Danfoss Turbocor TT Series, Installation Manual

Page 1: ...Danfoss Turbocor Twin Turbine Centrifugal Compressors TT TG Series Compressors Applications and Installation Manual Revision N http turbocor danfoss com...

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Page 3: ...C Converter 26 3 5 Magnetic Bearing System 26 3 5 1 Overview 26 3 5 2 Bearing Control System 26 4 Control Interface Wiring 28 4 1 Control Wiring Connection Guidelines 29 4 2 Interface Cable 30 4 3 Com...

Page 4: ...1 TT300 and TT400 Sound Power Measurements 71 15 1 1 Results 71 16 Physical Data 75 16 1 Clearance 75 16 2 Center of Gravity 77 16 3 Torque Specifications 86 17 Piping Considerations 87 18 Environmen...

Page 5: ...e 37 Table 6 2 Acceptable Frequency Range 37 Table 6 3 FLA and LRA Value Range 38 Table 6 4 Main Cable Connector Plate Hole Sizes 42 Table 13 1 Recommended Minimum Copper Tube Size 60 Table 13 2 Low L...

Page 6: ...lve Medium Temperature Compressors Only 67 Figure 14 6 Typical Refrigeration Piping Schematic With Multiple DX Evaporators 68 Figure 14 7 Typical Refrigeration Piping Schematic Using Multiple Compress...

Page 7: ...lines provided in this manual are AS IS with no warranty of any kind either express or implied including without limitation any implied warranties of condition uninterrupted use merchantability or fit...

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Page 9: ...d into the following sections 1 Overview of the TT TG series compressors provides an overview of the Twin Turbo and Total Green TT and TG series compressors including an introduction to the compressor...

Page 10: ...outcome of the procedure being performed NOTE Indicates something to be noted by the reader NOTE DANGER Indicates an essential operating or maintenance procedure practice or condition which if not str...

Page 11: ...pressure divided by the absolute suction pressure CSA Canadian Standards Association www csa ca DC Bus High DC voltage simultaneously connected to multiple compressor components via metallic bus bars...

Page 12: ...insufficient power to sustain safe and normal operation and is typically due to a loss of power Genlanolin A type of grease In certain climates where the dew point falls below the operating temperatur...

Page 13: ...agnetic field and is also a parameter used to evaluate the strength of the permanent magnets of the shaft One practical application is to use this phenomenon to indirectly measure motor speed as well...

Page 14: ...ly re enter the compressor fluid path creating a cavitating effect This is an undesirable situation that should be avoided Thrust Bearing A bearing that absorbs the axial forces produced in a centrifu...

Page 15: ...e with refrigerant R134a The TG series compressor is for use with R1234ze E refrigerant only ASHRAE standard 34 has classified this refrigerant as R1234ze E with safety classification of A2L ASHRAE St...

Page 16: ...below 1 C ambient if refrigerant circuit is maintained at a minimum of 1 C Saturated temperature The compressor should not be operated at an altitude higher than 3000m The compressor should be stored...

Page 17: ...y permanent magnet synchronous motor powered by pulse width modulating PWM voltage supply The high speed variable frequency operation that affords high speed efficiency compactness and soft start capa...

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Page 19: ...conditions The first compression element the gas encounters is the first stage impeller The centrifugal force produced by the rotating impeller results in an increase in both gas velocity and pressure...

Page 20: ...lve opens If the temperature increases to the point where it equals a higher temperature threshold the second solenoid valve opens From the outlet of the orifices the refrigerant is directed to the he...

Page 21: ...d leakage BMCC From IGBT Temp Sensor From SCR Temp Sensor IGBT SCR ORIFICE ORIFICE Solenoid B Solenoid A Liquid Refrigerant Inlet BMCC From Motor Cavity Temp Sensor From Motor Winding Temp Sensor Moto...

Page 22: ...ration 2 3A Calibration Customer Chiller Control Communications Interface Diagnostic Terminal Internet RS 485 Comms to Chiller or Building Management System User Interface Serial Driver Module 15VDC 2...

Page 23: ...controlled sequence preventing damage to components 3 4 2 Soft Start Board The Soft Start Board limits inrush current by progressively increasing the conduction angle of the SCRs This technique is us...

Page 24: ...stationary surfaces A digital bearing controller and motor controller provide the PWM command signals to the Bearing PWM Amplifier and IGBT Inverter respectively The bearing controller also collects s...

Page 25: ...in modules with the power electronics IGV stepper motor motor cooling solenoids rotor position sensors and pressure temperature sensors The Backplane also features on board low voltage DC DC converte...

Page 26: ...sition commands to the 250VDC PWM signals that are applied to each bearing actuator coil Rotor position sensors are located on rings attached to the front and rear radial bearing assemblies The front...

Page 27: ...r Touchdown Bearings Touchdown Bearings Target Sleeve Y axis Position Sensor Y axis Position Sensor Channels Fx Fy Channels Rx Ry Channel Axi 250 VDC Position Command Signals Bearing Motor Compressor...

Page 28: ...sor Running N O Contact Compressor Running N O Contact Pressure Sensor Signal 1 5Volts Sensor 5V Sensor 0V Temperature Sensor Signal 1 5Volts Universal Analog Output Universal Analog Output Universal...

Page 29: ...l the auxiliary expansion valve economizer Demand 0 10V Analog input from customer supplied controller to drive the compressor i e 0 max kW input with a deadband of 2VDC for the respective compressor...

Page 30: ...le in the Spare Parts Selection Guide For RS 485 communication the maximum cable length should not exceed 100 meters 328 feet If using RS 232 communication the cable length should not exceed 15 meters...

Page 31: ...ion and electrical noise 4 3 Compressor I O Board Mounting Details Figure 4 4 Compressor I O Board Control Interface Wiring NOTE The UL listed enclosure should protect against moisture and other corro...

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Page 33: ...ion which are typcially deemed appropriate for Water Cooled condiitons These values allow for adjustment for compressors placed in Air Cooled applications which can have the value increased up to 1730...

Page 34: ...5 2 Discharge Temperature Trip Settings Unit Compressor TG230 ST TG230 MT TG310 ST TG390 ST TG520 ST TT300 ST TT300 MT TT350 ST TT400 ST TT700 ST F Trip 212 194 203 194 194 212 194 203 194 194 C Trip...

Page 35: ...ilding applications An OEMs use of Turbocor Compressors in applications other than stationary building applications e g Marine Applications is considered a non standard application and is not eligible...

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Page 37: ...y from DTC unless otherwise stated by DTC This includes any application of a 400V compressor in a 380V application without the use of a transformer to correct the voltage going into the compressor NOT...

Page 38: ...0 380V 60 170 66 187 60 66 TT400 400V 60 170 66 187 60 66 TT400 460V 60 150 66 165 60 66 TT400 575V 60 120 66 132 60 66 TT700 380V 60 206 66 227 60 66 TT700 400V 60 196 66 216 60 66 TT700 460V 60 170...

Page 39: ...e and immediately before the compressor that is downstream from the line reactor Contact DTC for more information 6 4 Motor Insulation Class All TT TG Series compressors have a motor insulation Class...

Page 40: ...and grease and paint free 4 At one point usually the entrance of the power supply panel all grounds should be connected together refer to Section 6 11 From an EMC standpoint it is best to categorize d...

Page 41: ...eep power cables and interface cables separate Use metal cable glands for shielded cables The wire loom going to the panel door should be shielded using a metal braided hose that is connected to groun...

Page 42: ...arried inside of a code approved electrical metallic conduit of the flexible or rigid types The mains input cable should be CSA UL or CE approved three wire with a common shield and single ground The...

Page 43: ...perating map which is in the speed control range only As the compressor reduces speed and mechanical unloading is enabled such as the closing of the variable IGV the tolerance increases to 10 The cond...

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Page 45: ...to the FLA rating of the particular compressor The lower limit is related to minimum pressure ratios required to effect proper motor and power electronics cooling with standard refrigerant circuit co...

Page 46: ...e capacity will be dependent on specific operating characteristics of each compressor model Refer to the current authorized compressor selection rating software for more exact values and conditions Fi...

Page 47: ...s related to the FLA rating of the particular compressor The lower limit is related to minimum pressure ratios required to effect proper motor and power electronics cooling with standard refrigerant c...

Page 48: ...s related to the FLA rating of the particular compressor The lower limit is related to minimum pressure ratios required to effect proper motor and power electronics cooling with standard refrigerant c...

Page 49: ...um SDT for compressors with an FLA less than that is lower than the upper bound of the operating envelope and depends on the FLA rating 1 The actual obtainable capacity will be dependent on specific o...

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Page 51: ...fugal compression the minimum stable load is dependent on the pressure ratio imposed on the compressor by the chiller system All compressor performance including unloading should be determined through...

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Page 53: ...required to start against a pressure ratio of 2 4 or greater Load balancing valve hot gas bypass the LBV is piped downstream of the check valve and is primarily used in low load conditions to keep th...

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Page 55: ...of 108 M AP 001 EN Rev N Product Certification All TT and TG Series compressors are ETL and CE listed and have been tested in accordance with UL Standard 984 and CSA Standard C22 2 11 Product Certifi...

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Page 57: ...e DC voltage to an adjustable three phase AC voltage Signals from the compressor controller shall determine the inverter output frequency voltage and phase thereby regulating the motor speed In case o...

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Page 59: ...iderations that ensure oil return such as multiple risers and traps are not required In most cases larger diameter lines will result in better compressor performance and efficiency 4 For improved effi...

Page 60: ...on Software on the Customer Service and Support Performance Tools section of the DTC web page www turbocor com The circuit must be properly designed to reflect the specified heat exchanger approach wi...

Page 61: ...13 2 Low Lift Pump Sizing The standard TT TG control limits compressor speed and capacity below a 1 5 pressure ratio to ensure adequate motor inverter cooling When enabled the low lift option is meant...

Page 62: ...such as hot building start up can limit the maximum capacity of the centrifugal compressor If more capacity is desired it is advisable to raise the discharge pressure temporarily to increase the pres...

Page 63: ...ith Subcooler Evaporator Sight Glass Check Valve Expansion Valve Motor Cooling Port Suction Port Economizer Port Discharge Port Sight Glass Filter Drier Check Valve Refrigerant Pump Pressure Regulatin...

Page 64: ...and Load Balancing Valve Motor Cooling Port Suction Port Economizer Port Discharge Port Sight Glass Sight Glass Filter Drier Filter Drier Evaporator Expansion Valve Expansion Valve Staging Valve Stag...

Page 65: ...Piping Schematic With Flash Tank Economizer Motor Cooling Port Suction Port Economizer Port Discharge Port Sight Glass Filter Drier Evaporator Expansion Valve Sight Glass Economizer Tank Condenser wi...

Page 66: ...al Refrigeration Piping Schematic With Sub Cooler Circuit Economizer Motor Cooling Port Suction Port Economizer Port Discharge Port Sight Glass Filter Drier Evaporator Sight Glass Expansion Valve Cond...

Page 67: ...hematic Using Motor Cooling Pressure Regulating Valve Medium Temperature Compressors Only Motor Cooling Port Suction Port Economizer Port Discharge Port Sight Glass Filter Drier Expansion Valve Conden...

Page 68: ...on Piping Schematic With Multiple DX Evaporators Motor Cooling Port Suction Port Economizer Port Discharge Port Sight Glass Filter Drier Filter Drier Sight Glass Expansion Valve Expansion Valve Expans...

Page 69: ...Port Motor Cooling Port with integral strainer Suction Port Economizer Port Discharge Port Motor Cooling Port with integral strainer Suction Port Economizer Port Discharge Port Sight Glass Sight Glass...

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Page 71: ...es while the compressor is installed on top of a building The sound data below should be used as a guide only The following sound measurements are based on a specific physical setup such as suction di...

Page 72: ...5 7 62 6 630 60 2 58 4 630 71 8 69 8 800 65 1 64 5 800 67 7 67 2 1000 76 5 76 7 1000 70 5 70 6 1250 66 2 66 9 1250 82 3 83 0 1600 69 9 71 0 1600 72 6 73 9 2000 69 6 70 9 2000 73 3 74 7 2500 68 6 69 9...

Page 73: ...z Linear scale dB A weighted dBA Third octave band Hz Linear scale dB A weighted dBA 160 51 65 160 55 70 200 49 61 200 50 62 250 60 70 250 61 70 315 60 68 315 62 69 400 64 71 400 65 75 500 63 65 500 6...

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Page 75: ...144 kg TG520 318 lbs 144 kg 16 Physical Data Adequate clearance around the compressor is essential to facilitate maintenance and service Removal of the compressor top and service side covers requires...

Page 76: ...2 8 67 TT350 TT400 TT500 O RING GROOVE OD 88 9 3 499 WIDTH 4 1 0 1614 ID 80 7 3 177 O RING GROOVE OD 33 3 1 311 TT300 TG230 41 3 1 659 TT350 TT400 TT500 TT700 WIDTH 4 1 0 1614 ID 25 1 0 988 TT300 TG2...

Page 77: ...Page 77 of 108 M AP 001 EN Rev N Physical Data 16 2 Center of Gravity Figure 16 4a Center of Gravity...

Page 78: ...TT400 TG390 TT700 TG520 CG LINE Length of Center of Gravity m in XL 0 257 10 13 0 249 9 81 0 247 9 74 0 251 9 87 Width of Center of Gravity m in YL 0 151 5 95 0 153 6 03 0 152 5 97 0 150 5 91 Compres...

Page 79: ...ysical Data Compressor valve flange details are shown in Figures 16 5 through 16 14 Refer to the product specifications in the Spare Parts Selection Guide for further details Figure 16 5 Discharge Por...

Page 80: ...Page 80 of 108 M AP 001 EN Rev N Physical Data Figure 16 6 Discharge Port Details TT350 and TG310 Figure 16 7 Discharge Port Detail TT400 and TG390 Gas Flow Gas Flow...

Page 81: ...Page 81 of 108 M AP 001 EN Rev N Physical Data Figure 16 8 Discharge Port Detail TT700 and TG520 Gas Flow...

Page 82: ...Page 82 of 108 M AP 001 EN Rev N Physical Data Figure 16 9 Suction Port All Models...

Page 83: ...Page 83 of 108 M AP 001 EN Rev N Physical Data Figure 16 10 Suction Port Detail DD All Models Figure 16 11 Suction Port Detail DD TT700 and TG520 Gas Flow Gas Flow...

Page 84: ...Page 84 of 108 M AP 001 EN Rev N Physical Data Figure 16 12 TT300 Flange Footprint Details Figure 16 13 TT350 TG310 TG390 and TT400 Flange Footprint Details...

Page 85: ...ev N Physical Data Figure 16 14 TT700 and TG520 Flange Footprint Details Port Thread Size Hole Depth mm Torque Nm Suction M16 X 2 34 5 75 Discharge M10 X 1 5 20 22 Economizer M10 X 1 5 20 22 Table 16...

Page 86: ...A C Bus Bars 6 4 53 DC Capacitors and Bleed Resistor 2 1 18 IGBT Mounting Screws 6 4 53 Shraeder Valves 15 11 133 Motor Cooling Body body nut E Housing and later 25 18 221 Motor Cooling Compression N...

Page 87: ...ooling line NOTE Some applications may require alternative arrangements Contact DTC for further assistance if required CAUTION The discharge line must be fitted with a non return valve to prevent reve...

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Page 89: ...nsate Insulation should be installed on the suction valve piping and the end cap as this is where condensation is most likely to form It is recommended to fit an End Cap insulator in a humid environme...

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Page 91: ...cessive vibration Due to the flexibility of the compressor s isolation mounts compressor vibration during transit can fracture the motor cooling line s rigid piping DTC suggests the temporary installa...

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Page 93: ...ould not extend from the compressor mounting rails to the base frame see Figure 20 3 and Figure 20 4 3 Check that the compressor mounting rails are level 5mm 3 16 in the lateral and longitudinal plane...

Page 94: ...re 20 2 Mounting Base TT and TG series NOTE If isolation pads are used at the four 4 mounting base points the overall height of the compressor will change Be sure to measure accordingly based on the i...

Page 95: ...langes to the compressor O rings must be of type EPDM also known by the compound E0740 75 for R1234ze refrigerant O ring grease must be silicone based and compatible with R1234ze CAUTION The motor coo...

Page 96: ...ol wiring connections to the compressor I O Board Table 16 1 Control Wiring Details provides details for the module terminal connections The interface cable connects the compressor to the compressor I...

Page 97: ...Page 97 of 108 M AP 001 EN Rev N Figure 20 6 Compressor I O Board Connections Installation Interface Cable Compressor I O Board...

Page 98: ...rounding Improper grounding can be identified by measuring the voltage between the customer s negative terminals and the ground J1 COM or Modbus shield terminal on the compressor I O board see Figure...

Page 99: ...e that the interlock contacts are closed The measured value should be less than 1 Figure 20 8 Interlock Circuit Tests Measure the voltage between each customer interlock terminal and the frame ground...

Page 100: ...for 90 C 194 F minimum with a maximum current rating corresponding to the LRA value on the compressor nameplate Keep power cables and control interface cables in separate conduits Use metal cable gla...

Page 101: ...Nut Mains Stud 3 8 16 1 5 long Compression Lug AC Input Connection Upper Nut 10 Nm 7 ft lb Jam Nut 7 Nm 62 in lb Figure 20 10 Ground Post Nuts 7 Attach the three main power cables to the compressor t...

Page 102: ...102 of 108 M AP 001 EN Rev N 11 Seal any gaps between the cabling and the mains input bracket to minimize any dust ingress into the compressor 12 Replace the mains input cover and secure it the faste...

Page 103: ...y panel 2 Attach the AC line wires to the line reactor output terminals as shown in 3 If a harmonic filter is being installed attach its AC line wires to the line reactor output terminals 4 Attach the...

Page 104: ...Page 104 of 108 M AP 001 EN Rev N Appendix A Power Line Accessories Installation Figure A 1 Line Reactor Connections...

Page 105: ...und lug to the main ground bus and tighten the nut see Figure B 2 1 Insert the load wires from the line side of the line reactor into the terminals labelled L1 L2 and L3 on the Load side of the filter...

Page 106: ...Page 106 of 108 M AP 001 EN Rev N Figure B 1 Interconnection Layout Figure B 2 Grounding Diagram Appendix B Power Line Accessories Installation...

Page 107: ...an 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...

Page 108: ...distinct variable speed technology specialists Today we operate from engineering and manufacturing facilities spanning across three continents Danfoss Inverter Scrolls Danfoss Turbocor Compressors Da...