Honeywell PCR 100 Thermostat User Manual

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PCR-100  
PCR-110  
Installation and Operating  
Instructions  
Electronic thermostat  
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TABLE OF CONTENTS  
1
1 Unpacking the unit and conditions of use  
2 General instructions  
3 Use and function  
3
3
3
3
4
1
1
3
.1 Use for the purpose intended  
.2 Function  
3
1
4 Safety  
4
4
5
4
.1 Sources of danger  
.2 Safety precautions  
4
1
5 Installation and commissioning  
5
5
6
5
.1 Mechanical installation  
.2 Electrical installation  
5
1
6 Operation of the controller  
7
6
6
6
6
6
.1 Switching on the operating voltage  
8
8
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9
9
.2 Display  
.3 Key functions  
.4 Adjusting the cold store temperature  
.5 Manual defrost  
1
7 Programming  
9
10  
11  
7
.1 Input parameters and ranges  
7.2 Sensor calibration (Parameter E 06)  
18 Maintenance  
12  
1
9 Appendix  
12  
12  
9
.1 Alarm messages  
1
0 Conditions of warranty  
13  
13  
11 Technical data  
2
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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 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  
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This controller is designed to control ambient temperatures or  
media temperatures in refrigeration or heating systems.  
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The 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.  
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Only connect sensors supplied with the unit. If a replacement  
sensor is required, only use sensors of the same type  
(
Part No. H61007 ).  
The 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.  
Please take the application limits into account  
(
see Technical Data in section 11).  
3
.2 Function  
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PCR-100 and PCR-110 are general-purpose thermostats, each with  
a relay output and wide temperature control range  
(
–55 °C to +50 °C).  
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The controllers have different housings:  
PCR-100: Modular housing for 35 mm standard rails  
PCR-110: “Snap-in” installation housing, which fits into aperture  
2
8.5 x 70.5 mm.  
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Control performance: 2-step, on/off, with reversible direction for  
heating and refrigerating.  
Defrost option for chilling systems if continuous operation of the  
evaporator fan is foreseen in the switching box.  
Easy to operate thanks to digital input of setpoint value and  
switching difference.  
Data is not lost, even if there is a power failure, for at least  
10 years.  
Alarm output.  
4
Safety  
4
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.1 Sources of danger  
Caution - Mains voltage!  
Never 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.  
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Even 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.  
Never 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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If 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:  
the housing has damage which is visible,  
the unit is no longer operational or  
it has been stored for a long time in unfavourable conditions.  
The 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  
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All electromagnetic loads (solenoid valves, contactors, horns,  
motors) should be interference suppressed directly at the coil with  
RC elements.  
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Please 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.  
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Sensor leads are to be routed separately from mains voltage wires:  
the clearance should be at least 5 cm.  
Sensor leads must not be routed in multiple cables with other leads  
carrying mains voltage, otherwise the system may malfunction.  
Tighten the terminals carefully; excessive strain will result in  
damage to the controller.  
5
Installation and commissioning  
5
.1 Mechanical installation  
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4 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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Snap – 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)  
l box cover plate  
m)  
move lateral plastic spacers from  
the mounting frame. For the final fixing of the unit the side screws  
have to be tightened carefully.  
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Use 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:  
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Instructions:  
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For PCR-110 the total current via terminal 5 of the common relay  
connection must not exceed 10 A.  
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Pay attention to the contact loading of the relay (8A/5A resistive  
load, 2A/1A inductive load). As a general rule, contactors are  
recommended.  
The 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.  
It 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.  
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The 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 :  
Off:  
Relay on.  
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).  
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Display of setpoint  
value  
Press and hold down  
key.  
Clear alarm  
messages  
Press key.  
(If the sensor is faulty, switch  
mains voltage ON/OFF).  
Manual defrost  
initiation  
Press  
key for 5 secs.  
Display of time  
until the next  
defrost  
Press  
and keys in sequence  
and hold both down.  
(Display in hours and minutes).  
Display limit value  
for excess  
Press  
key.  
temperature  
(
cold store sensor T1)  
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Input values are always changed using the  
the key held down.  
Input parameters, e.g. the switching difference is shown as “E”  
with a 2-digit number, e.g. “E 01”.  
or  
key with  
Access 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.  
To exit from the programming level and save the data, press  
the key after the last input parameter. If no key is pressed in the  
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programming level for 10 minutes, this mode will be exited  
without the data being saved.  
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Do not display altered parameter data before saving the data, as it  
would be reversed to its original value in the process.  
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.4 Setting the cold store temperature  
Press and hold down the  
in question using the  
key. Adjust the setpoint on the value  
key.  
or  
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:  
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Press and hold down firmly the keys at the same time  
for approx. 5 seconds. (E00 appears on display.)  
Use or key to select parameters.  
and  
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Setting: Press and hold down the  
to the desired figure using the  
key. Adjust the setpoint value  
key.  
or  
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Do not display altered parameter data before saving the data, as it  
would be reversed to its original value in the process.  
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7.1 Input parameters and input ranges:  
Parameter on display  
Setting range  
and or  
(
or  
)
(
)
Preset  
E00 Cold store temperature difference 1 to 20 K  
E01 Min. permissible  
2 K  
cold store temp.  
–55 °C to E02  
–55 °C  
+50 °C  
E02 Max. permissible  
cold store temp.  
E01 to +50 °C  
E03 Delay time,  
relay energizing  
E04 Alarm temperature difference  
0 to 15 mins.  
–50 K to +50 K  
5 mins.  
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  
E06 Sensor calibration T1  
E07 Mode selection  
0 to 99 mins.  
–5 to +5 K  
1 = Cooling,  
10 mins.  
0 K  
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)  
E10 Max. display delay  
0 to 99 mins.  
0 to 99 mins.  
25 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  
de-energized  
= Relay  
2
if sensor T1 defective  
1
2
permanently  
energized  
= On/off in  
sequence,  
according to  
the times set  
in E12 and  
E13.  
E12 “On” time at E11  
E13 “Off” time at E11  
1 to 99 mins.  
1 to 99 mins.  
15 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 in 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).  
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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  
AL1  
Meaning  
Data lost from program memory.  
The preset values will be used as an  
emergency program.  
The setpoint will be set to +4 °C.  
AL2  
AL3  
AL4  
AL5  
Limit value (= specified value + E04) at sensor T1  
exceeded and delay time E05 elapsed.  
The sensor temperature is over 50 °C  
or below –55°C.  
The specified setpoint value is outside  
the limits E01 and E02  
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  
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Warranty 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.  
All functional faults caused by poor workmanship or faulty  
materials will be repaired free of charge during the warranty  
period.  
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More extensive claims, in particular for consequential damage, are  
excluded.  
Damage 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:  
Rated wattage:  
Display:  
230 V AC ± 10%, 50/60 Hz  
2.1 watts  
3-digit, 7-segment LED, red, 14.2 mm  
1 K  
Resolution:  
Measuring range:  
Outputs:  
–55 to +50 °C  
1 relay with changeover contact,  
8
1
5
A, 230 V AC, resistive load  
relay with N.O. contact,  
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:  
Display accuracy:  
Two-step  
± 0.5 K internal, ±1 digit, at 25 °C  
Operating conditions:  
0 to 50 °C, 30 to 85 % R.H.,  
excluding dew  
Storage temperature:  
Data back-up:  
Sensor:  
–20 to +80 °C  
Non-volatile memory (EEPROM)  
1 PTC  
Sensor cable length:  
Range where cable  
2.5 m  
–30 °C to +80 °C not fixed  
–40 °C to +80 °C fixed  
±2 %  
can be used:  
Sensor accuracy:  
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:  
Terminals:  
Housing: IP 20, Front panel: IP 52  
Class of protection 2  
10 A screw-type terminal strips,  
with wire protection,  
tightening torque 0.6 Nm  
Max. core cross section 1.5 mm  
2
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:  
Model designation:  
FLICA, Electronic thermostat  
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.  
nd  
Mosbach, March 22 , 1999  
Honeywell Flica  
Honeywell AG  
Hardhofweg  
D-74821 Mosbach  
i.V. Dr. Osthues  
R & D / Production Manager  
15  
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Automation and Control Solutions  
Honeywell GmbH  
Hardhofweg • 74821 Mosbach / Germany  
Phone: +49 (0) 62 61 / 81-475  
Manufactured for and on behalf of the  
Environment and Combustion Controls  
Division of Honeywell Technologies Sàrl,  
Ecublens, Route du Bois 37, Switzerland  
by its autorised representative Honeywell GmbH  
Fax:  
+49 (0) 62 61 / 81-461  
E-Mail: Cooling.Mosbach@honeywell.com  
www.honeywell-cooling.com  

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