Danfoss Turbocor TT Series Installation Manual
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Danfoss Turbocor TT Series Installation Manual

Twin-turbine centrifugal compressors
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Applications and Installation Manual - Revision N
Danfoss Turbocor® Twin-Turbine
Centrifugal Compressors
TT & TG Series Compressors
®
http://turbocor.danfoss.com

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  • Page 1 Applications and Installation Manual - Revision N Danfoss Turbocor® Twin-Turbine Centrifugal Compressors TT & TG Series Compressors ® http://turbocor.danfoss.com...
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  • Page 3: Table Of Contents

    Content 1 Introduction ............................9 1.1 Scope ........................................9 1.2 Organization of this Manual ................................9 1.3 Document Symbols ................................... 10 1.4 Definitions ......................................11 2 Overview of the TT/TG Compressor ....................15 2.1 TT/TG Compressor Nomenclature ..............................15 2.2 Refrigerant Type ....................................15 2.2.1 TG Series .....................................
  • Page 4 Content 8 Operating Envelopes ........................45 9 Minimum Unloading Capacity ......................51 10 Control Logic Guidelines for Multiple Compressors ..............53 11 Product Certification ........................55 12 Guide Specifications ........................57 12.1 General........................................ 57 12.2 Refrigerant ......................................57 12.3 Compressor Bearings ..................................57 12.4 Capacity Control ....................................57 12.5 Compressor Motor ..................................
  • Page 5 List of Tables Table 1-1 - Application Manual Applicability .............................9 Table 1-2 - Definitions ....................................11 Table 2-1 - Refrigerant Used with Turbocor Compressors ......................15 Table 3-1 - Backplane LEDs ..................................25 Table 4-1 - Control Wiring Details ................................ 29 Table 5-1 - Discharge Pressure Alarm and Trip Settings ......................
  • Page 6 List of Figures Figure 2-1 - Compressor Nomenclature ............................15 Figure 2-2 - Major Components ................................16 Figure 3-1 - Compressor Fluid Path TG230 / TT300 ........................19 Figure 3-2 - Compressor Fluid Path (TG310, TT350, TG390, TT400, TG520, and TT700) ........... 20 Figure 3-3 - Compressor Cooling Circuit (TG230 / TT300) ......................
  • Page 7 Proprietary Notice Copyright, Limitations of Liability and Revision Rights. This publication contains proprietary information to Danfoss Turbocor Compressors (DTC). By accepting and using this manual, the user agrees that the information contained herein is utilized solely for operating DTC equipment or third party vendor equipment intended for communication with DTC equipment over a serial communication link.
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  • Page 9: Introduction

    (to 1 KV high power AC & DC) as well as complex control systems. Some potential safety situations may not be foreseen or covered in this guide. Danfoss Turbocor Compressors (DTC) assumes personnel using this manual and working on DTC compressors are familiar with, and carry out all safe work practices necessary to ensure safety for personnel and equipment.

  • Page 10: Document Symbols

    Introduction 1.3 Document Symbols The following symbols are used in this document. NOTE: Indicates something to be noted by the reader. NOTE DANGER: Indicates an essential operating or maintenance procedure, practice, or condition, which, if not strictly observed, could result in serious injury to or death of personnel or long-term health hazards.

  • Page 11: Definitions

    D-Sub connectors on either side of the I/O cable are both types of D-Sub connectors. Danfoss Turbocor compressors Inc. Electrically Erasable Programmable Read Only Memory. A small chip holds bits of data code that can be rewritten and erased by an electrical charge, one byte at a time. EEPROM data EEPROM cannot be selectively rewritten;...
  • Page 12 Introduction Acronym / Term Definition Electromagnetic Compatibility Electromotive Force Electromagnetic Interference EMI Filter A circuit or device that provides electromagnetic noise suppression for an electronic device Extended Performance Compressor ETL Testing Laboratories, now a mark of Intertek Testing Services Electronic Expansion Valve. Pressure-independent refrigerant metering device driven by electrical input A record of events occurring during the compressor’s lifecycle, indicating when events and Event Log...
  • Page 13 Introduction Acronym / Term Definition Light-Emitting Diode The elevation or suspension of the compressor shaft by the magnetic field created by the Levitation magnetic bearings. A transformer-like device designed to introduce a specific amount of inductive reactance into a circuit. When this occurs, it limits the change in current in the line, which in turn Line Reactor filters the waveform and attenuates electrical noise and harmonics associated with an inverter/drive output.
  • Page 14 Similar to a Vaned Diffuser, except that it does not possess any de-swirl vanes Volts Direct Current Variable Frequency Drive * Danfoss Turbocor’s commitment to excellence ensures continuous product improvements. * Subject to change without notice. Page 14 of 108...

  • Page 15: Overview Of The Tt/Tg Compressor

    Overview of the TT/TG Compressor 2 Overview of the The TT/TG Centrifugal series of compressors is a group of compressors that covers the TT/TG Compressor nominal capacity range from 90 to 200 Tons (TT) and 70 to 150 Tons (TG) tons. The TT/TG series of compressors are an oil free centrifugal design based on magnetic bearing technology.

  • Page 16: Environment

    Humidity: 0-95% Non Condensing NOTE • Contact Danfoss Turbocor for lower ambient temperature operations. Refer to “Operating Envelopes, ” for details of the operating conditions. These conditions are in line with the AHRI 540 Standard. • All compressors/components should be protected from environments that could cause corrosion to exposed metals. For outdoor installations, a weather-proof enclosure with vents is recommended to house the compressor.

  • Page 17: Compressor Module

    Overview of the TT/TG Compressor 2.5 Compressor Module This section provides a brief overview of the Compressor Module. The Compressor Module is comprised of three (3) portions: • Aerodynamics - The aerodynamics portion manages the compression of refrigerant through the compressor from suction to discharge comprising centrifugal and IGV technologies.
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  • Page 19: Functional Description

    Functional Description 3 Functional Description Compressor operation begins with a call for cooling from a chiller controller. The compressor controller then begins compressor ramp-up. 3.1 Main Fluid Path The following paragraphs describe the flow of refrigerant from the intake to the discharge port of the compressor (see Figure 3-1 and Figure 3-2).

  • Page 20: Motor Cooling

    Functional Description Figure 3-2 - Compressor Fluid Path (TG310, TT350, TG390, TT400, TG520, and TT700) Volute Assembly Discharge Port High - Pressure / High - Temperature Low - Pressure / Low - Temperature Gas 2nd Stage Impeller Inlet Guide Vanes (IGV) Vaneless Diffuser 1st Stage Impeller De-swirl Vanes...

  • Page 21: Figure 3-3 - Compressor Cooling Circuit (Tg230 / Tt300)

    Functional Description Figure 3-3 - Compressor Liquid Refrigerant Cooling Circuit (TG230 / Inlet TT300) Solenoid Solenoid BMCC From SCR Temp. Sensor ORIFICE ORIFICE From IGBT Temp. Sensor IGBT BMCC From Motor From Motor Winding Temp. Cavity Temp. Sensor Sensor Motor/Rotor cooling gas and leakage Cooling path...

  • Page 22: Inlet Guide Vanes

    Functional Description 3.3 Inlet Guide Vanes The Inlet Guide Vane (IGV) assembly is a variable-angle guiding device that is used for capacity control. The IGV assembly consists of movable vanes and a motor. The vane opening is determined by the BMCC and controlled by the Serial Driver. The IGV position can vary between 0-110% where 0% is fully closed and 110% is fully open with the vanes at a 90°...

  • Page 23: Motor Drive System

    Functional Description 3.4.1 Motor Drive System Normally, AC power to the compressor remains on even when the compressor is in the idle state. The compressor motor requires a variable-frequency three-phase source for variable- speed operation. The AC line voltage is converted into a DC voltage by Silicon-Controlled Rectifiers (SCRs).

  • Page 24: Expansion Valve Control

    Functional Description 3.4.6 Expansion Valve The on-board Electronic Expansion Valve (EXV) driver uses manual control only. Control Depending on the application, a load balancing (hot gas bypass) valve can be manually driven by the auxiliary EXV output. Load balancing allows the compressor to obtain lower capacities at higher pressure ratios.

  • Page 25: Bearing Pwm Amplifier

    Functional Description 3.4.10 Bearing PWM The Bearing PWM Amplifier supplies current to the radial and axial magnetic bearing Amplifier actuators. The PWM Amplifier consists of high-voltage switches that are turned on and off at a high frequency, as commanded by the PWM signal from the BMCC. 3.4.11 Serial Driver The Serial Driver module performs serial-to-parallel conversion on the stepper motor drive signals from the BMCC.

  • Page 26: High-Voltage Dc-Dc Converter

    Functional Description 3.4.13 High-Voltage DC- DC-DC converters supply and electrically isolate the high and low DC voltages that are DC Converter required by the control circuits. The HV DC-DC Converter delivers 24VDC and 250VDC from an input of 460-900VDC. The 24VDC and 250VDC are used to power the Backplane and magnetic bearing PWM Amplifier, respectively.

  • Page 27: Figure 3-7 - Magnetic Bearing Control System

    Functional Description Figure 3-7 - Magnetic Bearing Control System Bearing-Motor- Position Feedback Position Feedback Compressor Controller (BMCC) Channel Assignments Axi s Bea ri ng Cha nnel Position Command Front Ra di a l Signals Front Ra di a l Rea r Ra di a l Shaft Shaft Bearing...

  • Page 28: Control Interface Wiring

    Control Interface Wiring 4 Control Interface Wiring The Compressor I/O Board is the entry point for control wiring from the chiller/plant to the compressor. Refer to Figures 4-1 and 4-2 for the proper Compressor I/O Board connectivity. Figure 4-1 - Typical Control Wiring RS232 Monitoring Connector (DB9) EXV Phase 1A...

  • Page 29: Control Wiring Connection Guidelines

    Control Interface Wiring Table 4-1 - Control Wiring Details Description COM (shield) Shield for RS-485 communication Modbus RS-485 NetB/NetA Modbus over RS-485 communication port Stepper Motor 1 Phase 1A, 1B, 2A, Optional output connections for controlling the main electronic expansion 2B and valve (evaporator) or auxillary electronic expansion valve (economizer or load Stepper Motor Phase 1A, 1B, 2A,...

  • Page 30: Interface Cable

    Control Interface Wiring 4.2 Interface Cable The cable that carries the I/O communication to the compressor is 5 meters (16.4 feet) in length and is equipped with high-density 44-pin connectors (female at one end and male at the other end). An extension cable is available from your local supplier. An optional 10 meter (32.8 ft) cable is also available in the Spare Parts Selection Guide.

  • Page 31: Compressor I/O Board Mounting Details

    Control Interface Wiring 4.3 Compressor I/O Board The Compressor I/O Board (Figure 4-4) must be installed in a UL-approved electrical Mounting Details enclosure equipped with DIN EN 50022, 50035, or 50045 mounting rails. The board should be mounted in a dry area free from vibration and electrical noise. NOTE The UL listed enclosure should protect against moisture and other corrosive elements.
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  • Page 33: General Specifications

    General Specifications 5 General Specifications • Compressor - Semi-hermetic design 5.1 Construction • Main Housing - Dimensionally-stabilized aluminum • Covers - High-impact, UV stabilized, flame-resistant polymer. • Covers - High-impact, UV stabilized, flame- resistant polymer. TG series is identified by green cover. •...

  • Page 34: Maximum Discharge Temperature

    General Specifications 5.3 Maximum Discharge The maximum temperature that the compressor can operate is regulated directly by the Trip Temperature Limit. The Maximum Discharge Temperature Limits are defined in Table 5-2. Table 5-2 - Discharge Temperature Trip Settings Unit Compressor TG230 ST TG230 MT TG310 ST TG390 ST...

  • Page 35: Suction Pressure Limits

    General Specifications 5.4 Suction Pressure The Suction Pressure alarm and trip limits are displayed in the Table 5-5. Limits Table 5-5 - Suction Pressure Alarm and Trip Settings Alarm Trip Model kPa(g) PSIG kPa(g) PSIG TG230ST TG230MT TG310 TG390 TG520 TT300ST TT300MT TT350...
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  • Page 37: Electrical Specifications

    Electrical Specifications 6 Electrical Specifications 6.1 Supply Voltage and Turbocor compressors are designed to operate with a power supply that is within an Frequency acceptable tolerance for each nominally rated voltage and frequency. The tables below specify the acceptable supply voltage and frequency ranges. Using a supply voltage/ frequency at or beyond the range limit will cause the compressor to shut down.

  • Page 38: Disconnects

    Electrical Specifications Table 6-3 - FLA and LRA Default Value Range Model Voltage Max* TG230 380V TG230 400V TG230 460V TG230 575V TG310 380V TG310 400V TG310 460V TG390 380V TG390 400V TG390 460V TG390 575V TG520 380V TG520 400V TG520 460V TT300...

  • Page 39: Motor Insulation Class

    Electrical Specifications 6.4 Motor Insulation Class All TT/TG Series compressors have a motor insulation Class H rating or better according to the NEMA/UL Standard. 6.5 AC Input Line/Power Most codes require that upstream branch protection be provided to protect input power Electronic Component wiring personnel and switching equipment from damage in the event of an over current Protection...

  • Page 40: Surge Protection

    Electrical Specifications strands, is recommended for best grounding performance. The multiple-strand cabling provides more surface area in order to conduct the high frequencies that are on the grounding cable. Radiation of noise is also a concern for power line routing as it can effectively bypass the filter.

  • Page 41: Equipment Panel

    Electrical Specifications Figure 6-1 - Typical Ground Connections 6.11 Equipment Panel Normally, the line reactor, EMI/EMC filter(s), and the harmonic filter will be installed in a panel. This could be the same panel where the controls are located. When designing a panel, attention should be given to the following recommendations: •...

  • Page 42: Mains Input Cable Specification

    Electrical Specifications 6.12 Mains Input Cable The aim of electrical cables is to be a carrier (conductor) for electrical power. The influence Specification of the power source on the environment, or the influence of the environment on the power source, should be such that neither the proper functioning of the compressor nor equipment in its environment is adversely affected.

  • Page 43: Compressor Performance

    Compressor Performance 7 Compressor Performance 7.1 Performance Ratings Compressor performance, including applicable capacity range, varies based on the operating conditions. The capacity range, efficiency, and other operational information for each compressor can be determined only by using the authorized software known as the “Compressor Performance Rating Engine”...
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  • Page 45: Operating Envelopes

    Operating Envelopes 8 Operating Envelopes Figure 8-1 - Operating Envelope, TT300 and TG230 NOTE The maximum Saturated Discharge Temperature (SDT) of the operating envelope represents the limit for compressors with maximum FLA settings. The SDT for a compressor with a lower maximum current rating is lower than that shown and is related to the FLA rating of the particular compressor.

  • Page 46: Figure 8-2 - Operating Envelope, Tt300 And Tg230 (Medium Temperature Compressor)

    Operating Envelopes Figure 8-2 - Operating Envelope, TT300 and TG230 (Medium Temperature Compressor) The actual obtainable capacity will be dependent on specific operating characteristics of each compressor model. Refer to the current authorized compressor selection/rating software for more exact values and conditions. Page 46 of 108 M-AP-001-EN Rev.

  • Page 47: Figure 8-3 - Operating Envelope, Tt350 And Tg310

    Operating Envelopes Figure 8-3 - Operating Envelope, TT350 and TG310 NOTE The maximum Saturated Discharge Temperature (SDT) of the operating envelope represents the limit for compressors with maximum FLA settings. The SDT for a compressor with a lower maximum current rating is lower than that shown and is related to the FLA rating of the particular compressor.

  • Page 48: Figure 8-4 - Operating Envelope, Tt400 And Tg390

    Operating Envelopes Figure 8-4 - Operating Envelope, TT400 and TG390 NOTE The maximum Saturated Discharge Temperature (SDT) of the operating envelope represents the limit for compressors with maximum FLA settings. The SDT for a compressor with a lower maximum current rating is lower than that shown and is related to the FLA rating of the particular compressor.

  • Page 49: Figure 8-5 - Operating Envelope, Tt700 And Tg520

    Operating Envelopes Figure 8-5 - Operating Envelope, TT700 and TG520 NOTE The maximum Saturated Discharge Temperature (SDT) of the operating envelope represents the limit for compressors with maximum FLA settings. The maximum SDT for compressors with an FLA less than that is lower than the upper bound of the operating envelope and depends on the FLA rating.
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  • Page 51: Minimum Unloading Capacity

    Minimum Unloading Capacity Due to the nature of centrifugal compression, the minimum stable load is dependent 9 Minimum Unloading Capacity on the pressure ratio imposed on the compressor by the chiller system. All compressor performance, including unloading, should be determined through use of the relevant compressor selection/rating programs.
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  • Page 53: Control Logic Guidelines For Multiple Compressors

    Control Logic Guidelines For Multiple Compressors 10 Control Logic Guidelines Due to the nature of centrifugal compression, special control logic must be implemented for for Multiple Compressors proper staging of multiple Turbocor compressors when installed on a common circuit. This section is intended only as a guide without going into details.
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  • Page 55: Product Certification

    Product Certification All TT and TG Series compressors are ETL and CE listed and have been tested in accordance 11 Product Certification with UL Standard 984 and CSA Standard C22.2. Page 55 of 108 M-AP-001-EN Rev. N...
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  • Page 57: Guide Specifications

    Guide Specifications This section contains written specifications for the TT and TG series compressors for use in 12 Guide Specifications system design specifications. 12.1 General Construction shall utilize a two-stage, variable-speed, centrifugal compressor design requiring no oil for lubrication. Compressor shall be constructed with cast aluminum casing and high-strength thermoplastic electronics enclosures.
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  • Page 59: System Design Guidelines

    System Design Guidelines In addition to the instructions detailed in the TT and TG series technical documentation set, 13 System Design this section provides basic guidelines and requirements for the design and manufacture of Guidelines R134a systems equipped with DTC compressors. Refer to the applicable DTC technical manual for applications, operating, installation, and commissioning instructions.

  • Page 60: Economizer Option

    System Design Guidelines Table 13-1 - Recommended TT300/TG230 TT350/TG310 TT400/TG390 TT700/TG520 Minimum Copper Tube Size Suction 4" 4" 5" 5" Discharge 2 5/8" 3 1/8" 4" 4" NOTE If steel pipe is used, the pipe must be selected to give the equivalent inside diameter to copper pipe. Properly tapered trumpets with smooth transitions must be used to connect the compressor flanges to the pipework.

  • Page 61: Electrical Requirements

    The recommended valve is 7/8” (e.g., Danfoss KVP 22 or equivalent), set at a corresponding pressure to 0.8°C (34°F) saturated temperature (depending on the used refrigerant). The motor/ electronics cooling outlet port is fitted with a 5/8”...

  • Page 62: Limited Capacity At Low Pressure Ratios

    If more capacity is desired, it is advisable to raise the discharge pressure temporarily to increase the pressure ratio (point B) until the sensible heat in the building is dissipated. Figure 13-1 - Centrifugal Performance Dynamics NOTE Contact Danfoss Turbocor for compressor selection and technical advice. Page 62 of 108 M-AP-001-EN Rev. N...

  • Page 63: Sample Refrigeration Circuits

    Sample Refrigeration Circuits 14 Sample Refrigeration Circuits Figure 14-1 - Typical Refrigeration Piping Schematic Discharge Port Motor Cooling  Economizer  Port Port     Suction  Port   Sight  Glass Filter/ Drier       Staging    Check  Valve Valve Evaporator   Optional configuration for    Low Lift operation (CC 4.1 & later) Check ...

  • Page 64: Figure 14-2 - Typical Refrigeration Piping Schematic With Staging And Load Balancing Valve

    Sample Refrigeration Circuits Figure 14-2 - Typical Refrigeration Piping Schematic With Staging and Load Balancing Valve Discharge Port Economizer Motor Cooling Port Port Suction Port Sight Sight Glass Glass Filter/ Filter/ Drier Drier Check Valve Evaporator Staging Staging Valve Valve Load Load Balancing...

  • Page 65: Figure 14-3 - Typical Refrigeration Piping Schematic With Flash Tank Economizer

    Sample Refrigeration Circuits Figure 14-3 - Typical Refrigeration Piping Discharge Port Schematic With Flash Tank Economizer  Motor Cooling  Economizer Port Port     Suction  Port   Sight  Glass Filter/ Drier       Check  Valve   Staging  Evaporator     Solenoid  Valve Valve Condenser with Subcooler...

  • Page 66: Figure 14-4 - Typical Refrigeration Piping Schematic With Sub-Cooler Circuit Economizer

    Sample Refrigeration Circuits Figure 14-4 - Typical Refrigeration Piping Schematic With Sub-Cooler Circuit Economizer Discharge Port Economizer  Motor Cooling  Port Port     Suction  Port   Sight  Glass     Filter/ Drier   Check  Staging  Valve Valve Evaporator   Condenser with  Subcooler Expansion  Valve  ...

  • Page 67: Figure 14-5 - Typical Refrigeration Piping Schematic Using Motor-Cooling Pressure Regulating Valve

    Sample Refrigeration Circuits Figure 14-5 - Typical Refrigeration Piping Schematic Using Motor- Cooling Pressure Regulating Valve (Medium Temperature Compressors Only) Discharge Port Motor Cooling  Pressure  Port Regulating  Valve         Sight  Glass Filter/ Suction  Drier     Port     Economizer ...

  • Page 68: Figure 14-6 - Typical Refrigeration Piping Schematic With Multiple Dx Evaporators

    Sample Refrigeration Circuits Figure 14-6 - Typical Refrigeration Piping Schematic With Multiple DX Evaporators Discharge Port Economizer  Motor Cooling  Port Port     Suction  Port Sight  Glass   Filter/   Drier   Staging  Valve Check  Valve         Evaporator Expansion   ...

  • Page 69: Figure 14-7 - Typical Refrigeration Piping Schematic Using Multiple Compressors On A Common Circuit With A Flooded Evaporator

    Sample Refrigeration Circuits Figure 14-7 - Typical Refrigeration Piping Schematic Using Multiple Compressors on a Common Circuit With a Flooded Evaporator Condenser with Subcoole r Load Balance Valve Filter/ Filter/ (optional) Drier Drier Check Check Valve Valve Filter/ Filter/ Staging Staging Drier Drier...
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  • Page 71: Sound And Power Specifications

    Sound and Power Specifications 15 Sound and Power Specifications 15.1 TT300 and The sound power levels on the TT300 and TT400 compressors are measured in compliance TT400 Sound Power with ISO 9614-1 (1993) and are given in decibels and in A-scale dB(A). Measurements Three series of sound power measurements were performed on the unit while in two different modes:...

  • Page 72: Table 15-3 - Sound Power At Third Octave Band, Tt300 Compressor

    Sound and Power Specifications Table 15-3 - Sound Power at Third Octave Band, TT300 Compressor Sound Power, 250kW (70 Ton) Sound Power, 315kW (90 Ton) Third octave band Third octave band Linear scale (dB) A-weighted (dBA) Linear scale (dB) A-weighted (dBA) (Hz) (Hz) 55.5...

  • Page 73: Table 15-6 - Sound Power At Third Octave Band Of Tt400 Compressor

    Sound and Power Specifications Table 15-6 - Sound Power at Third Octave Band of TT400 Compressor Sound Power, 420kW (120 Ton) Sound Power, 525kW (150 Ton) Third octave band Third octave band Linear scale (dB) A-weighted (dBA) Linear scale (dB) A-weighted (dBA) (Hz) (Hz)
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  • Page 75: Physical Data

    Physical Data This section contains data relative to compressor mounting, service clearance, and piping 16 Physical Data connections. NOTE The dimensions in Figure 16-2 through 16-4 show measurements in metric with imperial in parenthesis. Table 16-1 - Physical Length Width Height Shipping weight Dimensions...

  • Page 76: Figure 16-2 - Service Side View All Models

    Physical Data Figure 16-2 - Service Side View All Models 484.3 Figure 16-3 - Discharge Side View Discharge Port 229.7 (9.04”) (TT300) 220.2 (8.67”) (TT350, TT400, TT500) 787.6 (31.00) 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 &...

  • Page 77: Center Of Gravity

    Physical Data 16.2 Center of Gravity Figure 16-4a - Center of Gravity Page 77 of 108 M-AP-001-EN Rev. N...

  • Page 78: Table 16-2 - Center Of Gravity X-Y Coordinates

    Physical Data Figure 16-4b - Center of Gravity Table 16-2 - Center of Gravity X-Y Coordinates Description Parameter TT300 / TG230 TT350 / TG310 TT400 / TG390 TT700 / TG520 Length of Center of Gravity m (in) 0.257 10.13 0.249 9.81 0.247 9.74...

  • Page 79: Figure 16-5 - Discharge Port Details (Tt300 And Tg230)

    Physical 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 Port Details (TT300 and TG230) Gas Flow Page 79 of 108 M-AP-001-EN Rev.

  • Page 80: Figure 16-6 - Discharge Port Details (Tt350 And Tg310)

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

  • Page 81: Figure 16-8 - Discharge Port Detail (Tt700 And Tg520)

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

  • Page 82: Figure 16-9 - Suction Port (All Models)

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

  • Page 83: Figure 16-10 - Suction Port Detail Dd (All Models)

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

  • Page 84: Figure 16-12 - Tt300 Flange Footprint Details

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

  • Page 85: Table 16-3 - Screw Hole Specifications

    Physical Data Figure 16-14 - TT700 and TG520 Flange Footprint Details Table 16-3 - Screw Hole Port Thread Size Hole Depth (mm) Torque (Nm) Specifications Suction M16 X 2 34.5 Discharge M10 X 1.5 Economizer M10 X 1.5 Page 85 of 108 M-AP-001-EN Rev.

  • Page 86: Torque Specifications

    Physical Data 16.3 Torque Specifications Table 16-4 - Torque Description Ft.Lb. In.Lb. Specifications IGV and End Bell bolts Pressure/Temp sensor IGV Power Feed Through Bearing Power and Sensor Feed Throughs Cavity Sensor E-Housing and later SCR Mounting Screws A/C Bus Bars DC Capacitors and Bleed Resistor IGBT Mounting Screws Shraeder Valves...

  • Page 87: Piping Considerations

    Piping Considerations 17 Piping Considerations Care should be exercised when selecting pipe sizes as they will vary according to their application. Section 14, “Sample Refrigeration Circuits, ” provides examples of compressor piping arrangements for the most common applications. The motor-cooling line should be channeled from the liquid line; refer to Section 13.3 for more information.
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  • Page 89: Environmental Considerations

    Environmental Considerations 18 Environmental Considerations 18.1 Humidity If the compressor is installed in a humid environment, drip trays may be required to collect condensate. Insulation should be installed on the suction valve/piping and the end cap as this is where condensation is most likely to form. It is recommended to fit an End Cap insulator in a humid environment.
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  • Page 91: Shipping Considerations

    Shipping Considerations 19 Shipping Considerations 19.1 Vibration When shipping the compressor as an integral part of a chiller unit, precautions should be taken to protect the compressor motor cooling line from excessive vibration. Due to the flexibility of the compressor’s isolation mounts, compressor vibration during transit can fracture the motor cooling line’s rigid piping.
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  • Page 93: Installation

    Installation 20 Installation 20.1 Unpacking and The compressor should be carefully inspected for visible signs of damage. Check for loose Inspection bolts and damage to covers or outer casing. Damage should first be reported to the carrier, not DTC. DTC Customer Support and Service can be contacted to assist in determining the extent of damage or if compressor should be returned to DTC.

  • Page 94: Mounting Base

    Installation 20.4 Mounting Base The compressor must be mounted on a rigid surface of sufficient structural integrity to support the weight of the compressor and valves (see Figure 16-4b and Table 16-2). A mounting kit is available to isolate the compressor from the supporting structure and to minimize vibration from other rotating equipment.

  • Page 95: Piping Connections

    Installation Figure 20-4 - Correct Compressor Mounting Pad Installation • • • CAUTION • • • 20.5 Piping Connections Install new O-rings when attaching flanges to the compressor. O-rings must be of type EPDM (also known by the compound # E0740-75 for R1234ze refrigerant).

  • Page 96: Control Wiring

    Installation Figure 20-5 - Motor-Cooling Connection and Access Port Motor Cooling Inlet Schrader Valves 20.6 Control Wiring The compressor I/O Board enables communication of control and status signals between the compressor controller and external equipment. These signals include, among others, cooling demand, input, stepper motor control inputs and outputs, alarm and interlock contacts, and Modbus protocol communications.

  • Page 97: Figure 20-6 - Compressor I/O Board Connections

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

  • Page 98: Circuit Grounding

    Installation 20.6.2 Circuit Grounding Improper grounding or voltage in circuits connected to the compressor I/O board can lead to component failures. In particular, the interlock and analog output circuits are sensitive to improperly connected external circuits (see Figure 20-7). Prior to connecting the control wiring to the compressor I/O board, check for improper grounding.

  • Page 99: Voltage-Free Contacts

    Installation 20.6.3 Voltage-Free Prior to connecting the interlock terminals of the compressor I/O board, measure the Contacts resistance across the customer’s interlock terminals (see Figure 20-8). Ensure that the interlock contacts are closed. The measured value should be less than 1Ω. Figure 20-8 - Interlock Circuit Tests Measure the voltage between each customer interlock terminal and the frame ground while...

  • Page 100: Power Wiring

    Installation 20.7 Power Wiring This section describes the connection of the power wiring to the compressor. NOTE The AC input cable should be CSA, UL, or CE approved, 3-wire with a common shield and single ground. It is recommended that the cable be double-jacketed;...

  • Page 101: Figure 20-10 - Ground Post Nuts

    Installation 5. Attach the ground cable to the ground post on the compressor housing. 6. Attach and secure the upper nut and jam nut to the ground post (see Figure 20-10). Upper Nut - 10 Figure 20-10 - Ground Post Nuts (7 ft.lb.) Jam Nut - 7 Nm...
  • Page 102 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 fasteners. Page 102 of 108 M-AP-001-EN Rev. N...

  • Page 103: Appendix A: Power Line Accessories Installation

    Appendix A: Power Line Accessories Installation A.1 Line Reactor These instructions apply to the installation of the line reactor kit in a main supply panel. See Installation Instructions the Spare Parts Selection Guide for product specifications. A.1.1 AC Line Cable NOTE Connection (From External Disconnect)

  • Page 104: Figure A-1 - Line Reactor Connections

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

  • Page 105: Appendix B: Power Line Accessories Installation

    Appendix B: Power Line Accessories Installation B.1 EMI/EMC Filter 1. Mount the filter on the floor or on a wall in a vertical position. Installation Instructions 2. Ensure there is a minimum of 60mm (2 3/8”) of space for the cooling slots. B.1.1 Line Side Connection Input and output filter leads should be separated by a maximum practical distance within...

  • Page 106: Figure B-1 - Interconnection Layout

    Appendix B: Power Line Accessories Installation Figure B-1 - Interconnection Layout Figure B-2 - Grounding Diagram Page 106 of 108 M-AP-001-EN Rev. N...
  • Page 107 Quick access to Danfoss Turbocor® troubleshooting. compressor The new version of the Danfoss TurboTool® 2.0 app for all your full service 24/7 Danfoss Turbocor® compressor needs. Access to Danfoss Turbocor® The user can select from a list The TurboTool® app makes...
  • Page 108 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 M-AP-001-EN Rev. N © Copyright Danfoss Turbocor Compressors Inc. | 2018.12...

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