Danfoss Turbocor TT300 Service Manual
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Danfoss Turbocor TT300 Service Manual

Twin-turbine centrifugal compressors
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Summary of Contents for Danfoss Turbocor TT300

  • Page 1 Service Manual Danfoss Turbocor® Twin-Turbine Centrifugal Compressors TT & TG Series Compressors ® http://turbocor.danfoss.com...
  • Page 2 THIS PAGE INTENTIONALLY LEFT BLANK...
  • Page 3 List of changes Revision Date Page Description of Change January, 2017 Major revision “F” compressor changes throughout the manual. August, 2017 54-57 Added IGBT Control Card Replacement instructions. Added R513A refrigerant October, 2017 Updated Figure 95 (SMT Tool Suite Lancher Strip) 123-124 Removed Appendix B Soft Start Board 3 of 132...
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  • Page 5: Table Of Contents

    Table of Contents Table of Contents ..........................5 List of Tables ............................8 List of Figures ............................9 Proprietary Notice ..........................11 Introduction ............................13 1.1 Purpose ........................................13 1.2 Organization.......................................13 1.3 Commitment to Quality .................................14 1.4 Safety Summary ....................................14 1.4.1 Danger Notification ................................14 1.4.2 Caution Notification ................................14 1.4.3 Note......................................14 1.5 Precautions ......................................14 1.6 Refrigerant Type ....................................15...
  • Page 6 Table of Contents 3.7 Inverter .........................................52 3.7.1 Function .....................................52 3.7.2 Connections .....................................52 3.7.3 Verification ....................................53 3.7.4 Removal and Installation ..............................54 3.8 Motor ........................................59 3.8.1 Function .....................................59 3.8.2 Motor Protection ..................................59 3.8.3 Connections .....................................59 3.8.4 Verification ....................................60 3.9 High-Voltage DC/DC Converter ..............................62 3.9.1 Function .....................................62 3.9.2 Connections .....................................62 3.9.3 Verification ....................................63...
  • Page 7 Table of Contents 3.19 Cavity Temperature Sensor.................................89 3.19.1 Function ....................................89 3.19.2 Connections...................................89 3.19.3 Verification .....................................90 3.19.4 Removal and Installation ..............................91 3.20 Pressure/Temperature Sensor ..............................92 3.20.1 Function ....................................92 3.20.2 Connections...................................92 3.20.3 Verification .....................................92 3.20.4 Removal and Installation ..............................93 Troubleshooting ..........................94 4.1 Alarm and Fault Indications ................................94 4.1.1 Alarm Types ....................................94 4.1.2 Fault Types ....................................94 4.2 Troubleshooting With the Service Monitoring Tools Software ..................97...

  • Page 8: List Of Tables

    List of Tables Table 1 - Refrigerant Used with Danfoss Turbocor Compressors ...................15 Table 2 - Expected DC Bus Voltage ..............................21 Table 3 - Compressor Fluid Paths ................................22 Table 4 - Compressor Component Identification (Covers On) ....................29 Table 5 - Compressor Component Identification (Covers Off ) (TT300/TG230) ..............30 Table 6 - Compressor Sensors, Cables, and Indicators (TT300/TG230) .................31...

  • Page 9: List Of Figures

    List of Figures Figure 1 - Danger Notification Example ............................14 Figure 2 - Caution Notification Example ............................14 Figure 3 - Note Example ..................................14 Figure 4 - ESD Label ....................................16 Figure 5 - Mains Plate and Ground Post ............................17 Figure 6 - Compressor Grounding Points ............................17 Figure 7 - DC Bus Test Harness Diagram ............................18 Figure 8 - DC Bus Harness Connection Diagram ...........................18 Figure 9 - Soft Start Board ..................................19...
  • Page 10 List of Figures Figure 63 - Cooling Valve Bodies .................................68 Figure 64 - Motor Cooling Solenoid Actuators ..........................69 Figure 65 - Motor Cooling Solenoid Cable Connector ........................69 Figure 66 - Solenoid Cooling Path (TT300/TG230 Shown) ......................70 Figure 67 - IGV Connections .................................71 Figure 68 - IGV Motor Feed Through ..............................72 Figure 69 - Disconnecting Power to the IGV Motor ........................73 Figure 70 - BMCC Insertion Guides..............................74...

  • Page 11: Proprietary Notice

    DTC or equipment from other vendors provided that such equipment is intended or revenue, loss of damage or equipment, loss for communication with Danfoss Turbocor of computer programs, loss of data, the costs to equipment over a serial communication link. This substitute these, or any claims by third parties.
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  • Page 13: Introduction

    1.1 Purpose This Service Manual is intended to provide service •A functional description of the various procedures specific to the Danfoss Turbocor TT components of the compressor and TG Series compressors. It is not intended to teach basic fundamental safety, refrigeration, •Information regarding procedures necessary...

  • Page 14: Commitment To Quality

    Example; When 1.3 Commitment to DTC is committed to quality service and customer Danfoss Turbocor is dedicated to satisfying our Quality satisfaction as outlined by our Quality Policy: customers by providing “Best in Class” in terms of quality, value, and on-time delivery while striving for continuous improvement.

  • Page 15: Refrigerant Type

    “R1234ze(E) with safety classification of A2L. ” ASHRAE Standard 34, 2010 Addendum 1 contains the change to the standard. Compressor Refrigerant Table 1 - Refrigerant Used with Danfoss Turbocor TT Series R134a/R513A Compressors TG Series R1234ze NOTE Do not use recycled refrigerant as it may contain oil, which can affect system reliability. The refrigerant should be pure and stored in virgin containers.

  • Page 16: Handling Electronic Static Devices

    Introduction 5. Wait at least 20 minutes for the DC bus 6. Remove the top cover, taking particular care capacitors to discharge. not to touch ANY components underneath. • • • DANGER • • • Removing the top cover will expose you to a high voltage hazard of up to 860VDC. Wait at least 20 minutes to allow the DC capacitors to discharge and ensure there is no Mains Input voltage present before removing the cover.

  • Page 17: Figure 5 - Mains Plate And Ground Post

    Introduction 1. Isolate the compressor power. 2. Clip the ESD strap ground clip to the compressor ground post. See white arrow in Figure 5 (Mains Plate and Ground Post). Figure 5 - Mains Plate and Ground Post Ground Post Mains Plate 3.

  • Page 18: Dc Bus Test Harness Installation And Removal

    Introduction 1.9 DC Bus Test Harness A DC bus test harness must be used when normal operation. When checks are complete, Installation and Removal testing the voltages of the compressor’s power disconnect and remove the test harness. Refer to electronics. The DC bus test harness is not Figure 8 (DC Bus Harness Connection Diagram) designed to be left in the compressor during for a connection diagram.

  • Page 19: Installation Of The Dc Bus Test Harness

    Introduction 1.9.1 Installation of the 1. Isolate the compressor power and remove the of the Compressor” section of this manual. DC Bus Test Harness top cover as described in the “Electrical Isolation • • • CAUTION • • • Use your ESD wrist strap before touching the Soft Start Board or any electronic components. 2.

  • Page 20: Figure 11 - Connect Test Harness To Compressor

    Introduction 7. Connect the two plugs of the DC bus test harness into the Soft Start Board. See Figure 11 (Connect Test Harness to Compressor). Figure 11 - Connect Test Harness to Compressor 8. Route the cables through the cable passage on either side of the HV DC-DC Converter, down into the service side.

  • Page 21: Dc Bus Test Harness Use

    Introduction 1.9.2 DC Bus Test Harness 1. Install the DC bus test harness as described voltmeter lead into the DC(+F) test harness lead, in the “Installation of the DC Bus Test Harness” and the negative voltmeter lead into the DC(-) section of this manual.

  • Page 22: Compressor Fundamentals

    Compressor Fundamentals Compressor operation begins with a demand See the OEM Programming Guide for further signal applied to the compressor. The startup details. sequence is configurable in the startup settings. 2.1 Main Fluid Path The compressor is a two-stage centrifugal type energy is added to the refrigerant.

  • Page 23: Figure 14 - Cooling Inlet Adaptors

    Compressor Fundamentals Figure 14 - Cooling Inlet Prior to Major Revision “E” Adaptors TT300 Only Major Revision “E” and Later (3/8” with strainer) (1/2” with strainer) All Other Models (1/2” without strainer) Liquid refrigerant is internally channeled to controlled rectifier (SCR) temperature reaches its two solenoid valves.

  • Page 24: Figure 15 - Compressor Motor And Power Electronics Cooling (Tt300/Tg230 Serial Cooling)

    Compressor Fundamentals Figure 15 - Compressor Motor and Power Electronics Cooling (TT300/TG230 Serial Cooling) 24 of 132 M-SV-001-EN Rev.E...

  • Page 25: Figure 16 - Compressor Motor And Power Electronics Cooling (All Models Except Tt300/Tg230 Serial Cooling)

    Compressor Fundamentals Figure 16 - Compressor Motor and Power Electronics Cooling (All Models Except TT300/TG230 Serial Cooling) 25 of 132 M-SV-001-EN Rev.E...

  • Page 26: Capacity Control

    Compressor Fundamentals 2.3 Capacity Control Capacity control of the compressor is achieved impeller rotation to increase energy efficiency primarily by speed modulation. When unloading, during part load operation. the compressor’s first action is to reduce speed to slightly above the minimum (surge) speed for Speed modulation is achieved by the use of the pressure ratio present at the time.

  • Page 27: Figure 17 - Compressor Energy And Signal Flow Connections (Tt300/Tg230 Shown)

    Compressor Fundamentals Figure 17 - Compressor Energy and Signal Flow Connections (TT300/TG230 Shown) The order of power and signal flow through 5. DC bus provides DC voltage to Inverter. the compressor components is as follows (see Figure 17 (Compressor Energy and Signal Flow 6.

  • Page 28: Figure 18 - Compressor Energy And Control Flow Block Diagram

    Compressor Fundamentals Figure 18 - Compressor Energy and Control Flow Block Diagram 28 of 132 M-SV-001-EN Rev.E...

  • Page 29: Compressor Components

    Compressor Components This section provides compressor component identification, and steps necessary to replace a locations and functional descriptions, verification component. and troubleshooting methods, cable connection 3.1 Component This section identifies the major parts of the Identification compressor. Figure 19 - Compressor Components Identification (Covers On) Component...

  • Page 30: Table 5 - Compressor Component Identification (Covers Off) (Tt300/Tg230)

    Compressor Components Figure 20 - Compressor Component Identification (Covers Off) (TT300/TG230) Component Component Table 5 - Compressor Component Identification Bearing Motor Compressor Controller Compressor I/O Board (Covers Off) (TT300/TG230) (BMCC) Bearing Pulse Width Modulation Soft Start Board (PWM) Amplifier Insulated Gate Bipolar Transistor Silicon-Controlled Rectifier (SCR) (IGBT) Inverter High-Voltage (HV) DC-DC Converter...

  • Page 31: Table 6 - Compressor Sensors, Cables, And Indicators (Tt300/Tg230)

    Compressor Components Figure 21 - Compressor Sensors, Cables and Indicators (TT300/ TG230) Component Component Table 6 - Compressor Sensors, Cables, and Discharge Temperature / Pressure Suction Temperature/Pressure Sensor Indicators (TT300/TG230) Sensor Inlet Guide Vanes (IGV) Position Motor-Winding Sensors Indicator Motor-Cooling Solenoids Bearing Sensor Ring Cable (Front) Bearing Sensor Ring Cable (Rear) PWM Current Output (Front Bearing)

  • Page 32: Table 7 - Compressor Component Identification (Covers Off ) (Tt350/Tt400/Tt500/Tt700/Tg310/Tt390/Tt520)

    Compressor Components Figure 22 - Compressor Component Identification (Covers Off) (TT350/TT400/ TT500/TT700/TG310/TG390/TG520) Component Component Table 7 - Compressor Component Identification Compressor I/O Board Serial Driver (Covers Off) (TT350/TT400/ TT500/TT700/TG310/TT390/ Bearing Motor Compressor Controller Soft Start Board (BMCC) TT520) Insulated Gate Bipolar Transistor Bearing Pulse Width Modulation (IGBT) Inverter (PWM) Amplifier...

  • Page 33: Table 8 - Compressor Sensors, Cables, And Indicators (Tt350/Tt400/Tt500/Tt700/Tg310/Tg390/Tg520)

    Compressor Components Figure 23 - Compressor Sensors, Cables, and Indicators (TT350/TT400/ TT500/TT700/TG310/TG390/TG520) Component Component Table 8 - Compressor Sensors, Cables, and Discharge Temperature / Pressure Bearing Sensor Ring Cable Indicators (TT350/TT400/ Sensor TT500/TT700/TG310/TG390/ Motor-Winding Sensors Suction Temperature/Pressure Sensor TG520) Inlet Guide Vanes (IGV) Position Motor-Cooling Solenoids Indicator Bearing Pulse Width Modulation...

  • Page 34: Compressor - Removal And Installation

    Compressor Components 3.2 Compressor - Removal and Installation • • • CAUTION • • • 3.2 .1 Refrigerant Containment Isolation and recovery of the refrigerant must be performed by a qualified service technician adhering to industry/ASHRAE standards. 1. Close the suction, discharge, and economizer 3.
  • Page 35 Compressor Components 1.Inspect the compressor to ensure all 4. Remove the motor cooling inlet adapter cap. connections and fasteners are correctly installed. See Section 3.2.3.1 (Compressor Replacement Considerations for Motor Cooling Adapter). 2. Relieve the inert gas pressure through the motor cooling Schrader valve.

  • Page 36: Figure 24 - Major Revision "E" Compressor Fittings

    Compressor Components Figure 24 - Major Revision “E” Compressor Fittings The following link will provide general http://www.hoseandfittingsetc.com/product/ information on ORFS fittings: fittings/tube-fittings/o-ring-face-seal-fittings/ orfs-nuts-sleeves/ Field installation from old style fitting 3. Source appropriate OEM specified and procured flexible line. Flexible Line 4.

  • Page 37: 3-Phase Main Voltage Input Terminal Block

    All compressors must be fitted frequency of 50/60Hz. with class T fast-acting fuses to protect the solid state Inverter. Danfoss Turbocor control does Refer to Figure 25 (Main AC Input Terminal) to NOT directly measure 3-phase power values.

  • Page 38: Verification

    Compressor Components 3.3.3 Verification 3.3.3.1 3-Phase AC Input The compressor requires a 3-phase power source Verification with UL-approved or CE-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.

  • Page 39: Removal And Installation

    Compressor Components AC Input Table 9 - Expected AC Voltage Range Nameplate Voltage Acceptable Voltage Range 575VAC 518 to 632VAC 460VAC 414 to 506VAC 400VAC 360 to 440VAC 380VAC 342 to 418VAC 5. If the meter does not show any reading, it 6.

  • Page 40: Figure 30 - Ac Input To Scrs (Tt300/Tg230)

    Compressor Components 3.3.4.2 Terminal Block 1. Isolate the compressor power as described 3. Remove the screws that secure the fuse Removal (TT300/TG230) in the “Electrical Isolation of the Compressor” assembly to the SCR at the AC input. Make note section of this manual. of the Soft Start Cable Harness locations.

  • Page 41: Soft Start Board

    Compressor Components Figure 32 - Screws Securing Terminal Block to Casting 3. Install the three bus bars to the terminal block 5. Connect the three connectors of the Soft Start and secure them. See Figure 29 (Terminal Block Cable Harness to the bus bars. See Figure 28 Bus Bars).

  • Page 42: Connections

    Compressor Components 3.4.2 Connections See Figure 33 (Soft Start Board) for cable connection locations: Figure 33 - Soft Start Board J8 - SCR Gate cable connector F1 - DC Bus fuse F5 - “B” Phase Transformer fuse Cooling Fan High Voltage AC/ DC connector F4 - “A”...

  • Page 43: Removal And Installation

    Compressor Components the DC/DC 7. Using a multimeter set for resistance measurements, place the leads on the ends 6. Using a multimeter set for resistance of the F4 and F5 fast-acting fuses. The reading measurements, place the leads on the ends of should be around 30-38Ω...

  • Page 44: Silicon-Controlled Rectifier

    Compressor Components 3.5 Silicon-Controlled Rectifier 3.5.1 Function The AC input voltage is connected to the SCRs Board generates the gate signal and outputs by the Mains Input bus bars. The SCRs are used pulses of 0-12VDC to the SCRs to control the in- to convert the AC voltage into DC voltage.

  • Page 45: Table 10 - Scr Diode Values

    Compressor Components Gate Figure 36 - Silicon-Controlled Rectifier Terminals Gate TT300/TG230 TT350, TT400, TT500, TT700, TG310, TG390, and TT520 5. All other terminals should read infinity or open in both directions (polarity). See Table 10 (SCR Diode Values). Positive (+) Lead Negative (-) Lead Expected Result Table 10 - SCR Diode Values...

  • Page 46: Removal And Installation

    Compressor Components NOTE 3.5.3.3 SCR Temperature Sensor Verification The temperature sensor in the SCR manifold is a negative temperature coefficient (NTC) type 10KΩ @ 70°F (21°C). 1. Isolate compressor power and remove the 2. Disconnect the SCR temperature sensor cable Service Side Cover.
  • Page 47 Compressor Components 3.5.4.3 SCR Installation 1. Apply a thin layer of heat sink paste to the 4. Install the AC Mains Input bus bars. See Figure bottom of the SCRs. 35 (SCR Connections). 2. Install the SCRs to the cooling manifold. 5.

  • Page 48: Dc Bus

    Compressor Components 3.6 DC Bus 3.6.1 Function The DC bus includes the bus bars, DC capacitors, Snubber capacitors reduce noise associated with snubber capacitors, and bleed resistors. See the Inverter switching frequency. Figure 38 (DC Bus Components Identification). Bleed resistors are used to discharge the The SCRs output DC voltage to the bus bars.

  • Page 49: Connections

    Compressor Components 3.6.2 Connections See Figure 39 for location of the DC bus 2. -DC to Soft Start and DC/DC connections. 3. DC bus to Inverter 1. +DC to Soft Start 3.6.3 Verification Use the DC bus test harness to determine if DC bus voltage is within the correct range for the 3.6.3.1 DC Bus Voltage application.

  • Page 50: Figure 40 - Removing Attaching Hardware From Dc Bus Bars (Tt300/Tg230 Pictured)

    Compressor Components Figure 40 - Removing Attaching Hardware from DC Bus Bars (TT300/TG230 Pictured) 4. Using needle-nose pliers, carefully remove the 7. Remove the snubber capacitors. SCR gate cable harness (TT350, TT400, TT500, and TT700 only). 8. Remove the nylon nuts at the base of the DC Capacitor Assembly, located under the main 5.

  • Page 51: Figure 42 - Insulating Mylar On Inverter (Tt300/Tg230 Only)

    Compressor Components 3.6.4.2 DC Bus 1. (TT300/TG230 only) Place the insulating Mylar Installation on the Inverter. See Figure 42 (Insulating Mylar on Inverter). Figure 42 - Insulating Mylar on Inverter (TT300/TG230 Only) 2. Place the DC capacitors and DC bus on the 7.

  • Page 52: Inverter

    Compressor Components 3.7 Inverter 3.7.1 Function The function of the Inverter (also known as the DC bus voltage information to the BMCC via the IGBT) is to take the DC bus voltage as an input Backplane. Motor currents and voltages displayed and generate the AC output voltage to the in the SMT cannot be directly compared or compressor motor at the required fundamental...

  • Page 53: Verification

    Compressor Components 3.7.3 Verification This procedure only verifies the Inverter diodes. 3. Remove the DC Capacitor Assembly. The Inverter Control Board cannot be verified in 3.7.3.1 Inverter the field. A faulty Inverter may also appear as an 4. Remove the copper standoffs and fasteners Verification “Inverter Error Signal Active”...

  • Page 54: Removal And Installation

    3.7.4 Removal and • • • CAUTION • • • Installation Removal of the Inverter mounting screws will release refrigerant. Isolation and recovery of the refrigerant must be performed by a qualified service technician adhering to industry/ASHRAE standards. This section details the steps to remove and properly and the IGBT Control Card has been install the IGBT Control Card (all models except confirmed to have failed, follow the removal and...

  • Page 55: Figure 47 - Long Spring Pin Locations

    9. Set aside the driver screws for re-use. 10. Properly discard the old driver board. • • • CAUTION • • • Do not move or touch any spring pins unless they are not in proper alignment. Damage or misalignment of spring pins can cause failure of the entire Inverter module.

  • Page 56: Figure 49 - Spring Pin Removal

    3. Discard the defective spring pins and inspect the IGBT for any foreign objects. Figure 49 - Spring Pin Removal 4. Insert the new pins carefully and verify they Spring Pins). line up in the notches. Refer to Figure 50 (Seated Figure 50 - Seated Spring Pins 5.

  • Page 57: Figure 52 - Initial Tightening Pass Sequence

    9. Insert the remaining screws and tighten the the first pass and the screws should only be snug screws from center outward according to Figure and not torqued at this step. 52 (Initial Tightening Pass Sequence). This will be Figure 52 - Initial Tightening Pass Sequence 10.

  • Page 58: Figure 54 - Removing The Inverter (Tt300/Tg230 Shown)

    Compressor Components • • • CAUTION • • • Removal of the Inverter mounting screws will release refrigerant. Isolation and recovery of the refrigerant must be performed by a qualified service technician adhering to industry/ASHRAE standards. 3.7.4.3 Inverter Removal 1. Isolate the compressor power as described 9.

  • Page 59: Motor

    Compressor Components 3.8 Motor 3.8.1 Function The motor type employed is a permanent section of the motor is similar in design to a magnet, synchronous speed motor. The winding standard 3-phase star-connected Stator. 3.8.1.1 Stator The Stator operates as the force that drives the shaft, utilizing the HV DC pulses provided to the motor windings by the Inverter.

  • Page 60: Verification

    Compressor Components 3.8.4 Verification • • • CAUTION • • • 3.8.4.1 Stator Insulation Do not attempt to perform an insulation test on a component under vacuum. This can cause insulation breakdown or failure Verification during the testing process. 1. Isolate the compressor power as described 3.

  • Page 61: Figure 56 - Stator Thermistor R/T Curve 1

    Compressor Components Figure 56 - Stator Thermistor R/T Curve 1 61 of 132 M-SV-001-EN Rev.E...

  • Page 62: High-Voltage Dc/Dc Converter

    Compressor Components 3.9 High-Voltage DC/DC Converter 3.9.1 Function The HV DC/DC Converter provides the Backplane DC bus voltage (460-900VDC) is supplied to the with +24VDC (with respect to 0V) and HV+ HV DC/DC converter through the Soft Start Board (+250VDC with respect to HV-) for the Bearing F1 fuse.

  • Page 63: Verification

    Compressor Components 3.9.3 Verification 1. Isolate the compressor power as described 3. Turn on the mains power to the compressor. 3.9.3.1 Input Voltage in the “Electrical Isolation of the Compressor” Verification section of this manual. 4. Using the DC bus test harness, verify the expected voltages are present.

  • Page 64: Removal And Installation

    Compressor Components 3.9.4 Removal and Installation 3.9.4.1 HV DC/DC 1. Isolate the compressor power as described 4. Loosen the screws next to the Inverter. Converter Removal in the “Electrical Isolation of the Compressor” section of this manual. 5. Remove the screws located on front side of the converter.

  • Page 65: Backplane Connections And Test Points

    Compressor Components 3.10.2 Backplane The Backplane connections and test points are Connections and Test indicated in Figure 60 (Backplane Connections Points and Test Points). Figure 60 - Backplane Connections and Test Points J16: Motor-Cooling Solenoids Control Port +15V Test Point +5V Test Point 24V Test Point J17: SCR Temperature Sensor Port...

  • Page 66: Removal And Installation

    Compressor Components NOTE 3.10.2.2 Backplane Verification The test-point LEDs are ON if any voltage is present. The test points must be measured to determine the actual voltage. 1. Remove the Service Side Cover. 5. Using a multimeter set for resistance measurements, place the multimeter leads in 2.

  • Page 67: Serial Driver

    Compressor Components 8. Remove the Backplane from the housing. 3.10.3.2 Backplane 1. Align the Backplane with the mounting Installation 5. Remove the Inverter ground screw from top holes, ensuring the cavity temperature sensor connector is available. right of the Backplane. 2.

  • Page 68: Removal And Installation

    BMCC to the Serial Driver. The orifice body. For solenoid identification by actuator cable is clipped to J16 on the Backplane. model, reference the Danfoss Turbocor Spare See Figure 60 (Backplane Connections and Test Parts Guide.

  • Page 69: Verification

    Compressor Components Figure 64 - Motor Cooling Solenoid Actuators 3.12.3 Verification • • • CAUTION • • • 3.12.3.1 Resistance Measurement of Cooling When actuator coils are removed from the solenoids, they must be replaced in the same location. Incorrect installation can result in damage to compressor components.

  • Page 70: Removal And Installation

    Compressor Components 3.12.3.2 Output Voltage 1. Remove the Service Side Cover. 3. When the solenoids are energized, measure to Solenoids the +24V test point on the Backplane to verify 2. To ensure the Serial Driver is providing power the Serial Driver is providing power to the motor to the solenoids, look for the Cool-L and Cool-H cooling solenoids.

  • Page 71: Igv

    Compressor Components For split cooling models ONLY mark on the outside of the component or by the presence of an “R” affixed to the coil. See Figure •The actuator coil positions are dedicated. 64 (Motor Cooling Solenoid Actuators). •The coils can be disassembled to verify the wire •The left-side coil can be identified by no mark colors for proper reinstallation.

  • Page 72: Verification

    Compressor Components 3.13.3 Verification 3.13.3.1 IGV Stepper 1. Isolate compressor power. 3. Measure the resistance between terminals 1 Motor Verification and 2, and 3 and 4 of the IGV Motor feed through. 2. Disconnect the compressor controller cable The measured value should be between 46Ω and from the suction pressure/temperature sensor 59Ω.

  • Page 73: Bmcc

    Compressor Components 3.13.4.1 IGV Removal 1. Isolate compressor power. 3. Detach the connector on the IGV Housing. See Figure 69 (Disconnecting the Power to the IGV 2. To disconnect power to the IGV Motor, remove Motor). the clamp securing the connector. See Figure 68 (IGV Motor Feed Through).

  • Page 74: Verification

    Compressor Components • • • CAUTION • • • 3.14.3 Verification When the BMCC is disconnected from the Backplane, it is important that the Inverter remain connected. Either the BMCC or Inverter is required to be connected to the Backplane before applying power to the compressor. 3.14.3.1 BMCC Power 1.

  • Page 75: Compressor Interface Module

    Compressor Components 3. Reinstall the Serial Driver. 6. If a BMCC that is not original to the compressor is installed, a calibration must be completed and 4. Reinstall Service Side Cover. saved to the EEPROM to match the BMCC to the compressor.
  • Page 76 Compressor Components 3.15.2.1 Compressor J1 – RS-485 communication port • EXV2 – Pin 1 to 4 Interface Module Connection Descriptions J5 – Liquid Level input • Jumper JP2 required at end of Modbus line. J2 – Input/output • LIQ LEV 1 – Pin 4 to 6 – Liquid level sensor driving the electronic expansion valve1 (EXV1).

  • Page 77: Verification

    Compressor Components - Refer to the Application Manual for thermistor - Refer to the OEM Programming Guide for specifications. software implications. • Spare P: External pressure sensor input D1 to D8 – EXV LED indicators: Red: 2 sets of 4 LEDs for EXV 1 &...

  • Page 78: Removal & Installation

    Compressor Components 3.15.3.3 Interlock 1. Ensure the compressor interface cable is • If the measured value is not 0VDC, locate and Verification properly attached to the Backplane and to the remove the source of the voltage. CIM and the BMCC is properly attached to the Backplane.

  • Page 79: Bearing Pulse Width Modulator Amplifier

    Compressor Components 3.15.4.2 Compressor I/O 1. Install the left foot of the replacement board 2. Reconnect all external connections and wiring Board Installation into the rail and press the right side of the board on the CIM. down until it engages the rail. 3.

  • Page 80: Connections

    Compressor Components 3.16.2 Connections J1 on the Backplane is the PWM connection port. There are different housings for the Turbocor See Figure 75 (Bearing Power Feed Throughs and compressors. The Major Revision “E” and earlier PWM Connection Port). compressors utilize feed throughs with external male pins while the Major Revision “F”...

  • Page 81: Verification

    Compressor Components NOTE 3.16.3 Verification A faulty PWM Amplifier may be the result of a bearing failure and may cause a failure of the DC/DC resulting in a blown F1 fuse on the Soft Start. If a PWM Amplifier is found to be faulty, the bearing actuator coils, DC/DC and F1 Fuse must also be verified. Several verification methods are available for the •...

  • Page 82: Figure 77 - Connecting Leads To Pwm Connector And Hv- Test Point

    Compressor Components Figure 77 - Connecting Leads to PWM Connector and HV- Test Point Red (+) Lead to HV- Major Revision “E” and Earlier Major Revision “F” and Later Black (-) Lead to PWM Molex Connector Black (-) Lead to PWM Connector 6.

  • Page 83: Removal And Installation

    Compressor Components 3.16.4 Removal and Installation 3.16.4.1 PWM Amplifier 1. Isolate compressor power and wait for the LEDs disconnect the Molex connector for the PWM and Removal on the Backplane to turn off. bearing feed through. 2. Remove the Serial Driver. 5.

  • Page 84: Magnetic Bearings

    Compressor Components 3.17 Magnetic Bearings 3.17.1 Function The compressor shaft and impellers levitate Figure 80 (Radial Magnetic Bearings) and Figure during operation and float on a magnetic 72 (Axial Magnetic Bearing). Centered rotation is cushion created by the magnetic bearings. instantaneously self-corrected and maintained by Permanent magnets do most of the work and the bearing control loop.

  • Page 85: Connections

    Compressor Components 3.17.2 Connections PWM connectors supply power at the bearing power feed throughs. See Figure 82 (Bearing Power Feed Throughs). Figure 82 - Bearing Power Feed Throughs Major Revision “E” and Earlier Major Revision “F” and Later Front Radial Bearing Power Feed Through Rear Radial and Axial Bearing Power Feed Through...

  • Page 86: Table 14 - Magnetic Bearing Coil Resistance Values

    Compressor Components Compressor Model & Design Sequence Table 14 - Magnetic Bearing Coil Resistance Values TT350 Feed Through Pin TT300, TT400C, E, F, Connector Location Bearing Identification TT400P, TT500, TT700, Identification TG230, & TG390 TG310, & TG520 1 & 6 2.70 - 3.25Ω...

  • Page 87: Table 15 - Bearing Amperage Ranges

    Compressor Components Figure 85 - Front and Rear Rear Front Bearing Feed Throughs with Molex Connectors 3.17.3.2 Bearing 1. Connect to the compressor using the SMT. 3. In the bearing section, verify the bearing Current Verification amperages displayed are within the range 2.

  • Page 88: Bearing Sensors

    Compressor Components 3.18 Bearing Sensors 3.18.1 Function Bearing sensors feed back real-time shaft orbit information to the bearing control loop. See Figure 74 (Bearing Control Signal Flow). 3.18.2 Connections The Bearing Sensors are connected internally to The bearing sensor feed throughs are connected the Bearing Sensor feed throughs located above to the bearing sensor cables which connect to J9 the front and rear bearing power feed throughs.

  • Page 89: Verification

    Compressor Components 3.18.3 Verification 3.18.3.1 Bearing Sensor 1. Isolate compressor power and wait for the LEDs • NOTE: There are no connections on Pins 1 & 4 and Resistance Verification on the Backplane to turn off. 1 & 9 on the rear bearing sensor feed through. 2.

  • Page 90: Verification

    Compressor Components 3.19.3 Verification 1. Isolate compressor power. • The Cavity Temperature Sensor is a 10KΩ @ 77°F (25°C) NTC thermistor. The resistance value 2. Remove the Service Side Cover, verifying the should correspond to Figure 91 (Temperature vs. LEDs on the Backplane have turned off. Resistance).

  • Page 91: Removal And Installation

    Compressor Components 3.19.4 Removal and Installation 3.19.4.1 Cavity 1. Isolate compressor power. 4. Remove the Serial Driver, BMCC, PWM, and the Temperature Removal Backplane. 2. Isolate the compressor and recover the refrigerant according to industry standards. 5. Remove the cavity temperature sensor. See Figure 92 (Cavity Temperature Sensor Removal).

  • Page 92: Pressure/Temperature Sensor

    Compressor Components 3.20 Pressure/ Temperature Sensor 3.20.1 Function The suction and discharge pressure/temperature are used to calculate pressure ratios, saturated sensors are used to inform the compressor of temperatures, superheat and the location within the operating pressures and temperatures at the operating envelope where the compressor is the suction and discharge ports.

  • Page 93: Removal And Installation

    Compressor Components Figure 94 - Pressure/ Temperature Sensor Pin Locations 3.20.4 Removal and Installation 3.20.4.1 Pressure/ The following procedure applies to both suction 2. Isolate the compressor; recover the refrigerant Temperature Sensor and discharge pressure/temperature sensors. according to industry standards. Removal 1.

  • Page 94: Troubleshooting

    Troubleshooting 4.1 Alarm and Fault The first step in troubleshooting is to gather as and compressor starts, as well as the value of Indications many facts as possible. Compressor fault and pertinent parameters at the time of the fault. event logs provide factual historical information These logs should be reviewed in detail to gain that will indicate the exact reason that the information to allow efficient troubleshooting for...

  • Page 95: Table 18 - Compressor Fault Types

    Troubleshooting Compressor Description Table 18 - Compressor Fault Types Inverter Temperature The measured Inverter temperature has exceeded the fault limit. Discharge Temperature The measured discharge temperature has exceeded the fault limit. Suction Pressure The measured suction pressure has exceeded the fault limit. The measured discharge pressure has exceeded the fault limit.

  • Page 96: Table 19 - Motor Fault Types

    Troubleshooting Compressor Description Table 19 - Motor Fault Types Motor Single Phase Overcurrent Measured peak current value of any single phase to motor (from Inverter) Fault exceeds the fault limit. The measured DC bus voltage has exceeded the Maximum Bus Voltage DC Bus Overvoltage Fault limit.

  • Page 97: Troubleshooting With The Service Monitoring Tools Software

    Troubleshooting 4.2 Troubleshooting With The Service Monitoring Tools (SMT) software Depending on compressor access level, the the Service Monitoring package can be used to view detailed compressor following tools may be available from the SMT Tools Software information for operational status indications and Tool Suite Launcher Strip.

  • Page 98: Compressor Fault Troubleshooting

    Troubleshooting Table 21- Service Monitoring Tools Icons (Continued) Icon Tool Description View and configure the compressor operation, shutdown configuration, IGV startup, Compressor Configuration communication configuration, surge/choke, and other operational configuration parameters. View, modify and commit site-specific compressor parameter values of a connected Compressor compressor, as well as import and export configurations between portable files.

  • Page 99: Figure 96 - Fault Trigger Methods

    Troubleshooting Figure 96 - Fault Trigger Methods Fault Reset: A fault that does not require a A fault demanding a power cycle (Lock-Out power cycle to clear (non-critical) can be reset in Fault) is resettable by cycling the mains power the following manner: Interlock must be closed, to the compressor.

  • Page 100: Table 22 - Compressor Faults

    Troubleshooting Table 22 - Compressor Faults Compressor Fault Trigger Troubleshooting Description Method Indicates the Inverter cooling is insufficient. If this fault occurs three times within a 30-minute period, a Lock-Out Fault will occur. CAUTION: Repeated occurrences of this alarm can result in Inverter failure. Ensure the liquid motor-cooling line has sufficient liquid supply and is not blocked.
  • Page 101 Troubleshooting Table 22 - Compressor Faults (Continued) Compressor Fault Trigger Troubleshooting Description Method Review fault log for indication of values out of specified ranges recorded at time of fault. Verify the questionable sensor and related connections for failure. Inverter temperature: The sensor embedded in the Inverter requires a replacement of the Inverter if determined faulty.

  • Page 102: Motor Faults/System Status

    Troubleshooting 4.2.2 Motor Faults/System Status Table 23 - Motor Faults Motor Fault Trigger Troubleshooting Description Method One phase of the Inverter to motor is generating high current. Review Fault and Event Log details to determine conditions related to the fault. This fault can be a result of liquid carryover, a loss of shaft magnetic strength, see Back EMF is Low fault, or Inverter failure, see Inverter Error fault.

  • Page 103: Bearing Status

    Troubleshooting Table 23 - Motor Faults (Continued) Motor Fault Trigger Troubleshooting Description Method Suggests the measured 24VDC supply voltage is out of range. Measure the 24VDC test points at the Backplane. Compare the measured voltages to the displayed readings in the Compressor Monitor Tool and Fault and Event 24VDC Under/Over Log details to determine conditions related to the fault.

  • Page 104: Bearing Calibration

    Troubleshooting 4.3 Bearing Calibration 4.3.1 When to Calibrate the Bearings 4.3.1.1 Calibration When A bearing calibration can be performed at performed, a calibration report should be created Commissioning commissioning for the purpose of comparing and saved for future comparison. There is no current calibration values to factory saved requirement to save the calibration to EEPROM calibration values.

  • Page 105: Figure 97 - Bearing Calibration Tool

    Troubleshooting Figure 97 - Bearing Calibration Tool If the message “Calibration Failed” or “Levitation •Ensure the RS485 at J1 on the I/O board is Failed” appears when attempting to calibrate, it disconnected from external communication; indicates the steps expected by the SMT have if the chiller controller automatically sets the not been completed.

  • Page 106: After Calibration Is Complete

    Troubleshooting 4.3.3 After Calibration is The message “Calibration Complete” appears • Save to EEPROM (If the Save to RAM & EEPROM Complete when all SMT calibration steps are complete, radio button is selected on the Connection regardless of the results. There will be three Manager Window) options available after the calibration has completed.

  • Page 107: Calibration Report Analysis

    Troubleshooting 4.3.5 Calibration Report 1. Data in Report: The difference between the • Interpretation: Bearing electrical fault or shaft Analysis “Latest Calibration” and “Stored Calibration” is less is obstructed. than 30 percent. • Action: Verify the bearings. • Interpretation: Successful calibration. •...

  • Page 108: Figure 98 - Bearing Calibration Flow

    Troubleshooting Figure 98 - Bearing Calibration Flow Do not save calibration to EEPROM. Create a calibration report. Return compressor to Successful Re- normal operation Calibration. Return Verify the compressor to bearings normal operation Verify the bearing sensors Could the shaft run Does shaft Shaft is Does shaft levitate...

  • Page 109: Compressor Connection Status Indications

    Troubleshooting 4.4 Compressor • Disconnected: no connection exists with a • No compressor found: Any serial ports or Connection Status compressor or remote compressor host connections have been established, but a valid Indications compressor was not able to be detected •...
  • Page 110 Troubleshooting • If the SCRs pass test, replace the Soft Start then • If all voltages are within +/- 10%, proceed to repeat Step 13. Step 26. • If one or more of the SCRs test faulty, replace all • If either voltage is not within +/- 10%, isolate three of the SCRs then repeat Step 12.

  • Page 111: Determining The Cause Of An Energy Drain

    Troubleshooting 4.5.2 Determining the Cause of an Energy Drain 4.5.2.1 Determining if 1. Remove the Service Side Cover. 4. Remove the Serial Driver. Serial Driver is Draining Energy 2. Test the Backplane voltages at the +24V, +15, 5. Re-apply the compressor power +5, and -15 VDC test points.

  • Page 112: Determining The Cause Of Blown Soft Start Fuses

    Troubleshooting • If all voltages are within (+/- 10%) the PWM is • If any of these voltages are not within (+/- 10%) draining energy. another component is draining energy. 4.5.2.4 Determining 1. Remove the Service Side Cover. • If the +24V reading drops below 22VDC at if Inverter is Draining the moment the demand to drive is given, the Energy...

  • Page 113: Troubleshooting An Open Interlock

    Troubleshooting 4.5.4 Troubleshooting an 1. Verify the interlock, see Section 3.15.3.3. 4. Move the wire to the SPEED-(neg) at the J2 Open Interlock connector of the I/O board. 2. Ensure there is 0VDC (no external power applied) on the interlock circuit. 5.

  • Page 114: Maintenance

    Maintenance 5.1 Preventive Table 25 (Preventative Maintenance Tasks) lists Maintenance Tasks tasks that should be performed on a regular basis to maintain optimal performance of the system. Table 25 - Preventive Maintenance Tasks Frequency Item Task 6 Mos 12 Mos Other General Check physical condition of compressor.

  • Page 115: Moisture Prevention Measures

    Maintenance 5.2 Moisture Prevention Measures 5.2.1 Required Items This section applies to all TT and TG compressors. electrical connections. Condensation issues may become exaggerated in hot and humid The following steps are recommended to prevent conditions. condensate infiltration and stagnation in the Consumables: •...

  • Page 116: Figure 100 - Motor Cooling Valve Solenoids

    Maintenance 5. Remove the Motor-Cooling Valve Solenoid Coils by removing the screws on each solenoid. • • • CAUTION • • • The solenoid actuators are dedicated on all models except TT300/TG230. Provide a position reference mark before removal. 6. Dry off any condensate around the solenoids. Figure 100 - Motor Cooling Valve Solenoids 7.

  • Page 117: Figure 102 - Dielectric Grease Under Gasket

    Maintenance 17. Apply thin coating of dielectric grease to gaskets. See Figure 102 (Dielectric Grease Under the underside of bearing power feed through Gasket). Figure 102 - Dielectric Grease Under Gasket 18. Install the greased neoprene gaskets over the through pins. feed through pins.

  • Page 118: Figure 105 - Motor-Winding Sensor Dielectric Grease Application

    Maintenance 5.2.1.2 Service Side 1. Install the bearing sensor cables. the exterior of the bearing sensor feed through Assembly connectors. 2. Apply a thin coating of dielectric grease to • • • CAUTION • • • Do not apply any dielectric grease directly to bearing sensor feed through DB9 pins, only apply grease around bearing sensor feed through connectors after the cables are connected to prevent moisture from entering the pin area.

  • Page 119: Figure 106 - Motor Bus Bar Screws

    Maintenance Figure 106 - Motor Bus Bar Screws 9. Dry off any condensate around the SCR screws. 13. Wait for surfaces to dry completely. 10. Remove any debris or dust from the SCR 14. Once they are dry, apply a coat of rust screws.
  • Page 120 THIS PAGE INTENTIONALLY LEFT BLANK 120 of 132 M-SV-001-EN Rev.E...

  • Page 121: Appendix A Acronyms/Terms

    Part of a centrifugal compressor in the fluid module that transforms the high-velocity, low-pressure gas exiting the impeller into Diffuser high-pressure, low-velocity gas discharged into the condenser. Down-Trip Voltage A voltage threshold where, if the incoming AC voltage drops below it, the Soft Start will shut down. Danfoss Turbocor Compressors Inc. 121 of 132 M-SV-001-EN Rev.E...
  • Page 122 Appendix A Acronyms/Terms Table 26 - Acronyms/Terms (Continued) Acronym / Term Definition Electrical Erasable Programmable Read Only Memory: A type of non-volatile memory used in computers and other electronic EEPROM devices to store small amounts of data that must be saved when power is removed. It has a limited number of times it can be reprogrammed and an unlimited number of reads.
  • Page 123 Appendix A Acronyms/Terms Table 26 - Acronyms/Terms (Continued) Acronym / Term Definition Permanent Magnet Type of motor that uses permanent magnets to produce torque. Motor Portable Document Format. A format created by Adobe Systems, Inc. that uses Adobe Acrobat software to create documents that can be shared for reading and printing without needing the source document’s creation tool.

  • Page 124: Appendix B Compressor Troubleshooting Flowcharts

    Appendix B Compressor Troubleshooting Flowcharts This appendix contains flowcharts for 108) and Compressor Voltage Troubleshooting Compressor Operation Troubleshooting (Figure (Figure 109 and Figure 110). Figure 108 - Compressor Operation Troubleshooting Flowchart 124 of 132 M-SV-001-EN Rev.E...

  • Page 125: Figure 109 - Compressor Voltage Troubleshooting Chart 1

    Appendix B Compressor Troubleshooting Flowcharts Figure 109 - Compressor Voltage Troubleshooting Chart 1 125 of 132 M-SV-001-EN Rev.E...

  • Page 126: Figure 110 - Compressor Voltage Troubleshooting Chart 2

    Appendix B Compressor Troubleshooting Flowcharts Figure 110 - Compressor Voltage Troubleshooting Chart 2 126 of 132 M-SV-001-EN Rev.E...

  • Page 127: Appendix C Compressor Test Sheet

    Appendix C Compressor Test Sheet Verification Component Test Point Expected Value Measured Value Section Backplane DC Voltage 0V to 24V 22 to 26 VDC 3.10.2.2 0V to +15V 14.75 to 15.25 VDC 3.10.2.2 -14.75 to -15.25 0V to -15V 3.10.2.2 0V to 5V 4.75 to 5.25 VDC 3.10.2.2...
  • Page 128 Appendix C Compressor Test Sheet Verification Component Test Point Expected Value Measured Value Section Phase 2: - Lead on AC 0.275V – 0.4V 3.7.3 Output to - DC input Phase 2: - Lead on AC Open 3.7.3 Output to + DC input Phase 3: - Lead on AC 0.275V –...
  • Page 129 Appendix C Compressor Test Sheet Verification Component Test Point Expected Value Measured Value Section F4 & F5 30-38Ω 3.4.3.2 Solenoid Actuators 4.8 W 108Ω – 132Ω 3.12.3 9.3 W 56.25Ω – 68.75Ω 3.12.3 Stator Resistance Phase 1:2 > 0.0Ω and < 1Ω 3.8.4.2 Phase 1:3 >...
  • Page 130 Notes 130 of 132 M-SV-001-EN Rev.E...
  • Page 131 Mobile Application | TurboTool® App DanfossTurboTool® App quick access to compressor troubleshooting 24/7 Access to Danfoss Turbocor® compressor troubleshooting on site Scan here to download the App 131 of 132 M-SV-001-EN Rev.E...
  • Page 132 Our products can be found in a variety of applications such as rooftops, chillers, residential air conditioners, heatpumps, coldrooms, supermarkets, milk tank cooling and industrial cooling processes. http://turbocor.danfoss.com Danfoss Turbocor 1769 E. Paul Dirac Drive 1769, Tallahassee FL 32310 USA | +1 850 504 4800 © Danfoss | DCS (CC) | 2017.11 M-SV-001-EN Rev.E...

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