Heatcraft Refrigeration Products H-IM-79D User Manual
™
H-IM-79D February, 2004
Replaces H-IM-79C (12/03)
Part Number 25001401
Installation & Operation
Manual
Index
Beacon II Board layout........................................................................................................3
Installation Tips ...................................................................................................................4
Brazing
Power Supply
Wiring ..............................................................................................................................5
Multiple Evaporator Configuration .......................................................................................6
Box Temperature control setting
Leak Testing
Refrigerant Charging...........................................................................................................7
Start Up Operation ......................................................................................................... 8-11
Operating Mode Display.................................................................................................... 11
Programming and reviewing settings and changes.......................................................12-13
Monitoring Items ...............................................................................................................14
Locking Beacon II board....................................................................................................15
Status Indicator LED ....................................................................................................15-16
Low Ambient Operation .....................................................................................................16
Pumpdown...................................................................................................................16-17
Defrost .......................................................................................................................17-18
Alarms ............................................................................................................................18
Error Indicator
Evaporator fans shutdown by operators ............................................................................19
Checking Operation of Expansion valve .......................................................................20-21
Power Failures
Service Mode
Spare Sensor Terminals
Checking sensors .............................................................................................................21
Program review button
Select button
Enter button
Monitor button
Force Defrost button
Force Service button
Reset Time button
Clear/Test button
Sensor resistance/temperature table
System Defaults................................................................................................................22
Parts List
Operational limits ..............................................................................................................23
Expansion V alve Capacity
Diagnostics ..................................................................................................................24-27
Wiring diagrams ...........................................................................................................28-33
Preventive Maintenance....................................................................................................34
Service Record ............................................................................................................35-36
2
Heater
Relay
Beacon II Board Layout
BEACON II BOARD
Fan
Relay
LED
Display
Room
Sensor
Defrost
Sensor
Expansion
Valve
Connection
Selection
Buttons
Suction
Sensor
Suction
Pressure
© 2004, Heatcraft Refrigeration Products LLC
24V
Terminal
Block
3
Installation
Installation Tips
• Use a minimum 18 gauge wire for all low voltage connections.
• 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.
Note: On multiple evaporators, since a transformer is in each evaporator, the voltage
tap must be set on each evaporator.
• Refer to wiring schematic shipped on units for unit wiring. Schematics in this Installation
& Operation Manual are typical wiring schematics only.
• Program ALL slave evaporators as SLAVES.
• Evaporators are shipped from our factory with a preset box setpoint temperature of 35°F
for air defrost and -10°F for electric defrost. If your box setpoint temperature
requirements are different this must be set using directions outlined under “Room
Temperature Control”.
• The suction line temperature sensor MUST be removed from the suction line before
brazing the suction tubing. The sensor MUST then be reinstalled on the suction line
after brazing is completed and the tubing has cooled. Insulate when finished.
• The low pressure switch time delay relay, located in the condensing unit, must be set to
1 minute.
• If electrical power will be connected prior to evacuation and charging of system, unplug
electric expansion valve from board until system is ready to be evacuated, leak tested
and charged.
• Some systems may require the crankcase heater be energized 24 hours prior to startup. The Beacon should be de-energized for this period by placing it in the SERVICE
MODE. This is done by pressing the “FORCE SERVICE” button twice. To start the
system cooling, press the “CLEAR” button.
• Room sensors must be left connected on ALL evaporators.
• A pressure transducer is installed on the evaporator. Do not leak test system above 150
PSI or damage to transducer could occur. If leak testing must be greater than 150 psig,
disconnect the transducer from he suction header and reconnect after testing is
complete.
CONDENSING UNIT
The condensing unit control panel contains the relays, contactors, time delay 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 sufficient clearances around unit for adequate air flow and access.
EVAPORATOR UNIT
The evaporator contains the Beacon II controller, electric expansion valve, pressure
transducer, distributor, orifice, transformer and three sensors. These components are all
factory mounted and wired. The three sensors are factory mounted and provide input to the
controller from the following: defrost temp., suction temp., room temp.
Each evaporator unit must be installed using proper refrigeration practices and codes.
Make sure the piping is correctly sized and properly routed. It is highly recommended that
the liquid and suction lines be insulated. There must also be good clearance around unit.
See Heatcraft Refrigeration Installation & Operation Manual for more details.
4
Brazing
Refrigerant Line Brazing (
The electric expansion valve and the suction temperature sensor on the suction line are
factory installed. Care must be taken when brazing these lines at the evaporator.
a temperature may destroy these components. Heat absorbing compounds or “wet
rags” must be used to protect the electric expansion valve when brazing the
refrigerant line connections. The suction line sensor should be removed before
brazing.
CAUTION
)
Too high
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.
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.
This must be done for all the
On Beacon II systems the main power for the evaporator can be supplied separately from
the power supply of the condensing unit. All wiring, however, must comply with local
electrical codes.
WIRING
Wiring between the condensing unit and the unit cooler(s) will be as follows (see wiring
diagrams):
• High voltage - There may be high voltage on the defrost heater relay and the fan relay.
The evaporator may also be connected to a separate power supply from the condensing
unit. See unit cooler spec. plate for ampacity.
• Low voltage - 24V Class II control circuit. A total of five low voltage leads are required to
connect the condensing unit to the evaporator. (See wiring diagram.) Two of these leads
are for connecting the outdoor temperature sensor. The other three leads are for
connecting the compressor relay, service relay and 24V Common inputs.
wiring must be run separate from the line voltage wiring.
• Low voltage wiring must be 18 gauge minimum. For low voltage wiring, maximum
distances are:
Condensing unit to Master evaporator 500 ft.
Between evaporators 500 ft.
Smart Controller to Master evaporator 1000 ft.
All 24 volt
5
Wiring/Configuration
WIRING (cont’d.)
• Multiple units – The
Connection sequence must follow the
the
• Alarm circuit - The onboard alarm is a dry set of NC contacts which closes to indicate an
alarm. The type and wiring for the alarm is customer specified. Note that the alarm
circuit does not distinguish or indicate what has caused the alarm.
• All wiring must comply with all applicable codes and ordinances.
multi-out
back to the
MULTIPLE EVAPORATOR CONFIGURATION (Master/Slave)
If there are multiple evaporators on a system, the program for each SLAVE evaporator
must be changed to identify it as a SLAVE. To do so, press the “PROGRAM REVIEW”
button repeatedly until “SLA” appears then use the “SELECT” knob to select “YES” then
press “ENTER”. All Beacon II boards are shipped with the factory default as a “MASTER”
evaporator. Place all boards in the “Service” mode while you program the setpoints to avoid
errors and alarms which may cause troubles at startup.
multi-in
multi-in
and
multi-out
terminal in a daisy chain loop.
are the communication connections.
multi-out
terminal to the
multi-in
terminal and
VERY IMPORTANT: This must be done for each slave board.
Up to 4 evaporators can be connected as a master/slave configuration. DO NOT remove
the room sensor from any of the Beacon II boards. This also applies when connected
to the optional Smart Controller.
M
CU
M = Master Evaporator S = Slave Evaporator CU = Condensing Unit
S
S
S
Each Beacon II board power is supplied by a transformer in the evaporator on which it is
mounted. Do not run any 24 VAC wires between Beacon II boards on the evaporators.
6
Box Temp Control Settings
BOX TEMPERATURE CONTROL SETTINGS
• There is an on board room thermostat on the Beacon II board which can be adjusted
to the desired room temperature. The temperature differential is 2° F.
Temperature Differential
When a system is in the cooling mode and the box setpoint is 35°F, the system will
continue to cool until the box temperature gets to 34°F. At this point the compressor will
pumpdown and shut off. The system will restart cooling when the box temperature has
risen to 36°F.
It is important to note that Beacon II has a minimum 2 minute “ON” time and a minimum
4 minute “OFF” time. This means that the system will run in the cooling mode a
minimum of 2 minutes even if the setpoint temperature is met. In applications where the
system is grossly oversized, the box temperature could go below the differential
temperature before the system cycles off.
In the “OFF” cycle the system will be off for a minimum of 4 minutes even if the box
temperature goes above the differential temperature, before cooling will be restarted.
• The on board room thermostat is factory set at 35°F for Air Defrost systems and
-10°F for electric defrost system.
LEAK TESTING
After all lines are connected, the entire system must be leak tested. The complete system
should be pressurized to not more than 150 psig with refrigerant and dry nitrogen. The use
of an electronic type 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.
REFRIGERANT CHARGING
Beacon II systems are shipped standard with a head master valve (Scroll compressor
models has a 100 Psi head master valve. All other models have a 180 Psi head master
valve.) The maximum system refrigerant capacity is the receiver capacity as listed in the
sales literature plus the liquid line capacity. Do not add more refrigerant to the system than
90% of the receiver capacity.
7
Start-Up Operation
Start-Up Operation
SINGLE SYSTEM with 1 EVAPORATOR
• 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 at 1 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.
• Turn power on
• On the evaporator
-Use the “PROGRAM REVIEW ” button to scroll through settings.
-Check “
Electric Defrost R-404A. Change to the refrigerant being used.
-Check
electric defrost –10°F. Change to the desired temperature.
-Review and change other setting if necessary
-See procedures below on how to change settings.
rEF
” (Refrigerant Type). Factory defaults are: Air Defrost R-22,
“bot”
(Box Temperature). Factory defaults are: air defrost 35°F and
CU M
M = Master Evaporator CU= Condensing unit
8
Start-Up Operation
SINGLE SYSTEM with MULTIPLE EVAPORATORS
• 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 at 1 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 ambient. 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.
• Turn power on.
• On MASTER evaporator
- DO NOT REMOVE the Room Sensor from any evaporator
- Use the “PROGRAM REVIEW” button to scroll through settings.
- Check “
defrost R-404A. Change to the refrigerant being used.
- Check
electric defrost –10°F. Change to the desired temperature.
- Review and change other setting if necessary.
- See procedures below on how to change settings.
• On SLAVE evaporators. All Beacon II boards are shipped with the factory default as
a “MASTER” evaporator.
- DO NOT REMOVE the Room Sensor from any evaporator
- Each SLAVE Evaporator must be changed to identify it as a SLAVE. Use the
“PROGRAM REVIEW” button to scroll until
“SELECT” knob to select “YES” then press “ENTER”.
rEF
” (Refrigerant Type). Factory defaults are: air defrost R-22, electric
“bot”
(Box Temperature). Factory defaults are: air defrost 35°F and
“SLA”
appears, then use the
M
CU
M = Master Evaporator S = Slave Evaporator CU = Condensing Unit
S
S
9
S
Start-Up Operation
MULTIPLE SYSTEMS with MULTIPLE EVAPORATORS
(Requires a Smart Controller)
• Check all wiring connections to be sure they are correct and tight.
• On condensing units
- Check setting of Time Delay relay. It should be set at 1 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
ambient. 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.
• Turn power on.
• On MASTER Evaporator
- DO NOT REMOVE the Room Sensor from any evaporator
• On SLAVE evaporators. All Beacon II boards are shipped with the factory default as a
“MASTER” evaporator.
- Each SLAVE evaporator must be changed to identify it as a SLAVE. Use the
“PROGRAM REVIEW” button to scroll until
knob to select “YES” then press “ENTER”.
• Use the Beacon II Smart Controller to set system parameters. See Beacon II Smart
Controller installation instructions for more details.
“SLA”
appears, then use the “SELECT”
MULTIPLE SYSTEM CONNECTION
(See Smart Controller instruction manual for more details.)
SYSTEM 1
SS
M
CU
S
CU
SYSTEM 2 SYSTEM 3
SS
M
S
SMART
CONTROLLER
CU
CU
SS
M
MS
S
SYSTEM 4
S
S
M = Master Evaporator S = Slave Evaporator CU = Condensing Unit
10
Start-Up Operation
INITIAL POWER ON
At the initial application of power to the system, the compressor and the evaporator fans
will be in a 4 minute hold-off cycle and will not start immediately. When there is a call for
COOLING, the expansion valve (EEV) opens, then the compressor is started. The
compressor will then run for a minimum of 2 minutes in the “hold-on” cycle. (This means
that the compressor will run for a minimum of 2 minutes before shutting off even if the box
temperature is met.)
The LED alternately displays
cooling,
the LED will alternately display
On multiple evaporator systems the MASTER evaporator will display
TEMPERATURE
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
dLY
will show while the expansion valve is opening. After the compressor starts
and
Coo
BOX TEMPERATURE
BOX TEMPERATURE
. The SLAVE evaporators will display
and
and
MODE
Coo
of operation. On a call for
.
BOX
Coo
only.
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 four minute “Hold-off” can be bypassed and the system started immediately by
pressing the “Reset” button on the Beacon II board.
OPERATING MODE DISPLAY
oFF
Coo
Pdn
dEF
drn
dLY
tSt
SEr
- Off
- Cooling
- Pumpdown
- Defrost
- Draining
- Delay
- Test
- Service
11
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