Danfoss Turbocor TT-300 User Manual
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Danfoss Turbocor TT-300 User Manual

Twin-turbine centrifugal compressor
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TWIN-TURBINE CENTRIFUGAL
COMPRESSOR
MODEL TT-300
SERVICE MONITOR USER MANUAL
Danfoss Turbocor Compressors Inc.
ECD-00007M Rev. 1

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Summary of Contents for Danfoss Turbocor TT-300

  • Page 1 TWIN-TURBINE CENTRIFUGAL COMPRESSOR MODEL TT-300 SERVICE MONITOR USER MANUAL Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1...

  • Page 2: Table Of Contents

    Monitor Program Data and Controls Main System Bearing Calibration Bearing Calibration Procedure Calibration Data Interpretation “Gain” Interpretation “Offset” Interpretation Compressor Control Compressor Control Modes Calibration Manual Control Analog Input Modbus Network Chiller Control Compressor Faults/Alarms Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1...
  • Page 3 Compressor Controller Impeller Specific Settings Compressor Controller (CC) Critical Fault Lock Outs Refrigerant Compressor Event Log History Data Trending Graphs Trending & Data Acquisition Compressor Map Fault Captures Data Capture Appendix A: Determination of Actual Power Setting Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1...

  • Page 4: Introduction

    Turbocor compressor and to provide status information about the compressor. Furthermore, it can be used as a tool for troubleshooting purposes. This manual describes the functions provided by the Turbocor Service Monitor program. Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1...

  • Page 5: System Requirements

    Framework applications; all dialog boxes and error messages will be in English. If you want dialog boxes and error messages in another language, you must also install the corresponding language pack. For more information, see the .NET Framework Downloads page. Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1...

  • Page 6: Getting Started

    Figure 3 shows the PC and adapter connections to the Modbus for a multiple compressor application. In this case, set the termination jumper only on the Chiller Interface module that is connected at the end of the Modbus cable run. Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1...
  • Page 7 Getting Started Figure 2 PC to Modbus Connection (single compressor with > 10 m cable length) Figure 3 PC to Modbus Connection (multiple compressors with > 10 m cable length) Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1...

  • Page 8: Monitor Program Installation

    “Start” menu, select “Settings” → Click the Close button to exit the setup wizard. “Control Panel”. Double-click “Add/Remove Programs”. From the list, select “Danfoss Turbocor Service Monitoring Tool” and then click the “Remove” button. Starting the Monitor Program To start the monitor program: from the “Start”...

  • Page 9: Entering User Input

    Stop Bits - 1 or 2. (1: default) “Window”→ “Connection” from the menu bar, or click on Slave Address - 1-63. (1: default) the “Serial Port Connection” icon located below the menu bar. Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1...

  • Page 10: Compressor Configuration

    Refer to Figure 6. Select the appropriate compressor control method. There are three modes available: • Analog Input: compressor loading controlled using Figure 5 Commissioning Set-up Wizard an analog demand signal of 0-10 VDC from an Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1...

  • Page 11: Start-Up Settings

    Application manual) to be 135 kPa. This temporary alarm is only active while either the Entering- or Leaving Chilled Water the Suction Pressure Delay timer is counting down. temperature input on the Chiller Interface module. Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1...

  • Page 12: Electronics Valve Control

    (Refer to Figure 9) Enter the Valve Starting Position Delay Time. The delay is the amount of time (from compressor start-up) Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1...
  • Page 13 2 minutes rather than close the vane or change the speed. Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1...

  • Page 14: Analog Output Setup

    • Superheat - FlangeP, LIQT terminals on the Chiller Interface module). The options are: • Suction Pressure. • Leaving Temp • Load Balance • Entering Temp • HP • Liquid Temp • IGV Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1...

  • Page 15: Modbus Communications

    For immediate downloading of the configuration data to the external PLC, computer or building management system. compressor, click the Download to Compressor button. To enable the new configuration data, perform the following steps: Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1...

  • Page 16: Using A Saved Configuration File

    Once reconnected, the text in the right-hand pane of the Serial Port Connection dialog box appears in red. When the text turns black, it indicates that the new Figure 14 Download Settings Screen (After Download) Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1...

  • Page 17: Controlling User Access

    To change the access code, select “Access Codes” from the “Advanced” menu item; refer to Figure 15. Figure 15 Navigating to the Access Code Change Form Figure 16 Access Code Change Form Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1...

  • Page 18: Starting And Stopping The Compressor

    (The maximum power available is dependent on the compressor model.) The compressor will levitate and spin up. Refer to Figure 17 Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1...

  • Page 19: How To Stop The Compressor

    5.3.2 How to Stop the Compressor On the Chiller Control form, uncheck the Chiller Enable Status box. The compressor will ramp down to 0 RPM and de-levitate. Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1...
  • Page 20 Service Monitor User Manual Figure 18 Chiller Control Form Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1...

  • Page 21: Monitor Program Data And Controls

    PC system time, and is displayed in description of the “General Data Page” parameters. HH:MM format. To clear the graphs, click on the “Reset Graphs” button. The “General Data Page” also plots the following parameters with respect to time: Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1...
  • Page 22 6.3.2 "Compressor Faults/Alarms" for fault details. Alarm Text Box Displays the compressor’s most recent active alarm. Refer to 6.3.2 "Compressor Faults/Alarms" for alarm details. Interlock Status Displays the status of the interlock: either open or closed. Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1...

  • Page 23: Bearing Calibration

    FRX Min Minimum DC voltage indicating minimum front radial x displacement. FRX Max Maximum DC voltage indicating maximum front radial x displacement. FRY Min Minimum DC voltage indicating minimum front radial y displacement. Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1...
  • Page 24 Gain Formula: Fixed Voltage / (Ax Min Voltage - Ax Max Voltage) Ax Offset Difference between the axial sensor zero and the touchdown axial center. Refer to Figure 23. Ax HW Offset Hardware offset. Time Stamp Date and time of calibration. Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1...

  • Page 25: Bearing Calibration Procedure

    If the bearing calibration is still not successful, contact Figure 23 Axial Bearing Offset Turbocor technical support. For the following parameters in the “Startup Check Calibration Data” window, compare the values between Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1...

  • Page 26: Calibration Data Interpretation

    Enter. It is readings important to press Enter as this causes the user input to be validated. • View the compressor control faults and alarms • View the system messages Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1...
  • Page 27 Monitor Program Data and Controls Figure 24 Compressor Controller Form Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1...
  • Page 28 Gauge pressure as measured from a pressure transducer connected to the terminals marked “SPARE P” on the Chiller Interface module. External Temperature Temperature as measured from a thermistor connected to the terminals marked “SPARE T” on the Chiller Interface module. Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1...

  • Page 29: Compressor Control Modes

    The compressor must be de-levitated, and the Chiller "Bearing Calibration" on page 20. Interface interlock circuit must be open for the compressor Use Manual Control mode when servicing or to be calibrated. troubleshooting the compressor. Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1...

  • Page 30: Analog Input

    Insufficient charge or insufficient system load Discharge Pressure Fault / Alarm Faulty condenser Note: A “Discharge Pressure” fault will lock out the compressor. The compressor will have to be powered down and restarted. Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1...

  • Page 31: Motor Monitoring

    Enter as this causes the user input to be validated. To view the “Variable Speed Permanent Magnet Motor Monitoring” window, select “Window”→ “Motor” from the menu bar, or click on the “Motor Monitor” icon located Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1...
  • Page 32 Inverter temperature as measured by thermistor mounted under the IGBT Inverter. Back EMF Value Internal motor voltage Fault Code Hexadecimal motor fault code from the bearing motor control. Alarm Code Hexadecimal motor alarm code from the bearing motor control. Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1...

  • Page 33: Motor Faults / Alarms

    If a fault or alarm occurs, refer to This section describes the possible faults displayed in the the Troubleshooting Manual for the appropriate “Variable Speed Permanent Magnet Motor Monitoring” procedure(s) to follow. Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1...

  • Page 34: Magnetic Bearing Monitoring

    Enter. It is unbalance important to press Enter as this causes the user input to be • View bearing faults and alarms validated. Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1...
  • Page 35 Rear X Bearing Force (Amps) Current required to counteract rear x unbalance force. Rear Y Bearing Force (Amps) Current required to counteract rear y unbalance force. Fault Code Hexadecimal bearing fault code from the bearing motor control. Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1...

  • Page 36: Bearing Faults

    To access the stepper motor control settings, select the • Control the analog output “Stepper Motor” tab. The “EXV#1 Control Settings” controls the stepper motor connected to “EXV1” on the Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1...
  • Page 37 Table 13 describes the analog output control parameters. validated. NOTE: The measurement unit (metric/imperial) displayed depends on the measurement unit previously set. To verify or change Figure 27 Electronic Valve Data / Tuning Form Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1...
  • Page 38 Number of steps from fully closed to fully open for the installed stepper motor driven device. Graph Displays the “Process Value” parameter with respect to time. The time corresponds to the PC system time, and is displayed in HH:MM format. Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1...

  • Page 39: Chiller Control

    Chiller Control The “Chiller Control” window allows the user to control • Entering chiller water or air temperature one of the following: • Evaporating (saturated suction) temperature • Leaving chiller water or air temperature Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1...
  • Page 40 The measurement unit (metric/imperial) displayed depends on the measurement unit previously set. To verify or change the measurement unit, refer to section 6.3 "Compressor Control" on page 23. Figure 28 Chiller Control Form Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1...

  • Page 41: System Information

    “Advanced”→ “System Information” from the menu bar. to System Time” synchronizes the DSP time with the system time. The “System Information” window displays the current DSP time (i.e. real time) and the current system time (i.e. Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1...

  • Page 42: Compressor Info

    “Eeprom Settings” from the menu bar, or click on the Viewing and/or modifying the EEPROM settings is “Eeprom Settings” icon located below the menu bar. restricted to users with mid level or high level access codes. Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1...

  • Page 43: Compressor Controller Settings

    • Imperial Units - Psi, ºF, ºR Refer to 6.3.1 "Compressor Control Modes" for details on how to change the measurement unit. Chiller Control Parameters: Refer to 6.7 "Chiller Control" on page 36 for further details. Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1...

  • Page 44: Compressor Controller Alarms

    “Inverter Temperature” and the “SCR pressure values the compressor will tolerate before Temperature” alarm limits cannot be altered, as changing activating an alarm. these limits may cause the compressor to malfunction. Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1...
  • Page 45 Ratio of the absolute discharge pressure and the absolute suction pressure. Current Draw - Amps 3-phase mains input current. SCR Temperature Temperature of the SCR heat sink plate. Anti Start Temperature IGBT Inverter temperature limit at compressor startup. Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1...

  • Page 46: Compressor Controller Fault Limits

    Once a fault occurs, the compressor motor will trip and the fault will be reported in the “Compressor Controller” window as well as in the “Event Log” window. Figure 32 EEPROM Settings - Compressor Controller Fault Limits Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1...

  • Page 47: Compressor Stepper Motor Settings

    Select the “Stepper Motor Controls” tab to view and change the compressor’s stepper motor settings. Specifically, it allows the user to view the maximum motor steps and the initial motor steps at compressor startup. For the electronic Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1...

  • Page 48: Stepper Motor Valve Controls

    (EXV#2). EXV#2 refers to the electronic expansion valve connected to “EXV2” at the Chiller Interface module. Table 18 describes the EXV settings. To update the EXV settings, refer to section 6.6 "Electronic Valve Data / Tuning" on page 33. Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1...
  • Page 49 Monitor Program Data and Controls Figure 34 EEPROM Settings - Stepper Motor Valve #1 Controls Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1...

  • Page 50: Analog Output Controls

    Select the “Analog Output” tab to view the analog output "Electronic Valve Data / Tuning" on page 33. control settings. The Analog Output Control Settings control the output labeled “Analog” on the Chiller Interface module. Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1...
  • Page 51 Monitor Program Data and Controls Figure 35 EEPROM Settings - Analog Output Controls Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1...

  • Page 52: Compressor Controller Impeller Specific Settings

    6.9.7 Compressor Controller Impeller are those that define the operational envelope of the specific compressor model. Specific Settings Select the “Impeller Settings” tab to view the compressor controller impeller specific settings. The parameters shown Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1...

  • Page 53: Compressor Controller (Cc) Critical Fault Lock Outs

    “Limit of Alarms in minutes: Buffer”, within the “Moving Window Hold Time” of 30 minutes, then a “Lock Out Fault” occurs and the motor will • Anti-start temperature alarm trip. Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1...

  • Page 54: Refrigerant

    Click on the “Stop Download” button anytime to stop the • The icon denotes a compressor fault. download. The downloaded events may be saved to a file by clicking on the “Save Data to File” button. The “Current Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1...

  • Page 55: History Data

    To view the “Compressor History Data” window, select with information about the compressor energy usage. “Window”→ “Load Profile” from the menu bar, or click on the “Load Profile Graphs” icon located below the menu bar. Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1...

  • Page 56: Trending

    For each graph, the parameter plotted may be changed at time. The time displayed is the PC system time, and is any time by selecting a different parameter from the drop- shown in HH:MM format. Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1...
  • Page 57 90º to the pipe line (Fully closed). 110% means 10º over turned from fully open. Suction Pressure The actual suction gauge pressure at the compressor flange as measured by the suction pressure transducer. Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1...
  • Page 58 3 Phase Power (kW) 3-phase AC input power (mains input) Inverter Temperature Inverter temperature as measured by thermistor mounted under the IGBT Inverter. Front Orbit Average Percentile indicating the average front orbit displacement. Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1...

  • Page 59: Trending & Data Acquisition

    • Actual Compressor Speed [RPM] • Suction Temperature • Minimum Compressor Speed [RPM] • Discharge Temperature (estimated surge) • Liquid Temperature • Maximum Compressor Speed [RPM] • Entering Air/Water Temperature (choke) Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1...

  • Page 60: Compressor Map

    To view the “Compressor Map” window, select operating envelope of the compressor, and to estimate its “Window”→ “Performance Map” from the menu bar, or capacity and performance. click on the “Compressor Envelope” icon located below the menu bar. Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1...
  • Page 61 Figure 43 Compressor Map the measurement unit, refer to section 6.3 "Compressor Control" on page 23. The outputs section shows the estimated capacity and performance of the compressor, given the set of inputs. The Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1...

  • Page 62: Fault Captures

    .csv file, which may be viewed using a The “Current Index”, located above the “Descriptive Fault spreadsheet editor such as MS Excel. Information” box, is the index of the fault that occurred, for which the compressor state is being described. Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1...

  • Page 63: Data Capture

    “Acquiring Data” message box disappears, click on the “Data Preview” button to view the compressor data. The acquired data may be saved to file by clicking on the “Save Data to File” button. Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1...
  • Page 64 Service Monitor User Manual Figure 46 Compressor Data Capture Screen Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1...
  • Page 65 Ratio of the actual number of steps sent to the stepper motor over the maximum number of steps the motor is allowed to drive. Range: 0%-100%. Motor-Cooling Solenoids Number of motor-cooling solenoids open. Open Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1...
  • Page 66 By Force [Amps] Current required to counteract rear y unbalance force. 3 Phase Amps Mains (AC) input current. 3 Phase Voltage Mains (AC) input voltage. Compressor Real Time Clock Time of data capture. Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1...

  • Page 67: Appendix A: Determination Of Actual Power Setting

    The demand % for a 6.50 VDC input is: Recall that in Modbus network input mode, the demand is manually set through the Monitor program. In this case, the demand is set to 56.2%. Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1...
  • Page 68 = 24.783*2.80-14.06 = 55.32 kW The actual maximum power is: PWRmax= 55.32 * (340 / 356) = 52.83 kW The desired 3 phase power input is then : Desired power = 52.83 * .562 = 29.69 kW Danfoss Turbocor Compressors Inc. ECD-00007M Rev. 1...

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