Danfoss Light Commercial Refrigeration Compressors: Gd30Fdc
Danfoss Light Commercial Refrigeration Compressors: Gd30Fdc
http://cc.danfoss.com
Content
FRCC.PC.040.A1.02 3
About the product
Many vehicles for transportation of goods or FDC1 electronic driver includes Smart Speed® as
recreation, such as trucks, caravans, boats, cars, programming option, which is a plug-in system
etc. are often equipped with cooling appliances. for automatically self adapting compressor speed
The compressors for such mobile applications to current thermal load.
must be designed to operate from a low voltage
DC power supply. These compressors must also Smart Speed® reduces the number of thermostat
be compact in their dimensions, highly reliable cycles by minimizing compressor speed,
and yield high performances. enlarging on-time at every thermostat cycle,
so that start/stop energy loses are substantially
GD30FDC is an answer to the needs of users reduced. Lowest speed yields also highest
requiring comfort and reliability in their evaporating temperature, and so highest C.O.P
travelling, either on holidays, at work or in and lowest energy consumption. Pull-down is
any other circumstance where a DC powered done at maximum programmed speed, so pull-
refrigerator is utilised. The GD30FDC is designed down time is very short with respect to fixed
to operate silently, efficiently and reliably even up speed systems. No design parameters neither of
to angles of tilt of 30º, working with refrigerant the compressor nor the appliance are required to
R134a. Its design is based on the “D” series, which be programmed, so Smart Speed® can be easily
has been successfully present in the market since used in all appliances with no design efforts.
1984, and has had sales of 15 million units.
FDC1 electronic driver includes also Sleep and
GD30FDC compressor is not designed for off- Sleep Energy Saving as programming option,
road mobile applications. If you are interested which is a plug-in system specially conceived
in this type of mobile applications, it has to be for mobile air conditioners avoiding any other
specifically approved by the manufacturer. electronic device. Sleep and Sleep Energy Saving
makes the air conditioner work for four hours
GD30FDC can be powered at any voltage within since start-up. Sleep Energy Saving makes the
the 12 to 42V DC range, and is designed for compressor run at maximum programmed speed
capillary tube expansion. Each unit is supplied during the first hour, when highest cooling
with a dedicated electronic driver (FDC1), which capacity is needed, and lowers compressor speed
features all the protections for both the battery progressively to minimum velocity three hours
and the driver itself, including the compressor later. Maximum comfort and minimum energy
motor. The driver automatically adjusts itself to consumption is thus achieved.
the voltage of the power supply.
GD30FDC starting capability is as low as 10V
Evaporation temperature range: -30ºC to +10ºC. under any balanced pressure. It also admits a
Condensation temperature range: up to 65ºC. certain remaining differential pressure when
Pull-down peak: 70ºC. thermostat off-time is abnormally short. For
Ambient temperature range: -10 to 55ºC (65ºC at improving even more the starting capability,
starting). FDC1 electronic driver is supplied with a 3
minutes minimum thermostat off-time. The delay
In case of ambient temperature lower than 0ºC, is a programming option which can be easily
an oil heater will be needed. removed if no delay is preferred for any reason.
The electronic control unit FDC1 is supplied with FDC1 also includes a 1 second filter at the
the exclusive Serial Port Interface (SPI), featuring thermostat input to prevent the appliance from
a RJ11 telephone type connector. SPI allows the wrong operation due to typical micro switching
electronic driver to be connected to a computer produced by vibrations in those appliances that
for programming purposes using the FxC fit tilt switches at the thermostat circuit. So,
programming package (hardware and software, analogical filtering is not needed.
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.
4 FRCC.PC.040.A1.02
Wiring and Connections
General rules GD30FDC must always be powered through The unit is protected against damage caused by
the dedicated electronic driver FDC1, which wrong polarity of the supply, The compressor will
is supplied with the compressor as a separate not run correctly if it’s wrongly connected.
device.
“-“ POWER INPUT TERMINAL OF THE ELECTRONIC
NEVER CONNECT THE COMPRESSOR’S HERMETIC DRIVER SHOULD BE REFERRED TO THE CHASSIS
PINS (FUSITE) TO THE TERMINALS OF A BATTERY OF THE VEHICLE AS WELL AS THE APPLIANCE
OR ANY OTHER DC OR AC SOURCE DIRECTLY. FRAME*
DO NOT TRY TO FIT AN ELECTRONIC DRIVER A FUSE MUST BE PLACED BETWEEN THE “+” POLE
OTHER THAN THE FDC1. THE COMPRESSOR WILL OF THE BATTERY OR DC POWER SUPPLY AND THE
NOT OPERATE AND IRREVERSIBLE DAMAGE MAY “+” POWER INPUT TERMINAL OF THE ELECTRONIC
OCCUR. DRIVER*
The FDC1 driver is directly connected to the 12V SYSTEMS: 30A FUSE
battery poles as well as to the compressor pins. 24V SYSTEMS: 15A FUSE
It checks battery voltage and adjusts itself to the 42V SYSTEMS: 10A FUSE
voltage value for proper compressor operation,
or switches itself off if the battery voltage is not In some special vehicles chassis is connected to
adequate. The driver also controls the compressor “+” terminal of the battery instead of “-“ terminal
speed. (positive reference systems). In such cases “+”
should be understood as “-“ and vice-versa.
ALWAYS RESPECT THE POLARITY OF THE BATTERY
WITH THE POWER INPUT TERMINALS OF THE In systems powered by a variable DC source, the
ELECTRONIC DRIVER. fuse should be selected following the rules above
mentioned, considering the maximum voltage at
the variable DC Source.
Voltage drop in the To avoid excessive voltage drop in the leads, their
power leads length and cross section must be related to the
voltage supply as indicated in Table 1.
If any kind of connector or switch is placed higher than 5mΩ, the maximum length of the
between the battery poles and the power wires indicated in Table 1 should be halved or the
terminals of the electronic driver, its resistance cross section doubled.
should be less than 10mΩ. If the resistance is
FRCC.PC.040.A1.02 5
Wiring and Connections
When connecting the electronic driver to the possible because the electronic box cannot be
compressor, any position of the connector assembled. The connector should be rotated 120º
is possible under an electrical point of view. clockwise or counter clockwise with respect to
However, in practice, the vertical position is not the vertical position as shown below.
6 FRCC.PC.040.A1.02
The serial port interface (SPI)
The electronic control unit FDC1 is supplied with • Connect the electronic driver as slave to an
the exclusive Serial Port Interface (SPI), featuring Electronic Integral Manager of the appliance with
a RJ11 telephone type connector. This port serial communication capabilities (Rx, Tx and
allows the electronic driver to be connected to COM), to allow working with variable speed. SPI
a computer for programming purposes using provides a 5 V output, limited to 25mA, to power
the FxC programming package (hardware and up the EIM.
software) provided by the manufacturer upon
request. Optionally, the SPI can be configured to: Figure 3 Shows the RJ11 male connector which
can be plugged to the SPI and the usage of each
• Install a LED to display the intervention of any terminal in it.
alarm.
• Set up either the compressor speed or the
battery protection level, through physical
connections between IN1, IN2 and COM.
FRCC.PC.040.A1.02 7
Operating voltage
From the value of the applied voltage, the The compressor can be powered by a variable DC
electronic driver automatically decides the rated source as, for instance, a photovoltaic panel, in
voltage range of the supply. Three possible which the output voltage strongly depends on
ranges are considered: the intensity of sunlight radiation. In these special
cases the driver should be programmed with
12 to 14V: actual voltage is below 17V rated, minimum and maximum voltages. These
24 to 28V: actual voltage is within 17 and 33V values should be within the allowable DC voltage
36 to 42V: actual voltage is within 33 and 42.4V power supply (10 V to 42.4V).
8 FRCC.PC.040.A1.02
Battery protection system
In Table 2, ΔV is the difference between cut-out · Voltage limits are set up by means of a PC
and cut-in, that is, the cut-in value is the result of through its serial or USB port connected to
adding ΔV to the cut-out value. the electronic driver SPI. It can be done by the
customer itself using the FxC programming
• Externally, using COM, IN1 and IN2 of SPI: package.
· This option prevents from the possibility of · The cut-out (battery voltage at which the
setting up the speed externally using COM, IN1 driver stops operating) and the cut-in (battery
and IN2 of SPI as defined in point 6. voltage at which driver re-starts operation
after a cut-off ) values are set up by connecting
· The external battery protection set up option the SPI connector terminals IN1 and IN2 to
must be previously programmed for external COM. According to the connection made, four
adjustment of the protection limits. protection levels can be selected as shown in
Table 3.
FRCC.PC.040.A1.02 9
Setting up the speed
It is possible to operate the compressor at fixed When setting up a fixed speed, maximum speed
or variable speed under different running modes, can be limited by the available battery voltage in
options and parameters. The electronic driver the following way, maximum speed would be:
is supplied by the manufacturer with standard
running mode and external control of the speed, · 1,500 rpm when the battery voltage is equal to
with minimum speed of 1,500 rpm and maximum the cut-in voltage.
speed 3,500 rpm. Default running mode, options · Programmed fixed speed when the battery
and parameters can be changed to optimize voltage is equal to or greater than the maximum
compressor performance for a given appliance, nominal voltage (14V, 28V and 42V for 12V, 24V
by programming, connecting a PC to the SPI and 42V systems respectively).
by means of the FxC programming package · A linear function of the battery voltage in the
provided by the manufacturer upon request. range between the cut-in and the maximum
Running modes and options are: nominal voltages.
10 FRCC.PC.040.A1.02
Setting up the speed
If off sleep mode is selected, the appliance will communication capabilities. The EIM reads
run continuously at selected fixed speed Smin or the actual temperature inside the appliance,
Smax. compares it with the set point temperature,
and decides if the compressor should operate
• Sleep Energy Saving mode: or not, and if so, at which speed. The EIM
communicates how the compressor should
Compressor will run during four hours. During operate and, eventually, records any abnormal
first hour compressor will run at selected speed. circumstance that might occur. For details about
During next three hours speed will decrease up the communication protocol, please, contact
to 1,500 r.p.m. Programming Sleep Energy Saving Danfoss.
is done in the same way as Sleep.
IF ANY VARIABLE SPEED MODE IS TO BE
• Slave mode: PROGRAMMED, CHECK CAREFULLY FOR TUBE,
CONDENSER AND EVAPORATOR RESONANCES.
Under this mode, variable speed is controlled by NATURAL FREQUENCIES SHOULD BE 75 Hz UP TO
an Electronic Integral Manager of the appliance AVOID VIBRATIONS.
(EIM) permanently connected to the electronic
driver FDC1 through the SPI, using its serial
FRCC.PC.040.A1.02 11
Programming the electronic driver
In order to program the electronic driver FDC1, 7.3 Sleep and Sleep Energy saving modes. Select
a personal computer together with the FxC maximum fixed speed or external switcher
programming package are required (provided by connected to SPI and proceed as described in
the manufacturer upon request). To this purpose, 7.1.1 or
perform the following steps:
7.4 Slave mode
1. Install the programming software, following
the instructions of the wizard. 8. Select the battery protection mode and the
protection parameters from:
2. Connect the programming interface to a PC
using a serial/ serial or USB/serial cable supplied 8.1 Internal protection: choose between normal
with the hardware. and special voltage systems.
3. Power on the programming interface using the 8.1.1 For normal voltage systems, enter cut-out,
AC/DC adapter supplied with the hardware. cut-in andmaximum voltage values for every
voltage system, accounting for the limits shown
4. Connect the FDC1 electronic driver to the in Table 2 of point 5.
programming interface using the double RJ11
cable supplied with the hardware. 8.1.2 For special voltage systems, enter cut-out,
cut-in andnominal and maximum voltage values
5. Run the programming file FDC.exe. accounting for the limits shown in Table 2 of
point 5.
6. From the top menu, load an existing
configuration and go to step 9, or go through 8.2 External protection. Protection values are
step 7. shown in Table 3 of point 5. External protection is
incompatible with external speed selection (step
7. Select the running mode, options and 7.2).
parameters, between:
9. Select thermostat delay 3 minutes for
7.1 Standard mode. improved starting.
7.1.1 Select maximum fixed speed and enter a 10. Click “Apply”. The FDC1 electronic driver
value within 1,500 and 3,500 r.p.m. as described is now programmed and ready to drive the
in point 6, if desired select speed limited by compressor.
available battery voltage, or
11. From the top menu, save the current
7.1.2 Select external switcher connected to SPI configuration if desired.
and enter low and high speed values within 1,500
and 3600 r.p.m. as described in point 6. External 12. To program another FDC1 unit, plug it in,
speed selection is incompatible with external apply current configuration or return to step 6 to
battery protection (step 8.2). change configuration.
7.2 Smart Speed® mode. Select maximum fixed 13. Click exit to finish.
speed or external switcher connected to SPI and
proceed as described in 7.1.1 or 7.1.2 respectively.
12 FRCC.PC.040.A1.02
Protections and alarms
GD30FDC is electronically protected against a When the alarm is on, ten automatic attempts
number of possible malfunctions and failures: to restart the compressor will be available.
In case of battery protection, the number of
• Battery discharge: refer to point 5 for details. automatic attempts to restart is unlimited.
Once the sequence of automatic attempts to
• Fan over current: protects the compressor and restart the compressor is finished, the unit will
the electronic driver against fan over current due remain permanently unable to operate until it
to start or running overload, or short-circuit. is switched off and on again from the power
supply. The intervention of the thermostat during
• Starting failure: if the running speed is not the sequence of automatic restart attempts
achieved during the starting sequence, the unit interrupts and resets the sequence.
stops and retries the start up after one minute.
The SPI can be configured in a way that a LED can
• Compressor overload: This protection operates be connected between terminals 3 and 4 (see Fig.
when the compressor speed drops below the 2 in point 3) in order to display the intervention
set up speed, or when the current drawn in is of any alarm, and to identify its cause. The
excessive, thus preventing the appliance from visualisation consists of a sequence of flashes
operating under overload conditions, causing of the LED repeating every 5 seconds, until the
refrigerating overload or compressor failure. cause of the alarm disappears. The code of the
flashing sequence corresponding to each alarm is
• Electronic driver overheat: In case the indicated in Table 6:
temperature of the electronic components of the
control becomes too high, an internal sensor will
stop the unit.
3 starting failure
4 compressor overload
6 internal error
If the FDC1 electronic driver is connected to transmitted to the EIM, which in turn will manage
an Electronic Integral Manager (EIM) of the the information for displaying and acting
appliance as a slave through the SPI, in case of an purposes.
alarm intervention, a digital alarm code will be
FRCC.PC.040.A1.02 13
Compressor Cooling
An adequate heat removal mechanism from FREE AIR CIRCULATION OVER THE COMPRESSOR
both the electronic driver and the compressor AND THE ELECTRONIC DRIVER MUST ALWAYS BE
is fundamental for an optimal performance GUARANTEED.
and reliability of the unit. The cooling method
should be selected depending on the working Table 6 shows the recommended cooling method
conditions of the appliance, with major for a standard condensation temperature of 55ºC.
factors being the compressor’s velocity and The table should be taken as a recommendation,
the evaporation temperature, and also, but as the only way to validate a design is testing
secondary, the condensation temperature. the appliance at the highest evaporation,
condensation and ambient temperature,
verifying that the electronic driver overheat
protection does not act.
Evaporation Temperature
r.p.m.
-30 -25 -20 -15 -10 -5 0 5 10
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 Fan Fan Fan N/A N/A
Supply • GD30FDC compressor including FDC1 electronic • Pack of GD30FDC compressor including: FDC1
driver delivered in pallets of 144 units. electronic driver, set of connectors for external
speed selection and spare part guide.
• Pack of FDC1 electronic driver, set of connectors
for external speed selection and spare part guide.
14 FRCC.PC.040.A1.02
Dimensions
FRCC.PC.040.A1.02 15
Technical Data
Compressor
Displacement cm3 3.00
Diameter mm 18.00
Stroke mm 12.10
Net weight kg 5.4
Oil type ISO VG 22 ESTER
Oil charge cm3 240
Application
Application LBP - MBP - HBP
Refrigerant R134a
Evaporation temp. range ºC -30 to +10
Expansion system CAPILLARY
Compressor cooling Static or fan depending on working conditions
Max. ambient temperature ºC 43
Electrical
Voltage V DC 12 to 42
Voltage range V DC 10 to 42.4
Motor
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 25ºC (R-S/R-T/S-T) Ω 0.80
16 FRCC.PC.040.A1.02
Technical Data
Electronic driver
Model FDC1
Type Fully digital & programmable μP based
12V/0.5A Fan
Compressor speed or battery protection level switcher
Supported devices Alarm LED
15V/25mA electronic thermostat
5V/25mA Electronic Integral Manager
Communication port Serial Port Interface (SPI)
RS-232 serial port
Communication capabilities 2-digit, 4-level switcher
Alarm LED
Compressor speed selection By programming or switching*
By Programming or switching*
Battery protection level selection
*only one at a time
Battery protection
Fan over current
Starting failure
Compressor overload
Protections
Electronic driver overheat
Fan over current
Starting failure
Compressor overload
Standard
Smart Speed
Programmable running modes Sleep
Sleep Energy Saving
Slave
Running mode: Standard
Speed selection: external switcher
Lower/higher speed: 1500/3500 r.p.m.
Setup by default 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
Test Conditions
Evaporating temperature ºC -23.3
Condensing temperature ºC 55
Liquid temp. entering expansion ºC 32
Ambient and return temp. ºC 32
Voltage V DC 12
FRCC.PC.040.A1.02 17
Technical Data
Performance data
Current (A)
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 5.29 5.91 6.52 7.16
2500 3.13 3.66 3.85 4.39 5.23 6.06 6.88 7.65 8.40 9.1
3000 3.70 4.31 4.53 5.25 6.39 7.35 8.35 9.3 10.1 -
3500 4.18 4.80 5.08 5.93 7.44 8.51 9.7 10.8 - -
ASHRAE CECOMAF
Condensation temperature: 55ºC 55ºC
Liquid temperature entering expansion: 32ºC 55ºC
Ambient and return temperature: 32ºC 32ºC
Voltage: 12 V DC
18 FRCC.PC.040.A1.02
Danfoss Commercial Compressors
is a worldwide manufacturer of compressors and condensing units for refrigeration and HVAC applications. With a wide range
of high quality and innovative products we help your company to find the best possible energy efficient solution that respects
the environment and reduces total life cycle costs.
We have 40 years of experience within the development of hermetic compressors which has brought us amongst the global
leaders in our business, and positioned us as distinct variable speed technology specialists. Today we operate from engineering
and manufacturing facilities spanning across three continents.
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Our products can be found in a variety of applications such as rooftops, chillers, residential air conditioners,
heatpumps, coldrooms, supermarkets, milk tank cooling and industrial cooling processes.
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FRCC.PC.040.A1.02 - Danfoss Light Commercial Refrigeration Compressors made by Huayi © Danfoss | DCS (CC) | 2015.10