Honeywell PCR-100 User manual

PCR-100
PCR-110
Installation and Operating
Instructions
Electronic thermostat
EB-PCR-02 EN1H-1925GE23 R0106

2
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
16 Operation of the controller 7
6.1 Switching on the operating voltage 8
6.2 Display 8
6.3 Key functions 8
6.4 Adjusting the cold store temperature 9
6.5 Manual defrost 9
17 Programming 9
7.1 Input parameters and ranges 10
7.2 Sensor calibration (Parameter E 06) 11
18 Maintenance 12
19 Appendix 12
9.1 Alarm messages 12
10 Conditions of warranty 13
11 Technical data 13

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 trans-
portation. 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 instances, 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 inter-
ference), 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 temperatures or
media temperatures in refrigeration or heating systems.
IThe controller must not be used as a safety cut-out device or excess
temperature limiter.
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If the unit 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
sensor is required, only use sensors of the same type
(Part No. H61007 ).
IThe controller is not intended for use in vehicles because the possi-
ble operating voltage ranges, interference level and environmental
operating exceed the limits for which the controller can be used.
IPlease take the application limits into account
(see Technical Data in section 11).
3.2 Function
IPCR-100 and PCR-110 are general-purpose thermostats, each with
a relay output and wide temperature control range
(–55 °C to +50 °C).
IThe controllers have different housings:
PCR-100: Modular housing for 35 mm standard rails
PCR-110: “Snap-in” installation housing, which fits into aperture
28.5 x 70.5 mm.
IControl performance: 2-step, on/off, with reversible direction for
heating and refrigerating.
IDefrost option for chilling systems if continuous operation of the
evaporator fan is foreseen in the switching box.
IEasy to operate thanks to digital input of setpoint value and
switching difference.
IData is not lost, even if there is a power failure, for at least
10 years.
IAlarm output.
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 tempe-
rature in combination with high atmospheric humidity may lead to
the formation of condensed water.
IEven if the control circuit is switched off, high voltage may still be
applied to the controller. 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.
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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:
u the housing has damage which is visible,
u the unit is no longer operational or
u it 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, 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.
5 Installation and commissioning
5.1 Mechanical installation
I4 DIN Standard modular housings to be mounted on a
standarr rail:
a) housing with 2 mounting tabs:
Open out the side mounting tabs; clip the unit on to 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 a
screw driver, lift unit.
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ISnap – in housings:
Fit the unit in an aperture 28,5 x 70,5 mm and secure it with the
relevant mounting frame.
a) housings with terminal box coverplate
(max. wall thickness 22 mm)
b) housings without terminal box cover plate
(max. wall thickness 18 mm)
for walls thicker than 10 mm: remove lateral plastic spacers from
the mounting frame. For the final fixing of the unit the side screws
have to be tightened carefully.
IUse a cable clamp to secure sensor T1 in a suitable position.
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:
6

☛Instructions:
IFor PCR-110 the total current via terminal 5 of the common relay
connection must not exceed 10 A.
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/protec-
tive 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 controllers
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).
6 Operation of the controller
Front view of controller:
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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 a later point can be adapted for individual require-
ments.
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.
Two spot indicators show the switching status of the relays during
operation:
Pos. 1: On : Relay on.
Off: Relay off.
Flashes: Start-up delay E03
active.
Pos. 3: On : Defrost interval is active –
relay de-energized.
6.3 Functions of keys
☛Never operate the keys with sharp objects
(screwdriver or similar).
Display of setpoint Press and hold down key.
value
Clear alarm Press key.
messages (If the sensor is faulty, switch
mains voltage ON/OFF).
Manual defrost Press key for 5 secs.
initiation
Display of time Press and keys in sequence
until the next and hold both down.
defrost (Display in hours and minutes).
Display limit value Press key.
for excess
temperature
(cold store sensor T1)

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IInput values are always changed using the or key with
the key held down.
IInput parameters, e.g. the switching difference is shown as “E”
with a 2-digit number, e.g. “E 01”.
IAccess to the programming level is by pressing the and
key at the same time for 5 seconds.
The parameters to be changed can then be accessed by pressing
the and keys.
ITo exit from the programming level and save the data, press
the key after the last input parameter. If no key is pressed in the
programming level 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 on the value
in question using the or key.
Adjustment is possible within the limits of the input parameters E01
and E02.
The factory setting is +4°C.
6.5 Manual defrost
Press and hold down the key for 5 seconds. The manual defrosting
process will be initiated by forcibly de-energizing the relay.
If parameter E09 is set to 0: no defrosting will be started.
7 Programming
Access to the programming level:
IPress and hold down firmly the and keys at the same time
for approx. 5 seconds. (E00 appears on display.)
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 on display Setting range
( or ) ( and or ) Preset
E00 Cold store temperature difference 1 to 20 K 2 K
E01 Min. permissible
cold store temp. –55 °C to E02 –55 °C
E02 Max. permissible
cold store temp. E01 to +50 °C +50 °C
E03 Delay time,
relay energizing 0 to 15 mins. 5 mins.
E04 Alarm temperature difference –50 K to +50 K 20 K
If the set temperature difference E04 is negative, an alarm is given
if it is too cold in the refrigerated area,
e.g. E04 = –10 K, cold store setpoint value = 18°C
➝alarm at –28 °C in refrigerated area.
If the set temperature difference E04 is positive, the alarm is given
if it is too warm in the refrigerated area,
e.g. E04 = +10 K, cold store setpoint value = –18°C
➝alarm at –8°C in refrigerated area.
Attention: any change of coldstore set point value changes also the
alarm temperature.
If E04 is set to 0, no alarm will be given.
E05 Alarm delay time 0 to 99 mins. 10 mins.
E06 Sensor calibration T1 –5 to +5 K 0 K
E07 Mode selection 1 = Cooling, 1
2 = Heating
E08 Time between 2 defrost cycles 1 to 24 hours 8 hours
(switch off cooling)
☛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.
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☛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.
E09 Defrost time (0 = no defrosting) 0 to 99 mins. 25 mins.
E10 Max. display delay 0 to 99 mins. 15 mins.
after defrosting
☛During the defrosting process, the last current tempe-
rature before defrosting started is retained in the dis-
play. After defrosting, the display returns to the instan-
taneous temperature when the stored value is reached
again or, at the latest, after time E10 has elapsed.
E11 Operating of relay 0 = Relay 2
if sensor T1 defective de-energized
1 = Relay
permanently
energized
2 = On/off in
sequence,
according to
the times set
in E12 and
E13.
E12 “On” time at E11 1 to 99 mins. 15 mins.
E13 “Off” time at E11 1 to 99 mins. 15 mins.
Exiting programming mode:
Press the key after the last level has been entered.
7.2 Sensor calibration (parameter E06)
The sensor can be calibrated.
Note on sensor calibration: Additional line resistance of 7 qin each
case, caused by sensor cable extension, results in a change in the
temperature display by +1K.
How to proceed: Measure the temperature with a calibrated
thermometer or submerge the sensor in well-mixed ice water (0 °C).
Compare the measured temperature with the temperature shown 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. 2K).
The temperature display is then corrected by the set value.
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 pas-
sed, 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 Appendix
9.1 Alarm messages
If an alarm occurs, the alarm output will be activated and on the dis-
play a code will alternate with the cold store temperature.
Display Meaning
AL1 Data lost from program memory.
The preset values will be used as an
emergency program.
The setpoint will be set to +4 °C.
AL2 Limit value (= specified value + E04) at sensor T1
exceeded and delay time E05 elapsed.
AL3 The sensor temperature is over 50 °C
or below –55°C.
AL4 The specified setpoint value is outside
the limits E01 and E02
AL5 Temperature sensor T1 – short circuit of break in wiring.
Compressor operates as a function of parameter E11
Clearing the 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.
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10 Conditions of warranty
IWarranty is provided for a period of 24 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 hand-
led incorrectly or by non-compliance with the operating instruc-
tions shall not be covered by the warranty.
The warranty shall be invalidated if any work is carried out
on the appliance.
11 Technical data
Mains voltage/frequency: 230 V AC ± 10%, 50/60 Hz
Rated wattage: 2.1 watts
Display: 3-digit, 7-segment LED, red, 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
1 relay with N.O. contact,
5 A, 230 V AC, resistive load,
(alarm)
Caution: For PCR-110 the total current via the common relay
connection, terminal no. 5, must not exceed 10 A.
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Control performance: Two-step
Display accuracy: ± 0.5 K internal, ±1 digit, at 25 °C
Operating conditions: 0 to 50 °C, 30 to 85 % R.H.,
excluding dew
Storage temperature: –20 to +80 °C
Data back-up: Non-volatile memory (EEPROM)
Sensor: 1 PTC
– Sensor cable length: 2.5 m
– Range where cable –30 °C to +80 °C not fixed
can be used: –40 °C to +80 °C fixed
– Sensor accuracy: ±2 %
Housing: PCR-100: L x W x H = 85 x 70 x 61 mm
PCR-110: L x W x H = 70 x 74 x 32 mm
ABS plastic, self-extinguishing
(UL 94 V0)
Protective rating: Housing: IP 20, Front panel: IP 52
Class of protection 2
Terminals: 10 A screw-type terminal strips,
with wire protection,
tightening torque 0.6 Nm
Max. core cross section 1.5 mm2
Weight: PCR-100: Approx. 330 g (inc. sensor).
PCR-110: Approx. 240 g (inc. sensor).
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 Directive 89/336/EEC
and the
EC Low Voltage Directive 73/23/EEC
Product: FLICA, Electronic thermostat
Model designation: PRC-100, PCR-110
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