Heatcraft Refrigeration Products II User's Manual
Contents
1. 711 5 25006501 September 2002 Replaces 711 4 5 02 INSTALLATION amp OPERATING INSTRUCTIONS MCCU Condensing Units The Cold Standard TABLE of CONTENTS General Safety Information 2 Condensing Unit Specifications 2 Evaporator Specifications 3 Evaporator Placement 4 Condensing Unit 5 Condensing Unit Rigging 6 Refrigeration Piping and Line Sizing 7 Refrigeration Piping 8 10 Leak Detection and Evacuation 11 Field Wumg 12 13 Beacon Controller 14 26 Refrigeration Charging 27 Operational Check Out 28 System Balancing 28 Preventive Maintenance 29 31 DIAQNOSUCS ui 32 35 Pants uu T 36 Wiring Diagrams 37 42 Start up Checklist 43 44 Beaconll REFRIGERATION SYSTEM 2175 Park Place Blvd Stone Mountain G2. Transducer open not installed Clearing Alarms Alarms 1 High Box Temp and A2 Low Box Temp will clear automatically if the Box Temperature decreases or increases to below or above the Alarm set point temperature Placing the system in the Service mode or turning off power will clear the A3 Alarm Replacing the Room Sensor Suction sensor or Pressure Transducer will clear the A4 Alarm Error Indicator LED At initial power up each Beacon II board checks for system errors The system error check involves checking the various temperature sensors to determine whether any of these sensors are shorted or open The system will pumpdown and cycle off and will not restart until the fault is cleared or the circuit breaker reset for the following conditions Suction sensor shorted open or not installed Room temperature sensor shorted 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 Superheat too low High pressure or low pressure cutout Oil pressure After the third try the system will shut down and not try to restart The Alarm contacts will be closed and an alarm message displayed on the LED ERROR CODES Room temperature sensor shorted open or not installed E2 Defrost temperature sensor shorted
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4. Suction Sensor Suction Pressure a Baren 1 buU 2 9 OUTDOOR Sp Grp wan out SER cour 13 Beacon Controller Installation Tips Use a minimum 18 gauge wire for all low voltage connections The Beacon II board get its 24 VAC power supply from a transformer mounted in the electrical end of each evaporator On 208 240 volt systems the multi tap transformer is shipped from our factory wired for 240 volts If your supply voltage is 208 volt you must change to the 208 volt tap on the transformer Refer to wiring schematic shipped on units for wiring Schematics in this Installation and Operation Manual are typical wiring schematics only Program ALL slave evaporators as SLAVES Evaporators are shipped from our factory with a preset box setpoint temperature of 35 F for air defrost and 10 F for electric defrost If your box setpoint temperature requirements are different this must be set using directions outlined under Room Temperature Control The suction line temperature sensor MUST be removed from the suction line before brazing the suction tubing The sensor MUST then be reinstalled on the suction line after brazing is completed and the tubing has cooled Insulate when finished The low pressure switch time delay relay located in the condensing unit must be set to one minute Some systems may require the crankcase heater to be energized 24 hours prior to start up The Beacon
5. dFF This is the maximum time allowed for a coil to remain in defrost Defrost will be terminated if the defrost end temperature is not attained when this time has expired On multiple evaporator systems this is controlled by the MASTER unit Each board should have the same setting Default Electric defrost 15 30 minutes and defrost is 40 minutes Defrost End Temperature dFt This is the temperature at which the defrost will be terminated Default Electric defrost 15 60 F and ar defrost 15 445 F Defrost Delay Start Time dFS This allows the delay of the start of the defrost Default 0 5 hours to 23 5 hours 18 Beacon Controller Programming And Reviewing Settings Changes continued Alarm High Temperature ALH Temperature at which a high box temperature alarm will be triggered This does not apply during defrost Default Electric defrost 15 5 F and ar defrost 15 50 Alarm Low Temperature ALL Temperature at which a low box temperature alarm will be triggered Default Electric defrost is 15 F and air defrost 15 30 Alarm Time ALt Time which high temperature or low temperature conditions must exceed before alarm is triggered Default 60 minutes F C Select units to display temperature Fahrenheit or Celsius Default Fahrenheit When C is selected a red dot will appear in the right bottom corner of the LED display o
6. 2 Check Voltage to Evaporator Transformer Go to 3 Check Transformer Secondary Output Volts next step 4 Check Voltage at Control Board 24V and C 5 Replace Control Board 1 Check Compressor internal overloads 2 Check Control Power to Condensing Unit 24 Volts across COMP and C at board Go to 3 Check Compressor Contactor Coil Voltage next step 4 Check Compressor Contactor pulled in Check Sensor and Board Connection Check Sensor and Board Connection Check Sensor and Board Connection Check Transducer and Board Connection Check Sensor wiring and Board Connection 1 Check Refrigerant Type 2 Check coil for ice 3 Check Control Board step position from board LED 4 Check Electric Expansion Valve Closure Go to next step 5 Compressor Not Operating 6 Check Suction Temperature Sensor 7 Check Suction Pressure Transducer 32 IF NOT OK 1 2 3 4 Check fuses and circuit breakers Check field wiring for breaks Replace if necessary Check factory wiring and connections Wait for reset Check transformer voltage secondary and primary and wiring of 208V power taps Check internal condensing unit wiring Replace as needed Replace as needed Replace as needed Replace as needed Replace as needed Replace or remove 1 2 Compare board setpoint and refrigerant Defrost coil and check defrost cycle settings setpoints defrost sensor and heater amps Replace board if EEV steps not at
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8. 2 Pumpdown system see if LPS opens or if it times out EEV is bad or LPS is set incorrectly if times out See Pumpdown Check overloads and contactor Compare board sensor reading against actual suction line temperature Compare pressure reading against gauges Z Diagnostics Beacon Il Troubleshooting Guide continued PROBLEM Step ACTION ITEM IF NOT OK T Check wiring connection to the board Correct field wiring to the board 2 Low Pressure Safety LPS Tripped Check for correct refrigerant type Change setpoint to match refrigerant Check refrigerant charge Add more refrigerant to proper charge Check LPS setting Correct LPS setting Check LPS wiring Correct LSP wiring Check EEV operation stuck Clean or replace EEV Check coil for icing Defrost coil see 6 step 2 Check for correct superheat reading Check replace sensor or transducer Check for correct nozzle selection Replace distributor nozzle Check for clogged EEV inlet screen Replace EEV Check line sizing Correct line sizing Check LPS time delay relay setting Reset to 1 minute Check operation of LPS Replace Low Pressure Safety Switch 3 High Pressure Safety HPS Tripped Check for system overcharge Reclaim recover excess charge Check for non condensables Remove all non condensables Check condenser fan motor and blade Repair or replace motor and or blade Check for dirty con
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10. MORE of operation On a call for cooling dLY will show while the expansion valve is opening After the compressor starts the LED will alternately display TEMPERATURE and Coo When the room thermostat setting is satisfied and if the compressor ran for at least 2 minutes the EEV will close and the compressor will pumpdown and shut off The evaporator fans will continue to run The LED will alternately display 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 for a minimum 2 minutes hold on cycle The 4 minute hold off can be bypassed and the system started immediately by pressing the Reset button the Beacon II board Figure 14 Operating Mode Display oFF Coo Cooling Pumpdown dEF Defrost Draining dLY Delay tSt Test SEr Service 16 Beacon Controller Programming And Reviewing Settings Changes The Program Review button is used to program review and change all program settings for the system Press PROGRAM REVIEW button The Setpoint item will appear on the LED After a few seconds delay the Setpoint value will display Each time the button is pressed a differ
11. a minimum evacuation to 500 microns In addition a vacuum decay test is strongly recommended to assure there is not a large pressure differential 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 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 they should remain closed A deep vacuum gauge capable of registering pressure in microns should be attached to the system for 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 a 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 Refrigerant used during evacuation can not be vented Reclaim all used refrigerant EPA regulations are constantly being updated Ensure your procedures follow correct regulations Repeat this operation a second time Open the compressor s service valves and
12. ability to delay the starting of the first defrost DEFROST DELAY START TIME Example The system is first powered up at 8 00 AM and is programmed for 4 defrosts per day The user would like the first defrost at 10 00 AM To accomplish this use the PROGRAM REVIEW button to scroll to dFS Use the SELECTOR switch to select 2 hours delay start then press ENTER The first defrost will now occur at 10 00 AM and then a defrost will occur every 6 hours thereafter DEFROST SCHEDULE IN MEMORY Beacon II does not have a real time clock but it keeps track of the time that has elapsed in its memory It also keeps in memory the number of defrosts scheduled and how much time has elapsed between defrosts If a power failure occurs when power is restored Beacon II will remember how many defrosts are scheduled and it will remember how much time was left until the next defrost It will then defrost based on this timing So if the power failure lasted 15 minutes the defrost schedule will be off by 15 minutes ELECTRIC DEFROST MODE When a defrost is initiated the EEV closes the compressor is allowed to pumpdown and shut off The evaporator fans are cycled off and the defrost heaters are energized There is a 2 minute condensate drain down period after which the compressor is started for a refreeze period The evaporator fan stays off fan delay The refreeze period will last until the evaporator suction temperature is at 28 F or 2 minutes has
13. box setpoint is 35 F the system will continue to cool until the box temperature gets to 34 F At this point the compressor will pumpdown and shut off The system will restart cooling when the box temperature has risen to 36 F It is important to note that Beacon has a minimum 2 minute ON time and a minimum 4 minute OFF time This means that the system will run 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 temperature could go below the differential temperature before the system cycles off In the OFF cycle the system will be off for a minimum of 4 minutes even if the box temperature goes above the differential temperature before cooling will be restarted The on board room thermostat is factory set at 35 F for air defrost systems and 10 F for electric defrost systems 15 Beacon Controller Initial Power On At the initial application of power to the system the compressor and the evaporator fans will be in a 4 minute hold off cycle and will not start immediately When there is a call for COOLING the expansion valve EEV opens then the compressor is started The compressor will then run for a minimum of 2 minutes in the hold on cycle This means that the compressor will run for a minimum of 2 minutes before shutting off even if the box temperature is met The LED alternately displays TEMPERATURE and
14. evacuate the entire system to 500 microns absolute pressure Raise the pressure to 2 psig with the refrigerant and remove the vacuum pump 11 WARNING wiring must be done accordance with applicable codes and local ordinances The field wiring should enter the areas as provided on the unit The wiring diagram for each unit is located on the 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 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 characteristic for wiring the unit 2 Consult the wiring diagram in the unit cooler and in the condensing unit for proper connections 3 Wire type should be of copper conductor only and of the proper size to handle the connected load 4 The unit must be grounded 5 For multiple evaporator systems follow the wiring diagrams for multiple evaporator systems carefully This will assure complete defrost of all evaporators in the system 6 remote defrost Timer is to be used the Timer should be located outside the refrigerated space Note Control wiring from the Ice Machines must be connected to the relays in the MCCU Control Panel to properly energize condenser fans Table 3 Fan Cycling Relay Hoshizaki ice machines Relay Remote Unit Voltage r
15. is suction superheat at the compressor 1 Measure the suction pressure 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 the suction line about one foot back from the compressor using an accurate thermometer 3 Subtract the saturated temperature from the actual suction line temperature The difference is superheat Too low a suction superheat can result in liquid being returned to the compressor This will cause dilution of the oil and eventual failure of the bearings and rings or in the extreme case valve failure or even slugging of the compressor Too high a suction superheat will result in excessive discharge temperatures which causes a break down of the oil and results in piston ring wear piston and cylinder wall damage It should also be remembered that the system capacity decreases as the suction superheat increases For maximum system capacity suction superheat should be kept as low as is practical Copeland mandates a minimum superheat of 20 F and a maximum of 45 F at the compressor Heatcraft recommends a superheat of Adjust the superheat by changing the superheat setting on the board to increase or decrease as needed to obtain desired superheat value at the compressor 28 Preventive Maintenance Routine preventive maintenance of any mechanical equipment is critical t
16. of pre cooler additional 2 or 4 barrel machines S po harged li vault amp vault freezer cnarged lines furnished by ice manufacturer Vault Cooler Ice Vault Machine Sandwich Storage Freezer Cases Slurpee Roof Penetrations All piping and control wiring penetrations are done underneath the fan section of the condensing unit Refer to building plans for job details of roof penetration scheme The 4 PVC pipe penetrations shown above is a guide for all parties involved Head Pressure Controls Heatcraft does NOT supply headmaster control for the individual display case circuits Refer to case manufacturers installation instructions for specific provisions needed for head pressure control Note Heatcraft does include headmaster controls on the ice machine circuit If the ice machine equipment from the vendor includes a headmaster already it will be necessary to clip the pigtail on the headmaster valve supplied by Heatcraft to disable it from operating and conflicting with the ice machine headmaster 10 Leak Detection Evacuation Leak Testing After all lines are connected the entire system must be leak tested The complete system should be pressurized to not more than 150 PSIG with refrigerant and dry nitrogen The use of an electronic type of leak detector is highly recommended because of its greater sensitivity to small leaks As a further check i
17. open or not installed E3 Suction temperature sensor shorted open or not installed E4 Suction pressure transducer shorted open or not installed E5 Outdoor temperature sensor shorted E6 Low superheat E7 Compressor shut down high or low pressure switch open or oil pressure switch open E9 Multi in multi out wiring error 23 Beacon Controller Evaporator Fans Shut Off In some installations it is desirable to shut off the evaporator fans periodically This is easily accomplished on Beacon by wiring a single pole single throw switch SPST between the terminals marked SERVICE and on the Beacon II board Closing this switch will cause the system to pumpdown and shut off Air defrost fan motors must be wired through the fan relay on the Beacon II board for this to be effective on air defrost systems The entire system will be shut off and remain off until the SPST switch is opened Air defrost evaporator fans are setup to run constantly If there is a need to shut down the evaporator fans on an air defrost system it can be accomplished by wiring the evaporator fan motor or evaporator fan motor contactor through the fan relay on the Beacon board When this is done and the air defrost system is placed in SERVICE the evaporator fans will shut off when the system is in pumpdown Power Failures In the event of a power failure Beacon II will automatically close the expansion valv
18. or lower by 5 000 ohms approximately the sensor should be replaced Resistance of sensors at various temperatures Table 4 Resistance Temperature Specification Temperature F Ohms Temperature E Ohms 32 32 650 42 330 55 330 72 950 97 070 130 410 176 960 24 Beacon Controller System Defaults Table 5 System Defaults Parameters Code Refrigerant Box Temperature Superheat Slave Evaporator No of Defrosts Per Day Defrost Fail Safe Time Defrost End Temperature Defrost Delay Start Time Alarm High Temperature Alarm Low Temperature Alarm Time Temperature Units Figure 15 Control Sensor And Piping Control Sensors amp Piping Beacon II Controller Room Temp Defrost Spare Sensor Temp Sensor Sensor by others Suction Temp Electric Evaporator e Distributor 25 Beacon Controller Checking Operation Of Expansion Valve EEV To check if the expansion valve is closing properly Install a pressure gauge set to suction line at the condensing unit With the system running close the valve on the liquid line at the condensing unit The system should pump down and shut off on the Low Pressure switch LPS If the system does not pump down and trip on the LPS then the compressor valves are weak and needs to be changed Afte
19. should be de energized for this period by placing it in the SERVICE MODE This is done by pressing the FORCE SERVICE button twice To start the system cooling press the CLEAR button Room sensors must be left connected ALL evaporators Apressure transducer is installed on the evaporator Do not leak test system above 150 PSI or damage to transducer could occur Condensing Unit The condensing unit control panel contains the relays contactors and a terminal block which is appropriately marked to match the low voltage wiring connections A sensor for outdoor air temperature measurement is installed on the condensing unit Condensing unit must be installed using proper refrigeration practices and codes Make sure there is good airflow and good clearances around unit Evaporator Unit The evaporator contains the BEACON II controller s electric expansion valve s pressure transducer distributor s orifice s transformer and three sensors These components are all factory mounted and wired The three sensors are factory mounted and provide input to the controller from the following defrost temp suction temp room temp Each evaporator unit must be installed using proper refrigeration practices and codes Make sure the piping is correctly sized and properly routed It is highly recommended that the liquid and suction lines be insulated There must also be good clearance around the unit See Heatcraft Refrigeration
20. tubing properly sealed against contamination c Suction lines should slope 1 4 per 10 feet towards the compressor in direction of flow 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 of 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 Remove temperature sensor attached to suction line on Beacon systems before brazing of the solder joint internally Flux only the male portion of the connection never the female After brazing remove excess flux Wrap expansion valves with wet rags during brazing to the liquid line CAUTION If the temperature gets too high these components may be damaged Heat absorbing compounds or wet rags must be used to protect the expansion valve when brazing to the refrigerant piping line connections and the suction line sensor must be removed per a
21. when supplied Check auxiliary relay Replace auxiliary relay Check demand cooling device Replace faulty demand cooling device 8 Check compressor relay on board Replace board if relay is faulty 33 Diagnostics Z Beacon Il Troubleshooting Guide continued PROBLEM Step ACTION ITEM IFOK IF NOT OK E9 Wulti out to Multi in 1 Check for 24 volts power to the board 1 If no voltage see LED is not lit above Communication Wiring for low voltage see 88888 LED display only shows after initial 2 Check for crossed communication wiring Go to 2 Correct wiring from Master unit Multi out successful connection multi out not wired to multi in terminals next step to Multi in of Slave unit etc to all Slaves and return to Master See wiring diagrams 3 Check for broken communication wiring 3 Correct wiring between first Slave with error to previous board in the sequence E9 continued Master Slave 1 Slave 2 Slave 3 Communication Error 5 in out in out out 5 3 Break in the designated 2 3 lines will cause errors 4 as follows Line Master Slave Slave 2 Slave 3 E9 E9 E9 E9 EQ no error EQ E9 E9 no error no error E9 E9 no error no error no error SMART Master Slave 1 Slave 2 Slave 3 in in out in out in out in G With SMART 5 Contro
22. 2175 W Park Place Blvd Stone Mountain Georgia 30087 HEATCRAFT 770 465 5600 Fax 770 465 5990 Refrigeration Products gt www heatcraftrpd com e mail hrpd feedback heatcraft com
23. Data Condensing Unit Model Compressor Location CRN5 500 Cooler 208 230 3 60 MCCU56049B2N KALA 016E Freezer 208 230 3 60 RS55C1E Ice Storage 208 230 1 60 CR37KQ Cooler 208 230 3 60 MCCUCSTORE3B2N KALA 016E Freezer 208 230 3 60 KALB 010E Ice Merch 208 230 1 60 CR53KQ Cooler 208 230 3 60 MCCUCSTORE4B2N KALA 016E Freezer 208 230 3 60 KALB 010E Ice Merch 208 230 1 60 CRN5 0500 Cooler 208 230 3 60 MCCUCSTORES5B2N KALA 016E Freezer 208 230 3 60 KALB 010E Ice Merch 208 230 1 60 MCA Minimum Circuit Ampacity MOP Maximum Overcurrent Protection Evaporator Specifications Table 2 Evaporator Specification Data Dimensions WEIGHT Ibs Evaporator Model Location Capacity A Liq OD BTUH _ 2 79 82 _ r 7 2 C CR s 923 636 CL r ES ADT208BHB2N2K 20 800 77 50 65 25 Figure 2 22mm 7 8 Electrical Knockouts 2 8 54 44 2 4 316 38 106 3 4 44 Electrical Connection 716 341 6 118 156 14 15 16 379 I5 407 mm 3 4 MPT 14 NPSI Drain Connection Figure 3 REAA HANGERS SPACE UNIT 2 FROM WALL L C SUCTION LINE SIZES 09 12 16 28 19 32 SUCTION LINE SIZES 21 35 53 besche ELECTRICAL z NNEGTISN CONNECTION 09 28 35 53 5 16 x 5 8 x 1 KEYHDLE SLOT He
24. Installation Manual for more details 14 Beacon Controller Refrigerant Line Brazing CAUTION The electric expansion valve and the suction temperature sensor on the suction line are factory installed Care must be taken when brazing these lines at the evaporator Too high a temperature may destroy these components Heat absorbing compounds or wet rags must be used when brazing the refrigerant line connections The suction line sensor should be removed before brazing Power Supply The Beacon board gets its 24 VAC power supply from a transformer mounted in the electrical end of each evaporator On 208 240 volt systems the multi tap transformer is shipped from our factory wired for 240 volts your supply voltage is 208 volt you must change to the 208 volt tap on the transformer VERY IMPORTANT If the supply voltage to the evaporator is 208 volts the primary tap of the transformer must be moved to the 208 volt tap This must be done for all the evaporators on that system If the 24 VAC power supply falls below 18 VAC the system may power down and shut off When the power supply is corrected to 24 VAC the system will restart after the four minute hold off period and resume normal operation On Beacon systems the main power for the evaporator can be supplied separately from the power supply of the condensing unit All wiring however must comply with local electrical codes Wiring Wiring between the condensing uni
25. LEAR TEST Pressing this button ONCE will return the LED display to the default display CLEAR With the system in the OFF mode pressing and holding this button will start the TEST mode In the TEST mode it will cycle through each output TEST STATUS INDICATOR LED A red 3 digit alphanumeric LED on the Beacon II board indicates status alarms and error codes Status LED Display Description OFF Box Temp Box Temperature Mode is displayed All Evaporators COOLING Single Evaporator Box Temp Coo Box Temperature Mode is displayed Multiple Evaporators Master Evap Box Temp Coo Box Temperature Mode is displayed Slave Evaps Coo Operating Mode is displayed Pumpdown All Evaporators Pdn DEFROST All Evaporators dEF TEST Evaporators tSt SERVICE All Evaporators SEr ALARMS Al High Box Temp A2 Low Box Temp A3 System Start Up Failure Compressor does not start after 3 times Four minutes between each try 4 Input Fault Box Temp Suction Temp Pressure Transducer open or not installed 20 Controller STATUS INDICATOR LED continued Status LED Display Description ERRORS Room temperature sensor shorted open or not installed E2 Defrost temperature sensor shorted open or not installed E3 Suction temperature sensor shorted open or not installed E4 Suction pressure transducer shorted open or not installed 5 Out
26. N ATNO SYOLITOINOD ISN 41 Wiring Diagram Diagram 1 Ice Machine Fan Cycle Wiring Fan Cycling Interlocking Connections x Relay 4 R4 is for condenser fan operation for the D Ice Machine circuit located with the left fan Relay is Ice Machine 208 240V IW 5 Hoshizaki ice machines require a 115 volt relay which must be field supplied replacing the factory relay 42 Date of Start up Location CONDENSING UNIT MODEL SERIAL COOLER UNIT MODEL SERIAL COOLER UNIT MODEL SERIAL COOLER UNIT MODEL SERIAL FREEZER UNIT MODEL SERIAL FREEZER UNIT MODEL SERIAL ELECTRICAL Check Primary Supply voltage If 208 V change transformer wiring in the Cooler and Freezer to the 208 V tap OYES Check Compressor Amps for COOLER and FREEZER compressors Should match nameplate OYES ONO PIPING 15 suction line trapped at the Cooler OYES ONO Is suction line trapped at the Freezer OYES LINO DRAIN LINES Are lines sloped properly OYES ONO Is line trapped outside the Cooler OYES ONO Is drain line trapped outside the Freezer OYES ONO 15 heat tape wrapped along entire length of the drain line in the Freezer OYES ONO 15 heat tape plugged in and heating the drain line OYES INSULATION Are Liquid lines fully insulated OYES ONO Are Suc
27. O Start the FREEZER only Does the compressor start and evaporator fans run for this FREEZER OYES ONO Start up Checklist RECORD OUTDOOR TEMPERATURE F SYSTEM VOLTAGE 2 Volts _ PH _ Cooler Compressor Amps Li l2 Ll3 Freezer Compressor Amps 1 l2 Ll3 Ice Storage Compressor Amps 1 _____12 Ll3 Cooler Discharge Pressure PSIG Freezer Discharge Pressure PSIG Storage Discharge Pressure PSIG Cooler Suction Pressure _ PSIG Freezer Suction Pressure PSIG Storage Suction Pressure PSIG Cooler Suction Temp E Freezer Suction Temp 22 205 Ice Storage Suction Temp _ F Cooler Refrigerant Charge Ibs Freezer Refrigerant Charge Ibs Storage Refrigerant Charge lbs Cooler Compressor Superheat _ F Freezer Compressor Superheat F Storage Compressor Superheat _ F Cooler Evaporator Superheat ZE Freezer Evaporator Superheat F Storage Evaporator Superheat SF Cooler Discharge Temp _ F Freezer Discharge Temp Ice Storage Discharge Temp F 44 Notes 45 Notes 46 Notes 47 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 Since product improvement 15 continuing effort at Heatcratt Refrigeration Products we reserve the right to make changes in specifications without notice
28. Safety Switch Compare equipment capacity with requirements Go to Check box temperature setpoint next step Check compressor performance Check condenser coil for dirt debris Check condenser for non condensables Check condenser fan operation Check for correct refrigerant type Check for iced evaporator coil Check defrost parameters Check superheat setpoint too high Check display values F or C Placing system into SERVICE MODE BOARDS ONLY Use Remote Service Switch in condensing unit Pressing Force Service button board twice Connection between Ser and C on board all are wired in parallel all will activate mode ONLY Master board on multiple evaporator systems with SMART Controller Use Remote Service Switch in condensing unit Connection between Ser and C on board From program menu of Smart Controller Change SERVICE setpoint to On all are wired in parallel any all will activate mode ONLY Master board on multiple evaporator systems 35 IF NOT OK 1 Check power to condensing unit Check position of Service Mode switches Check compressor overloads and contactor 2 Add or remove refrigerant to proper charge 3 Check EEV operation Check control board EEV signal Check suction sensor and transducer 4 Check EEV inlet screen and restrictions Check liquid line sizing Check head pressure controls 5 Check everything for E7 LPS above 6 Add or replace with more larger equipment 7 Corre
29. TCH AWAY FROM UNIT MCCU UNIT ON ROOF 3 8 LIQUID LINE 7 DOWN EVERY 6 0 FT PITCH DOWN TOWARD UNIT ROOF PENETRATION BY OTHERS SEE ARCH PLANS Ze 3 8 LIQUID LINE bos SUCTION LINE BEACON ELECTRIC EXPANSION VALVE er L 5 SUCTION LINE MOUNTED INSULATED WITH 3 4 WALL ARMAFLEX OR EQUAL PIPING DIAGRAM FOR THE R404a LOW TEMPERATURE FREEZER REFRIGERATION SYSTEM 10 VAULT STORAGE FREEZER NOT TO SCALE Refrigeration Piping Suction Lines NOTE If the suction line must rise to the point higher than the suction connection on the evaporator a suction line trap at the outlet of the evaporator must be provided Horizontal suction lines should slope away from the evaporator toward the compressor at the rate of 1 4 per 10 feet for good oil return When multiple evaporators are connected in series using a common suction line the branch suction lines must enter the top of the common suction line Suction lines that are outside of refrigerated space must be insulated See Line Insulation for more information Suction Line Risers NOTE To provide proper oil return a suction trap must be provided at the base of all suction risers Prefabricated wrought copper traps are available or a trap can be made by using two street ells and one regular ell The suction trap must be the same size as the suction line For long vertical ri
30. ached normal operating conditions and the oil charge has been properly adjusted to maintain the oil level at the center of the sight glass k At initial start up the system may cycle off at 2 minutes and display a low superheat error then restart itself This cycle may be repeated a few times Do not shut the system off Let the system run as it may take a few cycles for the electric expansion valve to attain the correct setting for the desired superheat CAUTION Extreme care must be taken in starting compressors for the first time after system charging At this time all of the oil and most of the refrigerant might be in the compressor creating a condition which could cause compressor damage due to slugging Activating the crankcase heater for 24 hours prior to start up is recommended no crankcase heater is present then directing 500 watt heat lamp or other safe heat source on the lower shell of the compressor for approximately thirty minutes will be beneficial in eliminating this condition which might never reoccur 27 Operational Checkout After the system has been charged and has operated for at least 2 hours at normal operating conditions without any indication of malfunction it should be allowed to operate overnight on automatic controls Then a thorough re check of the entire system operation should be made as follows a Check compressor discharge and suction pressures If not within system design limits determine
31. air cooled equipment is the provision for a supply of ambient air to the condenser and removal of heated air from the condensing unit or remote condenser area Where this essential requirement is not adhered to it will result in higher head pressures which cause poor operation and potential failure of equipment Units must not be located in the vicinity of steam hot air or fume exhausts Corrosive atmospheres require custom designed condensers Another consideration which must be taken is that the unit should be mounted away from noise sensitive spaces and must have adequate support to avoid vibration and noise transmission into the building Units should be mounted over corridors utility areas rest rooms and other auxiliary areas where high levels of sound are not an important factor Sound and structural consultants should be retained for recommendations Refer to actual building plans for unit locations Figure 4 Condensing Unit Placement 3 Feet minimum Clearance to 3 Feet from the Next Unit 3 Feet ildi minimum L V O Clearance from MCCU to an Open Block Wall or Shrubs N FRONT UNIT q 3 Feet minimum Clearance for Contractor to Service Unit Condensing Unit Rigging Figure 5 Condensing Unit Rigging Adequate rigging measures must be taken to support unit weight and to protect the unit from damage during unloading and placement process Rigging holes have been provided in legs
32. and under the unit compressor frame to assist Rigging Holes Spreader bars may be used to protect unit from damage Disconnect Refer to the building plans for construction details Roof Opening Flashed and Refer to the Sealed building plans for construction details u 82 01 C L Mounting J Dimensions C L 5 55 07 C L 26 94 C L Refrigeration Piping And Line Sizing Refrigeration Piping And Line Sizing The system as supplied by Heatcraft was thoroughly cleaned and dehydrated at the factory Foreign matter may enter the system by way of the evaporator to condensing unit piping Therefore care must be used during installation of the piping to prevent entrance of foreign matter Install all refrigeration system components in accordance with applicable local and national codes and in conformance with good practice required for the proper operation of the system The refrigerant pipe size should be selected from the tables in Refrigeration System Installation Manual Part Number 25001201 The interconnecting pipe size is not necessarily the same size as the stub out on the condensing unit or the evaporator The following procedures should be followed a Do not leave dehydrated compressors or filter driers on condensing units open to the atmosphere any longer than is absolutely necessary b Use only refrigeration grade ACR copper
33. atcraft Refrigeration Products 2002 Evaporator Placement Typical Layouts for Illustration refer to build plans for actual room layout and equipment location The ADT LET units are draw through units For best operation they should be located away from entry doors and at least 18 from the wall with the fans blowing into the room Make sure the units are flush mounted to the ceiling to insure proper drainage for defrost water Figure 3 Evaporator Placement In Cooler Freezer H Total A A height of 112H 112H 2 ___ __ r tian RAUEN ARROW Surface n gt evaporator Two evaporators NOTE Always avoid placement of Unit Coolers directly above doors and door openings where low temperature is being maintained and wherever possible for medium temperature in 7 J pe gll Cooler Freezer with Glass Display Doors Elevation view of glass display door cooler or freezer Be sure air discharge blows above not directly at doors Provide baffle if door NOTE Whenever possible always try to position extends above blower level the evaporator to blow towards the vault door Never position it over or adjacent to a door opening Condensing Unit Placement Space and Location Requirements The most important consideration which must be taken into account when deciding upon the location of
34. bove instructions Do not use bull head tees This will cause oil return problems and can cause poor performance If isolation valves are installed at the evaporator full port ball valves should be used Figure 6 Refrigeration Piping Diagrams SLOPE DOWN TO UNIT Z SS TOMCCU UNIT ON ROOF PITCH AWAY FROM UNIT 3 8 LIQUID LINE BRACE DOWN EVERY 6 0 FT PITCH DOWN TOWARD UNIT neuem amines ROOF PENETRATION BY OTHER SUCTION LINE SLOPE DOWN TO UNT PITCH AWAY FROM UNIT 1 2 LIQUID LINE MCCU UNIT ON ROOF 7 BRACE DOWN EVERY 6 0 FT 1 1 8 SUCTION LINE PITCH DOWN TOWARD UNIT ROOF PENETRATION BY OTHERS SEE ARCH PLANS 1 2 LIQUID LINE BEACON ELECTRIC EXPANSION VALVE SA 1518 SUCTION LINE ATER 1 118 SUCTION LINE MOUNTED INSULATED WITH 3 4 WALL ARMAFLEX OR EQUAL PIPING DIAGRAM FOR THE R22 MEDIUM TEMPERATURE COOLER REFRIGERATION SYSTEM 10 DOOR VAULT COOLER NOT TO SCALE SEE ARCH PLANS Nig 3 8 LIQUID LINE BEACON ELECTRIC EXPANSION VALVE TYP 5 12 SUCTION LINE MOUNTED 1 2 SUCTION LINE INSULATED WITH 3 4 WALL ARMAFLEX OR EQUAL PIPING DIAGRAM FOR THE R404a LOW TEMPERATURE FREEZER REFRIGERATION SYSTEM VAULT ICE MERCHANDISER NOT TO SCALE SLOPE DOWN TO UNIT PI
35. cantly greater than most of the other piping Extra supports are relatively inexpensive as compared to refrigerant loss Figure 10 Evap 1 Line Insulation After the final leak test refrigerant lines exposed to high or low ambient conditions should be insulated to reduce heat loss or gain and prevent the formation of flash gas in the liquid lines Suction lines should be insulated with 3 4 wall Armstrong Armaflex or equivalent Liquid lines should also be insulated with 1 2 inch wall insulation or better The insulation located in outdoor environments should be protected from UV exposure to prevent deterioration of insulating value Refrigeration Piping Figure 11 Piping Connection Layout MCCU e e o ode oo c e e e eu uie e o cio e oio o ei e o o e o aio o o a e o e o o o e o eto e o eie e oo lo o o ole 2 sets hard piped from MCCU to sandwich cases 4 Cases e tp te 2 Slurpee Ice Storage Machines Vault Freezer Machine Cooler 2 sets of pre charged line sets from Hard sisson Hard pipe from IMI Cornelius pip MCCU to vault bs as MCCU to Bohn 2 extra circuits for stores that install sab 1 set
36. ct setpoint to proper value 8 Check compressor application limitations Check integrity of compressor operation impaired worn or damaged components 9 Clean condenser coil 10 Remove all non condensables 11 Replace repair fan blade motor cycling Switch or make corrective adjustments 12 Compare board setpoint and refrigerant 13 Defrost coil and check defrost cycle see E2 settings setpoints and defrost sensor 14 Correct defrost setpoints in program frequency and termination of defrosts 15 Correct setpoint for more cooling surface 16 Correct setpoint for proper display values Terminating SERVICE MODE BOARDS ONLY 1 Must terminate using same switch 2 Press Clear button on board 3 Open connection between Ser and C Note If multiple switches were placed in Service Mode all must be open to terminate the mode with SMART Controller Il 1 Must terminate using same switch 2 Open connection between Ser and C 3 From program menu of Smart Controller Change SERVICE setpoint to Off Note If multiple switches were placed in Service Mode all must be open to terminate the mode Table 6 Beacon Parts List PART HRP PART Beacon Control Board 28910101 Temperature Sensor Kit Blue Leads 89904902 Transformer 240 24 volt 40 VA 22529602 Pilot Relay 22511401 Contactor for Compressor 40 amp with 24 volt Coil 2252440 Terminal Block Condensing Unit 2251266 Low Press
37. ctions Be sure they are all correct and tight b Check voltage taps on transformer The transformer is shipped wired to 240 voltage tap connection If your supply voltage is 208 volt systems change to 208 voltage tap b Check setting of time delay relay for low pressure switch in condensing unit It should be set at two minutes the third marker c Check high and low pressure controls pressure regulating valves oil pressure safety controls and all other safety controls and adjust them if necessary d 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 especially in cold ambients e Liquid line should always be insulated f Wiring diagrams instruction bulletins etc attached to the condensing units should be read and filed for future reference 9 All fan motors air cooled condensers evaporators etc should be checked for proper rotation Fan motor mounts should be carefully checked for tightness and proper alignment h Observe system pressures during charging and initial operation Do not add oil while the system is short of refrigerant unless oil level is dangerously low i Continue charging until system has sufficient refrigerant for proper operation Do not overcharge Remember that bubbles in a sight glass may be caused by a restriction as well as a shortage of refrigerant j Do not leave unit unattended until the system has re
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39. denser coil Clean condenser coil Check head pressure controls Adjust or replace faulty controls Check fan cycling controls Adjust or replace faulty controls Check liquid 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 proper piping practices Go to Correct piping to minimize oil logging Check for low superheat see 6 next step Correct per steps in 6 Check operation of auxiliary relay R6 Replace auxiliary relay Check OPS sensor Replace faulty OPS sensor Check operation of OPS Replace faulty OPS 5 Compressor Module Tripped when supplied Check module Replace faulty module Check superheat at compressor inlet Reduce superheat TXV adjust etc Check compressor for overheating Correct overheating problem Check suction pressure too low Consider crankcase pressure regulator or other measures 6 Phase Loss Monitor PLM Tripped Check presence of all phase legs Correct power phase problem Check power supply Correct power supply problems Check operation of PLM Replace faulty PLM Demand Cooling
40. door temperature sensor shorted E6 Low superheat during cooling E7 Compressor shutdown high or low refrigerant pressure or low oil pressure E9 Multi in Multi out wiring error OTHERS Coo Room Temperature sensor open or not connected Instead of displaying box temperature Loc Board is locked Settings cannot be changed UnL Unlock the board settings Low Ambient Operation All units are shipped standard with head master valves Scroll compressor units have a 100 PSI head master valve and all other systems have a 180 PSI head master valve Condensing units with multiple condenser fans will have one or more fans cycle on Pressure Fan Cycling switch An adjustable Time Delay relay factory set at 1 minute is wired across the Low Pressure Switch LPS In cold ambient this allows time for the suction pressure to build up and prevent nuisance tripping of the LPS In warmer ambient this time delay relay can be adjusted to 0 minutes Pumpdown At the end of each cooling cycle when the box temperature is met the Beacon system will pumpdown and shut off the compressor To pumpdown the EXV closes and the compressor runs until one of the following occurs the low pressure switch opens the suction pressure at the evaporator is 4 psig a total of two minutes has elapsed When any of these three conditions occur the compressor will turn off and not restart until there is a call for cooling Periodic pumpdown While in the OFF cycle
41. e to prevent refrigerant from migrating throughout the system After power returns with 24 VAC at the board the system will restart in the cooling mode after the 4 minute hold off period Spare Sensor Terminals Beacon 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 4 below If a product temperature simulator is used it must meet the resistance temperature specification listed in Table 4 below The temperature range for this input is 30 F to 140 F Sensors on the Beacon II system as supplied will not simulate product temperature This input can be monitored on the LED display by using the MONITOR button and scrolling the The values displayed will be the temperature of the spare sensor Checking Sensors DO NOT REMOVE SENSORS FROM EVAPORATOR FOR CHECKING Use the monitor button to display the value the sensors are reading on the LED suction temp SCt defrost temp dFt or room temp Compare this value to the measured value with a thermometer at each of these points If they do not match change the sensor or The sensors can be checked for their proper operation by placing it in a cup of ice water Stir the ice water and measure the resistance of the sensor At 32 F the resistance should be 32 650 ohms If it is higher
42. elapsed After this sequence the system is back in the refrigerating mode and the evaporators fans are not running AIR DEFROST MODE The sequence is the same as for electric defrost except that there are no heaters and the evaporator fans run continuously 22 Beacon Controller Alarms Beacon provides set of dry contacts for use in signaling an alarm These contacts be connected to a light a buzzer a bell etc which will be activated when an alarm condition occurs When the Beacon is energized the alarm contacts are OPENED When an alarm condition is detected the contacts are CLOSED Conditions under which the alarm contacts will close are High Box Temperature LED Display A1 Room temperature has exceeded the Alarm High ALH value for the Alarm time ALt programmed Low Box Temperature LED Display A2 Room temperature has dropped below the Alarm Low ALL value for the Alarm time ALt programmed System Start Up Failure LED Display A3 Compressor does not start after three tries Four minutes between each try Input Fault LED Display A4 Box Temp Suction Temp Pressure Transducer open or not installed Power Failure Loss of power to the Evaporator ALARM CODES A1 High Box Temp A2 Low Box Temp System Start Up Failure Compressor does not start after 3 times Four minutes between each try 4 Input Fault Box Temp Suction Temp Pressure
43. ent setpoint item is displayed PROGRAM REVIEW Next use the SELECT knob to change value of Setpoint 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 thus will not be changed PROGRAM REVIEW ITEMS Set Defrost Type A ror 2 2 rEF Set Refrigerant Type R22 R404A R507 bot Set Box Temperature 30 F to 70 F SUP Set Superheat 4 F to 20 F SLA Set Board as a Slave Yes or No dFn Set Number of Defrosts Per Day 1 2 3 4 5 6 8 10 or 12 per day dFF Set Defrost Fail safe Time 10 to 200 minutes Set Defrost End Temperature 40 F to 100 F dFS Set Defrost Delay Start Time 0 5 Hours to 23 5 Hours ALH Set Alarm High Temperature 40 F to 90 F ALL Set Alarm Low Temperature 40 F to 90 F ALt Set Alarm Time 2 to 120 minutes FC Set Fahrenheit Celsius Temperature Units F 17 Controller Programming And Reviewing Settings Changes continued Use the PROGRAM REVIEW button to select these items PROGRAM REVIEW Defrost Type Selection is made for air defrost electric defrost coil This will automatically set the system factory defaults for air defrost and electric defrost See default setting
44. eorgia 30087 HEATCRAFT 770 465 5600 Fax 770 465 5990 Refrigeration Products www heatcraftrpd com e mail hrpd feedback heatcraft com General Safety Information General Safety Information 1 Installation and maintenance to be performed only by certified personnel who are familiar with this type of equipment 2 Make sure that all field wiring conforms to the requirements of the equipment and all applicable national and local codes 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 Inspection Responsibility should be assigned to a dependable individual at the job site to receive material Each shipment should be carefully checked against the bill of lading The shipping receipt should not be signed until all items listed on the bill of lading have been accounted for Check carefully for concealed damage Any shortage or damages should be reported to the delivering 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 prevent damage Heavy equipment should be left on its shipping base until it has been moved to the final location Condensing Unit Specifications Figure 1 r 85 44 87 24 Table 1 Condensing Unit Specification
45. equire a 115 volt relay R4 Ice Machine 208 240 which must be field supplied replacing the factory relay Figure 12 12 Field Wiring WARNING All wiring must be done in accordance with applicable codes and local ordinances The field wiring should enter the areas as provided on the unit The wiring diagram for each unit is located on the 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 characteristic for wiring the unit 2 Consult the wiring diagram in the unit cooler and in the condensing unit for proper connections 3 Wire type should be of copper conductor only and of the proper size to handle the connected load 4 The unit must be grounded Figure 13 Beacon Il Board Heater Ki EVAPORATOR K2 DEFROST HEATER ALARM E A Fan 9 me 1 LED Display Room Sensor Expansion Valve Connection Weg E 1 53 3455 3 EXV TEST Selection Buttons n 92467 DIN za INTEL y 2 OL XN ee gt 24 HEXTCRAFT INC BEACON
46. f the Beacon board Use the MONITOR button to review these items SUP Superheat F ESP Expansion Valve Stems 0 to 255 steps MONITOR SCT Suction Temperature F MONITOR 551 Saturated Suction Temperature F SCP Suction Pressure at Evaporator PSIG Odi Outdoor Temperature F Defrost Sensor Temperature F dFE Last Defrost Elapsed Time minutes AC Board Voltage SPt Spare Temperature Reading Use this button to FORCE DEFROST DEFROST To force a defrost press the FORCE DEFROST button The system will pumpdown and shut off the compressor The heaters are then turned on The display will show dEF Use this button to RESET TIME 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 the expansion valve opens This display will show Use this button to FORCE SERVICE Pressing this button TWICE will cause the system to pumpdown and the compressor to shut off The system will remain off until the CLEAR button is pressed While in the FORCE SERVICE the LED display will show SEr 19 Beacon Controller Programming And Reviewing Settings Changes continued Use this button to C
47. if there isn t a call for cooling box set point temperature is met but the evaporator suction pressure has risen to 10 psig the low pressure switch has closed The system will initiate a pumpdown This periodic pumpdown will occur at 4 minute intervals when these two conditions are met 21 Beacon Controller Service Mode A single pole single throw switch SPST is supplied in each condensing unit for shutting off the system Closing the Service switch in the condensing unit will cause the system to pumpdown and shut off Ser will be displayed on the Beacon board LED and SERVIC is displayed on the Smart Controller LCD display The evaporator fan and heaters will be de eneergized in the Service Mode The system will not restart until the SPST switch is placed in the NORMAL or OFF position or The system can be pumped down by pressing the SERVICE button twice To restart the system press the CLEAR button or The system can be pumped down for service by closing the liquid line service valve in the condensing unit then closing the suction line service valve when the system trips on the low pressure switch Defrost DEFROST TIMING When power is first applied to the system its timer starts counting time If 4 defrosts are programmed it will initiate a defrost every 6 hours from when power was first applied Beacon does not have a real time clock Beacon II does provide the
48. iquid line drier in the refrigerant supply line between the service gauge and the liquid service port of the receiver This extra drier will insure that all refrigerant supplied to the system is clean and dry 2 When initially charging a system that is in a vacuum liquid refrigerant can be added directly into the receiver tank to break the vacuum Weighing in the charge is recommended with the initial charge consisting of approximately 2 pounds per system compressor horsepower 3 Remove the refrigerant drum and connect it to the suction side of the compressor to charge with refrigerant vapor into the low side of the system until the pressure is above atmospheric 4 Start the system and finish charging until the sight glass indicates a full charge and the proper amount has been weighed in a total of 4 to 5 pounds per system compressor horsepower 5 If 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 Note Maximum refrigerant charge for the cooler system should not exceed 20 R 22 Maximum refrigerant charge for the freezer systems should not to exceed 10 R404A Check Out amp Start Up After the installation has been completed the following points should be covered before the system is placed in operation a Check all electrical and refrigerant conne
49. ller II Line SMART Master Slave Slave 2 Slave 3 1 COMM E9 no error no error no error 2 COMM no error E9 E9 E9 3 COMM no error no error E9 E9 4 COMM no error no error no error E9 5 COMM no error no error no error no error PROBLEM tep ACTION ITEM IE K_ 88888 LED display 1 Check Voltage to Evaporator Transformer 1 Check field wiring for breaks or shorts power is below 18V and 2 Check Transformer Secondary Output Volts Go to 2 Replace if necessary appears at initial power 3 Check Voltage at Control Board 24 and C next step 3 Check factory wiring and connections 4 Check Voltage at SMART Controller 4 Check field wiring from board 1 Check for low voltage 1 Check all steps for 88888 LED display LED displays dLy Go to Voltage could drop off too fast to show then oFF with no 2 Check for short in field wiring from comp on next step 2 Check internal factory wiring to displayed errors board to condensing unit terminal connection compressor contactor 3 Replace defective contactor holding coil 34 Z Diagnostics Beacon Il Troubleshooting Guide continued PROBLEM Cannot get to box temperature Service Mode SEr is displayed Step ACTION ITEM 1 9 10 11 12 13 15 16 IF OK Check system operation Is it running Check system charge Check for proper operating superheat Check for high superheat and EEV wide open Check Low Pressure
50. o its long term reliability During even normal operation all equipment will expeerience some deterioration during its lifetime caused by wear and evironmental influences For that reason regularly scheduled maintenance of your refrigeration equipment is required in order to keep it operating to its maximum efficiency while avoiding potentially costly repairs of a premature failure due to equipment neglect The following is Heatcraft s minimum recommendations for regularly scheduled preventive maintenance of your 7 Eleven refrigeration system Qualified and licensed refrigeration companies only should perform all preventive and corrective maintenance on refrigeration equipment While we cannot guarantee that close adherence to these recommendations will eliminate all equipment problems it will greatly reduce the potential for mechanical and electrical failures thus providing increased reliability Go to pages 30 31 for the Preventive Maintenance Tables 29 p nb se pue ue py pue sesse poepouloo usniq Suonoeuuoo pezeJq 1 190002 soj z UOISOJOD pue Sxee jo SUDIS JO jpedsu SJ0je nuin22e uonons j2edsu pue uonueme esoj Keg Jo sxoeJo JO SUBIS yoaug enpiseJ ou Y esn ejeudoJ
51. pected of not functioning properly the motor windings resistance should be measured This is a bipolar motor with two windings Measure the resistance at the pins on top of the valve between locations A and B or C and D Note that the pins are not labeled A B C D This labeling is just for reference Also two of the pins at location B and location D have a wider spacing between them than between location A and C Figure 16 Expansion Motor Winding Pins For valve sizes 29320003 and 29320004 the resistance measured between pin locations A and B or C and D should be approximately 336 Ohms when the valve is at 75 F For valve sizes 29320007 29320008 29320013 and 29320014 the resistance measured between pin locations A and B or C and D should be approximately 116 Ohms when valve is at 75 F Measuring resistance between locations A and C or B and D will always show Open because these locations are between the motor windings When the valve is opening or closing the voltage measured between A and B or C and D should be between 20 to 22 VAC Measuring the DC volt of the EXV TEST pins on the board will also indicate if the expansion valve is open or close 0 volts DC indicates the valve us closed 5 volts DC indicates the valve is fully open A Values between 0 and 5 volts indicates how much the valve is open or close 26 Refrigeration Charging Refrigeration Charging 1 Install a l
52. r the system pumps down and trip on the LPS turn off the power to the Beacon board then turn the power back on This will cause the Expansion valve to close Open the valve on the liquid line at the condensing unit The suction pressure reading on the gauge set should not increase If the suction pressure increases then the expansion valve is leaking and should be changed The expansion valve position can be monitored from the LED display pressing the MONITOR button and scrolling to ESP This will indicate the number of steps the valve is open This can also be checked by using the EXV test pins on the board This is indicated by a 0 to 5 Volts DC signa At 0 Volt the valve is closed and at 5 Volts the valve is fully open At values between 0 and 5 Volt the valve will be opened proportionately 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 If the system is running use the MONITOR button to display SCP Evaporator Suction Pressure Record the pressure displayed While the system is running press the FORCE SERVICE button Observe the pressure while the system is pumping down The pressure should decrease If it does not this indicates defective valve Expansion Valve Motor Winding Resistance If the expansion valve is sus
53. s Please note that the refrigerant type oe au tfor air defrost is R22 and for electric defrost it is R404A All units are shipped with factory default settings Refrigerant Type rEF Selection for type of refrigerant R22 R404A or R507 Default Air defrost 15 122 and for electric defrost 15 R404A Box Temperature bot Select box temperature setpoint Selection range is 30 F to 70 F Default Electric defrost 10 F and ar defrost 35 F Superheat SUP Evaporator superheat is controlled by the board on each evaporator Each board measures the evaporator saturation suction temperature and the suction pressure to determine the superheat The superheat value at the evaporator can be changed to ensure a 20 F to 30 F superheat at the compressor Default SE Evaporator Board SLAVE SLA On multiple evaporator systems each evaporator board has to be programmed to be a MASTER or a SLAVE Each board is shipped from our factory set as a MASTER You must make this change to each SLAVE evaporator A selection of YES is made for this setting Default MASTER on each board For a single evaporator system no change s required Number of Defrosts Per Day selection must be made for the number of defrosts cycles per day 1 2 3 4 5 6 8 10 or 12 per day If no selection is made Default Electric defrost 15 4 per day and air defrost 15 2 per day Defrost fail safe
54. sers additional traps may be necessary Generally one trap is recommended for each length of pipe approximately 20 feet to insure proper oil movement See Figure 7 below for methods of constructing proper suction line P traps Figure 7 Suction P traps Reduce Here Slope 1 4 per 10 ft toward compressor INCORRECT CORRECT Condensate Drain Lines Copper drain lines should be used and properly protected from freezing In running drain lines provide a minimum of 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 systems Traps in the drain line must be located warm ambient We recommend a trap on all Figure 8 Drain Line evaporators 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 is continuously on It is recommended that the drain line be insulated to prevent heat loss A heat input of 20 watts per lineal foot of drain line for 0 18 C room applications and 30 watts per lineal foot for 20 F 29 C rooms is satisfactory DRAIN LINE MIN Inspect the drain pan periodically to insure free drainage of condensate If the drain pan con
55. t and the unit cooler s will be as follows see attached wiring diagrams High voltage There may be high voltage on the defrost heater relay and the fan relay The evaporator may also be connected to a separate power supply from the condensing unit See unit cooler spec plate for ampacity Low voltage 24V Class 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 other three leads are for connecting the compressor relay service relay and 24V Common inputs All 24 volt wiring must be run separate from the line voltage wiring Low voltage wiring must be 18 gauge minimum For low voltage wiring maximum distances are Condensing unit to MASTER evaporator 500 ft Smart Controller to MASTER evaporator 1 000 ft Alarm circuit The onboard alarm is a dry set of NC contacts which closes to indicate an alarm The type and wiring for the alarm is customer specified Note that the alarm circuit does not distinguish or indicate what has caused the alarm All wiring must comply with all applicable codes and ordinances Box Temperature Control Settings There is on board room thermostat on the Beacon board which can be adjusted to the desired room temperature The temperature differential is 2 F Temperature Differential When a system is in the cooling mode and the
56. t is recommended that this pressure be held for a minimum of 12 hours and then rechecked For a satisfactory installation the system must be leak tight Leak detection can be carried out in the conventional manner If HCFC or CFC tracer gas is used care must be taken to completely remove all traces of the gas prior to introducing HFC s Electronic leak detectors are now available that will sense HFC s This is considered preferable since it removes the possibility of chlorine remaining in the system after leak testing with HCFC s and or HCFC 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 Within the last several years manufacturers have developed fluorescent dye leak detection systems for use with refrigerants These dyes mix with the lubricant and when exposed to an ultraviolet light fluoresce indicate the location of leaks Copeland has tested and approved the Rigid System Safe dye and found it to be compatible with the compressor materials in systems Evacuation CAUTION Do not use the refrigeration compressor to evacuate the system Do not start the compressor while it is in a vacuum Due to the smaller molecule size of HFC s they will tend to leak more readily than CFC Consequently it is of the utmost importance that proper system evacuation and leak detection procedures be employed Copeland recommends
57. tains standing water check for proper installation The drain pan should be cleaned regularly with warm soapy water VAPOR SEAL TRAP WARNING All power must be disconnected OPEN before cleaning The drain pan also serves as DRAIN cover for hazardous moving parts Operation NOTE Always trap drain lines individually of unit without drain pan constitutes a hazard to prevent vapor migration Refrigeration Piping Figure 9 Example of Pipe Support 1 Normally any straight run of tubing must be supported in at least two locations near each end of the run Long runs require additional supports The refrigerant lines should be supported and fastened properly As a guide 3 8 to 7 8 should be 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 2 When changing directions in a run of tubing no corner should be left unsupported Supports should be placed a maximum of 2 feet in each direction from the corner 3 Piping attached to a vibrating 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 Donotuse 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 operation and add supports wherever line vibration is signifi
58. tion lines fully insulated OYES ONO ONO Start up Checklist SETTINGS Check Beacon board settings for the following FREEZER Refrigerant Type R404A Box Setpoint Temp 10 F Superheat 8 F No of Defrost Day 4 Defrost End Temp 65 F COOLER ICE STORAGE Refrigerant Type R22 R404A Box Setpoint Temp 35 F 28 F Superheat 8 F 8 No of Defrost Day 2 4 Defrost End Temp 50 F 50 F SYSTEM CHECKS 43 Check Compressor Superheat for the COOLER Should be between 20 F amp 30 F OYES ONO Check Compressor Superheat for the FREEZER Should be between 20 F amp 30 F OYES ONO unit into a Defrost Check heater amps Should match nameplate amps OYES ONO Check LPS Time Delay Relays Should be set at 1 minute for both the COOLER and FREEZER OYES ONO Check Low Pressure Switch on FREEZER Should be set at 0 psig Cut out 10 psig Cut in OYES ONO Did FREEZER and COOLER cycle off on LPS at Set point Temperature OYES ONO Is the sight glass free of bubbles OYES ONO Are the COOLER and FREEZER fans at proper speeds OYES ONO Check system for refrigerant leaks Are there leaks on the COOLER FREEZER CONDENSING UNIT or INTERCONNECTING PIPING OYES ONO Check system piping for unusual vibration or noise Is there any unusual vibration or noise on the COOLER FREEZER CONDENSING UNIT or INTERCONNECTING PIPING OYES ON
59. ure Switch Time Delay Relay 22536801 Electric Expansion Valve ESB 4 3 8 X 3 8 Conn 29320004 ESB 10 3 8 X 3 8 Conn 29320007 Expansion Valve Molded Connector Bipolar valves 22515201 Pressure Transducer 28911201 Pressure Transducer Harness 22515101 Beacon SMART CONTROLLER II 89704301 SMART CONTROLLER Software Package 89704101 Only the sensor with blue leads is shipped as a Service Replacement Part SMART CONTROLLER Software Package is sold separately Table 7 Condensing Unit HRP Parts Top Panel 35617803 Front Panel LH 35617903 LH Eront Panel RH 5292803 Rd Table 8 Unit Cooler HRP Parts Fan Motor 2538009 Fan Blade 2293030 Fan Motor PSC208 230 Fan Guard mc Fan Contactor 25 30 240 2259996 Motor Mount EPEE oe Fan Blade pU Expansion Valve Col Heater LET Fan Relay 240 V 1007950 Low Pressure Switch 28913401 High Pressure Switch 28913201 Receiver 6 x 27 27304701 Receiver 6 x 12 27304702 Compr Contactor 40 30 24 V 2252440 Circuit Breaker 40A 30 2253040 Compr Contactor 25 30 24 V 2255845 Circuit Breaker 15A 30 2253015 Crankcase Heater 7077982 Compr Contactor 30A 30 24 V 2254304 Circuit Breaker 15A 20 22536502 Crankcase Heater 24701402 36 iagrams m iring W Diagram 1 T aeee Cd FA D 8 3009 ZHOS Hd 0 Z7HO09 Hd
60. why and take corrective action b Check liquid line sight glass and expansion valve operation If there are indications that more refrigerant is required leak test all connections and system components and repair any leaks before adding refrigerant c Using suitable instruments carefully check line voltage and amperage at the compressor terminals Voltage must be within 10 of that indicated on the condensing unit nameplate If high or low voltage is indicated notify the power company If amperage draw is excessive immediately determine the cause and take corrective action On 3 phase motor compressors check to see that a balanced load is drawn by each phase d The maximum approved settings for high pressure controls on Heatcraft air cooled condensing equipment is 400 psig On air cooled systems check as follows Disconnect the fan motors or block the condenser inlet air Watch high pressure gauge for cutout point Re check all safety amp operating controls for proper operation and adjust if necessary Check head pressure controls for pressure setting Check crankcase heater operation if used Install instruction card and control system diagram for use of building manager or owner System Balancing IMPORTANT In order to obtain the maximum capacity from a system and to ensure trouble free operation it is essential to balance each and every system annan The critical value to be checked here
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