Honeywell PCR-300 User manual

PCR-300

PCR-300 RC

Installation and Operating

Instructions

Electronic refrigeration control

EB-PCR-04 EN1H-1924GE23 R1207

TABLE OF CONTENTS

11 Unpacking the unit and conditions of use 3

12 General instructions 3

13 Use and function 3

3.1 Use for the purpose intended 3

3.2 Function 4

14 Safety 4

4.1 Sources of danger 4

4.2 Safety precautions 5

15 Installation and commissioning 5

5.1 Mechanical installation 5

5.2 Electrical installation 6

5.3 Setting the DIP switch for the emergency setpoint and

clock back-up battery 8

16 Operating of the controller 9

6.1 Switching on the operating voltage 9

6.2 Display 9

6.3 Key functions 10

6.4 Adjusting the cold store temperature 11

6.5 Changing the cold store temperature difference, defrost cycle,

and alarm temperature 11

6.6 Setting the time (PCR-300RC only) 11

6.7 Manual defrost 12

17 Programming 13

7.1 Input parameters and ranges 13

7.2 Sensor calibration (parameters E 15 and E 16) 15

18 Maintenance 16

19 Alarm messages 16

10 Problem solving 17

11 Conditions of warranty 17

12 Technical data 18

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 “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

IThis 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.

IThe controller must 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.

IOnly connect sensors supplied with the unit. If a replacement sen-

sor is required, only use sensors of the same type (part no. H61007).

IThe 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.

IPlease 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.

ICompressor control (dependent upon cold store

temperature) with delayed start-up.

IEvaporator fan control

uFan either in combination with compressor or

uoperating continuously or

uswitched via the evaporator thermostat.

IDefrost control limited thermostatically,

either for electrical heating or hot-gas defrosting

IAlarm 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 Safety

4.1 Sources of danger

ICaution - Mains voltage.

INever expose the unit to 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.

IEven 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.

INever 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.

IIf 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:

uThe housing has damage which is visible,

uthe unit is no longer operational or

uit has been stored for a long time in unfavourable conditions.

IThe 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

IAll electromagnetic loads (solenoid valves, contactors, alarm horns,

motors) should be interference suppressed directly at the coil with

RC elements.

IPlease note the maximum contact rating of the relays and

terminals.

If this is not observed, there is a risk that the contacts may pit or

stick, with the result that the refrigeration system will not operate

correctly and the refrigerated items may be damaged.

ISensor leads are to be routed separately from mains voltage wires.

The clearance should be at least 5 cm.

ISensor leads must not be routed in multiple cables with other leads

carrying mains voltage, otherwise the system may malfunction.

ITighten the terminals carefully; excessive strain will result in

damage to the controller.

IPCR-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 Installation and commissioning

5.1 Mechanical installation

I4 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.

IMounting of sensor:

IUse a cable clamp to secure sensor T1 in a suitable position.

ISecure 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

☛CAUTION: The mains 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:

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

☛The unit is equipped with an opto-decoupled electronic

alarm output.

Take note of the alarm output limit values.

ISupply voltage: Max. 250 V AC.

IMinimum load: 40 mA

IMaximum load: 80 mA

IIf an inductive load (contactor or horn) is connected, connect

an RC element directly at its coil.

☛Instructions:

IPay attention to the contact loading of the relay

(8A / 5A resistive load, 2A / 1A inductive load). As a general rule,

contactors are recommended.

IThe maximum tested sensor cable length is 50 m, with a minimum

cross section of 2 x 0.75 mm2. Solder the extension cable to the

sensor cable to prevent contact resistances.

IIt 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.

IThe 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

Carefully lift the housing cover off the side, using your fingers.

ISelection 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

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.

☛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.

6 Operation of the controller

Front view of controller:

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 pressing the 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.

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

☛Never operate the keys with sharp objects

(screwdriver or similar).

Display of setpoint Press and hold down key.

temperature

Clear alarm Press key.

messages (If the sensor is faulty, switch

mains voltage ON/OFF.)

Evaporator Press and keys in sequence

temperature and hold both down.

display

Manual defrost Press key for 5 secs.

initiation

Display of time Press and 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)

IChange input values by using the and keys with

the key pressed down.

IInput parameters, e.g. the switching difference, are indicated by

“E” and a 2-digit number, e.g. “E01”.

IThe input parameters are grouped together in two programming

levels.

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