Danfoss GLT80TDC User manual

Danfoss Light Commercial
Refrigeration Compressors
GLT80TDC
Electronic driver connection manual, 12-42V, Direct Current - R134a
Installation guide
lightcommercialrefrigeration.danfoss.com

Content
Wiring and Connections ...................................................................................................... 4
Setting up the speed............................................................................................................ 6
Operating voltage................................................................................................................ 7
Battery protection system .................................................................................................. 8
Protections and alarms........................................................................................................ 9
3FRCC.PI.044.A1.02

Wiring and Connections
GLT80TDC must always be powered through
the dedicated electronic driver FDC3, which
is supplied with the compressor as a separate
device.
NEVER CONNECT THE COMPRESSOR’S HERMETIC
PINS (FUSITE) TO THE TERMINALS OF A BATTERY
OR ANY OTHER DC OR AC SOURCE DIRECTLY.
DO NOT TRY TO FIT AN ELECTRONIC DRIVER
OTHER THAN THE FDC3. THE COMPRESSOR WILL
NOT OPERATE AND IRREVERSIBLE DAMAGE MAY
OCCUR.
The FDC3 driver is directly connected to the
battery poles as well as to the compressor pins.
It checks battery voltage and adjusts itself to the
voltage value for proper compressor operation,
or switches itself o if the battery voltage is not
adequate. The driver also controls the compressor
speed.
ALWAYS RESPECT THE POLARITY OF THE BATTERY
WITH THE POWER INPUT TERMINALS OF THE
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.
THE 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: 30A FUSE
42V SYSTEMS: 20A FUSE
In some special vehicles, the 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.
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.
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 should be doubled.
In case of using a long cable to connect battery
and electronic driver, it is recommended using a
cable with low inductance.
General rules
Voltage drop in the
power leads
Cross section mm2Rated Operating Range
12 - 14 V 24 - 28 V 36 - 42 V
4 2.5 2.5 3
6 4 4 6
10 6 6 9
Table 1: Maximum length
of leads (m)
4FRCC.PI.044.A1.02

Wiring and Connections
The FDC3 electronic driver features a terminal
board where all connections are made. The
terminal layout is described in Fig. 1:
Wiring Diagram
PC
SPI
ELECTRONIC INTEGRAL MANAGER
CONTROL PANEL
THERMOSTAT
ELECTROMECHANICAL
OR ELECTRONIC
FAN 12V
BATTERY
FUSE FDC3
ELECTRONICAL DRIVER
24÷42V
ALARM SWITCHER
Fig 1. FDC3 wiring
scheme
NO RESISTOR IS NEEDED TO BE INSTALLED IN
FDC3 ELECTRONIC DRIVER
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 connected
as shown below:
Fig 2. Connection of the
FDC3 electronic driver to
the compressor
5FRCC.PI.044.A1.02

Setting up the speed
The electronic control unit FDC3 is supplied
with the exclusive Serial Port Interface (SPI),
featuring a RJ45 telephone type connector. This
port is congured to set up the compressor
speed through physical connections between
their terminals. To facilitate this procedure, three
connector cables are supplied together with the
electronic driver. The compressor will run at a
certain speed depending on the used connector,
as shown in Table 2:
Furthermore, if a FDC programming kit is
available, the new FDC3 electronic driver can
be set up by programming it using the kit and a
computer.
NEVER USE FDC3 ELECTRONIC DRIVER IN OTHER
DC COMPRESSOR DIFFERENT THAN GLT80TDC.
If the compressor or the FDC3 electronic driver
should be replaced for servicing a refrigerator or
a freezer, one of the next procedures should be
followed.
1. If a FDC programming kit is available, use it
to check the setting of the old FDC3 electronic
driver and set up the new one by programming
the same parameters.
2. Otherwise, check the old FDC3 electronic driver
for the presence of a connector at the SPI to set
up the speed. If so, take it away and connect it
again at the new FDC3 electronic driver.
3. Otherwise check the appliance for some
information about compressor speed set up. If
so, select the proper connector which gives the
nearest speed set up from table 2.
1. Check for compressor displacement D0and
Speed S0. Then calculate the required velocity of
GLT80TDC as follows:
S = D0· S0/ 3 (D0in cm3)
and set up GLT80TDC speed by programming (if
FDC programming kit is available) or by selecting
a proper connector according to Table 2.
Table 2. Compressor
speed for each connector
Replacing a GLT80TDC
compressor or FDC3
electronic driver
Replacing a dierent
brand DC compressor
Connector Speed
NONE 2000
BLACK 2500
BLUE 3000
RED 3500
6FRCC.PI.044.A1.02

Operating voltage
GLT80TDC is designed to operate in a wide range
of DC voltages, supplied either by a battery or by
any other kind of ltered DC power supply.
DC VOLTAGE SUPPLY ALLOWED is 10V to 42.4V
If the battery voltage is below 17V, the controller
will assume that are working in a system of 12-
14V; if the voltage is greater than 17V and less
than 33V, assume that are working in a system
of 24-28V and if the voltage is greater than 33V
assume that are working in a system of 36-42V.
The output power is 450W (Nominal) 500W
(Maximum). 12-14V systems the output power
is limited to 250W. In any case, the minimum
operating voltage is 9V and maximum of 46.2 V,
admitting, once initiated the launch, a minimum
voltage of 8V during the rst minute.
From the value of the applied voltage, the
electronic driver automatically decides the rated
voltage range of the supply. Three possible
ranges are considered:
12 to 14V: voltage is below 17V
24 to 28V: voltage is within 17 and 33V
36 to 42V: voltage is within 33 and 42.4V
7FRCC.PI.044.A1.02

There is a protection system for the battery
that prevents the compressor from operating if
the available voltage becomes too low. Battery
protection level is set up for working under
normal circumstances in most appliances. Cut-
out and cut-in values are:
12V system: cut-out = 10.0V; cut-in = 11.5 V
24V system: cut-out = 22.0V; cut-in = 24.5V
42V system: cut-out = 36.0V; cut-in = 38.5 V
Other values can be set up if a FDC programming
kit is available.
Battery protection system
8FRCC.PI.044.A1.02

Protections and alarms
GLT80TDC is electronically protected against a
number of possible dysfunctions and failures:
• Battery discharge.
• Fan over current: protects the compressor and
the electronic driver against fan over current
due to start or running overload, or short-circuit.
• Starting failure: if the running speed is not
achieved during the starting sequence, the unit
stops and retries the start up after one minute.
• Compressor overload: it operates when
the compressor speed drops below the set
up speed, or when the current drawn in is
excessive, and thus preventing the appliance
from operating under overload conditions that
may cause otherwise refrigeration overload or
compressor failure.
• Electronic driver overheat: if the temperature
of the electronic components of the control
becomes too high, an internal sensor will stop
the unit.
In case of overheating, one automatic attempt
to restart the compressor is allowed. In case of
battery protection, there is no limit of automatic
attempts to restart. In case of any other
protection occurring, there will be two automatic
attempts to re-start the compressor.
Once the sequence of automatic attempts to
restart the compressor is nished, the unit will
remain permanently unable to operate until
switched o and on again from the power
supply. The intervention of the thermostat during
the sequence of automatic restart attempts
interrupts and resets the sequence.
9FRCC.PI.044.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.
FRCC.PI.044.A1.02 - Danfoss Light Commercial Refrigeration Compressors made by Huayi © Danfoss | DCS (CC) | 2016.03
Our products can be found in a variety of applications such as rooftops, chillers, residential air conditioners,
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