Bohn MAC8X Installation Manual

MAC Series

™

Condensing Units

H-IM-67G July 2011 Part #25006401

Replaces H-IM-67G (12/03)

Installation and Operation Manual

TABLE of CONTENTS

General safety and inspection

Condensing unit specifications .........................................2

Evaporator unit specifications ...........................................3

Evaporator placement .......................................................4

Condensing Unit placement...............................................5

Refrigerant piping and line sizes ....................................6-8

Leak detection and evacuation ..........................................9

Field wiring .....................................................................10

Beacon II Controller

Installation ....................................................................11

Refrigerant line brazing
Power supply

Wiring ..........................................................................12

Box temp control settings
Refrigerant charging

Start-up operation .........................................................13

Initial power on

Operating mode display ...............................................14

Program & review settings/changes ........................15-18

Low ambient operation

Pumpdown ..............................................................19-20

Defrost ..........................................................................20

Alarms and error indicator LED ..................................21

Evaporator fans shut down by operators
Power failure
Space sensor terminal

Checking sensors .........................................................22

System defaults

Control sensor and piping ............................................23

Checking operation of exp. valve

Exp. valve motor winding resistance ........................... 24

Smart Controller ......................................................25-36

Operational checkout ...................................................37

Preventive maintenance...........................................38-40

Diagnostics .................................................................41-44

Beacon II parts lists ....................................................45-46

Startup Checklist ........................................................47-48

Wiring diagrams .........................................................49-51

Warranty information ...................................................... 52

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.

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.

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.

Table 1. Condensing Unit Specifications

Receiver
Model Location Compressor Voltage HP Unit Unit Unit 90% full
MCA MOP kW lbs.
Freezer ZF15K4E 208-230/3/60 3 1/2 22.0

MAC5X

Cooler RST43C1E 208-230/1/60 1/2 9.0
Freezer ZF13K4E 208-230/3/60 3 22.0

MAC7X

Cooler CS10K6E 208-230/1/60 1 1/2 9.0
Freezer ZF15K4E 208-230/3/60 3 1/2 22.0

MAC8X

Cooler CS10K6E 208-230/1/60 1 1/2 9.0

MCA = Minimum Circuit Ampacity MOP = Maximum Overcurrent Protection
Note: Remote circuits internal volume = .10 cu. ft. Approximate unit weight = 825 lbs.

36.2 50.0 6.4

33.8 45.0 6.4

41.0 50.0 6.5

2

Evaporator Unit Specifications

Table 2. Evaporator Unit Specifications

Evaporator Model Location Cap. No. of Dimensions (in.) Connections (In. Amps Weight

BTUH Fans A B Suct. ID Liq. OD Mtrs. Htrs. (lbs.)

MAC5X ADT052BEB2N6MK Cooler 5,200 1 29.50 17.25 5/8 1/2 0.5 — 31
LET160BEB2N6MK Freezer 16,000 4 77.50 65.25 1 1/8 1/2 2.0 15.7 81
MAC7X ADT104BEB2N6MK Cooler 10,400 2 45.50 33.25 7/8 1/2 1.0 — 49
LET120BEB2N6MK Freezer 12,000 3 61.50 49.25 7/8 1/2 1.5 11.7 60
MAC8X ADT104BEB2N6MK Cooler 10,400 2 45.50 33.25 7/8 1/2 1.0 — 49
LET160BEB2N6MK Freezer 16,000 4 77.50 65.25 1 1/8 1/2 2.0 15.7 81

Figure 2.

© 2011 Heatcraft Refrigeration Products LLC

3

Evaporator Placement

Figure 3. Evaporator Placement In Cooler/Freezer

Loading Door

1

Freezer

Note: Whenever possible always try to position the evaporator to blow towards the walk-in door. Never position the

evaporator over or adjacent to a door opening.

1

Cooler

Loading Door

or

Freezer

1

Cooler

1

Evaporator Minimum Unit Clearance

1 1/2 H

Top View

1 1/2 H

1 1/2 H

Side View

1 1/2 H

H = Total Height of Unit’s Coil Surface

1/2 W 1/2 W

H

W

2 H

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

Figure 4.

(minimum)

Clearance =

3 Feet from

Building

Wall



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.)



3 Feet





an Open Block

Wall or Shrubs.

3 Feet

(minimum)

Clearance to



3 Feet

(minimum)
Clearance for
Contractor to

Service Unit.

5

Refrigeration Piping And Line Sizing

Refrigeration Piping And Line Sizing

The system as supplied by Bohn/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

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 pre­ vent scaling and oxidation inside the tubing. Dry
nitrogen is preferred.

(g) Use only a suitable silver solder alloy on suction and
liquid lines.

national codes and in conformance with good practice required
for the proper operation of the system. The interconnecting pipe
size is not necessarily the same size as the stub-out on the con­densing unit or the evaporator.

(h) Limit the soldering paste of flux to the minimum re­ quired 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.

Table 3. Recommended Line Size In Equivalent Lengths

Model Room Max. Max. Suction Line Liquid Line
Riser 25’ 50’ Plus 50’ 25’ 50’ Plus 50’

Freezer 1 1/8” 7/8” 1 1/8” Consult Factory 3/8” 3/8” Consult Factory

MAC5X

Cooler 5/8” 5/8” 5/8” Consult Factory 3/8” 3/8” Consult Factory
Freezer 7/8” 7/8” 7/8” Consult Factory 3/8” 3/8” Consult Factory

MAC7X

Cooler 7/8” 7/8” 7/8” Consult Factory 3/8” 3/8” Consult Factory
Freezer 1 1/8” 7/8” 1 1/8” Consult Factory 3/8” 3/8” Consult Factory

MAC8X

Cooler 7/8” 7/8” 7/8” Consult Factory 3/8” 3/8” Consult Factory

Remote Precharged Circuits

The remote precharged circuits are provided with a factory
holding charge of R-404A. The system charge is located in
the appropriate drink and ice machines. Schrader valve fittings
are provided for liquid line charging at the condensing unit.

Consult the appropriate drink and ice machine manufacturers for
details on installation of precharged lines.

6

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.

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 5 below for methods of
constructing proper suction line P-traps.

Condensate Drain Lines

Copper drain lines should be used and properly protected
from freezing. In running drain lines, provide a minimum
of 1/4 inch 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. See Fig­ure 6. 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. The drain line must
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.

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.

Figure 5. Suction P-traps

Figure 6. Drain Line

Note: Always trap drain lines individually to prevent
vapor migration.

7

Refrigeration Piping

Figure 7. Example of Pipe Support

1. See Figure 7.

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.

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 must be insulated with 3/4”
wall Armstrong “Armaflex” or equivalent. Liquid lines

must 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.

8

Leak Detection And Evacuation

Leak Detection

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.

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.

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 of
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 evacuate the
entire system to 500 microns absolute pressure.

Raise the pressure to 2 psig with the refrigerant and
remove the vacuum pump.

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.

9

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

Figure 9. Beacon II Board

Defrost

Heater

Relay

Evaporator

Fan

Relay

EXV

Test Pins

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.

Alarm

Contacts

Expansion

Valve

Connection

LED

Display

Spare

Temperature

Room

Temperature

Defrost

Temperature

Suction

Temperature

Suction

Pressure

Selection

Buttons

Terminal

Block

10

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.

• 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 1 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.

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. See Figure 4,
page 5.

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. Liquid and suction
lines MUST be insulated. There must also be good
clearance around the unit.
See Figure 3, page 4.

• A pressure transducer is installed on the
evaporator. Do not leak test system above 150
PSI or damage to transducer could occur.

• Refer to the Beacon II Smart Controller
Installation Manual, shipped with the Beacon II
Smart Controller, for installation, programming
and monitoring information.

11

Beacon II 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 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.

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.

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. 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.

All 24 volt wiring must be run separate from the line
voltage wiring.

• Number of wires in low voltage wiring
bundles:

MAC to cooler evaporator - 5
MAC to freezer evaporator - 5

Cooler evaporator to Smart Controller - 6
Freezer evaporator to Smart Controller - 4

• Low voltage wiring must be 18 gauge
minimum. For low voltage wiring, maximum
distances are:

Condensing unit to evaporator 500 ft.
Smart Controller to evaporator 1,000 ft.

• Alarm circuit – The onboard alarm (120vac2a)
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.

MAC5X MAC7X MAC8X

Note: All four corner brass spacers on the Beacon II board
should have sheet metal screws and they all should be
screwed in. By doing this, the board will have a ground
reference. Make sure the evaproator is grounded.

12

Beacon II Controller

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

Refrigerant Charging

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 tem­ perature could go below the differential tem­ perature before the system cycles off.

In the “OFF” cycle, the system will be off for a
minimum of 4 minutes even if the box tempera­ ture 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.

The cooler and freezer systems utilize refrigerant side
head pressure control. Charge each system by adding
an initial charge of 5 lbs. of R-404a refrigerant to the
liquid side of the receiver. This initial charge will allow
the system to start. With the system running, continue to
add refrigerant to the system until the sight glass is clear.

Operate system until the cooler/freezer box achieves the
desired temperature. The sight glass should be clear with
no bubbles or flashing of refrigerant. Now the additional
charge for the flooded condenser is to be weighed into
each system in the amount as shown in Table 4.

Table 4.

Ambient Freezer Cooler Freezer Cooler Freezer Cooler
°F. ZF15 RST43 ZF13 CS10 ZF15 CS10
80 6.0 4.0 3.0 4.0 6.0 4.0
70 5.0 3.0 2.0 3.0 5.0 3.0
60 3.0 3.0 1.0 3.0 3.0 3.0
50 2.0 2.0 1.0 2.0 2.0 2.0

40 1.0 1.0 1.0 1.0 1.0 1.0
30 1.0 1.0 0.5 1.0 1.0 1.0

20 0.5 0.5 0.5 0.5 0.5 0.5
10 0.5 0.5 0.5 0.5 0.5 0.5
0 0.5 0.5 0.5 0.5 0.5 0.5

Start-Up Operation

• Check all wiring connections to be sure they

are correct and tight.

• On condensing unit:

- Check the setting of Time Delay relay.
It should be set a one minute (the
second marker).

- Check the Low Pressure switch
setting on freezer units. It must be set to

0 PSIG cutout, 10 PSIG cut-in to allow
positive start and operation, especially in
cold ambients. This can be changed to
a higher value in warmer climates.
On cooler units, the Low Pressure switch
has a fixed setting and cannot be adjusted.

13

Beacon II 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 “hold­on” 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 BOX TEMPERATURE
and MODE 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 BOX
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 oFF 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 on the
Beacon II board.

Figure 10. Operating Mode Display

oFF – Off
Coo – Cooling
Pdn – Pumpdown
dEF – Defrost
drn – Draining
dLY – Delay
tSt – Test
SEr – Service

14

Beacon II Controller

Programming And Reviewing
Settings/Changes

The Program Review button is used to program, review
and change all program settings for the system.

1) 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 different setpoint item is displayed.

PROGRAM

REVIEW

Note: If Smart Controller is in use, do not
program the board-- go to pg. 31 to program
Smart Controller.

“PROGRAM REVIEW” ITEMS

A-E – Set Defrost Type
(Air or ELE)

rEF – Set Refrigerant Type
(R22, R404A or R507)

bot – Set Box Temperature
(-30°F to +70°F)

SUP – Set Superheat
(4°F to 20°F)

2) Next, use the “SELECT” knob to change value of
Setpoint Item.

SELECT

3) 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.

ENTER

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)

dFt – 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)

– Set Alarm Time

ALt

(2 to 120 minutes)

F-C

– Set Fahrenheit/Celsius

Temperature Units (°F / °C)

15

Beacon II Controller

Programming And Reviewing Settings/Changes (continued)

Use the “PROGRAM REVIEW” button to select these items:

PROGRAM

• Defrost Type – “A-E” – Selection is made
for air defrost or electric defrost coil. This will
automatically set the system factory defaults
for air defrost and electric defrost. (See default
settings). Please note that the refrigerant type
default for 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 is R22 and for electric
defrost is R404A.

• Box Temperature – “bot” – Select box
temperature setpoint. Selection range is -30°F
to +70°F.

Default: Electric defrost -10°F and air
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: 8°F.

Default: MASTER on each board. For a
single evaporator system, no change is
required.

• Number of Defrosts Per Day – “dFn” – A
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 is 4 per day and air
defrost is 2 per day.

• Defrost fail-safe – “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.

Default: Electric defrost is 30 minutes and air
defrost is 40 minutes.

• Defrost End Temperature – “dFt” – This is the
temperature at which the defrost will be
terminated.

Default: Electric defrost is +60°F and air
defrost is +45°F.

• Defrost Delay Start Time – “dFS” – This allows
the delay of the start of the defrost.

Default: 0.5 hours to 23.5 hours.

16

Beacon II 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 is +5°F and air defrost
is +50°F.

• Alarm Low Temperature – “ALL” – Temperature
at which a low box temperature alarm will be
triggered.

Default: Electric defrost is -15°F and air
defrost is +30°F.

• Alarm Time – “ALt” – Time which high
temperature or low temperature conditions must
exceed before alarm is triggered.

Default: 60 minutes.

• °F/°C – “F-C” – Select units to display
temperature. Fahrenheit or Celsius.

FORCE

DEFROST

Use this button to “FORCE 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”.

RESET

TIME

Default: Fahrenheit.

Use the “MONITOR” button to review these items

SUP – Superheat (°F)
ESP – Expansion Valve Stems (0 to 255 steps)

SCt – Suction Temperature (°F)
SSt – Saturated Suction Temperature (°F)
SCP – Suction Pressure at Evaporator

(PSIG / “HG)

Odt – Outdoor Temperature (°F)
dFt – Defrost Sensor Temperature (°F)
dFS – Time Left to New Defrost (hours)

(on 1.8 versions)

dFE – Last Defrost Elapsed Time (minutes)
AC – Board Voltage
SPt – Spare Temperature Reading
reL –Release version of chip software

MONITOR

Use this button to “RESET 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 “dLy”.

FORCE

SERVICE

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”.

17

Beacon II Controller

Programming And Reviewing Settings/Changes (continued)

Use this button to “CLEAR/TEST”
Pressing this button ONCE will return the LED display
to the default display. 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.

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 / oFF Box Temperature / Mode is displayed
All Evaporators

•COOLING
Single Evaporator Box Temp / Coo Box Temperature / Mode is displayed

• Pumpdown
All Evaporators Pdn

• DEFROST
All Evaporators dEF

• TEST
All Evaporators tSt

•SERVICE
All Evaporators SEr

• ALARMS A1 High Box Temp
A2 Low Box Temp
A3 System Start-Up Failure
Compressor pumps down and tries
to restart after 4 minutes.
A4 Input Fault
Box Temp., Suction Temp., Pressure
Transducer open or not installed

18

Beacon II Controller

Status Indicator LED (continued)

Status LED Display Description

• ERRORS E1 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
E5 Outdoor 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

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 EEV closes and the compressor runs
until the low pressure switch opens or 2 minutes has
elapsed. The compressor is then off and remains off until
the start of the next cooling cycle.

While in the off cycle, the system will initiate a short
pumpdown at 4-minute intervals, only if the Low
Pressure Switch closes, to ensure that any refrigerant
leakage will not cause a problem.

For Manual Pumpdown, a single pole, single throw
switch can be used to connect “SERVICE” and
“Com”. This can be done at the Beacon II board on the
evaporator or at the terminal board in the condensing
unit. This will cause the system to pump down and shut
off.

Note: The system will not restart until the switch has been
opened. The Beacon II board will display “SEr”.

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 on the receivers in the
condensing unit, then closing the suction line service valve
when the system trips on the low pressure switch.

19

Beacon II Controller

Service Mode

A SPST switch (S1 & S2) is supplied, for each system,
in the condensing unit for shutting off the system.
Closing the “Service” switch in the condensing unit will
cause the expansion valve to close and the compressor
to pumpdown and shutoff. “SEr” will be the onboard
LED display and “SERVIC” is displayed on the Smart
Controller. The evaporator and heater relays on the
Beacon II board will then be deactivated. The system will
not restart until the switch is placed in the “NORMAL”
or off position.

When the “Service” switch in the condensing unit is
closed or ‘on’ (labeled SERVICE), the system is in the
service mode. If the switch is ‘off’ (labeled NORMAL),
the system is in normal operation

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 II does not have a real time clock.
Beacon II does provide the 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.

TIME REMAINING UNTIL NEXT DEFROST

To find out how much time is left until the next defrost is
scheduled, use the “MONITOR” button to scroll to dFS.
The time displayed will be how much time until the next
scheduled defrost.

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 and 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 3 minutes has 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.

20

Alarms

Beacon II Controller

Beacon II provides a set of dry contacts for use in
signaling an alarm. These contacts can be connected
to a light, a buzzer, a bell, etc., which will be activated
when an alarm condition occurs. When the Beacon II 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.

ALARM CODES
A1 High Box Temperature

A2 Low Box Temperature
A3 System Start-Up Failure
Compressor pumps down and tries to restart after four minutes.
A4 Input Fault Box Temperature, Suction Temperature, Pressure
Transducer open or not installed

• System Start-Up Failure – LED Display: A3 –
Compressor pumps down and tries to restart after four
minutes.

• Input Fault – LED Display: A4 – Box Temp., Suction
Temperature, or Pressure Transducer open or not
installed.

• Power Failure – Loss of power to the Evaporator.

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

ERROR CODES
E1 – 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
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

The system will pumpdown, cycle off and try to restart
for these faults. Each try will be after the 4 minutes “Hold
Off” period, for the following fault conditions:
– High pressure or low pressure cutout
– Oil pressure

After the fourth try, the Alarm contacts will be closed and
an alarm message displayed on the LED.

21

Beacon II Controller

Evaporator Fans Shut Down By
Operators

In some installations, it is desirable to shut off the
evaporator fans for product loading. This is easily
accomplished on Beacon II by wiring a single pole
switch (SPST) between the terminals on the Beacon II
board marked “SERVICE” and “COM”. Closing this
switch will cause the system to pumpdown and shut off
the compressor and the evaporator fans. The switch must
be reopened before the system will restart. This SPST
switch and wiring is field supplied and field installed.

Power Failures

In the event of a power failure, Beacon II will
automatically close the expansion valve 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 II 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 5 below.

If a product temperature simulator is used, it must meet
the resistance/temperature specification listed in Table 5.
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 SPt. The values
displayed will be the temperature of the spare sensor.

Checking Sensors

DO NOT REMOVE SENSORS FROM COIL 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.

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 or lower by 5,000
ohms approximately, the sensor should be replaced.

Table 5. Resistance / Temperature Specification

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 12,490 5 72,950
59 15,710 -4 97,070
50 19,900 -13 130,410
41 25,400 -22 176,960

22

System Defaults

Table 6. System Defaults

Parameters Code Cooler Freezer

Refrigerant rEF R404A R404A
Box Temperature bot 35°F -10°F
Superheat SUP 8°F 8°F
Slave Evaporator SLA No No
No. of Defrosts Per Day dFn 2 4
Defrost Fail-Safe Time dFF 40 min. 30 min.
Defrost End Temperature dFt 45°F 60°F
Defrost Delay Start Time dFS 0 hrs. 0 hrs.
Alarm High Temperature ALH 50°F 5°F
Alarm Low Temperature ALL 30°F -15°F
Alarm Time ALt 60 min. 60 min.
Temperature Units F-C °F °F

Beacon II Controller

Figure 11. Control Sensor And Piping

23

Beacon II Controller

Checking Operation Of Expansion Valve
(EEV)

1. 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
receiver, at the condensing unit. The system should pumpdown
and shut off on the Low Pressure switch (LPS). If the system
does not pumpdown and trip on the LPS then the compressor
valves are weak and needs to be changed.

After the system pumps-down and trip on the LPS, turn off the
power to the Beacon II board, then turn the power back on. This
will cause the Expansion valve to close.

Open the valve on the liquid receiver, 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.

2. 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.

Expansion Valve Motor Winding Resistance

This can also be checked by using the EXV test pins on
the board. This is indicated by a 0 to 5 Volts DC signal.
At 0 Volts the valve is closed and at 5 Volts the valve is
fully open. At values between 0 and 5 Volts, the valve
will be opened proportionately.

3. 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.

4. 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 a
defective valve.

If the expansion valve is suspected 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).

Resistance reading at 150 at 75° F

“C” is largest spade

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 is closed. 5 volts DC indicates the valve is fully open. A value between 0
and 5 volts indicates how much the valve is open or close.

24

Beacon II Smart Controller

The Smart Controller performs all of the
standard Beacon functions with the additional
benefit of remote monitoring. The Smart
Controller is mounted in the manager’s office
and the refrigeration system can be monitored
and changed without going to the cooler or
freezer. The Smart Controller with LCD display
will also alert you to any alarm conditions in

your refrigeration system. The Smart Controller
will display the problem in addition to letting
you know when to call for service. See pages
49-51 for proper wiring instructions. Refer to the
installation and operation manual that ships with
each Smart Controller for complete instructions.

NOTE: One Smart Controller controls both the
cooler and freezer.

25

Beacon II Smart Controller Features

The Beacon II Smart Controller performs
all the standard Beacon functions with the
additional benefit of:

a ) Remote mounting for easy
access
b ) Remote monitoring and
programming
c ) Controlling four completely
separate systems
d ) Logging data
e ) Smart Defrost
f ) Access via PC or modem
g ) Has buzzer to signal alarms
h ) Locking keypad

Beacon II Smart Controller allows complete
programming and monitoring of the system.
The Controller display has the following buttons:
COOLING, DEFROST, PROG REVIEW,
MONITOR, ENTER, CLEAR, SETPOINT AND
TIME.

The normal LCD display will show the
Programmed Box Set-point temperature. Actual
Box Temperature, the Current Time of day and
the Mode (i.e. COOL, DEFROST or OFF).
When multiple systems are being controlled, the
system number (i.e. SYS 1, SYS 2, SYS 3, SYS

4) will also be displayed on the LCD.

26

Beacon II Smart Controller Features

• Monitoring of the complete refrigeration
system.

• Programming of a variety of
parameters for the optimum control of
the refrigeration system.

• The Beacon II Smart Controller has a
Liquid Crystal Display (LCD)
which shows: current time, actual box
temperature, box temperature set-point
and if there is an alarm or fault
condition.

• Data Logging.

• Smart Defrost to save energy on
defrost.

• Sounds a buzzer to indicate an Alarm
condition.

• Can be mounted up to 1000 ft. away
from the system being controlled.

• Each Beacon II Smart Controller can
control four independent systems
with up to 4 evaporators on each
system.

• An RS232 port is provided which
allows connection to system via PC
or Modem.

• A Backup battery will maintain the clock
settings for 10 years.

• Double E PROM Chip will maintain
program settings indefinitely.

• Password protection system (with Smart
Ware).

• Locking feature to prevent
unauthorized access to program
settings.

System

Number

Time of Day

Set-point

Slide Bar

Box Set-point

Temperature

Operating

Mode

Box

Temperature

System

Selection Bar

27

Installation

Installation

The Smart Controller should be installed in a
location where the large Liquid Crystal Display
(LCD) can be viewed easily, yet is secure and
vibration free. Because of the LCD screen,
the Smart Controller II should not be mounted
where it will experience temperatures below 40
ºF or above 100 ºF.

Beacon II Smart Controller Base

A terminal strip for wiring connections is located
on the base of the Smart Controller. To access
this terminal strip, pull both halves of the Smart
Controller housing apart. Mounting holes are
located in the plastic base.

Terminal

Strip

RS232

Connector

28

Wiring

Wiring

All 24 volt wiring must be run separate from
the line voltage wiring.

The terminal strip in the Smart Controller
is labeled similarly to that of the Beacon II
boards. Connect the corresponding terminals to
those on the Beacon board.

For single Refrigeration system:

Connect MULTI OUT 1 from the Smart
Controller to the MULTI IN on the
Beacon board on the Evaporator.
Then connect MULTI IN 1 from the
Smart Controller to the MULTI OUT on
the Beacon board on the Evaporator.
See typical wiring diagram at the back
of these instructions.

For MULTIPLE independent Refrigeration
systems:

For the first system, connect MULTI
OUT 1 from the Smart Controller to
the MULTI IN on the Beacon board
on the Evaporator in this first system.
Then connect MULTI IN 1 from the
Smart Controller to the MULTI OUT on
the Beacon board on the Evaporator on
this first system. DO NOT disconnect
the Room sensor from any of the
Evaporators. See typical wiring diagram
at the back of these instructions.

A minimum 18 gauge wire should be used. All
low voltage wiring must be run separate from
high voltage wiring.

Power Supply

The Beacon II Smart Controller gets its 24
VAC power supply from an evaporator. When
controlling multiple systems, the Beacon
II Smart Controller is powered from the
evaporator of only one of the systems. If a power
interruption occurs to the system supplying the
Smart Controller II, the Smart Controller II LCD
screen will go blank. The other systems will,
however, continue to operate and maintain their
box temperature.

If the Beacon II Smart Controller LCD displays
all “88888” this indicates that the power supply
is below 18 VAC. When this occurs the system
will 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. The Beacon II Smart
Controller LCD display will then be normal.

INITIALIZATION of Beacon II Smart
Controller

When power is first applied to the Beacon II
Smart Controller, it checks the configuration of
the system to which it is connected and stores
this in its memory. Beacon II Smart Controller
checks how many condensing units there are and
how many evaporators are connected to each
condensing unit. This is called Initialization.

Whenever a system is added, removed or
modified (changing the number of evaporators
on a condensing unit), while connected to the
Beacon II Smart Controller, the Beacon II Smart
Controller must be re-initialized.

29

Initialization of Beacon II Smart Controller

INITIALIZATION of BEACON II SMART CONTROLLER

When power is first applied to the Beacon II
Smart Controller it checks the configuration of
the system to which it is connected and stores
this in its memory. Beacon II Smart Controller
checks how many condensing units there are
and how many evaporators are connected
to each condensing unit. This is called
Initialization.

Whenever a system is added, removed or
modified (changing the number of evaporators
on a condensing unit), while connected to the
Beacon II Smart Controller, Beacon II Smart
Controller must be re-initialized.

Make sure all wiring changes to the system and
Beacon II Smart Controller are complete before
initializing the Beacon II Smart Controller.

INITIALIZATION STEPS

• Put all systems in “SERVICE” using
the service switch, before turning on
power.

• Press and Hold both the “ENTER”
and “CLEAR” buttons on Smart
Controller.

• Hold both the “ENTER” and
“CLEAR” buttons down until the
LCD screen of the Smart Controller
displays “EEROM?”

• When “EEROM?” is displayed,
release both buttons and press the
“ENTER” button.

After “WAIT” is displayed it may take up to 2
minutes for the initialization to be completed and
the normal LCD screen is displayed.

• If unsuccessful “NOCHG” will appear

• CLOCK (+ –) This is used to set
the time of day on the display.

• Depress the + button to move the
clock forward

• Depress the - button to move the
clock backward

• When in PROG Mode, these are
used to step through values for
setting superheat etc.

• COOLING: Depressing this button
will start the system in the cooling
cycle immediately (The 4 minutes
“Hold Off” is bypassed). This button
will illuminate to indicate that
the Cooling function is “ON”. System
operation will be as described under
REFRIGERATION MODE in the
Beacon II installation manual.

Pressing the COOLING button while the system
is cooling, and the button illuminated, will
pumpdown the system and turn it off.

• DEFROST: Depressing this button
will force the system into defrost
immediately (The “Hold Off/Hold
On” times are bypassed). This button
will illuminate to indicate that the
Defrost function is “ON”. When in
Defrost, pressing this button twice will
end defrost.

• The Smart Controller LCD screen
will display “WAIT.”

30

Programming Beacon II Smart Controller

• MONITOR: Depressing the MONITOR
button will display the operating parameters
shown on page 32.

If one Beacon II Smart Controller is controlling two
or more independent systems, you must press the
SELECTION BAR to display information on the system
you want to monitor.

• PROG REVIEW: This button allows
stepping through each of the setpoints for
initial setup and to make changes.

If one Beacon II Smart Controller is controlling two
or more independent systems, you must press the
SELECTION BAR to display information on the system
you want to make program changes.

• CLEAR: Used to clear incorrect entries while
programming or to return to the System
display when monitoring.

• TIME: Slide-bar is used to set the thermostat
clock for Defrost times.

• SETPOINT: Slide-bar is used to change
settings while programming.

• ENTER: To enter new settings into the
program. NOTE: Settings are recorded in
memory even if power fails.

Programming BEACON II SMART
CONTROLLER

To make a change, press the PROG REVIEW3 button
until the setpoint that needs changing is displayed. The
SETPOINT Slide-bar is then used to change to the
desired new setting. When the new desired setting is
displayed, press the “ENTER” button. The new setting
is now programmed into the Beacon II Smart Controller
memory.

Press the PROG REVIEW button and follow the steps
below:

• DEFTYP – ELE or AIR: Select for Electric
Defrost or Air Defrost then press “ENTER”.
This selection will automatically set the
defaults for Air and Electric Defrost.
Important: This will set the refrigerant type
to R22 for Air and R404A for Electric. You
must change to the refrigerant you are
using in your application.

• REFTYP – 22, 404, 507

• BOXTMP – Box Temperature: -30º F to 70º F.

Use “SETPOINT” slide-bar to get desired
temperature, then press “ENTER”)

• SUPRHT – Superheat: 4 to 20 º F.

Use “SETPOINT” slide-bar to select desired
superheat temperature, then press “ENTER”.

• SMT DFT : Smart Defrost: On/Off.

Use “SETPOINT” slide-bar to turn it ON or
OFF, then press “ENTER” (for version 1.2.
When Smart Defrost is turned on, 8 defrost
periods per day will automatically be
programmed. These will be at 12:00 am,
3:00 am, 6:00 am, 9:00 am, 12:00 pm,
3:00 pm, 6:00 pm, and 9:00 pm. Also, the
defrost fail safe time will be set to 60 minutes,
and the defrost termination temperature will
be set to 55°F. The user can change these as
needed for the application).

• DEF ST - Defrost Start time: Up to 12

settings per day (For dF 1, use the “TIME”
slide-bar to select first defrost time, then
press “ENTER”. Use + button to scroll to next
defrost period, dF 2, use “TIME” slide-bar to
select second defrost time and press
“ENTER”. Repeat steps for each required
defrost period). If defrost times are not
programmed the system will use the
defaults: Electric Defrost - four per day at
4:00 AM, 10:00 PM, 4:00 PM, 10:00 AM.
Air Defrost - two per day at 9:00 AM, 9:00 PM.

• DEFSAF – Defrost Fail Safe Time:

10 to 200 minutes. When this time has
elapsed, the defrost cycle will end, even if the
programmed Defrost Termination
temperature was not achieved. Use
“SETPOINT” slide-bar to select desired time,
then press “ENTER”.

• DEFTMP – Defrost Termination

Temperature: 40 to 100º F. Use “SETPOINT”
slide-bar to select desired temperature, then press
“ENTER”.

• ALR HI – Alarm High Temperature.

-40 to 90º F. Use “SETPOINT” slide-bar to

select desired temperature, then press “ENTER”.

• ALR LO – Alarm Low Temperature

-40 to 90º F. Use “SETPOINT” slide-bar to

Continued to Page 32

31

Monitoring with Beacon II Smart Controller

Continued from Page 31
select desired temperature, then press “ENTER”.

• ALRMIN – Alarm Time, in minutes.
Condition must exceed before alarm is
indicated: 2 to 120 min. Use “SETPOINT”
slide-bar to select desired time, then press
“ENTER”.

• º F / º C – º F or º C. Use “SETPOINT”
slide-bar to select then press “ENTER”.

• 12/24H – Clock: 12H is for standard time.
24H is for international time. Use
“SETPOINT” slide-bar to select, then press

MODBUS OFF
By default MODBUS OFF should show on

the Smart controller. The new Smart controller has two
ports: RS232 and RS485. MODBUS communication is
via RS485, and Smart II software for PC is via RS232.
The hardware interface is available for the MODBUS
communication, but the current software version does
not have MODBUS protocol.

“ENTER”.

• TEST : OFF or ON: Puts all evaporators in
TEST mode. Use with Caution. This will
cycle each output at 10 second intervals.
Use “SETPOINT” slide-bar to select, then
press “ENTER”. Return to “OFF” and then
press “ENTER” to end the test.

• SERVIC – ON or OFF: When placed in the
ON mode this will pump the system
down and shut it off. The system will not
restart until SERVIC is placed back in the
OFF mode.

For now, customers should not change the default set­ting of the MODBUS selection. They should leave it as:
MODBUS OFF.

ORG 4-4

Smart Controller defaults to “ORG 4-4”. ORG 4-4 means
four systems with 4 evaporators each. There are some jobs
in the field that have 8x4 systems. Only a few jobs should
change the selection from ORG 4-4 to 8x4 selection. Ma­jority of the customers should leave the original selections.

MONITORING with BEACON II SMART CONTROLLER

The Monitoring function can be used to monitor live system
data. The information displayed, such as superheat, is the actual
superheat of the system as it is changing.

Press the MONITOR button and follow the steps below:

• SUPRHT – Superheat (use + button to
check superheat of other evaporators, if
Master/slave)

• EXVSET - Expansion valve step setting
(Stepper motor setting 0 to 255 steps: use
+ button to check other evaporators if
Master/slave)

• SUCTMP – Evaporator Suction
temperature (Measured by the Suction
sensor) Use + button to check other evaporators
if Master/slave

• SSVTMP – Saturated Suction
temperature at the Evaporator. Use + button to
check other evaporators if Master/slave

• SUCPRE – Evaporator Suction Pressure
Use + button to check other evaporators
if Master/slave)

• OD TMP – Actual outdoor ambient
temperature. Use + button to check other
evaporators if Master/slave
(Measured at the condensing unit)

• DEFTMP – Evaporator coil temperature
(Used to terminate defrost) Use + button to check
other evaporators if Master/slave

• DEFTIM - Defrost Time:
Length of last defrost. Use + button to check
other evaporators if Master/slave

• CMPCYC - Compressor Cycles:
No of Compressor Cycles since
12:00 midnight. Use + button to check other
evaporators if Master/slave

• CMPRUN - Compressor run time
(Measured since 12:00 midnight) Use + button to check
other evaporators if Master/slave

• SPRTMP – Spare sensor
temperature input. Use + button to check other

evaporators if Master/slave

• VERSON – Software Version: For each
controller (use + button to check other
evaporators, if Master/slave)

• VERSON - Software Version:
for Beacon II Smart Controller

When multiple evaporators are connected as master/slave
depressing the + or - button will display information specific to
each evaporator. Units in a master/slave connection are numbered
1 through 4.

The first evaporator connected to the SMART CONTROLLER
MULTI-OUT Terminals is Evaporator UN1 (Should be master).

32

Locking Beacon II Smart Controller

LOCKING BEACON II SMART
CONTROLLER

BEACON II SMART CONTROLLER is
lockable to prevent programmed settings to be
changed by unauthorized personnel. When the
Controller is Locked, all the Buttons, except
for the Monitor and Prog Review Buttons, are
disabled.

To LOCK the settings, do the following:

• Press “PROG REVIEW” button.

• Press and hold “MONITOR” button

• While holding “MONITOR” button,
Press “ENTER” button.

• The LCD will display LOCK

The error code will flash alternately with the
normal display information. When the error
condition is corrected, the error code will
no longer be displayed and only the normal
information will be displayed.

WIRING ERROR

If the Beacon II Smart Controller LCD displays
+COMM+ , this indicates that there is an error in
the communication wiring or that the wiring is
broken or disconnected.

The communication wiring is the MULTI IN and
MULTI OUT connections. Check to make sure
the OUT is connected to IN. Never connect OUT
to OUT or IN to IN.

This will prevent unauthorized persons from
changing any settings.

To UNLOCK the Controller, repeat these steps.

ERROR CODES

• BXSEN - Room temperature sensor
shorted, open or not installed

• DFSEN - Defrost temperature
sensor shorted, open or not installed

• STSEN - Suction Temperature
sensor shorted, open or not installed

• SPSEN - Suction pressure
transducer shorted, open or not installed

• ODSEN - Outdoor temperature
sensor shorted

• SUPLO - Superheat too low

• SHTDN - Compressor shutdown
(High or low refrigerant pressure or
low oil pressure)

33

Alarm Codes

Alarm Codes

• *BOXHI : Box temperature too high

• *BOXLO : Box temperature too low

• *STRUP :System Start-up failure
Compressor pumps down and tries
to restart after 4 minutes.

• *INFLT : Input fault (Box Temp.,
Suction Temp., Pressure Transducer
open or not installed)

• Power failure

When an ALARM condition occurs, the
BEACON II SMART CONTROLLER will
display “CALL FOR SERVICE”, the ALARM
code, the SYSTEM Number and will sound an
internal buzzer.

The alarm code will flash alternately with the
normal display information. When the alarm
condition is corrected, the alarm code will
no longer be displayed and only the normal
information will be displayed.

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.

• Oil pressure

• High pressure or low pressure cutout

After the fourth try, the Alarm contacts will be
closed and an alarm message displayed on the
LCD screen. To clear this condition, the system
should be cycled through the “Service” mode
after correction is complete.

On Multiple systems the Alarm contacts on each
of the Master Evaporator will announce Alarms
for that system.

ALARM BUZZER

The ALARM buzzer will sound when an Alarm
condition occurs. This buzzer will turn off when
the Alarm condition is cleared. The buzzer can
also be silenced at any time by pressing the
“CLEAR” button.

The system will pumpdown and cycle off and
will not restart until the fault is cleared for the
following conditions:

• Suction sensor shorted, open or
not installed

• Room temperature sensor shorted,
open or not installed

• Pressure Transducer open or
not installed

34

Smart Defrost

Data Logging

Beacon II Smart Controller logs system data in its
memory every 15 minutes. The length of time it records
data is dependent on how many systems are being
controlled by the Beacon II Smart Controller. It keeps
writing data to its memory until the memory is full.
When the memory is full it will overwrite its oldest
stored data in memory with newly recorded data.

Data recorded:
System Mode, Box Temperature, AUX
Temperature, Superheat, Suction Pressure
and the Number of Compressor cycles
since midnight.

Errors and Alarms recorded:
Date, Time, System #, Unit #, Error type,
Alarm type, Error duration and Alarm
duration

Length of data recorded:
One System = 30 days
Two Independent Systems = 15 days
Three Independent Systems = 10 days
Four Independent Systems =7 days

Recording intervals:
Every 15 minutes

All recorded data will have a date/time stamp.

On multiple evaporator systems, the data recorded is
from the master evaporator only. This data is available
via connection to a PC through the Smart Controller’s
RS232 serial port. The data can be viewed on a PC using
our Windows based SMART II software and can be
imported into an Excel spreadsheet.

Smart Defrost

The Beacon II Smart Controller continuously monitors the
system performance to determine the need for defrost. It
uses a variety of data such as the outdoor ambient and box
temperature in it’s decision making process.

Activating Smart Defrost:

You must program multiple defrost times into the Smart
Controller to provide flexibility for the system to defrost
the coil properly. Smart Defrost will only allow the system
to defrost at a programmed defrost time. The system will
not defrost in between programmed defrost times. Hence,
we recommend that a minimum of 8 defrost periods be
programmed when Smart Defrost is turned on. The system
will not defrost eight times per day but with this many
defrost periods it will have better options to keep the coil
clear.

To activate Smart Defrost, press the “PROG REVIEW”
button until “
” is displayed.

Move the “SETPOINT” slide-bar to “ON” then press
“ENTER”. Press “CLEAR” to return to the main screen.

For version 1.2., when Smart Defrost is turned
on, 8 defrost periods per day will automatically
be programmed. These will be at 12:00 am,
3:00 am, 6:00 am, 9:00 am, 12:00 pm, 3:00 pm,
6:00 pm, and 9:00 pm. Also, the defrost fail safe
time will be set to 60 minutes, and the defrost
termination temperature will be set to 55°F.
The user can change these as needed for the
application.

Deactivating Smart Defrost:

Real-time data can also be recorded and stored on a
Desktop PC while the PC is connected to the Smart
Controller. The PC will continuously request information
from the Smart Controller regarding system operation
and setup and record this data every minute, in an Excel
Spreadsheet. This information is stored to the PC hard
drive, which depending on the size of the hard drive,
would allows for many days of recording. This data may
also be periodically saved on a disk by the user.

The SMART II software is sold separately from the
Beacon II Smart Controller.

To turn Smart Defrost off move the “SETPOINT” slide-bar
to “OFF” then press “ENTER”. Press “CLEAR” to return
to the main screen.

35

PC and Modem Access

PC & Modem Access

For access to the system from a PC directly or via a modem, the SMART II Software must be
purchased and installed on your PC. With PC access, ALL system settings can be monitored,
changed or logged from a remote location. The stored data can be viewed in an Excel spreadsheet.

PC or Gateway Communication with the Smart Controller

When connecting a PC or a Gateway to the Smart Controller, use a separate 24VAC power supply
for the Smart Controller. This will ensure the PC or the gateway device is electrically isolated from
the Beacon board in the evaporator.

If the application is using a gateway on the Smart Controller for the remote monitoring, use a sepa­rate power supply for the gateway.

Do not share same power supply for the gateway and the smart controller.

Vantage

- Vantage Kit interfaces the Smart Controller via the RS232 Ribbon Cable.

- One Vantage Kit for each Smart Controller

- The Hub is not needed when using Vantage

- The kit comes with 24 VAC/DC adapter, internet cable, and RS232 Ribbon Cable

The Vantage Console sends the data of all Beacon II systems that are attached to the Smart
Controller to Heatcraft data site. (To view the data or register to the site, please contact Heatcraft)

When using Vantage or any other remote monitoring systems (PC or laptops), make sure the Smart
Controller does not get its power from the Beacon II System. It should use a separate floating
transformer.

Grounding

The earth/chassis ground connections on the new Beacon II and Smart Controller are used for
common-mode noise filetering and should be connected to a good chassis ground or earth ground for
best noise immunity.

- Beacon II Board

- All four corner brass spacers on the Beacon II board should ahv esheet-metal screws
and they should all be screwed in.

- Smart Controller

- Run a 20 AWG or larger wire from TB11 of the Smart Controll SUB-BASE to
ground (the sub-base terminal block connectors are numbered from TB1 on the left
to TB13 on the right).

36

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. A thorough recheck of the entire system
operation should be made as follows:

(a) Check compressor discharge and suction
pressures. If not within system design limits,
determine 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 termi­ nals. 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 deter­ mine 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 pres­ sure controls on Bohn/Heatcraft air cooled con­ densing 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.

• Recheck all safety & operating controls for proper

operation and adjust if necessary.

(e) Check head pressure controls for pressure setting.

(f) Check crankcase heater operation if used.

(g) Install instruction card and control system diagram
for use of building manager or owner.

Check-Out & 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 connections.
Be sure they are all correct and tight.

(b) Check voltage taps on transformer. The transform­ er is shipped wired to 240 voltage tap/connection.
If your supply voltage is 208 volt systems, change
to 208 voltage tap.

(d) Check high and low pressure controls, pressure
regulating valves, oil pressure safety controls, and all
other safety controls and adjust them, if necessary.

(e) 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.

(f) Liquid line should always be insulated.

(g) Wiring diagrams, instruction bulletins, etc. attached
to the condensing units should be read and filed for
future reference.

(h) All fan motors on air cooled condensers, evapora­ tors, etc. should be checked for proper rotation.
Fan motor mounts should be carefully checked for
tightness and proper alignment.

(i) 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.

(j) Continue charging until system has sufficient refriger­ ant for proper operation. Do not overcharge. Re­ member that bubbles in a sight glass may be caused
by a restriction as well as a shortage of refrigerant.

(k) Do not leave unit unattended until the system has
reached normal operating conditions and the oil
charge has been properly adjusted to maintain the
oil level at the center of the sight glass.

(l) At initial start-up, the system may cycle off at 2 min­ utes 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.
If no crankcase heater is present, then directing a 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.

(c) Check setting of time delay relay for low pressure
switch in condensing unit. It should be set at one
minute (the second marker).

37

Preventive Maintenance

Routine preventive maintenance of any me­chanical equipment is critical to its long term
reliability. During even normal operation all
equipment will experience some deterioration
during its lifetime caused by wear and environ­mental 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
Bohn/Heatcraft’s minimum recommendations

for regularly scheduled preventive maintenance
of your McDonald’s 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.

38

CONDENSING UNIT

QUARTERLY SEMI-ANNUALLY DATE DATE DATE DATE

Visually inspect unit  

1

Look for signs of oil stains on interconnection piping and condenser coil. Pay close attention to

areas around solder joints, building penetrations and pipe clamps. Check any suspect areas with an

electronic leak detector

 

2

Check condition of moisture indicator in the sight glass of all systems. Look for indication of moisture

or flash gas.

 

3 Check condition of condenser. Look for accumulation of dirt and debris. Clean as required.  

4 Check for unusual noise or vibration. Take corrective action as required.  

5

Inspect wiring for signs of wear or discoloration

 

Clean condenser coil and blades 

1

Periodic cleaning can be accomplished by using a brush, pressurized water and a commercially

available foam coil cleaner. If foam cleaner is used, it should not be an acid based cleaner. Follow

label directions for appropriate use



2

Rinse until no residue remains



Check operation of condenser fans 

1

Check that each fan rotates freely and quietly. Replace any fan motor that does not rotate smoothly

or makes excessive noise.



2 Check all fan blade set screws and tighten as required 

3

Check all fan blades for signs of cracks, wear or stress. Pay close attention to the hub and spider.

Replace blades as required.



4

Verify that all motors are mounted securely



Inspect electrical wiring and components 

1 Verify that all electrical and ground connections are secure, tighten as required. 

2

Check condition of compressor, defrost heater and condenser fan contactors. Look for

discoloration and pitting. Replace as required



3 Check operation and calibration of all timers, relays pressure controls and safety controls 

4

Clean electrical cabinet. Look for signs of moisture, dirt, debris, insects and wildlife. Take corrective

action as required



5

Verify operation of crankcase heaters by measuring amp draw



Check refrigeration cycle for all systems 

1 Check suction and discharge temperatures & pressures. If abnormal take appropriate action 

2 Check operation of liquid injection on freezer system 

3 Check pressure drop across all filters and driers. Replace as required. 

4

Verify that superheat at the compressor conforms to specification. (30F to 45F)



Inspect suction accumulators 

1 Inspect all accumulators for signs of leaks and corrosion. 

2 Pay close attention to all copper to steel brazed connections 

3 Wire brush all corroded areas and peeling paint. 

4 Apply an anticorrosion primer and paint as required. 

5

Re-attach insulation and replace any damaged sections

Preventive Maintenance

39

Visually inspect unit

1 Look for signs of corrosion on fins, cabinet, copper tubing and solder joints

Identify fan cell(s) causing vibration and check motor and blade carefully.

electronic leak detector.

draining.

airflow through coils

Verify Box setpoint temperature is being met

Clean Evaporator coil and blades

service applications.

2 Flush and rinse coil until no residue remains. 

Check the operation of all fans and ensure airflow is unobstructed

smoothly or makes an unusual noise.

Inspect electrical wiring and components

be damaged

4 Look for abnormal accumulation of ice patterns and adjust defrost cycles accordingly

only)

7 Check low voltage wiring at Beacon board for broken wires

Check voltage at Beacon board. Should be between 18 to 30 Volts

Check Beacon sensors

1 Press MONITOR button to display sensor reading for Box Temp., Suction Temp. and Defrost Temp. 

LED readings should match measured values, within 3 °F at same locations as sensors.

Check Beacon Pressure Transducer

Check Drain Line Heater

Refrigeration Cycle

1 Check unit cooler superheat and compare reading for your specific application

2

Visually inspect coil for even refrigerant distribution

Preventive Maintenance









































QUARTERLY SEMI-ANNUALLY DATE DATE DATE DATE

 

 

 

 

 

 

 

Never use an acid based cleaner. Always

Look for excessive or unusual vibration for fan blades or sheet metal panels when in operation.

Look for oil stains on headers, return bends, and coil fins. Check any suspect areas with an

Check drain pan to insure that drain is clear of debris, obstructions or ice build-up and is free

2

UNIT COOLERS

Insure that there is sufficient clearance free of obstructions around unit coolers to allow proper

3

4

5

Periodic cleaning can be accomplished by using a brush, pressurized water or a commercially

available Evaporator Coil Cleaner or mild detergent.

6

Pay close attention to drain pan, drain line and trap.

follow label directions for appropriate use. Be sure the product you use is approved for use in food

1

Check that each fan rotates freely and quietly. Replace any fan motor that does not rotate

3

1

2 Check all fan set screws and tighten if needed. 

3 Check all fan blades for signs of stress or wear. Replace any blades that are worn, cracked or bent. 

Verify that all fan motors are securely fastened.

Visually inspect all wiring for wear, kinks, bare areas and discoloration. Replace any wiring found to

4

1

2 Verify that all electrical and ground connections are secure, tighten if necessary. 

3 Check operation/calibration of all fan cycle and defrost controls when used. 

5 Compare actual defrost heater amp draw against unit data plate. (freezer only) 

Visually inspect heaters to ensure even surface contact with the coil. If heaters have creeped

decrease defrost termination temperature and be sure you have even coil frost patterns. (freezer
6

8

40

Measured suction pressure should match LED displayed value within 2 Psig.

2 Use an accurate Thermometer to measure temperatures at the same locations as the sensors. 

3

1 Press MONITOR button to display Suction Pressure reading at the Evaporator 

2 Use an accurate Gauge Set to measure Evaporator Pressure. 

Check that heater is wrapped around entire length of drain line inside the walk-in freezer

3

1 Check heater amps 

2

Diagnostics

Beacon II Troubleshooting Guide

PROBLEM Step ACTION ITEM IF OK IF NOT OK

1. Check Primary Power Supply Disconnect 1. Check fuses and circuit breakers

2. Check Voltage to Evaporator Transformer Go to 2. Check field wiring for breaks
LED is not lit. 3. Check Transformer Secondary Output Volts next step 3. Replace if necessary

4. Check Voltage at Control Board (24V and C) 4. Check factory wiring and connections

5. Replace Control Board

1. Check Compressor internal overloads 1. Wait for reset

2. Check Control Power to Condensing Unit 2. Check transformer voltage (secondary and
LED shows Coo, but (24 Volts across “COMP” and “C” at board) Go to primary) and wiring of 208V power taps.
compressor will not run. 3. Check Compressor Contactor Coil Voltage next step 3. Check internal condensing unit wiring

4. Check Compressor Contactor “pulled in” 4. Replace as needed

ERROR CODES:
E1 Room Sensor Check Sensor and Board Connection Replace as needed
E2 Defrost Sensor Check Sensor and Board Connection Replace as needed
E3 Suction Sensor Check Sensor and Board Connection Replace as needed
E4 Suction Transducer Check Transducer and Board Connection Replace as needed
E5 Outdoor Sensor Check Sensor, wiring and Board Connection Replace or remove

1. Check Refrigerant Type 1. Compare board setpoint and refrigerant

2. Check coil for ice 2. Defrost coil and check defrost cycle
settings/setpoints, defrost sensor and
heater amps.
E6 Low Superheat 3. Check Control Board step position from board LED 3. Replace board if EEV steps not at 2.
During Cooling 4. Check Electric Expansion Valve Closure Go to 4. Pumpdown system. See if LPS opens or if it
(0°F for 2 minutes) next step times out (EEV is bad or LPS is set
incorrectly, if times out) – See Pumpdown.

5. Compressor Not Operating 5. Check overloads and contactor.

6. Check Suction Temperature Sensor 6. Compare board sensor reading against
actual suction line temperature.

7. Check Suction Pressure Transducer 7. Compare pressure reading against gauges.

41

Diagnostics

Beacon II Troubleshooting Guide (continued)

PROBLEM Step ACTION ITEM IF OK IF NOT OK

1. 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 E6, 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 condenser 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 E6) next step • Correct per steps in E6

• 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

7. Demand Cooling (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

42

Diagnostics

Beacon II Troubleshooting Guide (continued)

PROBLEM Step ACTION ITEM IF OK IF NOT OK

E9 Multi-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
successful connection) (multi-out not wired to multi-in terminals) next step

3. Check for broken communication wiring

Break in the designated
lines will cause errors
as follows:

[With SMART
Controller II]

Line # SMART Cooler or Freezer
1 +COMM+ E9
2 +COMM+ no error

SMART II

in out

Cooler or Freezer

in out

1
2

PROBLEM Step ACTION ITEM IF OK IF NOT OK

88888 LED display 1. Check grounding of board

2. Check Voltage to Evaporator Transformer 1. Check field wiring for breaks or shorts

(power is below 18V and 3. Check Transformer Secondary Output Volts Go to 2. Replace if necessary

appears at initial power) 4. Check Voltage at Control Board (24 and C) next step 3. Check factory wiring and connections

5. Check Voltage at SMART Controller II 4. Check field wiring from board

1. Check grounding of board

2. 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 3. 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.

4. Replace defective contactor (holding coil)

43

Diagnostics

Beacon II Troubleshooting Guide (continued)

PROBLEM Step ACTION ITEM IF OK IF NOT OK

1. Check system operation: Is it running? 1. Check power to condensing unit
Check position of Service Mode switches
Check compressor overloads and contactor

2. Check system charge 2. Add or remove refrigerant to proper charge

3. Check for proper operating superheat 3. Check EEV operation
Check control board EEV signal
Check suction sensor and transducer

4. Check for high superheat and EEV wide open 4. Check EEV inlet screen and restrictions
Check liquid line sizing
Check head pressure controls

5. Check Low Pressure Safety Switch 5. Check everything for E7 LPS above
Cannot get to 6. Compare equipment capacity with requirements Go to 6. Add or replace with more/larger equipment
box temperature 7. Check box temperature setpoint next step 7. Correct setpoint to proper value

8. Check compressor performance 8. Check compressor application limitations
Check integrity of compressor operation
(impaired, worn or damaged components)

9. Check condenser coil for dirt/debris 9. Clean condenser coil

10. Check condenser for non-condensables 10. Remove all non-condensables

11. Check condenser fan operation 11. Replace/repair fan blade, motor, cycling
switch or make corrective adjustments.

12. Check for correct refrigerant type 12. Compare board setpoint and refrigerant

13. Check for iced evaporator coil 13. Defrost coil and check defrost cycle (see E2)
settings/setpoints and defrost sensor

14. Check defrost parameters 14. Correct defrost setpoints in program
(frequency and termination of defrosts)

15. Check superheat setpoint (too high?) 15. Correct setpoint for more cooling surface

16. Check display values (°F or °C) 16. Correct setpoint for proper display values

Placing system into SERVICE MODE Terminating SERVICE MODE
(BOARDS ONLY) (BOARDS ONLY)

1. Use Remote Service Switch in condensing unit 1. Must terminate using same switch

2. Pressing “Force Service” button board* twice 2. Press “Clear” button on board

3. Connection between “Ser” and “C” on board* 3. Open connection between “Ser” and “C”
(all are wired in parallel; all will activate mode) (Note: If multiple switches were placed in Service
Service Mode *ONLY Master board on multiple evaporator systems Mode, all must be “open” to terminate the mode.)
(SEr is displayed)

(with Beacon II Smart Controller) (with Beacon II Smart Controller)

1. Use Remote Service Switch in condensing unit 1. Must terminate using same switch

2. Connection between “Ser” and “C” on board* 2. Open connection between “Ser” and “C”

3. From program menu of Beacon II Smart Controller, 3. From program menu of Beacon II Smart Controller,
Change SERVICE setpoint to “On”. Change SERVICE setpoint to “Off”
[all are wired in parallel; any/all will activate mode.] [Note: If multiple switches were placed in Service
*ONLY Master board on multiple evaporator systems Mode, all must be “open” to terminate the mode.)

44

Parts

Table 7. Condensing Unit Parts List

CONDENSING UNITS

PART DESCRIPTION

Compressor - Freezer ZF15K4E ZF13K4E ZF15K4E
Compressor - Cooler RST43C1E CS10K6E CS10K6E
Disconnect Fuses 22510113 22510112 22510113
Start Relay - Cooler 1007647 1007660
Start Capacitor - Cooler 7076959 7076957
Run Capacitor - Cooler 7076950 7075858
Compressor Contactor - Cooler 2254304
Compressor Contactor - Freezer 2255845
Condenser Fan Motor 25399101
Condenser Fan Blade 22999901
Fan Guard 23104401
Head Pressure Valve:
Cooler 29317401
Freezer 29317303 29317304 29317304
High Pressure Control 28903201
Low Pressure Control - Freezer 2891402
Low Pressure Control - Cooler 2890099
Low Pressure Time Delay 22536801
Crankcase Htr - Freezer 24701301
Fan Cycling Thermostat 2890019
Ambient Temperature Sensor* 88904902
Evaporator Fuses - Freezer 22510002
Evaporator Fuses - Cooler 22510001
Fan Relay (R3, R4 - 240v) 22505201
Fan Relay (R1, R2 - 24v) 22521901
Terminal Block 2251423

MAC5X

MAC7X

MAC8X

Table 8. Evaporator Parts List

PART DESCRIPTION PART NUMBER EVAPORATORS

Fan Motor 25317701 ALL
Fan Blade 5140C ALL
Fan Guard 37000701 ALL
24752002 LET090BEB2N6MK
Defrost Heater 24752003 LET120BEB2N6MK
24752004 LET160BEB2N6MK
24752202 LET090BEB2N6MK
Defrost Pan Heater 24752203 LET120BEB2N6MK
24752204 LET160BEB2N6MK
29326201 ADT070BEB2N6MK
29326201 LET090BEB2N6MK
29326201 ADT052BEB2N6MK
29326201 LET120BEB2N6MK
Electric Expansion Valve 29326201 ADT052BEB2N6MK
29326201 LET160BEB2N6MK
29326201 ADT104BEB2N6MK
29326201 LET120BEB2N6MK
29326201 ADT104BEB2N6MK
29326201 LET160BEB2N6MK
Expansion Valve Harness 22592101 ALL
Beacon II Control Board 28910101 ALL
Temperature Sensor Kit* 89904902 ALL
Transformer (240/24 - 40 VA) 22529602 ALL
Pressure Transducer 28911201 ALL
Pressure Transducer Harness 22515101 ALL

*Only the sensor with white leads is shipped as a Service Replacement Part.

45

Beacon II Smart Controller

Table 9. Beacon II Smart Controller Parts List

PART
PART DESCRIPTION NUMBER

Beacon II Smart Controller 89704301
*Smart Controller Software Package 89704101

*Smart Controller Software Package is sold separately.

Table 10. Beacon II Operational Limits

OPERATIONAL LIMITS

Voltage 18 VAC to 30 VAC
Controlling Box Temp. Range -30°F to 70°F
Box Temp. Dead-Band +/-1°F
Cold Ambient Limits Start and operate to -20°F

46

Startup Checklist

Date of Start-up
Store Address

CONDENSING UNIT
MODEL #
SERIAL #
COOLER 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
YES

• Check compressor amps for COOLER and
FREEZER compressors. Should match
nameplate.
YES NO

PIPING

• Is suction line trapped at the cooler?
YES NO

• Is suction line trapped at the freezer?
YES NO

DRAIN LINES

• Are drain lines sloped properly?
YES NO

• Is drain line trapped outside the cooler?
YES NO

• Is drain line trapped outside the freezer?
YES NO

• Is heat tape wrapped along entire length of
the drain line in the Freezer?
YES NO

• Is heat tape plugged in and heating the drain
line?
YES NO

INSULATION

• Are liquid lines fully insulated?
YES NO

• Are suction lines fully insulated?
YES NO

SETTINGS

• Check Beacon II 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
Refrigerant Type R404A
Box Setpoint Temp. 35°F.
Superheat 8°F.
No. of Defrost/Day 2
Defrost End Temp. 50°F.

SYSTEM CHECKS

• Check compressor superheat for the
COOLER (Should be between 20°F. & 30°F.)
YES NO

• Check compressor superheat for the
FREEZER (Should be between 20°F. & 30°F.)
YES NO

• Force unit into a defrost check heater amps.
Should match nameplate amps.
YES NO

• Check LPS time delay relays. Should be
set at 1 minute for both the COOLER and
FREEZER.
YES NO

• Check low pressure switch on FREEZER. Should be set
at 0 psig Cut-out/10 psig Cut-in.

YES NO

• Did FREEZER and COOLER cycle off on LPS at set­point temperature?

YES NO

• Is the sight glass free of bubbles?

YES NO

• Are the COOLER and FREEZER fans at proper speeds?

YES NO

• Check system for refrigerant leaks. Are there any leaks
on the COOLER, FREEZER, CONDENSING UNIT or
INTERCONNECTING PIPING?

YES NO

• Check system piping for unusual vibration or
noise. Is there any unusual vibration or noise on the
COOLER, FREEZER, CONDENSING UNIT or
INTERCONNECTING PIPING?

YES NO

• Start the FREEZER only. Does the compressor start and
evaporator fans run for this FREEZER?

YES NO

47

Startup Checklist

RECORD

OUTDOOR TEMPERATURE ______°F.

SYSTEM VOLTAGE ______Volts ______PH ______Hz

Cooler compressor amps ______L1 ______L2 ______L3

Freezer compressor amps ______L1 ______L2 ______L3

Cooler discharge pressure ______PSIG

Freezer discharge pressure ______PSIG

Cooler suction pressure ______PSIG

Freezer suction pressure ______PSIG

Cooler suction temperature ______°F.

Freezer suction temperature ______°F.

Cooler refrigerant charge ______lbs.

Freezer refrigerant charge ______lbs.

Cooler compressor superheat ______°F.

Freezer compressor superheat ______°F.

Cooler evaporator superheat ______°F.

Freezer evaporator superheat ______°F.

Cooler discharge temperature ______°F.

Freezer discharge temperature ______°F.

48

Wiring Diagrams

Diagram 1. Low Profile Evaporator Wiring

49

Diagram 2. MAC Unit Wiring

Wiring Diagrams

50

COOLER

FREEZER

Diagram 3. 24 Volt Connection Wiring With Smart Controller

Wiring Diagrams

Diagram 3. 24 Volt Connection Wiring with Smart Controller

51

For Warranty Service 24 Hours a Day, 7 Days a Week

A Brand of Heatcraft Refrigeration Products LLC

2175 West Park Place Blvd. • Stone Mountain, GA 30087

770.465.5600 • Fax: [phone]
www.heatcraftrpd.com

Call Toll Free (877) HTCRAFT (877-482-7238)

Warranty Coverage

Standard Parts & Labor - 2 Years

Beacon Parts (TXV, Sensors, Board, Smart Controller) - 3 Years

Compressor Part - 5 Years

Due to ongoing efforts in product improvement, specifications are subject to change without notice.

52