SECOP 8238-65 Electronic Unit for BDN45F/50K Compressors Instructions

SECOP 8238-65 Electronic Unit for BDN45F/50K Compressors

Introduction

The electronic unit is a dual-voltage device. This means that the same unit can be used in 12V or 24V power supply systems. Maximum voltage is 17V for a 12V system and 34V for a 24V power supply system. It can be connected to a PC through the Secop Gateway communication interface on the terminal LIN and C (Fig. 1). Communication gateway modules incl. communication cables can be ordered at Secop (Fig. 8). The PC interface allows you to create different settings and reads out several measurements by using the software TOOL4COOL® supplied by Secop.

Periphery

*The previous gateway (105N9501) is not fully compatible with electronics using LIN bus above 24V. Please use the most recent gateway version.

Installation

Installation (Fig. 3)
Attach the electronic unit by pressing it linearly onto the compressor Fusite® connector and brackets. Press until both screwheads snap in place. Optionally the unit can be secured against excessive vibration with a third screw (Fig. 3).

Power supply

Power supply (Fig. 1)
The electronic unit must always be connected directly to the battery poles. Connect the plus to + and the minus to –, otherwise, the electronic unit will not work. The electronic unit is protected against reverse battery connection. For protection during installation, a fuse must be mounted in the + cable as close to the battery as possible. A 15A fuse for 12V and a 15A fuse for 24V circuits are recommended. If a main switch is used, it should be rated to a current of min. 20A.
The wire dimensions in Fig. 4 must be observed. Avoid extra junctions in the power supply system to prevent voltage drops from affecting the battery protection setting.

• R1 = speed/battery protection non-PC option (resistor)

The + output above LIN is not suitable to supply the controller with power. It is an unprotected output, directly connect to battery +.

• Rated max. current: 1A

Wire dimensions DC

Wire dimensions DC Fig. 4

Size| Max. length 12V operation| Max. length 24V operation|
---|---|---|---
Cross section [mm2]| AWG

[Gauge]|
[m]| [ft.]| [m]| [ft.]|
2.5| 12| 2.5| 8| 5| 16|
4| 12| 4| 13| 8| 26|
6| 10| 6| 20| 12| 39|
10| 8| 10| 33| 20| 66|

• Length between battery and electronic unit

Battery protection settings

Battery protection (Fig. 2)
The compressor stops and restarts again according to the designated voltage limits measured on the + and – terminals of the electronic unit. The standard settings for 12V and 24V power supply systems are shown in Fig. 2. (PC option). Other settings are (Fig. 5) optional if a connection that includes a resistor (R1) is established between terminals C and P (non-PC option).

Thermostat (Fig. 1)
The thermostat is connected between terminals C and T. Either an NTC (electrical thermostat) or a mechanical thermostat can be connected. Three different thermostat modes can be chosen in the software – Auto (both NTC and mechanical), NTC, or Mechanical. The standard setting is Auto. In the case of using a NTC the set point in the range between -40ºC and 40ºC is set with the software and the temperature can also be seen by using the interface. When using the Auto setting in the software it is not possible to obtain NTC failures, so it is recommended to set the thermostat mode to NTC when using a NTC.

Customer display (Fig. 1)
A Customer designed display can be supplied by the electronic unit and used to control e.g. the speed settings, battery protection settings or temperature settings. The used display can communicate with the electronic unit via the LIN terminal and Modbus protocol. The display power supply can be achieved via an unprotected output of the battery voltage and C. For more detailed recommendations on how to use and initialize a customer display please contact Secop. Do not use the battery + terminal above LIN to supply the controller with power.

Speed selection

Speed selection (Fig. 5)
The compressor will run with a fixed speed of 3,000 rpm when the thermostat is switched on. Other fixed compressor speeds and start speeds in the range between 2,300 and 4,500 rpm can be obtained when changing the speed settings in the software (PC option) or with resistor R1 (non PC option). A connected resistor overrules the speeds con-figured by software. A start delay in the range from 0 – 240 sec. (factory setting 2 sec.) after thermostat, cut-in can also be chosen.

R1 [kΩ]| Duty Cycle [%]| Speed [RPM]| Cut in level [V]| Cut out level [V]| Cut in level [V]| Cut out level [V]| Mode
---|---|---|---|---|---|---|---
open| 0| Maintain| Maintain current value. Can be changed via Modbus| Delivery/external display
91| 9| Maintain| Maintain current value. Can be changed via Modbus| ECO on
68| 12| Maintain| Maintain current value. Can be changed via Modbus| ECO off
51| 15| Maintain| Battery protection off (full envelope 9.6V to 34V)| Solar on
43| 18| Maintain| Reset battery protection to default. Maintain speed| Solar off
36| 21| Maintain| 11.7| 10.4| 22.6| 21.3| Reset battery
---|---|---|---|---|---|---|---
30| 24| 3000| 11.7| 10.4| 22.6| 21.3| Reset battery/speed
---|---|---|---|---|---|---|---
27| 27| 4500| Maintain current value. Can be changed via Modbus| Default mode
---|---|---|---|---
22| 30| 4500| 10.9| 9.6| 22.6| 21.3
20| 33| 4500| 11.4| 10.1| 23.6| 22.3
18| 36| 4500| 12.4| 11.1| 24.6| 23.3
15| 39| 4500| 13.4| 12.1| 25.6| 24.3
13| 42| 3800| Maintain current value. Can be changed via Modbus
12| 45| 3800| 10.9| 9.6| 22.6| 21.3
11| 48| 3800| 11.4| 10.1| 23.6| 22.3
9.1| 51| 3800| 12.4| 11.1| 24.6| 23.3
8.2| 54| 3800| 13.4| 12.1| 25.6| 24.3
7.5| 57| 3200| Maintain current value. Can be changed via Modbus
6.2| 60| 3200| 10.9| 9.6| 22.6| 21.3
5.6| 63| 3200| 11.4| 10.1| 23.6| 22.3
5.1| 66| 3200| 12.4| 11.1| 24.6| 23.3
4.3| 69| 3200| 13.4| 12.1| 25.6| 24.3
3.9| 72| 2700| Maintain current value. Can be changed via Modbus
3.3| 75| 2700| 10.9| 9.6| 22.6| 21.3
2.7| 78| 2700| 11.4| 10.1| 23.6| 22.3
2.2| 81| 2700| 12.4| 11.1| 24.6| 23.3
1.8| 84| 2700| 13.4| 12.1| 25.6| 24.3
1.5| 87| 2300| Maintain current value. Can be changed via Modbus
1.0| 90| 2300| 10.9| 9.6| 22.6| 21.3
0.68| 93| 2300| 11.4| 10.1| 23.6| 22.3
0.36| 96| 2300| 12.4| 11.1| 24.6| 23.3
0.051| 99| 2300| 13.4| 12.1| 25.6| 24.3

Fan (Fig. 1)
A fan can be connected to the FAN OUT terminals. Connect the plus to F+ (FAN OUT) and the minus to F-. Since the output voltage between the terminals F+ (FAN OUT) and F- is always regulated to 12V, a 12V fan must be used for both 12V and 24V power supply systems.

• The fan output can supply a continuous power of 6Wavg.
• Fan settings can be adjusted via TOOL4COOL®. It is also possible to set a start delay on the fan in the range of 0 – 240 sec.
• Factory default setting for a fan is 0 seconds. Fan speed can be adjusted through the interface from 40 – 100%.

Recommended connector types

Recommended connector types Fig. 6

Crimp,

0.5 – 0.75 mm2

| Molex: 945180100
Crimp

0.75 – 2.5 mm2

| Molex: 945180201
Crimp for 2 wires

1.5 – 3.0 mm2 total

| Molex: 945180400

Error handling

Error handling (Fig. 7)
If the electronic unit records an operational error, the error can be read out in the software (PC option). Error codes are defined as shown in Fig. 7. A standard light emitting diode (LED) can alternatively be connected between the terminals LIN and +, when using a series resistor of about 1800 Ohm. In case the electronic unit records an operational error, the diode will flash a number of times. The number of flashes depends on what kind of operational error was recorded. Each flash will last ⅕ second. After the actual number of flashes, there will be a delay with no flashes so that the sequence for each error recording is repeated every 4 seconds (non-PC option).

Operational errors (PC or non-PC option)

Error code or LED flashes| Error type

Can be read out in the software

TOOL4COOL®

---|---
7| Communication error

(Communication of master controller stopped for 15 minutes (default))

6| Thermostat failure

(If a NTC thermistor is short-circuit or has no connection, the electronic unit will enter manual mode).

5| Thermal cut-out of electronic unit (PCB or machine compartment temperature exceeds minimum or maximum limits).
4| Minimum motor speed error

(If the refrigeration system is too heavily loaded, the motor cannot maintain minimum speed at approximately 2,150 rpm).

3| Motor start error

(The rotor is blocked or the differential pressure in the refrigeration system is too high (>5 bar)).

2| Fan over-current cut-out

(The fan is overloading the electronic unit).

1| Battery protection cut-out

(The voltage is outside the cut-out setting).

Machine compartment temperature
The electronic unit disables the compressor operation in case its PCB exceeds the maximum limits. The electronic unit does not limit the compressor to operate in its released conditions. It must be ensured the machine compartment temperature does not exceed the compressor’s maximum ratings, otherwise, it might be damaged.

• Min. PCB temperature: -10°C (14°F)
• Max. PCB temperature: 110°C (230°F)

Please refer to the compressor datasheet regarding operating conditions and machine compartment temperature.

The communication port of the electronic unit

The communication port of the electronic unit (terminal LIN, +, and C) has two functions:

1. Communication mode (PC option):
   The first 15 seconds after power up/wake up, both devices (compressor & PC) try to communicate. In case a successful connection is made, the port will stay in communication mode until the next power-up/wake-up.

2. Diode output mode (non-PC option):
   After 15 seconds with no communication link successful established, the unit switches to diode output mode. No communication is possible until the next power-up/wake-up.

To ensure a trouble-free connection using TOOL4COOL®, the following method is recommended:
Change the default TOOL4COOL® network setup to allow TOOL4COOL® to search for the electronic unit every 3 seconds. While TOOL4COOL® is sear-ching, power up the electronic unit and wait for a connection. The following shows how to arrange this setup.

Preconditions:

• The electronic unit is physically connected via the gateway to the PC, but the power to the electronic unit is not yet switched on.
• In the example to the right, the electronic unit is connected to the COM1 network.

Note:
Next to the USB connector of the gateway, there are also two LEDs visible:

RED LED:
blinks when TOOL4COOL® sends a command to the electronic unit. This must blink every second while TOOL4COOL® is trying to establish a connection with the electronic unit.

GREEN LED:
blinks when the electronic unit responds to a TOOL4COOL® command.

• The node address of the electronic unit must match the command from TOOL4COOL®
• (The network setting above tells TOOL4COOL® to search for unit node address 1 every 3 sec.).

Description

3. Leave the other settings at their default value and click OK twice.Now TOOL4COOL® will only look for an electronic unit with address 1, but every 3 seconds. This will ensure that the connection is established within the 15-second time limit after powering up the unit.

Leave all other options unchanged.

| **
8| Power up the electronic unit
9**| The first time the unit is connected, TOOL4COOL® needs to obtain the parameter file from the unit before a connection is shown by the red arrow. Allow a few minutes for this task to complete.

You also can read the current status by selecting the network and then select the tab Unit Status.

|
10| Look under Error/Message

In this example, no errors or messages appear and the unit is working properly.

11| If the parameter file was already loaded into TOOL4COOL®, a connection should be visible in less than 10 seconds.

A red arrow is added before the network name to indicate that a unit is ready.

|

Click the red arrow to open the menu of the electronic unit.

Secop accepts no responsibility for possible errors in catalogs, brochures, and other printed material. Secop reserves the right to alter its products without notice. This also applies to products already on order provided that such alterations can be made without subsequential changes being necessary to specifications already agreed. All trademarks in this material are the property of the respective companies. Secop and the Secop logotype are trademarks of Secop GmbH. All rights reserved. www.secop.com.

References

• Secop Solutions for Commercial Refrigeration | Secop

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