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.
(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
1 1/2 H
1 H
1 1/2 H
1 1/2 H
height of
unit coil
surface.
1 1/2 H
1 1/2 H
1 1/2 H
3 H
1 1/2 H
NOTE:
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.
Whenever possible, always try to position
the evaporator to blow towards the vault
door. Never position it over or adjacent to
a door opening.
Elevation view of glass display
door cooler or freezer. Be sure air
discharge blows above, not directly
at doors. Provide baffle if door
extends above blower level.
4
Condensing Unit Placement
Space and Location Requirements
The most important consideration which must be taken into account when deciding upon the location of aircooled 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
Building
Wall
the Next Unit
3 Feet
(minimum)
Clearance
from MCCU to
an Open Block
Wall or
Shrubs.
3 Feet
(minimum)
Clearance for
Contractor to
Service Unit.
5
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 and under the unit compressor
compartment frame to assist.
Spreader bars may be used to protect
unit from damage.
Refer to the
building plans
for construction
details.
Top of Roof
Roof Opening
Flashed and
Sealed
Rigging Holes
Disconnect
Curb
Refer to the
building plans
for construction
details.
6
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 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 II systems before brazing of the solder joint
internally . Flux only the male portion of the connection – never the female. After brazing, remove excess flux.
(j) 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 above instructions.
(k) Do not use “bull head” tees. This will cause oil return problems and can cause poor performance.
(l) If isolation valves are installed at the evaporator, full port ball valves should be used.
Figure 6. Refrigeration Piping Diagrams
SLOPE DOWN TO UNIT
PITCH AWAY FROM UNIT
1/2” LIQUID LINE
1-1/8” SUCTION LINE
7/8”
BEACON
ELECTRIC
EXPANSION
VALVE
(TYP.)
FACTORY
MOUNTED
7/8”
3/8”
L
S
PIPING DIAGRAM FOR THE
(R22) MEDIUM TEMPERATURE COOLER
REFRIGERATION SYSTEM
10 DOOR VAULT COOLER
NOT TO SCALE
ROOF PENETRATION BY OTHERS
(SEE ARCH. PLANS)
1/2” LIQUID LINE
1/2”
L
S
S
1-1/8” SUCTION LINE
INSULATED WITH 3/4”
WALL ARMAFLEX OR EQUAL
TO MCCU
UNIT ON ROOF
BRACE DOWN
EVERY 6.0 FT.
PITCH DOWN
TOWARD UNIT
SLOPE DOWN TO UNIT
PITCH AWAY FROM UNIT
3/8” LIQUID LINE
SUCTION LINE
BEACON
ELECTRIC
EXPANSION
VALVE
(TYP.)
FACTORY
MOUNTED
(R404a) LOW TEMPERATURE FREEZER
VAULT ICE MERCHANDISER
1/2”
3/8”
PIPING DIAGRAM FOR THE
REFRIGERATION SYSTEM
NOT TO SCALE
ROOF PENETRATION BY OTHERS
L
S
INSULATED WITH 3/4”
WALL ARMAFLEX OR EQUAL
UNIT ON ROOF
BRACE DOWN
EVERY 6.0 FT.
PITCH DOWN
TOWARD UNIT
(SEE ARCH. PLANS)
3/8” LIQUID LINE
S
1/2” SUCTION LINE
TO MCCU
SLOPE DOWN TO UNIT
PITCH AWAY FROM UNIT
3/8” LIQUID LINE
SUCTION LINE
ROOF PENETRATION BY OTHERS
BEACON
ELECTRIC
EXPANSION
VALVE
(TYP.)
FACTORY
MOUNTED
(R404a) LOW TEMPERATURE FREEZER
-10° VAULT STORAGE FREEZER
5/8”
L
3/8”
S
PIPING DIAGRAM FOR THE
REFRIGERATION SYSTEM
NOT TO SCALE
TO MCCU
UNIT ON ROOF
BRACE DOWN
EVERY 6.0 FT.
PITCH DOWN
TOWARD UNIT
(SEE ARCH. PLANS)
3/8” LIQUID LINE
S
5/8” SUCTION LINE
INSULATED WITH 3/4”
WALL ARMAFLEX OR EQUAL
7
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 risers, 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
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 in a warm ambient. We recommend a trap on all
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 0ºF (-18°C) room applications and 30 watts
per lineal foot for -20°F (-29°C) rooms is satisfactory.
Inspect the drain pan periodically to insure free drainage of
condensate. If the drain pan contains standing water, check
for proper installation. The drain pan should be cleaned
regularly with warm soapy water.
Figure 8. Drain Line
WARNING: All power must be disconnected
before cleaning. The drain pan also serves as
cover for hazardous moving parts. Operation
of unit without drain pan constitutes a hazard.
NOTE: Always trap drain lines individually
to prevent vapor migration.
8
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. Do not use 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 significantly greater than most of the other piping. Extra supports are relatively inexpensive as
compared to refrigerant loss.
Figure 10.
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.
9
Refrigeration Piping
Figure 11. Piping Connection Layout (MCCU)******
2 sets hard piped
from MCCU to
sandwich cases
2 sets of pre-charged line sets from
IMI Cornelius
2 extra circuits for stores that install
additional. 2 or 4 barrel machines
4”
Hard pipe from
MCCU to Bohn
evaporators in ice
vault & vault freezer
4”
4”
4”4”4”4”4”
1 set of pre-
charged lines
furnished by ice
manufacturer
Hard pipe from
MCCU to vault
cooler
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 And 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, it 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 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-of f 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.
Repeat this operation a second time.
Open the compressor’s service valves and evacuate the entire system to 500 microns absolute pressure.
Raise the pressure to 2 psig with the refrigerant and remove the vacuum pump.
Reclaim all used refrigerant. EP A regulations are constantly
being updated. Ensure your procedures follow correct regulations.
11
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 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. If a 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
Relay #Remote UnitVoltage
R4Ice Machine208-240**
Figure 12.
** Hoshizaki ice machines
require a 115 volt relay
which must be field supplied
replacing the factory relay.
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 II Board
Heater
Relay
Fan
Relay
LED
Display
Room
Sensor
Defrost
Sensor
Expansion
Valve
Connection
Selection
Buttons
24 V.
Terminal
Block
Suction
Sensor
Suction
Pressure
13
Beacon II 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 II
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 on ALL evaporators.
• A pressure 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 Installation Manual for more
details.
14
Beacon II Controller
Refrigerant Line Brazing (
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.
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.
CAUTION
)
Too high a temperature may destroy
Power Supply
The Beacon II 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. If 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.
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 II 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.
This must be done for all the evaporators on that system.
Wiring
Wiring between the condensing unit 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 II 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.
• Low voltage wiring must be 18 gauge minimum. For low voltage wiring, maximum distances are:
Condensing unit to MASTER evaporator500 ft.
Smart Controller to MASTER evaporator1,000 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.
All 24 volt wiring must be run separate from the line voltage wiring.
Box Temperature Control Settings
•There is an on board room thermostat on the Beacon II 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 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 II 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
Loading...
+ 33 hidden pages
You need points to download manuals.
1 point = 1 manual.
You can buy points or you can get point for every manual you upload.