New controllers with telematics ease installation and improve monitoring

May 26, 2018

Features and benefits of the new GAH controller.

  1. Electronic fuses

Internal sensing will detect over current and open circuit. If a fault is sensed the board will shut that output down and then attempt to restart the output a set number of times before a fault is logged.

  1. Fault codes and Diagnostics

The in-cab display will flash the fault code. Depending on the fault, some codes will allow the rest of the unit to function, others will stop the unit. (For instance, the condenser fan if the vehicle is travelling fast enough to dissipate the heat from the condenser coil).

Every fault is logged with a start and end time and date into the memory. Some faults not related to the outputs are also displayed and logged such as when mains is connected and ignition is on (PSc) and when a door is open (DS1 or DS2). Faults can also be referred to as Alarms, for example a door switch activation is not a fault.

  1. Temperature logging

All coil and return air temperatures plus the discharge pressure are logged at a pre-defined interval of between 2 and 300 seconds, these log files can be accessed by engineers.

  1. Door switch inputs

A door switch or switches can be wired back to the condenser. The door openings will be logged as per the other alarms i.e. a start and end time will be logged. The action taken when doors are opened can be set to either turn off just the evaporator fan or the whole fridge unit or an individual compartment in the case of a dual system

  1. Preventative maintenance

Run hours for all outputs are recorded, we can use this data to carry out preventative maintenance on scheduled maintenance visits. I.e. if a fan is still operating but close to its maximum run hours, it would be sensible to change it rather than wait until it fails. This will increase the customers up time.

  1. In cab display

The in cab display is now a blue LCD, the previous controller was red. This will make it simple to differentiate between the old style units and the new ones. The display has 2 brightness settings, bright for daytime and, if required, not so bright for night time use if needed.

The display now only needs a small 4-core cable run to it. This cable has the correct plug already fitted so install time will be significantly reduced.

The new display enclosure can be assembled in 2 different ways to enable dash board mount or windscreen mounting (where the interior mirror normally is). There is a suitable sticky pad pre-fitted for this.

There is now no separate on/off switch, the unit is turned on/off via the standby button on the display itself. The way that set points etc. are changed remains the same as older units.

  1. Install wiring – Evaporators

Previously, cables had to be run from the evaporator to the front of the vehicle and also from the condenser back to the evaporator. Now, the evaporators are all pre-wired and all cables will be run from the evaporator to the condenser only. This can be done at the same time as the hoses are run.

  1. Connectivity

Engineers are able to connect to the board via a PDA or any other android device. This enables them to see all fault codes, the run hours and temperature log files. We are also able to carry out updates to the board if ever required.

Building on this we are planning a commissioning APP available to installers which will negate the need for a paper based commissioning sheet. The APP will also be able to monitor and log the pull down and test all of the functionality automatically without supervision from the engineer.

  1. Fan speed control

All of the fans on the system are now electronically controlled. This means we can “soft start” them which means there is no inrush current, this will prolong the life of the fans, make the system more efficient and also make the starting much quieter. The fans are also speed controlled on both the condenser and evaporator based on system load. For example; when the outside temperature is low and the system is not under much load the condenser fans will slow down, this makes the unit more efficient and also much quieter, especially on standby.

  1. Smart Fan kit

Twin Temp fan kit wiring is now much simpler, if the fan kit is ordered at the same time as the condenser we will program the functionality before delivery. The board will soft start the fan in the same way the other fans are controlled and the board will also monitor the fan output for over current and open circuit. The board will also log faults and temperatures for the fan kit as per a conventional evaporator. The fan kit is now “smart” in its operation, this means if the air temperature of the frozen compartment is not at a useful temperature to satisfy the fan kit controlled compartment the fan will not switch on. The fan kit can now heat as long as the supplying compartment temperature allows.

If a fan kit is ordered for retrofit we will supply a USB stick that will adjust the unit parameters for the fan kit.

If a customer fits their own fan kit we can marry that up to our board and control their fan as long as it is a brushed DC fan and we know the full load current, it will need to use our temperature probe and in cab display though. This will then benefit from all of the above “smart” features. Ideally this could be set up via the commissioning APP (when available). If a customer wants to fit a standalone fan kit it will have to be completely independent to our system, it will not be able to interface with our unit at all.

  1. The future….

There is scope in the future that all log files and fault codes can be accessed wirelessly and fed directly to the customer in real time, this is not available currently but if coupled with a 3G modem we can integrate this information into the customer’s vehicle tracking software etc. in real time. There is also scope to be able to adjust settings remotely such as set points, temperature log intervals, initiating a manual defrost and even turn the unit on/off which could be done when a vehicle has completed its last drop off thus saving fuel on the return journey.