Pego PLUS100 AB User manual

REV. 01/04
PLUS100 AB
Use and maintenance manual
READ AND KEEP
REV. 02-18
ENG
ELECTRICAL BOARDS FOR REFRIGERATING INSTALLATIONS

Page 2
USE AND MAINTENANCE MANUAL
Rev. 02-18
PLUS100 AB
INTRODUCTION
Page 3 1.1 General
Page 3 1.2 Product ID codes
Page 4 1.3 Overall dimensions
Page 4 1.4 Identification data
INSTALLATION
Page 5 2.1 Important information for installer
Page 5 2.2 Standard assembly and use kit
FUNCTIONS
Page 6 3.1 Functions managed by the PLUS100 AB
TECHNICAL CHARACTERISTICS
Page 7 4.1 Technical characteristics
Page 8 4.2 Warranty terms
PARAMETER PROGRAMMING
Page 9 5.1 LCD areas
Page 10 5.2 Control panel
Page 11 5.3 LCD display
Page 12 5.4 General features
Page 12 5.5 Key to symbols
Page 12 5.6 Setting and displaying the set-points
Page 13 5.7 Programming the type of work
Page 17 5.8 Level 1 programming
Page 18 5.9 List of Level 1 variables
Page 19 5.10 Level 2 programming
Page 20 5.11 List of Level 2 variables
Page 22 5.12 Switching on the PLUS100 AB electronic controller
Page 22 5.13 Compressor activation/deactivation conditions
Page 22 5.14 Cooling cycle activation/deactivation conditions
Page 23 5.15 Manual defrost
Page 23 5.16 Hot gas defrost
Page 23 5.17 Modifying date and time
TROUBLESHOOTING
Page 24 6.1 Troubleshooting guide
APPENDICES
Page 26 A.1 EU declaration of conformity
Page 27 A.2 PLUS100 AB connections diagram
CONTENTS
CHAP. 1
CHAP. 2
CHAP. 5
CHAP. 6
CHAP. 3
CHAP. 4

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USE AND MAINTENANCE MANUAL
Rev. 02-18
PLUS100 AB
GENERAL
The electronic controllers of the PLUS100 series have been designed to control static or
ventilated cold rooms.
The PLUS100 AB electronic board allows the user to control all the components on a
refrigeration unit. The board allows the user to control and power the main refrigeration
system components such as the compressor, evaporator fans, defrosting elements and
room light.
There is also a product cooling function: the cooling can be ended as a function of time or
the temperature of the product skewering sensor.
PRODUCT ID CODES
PLUS100 AB Controller for cooling and storage rooms.
1.1
1.2
CHAPTER 1: INTRODUCTION
CHAP. 1 - Introduction

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USE AND MAINTENANCE MANUAL
Rev. 02-18
PLUS100 AB
OVERALL DIMENSIONS
IDENTIFICATION DATA
The unit described in this manual has, on its side, an ID plate showing all the relevant
identification data:
• Name of Manufacturer
• Code of the electrical board
• Serial number
• Power supply voltage
1.3
1.4
CHAP. 1 - Introduction

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USE AND MAINTENANCE MANUAL
Rev. 02-18
PLUS100 AB
IMPORTANT INFORMATION FOR THE INSTALLER
1. Install the device in places where the protection rating is observed and try not to
damage the box when drilling holes for wire/pipe seats.
2. Do not use multi-polar cables in which there are wires connected to inductive/power
loads or signalling wires (e.g. probes/sensors and digital inputs).
3. Do not fit power supply wiring and signal wiring (probes/sensors and digital inputs) in
the same raceways or ducts.
4. Minimise the length of connector wires so that wiring does not twist into a spiral shape
as this could have negative effects on the electronics.
5. Fit a general protection fuse upstream from the electronic controller.
6. All wiring must be of a cross-section suitable for relevant power levels.
7. When it is necessary to make a probe/sensor extension, the wires must be of the
correct cross-section, which in any case must be at least 1mm2.
STANDARD ASSEMBLY AND USE KIT
The PLUS100 AB system is supplied with the following assembly and utilisation items:
n°1 console fixing bracket;
n°2 temperature sensors (piercing temperature probe not included);
n°1 user’s manual;
CHAPTER 2: INSTALLATION
CHAP. 2 - Installation
2.1
2.2

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USE AND MAINTENANCE MANUAL
Rev. 02-18
PLUS100 AB
FUNCTIONS CONTROLLED BY THE PLUS100 AB
-Display and adjustment of room temperature.
-Display of skewering sensor temperature.
-Display of evaporator temperature.
-System control activation/deactivation.
-System warnings (sensor error, min-max temperature alarms, compressor safety
device).
-Evaporator fan control.
-Automatic/manual defrost control (static, with elements, cycle inversion).
-Switching on of room light with panel key or via door switch.
-Clock for defrosts in real time clock.
-Alarm relay.
CHAP. 3 - Functions
CHAPTER 3: FUNCTIONS
3.1

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USE AND MAINTENANCE MANUAL
Rev. 02-18
PLUS100 AB
TECHNICAL CHARACTERISTICS
Power supply
Voltage
230 V~ 10% 50-60Hz
MAX power absorption
~ 7 VA
Climatic conditions
Working temperature
-10 ÷ 60 °C
Storage temperature
-30 ÷ 70 °C
Relative humidity
Below RH 90%
General characteristics
Type of sensors that can be connected
NTC 10K 1%
Resolution
1°C
Sensor read precision
± 0.5°C
Read range
-45…+45
Output characteristics - max applicable load (230VAC)
Compressor (non-powered contact)
1500 W (AC3)
Elements (non-powered contact)
1500 W (AC1)
Fans (non-powered contact)
500 W (AC3)
Room light (non-powered contact)
800 W (AC1)
Alarm contact (non-powered contact)
800 W (AC1)
Dimensional characteristics
Dimensions
19.3 cm x 7.9 cm x 20.3 cm (HxDxL)
Insulation / mechanical characteristics
Box protection rating
IP 65
Box material
ABS self-extinguishing
Type of insulation
Class II
CHAP. 4 –Technical characteristics
CHAPTER 4: TECHNICAL CHARACTERISTICS
4.1

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USE AND MAINTENANCE MANUAL
Rev. 02-18
PLUS100 AB
WARRANTY TERMS
PLUS100 AB series products are covered by a 24-months warranty against all
manufacturing defects as from the date indicated on the product ID code.
In case of defect the product must be appropriately packaged and sent to our production
plant or to any authorized Service Center with the prior request of the Return Authorization
Number.
Customers are entitled to have defective products repaired, spare parts and labour
included. The costs and the risks of transport are at the total charge of the Customer.
Any warranty action does not extend or renew its expiration.
The Warranty does not cover:
Damages resulting from tampering, impact or improper installation of the product and
its accessories.
Installation, use or maintenance that does not comply with the instructions provided
with the product.
Repair work carried out by unauthorized personnel.
Damage due to natural phenomena such as lightning, natural disasters, etc…
In all these cases the costs for repair will be charged to the customer.
The intervention service in warranty can be refused when the equipment is modified or
transformed.
Under no circumstances Pego S.r.l. will be liable for any loss of data and information,
costs of goods or substitute services, damage to property, people or animals, loss of sales
or earnings, business interruption, any direct, indirect, incidental, consequential,
damaging, punitive, special or consequential damages, in any way whatsoever caused,
whether they are contractual, extra contractual or due to negligence or other liability arising
from the use of the product or its installation.
Malfunction caused by tampering, bumps, inadequate installation automatically declines
the warranty. It is compulsory to observe all the instructions in this manual and the
operating conditions of the product.
Pego S.r.l. disclaims any liability for possible inaccuracies contained in this manual if due
to errors in printing or transcription.
Pego S.r.l. reserves the right to make changes to its products which it deems necessary
or useful without affecting its essential characteristics.
Each new release of the Pego product user manual replaces all the previous ones.
As far as not expressly indicated, is applicable the Law and in particular the art. 1512 C.C.
(Italian Civil Code).
For any controversy is elected and recognized by the parties the jurisdiction of the Court of
Rovigo.
4.2
CHAP. 4 –Technical characteristics

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USE AND MAINTENANCE MANUAL
Rev. 02-18
PLUS100 AB
LCD AREAS
1. Display of current month (previous months also remain lit).
2. Indicator/warning LEDs:
a. Cold: cooling in progress.
b. Quick freezing: rapid freezing in progress.
c. Temperature freezing cooling/freezing by temperature (PR1, PR2, PR3).
d. Time freezing cooling/freezing by time (PR4, PR5, PR6).
CHAP. 5 –Parameter programming
CHAPTER 5: PARAMETER PROGRAMMING
5.1



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USE AND MAINTENANCE MANUAL
Rev. 02-18
PLUS100 AB
CONTROL PANEL
1. COOLING CYCLE START key (if pressed for a few seconds the cooling
cycle starts)
2. UP / MUTE BUZZER ALARM key (if pressed for 5 seconds, together with
key 1, recorded alarms are displayed)
3. STAND BY key (system shuts down, room temperature light flashes)
4. SET key, room temperature
5. DOWN / MANUAL DEFROST key
6. ROOM LIGHT key
CHAP. 5 –Parameter programming
5.2







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USE AND MAINTENANCE MANUAL
Rev. 02-18
PLUS100 AB
LCD DISPLAY
1. Ambient temperature / parameters (for values greater than +45°C the word HOT is
displayed).
2. Evaporator temperature / product sensor temperature / day of current month (see
setting on parameter tEu on 1st level programming) / parameters (during
programming) (for values greater than +45°C the word HOT is displayed).
3. Time / date / time parameter values.
4. Programming (control is in programming mode).
5. Cold (compressor call indicator).
6. Defrost.
7. Fans (flashing during fan stop –parameter F5).
8. Light.
9. Alarm.
10.Stand-by (flashing in stand-by. Outputs deactivated).
CHAP. 5 –Parameter programming
5.3











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USE AND MAINTENANCE MANUAL
Rev. 02-18
PLUS100 AB
GENERAL
To enhance safety and simplify the operator’s work, the PLUS100 AB system has two
programming levels; the first level (Level 1) is used to configure the frequently-modified
SET-POINT parameters. The second programming level (Level 2) is for general parameter
programming of the various controller work modes.
It is not possible to access Level 2 programming directly from Level 1: you must exit the
programming mode first.
KEY TO SYMBOLS
For purposes of practicality the following symbols are used:
• () the UP key is used to increase values and mute the buzzer;
• () the DOWN key is used to decrease values and force defrosting.
SETTING AND DISPLAYING THE SET-POINTS
1. Press the SET key to display the current SET-POINT (temperature).
2. Hold down the SET key and press the () or () keys to modify the SET-POINT.
Release the SET key to return to room temperature display: the new setting will be saved
automatically.
5.4
CHAP. 5 –Parameter programming
5.5
5.6

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USE AND MAINTENANCE MANUAL
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PLUS100 AB
PROGRAMMING THE TYPE OF WORK (User level)
To gain access to the programs menu it is necessary to:
1. Press the key 1 .
2. Use the arrow keys to select the program (PR1....PR6).
3. Press the SET key.
4. After selecting the desired variable it will be possible:
• To modify the setting by holding the SET key pressed and pressing the () or ()
keys.
When the modifications have been made press key 1 to return to program selection (at this
point it is possible to modify another program or start the work cycle).
The STAND-BY key allows the user to exit selection and return to manual storage.
Program PR1: temperature-based cooling
Program for product cooling by positive temperature. Cooling ends when the core of the
product reaches temperature At1. A maximum safety time is set on parameter Ab1. When
cooling is over the controller automatically goes to storage mode with the ST1 setting. ST1
also has the function of controlling the compressor, which stops if the room temperature
reaches temperature ST1-r1. The compressor is reactivated on reaching temperature ST1.
VARIABLES
MEANING
VALUES
DEFAULT
At1
End of PR1 cooling temperature
-45 +45 °C
5°C
ST1
Storage temperature at end of cooling / lower
compressor stop limit (- differential r1)
The compressor stops during cooling if the ambient
temperature drops below ST1-r1. The fans continue to run
-45 +45 °C
5°C
Ab1
Maximum safety duration of PR1 cooling
0:10:00…10:00:00
4:00:00
5.7
CHAP. 5 –Parameter programming

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USE AND MAINTENANCE MANUAL
Rev. 02-18
PLUS100 AB
Program PR2: temperature-based freezing
Product freezing program. Freezing ends when the product core temperature reaches At2.
A maximum safety time is set on parameter Ab2. When freezing is over the controller
automatically goes to storage mode with the ST1 setting. The compressor works
continuously.
Program PR3: temperature-based cooling and freezing
Program for product cooling and freezing by positive temperature. When room
temperature drops below the STS setting the switch from cooling to freezing takes place.
Freezing continues until the end of the cycle even in the event of a power cut or a rise in
temperature. Freezing ends when the product core reaches temperature At3. A maximum
safety time is set on Ab3. At the end of freezing the control automatically goes to storage
mode as per the ST3 setting. ST3 also has the function of controlling the compressor
during cooling (the compressor stops if ambient temperature reaches ST3-r1). The
compressor is reactivated on reaching ST3. During freezing the compressor works
continuously.
VARIABLES
MEANING
VALUES
DEFAULT
At2
End of freezing temperature PR2
-45 +45 °C
-20°C
ST2
Storage temperature setting at end of freezing
The compressor does not stop for the entire duration of
freezing.
-45 +45 °C
-20°C
Ab2
Maximum safety duration of PR2 freezing
0:10:00…10:00:00
4:00:00
VARIABLES
MEANING
VALUES
DEFAULT
At3
End of PR3 Cooling/Freezing temperature
-45 +45 °C
-20°C
ST3
Storage temperature at end of cooling-freezing / lower
compressor stop limit (- differential r1).
The compressor stops during cooling if ambient
temperature drops below ST3-r1. The fans continue to run.
-45 +45 °C
-20°C
Ab3
Maximum safety duration of PR3 cooling-freezing
0:10:00…10:00:00
0:30:00
CHAP. 5 –Parameter programming

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USE AND MAINTENANCE MANUAL
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PLUS100 AB
Program PR4: time-based cooling
Program for product cooling by time. Cooling ends when the maximum time Ab4 has
expired. When cooling is over the controller automatically goes to storage mode with the
ST4 setting. ST4 also has the function of regulating the compressor, which stops if room
temperature reaches temperature ST4-r1. The compressor is reactivated on reaching
temperature ST4.
Program PR5: time-based freezing
Product freezing program by time. Freezing ends when maximum time Ab5 has expired.
When freezing is over the controller automatically goes to storage mode with the ST5
setting. The compressor works continuously.
VARIABLES
MEANING
VALUES
DEFAULT
ST4
Storage temperature at end of cooling / lower
compressor stop limit (- differential r1)
The compressor stops during cooling if the ambient
temperature drops below ST4-r1. The fans continue to run.
-45 +45 °C
5°C
Ab4
Maximum safety duration of PR4 cooling
0:10:00…10:00:00
4:00:00
VARIABLES
MEANING
VALUES
DEFAULT
ST5
Storage temperature setting at end of freezing
The compressor does not stop for the entire duration of
freezing
-45 +45 °C
-20°C
Ab5
Maximum duration of PR5 freezing
0:10:00…10:00:00
1:00:00
CHAP. 5 –Parameter programming

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USE AND MAINTENANCE MANUAL
Rev. 02-18
PLUS100 AB
Program PR6: time-based cooling and freezing
Program for product cooling and freezing by time. When room temperature drops below
the STS setting the switch from cooling to freezing takes place. Freezing continues until
the end of the cycle even in the event of a power cut or a rise in temperature. Freezing
ends when the maximum time Ab6 expires. At the end of freezing the control automatically
goes to storage mode as per setting ST6. ST6 also has the function of regulating the
compressor during cooling (the compressor stops if ambient temperature reaches ST6-r1).
The compressor is reactivated on reaching ST6. During freezing the compressor works
continuously.
VARIABLES
MEANING
VALUES
DEFAULT
ST6
Storage temperature at end of cooling-freezing / lower
compressor stop limit (- differential r1).
The compressor stops during cooling if ambient
temperature drops below ST6-r1. The fans continue to run.
-45 +45 °C
-20°C
Ab6
Maximum duration of PR6 cooling-freezing
0:10:00…10:00:00
3:00:00

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USE AND MAINTENANCE MANUAL
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PLUS100 AB
LEVEL 1 PROGRAMMING (User level)
To gain access to the Level 1 configuration menu proceed as follows:
1. Press the () and ()keys simultaneously and keep them pressed for a few seconds
until the first programming variable appears on the display.
2. Release the () and ()keys.
3. Select the variable to be modified using the () or () key.
4. When the variable has been selected it is possible:
• to display the setting by pressing SET.
• to modify the setting by pressing the SET key and the () or ()keys.
When configuration values have been set you can exit the menu by pressing the ()
and ()keys simultaneously for a few seconds until the room temperature reappears.
5. The new settings are saved automatically when you exit the configuration menu.
CHAP. 5 –Parameter programming
5.8

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USE AND MAINTENANCE MANUAL
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PLUS100 AB
LIST OF LEVEL 1 VARIABLES (User level)
VARIABLE
MEANING
VALUES
DEFAULT
r0
Temperature differential referred to main SETPOINT
1 - 10 °C
2°C
r1
Ambient temperature limit during cooling The compressor
stops and the fans are activated during the cooling phase if the
ambient temperature drops below this differential with respect to
the program-specific storage temperature (ST1, ST3, ST4,
ST6). The compressor restarts on re-attainment of the settings
(ST1, ST3, ST4, ST6).
1 - 50 °C
5°C
d0
Defrost interval (hours)
0 - 24 hours
4 hours
d2
End-of-defrost setpoint.
Defrost is not executed if the temperature read by the defrost
sensor is greater than value d2
(If the sensor is faulty defrosting is time-based)
-35 - 45 °C
10°C
d3
Maximum defrost duration (minutes)
1 - 240 min
25 min
d7
Drip duration (minutes)
At the end of defrosting the compressor and the fans remain at
standstill for time setting d7: the defrost LED on the front of the
panel flashes.
0 - 30 min
0 min
F5
Fan pause after defrost (minutes)
Allows fans to be kept at standstill for a time F5 after dripping.
This time is counted from the end of dripping. If dripping is not
set the fan pause is executed directly after the end of defrosting.
During the pause the fan icon flashes.
0 - 10 min
0 min
A1
Minimum temperature alarm
(active only during storage)
Allows user to define a minimum cold room storage
temperature. Below the value A1 a warning is given: the alarm
LED and the displayed temperature flash and the fault is also
highlighted by an internal buzzer.
-
-45°C
A2
Maximum temperature alarm
(active only during storage).
Allows user to define a maximum cold room storage
temperature. Above the value A2 a warning is given: the alarm
LED and the displayed temperature flash and the fault is also
highlighted by an internal buzzer.
-
+45°C
tEu
Displays evaporator sensor temperature / current day-date /
product sensor temperature
0 = displays the day
on the LCD
1 = displays
evaporator
temperature on LCD
(nothing displayed if
dE=1
2 = displays product
sensor
2
5.9
CHAP. 5 –Parameter programming

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PLUS100 AB
dFr
Real-time defrost enable
With d0=0 and dFr=1 it is possible to set up to 6 defrosts in real
time in a day by using the parameters dF1…dF6
0 disabled
1 enabled
0
dF1…dF6
Programming defrost times
It is possible to set up to 6 defrosting times
00:00:00 -
23:50:00
--
STS
Freezing SET
Manages the switch from cooling to freezing in programs PR3
and PR6.
-45 - +45 °C
-10°C
LEVEL 2 PROGRAMMING (Installer level)
To access the second programming level press the UP () and DOWN ()keys and the
LIGHT key simultaneously for a few seconds.
When the first programming variable appears the system automatically goes to stand-by.
1. Select the variable to be modified by pressing the UP () and DOWN ()keys. When
the parameter has been selected it is possible to:
View the setting by pressing the SET key.
Modify the setting by holding the SET key down and pressing the () or ()key.
2. When configuration settings have been completed you can exit the menu by pressing
the () and ()keys simultaneously and keeping them pressed until the room
temperature value reappears.
3. Changes are saved automatically when you exit the configuration menu.
4. Press the STAND-BY key to enable electronic control.
CHAP. 5 –Parameter programming
5.10

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PLUS100 AB
LIST OF LEVEL 2 VARIABLES (Installer level)
VARIABLE
MEANING
VALUES
DEFAULT
AC
Door switch input status
0 = normally open
1 = normally closed
0
F3
Fan status with compressor off
0 = Fans working
continuously
1 = Fans working only when
compressor working
1
F4
Fan pause during defrost
0 = Fans working during
defrost
1 = Fans not working during
defrost
1
F6
Air re-circulate fan activation
The fans come on for a time defined by F7 if
they have not come on for the time F6.
If the moment of activation coincides with
defrosting there is a wait until defrosting has
been completed.
0 –240 min
0
(function
deactivated)
F7
Air re-circulate fans activation duration
Fan operation time for F6
0-240 sec
0:00:10
dE
Sensor presence
By excluding the evaporator sensor defrosts
occur cyclically according to a period d0 and
end when an external device that closes the
remote defrost contact trips or when time d3
expires.
0 = evaporator sensor present
1 = evaporator sensor absent
0
dE1
Product sensor presence
(piercing temperature probe)
With dE1=1 it is possible to disconnect the
product sensor without an error warning and
cooling is time-based only.
0 = product sensor present
1 = product sensor absent
0
dC
Remote defrost input status
0 = NO
1 = NC
0 = NA
d1
Defrost type, cycle-inversion (hot gas) or
by heating element
1 = hot gas
0 = element
0
d4
End-of-cooling defrost
This parameter decides whether, at the end
of the cooling phase, a defrost has to be
carried out immediately (d4=0) or if the
defrosts follow the settings independently
(d4=1).
If d4=0 a defrost will in any case take place
even if timed defrosts are enabled.
0 –1
default 0
Ad
Network address for connection to the
TeleNET supervision system.
0 - 31
0
Ald
Minimum and maximum temperature
signalling and alarm display delay.
1…240 min
2:00:00
C1
Minimum time between shutdown and
subsequent switching on of the
compressor.
0…15 min
0 min
CAL
Cold room sensor value correction
-10…+10
0
CAP. 5 - Programmazione dati
CHAP. 5 –Parameter programming
5.11