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

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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
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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
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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.
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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

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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

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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

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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
b
a
S1 S2 S3

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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
C

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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