DC Cooling Unit

MODEL : TDC 500A / TDC 300A

DC Cooling unit
Instruction Manual

Contents

1. DC Cooling unit

...............3

2. Technical Specifications .................................................4

3. Installation procedure . 5

4. Operation/Working

........................................ 6

5. Compressor Controller .................................................. 7

6. Operating instructions of the Temp Controller ............. 15

7. Wiring Diagram

--------------------------------------------- 21

7. Contact Details.......................................................... 22

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 .

Technical Specification for DC Cooling unit

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
Watts
Watts
V
V
V
Amps
Amps
Watts
C

Db(A)
IP
gm

TDC - 500A
500
300
48
40
58
6.5
6.8
315
15 - 55
65
IP54
320

mm
Kg

580 X 325 X 320

25
External
Outdoor/ Indoor
RAL 7035

27
0 - 50

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
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.

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 +55C 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

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 0C (32F) to +55C (131F) 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

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 80C 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 80C (176F) 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.

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
second on and 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

10

11

12

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

Max High Temp limit & alarm.

P3

Min Low Temp limit & alarm.

P4

To set Differential (Hysteresis).

P5

Probe calibration.

P6

Time Delay (Relay restart after cutoff).

AL

Alarm - To activate Alarm Relay.

Ad

Power On Time Delay For Alarm.

E1

Evaporator Fan feedback Enable/disable.

E2

Condenser Fan feedback Enable/disable.

E3

Compressor feedback Enable/disable.

F1

To set evaporator fan speed.

F2

To set condenser fan speed.

E4

Relay status on probe failure.

LP

Keypad Lock.

FS

Restore factory defaults.

EP

End Programming & Keypad functions.

Key Introduction
Operating messages
LED Indications
Technical Data
Connection Diagram
Panel cutout, dimensions & Bezel

15

Operating instructions of the Temp Controller

Sr.No
.

Parameter

Set Point
(SP)

Parameter setting method.

Function: To set the cut out point of the

controller.

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.

Press PRG
key for 2
seconds and

To set other parameters.

Range
Min

Max

Fact.
Set

(P3+1)OC

(P2-1)OC

27OC

(SP+1)OC

50OC

35OC

10OC

(SP-1)OC

10OC

1OC

10OC

2OC

Display will show P2 flash. To go to other

parameters, use up / down keys.

release.

P2

To change
the P2
parameter,
press the
set key.

H
(Message on
Display)
P3

To change
the P3
parameter,
press the
set key.

L
(Message on
Display)

P4

16

Function: To set maximum allowable high

temperature limit & alarm.
Use UP/DOWN keys to set desired value.
Once set at a particular value, this will not
allow the
set point to go above this value and below P3
setting.
Example : Setting this parameter at 30OC
will not allow the set point to go above 30OC.
Also, if the temperature reaches 30OC, 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.
Function: To set minimum allowable low
temperature limit and alarm.
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 10OC
will not allow the set point to go below 10OC.
Also, if the temperature reaches 10OC, 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.
Function: To set the differential.

To change
the P4
parameter,
press the
set key.

Use UP/DOWN keys to set desired value.

Differential between cut out and cut in
temperature can be set between 1OC to
10OC.
Example : If the set point is set at 10OC and
differential is set at 2OC, then when the
system reaches 10OC, the relay will cut out.
Since the differential is 2, the relay will cut
in (restart) at 12OC (10OC+2OC).

P5

Function: To set probe calibration.

To change
the P5
parameter,
press the
set key.

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.

-9OC

10OC

0OC

0Min

20Min

3Min

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
28OC, whereas the actual temperature is
30OC. 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 30OC (28OC + 2OC).

P6

To change
the P6
parameter,
press the
set key.

Function: To set time delay between relay

restart time.
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.

17

AL

Function: To activate alarm relay.

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 Min

30 Min

0 Min

99

99

0 = De-activates alarm relay.

1 = Activates alarm relay.
Ad

To change
the Ad
parameter,
press the set
key.

Function : To set power on time delay for

alarm relay.
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 .

E1

To change
the E1
parameter,
press the set
key.

10

E2
To change
the E2
parameter,
press the set
key.

Function : Evaporator Fan feedback

Enable/disable.
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.

Function : Condenser Fan feedback

Enable/disable.
Use the UP/DOWN keys to set desired
value. If set
0 = Condenser Fan feedback sensing
Disable.
1 = Condenser Fan feedback sensing is
Enable.

11

E3
To change
the E3
parameter,
press the set
key.

Function : Compressor Fan feedback

Enable/disable.
Use the UP/DOWN keys to set desired
value. If set
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

18

F1

Function : To set evaporator fan speed.

13

AL

Function: To activate alarm relay.

To change
the F1
parameter,
press the set
key.

Use the UP/DOWN keys to set desired

value.

F2

Function : To set condenser fan speed.

To change
the F2
parameter,
press the set
key.
14

99

99

Example : If this parameter is set to 99%.

Evap. fan will run at 99% speed.

Use the UP/DOWN keys to set desired

value.
Example : If this parameter is set to 99%.
Condenser fan will run at 99% speed.

E4

Function : Relay status on Probe Failure.

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.

To change
the LP
parameter,
press the set
key.

Use up/down keys to set desired value.

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

17

19

FS

Function : To restore default settings of

the controller.

To change
the FS
parameter,
press the set
key.

When set to 1 all parameters

programmed to factory values.

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.

are

Useful to debug setting related problems.

Key Introduction :
Down/prg
Key

Used to enter into the program mode.

Used in program mode to decrement parameter value .

RST

UP Key

Used in program mode to increment parameter value.

SET Key

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

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 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 70OC

EF

Evaporator Fan Feedback Fault.

CF

Condenser Fan Feedback Fault .

FF

Compressor Feedback Fault.

LED Indications :
LED
LED Status Description

20

ON

Evaporator Fan is ON.

FLASHING

Evaporator Fan is in Power ON time delay .

OFF

Evaporator Fan is OFF

ON

Condenser Fan is ON.

OFF

Condenser Fan is OFF.

ON

Compressor is ON.

FLASHING

Compressor is in time delay.

OFF

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.

OFF

Keypad is Unlocked.

TECHNICAL DATA
Housing
Front cover
Dimensions
Panel Cutout
Mounting
Front protection
Connections
Display
Data storage
Power input
Operating temp.
Output :
Cond. & Evap. Fan
Relay1
Alarm
Storage temp
Input
Range
Resolution
Accuracy
Probe tolerance at 25OC
Pass Word protected

21

:
:
:
:
:
:
:
:
:
:
:

Black ABS plastic.

Polycarbonate plastic & ABS plastic
Front - 75 X 32.5 mm, depth 71mm.
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.
5OC to 50OC(non-condensing).

:
:
:
:
:
:
:
:
:

48VDC,1A Max.
8(3)A/250Vac
5A/250Vac
-20OC to 70OC(non-condensing).
NTC probe, SZ-N75.
0OC to 50OC
1OC.
+/- 1OC.
+/- 0.3OC.

CONNECTION DIAGRAM :

TEC-7454 Wiring Diagram

CW

EY

C1

UV
SP

+F

Yellow

-F

Yellow
White

Evap. Fan

Red

-B

Black

22

CW

-B
+B

CY

EY

-B
+B

EW

White

+B

SP

G
Grey
Grey

48VDC

FT

Temp. Sensor

FT

C2

FT

Cond. Fan

*All Connecting wires to respective colors should be same color

+B
-B

Controller-Compressor

CY

EW

Green

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

Customer Care

Hotline No
18004250002

Mail ID

Tecumseh Products India Pvt. Ltd.

38 KM Stone, Delhi Mathura Road,
Ballabgarh, Harayana 121004,
India.
Tel: 0091-129-2307216-220
Direct: 0091-129-2307224

23

customercare.india@tecumseh.com