Danfoss ERC 112 Electronic Refrigeration Controller

Introduction

The ERC 112 is an electronic refrigeration controller with an LED display, designed for bottle coolers and commercial fridges and freezers. It offers flexibility, easy and reliable installation, and high quality, making it particularly suited for OEM customers.

Application: Temperature control for refrigeration appliances, front panel mounting.

Advantages: Features a latest generation CPU, ample memory, and high-end electronic components for versatile software. It supports three password-protected user levels, allowing control over more than 300 parameters to meet individual requirements.

Approvals: Complies with R290/R600a end-use applications according to EN/IEC 60335-2-24 and EN/IEC 60335-2-89, glow wire according to EN/IEC 60335-1, IEC/EN 60730, UL60730, NSF, CQC, and EAC standards.

Password Protection: Access levels can be set separately for each parameter using KoolProg Software. Three levels exist: Level 1 (shop access), Level 2 (technicians), and Level 3 (OEMs). Passwords can be altered, but higher-level passwords cannot be changed by lower-level users.

Typical Applications

The ERC 112 is suitable for various applications, including:

• Glass Door Merchandiser (No-frost freezer/sub-zero cooler)
• Gastro No-frost freezer/Cooler

Detailed wiring diagrams and product codes for different configurations (e.g., ERC 112D, ERC 112C) are provided for these applications.

Product Overview

Display: Features a 3-digit LED display with decimal point and multi-functionality icons. Available in red or blue.

Buttons: The controller has buttons that can be configured for functions like ECO, Night Mode, Light, Standby, and Super Chill.

Clips: Used for rear mounting to secure the controller. Not used with front mounting.

Front Frame: Provides a finished look and can be used to secure the controller during front mounting.

Inputs: The controller has 5 inputs (4 analogue/digital, 1 digital) that are configurable for various sensors (cabinet air, evaporator, condenser, light, motion, door signal) and optional external buttons.

Quick Programming

Programming can be done using:

• KoolProg Software: For PC-based programming, offering easy parameter setting. Downloadable from the Danfoss website.
• KoolKey (EKA200): A smart device acting as a gateway for PC connection with KoolProg or as a programming key for fast programming.
• Mass Programming Key (EKA 201): A simple programming key for production assembly lines, requiring KoolProg software.

Refer to specific installation guides for KoolKey and EKA 201.

Technical Specifications

Power Supply: 100-240 V AC Switch mode, average 0.7 W.

Purpose of Control: Commercial Refrigeration Applications.

Construction: Electronic control for Class I and Class II appliances.

Automatic Action: Micro-disconnection on operation type 1.B.

Inputs: 5 inputs (4 analogue/digital, 1 digital), user-specific assignment.

Outputs: Multiple outputs (DO1 to DO6) with various ratings, supporting compressor, fan, lights, and defrost heater/valve.

Probes: Compatible with Danfoss NTC sensors and Danfoss ECO accessories (Light, Motion, Door sensors), and Danfoss Pt 1000 ohm/0°C sensors.

Programming: Via Danfoss KoolProg PC software, docking station, or programming key.

Assembly: Front mounting with brackets.

Display: 3-digit LED display with decimal point and multi-functionality icons (°C/°F).

Keypad: 4 buttons (integrated IP65 design).

Operating Conditions: 0-+55 °C, 93% RH (non-condensing).

Storage Conditions: -40-+85 °C, 93% RH.

Range of Measurement: -40 - +85 °C with standard sensors; -40 - +200 °C with NTC 100K sensors.

Protection: Front: IP65; Rear: IP31 (IP00 for connectors).

Environmental: Pollution degree II, non-condensing.

Resistance to heat & fire: Category D (UL94-V0).

EMC category: Category I.

Over Voltage Category: Category II (IEC 60664-1).

Temperature for Ball Pressure Test: According to EN 60730-1, Annex G.

For SELV Circuits: Input probes or digital inputs connected to SELV limited energy >15W.

Operating Cycles: Compressor relay: >175,000 at full load (16A).

Approvals: R290/R600a applications, Glow wire, IEC/EN 60730, UL60730, NSF, CQC, EAC, Ukraine.

IMPORTANT NOTE: Inputs are not galvanic isolated and are connected directly to the mains supply. Door-switches, sensors, and cables must fulfill reinforced insulation requirements.

Dimensions: Provided for front and rear mounting.

Connections

Wiring diagrams illustrate connections for ERC 112C and ERC 112D models, showing power supply, outputs (DO1-DO4), and inputs (AI/DI's S1-S4, Di).

Note: S4 Port can also be used to connect other sensors and Door sensor.

Code Numbers

A comprehensive list of code numbers for various ERC 112 models, including different display colors, buzzer options, and STM32 versions, is provided. This section also lists code numbers for light sensors, magnetic door sensors, cable door sensors, motion sensors, clips, programming tools (KoolKey, Mass Programming Key), interface cables, and temperature sensors with varying lengths and types.

Operation

Programming Tools: The controller can be configured using KoolProg, KoolKey (as Gateway or Copy Key), Docking Station, or the front panel buttons.

Manual Operation with Buttons (Direct Access): Allows direct access to functions like ECO/Night Mode, Light, and temperature set point adjustments using the front panel buttons.

Examples of Operation:

• Changing Desired Temperature Set point: Navigate using up/down buttons.
• Turning ON/OFF ECO Function: Press the "ECO" button.
• Turning ON/Off Light: Press the "Light" button.
• Acknowledging Alarms: Press any button to acknowledge a flashing alarm message.
• Password Protection: Access the menu by holding "^" and "v" buttons. Three levels of access (Shop, Service, OEM) are available.
• Changing a Parameter: Access the menu and navigate through parameter groups and settings using the buttons.

Info Menu: Provides key information about the controller, such as highest, lowest, and average cab air temperatures, and active alarms. Temperature values can be reset.

Note: Incorrect parameter settings can lead to inadequate cooling, energy consumption issues, alarms, and potential breaches in food hygiene principles. Only trained operators should change parameters.

Menu/Functions

This section details various parameters and their settings, categorized as:

• Thermostat settings: Set point ("SEt"), differential ("diF"), limits ("HSE", "LSE"), initial cut-in ("ici"), seasonal offset ("SP2", "dF2").
• Fan settings: Control method ("FCt"), ON/OFF delays ("Fod", "FSd"), cycles ("FoC", "FSC"), minimum stop time ("FSt"), fan stop on door open ("FdC"), fan limit temperature ("FLt"), and fan limit delta temperature ("FdF").
• Light settings: Cabinet light control ("CLC") and light OFF delay ("Lod").
• Pull Down settings: Initiate temperature ("Pit"), cycling duration ("PCy"), defrost interval ("Pdi"), duration ("Pdd"), limit temperature ("PLt"), and reduction temperature ("Prt").
• Defrost settings: Type ("dFt"), adaptive defrost ("Add"), terminate temperature ("dtt"), reset temperature ("drt"), minimum/maximum intervals ("dii", "dAi"), minimum/maximum times ("dit", "dAt"), drip off time ("dot"), fan delay after defrost ("Fdd"), fan start temperature ("Ftd"), defrost fan on ("dFA"), defrost by accumulated compressor run time ("dCt"), defrost by continuous compressor ON time ("doc"), defrost start evaporator temp ("dEt"), defrost at ("ddt"), initial defrost interval ("idi"), initial defrost duration ("idd").
• Compressor settings: Voltage protection ("uPt", "uLi", "uLo", "uHi"), sensor error type ("EHd"), error run time ("Ert"), error stop time ("ESt"), minimum stop time ("CSt"), minimum run time ("Crt"), maximum OFF time ("Cot"), compressor door open delay ("Cdd"), system resume after door open ("Srt"), power ON delay ("Pod"), power ON temperature ("Pot"), second compressor delay ("Scd").
• Condenser Protection settings: Condenser alarm limit ("CAL"), condenser block limit ("CbL"), condenser OK limit ("CoL"), condenser low limit ("CLL").
• Display settings: Intensity auto control ("dic"), display intensity ("din"), display unit ("CFu"), temp sensor to display ("trs"), display resolution ("rES"), display range limit ("rLt"), display delay ("ddL"), and display offset ("doF").
• Alarm settings: High Temp Alarm ("HAt"), Low Temp Alarm ("LAt"), alarm delays ("Htd", "Ltd"), pull down delay ("Pdd"), door open delay ("dod"), voltage alarm ("uAL"), leakage alarm ("LEA"), alarm buzzer duration ("Abd"), auto clear of alarm/error/ACA ("ACA").
• Automatic Heater settings: Automatic Heater Mode Enable ("AuH"), Energy Mode Delay ("End"), Auto Heat set point ("AHS"), Auto heat differential ("AHd").
• ECO strategy: ECO ON/OFF ("ECO"), door actions ("EdA"), PIR actions ("EPA"), action counter time ("ECt"), door delay ("Edd"), PIR delay ("EPd"), shop light day/night ("SLd", "SLn"), time to pull down ("tto"), light source delay on ECO ("LSd").
• ECA (ECO management): Early wake up ON/OFF ("Euu"), shop close hour ("CLH"), early wake up time offset ("ErL"), holiday length ("HOL").
• ECO management: Eco Temperature Offset ("Eto"), Holiday Temperature Offset ("Hto"), ECO Differential ("die"), ECO Fan on cycle ("FOE"), ECO Fan stop cycle ("FSE"), ECO Cabinet light control ("ELC"), Eco Light Delay ("ELd").
• ASi (Assignments settings): MODBUS Safety ("USA").

Inputs and outputs are configurable

The controller allows for flexible configuration of inputs and outputs. Users can define the type of sensor attached to each input (temperature, light, digital) and its application (control, condenser, evaporator, light, motion, door contact, ECO mode, bus communications).

Note: Coded sensors may limit the number of possible configurations. Danfoss supplies 2-pole defrost sensors, typically used for input S3.

Troubleshooting

This section provides a guide to common problems, their probable causes, and recommended remedies:

• Compressor does not start: Check compressor delay timer, voltage, or defrost status.
• Fan does not start: Check door contact or pull-down mode.
• Defrost does not start: Check pull-down mode or defrost parameters.
• Alarm does not sound: Check alarm delay or pull-down delay.
• Display brightness is weak: Replace ambient light sensor or adjust settings.
• ECO/Normal mode shift issues: Check ambient light sensor or settings.
• Display alternates between condenser and temperature: Clean condenser or check related parameters.
• Display alternates between high and temperature: Check temperature settings.
• Display alternates between low and temperature: Check temperature settings.
• Display shows "dEf": Defrost in progress.

A table details alarm codes (Hi, Lo, Con, dor, uHi, uLi, LEA, E01-E04), their trigger conditions, automatic clearance, outputs, and comments, assisting in diagnosing and resolving issues.

Sensor Placement

Guidelines are provided for the correct placement of various sensors:

• Control sensor: Essential for compressor control and temperature display. Placement varies for vertical coolers with fans, vertical freezers with fans, and coolers without fans.
• Evaporator sensor: Used only for de-icing; placement should be where ice melts last.
• Condenser sensor: Protects the compressor against high pressure due to blocked condensers or failed fans. Placement should be at the liquid side of the condenser with good thermal conductivity.
• Ambient light sensor: Used to detect opening hours of the shop. Placement should avoid interior light interference.
• Door sensor: Detects buying activity and stops the fan when the door is opened. Danfoss does not supply the door switch itself.