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Danfoss Manuals
Air Compressor
Turbocor TT500
Service manual
Danfoss Turbocor TT500 Service Manual
Twin-turbine centrifugal compressors
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Table of Contents
List of Tables
List of Figures
Proprietary Notice
Introduction
Purpose
Organization
Commitment to Quality
Safety Summary
Danger Notification
Caution Notification
Note
Precautions
Figure 1 - Danger Notification Example
Figure 2 - Caution Notification Example
Figure 3 - Note Example
Refrigerant Type
R134A/R513A
R1234Ze
Electrical Isolation of the Compressor
Table 1 - Refrigerant Used with Danfoss Turbocor Compressors
Handling Electronic Static Devices
ESD Protection/Grounding
Figure 4 - ESD Label
Figure 5 - Mains Plate and Ground Post
Figure 6 - Compressor Grounding Points
DC Bus Test Harness Installation and Removal
Figure 7 - DC Bus Test Harness Diagram
Figure 8 - DC Bus Harness Connection Diagram
Figure 10 - Connect Test Harness to Soft Start Board
Figure 9 - Soft Start Board
Installation of the DC Bus Test Harness
Figure 11 - Connect Test Harness to Compressor
Figure 12 - Cable Passage
DC Bus Test Harness Use
Removal of the DC Bus Test Harness
Table 2 - Expected DC Bus Voltage
Compressor Fundamentals
Main Fluid Path
Motor and Power Electronics Cooling
Table 3 - Compressor Fluid Paths
Figure 13 - Compressor Fluid Paths
Figure 14 - Cooling Inlet Adaptors
Figure 15 - Compressor Motor and Power Electronics Cooling (TT300/TG230 Serial Cooling)
Figure 16 - Compressor Motor and Power Electronics Cooling (All Models Except TT300/TG230 Serial Cooling)
Capacity Control
Compressor Energy and Signal Flow
Figure 17 - Compressor Energy and Signal Flow Connections (TT300/TG230 Shown)
Figure 18 - Compressor Energy and Control Flow Block Diagram
Compressor Components
Component Identification
Table 4 - Compressor Component Identification (Covers On)
Figure 19 - Compressor Components Identification (Covers On)
Table 5 - Compressor Component Identification (Covers Off) (TT300/TG230)
Figure 20 - Compressor Component Identification (Covers Off) (TT300/TG230)
Table 6 - Compressor Sensors, Cables, and Indicators (TT300/TG230)
Figure 21 - Compressor Sensors, Cables and Indicators (TT300/TG230)
Table 7 - Compressor Component Identification (Covers off ) (TT350/TT400/TT500/TT700/TG310/TT390/TT520)
Figure 22 - Compressor Component Identification (Covers off ) (TT350/TT400/TT500/TT700/TG310/TG390/TG520)
Table 8 - Compressor Sensors, Cables, and Indicators (TT350/TT400/TT500/TT700/TG310/TG390/TG520)
Figure 23 - Compressor Sensors, Cables, and Indicators (TT350/TT400/TT500/TT700/TG310/TG390/TG520)
Compressor - Removal and Installation
Refrigerant Containment
Compressor - Removal
Compressor - Installation
Figure 24 - Major Revision "E" Compressor Fittings
3-Phase Main Voltage Input Terminal Block
Function
Connections
Figure 25 - Main AC Input Terminal TT300/TG230
(Left) TT350/TT400/TT500/TT700/TG310/TG390/TG520 (Right)
Verification
Figure 26 - Measuring the AC Input Voltage on the AC Input Terminals
Figure 27 - Measuring 3-Phase AC Input (TT300/TG230 Only)
Removal and Installation
Table 9 - Expected AC Voltage Range
Figure 28 - Terminal Block Bus Bars (TT350/TT400/TT500/TT700/TG310/TG390/TG520)
Figure 29 - Terminal Block Bus Bars (TT350/TT400/TT500/TT700/TG310/TG390/TG520)
Figure 30 - AC Input to Scrs (TT300/TG230)
Figure 31 - Terminal Block Spacers
Soft Start Board
Function
Figure 32 - Screws Securing Terminal Block to Casting
Connections
Verification
Figure 33 - Soft Start Board
Removal and Installation
Figure 34 - Mains Input
Silicon-Controlled Rectifier
Function
Connections
Verification
Figure 35 - SCR Connections (TT300 - Left/Tg230 - Right)
Table 10 - SCR Diode Values
Table 11 - SCR Gate Resistance Ranges
Figure 36 - Silicon-Controlled Rectifier Terminals
Removal and Installation
Figure 37 - J17 Connector
DC Bus
Function
Figure 38 - DC Bus Components Identification
Connections
Verification
Removal and Installation
Figure 39 - Soft Start Cable Harness to DC Bus
Figure 40 - Removing Attaching Hardware from DC Bus Bars (TT300/TG230 Pictured)
Figure 41 - Removing DC Capacitor Assembly (TT300/TG230)
Figure 42 - Insulating Mylar on Inverter (TT300/TG230 Only)
Inverter
Function
Connections
Figure 43 - Inverter Connections
Verification
Figure 44 - Inverter Connections (TT300/TG230)
Removal and Installation
Figure 45 - Driver Board Screw Removal
Figure 46 - Driver Board Removal
Figure 47 - Long Spring Pin Locations
Figure 48 - Spring Pin Identification
Figure 49 - Spring Pin Removal
Figure 50 - Seated Spring Pins
Figure 51 - Driver Board Placement
Figure 52 - Initial Tightening Pass Sequence
Figure 53 - Final Torque
Figure 54 - Removing the Inverter (TT300/TG230 Shown)
Motor
Function
Motor Protection
Connections
Figure 55 - Connection to Stator
Verification
Figure 56 - Stator Thermistor R/T Curve 1
High-Voltage DC/DC Converter
Function
Connections
Figure 57 - DC/DC Converter Connections
Verification
Figure 58 - J3 24VDC Output Connector
Removal and Installation
Backplane
Function
Figure 59 - HV DC/DC Converter Removal
Backplane Connections and Test Points
Figure 60 - Backplane Connections and Test Points
Figure 61 - LED Locations
Removal and Installation
Table 12 - Backplane Test Point Values
Figure 62 - Removing the Backplane
Serial Driver
Function
Connections
Verification
Removal and Installation
Solenoids and Actuators
Function
Connections
Figure 63 - Cooling Valve Bodies
Verification
Table 13 - Solenoid Actuator Coil Resistance Ranges
Figure 64 - Motor Cooling Solenoid Actuators
Figure 65 - Motor Cooling Solenoid Cable Connector
Removal and Installation
Figure 66 - Solenoid Cooling Path (TT300/TG230 Shown)
Igv
Function
Connections
Figure 67 - IGV Connections
Verification
Removal and Installation
Figure 68 - IGV Motor Feed through
Bmcc
Function
Connections
Figure 69 - Disconnecting Power to the IGV Motor
Verification
Removal and Installation
Figure 70 - BMCC Insertion Guides
Compressor Interface Module
Function
Connections
Figure 71 - Compressor Interface Module Ports
Figure 72 - Compressor Interface Module Jumper Locations
Verification
Removal & Installation
Figure 73 - Removing the Compressor Interface Module from the DIN Rail
Bearing Pulse Width Modulator Amplifier
Function
Figure 74 - Bearing Control Signal Flow
Connections
Figure 75 - Bearing Power Feed Throughs and PWM Connection Port
Figure 76 - Bearing PWM Amplifier
Verification
Figure 77 - Connecting Leads to PWM Connector and HV- Test Point
Figure 78 - Connecting Leads to PWM Connector and HV+ Test Point
Removal and Installation
Figure 79 - Removing the PWM Amplifier
Magnetic Bearings
Function
Figure 80 - Radial Magnetic Bearings
Figure 81 - Axial Magnetic Bearing
Connections
Verification
Figure 82 - Bearing Power Feed Throughs
Table 14 - Magnetic Bearing Coil Resistance Values
Figure 83 - Rear Bearing 6-Pin Orientation (TT300 Serial Numbers <081015110 Only)
Figure 84 - Front Bearing 4-Pin Orientation
Table 15 - Bearing Amperage Ranges
Figure 85 - Front and Rear Bearing Feed Throughs with Molex Connectors
Figure 86 - Compressor Monitor Tool
Bearing Sensors
Function
Connections
Figure 87 - Bearing Sensor Feed Throughs
Figure 88 - Bearing Sensor Cables
Verification
Cavity Temperature Sensor
Function
Connections
Table 16 - Bearing Sensor Coil Resistance
Figure 89 - Bearing Sensor Pin Locations
Verification
Figure 90 - Cavity Temperature Sensor Terminal
Figure 91 - Temperature Vs. Resistance
Removal and Installation
Figure 92 - Cavity Temperature Sensor Removal
Pressure/Temperature Sensor
Function
Connections
Verification
Figure 93 - Pressure/Temperature Cable Terminals
Removal and Installation
Figure 94 - Pressure/Temperature Sensor Pin Locations
Troubleshooting
Alarm and Fault Indications
Alarm Types
Fault Types
Table 17 - Alarm Types
Table 18 - Compressor Fault Types
Table 19 - Motor Fault Types
Table 20- Bearing Fault Types
Troubleshooting with the Service Monitoring Tools Software
Figure 95 - SMT Tool Suite Launcher Strip
Table 21 - Service Monitoring Tools Icons
Compressor Fault Troubleshooting
Figure 96 - Fault Trigger Methods
Table 22 - Compressor Faults
Motor Faults/System Status
Table 23 - Motor Faults
Bearing Status
Table 24 - Bearing Status
Bearing Calibration
When to Calibrate the Bearings
Performing a Calibration
Figure 97 - Bearing Calibration Tool
After Calibration Is Complete
Create a Calibration Report
Calibration Report Analysis
Figure 98 - Bearing Calibration Flow
Compressor Connection Status Indications
System and Compressor Level Troubleshooting
Compressor Voltage Troubleshooting
Determining the Cause of an Energy Drain
Determining the Cause of Blown Soft Start Fuses
Troubleshooting an Open Interlock
Troubleshooting the Inverter
Maintenance
Preventive Maintenance Tasks
Table 25 - Preventive Maintenance Tasks
Moisture Prevention Measures
Required Items
Figure 99 - Module Removal
Figure 100 - Motor Cooling Valve Solenoids
Figure 101 - Neoprene Gasket Removal
Figure 102 - Dielectric Grease under Gasket
Figure 103 - PWM Connectors
Figure 104 - Dielectric Grease on Screws
Figure 105 - Motor-Winding Sensor Dielectric Grease Application
Figure 106 - Motor Bus Bar Screws
Figure 107 - SCR Screw Dielectric Grease Application
Appendix A Acronyms/Terms
Table 26 - Acronyms/Terms
Appendix B Compressor Troubleshooting Flowcharts
Figure 108 - Compressor Operation Troubleshooting Flowchart
Figure 109 - Compressor Voltage Troubleshooting Chart 1
Figure 110 - Compressor Voltage Troubleshooting Chart 2
Appendix C Compressor Test Sheet
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Service Manual
Danfoss Turbocor® Twin-Turbine
Centrifugal Compressors
TT & TG Series Compressors
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http://turbocor.danfoss.com
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Table of Contents
Troubleshooting
Troubleshooting
94
Troubleshooting With the Service Monitoring Tools Software
97
Compressor Fault Troubleshooting
98
Compressor Connection Status Indications
109
Troubleshooting an Open Interlock
113
Appendix B Compressor Troubleshooting Flowcharts
124
Figure 109 - Compressor Voltage Troubleshooting Chart 1
125
Figure 110 - Compressor Voltage Troubleshooting Chart 2
126
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