Danfoss TGH Series, Applications And Installation Manual

Page 1: ...Danfoss Turbocor Twin Turbine Centrifugal Compressors TTS TGS TTH TGH Compressors Applications and Installation Manual Revision Q http turbocor danfoss com ...

Page 2: ...Rev Q List of Changes Revision Date Page Description of Change P 06 12 2019 Redevelopment of manual to include TTH TGH compressors P 1 12 12 2019 Update to include TG490 and Medium Temp Q 04 06 2020 Major Revision H upgrade ...

Page 3: ...on Pressure Limits 37 5 5 Standards Compliance 37 Chapter 6 0 Electrical Specifications 39 6 1 Supply Voltage and Frequency 39 6 2 Compressor Current Limit and Operating Range Settings 39 6 3 Disconnects 40 6 4 Motor Insulation Class 41 6 5 AC Input Line Power Electronic Component Protection 41 6 6 Power Line Contactor 41 6 7 CE Compliance and EMI EMC Filtering 41 6 8 Surge Protection 42 6 9 Line ...

Page 4: ...ications 75 15 1 TTS300 and TTS400 Sound Power Measurements 75 Chapter 16 0 Physical Data 79 16 1 Clearance 79 16 2 Torque Specifications 92 Chapter 17 0 Piping Considerations 93 Chapter 18 0 Environmental Considerations 95 18 1 Humidity 95 18 2 Vibration 95 Chapter 19 0 Shipping Considerations 97 19 1 Vibration 97 Chapter 20 0 Installation 99 20 1 Unpacking and Inspection 99 20 2 Rigging Requirem...

Page 5: ...cceptable Frequency Range 39 Table 6 3 FLA and LRA Value Range 40 Table 6 4 Main Cable Connector Plate Hole Sizes 44 Table 13 1 Recommended Minimum Copper Tube Size 61 Table 13 2 Low Lift Pump Sizing 64 Table 15 1 Sound Power Measurements for TTS300 75 Table 15 2 Sound Pressure Calculation for TTS300 75 Table 15 3 Sound Power at Third Octave Band TTS300 Compressor 76 Table 15 4 Sound Power Measure...

Page 6: ...ration Piping Schematic Using Motor Cooling Pressure Regulating Valve TTH TGH Medium Temperature Compressors Only 70 Figure 14 7 Typical Refrigeration Piping Schematic With Multiple DX Evaporators 71 Figure 14 8 Multiple Compressors Single Circuit Piping Schematic 72 Figure 14 9 TTH TGH Piping Schematic with Required Economizer Closed Type and Vapor Line Solenoid 73 Figure 14 10 TTH TGH Piping Sch...

Page 7: ... Figure 20 7 Interlock and Motor Speed Connections 104 Figure 20 8 Interlock Circuit Tests 105 Figure 20 9 Typical Electrical Connections 106 Figure 20 10 Ground Post Nuts 106 Figure 20 11 Compressor AC Input Terminals 107 Figure A 1 Line Reactor Connections 109 Figure B 1 Interconnection Layout 111 Figure B 2 Grounding Diagram 112 ...

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Page 9: ...t indirect special incidental or consequential damages arising out of the manufacture use or the inability to manufacture or use information contained in this manual even if advised of the possibility of such damages In particular Danfoss LLC is not responsible for any costs including but not limited to those incurred as a result of lost profits or revenue loss of damage or equipment loss of compu...

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Page 11: ...nto the following sections 1 Overview of the TTS TGS series compressors provides an overview of the Twin Turbo and Total Green TTS and TGS series compressors including an introduction to the compressor 2 Compressor Module provides details on the Compressor Module of the compressor including product capacity and application range maximum pressure alarm and fault limits 3 System Design Guidelines pr...

Page 12: ...ch if not strictly observed could result in serious damage or destruction of equipment WARNING CAUTION Indicates an essential operating or maintenance procedure practice or condition which if not strictly observed could result in damage to equipment or potential problems in the outcome of the procedure being performed CAUTION ...

Page 13: ...ditions Compression Ratio The absolute discharge pressure divided by the absolute suction pressure CSA Canadian Standards Association www csa ca DC Bus High DC voltage simultaneously connected to multiple compressor components via metallic bus bars including the capacitors DC Capacitor Assembly An assembly of four DC capacitors four bleeder resistors and positive and negative bus bars DC DC Conver...

Page 14: ...ient power to sustain safe and normal operation and is typically due to a loss of power Genlanolin A type of grease In certain climates where the dew point falls below the operating temperature of some of the electronic components it is necessary to apply Genlanolin to certain parts of the compressor to prevent moisture accumulation Harmonics Harmonics are multiples of the fundamental frequency di...

Page 15: ...tic field and is also a parameter used to evaluate the strength of the permanent magnets of the shaft One practical application is to use this phenomenon to indirectly measure motor speed as well as estimate position NEC National Electric Code www necplus org Nm Newton meter A unit of torque 1 Nm 0 738 pound force foot lbf f NTC Negative Temperature Coefficient Refers to thermistor characteristic ...

Page 16: ...ust Bearing A bearing that absorbs the axial forces produced in a centrifugal compressor by the refrigerant pressure differential across the impeller Ton The basic unit for measuring the rate of heat transfer 12 000 BTU H 3 516 kw H Touchdown Bearings Carbon races or ball bearing for the purpose of preventing mechanical interference between the shaft and the magnetic bearings should they lose powe...

Page 17: ...ure of the Type Code to the new structure Additionally the Series indicators not have an additional character in order to differentiate the standard compressors from high lift compressors Unless the compressor is a high lift design an S will be added e g TTS350 A high lift compressor will have an H in the Series designation e g TTH375 Throughout this manual it shall be assumed that if a series des...

Page 18: ...um Temp KHK Listed Mains Plate Size character 10 1 Mains Plate 2 00 2 Mains Plate 2 48 3 Mains Plate 3 00 4 Mains Plate 3 50 I O Board Option character 11 S I O Board included with 5m cable M No I O Board 5m cable included Software character 19 22 S123 Software Revision Future Option character 18 X Reserved Future Option character 17 X Reserved Accessories Configuration character 16 0 No accessori...

Page 19: ...t the top side power electronics to ensure there are no signs of oxidation or any other signs of moisture or condensation Ensure all covers are in place and secured The Danfoss Turbocor compressors have integrated seals in each cover which prevent ingress of moisture and contaminants however if the covers are not in place and properly secured outside air and contaminates can intrude and potentiall...

Page 20: ...mics portion manages the refrigerant compression process from the suction to the discharge including the inlet guide vane assembly Motor The motor portion contains a direct drive high efficiency permanent magnet synchronous motor powered by pulse width modulating PWM voltage supply The high speed variable frequency operation that affords high speed efficiency compactness and soft start capability ...

Page 21: ... load conditions The first compression element the gas encounters is the first stage impeller The centrifugal force produced by the rotating impeller results in an increase in both gas velocity and pressure The high velocity gas discharging from the impeller is directed to the second stage impeller through de swirl vanes The gas is further compressed by the second stage impeller and then discharge...

Page 22: ...cover The orifices cause the refrigerant to expand thereby lowering its temperature Both valves open in response to the temperature sensed in the motor and inverter From the outlet of the orifices the refrigerant is directed to the heatsink plate of the inverter and to the underside of the SCR heatsink The refrigerant also passes through grooves surrounding the motor stator As the refrigerant flow...

Page 23: ...tor Cavity Temp Sensor From Motor Winding Temp Sensor Motor Rotor cooling gas and leakage BMCC From Inverter Temp Sensor Inverter SCR ORIFICE ORIFICE Solenoid E Solenoid M Liquid Refrigerant Inlet BMCC From Motor Cavity Temp Sensor From Motor Winding Temp Sensor Motor Rotor cooling gas and leakage BMCC From Inverter Temp Sensor Inverter SCR ORIFICE ORIFICE Solenoid E Solenoid M Liquid Refrigerant ...

Page 24: ...ntrol Overview Refer to Figure 3 6 Compressor Control System Functional Block Diagram which shows a functional block diagram of the compressor control and monitoring system Refer to Figure 3 8 Magnetic Bearing Control System which displays the component locations The major components include Motor Drive Soft Start Board Bearing Motor Compressor Controller BMCC Bearing PWM Amplifier Backplane Seria...

Page 25: ...acitors are charging up The soft start function and the variable speed drive combined limit the inrush current at startup Backplane 2 3A Calibra on Front Radial Bearing Rear Radial Bearing Axial Bearing 2 3A Calibra on 2 3A Calibra on Customer Chiller Control Communica ons Interface Diagnos c Terminal Internet RS 485 Comms to Chiller or Building Management System User Interface Serial Driver Modul...

Page 26: ...verall pressure ratio and thereby reduces the lift enabling the compressor to reduce speed unload 3 4 7 Motor Bearing Control The magnetic bearing system physically supports a rotating shaft while enabling non contact between the shaft and surrounding stationary surfaces A digital bearing controller and motor controller provide the PWM command signals to the Bearing PWM Amplifier and Inverter resp...

Page 27: ...low except for the alarm LED which is green red Table 3 1 Backplane LEDs describe the LEDs functions Table 3 1 Backplane LEDs 3 4 13 High Voltage DC DC Converter DC DC converters supply and electrically isolate the high and low DC voltages that are required by the control circuits The HV DC DC Converter delivers 24VDC and 250VDC from an input of 460 900VDC The 24VDC and 250VDC are used to power th...

Page 28: ...X Y and Z axes The rotor position along the Z or axial axis is read by measuring the distance between the sensor and a target sleeve mounted on the rotor The rear sensor ring contains sensors that read the position along the X and Y axes Information from the position sensors is continuously fed back to the bearing controller Figure 3 8 Magnetic Bearing Control System Impellers Z axis Position Sens...

Page 29: ...EXV Phase 2B EXV 2 Economizer or load balancing valve Level Sensor 15V Sensor Signal 1 5Volts Level Sensor 0V Level Sensor 15V Sensor Signal 1 5Volts Level Sensor 0V Level Sensor 1 Evaporator Level Sensor 2 Economizer Liquid Temperature Liquid Temperature Compressor Running N O Contact Compressor Running N O Contact Pressure Sensor Signal 1 5Volts Sensor 5V Sensor 0V Temperature Sensor Signal 1 5V...

Page 30: ...ld REF Shield REF 120Ω PLC COM NETB NETA MODBUS Retain Termination Jumper in Last Board Remove Termination Jumper in All Intermediate Boards Termination Resistor should only be included if one is not included in the PLC If the PLC has a resistor installed do not add an addi tional one If the PLC does not have a resistor installed then one should be installed ...

Page 31: ...ersal analog output manually controlled as a percentage of total voltage written through Modbus This can be configured for 0 5V or 0 10V via on board jumpers Entering Chilled Water Temp Analog input indicating water temperature The temperature sensor must be an NTC type 10K 25 C thermistor Refer to Application Manual for thermistor specification Leaving Chilled Water Temp Analog input indicating w...

Page 32: ...d must not be grounded as this would create a ground loop Refer to Figure 4 2 Modbus Grounding Diagram on page 30 4 2 Interface Cable The cable that carries the I O communication to the compressor is 5 meters 16 4 feet in length and is equipped with high density 44 pin connectors female at one end and male at the other end An extension cable is available from your local supplier An optional 10 met...

Page 33: ... should be mounted in a dry area free from vibration and electrical noise Figure 4 4 Compressor I O Board 4 3 1 Compressor I O Board Mounting Instructions 1 Tilt the I O Board as shown in Figure 4 5 Compressor I O Board Installation in order to engage it into the DIN Rail 2 Lower the I O Board until it snaps into place Figure 4 5 Compressor I O Board Installation NOTE The UL listed enclosure shoul...

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Page 35: ...2 Trip Limit It is also controlled by a Pressure Ratio alarm limit monitoring the ratio between the Discharge and Suction Pressures Table 5 1 Discharge Pressure Alarm and Trip Settings In the TGS230 TTS300 compressors the alarm and trip settings default to lower values of operation which are typically deemed appropriate for Water Cooled conditions These values allow for adjustment for compressors ...

Page 36: ...300 compressor allows for adjustment of this setting Compressors which are placed in Air Cooled applications can have this value increased up to 4 8 NOTE Pressure ratio must be calculated using absolute pressures Refer to the OEM Programming Guide to identify the specific register associated with the Pressure Ratio Alarm Limit Beyond these control limits the Maximum Design High Side Pressure for t...

Page 37: ...onditions 5 5 Standards Compliance It is the responsibility of the Original Equipment Manufacturer OEM to ensure that proper safety protocols are in place and that the chiller system has been designed in a manner that is compliant with all applicable local national and international codes and regulatory requirements governing the use of refrigerants pressure vessels and electrical power OEMs must ...

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Page 39: ...TTS TGS Compressor Nomenclature section of this manual for details on the compressor voltage availability Table 6 2 Acceptable Frequency Range 6 2 Compressor Current Limit and Operating Range Settings The new compressor controller version 3 0 0 and above see Section 1 1 Scope on page 11 is designed to allow a user to configure the current setting based on the intended application The compressor de...

Page 40: ...30 400V 40 106 44 117 40 44 TGS230 460V 40 99 44 110 40 44 TGS230 575V 40 79 44 88 40 44 TGS310 380V 50 150 55 165 50 55 TGS310 400V 50 150 55 165 50 55 TGS310 460V 50 135 55 145 50 55 TGS390 380V 50 123 55 137 50 55 TGS390 400V 50 123 55 137 50 55 TGS390 460V 50 108 55 120 50 55 TGS390 575V 50 86 55 96 50 55 TGS490 380V 50 210 55 231 50 55 TGS490 400V 50 210 55 231 50 55 TGS490 460V 50 180 55 198...

Page 41: ...st be done using the FLA of the affected compressor to the next highest amp but in any event should be a minimum of FLA x 1 25 Fast acting fuses must be installed as close as possible and immediately before the compressor that is downstream from the line reactor Contact Danfoss LLC for more information 6 6 Power Line Contactor The power line contactor is optional Consult local safety regulations t...

Page 42: ...lation of the line reactor should be according to Figure 20 9 Typical Electrical Connections on page 106 The rule of selecting the Line Reactor is PReactor_Rated kW FLA A URated V 1 73 0 9 1 25 1000 6 10 Harmonic Current Filtering IEEE 519 If it is necessary to provide additional current harmonic reduction beyond that provided by the standard 5 line reactor Danfoss LLC recommends the installation ...

Page 43: ... ground in accordance with relevant electrical codes and standards such as NEC Section 250 in the U S or its equivalent for other countries Special filtering and measuring may be required in installations such as hospitals that are prone to being influenced by other electronic equipment 6 13 Mains Input Cable Specification The aim of electrical cables is to be a carrier conductor for electrical po...

Page 44: ...ption of 45 W Model 380V 400V 460V 575V TTS300 TGS230 2 5 2 5 2 5 2 5 TTS350 TGS310 2 5 2 5 3 N A TTS400 TGS390 2 5 2 5 3 3 TGS490 2 5 2 5 3 N A TTS700 TGS520 2 5 2 5 3 N A TTH375 TGH285 2 5 2 5 3 N A NOTE The plate hole sizes shown in Table 6 4 are standard production sizes for standard compressors released at the time of this publication OEMs have the flexibility to change those sizes according ...

Page 45: ...ven operating conditions This tolerance band is valid for the area of the operating map which is in the speed control range only As the compressor reduces speed and mechanical unloading is enabled such as the closing of the variable IGV the tolerance increases to 10 The conditions considered are only the flange to flange conditions seen at the compressor rather than the conditions seen at other po...

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Page 47: ...rating is lower than that shown and is related to the FLA rating of the particular compressor The lower limit is related to minimum pressure ratios required to effect proper motor and power electronics cooling with standard refrigerant circuit components 1 The actual obtainable capacity will be dependent on specific operating characteristics of each compressor model Refer to the current authorized...

Page 48: ...0 and TGS230 Medium Temperature Compressor 1 1 The actual obtainable capacity will be dependent on specific operating characteristics of each compressor model Refer to the current authorized compressor selection rating software for more exact values and conditions ...

Page 49: ...wer than that shown and is related to the FLA rating of the particular compressor The lower limit is related to minimum pressure ratios required to effect proper motor and power electronics cooling with standard refrigerant circuit components 1 The actual obtainable capacity will be dependent on specific operating characteristics of each compressor model Refer to the current authorized compressor ...

Page 50: ... than that shown and is related to the FLA rating of the particular compressor The lower limit is related to minimum pressure ratios required to effect proper motor and power electronics cooling with standard refrigerant circuit components 1 The actual obtainable capacity will be dependent on specific operating characteristics of each compressor model Refer to the current authorized compressor sel...

Page 51: ...FLA settings The maximum SDT for compressors with an FLA less than that is lower than the upper bound of the operating envelope and depends on the FLA rating 1 The actual obtainable capacity will be dependent on specific operating characteristics of each compressor model Refer to the current authorized compressor selection rating software for more exact values and conditions ...

Page 52: ... settings The maximum SDT for compressors with an FLA less than that is lower than the upper bound of the operating envelope and depends on the FLA rating 1 The actual obtainable capacity will be dependent on specific operating characteristics of each compressor model Refer to the current authorized compressor selection rating software for more exact values and conditions ...

Page 53: ...he nature of centrifugal compression the minimum stable load is dependent on the pressure ratio imposed on the compressor by the chiller system All compressor performance including unloading should be determined through use of the relevant compressor selection rating programs ...

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Page 55: ... staging valve must be injected downstream of the main EXV in order to de superheat the gas prior to entering the suction of the compressor CAUTION If the staging valve is used as load balancing valve HGBP there are two major risks Check valve chattering if the bypassed flow is too high this chattering will lead to bearing faults due to vibrations Please contact Danfoss LLC for further information...

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Page 57: ...57 of 114 M AP 001 EN Rev Q Chapter 11 0 Product Certification All TTS TGS TTH TGH Series compressors are ETL and CE listed and have been tested in accordance with UL Standard 984 and CSA Standard C22 2 ...

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Page 59: ...sed by position sensors to provide real time repositioning of the rotor shaft controlled by onboard digital electronics 12 4 Capacity Control The compressor shall have a Variable Frequency Drive VFD for linear capacity modulation high part load efficiency and reduced in rush starting current It shall include an Inverter that converts the DC voltage to an adjustable three phase AC voltage Signals f...

Page 60: ...ce 12 6 1 Ancillary Devices A check valve shall be installed on the discharge port of all compressors to protect against backflow of refrigerant during coast down It is recommended that the valve be located after the properly designed discharge cone adaptor preferably close to the condenser in the packaged system The system must include an appropriately sized 5 impedance Line Reactor One Line Reac...

Page 61: ...ularly at low compression ratios 5 Take all necessary precautions to prevent any possibility of liquid floodback to the compressor This means consideration during the ON and OFF cycles particularly in multiple compressor installations This WILL include but is not limited to the inclusion of a liquid line solenoid valve and piping evaporator and condenser arranged in a manner that prevents free dra...

Page 62: ...m The circuit must be properly designed to reflect the specified heat exchanger approach with minimized pressure drops across the liquid side and expansion side Piping design including expansion device selection and pipe sizing should be in accordance with best practices NOTE To prevent reverse rotation and potential bypass of gas through an idle compressor the economizer circuit must be isolated ...

Page 63: ...et port is fitted with a 5 8 flare adapter NOTE Danfoss LLC highly recommends the insulation of the suction and inter stage pipe as well as the bottom of the compressor for MT applications to prevent ice buildups 13 5 2 Low Lift Application The standard TTS TGS control limits compressor speed and capacity above a 1 5 pressure ratio to ensure adequate motor inverter cooling When enabled the low lif...

Page 64: ...w pressure ratio due to high evaporator load conditions such as hot building start up can limit the maximum capacity of the centrifugal compressor If more capacity is desired it is advisable to raise the discharge pressure temporarily to increase the pressure ratio point B until the sensible heat in the building is dissipated Figure 13 2 Centrifugal Performance Dynamics NOTE Contact Danfoss LLC fo...

Page 65: ...ser with Subcooler Evaporator Sight Glass Check Valve Expansion Valve Motor Cooling Port Suction Port Economizer Port Discharge Port Sight Glass Filter Drier Check Valve Refrigerant Pump Pressure Regulating Valve Check Valve Optional configuration for Low Lift operation CC 4 1 later Staging Valve NOTE Service valves are optional ...

Page 66: ...ooling Port Suction Port Economizer Port Discharge Port Sight Glass Sight Glass Filter Drier Filter Drier Evaporator Expansion Valve Expansion Valve Staging Valve Staging Valve Load Balancing Valve Load Balancing Valve Condenser with Subcooler Filter Drier Filter Drier Sight Glass Check Valve NOTE Service valves are optional ...

Page 67: ... Economizer Motor Cooling Port Suction Port Economizer Port Discharge Port Sight Glass Filter Drier Evaporator Expansion Valve Sight Glass Economizer Tank Condenser with Subcooler Filter Drier Expansion Valve Sight Glass Check Valve S Solenoid Valve Staging Valve NOTE Service valves are optional ...

Page 68: ...atic With Closed Type Economizer Motor Cooling Port Suction Port Economizer Port Discharge Port Sight Glass Filter Drier Evaporator Sight Glass Expansion Valve Condenser with Subcooler S Solenoid Valve Expansion Valve Check Valve Staging Valve NOTE Service valves are optional ...

Page 69: ...ulating Valve TTS300 TGS230 Medium Temperature Compressors Only Motor Cooling Port Suction Port Economizer Port Discharge Port Sight Glass Filter Drier Expansion Valve Condenser with Subcooler Sight Glass Pressure Regulating Valve Filter Drier Evaporator Check Valve Staging Valve NOTE Service valves are optional ...

Page 70: ...Regulating Valve TTH TGH Medium Temperature Compressors Only Motor Cooling Port Suction Port Economizer Port Discharge Port Sight Glass Filter Drier Condenser with Subcooler Pressure Regulating Valve Filter Drier Check Valve Staging Valve Evaporator Expansion Valve Sight Glass NOTE Service valves are optional ...

Page 71: ... DX Evaporators Motor Cooling Port Suction Port Economizer Port Discharge Port Sight Glass Filter Drier Filter Drier Sight Glass Expansion Valve Expansion Valve Expansion Valve Evaporator Evaporator Evaporator Condenser with Subcooler Check Valve Staging Valve NOTE Service valves are optional ...

Page 72: ...rt Discharge Port Motor Cooling Port with integral strainer Suction Port Economizer Port Discharge Port Motor Cooling Port with integral strainer Suction Port Economizer Port Discharge Port Sight Glass Sight Glass Filter Drier Filter Drier EXV Sight Glass Staging Valve Staging Valve Staging Valve Staging Valve Sight Glass Sight Glass Check Valve Check Valve Load Balance Valve Condenser with Subcoo...

Page 73: ...damage to the compressor NOTE All TGH TTH compressors MUST include an economizer flash or plate style If an economizer is not provided significant instability should be expected and the operating range of the compressor will be limited Motor Cooling Port Suction Port Economizer Port Discharge Port Sight Glass Filter Drier Evaporator Sight Glass Expansion Valve Condenser with Subcooler S Solenoid V...

Page 74: ...er Port Discharge Port Sight Glass Sight Glass Filter Drier Filter Drier Condenser with Subcooler Filter Drier Filter Drier Filter Drier Expansion Valve Expansion Valve Sight Glass Sight Glass Check Valve Staging Valve S Solenoid Valve S Solenoid Valve Economizer Tank Evaporator Expansion Valve Expansion Valve Sight Glass Sight Glass NOTE Service valves are optional ...

Page 75: ... TTS400 Compressor presents the results of sound pressure calculations for various distances while the compressor is installed on top of a building Disclaimer The sound data below should be used as a guide only The following sound measurements are based on a specific physical setup such as suction discharge piping evaporator and condensers as well as specific pressure ratios Any OEM system design ...

Page 76: ... 315 68 7 62 0 315 69 9 63 4 400 66 9 62 3 400 66 6 62 2 500 71 5 68 6 500 65 7 62 6 630 60 2 58 4 630 71 8 69 8 800 65 1 64 5 800 67 7 67 2 1000 76 5 76 7 1000 70 5 70 6 1250 66 2 66 9 1250 82 3 83 0 1600 69 9 71 0 1600 72 6 73 9 2000 69 6 70 9 2000 73 3 74 7 2500 68 6 69 9 2500 72 8 74 3 3150 72 3 73 6 3150 75 3 76 7 4000 71 3 72 3 4000 74 6 75 8 Operation Mode Sound Power A Scale dBA Sound Powe...

Page 77: ...B A weighted dBA Third octave band Hz Linear scale dB A weighted dBA 160 51 65 160 55 70 200 49 61 200 50 62 250 60 70 250 61 70 315 60 68 315 62 69 400 64 71 400 65 75 500 63 65 500 62 66 630 78 79 630 76 79 800 80 81 800 78 80 1000 83 82 1000 82 83 1250 82 81 1250 81 81 1600 77 76 1600 75 74 2000 77 76 2000 75 74 2500 75 74 2500 76 76 3150 75 75 3150 75 76 4000 72 71 4000 73 73 ...

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Page 79: ...31 02 788mm 20 4 518mm 19 17 487mm 318 lbs 144 kg 135 6 kg 299 lbs 133 4 kg 294 lbs TTH375 TGH285 36 7 932mm 23 2 590mm 19 17 487mm 400 lbs 181 kg 166 kg 366 lbs 163 7 kg 361 lbs 16 1 Clearance Adequate clearance around the compressor is essential to facilitate maintenance and service Removal of the compressor top and service side covers requires a minimum clearance of 24 600mm and 16 406mm respec...

Page 80: ...ont view Scale 1 2 MOTOR COOLING FITTING SIZE 1 2 SWEAT CONNECTION Discharge Port 229 7 9 04 TT300 TG230 220 2 8 67 TT350 TT400 TT500 TT700 TG310 TG520 O RING GROOVE OD 88 9 3 49 WIDTH 4 1 0 16 ID 80 7 3 17 O RING GROOVE OD 33 3 1 31 TT300 TG230 41 3 1 62 TT350 TT400 TT500 TT700 WIDTH 4 1 0 16 ID 25 1 0 98 TT300 TG230 33 1 1 30 TT350 TT400 TT500 TT700 TG310 TG390 TG520 150 66 5 93 All Compressors ...

Page 81: ...TTH TGH Suction Side View Figure 16 5 TTH TGH Service Side View Front view Scale 1 2 79 996 3 15 8 5 0 9 6 3 3 5 705 5 27 78 4 8 7 2 3 1 9 1 8 484 35 19 07 560 55 22 07 272 49 10 73 2 0 3 1 8 3 1 7 5 1 2 5 58 26 2 29 174 99 6 89 920 75 36 25 ...

Page 82: ...Discharge Side View Front view Scale 1 1 150 5 9 300 11 81 360 14 17 3 1 6 1 1 2 4 4 4 8 7 2 3 1 9 1 8 220 8 66 589 56 23 21 O RING GROOVE OD 88 9 3 499 WIDTH 4 1 0 1614 ID 80 7 3 177 O RING GROOVE OD 41 3 1 625 WIDTH 4 1 0 1614 ID 33 1 1 30 O RING GROOVE OD 98 4 3 87 ID 90 2 3 55 Width 4 1 0 16 ...

Page 83: ... TTH TGH Compressors Figure 16 9 Center of Gravity Top View Excluding TTH TGH Compressors 150 66 5 93 8 7 3 4 3 4 4 2 9 0 4 4 1 1 4 3 220 2 8 67 3 8 1 1 5 Z L 2 2 7 1 8 9 4 167 6 57 787 30 98 Rear view Scale 1 2 249 9 80 XL 3 0 0 1 1 8 1 1 5 3 1 6 0 3 Y L Center of Gravity view Scale 1 2 ...

Page 84: ...tor Side View Figure 16 11 TTH TGH Center of Gravity Top View Left view Scale 1 2 2 8 9 7 5 1 1 4 1 705 7 27 78 2 4 1 0 5 9 4 9 Z L Center of Gravity view Scale 1 2 182 3 7 18 484 35 19 07 1 5 0 5 9 1 1 5 9 8 9 6 2 9 Y L 3 0 0 1 1 8 1 5 8 9 4 1 6 2 3 2 3 0 4 3 4 6 1 1 9 8 XL ...

Page 85: ...lection Guide for further details Figure 16 12 Discharge Port Detail TTS300 and TGS230 Description Parameter TTS300 TGS230 TGS490 TTS350 TGS310 TTS400 TGS390 TTS700 TGS520 TTH375 TGH285 CG LINE Length of Center of Gravity m in XL 257 mm 10 13 249 mm 9 80 247 mm 9 74 251mm 9 87 182 3 mm 7 18 Width of Center of Gravity m in YL 151 mm 5 95 153 1 mm 6 03 152 mm 5 97 150 mm 5 91 159 9 mm 6 29 Height of...

Page 86: ...86 of 114 M AP 001 EN Rev Q Figure 16 13 Discharge Port Detail TTS350 and TGS310 Figure 16 14 Discharge Port Detail TTS400 and TGS390 Gas Flow Gas Flow ...

Page 87: ...87 of 114 M AP 001 EN Rev Q Figure 16 15 Discharge Port Detail TTS700 TGS490 and TGS520 Figure 16 16 Discharge Port Detail TTH375 and TGH285 Gas Flow ø72 075 2 84 ø36 1 41 2 65 1 90 ...

Page 88: ...88 of 114 M AP 001 EN Rev Q Figure 16 17 Suction Port All Models ...

Page 89: ...89 of 114 M AP 001 EN Rev Q Figure 16 18 Suction Port Detail DD All Models Excluding TTS700 and TGS520 Figure 16 19 Suction Port Detail DD TTS700 TGS490 and TGS520 Gas Flow Gas Flow ...

Page 90: ...90 of 114 M AP 001 EN Rev Q Figure 16 20 TTS300 and TGS230 Flange Footprint Details Figure 16 21 TTS350 TGS310 TTS400 TGS390 TTH375 and TGH285 Flange Footprint Details ...

Page 91: ...read Spec Thread Depth mm Recommended Torque Nm Suction M16 34 5 75 Discharge M10 20 32 Economizer M10 20 32 WARNING Refer to the manufacturer fastener specifications and torque as required but do not exceed the torque values listed in Table 16 3 Screw Hole Specifications If this value is exceeded damage to compressor housing threads may occur ...

Page 92: ...er and Sensor Feedthroughs 5 4 44 Cavity Sensor E Housing and Later 13 10 115 SCR Mounting Screws 7 5 62 A C Bus Bars 6 4 53 DC Capacitors and Bleed Resistor 2 1 18 IGBT Mounting Screws 6 4 53 Shraeder Valves 15 11 133 Motor Cooling Body Body Nut E Housing and Later 25 18 221 Motor Cooling Compression Nut E Housing and Later 11 8 97 Cover Plate 13 10 115 Hermetic Feedthrough 22 16 195 Motor Coolin...

Page 93: ...on of a sight glass and full flow liquid dryer in the motor cooling line NOTE Some applications may require alternative arrangements Contact Danfoss LLC for further assistance if required CAUTION The discharge line must be fitted with a non return valve to prevent reverse flow into the discharge port which can cause damage to compressor components All pipe work should be carried out in accordance ...

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Page 95: ...ensate Insulation should be installed on the suction valve piping and the end cap as this is where condensation is most likely to form It is recommended to fit an End Cap insulator in a humid environment NOTE The End Cap insulator is not available for TGH TTH compressors 18 2 Vibration External copper piping should be braced to minimize the transfer of vibration to the compressor ...

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Page 97: ...Due to the flexibility of the compressor s isolation mounts compressor vibration during transit can fracture the motor cooling line s rigid piping Danfoss LLC suggests the temporary installation of an anti vibration bracket between the compressor s base frame and mounting rail during transit as shown in Figure 19 1 Anti Vibration Bracket Figure 19 1 Anti Vibration Bracket Anti Vibration Bracket Co...

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Page 99: ...e compressor to protect it from damage Two eyebolts one at each end are provided for compressor rigging A spreader bar should be used to safely position the compressor into its final location refer to Figure 20 1 Rigging Set up 20 3 Unit Placement 1 If mounting the compressor with the Danfoss LLC mounting kit refer to Appendix B Mounting Kit Instructions if not install four isolation pads in accor...

Page 100: ...ing base points the overall height of the compressor will change Be sure to measure accordingly based on the insulator used 1 If isolation pads are used install four 4 pads in accordance with the footprint dimensions given in Figure 20 2 Mounting Base TTS TGS TTH TGH Series 2 Mount the compressor onto the isolation pads Ensure the compressor mounting rails are properly isolated from the base frame...

Page 101: ...lanking plates Isolation and recovery of the refrigerant must be performed by a qualified technician Always wear proper safety equipment when handling refrigerants Refer to Figure 20 5 Motor Cooling Connection and Access Port 1 After releasing the pressure remove the suction and discharge connection blanking plates from the new compressor 2 Attach the suction discharge and economizer if applicable...

Page 102: ...ntrol Wiring Details on page 31 provides details for the module terminal connections CAUTION Incorrect wiring of the terminals can severely damage the module and other components The interface cable connects the compressor to the compressor I O board To connect the cable 1 Plug the cable connector into connector J6 on the compressor I O board For RS 485 communication the total length of the interf...

Page 103: ...103 of 114 M AP 001 EN Rev Q Figure 20 6 Compressor I O Board Connections Interface Cable Compressor I O Board ...

Page 104: ... shield terminal on the compressor I O board refer to Figure 20 7 Interlock and Motor Speed Connections If the measured voltage is not zero 0 determine the source of the voltage The most likely cause of voltage is insufficient insulation of the external circuit In case of uncertainty of the grounding connect the negative terminals of the external circuit to a ground and then connect the external g...

Page 105: ...al Connections on page 106 20 7 Power Wiring This section describes the connection of the power wiring to the compressor Figure 20 9 Typical Electrical Connections on page 106 shows a typical schematic for the compressor s electrical connections I Lock I Lock Interlock Circuit Interlock Circuit NOTE The AC input cable should be CSA UL or CE approved 3 wire with a common shield and single ground It...

Page 106: ...rminals on page 107 Continue to Step 8 for TT300 TG230 compressors For all other TTS TGS compressors continue to Step 9 Figure 20 10 Ground Post Nuts 8 The three 3 compression lugs on the TTS300 TGS230 compressors need to be torqued to 20 Nm 15 ft lbs Upper Nut 10 Nm 7 ft lb Jam Nut 7 Nm 62 in lb Harmonic Filter optional Surge Suppressor optional EMI EMC Filter optional Line Reactor AC Input Volta...

Page 107: ...essor 12 Replace the mains input cover and secure it the fasteners Seal Bracket Opening TTS300 TGS230 Compressors All TTS TGS TTH TGH Models Prior to Revision H Except TTS300 TGS230 Upper Nut Jam Nut Mains Stud 3 8 16 1 5 long Mains Input Pressure Screw AC Input Connection Terminal Block Adapter All TTS TGS TTH TGH Models Revision H Except TTS300 TGS230 Mains Stud 3 8 16 1 5 long AC Input Connecti...

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Page 109: ... panel using approved methods e g cable gland A 1 2 AC Line Cable Connection to Compressor Terminal 1 Feed the AC line cable through the opening in the side of the main supply panel 2 Attach the AC line wires to the line reactor output terminals as shown in Figure A 1 Line Reactor Connections 3 If a harmonic filter is being installed attach its AC line wires to the line reactor output terminals 4 ...

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Page 111: ...ide Connection 1 Insert the load wires instead of the line side of the line reactor into the terminals labeled L1 L2 and L3 on the Load side of the filter Tighten the terminal screws 2 Attach the ground lug to the main ground bus and tighten the nut B 1 3 Harmonic Filter 1 If a harmonic filter is to be installed follow the manufacturers instructions 2 Connection of a harmonic filter should be made...

Page 112: ...112of114 M AP 001 EN Rev Q Figure B 2 Grounding Diagram Grounding Diagram Filter Ground Lug Short Heavy Braided Cable Main Ground Bus ...

Page 113: ... from a list of symptoms in the app that match the problems exhibited by the compressor being serviced The app will then list potential causes solutions to the problem and service literature to reference for further information The app provides the correct operating parameters for key components no need to keep reference documents on hand You no longer need to keep hundreds of pages of parts catal...

Page 114: ...s as distinct variable speed technology specialists Today we operate from engineering and manufacturing facilities spanning across three continents Danfoss Inverter Scrolls Danfoss Turbocor Compressors Danfoss Scrolls Danfoss Optyma Condensing Units Danfoss Maneurop Reciprocating Compressors M AP 001 EN Rev Q Danfoss DCS CC 2020 05 Our products can be found in a variety of applications such as roo...