USER MANUAL GLT80TDC - Huayi Compressor Barcelona
Contents
1. POWER IN PUT TERMINAL OF THE ELECTRONIC DRIVER 12V SYSTEMS 30A FUSE 24V SYSTEMS 30A FUSE 42V SYSTEMS 20A FUSE In some special vehicles chassis is connected to termi nal of the battery instead of terminal positive reference systems In such cases should be understood as and vice versa In systems powered by a variable DC source the fuse should be selected following the rules above mentioned considering the maximum voltage at the variable DC Source If any kind of connector or switch is placed between the bat tery poles and the power terminals of the electronic driver its resistance should be less than 10m If the resistance is higher than 5mQ the maximum length of the wires indicated in Table 1 should be halved or the cross section doubled In case of using a long cable to connect battery and electronic driver it is recommended using a cable with low inductance Wiring Diagram The FDC3 electronic driver features a terminal board where all connections are made The terminal lay out is described in Figure 2 THERMOSTAT ELECTROMECHANICAL OR ELECTRONIC FDC3 ELECTRONIC DRIVER USER MANUAL GLT80TDC ELECTRONIC INTEGRAL MANAGER SWITCHER ALARM CONTROL PANEL Fig 2 FDC3 wiring scheme Fig 3 Connection of FDC3 driver to the compressor 4 The serial port interface2. The electronic control unit FDC3 is supplied with the exclu sive Serial Port Interface SPI featuring a RJ45 telephone type connector This port allows the electronic driver to be connect ed to a computer for programming purposes using the FxC programming package hardware and software provided by Cubigel Compressors under request Optionally the SPI can be configured to e Install a LED to display the intervention of any alarm e Set up either the compressor speed or the battery protection level through physical connections between IN1 IN2 and COM e Connect the electronic driver as slave to an Electronic In tegral Manager of the appliance with serial communication capabilities Rx Tx and COM to allow working with variable speed SPI provides a 5 V output limited to 25mA to power up the EIM TO PROGRAM THE ELECTRONIC FDC3 DRIVER BY MEANS OF THE FXC PROGRAMMING KIT THE FDC3 DRIVER MUST BE POWERED BY THE BATERY cubigel USER MANUAL GLT80TDC Figure 4 Shows the RJ45 male connector which can be plugged to the SPI and the usage of each terminal in it Fig 4 SPI terminals 5 Operating voltage GLT80TDC is designed to operate in a wide range of DC volt ages supplied either by a battery or by any other kind of fil tered DC power supply DC VOLTAGE SUPPLY ALLOWED 10V to 42 4V Functional modes e Standard Default From the value of the applied voltage the electronic driver automatically decides the r
3. scribed in point 6 External speed selection is incompatible with external battery protection step 8 2 7 2 Smart Speed mode Select maximum fixed speed or ex ternal switcher connected to SPI and proceed as described in 7 1 1 or 7 1 2 respectively cubigel 7 3 Sleep and Sleep Energy saving modes Select maximum fixed speed or external switcher connected to SPI and proceed as described in 7 1 1 or 7 1 2 respectively 7 4 Slave mode 8 Select the battery protection mode and the protection pa rameters from 8 1 Internal protection choose between normal and special voltage systems 8 1 1 For normal voltage systems enter cut out cut in and maximum voltage values for every voltage system Cubigel Compressors accounting for the limits shown in Table 2 of point 5 8 1 2 For special voltage systems enter cut out cut in and nominal and maximum voltage values Cubigel Compressors accounting for the limits shown in Table 2 of point 5 8 2 External protection Protection values are shown in Table 3 of point 5 External protection is incompatible with external speed selection step 7 2 9 Select thermostat delay 3 minutes for improved starting 10 Click Apply The FDC3 electronic driver is now pro grammed and ready to drive the compressor 11 From the top menu save the current configuration if de sired 12 To program another FDC3 unit plug it in apply current configuration or return to step 6 to change co
4. 13 1 3 000 152 6 33 251 10 5 388 16 2 3 500 177 7 38 296 12 3 468 19 5 Condensing temperature 55 C Ambient and suction temperature 35 C Liquid subcooling 9K Test voltage 24V DC Only for 24 42 V DC voltage supply 12 Supply GLT80TDC compressor including FDC3 electronic driver 120 pieces pallets cubigel compressors 10 20 OG 108119 TYNNVIN H3SN HUAYI Ar COMPRESSOR BARCELONA Huayi Compressor Barcelona S L Antoni Forrellad 2 08192 Sant Quirze del Vall s BCN Spain Phone 34 93 710 60 08 Fax 34 93 710 69 58 www huayicompressor es
5. MANUAL I O SWITCH AND OR STARTING DELAY e Sleep mode Compressor will run during four hours after start up The speed can be limited by a fixed programmed value and even more by the available battery voltage as described in standard mode The speed can also be limited by external switching in a similar way as described in standard mode Cubigel Compressors ac cording to table 5 0 0 1 1 S off 1 SEE on Table 5 External selection of the velocity 0 Open connection 1 Shortened USER MANUAL GLT80TDC If off sleep mode is selected the appliance will run continu ously at selected fixed speed Smin OT Smax e Sleep Energy Saving mode Compressor will run during four hours During first hour com pressor will run at selected speed During next three hours speed will decrease up to 2 000 r p m Programming Sleep En ergy Saving is done in the same way as Sleep e Slave mode Under this mode variable speed is controlled by an Electronic Integral Manager of the appliance EIM permanently connect ed to the electronic driver FDC3 through the SPI using its se rial communication capability The EIM reads the current tem perature inside the appliance compares it with the set point temperature and decides if the compressor should operate or not and if so at which speed The EIM communicates how the compressor should operate and eventually records and dis plays any abnormal circumstance that might occur Fo
6. speed enlarging on time at every ther mostat cycle so that start stop energy loses are substantially reduced Lowest speed yields also highest evaporating tem perature and so highest C O P and lowest energy consump tion Pull down is done at maximum programmed speed so pull down time is very short with respect to fixed speed sys tems No design parameters neither of the compressor nor the appliance are required to be programmed so Smart Speed can be easily used in all appliances with no design efforts cubigel FDC3 electronic driver includes Sleep and Sleep Energy Sav ing as programming option which are plug in systems spe cially conceived for mobile air conditioners avoiding any other electronic device Sleep and Sleep Energy Saving make the air conditioner work for four hours since start up Sleep Energy Saving makes the compressor run at maximum programmed speed during the first hour when highest cooling capacity is needed and lowers progressively the compressor speed up to minimum velocity three hours later Maximum comfort and minimum energy consumption are thus achieved GLT80TDC starting capability is as low as 10 V under any bal anced pressure it also admits a certain remaining differential pressure when thermostat off time is abnormally short For improving even more the starting capability FDC3 electronic driver can be programmed with a 3 minutes minimum thermo stat off time The delay is a programming option whic
7. SO VG 22 ESTER Oil charge cms 330 e High Temperature Cubigel Compressors according with CECOMAF GT 4002 standard e Wear Cubigel Compressors according with CECOMAF GT 4003 standard e ON OFF Cubigel Compressors according with CECOMAF GT 4004 standard e Vibrations Cubigel Compressors according with ASTM 5728 Level standard Application MBP HBP A C Refrigerant R134a Evaporation temp range OG 25 to 10 Expansion system CAPILLARY Compressor cooling Fan Max ambient temperature AG 43 Voltage V DC 12 to 42 Voltage range V DC 10 to 42 4 Type Brush less Sensor less PMM Phase number 3 Pole number 6 Locked rotor current 12 24 42 V A 1271288 Resistance at 25 C R S R T S T 0 0 36 cubigel compressors Model FDC3 Type Fully digital amp programmable uP based Supported devices 12V 1A Fan Compressor speed or battery protection level switcher Alarm LED 15V 25mA electronic thermostat 5V 25mA Electronic Integral Manager Communication port Serial Port Interface SPI Communication capabilities RS 232 serial port 2 digit 4 level switcher Alarm LED Compressor speed selection By programming or switching Battery protection level selection By Programming or switching only one at a time Protections Battery protection Fan over current Starting failure Compressor overload Electronic driver overheat Fa
8. USER MANUAL GLT80TDC User manual for 24 42V Direct Current Compressor GLT80TDC Gubigel AYI AB lt omenesson AMA Wear 260 0 00 28 2 SI INDEX 1 About the Product Installation and application Wiring and connections The Serial Port Interface SPI Operating voltage Battery protection system Setting up the speed Programming the electronic driver Protections and alarms O O AON DO UA 8 W PD k Compressor cooling Technical data Supply ak N 1 About the product Many vehicles for transportation of goods or recreation such as trucks caravans boats cars etc are often equipped with cooling appliances and air conditioners The compressors for such mobile applications must be designed to operate from a low voltage DC power supply These compressors must also be compact in their dimensions highly reliable and yield high performances GLT80TDC is Cubigel Compressors s answer to the needs of users requiring comfort and reliability in their travelling either on holidays at work or in any other circumstance where a DC powered air conditioner is utilised The GLT80TDC is designed to operate silently efficiently and reliably even up to angles of tilt of 20 and works with the environmentally friendly refrig erant R134a Its design is based on Cubigel Compressors L series which has been successfully present in the market since 1964 and has had sales o
9. ated voltage range of the supply Three possible ranges are considered 12 to 14V actual voltage is below 17V 24 to 28V actual voltage is within 17 and 33V 36 to 42V actual voltage is within 33 and 42 4V compressors 1 5V 25nA 2 Rx 3 IN 4 COM 5 LED 6 IN2 7 1X 8 EN e Special programming option The compressor can be powered by a variable DC source as for instance a photovoltaic panel in which the output volt age strongly depends on the intensity of sunlight radiation In these special cases the driver should be programmed with rat ed minimum and maximum voltages These values should be within the allowable DC voltage power supply 10 V to 42 4V Rated voltage and voltage limits are programmed by the ap pliance manufacturer by means of a PC connected through the serial port to the driver Serial Port Interface using the FxC programming package provided by Cubigel Compressors un der request USER MANUAL GLT80TDC 6 Battery protection system There is a protection system for the battery that prevents the compressor from operating if the available voltage becomes too low The battery protection level should be set up as fol lowing e By programming Voltage limits for battery protection can be freely set by the customer for every system 12 14V 24 28V 36 42V or special by means of the serial port of a PC connected to the SPI port of the electronic driver using the FxC programming package pro
10. e SPI can be configured in a way that a LED can be con nected between terminals 3 and 4 see Fig 2 in point 3 in order to display the intervention of any alarm and to identify its cause The visualisation consists of a sequence of flashes of the LED repeating every 5 seconds until the cause of the alarm disappears The code of the flashing sequence corresponding to each alarm is indicated in Table 6 1 battery protection fan over current starting failure electronic driver overheat 2 3 4 compressor overload 5 i internal error Table 6 Alarm codification In case of an alarm display if the FDC3 electronic driver is con nected as a slave to the appliance s Electronic Integral Man ager EIM through the SPI a digital alarm code will be trans mitted to the EIM which in turn will manage the information for displaying and acting purposes cubigel compressors USER MANUAL GLT80TDC 10 Compressor Cooling GLT80TDC should always be fan cooled FDC3 electronic driv to be cooled properly Best results are obtained when both er has its own fan to cool its power components but enough compressor and driver are cooled with fresh air coming directly fresh air is needed in the surroundings of the electronic driver from outside before being heated up in appliance condenser 11 Technical Data Displacement cm3 8 10 Diameter mm 24 29 Stroke mm 17 48 Net weight kg 10 2 Oil type I
11. ections General rules GLT80TDC must always be powered through the dedicated electronic driver FDC3 which is supplied with the compressor as a separate device NEVER CONNECT THE COMPRESSOR HERMETIC PINS FUSITE TO THE TERMINALS OF A BATTERY OR ANY OTH ER DC OR AC SOURCE DIRECTLY DO NOT TRY TO FIT AN ELECTRONIC DRIVER OTHER THAN THE FDC3 THE COMPRESSOR WILL NOT OPERATE AND IRREVERSIBLE DAMAGE MAY OCCUR The FDC driver is directly connected to the battery poles as well as to the compressor pins It checks battery voltage and adjusts itself to the voltage value for proper compressor operation or switches itself off if the battery voltage is not adequate The driver also controls the compressor speed ALWAYS RESPECT THE POLARITY OF THE BATTERY WITH THE POWER INPUT TERMINALS OF THE ELECTRONIC DRIVER Voltage drop in the power leads To avoid excessive voltage drop in the leads their length and cross section must be related to the voltage supply as indi cated in Table 1 10 6 6 Table 1 Maximum length of leads m compressors The unit is protected against damage caused by wrong polar ity of the supply The compressor will not run correctly if it s wrongly connected NEGATIVE POWER INPUT TERMINAL OF THE ELEC TRONIC DRIVER SHOULD BE EARTHED TO THE CHASSIS OF THE VEHICLE AS WELL AS THE APPLIANCE FRAME A FUSE MUST BE PLACED BETWEEN THE POLE OF THE BATTERY OR DC POWER SUPPLY AND THE
12. f more than 200 million units USER MANUAL GLT80TDC GLT80TDC is designed for capillary tube expansion and can be powered at 24 and 42V DC and also at 12V with some restriction Each unit is supplied with a dedicated electronic driver FDC3 which features all the protections for both the battery and the driver itself including the compressor motor The driver automatically adjusts itself to the voltage of the power supply Evaporating temperature range 25 C to 10 C Condensing temperature range up to 65 C Pull down peak 70 C Ambient temperature range 10 to 55 C 65 C at starting In case of ambient temperature lower than 0 C an oil heater will be needed USER MANUAL GLT80TDC The electronic control unit FDC3 is supplied with the exclusive Serial Port Interface SPI featuring a RJ45 telephone type connector SPI allows the electronic driver to be connected to a computer for programming purposes using the FxC pro gramming package hardware and software provided by Cu bigel Compressors under request and allows the communi cation with an Electronic Integral Manager of the appliance EIM and making the compressor work in slave mode FDC3 electronic driver includes Smart SpeedQ as program ming option which is a plug in system for automatically self adapting compressor speed to current thermal load in refrig erating appliances Smart Speed reduces number of thermostat cycles by mini mizing compressor
13. for 12V 24V and 42V systems respectively A linear function of the battery voltage in the range between the cut in and the maximum nominal voltages This option is particularly useful for eutectic plates systems cubigel compressors If external switching is programmed the speed is set up by the connection of the SPI connector terminals IN1 and IN2 to COM for minimum maximum speeds and two intermediate veloci ties Cubigel Compressors according to Table 4 Smin Smin 1 3 Smax Smin Smin 2 3 Smax Smin Smax Table 4 External selection of the velocity 0 Open connection 1 Shortened gt 1 10 1 410 176 External speed set up option must be previously programmed for external adjustment of its minimum Smin and maximum Smax limits External switching prevents from the possibility of setting up the battery protection externally using COM IN1 and IN2 of SPI as defined in point 5 e Smart Speed mode Compressor will run at variable speed at its highest perfor mance depending of the current thermal load The speed can be limited by a fixed programmed value and even more by the available battery voltage as described in standard mode The speed can also be limited by external switching in the same way as described in standard mode NO SWITCH MANUAL I O TILT ETC IS ALLOWED TO BE CONNECTED IN SERIES WITH THE THERMOSTAT IF ELECTRONIC THERMOSTATS ARE TO BE FIT AVOID THOSE THAT INCORPORATE
14. h can be easily enabled by means of the FxC programming kit FDC3 also includes a 1 second filter at the thermostat input to prevent the appliance from wrong operation due to typical micro switching produced by vibrations in those appliances that fit tilt switches at the thermostat circuit So analogical filtering is not needed USER MANUAL GLT80TDC 2 Installation and application Maximum tilt angle The maximum tilt angle allowed in GLT80TDC compressor stopped or running in any of the 2 below mentioned recommended positions is 20 and maximun tilt angle in the 2 below not recommended position is 15 Apart from this specification below diagrams show the recommended and not recommended positions while the compressor is running in the application RECOMMENDED POSITIONS B max 20 NOT RECOMMENDED POSITIONS a max 15 Fig 1 Maximum tilt angle If compressor has been stopped during a certain period of time with an inclination higher than 15 it is strongly recom Off road applications GLT80TDC compressor is not designed for off road mobile applications If you are interested in this type of mobile ap mended to not start up the compressor immediately after coming back to the correct position We recommend waiting at least 30 minutes before starting up the compressor plications it has to be specifically approved by Cubigel Com pressors compressors USER MANUAL GLT80TDC 3 Wiring and Conn
15. n over current Starting failure Compressor overload Electronic driver overheat Programmable running modes Standard Smart Speed Sleep Sleep Energy Saving Slave Default settings Running mode Standard Speed selection external switcher Lower higher speed 2000 3500 r p m Battery protection fixed voltage level standard system Cut out 12 24 42 V systems 12 22 38 2 V Cut in 12 24 42 V systems 10 8 20 36 2 V 3 minutes thermostat delay off Cooling capacity Ww 577 712 842 968 Cooling capacity kCal h 497 613 725 834 Input power wW 247 315 388 468 EER kCal Wh 2 01 1595 1 87 1 78 COP W W 2 34 2 26 Pollitt 2 07 Current A 10 3 13 1 16 2 915 Evaporating temperature AG 7 2 Condensing temperature C 55 Subcooling K 9 Ambient and return temp OG 35 Voltage Test V DC 24 Only for voltage supply VDC 24 42 USER MANUAL GLT80TDC cubigel compressors USER MANUAL GLT80TDC wo T S w T CD N N o bu y 4 I 208 J Fig 5 GLT80TDC outline drawing Performance data 2 000 100 1 15 228 1 64 497 2 34 2 500 123 TE 285 1 62 613 2 26 3 000 145 Ti 341 1 58 725 2 17 3 500 166 1 09 392 1 54 834 2 07 2 000 101 4 21 162 6 75 247 10 3 2 500 127 5 29 204 8 5 315
16. nfiguration 13 Click exit to finish USER MANUAL GLT80TDC 9 Protections and alarms GLT80TDC is electronically protected against a number of possible malfunctions and failures e Battery discharge refer to point 5 for details e Fan over current protects the compressor and the electronic driver against fan over current due to start or running overload or short circuit e Starting failure if the running speed is not achieved during the starting sequence the unit stops and retries the start up after one minute e Compressor overload This protection operates when the compressor speed drops below the set up speed or when the current drawn in is excessive thus preventing the appliance from operating under overload conditions causing refrigerat ing overload or compressor failure e Electronic driver overheat In case the temperature of the electronic components of the control becomes too high an internal sensor will stop the unit When the alarm is on ten automatic attempts to restart the compressor will be available In case of battery protection the number of automatic attempts to restart is unlimited Once the sequence of automatic attempts to restart the compressor is finished the unit will remain permanently unable to operate un til it is switched off and on again from the power supply The in tervention of the thermostat during the sequence of automatic restart attempts interrupts and resets the sequence Th
17. ow 1 0 9 0 10 5 20 0 22 5 34 0 36 5 High 0 1 11 0 12 5 24 0 26 5 38 0 40 5 Very high 1 1 12 0 13 5 26 0 28 5 40 0 42 5 Table 3 IN1 IN2 and COM connection for battery protection set up O open connection 1 shortened o NG USER MANUAL GLT80TDC 7 Setting up the speed It is possible to operate the compressor at fixed or variable speed under different running modes options and parameters The electronic driver is supplied by Cubigel Compressors with standard running mode and external control of the speed with minimum speed of 2 000 rpm and maximum speed 3 500 rpm Default running mode options and parameters can be changed to optimize compressor performance for a given appliance by programming connecting a PC to the SPI by means of the FxC programming package provided by Cubigel Compressors un der request Running modes and options are e Standard mode Compressor speed is a fixed programmed value or switched externally from programmed minimum and maximum value in four steps The switch should be connected to the SPI and should remain plugged during compressor operation When setting up a fixed speed maximum speed can be limited by the available battery voltage in the following way maximum speed would be 2 000 rpm when the battery voltage is equal to the cut in voltage Programmed fixed speed when the battery voltage is equal to or greater than the maximum nominal voltage 14V 28V and 42V
18. r details about the communication protocol please contact Cubigel Compressors IF ANY VARIABLE SPEED MODE IS TO BE PROGRAMMED CHECK CAREFULLY FOR TUBES CONDENSER AND EVAP ORATOR RESONANCES NATURAL FREQUENCIES SHOULD BE 75 Hz UP TO AVOID VIBRATIONS cubigel GUDI USER MANUAL GLT80TDC 8 Programming the electronic driver In order to program the electronic driver FDC3 a personal com puter together with the FxC programming package are required provided by Cubigel Compressors under request To this pur pose perform the following steps 1 Install the programming software following the instructions of the wizard 2 Connect the programming interface to a PC using the serial cable supplied with the hardware 3 Power on the programming interface using the AC DC adapter supplied with the hardware 4 Connect the FDC3 electronic driver to the programming in terface using the double RJ45 cable supplied with the hard ware 5 Run the programming file FDC exe 6 From the top menu load an existing configuration and go to step 9 or go through step 7 Select the running mode options and parameters between 7 1 Standard mode 7 1 1 Select maximum fixed speed and enter a value within 2 000 and 3 500 r p m as described in point 6 if desired select speed limited by available battery voltage or 7 1 2 Select external switcher connected to SPI and enter low and high speed values within 2 000 and 3 500 r p m as de
19. vided by Cubigel Compressors under request In that op tion cut out and cut in values must respect the rule defined by Table 2 12 14 9 0 12 0 1 0 1 5 24 28 200 260 20 30 36 42 340 400 20 30 Special 90 400 10 30 Table 2 Limits of battery protection parameters In Table 2 AV is the difference between cut out and cut in that is the cut in value is the result of adding AV to the cut out value e Externally using COM IN1 and IN2 of SPI This option prevents from the possibility of setting up the speed externally using COM IN1 and IN2 of SPI as defined in point 6 The external battery protection set up option must be previ ously programmed for external adjustment of the protection limits Voltage limits are set up by means of a PC through its serial port connected to the electronic driver SPI It can be done by the customer itself using the FxC programming package The cut out battery voltage at which the driver stops oper ating and the cut in battery voltage at which driver re starts operation after a cut off values are set up by connecting the SPI connector terminals IN1 and IN2 to COM Cubigel Com pressors according to the connection made four protection levels can be selected as shown in Table 3 Protection Connection to COM 12 14 V 24 28 V 36 42 V level IN IN2 cut out cut in cut out cut in cut out cut in Standard 0 0 10 0 11 5 22 0 24 5 36 0 38 5 L
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