Huayi cubigel GLT80TDC User manual

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USER MANUAL
GLT80TDC
User manual for 24-42V
Direct Current Compressor GLT80TDC

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INDEX
1. About the Product
2. Installation and application
3. Wiring and connections
4. The Serial Port Interface (SPI)
5. Operating voltage
6. Battery protection system
7. Setting up the speed
8. Programming the electronic driver
9. Protections and alarms
10. Compressor cooling
11. Technical data
12. Supply
1. About the product
Many vehicles for transportation of goods or recreation,
such as trucks, caravans, boats, cars, etc. are often
equipped with cooling appliances and air conditioners. The
compressors for such mobile applications must be designed
to operate from a low voltage DC power supply. These com-
pressors must also be compact in their dimensions, highly
reliable and yield high performances.
GLT80TDC is Cubigel Compressors®’s answer to the
needs of users requiring comfort and reliability in their
travelling, either on holidays, at work or in any other cir-
cumstance where a DC powered air conditioner is utilised.
The GLT80TDC is designed to operate silently, efficiently
and reliably even up to angles of tilt of 20º, and works
with the refrigerant R134a. Its design is based on Cubigel
Compressors®’ “L” series, which has been successfully
present in the market since 1964, and has had sales of more
than 200 million units.
GLT80TDC is designed for capillary tube expansion and can
be powered at 24 and 42V DC, and also at 12V with some
restriction. Each unit is supplied with a dedicated electronic
driver (FDC3), which features all the protections for both the
battery and the driver itself, including the compressor motor.
The driver automatically adjusts itself to the voltage of the
power supply.
Evaporating temperature range: -25ºC to +10ºC.
Condensing temperature range: up to 65ºC. Pull-down
peak: 70ºC.
Ambient temperature range: -10 to 55ºC (65ºC at starting).
In case of ambient temperature lower than 0ºC, an oil heater
will be needed.

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The electronic control unit FDC3 is supplied with the exclu-
sive Serial Port Interface (SPI), featuring a RJ45 telephone
type connector. SPI allows the electronic driver to be con-
nected to a computer for programming purposes using
the FxC programming package (hardware and software,
provided by Huayi Compressor Barcelona under request),
and allows the communication with an Electronic Integral
Manager of the appliance (EIM), and making the compressor
work in slave mode.
FDC3 electronic driver includes Smart Speed® as program-
ming option, which is a plug-in system for automatically
self adapting compressor speed to current thermal load in
refrigerating appliances.
Smart Speed® reduces number of thermostat cycles by
minimizing compressor speed, enlarging on-time at every
thermostat cycle, so that start/stop energy loses are sub-
stantially reduced. Lowest speed yields also highest evapo-
rating temperature, and so highest C.O.P. and lowest energy
consumption. Pull-down is done at maximum programmed
speed, so pull-down time is very short with respect to fixed
speed systems. No design parameters neither of the com-
pressor nor the appliance are required to be programmed,
so Smart Speed® can be easily used in all appliances with
no design efforts.
FDC3 electronic driver includes Sleep and Sleep Energy
Saving as programming option, which are plug-in systems
specially conceived for mobile air conditioners avoiding any
other electronic device. Sleep and Sleep Energy Saving
make the air conditioner work for four hours since start-up.
Sleep Energy Saving makes the compressor run at maxi-
mum programmed speed during the first hour, when highest
cooling capacity is needed, and lowers progressively the
compressor speed up to minimum velocity three hours later.
Maximum comfort and minimum energy consumption are
thus achieved.
GLT80TDC starting capability is as low as 10 V under any
balanced pressure; it also admits a certain remaining dif-
ferential pressure when thermostat off-time is abnormally
short. For improving even more the starting capability, FDC3
electronic driver can be programmed with a 3 minutes
minimum thermostat off-time. The delay is a programming
option which can be easily enabled by means of the FxC
programming kit.
FDC3 also includes a 1 second filter at the thermostat input
to prevent the appliance from wrong operation due to typical
micro switching produced by vibrations in those appliances
that fit tilt switches at the thermostat circuit. So, analogical
filtering is not needed.

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2. Installation and application
Maximum tilt angle
The maximum tilt angle allowed in GLT80TDC compres-
sor (stopped or running) in any of the 2 below mentioned
recommended positions is 20º, and maximum tilt angle in
the 2 below not recommended position is 15º. Apart from
this specification, below diagrams show the recommend-
ed and not recommended positions while the compressor
is running in the application.
RECOMMENDED POSITIONS
NOT RECOMMENDED POSITIONS
β max=20º
α max=15º
Fig.1: Maximum tilt angle
If compressor has been stopped during a certain period of
time with an inclination higher than 15º, it is strongly recom-
mended to not start up the compressor immediately after
coming back to the correct position. We recommend wait-
ing at least 30 minutes before starting up the compressor.
Off-road applications
GLT80TDC compressor is not designed for off-road mobile
applications. If you are interested in this type of mobile ap-
plications, it has to be specically approved by Huayi Com-
pressor Barcelona.

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3. Wiring and Connections
General rules
GLT80TDC must always be powered through the dedicated
electronic driver FDC3, which is supplied with the compres-
sor as a separate device.
NEVER CONNECT THE COMPRESSOR 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 OPER-
ATE 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 off 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 ELEC-
TRONIC DRIVER
The unit is protected against damage caused by wrong po-
larity of the supply. The compressor will not run correctly if
it’s wrongly connected.
“-“ NEGATIVE POWER INPUT TERMINAL OF THE ELEC-
TRONIC DRIVER SHOULD BE EARTHED, 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 chassis is connected to “+” ter-
minal of the battery instead of “-“ terminal (positive refer-
ence 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.
Voltage drop in the power leads
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.
Table 1: Maximum length of leads (m)
Cross section
mm2
Rated 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
If any kind of connector or switch is placed between the bat-
tery 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 doubled.
In case of using a long cable to connect battery and elec-
tronic driver, it is recommended using a cable with low in-
ductance.

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Wiring Diagram
The FDC3 electronic driver features a terminal board where
all connections are made. The terminal lay out is described
in Figure 2:
Fig.2: FDC3 wiring scheme
Fig.3: Connection of FDC3 driver to the compressor
4. The serial port interface
The electronic control unit FDC3 is supplied with the exclu-
sive Serial Port Interface (SPI), featuring a RJ45 telephone
type connector. This port allows the electronic driver to be
connected to a computer for programming purposes using
the FxC programming package (hardware and software) pro-
vided by Huayi Compressor Barcelona under request. Op-
tionally, the SPI can be congured to:
• Install a LED to display the intervention of any alarm.
• Set up either the compressor speed or the battery protec-
tion level, through physical connections between IN1, IN2
and COM.
• Connect the electronic driver as slave to an Electronic In-
tegral Manager of the appliance with serial communication
capabilities (Rx, Tx and COM), to allow working with vari-
able speed. SPI provides a 5 V output, limited to 25mA, to
power up the EIM.
TO PROGRAM THE ELECTRONIC FDC3 DRIVER BY
MEANS OF THE FXC PROGRAMMING KIT THE FDC3 DRIV-
ER MUST BE POWERED BY THE BATERY.

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Fig.4: SPI terminals
5. 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: 10V to 42.4V
Functional modes
• Standard (Default):
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: actual voltage is below 17V
24 to 28V: actual voltage is within 17 and
33V 36 to 42V: actual voltage is within 33 and 42.4V
• Special (programming option):
The compressor can be powered by a variable DC source
as, for instance, a photovoltaic panel, in which the output
voltage strongly depends on the intensity of sunlight radia-
tion. In these special cases the driver should be programmed
with rated, minimum and maximum voltages. These values
should be within the allowable DC voltage power supply (10
V to 42.4V).
Rated voltage and voltage limits are programmed by the ap-
pliance manufacturer by means of a PC connected through
the serial port to the driver Serial Port Interface, using the
FxC programming package provided by Huayi Compressor
Barcelona under request.
Figure 4 Shows the RJ45 male connector which can be
plugged to the SPI and the usage of each terminal in it.

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6. Battery protection system
Rated
voltage
range (V)
Cut-out (V) ΔV
min max min max
12-14 9,0 12,0 1,0 1.5
24-28 20,0 26,0 2,0 3,0
36-42 34,0 40,0 2,0 3,0
Special 9,0 40,0 1,0 3,0
Table 2. Limits of battery protection parameters
Table 3. IN1, IN2 and COM connection for battery protection set up 0=open connection; 1=shortened
Protection limits (V) Rated operating voltage range
Protection
level
Connection to COM 12-14 V 24-28 V 36-42 V
IN1 IN2 cut-out cut-in cut-out cut-in cut-out cut-in
Standard 0 0 10,0 11,5 22,0 24,5 36,0 38,5
Low 1 0 9,0 10,5 20,0 22,5 34,0 36,5
High 0 1 11,0 12,5 24,0 26,5 38,0 40,5
Very high 1 1 12,0 13,5 26,0 28,5 40,0 42,5
There is a protection system for the battery that prevents the
compressor from operating if the available voltage becomes
too low. The battery protection level should be set up as fol-
lowing:
• By programming:
Voltage limits for battery protection can be freely set, by the
customer for every system (12-14V, 24-28V, 36-42V or spe-
cial) by means of the serial port of a PC connected to the
SPI port of the electronic driver using the FxC programming
package provided by Huayi Compressor Barcelona under
request. In that option cut-out and cut-in values must re-
spect the rule dened by Table 2.
In Table 2, ΔV is the difference between cut-out and cut-in,
that is, the cut-in value is the result of adding ΔV to the cut-
out value.
• Externally, using COM, IN1 and IN2 of SPI:
· This option prevents from the possibility of setting up the
speed externally using COM, IN1 and IN2 of SPI as dened
in point 6.
· The external battery protection set up option must be previ-
ously programmed for external adjustment of the protection
limits.
· Voltage limits are set up by means of a PC through its serial
port connected to the electronic driver SPI. It can be done
by the customer itself using the FxC programming package.
· The cut-out (battery voltage at which the driver stops oper-
ating) and the cut-in (battery voltage at which driver re-starts
operation after a cut-off) values are set up by connecting the
SPI connector terminals IN1 and IN2 to COM. according to
the connection made, four protection levels can be selected
as shown in Table 3.

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7. Setting up the speed
It is possible to operate the compressor at xed or variable
speed under different running modes, options and parame-
ters. The electronic driver is supplied by Huayi Compressor
Barcelona with standard running mode and external control
of the speed, with minimum speed of 2,000 rpm. and max-
imum speed 3,500 rpm. Default running mode, options and
parameters can be changed to optimize compressor perfor-
mance for a given appliance, by programming, connecting a
PC to the SPI by means of the FxC programming package
provided by Huayi Compressor Barcelona under request.
Running modes and options are:
• Standard mode:
Compressor speed is a xed programmed value or switched
externally from programmed minimum and maximum value
in four steps. The switch should be connected to the SPI and
should remain plugged during compressor operation.
When setting up a xed speed, maximum speed can be limit-
ed by the available battery voltage in the following way, max-
imum speed would be:
· 2,000 rpm when the battery voltage is equal to the cut-in
voltage.
· Programmed xed speed when the battery voltage is equal
to or greater than the maximum nominal voltage (14V, 28V
and 42V for 12V, 24V and 42V systems respectively).
· A linear function of the battery voltage in the range between
the cut-in and the maximum nominal voltages.
This option is particularly useful for eutectic plates systems.
If external switching is programmed, the speed is set up by
the connection of the SPI connector terminals IN1 and IN2 to
COM for minimum, maximum speeds, and two intermediate
velocities Huayi Compressor Barcelona according to Table 4:
Connection to COM Speed of the motors (rpm)
IN1 IN2
0 0 Smin
1 0 Smin+1/3 (Smax-Smin)
0 1 Smin+2/3 (Smax-Smin)
1 1 Smax
Table 4. External selection of the velocity 0=Open connection 1=Shortened
External speed set up option must be previously programmed
for external adjustment of its minimum (Smin) and maximum
(Smax) limits.
External switching prevents from the possibility of setting up
the battery protection externally using COM, IN1 and IN2 of
SPI as dened in point 5.
• Smart Speed® mode:
Compressor will run at variable speed at its highest perfor-
mance depending of the current thermal load. The speed can
be limited by a xed programmed value and even more by
the available battery voltage as described in standard mode.
The speed can also be limited by external switching in the
same way as described in standard mode.

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Connection to COM Speed of the
motors (rpm) Sleep mode
IN1 IN2
0 0 Smin off
1 0 Smin on
0 1 Smax off
1 1 Smax on
Table 5. External selection of the velocity 0=Open connection; 1=Shortened
NO SWITCH (MANUAL I/O, TILT, ETC.) IS ALLOWED TO
BE CONNECTED IN SERIES WITH THE THERMOSTAT.
IF ELECTRONIC THERMOSTATS ARE TO BE FIT, AVOID
THOSE THAT INCORPORATE MANUAL I/O SWITCH AND/
OR STARTING DELAY.
• Sleep mode:
Compressor will run during four hours after start-up. The
speed can be limited by a xed programmed value and
even more by the available battery voltage as described in
standard mode. The speed can also be limited by external
switching in a similar way as described in standard mode
according to table 5:
If off sleep mode is selected, the appliance will run continu-
ously at selected xed speed Smin or Smax.
• Sleep Energy Saving mode:
Compressor will run during four hours. During rst hour com-
pressor will run at selected speed. During next three hours
speed will decrease up to 2,000 r.p.m. Programming Sleep
Energy Saving is done in the same way as Sleep.
• Slave mode:
Under this mode, variable speed is controlled by an Electron-
ic Integral Manager of the appliance (EIM) permanently con-
nected to the electronic driver FDC3 through the SPI, using
its serial communication capability. The EIM reads the cur-
rent temperature inside the appliance, compares it with the
set point temperature, and decides if the compressor should
operate or not, and if so, at which speed. The EIM commu-
nicates how the compressor should operate and, eventually,
records and displays any abnormal circumstance that might
occur. For details about the communication protocol, please,
contact Huayi Compressor Barcelona.
IF ANY VARIABLE SPEED MODE IS TO BE PROGRAMMED,
CHECK CAREFULLY FOR TUBES, CONDENSER AND
EVAPORATOR RESONANCES. NATURAL FREQUENCIES
SHOULD BE 75 Hz UP TO AVOID VIBRATIONS.

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8. Programming the electronic driver
In order to program the electronic driver FDC3, a personal
computer together with the FxC programming package are
required (provided by Huayi Compressor Barcelona under re-
quest). To this purpose, perform the following steps:
1. Install the programming software, following the instruc-
tions of the wizard.
2. Connect the programming interface to a PC using the se-
rial cable supplied with the hardware.
3. Power on the programming interface using the AC/DC
adapter supplied with the hardware.
4. Connect the FDC3 electronic driver to the programming
interface using the double RJ45 cable supplied with the hard-
ware.
5. Run the programming le FDC.exe.
6. From the top menu, load an existing conguration and go
to step 9, or go through step
7. Select the running mode, options and parameters, be-
tween:
7.1 Standard mode.
7.1.1 Select maximum xed speed and enter a value within
2,000 and 3,500 r.p.m. as described in point 6, if desired se-
lect speed limited by available battery voltage, or
7.1.2 Select external switcher connected to SPI and enter
low and high speed values within 2,000 and 3,500 r.p.m. as
described in point 6. External speed selection is incompatible
with external battery protection (step 8.2).
7.2 Smart Speed® mode. Select maximum xed speed
or external switcher connected to SPI and proceed as de-
scribed in 7.1.1 or 7.1.2 respectively.
7.3 Sleep and Sleep Energy saving modes. Select maximum
xed speed or external switcher connected to SPI and pro-
ceed as described in 7.1.1 or 7.1.2 respectively.
7.4 Slave mode
8. Select the battery protection mode and the protection pa-
rameters from:
8.1 Internal protection: choose between normal and special
voltage systems.
8.1.1 For normal voltage systems, enter cut-out, cut-in and
maximum voltage values for every voltage system, account-
ing for the limits shown in Table 2 of point 5.
8.1.2 For special voltage systems, enter cut-out, cut-in and
nominal and maximum voltage values accounting for the lim-
its shown in Table 2 of point 5.
8.2 External protection. Protection values are shown in Table
3 of point 5. External protection is incompatible with external
speed selection (step 7.2).
9. Select thermostat delay 3 minutes for improved starting.
10. Click “Apply”. The FDC3 electronic driver is now pro-
grammed and ready to drive the compressor.
11. From the top menu, save the current conguration if de-
sired.
12. To program another FDC3 unit, plug it in, apply current
conguration or return to step 6 to change conguration.
13. Click exit to nish.

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9. Protections and alarms
GLT80TDC is electronically protected against a number of
possible malfunctions and failures:
• Battery discharge: refer to point 5 for details.
• Fan over current: protects the compressor and the elec-
tronic 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: This protection operates when the
compressor speed drops below the set up speed, or when
the current drawn in is excessive, thus preventing the ap-
pliance from operating under overload conditions, causing
refrigerating overload or compressor failure.
• Electronic driver overheat: In case the temperature of the
electronic components of the control becomes too high, an
internal sensor will stop the unit.
When the alarm is on, ten automatic attempts to restart the
compressor will be available. In case of battery protection,
the number of automatic attempts to restart is unlimited.
Once the sequence of automatic attempts to restart the
compressor is nished, the unit will remain permanently un-
able to operate until it is switched off and on again from the
power supply. The intervention of the thermostat during the
sequence of automatic restart attempts interrupts and resets
the sequence.
The SPI can be congured in a way that a LED can be con-
nected between terminals 3 and 4 (see Fig. 2 in point 3) in
order to display the intervention of any alarm, and to identify
its cause. The visualisation consists of a sequence of ashes
of the LED repeating every 5 seconds, until the cause of the
alarm disappears. The code of the ashing sequence corre-
sponding to each alarm is indicated in Table 6:
No. of flashes Type of failure
1 Battery protection
2 Fan over current
3 Starting failure
4 Compressor overload
5 Electronic driver overhead
7 Internal error
Table 6. Alarm codication
In case of an alarm display, if the FDC3 electronic driver is
connected as a slave to the appliance’s Electronic Integral
Manager (EIM) through the SPI, a digital alarm code will be
transmitted to the EIM, which in turn will manage the infor-
mation for displaying and acting purposes.

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10. Compressor Cooling
GLT80TDC should always be fan cooled. FDC3 electronic
driver has its own fan to cool its power components -. Best
results are obtained when both, but enough compressor
11. Technical Data
and driver are cooled with fresh air coming directly fresh air
is needed in the surroundings of the electronic driver to be
cooled properly from outside, before being heated up in ap-
pliance condenser.
Compressor
Displacement cm38.10
Diameter mm 24.29
Stroke mm 17.48
Net weight kg 10.2
Oil type ISO VG 22 ESTER
Oil charge cm3330
Reliability GLT80TDC pass following reliability tests:
• High Temperature: according with CECOMAF GT-4002 standard
• Wear: according with CECOMAF GT-4003 standard
• ON/OFF: according with CECOMAF GT-4004 standard
• Vibrations: according with ASTM 5728 Level I standard
Application
Application MBP - HBP – A/C
Refrigerant R134a
Evaporation temp. range ºC -25 to +10
Expansion system CAPILLARY
Compressor cooling Fan
Max. ambient temperature ºC 43
Motor
Type Brush-less, Sensor-less, PMM
Phase number 3
Pole number 6
Locked rotor current (12, 24, 42 V) A 12, 12, 8
Resistance at 25ºC (R-S/R-T/S-T) Ω 0.36
Electrical
Voltage V DC 12 to 42
Voltage range V DC 10 to 42.4

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Electronic driver
Model FDC3
Type Fully digital & programmable μP based
Supported devices
12V/0.5A Fan
Compressor speed or battery protection level switcher
Alarm LED
15V/25mA electronic thermostat
5V/25mA Electronic Integral Manager
Communication port Serial Port Interface (SPI)
Communication capabilities
RS-232 serial port
2-digit, 4-level switcher
Alarm LED
Compressor speed selection By programming or switching*
Battery protection level selection By Programming or switching*
*only one at a time
Protections
Battery protection
Fan over current
Starting failure
Compressor overload
Electronic driver overheat
Fan over current
Starting failure
Compressor overload
Electronic driver overheat
Programmable running modes
Standard
Smart Speed
Sleep
Sleep Energy Saving
Slave
Setup by default
Running mode: Standard
Speed selection: external switcher
Lower/higher speed: 2000/3500 r.p.m.
Battery protection: xed voltage level; standard system
Cut-out (12/24/42 V systems): 12/22/38,5 V
Cut- in (12/24/42 V systems): 10.8/20.0/36.2 V
3 minutes thermostat delay: on
Test Conditions
Evaporating temperature ºC -7,2
Condensing temperature ºC 55
Liquid temp. entering expansion ºC 32
Ambient and return temp. ºC 35
Voltage V DC 24
*Only for voltage supply V DC 24-42
Nominal performance at rpm 2000 2500* 3000* 3500*
Cooling capacity W 577 712 842 968
Cooling capacity kCal/h 497 613 725 834
Input power W 247 315 388 468
EER kCal/(Wh) 2.01 1,95 1.87 1.78
COP W/W 2.34 2,26 2,17 2,07
Current A 10.3 13.1 16.2 19.5

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Fig.5: GLT80TDC outline drawing
Condensing temperature = 55ºC
Ambient and suction temperature = 35ºC
Liquid subcooling = 9K
Test voltage = 24V DC
*Only for 24-42 V DC voltage supply
12. Supply
GLT80TDC compressor including FDC3 electronic driver (120 pieces pallets).
r.p.m. T evap = -25ºC T evap = -10ºC T evap = +7,2ºC
Q (kCal/h) COP Q (kCal/h) COP Q (kCal/h) COP
2,000 100 1.15 228 1.64 497 2.34
2,500 123 1.13 285 1.62 613* 2.26*
3,000 145 1.11 341* 1.58* 725* 2.17*
3,500 166 1.09 392* 1.54* 834* 2.07*
r.p.m. T evap = -25ºC T evap = -10ºC T evap = +7,2ºC
W I (A) W I (A) W I (A)
2,000 101 4.21 162 6.75 247 10.3
2,500 127 5.29 204 8.5 315* 13.1*
3,000 152 6.33 251* 10.5* 388* 16.2*
3,500 177 7.38 296* 12.3* 468* 19.5*
Performance data

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Huayi Compressor Barcelona, S.L.
Antoni Forrellad, 2 · 08192
Sant Quirze del Vallès · BCN · Spain
Phone: [phone]
Fax [phone]
www.huayicompressor.es
USER MANUAL GLT80TDC · 08/2021