PROCOLD S.R.L.: Distributed in Europe by
PROCOLD S.R.L.: Distributed in Europe by
PROCOLD S.r.l.
Chivasso (TO) Italy Tel (+39) 011 917 22 02 Fax (+39) 011 910 29 65 [email protected] www.procold.it
COMPRESSORS
COMPRESSORS
COMPRESSORS
INDEX
1. About the Product 2. Wiring and connections 3. The Serial Port Interface (SPI) 4. Operating voltage 5. Battery protection system 6. Setting up the speed 7. Programming the electronic driver 8. Protections and alarms 9. Compressor cooling 10. Technical data 11. Supply
Septembre 2006
COMPRESSORS
The electronic control unit FDC1 is supplied with the exclusive Serial Port Interface (SPI), featuring a RJ11 telephone type connector. SPI allows the electronic driver to be connected to a computer for programming purposes using the FDC programming package (hardware and software, provided by ACC under request), and allows the communication with an Electronic Integral Manager of the appliance (EIM), and making the compressor work in slave mode. FDC1 electronic driver includes Smart Speed as programming option, which is a plug-in system for automatically self-adapting compressor speed to current thermal load. Smart Speed reduces the number of thermostat cycles by minimizing compressor speed, enlarging on-time at every thermostat cycle, so that start/stop energy loses are substantially reduced. Lowest speed yields also highest evaporating temperature, and so highest C.O.P. and lowest energy consumption. Pull-down is done at maximum programmed speed, so pull-down time is very short with respect to fixed speed systems. 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. FDC1 electronic driver includes also Sleep and Sleep Energy Saving as programming option, which are plug-in systems specially 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 compressor speed progressively to minimum velocity three hours later. Maximum comfort and minimum energy consumption are thus achieved. GD30FDC starting capability is as low as 10V under any balanced pressure. It also admits a certain remaining differential pressure when thermostat off-time is abnormally short. For improving even more the starting capability, FDC1 electronic driver is supplied with a 3 minutes minimum thermostat off-time. The delay is a programming option which can be easily removed if no delay is preferred for any reason. FDC1 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.
September 2006
COMPRESSORS
Cross section mm 2
2.5 4 6 10
1.5 2.5 4 6
3 5 8 12
4.5 7.5 12 18
September 2006
COMPRESSORS
If any kind of connector or switch is placed between the battery poles and the power terminals of the electronic driver, its resistance should be less than 10m. If the resistance is higher than 5m, the maximum length of the wires indicated in Table 1 should be halved or the cross section doubled. Wiring Diagram The FDC1 electronic driver features a terminal board where all connections are made. The terminal lay out is described in Figure1:
Fig. 1. FDC1 Wiring scheme When connecting the electronic driver to the compressor, any position of the connector is possible under an electrical point of view. However, in practice, the vertical position is not possible because the electronic box cannot be assembled. The connector should be rotated 120 clockwise or counter clockwise with respect to the vertical position as shown below.
September 2006
COMPRESSORS
Figure 3 Shows the RJ11 male connector which can be plugged to the SPI and the usage of each terminal in it.
4. OPERATING VOLTAGE
GD30FDC is designed to operate in a wide range of DC voltages, supplied either by a battery or by any other kind of filtered DC power supply. DC VOLTAGE SUPPLY ALLOWED: 10V to 42.4V Functional modes Standard (Default): From the value of the applied voltage, the electronic driver automatically decides the rated 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
Special (programming option): The compressor can be powered by a variable DC source as, for instance, a photovoltaic panel, in which the output voltage strongly depends on the intensity of sunlight radiation. In these special cases the driver should be programmed with rated, 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 appliance manufacturer by means of a PC connected through the serial port to the drivers Serial Port Interface, using the FDC programming package provided by ACC under request.
September 2006
COMPRESSORS
12 - 14 24 - 28 36 - 42 Special
In Table 2, V is the difference between cut-out and cut-in, that is, the cut-in value is the result of adding V to the cut-out value. 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 previously 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 drivers SPI. It can be done by ACC or by the customer itself using the FDC programming package. The cut-out (battery voltage at which the driver stops operating) 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. According to the connection made, four protection levels can be selected as shown in Table 3.
Protection limits (V) Protection level Connection to COM IN1 IN2 12 -14 V cut-out cut-in Rated operating voltage range 24 - 28V cut-out cut-in 36 - 42 V cut-out cut-in
0 1 0 1
0 0 1 1
Table 3. IN1, IN2 and COM connection for battery protection set up
September 2006
COMPRESSORS
. 1,500 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 . 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. If external switching is programmed, the speed is set up by the connection of the SPI terminals IN1 and IN2 to COM for minimum and maximum speeds, and two intermediate velocities according to Table 4: nominal voltage (14V, 28V and 42V for 12V, 24V and 42V systems respectively).
Speed of the motors (rpm) Smin Smin + 1/3(Smax-Smin) Smin + 2/3(Smax-Smin) Smax
0 1 0 1
0 0 1 1
0=Open connection
1=Shortened
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. Smart Speed mode: Compressor will run at variable speed at its highest performance 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.
September 2006
COMPRESSORS
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 MANUAL I/O SWITCH AND/OR STARTING DELAY. 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, according to table 5:
Connection to COM IN1 IN2 Speed of the motors (rpm) Smin Smin Smax Smax Sleep mode
0 1 0 1
0 0 1 1
off on off on
If off sleep mode is selected, the appliance will run continuously at selected fixed speed Smin or Smax. Sleep Energy Saving mode: Compressor will run during four hours. During first hour compressor will run at selected speed. During next three hours speed will decrease up to 1,500 r.p.m. Programming Sleep Energy Saving is done in the same way as Sleep. Slave mode: Under this mode, variable speed is controlled by an Electronic Integral Manager of the appliance (EIM) permanently connected to the electronic driver FDC1 through the SPI, using its serial communication capability. The EIM reads the current temperature 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 displays any abnormal circumstance that might occur. For details about the communication protocol, please, contact ACC. IF ANY VARIABLE SPEED MODE IS TO BE PROGRAMMED, CHECK CAREFULLY FOR TUBES, CONDENSER AND EVAPORATOR RESONANCES. NATURAL FREQUENCIES SHOULD BE 75 Hz UP TO AVOID VIBRATIONS.
September 2006
COMPRESSORS
6. From the top menu, load an existing configuration and go to step 9, or go through step 7. 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 1,500 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 1,500 and 3,500 r.p.m. as described in point 6. External speed selection is incompatible with external battery protection (step 8.2). 7.2 7.3 7.4 Smart Speed mode. Select maximum fixed speed or external switcher connected to SPI and proceed as described in 7.1.1 or 7.1.2 respectively. 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. Slave mode
8. Select the battery protection mode and the protection parameters 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, 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 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).
September 2006
COMPRESSORS
9. Select thermostat delay 3 minutes for improved starting. 10. Click Apply. The FDC1 electronic driver is now programmed and ready to drive the compressor. 11. From the top menu, save the current configuration if desired. 12. To program another FDC1 unit, plug it in, apply current configuration or return to step 6 to change configuration. 13. Click exit to finish.
1 2 3 4 5 7
battery protection fan overcurrent starting failure compressor overload electronic drive overheat internal error
In case of an alarm display, if the FDC1 electronic driver is connected as a slave to the appliances Electronic Integral Manager (EIM) through the SPI, a digital alarm code will be transmitted to the EIM, which in turn will manage the information for displaying and acting purposes.
10
September 2006
COMPRESSORS
9. COMPRESSOR COOLING
An adequate heat removal mechanism from both the electronic driver and the compressor is fundamental for an optimal performance and reliability of the unit. The cooling method should be selected depending on the working conditions of the appliance, with major factors being the compressor speed and the evaporation temperature, and also, but secondary, the condensation temperature. FREE AIR CIRCULATION OVER THE COMPRESSOR AND THE ELECTRONIC DRIVER MUST ALWAYS BE GUARANTEED. Table 6 shows the recommended cooling method for a standard condensation temperature of 55C. The table should be taken as a recommendation, as the only way to validate a design is testing the appliance at the highest evaporation, condensation and ambient temperature, verifying that the electronic driver overheat protection does not act.
Evaporation Temperature -30 -25 -20 -15 -10 -5 0 5 10
r.p.m.
Table 6. Recommended cooling method. Condensation temperature: 55C. N/A: not allowed
The electronic driver features two contacts where to connect the fan in case of compressor fan cooling as described in point 2.
Approvals GD30FDC is in compliance with the following directives and approvals: Low Voltage Directive 73/23/EEC (CE-marking) Electromagnetic Compatibility Directive for Automotive Industry 95/54/EC (e-marking: e9 6013) VDE approval CCC approval UL approval (in process) ACC declares that production starting January 2006 is RoHS compliant Reliability GD30FDC pass following reliability tests: High Temperature: according with CECOMAF GT-4002 standard Wear: according with CECOMAF GT-4003 standard ON/OFF: according with CECOMAF GT-4004 standard Vibrations: according with ASTM 5728 Level I standard
September 2006
11
COMPRESSORS
Application Application Refrigerant Evaporation temp. range Expansion system Compressor cooling Max. ambient temperature Electrical Voltage Voltage range Motor Type Phase number Pole number Locked rotor current (12, 24, 42 V) Resistance at 25C (R-S/R-T/S-T) Electronic driver Model Type Supported devices
LBP - MBP - HBP R134a -30 to + 10 Capillary Static or fan depending on working conditions 43
V DC V DC
12 to 42 10 to 42.4
FDC1 Fully digital & programmable P based 12V/0.5A Fan Compressor speed or battery protection level switcher Alarm LED 15V/25mA electronic thermostat 5V/25mA Electronic Integral Manager
Serial Port Interface (SPI) RS-232 serial port 2-digit, 4-level switcher Alarm LED By programming or switching* By Programming or switching* *only one at a time
Protections
Battery protection Fan over current Starting failure Compressor overload Electronic driver overheat Fan over current Starting failure Compressor overload Electronic driver overheat
Default settings
Running mode: Standard Speed selection: external switcher Lower/higher speed: 1500/3000 r.p.m. Battery protection: fixed voltage level; standard system
12
September 2006
COMPRESSORS
Cut-out (12/24/42 V systems): 11.5/24.5/38,5 V Cut- in (12/24/42 V systems): 10.0/22.0/36.0 V 3 minutes thermostat delay: on
Nominal performance at Cooling capacity Cooling capacity Input power EER COP Current
Test Conditions Evaporation temperature Condensation temperature Liquid temp. entering expansion Ambient and return temp. Voltage
C C C C V DC
-23.3 55 32 32 12
Dimensions
September 2006
13
COMPRESSORS
1500 2000 2500 3000 3500 1500 2000 2500 3000 3500 1500 2000 2500 3000 3500 1500 2000 2500 3000 3500 1500 2000 2500 3000 3500 1500 2000 2500 3000 3500
19 26 32 37 41 18 25 30 35 39 23 30 38 44 50 0.97 1.01 0.99 0.97 0.95 0.79 0.84 0.80 0.79 0.78 1.90 2.49 3.13 3.70 4.18
25 36 45 52 57 24 34 42 49 54 25 35 44 52 58 1.17 1.21 1.19 1.17 1.15 0.97 0.98 0.96 0.95 0.94 2.07 2.88 3.66 4.31 4.80
28 40 50 58 64 26 26 38 47 55 60 1,24 26 36 46 54 61 6 1.24 1.28 1.26 1.24 1.22 1.03 1.05 1.02 1.01 0.98 2.19 3.03 3.85 4.53 5.08
33 49 62 72 79 31 46 58 68 74 29 40 53 63 71 1.33 1.41 1.37 1.33 1.29 1.07 1.14 1.12 1.08 1.04 2.40 3.37 4.39 5.25 5.93
43 64 82 97 109 41 60 77 91 103
Input Power (W)
60 87 110 129 144 57 82 104 122 136 41 56 73 88 102 1.70 1.82 1.76 1.70 1.64 1.39 1.48 1.43 1.38 1.33 3.42 4.63 6.06 7.35 8.51
78 112 142 168 190 73 106 134 158 179 47 64 83 100 116 1.95 2.05 2.00 1.95 1.90 1.57 167 1.62 1.59 1.54 3.88 5.29 6.88 8.35 9.70
CECOMAF 55C 55C 32C
100 142 180 214 244 94 134 170 202 230 52 71 92 112 130 2.23 2.33 2.28 2.23 2.18 1.80 1.89 1.85 1.81 1.77 4.35 5.91 7.65 9.30 10.80
126 179 227 270 119 169 214 254 57 78 101 122 2.58 2.66 2.62 2.58 2.10 2.16 2.12 2.09 4.73 6.52 8.40 10.10 -
160 223 281 150 210 264 63 86 110 2.94 3.02 2.98 2.37 2.45 2.41 5.27 7.16 9.10 -
34 47 63 77 89
C.O.P. ASHRAE (W/W)
1.47 1.57 1.52 1.47 1.42 1.21 1.27 1.23 1.19 1.15
Current (A)
Condensation temperature: Liquid temperature entering expansion: Ambient and return temperature: Voltage: 12 V DC
11. SUPPLY
GD30FDC compressor including FDC1 electronic driver delivered in pallets of 144 units. Pack of GD30FDC compressor including: FDC1 electronic driver, set of connectors for external speed selection and spare part guide. Pack of FDC1 electronic driver, set of connectors for external speed selection and spare part guide.
14
September 2006
COMPRESSORS
Appliances Components Companies is a world leading Group manufacturing components for household and commercial appliances, with 10 production plants strategically located in Europe and China and more than 20 million compressors produced annually. ACCs strong network of Customers includes the most important and well known producers of appliances worldwide. Innovation and reliability are the keys to become a complete global partner, and our long-term relationships with customers and suppliers guarantee a mutual benefit in the development of the business. ACC Spain is the company responsible to manage the Commercial Cold division within the ACC group by supplying hermetic compressors and in-house condensing units to the commercial refrigeration market in more than 80 countries worldwide. ACC Spain continues with the experience and leadership acquired by Cubigel to improve the quality of customer service and bring forward in the market a wide range of compressors produced with the highest standards, thanks to an important technological and production capacity and top R&D Labs. Introducing the most innovative option in mobile refrigeration: the 12-42 V DC compressor. Its highly performing electronics allow a wide variety of programming functions. Its drivers feature self-controls that guarantee reliability of the product in front of any circumstance, battery exhaustion or any other situation of risk. Compact in dimensions and designed to operate in heavy duty conditions, the GD30FDC compressor is silent, efficient and can work even with a strong tilt (30), and it is especially suitable for mobile applications in boats, trucks, private cars or medical appliances in ambulances.
April 2005 DISTRIBUTED by PROCOLD S.r.l. -Italy- (+39) 011 917 22 02 [email protected]
COMPRESSORS
NOTES
April 2005 DISTRIBUTED by PROCOLD S.r.l. -Italy- (+39) 011 917 22 02 [email protected]
ACC Spain, S.A. P.O. Box 3283 08200 Sabadell - Spain Phone: +34 93 746 41 71 Fax: +34 93 712 28 64 E-mail: [email protected]
www.the-acc-group.com
0504