Danfoss 102 User manual

www.danfoss.com/erc

This reference manual is intended to be used primarily by OEMs for the purposes of programming ERC 102.

It may also be useful for technicians. It is not intended as a user guide for end users.

ERC 102 refrigeration controller

Reference manual

MAKING MODERN LIVING POSSIBLE

Table of Content

1. INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2. CONTENT OF THE BOX

2.1 Main product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2.2 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2.3 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3. OVERVIEW OF THE PRODUCT

3.1 Control buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

3.2 Connector inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

3.3 Connector outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3.4 Top label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

4. MOUNTING

4.1 Rear mounting – Option 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

4.1.1 Unmounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

4.2 Front mounting – Option 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

4.2.1 Unmounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

4.3 Fully-integrated design. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

5. CONTROLLING/NAVIGATION

5.1 KoolProg and Gateway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

5.2 Docking station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

5.3 Manual operation with buttons (Direct Access) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

5.3.1 ERC Front and Button Functionallity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

5.3.2 Direct functions for access. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

5.3.3 Operating the menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

5.3.4 Menu structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

5.3.5 Password protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

6. CONFIGURATION OF INPUTS AND OUTPUTS

6.1 Changing input and output conﬁguration settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

6.2 Program the buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

6.3 Set passwords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

6.4 Set lighting function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

ERC 102 Reference manual

7. PARAMETERS

7.1 Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

7.2 Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

7.3 Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

7.4 Defrost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

7.5 Fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

7.6 Energy management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

7.7 Pull down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

7.8 Automatic heater control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

7.9 Condenser protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

7.10 Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

7.11 Assignments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

7.12 Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

8. TECHNICAL SPECS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

APPENDIX

I Parameter quick list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

II Code numbers and lenghts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

III Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

IV Typical applications – wiring diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

IV.1 Typical Wiring Diagram, ERC 102D, Glass Door Merchandiser,

No-frost freezer / sub-zero cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

IV.2 Typical Wiring Diagram, ERC 102C, Glass Door Merchandiser . . . . . . . . . . . . . . . . . . . . . 54

IV.3 Typical Wiring Diagram, ERC 102D, Gastro No-frost freezer . . . . . . . . . . . . . . . . . . . . . . 55

IV.4 Typical Wiring Diagram, ERC 102C, Gastro Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

V Application speciﬁcatons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

V.1 Control sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

V.2 Evaporator sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

V.3 Condenser sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

V.4 Ambient light sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

V.5 Door sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

ERC102 Application Matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

ERC 102 Reference manual

1. INTRODUCTION

The ERC 102 is an electronic refrigeration controller with an LED display especially developed for bottle

coolers and commercial fridges and freezers. It is particularly suited for OEM customers where time, easy and

reliable installation and high quality need to go hand in hand with ﬂexibility.

The latest generation CPU, plenty of memory and high-end electronic components allow for a uniquely

versatile software. Three separate password-protected user levels can be used to control more than 200

diﬀerent parameters to ﬁt all individual requirements.

ERC 102’s IP rated body, advanced materials and internationally approved hardware design open it up for use

in almost any climate globally, indoors as well as outdoors.

Laboratory work with ERC 102 is rendered easy and ﬂexible. Danfoss KoolProg software with a USB-powered

gateway accelerate programming; on the OEM assembly line, just one Danfoss unique Docking station can

easily program up to 3,000 controllers a day – at zero inventory cost.

It uses a globally-compatible, lightweight, switch mode power supply.

All components have been carefully selected to help reduce the CO2 footprint. The globally-compatible

internal power supply uses an average of just 0.7W – 4 times less than an average controller today.

Sensors include ambient light for display brightness, which also detect shop opening hours for

energy-saving routines. Door and temperature sensors provide input for controlling the compressor,

the light, the fan and automatic defrosting.

ERC 102 Reference manual

2. CONTENT OF THE BOX

2. 1 Main product

2.2 Accessories

ERC 102 control unit without front frame.

NOTE: The front frame is included in the sample box.

If delivered in a sample box the following content

is shipped. The sample box is not available for other

than sample purposes.

See Appendix II for code numbers and lengths.

For box lots (pcs per box), please contact your local

Danfoss representative.

Control temperature sensor: see Appendix II for

diﬀerent lengths and connector types.

Condenser temperature sensor: should be

mounted on the condenser. For detailed

mounting instructions, please contact your

local Danfoss representative.

NOTE: This sensor is not included in the sample box .

Defrost sensors can also be used as condenser

sensors.

Defrost temperature sensor: should be mounted on

the evaporator. For detailed mounting instructions,

please contact your local Danfoss representative.

NOTE: Defrost sensors can also be used as condenser

sensors.

ERC 102 Reference manual – 2 CONTENT OF THE BOX

Door sensor connector cable: please see Appendix II

for lengths and code numbers.

NOTE: Door sensor: is optional and is a connector

and cable with spade terminals compatible with door

contacts used in refrigeration applications.

Clips: are used to secure the ERC 102 in place in

the case of rear mounting. They are not used with

front mounting. There are two identical clips, one

placed on either side of the ERC 102. See Chapter 4

– Mounting – for further details.

Light sensor: is optional and is used to measure the

level of ambient light around the cabinet so

that night and day (Economy / Normal) modes

of operation can automatically be set, as well

as the brightness of the display.

Power plug: for laboratory use, low quantity

OEM production or whenever spade connectors are

not available.

ERC 102 Reference manual – 2 CONTENT OF THE BOX

2.3 Connections

Programming an individual unit in a laboratory:

the USB gateway requires KoolProg Software

running on a PC. It enables parameters to be set in

real time and an array of status information to be

read (bidirectional connection). This method is used

to determine the correct parameters during R&D.

Once the desired settings have been determined,

a KoolProg ERC speciﬁc parameter ﬁle is saved to the

EKA183 USB copy key for later mass programming.

The USB Gateway is a laboratory tool, oﬀering fast

and easy programming of any ERC102 controller.

KoolProg software installation is provided;

the gateway is standard inventory for OEM labs.

Mass programming on an assembly line:

the docking station is used for high volume

programming of ERC controllers, for example

on an assembly line. The docking station is a

write-only device.

See above (Programming an individual unit) for

preparing the EKA183 USB copy key, which is to

be inserted into the docking station. The settings

are then loaded into each successive controller

in a matter of seconds.

KoolProg software is not required for mass

programming.

Note: please refer to the koolprog manual for more

details about programming.

KoolProg: is the software from Danfoss for

programming the ERC 102 via a USB cable and

a PC rather than with the front panel buttons.

Please refer to the KoolProg manual for details.

ERC 102 Reference manual – 2 CONTENT OF THE BOX

The ERC 102 is a state-of-the art, IP65 (front)-rated

refrigeration controller for use in both Glass Door

Merchandising and Commercial Fridges and Freezer

applications.

With four inputs and four outputs, powerful

algorithms and input from multiple sensors, the ERC

102 delivers both energy-saving routines and

compressor, light, fan and defrost control.

Together with the Danfoss docking station,

programming of pre-prepared parameter sets can

be achieved in just ﬁve seconds. There are over 200

parameters (see Chapter 7) including innovative

features such as night mode detection,

store opening detection, door open alarm control

and display dimming for restaurants.

The ERC 102 can also be programmed via USB using

the Danfoss KoolProg software, allowing the most

suitable parameter ﬁndings to be found quickly

during the application development process.

It is also possible to operate and program the

controller using the control buttons (only when

actually installed in a refrigerator / freezer).

Overview of ERC 102 models:

Model: Digital outputs:

ERC 102A 1 relay

ERC 102C 3 relays

ERC 102D 4 relays

3. OVERVIEW OF THE PRODUCT

3.2 Connector inputs

Connect up to four Danfoss original sensors according

to your application needs.

There are three analogue inputs: S1, S2 and

S3 ( a).

Supported input options:

· Ambient light - analogue data [luminens]

· Cabinet (air) temperature - analogue data [°C]

· Evaporator temperature - analogue data [°C]

· Condenser temperature - analogue data [°C]

· Digital input - binary data [on/oﬀ]

There is one digital input: diC ( b) for PC

communication being used either with a door

sensor or with the USB Gateway.

NOTE: for detailed information refer to section 6.1.

The ambient light sensor can be used for determin-

ing shop open / closed times for economy mode

switching, for determining the brightness of the LED

display or both.

3.1 Control buttons

The ERC 102 has four buttons (circled in image)

on the front which can be programmed to perform

diﬀerent functions. See Chapter 6 – Conﬁguration of

inputs and outputs for detailed information.

ERC 102 Reference manual – 3 OVERVIEW OF THE PRODUCT

S1 S2 S3

3.4 Top label

The illustration shows an example of a top label

aﬃxed to an ERC 102D. The examples show what

is connected:

• Output 1 is used to switch the compressor

on and oﬀ.

• Outputs 2 and 3 are power – Live and Neutral.

• Output 4 is used to switch the heater on and oﬀ.

• Output 5 is used to switch the fan on and oﬀ.

• Output 6 is used to switch the light on and oﬀ.

• Input D (S1) is connected to a Cabinet Sensor to

measure temperature inside the cabinet.

• Input C(di) is used for Communications – a docking

station or KoolProg software running on a PC.

• Input B(S2) is connected to an Evaporator

Temperature Sensor.

• Input A(S3) is connected to an Ambient Light Sensor.

NOTE: Parameters depend on the code number sup-

plied. Please refer to the code number

speciﬁc technical drawing or use the KoolProg infor-

mation menu. For other applications,

a condenser sensor and a door sensor may

be used.

3.3 Connector outputs

All four outputs ( c) are digitally controlled

on/oﬀ relays.

Functions controlled are:

• Compressor

• Pilot Relay

• Heater

• Defrost heater / valve for hot gas

• Alarm

• Fan

• Light

ERC 102 Reference manual – 3 OVERVIEW OF THE PRODUCT

There are three options for mounting the ERC 102

in a freezer or refrigerator.

SAFETY INFO

Risk of electrocution!

For mounting: Do not connect mains power until

the controller is correctly mounted.

For unmounting: Disconnect the power supply

before unmounting.

4. MOUNTING

1. Insert the ERC 102 into the cabinet.

2. Attach the clips to each side of the ERC 102.

3. Place the front frame on to the ERC 102 and click

it into place.

4. Connect the sensors and outputs as required and

then the power cable (see Chapter 6 – parameters

for information about programming which inputs

and outputs are applicable to your conﬁguration).

4.1 Rear mounting – Option 1

ERC 102 Reference manual – 4 MOUNTING

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