TDC 500A Manual

DC Cooling UnitMODEL : TDC – 500A / TDC – 300A

DC Cooling unit

Instruction Manual

2

Contents

1. DC Cooling unit ...............3

2. Technical Specifications .................................................4

3. Installation procedure …………………………………………. 5

4. Operation/Working ........................................ 6

5. Compressor Controller .................................................. 7

6. Operating instructions of the Temp Controller ............. 15

7. Wiring Diagram --------------------------------------------- 21

7. Contact Details.......................................................... 22

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Refrigeration Unit.

Refrigeration is a process in which work is done to move heat from a low temperature to a high temperature and typically also from one location to another. The work of heat transport is traditionally driven by mechanical work, but can also be driven by heat, magnetism, electricity, laser, or other means. Refrigeration has many applications, including, but not limited to: household refrigerators, industrial freezers, cryogenics, and air conditioning. Heat pumps may use the heat output of the refrigeration process, and also may be designed to be reversible, but are otherwise similar to refrigeration units.

Refrigeration Unit is an integral part of the chamber/enclosure/shelter duly charged and factory fitted, ready to use unit with 48V DC power supply. Indoor unit Air circulation is from the top as shown in the fig for better air circulation. This is also in-line with natural flow of Hot Air moving upward. In the unique design it is ensured that there are no Hot Pockets built at remote ends of shelter enclosure , chamber. The evaporator fan is a centrifugal fan which sucks the air from the chamber and forces the air thru the cooling coil. The rear fan is centrifugal fan. Suitable drain hole is provided at bottom for condensate water. The refrigeration cycle used is a vapor compression cycle which is a common method used in the industry and very user friendly and easily available in the market. The refrigerant used in this system is R-134a .

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Technical Specification for DC Cooling unit

Tecumseh DC Cooling unit

Model Units TDC - 500A

Cooling Capacity & Operational Watts 500

Useful Cooling output @L27L45 Watts 300

Rated Operating Voltage V 48

Low Voltage V 40

High Voltage V 58

Rated Current Amps 6.5

Start up Current Amps 6.8

Power Consumption @L27L45 Watts 315

Environment protection& Performance

Working Temperature range ° C 15 - 55

Noise Level Db(A) 65

Protection from dust and rain IP IP54

Refrigerant / Gas Charge Qty gm 320

Dimensions , Weight , Mounting

External Dimensions ( HXWXD ) mm 580 X 325 X 320

Weight Kg 25

Mounting Type External

Application Outdoor/ Indoor

Color RAL 7035

Controller

Temperature Setting - Default ° C 27

Temperature Setting range ° C 0 - 50

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Installation Procedure:

Step - 1 Inspect the unit visually before opening the packing for any damages. If any damage observed please do not acknowledge the receipt and inform the manufacturer for claiming transit damages.

Step - 2

If no transit damages are seen visually, open the packing box.

Step – 3

Remove the packing box . Step - 4

Locate the unit on the base where the cooling unit has to be installed.

Step - 5 Make the cut out for cooling unit mounting as per template . Install the unit by fixing the bolts . Provide the necessary wiring connection as per wiring diagram . Please do not switch on the unit for 30 minutes as the oil in the compressor and system needs to be settled down .

Step – 6

Temperature settings done on controller are preset factory settings. Please do not disturb the settings as these may decrease the cooling Capacity and lead to higher temperatures inside the chamber .

Note : 1.Do not tamper the controller factory settings by changing the set points. 2.Only a qualified electrician/refrigeration engineer has to handle the unit for safe working. 3. Due to continuous research and development the design is subject to change without any prior notice

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Operation/Working of Refrigeration unit

Whenever the input supply is given to the unit the evaporator fan turn on and after 3 minutes time delay both compressor and the condenser fan turns on. The sensor provided in the cabinet senses the inside cabinet temperature and if the temperature is more than 29 Deg C the compressor and condenser fan turns on. As the temperature of the cabinet drops down to 27 Deg C the compressor and the condenser fan turns off. The compressor controller is designed for an operating voltage of 48 +/- 20%. Detailed operation and faulty condition details are provided below. Temperature controller operation and logic is also provided along with this manual.

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Compressor Controller

Device Overview

Features

• 4 poles sensor-less variable speed BLDC motor controller

• 325 W maximum output power

• 39 - 60 VDC input range

• 1800 – 4200 rpm speed

• 1.0 - 4.75V analog speed set input (resistor programmable for fixed speed)

• 0 to +55°C operating temperature

• Under/Over voltage shutdown (resistor programmable under voltage thresholds)

• Locked rotor detection

• Thermal shutdown – for power devices

• Over current shutdown – for power devices

• Low speed shutdown

• TTL Fault output

• LED fault indicator

• Fan output, +12VDC @ 0.5A with voltage detection

• Reverse polarity protection

Description The TH motor controller has been designed to provide efficient control and monitoring of a 4 pole 48VDC brushless/sensor-less hermetic TH compressor. The controller will provide a constant speed as specified by the speed command input (1800 - 4200 RPM) unless one of the following limitations occurs: Power limitation, this limits the average power the drive puts into the motor. If the load requires more than 325 W into the motor, the controller will shutdown the motor The compressor on/off operation is controlled by 0V – 5V analog input. For fixed speed applications a resistor can be installed between ground at the controller and the speed input. (see resistor selection chart) The controller is designed to work in ambient temperatures from 0°C (32°F) to +55°C (131°F) and presents several fault sensors to protect the module, the power supply and the compressor. Visual Fault information is available through an LED that is uniquely flashed for each fault condition. A TTL fault output is also available that is high when fault is active.

Operation Analog Speed Control (default) A 0 - 5VDC non-isolated analog input can be used to control the motor speed, off / on operation. When the analog input is between 0.26 and 0.99V or greater than 4.75V the

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compressor is off. When the analog input is between 0V and .25V, the compressor will run at a fixed speed of 3000 RPM. If the analog input is above 0.99V and below 4.75V the compressor will start and ramp up at a rate of 600 RPM per second to the commanded speed. The speed command is mapped to 1V is 1800 RPM and 4.75V is 4200 RPM. Once the motor begins to run it will require the input voltage to go lower than 0.8V or higher than 4.75V to stop the motor (hysteresis). The motor controller will run the motor at the set-point speed unless a voltage, current or power limitation is exceeded. Fixed Speed Control A fixed motor speed can be set through an external resistor connected between ground at the controller and the speed input. A switch in series with the resistor can be used to turn the motor on and off in this configuration. See speed resistor selection chart. Fault Detection The compressor is turned off when any of the faults described below are detected. Faults are indicated on the fault output pin and flashed on the LED. The fan output is disabled for all faults except motor faults where the fan output will continue to be active if the run command is present. Faults

• Motor Fault – If the compressor fails to start the fault output will be activated and a motor fault will be indicated on the LED. The controller will delay for 60 seconds before attempting to restart. Also the compressor must maintain a minimum speed of 1500 RPM for proper lubrication. If the controller is unable maintain 1500 RPM it will turn the compressor off then set the fault output and display motor fault. The controller will delay for 60 seconds before attempting to restart. If a motor fault occurs and the controller is commanded to run the fan output will continue to be active during the 60 second fault timer. All other fault conditions the fan output will be disabled until the fault is cleared.

• Under/Over voltage - The controller will continuously monitor the input voltage, if the input voltage exceeds the upper or lower limits it will turn the compressor off and set the fault output and display the appropriate fault message on the LED. The controller will then delay for 60 seconds. After the delay the controller will wait for the input voltage to be within specifications, if the voltage is within specification the controller will turn off the fault indicators and attempt to restart the compressor. The voltage trip points are detailed below for each operating mode.

• Short-Circuit (motor-phase to phase) Current Detection – The controller monitors the motor current and will turn the compressor off then set the fault output and display the appropriate fault message if the current exceeds an internal pre-determined current threshold. The controller will delay for 60 seconds before attempting to restart. The controller will attempt to start ten times. After the tenth cycle the controller will enter into a lockout state that requires a power cycle to clear the fault.

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*** When Lock-out has occurred the controller will turn the Fault LED ON. It will not flash when the controller is in lockout.

• Power devices temperature above limit - if the power devices have exceeded there maximum operating temperature 80°C the controller will turn the compressor off then set the fault output and display the appropriate fault message. The controller will delay for 60 seconds. After the delay the controller will monitor the power device temperature and if it has fallen below 80°C (176°F) the controller will clear the fault indicators and attempt to restart the compressor.

Fan Voltage Out of Tolerance – The controller continuously monitors the fan voltage. If the fan voltage is outside of the specified region due to excessive load current the controller will turn the and fan output off and turn off the compressor. The controller will then set the fault output and display the appropriate fault message. The controller will delay for 60 seconds before attempting to turn the fan output on and restarting the compressor. General Hardware Error – This error occurs when one or more of several conditions are present in the system. The system consists of two Controllers, if the communication between the controllers is lost this can cause the error. Other examples of what can cause this error include: a difference of measured voltages, if the microcontrollers are measuring different voltages at the same point, and a difference in the current consumption measurements.

LED Fault Indicator and Fault output The controller will signal a fault condition by outputting a logic high value on the fault output. The output is a TTL level signal capable of directly driving +/- 5mA. The controller will indicate a fault condition by flashing the fault LED. The Flashing pattern will be ¼ second on and ¼ second off for each count, then dwells 5 seconds and repeat until the fault(s) are cleared. Listed below are the fault codes. If the controller enters fault lockout from over current faults the LED will stay lit and not flash. 1 flash – Motor Fault 2 flashes – Under Voltage 3 flashes – Over Voltage 4 flashes – Over Temperature 5 flashes – Over Current / Over Power 6 flashes – Fan Voltage out of Tolerance 7 flashes – General Hardware Error 8 flashes – System Integrity Fault

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FAN output Fan Power is on any time compressor is commanded to run and the fan fault is not active. The fan out is a current source. When the fan turns on it can support a current of 1A for 1 second. After the startup if the fan current exceeds 0.5A the controller will detect a voltage out of tolerance and then turn off the fan output and the compressor, set the fault output and display the appropriate fault message. The controller will delay for 60 seconds before attempting to turn on the fan output and restarting the compressor.

Serial Port Diagnostic Messages The controller will report the model number on power up. The motor controller will report real time power device temperature, compressor speed, motor input voltage, compressor current and fault status on the serial port. Serial port configured for 19200 baud, 8 data bits, 1 stop bit, no parity, no flow control. Access to the connector will require the module to be disassembled. This port is not intended for end use. It is only present for debugging and testing during the development and testing of the controller.

Engineering Specifications Operating Characteristics

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Model No: TEC-7454

GENERAL DESCRIPTION The TEC- 7454 is a single set point controller. It is specifically designed for application where in the compressor cuts off a set point and is restarted at temperature set point plus differential (P4 parameter). Additionally the TEC-7454 offers several protection features that are easily understood by the example in the instructions below. A numbers of parameters are displayed alphanumerically to set up the instruments for each specific application.

INDEX

Parameter Name

Description

P2 Max High Temp limit & alarm.

P3 Min Low Temp limit & alarm.

P4 To set Differential (Hysteresis).

P5 Probe calibration.

P6 Time Delay (Relay restart after cutoff).

AL Alarm - To activate Alarm Relay.

Ad Power On Time Delay For Alarm.

E1 Evaporator Fan feedback Enable/disable.

E2 Condenser Fan feedback Enable/disable.

E3 Compressor feedback Enable/disable.

F1 To set evaporator fan speed.

F2 To set condenser fan speed.

E4 Relay status on probe failure.

LP Keypad Lock.

FS Restore factory defaults.

EP End Programming & Keypad functions.

Key Introduction

Operating messages

LED Indications

Technical Data

Connection Diagram

Panel cutout, dimensions & Bezel

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Operating instructions of the Temp Controller

Sr.No.

Parameter Parameter setting method. Range

Min Max Fact. Set

1

Set Point

(SP)

Press and

hold set key for 2 seconds and release

Function: To set the cut out point of the controller.

(P3+1)OC (P2-1)OC 27OC

Display will change to set value. The set point value can now be changed by using the UP/DOWN keys. After setting the desired value, press the set key and you will see “- -" which confirms that the set point has been stored in memory.

2

Press PRG key for 2 seconds and

release.

To set other parameters.

Display will show ‘P2’ flash. To go to other parameters, use up / down keys.

2

P2

To change the P2 parameter, press the set key.

(Message on Display)

Function: To set maximum allowable high temperature limit & alarm.

(SP+1)OC 50OC 35OC

Use UP/DOWN keys to set desired value. Once set at a particular value, this will not allow the

set point to go above this value and below P3 setting.

Example : Setting this parameter at 30OC will not allow the set point to go above 30OC. Also, if the temperature reaches 30OC, the display will show Ht (High Temp.) indicating that the temperature has reached or gone above the value in this parameter and at this point the alarm relay will activate.

3 P3


(Message on Display)

Function: To set minimum allowable low temperature limit and alarm.

10OC (SP-1)OC 10OC

Use UP/DOWN keys to set desired value. Once set at a particular value, this will not allow the set point to go below this value and above P2 setting.

Example : Setting this parameter at 10OC will not allow the set point to go below 10OC. Also, if the temperature reaches 10OC, the display will show Lt (Low Temp.) indicating that the temperature has reached or gone below the value in this parameter and at this point the alarm relay will activate.

4 P4 Function: To set the differential. 1OC 10OC 2OC

L

H

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Use UP/DOWN keys to set desired value. Differential between cut out and cut in temperature can be set between 1OC to 10OC.

Example : If the set point is set at 10OC and differential is set at 2OC, then when the system reaches 10OC, the relay will cut out. Since the differential is 2, the relay will cut in (restart) at 12OC (10OC+2OC).

5 P5


Function: To set probe calibration. -9OC 10OC 0OC

Use UP/DOWN keys to set desired value. In time it may be possible that the display may be offset by a degree or so.

To compensate for this error, you may need to add or minus the degrees required to achieve the correct temperature.

Example : The temperature on the display is 28OC, whereas the actual temperature is 30OC. You will need to set the P5 mode to 2, which means that once out of the programming parameter, the display will show the temperature 30OC (28OC + 2OC).

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P6


Function: To set time delay between relay restart time.

0Min 20Min

3Min

Use UP/DOWN keys to set desired value. This parameter is used to protect the compressor from restarting in a short period of time and can be set between 0 to 99 minutes.

Example : If this parameter is set at 3 minutes, the relay will cut off at the set temperature, but will not restart for a minimum of 3 minutes, even if the differential is achieved earlier. This parameter is good to protect the life of the compressor when there are power fluctuations and the compressor is switched off and on within a few seconds.

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7 AL

To change the AL parameter, press the set key.

Function: To activate alarm relay. 0 1 1

Use the UP/DOWN keys to set alarm on or off. Once set to on, the alarm relay will come on in case the temperature reaches or goes above or below the points set in parameter P2 & P3 and if the probe fails.

0 = De-activates alarm relay.

1 = Activates alarm relay.

8 Ad

To change the Ad parameter, press the set key.

Function : To set power on time delay for alarm relay.

0 Min 30 Min 0 Min

Use up/down keys to set desired value. This parameter sets a time delay on power on for the alarm.

Example : If this parameter is set to 20min once the unit is powered on the alarm relay will not activate for 20 minutes even if there is a fault. This is very useful to eliminate the nuisance alarm when a unit is switched on and the ambient is above the Max set limit in P2.This delay is applicable for High temperature alarms .

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E1

To change the E1 parameter, press the set key.

Function : Evaporator Fan feedback Enable/disable.

0 1

1

Use the UP/DOWN keys to set desired value. If set

0 = Evaporator Fan feedback sensing is Disabled.

1 = Evaporator Fan feedback sensing is Enabled.

10 E2


Function : Condenser Fan feedback Enable/disable.

0 1 1


0 = Condenser Fan feedback sensing Disable.

1 = Condenser Fan feedback sensing is Enable.

11 E3


Function : Compressor Fan feedback Enable/disable.

0 2 1


0 = Compressor F/B is disabled.

1 = Compressor F/B is enabled.

(Auto Reset)

2 = Compressor F/B is enabled.

(Manual reset, 3 retrials in 1 hour.)

12 F1 Function : To set evaporator fan speed. 0 99 99

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7 AL Function: To activate alarm relay. 0 1 1

To change the F1 parameter, press the set key.

Use the UP/DOWN keys to set desired value.

Example : If this parameter is set to 99%. Evap. fan will run at 99% speed.

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F2

To change the F2 parameter, press the set key.

Function : To set condenser fan speed. 0 99

99


Example : If this parameter is set to 99%. Condenser fan will run at 99% speed.

14 E4


Function : Relay status on Probe Failure. 0 2 1


When set to 0 the relay status is ON.

When set to 1, the compressor performs a duty cycle of 10 minutes ON and 4 minutes OFF.

When set to 2 the relay status is OFF.

15 LP

To change the LP parameter, press the set key.

Function : To lock keypad. 0 1 1

Use up/down keys to set desired value.

This Parameter can lock the keypad so that tampering is not possible by by-standers.

0 = keypad unlocked

1 = keypad locked

When locked all parameters can only be viewed, but not modified.

16 FS

To change the FS parameter, press the set key.

Function : To restore default settings of the controller.

0 1 0

When set to 1 all parameters are programmed to factory values.

Useful to debug setting related problems.

17 EP

To end programming press the set key.

Function : To end programming.

Once the set key is pressed, the control goes into the normal mode and displays the temperature and all settings are recorded.

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Key Introduction :

Down/prg Key

Used to enter into the program mode.

Used in program mode to decrement parameter value .

UP Key Used in program mode to increment parameter value.

SET Key In program mode used to set the changed value of parameter.

RST This key is used to reset any Manual faults present for Controller ( Compressor Feedback.)

This key will reset the alarm relay.

Operating messages and Icon Status

Message Description

Ht High temperature alarm for Room .Means room temperature is above the set value of Ht parameter.

Lt Low temperature alarm for Room .Means room temperature is below the set value of Lt parameter.

PF Room ,Supply temperature or Supply temperature fail means sensor not connected or out of range . Range Temperature : 0 to 70OC

EF Evaporator Fan Feedback Fault.

CF Condenser Fan Feedback Fault .

FF Compressor Feedback Fault.

LED Indications :

LED LED Status Description

ON Evaporator Fan is ON.

FLASHING Evaporator Fan is in Power ON time delay .

OFF Evaporator Fan is OFF

ON Condenser Fan is ON.

OFF Condenser Fan is OFF.

ON Compressor is ON.

FLASHING Compressor is in time delay.

OFF Compressor is OFF.

ON Alarm relay is ON due to faults like Room Sensor, Room High Temperature Fault, Room Low Temperature Fault, Compressor Feedback Fault, Evaporator/Condenser Feedback Fault.

ON Keypad is Locked.

OFF Keypad is Unlocked.

RST

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TECHNICAL DATA Housing : Black ABS plastic. Front cover : Polycarbonate plastic & ABS plastic Dimensions : Front - 75 X 32.5 mm, depth 71mm. Panel Cutout : 29 X 71mm Mounting : Flush panel mounting with bracket. Front protection : I.P65. Connections : Mini-fit type connector. Display : 2 X 14.2 mm (0.56") LED. Data storage : Non-volatile EEPROM memory Power input : 48Vdc. Operating temp. : 5OC to 50OC(non-condensing). Output : Cond. & Evap. Fan : 48VDC,1A Max. Relay1 : 8(3)A/250Vac Alarm : 5A/250Vac Storage temp : -20OC to 70OC(non-condensing). Input : NTC probe, SZ-N75. Range : 0OC to 50OC Resolution : 1OC. Accuracy : +/- 1OC. Probe tolerance at 25OC : +/- 0.3OC. Pass Word protected

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CONNECTION DIAGRAM :

1 2 3 4

5 6 7 86 5 4

3 2 1

1

2

EW CW

CY EY

FT

Evap. Fan

FT

UV

SP

G

+F

-F

+B

- B

Co

ntro

ller-C

om

pre

ssor

Cond. Fan

Yellow

Yellow

White

White

Green

SP

G

FT

Red

Black

+B

-B

EY

EW CY

CW-B

+B-B+B

*All Connecting wires to respective colors should be same color

TEC-7454 Wiring Diagram

GreyGrey

48VDC

Temp. Sensor

C1C2

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Contact Details;

Tecumseh Products India Pvt. Ltd. Plant & Regd. Office: Balanagar Township, Hyderabad - 500 037. (A,P,) India Tel: +91-040-30116993/94 [email protected]

Customer Care

Hotline No

18004250002 Mail ID [email protected]

Tecumseh Products India Pvt. Ltd. 38 KM Stone, Delhi Mathura Road, Ballabgarh, Harayana – 121004, India. Tel: 0091-129-2307216-220 Direct: 0091-129-2307224

TDC 500A Manual

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