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REV. A 809-129A

ELECTRONIC CONTROLLER

SERVICE KIT

Installation, Operation and Troubleshooting Manual

Phone: (888) 845-9800 Fax: (800) 253-5168 Website: www.beverageair.com

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REV. A 809-129A

Important Information, Please Read

REMEMBER, SAFETY FIRST. PLEASE BE SAFE AT ALL TIMES

When using electrical appliances, basic safety measures should always be taken. These include, but are NOT limited to: -following manufacturers installation instructions -having service done only by qualified technicians

IMPORTANT – HC MODELS

Please use care when moving or handling this equipment. It is equipped with flammable refrigerant and damage to refrigerant tubing will increase the risk of a leak.

When service is required, seek factory authorized technicians trained to safely maintain and service systems that utilize flammable refrigerants, such as R290. RSES offers such training and certification.

Use factory authorized replacement parts to minimize the risk of possible ignition.

IMPORTANT INFORMATION

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REV. A 809-129A

TABLE of CONTENTS

1. Introduction

1.1 Function of Controller Kit 4

1.2 Parts Included in Kit 4

1.3 Verify Kit is Required 5

2. Installation

2.1 Access to Faulty Control 6

2.2 Removing Faulty Control 6

2.2.1 DIXELL XR02CX (REFRIGERATOR) 6

2.2.2 DIXELL XR06CX (FREEZER) 7

2.2.3 ELIWELL nEW974 (REFRIGERATOR) 8

2.2.4 ELIWELL nEW974 (COIL SENSING REFRIGERATOR) 9

2.2.5 ELIWELL nEW974 (FREEZER) 10

2.2.6 ELIWELL EWPlus 978 (REFRIGERATOR) 11

2.2.7 ELIWELL EWPlus 978 (FREEZER) 11

2.2.8 ELIWELL EWPlus 978 EO (REFRIGERATOR) 12

2.2.9 ELIWELL EWPlus 978 EO (FREEZER) 12

2.2.10 DANFOSS ERC112C (REFRIGERATOR) 13

2.2.11 DANFOSS ERC112D (FREEZER) 14

2.3 Installing New Control 15

2.4 Access to Control Parameters 15

2.5 Adjusting Parameters to Unit Operation 15

2.5.1 Refrigerator Parameter Table 16

2.5.2 Freezer Parameter Table 16

2.6 Cycle Power 16

2.7 Monitor Operation 16

2.8 Adjust Off-Set If Needed 16

3. Electronic Controls

3.1 Standard Control Functions 17

3.2 Control Panel Display 17

3.3 Keyboard Functions 18

3.4 Control Panel Connections 18

3.5 Changing the Set Point 19

3.6 Electronic Controller Alarms 19

4. Trouble Shooting Chart

5.1 General 21

5.2 Refrigerator Ladder Diagram 22

5.3 Freezer Ladder Diagram 23

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REV. A 809-129A

INTRODUCTION

1.1 Function of Controller Kit The Beverage-Air Electronic Controller Kit is to be a replacement kit for controllers that have become faulty. There are two versions of this kit, the Refrigerator Kit and the Freezer Kit. The controller included with this kit has been designed to replace a variety of controls. If the instructions in this manual are followed properly then the unit being serviced will work as intended with minimal time and labor.

NOTE: THE CABINET TEMPERATURE AND DISPLAY TEMPERATURE MAY VARY ±3°F

1.2 Parts Included with Kit

Quantity Description Beverage-Air Part Number

1x Refrigerator Service Control

or Freezer Service Control

502-514D-09 (REF) or 502-514D-10 (FRZ)

1x Electronic Control Service Kit Manual 809-129A

1x DANFOSS INPUT WIRE HARNESS *‡ 515-364D

6x CONNECTOR – 2 LEVER NUT 505-176D-01

2x CLIP-DANFOSS CONTROLLER 604-264D

6x ¼” Insulated Female Connector 504-299A

*Evap Sensor Adapter will only be used with freezers and coil sensing refrigerators ‡Digital Input Adapter Cable will only be used with freezers and refrigerators that have solid door with

lights controlled with the controller. Dependent on wiring, see installation instructions for more Info.

DANFOSS INPUT WIRE HARNESS

AIR SENSOR WIRES

DIGITAL INPUT WIRES EVAP SENSOR WIRES

.

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REV. A 809-129A

1.3 Verify Kit is Required Before attempting to change out the original control in the unit, make sure all the probes are working properly. A faulty probe in the system may look like a malfunctioning controller. To check the probes, disconnect them from the controller. Using an ohmmeter, measure the resistance between the probe wires. The resistance of the probes changes based on the temperature of the cabinet. Refer to the charts below to compare the probe resistance to cabinet temperature. If the values do not match, the probes may be faulty and require replacement. Contact our technical service department for further information. +1 (800) 684 - 1199

5k NTC THERMISTOR 10K NTC THERMISTOR

RESISTANT VALUES MAY NOT BE EXACT. MAY VARY ±200 OHMS

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REV. A 809-129A

INSTALLATION

2.1 Removing Faulty Control

1. Remove mounting clips from controller. There are 2 clips on each controller. Push on the clips to release

the catch then slide the clips off.

2.2 Wiring New Control

Each type of control has its own specific wiring. Find the control you are replacing below and follow the instructions. Make sure all wires and sensors are routed through the controller mounting knock out before continuing.

2.2.1 DIXELL XR02CX TO DANFOSS ERC112D (Refrigerator)

1. Unplug wires and probe from Dixell XR02CX 2. Using one of the Wire Caps from the kit, cap red wire and wrap with electrical tape 3. Cut the connector off the probe wire and strip each wire back ¼”. 4. Using the Air Sensor Adapter Cable from the Kit, insert one wire from the sensor into each

lever nut and close them. 5. Plug the sensor into the “S1” input on the new Danfoss ERC112D 6. Plug each wire into the new control as shown below

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REV. A 809-129A

INSTALLATION

2.2.2 DIXELL XR06CX TO DANFOSS ERC112D (Freezer)

1. Unplug wires and probe from Dixell XR06CX 2. Using two of the Wire Caps from the kit, cap two of the black wires and wrap with electrical

tape 3. Cut the connector off the probe wires and strip each wire back ¼”. 4. Using the Adapter Cables from the Kit, insert one wire from the air probe into each of the air

probe adapter lever nuts, one wire from each evap probe into the evap probe adapter lever nuts

5. Plug the air sensor into the “S1” input on the new Danfoss ERC112D, plug the evap sensor into “S2”, Plug the Digtal input for the door into “di”

6. Plug each wire into the new control as shown below

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REV. A 809-129A

INSTALLATION

2.2.3 ELIWELL nEW974 TO DANFOSS ERC112D (Refrigerator)

1. Unplug wires and probe from Eliwell nEW974 2. Using two of the Wire Caps from the kit, cap two of the black wires and wrap with electrical

tape. 3. Cut the connector off the probe wires and strip each wire back ¼”. 4. Using the Adapter Cables from the Kit, insert one wire from the air probe into each of the air

probe adapter lever nuts, one wire from each evap probe into the evap probe adapter lever nuts

5. Plug the air sensor into the “S1” input on the new Danfoss ERC112D, plug the evap sensor into “S2”, Plug the Digtal input for the door into “di”

6. Plug each wire into the new control as shown below

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REV. A 809-129A

INSTALLATION

2.2.4 ELIWELL nEW974 TO DANFOSS ERC112D (Coil-Sensing Refrigerator)

1. Unplug wires and probe from Eliwell nEW974 2. Cut the connector off the probe wires and strip each wire back ¼”. 3. Using the Adapter Cables from the Kit, insert one wire from the air probe into each of the air

probe adapter lever nuts, one wire from the evap probe into each evap probe adapter lever nuts, one wire from the digital input into

4. Plug the air sensor into the “S1” input on the new Danfoss ERC112D, plug the evap sensor into “S2”, Plug the Digtal input for the door into “di” if available.

5. Plug each wire into the new control as shown below

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REV. A 809-129A

INSTALLATION

2.2.5 ELIWELL nEW974 TO DANFOSS ERC112D (Freezer)

1. Unplug wires and probe from Eliwell nEW974 2. Cut the connector off the probe wires and strip each wire back ¼”. 3. Using the Adapter Cables from the Kit, insert one wire from the air probe into each of the air

probe adapter lever nuts, one wire from the evap probe into each evap probe adapter lever nuts, one wire from the digital input into (if provided)

4. Plug the air sensor into the “S1” input on the new Danfoss ERC112D, plug the evap sensor into “S2”, Plug the Digtal input for the door into “di” if available.

5. Plug each wire into the new control as shown below

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REV. A 809-129A

INSTALLATION

2.2.5 ELIWELL EWPlus 978 TO DANFOSS ERC112D (Refrigerator)

1. Unplug wires and probe from Eliwell EWPlus 978 2. Cut the connector off the probe wires and strip each wire back ¼”. 3. Using the Adapter Cables from the Kit, insert one wire from the air probe into each of the air

probe adapter lever nuts, one wire from the digital input into each of the D.I. adapter lever nuts (if provided)

4. Plug the air sensor into the “S1” input on the new Danfoss ERC112D, Plug the Digtal input for the door into “di” if available.

5. Plug each wire into the new control as shown below

2.2.5 ELIWELL EWPlus 978 TO DANFOSS ERC112D (Freezer)

1. Unplug wires and probe from Eliwell EWPlus 978 2. Cut the connector off the probe wires and strip each wire back ¼”. 3. Using the Adapter Cables from the Kit, insert one wire from the air probe into each of the air

probe adapter lever nuts, one wire from the evap probe into each evap probe adapter lever nuts, one wire from the digital input into each of the D.I. adapter lever nuts

4. Plug the air sensor into the “S1” input on the new Danfoss ERC112D, plug the evap sensor into “S2”, Plug the Digtal input for the door into “di” if available.

5. Plug each wire into the new control as shown below

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REV. A 809-129A

INSTALLATION

2.2.5 ELIWELL EWPlus 978 EO TO DANFOSS ERC112D (Refrigerator)

1. Unplug wires and probe from Eliwell EWPlus 978 EO 2. Cut the connector off the probe wires and strip each wire back ¼”. 3. Using the Adapter Cables from the Kit, insert one wire from the air probe into each of the air

probe adapter lever nuts, one wire from the evap probe into each evap probe adapter lever nuts, one wire from the digital input into each of the D.I. adapter lever nuts

4. Plug the air sensor into the “S1” input on the new Danfoss ERC112D, plug the evap sensor into “S2”, Plug the Digtal input for the door into “di” if available.

5. Plug each wire into the new control as shown below

2.2.5 ELIWELL EWPlus 978 EO TO DANFOSS ERC112D (Freezer)

1. Unplug wires and probe from Eliwell EWPlus 978 EO 2. Cut the connector off the probe wires and strip each wire back ¼”. 3. Using the Adapter Cables from the Kit, insert one wire from the air probe into each of the air

probe adapter lever nuts, one wire from the evap probe into each evap probe adapter lever nuts, one wire from the digital input into each of the D.I. adapter lever nuts

4. Plug the air sensor into the “S1” input on the new Danfoss ERC112D, plug the evap sensor into “S2”, Plug the Digtal input for the door into “di” if available.

5. Plug each wire into the new control as shown below 6.

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REV. A 809-129A

INSTALLATION

2.2.5 DANFOSS ERC112C TO DANFOSS ERC112D (Refrigerator)

1. Unplug wires and probe from Danfoss ERC112C 2. Plug the air sensor into the “S1” input on the new Danfoss ERC112D, plug the evap sensor

into “S2” (if provided), Plug the Digtal input for the door into “di” if available (if provided). 3. Plug each wire into the new control as shown below

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REV. A 809-129A

INSTALLATION

2.2.5 DANFOSS ERC112D TO DANFOSS ERC112D (Freezer)

1. Unplug wires and probe from Danfoss ERC112C 2. Plug the air sensor into the “S1” input on the new Danfoss ERC112D, plug the evap sensor

into “S2” (if provided), Plug the Digtal input for the door into “di” if available (if provided). 3. Plug each wire into the new control as shown below

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REV. A 809-129A

UP

DOWN

ESC

OK

INSTALLATION

2.3 Installing New Control

Insert the controller back into the mounting bracket or instrument panel. Slide the clips from the kit up the side of the controller until the controller is secured. After the controller is installed return power to the unit.

2.4 Access to Control Parameters

1. Press “up/down” and hold 5 seconds to access the menu

The display shows “PAS” 2. Press “OK” (Button “SC”) 3. Press “up” to reach password 17 4. Press “OK” (Button “SC”)

2.5 Adjusting Parameters to Unit Operation

Below is a step by step process on how to adjust the parameters. After that will be a list of parameters that will need changed based on the application.

1. First parameter group is shown "tHE". 2. Press "up/down" to find the desired group 3. Press "OK". 4. First parameter is shown. 5. Press "up/down" to find the desired parameter. 6. Press "OK". 7. Press "up/down" to find the desired setting. 8. Press "OK".

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REV. A 809-129A

INSTALLATION

2.5.1 Refrigerator Parameter Table

Application Folder Parameter Description New Value

Light Operation

(Only applies to Hydrocarbon models)

No light No Change needed

Glass Door Lig CLC Cabinet Light Source Control on

Solid Door Lig CLC Cabinet Light Source Control dor

→ ASi diC Digital Input Configuration doC

Defrost Operation

Coil Sensing Refrigerator

dEF dFt Defrost Type nat

Coil Sensing Refrigerator

ASi S2A Sensor 2 Application EuA

Temperature Off-Set

(Only applies when changing from any other controller to Danfoss.

If the original control was Danfoss DO NOT change.)

Any Refrigerator

ASi t1A Air Temperature Adjustment 18

Coil Sensing Refrigerator

ASi t2A Evaporator Temperature Adjustment 18

2.5.2 Freezer Parameter Table

Application Folder Parameter Description New Value

Light Operation

(Only applies to Hydrocarbon models)

No light No Change needed

Glass Door Lig CLC Cabinet Light Source Control on

Solid Door Lig CLC Cabinet Light Source Control dor

→ ASi diC Digital Input Configuration doC

Temperature Off-Set

(Only applies when changing from any other controller to Danfoss.

If the original control was Danfoss DO NOT change.)

Any Freezer ASi t1A Air Temperature Adjustment 11

Any Freezer ASi t2A Evaporator Temperature Adjustment 11

2.6 Cycle Power

After the parameters are changed to the correct settings, unplug the unit and plug it back in.

2.7 Monitor Operation

Monitor the operation of the unit to make sure the cycle temperature is within ±3°F. If the desired

temperature is met then the unit is ready to be loaded with product. If the desired temperature is not met continue to next step.

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STANDARD CONTROL FUNCTIONS

2.8 Adjust Off-Set If Needed If the temperature off set is not reaching the correct cabinet temperature then adjust parameter “t1A” higher than the recommended value listed above. 3.1 Standard Control Functions

Refrigerator

Freezer

3.2 Control Panel Display

Defrost LED

Alarm LED

On fixed: Defrost active On fixed: ALARM Present

Off: Defrost is off Flashing: ALARM Silenced

Off: No Alarm

Fan LED

Compressor LED

On fixed: Fan active On fixed: Compressor active

Off: Fan Off Flashing: Delay, protection or activation blocked

Off: No Alarm

Condition

Co

mp

res

so

r

Co

nd

en

ser

Fan

Evap

ora

tor

Fan

Lig

hts

Cabinet Temp > Setpoint + Differential ON ON ON ON or OFF

Cabinet Temperature <= Setpoint OFF OFF ON ON or OFF

Defrost OFF OFF ON ON or OFF

Condition

Co

mp

res

so

r

Co

nd

en

ser

Fan

Evap

ora

tor

Fan

Defr

ost

Heate

r

Face/D

oo

r

Heate

r

Dra

in H

eate

r

Lig

hts

Cabinet Temp > Setpoint + Differential ON ON ON OFF ON ON ON or OFF

Cabinet Temperature <= Sepoint OFF OFF OFF OFF OFF ON ON or OFF

Defrost OFF OFF OFF ON OFF ON ON or OFF

DOWN

DEFROST (ESC)

SELECT (OK)

NOTE: When switched on, the instrument panel performs a lamp test for a few seconds.

UP

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STANDARD CONTROL FUNCTIONS

3.3 Keyboard Functions

3.4 Control Panel Connections

UP Press and release • Scrolls the menu items • Increases the values

DOWN Press and release • Scrolls the menu items • Decreases the values

DEFROST (ESC) Press and release • Returns up one level with respect to

the current menu • Activates Defrost

SET (ENTER) Press and release • Confirms the parameter value • Toggles light on/off

UP

DOWN

DEFROST (ESC)

SELECT (OK)

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REV. A 809-129A

STANDARD CONTROL FUNCTIONS

3.5 Changing the Set Point

3.6 Electronic Controller Alarms

The alarm condition is always signaled by the alarm icon . To turn off the relative icon will continue flashing.

NOTE: If alarm exclusion times are in progress (ALA folder of the parameter table), the alarm is not signaled.

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STANDARD CONTROL FUNCTIONS

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TROUBLE SHOOTING

4.1 General

SERVICE AND REFRIGERATION SYSTEM CHART ANALYSIS

Malfunction Possible Cause Solution

Compressor will not start – no hum Line cord not plugged in Plug cord in

Compressor starts and runs but unit does not begin to cool on initial start-up (MT

Bare Tube Condenser Models only)

Ambient is below 60°F Warm unit to above 60°F prior to initial

start-up.

Unit runs OK, but short cycles

Overload protector. Check wiring diagram for correct

wiring

Cold control. Differential set too close

Overcharge. Reduce refrigerant charge.

Air in system. Recover and recharge.

Undercharge. Fix leak and recharge with refrigerant.

Unit operates long or continuously

Dirty condenser Clean condenser

Shortage of refrigerant. Fix leak, add charge, correct charge

Temp control contacts stuck or frozen

Replace Temp control

Evaporator coil iced. Defrost

Restriction in refrigeration system. Determine location and remove.

Start capacitor open, shorted or blown.

Relay contacts not opening properly. Replace relay

Low voltage to unit. Determine reason and correct.

Improper relay. Replace.

Run capacitor open, shorted or blown.

Improper capacitor. Determine correct size and replace.

Excessively high line voltage (110% of rated max).

Determine reason and correct.

Relay defective or burned out.

Line voltage too high or too low. Determine reason and replace.

Relay being influenced by loose vibrating mounting.

Remount rigidly.

Space temperature too high.

Control setting too high. Reset control.

Overcharged with refrigerant Recover refrigerant and recharge with Proper charge specified on data plate

Inadequate air circulation. Improve air movement

Cooler freezing beverage Temperature control Reset control

Unit noisy

Loose parts or mountings Find and tighten

Tubing rattle Reform to be free of contact

Bent fan blade causing vibration Replace blade

Fan motor bearings worn Replace motor

WARNING: ALL SERVICING MUST COMPLY WITH STATE AND FEDERAL REGULATIONS

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TROUBLE SHOOTING

4.2 Refrigerator Wiring Diagram

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TROUBLE SHOOTING

4.2 Freezer Wiring Diagram