Emerson PMAC II User manual

Pulse Modulating Anti-Sweat Control

(PMAC II) Installation and Operation

Manual

026-1501 Rev 6

Emerson

1065 Big Shanty Road NW, Suite 100

Kennesaw, GA 30144, USA

Phone 770-425-2724

Fax: 770 425-9319

Please Note: This manual covers the PMAC II (P/N 851-1000) family of anti-sweat



panels. Information on the PMAC II Solo (P/N 851-1100) anti-sweat controller is



contained in P/N 026-1503, PMAC II Solo Installation and Operation Manual.

Table of Contents • i

Contents

1 OVERVIEW ................................................................................................................................................................... 3

1.1. FEATURES ..................................................................................................................................................................... 3

2 INSTALLATION ........................................................................................................................................................... 4

2.1. LOCATION AND WIRING ............................................................................................................................................... 4

2.1.1. PMAC II Field Wiring........................................................................................................................................... 5

2.2. 8DO BOARD CONFIGURATION (STANDARD PMAC II ONLY) ..................................................................................... 6

2.2.1. Digital Outputs...................................................................................................................................................... 6

2.2.2. Fail-Safe Dip Switch ............................................................................................................................................. 6

2.2.3. Network Jumpers................................................................................................................................................... 6

3 ALARM CONFIGURATION....................................................................................................................................... 8

3.1. THE ALARM CONTACTS ON THE PMAC II TERMINAL STRIP ...................................................................................... 8

3.1.1. Connecting the Alarm Contacts to an Input Board............................................................................................... 8

3.2. PANEL OVERHEAT ALARMING (ALL MODELS) ............................................................................................................ 8

3.2.1. Overheat Warning................................................................................................................................................. 8

3.2.2. Panel Overheat Shutdown..................................................................................................................................... 8

4 CONFIGURING RMCC, BEC, EINSTEIN AND E2 ................................................................................................ 9

4.1. BEC AND RMCC PAGE LAYOUT ................................................................................................................................. 9

4.2. PROGRAMMING THE BEC............................................................................................................................................. 9

4.2.1. Input Definitions ................................................................................................................................................... 9

4.2.2. Output Definitions................................................................................................................................................. 9

4.2.3. Dewpoint/Humidity Offsets ................................................................................................................................... 9

4.2.4. Outputs Setup ........................................................................................................................................................ 9

4.2.5. Setpoints .............................................................................................................................................................. 10

4.3. PROGRAMMING THE RMCC ....................................................................................................................................... 10

4.3.1. Input Definitions ................................................................................................................................................. 10

4.3.2. Output Definitions............................................................................................................................................... 10

4.3.3. Dewpoint/Humidity Offsets ................................................................................................................................. 10

4.3.4. Anti-Sweat Circuit Setpoints ............................................................................................................................... 11

4.4. PROGRAMMING THE EINSTEIN OR E2......................................................................................................................... 11

4.4.1. Adding an Anti-Sweat Application...................................................................................................................... 12

4.4.2. Configuring Anti-Sweat Applications ................................................................................................................. 12

5REPLACEMENT PARTS LIST ................................................................................................................................16

Features Overview • 3

1 Overview

The Pulse Modulating Anti-Sweat Control (PMAC II,

P/N 851-1000), shown in Figure 1-1, is a solid state, anti-

sweat heater controller designed to dramatically reduce the

cost of operating anti-sweat heaters on low-temperature

door-type cases found in most supermarkets.

Normally, anti-sweat heaters operate continuously with

no controls, even though 100% operation is required only

when in-store humidity levels are high. A PMAC II pro-

vides a means for pulsing power to the heaters based on en-

vironmental conditions, so that heaters will be on for less

time during periods where the in-store dewpoint is low.

This reduces operating costs by limiting heater operation,

and increases heater life by limiting heat cycle fatigue since

the heaters are rarely turned off completely.

Depending on the model selected, the PMAC II may

have 16, 20, or 28 heater channels available. Each channel

supports a load of up to 16 amps.

The PMAC II relies on a site controller to control anti-

sweat heater ON percentage based on the in-store dew-

point. The PMAC II panel is compatible with the Building

Environmental Control (BEC), Refrigeration Monitor and

Case Control (RMCC), and Einstein RX or BX, or an E2

site controllers.

The RMCC is capable of controlling up to eight heater

circuits in a single zone, while the BEC allows PMAC II-

controlled heater circuits to be operated in two separate

zones. Two-zone control allows heaters in higher humidity

zones, such as door cases near prep rooms, to be controlled

separately from other case heaters. An E2 RX or BX can be

configured with up to eight zones.

1.1. Features

• Full Solid-State Control

• Quiet Operation

• Easily added to existing systems

• Remote communications through the BEC, RMCC,

Einstein RX/BX, or E2 controllers

• Controlled by the store environment (humidity and

temperature)

•Centrally-located panel

• Easy installation

Figure 1-1 - PMAC II Detail

4 • PMAC II I&O Manual 026-1501 Rev 6

2 Installation

This section of the manual covers wiring and installa-

tion for the PMAC II panels.

2.1. Location and Wiring

The following steps provide location and wiring in-

structions for the PMAC II panel. Figure 2-3 shows this

typical layout. Figure 2-5 shows the PMAC II internal wir-

ing connections.

1. Mount the PMAC II panel in a central loca-

tion such as a motor or electrical room. The

panel should be where there is good air flow

(not in a closet). Keep a 6-12 inch clearance

on top and bottom for good air flow. The

room’s ambient temperature should always

be below 100° F. Figure 2-1 and Figure 2-2

have the mounting dimensions.

2. Provide 120 VAC (15 amp circuit) to the

PMAC II panel through a store circuit break-

er. See the layout design in Figure 2-3.

3. Provide power to the case heaters from the

store circuit breaker panel through the

PMAC II panel terminal strip using #10-12

AWG wire, as shown in Figure 2-4.

Figure 2-1 - PMAC II Dimensions for the 16 and 20 Channel

Figure 2-2 - PMAC II Dimensions for the 28 Channel

24.0”

20.0”

8.0”

Mounting

Holes

16.75”

17.8”

35.0”

27.0”

8.0”

Mounting

Holes

24.5”

26.0”

WARNING: For proper cooling, the door

must be closed at times when unit is in opera-

tion.

Figure 2-3 - Typical Layout

Figure 2-4 - Typical Heater Wiring Layout

Location and Wiring Installation • 5

4. Connect the PMAC II panel 8DO board to the

existing RMCC or BEC COM A or COM D

network, as shown in Figure 2-5, using a

Belden #8761 (two-conductor, shielded,

22AWG) or equivalent communication ca-

ble.

2.1.1. PMAC II Field Wiring

1. Provide 120VAC (15 amps circuit) to the

PMAC terminal block through a store circuit

breaker. Wire 120VAC Hot, 120 VAC Neu-

tral, and Ground as indicated by the Step 1

arrows of Figure 2-5 for the 16 Channel, Fig-

ure 2-6 for the 20 Channel, and Figure 2-7

for the 28 Channel.

2. A normally closed alarm contact is provided

on the terminal strip as indicated by the Step

2arrows of Figure 2-5 for the 16 Channel,

Figure 2-6 for the 20 Channel, and Figure 2-

7for the 28 Channel.

3. Step 3 of Figure 2-5 for the 16 Channel, Fig-

ure 2-6 for the 20 Channel, and Figure 2-7

for the 28 Channel indicates the terminal

block positions to wire the Emerson 485 I/O

Network. Polarity must be respected while

mak-ing these connections.

2.1.1.1. Single Channel Expansion Ports

The 20 Channel PMAC has two expansion ports (Fig-

ure 2-6), and the 28 Channel PMAC has six single expan-

sion ports (Figure 2-7). These expansion ports can be used

to attach single channel PMACs if desired (P/N 851-1010).

NOTE: When running power to the case heat-

ers, include the neutral lead in the same con-

duit as the hot lead to prevent conduit

overheating.

Figure 2-5 - Wiring Detail for 16 Channel

Figure 2-6 - Wiring Detail for 20 Channel

120 HOT

120

NEUTRAL

RS 485+

RS 485-

GROUND

ALARM

TO EARTH

GROUND

Step 1 Step 3

Step 2

Humidity

+12V

Ground

HiTemp

AlarmNC

120VAC

Neutral

120VAC

Hot

COM485

black-

COM485

white+

Hi Temp

AlarmNC

COM485

shield

ExpB

12VDC+

ExpB

12VDC-

ExpA

12VDC-

ExpA

12VDC+

St 1 St 2 S

Expansion Ports x 2

Figure 2-7 - Wiring Detail for 28 Channel

SC-PMAC

#5+

SC-PMAC

#5-

SC-PMAC

#4-

SC-PMAC

#4+

SC-PMAC

#3+

SC-PMAC

#3-

SC-PMAC

#2+

Alarm

Ground

120VAC

Neutral

COM485

shield

COM485

white +

SC-PMAC

#1+

COM485

black-

SC-PMAC

#2-

SC-PMAC

#1-

SC-PMAC

#6+

SC-PMAC

#6-

FUSE

120VAC

HOT

Step 1 Step 3Step 2

Expansion Ports x 6

6 • PMAC II I&O Manual 026-1501 Rev 6

2.2. 8DO Board Configuration

(Standard PMAC II Only)

The 8DO (Digital Output) Expansion Board, supplied

with the PMAC II panel, and shown in Figure 2-8, is used

to connect refrigeration and environmental control compo-

nents, which must be controlled by digital output, to an RS-

485 I/O Network. An adjustable dip switch, rotary dials,

and jumpers are used to configure the 8DO board to fit a va-

riety of applications. Table 2-1 provides the required infor-

mation to configure the 8DO board to allow

communication between the RMCC, E2 or BEC, the

PMAC II panel, and the case heaters.

2.2.1. Digital Outputs

The 8DO Expansion Board uses eight digital outputs,

which modulate at a programmable frequency regulated by

a signal sent from the controller via the I/O Network.

Each of the eight outputs is designed to drive a solid-

state device, and is capable of supplying approximately

150 mA at +12 volts (unregulated). Each output has current

limiting circuitry to prevent damage when short-circuited.

When an output is overloaded, the corresponding LED in-

dicator flashes quickly, indicating current limiting is in ef-

fect.

2.2.2. Fail-Safe Dip Switch

The fail-safe dip switch, S3, allows the user to provide

continuous voltage to the case heaters during network com-

munication loss. The fail-safe dip switches should always

remain in the UP position to ensure voltage is always pro-

vided to the case heaters. If the switches are set in the

DOWN position, no voltage will be sent to the heaters dur-

ing network communication loss.

2.2.3. Network Jumpers

The network jumpers—JU1, JU2, and JU3—define

whether the PMAC II 8DO board is the first or last board,

or a middle board on the RS-485 communication network.

Figure 2-8 - 8DO Board

NOTE: Connection of the PMAC II panel

8DO board must meet all networking require-

ments of the BEC, RMCC, or E2 controllers.

Table 2-1 defines the proper settings for the

PMAC II 8DO board. Refer to the controller’s installa-

tion and operation manual for further information.

Component Required

Setting

Action/Notes

Fail-Safe Dip

Switch (S3)

Positions 1-4,

UP Position 5,

unused

Provides continuous

12VDC to the PMAC

II relays during net-

work communica-

tion loss.

Rotary Dials

(S1)

(S2)

Addresses the PMAC

II 8DO board as the

#1 8DO board on the

RS-485 Network.

Jumpers

JU1

JU2

JU3

UP/DOWN

If the PMAC II 8DO

board is the last board

on the RS-485 Net-

work, set all three of

the jumpers UP. If the

board is in the middle

of the RS-485 Net-

work, set the jumpers

DOWN.

Network Connec-

tion

Connect to

RS-485 Net-

work

Must “daisy-chain"

with other network

boards.

Table 2-1 - PMAC II 8DO Setup

8DO Board Configuration (Standard PMAC II Only) Installation • 7

Power Connection

The PMAC II 8DO board requires 24VAC (center tap

ground) from the PMAC II transformer and converts it to

12VDC to drive the PMAC II relays.

Network Connection

RS-485 Network communication is provided through

the network communication connection as shown in Fig-

ure 2-8, Table 2-1, and described in the Location and Wir-

ing sections of this manual.

8 • PMAC II I&O Manual 026-1501 Rev 6

3 Alarm Configuration

This section explains the alarm capabilities of the

PMAC II and how to set up alarm annunciation and/or re-

porting using the panel’s ALARM output contacts.

3.1. The Alarm Contacts on the

PMAC II Terminal Strip

The terminal strip at the bottom the PMAC II interior

has two terminals labeled ALARM, which are Normally

Closed, and which OPEN whenever certain abnormal sys-

tem conditions occur.

3.1.1. Connecting the Alarm Contacts to

an Input Board

You may wish to connect the digital ALARM output

from the PMAC II panel to a digital input on an Emerson

16AI board or other input device, so that the status of the

PMAC II can be monitored by the central site controller.

Refer to your site controller’s user manual for

information on how to do this. Set up the ALARM output

as a standard digital sensor that is OPEN during alarm

conditions and CLOSED when the system isfunctioning

normally.

If the ALARM contacts are connected to a point on a

16AI or other input board, you may configure the controller

to generate an alarm or perform some other control func-

tion to respond to this alarm condition. Refer to the control-

ler’s user manual for information on how to do this.

3.2. Panel Overheat Alarming (All

Models)

The PMAC II has a feature that prevents equipment

damage as a result of overheating. When the temperature

inside the panel rises above the warning level (165°F), the

normally closed alarm contact will open. If the temperature

continues to rise and exceeds 180°F, the anti-sweat chan-

nels will be shut down.

3.2.1. Overheat Warning

The "warning level" for the PMAC II panel is 165°F. If

a panel interior temperature above 165°F is reached during

operation, a sensor located on one of the upper heat sinks

will open. In a standard PMAC II panel, this will cause the

ALARM contacts on the terminal strip to be set to OPEN.

3.2.2. Panel Overheat Shutdown

If, after the warning level is reached, the temperature

continues to rise above 180°F, another thermal sensor will

open and the unit will completely shut down. The unit will

remain shut down until the temperature returns to a normal

level.

BEC and RMCC Page Layout Configuring RMCC, BEC, Einstein and E2 • 9

4 Configuring RMCC,

BEC, Einstein and E2

A BEC, RMCC, Einstein, or E2 is capable of control-

ling eight anti-sweat heater circuits. BECs allow the eight

heaters to be controlled in two different zones, RMCCs one

zone, and Einstein & E2’s eight zones. Each zone requires

its own dewpoint sensor and setpoint(s). A humidity sensor

and temperature sensor may be used in lieu of a dewpoint

sensor.

The following sections outline the procedure for setting

up anti-sweat control in the BEC, RMCC, Einstein, and E2.

For detailed information on system programming, users

should consult the site controller’s user documentation.

4.1. BEC and RMCC Page Layout

Each data screen used in anti-sweat setup is shown in

sections to follow. Data ranges for data fields—the infor-

mation supplied in the help prompt lines—are displayed in

brackets and bold type [-99° - 99°] either at the heading for

the particu-lar field description, or—when a heading does

not exist— within the body of the description. Suggested or

default values for a particular entry are always shown in

brackets and bold type immediately following the data

range [-99° - 99°] [-15.5].

4.2. Programming the BEC

4.2.1. Input Definitions

From the Main Menu, press ’7 1’ to access the Input

Definitions screen.

Define 16AI or 8IO board and point addresses for the

anti-sweat humidity and temperature sensors. Use the

down arrow keys to locate the following inputs: (ASC

HUM1, ASC TEMP 1, ASC HUM2, ASC TEMP 2) and

the anti-sweat override inputs (ASC #1 OVRD - ASC #8

OVRD). Refer to P/N 026-1103, Building Environmental

Control I&O Manual, Section 6.10.1., Input Definition, for

more information.

4.2.2. Output Definitions

From the Main Menu, press ’7 2’ to access the Out-

put Definitions screen.

Define 8RO and/or 8DO board and point addresses for

the anti-sweat heater zones. Use the down arrow keys to lo-

cate the following outputs: (ANTI-SWT 1 - ANTI-SWT 8).

Refer to P/N 026-1103, Building Environmental Con-trol

I&O Manual, Section 6.10.2., Output Definition, for more

information.

4.2.3. Dewpoint/Humidity Offsets

From the Main Menu, press ’3 2 1’ to access the

Dewpoint/Humidity Offsets screen.

If the dewpoint cell or relative humidity sensor is

known to read high or low, offsets may be specified in the

Dewpoint Offset and Humidity Offset fields to correctly

calibrate the sensors. Users may enter a value from -20% to

20% or from -20° to 20°.

4.2.4. Outputs Setup

From the Main Menu, press ’3 2 2’ to access the

Anti-Sweat Outputs Setup screen.

Setup data such as heater interval times, names, and

board and circuit assignments are entered in the Anti-Sweat

Outputs Setup screen.

ON/OFF Interval [1 - 999 sec.] [10 sec.]

All anti-sweat circuits pulse heaters ON for a percent-

age of a defined time interval. This interval is entered in the

ON/OFF Interval field. If an 8DO board is being used, the

value should be less than 240 seconds.

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