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DC Cooling unit
Instruction Manual
Contents
1. DC Cooling unit
...............3
3. Installation procedure . 5
4. Operation/Working
........................................ 6
7. Wiring Diagram
--------------------------------------------- 21
7. Contact Details.......................................................... 22
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 .
Units
Watts
Watts
V
V
V
Amps
Amps
Watts
C
Db(A)
IP
gm
TDC - 500A
500
300
48
40
58
6.5
6.8
315
15 - 55
65
IP54
320
mm
Kg
27
0 - 50
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
Compressor Controller
Device Overview
Features
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 0C (32F) to +55C (131F) 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
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.
*** 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 80C 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 80C (176F) 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.
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.
Engineering Specifications
Operating Characteristics
10
11
12
13
14
P3
P4
P5
Probe calibration.
P6
AL
Ad
E1
E2
E3
F1
F2
E4
LP
Keypad Lock.
FS
EP
15
Sr.No
.
Parameter
Set Point
(SP)
Press and
hold set key
for 2
seconds
and release
Press PRG
key for 2
seconds and
Range
Min
Max
Fact.
Set
(P3+1)OC
(P2-1)OC
27OC
(SP+1)OC
50OC
35OC
10OC
(SP-1)OC
10OC
1OC
10OC
2OC
release.
P2
To change
the P2
parameter,
press the
set key.
H
(Message on
Display)
P3
To change
the P3
parameter,
press the
set key.
L
(Message on
Display)
P4
16
To change
the P4
parameter,
press the
set key.
P5
To change
the P5
parameter,
press the
set key.
-9OC
10OC
0OC
0Min
20Min
3Min
P6
To change
the P6
parameter,
press the
set key.
17
AL
To change
the AL
parameter,
press the set
key.
0 Min
30 Min
0 Min
99
99
To change
the Ad
parameter,
press the set
key.
E1
To change
the E1
parameter,
press the set
key.
10
E2
To change
the E2
parameter,
press the set
key.
1=
11
E3
To change
the E3
parameter,
press the set
key.
12
18
F1
13
AL
To change
the F1
parameter,
press the set
key.
F2
To change
the F2
parameter,
press the set
key.
14
99
99
E4
To change
the E4
parameter,
press the set
key.
15
LP
To change
the LP
parameter,
press the set
key.
16
17
19
FS
To change
the FS
parameter,
press the set
key.
EP
To end
programming
press the set
key.
are
Key Introduction :
Down/prg
Key
RST
UP Key
SET Key
RST
This key is used to reset any Manual faults present for Controller
( Compressor Feedback.)
This key will reset the alarm relay.
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
EF
CF
FF
LED Indications :
LED
LED Status Description
20
ON
FLASHING
OFF
ON
OFF
ON
Compressor is ON.
FLASHING
OFF
Compressor is OFF.
ON
ON
Keypad is Locked.
OFF
Keypad is Unlocked.
TECHNICAL DATA
Housing
Front cover
Dimensions
Panel Cutout
Mounting
Front protection
Connections
Display
Data storage
Power input
Operating temp.
Output :
Cond. & Evap. Fan
Relay1
Alarm
Storage temp
Input
Range
Resolution
Accuracy
Probe tolerance at 25OC
Pass Word protected
21
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
48VDC,1A Max.
8(3)A/250Vac
5A/250Vac
-20OC to 70OC(non-condensing).
NTC probe, SZ-N75.
0OC to 50OC
1OC.
+/- 1OC.
+/- 0.3OC.
CONNECTION DIAGRAM :
EY
C1
UV
SP
+F
Yellow
-F
Yellow
White
Evap. Fan
Red
-B
Black
22
CW
-B
+B
CY
EY
-B
+B
EW
White
+B
SP
G
Grey
Grey
48VDC
FT
Temp. Sensor
FT
C2
FT
Cond. Fan
+B
-B
Controller-Compressor
CY
EW
Green
Contact Details;
Tecumseh Products India Pvt. Ltd.
Plant & Regd. Office:
Balanagar Township,
Hyderabad - 500 037. (A,P,) India
Tel: +91-040-30116993/94
Info@tecumsehindia.com
Customer Care
Hotline No
18004250002
Mail ID
23
customercare.india@tecumseh.com