Danfoss 101N0715 User manual

MAKING MODERN LIVING POSSIBLE
BD Controller 101N07xx Series 24 V DC
with Tool4Cool® LabEdition software
Operating Instructions

Operating Instructions BD Controller 101N07xx Series 24 V DC
2DEHC.PS.100.I.02

Operating Instructions BD Controller 101N07xx Series 24 V DC
3
DEHC.PS.100.I1.02
1.0 Introduction
1.1 Applications.................................................................................................................................. 5
1.2 Capability ...................................................................................................................................... 5
1.3 Functions ...................................................................................................................................... 5
1.4 Programming Interface ........................................................................................................... 5
2.0 Installation
2.1 Checklist ........................................................................................................................................ 7
2.2 Connect cables ........................................................................................................................... 8
2.3 Install and configure software .............................................................................................. 9
4.0 Parameters
4.1 Parameter Overview................................................................................................................13
4.2 Description of Parameters ....................................................................................................15
4.2.1 Main Functions ...........................................................................................................15
4.2.2 Battery protection .....................................................................................................15
4.2.3 Compressorn ..............................................................................................................16
4.2.4 Condenser fan.............................................................................................................17
4.2.5 Evaporator fan ............................................................................................................17
4.2.6 Thermostat...................................................................................................................18
4.2.7 ECO function................................................................................................................19
4.2.8 Compressor safety.....................................................................................................20
4.2.9 Communication..........................................................................................................20
4.2.10 Product information.................................................................................................21
4.2.11 Customer register .....................................................................................................21
4.2.12 Actual error..................................................................................................................21
4.2.13 Inverter Temperature (PCB) ...................................................................................22
3.0 Operation
3.1 User interface ............................................................................................................................11
3.2 Operation ...................................................................................................................................11
5.0 Ordering ..........................................................................................................................................25
6.0 More Information ......................................................................................................................27

4

TOOL COOL
4®
BD Controller
101N07xx Series
24 V DC
5
DEHC.PS.100.I1.02
1.1 Applications
1. Introduction
The BD350GH 24 V DC compressor system is intended mainly for in parking anti-idle applications.
Secondary applications could be
• Spotcoolinginbuses,golfcarts,smallerboats,forklifts,campersetc
• Aircargocooling
• Coolingofswitchboardsandbatteriesinradiostationsforcellularphones
1.2 Capability The cooling capacity of the compressor is approx. 900 Watt @ Pe/Pc ~+15/+55°C
The system is able to operate in ambient temperatures up to +55 ºC (131 F).
The operating conditions are High Back Pressure (HBP).
1.3 Functions The main functions of BD350GH compressor systems are:
• Motor/Compressorspeedcontrol
• Thermostatcontrol(ON/OFForelectronicviaNTCtemperaturesensor)
• ECOfunctiontooptimizecompressorspeedforminimumpowerconsumption
• Condenserfancontrol
• Evaporatorfancontrol
• Communicationinterface
• Monitoringfunction
• Error&eventlog
• Batteryprotectionfunctions
• MainSwitch
• Logofspecicparameters
• OptimizationofspecicparametersviaPCsoftwarebeforecommencingmassproduction
1.4 Programming
Interface
The controller can be accessed using either
-theDanfosssoftwaretool,Tool4Cool®LabEdition,or
- a custom interface. Please contact Danfoss for further information regarding custom interfaces.

6

TOOL COOL
4®
BD Controller
101N07xx Series
24 V DC
7
DEHC.PS.100.I1.02
2. Installation
2.1 Checklist
Installation involves the following steps:
• Checklist
• Cableconnection
• Softwareinstallationandconguration
Ordering: See section 5.0
Check that you have the following:
BD electronic controller
101N07xx Series 24V DC
101N0715•
101N0710 (discontinued)•
Tool4Cool®LabEditionsoftware
installation CD
NTC temperature sensor
(alternative: mechanical thermostat)
DC line cords
Product key for BD compressor controller
(not necessary with Tool4Cool®Version1.02) DH3TT6RBAD1GW8G68ZM1N8G62ZMCOO916IER6GH2YZEIR
Danfoss One Wire/LIN gateway with
connection cables
Gateway•
One Wire/LIN gateway•
Communication cable
USB port connector to PC•
USB 2.0 A/B cable•

Operating Instructions BD Controller 101N07xx Series 24 V DC
8DEHC.PS.100.I.02
Wiring diagram
2.2 Connect cables
8633
Main switch
Fuse
Power supply
Fan
-
+
Fan
-
+
NTC resistor
– t°
option 1option 2
optional
optional
mech. Thermostat
One Wire
LIN Gateway
Te rminal plug
USB
(only for supply)
COM
USB Danfoss One Wire
LIN GatewayOneWire
/ LIN
USB Code no.: 105N9501
RS232/485
USB 2.0
Electronics
(One Wire / LIN)
RS232
RS485
Tx Rx
option 2
option 1
USB 2.0 A/B Cable
COM port connector to PC
NTC temperature sensor
Electronic Unit
One Wire/LIN Gateway Communication Cable
USB port connector to PC
USB port connector to PC
Gateway
Power supply cableSerial RS232 Cable with USB Voltage Supply

Operating Instructions BD Controller 101N07xx Series 24 V DC
9
DEHC.PS.100.I1.02
2.3 Install and
configure
software
Wire dimensions
The compressor control unit has the following connections:
I,C,+ Modbusdatacommunication.I=communicationC&+powersupply.
C,T Thermostatconnection.ADanfossNTCtemperaturesensor(option2)canbeconnectedora
mechanical ON/OFF thermostat (option 1)
Fe,+ Evaporatorfan(Optional)24VDC,0-24V,max60Wattpoweroutput,pulsewidth 
modulated.
Fc,+ Condenserfan(optional)24VDC,0-24V,max40Wattpoweroutput,pulsewidth
modulated.
-,+ Mainsupplyvoltage.Nominalvoltage24VDC,range:17to31.5VDC
Size Max. length*
24V operation
Cross
section
[mm2]
AWG
[Gauge] [m] [ft.]
2 x 4
2 x 6
11
9
1.5
2
4.92
6.60
For brief software installation and configuration instructions please refer to BD Controller 101N07xx
Series 24 V DC with Tool4Cool® LabEdition Software - Quick Start Guide.
For detailed instructions please refer to Tool4Cool® LabEdition Operating Instructions.
ThesemanualsaresuppliedwiththeTool4Cool®software.
* Length between battery and electronic unit

10

TOOL COOL
4®
BD Controller
101N07xx Series
24 V DC
11
DEHC.PS.100.I1.02
3. Tool4Cool® software interface
3.1 User interface ThecontrollercanbeprogrammedandoptimizedfromaPCusingtheTool4Cool®software
AnexampleoftheTool4Cool®userinterfaceshowingthemainparametergroupsoftheBD350GH
compressor is shown below.
Example:
3.2 Operation TheTool4Cool®softwareenablestheusertoobserveanddocumentcertainaspectsofthecompressor
operation via the controller. The output of the software is in the form of data logs and plots.
UsingTool4Cool®theusercanalsochangethesettingsofthecontrollerparameters,andcopysettings
from one controller to another.
Please refer to the Tool4Cool® LabEdition Operating Instructions for operation instructions.
EXAMPLE
menus may differ

12

TOOL COOL
4®
BD Controller
101N07xx Series
24 V DC
13
DEHC.PS.100.I1.02
4. Parameters
Parameter Group Parameter Description Default Max value Min value Step Unit Type
Main functions Main switch On/Off regulation of power supply to
controller OFF ON OFF 1
Battery
protection Battery cutout level Battery protection cut-out voltage
level 21.3 27 19 0.1 Volt Setting
Battery cutin diff. Voltage difference between battery
cut-in and cut-out 3.9 10 0.5 0.1 Volt Setting
Cutout delay Time to cut-out when non-critical
battery protection implemented 3 60 0 1 Seconds Setting
Cut-in level Calculated value.
Cutin=Cutout+Di. 0.1 Volt Measurement
Supply voltage Real-time voltage measured
on+&-terminals 0.1 Volt Measurement
Compressor Requested speed Compressor speed and therefore
capacity definition 4000 4000 2500 100 rpm Setting
Start delay Time to start after
compressor is switched ON 4 240 2 1 Seconds Setting
Start speed
Optional startup speed lower than
Requestedspeed,duringtheperiod
Start time.
2500 4000 2500 100 rpm Setting
Start time
Period of time elapsing after startup
of compressor until Requested speed
is reached
30 600 0 1 Seconds Setting
Compressor speed Real-time speed (+/- 10%) 1 rpm Measurement
Condenser fan Cond. Fan voltage Supply voltage to the
condenser fan. 24 31 12 1 Volt Setting
Fan speed Condenserfanspeedsynchronized
with compressor operation 100 100 40 10 % Setting
Fan start delay Time to start as a function of
Thermostat 0 240 0 1 Seconds Setting
Fan stop delay Time to stop as a function of
Thermostat 0 240 0 1 Seconds Setting
Fan forced ON Force condenser fan continuously
ON or OFF OFF ON OFF 1 Setting
Detect missing fan Detect whether condenser fan is
connected OFF ON OFF 1 Setting
Fan speed Real-time condenser fan speed 1 % Measurement
Evaporator fan Evap. Fan voltage Supply voltage to the evaporator fan. 24 31 12 1 Volt Setting
Fan speed
Evaporator fan speed
synchronizedwith
compressor operation.
100 100 40 10 % Setting
Fan start delay Time to fan start as a
function of Thermostat 0 240 0 1 Seconds Setting
Fan stop delay Time to fan stop as a
function of Thermostat 0 240 0 1 Seconds Setting
Fan forced ON Force evaporator fan
continuously ON or OFF OFF ON OFF 1 Setting
Detect missing fan Detect whether evaporator fan is
connected OFF ON OFF 1 Setting
Fan speed Real-time evaporator fan speed 1 % Measurement
The user can change settings and observe real-time measurements (read-only)
in the following parameters.
The table in 4.1 Parameter Overview is intended for easy reference.
For more detail, please refer to 4.2 Description of Parameter Groups.
4.1 Parameter
Overview

Operating Instructions BD Controller 101N07xx Series 24 V DC
14 DEHC.PS.100.I.02
Customer
register Register 1 Custom-designed interface parameter 65535 65535 0 1 Setting
Register 2 Custom-designed interface parameter 65535 65535 0 1 Setting
Register 3 Custom-designed interface parameter 65535 65535 0 1 Setting
Register 4 Custom-designed interface parameter 65535 65535 0 1 Setting
Register 5 Custom-designed interface parameter 65535 65535 0 1 Setting
Register 6 Custom-designed interface parameter 65535 65535 0 1 Setting
Register 7 Custom-designed interface parameter 65535 65535 0 1 Setting
Register 8 Custom-designed interface parameter 65535 65535 0 1 Setting
Register 9 Custom-designed interface parameter 65535 65535 0 1 Setting
Register 10 Custom-designed interface parameter 65535 65535 0 1 Setting
Actual error Actual error
0=Noerror
1=Voltagefailure
2=Fanfailure
3=Motorfailure
4=Min.speedfailure
5=Max.speedfailure
6=Thermalfailure
7=NTCSensorFailure
Measurement
Inverter
temperature
(PCB)
Inverter temperature
(PCB) Controller overheating protection ºC Measurement
Compressor restart delay Delay before restart after overheating
of inverter 60 120 60 1 Seconds Setting
Parameter Parameter Group Description Default Max value Min value Step Unit Type
Thermostat Thermostat type Detect mechanical or NTC sensor
thermostat Auto Electronic Setting
Cutout temperature Compressor cuts out below cutout
temperature +25 +40 -40 1 Celsius
(ºC) Setting
Difference 3 15 1 1 Kelvin (K) Setting
Forced ON Force thermostat operation to con-
tinuously ON or OFF OFF ON OFF 1 Setting
Runtime
During cooling OFF (Thermostat cut-
out),theRuntimewillshowthetime
for the last cooling period. Runtime is
reset at cooling ON period. At power-
up the reading is reset.
1 Minutes Measurement
Actual temperature
Real-time air temperature when an
NTC sensor is used. When a mechani-
calthermostatisused,onlythermo-
stat status ON or OFF is displayed.
ºC Measurement
Compressor
safety Compressor restart time Delay before restart after short
cycling 60 120 60 1 Seconds Setting
Communication Node Number Modbus address 1 247 1 1 Setting
Bits per seconds Communication speed 19200 19200 9600 9600 bps Setting
Communication options 0=Disabled
1=Enabled 0 1 0 1 Setting
Communication timeout Maximum duration of each communi-
cation attempt 900 7200 15 1 seconds Setting
Setting protection code
&status
Privacy function code must be
entered twice 0 9999 0 1 Setting
Product
information Unit name
The user’s own identification name
for the unit can be entered here
(optional)
Setting
Vendor name Vendor name Measurement
Product code no Danfoss product code number Measurement
Software version Controller software version Measurement
Unit ID Danfoss unit ID Measurement
Production date Danfoss production date Measurement
Lot no Danfoss lot no. Measurement
Serial no Danfoss serial no. Measurement

Operating Instructions BD Controller 101N07xx Series 24 V DC
15
DEHC.PS.100.I1.02
4.2 Description of
Parameters
4.2.1 Main Functions
In order to start and stop the compressor the Main Switch can be set to ON or OFF .
OEMs making an interface with custom design electronics via Modbus must be able to control the
CCU ON / OFF via the Main Switch.
ON: All functions are active.
OFF: Allmainfunctionsareinactive,however
• Batterymonitoringactive
• NTCtemperaturesensormonitoringactive
• Auxiliarytemperaturesensormonitoringactive
• PCBinvertertemperaturemonitoringactive
4.2.2 Battery protection
The battery protection serves to avoid permanent damage to the battery by discharge.
The setting range is from 19 to 27 V DC.
Critical stop without delay if voltage drops below 17 V DC or exceeds 31.5 V DC
Tolerances are ± 0.30 V DC
31.5 V DC
Name Default Max value Min value Step Unit
Main switch OFF ON OFF 1 -
Settings:
Settings
Name Default Max value Min value Step Unit
Battery cutout level 21.3 27 19 0.1 Volt
Battery cutin diff. 3.9 10 0.5 0.1 Volt
Cutout delay 3 60 0 1 Seconds

Operating Instructions BD Controller 101N07xx Series 24 V DC
16 DEHC.PS.100.I.02
4.2.3 Compressor
The speed and thereby the capacity of the compressor is set using the Requested speed parameter.
Duringstartup,thecompressorcanberunatalowerspeed,Start speed,thanRequestedspeed.
The duration of the period running at Start speed is set using the Start time parameter.
The compressor is protected against operation below minimum speed. Lubrication of the compressor
will be very poor at excessively low speed and therefore low speed operation can lead to destruction
of the compressor. Speed limits are: min 1850 rpm; max speed 4300 rpm.
Ifthecompressorspeedfallsbelowtheminimumorexceedsthemaximumspeed,thecompressorwill
stop and an alarm Min speed failure or Max. speed failure will be sent. The compressor will try to restart
after the set Restart time. The Restart time default is 60 sec.
The fans will continue to run.
Name Default Max value Min value Step Unit
Requested speed 4000 4000 2500 100 rpm
Start delay 4 240 2 1 Seconds
Start speed 2500 4000 2500 100 rpm
Start time 30 600 0 1 Seconds
Settings
Measurements
Name Description Step Unit
Compressor speed Real-time compressor speed(+/-10%) 1 rpm
Measurements
Name Description Step Unit
Cut-in level Calculatedvalue.Cutin=Cutout+Di. 0.1 Volt
Supply voltage Real-time-voltagemeasuredon+&-terminals 0.1 Volt

Operating Instructions BD Controller 101N07xx Series 24 V DC
17
DEHC.PS.100.I1.02
4.2.4 Condenser fan
Thespeedofthecondenserfancanbecontrolledinordertosaveenergy,reducenoiseandoptimize
the fan operation.
Thefanissynchronizedwiththecompressoroperation.
Start and stop delays can be set up as a function of the state of the parameter Thermostat.
Furthermore,thefancanbesettoruncontinuously(forcedONoperation).
Somefandefectsaredetectable,andaredisplayedintheparameterError.
The speed of the fan can be controlled in the range from 40% to 100%.
Measurements
Name Default Max value Min value Step Unit
Cond. Fan voltage 24 31 12 1 Volt
Fan speed 100 100 40 10 %
Fan start delay 0 240 0 1 Seconds
Fan stop delay 0 240 0 1 Seconds
Fan forced ON OFF ON OFF 1 -
Detect missing fan OFF ON OFF 1 -
Name Description Step Unit
Fan speed Actual fan speed 1 %
4.2.5 Evaporator fan
Thespeedoftheevaporatorfancanbecontrolledinordertosaveenergy,reducenoiseandoptimize
the fan operation.
Thefanissynchronizedwiththecompressoroperation.
Start and stop delays can be set up as a function of the state of the parameter Thermostat.
Furthermore,thefancanbesettoruncontinuously(forcedONoperation).
Somefandefectsaredetectable,andaredisplayedintheparameterError.
The speed of the fan can be controlled in the range from 40% to 100%.
Settings
Measurements
Name Default Max value Min value Step Unit
Evap. Fan voltage 24 31 12 1 Volt
Fan speed 100 100 40 10 %
Fan start delay 0 240 0 1 Seconds
Fan stop delay 0 240 0 1 Seconds
Fan forced ON OFF ON OFF 1 -
Detect missing fan OFF ON OFF 1 -
Name Description Step Unit
Fan speed Real-time fan speed 1 %
Settings

Operating Instructions BD Controller 101N07xx Series 24 V DC
18 DEHC.PS.100.I.02
4.2.6 Thermostat
Thermostat type
Twotypesofthermostatcanbeutilizedfortemperaturecontrol.
Electronic thermostat (NTC sensor)
Disconnected sensor error alarm (NTC sensor failure) is sent when the measured temperature is > +100ºC
Short circuited sensor error alarm (NTC sensor failure) is sent when the measured temperature < - 60ºC
Mechanical thermostat
AmechanicalON/OFFthermostatcanbeconnectedatterminalsC&T.
No detection of faulty thermostat is provided when an ON/OFF thermostat is used.
Automatic thermostat selection
The Thermostat parameter displays the type of thermostat connected to the controller: either a me-
chanical thermostat or NTC temperature sensor.
An NTC sensor is recommended for the temperature range -60 ºC to +100 ºC
A mechanical thermostat is recommended for temperatures below -60 ºC and above +100 ºC
Note: An NTC sensor error is not detectable when the NTC sensor is operating in automatic thermo-
stat selection mode.
Settings
Name Default Max value Min value Step Unit
Thermostat type Auto Electronic - - -
Cutout temperature + 25 + 40 -40 1 Celcius (ºC)
Difference 3 15 1 1 Kelvin (K)
Forced ON OFF ON OFF 1 -
Name Description Step Unit
Runtime Runtime is provided to record cooling-time
(thermostat cut-in period). The runtime is
updatedduringcooling,startingwith0at
start of cooling.
DuringcoolingOFF(Thermostatcut-out),
the Runtime parameter will show the time for
the last cooling period. Runtime is reset at
thebeginningofacoolingONperiod,andat
power-up.
1 Minutes
Actual temperature Real-time air temperature when a NTC sensor
is used.
Whenamechanicalthermostatisused,only
thermostat status ON or OFF is displayed.
- ºC
Measurements

Operating Instructions BD Controller 101N07xx Series 24 V DC
19
DEHC.PS.100.I1.02
4
Settings:
Name Default Max value Min value Step Unit
ECO mode OFF ON OFF 1
ECO speed BD350GH 2500 4000 2500 1 rpm
ECO temperature 25 40 -40 0.1 Celsius (°C)
Automatic
ECO temperature 11010=OFF 1=ON
4.2.7 ECO function
Operation in ECO mode reduces energy consumption and noise by controlling compressor speed as a
function of temperature. ECO mode can be selected only when using an NTC temperature sensor.
InECOmode,
• whenoperatingbelowECOtemperature,compressorsrunatthesetECOspeed,andtheStart
speedsettingwillbeoverruled,ifitdiersfromECOspeed.
• whenoperatingaboveECOtemperature,thecompressorsrunatRequestedspeed.

Operating Instructions BD Controller 101N07xx Series 24 V DC
20 DEHC.PS.100.I.02
4.2.8 Compressor safety
In order to prevent the compressor from short cycling a minimum restart time is built in.
After timeout of Compressor restart time a new start of the compressor is permitted.
Settings
4.2.9 Communication
Lost communication
InanetworksystemwithcustomdesignedinterfacemodulesactingasmasterontheModbus,itis
desirable to stop the compressor from running when communication to the master is lost.
If communication is lost it will not be possible for the customer to stop the compressor as long as cool-
ing is requested.
Thefunctionwillstopthecompressorafteracertaintime,(Communication time out) when there is no
contacttothemastercontroller.ThestopisrealizedthroughtheMainSwitch. The Main Switch will be
set to OFF. It will remain OFF until the master controller sets it back to ON via Modbus.
Protection of settings
A coded privacy function protects customers’ settings from being read by third parties.
The code must be verified by entering twice.
Settings
Name Default Max value Min value Step Unit
Compressor
restart time 60 120 60 1 Seconds
Name Default Max value Min value Step Unit
Node number 1 247 1 1 -
Bits per second 19200 19200 9600 9600 0=Disabled
1=Enabled
Communication 0 1 0 1 Seconds
Communication
timeout 900 7200 15 1 -
Setting protection
code & status 0 9999 0 1 -