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Danfoss TGH285, Service Manual

The Danfoss TGH285 is a versatile product designed to enhance energy efficiency. Our Applications and Installation Manual provides comprehensive instructions on how to install and operate the TGH285. Download this manual for free at 88.208.23.73:8080 to maximize your knowledge and make the most of this innovative product.

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M-SV-001-EN Rev. G

Motor Fault 

Descritpion

Trigger 

Method

Troubleshooting

DC Bus Under/Over

Voltage Fault

DFT

•  At 0 RPM: If the measured DC Bus voltage is lower than Soft Start charge voltage, a DC bus voltage fault is 

recorded. All 3-phase voltage information displayed in the SMT is calculated from DC bus voltage, as measured by 

the Inverter.

•  Typically, this fault is recorded when power to the compressor is removed.
•  Measure the incoming main AC voltage.
•  Compare the measured voltages to the displayed readings in the Compressor Monitor Tool and Fault and Event 

Log details to determine conditions related to the fault.

•  Measure the DC bus voltage using the DC Bus Test Harness. Refer to "1.10.1 General Verification and Installation of 

the DC Bus Test Harness" on page 22.

•  Verify the Soft Start. Refer to "4.15.2 Soft Start Verification" on page 109.
•  Verify the SCRs. Refer to "4.19.2 SCR Verification" on page 135.
•  Verify the connections to the Inverter. Refer to "4.23.2.1 Inverter Verification" on page 165.

24VDC Under/Over

Voltage Fault

RFT

•  Suggests the measured 24VDC supply voltage is out of range.
•  Measure the 24VDC test points at the Backplane. Refer to "4.26.2.2 Backplane Verification" on page 210.
•  Compare the measured voltages to the displayed readings in the Compressor Monitor Tool and Fault and Event 

Log details to determine conditions related to the fault.

•  If the measured voltage is incorrect, verify the DC-DC Converter. Refer to "4.25.2 DC-DC Converter Verification" on 

page 201.

•  Determine that one of the modules is not draining energy. Refer to "5.5.2 Determining the Cause of an Energy 

Drain" on page 257.

•  If the fault occurs when the compressor is given the demand to run, the Inverter may be causing the 24VDC fault.

Low Motor Back 

EMF

Fault

DFT

•  The calculated magnetic strength of the shaft has fallen below the minimum limit. This can be a temporary effect 

due to high load and elevated temperatures (will recover when cavity temperature cools) or due to a permanent 

demagnetization of the shaft.

•  If this fault occurs three times within a 30-minute period, a Lock-Out Fault will occur.
•  Compare the Back EMF value to the displayed readings in the Compressor Monitor Tool and Fault and Event Log 

details to determine conditions related to the fault.

•  Permanent damage to Back EMF can be caused by insufficient motor cooling, repeated overheating of cavity, 

faulty Inverter, faulty BMCC, repeated Rotor May Be Locked or Single phase Over-Current faults. See Inverter Error.

•  Verify the Inverter. Refer to "4.23.2.1 Inverter Verification" on page 165.
•  Verify the Stator. Refer to "4.24.4 Motor Verification" on page 192.

Generator Mode

Active

DFT

•  Indicates, at greater than 0 RPM, the measured actual DC Bus voltage has fallen below the Generator Mode 

Enabled Level value. Also, could be electronic “noise” when no actual drop in voltage has occurred.

•  Measure the incoming main AC voltage.
•  Measure the DC bus voltage using the DC Bus Test Harness.
•  Compare the measured voltages to the displayed readings in the 

Compressor Monitor Tool

 and Fault and Event Log 

details to determine conditions related to the fault.

•  Typically, this fault is recorded when power to the compressor is removed while it is running.

EEPROM Checksum

Fault

INS

•  Indicates there is an error reading the EEPROM in the BMCC.
•  Perform a bearing calibration and save to EEPROM, cycle the power.
•  If the error is still present, the BMCC must be replaced.

SCR Ripple Voltage

Fault

AFT

•  Indicates that a voltage imbalance may exist between the incoming AC phases.
•  Measure the difference in current and voltage between the phases.
•  If there is a current imbalance (more than 5%) between the phases, verify the incoming AC power supply.
•  Review the Compressor Monitor Tool for SCR Voltage Ripple readings at the time of the fault.
•  Phase imbalance can be caused by a faulty SCR, SCR Gate, Gate control from the Soft Start Board, or a faulty power 

capacitor.

•  Verify the SCRs. Refer to "4.19.2 SCR Verification" on page 135.
•  Verify the Soft Start Board. Refer to "4.15.2 Soft Start Verification" on page 109.

Summary of Contents for TGH285

Page 1: ...Danfoss Turbocor Twin Turbine Centrifugal Series Compressors TTS TGS TTH TGH Series Compressors Service Manual Revision G http turbocor danfoss com ...

Page 2: ...al covers Major Revision F and later compressors If you have a Major Revision E or earlier compressor we suggest downloading Service Manual Revision E from our website since there are some steps that are unique ...

Page 3: ...odule 63 4 5 Compressor Interface Cable 66 4 6 Compressor Controller Cable Harness 67 4 7 Solenoids and Coils 72 4 8 Interstage Pipe TTH TGH 77 4 9 Compressor Housing End Cap 78 4 10 IGV 80 4 11 Mains Plate Bracket 93 4 12 3 Phase Main Voltage Input Terminal Block 95 4 13 Input Mains Bus Bars Except TTS300 TGS230 103 4 14 Terminal Block Fuse Replacement 105 4 15 Soft Start 107 4 16 SCR DC Bus Bar ...

Page 4: ...of Contents Chapter 6 0 Maintenance 263 6 1 Preventative Maintenance Tasks 263 6 2 Moisture Prevention Measures 264 Appendix A Acronyms Terms 269 Appendix B Compressor Troubleshooting Flowcharts 271 Appendix C Compressor Test Sheet 277 ...

Page 5: ... 4 27 SCR DC Bus Bar Torque Specifications 121 Table 4 28 Soft Start AC DC Harness Torque Specifications 133 Table 4 29 SCR Diode Values 137 Table 4 30 SCR Gate Resistance Ranges 137 Table 4 31 SCR Temperature Sensor Torque Specifications 141 Table 4 32 SCR Torque Specifications 149 Table 4 33 SCR Cooling Manifold Torque Specifications 155 Table 4 34 DC Capacitor Bus Bar Assembly Torque Specificat...

Page 6: ... Removing the Compressor Interface Module from the DIN Rail 66 Figure 4 20 Compressor Interface Cable 67 Figure 4 21 Compressor Controller Cable Harness Variants 68 Figure 4 22 Backplane Connections 69 Figure 4 23 Pressure Temperature and SCR Temperature Sensor Locations TTS300 TGS230 69 Figure 4 24 Pressure Temp and SCR Temp Sensor Locations TTS TGS 70 Figure 4 25 Pressure Temperature Sensors TTH...

Page 7: ...00 TGS230 101 Figure 4 89 Input Terminal Block Installation TTS TGS TTH TGH Rev F and Earlier Except TTS300 TGS230 101 Figure 4 90 Input Terminal Block Installation TTS TGS TTH TGH Rev H Except TTS300 TGS230 102 Figure 4 91 Input Mains Bus Bar Examples 103 Figure 4 92 AC DC Bus Bus Bar Connectors TTS TGS TTH TGS Rev F and earlier Except TTS300 TGH230 104 Figure 4 93 AC DC Bus Bus Bar Connectors TT...

Page 8: ... 4 158 SCR Removal TTS300 TGS230 143 Figure 4 159 SCR Gate Cable and AC DC Harness Connections TTS TGS TTH TGH Rev F and Earlier Except TTS300 TGS230 143 Figure 4 160 SCR Gate Cable and AC DC Harness Connections TTS TGS TTH TGH Rev H Except TTS300 TGS230 144 Figure 4 161 SCR Bus Fastener Removal TTS TGS TTH TGH Rev F and Earlier Except TTS300 TGS230 144 Figure 4 162 SCR Bus Fastener Removal TTS TG...

Page 9: ...TGH Except TTS300 TGS230 179 Figure 4 223 DC DC Removal TTS TGS TTH TGH Rev F and Earlier Except TTS300 TGS230 180 Figure 4 224 Motor Winding Sensor Removal 180 Figure 4 225 Inverter Removal TTS TGS TTH TGH Except TTS300 TGS230 180 Figure 4 226 Inverter O ring Removal TTS TGS TTH TGH Except TTS300 TGS230 181 Figure 4 227 SCR Manifold Return Brass Fitting Removal TTS TGS TTH TGH Except TTS300 TGS23...

Page 10: ...earing Power Feedthrough Alignment Pin 227 Figure 4 289 Bearing Power Feedthrough Torque Sequence 227 Figure 4 290 Bearing Sensor Feedthroughs 228 Figure 4 291 Bearing Sensor Pin Locations 229 Figure 4 292 Bearing Sensor Feed Through Removal 230 Figure 4 293 Bearing Sensor 9 Pin Feedthrough Connector Torque Sequence 230 Figure 4 294 BMCC Insertion Guides 231 Figure 4 295 Cavity Sensor 231 Figure 4...

Page 11: ...ecial 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 computer programs ...

Page 12: ... support Revision F and later compressors F 1 6 10 2019 15 16 Upodated Typecode figures 1 1 and 1 2 F 2 11 10 2019 18 19 28 Updated TGS490 compressor with R515B refrigerant F2 11 10 2019 36 Removed helium and changed the inert gas pressure to 15 psi F2 11 10 2019 98 Updated F4 and F5 fuse description G 5 27 2020 all Manual updated to include all Major Revision H changes ...

Page 13: ...3 R515B 19 1 8 Electrical Isolation 19 1 9 Handling Static Sensitive Devices 20 1 9 1 ESD Protection Grounding 21 1 10 DC Bus Test Harness Installation and Removal 22 1 10 1 General Verification and Installation of the DC Bus Test Harness 22 1 10 2 DC Bus Test Harness Installation for Closed Top Soft Start 23 1 10 3 General DC Bus Test Harness Removal 27 1 10 4 DC Bus Test Harness Removal for Clos...

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Page 15: ... adds an S for standard or H for High Lift Voltage Code Application Note T is dropped Major Revision Build Note This would change from an O to a 0 Existing New Removed Type Code Definition Product Series and Capacity TTS300 TT Series 300 Aero Config TTS350 TT Series 350 Aero Config TTS400 TT Series 400 Aero Config TTS500 TT Series 500 Aero Config TTS700 TT Series 700 Aero Config TGS230 TG Series 2...

Page 16: ...H Voltage Code character 8 E 380V 50Hz D 380V 60Hz H 400V 50Hz J 400V 60Hz G 460V 60Hz F 575V 60Hz Application character 9 S Standard Application M Medium Temperature Application J Standard Temp KHK Listed K Medium 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 cabl...

Page 17: ... of removing and installing the compressor Section 4 Compressor Components this section describes in depth component information the steps necessary to obtain measurements that verify a component is functional and the steps necessary to replace a compressor component Section 5 Troubleshooting this section describes troubleshooting using signals from the compressor to determine the specific source ...

Page 18: ...or long term health hazards A Danger notification is displayed in the format shown in Figure 1 3 Danger Notification Example Figure 1 3 Danger Notification Example 1 5 2 Caution Notification A CAUTION notification signifies an essential operation or maintenance procedure practice or condition which if not strictly observed could result in damage to or destruction of equipment or potential problems...

Page 19: ... Mains Input Cover on page 56 4 Using an appropriately rated voltage meter confirm the absence of AC voltage DANGER Do not touch any components when removing the Mains Input Cover 5 If AC voltage is not present reinstall the Mains Input cover and wait at least 20 minutes before removing either the Mains Input or Top Side Cover If AC voltage still exists go back to Step 2 to determine why the compr...

Page 20: ...l precautions that must be followed when providing service support in the field Service support personnel should create a safe static free environment Service personnel must use a commercially available service kit for handling static sensitive devices The kit typically includes Ground cord assembly Alligator clip Grounding wrist strap Wrist strap tester If a safe static control environment cannot...

Page 21: ...scribed in 1 8 Electrical Isolation on page 19 2 Remove the Mains Cover Refer to 4 2 1 Mains Input Cover on page 56 3 Clip the ESD strap ground clip to the compressor ground post Refer to Figure 1 9 Mains Plate and Ground Post Figure 1 9 Mains Plate and Ground Post 4 If you need to remove the Soft Start clip the ESD strap ground clip to the mains plate Refer to Figure 1 9 Mains Plate and Ground Po...

Page 22: ...nts are made via shrouded multimeter jacks on the opposite end of the cables Cable and personal protection are provided by inline fast acting fuses 1 4 x 1 1 4 62 milliamp 250V and current limiting 100kΩ 3W resistors Figure 1 11 DC Bus Test Harness Diagram Closed Top Soft Start Figure 1 12 DC Bus Test Harness Diagram Open Top Soft Start CAUTION Before using the DC bus test harness integrity of the...

Page 23: ...iagram Open Top Soft Start for harness fuse and resistor locations The reading for the resistor should be approximately 100kΩ and the reading for the fuse should be 29Ω 5 Continue to the appropriate section below based on the particular Soft Start 1 10 2 DC Bus Test Harness Installation for Closed Top Soft Start 1 Disconnect the J1 and J7 connectors on the Soft Start Board Refer to Figure 1 13 Sof...

Page 24: ...connectors and harness so that the Top Cover can be reinstalled 6 Reinstall the Top Cover and Mains Input Cover Refer to 4 2 Compressor Covers on page 56 7 Remove ESD strap from the compressor and yourself ORIGINAL CONNECTIONS Harness to DC DC Converter Soft Start Top Side Harness to DC Bus and AC Line J1 J7 CONNECTIONS WITH DC BUS TEST HARNESS Harness to DC DC Converter Soft Start Top Side Harnes...

Page 25: ...C and connect to the 15VAC leads of the DC Bus Test Harness If the reading is zero isolate the three phase supply in accordance with 1 8 Electrical Isolation on page 19 When access is safe remove the four 4 fasteners that hold the Soft Start in position and check fuses F2 F3 F4 F5 F6 for continuity If any fuse is found to be an open circuit replace it and return to Step 6 13 If the 15VAC is not pr...

Page 26: ...meter lead into the DC test harness lead and the negative voltmeter lead into the DC test harness lead Refer to Table 1 3 Expected DC Bus Voltage on page 25 for the expected DC bus voltage If the DC bus voltage is not present or if it is outside the Expected DC Bus Voltage range shown in Table 1 3 Expected DC Bus Voltage on page 25 verify proper incoming AC input verify SCR Gates and verify SCR Di...

Page 27: ... from the socket of the DC Bus Test Harness 4 Reconnect the J8 connector into the Soft Start 5 Remove ESD strap from the compressor and yourself 6 Install all covers on the compressor Refer to 4 2 Compressor Covers on page 56 7 Return the compressor to normal operation 8 Disconnect the two 2 plugs of the compressor cable harness from the corresponding sockets of the DC bus test harness 9 Reconnect...

Page 28: ...ricate the O ring with a light coat of Super O Lube 4 Avoid rolling or twisting the O ring when maneuvering it into place 5 Keep the position of the O ring mold line constant NOTE It is strongly suggested that anytime an O ring is removed that a new O ring is used in its place ...

Page 29: ...29 of 282 M SV 001 EN Rev G Chapter 2 Compressor Fundamentals 2 1 Main Fluid Path 31 2 2 Motor and Power Electronics Cooling 31 2 3 Capacity Control 34 2 4 Compressor Energy and Signal Flow 34 ...

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Page 31: ...ute Vapor then enters the second stage impeller through a diffuser In the second stage impeller velocity energy is again added to the refrigerant and converted to the final discharge pressure in the discharge diffuser and volute From the second stage impeller refrigerant passes as a high pressure superheated vapor to the system discharge line Figure 2 1 Compressor Fluid Paths Table 2 1 Compressor ...

Page 32: ...tion around the power electronic components In the split cooling version Solenoid 1 is opened if either the cavity temperature or the motor temperature reaches its turn on point and Solenoid 2 is opened if the Inverter or SCR temperature reaches its turn on point Refer to cooling circuit diagram Figure 2 4 Split Cooling Path TTS TGS Except TTS300 TGS230 Serial Cooling and Figure 2 3 Split Cooling ...

Page 33: ...iquid Refrigerant Inverter Temp Sensor Impeller 1st Stage Impeller 2nd Stage Radial Bearing Axial Bearing Stator Rotor Radial Bearing Solenoid E Solenoid M Motor Cavity Temp Sensor BMCC From Motor Cavity Temp Sensor From Motor Winding Temp Sensor Motor Rotor cooling gas and leakage BMCC From Inverter Temp Sensor From SCR Temp Sensor Inverter SCR ORIFICE ORIFICE Solenoid E Solenoid M Liquid Refrige...

Page 34: ...the use of Inverter control To accomplish this the incoming 3 phase AC supply is converted to high voltage DC incorporating smoothing storage capacitors and then switched by the Inverter utilizing 3 phase rectifiers to give a simulated 3 phase AC supply of variable voltage and frequency to the compressor motor 2 4 Compressor Energy and Signal Flow During normal operation 3 phase power is required ...

Page 35: ...put terminal 2 AC voltage enters the SCRs and DC voltage powers the DC bus 3 The Soft Start Board limits the in rush current at power up by controlling the SCR gates 4 DC bus voltage from the SCRs charges the capacitors 5 DC bus provides DC voltage to Inverter 6 The Inverter converts the DC bus voltage into a variable frequency 3 phase simulated AC voltage to the Stator 7 The DC DC Converter uses ...

Page 36: ... voltage powers the DC bus 2 DC bus voltage from the SCRs charges the capacitors Soft Start limits the in rush current at power up by controlling the SCR gates DC bus provides DC voltage to the Inverter Inverter DC Bus connection Ground Backplane supplies low DC voltage to service side components Inverter connection DC DC converts DC bus voltage to provide 24 VDC and 250 VDC to backplane 4 Inverte...

Page 37: ... Module 15VDC 24VDC To Motor Cooling Solenoids To IGV Stepper Motor Compressor I O Board 0 10VDC 0 10VDC Compressor Inputs Compressor Outputs Bearing PWM Amplifier HV 17VDC 5VDC Control Feedback 15VDC 24VDC 5VDC 15VDC Control Feedback Control Feedback So Start Controller 0 12 VDC Variable Frequency 0 750Hz AC Voltage To Stator Va Vb Vc DC DC Converter 460 853 VDC 15 VAC 24VDC HV 250VDC 3 Phase 380 ...

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Page 39: ...mpressor Removal and Installation 3 1 Refrigerant Containment 41 3 2 Compressor Removal 41 3 3 Compressor Installation 42 3 4 Compressor Replacement Considerations for Motor Cooling Adapter 43 3 5 Exterior Connection Torque Specifications 45 ...

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Page 41: ...nnect the compressor from the refrigerant system connections suction discharge economizer and motor cooling line taking care when removing connections that there is no residual pressure 8 Install the Service Side Cover 9 Install the Mains Input Cover 10 Position the lifting hoist crane with the 2 point spreader bar directly above the lifting points 11 Using a properly rated chain cable connect the...

Page 42: ...r 7 Confirm that the compressor and spreader bar are properly balanced between the lifting points and the lifting hoist 8 Slowly lower the compressor until it is positioned within approximately 5 mm of the compressor mounts 9 Loosely install the rubber mounts and mounting fasteners to the base of the compressor 10 Slowly release the load from the crane so that compressor weight is supported by the...

Page 43: ...rmal operation 3 4 Compressor Replacement Considerations for Motor Cooling Adapter The housing connection seal is an ISO standard O ring seal and the external pipework connection is an ORFS In addition the line size has been standardized at 1 2 inch for all models and the fitting includes a built in removable strainer The current fitting consists of 1 body including both O rings 2 strainer 3 blank...

Page 44: ...red Clean flux and any excess filler from joint 5 Clean the O ring face of the sleeve ensuring no scratches or debris are present Apply a light amount of O ring lube to the face of the sleeve and assemble to the fitting Tighten the nut using two 2 wrenches one to hold body of fitting and one to tighten the nut This is done to prevent over torqueing the fitting in the compressor housing Rigid 3 8 i...

Page 45: ...GS230 compressors 20 15 177 Motor Cooling Body E housing and later 25 18 221 Motor Cooling Compression Nut E housing and later 11 8 97 Ground Post Top Nut 10 7 89 Ground Post Second Jam Nut 7 62 Ground Post Lower Nut 20 15 177 Suction Flange Fastener 34 5 75 55 664 Discharge Flange Fastener 20 32 24 283 Economizer Flange Fastener 20 32 24 283 Schrader Valve 15 11 133 Base Mounting Bolt 24 22 16 19...

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Page 47: ...nd Coil Removal and Installation 75 4 8 Interstage Pipe TTH TGH 77 4 8 1 Interstage Pipe Removal and Installation 77 4 8 2 Interstage Pipe Torque Specifications 78 4 9 Compressor Housing End Cap 78 4 9 1 Compressor Housing End Cap Removal and Installation 79 4 10 IGV 80 4 10 1 IGV Connections 80 4 10 2 IGV Verification 81 4 10 3 IGV Housing Removal and Installation 83 4 10 4 IGV Torque Specificati...

Page 48: ...tor Bus Bar Assembly Removal and Installation 158 4 22 4 DC Capacitor Bus Bar Assembly General Removal 158 4 22 5 DC Capacitor Bus Bar Assembly General Installation Steps 163 4 22 6 DC Capacitor Bus Bar Assembly Torque Specifications 164 4 23 Inverter 165 4 23 1 Inverter Connections 165 4 23 2 Inverter Verification 165 4 23 3 Inverter Cable Harness 166 4 23 4 Inverter Cable Harness Removal and Ins...

Page 49: ... 1 Bearing Sensor Function 228 4 31 2 Bearing Sensor Connection 228 4 31 3 Bearing Sensor Verification 229 4 31 4 Bearing Sensor Cable Removal and Installation 229 4 31 5 Bearing Sensor Removal and Installation 229 4 32 Cavity Temperature Sensor 231 4 32 1 Cavity Temperature Sensor Function 231 4 32 2 Cavity Temperature Sensor Connections 232 4 32 3 Cavity Temperature Sensor Verification 232 4 32 ...

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Page 51: ...ponent Identification This section identifies the major parts of the compressor Figure 4 1 Compressor Components Identification Covers On Table 4 1 Compressor Components Covers On 3 11 1 2 4 5 6 7 8 9 10 12 No Component No Component 1 Top Cover 7 Service Side Cover 2 Mains Input Cover 8 Rear Support Base 3 Lift Anchor Front 9 Compressor I O Board 4 Cable Harness Sensor 10 Compressor I O Board Cabl...

Page 52: ...nent No Component 1 Suction Pressure Temperature Sensor 8 Compressor Cooling Access Port Access Port 1 NOTE TTS300 TGS230 have only one access port 2 IGV Suction Port 9 Compressor Cooling Access Port 2 not available on TTS300 TGS230 compressors NOT SHOWN 3 PWM Amplifier 10 Motor Cooling Connection 4 BMCC 11 DC DC Converter 5 Serial Driver 12 Soft Start 6 Backplane 13 Inverter 7 Motor Cooling Solen...

Page 53: ... 9 8 6 1 2 3 4 5 7 10 11 12 13 14 No Component No Component 1 PWM Amplifier 8 Suction Pressure Temperature Sensor 2 BMCC 9 Motor Cooling Solenoids 3 Serial Driver 10 Motor Cooling Connection 4 Backplane 11 DC DC Converter 5 Compressor Cooling Access Port 12 Soft Start Board 6 IGV Suction Port 13 Inverter 7 Compressor Cooling Access Port 14 AC Mains Bus Bars ...

Page 54: ...xcludes TTH TGH Table 4 4 Compressor Components Capacitor Side Excludes TTH TGH 1 3 4 2 5 6 7 No Component No Component 1 Capacitors 5 Optional Pressure Regulating Port 2 IGV Position Indicator 6 IGV Motor Feedthrough 3 Economizer Port 7 Discharge Temperature Pressure Sensor 4 Discharge Port ...

Page 55: ...Capacitor Side TTH TGH Only 1 5 9 7 6 2 10 3 8 4 No Component No Component 1 Capacitors 6 Economizer Port 2 IGV Motor Feedthrough 7 Interstage Pipe 3 Optional Pressure Regulating Port 8 Interstage Temperature Pressure Sensor 4 Suction Temperature Pressure Sensor 9 Discharge Port 5 Suction Port 10 Interstage Temperature Pressure Sensor ...

Page 56: ... 1 Ensure that no residue remains on the contact surfaces of Mains Input Cover and Top Cover 2 Place the Mains Input Cover and secure it with the M5x15 fasteners Tighten according to the sequence shown in Figure 4 7 Mains Input Cover Torque Sequence on page 57 CAUTION Care must be taken in removal and installation of the covers to prevent the fasteners from falling in to the power electronic com p...

Page 57: ...fasteners and remove the cover 2 Remove the M5x15 fasteners that secure the Top Cover and remove the cover Top Cover Installation 1 Ensure that no residue remains on the contact surfaces of Top Cover and casting sides 2 Place the Top Cover and secure it with the M5x15 fasteners according to the sequence shown in Figure 4 8 Top Cover Follow the sequence twice The first time only tighten the fastene...

Page 58: ...n for the Backplane Serial Driver BMCC PWM feed throughs and cabling Figure 4 9 Service Side Cover 4 2 3 1 Service Side Cover Removal and Installation Service Side Cover Removal 1 Remove the M5x15 fasteners that secure the Service Side Cover and remove the cover Service Side Cover Installation 1 Ensure that no residue remains on the contact surfaces of the Service Side Cover and compressor housing...

Page 59: ...ane with the foam side up Refer to Figure 4 12 Capacitor Nylon Nuts for this and the following step 2 Install the nylon nuts to the base of the DC Capacitor Bus Bar Assembly under the main compressor housing and torque to 7 Nm 62 in lb Figure 4 12 Capacitor Nylon Nuts 3 Place the Capacitor Cover and secure it with the M5x15 fasteners from the Top Cover 4 Place the Capacitor Cover on the compressor...

Page 60: ...ording to the sequence in Figure 4 15 Capacitor Cover Torque Sequence Torque to 13 in lb on the second pass Figure 4 15 Capacitor Cover Torque Sequence 4 2 5 Compressor Cover Torque Specifications Table 4 6 Compressor Cover Torque Specifications Relief membrane should be visible when Capacitor Cover is installed Capacitor Cover Fastener M5x20 Capacitor Cover Fastener M5x15 5 places 1 5 3 2 4 6 Des...

Page 61: ...ling Adapter TTH375 TGH285 CAUTION A filter drier must be used in conjunction with the Cooling Adapter strainer is not a replacement The strainer is used as a backup to prevent damage to the solenoid orifices should any debris get past the filter drier Nut Inside thread 13 16 UN 2A 11 Nm 8 ft lb Braze Sleeve Strainer O ring Adapter Body Connection thread M16x1 5 25 Nm 18 ft lb O ring Nut Inside th...

Page 62: ...and finger tighten 4 Torque the cooling adapter body to the compressor housing to 25 Nm 18 ft lb 5 Install the screen inside the cooling adapter 6 Install the braze sleeve and nut minus the O ring Tighten the nut finger tight against the Cooling Adapter This will allow for the measurement and fitting of the liquid line Once the measuring and fitting of the liquid line has been completed unscrew th...

Page 63: ...2 Analog input to drive compressor 0 10V I LOCK Pin 3 4 Interlock safety switch must be part of a closed circuit to start compressor STATUS Pin 5 6 Output closed circuit compressor in normal operation open circuit compressor in alarm condition SPEED Pin 7 8 compressor motor speed output 0 5V 10 000 RPM volt NOTE No longer available for compressors running BMCC firmware versions CC3 0 and later D9 ...

Page 64: ...ions and Installation Manual for further information Jumpers JP5 LIQ LEV 1 JP6 LIQ LEV 2 For use with a voltage type level sensor with 15V supply and 0 5V signal Install jumpers between LVL pins 2a and 3a and Pins 2b and 3b Connect the sensor leads to the S and terminals on the Compressor I O Board consult vendor documentation for sensor lead identification For use with a resistive type float sens...

Page 65: ...o the compressor the BMCC is able to communicate with the user interface If the system is not able to connect verify The D9 green LED is on The cable connection between the Backplane port J7 and the CIM port J6 is properly attached The cable connection between the CIM at port J1 if using RS485 communication or at port J7 if using RS232 communication and the user s computer is properly attached The...

Page 66: ...rn off on the CIM 2 Remove all external connections from the CIM 3 Using a screwdriver apply leverage toward the left while lifting the right side of the CIM See Figure 4 19 Removing the Compressor Interface Module from the DIN Rail 4 Repeat the procedure for the other mounting foot to disengage the CIM from the DIN rail Figure 4 19 Removing the Compressor Interface Module from the DIN Rail 4 4 3 ...

Page 67: ...M 6 Remove the cable by grasping each connector J6 on CIM and J7 on Backplane and pulling away from the board connectors 4 5 2 2 Compressor Interface Cable Installation 1 Install the cable into the J6 connector on the CIM and the J7 connector on the Backplane 2 Tighten the connectors to secure the cable 3 Ensure the cable is routed properly and that the grommet is properly positioned in the compre...

Page 68: ...Removal and Installation on page 112 TTH TGH Compressors To Discharge Pressure Temperature Sensor To IGV Connector To Suction Pressure Temperature Sensor To Interstage Sensor To J17 on Backplane To J18 on Backplane To J19 on Backplane To J21 on Backplane All TTS TGS Rev G and Earlier Compressors All TTS TGS Rev H Compressors To SCR Temperature Sensor To Suction Pressure Temperature Sensor To IGV C...

Page 69: ... drive connector J21 Figure 4 22 Backplane Connections 7 Disconnect the cables from the suction and discharge pressure sensors Refer to Figure 4 23 Pressure Temperature and SCR Temperature Sensor Locations TTS300 TGS230 Figure 4 25 Pressure Temperature Sensors TTH375 TGH285 and Figure 4 25 Pressure Temperature Sensors TTH375 TGH285 on page 70 for this and the following step Figure 4 23 Pressure Te...

Page 70: ...gh Figure 4 26 IGV Connector Clamp 11 Remove the DC Capacitor Bus Bar Assembly Refer to 4 22 DC Capacitor Bus Bar Assembly on page 156 12 Remove the cable harness in stages so the same routing can be followed for the installation Compressor Controller Cable Harness Installation 1 Route the cable harness through the hole in the main compressor housing at the service side Refer to Figure 4 27 Cable ...

Page 71: ... 23 Pressure Temperature and SCR Temperature Sensor Locations TTS300 TGS230 on page 69 and Figure 4 25 Pressure Temperature Sensors TTH375 TGH285 for this and the following step 7 Connect the cables to the suction and discharge pressure sensors 8 Insert the molded rubber grommet in the notch in the main compressor housing 9 Install the four 4 Backplane connectors J17 J18 J19 and J21 Soft Start int...

Page 72: ...models The size can be identified by reading the number engraved into the solenoid orifice body For solenoid identification by model reference the Spare Parts Selection Guide Solenoid actuator coils are secured to the solenoids by nuts hand tightened at the back of each actuator Refer to Figure 4 29 Compressor Cooling Solenoid Coils Power is supplied to the Coils through the Backplane from the Ser...

Page 73: ...10 Solenoid Coil Resistance Ranges to find the expected resistance for the left and right Compressor Cooling Coils 6 To measure the resistance across the left Compressor Cooling Solenoid Coil place the meter probes at Pins 1 and 3 of the cable connector Refer to Figure 4 32 Compressor Cooling Solenoid Coil Cable Connector on page 74 7 To measure the resistance across the right Compressor Cooling C...

Page 74: ... present at one or both solenoid coils use a multimeter to test the back sides of pins 1 3 and pins 5 6 of the cooling solenoid coils WHILE they are energized Refer to Figure 4 32 Compressor Cooling Solenoid Coil Cable Connector Figure 4 33 Backplane Cool LEDs and 24V Test Points 4 7 3 3 Cooling Path Blockage Inspection 1 Isolate compressor power as described in Section 1 8 Electrical Isolation on...

Page 75: ...id Tube Plungers using a six point 13mm deep socket 7 Remove the O rings from the Solenoid Tube Plungers if plungers are to be reused 8 Remove the Orifice Valves using a 15 16 socket 9 Remove the two 2 O rings from the Orifice Valves if the valves are to be reused Figure 4 35 Solenoid Component Removal NOTE On current TTS350 TTS400 TTS500 TTS700 TGS310 TGS390 TGS490 TGS520 and certain TTS300 model...

Page 76: ...nce with standard industry practices 9 Install the Solenoid Coils in their proper location For split cooling models the coil positions are dedicated The right side coil can be identified by an R affixed to the coil The left side coil can be identified by an L affixed to the coil Refer to Figure 4 36 Solenoid Actuator Coil Position Figure 4 36 Solenoid Actuator Coil Position 10 Install the Beveled ...

Page 77: ...igure 4 38 Interstage Pipe Removal 4 8 1 2 Interstage Pipe Installation 1 Clean all mating surfaces 2 Obtain two 2 new O rings for the Interstage Pipe and lubricate them with O lube 3 Install the new O rings into the grooves of the Housing Extension and the Second Stage Suction Housing 4 Carefully line up the Interstage Pipe and insert a fastener into each flange 5 Install the remaining two 2 fast...

Page 78: ... 10 7 89 4 9 Compressor Housing End Cap The Compressor Housing End Cap may be removed if it is damaged or if there is a refrigerant leak between the mating surfaces There are no field serviceable components inside of the Compressor Housing End Cap After the assembly of the compressor its function is to prevent refrigerant from escaping It also contains an eyebolt to allow for installation and remo...

Page 79: ...rd the O ring 4 9 1 2 Compressor Housing End Cap Installation 1 Ensure that all components and threads are clear clean and oil free 2 Clean lubricate and install the O ring into the groove in the compressor housing 3 Carefully line up the Compressor Housing End Cap and loosely install several of the M10x40 fasteners to hold the end cap in place Refer to Figure 4 39 Compressor Housing End Cap TTS T...

Page 80: ...ial Driver in turn uses 15VDC to control the IGV stepper motor Figure 4 41 IGV Assembly 4 10 1 IGV Connections Refer to Figure 4 42 IGV Connections for the location of the IGV connections Figure 4 42 IGV Connections Table 4 14 IGV Components 2 1 3 4 5 No Component 1 The IGV assembly is bolted to the compressor housing 2 The compressor controller cable is held to the IGV Motor feed through by the c...

Page 81: ...or feed through terminals and the IGV Housing The measured value should be open or infinity Figure 4 43 IGV Motor Feedthrough 4 10 2 2 IGV Operation Verification Some of the steps contained within this section require the use of the SMT Refer to the Service Monitor Tool Manual regarding the proper usage of the SMT 1 Remove the Service Side Cover Refer to 4 2 3 1 Service Side Cover Removal and Inst...

Page 82: ...entage 100 Figure 4 48 IGV Open Percentage 100 7 On the Backplane there are four 4 LEDs that should light up when the IGV Motor is being driven Refer to Figure 4 50 Backplane Cool LEDs on page 83 Check that all four 4 LEDs are blinking D13 D14 D15 and D16 and that the IGV position indicator moves toward open Refer to Figure 4 42 IGV Connections on page 80 for the location of the IGV Position Indic...

Page 83: ...ing Assembly Removal 1 Isolate compressor power as described in Section 1 8 Electrical Isolation on page 19 2 Remove the clamp securing the IGV Connector Refer to Figure 4 52 IGV Harness Removal for this and the following step 3 Disconnect the IGV Motor Cable and Suction Sensor connector Figure 4 52 IGV Harness Removal IGV Stepper Motor LEDs Cool L Cool H LEDs 15V Test Point CAUTION Removal of the...

Page 84: ... separate the four pin Feedthrough from the IGV Housing Refer to Figure 4 54 IGV Feedthrough Removal Figure 4 54 IGV Feedthrough Removal 3 Disconnect the four 4 wires from the four pin Feed Through Note and record position of wire colors to their corresponding pins Expected 1 Red 2 Gray 3 Yellow and 4 Black Refer to Table 4 15 IGV Feedthrough Wiring Order NOTE The colors associated with each pin c...

Page 85: ...orm shaft Refer to Figure 4 56 IGV Motor Assembly Removal Support the bottom of the IGV Motor to prevent damage to the motor shaft A light tap on the motor locating screw with a hammer may help release the motor shaft from the worm gear Figure 4 56 IGV Motor Assembly Removal 7 Slide the Locking Collar Tool P N 100246 into the housing and over the worm shaft Ensure the drive pins are engaged in the...

Page 86: ...m Gear Removal Figure 4 59 Worm Gear Removal 10 Remove the snap ring from the worm gear shaft Refer to Figure 4 60 Large Worm Gear Bearing Removal for this and the following step 11 Remove the upper large bearing from the worm gear Figure 4 60 Large Worm Gear Bearing Removal 12 Remove the four 4 M6x55 fasteners that retain the IGV Throat assembly and lift the entire assembly from the IGV Housing R...

Page 87: ...n 1 Ensure that all components and threads are clear clean and oil free 2 Install the lower small worm gear bearing into the housing This may require a very light tap with a hammer Ensure the lower worm gear bearing is fully seated into the housing Refer to Figure 4 63 Small Worm Gear Bearing Installation Figure 4 63 Small Worm Gear Bearing Installation IGV Throat M6x55 fastener 4 places IGV Throa...

Page 88: ... fully closed 7 Fit the upper large bearing to the worm gear and install the snap ring Refer to Figure 4 65 Large Worm Gear Bearing Installation Figure 4 65 Large Worm Gear Bearing Installation 8 Install the worm gear into the housing by screwing the worm gear along the IGV Throat Gear Locate the worm gear shaft into the bottom small bearing 9 Place the threaded Locking Collar on the four 4 pins o...

Page 89: ...position of the flat surface of the shaft relative to the locating pin The flat surface should be oriented facing up ready to be inserted in the worm gear Refer to Figure 4 68 Shaft Position Figure 4 68 Shaft Position 14 Install the motor into the housing and align the motor shaft flat surface with worm gear adapter 15 Ensure the motor locating pin is aligned with the notch in the housing flange R...

Page 90: ...ar Alignment on page 89 17 Clean lubricate and install the O ring on the Feed Through before connecting the wires 18 Insert the motor wires onto the Feed Through pins in accordance with Table 4 16 IGV Feedthrough Pin to Wire Reference Also reference your notes from removal NOTE The colors associated with each pin could vary so be sure to refer to notes taken during removal Table 4 16 IGV Feedthrou...

Page 91: ...r Operation of the IGV can also be tested using the SMT driving the IGV manually once the IGV has been mounted on the compressor 22 Clean the mating surfaces of both the compressor and IGV 23 Clean lubricate and install the IGV Housing O ring 24 Re install the IGV on the compressor and finger tighten the fasteners 25 Tighten the fasteners in a crisscross pattern to 22 Nm 16 ft lb Figure 4 73 IGV H...

Page 92: ...proper operation and movement of the IGV assembly Refer to Figure 4 74 IGV Position Indicator to verify the position of the IGV Figure 4 74 IGV Position Indicator 4 10 4 IGV Torque Specifications Table 4 17 IGV Torque Specifications NOTE All IGV assemblies are fully open when the Position Indicator is in the top position Description Nm Ft Lb In Lb IGV Housing Fastener M10x40 22 16 195 IGV Feedthro...

Page 93: ...1 1 Mains Plate Bracket Removal 1 Isolate compressor power as described in Section 1 8 Electrical Isolation on page 19 2 Disconnect the mains input cables from the Terminal Block 3 Disconnect the main input ground cable and Soft Start ground wire from the ground post 4 Remove the cable gland that secures the mains input cable conduit to the Mains Plate 5 Remove the two 2 M6x16 fasteners that secur...

Page 94: ...TS TGS TTH TGH Rev H and Earlier Except TTS300 TGS230 Figure 4 77 Mains Input Nut Installation TTS300 TGS230 Compressors Figure 4 78 Mains Input Nut Installation TTS TGS TTH TGH Rev H and Earlier Except TTS300 TGS230 NOTE The TTS300 TGS230 series compressors do not utilize cable lugs Because of this torque specifications will vary depending on the type of cabling it is recommended to contact the m...

Page 95: ... series and another for all other TTS TGS TTH TGH series With the introduction of Revision H compressors all compressors except for the TTS300 TGS230 compressors have an upgraded Terminal Block design Refer to Figure 4 79 Input Terminal Block TTS300 TGS230 for TTS300 TGS230 compressors For all other compressors that are Revision G and earlier refer to Figure 4 81 Input Terminal Block TTS TGS TTH T...

Page 96: ...approved components in circuit with code compliant protection DANGER This equipment contains hazardous voltages that can cause injury or death Exercise extreme caution when working on energized circuits Always wear safety glasses when working around components energized by high voltage Faulty components can explode and cause serious eye injuries 4 12 1 2 Connecting the AC Input Cable 1 Isolate com...

Page 97: ...ls Repeat on load side of the fuses TT300 TG230 only Figure 4 82 Measuring the 3 Phase AC Input Voltage on the AC Input Terminals TTS300 TGS230 Figure 4 83 Measuring 3 Phase AC Input Voltage on AC Input Terminals TTS TGS TTH TGH Except TTS300 TGS230 4 Verify that the meter shows the expected AC measurement within the range as indicated in Table 4 19 Expected AC Voltage Range on page 98 The accepta...

Page 98: ...30 1 Remove the three 3 M6x16 fasteners that connect the Fast Acting Fuses to the SCRs Refer to Figure 4 84 Terminal Block Removal TTS300 TGS230 for this and the following four 4 steps 2 Remove the six 6 Fuse to Terminal Block fasteners that secure the fuses to the Terminal Block Adapter 3 Remove the fuses 4 Remove the insulating Mylar 5 Remove the Terminal Block fasteners that secure the Terminal...

Page 99: ... as an assembly On Rev H compressors the center AC Bus Bar must be removed to access a mounting fastener for the terminal block but the two 2 bus bars can remain attached 5 Remove the fasteners that secure the Terminal Block to the casting and remove the Terminal Block a Rev F and ealier compressors use two 2 M5x45 fasteners that attach the Terminal Block to the compressor housing b Rev H compress...

Page 100: ...x 16 3 places Terminal Block AC Bus Bar to Terminal Block Fastener M5x12 6 places Terminal Block to Compressor Fastener M5x45 2 places AC Bus Bar to SCR Fastener M8x20 3 places Terminal Block to SCR Cooling Plate Fastener M6x16 2 places Fuse Assembly AC Bus Bar to SCR Fastener M6x16 5 Nm 44 in lb 3 places Fuse Assembly to Terminal Block Fastener 6 places Mylar Fuse AC Bus Bar to SCR Terminal Block...

Page 101: ...ue to 20 Nm 15 ft lb Refer to Figure 4 88 Terminal Block Input Pressure Screws TTS300 TGS230 Figure 4 88 Terminal Block Input Pressure Screws TTS300 TGS230 7 Continue to Section 4 12 2 6 General 3 Phase Main Voltage Input Terminal Block Installation on page 102 4 12 2 5 3 Phase Main Input Terminal Block Installation TTH TGH TTH TGH Except TTS300 TGS230 Figure 4 89 Input Terminal Block Installation...

Page 102: ...torque the six 6 fasteners to 3 Nm 27 in lb and the three 3 M8x20 AC Bus Bar Fastners to 9 Nm 80 in lb b For Rev H compressors torque the six 6 M5x12 fastners to 2Nm 17 in lb and the three 3 M6x16 AC Bus Bars to SCR fasteners to 5 Nm 44 in lb 4 Reconnect the three 3 terminals of the Soft Start cable harness to the AC Bus Bars 5 Install the mains input cables to the Terminal Block and torque to 21 ...

Page 103: ...cure the AC Bus Bars to the SCRs Description Nm Ft Lb In Lb TTS300 TGS230 AC Bus Bar to SCR fastener M6x16 5 44 TTS300 TGS230 Terminal Block Mounting fastener M5x15 3 27 TTS300 TGS230 Fuse Assembly to Terminal Block fastener 4 35 AC Bus Bar to Terminal Block fastener Rev F and earlier excludes TTS300 TGS230 compressors 3 27 AC Bus Bar to Terminal Block fastener Rev H excludes TTS300 TGS230 compres...

Page 104: ...gure 4 92 AC DC Bus Bus Bar Connectors TTS TGS TTH TGS Rev F and earlier Except TTS300 TGH230 Figure 4 93 AC DC Bus Bus Bar Connectors TTS TGS TTH TGS Rev H Except TTS300 TGH230 4 13 2 2 Input Mains Bus Bar Installation 1 For Revision F and ealier compressors refer to Figure 4 92 AC DC Bus Bus Bar Connectors TTS TGS TTH TGS Rev F and earlier Except TTS300 TGH230 and do the following a Place the AC...

Page 105: ...stall the top covers Refer to 4 2 Compressor Covers on page 56 5 Return the compressor to normal operation 4 13 2 3 AC Bus Bar Torque Specifications Table 4 21 AC Bus Bar Torque Specifications Description Nm Ft Lb In Lb AC Bus Bar to Terminal Block fastener Rev F and earlier excludes TTS300 TGS230 compressors 3 27 AC Bus Bar to Terminal Block fastener Rev H excludes TTS300 TGS230 compressors 2 17 ...

Page 106: ...ck Fuse Removal 1 Isolate the compressor power as described in Section 1 8 Electrical Isolation on page 19 2 Remove the 5 16 18 fastener on the line side of the fuse 3 Remove the 5 16 18 nut from the load side of the fuse 4 Remove the fuse Figure 4 96 Terminal Block Fuse Removal 00 0Ω Multimeter Load Side A C Input Side Fuse Retaining Nut Load Side 5 16 3 places Fuse Retaining Fastener Input Side ...

Page 107: ... with Revision H compressors the Open Top Soft Start was introduced There is a significant visual difference between the two 2 variants refer to Figure 4 97 Soft Start Variants on page 107 for the visual differences The Rev A Open Top Soft Starts can handle all input voltages where as there are distinct versions of the Closed Top Soft Starts to handle specific voltages If a Closed Top Soft Start m...

Page 108: ...startup stage After DC bus voltage is built up it starts powering the DC DC converter Both PTCs in the AC input path and blocking diodes in DC input path protect the high power side electronics from the low power control side In addition to monitoring AC mains voltage and the HV DC bus the Open Top Soft Start also provides an onboard temperature sensor varistors and EMI filters for system protecti...

Page 109: ...harness refer to 1 10 DC Bus Test Harness Installation and Removal on page 22 with power applied to the compressor verify that the expected DC bus voltage is present for the application Refer to Table 1 3 Expected DC Bus Voltage on page 25 No DC voltage may indicate that the Soft Start is not controlling the SCRs 3 Using the DC bus test harness with power applied to the compressor verify that the ...

Page 110: ...arts The Soft Start part numbers and revisions are identified by a label on the side of the Soft Start mounting bracket The Soft Start revision follows immediately after the 6 digit part number Refer to Figure 4 100 Soft Start Label Location for details on the location of the label and the revision indicator Figure 4 100 Soft Start Label Location Label Location 220137T10986 Part Number Revision Le...

Page 111: ...urements place the leads on the ends of the F2 Nano fuse The reading should be less than 1Ω An open F2 fuse may indicate a problem with the DC DC 6 Using a multimeter set for resistance measurements place the leads on the ends of the F3 Nano fuse The reading should be less than 1Ω An open F3 fuse may indicate a problem with the Soft Start Circuit Board 7 Using a multimeter set for resistance measu...

Page 112: ...orceps to replace them 10 Install the Soft Start Refer to 4 15 6 Soft Start Installation Closed Top on page 116 11 Install the top covers Refer to 4 2 Compressor Covers on page 56 12 Return the compressor back to normal operation 4 15 3 Soft Start Removal and Installation This section covers the direct replacement of a Soft Start i e Open Top Soft Start to Open Top Soft Start or Closed Top Soft St...

Page 113: ... for all TTS TGS TTH TGH compressors 4 Remove the M5x15 fasteners that secure the Soft Start mounting bracket to the compressor Refer to Figure 4 104 Closed Top Soft Start Figure 4 104 Closed Top Soft Start 5 Lift the Soft Start and turn it over placing it board side up on the AC Bus Bars Refer to Figure 4 105 Soft Start Lift Figure 4 105 Soft Start Lift 6 Unplug cable connectors J1 J7 and J8 from...

Page 114: ...on page 19 2 Remove the Soft Start Temperature Harness Refer to Figure 4 107 Open Top Soft Start J7 Connector Figure 4 107 Open Top Soft Start J7 Connector 3 Disconnect the Soft Start ground wire by removing the nut and mains input ground wire from the ground post on the compressor housing at 3 phase connection point Refer to Figure 4 108 Ground Location Figure 4 108 Ground Location J8 J7 J1 J7 Co...

Page 115: ...sors 4 Unplug cable connectors J1 J2 and J8 from the Soft Start Figure 4 109 Open Top Soft Start Connector Removal 5 Remove the M5x20 fasteners that secure the Soft Start mounting bracket to the compressor Refer to Figure 4 110 Open Top Soft Start Removal Figure 4 110 Open Top Soft Start Removal 6 Remove the Soft Start assembly and place it in a safe location J2 J1 J8 Soft Start Fastener M5x20 4 p...

Page 116: ...ation 5 Install the J9 Soft Start Temperature Sensor connector Refer to Figure 4 102 Closed Top Soft Start J9 Connector on page 112 6 Connect the Soft Start ground wire and mains input ground wire onto the ground post on the compressor housing and install the spring washer and nut then torque the top nut to 7 Nm 62 in lb Figure 4 112 Ground Stud Location 7 Install the top covers Refer to 4 2 Compr...

Page 117: ...ired Refer to the specific spare part kit instructions for adapter board usage CAUTION Use of the adapter board on Open Top Soft Starts and on Soft Starts with revision Q and later may cause the fan not to start lead ing to Soft Start over temperature faults Not incorporating the adapter board on Soft Starts with revision P and earlier will cause premature failure of the Soft Start Fan Refer to th...

Page 118: ...r of the fan and will no longer be visible When the adapter boards are used the arrows will only be visible from the bottom side of the Soft Start Figure 4 115 Soft Start Fan Orientation 2 Install the four 4 fasteners to secure the fan and adapter board if equiped to the Soft Start and torque to 6 in lb Refer to Figure 4 116 Soft Start Fan Installation Figure 4 116 Soft Start Fan Installation Soft...

Page 119: ... Start fastener M5x15 or M5x20 5 44 Soft Start Fan fastener M5x35 6 Upper Nut 5 16 18 UNC 7 62 Jam Nut 5 16 18 UNC 7 62 Lower Nut 5 16 18 UNC 20 15 177 Cover fastener M5x15 13 4 16 SCR DC Bus Bar TTS300 TGS230 The SCR DC Bus Bars pass the DC voltage from the output of the SCRs to the DC Capacitor Bus Bar Assembly This procedure does not show the removal of the Soft Start since it is not required H...

Page 120: ...ar should be next to the SCR Gate pins aligned with the holes identified as 3 on the SCRs Refer to Figure 4 120 SCR DC Bus Bar to SCR Alignment for this and the following step Figure 4 120 SCR DC Bus Bar to SCR Alignment 2 Install the positive bus bar beside the negative bus bar aligned with holes identified as 2 on the diodes 3 The curved section of the bus bar should be installed upwards 4 Inser...

Page 121: ...21 Soft Start SCR Gate Cable Closed Top Soft Starts Figure 4 122 Soft Start SCR Gate Cable Open Top Soft Starts 4 17 2 Soft Start SCR Gate Cable Removal and Installation 4 17 2 1 Soft Start SCR Gate Cable Removal 1 Isolate the compressor power as described in Section 1 8 Electrical Isolation on page 19 2 Remove the six 6 Soft Start SCR Gate Cable connectors from the SCRs This may require the use o...

Page 122: ...123 Soft Start SCR Gate Cable Removal TTS300 TGS230 Figure 4 124 Soft Start SCR Gate Cable Removal at SCR TTS TGS TTH TGH Models Rev F and Earlier Except TTS300 TGS230 Figure 4 125 Soft Start SCR Gate Cable Removal at SCR TTS TGS TTH TGH Models Rev H Except TTS300 TGS230 SCR Gate Connectors 3 places Soft Start J8 Connector SCR Gate Connectors 3 places Soft Start J8 Connector Soft Start J2 Connecto...

Page 123: ...4 126 Closed Top Soft Start J8 Connector Top b For compressors with the Open Top Soft Start install the J2 connector Figure 4 127 Open Top Soft Start J2 Connector 2 Once the Cable Harness has been installed onto the Soft Start the cable should be routed toward the SCRs 3 Plug each pigtail into its respective SCR making sure you line up the key on the pigtail connector to the key of the SCR itself ...

Page 124: ...arnesses The installed harness will vary depending on the style of DC DC Soft Start and compressor model and revision The following steps provide detail on how to replace the Soft Start AC DC Harness It is not possible to illustrate all of the harness variations but the major differences that impact removal and installation are described in this manual Please refer to the Spare Parts Selection Gui...

Page 125: ...rbocor Compressors Inc Whole numbers One decimal place Two decimal places Angular Radius Chamfer 3 Radius Chamfer 3 Roughness Ra µm 0 5 0 1 0 05 1 0 2 0 5 Front view Scale 1 1 PERMANENTLY MARK OR LABEL DC PERMANENTLY MARK OR LABEL DC PERMANENTLY MARK OR LABEL DC PERMANENTLY MARK OR LABEL DC PERMANENTLY MARK OR LABEL L1 900649 SEE TABLE 1 L1 FOR CONNECTIONS PERMANENTLY MARK OR LABEL L3 900649 SEE T...

Page 126: ...30 J1 High Voltage AC DC Connector J1 Connector J4 Connector L1 L2 and L3 Spade Terminals 3 places J7 DC DC Trigger Signal Connector DC and DC Spade Terminals For use with potted DC DC For use with Rev H compressors L1 L2 and L3 Ring Terminals 3 places DC and DC Spade Terminals J1 Connector J8 DC Link J1 AC Inputs ...

Page 127: ... 2 DC ring terminals from the DC bus bar by removing the attaching hardware Refer to Figure 4 132 DC Ring Terminal Removal TTS300 TGS230 for this and the following step 4 Disconnect the DC ring terminal from the DC bus bar by removing the attaching hardware Figure 4 132 DC Ring Terminal Removal TTS300 TGS230 5 Remove the DC DC Connections If the DC DC is the potted style remove connectors J1 and J...

Page 128: ...f equiped connector Refer to Figure 4 135 Closed Top Soft Start J1 and J7 Removal NOTE Compressors utilizing the open frame DC DC design do not utilize the J7 Trigger Signal connector b For compressors with the Open Top Soft Start remove connectors J1 and J8 Refer to Figure 4 136 Open Top Soft Start J1 and J8 Removal on page 129 Figure 4 135 Closed Top Soft Start J1 and J7 Removal J3 24VDC J2 250V...

Page 129: ...compressors refer to Figure 4 138 AC Input Ring and DC Spade Connector Removal TTS TGS TTH TGH Rev H Except TTS300 TGS230 on page 130 3 Disconnect the DC and DC spade terminals from the DC bus bar a For Revision F and earlier compressors refer to Figure 4 137 AC Input Spade and DC Spade Connector Removal TTS TGS TTH TGH Rev F and Earlier Except TTS300 TGS230 b For Rev H compressors refer to Figure...

Page 130: ...n page 127 5 Remove the Soft Start AC DC Harness from the Soft Start a For compressors with the Closed Top Soft Start remove the J1 and J7 if equiped connector Refer to Figure 4 135 Closed Top Soft Start J1 and J7 Removal on page 128 NOTE Compressors utilizing the open frame DC DC design do not utilize the J7 Trigger Signal connector b For compressors with the Open Top Soft Start remove connectors...

Page 131: ...C DC connector to the DC DC Converter Refer to Figure 4 133 DC DC Connectors Open Frame on page 127 if this compressor contains the Open Frame DC DC Converter or to Figure 4 134 DC DC Connectors Potted on page 128 if this is a Potted DC DC Converter 8 If the DC DC Converter is the potted style install the J4 connector to the DC DC Converter Refer to Figure 4 134 DC DC Connectors Potted on page 128...

Page 132: ...Input and Spade Connector Installation TTS TGS TTH TGH Rev F and Earlier Except TTS300 TGS230 b For Rev H compressors refer to Figure 4 141 AC Input and Spade Connector Installation TTS TGS TTH TGH Rev H Except TTS300 TGS230 on page 133 5 Install the L1 L2 and L3 terminals from the AC Bus Bars a For Revision F and earlier compressors refer to Figure 4 140 AC Input and Spade Connector Installation ...

Page 133: ...th the AC input voltage and the DC voltage output from the SCRs the Soft Start Board generates the gate signal and outputs pulses of 0 12VDC to the SCRs to control the in rush current when power is initially applied to the compressor This is used at compressor start up while the DC capacitors are charging up The DC bus voltage output from the SCRs is approximately 1 35 times that of the AC input v...

Page 134: ...GS230 on page 135 to locate the following connections to the SCRs AC input to SCR SCR Gate cables to Soft Start SCR to DC bus Figure 4 143 SCR Connections TTS300 TGS230 TTS300 TGS230 all revisions TTS TGS TGH Series Rev H Two Hole Mount All TTS TGS TTH TGH Series compressors except TTS300 TGS230 Rev F and earlier Four Hole Mount SCR to DC Bus and SCR Gate Cables to Soft Start 3 places AC Input to ...

Page 135: ...igure 4 146 SCR Terminals Two Hole Mount on page 136 and Figure 4 147 SCR Terminals Four Hole Mount on page 136 for terminal locations 4 Perform this test for each SCR 5 Install the DC Bus Bars to the SCRs Refer to 4 22 3 DC Capacitor Bus Bar Assembly Removal and Installation on page 158 6 Install the top covers Refer to 4 2 Compressor Covers on page 56 7 Return the compressor to normal operation ...

Page 136: ... Perform this test for each SCR 6 Using a multimeter set for diode measurements place the black lead on terminal 1 of the SCR and place the red lead on terminal 3 The measured value should be between 0 3V and 0 45V Refer to Figure 4 146 SCR Terminals Two Hole Mount and Figure 4 147 SCR Terminals Four Hole Mount for terminal locations 7 Install the Capacitor and DC Bus Assembly and verify the SCR T...

Page 137: ...le 4 30 SCR Gate Resistance Ranges 4 19 2 4 SCR Temperature Sensor This section applies to TTS TGS Revision G and earlier compressors only The TTS TGS Revision H and TTH compressors do not utilize an SCR Temperature Sensor Figure 4 148 SCR Temperature Sensor Assembly 4 19 2 5 SCR Temperature Sensor Verification 1 Isolate the compressor power as described Section 1 8 Electrical Isolation on page 19...

Page 138: ... Removal TTS300 TGS230 1 If desired remove the discharge pressure temperature sensor connector Refer to 4 33 4 Pressure Temperature Sensor Removal and Installation on page 236 Figure 4 150 Discharge Pressure Temperature Sensor Connector Removal TTS300 TGS230 2 Remove the Terminal Block Refer to 4 12 2 2 Specific 3 Phase Main Voltage Input Terminal Block Removal TTS300 TGS230 on page 98 3 Disconnec...

Page 139: ...e from under the DC Bus Bar Assembly from the discharge side of the compressor Refer to Figure 4 153 SCR Temperature Sensor Connector TTS TGS TTH TGH Rev F and Earlier Except TTS300 TGS230 Figure 4 153 SCR Temperature Sensor Connector TTS TGS TTH TGH Rev F and Earlier Except TTS300 TGS230 5 If desired remove the discharge pressure temperature sensor connector Figure 4 154 Discharge Pressure Temper...

Page 140: ...re Sensor into the SCR Cooling Manifold and torque to 6 Nm 53 in lbs 2 Connect the discharge pressure temperature sensor connector if it was removed 3 Install the SCR Temperature Sensor Cable in the same location It should be on top of the SCR Cooling Manifold and next to the Inverter Refer to Figure 4 153 SCR Temperature Sensor Connector TTS TGS TTH TGH Rev F and Earlier Except TTS300 TGS230 on p...

Page 141: ... for this and the following four 4 steps 2 For Remove the three 3 fasteners that connect the Fast Acting Fuses to the SCRs 3 Remove the six 6 Fuse to Terminal Block fasteners that secure the fuses to the Terminal Block Adapter 4 Remove the fuses 5 Remove the insulating Mylar Description Nm Ft Lb In Lb TTS300 TGS230 AC Bus Bar to SCR fastener M6x16 5 44 TTS300 TGS230 Fuse to Terminal Block fastener...

Page 142: ... six 6 M6x16 fasteners that secure the and SCR Bus Bars to the SCRs 8 Remove the DC Bus Bars Figure 4 157 DC Bus Bar Removal TTS300 TGS230 9 Remove the two 2 M6x16 fasteners that secure each SCR to the SCR Cooling Manifold and remove the SCRs Figure 4 158 SCR Removal TTS300 TGS230 on page 143 for this and the following step AC Bus Bar to SCR Fastener M6x16 3 places Fuse to Terminal Block Fastener ...

Page 143: ...efer to Figure 4 159 SCR Gate Cable and AC DC Harness Connections TTS TGS TTH TGH Rev F and Earlier Except TTS300 TGS230 and Figure 4 160 SCR Gate Cable and AC DC Harness Connections TTS TGS TTH TGH Rev H Except TTS300 TGS230 on page 144 Figure 4 159 SCR Gate Cable and AC DC Harness Connections TTS TGS TTH TGH Rev F and Earlier Except TTS300 TGS230 Terminal Block SCR Cooling Manifold SCR to SCR Co...

Page 144: ...Bar from the SCRs a For Revision F and earlier compressors remove the six 6 M8x20 DC Bus fasteners from the SCRs Refer to Figure 4 161 SCR Bus Fastener Removal TTS TGS TTH TGH Rev F and Earlier Except TTS300 TGS230 b For Revision H compressors remove the six 6 M6x16 DC Bus fasteners from the SCRs Refer to Figure 4 162 SCR Bus Fastener Removal TTS TGS TTH TGH Rev H Except TTS300 TGS230 Figure 4 161...

Page 145: ... to Figure 4 163 SCR Removal TTS TGS TTH TGH Rev F and Earlier Except TTS300 TGS230 b For Revision H compressors remove the two 2 M6x16 fasteners that secure each SCR to the SCR Cooling Manifold and remove the SCRs Figure 4 163 SCR Removal TTS TGS TTH TGH Rev F and Earlier Except TTS300 TGS230 Figure 4 164 SCR Removal TTS TGS TTH TGH Rev H Except TTS300 TGS230 Capacitor DC Bus Bar to SCR Fastener ...

Page 146: ...anifold fasteners Figure 4 166 SCR Orientation TTS300 TGS230 5 Place the negative bus bar on the SCRs The negative bus bar should be next to the SCR Gate Connectors aligned with the holes identified as 3 on the SCRs Refer to Figure 4 167 Bus Bar Installation TTS300 TGS230 and Figure 4 168 Bus Bar Locations TTS300 TGS230 6 Install the positive bus bar beside the negative bus bar aligned with holes ...

Page 147: ... Block Adapter then install the two 2 fasteners for each of the three 3 fuse block assemblies and torque to 4 Nm 35 in lb 14 Install the three 3 M6x16 fasteners that connect the Fast Acting Fuses to the SCRs and torque to 5 Nm 44 in lb 15 Install the mains input cables to the Terminal Block and torque to 20 Nm 15 ft lb 16 Continue to Section 4 19 3 6 SCR General Installation on page 149 SCR Bus Ba...

Page 148: ...ten to 2 Nm 18 in lb Stage 2 Tighten to a final torque of 5 Nm 44 in lb b For Revision H compressors tighten the six 6 M6x16 fasteners to 5 Nm 44 in lb Figure 4 170 SCR Torque Sequence TTS TGS TTH TGH Rev F and Earlier Except TTS300 TGS230 4 Position the DC Bus Bar and Capacitor Assembly into place 5 Loosely install the Snubber Capacitors to the Inverter noting the leg orientation 6 Loosely instal...

Page 149: ...SCR Bus Bar Bolt M6 10 7 89 SCR to SCR Cooling Manifold fastener M6x16 5 44 SCR to SCR Cooling Manifold fastener M6x16 Rev H excluding TTS300 TGS230 5 44 TTS300 TGS230 Fuse to Terminal Block fastener 4 35 Soft Start Mounting fastener M5X15 5 44 Ground Post Top Nut 5 16 18 UNC 10 7 89 Ground Post Second Jam Nut 5 16 18 UNC 7 62 Cover fastener M5x15 13 Snubber Capacitor fastener M6x16 7 62 Nylon Cap...

Page 150: ...old Removal TTS TGS TTH TGH Except TTS300 TGS230 on page 151 4 20 2 SCR Cooling Manifold Removal TTS300 TGS230 1 Remove the Fuses Refer to 4 12 2 2 Specific 3 Phase Main Voltage Input Terminal Block Removal TTS300 TGS230 on page 98 2 If the SCR Cooling Manifold is to be replaced remove the SCR Bus Bars Refer to 4 16 1 SCR DC Bus Bar Removal and Installation on page 120 3 Remove the SCRs Refer to 4...

Page 151: ... Voltage Input Terminal Block Removal and Installation on page 98 9 Remove the DC Bus Bars and Capacitor Assembly Refer to 4 22 3 DC Capacitor Bus Bar Assembly Removal and Installation on page 158 10 If the SCR Cooling Manifold is to be replaced remove the SCRs Refer to 4 19 3 3 SCR Removal TTS TGS TTH TGH Except TTS300 TGS230 on page 143 11 Remove the four 4 M6x35 SCR Cooling Manifold fasteners t...

Page 152: ...m into the SCR cooling manifold Refer to Figure 4 175 SCR Cooling Plate O ring Installation TTS300 TGS230 Figure 4 175 SCR Cooling Plate O ring Installation TTS300 TGS230 4 Install the SCR Cooling Manifold to the Inverter Cooling Manifold using the two 2 M6x20 fasteners Torque to 7 Nm 62 in lb 5 Secure the insulation onto the backside of the SCR Cooling Manifold 6 Install the Inverter NOTE It is r...

Page 153: ... 2 Apply O Lube to a new Inverter Heat Sink O ring and place in the O ring grove in the Inverter Heat Sink Plate and install Refer to Figure 4 176 Inverter Heat Sink Plate O ring Installation TTS TGS TTH TGH Except TTS300 TGS230 Figure 4 176 Inverter Heat Sink Plate O ring Installation TTS TGS TTH TGH Except TTS300 TGS230 3 Clean the O ring grooves in the SCR Manifold Return Brass Fitting with a l...

Page 154: ...citor assembly over the Inverter Refer to 4 22 3 DC Capacitor Bus Bar Assembly Removal and Installation on page 158 11 Install the Terminal Block Assembly Refer to 4 12 2 5 3 Phase Main Input Terminal Block Installation TTH TGH TTH TGH Except TTS300 TGS230 on page 101 12 Install the mains input cables to the Terminal Block and torque to 21 Nm 15 ft lb 4 20 6 SCR Cooling Manifold General Installati...

Page 155: ...er M5X15 5 44 Ground Post Top Nut 5 16 18 UNC 10 7 89 Ground Post Second Jam Nut 5 16 18 UNC 7 62 Cover fastener M5x15 13 Snubber Capacitor fastener M6x16 7 62 Nylon Capacitor Nuts 7 62 Terminal Block Mounting fastener M5x45 Excludes TTS300 TGS230 compressors 4 35 AC Bus Bar to SCR fastener M8x20 Excludes TTS300 TGS230 compressors 9 80 Capacitor DC Bus Bar to SCR fastener M8x20 Excludes TTS300 TGS...

Page 156: ... Except TTS300 TGS230 on page 157 The SCRs output DC voltage to the bus bars The DC capacitors serve as energy storage and filter out the voltage ripple associated with the operation of the rectifier circuit and any voltage unbalance in the 3 phase supply The Snubber Capacitors reduce noise associated with the Inverter switching frequency The Bleed Resistors are used to discharge the capacitors af...

Page 157: ... Cable Harness to DC Bus for the location of the connections listed below 1 DC to Soft Start 2 DC to Soft Start and DC DC 3 DC bus to Inverter Figure 4 181 Soft Start Cable Harness to DC Bus Snubber Capacitors 3 places Bus Bar Balance Board DC Capacitors 4 places DC DC All Revision H Compressors Except TTS300 TGS230 DC DC TTS300 TGS230 DC DC All Pre Revision H Compressors Except TTS300 TGS230 ...

Page 158: ...al 2 Remove the Soft Start Refer to 4 15 Soft Start on page 107 3 Remove the Snubber Capacitors Refer to Figure 4 183 Snubber Capacitor Removal TTS300 TGS230 on page 159 4 Using a multimeter set for capacitance measurement place the leads on the capacitor terminals The measured value should be 0 42μF to 0 52μF 4 22 3 DC Capacitor Bus Bar Assembly Removal and Installation CAUTION The DC Bus Capacit...

Page 159: ...re 4 183 Snubber Capacitor Removal TTS300 TGS230 4 Remove the nylon nuts at the base of the DC Capacitor Bus Bar Assembly under the main compressor housing Refer to Figure 4 184 Capacitor Nut Removal TTS300 TGS230 Figure 4 184 Capacitor Nut Removal TTS300 TGS230 Soft Start DC DC to DC Bus Bolt Nut M6 SCR DC Bus Bars SCR DC Bus Bar Fastener M6x16 6 places DC Capacitor Bus Bar to SCR DC Bus Bar Bolt...

Page 160: ... Installation TTS300 TGS230 on page 163 4 22 4 2 DC Capacitor Bus Bar Assembly Removal TTS TGS TTH TGH Except TTS300 TGS230 7 Remove the six 6 DC bus fasteners from the SCRs Refer to Figure 4 186 SCR Bus Bar Removal TTS TGS TTH TGH Rev F and Earlier Except TTS300 TGS230 or Figure 4 187 SCR Bus Bar Removal TTS TGS TTH TGH Rev H Except TTS300 TGS230 on page 161 Figure 4 186 SCR Bus Bar Removal TTS T...

Page 161: ...300 TGS230 Figure 4 188 Snubber Capacitor Removal TTS TGS TTH TGH Except TTS300 TGS230 9 Remove the nylon nuts at the base of the DC Capacitor Bus Bar Assembly under the main compressor housing Refer to Figure 4 189 Capacitor Nut Removal TTS TGS TTH TGH Except TTS300 TGS230 Figure 4 189 Capacitor Nut Removal TTS TGS TTH TGH Except TTS300 TGS230 Capacitor DC Bus Bar to SCR Fastener M6x16 6 places S...

Page 162: ...bars Refer to Figure 4 190 Capacitor Assembly Removal TTS TGS TTH TGH Rev F and Earlier Except TTS300 TGS230 and Figure 4 191 Capacitor Assembly Removal TTS TGS TTH TGH Rev H Except TTS300 TGS230 Figure 4 190 Capacitor Assembly Removal TTS TGS TTH TGH Rev F and Earlier Except TTS300 TGS230 Figure 4 191 Capacitor Assembly Removal TTS TGS TTH TGH Rev H Except TTS300 TGS230 ...

Page 163: ...he DC Capacitor Bus Bar Assembly and torque to 7 Nm 62 in lb Refer to Figure 4 184 Capacitor Nut Removal TTS300 TGS230 on page 159 10 Connect the SCR Gate cable harness to the SCRs noting its orientation Refer to Figure 4 143 SCR Connections TTS300 TGS230 on page 134 11 Continue to 4 22 5 DC Capacitor Bus Bar Assembly General Installation Steps 4 22 4 4 DC Capacitor Bus Bar Assembly Installation T...

Page 164: ...R fastener M8x20 Excludes TTS300 TGS230 compressors 9 80 Terminal Block Mounting fastener M5x45 Excludes TTS300 TGS230 compressors 4 35 Capacitor DC Bus Bar to SCR fastener M8x20 Excludes TTS300 TGS230 compressors 9 80 Mains Input Pressure Screw 11 16 16 UNC TTS300 TGS230 compressors only 20 15 177 Mains Input Nut 3 8 16 UNC excludes TTS300 TGS230 compressors 21 15 186 Snubber Capacitor fastener M...

Page 165: ...ter Connections 4 23 2 Inverter Verification This procedure only verifies the Inverter diodes The Inverter Control Board cannot be verified in the field unless an inverter tester is used A faulty Inverter may also appear as an Inverter Error fault 4 23 2 1 Inverter Verification 1 Isolate the compressor power as described in Section 1 8 Electrical Isolation on page 19 2 Remove the Soft Start Module...

Page 166: ...rminal place the red multimeter lead on the DC terminal The measured value should be 0 275V 0 4V 10 Repeat Steps 6 through 9 for the remaining Inverter phases Figure 4 193 Inverter Diode Measurements Skiip 613 Shown 4 23 3 Inverter Cable Harness Figure 4 194 Inverter Cable Harness 4 23 4 Inverter Cable Harness Removal and Installation 4 23 4 1 Inverter Cable Harness Removal 1 Isolate the compresso...

Page 167: ... are no bent or broken pin connectors 8 Remove the Inverter Cable Harness ground connection from the Backplane Refer to Figure 4 196 Harness Removal from Backplane Figure 4 196 Harness Removal from Backplane 9 Cut any cable ties securing the Inverter Cable Harness and pull through the compressor housing passage 4 23 5 Inverter Cable Harness Installation 1 Insert the Inverter Cable Harness through ...

Page 168: ...e Specifications Table 4 35 Inverter Cable Harness Torque Specifications 4 23 6 Inverter Removal and Installation General Removal 1 Isolate compressor power as described in Section 1 8 Electrical Isolation on page 19 2 Isolate the compressor and recover the refrigerant according to industry standards Refer to 3 1 Refrigerant Containment on page 41 3 Disconnect the mains input wires from the Termin...

Page 169: ...blies TTS300 TGS230 for this and the following two 2 steps 3 Remove the two 2 fasteners from each of the three 3 fuse block assemblies 4 Remove the fuse assemblies along with the Mylar Figure 4 198 Fuse Block Assemblies TTS300 TGS230 5 Remove the Terminal Block from the compressor Figure 4 199 Terminal Block Removal TTS300 TGS230 AC Bus Bar to SCR Fastener M6x16 Fuse to Terminal Block Fastener SCR...

Page 170: ...acitor Bus Bar Assembly Removal and Installation on page 158 for this and the following step 11 Remove the nylon nuts at the base of the DC Capacitor Bus Bar Assembly under the main compressor housing Refer to Figure 4 184 Capacitor Nut Removal TTS300 TGS230 on page 159 12 Lift the DC Bus Bars and Capacitor Assembly out as an assembly 13 Remove the insulating Mylar from the Inverter if applicable ...

Page 171: ...ners from the Inverter Refer to Figure 4 203 Inverter Copper Tube Removal and the note below 15 Slide out all three 3 Inverter Copper Tubes Figure 4 203 Inverter Copper Tube Removal Mylar Motor Bus Bar Fastener M8x70 3 places Inverter Copper Tubes 3 places NOTE It is not necessary to completely remove the Motor Bus Bars ...

Page 172: ...ure 4 204 Inverter Cable Harness Removal TTS300 TGS230 17 Disconnect all wiring connections from the DC DC Converter Refer to Figure 4 205 Open Frame DC DC and Figure 4 206 Potted DC DC for the connector locations Figure 4 205 Open Frame DC DC Figure 4 206 Potted DC DC Harness Connector J4 24VDC J2 250VDC J1 DC Bus Input J3 24VDC J4 15VAC J2 250VDC J1 DC Bus Input ...

Page 173: ... DC DC Shown 20 Disconnect the wires from the Motor Winding Sensor Refer to Figure 4 208 Motor Winding Sensor Connector Removal Figure 4 208 Motor Winding Sensor Connector Removal 21 Loosen the M5x16 fastener containing the Retainer Clip and rotate the clip to allow for the connector to be removed Refer to Figure 4 209 Retainer Clip Rotation Figure 4 209 Retainer Clip Rotation DC DC Mounting Faste...

Page 174: ...20 M6x30 fasteners that secure the Inverter to the compressor main housing and carefully remove the Inverter and remove and discard the two 2 O rings underneath Figure 4 211 Inverter Assembly Removal TTS300 TGS230 IGV Motor Feedthrough Discharge Sensor Suction Sensor Cable Harness SCR Temperature Sensor Harness Inverter Assembly Mounting Fastener M6x30 20 places Large O ring Small O ring Inverter ...

Page 175: ...moval Steps TTS TGS TTH TGH Except TTS300 TGS230 1 Remove the three 3 AC wires of the Soft Start AC DC cable harness from the AC Bus Bars 2 Unplug the SCR Gate cable harness from the from the SCRs noting the orientation of the terminals Refer to Figure 4 213 SCR Connections TTS TGS TTH TGH Rev F and Earlier Except TTS300 TGS230 and Figure 4 214 SCR Connections TTS TGS TTH TGH Rev H Except TTS300 T...

Page 176: ...ners Refer to Figure 4 215 Terminal Block and AC Mains Input Bus Bar Removal TTS TGS TTH TGH Rev F and Earlier Except TTS300 TGS230 b For Revision H compressors leave the Terminal Block in place but remove the AC Mains Input Bus Bars Refer to Figure 4 216 Input Terminal Block Removal TTS TGS TTH TGH Rev H Except TTS300 TGS230 on page 177 Figure 4 215 Terminal Block and AC Mains Input Bus Bar Remov...

Page 177: ...r Tubes Figure 4 217 Inverter Copper Tube Removal TTS TGS TTH TGH Except TTS300 TGS230 7 Loosen the M5x16 IGV Feedthrough fastener that secures the Retainer Clip and rotate the clip to allow for the connector to be removed Refer to Figure 4 218 Retainer Clip Rotation AC Bus Bars Mains Input Nut 3 8 x 16 3 places Terminal Block AC Bus Bar to Terminal Block Fastener M5x12 6 places Terminal Block to ...

Page 178: ...TS300 TGS230 or to Figure 4 220 Compressor Cable Harness Removal TTH TGH Only for TTH only compressors Figure 4 219 Compressor Cable Harness Removal TTS TGS TTH TGH Except TTS300 TGS230 Figure 4 220 Compressor Cable Harness Removal TTH TGH Only Retainer Clip IGV Feedthrough Fastener M5x16 Cable Harness SCR Temperature Sensor Cable Discharge Sensor IGV Motor Feedthrough Suction Sensor TTS350 Revisi...

Page 179: ...harness from the top of the Inverter Refer to Figure 4 222 Inverter Harness Removal TTS TGS TTH TGH Except TTS300 TGS230 Figure 4 222 Inverter Harness Removal TTS TGS TTH TGH Except TTS300 TGS230 NOTE Removal of the SCR Cooling Manifold will require the manifold to rocked back and forth to disengage it from the SCR Manifold Return Brass Fitting If necessary use a flat blade screwdriver to gently p...

Page 180: ...DC from the Inverter Heat Sink Plate Figure 4 223 DC DC Removal TTS TGS TTH TGH Rev F and Earlier Except TTS300 TGS230 14 Disconnect the wires from the Motor Winding Sensor Refer to Figure 4 224 Motor Winding Sensor Removal Figure 4 224 Motor Winding Sensor Removal 15 Remove the 20 M6x30 fasteners that secure the Inverter to the compressor main housing Refer to Figure 4 225 Inverter Removal TTS TG...

Page 181: ...of the fitting Refer to Figure 4 227 SCR Manifold Return Brass Fitting Removal TTS TGS TTH TGH Except TTS300 TGS230 Figure 4 227 SCR Manifold Return Brass Fitting Removal TTS TGS TTH TGH Except TTS300 TGS230 4 23 6 3 Specific Inverter Installation Steps TTS300 TGS230 1 Clean O ring groove in the main compressor housing 2 Apply O Lube to the Inverter O ring and place the O ring in the compressor ho...

Page 182: ...be used to ensure to ensure proper torque is obtained 8 Carefully install the Inverter on the compressor housing with the SCR temperature sensor cable if equiped run on top where the SCR cooling manifold meets the Inverter Cooling Manifold 9 Torque the M6x30 Inverter fasteners in a diagonal pattern to 3 Nm 27 in lb on the first pass then to 8 5 Nm 75 in lb on the second pass Refer to Figure 4 229 ...

Page 183: ...the Soft Start harness from the DC bus assembly noting the orientation Torque the M6 fasteners to 10 Nm 7 ft lb Refer to Figure 4 230 DC Bus Installation TTS300 TGS230 for this and the following step 19 Connect the DC bus bars to the SCR s and torque the M6x16 fasteners to 5 Nm 44 in lb Figure 4 230 DC Bus Installation TTS300 TGS230 20 Install the Terminal Block and torque the M5x15 fasteners to 3...

Page 184: ...he compressor housing groove 3 Remove the backing material from the Inverter Cooling Manifold of the new Inverter Use caution to not damage the bottom sealing surface of the Inverter 4 Install the 18 M6x30 fasteners into the Inverter assembly with the exception of the four 4 M6x35 SCR Manifold fasteners and carefully lower the assembly onto the compressor housing Use the installed fasteners to pro...

Page 185: ...on the SCR Manifold Return Brass Fitting smaller one on top Apply O lube to each O ring before installation Refer to Figure 4 234 SCR Manifold Return Brass Fitting O ring Installation TTS TGS Except TTS300 TGS230 Figure 4 234 SCR Manifold Return Brass Fitting O ring Installation TTS TGS Except TTS300 TGS230 10 Carefully install the SCR cooling plate over the SCR Manifold Return Brass Fitting Press...

Page 186: ...Except TTS300 TGS230 20 Connect the Snubber Capacitors and torque to 7 Nm 62 in lb Refer to 4 22 3 DC Capacitor Bus Bar Assembly Removal and Installation on page 158 21 Tighten the DC Bus Assembly to the SCRs and torque the M8x20 fasteners to 9 Nm 80 in lb 22 Place the capacitor membrane foam side up underneath the main compressor housing and then Install the nylon nuts to the base of the DC Capac...

Page 187: ...mpressor power as described in Section 1 8 Electrical Isolation on page 19 2 Remove the Capacitor Cover Refer to 4 2 4 1 Capacitor Cover Removal and Installation on page 59 3 Disconnect the 3 phase A C input wires from the Terminal Block 4 Remove the Soft Start Refer to 4 15 3 Soft Start Removal and Installation on page 112 5 Remove the Terminal Block Assembly Refer to 4 12 2 3 Phase Main Voltage ...

Page 188: ...ure 4 239 Seated Spring Pins 2 There are two 2 different length spring pins if any are replaced be sure to replace with the same length spring pin Refer to Figure 4 240 Spring Locations and Table 4 36 Spring Identification Table for the locations of the long and short spring pins For an example of the difference between the two 2 different spring pin lengths refer to Figure 4 241 Spring Pin Identi...

Page 189: ... separate Be sure to hold both to avoid dropping the driver board if separation occurs If they do become separat ed carefully snap the cover back into place prior to assembly 7 For proper alignment insert two 2 of the fasteners in opposite corners of the Driver Board 8 Align the new Driver Board over the Inverter module with the connector towards the motor stator output bus bar the shape of Driver...

Page 190: ...ck Removal and Installation on page 98 16 Install the Soft Start Refer to 4 15 Soft Start on page 107 17 Connect all remaining cable harnesses 18 Install the Capacitor Cover Refer to 4 2 4 1 Capacitor Cover Removal and Installation on page 59 19 Install the top covers Refer to 4 2 Compressor Covers on page 56 20 Return the compressor to normal operation 4 23 8 Inverter Torque Specifications Table ...

Page 191: ...13 4 24 Motor Components 4 24 1 Function The motor type employed is a permanent magnet synchronous speed motor The winding section of the motor is similar in design to a standard 3 phase star connected Stator 4 24 1 1 Stator The Stator operates as the force that drives the shaft utilizing the HV DC pulses provided to the motor windings by the Inverter 4 24 1 2 Rotor The rotor is an integral part o...

Page 192: ...windings are intact 4 24 4 2 Stator Resistance Verification To verify the Stator resistance complete the following steps 1 Isolate the compressor power as described in Section 1 8 Electrical Isolation on page 19 2 Remove the Soft Start Refer to 4 15 3 Soft Start Removal and Installation on page 112 3 Remove the Copper Tubes that connect the motor bus bars to the Inverter 4 Using a multimeter set f...

Page 193: ...r R T Curve 1 4 24 5 Motor Assembly Removal and Installation This section contains steps that explain the removal and replacement of the Motor Bus Bars Copper Tubes Cover Plate and the High Power Feed Throughs The following steps apply to all TTS TGS TTH TGH compressors The TTS TGS TTH TGH compressors utilize two different styles of High Power Feedthroughs There is a clear physical distinction bet...

Page 194: ...ely install the three 3 M8x70 fasteners that secure the motor bus bars to the inverter output through the Copper Tubes Continue to Step 3 if the compressor contains PPS High Power Feedthroughs Continue to Step 4 if the compressor contains Stainless Steel High Power Feedthroughs 3 Install the three 3 M10x16 fasteners and lockwashers that secure the motor bus bars to the PPS High Power Feedthroughs ...

Page 195: ...er to 4 24 5 Motor Assembly Removal and Installation on page 193 4 Remove the three 3 Copper Tubes Refer to Figure 4 248 Copper Tube Removal Figure 4 248 Copper Tube Removal 4 24 5 4 Copper Tube Installation 1 Install the three 3 Copper Tubes and torque the M8x70 Motor Bus Bar fasteners to 14 Nm 10 in lb 2 Install the three 3 Motor Bus Bars Refer to 4 24 5 Motor Assembly Removal and Installation o...

Page 196: ...r Removal 9 Remove and discard the O ring from the compressor housing 4 24 5 6 Motor Cover Plate Installation 1 Clean the mating surfaces with a lint free cloth Inspect the sealing area for any damage 2 Lubricate and install the preformed O ring into the groove located in the Main housing 3 Install the wires on the inner thermistor terminals while holding the Cover Plate Refer to Figure 4 250 Ther...

Page 197: ...hers that secure the motor bus bars to the Stainless Steel High Power Feedthroughs and torque to 15 5 Nm 11 5 ft lb Be careful not to over tighten the bolts to the power feedthroughs Continue to Step 12 12 Torque the three 3 M8x70 fasteners that secure the motor bus bars to the inverter output to 14 Nm 10 ft lb 13 Install the Soft Start Refer to 4 15 3 Soft Start Removal and Installation on page 1...

Page 198: ...through assembly Refer to Figure 4 253 High Power Feedthrough Removal stainless steel Figure 4 253 High Power Feedthrough Removal stainless steel O ring 3 places High Power Feedthrough 3 places Ring Terminal to Feedthrough Fastener M10x16 3 places Lock washer 3 places Ring Terminal 3 places Thermistor terminal 3 places Lock washer 3 places High Power Feedthrough 3 places Ring Terminal to Feedthrou...

Page 199: ...erminals to the PPS High Power Feedthroughs using the M10x16 fasteners from the inside 6 Once the M10x16 fasteners are finger tight torque them to 14 Nm 10 ft lb Continue to Step 9 7 Secure the ring terminals to the Stainless Steel High Power Feedthroughs using the M10 nuts and washers from the inside 8 Once the nuts are finger tight torque them to 15 5 Nm 11 5 ft lb Continue to Step 9 9 Install w...

Page 200: ...bly Torque Specifications Table 4 38 Motor Assembly Torque Specifications High Power Feedthrough Motor Bus Bar Motor Thermistor Terminals Inverter to Motor Bus Bar fastener M8x70 Description Nm Ft Lb In Lb Soft Start Mounting fastener M5X15 5 44 Cover Plate fastener M8x25 18 13 159 High Power Feedthrough both styles 22 16 195 Inverter to Motor Bus Bar fastener M8x70 14 10 124 Motor Bus Bar to Feed...

Page 201: ...rough the Soft Start Board F1 fuse The Soft Start Board also powers the potted style DC DC Converter with 15VAC when the DC bus has reached minimum level Refer to Figure 4 258 Potted DC DC on page 204 and Figure 4 259 Open Frame DC DC on page 204 for the DC DC Converter input output I O connections Inputs J1 Bus Input J4 15VAC potted version only Outputs J2 250VDC J3 24VDC potted J4 24VDC open fra...

Page 202: ... for resistance measurements place the multimeter leads on the J2 250VDC output terminals Refer to Figure 4 258 Potted DC DC on page 204 and Figure 4 259 Open Frame DC DC on page 204 The result should be a rising or falling value not zero or infinity 4 Reverse the multimeter leads on the J2 250VDC output terminals The result should be a rising or falling value not zero or infinity 5 Place the mult...

Page 203: ... Soft Start J9 Connector b For Open Top Soft Starts disconnect the J7 connector Refer to Figure 4 107 Open Top Soft Start J7 Connector on page 114 6 Carefully cut any cable ties that may be securing the cable harness in place 7 Disconnect J4 J20 J22 and J24 from the Backplane Refer to Figure 4 265 Backplane Connections on page 208 8 Carefully pull the harness through the cable passage and remove R...

Page 204: ...4VDC J3 and 15VAC J4 from the DC DC Converter Refer to Figure 4 258 Potted DC DC Open frame style Three 3 connectors DC Bus Input J1 250VDC Output J2 and 24VDC output J4 from the DC DC Converter Refer to Figure 4 259 Open Frame DC DC Figure 4 258 Potted DC DC Figure 4 259 Open Frame DC DC 4 Loosen the M3x10 fasteners that are located next to the Inverter Refer to Figure 4 260 DC DC Converter Remov...

Page 205: ...lide under Refer to Figure 4 261 DC DC Rear Fastener Install Figure 4 261 DC DC Rear Fastener Install 4 Align the DC DC Converter with the mounting holes on the Inverter Heat Sink Plate by sliding the DC DC Converter under the partially installed rear fasteners 5 Install the new front M3x10 fasteners that secure the DC DC Converter to the Inverter Heat Sink Plate Torque all fasteners to 0 5 Nm 4 i...

Page 206: ...5 3 Soft Start Removal and Installation on page 112 8 Install the top covers Refer to 4 2 Compressor Covers on page 56 9 Return the compressor to normal operation 4 25 4 4 DC DC Torque Specifications Table 4 39 DC DC Torque Specifications Description Nm Ft Lb In Lb Soft Start Mounting fastener M5x15 5 44 DC DC Mounting fastener M3x10 0 5 4 Cover fastener M5x15 1 5 13 ...

Page 207: ...g solenoids bearing sensors and pressure temperature sensors It is a means to transfer control sensor and error information between the BMCC and other compressor components The Backplane also serves as the source of power to the parts connected to it It features onboard low voltage DC DC converters for converting 5V 15V 15V and 17V from its input of 24VDC Note that the 5V 15V and 15V are with resp...

Page 208: ...rt 2 J2 and J3 BMCC Connection Port 12 J21 IGV Motor Control Port 3 J8 Serial Driver Connection Port 13 Inverter Ground Screw 4 J7 I O Cable Connection 14 J11 and J12 Rear Bearing Sensor Cable to Ground either may be used 5 J24 Input of 24VDC from DC DC 15 J23 Cavity Sensor Input 6 J4 Input of 250VDC From DC DC 16 J10 Front Bearing Sensor Input 7 J16 Motor Cooling Solenoids Control Port 17 J9 Rear...

Page 209: ...t 2 HV Test Point 6 15V Test Point 3 17HV Test Point 7 24V Test Point 4 0V Test Point 8 15V Test Point 4 26 2 1 LED Locations The Backplane LEDs are indicated in Figure 4 267 Backplane LED Locations Left Side on page 209 and Figure 4 268 Backplane LED Locations Right Side on page 210 Figure 4 267 Backplane LED Locations Left Side 6 1 2 3 8 4 7 5 1 2 3 4 ...

Page 210: ...lane 5 Using a multimeter set for resistance measurements place the multimeter leads in the Backplane test points as defined in Table 4 43 Backplane Test Point Values on page 211 See Figure 4 266 Backplane Test Points on page 209 The results should be greater than the resistance specified in the table 6 If one of the test points does not output the expected voltage and the HV and 24V test points o...

Page 211: ...r to Figure 4 265 Backplane Connections on page 208 7 Remove the Inverter Ground fastener from the top right of the Backplane to release the Inverter cable ground ring 8 Replace the Inverter ground fastener 9 Remove the three 3 fasteners that secure the Backplane Frame to the housing Do not remove the fastener at the top left or bottom center of the Backplane so the circuit board remains in the fr...

Page 212: ... Serial Driver 8 Install the Service Side Cover Refer to 4 2 3 1 Service Side Cover Removal and Installation on page 58 9 Return the compressor to normal operation 4 26 3 3 Backplane Torque Specifications Table 4 44 Backplane Torque Specifications 4 27 Serial Driver Figure 4 270 Serial Driver 4 27 1 Serial Driver Function The Serial Driver is powered with 15VDC and 24VDC from the Backplane The Ser...

Page 213: ...e Side Cover Refer to 4 2 3 1 Service Side Cover Removal and Installation on page 58 7 Return the compressor to normal operation 4 27 3 2 Serial Driver Output Voltage Verification 1 Remove the Service Side Cover Refer to 4 2 3 1 Service Side Cover Removal and Installation on page 58 2 Isolate compressor power and wait for the Backplane LEDs to go out 3 Wait a minimum of one 1 minute 4 Reapply comp...

Page 214: ...fer to 4 2 3 1 Service Side Cover Removal and Installation on page 58 4 Return the compressor to normal operation 4 28 BMCC The BMCC is the central processor board of the compressor Based on sensor inputs it controls the bearing and motor system and maintains compressor control within the operating limits The BMCC uses 5VDC 15VDC and 15VDC power supplied from the Backplane The BMCC relays compress...

Page 215: ...ager tool 2 If the system is able to connect the BMCC is able to communicate with the user interface 3 If the system is not able to connect verify a The BMCC is properly connected to the Backplane b The I O cable connection between the Backplane and the Compressor I O Board is properly attached c The cable connection between the Compressor I O Board RS485 or RS232 and the user interface user PC or...

Page 216: ...prior to disposal Always refer to local requirements in your area to ensure the battery is properly disposed 4 28 3 2 BMCC Defective Battery Symptoms If the BMCC battery is good and no BMCC problems exist the BMCC will retain the current time after a power cycle However if after syncing the BMCC time with the current time from the computer that is connected to the BMCC the BMCC does not retain the...

Page 217: ...e Serial Driver from the Backplane and slide it slowly away from the compressor Refer to 4 27 4 Serial Driver Removal and Installation on page 213 5 Carefully disconnect the BMCC from the Backplane and slide it slowly away from the compressor Refer to Figure 4 276 BMCC Removal Figure 4 276 BMCC Removal 4 28 4 2 BMCC Installation Ground Terminal Top side CAUTION When replacing the BMCC a bearing ca...

Page 218: ... Service Side Cover on page 58 5 Return the compressor to normal operation 6 If a BMCC that is not original to the compressor is installed a calibration must be completed and saved to the EEPROM to match the BMCC to the compressor Refer to 5 3 Bearing Calibration on page 250 4 29 Bearing Pulse Width Modulator Amplifier Figure 4 278 PWM 4 29 1 PWM Function The PWM Amplifier supplies current to the ...

Page 219: ...Revision F and later compressor Figure 4 280 Bearing Power Feed Throughs and PWM Connection Port Impellers Z axis Position Sensor Sensor Ring Front Radial Bearing Motor Sensor Ring Rear Radial Bearing Axial Bearing X axis Position Sensor X axis Position Sensor Touchdown Bearings Touchdown Bearings Target Sleeve Y axis Position Sensor Y axis Position Sensor Channels Fx Fy Channels Rx Ry Channel Axi...

Page 220: ...HV and 5V test points 14 If the voltages do not change the PWM is not the source or not the only source of energy drain 4 29 3 2 Verify Functionality of the Five Output Channels 1 Verify the bearing coil resistances are within specification 2 Verify the bearing sensor resistances are within specification 3 Verify the voltages at the HV 17HV and 5V Backplane test points are within the expected volt...

Page 221: ...C 7 Repeat Step 6 for all 10 pin holes on both PWM connectors Figure 4 281 Connecting Leads to PWM Connector and HV and HV Test Points 8 Still set on diode measurement place the black multimeter lead on the HV test point of the Backplane and the red multimeter lead in the first pin hole of the PWM connector ensure the lead makes contact with the clip in the pin hole Refer to Figure 4 281 Connectin...

Page 222: ...rs for the PWM and bearing feed throughs 7 Install the BMCC Refer to 4 28 4 BMCC Removal and Installation on page 217 8 Install the Serial Driver Refer to 4 27 4 Serial Driver Removal and Installation on page 213 9 Install Service Side Cover Refer to 4 2 3 1 Service Side Cover Removal and Installation on page 58 10 Install the top covers Refer to 4 2 Compressor Covers on page 56 11 Return the comp...

Page 223: ... 30 3 1 Bearing Coil Verification 1 Isolate compressor power as described in Section 1 8 Electrical Isolation on page 19 2 Remove the Service Side Cover Refer to 4 2 3 1 Service Side Cover Removal and Installation on page 58 3 Verify the Backplane LEDs have turned off Six Pin Molex Connector Four Pin Molex Connector Front Radial Bearing Power Feedthrough J1 PWM Connection Rear Radial and Axial Bea...

Page 224: ... 3 2 Bearing Current Verification 1 Connect to the compressor using the SMT 2 Open the Compressor Monitor tool Refer to Figure 4 286 Compressor Monitor Tool on page 225 3 Look at the bearing section and verify that during compressor operation the bearing amperages displayed are within the range as defined in Table 4 47 Bearing Amperage Nominal Ranges on page 225 Compressor Model Design Sequence Co...

Page 225: ...the cable from J9 on the Backplane 7 Remove the cable from the 9 pin connector at the Rear Bearing Sensor Feedthrough 8 Remove the ground wire from J11 on the Backplane 4 30 3 4 Bearing Sensor Cable Installation 1 Ensure that all connectors are clean and free of grease and silicone gel 2 For the Front Bearing Sensor Cable refer to Steps 3 5 for the Rear Bearing Sensor Cable refer to Steps 6 9 3 In...

Page 226: ...9 2 Isolate the compressor and recover the refrigerant according to industry standards Refer to 3 1 Refrigerant Containment on page 41 3 Remove the Service Side Cover Refer to 4 2 3 1 Service Side Cover Removal and Installation on page 58 4 Pull the Serial Driver Module out of its slot Make sure you do not damage the connector pins Keep the module in a safe place Refer to 4 27 4 Serial Driver Remo...

Page 227: ...hrough Torque Sequence Figure 4 289 Bearing Power Feedthrough Torque Sequence 6 Leak test and evacuate in accordance with standard industry practices 7 Carefully install the PWM Refer to 4 29 4 PWM Removal and Installation on page 221 8 Plug the cable harness back into the 4 pin feed through and 6 pin feed through 9 Carefully install the BMCC Refer to 4 28 4 BMCC Removal and Installation on page 2...

Page 228: ...throughs located above the front and rear bearing power feed throughs The bearing sensor feed throughs are connected to the bearing sensor cables which connect to J9 and J10 on the Backplane Refer to Figure 4 290 Bearing Sensor Feedthroughs Figure 4 290 Bearing Sensor Feedthroughs Description Nm Ft Lb In Lb Inverter and Backplane Ground fastener M5x25 3 27 Backplane Mounting fastener M5x25 3 27 PW...

Page 229: ...4 291 Bearing Sensor Pin Locations 4 31 4 Bearing Sensor Cable Removal and Installation Refer to Figure 4 265 Backplane Connections on page 208 for connector locations in this section 4 31 5 Bearing Sensor Removal and Installation The following procedure will contain the same steps for either the Front or Rear Bearing Sensor Feedthrough 4 31 5 1 Bearing Sensor Feedthrough Removal 1 Isolate compres...

Page 230: ...Through Removal 4 31 5 2 Bearing Sensor Feedthrough Installation 1 Using a lint free cloth clean the mating surface on the compressor housing 2 Verify that the new O rings and 9 pin feed through are clean If not wipe off any contaminants with a lint free cloth 3 Apply O lube on each of the new O rings 4 Install the new O rings onto the new 9 pin feed through 5 Install the new 9 pin feed through 6 ...

Page 231: ... upper guide rails Refer to Figure 4 294 BMCC Insertion Guides Figure 4 294 BMCC Insertion Guides 11 Install the Service Side Cover 4 2 3 1 Service Side Cover Removal and Installation on page 58 12 Install the top covers Refer to 4 2 Compressor Covers on page 56 13 Return the compressor to normal operation 4 31 5 3 Bearing Sensor Torque Specifications Table 4 50 Bearing Sensor Torque Specification...

Page 232: ...he Cavity Temperature Sensor is a 10KΩ 77 F 25 C NTC thermistor The resistance value should correspond to the chart in Figure 4 297 Temperature vs Resistance 6 Measure the resistance of the Cavity Temperature Sensor terminals 1 and 3 to ground The resistance value should be open or infinite 7 Install the Service Side Cover Refer to 4 2 3 1 Service Side Cover Removal and Installation on page 58 8 I...

Page 233: ... and engage the first few threads by hand 4 Tighten the sensor to 13 Nm 10 ft lb 5 Leak test and evacuate in accordance with standard industry practices 6 Install the Backplane Refer to 4 26 3 Backplane Removal and Installation on page 211 7 Install the PWM Refer to 4 29 4 PWM Removal and Installation on page 221 8 Install the BMCC Refer to 4 28 4 BMCC Removal and Installation on page 217 9 Instal...

Page 234: ...temperature sensor is secured to the IGV above the suction port The discharge pressure temperature sensor is secured to the compressor housing above the discharge port Refer to Figure 4 300 Pressure Temperature Sensor Connections All TTS TGS Compressors and Figure 4 301 Pressure Temperature Sensor Locations TTH TGH for the location of the sensor locations Figure 4 300 Pressure Temperature Sensor C...

Page 235: ...inals 5 If the integrity of the cable is in question disconnect the compressor controller cable from the pressure temperature sensor and proceed to the next step 6 Place the leads on Terminal 1 3 of the pressure temperature sensor Refer to Figure 4 304 Pressure Temperature Sensor Pin Locations To verify pressure reading compare the readout of the service monitoring software to a calibrated gauge D...

Page 236: ...ressure Temperature Sensor Installation 1 Check and clean the O ring housing thread and O ring sealing surface in the IGV Housing 2 Apply lube to O ring 3 Insert the sensor and engage the first few threads by hand 4 Using a deep 15 16 socket tighten the sensor to 10 Nm 7 ft lb 5 Reconnect the sensor connector 6 Leak test and evacuate in accordance with standard industry practices 7 Return the comp...

Page 237: ...frigerant Containment on page 41 3 Disconnect the sensor connector 4 Using a deep 15 16 socket remove the sensor from the Interstage Pipe Figure 4 307 Interstage Pressure Temperature Sensor Removal 4 33 4 6 Economizer Pressure Temperature Sensor Installation TTH TGH Compressors Only 1 Check and clean O ring housing thread and O ring sealing surface in the compressor housing Apply O lube to O ring ...

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Page 239: ... 250 5 3 Bearing Calibration 250 5 3 1 When to Calibrate the Bearings 250 5 3 2 Performing a Calibration 251 5 3 3 After Calibration is Complete 252 5 3 4 Create a Calibration Report 252 5 3 5 Calibration Report Analysis 253 5 4 Compressor Connection Status Indications 255 5 5 System and Compressor Level Troubleshooting 255 5 5 1 Compressor Voltage Troubleshooting 255 5 5 2 Determining the Cause o...

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Page 241: ... The measured temperature has exceeded the fault limit Low Suction Pressure The measured suction pressure has exceeded the fault limit Discharge Pressure The measured discharge pressure has exceeded the fault limit Instantaneous lock out at fault level 3 Phase Over Current The calculated 3 phase current has exceeded the fault limit Instantaneous lock out at fault level Cavity Temperature The measu...

Page 242: ... Rotor may be Locked Back Electromotive Force EMF is low Winding Temperature The measured motor winding temperature has exceeded the fault limit High Suction Superheat The calculated Suction Superheat Temperature has exceeded the Fault limit Table 5 3 Compressor Status 2 Faults Compressor Description Suction Pressure Sensor Fault only available in 4 X Suction Temperature Sensor Fault only availabl...

Page 243: ...k EMF has fallen below the minimum Back EMF limit EEPROM Checksum Fault An error checksum error occurs reading the data table from the EEPROM Generator Mode Active At greater than 0 RPM and DC bus voltage low Generator mode is enabled switching the Inverter to rectifier function to maintain the DC bus voltage until the shaft comes to a stop and delevitates SCR Ripple Voltage Fault The DC bus volta...

Page 244: ...layback tool provides a method of reviewing operational conditions without a connection to the compressor It also creates a file to electronically transmit for peer review See the latest Service Monitoring Tools User Manual for use instructions The following principle is applied when having both a fault and or an alarm limit as triggers Refer to Figure 5 1 Fault Trigger Methods for explanations re...

Page 245: ...ge insufficient system load or a sudden drop in evaporator entering air water temperature or flow Check the charge system load and entering air water conditions Review the fault log for actual suction pressure entering air water temperature if available and other conditions that are recorded at the time of fault High Discharge Pressure Fault AFT Suggests the condenser may be faulty or insufficient...

Page 246: ...e 73 Verify the solenoid actuators Refer to 4 7 3 Solenoid Verification on page 73 Verify the Serial Driver Refer to 4 27 3 Serial Driver Verification on page 213 Verify SCR temperature sensor Refer to 4 19 2 5 SCR Temperature Sensor Verification on page 137 Verify SCRs Refer to 4 19 2 SCR Verification on page 135 Lock Out Fault INS If any or a combination of the faults listed below occurs more th...

Page 247: ...Verify the associated sensor and related connections Inverter Temperature Sensor Fault RFT Sensor errors occur when the sensor is providing a reading that is outside the normal readable temperature range and therefore must have an error in the reading or functional problem with the sensor Verify the associated sensor and related connections Cavity Temperature Sensor Fault RFT Sensor errors occur w...

Page 248: ...ted gas is entering the compressor suction port Verify the Inverter Refer to 4 23 2 1 Inverter Verification on page 165 Verify the Stator Refer to 4 24 4 Motor Verification on page 192 Inverter Error INS Indicates there is an error within the Inverter Control Board or no BMCC communication with the Inverter If this fault occurs three times within a 30 minute period a Lock Out Fault will occur Veri...

Page 249: ...will recover when cavity temperature cools or due to a permanent demagnetization of the shaft If this fault occurs three times within a 30 minute period a Lock Out Fault will occur Compare the Back EMF value to the displayed readings in the Compressor Monitor Tool and Fault and Event Log details to determine conditions related to the fault Permanent damage to Back EMF can be caused by insufficient...

Page 250: ...vitate Only Mode Using the Compressor Monitor levitate the shaft and record the bearing forces Greater than 2A indicates an issue Manually calibrate the bearings save to EEPROM and identify if bearing forces improve If the bearings cannot be calibrated after three attempts verify the PWM refer to 4 29 3 PWM Verification on page 220 bearing sensors refer to 4 31 3 Bearing Sensor Verification on pag...

Page 251: ...ues to momentarily levitate the shaft and compares the values to tolerance limits 5 3 2 1 Before Performing a Calibration Interlock must be open RS485 or other external compressor communication connection must be disconnected 5 3 2 2 Calibration 1 Open the SMT and connect to the compressor 2 Open the Bearing Calibration tool The Bearing Calibration tool displays Refer to Figure 5 2 Bearing Calibra...

Page 252: ...est calibration values overwrite stored values There is no requirement to save calibrations to EEPROM after performing a bearing calibration Comparing original factory calibration values stored in EEPROM to the latest calibration allows determination of long term changes Saving to EEPROM permanently overwrites existing stored calibration values Stored values are used for startup check at the next ...

Page 253: ...ed Action Verify the PWM Action Verify the bearings Action Verify the bearing sensors 4 Data in Report One or more of the gain values exceeds 3 0 Interpretation Bearing electrical fault or shaft is obstructed Action Verify the bearings Action Verify the bearing sensors Refer to Figure 5 3 Bearing Calibration Flow on page 254 5 Data in Report One or more of the bearing Force Current values exceeds ...

Page 254: ...idate create another report Start Begin bearing calibration Could shaft run and levitate without issue prior to calibration No Yes Does shaft levitate after Save to EEPROM Yes Does shaft levitate after Save to EEPROM No Start Calibration save to EEPROM Validate create report cycle power Yes No No Repeat up to 3 times End Bearings pass Bearing sensors pass PWM pass Yes Replace compressor Yes Replac...

Page 255: ...ins fuses If the name plate rated voltage is present proceed to Step 4 If any of the three phases are not present isolate compressor power then replace the fuses 4 Isolate the compressor power as described in the 1 8 Electrical Isolation on page 19 of this manual 5 Inspect all electronics for visible damage If no visible damage is present proceed to Step 6 If there is any type of visible damage re...

Page 256: ...3 BMCC refer to 4 28 4 BMCC Removal and Installation on page 217 and PWM refer to 4 29 4 PWM Removal and Installation on page 221 22 Re apply compressor power 23 Verify the HV and the 24 VDC test points on the Backplane If all voltages are within 10 proceed to Step 26 If either voltage is not within 10 isolate compressor power and wait for the LED s on the Backplane to go out then disconnect the J...

Page 257: ...in 10 proceed to Step 5 5 Isolate the compressor power and wait for the LEDs on the Backplane to turn off 6 Remove the BMCC refer to 4 28 4 BMCC Removal and Installation on page 217 ensure the Inverter cable remains connected 7 Re apply the compressor power 8 Test the Backplane voltages at the 24V 15 5 and the 15 VDC test points If all voltages are within 10 the BMCC is draining energy If any of t...

Page 258: ...DC Converter high voltage input Refer to 4 25 2 1 Input Voltage Verification on page 201 Verify the DC DC Converter Refer to 4 25 2 DC DC Converter Verification on page 201 Verify the PWM Refer to 4 29 3 PWM Verification on page 220 Verify the bearings Refer to 4 30 3 Bearing Verification on page 223 3 An open F2 fuse may indicate a problem with the DC DC Converter Verify the DC DC Converter 15VAC...

Page 259: ...ce the wire to the I LOCK neg at the J2 connector of the I O board 5 5 4 Troubleshooting the Inverter 1 Download the fault and event log 2 Review the fault and event log for any Inverter Error Signal Active faults Presence of an Inverter Error Signal Active fault indicates failure of the Inverter Replace the Inverter If no Inverter Error Signal Active fault is present continue with the next step 3...

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Page 261: ...261 of 282 M SV 001 EN Rev G Chapter 6 Maintenance 6 1 Preventative Maintenance Tasks 263 6 2 Moisture Prevention Measures 264 ...

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Page 263: ...ages Ensure electrical terminals are tight Check for signs of hot spots discoloration on power cables Check amperages during operation are as per design Check DC bus voltage Replace DC Capacitor Bus Bar Assembly Energized 10 years De energized 5 years Check operation of all system safety devices and interlocks Perform moisture prevention measures Replace Soft Start fan 5 Years Refer to Customer No...

Page 264: ...ectric grease can be applied by Finger Small brush 6 2 1 1 Service Side Disassembly 1 Isolate the compressor power as described in Section 1 8 Electrical Isolation on page 19 of this manual 2 Allow time for the compressor to reach ambient temperature 3 Remove the Service Side Cover from the compressor 4 Remove the I O Cable Serial Driver BMCC and PWM from the Backplane Board Make sure the board as...

Page 265: ...e around the motor winding sensor terminals high power feed throughs and motor bus bars 3 Using a soft bristle brush remove any debris or dust from the motor winding sensor terminals high power feed through and motor bus bar fasteners 4 Spray greaseless lubricant on the terminals power feed throughs and bus bar fasteners to remove any trace of moisture 5 Wipe off excess lube with a lint free rag 6...

Page 266: ...all three fuse assemblies Refer to 4 14 2 Terminal Block Fuse Removal and Installation on page 106 and Figure 6 4 Accessing Inside SCR to Cooling Manifold Fastener TTS TGS Compressors only Figure 6 4 Accessing Inside SCR to Cooling Manifold Fastener TTS TGS Compressors only 11 Remove any debris or dust from the SCR fasteners High Power Feedthrough Motor Thermistor Terminals Motor Bus Bar to Invert...

Page 267: ...pray on the SCR fasteners 16 Apply dielectric grease to the Bus Bar fasteners 17 Clean off any excess dielectric grease 18 Inspect all electrical connections 19 Install top covers on compressor Refer to 4 2 Compressor Covers on page 56 20 Return the compressor to normal operation Table 6 2 SCR Fastener Torque Specifications TTS300 TGS230 All TTS TGS TTH TGH Models Except TTS300 TGS230 Description ...

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Page 269: ...health and environmental protection and is a key indicator of a product s compliance with legislation The CE marking is affixed by manufacturers to their products By placing CE marking on a product manufacturers declare on their sole responsibility that the products comply with all the legal requirements in force in Europe Citation European Commission Directorate General for Enterprise and Industr...

Page 270: ...270 of 282 M SV 001 EN Rev G Acronym Term Definition SMT Service Monitoring Tool VDC Volts Direct Current or Volts DC º C Degrees Celsius º F Degrees Fahrenheit ...

Page 271: ...hart Sheet 1 Is the compressor operating correctly Is the Mains voltage within range End A Yes No Yes Repair Mains voltage problem No Are the LEDs on the I O Board lit Canyou communicatewithcompressor viaMonitoringProgram Yes Are the LEDs on the backplane board lit No Is the monitoring program indicating a fault Yes Are all backplane voltages OK No Yes Is I Lock circuit open Can fault be reset by ...

Page 272: ...ircuit Is there a demand displayed Yes No Restore demand input to the compressor Has the IGV reset No Yes Wait until IGV reset Is Inverter Temp below Maximum Start Temp No Yes Refer to Section 5 5 4 Troubleshooting the Inverter Have all Start Delay Timers have expired No Yes A Yes Wait until all Start Delay Timers have expired No End Refer to Section 5 0 Troubleshooting Yes No Can fault be reset b...

Page 273: ...olate compressor Refer to Electrical Isolation 1 7 Yes No Remove the Top Cover Inspect all electronics for visible damage Are there any signs of visible damage Verify Soft Start fuses Closed Top Soft Start Only No Replace damaged components Are the Soft Start fuses within specification Replace fuse and refer to Determining the Cause of the Blown Fuse 5 5 2 6 No Verify IGBT cable to the IGBT connec...

Page 274: ...test all SCRs and refer to SCR Verification 4 18 2 No 15VAC present Replace Soft Start and re install Top Cover SCRs pass test No Yes No Replace all three SCRs and re install Top Cover Install DC Bus Test Harness Refer to Installation of the DC Bus Test Harness 1 9 1 B A Yes Disconnect J2 and J3 J4 outputs from DC DC Re install Top Cover then re apply mains power Applicable for Potted DC DCs only ...

Page 275: ...om Backplane leaving only the J6 IGBT cable J4 250VDC and J24 VDC inputs connected Remove Serial Driver BMCC and PWM Re apply mains power Verify the HV and 24V test points on Backplane Are voltages within 10 No Replace DC DC Yes Verify the 17V 5 and the 15 and 15 voltage and resistance values Are all voltages within 10 No Replace Backplane Yes Electrically isolate compressor Re install all connect...

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Page 277: ...t J2 Charging or discharging Ω 4 25 2 4 Output Resistance Measurement J3 Charging or discharging Ω 4 25 2 4 Output Resistance Measurement J4 1MΩ 4 25 2 4 Output Resistance Measurement Front Bearing Feed Through Resistance TT300 TT400 C E F G TG230 TG390 1 to 2 2 7 to 25Ω 4 30 3 Bearing Verification TT300 TT400 C E F G TG230 TG390 3 to 4 2 7 to 25Ω 4 30 3 Bearing Verification TT350 TT400 P TT500 TT...

Page 278: ...ock 2 2 to 3 7 VDC 4 4 2 3 Interlock Verification Power Off J2 Removed I Lock to I Lock 22 kΩ 4 4 2 3 Interlock Verification Pressure Temperature Sensor Resistance 1 to 3 1 to 2 of the plug 10KΩ 77 F 25 C 4 32 3 Cavity Temperature Sensor Verification PWM Diode Lead in HV lead in PWM connector 0 39 0 46VDC 4 29 3 3 Verify Functionality of the Five Diode Sets Lead in HV C47 lead in PWM connector 0 3...

Page 279: ... 1Ω 4 15 2 2 Verifying Soft Start Fuses F3 F6 1Ω 4 15 2 2 Verifying Soft Start Fuses F4 F5 30 38Ω 4 15 2 2 Verifying Soft Start Fuses Solenoid Actuators 4 8 W 108Ω 132Ω 4 7 3 Solenoid Verification 9 3 W 56 25Ω 68 75Ω 4 7 3 Solenoid Verification Stator Resistance Phase 1 2 0 0Ω and 1Ω 4 24 4 2 Stator Resistance Verification Phase 1 3 0 0Ω and 1Ω 4 24 4 2 Stator Resistance Verification Phase 2 3 0 0...

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Page 281: ...n select 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 par...

Page 282: ...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 SV 001 EN Rev G Danfoss DCS CC 2020 05 Our products can be found in a variety of applications such as roo...

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