Application guidelines
Danfoss Light Commercial
Refrigeration Compressors
GD30FDC
Direct Current, 12-42 V, Mobile Applications
http://cc.danfoss.com
Content
About the product................................................................................................................ |
4 |
Wiring and Connections....................................................................................................... |
5 |
The serial port interface (SPI)............................................................................................... |
7 |
Operating voltage................................................................................................................. |
8 |
Battery protection system................................................................................................... |
9 |
Setting up the speed.......................................................................................................... |
10 |
Programming the electronic driver.................................................................................. |
12 |
Protections and alarms...................................................................................................... |
13 |
Compressor Cooling........................................................................................................... |
14 |
Supply.................................................................................................................................. |
14 |
Dimensions.......................................................................................................................... |
15 |
Technical Data..................................................................................................................... |
16 |
FRCC.PC.040.A1.02 3
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 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.
GD30FDC is an 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
refrigerator is utilised. The GD30FDC is designed to operate silently, efficiently and reliably even up to angles of tilt of 30º, working with refrigerant R134a. Its design is based on the “D” series, which has been successfully present in the market since 1984, and has had sales of 15 million units.
GD30FDC compressor is not designed for offroad mobile applications. If you are interested in this type of mobile applications, it has to be specifically approved by the manufacturer.
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 automatically adjusts itself to the voltage of the power supply.
Evaporation temperature range: -30ºC to +10ºC. Condensation temperature range: up to 65ºC. Pull-down peak: 70ºC.
Ambient temperature range: -10 to 55ºC (65ºC at starting).
In case of ambient temperature lower than 0ºC, 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 programming package (hardware and software, provided by the manufacturer upon 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 pulldown 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 is a plug-in system 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 cooling capacity is needed, and lowers compressor speed progressively 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 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.
4 FRCC.PC.040.A1.02
Wiring and Connections
General rules |
GD30FDC must always be powered through |
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the dedicated electronic driver FDC1, which |
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is supplied with the compressor as a separate |
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device. |
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NEVER CONNECT THE COMPRESSOR’S HERMETIC |
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PINS (FUSITE) TO THE TERMINALS OF A BATTERY |
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OR ANY OTHER DC OR AC SOURCE DIRECTLY. |
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DO NOT TRY TO FIT AN ELECTRONIC DRIVER |
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OTHER THAN THE FDC1. THE COMPRESSOR WILL |
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NOT OPERATE AND IRREVERSIBLE DAMAGE MAY |
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OCCUR. |
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The FDC1 driver is directly connected to the |
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battery poles as well as to the compressor pins. |
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It checks battery voltage and adjusts itself to the |
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voltage value for proper compressor operation, |
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or switches itself off if the battery voltage is not |
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adequate. The driver also controls the compressor |
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speed. |
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ALWAYS RESPECT THE POLARITY OF THE BATTERY |
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WITH THE POWER INPUT TERMINALS OF THE |
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ELECTRONIC DRIVER. |
The unit is protected against damage caused by wrong polarity 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 “+” POWER 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 “+” terminal 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.
Voltage drop in the power leads
Table 1: Maximum length of leads (m)
To avoid excessive voltage drop in the leads, their length and cross section must be related to the voltage supply as indicated in Table 1.
Cross section mm2 |
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Rated Operating Range |
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12 - 14 V |
24 - 28 V |
36 - 42 V |
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2.5 |
1.5 |
3 |
4.5 |
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4 |
2.5 |
5 |
7.5 |
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6 |
4 |
8 |
12 |
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10 |
6 |
12 |
18 |
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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 10mΩ. If the resistance is
higher than 5mΩ, the maximum length of the wires indicated in Table 1 should be halved or the cross section doubled.
FRCC.PC.040.A1.02 5
Wiring and Connections
Wiring Diagram |
The FDC1 electronic driver features a terminal |
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board where all connections are made. The |
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terminal lay out is described in Figure 1: |
Fig 1. FDC1 Wiring |
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scheme |
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Fig 2. Connection of the FDC1 electronic driver to the compressor
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 120º clockwise or counter clockwise with respect to the vertical position as shown below.
6 FRCC.PC.040.A1.02
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