plug-in, electronic digital thermostat with defrost control User manual
We wish to save you time and money! We can assure you that a thorough reading of this manual will guarantee correct installation and safe use of the product described. IMPORTANT BEFORE INSTALLING OR OPERATING ON THE DEVICE, CAREFULLY READ THE INSTRUCTIONS IN THIS MANUAL.
CONTENTS INTRODUCTION ……………………………………………………………………………………………………………30 GENERAL CHARACTERISTICS ................................................................................................................................4 1. 1.1 Models available ................................................................................................................................................................................4 1.1.1 PJ32S ..............................................................................
8. AVAILABLE ACCESSORIES .....................................................................................................................................35 8.1 Key for copying the parameters .......................................................................................................................................................35 8.2 Serial adapter for RS485 network ............................................................................................................................
plug-in INTRODUCTION The new plug-in family for refrigeration is made up of a new series of microprocessor-based electronic controls with LED display, designed for the management of display case and showcase refrigeration units. A range of models is available, providing the best solution for all applications, at the most competitive price.
plug-in 1. GENERAL CHARACTERISTICS 1.
plug-in 1.2 Characteristics Power supply The plug-in can be powered at: 230Vac or 115Vac using an internal transformer, or at 12Vac/Vdc without internal transformer. Aesthetics and ergonomics The LED signals are clearly visible by the backlighting of the three buttons or 3 symbols on the display.The front panel frame can be customised both in terms of colour and indications. LED display The temperature and the parameter settings are displayed by 'two and a half digits'.
plug-in 2. HARDWARE STRUCTURE The instruments in the PJ32* series are temperature controls used to manage refrigeration units (showcases and display cases). An application diagram is shown in the figure; also indicated are the possible accessories and expansion modules, as well as the connections for the inputs and outputs: 1. instrument; 2. plug-in frame; Power 3. temperature probes; 230Vac 4. power transformer (according to the models); 5. RS485 serial adapter module; 6. HACCP module; 7.
plug-in 2.2 Instrument and accessory codes The definition of the instrument codes is based on two categories: one for the simpler and more economical versions (Eco), and one for the versions complete with all functions (Top).
plug-in 2.2.2 NTC and PTC probes All PTC and NTC probes conforming to the CAREL standard can be used, with resistance values of 985 Ω at 25°C, for PTC, and of 10 kΩ for NTC. Below are some codes of the more common versions. description NTC probe, 6x15 mm bulb, plastic, NTC probe, 6x40 mm bulb, metal PTC probe, 6x40 mm bulb, metal, 1.
plug-in 2.3 User interface, meaning of operating indicators and LED display Figs. 2.3.1 and 2.3.2 shows the front panel of the plug-in: display and buttons. The front panel of the instrument features a three-digit display (ref. 4 ) and three LEDs for backlighting the buttons (refs. 1, 2 and 3 in Fig. 2.3.1), or alternatively three graphic symbols inside the area of the display (refs. 1, 2 and 3 in Fig. 2.3.2).
plug-in 3. INSTALLATION The installation operations for the plug-in controls can be grouped as follows: 1. mechanical installation; 2. electrical connections: probes, power supply and actuators; 3. setting of the operating parameters. 3.1 Mechanical installation 1. Insert the instrument in the previously created hole as per the drilling template, 71x29 mm; 2. for mounting using the bracket (for all Eco versions): lock the instrument onto the panel, by sliding the bracket; 3.
plug-in Fig. 3.2.1.1 3.2.2 Special warnings For the direct connection of the instruments and the layout and checking of the wiring, the following warnings must be carefully read and the diagrams adhered to; errors in connection can cause danger to the safety of the user and damage the instruments and connected components. Also remember that the units must be fitted with all the electromechanical safety devices required to ensure correct operation and the complete safety of the user.
plug-in Serial: serial connection to the supervisor system; TRF: 3VA transformer. * only on last module Fig. 3.4.2.1 WARNING: the diagrams show the serial connection including the RS485 serial interface adapter (see options) which is external to the instrument and must be powered separately. Versions with 115 and 230 Vac power supply are also available for the serial adapter. For reasons of EMI compatibility, a 3VA transformer (TRF in fig. 3.4.2.
plug-in 3.2.4 Electrical connections, PJ32 Fig. 3.2.5.1 Warnings: • before connecting the power, check the correct value of the power supply as shown on the label of the instrument; • all models use NTC probes, except for the PJ32S6E0*, which uses PTC probes; • for models S200 and S201 the alarm relay can be set as normally energised or normally de-energised, using parameter H1. Cod. +030221881 rel. 1.
plug-in 3.3 Setting the main operating parameters The plug-in series instruments are supplied ready to use. They are in fact programmed in the factory (default settings) to respond to the more common requirements. The programming is performed by assigning all the parameters the more frequently required value; the table below lists the parameters and the corresponding default value.
plug-in Based on the factory settings, the main functions are the following: • PJ32S: configured as a thermostat, with operation in degrees centigrade, set point at 4ºC and differential of 2ºC. The DEFROST operation is enabled by time at 8 hour cycles lasting 30 minutes (compressor stop only). The high and low temperature alarms are disabled. In the case of operation in continuous cycle, the duration is 4 hours and the temperature alarm is bypassed for 2 hours from the end of the cycle.
plug-in 4. PARAMETERS - DESCRIPTION 4.1 The configuration parameters The parameters can be classified in two groups for setting: • frequent parameters (indicated by type F in the following tables); • configuration parameters (type C), whose selection is ‘password’ protected to prevent unwanted tampering. The assigning of the parameters to groups F and C can also be programmed, but only via serial access using the key or a supervisory system.
plug-in /4: display control or food storage probe For instruments with two probes (S, Y, C), this parameter selects whether to display the temperature of the control probe (ambient probe) or the second probe, which in this case is used only to display the temperature of the food. The use of the second probe for this purpose means that it can no longer be used to control defrosting; the corresponding parameters must be modified as a consequence.
plug-in r3: enable alarm ED For models Y, X, C. With r3=1, the alarm is enabled and indicates end defrost due to the maximum time being reached. Warning: for the model S with defrosting enabled (H1=1), the alarm is not present in that the operation is by time only with compressor off. If required, the value set via the serial connection must be 0. Def.: 0 alarm ED inhibited. 4.
plug-in c3: minimum compressor on time Sets the minimum time the compressor stays on. The compressor is not shut-down unless it has been on for the minimum time selected. Def.: c3=0 (no minimum operation). Available on all models. t Fig. 4.6.4 c4: duty setting or safety probe In the event of the control probe fault alarm (that is the ambient probe is short-circuited or disconnected) this parameter ensures the operation of the compressor until the fault is resolved.
plug-in 4.7 d = defrost management parameters d0 dI dt dP d4 d5 d6 dd d8 d9 d/ defrost parameters type min max type of defrost (0=heat. element, 1=hot gas, 2=heat elem.
plug-in d4: defrost at instrument on Activates a defrost cycle when the instrument is turned on. The request for defrost when the unit is turned on has priority over the activation of the compressor and the activation of the continuous cycle. The possible values are: 0 = no, no defrost is performed when the instrument is turned on; 1 = yes, a defrost cycle is performed when the instrument is turned on. Forcing a defrost cycle when the instrument is turned on may be useful in special situations, e.g.
plug-in d9: defrost priority over compressor protection Overrides the compressor protection times (c1: minimum time between 2 successive starts, c2: minimum off time and c3: minimum on time) at the start of the defrost. The possible values are: 0 = the protection times are respected; 1 = the protection times are overridden; the defrost has priority and does not respect the compressor time settings.
plug-in AL: minimum temperature alarm Selects the low temperature alarm. The value of AL does not indicate the alarm temperature but rather the maximum difference allowed below the set point. For all models: low temperature alarm = (set point) - (value of AL) Note that changing the set point automatically changes the low temperature alarm, in that maximum difference allowed remains the same (=AL). The low temperature alarm has an automatic reset.
plug-in operation according to the standards in force. The electronic control on its own can not be used to guarantee safety in the event of serious alarms. For all models, including S with H1=1: A4 = 2: enable defrost An external contact can be connected to the multifunction input to enable or inhibit the defrost function. When the contact is open, the defrost is inhibited, while it is enabled when the contact is closed.
plug-in A7: external alarm detection delay (multifunction input) Sets the delay (in minutes) for detecting the external alarm when A4=1. Def.: A7=0. Available on all models. 4.
plug-in Fd: post dripping off (active both when F0=0 and F0=1) The fans, after the defrost, can be stopped for a further period (in minutes) defined by the value of Fd. This is useful to allow the evaporator to return to operating temperature after the defrost, thus avoiding forcing 'hot' air into the refrigerator. In the case of management by fan controller, the time Fd does not need to be selected, in that the controller makes the fans start again when the evaporator reaches operating temperature.
plug-in 4.10 H = other settings alarm parameters serial address H0 H1 special configurations: mod. S – enable defrost model with alarm relay –relay activation state H2 H4 H5 t type min C 0 C 0 disable keypad (0=no, 1=yes) enable buzzer 0 = enabled identification code set only by serial external parameters (optional modules) C C C F 0 0 -99 -127 max 199 1 uom flag def 1 1 1 1 99 127 flag 1 flag 1 byte 10 byte Tab. 4.10.
plug-in 5. OPERATING STATES The indication LEDs can have 3 states: • off, when the function indicated or the actuator in question is not in operation; • on, when the function indicated or the actuator in question is in operation; • flashing, when the operation is blocked by an alarm event, by a delay pending or by a specific status of the multifunction input. There are however special machine conditions in which the status of the signal LEDs are not immediately recognisable.
plug-in 6. PARAMETERS - MODIFICATION The instruments in the PJ32 series are managed by a microprocessor which allows the operation of the control to be adjusted to effective needs. For this purpose, there are special operating parameters. These parameters have been grouped into two families: • frequent parameters (hereafter indicated as type F); • configuration parameters (type C), whose selection is protected by a code, called the password, to prevent unwanted tampering.
plug-in 6.3 Modifying the parameters After having displayed the first parameter, either type C or type F, proceed as follows: 1. press or to reach the parameter which needs to be modified; 2. press 3. increase or decrease the value using the 4. press 5.
plug-in continued d d0 dI dt dP d4 d5 d6 dd d8 d9 d/ dC A A0 AL AH Ad A4 A7 F F0 F1 F2 F3 Fd H H0 H1 H2 H4 H5 t defrost parameters type of defrost (0= heating element,1= hot gas, 2= water or element by time, 3= hot gas by time) interval between two defrosts end defrost temperature maximum defrost duration or effective duration when d0=2 or 3 defrost at instrument on (0=no, 1=yes) defrost delay when the unit is turned on or from digital input (A4 or A5 =4) display off during defrost (0=no, 1=yes) drippin
plug-in 7. ALARMS, TROUBLESHOOTING 7.1 Anomalous or special operating conditions The instruments in the PJ32 series are able to automatically detect the main malfunctions with the consequent activation of the following actions: • the malfunction is signalled on the display with the corresponding alarm code. In particular, the instrument displays the alarm code and the temperature read by the probe, alternating.
plug-in EE shown during operation or when the unit is turned on error in reading the parameters from the memory. See Data error. Ed flashing The last defrost ended after exceeding the maximum duration rather than reaching the end defrost set temperature: • check parameters dt, dP and d4; • check the efficiency of the defrost function. The message will disappear if the next defrost ends at the set temperature.
plug-in 7.4 Troubleshooting The following table shows other anomalous operating situations which may arise in the various models. The more frequent causes are indicated and a number of checks are suggested.
plug-in 8. AVAILABLE ACCESSORIES 8.1 Key for copying the parameters Duplicates the configuration of an instrument (set values of all the parameters and visibility flags), allowing them to be transferred to other instruments, as long as these have the same hardware configuration (same code). The key consists of a remote control type box with a connecting cable to the serial port of the instrument, and features an on/off button and a two-colour signal LED (red/green).
plug-in 8.2 Serial adapter for RS485 network 8.2.1 General characteristics The optional RS485 serial module allows the plug-in instruments to be connected to the CAREL supervisory network, providing complete control and monitoring of the operation of the plug-in instruments connected. The system features the possibility of connecting up to 200 units, with a maximum total connection length of 1000 m.
plug-in 8.2.2 Installation The mounting of the RS485 serial module uses a standard DIN rail, for wall-mounting an adapter is supplied (DIN rail plate) to fasten to the wall, onto which module is mounted. The module-instrument connecting cable is supplied with the module and is 50 cm long; the RS485 module should thus be located at a distance that is compatible with this connection, which can not be extended.
plug-in 8.2.4.1 Accessing and modifying type t parameters The method for displaying and modifying the added parameters present in the options (t parameters) is different from that used for the standard parameters on the instrument. The main difference is the fact that all the t parameters are scrolled only using the • button and not the Up and Down buttons. The procedure is the following: access the parameters of the expansion module.
plug-in 8.3 Additional HACCP module 8.3.1 General characteristics The optional HACCP module expands the control functions of the plug-in family instruments by adding temperature control with the recording of alarm siutuations due to the exceeding of the maximum temperature threshlolds for significant periods, which may derive from operating anomalies either in the controlled machines or due to power failures.
plug-in 8.3.4 Parameters - description The HACCP module uses some parameters from the plug-in instrument and its own parameter for the alarm recognition algorithm, and produces a set of variables for recording the HA and HF events if these occur. It also features parameters for setting the clock and entering up to eight defrost events at programmed times. All the parameters can be displayed and modified using the display and the buttons on the connected plug-in instrument.
plug-in tr: added HA alarm delay This parameter is saved in the HACCP module and is different from the alarm detection delay (parameter Ad) of the plug-in instrument. The HA alarm detection delay is the sum of the two tr + Ad. Warning: if tr = 0 the detection of the HA and HF alarms is disabled. Def.
plug-in 8.3.
plug-in When the HF alarm is detected the following information, regarding the status parameters, is recorded: • temperature before the power failure; • duration of the power failure ; • time the power failure is detected (instant the power resumes ); • temperature reached on resumption of power; • number of events (HF) detected.
plug-in 9.
plug-in 9.
plug-in 10. DIMENSIONS Fig. 10.1 dimensions (mm) A B C D fixed screw terminals 81 36 68 65 CAREL reserves the right to modify or change its products without prior notice. Cod. +030221881 rel. 1.3 - 03/05/2006 46 removable terminals 81 36 78 65 Tab. 10.
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CAREL S.p.A. Via dell’Industria, 11 - 35020 Brugine - Padova (Italy) Tel. (+39) 049.9716611 Fax (+39) 049.9716600 http://www.carel.com - e-mail: carel@carel.com Cod: +030221881 rel. 1.
