Danfoss ERC 111 Bottle Cooler Controller Reference Manual

Introduction

The ERC 111 is an electronic refrigeration controller with an LED display, specifically designed for bottle coolers and commercial refrigerators and freezers. It is particularly suitable for OEM customers where time, easy and reliable installation, and high quality are paramount, alongside flexibility.

Approvals: Temperature control for refrigeration units. Front panel mounting.

Advantages: Features a latest-generation CPU, large memory capacity, and high-quality electronic components, enabling unique and versatile software. It supports three distinct password-protected user levels for controlling over 300 different parameters, allowing for adaptation to individual needs.

Homologations: Complies with standards for R290/R600a applications (EN/IEC 60335-2-24, Annex CC and EN/IEC 60335-2-89, Annex BB), incandescent wire (EN/IEC 60335-1), IEC/EN 60730, UL60730, NSF, CQC, and GOST R 60730.

Password Protection: Access levels can be set individually for each parameter using the 'Software tool'. There are three access levels: Level 1 for shop access, Level 2 for technicians, and Level 3 for OEMs. Passwords can be altered by users within their access level, but not for higher levels.

Typical Application

The ERC 111 is suitable for various refrigeration applications, including glass-door display cabinets and commercial refrigerators.

Display: LED display with 3 digits, multifunction icons, and decimal point. Available in red or blue. The top-left button can be configured as 'ECO' or 'Defrost'. The bottom-left button can be set to 'Standby'.

Buttons: 4 integrated buttons (IP65 rated) for user-programmable functions.

Clips: Two identical clips are used for rear mounting; not used for front mounting.

Front Frame: For front mounting, the controller is inserted into the opening, and the front frame is pressed into place, locking the controller.

Sensors:

• S1: Cabinet temperature sensor.
• S2: Defrost temperature sensor.
• di: Digital input.
• S1, S2, di: Connections for sensors.

The function of an input can be reprogrammed, but the connector position cannot be moved. The connector is designed for a single location.

Product General Description

The ERC 111 is an electronic refrigeration controller with an LED display, specifically designed for bottle coolers and commercial refrigerators and freezers. It is particularly suitable for OEM customers where time, easy and reliable installation, and high quality are paramount, alongside flexibility.

Quick Programming

Programming can be done via:

• Software for PC: Utilizes Danfoss software via a USB gateway and PC for parameter configuration, offering an alternative to front panel buttons.
• USB Gateway: A laboratory tool for quick and easy programming of any ERC controller connected directly to a PC. Includes the 'Software tool' installation kit for PC.
• USB Programming Device: Requires the 'Software tool' running on a PC for real-time parameter adjustment and status information. Parameter files can be saved to the USB device for mass programming.
• Docking Station: Used for high-volume programming, such as on assembly lines. The USB device is inserted into the docking station, and settings are loaded to each controller in seconds. 'Software tool' is not needed for mass programming.

Technical Specifications

Dimensions: Detailed diagrams show front and rear mounting dimensions.

Connections

A wiring diagram illustrates the connections for the compressor, power supply (100-240VAC SMPS), controller inputs (AI/DI's S1, S2, di), and optional communication with a PC via a gateway.

Code Numbers

A table lists various code numbers for different ERC 111 models, sensors, and programming accessories.

Operation

The controller can be operated in three ways:

• Software tool (software gateway): Allows easy parameter configuration via a USB gateway and PC.
• Docking station: For programming, contact your local Danfoss representative.
• Manual operation via buttons: Direct access to functions like setting temperature, defrost, or standby mode.

Examples:

• Changing the desired temperature setpoint: Press up/down buttons to access and adjust the setpoint. The display returns to the current temperature after 30 seconds.
• Alarm acknowledgment: Press any button to acknowledge an alarm message.
• Password protection: Access the menu by holding up/down buttons for 5 seconds, enter the password, and press OK.
• Changing a parameter: Access the menu, navigate to the desired parameter group and parameter, and adjust the value. Changes are saved after 30 seconds or by pressing 'Return' twice.

Important Note: Incorrect parameter settings can lead to inadequate refrigeration, excessive energy consumption, unnecessary alarms, and food safety violations. Only trained operators should change parameters.

Menu/Functions

This section details various menu parameters and their descriptions, including:

• Thermostat Configuration: Setpoint ('tHE'), Setpoint actual value ('SPr'), Thermostat differential ('diF'), Upper limit ('HSE'), Lower limit ('LSE').
• Initial Connection ('ici'): Controls compressor action on power-up.
• Pull Down Configuration ('Pud'): Settings for Super Cool function, including cycle duration ('PCY'), defrost interval ('Pdi'), and pull down duration limit ('Pdd').
• Defrost Configuration ('dEF'): Options for defrost type (electric, time, hot gas, natural), adaptive defrost ('Add'), terminate temperature ('dtt'), defrost restart temperature ('drt'), minimum defrost interval ('dii'), maximum defrost interval ('dAi'), minimum defrost time ('dit'), maximum defrost time ('dAt'), defrost with compressor ON ('dCt'), defrost by compressor run time ('doc'), evaporator start defrost temperature ('dEt'), defrost temperature difference ('ddt').

Compressor Configuration

Includes settings for compressor protection:

• Over-voltage protection ('uPt'): Enables voltage-related protection.
• Voltage limits ('uLi', 'uLo', 'uHi'): Set minimum and maximum voltage for compressor operation.
• Sensor error types ('EHd'): Options for handling sensor errors (none, control sensor error, automatic).
• Error execution time ('Ert'): Sets the duration for compressor operation in safety mode.
• Error stop time ('ESt'): Sets the duration for compressor inactivity in safety mode.
• Minimum stop time ('CSt'): Minimum idle time before compressor can start.
• Minimum run time ('Crt'): Minimum operating time before compressor can stop.
• Maximum stop time ('Cot'): Maximum idle time for the compressor.
• Start delay ('Pod'): Delay in seconds between power-up and compressor activation.
• Power factor ('PF1'): For relay 1, related to zero-crossing function.
• Start-up temperature ('Pot'): Accelerates initial pull-down in OEM assembly lines.

Condenser Protection Configuration

Requires a condenser temperature sensor. Protects against overheating due to dust accumulation.

• Condenser alarm limit ('CAL'): Sets the temperature at which an alarm is generated.
• Condenser lock-out limit ('CbL'): Sets the temperature at which the compressor shuts down.
• Condenser accept limit ('CoL'): Temperature at which the compressor can restart after being shut down due to exceeding 'CbL'.
• Condenser lower limit ('CLL'): Minimum temperature at which the compressor is allowed to start.

Display Configuration

Settings for display behavior:

• Display intensity ('din'): Sets screen brightness, either automatically based on ambient light or manually.
• Display unit ('CFu'): Selects between Celsius (°C) and Fahrenheit (°F).
• Sensor to display ('trs'): Selects which sensor's temperature to display (control, evaporator, condenser, or auxiliary).
• Display resolution ('rES'): Sets the display resolution for temperature readings (0.1, 0.5, or 1).
• Display range limit ('rLt'): Restricts the displayed temperature to connection/disconnection limits.
• Display delay ('ddL'): Provides a realistic temperature appearance by applying a moving average filter.
• Display compensation ('doF'): Allows for a relative temperature adjustment on the display.
• Defrost lock-out time ('dLt'): Locks the displayed temperature during defrost to show an ascending temperature.
• Display pull down state ('SHO'): Shows 'SC' when the system is in pull down mode.
• Display vacation ('SdF'): Shows 'HoL' during vacation mode.
• Display defrost ('SCS'): Shows 'DEF' when the system is in defrost mode.
• Compressor symbol ('Sds'): Toggles the compressor symbol display.
• Defrost symbol ('idp'): Toggles the defrost symbol display.
• Information menu display item: Configures items shown in the information menu (visible in 'Software tool' only).

Alarm Configuration ('ALA')

• High temperature alarm ('HAt'): Absolute value; disables alarms when set to maximum.
• Low temperature alarm ('LAt'): Absolute value; disables alarms when set to minimum.
• High temperature alarm delay ('Htd'): Minutes before alarm sounds for high temperature.
• Low temperature alarm delay ('Ltd'): Minutes before alarm sounds for low temperature.
• Pull down temperature delay ('Pdd'): Prevents high temperature alarm during pull down and after defrost.
• Voltage alarm ('uAL'): Enables or disables voltage alarms.
• Leak alarm ('LEA'): Detects leaks for compressor protection.
• Alarm bell duration ('Abd'): Sets the duration for which an alarm will sound.

ECS (Energy Saving Strategy)

• Pull down temperature time ('tto'): Time for ERC to enter vacation or ECO mode for service or pull down temperature.

ECA (ECO Management)

• ECO temperature compensation ('Hto'): Adjusts temperature relative to normal mode during vacation mode.

ASI (Configuration of Assignments)

• MODBUS security ('USA'): Enables or disables automatic MODBUS detection.
• Air temperature adjustment ('t1A'): Relative adjustment for control sensor temperature.
• Inputs and outputs are configurable: Define sensor type (temperature, light/digital) and application (control, condenser, evaporator, ECO, display, movement, door sensor).
• Sensor configuration ('S1C', 'S2C', 'S3C', 'S4C'): Assign sensor types (standard NTC 5K, high temperature NTC 100K).
• Sensor application ('S1A', 'S2A', 'S3A', 'S4A'): Assign sensor applications (none, control, evaporator, condenser, display only).
• D01 configuration ('01C'): Assign compressor control (direct, pilot relay).
• Button programming: Assign functions (short press/long press) for various buttons (e.g., setpoint adjustment, ECO mode, defrost, display intensity).

Service Information

Read-only parameters providing information for technicians and OEMs:

• Compressor accumulated run time ('ACt').
• ERC accumulated activity time ('AEt').
• Voltage ('uAC'): Current supply voltage.
• DOs status ('ous'): Current status of relays (open/closed).
• Relay 1 counter ('rL1'): Cycles of the compressor relay.
• Interval counter ('int'): Compressor run time since last defrost.
• Defrost time counter ('dnt'): Duration of the last defrost cycle.
• Serial number ('Snu'): Serial number from manufacturing.
• Software version ('Fir').
• Hardware version ('HAr').
• Order numbers ('onL', 'onH').
• OEM codes ('OEL', 'oEn', 'OEH').
• Parameter version ('PAr').
• Date of manufacture ('CHd').
• Set to default ('SFC'): Resets parameters to last known good OEM configuration.
• Condenser temperature ('Ctt').
• Evaporator temperature 1 ('Et1').
• Auxiliary temperature ('Aus').
• Raw air temperature ('att').

Display Messages:

• 'unP': Device not programmed (relay output blocked).
• 'Prg': Device programming not finished (relay output blocked).
• 'SC': Device in pull down mode (super cool).
• 'dEF': Device is defrosting.

Troubleshooting

This section addresses common problems and their probable causes and solutions:

• Compressor not starting: Check compressor delay timers, voltage, or if in pull down mode.
• Defrost not starting: Check defrost parameters or if in pull down mode.
• Alarm not sounding: Check alarm delay settings.
• Display alternating between condenser and temperature: Likely due to high condenser temperature; clean condenser.
• Display alternating between high and temperature: Check high temperature alarm settings.
• Display alternating between low and temperature: Check low temperature alarm settings.
• Display shows 'dEf': Defrosting in progress.

A table provides specific alarm triggers, their causes, and recommended solutions, including checking specific parameters and ensuring proper sensor connections.

Typical Applications

Illustrates typical applications such as glass-door display units and frost-free freezers/under-counter refrigerators, including wiring diagrams and sensor specifications.