixings provided. (a)
• Check the intended wall is strong enough to support
the total operational weight of the unit, including the
refrigerant charge.
• The two brackets should be spaced according to the unit
size (e.g. 590mm for 1 fan unit). Please see the diagram at
the end of this section for the spacing requirements.
• Use the angled bracket with straight side against the wall,
to mark out the drilling positions. Ensure that the rails are
installed as Drill all holes for M8 or M10 fixings. (c) below
such that unit is mounted horizontally.
• Drill all holes for M8 or M10 fixings. (c)
• Use suitable wall fixings to securely fix the angle brackets
to the wall.
• Fix the rails to the angle brackets with the M8 fixings
provided. Fix at all 4 positions & tighten securely. (b)
• Screw in the M8 fittings into the rails leaving a gap between
the bolt and the bracket, so that the keyhole fastenings can
be positioned before tightening fully.
• Lift the evaporator unit into position with the 4 fixings
protruding through the keyhole slots. (a)
• Push the evaporator back so the fixings are firmly located
in the small end of the keyhole slots and tighten securely
at all 4 positions.
• Use a spirit level to ensure the unit is level in both
directions. Use spacers as required to ensure the fall of the
drain pan is maintained to the rear of the unit.
3. Installing the units
306
235
46
966
611
for M8 or M10
fixings
Use all fixings
6x 11  Holes
• Check the intended wall is strong enough to support
the total operational weight of the unit, including the
refrigerant charge.
• Use the straight upright rails to mark out the drilling
positions on the wall (c). Ensure the rails are vertically
aligned, parallel to each other and horizontally level to
each other. Space the rails at 966mm apart.
• Drill all holes for M8 or M10 fixings as appropriate.
Mounting the evaporator unit on a
wall bracket
(Wolseley pt. no. 684222)

9
Cooling
4. Pipe sizing
Pipework runs up to a maximum of 30m (total equivalent length) are recommend between the BMOP and BMIEP units. Each instal-
lation must be evaluated for the total equivalent pipe run length, including equivalent lengths for bends, additional fittings and
vertical lifts etc. Please refer to the appropriate interconnecting pipe sizing chart (tables below) for a full selection.
Using interconnecting pipe sizing charts
The pipework sizes below are based on the nominal duty of the BMIEP and BMOP combination, as shown in the tables. Pipework
should be selected based on the total equivalent run length of the interconnecting pipework between the two units, and not just
the dimensional length. Equivalent lengths for all bends, piping components and vertical rises should be added to the basic run
lengths to achieve the total equivalent run lengths. When using the tables to determine pipe length, round up the equivalent
length and do not interpolate between values. For example, if the pipe run is between 10m and 20m, always use the 20m values.
Cellar temperature 10°C
Evaporator bracket centres
CONDENSING UNIT EVAPORATOR
UNIT CELLAR TEMPERATURE 10OC
MODEL UNIT CONN MODEL 10m 20m 30m
SUCTION LIQUID SUCTION LIQUID SUCTION LIQUID SUCTION LIQUID
BMOP-130-1 3/4“ 3/8“ BMIEP-448-37 5/8" 3/8" 5/8" 3/8" 3/4" 3/8"
BMOP-150-1 3/4“ 3/8“ BMIEP-448-48 5/8" 3/8" 3/4" 3/8" 3/4" 3/8"
BMOP-190-1 3/4“ 3/8“ BMIEP-448-48 5/8" 3/8" 3/4" 3/8" 3/4" 3/8"
BMOP-210-1 7/8“ 1/2“ BMIEP-448-48 5/8" 3/8" 3/4" 3/8" 7/8" 3/8"
BMOP-210-1 7/8“ 1/2“ BMIE-448-69 5/8" 3/8" 3/4" 3/8" 7/8" 3/8"
BMOP-210-1 7/8“ 1/2“ BMIEP-448-89 3/4" 3/8" 3/4" 3/8" 7/8" 1/2"
BMOP-250 -1/3 7/8“ 1/2“ BMIEP-448-89 3/4" 3/8" 3/4" 3/8" 7/8" 1/2"
BMOP-320-1/3 7/8“ 1/2“ BMIEP-448-89 3/4" 3/8" 7/8" 1/2" 1.1/8" 1/2"
BMOP-350-3 7/8“ 1/2“ BMIEP-448-89 7/8" 3/8" 7/8" 1/2" 1.1/8" 1/2"
BMOP-360-3 7/8“ 1/2“ BMIEP-448-133 7/8" 1/2" 1.1/8" 1/2" 1.1/8" 1/2"

Cooling
10
5. Pipework installation - supports and routing
Pipework to and from the units should be selected to suit the application and not the
connection size of the unit. Pipework should be supported independently from the
condensing unit and evaporator in a way that prevents the transmission of vibration
between the units. The suction line must be insulated.
At the installer’s discretion, liquid and suction lines may be run and clamped resting
against each other and insulated within the same insulation tube. This would increase
sub-cooling and improve Evaporator performance. A maximum of 6m vertical lift is
allowed in the pipework. Any vertical lift of the suction line must be accommodated
with a ‘Swan Neck’ in the pipe work to assist in oil return and prevent liquid flood back
during off cycle. Please refer to the diagram to the right.
A refrigerant filter drier is fitted in the BMIEP unit’s inlet pipework. During installation,
it is important that the pipework is not left open to atmosphere for any longer than
necessary. This causes moisture to be absorbed by the drier and reduces its normal
system drying capacity. The pipework bungs should only be removed just before brazing
of the pipework.
6. Brazing
A suitably qualified engineer should carry out brazing to a high standard of refrigeration practice.The Engineer should
ensure that:
• The working area is adequately ventilated.
• Appropriate PPE is worn throughout the process.
• The evaporator drain tray is removed before brazing.
• Care should be taken to avoid any direct flames being applied to the casework, controls or any area away from that being
brazed.
• Care should be taken when using nitrogen. Nitrogen is an asphyxiant and should only be used in well-ventilated areas with
appropriate procedures and mitigation measures in place, to prevent harm.
As well as following the above and adhering to best health and safety practices, the engineer should ensure that the following
is carried out:
• All pipe cuts are clean, and any swarf is removed
• Dry nitrogen is purged through system during brazing to minimize oxidization.
• Wet rags are used on all components close to brazing operations, and heat shields are used to protect the units.