Honeywell PCR-300 User manual

PCR-300
PCR-300 RC
Installation and Operating
Instructions
Electronic refrigeration control
EB-PCR-04 EN1H-1924GE23 R1207

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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

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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.
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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:
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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:

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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).

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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.
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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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uAccess the first programming level by pressing
the and keys at the same time for 5 seconds.
uThen use the and keys to access the parameters
to be changed.
uAccess the second programming level by pressing
the and and keys simultaneously
for 5 seconds.
ITo 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.
IDo 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 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:
IPress and hold down the and keys at the same time for
approx. 5 seconds (E01 appears in the display for
PCR-300 and E00 for PCR-300RC)
ISetting: Press and hold down the key. Adjust the setpoint value
to the desired figure using the or key.
Input parameters and input ranges:
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 20 K 2 K
E02 Time between 2 defrost cycles 1 to 24 h 8 hours
E03 Alarm temperature difference –50 K to +50 K 20 K

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:
E2’1 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)
The time is entered in increments
of 10 minutes in each case.
Caution: The times must be entered
in ascending order.
Exiting programming mode: Press the key after the last level has
been entered.
6.6 Setting the time (PCR-300RC only)
IPress and hold down the and keys at the same time for
approx. 5 seconds to access the first programming level
(Display: E00).
ISetting: Press and hold down the key and change
the time to the current time using the 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 key several times.
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6.7 Manual defrosting
Press and hold down the key for 5 seconds.
The manual defrosting process will be initiated.
7 Programming
Access to the second programming level:
IPress and hold down the , and keys at the same time for
approx. 5 seconds
(Display: E01 for PCR-300, E00 for PCR-300RC).
IUse or key to select parameters.
ISetting: Press and hold down the key. Adjust the setpoint value
to the desired figure using the or key.
IDo 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
( or ) ( and 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 2 K
E02 Time between 2 defrost cycles 1 to 24 hours 8 h
☛Once the controller has been switched on, defrosting 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)
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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 –50 K to + 50 K 20 K
E04 Delay time – Alarm 0 to 99 mins. 10 mins.
E05 Compressor start-up delay 0 to 15 mins. 5 mins.
E06 Defrost type 1 or 2 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 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.

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E15 Sensor calibration T1 –5 to +5 K 0 K
(cold store)
E16 Sensor calibration T2 –5 to +5 K 0 K
(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 mode:
Press the key after inputting the last level.
7.2 Sensor calibration (parameters E15 and E16)
The cold store and evaporator sensors can be calibrated.
Note: An additional resistance of 7 qin each case,
caused by the extension of the sensor cable,
results in a change in the temperature display by
+1K.
How to proceed: 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.

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8 Maintenance
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!
9 Alarm messages
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 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 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: Back-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
IWarranty 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.
IAll functional faults caused by poor workmanship or faulty
materials will be repaired free of charge during the warranty
period.
IMore extensive claims, in particular for consequential damage, are
excluded
IDamage 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.
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12 Technical data
Mains voltage/frequency 230 V AC ± 10% / 50/60 Hz
Rated wattage 2.5 watts
Display 3-digit, 7-segment, red LED, 14.2 mm
Resolution 1 K
Measuring range –55 to +50 °C
Outputs 1 relay with changeover contact, 8 A,
230 V AC, resistive load, (cooling).
1 relay with N.O. contact, 8 A
(5A PCR-300RC), 230 V AC,
resistive load, (defrost heating).
1 relay with N.O. contact, 8 A (5A -PCR-300RC),
230 V AC, resistive load (fan control).
Control response Two-step
Alarm output Opto bidirectional triode thyristor, 250 V AC,
max. load 80mA
Display accuracy ± 0.5K internal, ± 1 digit, at 25 °C
Operating conditions 0 °C to 50 °C, 30 to 85 % R.H., excluding dew
Storage temperature –20 °C to +80 °C
Data back-up Non-volatile memory (EEPROM)
Clock: Back-up battery, approx. 1 month
power reserve (PCR-300 RC only)
Emergency setpoint DIP switch under display cover
selection (off = +4 °C / on = –18 °C)
Sensor type PTC
– Number 2 sensors
T1 = Control signal to compressor relay
T2 = Control signal to defrost limitation and
fan control
– Cable length 2.5 m
– Range where cable –30 °C to +80 °C not fixed
can be used: –40 °C to +80 °C fixed
– Accuracy ± 2 %
Housing L x W x H = 85 x 70 x 61 mm,
ABS plastic, self-extinguishing (UL 94 V0)
Protective rating Housing: IP 20, front panel: IP 52
Class of protection 2
Terminals 250V / 10 A screw-type terminal strips,
with wire protection,
tightening torque 0.6 Nm
Max. core cross section 1.5 mm2
Weight 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.

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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 for 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 22nd, 1999 Honeywell Flica
Honeywell AG
Hardhofweg
D-74821 Mosbach
i.V. Dr. Osthues
R + D / Production Manager

Automation and Control Solutions
Honeywell GmbH
Hardhofweg • 74821 Mosbach / Germany
Phone: [phone] / 81-475
Fax: [phone] / 81-461
E-Mail: [email protected]
www.honeywell-cooling.com