USER MANUAL GD30FDC - Huayi Compressor Barcelona
Contents
1. is controlled by an Electronic Integral Manager of the appliance EIM permanently connect ed to the electronic driver FDC1 through the SPI using its se rial communication capabilities The EIM reads the actual 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 any abnormal circumstance that might occur For details about the communication protocol please contact Cubigel IF ANY VARIABLE SPEED MODE IS TO BE PROGRAMMED CHECK CAREFULLY FOR TUBE CONDENSER AND EVAPO RATOR RESONANCES NATURAL FREQUENCIES SHOULD BE 75 Hz UP TO AVOID VIBRATIONS USER MANUAL GD30FDC 7 Programming the electronic driver In order to program the electronic driver FDC1 a personal com puter together with the FxC programming package are required provided by Cubigel under request To this purpose perform the following steps 1 Install the programming software following the instructions of the wizard 2 Connect the programming interface to a PC using a serial serial or USB serial cable supplied with the hardware 3 Power on the programming interface using the AC DC adapter supplied with the hardware 4 Connect the FDC1 electronic driver to the programming in terface using the double RJ11 cable supplied with the hard ware 5 Run the programming file FDC e2. 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 USER MANUAL GD30FDC 2 Wiring and Connections General rules GD30FDC must always be powered through the dedicated electronic driver FDC1 which is supplied with the compressor as a separate device NEVER CONNECT THE COMPRESSOR S 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 FDC1 THE COMPRESSOR WILL NOT OPERATE AND IRREVERSIBLE DAMAGE MAY OCCUR The FDC1 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 op eration or switches itself off if the battery voltage is not ad equate 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 The unit is protected against dam
3. DC3 12 42V A ELECTRONIC DRIVER j BATTERY j ALARM SWITCHER THERMOSTAT CONTROL PANEL ELECTROMECHANICAL OR ELECTRONIC SPI Fig 1 FDC1 Wiring scheme When connecting the electronic driver to the compressor any sible because the electronic box cannot be assembled The position of the connector is possible under an electrical point connector should be rotated 120 clockwise or counter clock of view However in practice the vertical position is not pos wise with respect to the vertical position as shown below kJ WU Fig 2 Connection of the FDC1 electronic driver to the compressor cubigel USER MANUAL GD30FDC 3 The serial port interface SPI The electronic control unit FDC1 is supplied with the exclu sive Serial Port Interface SPI featuring a RJ11 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 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 protec tion level through physical connections between IN1 IN2 and COM Connect the electronic driver as slave to an Electronic In tegral Manager of the appliance with serial communication capabilities Rx Tx and COM to
4. USER MANUAL GD30FDC Compressors for mobile applications 12 42V Direct Current Compressor asli c 2g As YI sla ar CELONA INDEX About the Product d 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 AON O OA KF C Iw Compressor cooling 10 Supply 11 Dimensions 12 Technical data 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 The compressors for such mobile appli cations 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 GD30FDC is Cubigel s answer to the needs of users requir ing comfort and reliability in their travelling either on holidays at work or in any other circumstance where a DC powered refrigerator is utilised The GD30FDC is designed to operate silently efficiently and reliably even up to angles of tilt of 30 and works with the environmentally friendly refrigerant R134a Its design is based on Cubigel s D series which has been successfully present in the market since 1984 and has had sales of 15 million units USER MANUAL GD30FDC GD30FDC compressor is not designed for off road mobile a
5. W W Current A Cooling capacity 28 40 50 58 64 Input power 1 24 1 28 1 26 1 24 22 DAI9 3 03 3 85 4 53 5 08 Evaporating temperature 2 23 3 Condensing temperature XC 55 Liquid temp entering expansion 2 32 Ambient and return temp 32 Voltage V DC 12 cubigel compressors USER MANUAL GD30FDC Performance data DETUR ESO NER IEEE 7772772777 INST ENNIO EUREN OE Cooling Capacity ASHRAE kCal h 1500 19 25 28 33 43 60 78 100 126 160 2000 26 36 40 49 64 87 112 142 179 223 2500 32 45 50 62 82 110 142 180 227 281 3000 37 52 58 72 97 129 168 214 270 3500 41 57 64 Ife 109 144 190 244 Cooling Capacity CECOMAF W put Power W 1500 23 25 26 29 34 41 47 52 EN 63 2000 30 35 36 40 47 56 64 ifal 78 86 2500 38 44 46 53 63 73 83 92 101 110 3000 44 52 54 63 TT 88 100 112 122 3500 50 58 61 71 89 102 116 130 C O P ASHRAE W W C 0 P CECOMAF 1500 1 90 2 07 2 19 2 40 2 83 3 42 3 88 4 35 4 73 5 27 2000 2 49 2 88 3 03 3 37 3 95 4 63 5129 5 911 6 52 TG 2500 3 13 3 66 3 85 4 39 5 23 6 06 6 88 7 65 8 40 Oni 3000 3 70 4 31 4 58 2295 6 39 7 35 8 35 9 3 10 1 3500 4 18 4 80 5 08 5 93 7 44 8 51 om 10 8 ASHRAE CECOMAF Condensation temperature 55 C 55 C Liquid temperature entering expans
6. able 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 cubigel compressors finished the unit will remain permanently unable to operate un til itis 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 The 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 6 internal error Table 5 Alarm codification If the FDC1 electronic driver is connected to an Electronic Inte gral Manager EIM of the appliance as a slave through the SPI in case of an alarm intervention a digital alarm code will be transmitted to the EIM which in turn will manage the informa tion for displaying and acting purposes 9 Compressor Cooling An adequate heat removal mechanism from both the elec tronic driver and the compressor is fundamenta
7. able speed at its highest perfor mance depending of the actual 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 cubigel USER MANUAL GD30FDC 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 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 Compres sorsording to table 5 0 0 S off 1 0 Smin on o 1 C off i il Smax on Table 5 External selection of the velocity O Open connection 1 Shortened If off sleep mode is selected the appliance will run continu ously at selected fixed speed Smin or Smax 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 1 500 r p m Programming Sleep En ergy Saving is done in the same way as Sleep e Slave mode Under this mode variable speed
8. age caused by wrong polar ity of the supply The compressor will not run correctly if it s wrongly connected POWER INPUT TERMINAL OF THE ELECTRONIC DRIVER SHOULD BE REFERRED 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 POW ER INPUT TERMINAL OF THE ELECTRONIC DRIVER 12V SYSTEMS 30A FUSE 24V SYSTEMS 15A FUSE 42V SYSTEMS 10A 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 2 5 1 5 3 4 5 25 5 7 5 4 8 12 10 6 12 18 Table 1 Maximum length of leads m cubigel Gubi USER MANUAL GD30FDC If any kind of connector or switch is placed between the bat than 5mQ the maximum length of the wires indicated in Table tery poles and the power terminals of the electronic driver its 1 should be halved or the cross section doubled resistance should be less than 10m0Q If the resistance is higher Wiring Diagram The FDC1 electronic driver features a terminal board where all connections are made The terminal lay out is described in Figure 1 FDC1 F
9. allow working with variable speed SPI provides a 5 V output limited to 25mA to power up the EIM Figure 3 Shows the RJ11 male connector which can be plugged to the SPI and the usage of each terminal in it Rx IN1 COM LED or 5V 25mA IN2 TX QU N Fig 3 SPI terminals 4 Operating voltage GD30FDC 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 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 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 appli ance manufacturer by means of a PC connected through the serial port to the driver s Serial Port Interface using the FxC programming package provided by Cubi
10. compatible with external speed selection step 7 2 9 Select thermostat delay 3 minutes for improved starting 10 Click Apply The FDC1 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 FDC1 unit plug it in apply current configuration or return to step 6 to change configuration 13 Click exit to finish cubigel USER MANUAL GD30FDC 8 Protections and alarms GD30FDC is electronically protected against a number of pos sible malfunctions and failures Battery discharge refer to point 5 for details 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 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 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 avail
11. e 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 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 IN1 IN2 cut out cut in cut out cut in cut out cut in Standard 0 0 10 0 This 22 0 24 5 36 0 38 5 Low 1 0 9 0 10 5 20 0 22 5 34 0 36 5 High 0 1 11 0 1225 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 cubigel compressors 6 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 with standard run ning mode and external control of the speed with minimum speed of 1 500 rpm and maximum speed 3 500 rpm Default running mode options and parameters can be changed to op timize compressor performance for a given appliance by pro gramming connecting a PC to the SPI by means of the FxC programming package provided by Cubigel under request Running modes and options are Standard mode Compressor speed is a fixed programmed value or swi
12. g FDC1 electronic driver set of connectors for external speed selection and spare part guide e Pack of FDC1 electronic driver set of connectors for external speed selection and spare part guide cubigel USER MANUAL GD30FDC 11 Dimensions 6 HOLES 16 5 149 5 93 5 82 70 26 5 k 118 i 220 FRONT VIEW TOP VIEW Fig 4 GD30FDC outline drawing 12 Technical Data Displacement cms 3 00 Diameter mm 18 00 Stroke mm 12 10 Net weight kg 5 4 Oil type ISO VG 22 ESTER Oil charge cms 240 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 Cubigel Compressors declares that production starting January 2006 is RoHS compliant High Temperature according with CECOMAF GT 4002 standard e Wear according with CECOMAF GT 4008 standard ON OFF according with CECOMAF GT 4004 standard e Vibrations according with ASTM 5728 Level standard cubigel compressors Application LBP MBP HBP Refrigerant R134a Evaporation temp range C 30 to 10 Expansion system CAPILLARY Compressor cooling Static or fan depending on working conditions Max ambient temperature C 43 Vol
13. gel under request cubigel USER MANUAL GD30FDC 5 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 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 or USB port of a PC connected to the SPI port of the electronic driver using the FxC programming package provided by Cubigel under request In that option 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 3 0 36 42 340 4oo 20 3 0 Special 9 0 400 1 0 3 0 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 or USB port connected to the electronic driver SPI It can be done by the customer itself using th
14. ion 32 C 55 C Ambient and return temperature 32 C 32 C Voltage 12 V DC bigel m 1L0 20 O0SOECD WNNVW H3srn HUAYI EN 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
15. l for an opti mal performance and reliability of the unit The cooling meth od should be selected depending on the working conditions of the appliance with major factors being the compressor s velocity and the evaporation temperature and also but sec ondary the condensation temperature USER MANUAL GD30FDC FREE AIR CIRCULATION OVER THE COMPRESSOR AND THE ELECTRONIC DRIVER MUST ALWAYS BE GUARAN TEED Table 6 shows the recommended cooling method for a stan dard condensation temperature of 55 C 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 1500 Static Static Static Static Static Static Static Fan Fan 2000 Static Static Static Static Static Static Fan Fan Fan 2500 Static Static Static Static Static Fan Fan Fan Fan 3000 Static Static Static Static Fan Fan Fan Fan N A 3500 Static Static Static Fan Fa Fan Fan NA N A Recommended cooling method Condensation temperature 55 C 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 10 Supply e GD30FDC compressor including FDC1 electronic driver deliv ered in pallets of 144 units e Pack of GD30FDC compressor includin
16. pplications If you are interested in this type of mobile ap plications it has to be specifically approved by Cubigel Com pressors GD30FDC can be powered at any voltage within the 12 to 42V DC range and is designed for capillary tube expansion Each unit is supplied with a dedicated electronic driver FDC1 which features all the protections for both the battery and the driver itself including the compressor motor The driver au tomatically adjusts itself to the voltage of the power supply Evaporation temperature range 30 C to 10 C Condensation temperature range up to 65 C Pull down peak 70 C Ambient temperature range 10 to 55 C 65 C at starting cubigel USER MANUAL GD30FDC In case of ambient temperature lower than 0 C an oil heater will be needed 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 FxC pro gramming package hardware and software provided by Cu bigel under request and allows the communication with an Electronic Integral Manager of the appliance EIM and mak ing the compressor work in slave mode FDC1 electronic driver includes Smart Speed as program ming option which is a plug in system for automatically self adapting compressor speed to current thermal load Smart Speed reduces the number of the
17. rmostat cycles by minimizing compressor speed enlarging on time at every thermostat cycle so that start stop energy loses are sub stantially reduced Lowest speed yields also highest evapo rating 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 com pressor nor the appliance are required to be programmed so Smart Speed can be easily used in all appliances with no design efforts cubigel compressors FDC1 electronic driver includes also Sleep and Sleep En ergy Saving as programming option which is a plug in sys tem specially conceived for mobile air conditioners avoiding any other electronic device Sleep and Sleep Energy Saving makes 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 cool ing capacity is needed and lowers compressor speed pro gressively to minimum velocity three hours later Maximum comfort and minimum energy consumption is thus achieved GD30FDC starting capability is as low as 10V 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 FDC1 electronic driver is supplied with a 3 minutes minimum thermostat off
18. tage 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 11 6 4 Resistance at 25 C R S R T S T Q 0 80 Model FDC1 Type Fully digital amp programmable uP based 12V 0 5A Fan Supported devices Compressor speed or battery protection level switcher Alarm LED 15V 25mA electronic thermostat 5V 25mA Electronic Integral Manager Communication port Communication capabilities Serial Port Interface SPI 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 Fan over current Starting failure Compressor overload Programmable running modes Standard Smart Speed Sleep Sleep Energy Saving Slave Setup by default Running mode Standard Speed selection external switcher Lower higher speed 1500 3500 r p m Battery protection fixed voltage level standard system 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 USER MANUAL GD30FDC cubigel USER MANUAL GD30FDC Ww Cooling capacity kCal h Ww kCal Wh COP
19. tched 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 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 nominal voltage 14V 28V and 42V 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 USER MANUAL GD30FDC If external switching is programmed the speed is set up by the connection of the SPI terminals IN1 and IN2 to COM for mini mum and maximum speeds and two intermediate velocities according to Table 4 Smin Smin 1 8 Smax Smin Smin 2 3 Smax Smin Oj o as eS Smax Table 4 External selection of the velocity O 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 e Smart Speed mode Compressor will run at vari
20. xe 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 3600 r p m as de 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 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 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 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 in
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