Heatcraft Refrigeration Products BEACON 25001501 User's Manual
Contents
1. Refrigeration Products 02 01 Part Number 25001501 INSTALLATION INSTRUCTIONS FOR REFRIGERATION SYSTEM 2175 West Park Place Blvd Stone Mountain GA 30087 770 465 5600 Fax 770 465 5990 QUICK GUIDE Installation Start Up Operation Troubleshooting Installation Use 18 gauge wire for 24 volt connections between evaporators and condensing unit Remove suction line sensor before brazing reinstall suction sensor after brazing is completed and suction line has cooled insulate with insulation provided elf an electric defrost evaporator is being applied in a medium temperature application have the nozzle size checked for proper sizing Condensing Unit Set transformer primary connection for correct supply voltage 208V or 230V Check low pressure switch time delay relay for correct adjustment to 2 minutes Check low pressure switch for correct adjustment to 0 psig cut out 10 psig cut in Evaporator Check black jumpers for system settings change to match your application requirements Board are shipped from factory set for 359 medium temperature or 10 F low temperature change resistor for set point temperature to match application requirements eCheck sensor connections on board confirm that sensors are plugged onto correct terminals expansion valve EXV connections on board confirm that wires ar2. 1315 DUIS auo12v4 SI Av 38 AYT30 MIL UO DIL VIGHOS ONITHIA LINN 235 OIIVWSHOS VOIdAL SI I 04 ViJOdVA3E IVOIHL1OT13 H3OV3H NOIAVNIPHSL 1500330 50178101510 H3 1002 LINN 397 1508 440 HIV WIIdAL HLIM LINN SNISNJONOO O9 O9 BEACON CONTROLLER LARGE UNIT COOLER DISTRIBUTOR TUBE DEFROST TERMINATION HEADER END ELECTRICAL END EVAPORA TOR TES 1 THIS IS ONLY A TYPICAL WIRING SCHEMATIC SEE UNIT MOUNTED WIRING SCHEMATIC FOR ACTUAL WIRING 2 FOR I MODELS DO NOT WIRE TO TERMINALS T2 H2 ON TERMINAL BLOCK AND T2 CONTACTOR 3 TO PUMP SYSTEM DOWN ADJUST LOW PRESSURE SWITCH TIME DELAY SETTING TO O MINUTES BEFORE ACTIVATING THE PUMP DOWN SWITCH AFTER NORMAL SYSTEM OPERATION IS RESTORED TIME DELAY RELAY IS FACTORY FACTORY WIRING RESET THE TIME DELAY SWITCH TO 2 MINUTES ADJUSTED TO 2 MINUTES FIELD WIRING 34 BEACON CONTROLLER Notes Visit our web site at www heatcraftrpd com for Technical Literature Online Since product improvement is a continuing effort at Heatcraft we reserve the right to make changes in specifications without notice 2175 West Park Place Blvd Stone Mountain GA 30087 770 465 5600 770 465 5990
3. chart ELECTRIC DEFROST FACTORY SETTINGS DEFROST CYCLES OR TIME 6 PER DAY 2 HRS 4 PER DAY 3 HRS x 2 PER DAY 6 HRS _ 1 PER DAY 12 HRS ELAPSED X RUN TIME SUPERHEAT 6 F 8 x 12 F DEFROST FAIL SAFE 10 MIN 20 MIN 30 MIN x 40 MIN 60 MIN MEDIUM X LOW TEST X NORM TYPE 1 2 RESET TIME NORM FORCED DEFROST DEFROST END 50 F 70 F 90 F AIR DEFROST FACTORY SETTINGS DEFROST CYCLES OR TIME 6 PER DAY 2 HRS 4 PER DAY 3 HRS E 2 PER DAY 6 HRS 1 PER DAY 12 HRS ELAPSED X SUPERHEAT 6 F 8 F x 12 F DEFROST FAIL SAFE 10 MIN ES 20 MIN 30 MIN 40 MIN 60 MEDIUM X TEST X TYPE 1 RESET TIME X FORCED DEFROST X DEFROST END TEMP 50 F X 70 90 RUN TIME LOW NORM 2 NORM NORM NOTE When using the Beacon Smart Controller the Defrost End Temperature for each Beacon board must be set at 50 F It is recommended that the room temperature pot for all the slave units be adjusted to the maximum temperature 60 F when connected in a master slave configuration BEACON CONTROLLER PARTS LIST Parts Dept 800 686 7278 HRPD PART PART DESCRIPTION NUMBER Temperature Sensor 28900101 Transformer 208 240 24 volt 40 VA 22522301 Transformer 208 240 24 volt 75
4. Box temp is below t stat setting Loose wiring Bad sensor Discharge temp too high Beacon board defective Low pressure switch open Supply voltage too low Evap coil temp too high Wait 4 min Lower t stat setting Check all wire terminals tighten if necessary Check status light for problem sensor Check general diagnosis chart Check Status light if out replace board Check pressure switch setting Change transformer primary to correct supply voltage tap 208 or 240 volts Temporarily disconnect Evap Coil sensor from board reconnect when coil temp is lowered Q gt G O Cannot get to box temp Wrong t stat setting 2 Wrong selection on board ONOOA Comp run time too short Bad expansion valve Wrong charge Box temp fluctuate Evap coil iced up Wrong nozzle Low pressure switch tripping compressor 1 Check and adjust t stat 2 For box temp of 20 F and above select MEDIUM for box temp below 20 F select LOW 3 a Increase time between defrost b May need time delay across low pressure switch See Compressor cycles off at startup below Check if expansion valve is operating Check charging procedure Allow system to run longer Clear ice and check defrost setting Check if distributor tubes are sweating evenly if not have factory check nozzle selection for application 9 EXV closing d
5. T WIRING SCHEMATIC FOR ACTUAL WIRING PV RELAY R3 AD D 2 Vn ARE TaD oF CONDENSING UNIT HEATCRAFT PART NO 29651001 REV 29 BEACON CONTROLLER TYPICAL ELECTRIC DEFROST W REMOTE SMART CONTROLLER OISTRIBUTOR TUBE DEFROST TERMINATION FAN DELAY EVAP EVAP EVAP ROOM gt l D COIL OUT IN TES 1 AIR DEFROST WIRING TO THE MASTER REMOTE SMART CONTROLLER WILL BE THE AS SHOWN EVAPORATOR 2 THIS IS ONLY A TYPICAL WIRING SCHEMATIC SEE UNIT MOUNTED WIRING SCHEMATIC FOR ACTUAL WIRING 3 FIELD INSTALLED 24V AC RELAY RS SWITCH Sw WILL SHUT OFF IF THE EVAPORATOR FANS ARE TURNED OFF HEATCRAFT PART NO 2965400 REV H 30 BEACON CONTROLLER QSGMFINIW Z OL HOLIAS 47730 SAIL IHI 13539 ONIUIA 01313 ENIMIA ANOL2V4 OILVMGHOS ONIHIA TY2IdAL Y ANO SI SIHL 1 JOLAJ YAI 1531 15 4 BOLDSIMISIO NOOVIE HLIM LINN 9NISNSONO2 O9 O 2 80c 150045430 215193 13 WIIdAL BEACON CONTROLLER TYPICAL ELECTRIC DEFROST 460 3 60 CONDENSING UNIT WITH BEACON HEADER END ELECTRICAL END E VAPORA TOR TES THIS IS ONLY TYPICAL WIRING SCHEMATIC RESET THE TIME DELAY SWITCH TO 2 MINUTES TIME DELAY RELAY IS FACTORY ADJUSTED TO 2 MINUTES FIELD WIRING HEATCRAFT PART 2965030 REV D 32 BEACON CONTROLLER V AR O SS962 ON 1iUYd IL4YHOLV3H IS310NIH 01 O315nrav
6. below 50 F and above 10 F At the initial application of power to the system the compressor and the evaporator fans will be in a four minute hold off cycle and will not start immediately When there is a call for cooling the compressor starts and the electric expansion valve EEV stays closed for 12 seconds After 12 seconds the EEV goes to 7 8 open and the compressor is put in a four minute hold on cycle Superheat adjustments at two minute intervals will then follow When the room thermostat setting becomes satisfied and if the compressor ran for at least four minutes the EEV will close and the compressor will pump down and shut off The evaporator fans will continue to run When the room sensor detects a rise in temperature of approximately 2 F and the compressor has been off for at least four minutes the EEV will open to it s last position 30 seconds before the compressor is started Ambients below 10 F At the initial application of power to the system the compressor and the evaporator fans will be in a four minute hold off cycle and will not start immediately When there is a call for cooling the compressor starts and the electric expansion valve EEV stays closed for 12 seconds After 12 seconds the EEV goes to full open and the compressor is put in a four minute hold on cycle When the room thermostat setting becomes satisfied and if the compressor ran for at least four minutes the EEV will close and the compressor wi
7. not start immediately When there is a call for cooling the compressor starts and the electric expansion valve EEV stays closed for 12 seconds After 12 seconds the EEV goes to approximately half open and the compressor is put in a four minute hold on cycle This means that the compressor will run for a minimum of four minutes before shutting off When the room thermostat setting becomes satisfied and if the compressor ran for at least four minutes the EEV will close and the compressor will pumpdown then shut off The evaporator fans will continue to run When the room sensor detects a rise in temperature of approximately 2 F and the compressor has been off for at least four minutes the EEV opens to its last position 15 seconds before the compressor starts Super heat adjustments at two minute intervals will then follow During this time the compressor will be on a minimum four minute hold on cycle If the superheat drops to 2 F at anytime the valve will be adjusted at 45 second intervals If the compressor discharge line sensor reaches 225 F for four minutes the superheat will be lowered temporarily overriding the normal superheat routine to effectively keep the compressor discharge line tem perature from going any higher Discharge high fault will be displayed and the system will continue to operate A service person should check system to determine cause for high discharge temperature BEACON CONTROLLER Ambients
8. restarts Replace Check room air sensor if open replace After reconnecting wait 4 mins for compressor to restart Lower evaporator superheat to lower compressor suction gas temperature Check control settings Check motor for open circuit short circuit grounded windings or burn out Check all wire terminals tighten if necessary 8 Motor problems 9 Loose wiring Compressor noisy or 1 Flooding of liquid refrigerant into vibrating into crankcase 2 Compressor hold down nuts too tight or too loose Check expansion valve superheat setting on control board Loosen compressor hold down nuts until compressor floats freely on mounting springs 3 Worn compressor bad valves 3 Replace High head pressure 1 Too much refrigerant 1 Remove excess refrigerant 2 Non condensables in the system 2 Purge system of non condensables 3 Dirty condenser coil 3 Clean condenser coil 4 Condenser fan not running 4 Check electrical circuit including fuses 5 Discharge valve partially closed 5 Open valve 6 System running beyond condensing temperatures due to heavy load or out of equipment design paramaters Low head pressure 1 Insufficient refrigerant 2 Damaged valves in compressor 3 Winter operation w o head pressure valve Check system for leaks repair leaks amp add refrigerant Replace compressor Check refrigerant charge High suction pressure 1 Expansion valve over f
9. room temperature at the approximate temperatures shown These values are also to be used for setting the Beacon board thermostat Application Temperature F Ohms Low Temperature 25 182K Electric Defrost 20 150K 15 120K 10 100K 5 85K 0 70K Medium Temperature 20 30K Electric Defrost 25 25K 30 20K Medium Temperature 35 15K Air Defrost 40 10K 45 8K 50 5K 55 2K 60 BEACON CONTROLLER BEACON MICROPROCESSOR SETTINGS See Table 3 for more details Selections to be made by applying movable jumpers Defrost cycles or time Controlled by the board in master unit only Selection must be either elapsed time or run time If elapsed time is selected the number of defrost must be set at either 1 2 4 or 6 per day If no selection is made default is 4 defrosts per day If run time is selected the compressor run time must be set at either 2 3 6 or 12 hours If no selection is made default is 3 hours compressor run time Superheat Controlled by each board in each evaporator Selection must be either 6 8 or 12 F Close coupled systems will require the higher superheat selections If no selection is made no movable jumper applied the preprogrammed default is 8 F superheat Defrost fail safe Controlled by board in master unit Each board should have the same setting on multi evap systems Must be either 10 20 30 40 or 60 minutes If no selection is made default is 30 minutes Me
10. will blink off for two seconds on for two sec onds off for two seconds followed by a rapid sequence of blinks that if counted will indicate superheat OFF CYCLE During the thermostat off cycle the light will blink off for seven seconds and on for one sec ond which will then repeat DEFROST During defrost the light will blink off for one second and on for one second which will then repeat ALARMS Beacon provides a set of dry contacts that are normally closed for use in controlling an alarm These contacts can be connected to a light a buzzer or a bell which will be activated when an alarm condi tion occurs When the Beacon is energized the alarm contacts are OPENED When an alarm condition is de tected the contacts are CLOSED Conditions under which the alarm contacts will close are Power failure on or to a Beacon board Room temperature of 16 F or more above thermostat set point or 4 F below thermostat set point for more than 1 hour master controller only when not in defrost System will pump down and shut off It will restart after four minutes ERROR INDICATOR amp STATUS LIGHT At initial power up each Beacon 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 pump down and cycle off and will not restart until the fault is cleared or the circuit breaker reset for the foll
11. 0 5 72 950 59 15 710 4 97 070 50 19 900 13 130 410 41 25 400 22 176 960 EVAPORATOR FANS SHUT DOWN OPERATORS In some installations a switch is provided which allows an operator to de energize the evaporator fans while loading the freezer or cooler box This may cause the evaporator coil to freeze up The compressor can be de energized when the evaporator fan is de energized by wiring a 24V AC coil double pole single throw DPST relay into the fan circuit This relay R3 and the wiring is shown the TYPICAL WIRING 5 MATICS in the back of this installation manual For multiple evaporators additional relays wired in parallel to to break the other fans will be needed BEACON CONTROLLER OPTIONAL SMART CONTROLLER The Beacon Smart Controller performs all the standard Beacon functions with the additional benefit of remote mounting for easy access From the Smart Controller the refrigeration system can be monitored and the program parameters changed without the user going into the Cooler or Freezer Box The Smart Controller allows the following Monitoring Superheat of each evaporator The expansion valve setting No of steps open or closed The entering evaporator temperature Compressor discharge temperature Outdoor temperature Compressor run time Number of compressor cycles Maximum compressor discharge temperature Length of last defrost Programming Box temperature The de
12. OO SAYS HLIA H31SYW SNIHIM NOILIANNOD OA re 25 BEACON CONTROLLER 24 VOLT CONNECTION WIRING W SMART CONTROLLER CONNECTION DIAGRAM FOR SMART WITH ONE EVAPORATOR HEATCRAFT PART NO 2966080 REV A 26 BEACON CONTROLLER V AJ 10609962 14 821 2 SUgOLIVHOdVA3 H3HLO TIY NOSNZJS OZJAOWJH YSTIOULNOD LYVNS JHL O31293NNO2 3 19 YOSNAS WOOH hh E OSE TC EC TL Me v s SUOLVUOdVYA3 HLIM UT TIOMLNOS 503 43 11041 0 LYVWS M SNIHIM NOILIANNOD LIOA rZ 27 CONTROLLER 24 VOLT CONNECTION WIRING W SMART CONTROLLER CONNECTION DIAGRAM FOR SMART WITH THREE EVAPORATORS UNIT TB EVAPORATOR e NOTE 1 WHEN THE BEACON SYSTEM IS APPLIED IN THIS CONFIGURATION THE ROOM SENSOR MUST BE CONNECTED ON THE SMART CONTROLLER REMOVED THE ROOM SENSOR FROM ALL OTHER EVAPORATORS 2 HEATCRAFT PART NO 29660701 REV A 28 BEACON CONTROLLER TYPICAL AIR DEFROST DISTRIBUTOR TUBE DEFROST TERMINATION FAN DELAY SUCTION TUBE DISTRIBUTOR TUBE ENTERING AIR 2 FIRO ET UR BEY AC RELAY R3 AND SW F MUT Ci ARE TURNED HEATCRAFT PART NO 2965200 DISTRIBUTOR TUBE DEFROST TERMINATION FAN DELAY SUCTION TUBE DISTRIBUTOR TUBE ENTERING AIR Te re Y A TYPICAL WIRING SCHEMATIC
13. Red 10K 40 F To change the room set point remove the resistor attached to the Beacon board and attach the resistor value required for your set point temperature If you need a value not shipped in the packet you may purchase a 1 8W to 1 2W resistor from an electronics store i e RadioShack for the ohm values shown These resistors will control the room temperature at the approximate temperatures shown These values are also to be used for setting the Beacon board thermostat pot BEACON CONTROLLER ROOM TEMPERATURE CONTROL Cont d Another method of setting the room set point is to use the Beacon board thermostat pot If a value other than that available by using a fixed resistor is required the pot on the Beacon board can be used First you must discard the fixed resistor Then using a digital ohmmeter measure the resistance between the X and 200K as indicated in the illustration below Use a screwdriver to turn the thermostat pot until the resistance value is obtained for the desired room temperature according to Table 1 Install the jumper supplied in the bag across the terminal marked X when finished METER THERMOSTAT PUT TERMINALS Sus POT BEACON on BEACOMN BOARD bonn The Beacon Smart Controller See Beacon Smart Controller Installation amp Operating Instructions Part 25004101 for more details TABLE 1 Carbon Film Fixed Resistor selections that will control the
14. VA 10HP up 22538401 Relay for condenser Fan or Crankcase Heater 22511401 Contactor for Compressor 40 amp with 24 volt Coil 2252440 Control Board for Electric Defrost 28910001 Control Board for Air Defrost 28910002 Terminal Block 2251266 Low Pressure Switch Time Delay Relay 22536801 Electric Expansion Valve ESV 1 24 29310001 ESV 2 24 volt 29310002 ESV 4 24 volt uni polar valves 29310003 ESV 6 24 volt 29310004 ESV 8 24 volt 29310005 ESV 10 24 volt 29310006 ESV 25 24 volt bi polar valve 29320001 Expansion Valve Molded Connector 29310007 Optional Pump Down Switch 22510901 Beacon Smart Controller 89704401 Optional Smart Controller Software Package 89704501 Bi polar adapter board only used with 29320001 28920001 expansion valve To test the Beacon board place the test jumper to the TEST position The board will then cycle through each output for 10 seconds It will energize and de energize the fan motor electric heater expansion valve and compressor for 10 seconds When in the TEST mode the status light flashes quickly If a sensor is bad it will flash per the error chart AT THE END OF THE TEST RETURN THE JUMPER TO THE NORMAL POSITION BEACON OPERATIONAL LIMITS Box set point tolerance 2 F Down to 20 F outdoor ambient Allows start up amp operation Below 20 F outdoor ambient Requires head pressure control valve amp pressure fan c
15. at 105 F condensing for full sight glass System runs erratically 4 Q Check low voltage condition system will not operate properly below 18 VAC Check for high voltage condition system will not operate properly above 30 VAG Check if expansion valve is correctly wired on Beacon board Check EVAP IN amp EVAP OUT sensors for proper operation Is EEV wired properly Is system charged properly Check fan cycling operation Sensor was changed but fault signal still appears 4 If a sensor is changed out system power must be reset to clear fault System flashes low superheat fault Check if EVAP IN amp EVAP OUT sensors are correctly installed on board amp on copper tubing Check evaporator coil circuits if they are feeding evenly uneven feeding will cause flood back or sensors won t sense proper superheat Check if system is piped correctly incorrectly piped system will cause system flood back Check if expansion valve is correctly wired on Beacon board Expansion valve may be defective check by running through test mode Check for proper charge at 105 condensing for full sight glass System flashes low pressure high pressure or oil pressure fault O If outdoor temperature is below 50 F check to make sure time delay is set at 2 minutes If pumpdown switch is installed check to make sure it is wired correctly in the
16. board Unit Cycles on and off without 4 min time delay Incorrect wiring Low pressure switch tripping compressor Time delay bad or not set for 2 minutes 1a Check wiring 1b Bad Beacon board 2a EXV closing down due to low superheat check EVAP IN amp OUT sensors 2b Check refrigerant charge 2c Check if sensors are connected to correct terminals on Beacon board 19 BEACON CONTROLLER SERVICE DIAGNOSIS CHART cont d PROBLEM POSSIBLE CAUSE POSSIBLE CORRECTIVE ACTION Beacon Board Status 1 Supply voltage too high Light Flashes Erratically 2 Supply voltage too low 3 Bad board 1 2 Check 24 volt supply if above 30 volt correct immediately Change transformer primary to correct supply voltage tap 208 or 240 volts SERVICE DIAGNOSIS CHART GENERAL PROBLEM POSSIBLE CAUSE POSSIBLE CORRECTIVE ACTION Compressor will not run 1 Fused disconnect switch is open 2 Blown Fuse 3 Compressor motor protector open 4 Defective compressor contactor or holding coil 5 Open room air sensor air into coil 6 Compressor discharge too hot 7 Open low pressure high pressure or oil safety control Close switch Check reason fuse is blown replace fuse after problem is corrected Motor protector is automatic reset allow time for compressor to cool down so that protector will reset check unit for reason when compressor
17. circuit Check to make sure system is charged properly with refrigerant Check if expansion valve is operating properly Check if expansion valve is correctly wired on Beacon board Expansion valve may be defective Check for flood back to the compressor Check for proper piping amp oil return Possible bad low pressure high pressure or oil pressure switch 0 Possible bad time delay or mis wired 16 BEACON CONTROLLER BEACON TROUBLE SHOOTING GUIDE cont d System will not run 1 Check if red jumper wire next to blue pot is correctly connected across X terminals 2 Check red jumper wire terminals to make sure they are connected to the wire not the insulation 3 Check to make sure system is correctly wired 4 Check system for low voltage or high voltage conditions system must have voltage between 18 30 VAC for proper operation 5 Check if EVAP IN amp EVAP OUT sensors are correctly installed on the board amp on copper tubing 6 If system has Smart Controller check MULTI IN amp MULTI OUT connection at board amp at Smart Controller to make sure wires are not reversed Check if ROOM sensor is connected on Beacon board Check that room sensor is good by resistance check Check refrigerant charge 0 If voltage is too high above 30 volts or too low below 18 volts unit will not run Coil frost pattern is uneven 1 Check evaporator coil circuits if they are feed
18. d The Beacon timing for evaporator defrost is based on when power is first applied to the Beacon board i e if 4 defrosts per day will occur at 9 00 p m and every 6 hours thereafter the system will perform a defrost Some systems may require the crankcase heater to be energized 24 hours prior to start up the Beacon should be de energized for this period by disconnecting the 24V lead to the condensing unit terminal block To start the system this 24V lead must be re attached CONDENSING UNIT The condensing unit control panel will contain the relays contactors transformer and terminal block appropri ately marked to match the wiring connections to be made UNIT COOLER S Each unit cooler s will contain the Beacon controller an electric expansion valve a distributor orifice and four thermistor sensors These components are all factory mounted The 4 sensors provide input to the controller from the following evap in evap coil evap out and entering room air temperatures MASTER SLAVE CONNECTION The Beacon Controller allows multiple unit coolers to be connected in a master slave configuration Up to 6 Low Profile evaporators or up to 3 Medium Profile evaporators can be connected in a master slave configuration when using the standard factory shipped transformer When connected in a master slave configuration the entering room sensors must be disconnected from each of the slave units When connected to the Optional Smart Controlle
19. dium or low temperature All evaporators must have the same settings for the application For example on a master slave application all the units must have the same setting i e for medium tem perature they must all be set at medium Test or normal Factory set at normal Test is also used to check board for proper function Type 2 or type 1 Are not used Do not select Reset time or normal Resets all internal timers back to zero as though the unit was just powered up Keep jumper on normal except for momentary move to reset position If jumper is left on RESET position the four minute off time will be set to zero on power up Forced defrost or normal Forced defrost is used momentarily to force an extra defrost It will not reset the regularly scheduled defrost Select the normal position Note that when initiated the four minute Hold off and Hold on cycles will be in effect Defrost end temperature Select either 50 70 or 90 F If no selection is made preprogrammed default is 50 F REFRIGERANT CHARGING Be aware that the Beacon system does not normally require a condenser flooding valve and is capable of operating at lower than normal condensing temperature The condensing pressure will be raised by fan cycling only when needed to lower evaporator superheat to the selected value The system does not require a winter charge If the ambient is above 75 F charge just until the sight glass clears Wh
20. e plugged onto correct terminals elf system has multiple evaporators check master slave wiring Wire multi out from master to multi in on slave then from multi out of slave to multi in of master Start Up After system evacuation add correct refrigerant It may be necessary to adjust time delay relay TDR to 10 minutes temporarily to allow system charging Readjust TDR back to 2 minutes when done ambient above 75 F charge unit to a clear sight glass In colder ambients raise discharge to 105 F condensing and charge to a clear sight glass At initial start up system may cycle off on low superheat Let system cycle It may take 4 to 5 cycles for system to settle out elf Smart Controller is used make sure Defrost End Temp on the Beacon board is set to 50 F elf multiple evaporators are connected to a condensing unit the room sensor must be connected to the master evaporator only Disconnect the room sensor from all the other boards Sequence of Operation Cooling Beacon system has a built in 4 minutes hold on 4 minutes hold off cycle The system will run in cooling a minimum of 4 minutes and stay off a minimum of 4 minutes When power is first applied the system will not start for 4 minutes After 4 minutes the expansion valve opens and the compressor contactor circuit is energized shortly after the valve opens When the system is cooling the expansion valve is adjusted at 2 minutes int
21. eeding 2 High box temp pull down 3 System undersized Check expansion valve superheat setting on control board Wait for box temp to drop Check load amp design criteria 20 BEACON CONTROLLER SERVICE DIAGNOSIS CHART GENERAL PROBLEM POSSIBLE CAUSE POSSIBLE CORRECTIVE ACTION Low suction pressure 1 2 Insufficient refrigerant Freezer coil iced up 3 Plugged liquid line filter drier 4 5 Expansion valve starving coil Plugged suction filter Check system for leaks repair leaks amp add refrigerant Check defrost system operation amp correct fault condition Replace filter drier Replace suction filter Check expansion valve superheat setting on control board check expansion valve screen Loss of oil or loss of oil pressure Insufficient oil in the system Compressor short cycling Excessive liquid refrigerant in compressor crankcase Worn bearings Add oil until sight glass is 1 2 full Check low pressure control settings Check crankcase heater check expansion valve superheat setting on control board check for internal rupture of heat exchanger Replace compressor Freezer coil icing Insufficient refrigerant Wrong defrost end temp setting Wrong defrost fail safe setting Not enough defrost for application Coil not feeding properly System undersized Check system for lea
22. en charging in colder ambients it will be necessary to reduce the amount of air going through the condenser with the fans still running Simply reduce the effective face area to raise the discharge pressure above the equivalent 105 F condensing temperature and then proceed to charge to clear the sight glass Return to full condenser face area and allow the system to balance CONTROLLER OPERATING INSTRUCTIONS REFRIGERATION MODE START UP 1 Check all wiring connections to be sure they are correct and tight 2 Check voltage taps on transformer The transformer is shipped wired for 240 If your supply voltage is 208 volt systems charge to 208 voltage tap 3 Check setting of time delay relay in condensing unit It should be set at two minutes the third marker 4 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 5 At initial start up the system may cycle off at 4 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 6 Liquid line should always be insulated Ambients above 50 F At the initial application of power to the system the compressor and the evaporator fans will be in a four minute hold off cycle and will
23. ervals to obtain the set superheat If the superheat falls too low the expansion valve is adjusted at a much faster rate to bring the superheat up When the room temperature is obtained the expansion valve is closed and the system is pumped down until the low pressure switch opens or 2 minutes have elapsed BEACON CONTROLLER QUICK GUIDE cont d Defrost actual defrost time is determined when power is first applied to the system as well as the number of defrosts per day If a Smart Controller is used the actual defrost times are programmed into the Smart Controller At defrost the expansion valve closes then the system pumps down until the low pressure switch opens or 2 minutes have elapsed The compressor is now off fan motors are shut off and the heater contactor on the Beacon board is energized On systems with higher than 30 amps the heater contactor on the board is used to energize a larger amperage contactor Defrost is terminated when the evaporator coil sensor reaches the defrost termination temperature The heaters are turned off and the system goes through a short drain down period eAt the end of the drain down period the expansion valve opens and the compressor starts shortly after The fans do not run during this re freeze period At the end of the re freeze the fan motors start and the system is back in the cooling mode Trouble Shooting System flashes low pressure high pressure oil pres
24. frost start times up to eight settings Defrost fail safe time Defrost termination temperature Demand Smart Defrost Evaporator superheat High and low temperature limits for alarm Alarm conditions time limits Medium temperature or low temperature system F or G Set the clock Run quick test of the system Other features of the Smart Controller are The Smart Controller has a liquid crystal display LCD display which shows current time actual box tem perature box temperature set point and if there is an alarm or fault condition Can be placed far away from the system being controlled 500 1000 ft Locking feature to prevent unauthorized access to program settings Each Smart Controller can control multiple evaporators on a system up to 6 evaporators A RS232 port is provided which allows connection to a IBM compatible computer for monitoring the system remotely and changing of the box temperature Back up battery will maintain the clock settings for 10 years Double E Prom Chip will maintain program settings indefinitely Large easy to read LCD screen Smart Defrost the ability to defrost only when needed For more detailed information see the Smart Controller Installation and Operation manual 13 BEACON CONTROLLER The initial factory settings for the BEACON MICROPROCESSOR BOARD are indicated on the following
25. hat will interrupt the circuit to one wire of the room sensor to the Beacon board This will cause the system to pump down and shut off The system will not restart until the switch has re made the circuit to the room sensor Systems with Optional Pump Down Switch on the Condensing Unit The low pressure switch time delay relay will have to be adjusted from the factory set 2 minutes to 0 minutes before flipping the pump down switch After normal operation of the system is restored the low pres sure switch time delay relay must be adjusted back to the 2 minute setting CHECKING OPERATION OF EXPANSION VALVE EEV The expansion valve position is indicated by a 0 to 5 volts DC signal 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 By using a volt meter to measure the DC volts across the pins marked EXV TEST bare pins near LED on the Beacon board a determination can be made if the valve is open or closed This must be measured while the unit is cooling ELECTRIC DEFROST MODE If elapsed time has been selected this works just like a time clock the number of defrosts per day will depend on the number selected on the controller i e 1 2 4 or 6 If run time has been selected the number of defrosts per day will vary depending on the compressor run time i e 2 3 6 or 12 hr When a defrost is initiated the EEV valve closes the compressor
26. ing properly uneven feeding will cause uneven icing 2 If liquid line runs through cooled space may need to be insulated or nozzle reselected for conditions 3 If electric defrost coil for medium temperature applications medium temperature nozzle must be installed 17 BEACON CONTROLLER BEACON UNI POLAR EXPANSION VALVE TEST VOLTAGES VALVE OPEN VALVE CLOSED Notes ESV TEST de volts BLUE 44 15 6 0 15 8 RED 15 6 15 3 Beacon Board connection WHT BLK YEL 15 7 15 6 15 4 15 5 Com 24 Vdc 1 All volts shown are measured while in the TEST mode and are DC 2 The volts shown for each step BLUE RED WHT BLK are measured between the YEL Com amp the corresponding pin 3 The volts shown for each step is available only when the valve is activated The voltage value will increase when the valve is activated then will go to zero 4 ESV TEST volts will remain while the valve is open Temperature Sensors Coll Dafrast Room Tomp Sensor Temp Saen 4 exil Temp Sonor Suchi Filles Y a Compressor Discharge Temp Sensor Compressor Temp Senei Beacon Controller e Electric Expansion 1 Sight Glass Filter Drier Regalar BEACON CONTROLLER SERVICE DIAGNOSIS CHART BEACON PROBLEM POSSIBLE CAUSE POSSIBLE CORRECTIVE ACTION Compressor will not run 9 1 2 3 4 5 6 7 8 4 min off cycle
27. is allowed to pump down see pump down description the evaporator fans are cycled off and the defrost heaters are energized The master and all slave controllers must terminate their defrost either on temperature or time before the master controller will end the defrost cycle There is a 60 second condensate drain down time before the compressor is started followed by a 60 second evaporator fan hold off time fan delay After this sequence the controller s are back in the refrigerating mode and the EEV s open to the position prior to defrost AIR DEFROST MODE Usually the cycling on the thermostat will suffice to defrost the coil s when operating at room temps between 35 amp 45 However it will be necessary to set certain parameters Recommended values when operating near the 35 F range are as follows select elapsed time 2 defrost per day 40 min fail safe amp 50 F defrost end temp When operating near the 45 F range it is advisable to minimize the effect of the defrost by changing to a 10 min fail safe amp 50 F defrost end temp Note These are only recommended settings Other settings are available on the Beacon board BEACON CONTROLLER STATUS INDICATOR There is a red status indicator light on the Beacon board This light has a controlled blink sequence to indicate modes such as cooling superheat off defrost or error See status light blink sequence chart COOLING SUPERHEAT During the cooling mode the light
28. ks repair leaks amp add refrigerant Check unit cooler instructions Raise setting Check unit cooler instructions Raise setting Check for subcooled liquid incorrect nozzle selection insulate liquid line restricted coil Do heat load amp check sizing 21 CONTROLLER AIR DEFROST CONTROLLER NOTE FACTORY INSTALL JUMPERS AS SHOIN 1 NOIIVHSOIH43H INI LAJVHOLV3H r BOVLTOA HOIH TT TE 1 40 COMP DISCH MULTI IN OUT OD FAM COMP 18 30 VAC IN m AM a ELECTRIC DEFROST CONTROLLER C NOTE FACTORY INSTALL JUMPERS AS SHON 8990500 REV 22 BEACON CONTROLLER V AI 10809962 l1NVd LJVHOLV3H UOLVHOdVAS INO HLIA LINN ONISNSONO2 SNIHIM NOILIANNOD LIA re BEACON CONTROLLER INNECTION WIRING 24 VOLT CC H ONE SLAVE CONNECTION MASTER WI INIT WITH TWO EVAPORATORS CONDENSING L CONNECTED ON THE MASTER EVAPORATOR ONLY REMOVED THE ROOM SENSOR FROM ALL OTHER EVAPORATORS 2 HEATCRAFT PART NO 296560601 A 24 BEACON CONTROLLER V A3 10 09962 1950 2 SHO1VWHOdVA3 H3HLIO TIV NOMI HOSNSS WOOH OZJAOWJ3H HOLVHOdVAS UILSYW NO OSLIOSNNO2 38 1SNW HOSN3JS WOOM FHL 1 2 SIHL NI G3I lddV SI W315AS NOOV3G NIMM SUOLVHOdYAS UNOS HLIA LINN ENISNSONO2 NOIALOSNN
29. l position elf system has a Smart Controller Check to make sure room sensor is connected only to Smart Controller Check wiring of multi in and multi out to be per wiring in Installation amp Operation manual Check program in Smart Controller range must be on lo for low temp applications and hi for medium temp applications BEACON CONTROLLER INSTALLATION INSTRUCTIONS Before Installing or Starting Unit Use a minimum 18 gauge wire for low voltage connections to cooler condensing unit and Smart Controller Transformer is shipped wired for 240V primary if your supply voltage is 208V change to the 208V tap Refer to wiring schematic shipped on units for wiring schematics in the Installation amp Operation Manual are typical schematics If desired box temperature is different from preset factory temperatures 35 F air defrost 10 F electric defrost see Hoom Temperature Control Page 5 for options Check Beacon board jumper settings to ensure that they match the application requirements factory jumper settings are shown on Table 3 Page 14 The low pressure switch time delay relay located in the condensing unit must be set at 2 minutes Make sure all wiring connections are correct and tight 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 is coole
30. ll pump down until the low pressure switch trips or one minutes has elapsed The evaporator fans will continue to run When the room sensor detects a rise in temperature of approximately 2 F and the compressor has been off for at least four minutes the EEV will open to it s last position 30 seconds before the compressor starts CONDENSER FAN CYCLING Beacon condensing units will have pressure fan cycling and ambient fan cycling as standard On one fan condensing units pressure fan cycling with a setting of 150 psig cut out and 200 psig cut in is used On two fan condensing units one fan will be controlled by an ambient switch set at 50 F cut out and the other fan will be controlled by the pressure fan cycling switch BEACON CONTROLLER PUMP DOWN At the end of each cooling cycle when the box temperature is met the system will pumpdown and shut off To pumpdown the EEV closes and the compressor pumps down until the low pressure switch trips the unit off or two minutes have elapsed While in the off cycle the system will initiate a short pump down at four minute intervals if the low pressure switch is closed to ensure that any refrigerant leakage will not cause a problem To Manually Pump Down System 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 or Install a switch t
31. ltage wiring Compressor discharge line sensor Use 18 gauge wire Must be run separate from other high voltage power wiring Smart Controller Optional Use 18 gauge wire For extra long runs 16 gauge wire may be required Low voltage wiring must be run separate from other high voltage power wiring Slave unit s if used Connect the multi out terminal on the master unit to the multi in terminal on slave unit and the 24V 18 to 30 VAC from the master unit to the slave unit See wiring diagram Alarm circuit The onboard alarm is a dry set of NC contacts which closes to indicate an alarm Type and wiring for the alarm is customer specified Note that the alarm circuit does not distinguish or indicate what has caused the alarm See ALARMS Note All wiring must comply with all applicable codes and ordinances ROOM TEMPERATURE CONTROL Three methods are available e Each Beacon board is shipped with a fixed resistor attached that controls the room temperature set point Air defrost boards are set for 35 F with a 15K ohms resistor Electric defrost boards are set for 10 F with a 100K ohms resistor In the packet are additional resistors which can be used for other room temperature set points These resistors are color coded The table below shows the settings Resistor Color Resistor Value Set point Tape Ohms Temperature Black 100K 10 F Green 70K White 30K 20 F Blue 20K 30 F Yellow 15K 35 F
32. owing conditions Superheat sensor shorted or open Room temperature sensor shorted or jumper not installed The system will pump down cycle off and try to restart after the four minute hold off period for the following fault conditions Superheat too low High pressure oil pressure or low pressure cut out 11 BEACON CONTROLLER STATUS INDICATOR SEQUENCE Mode Blink Time Off Time Action Cooling 2 sec 2 sec Faster blinks for superheat count then repeat Off 1 7 sec Repeat Defrost 1 sec 1 sec Repeat Error 8 fast 2 sec Slower blinks for error code then repeat Error Codes One blink Superheat sensor shorted or open Two blinks Room temperature sensor shorted or jumper not installed Three blinks Compressor discharge temperature sensor shorted Four blinks High compressor discharge temperature Five blinks Superheat too low Six blinks High pressure oil pressure or low pressure cut out Seven blinks Defrost Termination sensor shorted Note See Table 2 for thermistor sensor resistance values at selected temperatures To check a sensor place it in an ice bath a cup with ice and water and stir The resistance should be 32 650 ohms at the 32 F bath temperature TABLE 2 Resistance of thermistor sensors at various temperatures Temperature F Ohms Temperature F Ohms 104 5 320 32 32 650 86 8 060 23 42 330 77 10 000 14 55 330 68 12 49
33. own due to low superheat check EVAP IN amp EVAP OUT sensors check refrigerant charge O1 Superheat light indicates 1 deg then 8 deg OQ Incorrect refrigerant charge Expansion valve oversized Superheat set too low System not stabilized Evap coil iced up Check refrigerant charge Check expansion valve size Raise superheat setting Allow system to run longer Clear ice O Freezer coil icing gt Insufficient refrigerant Wrong defrost termination setting Wrong defrost fail safe setting Evap fan not running Defrost heater not working Faulty defrost termination sensor Not enough defrost for conditions or infiltration Undersized system 4 Check system for leaks repair leaks amp add refrigerant Raise setting on the board Raise setting on the board Check fan circuit and board relay Check heater circuit and board relay Check sensor on evap coil WP Compressor Cycles off at startup w o pumping down Low pressure switch setting too high Low pressure switch tripping compressor Compressor out on thermal overload protector 1 Change low pressure cutout to 0 PSIG and 10 PSIG cut in 2a EXV closing down due to low superheat check EVAP IN amp OUT sensors 2b Check refrigerant charge 2c Check if sensors are connected to correct terminals on Beacon
34. r the Optional Smart Controller controls the master and all the slaves See Master Slave wiring connections on typical wiring diagrams During master slave operation there could be a delay in the reaction time of each slave to the master of up to 1 minute The length of time is dependent on how many slaves are connected to the system B BEACON CONTROLLER REFRIGERANT LINE BRAZING CAUTION The electric expansion valve on the liquid line 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 braz ing the refrigerant line connections and the suction line sensor removed per above instructions WIRING Wiring between the condensing unit and unit cooler s will be as follows see attached wiring diagrams High voltage To the defrost heaters if present and or fan motors See unit cooler spec plate for ampacity The evaporator may also be connected to a separate power supply Low voltage 24V 18 to 30 VAC Class II control circuit A total of 5 low voltage leads are required to connect the condensing unit to the evaporator Two of these leads are for connecting the compressor discharge sensor The other 3 leads are for connecting the compressor relay and the 24V transformer All 24 volt wiring must be separated from the line vo
35. sure fault Check system for refrigerant leak Check oil level in compressor Check system for non condensable Check low pressure switch for correct adjustment to O psig cut out 10 psig cut in If ambient is below 50 F may need to addd pressure fan cycling switch System flashes superheat sensor shorted or open Change evap in and evap out sensors System flashes room temp sensor discharge sensor defrost termination temp sensor shorted or open Change sensor as indicated System flashes superheat low Check evaporator coil circuits for uneven feeding if circuits are not feeding evenly 1 check nozzle sizing for the application and 2 expansion valve may be defective Check if evap in and evap out sensors are plugged into correct terminals on the board Check if system is overcharged System cooling but box temperature not met If a low temp evaporator is being used in medium temp application check nozzle size Check if transformer is on the correct voltage tap Check for low refrigerant charge Check pump down switch for incorrect wiring Check if discharge temperature is above 225 F remove discharge line sensor from discharge line Disconnect evaporator coil sensor from the board Check value of room temperature pot setting if value is correct pot may be defective Add fixed resistor System off and will not run Check if room sensor is connected on the board Check if system has a pump down switch put switch in norma
36. ycling switch Controlling box temp range 25 F to 60 F Voltage range at the board 18 VAC min 30 VAC max Surge protection at the up to 50 VAC 15 BEACON CONTROLLER BEACON TROUBLE SHOOTING GUIDE FAULT OR PROBLEM System runs 4 minutes then cycles off then repeats THINGS TO CHECK 1 Check if sensors are connected correctly if evaporator in out are switched this will cause low superheat Check if system is piped properly System will cycle off if discharge line gets above 225 F Check evaporator coil circuits if they are feeding evenly uneven feeding will cause flood back Check if expansion valve is correctly wired on Beacon board Evap Coil temp too high disconnect Evap Coil sensor to allow system to run amp lower temp reconnect when temp lowered Is the system wired properly between master amp condensing unit Check charge at 105 F condensing sight glass should be full Check fan cycling operation System runs continuously Check evaporator coil circuits if they are feeding evenly uneven feeding means coil is not being used fully Check if red jumper wire next to blue pot is connected also check if terminals on red jumper wire are tight Check if room sensor is connected Check if system is properly charged with refrigerant Is the system sized properly Check system charge
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