Honeywell PCR-300 User's Manual
Contents
1. 1 relay with N O contact 8 A 5A PCR 300RC 230 V AC resistive load fan control Two step Opto bidirectional triode thyristor 250 V AC max load 80mA 0 5K internal 1 digit at 25 C 0 C to 50 C 30 to 85 R H excluding dew 20 C to 80 C Non volatile memory EEPROM Clock Back up battery approx 1 month power reserve PCR 300 RC only DIP switch under display cover off 4 C on 18 C PTC 2 sensors T1 Control signal to compressor relay T2 Control signal to defrost limitation and fan control 2 5m 30 C to 80 C not fixed 40 C to 80 C fixed 2 LxWxH 85 x 70 x 61 mm ABS plastic self extinguishing UL 94 VO Housing IP 20 front panel IP 52 Class of protection 2 250V 10 A screw type terminal strips with wire protection tightening torque 0 6 Nm Max core cross section 1 5 mm Approx 420 g inc 2 sensors Only operate the unit in dry places Errors in the technical data are excepted We reserve the right to make changes without prior notice 18 EC Declaration of Conformity as defined in the EMC Directives 89 336 EEC and the EC Low Voltage Directives 73 23 EEC Product FLICA electronic coldstore control Model designation PRC 300 PCR 300RC has been developed designed and manufactured in accordance with the EC Standards listed above The following harmonized Standards have been applied EN 50081 1 1991 Part 1 for2. General conditions for the supply of goods and services issued by the ZVEI German Central Association for the Electrotechnical Industry shall apply Before disposing of the packaging please check it for loose functional parts and information leaflets So that we can process warranty claims please give an exact description of the defect with a photograph if appropriate and state the model designation of the unit Please keep these operating instructions at the place where the equipment is used 2 General instructions Work on the electrical devices and switching equipment may only be carried out by appropriately qualified personnel The relevant safety and environmental regulations must be followed FLICA equipment is free from PCBs PCTs asbestos formaldehyde cadmium and water repelling substances The design of the equipment has taken into account the Standards EN 50081 1 2 emitted interference EN 50082 1 immunity to interference EN 60335 1 electrical safety IEC 695 2 1 to 2 3 fire resistance glow wire test Safety tests have been performed in the factory on all equipment in accordance with EN 60335 1 DIN VDE 0700 T500 3 Use and Function 3 1 Use for the purpose intended e This controller is designed to control ambient and media temperatures in cold stores and refrigeration systems and to control existing defrost equipment for one refrigeration circuit in each case A e The controller must
3. Program memory data loss The preset values will be used as an emergency program The setpoint value will be set to 4 or 18 C depending on the selection of DIP switch 1 AL2 Limit value setpoint value E03 at sensor T1 exceeded and delay time E04 elapsed AL3 The sonsor temperature at sensor T1 is above 50 C or below 55 C AL4 The specified setpoint value is outside the limits E12 and E13 AL5 Cold store temperature sensor T1 short circuit or break in wiring Compressor switches as a function of parameter E17 AL6 Evaporator temperature sensor T2 short circuit or break in wiring Safety times are used for the fan run on function the fan is controlled with the compressor by the evaporator fan control E11 automatically switching from 3 to 1 After sensor T2 has been repaired E11 must be reset manually from 1 to 3 AL7 For PCR 300RC only Real time clock faulty switching over to interval defrosting interval 4 hours Clearing alarm Press the 4 key All alarm messages with the exception of AL2 are also reset by switching off the operating voltage AL2 can only be reset using the key 10 Problem solving Fault Cause Remedy Evaporator fan does not Evaporator Refit switch on during sensor T2 has sensor cooling when the fallen out of programmed setting the fins of parameter E11 is set to position 3 fan run on For PCR 300RC only Bac
4. by EB and a 2 digit number e g E01 e The input parameters are grouped together in two programming levels 10 Access the first programming level by pressing the 4 and keys at the same time for 5 seconds Ww Then use the 4 and Cj keys to access the parameters to be changed Access the second programming level by pressing the G and and keys simultaneously for 5 seconds To exit from the programming levels and save the data press the key after the last input parameter If no key is pressed in either of the programming levels for 10 minutes this mode will be exited without the data being saved Do not display altered parameter data before saving the data as it would be reversed to its original value in the process 6 4 Setting the cold store temperature Press and hold down the key Adjust the setpoint for the value in question using the 4 or key Adjustment is possible within the limits of the input parameters E12 and E13 The factory setting is 4 C 6 5 Changing the cold store temperature difference defrost cycle and alarm tempera ture Access to the first programming level Press and hold down the and P keys at the same time for approx 5 seconds E01 appears in the display for PCR 300 and E00 for PCR 300RC Setting Press and hold down the s key Adjust the setpoint value to the desired figure using the or key Input parameters and input r
5. installations do not thaw DIP switch 1 left Pos off bottom Setpoint value at 4 C for emergency operation Advisable for chilled storage Preset value Pos on top Setpoint value at 18 C for emergency operation Advisable for deepfreezers For PCR 300 RC only The back up battery must be switched on when the controller is started up so that the real time clock keeps operating if there is a power failure Activation of the back up battery DIP switch 2 right Pos off bottom Battery switched off when controller is stored or in transit The battery is switched off when the controller is delivered exhaustive discharge monitoring Pos on top Battery activated 8 Note It takes approximately 24 hours for the battery to achieve its full back up capacity The battery will provide cover for a power failure of approximately 1 month Front view of controller QOOOCDOOO00000O PCR 300 JAO SET OOOO OOQOOOQOOQOOOQO 6 1 Switching on the operating voltage The controller is started by means of a control switch provided by the customer The first time the controller is started pre programmed setting values are used which at later point can be adapted for individual requirements If alarm AL 2 temperature in refrigerated chamber too high or too low is displayed when the controller is switched on this can be cleared by pre
6. the trades sector emitted interference EN 50081 2 1993 Part 1 for the industrial sector emitted interference EN 50082 1 1991 Part 1 for the trades sector immunity to interference EN 60335 1 1993 03 09 IEC 335 1 1976 ed 2 Electrical safety part 1 general requirements EN 60730 1 1992 12 09 IEC 730 1 1986 ed 1 Automatic electronic controls Full technical documentation is available Operating instructions for the device are provided Mosbach March 22 1999 Honeywell Flica Honeywell AG Hardhofweg ter D 74821 Mosbach CA i V Dr Osthues R D Production Manager Honeywell Automation and Control Solutions Honeywell GmbH Hardhofweg 74821 Mosbach Germany Phone 49 0 62 61 81 475 Fax 49 0 62 61 81 461 E Mail Cooling Mosbach honeywell com www honeywell cooling com Manufactured for and on behalf of the Environment and Combustion Controls Division of Honeywell Technologies S rl Ecublens Route du Bois 37 Switzerland by its autorised representative Honeywell GmbH
7. water or moisture Risk of malfunction and short circuit Only use the unit when it is adjusted to normal ambient temperature 15 to 30 C Extreme changes in temperature in combination with high atmospheric humidity may lead to the formation of condensed water e Even if the control circuit voltage is switched off high voltage may still be applied to the unit For this reason isolate all electric circuits before starting any service work Never expose the unit to excessive heat dust and vibrations Avoid knocks and pressure loads If the housing is damaged there is a risk of an electric shock causing death or injury If the unit cannot be operated without the risk of danger it must be taken out of service and precautions taken so that it cannot be switched on again unintentionally This applies in particular if 2 The housing has damage which is visible 2 the unit is no longer operational or 2 it has been stored for a long time in unfavourable conditions The unit must not be opened If it is thought that the unit may be defective send it back to the dealer or manufacturer with a precise description of the fault 4 2 Safety precautions All electromagnetic loads solenoid valves contactors alarm horns motors should be interference suppressed directly at the coil with RC elements Please note the maximum contact rating of the relays and terminals If this is not observed there is a risk that the contacts m
8. Honeywell EN1H 1924GE23 R1207 EB PCR 04 PCR 300 PCR 300 RC Installation and Operating Instructions Electronic refrigeration control TABLE OF CONTENTS 11 Unpacking the unit and conditions of use 12 General instructions 13 Use and function 3 1 Use for the purpose intended 3 2 Function 14 Safety 4 1 Sources of danger 4 2 Safety precautions 15 Installation and commissioning 5 1 Mechanical installation 5 2 Electrical installation 5 3 Setting the DIP switch for the emergency setpoint and clock back up battery 16 Operating of the controller 6 1 Switching on the operating voltage 6 2 Display 6 3 Key functions 6 4 Adjusting the cold store temperature 6 5 Changing the cold store temperature difference defrost cycle and alarm temperature 6 6 Setting the time PCR 300RC only 6 7 Manual defrost 17 Programming 7 1 Input parameters and ranges 7 2 Sensor calibration parameters E 15 and E 16 18 Maintenance 19 Alarm messages 10 Problem solving 11 Conditions of warranty 12 Technical data au vi up A BW WwW WwW wW 1 Unpacking the unit and conditions of use Before and when unpacking the unit make a visual inspection to identify any possible damage which may have occurred during transportation Please look for loose parts dents scratches etc Report any damage immediately to the freight company Please see Conditions if damage has occurred In other cases the latest edition of the
9. amming mode Press the 4 key after the last level has been entered 6 6 Setting the time PCR 300RC only e Press and hold down the and 4 keys at the same time for approx 5 seconds to access the first programming level Display E00 e Setting Press and hold down the 6 key and change the time to the current time using the p or key increments of 10 minutes Display Setting range Preset E00 Time 00 0 to 23 5 hours 12 0 hours Exiting programming mode Press the P key several times 12 6 7 Manual defrosting Press and hold down the key for 5 seconds The manual defrosting process will be initiated Access to the second programming level e Press and hold down the 4 and keys at the same time for approx 5 seconds Display E01 for PCR 300 E00 for PCR 300RC Use 4 or key to select parameters Setting Press and hold down the set key Adjust the setpoint value to the desired figure using the 4 or key e Do not display altered parameter data before saving the data as it would be reversed to its original value in the process 7 1 Input parameters and input ranges Parameter in Display Setting range Preset gore sa and Gp or E00 Time only for PCR 300RC 00 0 to 23 5 hours 12 0 hours E01 Cold store temp difference 1 to 20 K 2K E02 Time between 2 defrost cycles 1 to 24 hours 8h Once the controller has been switched on de
10. anges Display Setting range Preset E00 Time for PCR 300RC only 0 00 to 23 5 12 0 see section 6 6 E01 Cold store temp difference 1 to 20K 2K E02 Time between 2 defrost cycles 1 to 24h 8 hours E03 Alarm temperature difference 50 Kto 50K 20K If the set temperature difference E03 is negative an alarm is given if it is too cold in the refrigerated area e g E03 10 K cold store setpoint 18 C alarm at 28 C in refrigerated area If the set temperature difference E03 is positive the alarm is given if it is too warm in the refrigerated area e g E03 10 K cold store setpoint value 18 C alarm at 8 C in the refrigerated area Attention any change of the cold store setpoint valve changes also the alarm temperature If E03 is set to 0 no alarm will be given PCR 300RC only E2 5 5st defrost time none 00 1 to 23 5 hours 19 0 hours 00 1 to 23 5 hours none E2 1 1st defrost time none 00 1 to 23 5 hours none E2 2 2st defrost time none 00 1 to 23 5 hours 01 0 hours E2 3 3st defrost time none 00 1 to 23 5 hours 07 0 hours E2 4 4st defrost time none 00 1 to 23 5 hours _ 13 0 hours E2 6 6st defrost time none The time is entered in increments of 10 minutes in each case Caution The times must be entered in ascending order Exiting progr
11. ay pit or stick with the result that the refrigeration system will not operate correctly and the refrigerated items may be damaged Sensor leads are to be routed separately from mains voltage wires The clearance should be at least 5 cm Sensor leads must not be routed in multiple cables with other leads carrying mains voltage otherwise the system may malfunction Tighten the terminals carefully excessive strain will result in damage to the controller PCR 300RC Set DIP switch 2 to off if the controller is going to be out of service for more than 3 months and when the controller is shipped This is to prevent damage occurring to the back up battery 5 1 Mechanical installation 4 Din standard modular housings to be mounted on a standard rail a housing with 2 mounting tabs open out the lateral mounting tabs clip the unit on the 35 mm rail and press tabs in again b housings with 1 mounting tab put housing on the upper 35 mm rail Clip the unit on the 35 mm rail lower tab clips on the rail automatically To remove the unit from the rail press in lower mounting tab with a screw driver lift unit e Mounting of sensor e Use a cable clamp to secure sensor T1 in a suitable position e Secure evaporator sensor T2 in the evaporator fin core at the point where it is suspected icing is the greatest It is advisable to use a point in the lower third of the finned evaporator 5 2 Electrical installation 4 CAUTION The mains
12. delay fan 0 to 500 secs 30 secs E11 Evaporator fan control 1 2 or 3 1 1 Fan with compressor 2 Continuous fan operation except during defrosting 3 Fan run on If there is an undershoot in the cold store temperature the fan is switched on by evaporator sensor T2 The fan is switched off again once the desired cold store temperature is attained or exceeded E12 Minimum permissible 55 C to E13 55 C cold store temp E13 Maximum permissible E12 to 50 C 50 C cold store temp E14 Display during defrosting 1 2 or 3 1 1 dEF in display 2 Current cold store temperature in display 3 Retaining temperature in display when defrosting is initiated until the current cold store temperature reaches the retained value again This is for a maxi mum of 15 minutes after the end of defrosting Evaporator drainage time E09 and time delay fan E10 are not respected at hot gas defrost mode E06 2 14 E15 Sensor calibration T1 5 to 5 K 0K cold store E16 Sensor calibration T2 5 to 5 K OK evaporator E17 Operation of 0 Relay de energizes 2 compressor relay 1 Relay is perma if cold store sensor T1 nently engergized is defective 2 Alternately ener gized de ener gized according to time set in E18 and E19 E18 On time at E17 1 to 99 mins 15 mins E19 Off time at E17 1 to 99 mins 15 mins To exit from the programming m
13. frosting occurs for the first time at the end of the first time interval After defrosting has been initiated manually the next time defrosting takes place is after a complete time interval has elapsed If the time interval between two defrost cycles is changed when the system is in operation the new time interval will not be applied until after the next time defrosting has occurred For PCR 300RC only E2 1 1st defrost time none 00 1 to 23 5 hours none E2 2 2st defrost time none 00 1 to 23 5 hours 01 0 hours E2 3 3st defrost time none 00 1 to 23 5 hours 07 0 hours E2 4 4st defrost time none 00 1 to 23 5 hours 13 0 hours E2 5 5st defrost time none 00 1 to 23 5 hours 19 0 hours E2 6 6st defrost time none 00 1 to 23 5 hours none 13 The time is entered in increments of 10 minutes in each case Important The times must be entered in ascending order E03 Alarm temperature difference 50Kto 50K 20K E04 Delay time Alarm 0 to 99 mins 10 mins E05 Compressor start up delay Oto 15 mins 5 mins E06 Defrost type 1or2 1 1 Electrical compressor off 2 Hot gas compressor on E07 Defrost limit temperature 0 to 50 C 8 C E08 Defrost time limit 1 to 99 mins 25 mins E09 Drainage time evaporator 0 to 99 mins 3 mins E10 Time
14. k up battery Switch on The real time clock is switched off back up stops or indicates the battery wrong time in the event see of a power failure Section 5 3 11 Warranty conditions e Warranty is provided for a period of 12 months starting at the date the item was delivered Proof of this should be furnished in the form of a delivery note or invoice e All functional faults caused by poor workmanship or faulty materials will be repaired free of charge during the warranty period More extensive claims in particular for consequential damage are excluded Damage or malfunctioning caused by the equipment being handled incorrectly or by non compliance with the operating instructions shall not be covered by the warranty The warranty shall be invalidated if any work is carried out on the appliance Mains voltage frequency 230 V AC 10 50 60 Hz Rated wattage Display Resolution Measuring range Outputs Control response Alarm output Display accuracy Operating conditions Storage temperature Data back up Emergency setpoint selection Sensor type Number Cable length Range where cable can be used Accuracy Housing Protective rating Terminals Weight 2 5 watts 3 digit 7 segment red LED 14 2 mm 1K 55 to 50 C 1 relay with changeover contact 8 A 230 V AC resistive load cooling 1 relay with N O contact 8A 5A PCR 300RC 230 V AC resistive load defrost heating
15. maximum tested sensor cable length is 50 m with a minimum cross section of 2 x 0 75 mm Solder the extension cable to the sensor cable to prevent contact resistances It is advisable to use shielded sensor extension cables All shields must be routed at the side of the controller to one earth protective potential The extension cable shield must not be connected on the sensor side otherwise bonding currents may occur via the shielding The controllers are designed respecting the highest degree of immunity to interference If the local interference level exceeds the immunity data might get lost AL1 in display and the controller switches to the preprogrammed setting values This is not a mulfunction of the controller In such cases the means to suppress interference have to be improved RC elements shielded lines 5 3 Setting the DIP switch for the emergency setpoint and the clock back up battery on off DIP Switch Carefully lift the housing cover off the side using your fingers e Selection of the emergency setpoint for the cold store temperature This will be activated if the data in the memory is lost and alarm AL1 is activated This sets all program parameters to the preset value The cold store temperature setpoint can be preset to 4 C or 18 C as desired This ensures that chilling systems with temperatures above zero do not freeze and deepfreeze
16. not be used as a safety cut out device or excess temperature limiter If the controller is used for purposes other than those stated here it shall not be considered to be use for the purpose intended e Only connect sensors supplied with the unit If a replacement sen sor is required only use sensors of the same type part no H61007 e The controller is not intended for use in vehicles because the possible operating voltage ranges interference level and environmental operating conditions exceed the limits for which the controller can be used e Please take the application limits into account see Technical Data chapter 12 3 2 Function The PCR 300 is a microprocessor controlled cold store control for refrigeration and deepfreeze systems with a modular housing for installation on 35 mm standard rails e Compressor control dependent upon cold store temperature with delayed start up e Evaporator fan control 2 Fan either in combination with compressor or 2 operating continuously or 2 switched via the evaporator thermostat e Defrost control limited thermostatically either for electrical heating or hot gas defrosting e Alarm output Defrosting is initiated via programmable intervals of time max 24 day The PCR 300 RC is provided with a real time clock with a back up battery for defrost control A maximum of six times per day can be programmed 4 1 Sources of danger e Caution Mains voltage e Never expose the unit to
17. ode Press the 4 key after inputting the last level 7 2 Sensor calibration parameters E15 and E16 The cold store and evaporator sensors can be calibrated Note How to proceed An additional resistance of 7 Q in each case caused by the extension of the sensor cable results in a change in the temperature display by 1K Measure the temperature at the sensor concerned with a calibrated thermometer or submerge the sensor in well mixed iced water 0 C Compare the measured temperature with the temperature displayed on the unit display If the measured temperature is lower than the one displayed set the negative difference as the programming value e g 2 K If the measured temperature is higher than the one displayed set the positive difference as the programming value e g 2 K The temperature display is then corrected by the set value The controller does not require any maintenance It does not have any fuses so if brief voltage spikes occur the refrigeration system will not stop operating for a prolonged period Once the disturbance has passed the controller will automatically start up again Cleaning the housing Only a dry anti static cloth may be used to wipe clean all plastic parts Do not use water or cleaning agents containing solvents If an alarm occurs the alarm output will be activated and on the display a code will alternate with the cold store temperature Display Meaning AL1
18. ssing the 4 key 6 2 Display During normal operation the current cold store temperature is displayed It is measured with cold store sensor T1 In the event of an alarm the most recent alarm message e g AL1 and the cold store temperature are displayed alternately 9 Three spot indicators show the switching status of the relays during operation Pos 1 On Compressor relay on Off Compressor relay off Flashes Compressor start up delay E05 active Pos 2 On Evaporator fan relay on Off Evaporator fan relay off Pos 3 On Defrost relay on Off Defrost relay off Flashes Drain time E09 is running 6 3 Key functions Pos 1 Pos 2 Pos 3 RBS BEE Never operate the keys with sharp objects screwdriver or similar Display of setpoint Press and hold down key temperature Clear alarm Press 4 key messages If the sensor is faulty switch mains voltage ON OFF Evaporator Press and 5 keys in sequence temperature and hold both down display Manual defrost Press key for 5 secs initiation Display of time Press and set keys in until the next sequence and hold both down defrost Display in hours and minutes Display limit Press key value for excess temperature alarm cold store sensor T1 e Change input values by using the P and keys with the set key pressed down e Input parameters e g the switching difference are indicated
19. voltage and system frequency must be the same as the nominal values on the device s rating plate Work on electrical systems must be performed by qualified personnel Relevant local safety regulations must be observed Wiring diagram Sensor Sensor T1 T2 eseeseeee ee o8O 1234567 8 9 101112 y Mains 230VAC A 50 60Hz 2 5 Watt PCR 300 RC 8A zsovac NAG Aarm aC 131415161718 19 2021 22 2324 009090900000099 L V Ev DEF N o Alarm PE Terminal Description 1 2 T1 Cold store sensor 3 4 T2 Evaporator sensor 10 12 Mains Power supply 13 15 V Compressor contactor cooling 17 18 Ev Evaporator fan contactor 20 21 Alarm Remote alarm indicator indicator lamp or contactor with RC element 23 24 Def Defrost heating contactor or hot gas valve i The unit is equipped with an opto decoupled electronic alarm output Take note of the alarm output limit values Supply voltage Max 250 V AC Minimum load 40 mA Maximum load 80 mA If an inductive load contactor or horn is connected connect an RC element directly at its coil Instructions Pay attention to the contact loading of the relay 8A 5A resistive load 2A 1A inductive load As a general rule contactors are recommended The
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