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DC Cooling Unit MODEL : TDC – 500A / TDC – 300A
DC Cooling Unit
MODEL : TDC – 500A / TDC – 300A

DC Cooling unit

Instruction Manual

DC Cooling unit Instruction Manual

Contents

1. DC Cooling unit

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3

  • 2. Technical Specifications

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4

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

  • 4. Operation/Working

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6

Contents 1. DC Cooling unit ............... 3 2. Technical Specifications ................................................. 4 3. Installation procedure ………………………………………….
  • 5. Compressor Controller

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  • 6. Operating instructions of the Temp Controller

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7

15

  • 7. Wiring Diagram

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  • 7. Contact Details

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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 .

Refrigeration Unit. Refrigeration is a process in which work is done to move heat from a

Technical Specification for DC Cooling unit

Tecumseh DC Cooling unit Model Cooling Capacity & Operational Useful Cooling output @L27L45 Rated Operating Voltage
Tecumseh DC Cooling unit
Model
Cooling Capacity & Operational
Useful Cooling output @L27L45
Rated Operating Voltage
Low Voltage
High Voltage
Rated Current
Start up Current
Power Consumption @L27L45
Environment protection& Performance
Working Temperature range
Noise Level
Protection from dust and rain
Refrigerant / Gas Charge Qty
Dimensions , Weight , Mounting
External Dimensions ( HXWXD )
Weight
Mounting Type
Application
Color
Controller
Temperature Setting - Default
Temperature Setting range
Units
TDC - 500A
Watts
500
Watts
300
V
48
V
40
V
58
Amps
6.5
Amps
6.8
Watts
315
15 - 55
° C
Db(A)
65
IP
IP54
gm
320
mm 580 X 325 X 320
Kg
25
External
Outdoor/ Indoor
RAL 7035
27
° C
0 - 50
° C

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

Installation Procedure: Step - 1 Inspect the unit visually before opening the packing for any damages.

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

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.

Operation/Working of Refrigeration unit Whenever the input supply is given to the unit the evaporator fan

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

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 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

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

compressor is off. When the analog input is between 0V and .25V, the compressor will run

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.

*** 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.

*** When Lock-out has occurred the controller will turn the Fault LED ON. It will not

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

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

FAN output Fan Power is on any time compressor is commanded to run and the fan
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12
12
13
13
14

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 Description Name P2 P3 P4 P5 P6 AL Ad E1 E2 E3 F1 F2 E4
Parameter
Description
Name
P2
P3
P4
P5
P6
AL
Ad
E1
E2
E3
F1
F2
E4
LP
FS
EP
Max High Temp limit & alarm.
Min Low Temp limit & alarm.
To set Differential (Hysteresis).
Probe calibration.
Time Delay (Relay restart after cutoff).
Alarm - To activate Alarm Relay.
Power On Time Delay For Alarm.
Evaporator Fan feedback Enable/disable.
Condenser Fan feedback Enable/disable.
Compressor feedback Enable/disable.
To set evaporator fan speed.
To set condenser fan speed.
Relay status on probe failure.
Keypad Lock.
Restore factory defaults.
End Programming & Keypad functions.
Key Introduction
Operating messages
LED Indications
Technical Data
Connection Diagram
Panel cutout, dimensions & Bezel

Operating instructions of the Temp Controller

Sr.No Parameter Parameter setting method. Range . Min Max Fact. Set 1 Set Point Function: To
Sr.No
Parameter
Parameter setting method.
Range
.
Min
Max
Fact.
Set
1
Set Point
Function: To set the cut out point of the
controller.
(P3+1)
O
C
(P2-1) O
C
27
O
C
(SP)
Press and
hold set key
for 2
seconds
and release
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
To set other parameters.
Display will show ‘P2’ flash. To go to other
parameters, use up / down keys.
release.
2
P2
Function: To set maximum allowable high
temperature limit & alarm.
(SP+1)
O
C
50 O C
35
O
C
To change
the P2
parameter,
press the
Use UP/DOWN keys to set desired value.
Once set at a particular value, this will not
allow the
set key.
set point to go above this value and below P3
setting.
Example : Setting this parameter at 30 O C
H
(Message on
Display)
will not allow the set point to go above 30 O C.
Also, if the temperature reaches 30 O C, 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
Function: To set minimum allowable low
temperature limit and alarm.
10 O C
(SP-1) O
C
10
O
C
To change
the P3
parameter,
press the
set key.
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 10 O C
will not allow the set point to go below 10 O C.
L
(Message on
Display)
Also, if the temperature reaches 10 O C, 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.
1 O C
10 O C
2 O C
To change Use UP/DOWN keys to set desired value. the P4 Differential between cut out and
To change
Use UP/DOWN keys to set desired value.
the P4
Differential between cut
out
and
cut
in
parameter,
temperature can be set between 1OC to
press the
10OC.
set key.
Example : If the set point is set at 10 O C and
differential is set at 2 O C, then when the
system reaches 10 O C, the relay will cut out.
Since the differential is 2, the relay will cut
in (restart) at 12 O C (10 O C+2 O C).
5
P5
Function: To set probe calibration.
-9 O C
10 O C
0 O C
To change
the P5
parameter,
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.
press the
set key.
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
28 O C, whereas the actual temperature is
30 O C. 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 30 O C (28 O C + 2 O C).
6
P6
Function: To set time delay between relay
restart time.
0Min
20Min
3Min
To change
the P6
parameter,
press the
set key.
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.
7 AL Function: To activate alarm relay. 0 1 1 To change the AL parameter, press
7
AL
Function: To activate alarm relay.
0
1
1
To change
the AL
parameter,
press the set
key.
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
Function : To set power on time delay for
alarm relay.
0 Min
30 Min
0 Min
To change
the Ad
parameter,
press the set
key.
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 .
9
E1
Function : Evaporator Fan feedback
Enable/disable.
0
1 1
To change
the E1
parameter,
press the set
key.
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
To change
the E2
parameter,
press the set
key.
Use the UP/DOWN keys to set desired
value. If set
0
= Condenser Fan feedback sensing
Disable.
= Condenser Fan feedback sensing is
Enable.
1
11
E3
Function : Compressor Fan feedback
Enable/disable.
0
2 1
To change
the E3
parameter,
press the set
key.
Use the UP/DOWN
value. If set
keys
to
set
desired
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
7 AL Function: To activate alarm relay. 0 1 1 To change the F1 parameter, press
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.
13
F2
Function : To set condenser fan speed.
0
99 99
To change
the F2
parameter,
press the set
key.
Use
the
UP/DOWN
keys
to
set
desired
value.
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
To change
the E4
parameter,
press the set
key.
Use the UP/DOWN keys to set desired
value.
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
Function : To lock keypad.
Use up/down keys to set desired value.
0
1
1
To change
the LP
parameter,
press the set
key.
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
Function : To restore default settings of
the controller.
0
1
0
To change
the FS
parameter,
press the set
key.
When set
to
1
all
parameters
are
programmed to factory values.
Useful to debug setting related problems.
17
EP
Function : To end programming.
To end
programming
press the set
key.
Once the set key is pressed, the control
goes into the normal mode and displays the
temperature and all settings are recorded.

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.

SET Key

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

RST
RST

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
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 70 O C
EF
CF
FF
Evaporator Fan Feedback Fault.
Condenser Fan Feedback Fault .
Compressor Feedback Fault.

LED Indications :

LED

LED Status

Description

 

ON

Evaporator Fan is ON.

  • OFF

FLASHING

Evaporator Fan is in Power ON time delay .

 

Evaporator Fan is OFF

ON

 

Condenser Fan is ON.

OFF

Condenser Fan is OFF.

 

ON

Compressor is ON.

  • OFF

FLASHING

Compressor is in time delay.

 

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.

ON

Keypad is Locked.

OFF

Keypad is Unlocked.

TECHNICAL DATA

Housing

Cond. & Evap. Fan

: Black ABS plastic.

 

Front cover

: Polycarbonate plastic & ABS plastic

Dimensions

: Front - 75

X

32.5 mm, depth 71mm.

Panel Cutout Mounting Front protection Connections Display Data storage Power input Operating temp.

: 29 X 71mm : Flush panel mounting with bracket. : I.P65. : Mini-fit type connector. : 2 X 14.2 mm (0.56") LED. : Non-volatile EEPROM memory : 48Vdc. : 5 O C to 50 O C(non-condensing).

Output :

: 48VDC,1A Max.

Relay1

: 8(3)A/250Vac

Alarm Storage temp Input Range Resolution Accuracy Probe tolerance at 25OC

: 5A/250Vac : -20 O C to 70 O C(non-condensing). : NTC probe, SZ-N75. : 0 O C to 50 O C : 1 O C. : +/- 1 O C. : +/- 0.3 O C.

Pass Word protected

TECHNICAL DATA Housing Cond. & Evap. Fan : Black ABS plastic. Front cover : Polycarbonate plastic

CONNECTION DIAGRAM :

TEC-7454 Wiring Diagram

Green FT FT Temp. Sensor C2 C1 UV 1 2 3 4 1 5 6 7
Green
FT
FT
Temp. Sensor
C2
C1
UV
1
2
3
4
1
5
6
7
8
2
SP
SP
6
5
4
G
G
3
2
1
Grey
Grey
+F
Yellow
-F
Yellow
White
+B
White
- B
-B
-B
+B
+B
Cond. Fan
Evap. Fan
Controller-Compressor
+B
Red
48VDC
-B
Black
*All Connecting wires to respective colors should be same color
CY
EW
EY
CW
FT
EY
EW
CY
CW

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

 

Hotline No

   

Customer Care

18004250002

Mail ID

customercare.india@tecumseh.com

Tecumseh Products India Pvt. Ltd.

  • 38 KM Stone, Delhi Mathura Road,

Contact Details; Tecumseh Products India Pvt. Ltd. Plant & Regd. Office: Balanagar Township, Hyderabad - 500

Ballabgarh, Harayana – 121004,

India. Tel: 0091-129-2307216-220 Direct: 0091-129-2307224