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108

M-AP-001-EN Rev. N

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

OUT

I/O
I/O

IN
IN
IN
IN

OUT
OUT
OUT
OUT

OUT

OUT
OUT
OUT

IN
IN
IN
IN

ModBus Common (Shield)
ModBus RS-485 NetB
ModBus RS-485 NetA

0-10V
Demand -
Interlock Contact - Safety N/C
Interlock Contact - Safety N/C
Compressor Status - N/O Contact
Compressor Status - N/O Contact

Entering Chilled Water

Temp. Sensor

Leaving Chilled Water

Temp. Sensor

EXV Phase 1A

EXV Phase 1B

EXV Phase 2A

EXV Phase 2B

EXV #1

(Evaporator or

load balancing

valve)

EXV Phase 1A
EXV Phase 1B

EXV Phase 2A

EXV Phase 2B

EXV #2

(Economizer or

load balancing

valve)

Level 15V

Sensor Signal , 1-5Volts

Level Sensor 0V

Level 15V

Sensor Signal , 1-5Volts

Level Sensor 0V

Level

Sensor

#1 (Evaporator)

Level

Sensor

#2 (Economizer)

Liquid Tempe

Liquid Temperature -

Compressor Running - N/O Contact

Pressure Sensor Signal, 1-5Volts

Sensor 0V

Temperature Sensor Signal, 1-5Volts

*Universal Analog

*Universal Analog Output -

* Universal output can be used for :

output manual control

0-5VDC or 0-10VDC

RS232 Monitoring Connector (DB9)

LIQDT

SPEED

ATUS

I/LOCK

DEMAND

COM

NET
A

NETB

EXV1

EXV2

1A
1B
2A
2B

OUT
OUT
OUT
OUT

OUT

OUT
OUT

OUT

RUN

ENTR

Y
LEA
VE

ANALOG

Float

ARE T

ARE P

No function

**Level sensor circuit can be configured

for two types of sensors using jumpers

JP5 and JP6. Refer to the Installation and

Operations Manual for details.

4 Control Interface Wiring

RS485-1

I-L

ock

CIM Board

RS485-1

I-L

ock

CIM Board

RS485-1

I-L

ock

CIM Board

REF

Shield

REF

Shield

REF

Shield

REF

120

PLC

COM NE

TB NE

MODBUS

Retain
Termination
Jumper in
Last Board

Remove Termination
Jumper in All
Intermediate Boards

Termination Resistor should only be included

if one is not included in the PLC. If the PLC

has a resistor installed, do not add an addi-

tional one. If the PLC does not have a resistor

installed, then one should be installed.

Figure 4-2 - ModBus

Grounding Diagram

Summary of Contents for TG230 Series

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

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Page 3: ...DC Converter 26 3 5 Magnetic Bearing System 26 3 5 1 Overview 26 3 5 2 Bearing Control System 26 4 Control Interface Wiring 28 4 1 Control Wiring Connection Guidelines 29 4 2 Interface Cable 30 4 3 Compressor I O Board Mounting Details 31 4 3 1 Compressor I O Board Mounting Instructions 31 5 General Specifications 33 5 1 Construction 33 5 2 Maximum Pressure 33 5 3 Maximum Discharge Temperature 34 ...

Page 4: ...5 1 TT300 and TT400 Sound Power Measurements 71 15 1 1 Results 71 16 Physical Data 75 16 1 Clearance 75 16 2 Center of Gravity 77 16 3 Torque Specifications 86 17 Piping Considerations 87 18 Environmental Considerations 89 18 1 Humidity 89 18 2 Vibration 89 19 Shipping Considerations 91 19 1 Vibration 91 20 Installation 93 20 1 Unpacking and Inspection 93 20 2 Rigging Requirements 93 20 3 Unit Pla...

Page 5: ...ge 37 Table 6 2 Acceptable Frequency Range 37 Table 6 3 FLA and LRA Value Range 38 Table 6 4 Main Cable Connector Plate Hole Sizes 42 Table 13 1 Recommended Minimum Copper Tube Size 60 Table 13 2 Low Lift Pump Sizing 61 Table 15 1 Sound Power Measurements for TT300 71 Table 15 2 Sound Pressure Calculation for TT300 71 Table 15 3 Sound Power at Third Octave Band TT300 Compressor 72 Table 15 4 Sound...

Page 6: ...alve Medium Temperature Compressors Only 67 Figure 14 6 Typical Refrigeration Piping Schematic With Multiple DX Evaporators 68 Figure 14 7 Typical Refrigeration Piping Schematic Using Multiple Compressors on a Common Circuit With a Flooded Evaporator 69 Figure 16 1 Suction Front View All Models 75 Figure 16 2 Service Side View All Models 76 Figure 16 3 Discharge Side View 76 Figure 16 4a Center of...

Page 7: ...elines provided in this manual are AS IS with no warranty of any kind either express or implied including without limitation any implied warranties of condition uninterrupted use merchantability or fitness for a particular purpose In no event shall DTC be liable for direct indirect special incidental or consequential damages arising out of the manufacture use or the inability to manufacture or use...

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Page 9: ...ed into the following sections 1 Overview of the TT TG series compressors provides an overview of the Twin Turbo and Total Green TT and TG series compressors including an introduction to the compressor 2 Compressor Module provides details on the Compressor Module of the compressor including product capacity and application range maximum pressure alarm and fault limits 3 System Design Guidelines pr...

Page 10: ... outcome of the procedure being performed NOTE Indicates something to be noted by the reader NOTE DANGER Indicates an essential operating or maintenance procedure practice or condition which if not strictly observed could result in serious injury to or death of personnel or long term health hazards WARNING Indicates an essential operating or maintenance procedure practice or condition which if not...

Page 11: ... pressure divided by the absolute suction pressure CSA Canadian Standards Association www csa ca DC Bus High DC voltage simultaneously connected to multiple compressor components via metallic bus bars including the capacitors DC Capacitor Assembly An assembly of four DC capacitors four bleeder resistors and positive and negative bus bars DC DC Converter DC DC converters supply and electrically iso...

Page 12: ... insufficient power to sustain safe and normal operation and is typically due to a loss of power Genlanolin A type of grease In certain climates where the dew point falls below the operating temperature of some of the electronic components it is necessary to apply Genlanolin to certain parts of the compressor to prevent moisture accumulation Harmonics Harmonics are multiples of the fundamental fre...

Page 13: ...magnetic field and is also a parameter used to evaluate the strength of the permanent magnets of the shaft One practical application is to use this phenomenon to indirectly measure motor speed as well as estimate position NEC National Electric Code www necplus org Nm Newton meter A unit of torque 1 Nm 0 738 pound force foot lbf f NTC Negative Temperature Coefficient Refers to thermistor characteri...

Page 14: ...dly re enter the compressor fluid path creating a cavitating effect This is an undesirable situation that should be avoided Thrust Bearing A bearing that absorbs the axial forces produced in a centrifugal compressor by the refrigerant pressure differential across the impeller Ton The basic unit for measuring the rate of heat transfer 12 000 BTU H 3 516 kw H Touchdown Bearings Carbon races or ball ...

Page 15: ...se with refrigerant R134a The TG series compressor is for use with R1234ze E refrigerant only ASHRAE standard 34 has classified this refrigerant as R1234ze E with safety classification of A2L ASHRAE Standard 34 2010 Addendum 1 contains the change to the standard ASHRAE Standard 15 Safety Standard has sent out an initial public review document outlining proposed changes to this standard to address ...

Page 16: ...e below 1 C ambient if refrigerant circuit is maintained at a minimum of 1 C Saturated temperature The compressor should not be operated at an altitude higher than 3000m The compressor should be stored and operated within the following ambient temperature ranges Storage 30 C to 70 C 22 F to 158 F Operation 1 C to 52 C 30 F to 125 F Mains Power Applied Non Operating Limit 25 C 13 F Humidity 0 95 No...

Page 17: ...cy permanent magnet synchronous motor powered by pulse width modulating PWM voltage supply The high speed variable frequency operation that affords high speed efficiency compactness and soft start capability Motor cooling is by liquid refrigerant injection Electronics The electronics is divided into two 2 sections Power electronics located on the top of the compressor including soft start DC DC SC...

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Page 19: ... conditions The first compression element the gas encounters is the first stage impeller The centrifugal force produced by the rotating impeller results in an increase in both gas velocity and pressure The high velocity gas discharging from the impeller is directed to the second stage impeller through de swirl vanes The gas is further compressed by the second stage impeller and then discharged thr...

Page 20: ...alve opens If the temperature increases to the point where it equals a higher temperature threshold the second solenoid valve opens From the outlet of the orifices the refrigerant is directed to the heatsink plate of the inverter and then to the underside of the SCR heatsink From there the refrigerant passes through grooves surrounding the motor stator As the refrigerant flows through the grooves ...

Page 21: ...nd leakage BMCC From IGBT Temp Sensor From SCR Temp Sensor IGBT SCR ORIFICE ORIFICE Solenoid B Solenoid A Liquid Refrigerant Inlet BMCC From Motor Cavity Temp Sensor From Motor Winding Temp Sensor Motor Rotor cooling gas and leakage BMCC From IGBT Temp Sensor From SCR Temp Sensor IGBT SCR ORIFICE ORIFICE Solenoid B Solenoid A Liquid Refrigerant Inlet Cooling path redirects outside of the compresso...

Page 22: ...bration 2 3A Calibration Customer Chiller Control Communications Interface Diagnostic Terminal Internet RS 485 Comms to Chiller or Building Management System User Interface Serial Driver Module 15VDC 24VDC To Motor Cooling Solenoids To IGV Stepper Motor Compressor I O Board 0 10VDC 0 10VDC Compressor Inputs Compressor Outputs Bearing PWM Amplifier HV not HV 17VDC not HV 5VDC Control Feedback 15VDC...

Page 23: ...a controlled sequence preventing damage to components 3 4 2 Soft Start Board The Soft Start Board limits inrush current by progressively increasing the conduction angle of the SCRs This technique is used at compressor start up while the DC capacitors are charging up The soft start function and the variable speed drive combined limit the inrush current at startup 3 4 3 Bearing Motor Compressor Cont...

Page 24: ... stationary surfaces A digital bearing controller and motor controller provide the PWM command signals to the Bearing PWM Amplifier and IGBT Inverter respectively The bearing controller also collects shaft position inputs from sensors and uses the feedback to calculate and maintain the desired shaft position The compressor controller monitors more than 60 parameters including Gas pressure and temp...

Page 25: ...g in modules with the power electronics IGV stepper motor motor cooling solenoids rotor position sensors and pressure temperature sensors The Backplane also features on board low voltage DC DC converters for generating 15V 15V 5V and 17V from an input of 24VDC The Backplane receives its 24VDC power input from the High Voltage HV DC DC Converter mounted on the topside of the compressor The Backplan...

Page 26: ...osition commands to the 250VDC PWM signals that are applied to each bearing actuator coil Rotor position sensors are located on rings attached to the front and rear radial bearing assemblies The front sensor ring contains sensors that read the rotor position along the X Y and Z axes The rotor position along the Z or axial axis is read by measuring the distance between the sensor and a target sleev...

Page 27: ...or Touchdown Bearings Touchdown Bearings Target Sleeve Y axis Position Sensor Y axis Position Sensor Channels Fx Fy Channels Rx Ry Channel Axi 250 VDC Position Command Signals Bearing Motor Compressor Controller BMCC Bearing PWM Amplifier Position Feedback Position Feedback Axis Bearing Channel X Front Radial Fx Y Front Radial Fy X Rear Radial Rx Y Rear Radial Ry Z Axial Axi Channel Assignments Sh...

Page 28: ...ssor Running N O Contact Compressor Running N O Contact Pressure Sensor Signal 1 5Volts Sensor 5V Sensor 0V Temperature Sensor Signal 1 5Volts Universal Analog Output Universal Analog Output Universal output can be used for output manual control 0 5VDC or 0 10VDC RS232 Monitoring Connector DB9 J6 J7 J1 J2 J4 J5 J3 J8 LIQDT SPEED STATUS I LOCK DEMAND COM NETA NETB EXV1 EXV2 1A 1B 2A 2B 1A 1B 2A 2B ...

Page 29: ...ol the auxiliary expansion valve economizer Demand 0 10V Analog input from customer supplied controller to drive the compressor i e 0 max kW input with a deadband of 2VDC for the respective compressor model Only available in 3 1 4 removed in 4 x forward Interlock Connects to a set of external normally closed contacts that typically open in the event of loss of chilled water or air flow Typically a...

Page 30: ...ble in the Spare Parts Selection Guide For RS 485 communication the maximum cable length should not exceed 100 meters 328 feet If using RS 232 communication the cable length should not exceed 15 meters 50 feet between the PC and the compressor refer to Figure 4 3 4 2 Interface Cable NOTE If an I O extension cable is used heat shrink tubing should be applied to the mating cable connectors to mainta...

Page 31: ...tion and electrical noise 4 3 Compressor I O Board Mounting Details Figure 4 4 Compressor I O Board Control Interface Wiring NOTE The UL listed enclosure should protect against moisture and other corrosive elements 4 3 1 Compressor I O Board Mounting Instructions 1 Tilt the I O Board as shown in Figure 4 5 in order to engage it into the DIN Rail 2 Lower the I O Board until it snaps into place Figu...

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Page 33: ...tion which are typcially deemed appropriate for Water Cooled condiitons These values allow for adjustment for compressors placed in Air Cooled applications which can have the value increased up to 1730 kPa g 250 PSIG for the Alarm and 1800 kPa g 260 PSIG for the Trip Table 5 1 Discharge Pressure Alarm and Trip Settings Model kPa g PSIG kPa g PSIG TG230ST 1239 180 1299 188 TG230MT 1116 162 1176 171...

Page 34: ... 5 2 Discharge Temperature Trip Settings Unit Compressor TG230 ST TG230 MT TG310 ST TG390 ST TG520 ST TT300 ST TT300 MT TT350 ST TT400 ST TT700 ST F Trip 212 194 203 194 194 212 194 203 194 194 C Trip 100 90 95 90 90 100 90 95 90 90 NOTE While the values here are represented in Gauge Pressure the values in the registers will be defined in Absolute Pressure Refer to the OEM Programming Guide to ide...

Page 35: ...uilding applications An OEMs use of Turbocor Compressors in applications other than stationary building applications e g Marine Applications is considered a non standard application and is not eligible for warranty under DTCs standard warranty Terms and Conditions It is the responsibility of the OEM to ensure that proper safety protocols are in place and that the chiller system has been designed i...

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Page 37: ...ty from DTC unless otherwise stated by DTC This includes any application of a 400V compressor in a 380V application without the use of a transformer to correct the voltage going into the compressor NOTE Refer to the TT TG Compressor Nomenclature section of this manual for details on the compressor voltage availability 6 Electrical Specifications The new compressor controller version 3 0 0 and abov...

Page 38: ...00 380V 60 170 66 187 60 66 TT400 400V 60 170 66 187 60 66 TT400 460V 60 150 66 165 60 66 TT400 575V 60 120 66 132 60 66 TT700 380V 60 206 66 227 60 66 TT700 400V 60 196 66 216 60 66 TT700 460V 60 170 66 187 60 66 Electrical Specifications An input disconnect for example a switch or circuit breaker must be installed in the line before the compressor in accordance with applicable local national and...

Page 39: ...le and immediately before the compressor that is downstream from the line reactor Contact DTC for more information 6 4 Motor Insulation Class All TT TG Series compressors have a motor insulation Class H rating or better according to the NEMA UL Standard The power line contactor is optional Consult local codes to determine if a contactor is necessary for your application 6 6 Power Line Contactor To...

Page 40: ... and grease and paint free 4 At one point usually the entrance of the power supply panel all grounds should be connected together refer to Section 6 11 From an EMC standpoint it is best to categorize different types of grounds and treat them independently see Figure 6 1 Safety ground Protective Earth PE and shields of mains cables Analog grounds shielding of interface cables Digital grounds Refere...

Page 41: ...Keep power cables and interface cables separate Use metal cable glands for shielded cables The wire loom going to the panel door should be shielded using a metal braided hose that is connected to ground at both ends Electrical panel must have a dedicated ground conductor in accordance with relevant electrical codes Verify that the panel ground conductor is sized in accordance with relevant electri...

Page 42: ...carried inside of a code approved electrical metallic conduit of the flexible or rigid types The mains input cable should be CSA UL or CE approved three wire with a common shield and single ground The cable must be rated for 90 C 194 F minimum at the maximum applicable current It is recommended that the cable be double jacketed i e teck cable type Refer to Table 6 4 for cable gland specifications ...

Page 43: ...operating map which is in the speed control range only As the compressor reduces speed and mechanical unloading is enabled such as the closing of the variable IGV the tolerance increases to 10 The conditions considered are only the flange to flange conditions seen at the compressor rather than the conditions seen at other points in the system The compressor performance ratings are based on using R...

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Page 45: ...d to the FLA rating of the particular compressor The lower limit is related to minimum pressure ratios required to effect proper motor and power electronics cooling with standard refrigerant circuit components 1 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 mor...

Page 46: ...le 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 Figure 8 2 Operating Envelope TT300 and TG230 Medium Temperature Compressor 1 ...

Page 47: ...is related to the FLA rating of the particular compressor The lower limit is related to minimum pressure ratios required to effect proper motor and power electronics cooling with standard refrigerant circuit components 1 The actual obtainable capacity will be dependent on specific operating characteristics of each compressor model Refer to the current authorized compressor selection rating softwar...

Page 48: ...is related to the FLA rating of the particular compressor The lower limit is related to minimum pressure ratios required to effect proper motor and power electronics cooling with standard refrigerant circuit components 1 The actual obtainable capacity will be dependent on specific operating characteristics of each compressor model Refer to the current authorized compressor selection rating softwar...

Page 49: ...mum SDT for compressors with an FLA less than that is lower than the upper bound of the operating envelope and depends on the FLA rating 1 The actual obtainable capacity will be dependent on specific operating characteristics of each compressor model Refer to the current authorized compressor selection rating software for more exact values and conditions Figure 8 5 Operating Envelope TT700 and TG5...

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Page 51: ...ifugal compression the minimum stable load is dependent on the pressure ratio imposed on the compressor by the chiller system All compressor performance including unloading should be determined through use of the relevant compressor selection rating programs 9 Minimum Unloading Capacity ...

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Page 53: ...s required to start against a pressure ratio of 2 4 or greater Load balancing valve hot gas bypass the LBV is piped downstream of the check valve and is primarily used in low load conditions to keep the compressor Online instead of cycling off It is possible to use a staging valve as a load balance valve HGBP but sizing and control can be a little more challenging and for that reason they are both...

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Page 55: ...5 of 108 M AP 001 EN Rev N Product Certification All TT and TG Series compressors are ETL and CE listed and have been tested in accordance with UL Standard 984 and CSA Standard C22 2 11 Product Certification ...

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Page 57: ...he DC voltage to an adjustable three phase AC voltage Signals from the compressor controller shall determine the inverter output frequency voltage and phase thereby regulating the motor speed In case of power failure the compressor shall be capable of allowing for a normal de levitation and shutdown Compressor speed shall be reduced as condensing temperature and or heat load reduces optimizing ene...

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Page 59: ...siderations that ensure oil return such as multiple risers and traps are not required In most cases larger diameter lines will result in better compressor performance and efficiency 4 For improved efficiency and better control particularly at low load low compression ratios electronic expansion valves EXVs are strongly recommended To take advantage of low pressure ratio operation to improve low lo...

Page 60: ...ion Software on the Customer Service and Support Performance Tools section of the DTC web page www turbocor com The circuit must be properly designed to reflect the specified heat exchanger approach with minimized pressure drops across the liquid side and expansion side Piping design including expansion device selection and pipe sizing should be in accordance with best practices It is essential th...

Page 61: ... 13 2 Low Lift Pump Sizing The standard TT TG control limits compressor speed and capacity below a 1 5 pressure ratio to ensure adequate motor inverter cooling When enabled the low lift option is meant to enable increased compressor speed and capacity at pressure ratios below 1 5 To ensure adequate cooling for extended operation with pressure ratios below 1 5 the chiller system must provide the su...

Page 62: ...s such as hot building start up can limit the maximum capacity of the centrifugal compressor If more capacity is desired it is advisable to raise the discharge pressure temporarily to increase the 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 13 5 ...

Page 63: ...with Subcooler Evaporator Sight Glass Check Valve Expansion Valve Motor Cooling Port Suction Port Economizer Port Discharge Port Sight Glass Filter Drier Check Valve Refrigerant Pump Pressure Regulating Valve Check Valve Optional configuration for Low Lift operation CC 4 1 later Staging Valve 14 Sample Refrigeration Circuits ...

Page 64: ...g and Load Balancing Valve Motor Cooling Port Suction Port Economizer Port Discharge Port Sight Glass Sight Glass Filter Drier Filter Drier Evaporator Expansion Valve Expansion Valve Staging Valve Staging Valve Load Balancing Valve Load Balancing Valve Condenser with Subcooler Filter Drier Filter Drier Sight Glass Check Valve ...

Page 65: ...n Piping Schematic With Flash Tank Economizer Motor Cooling Port Suction Port Economizer Port Discharge Port Sight Glass Filter Drier Evaporator Expansion Valve Sight Glass Economizer Tank Condenser with Subcooler Filter Drier Expansion Valve Sight Glass Check Valve S Solenoid Valve Staging Valve ...

Page 66: ...cal Refrigeration Piping Schematic With Sub Cooler Circuit Economizer Motor Cooling Port Suction Port Economizer Port Discharge Port Sight Glass Filter Drier Evaporator Sight Glass Expansion Valve Condenser with Subcooler S Solenoid Valve Expansion Valve Check Valve Staging Valve ...

Page 67: ...chematic Using Motor Cooling Pressure Regulating Valve Medium Temperature Compressors Only Motor Cooling Port Suction Port Economizer Port Discharge Port Sight Glass Filter Drier Expansion Valve Condenser with Subcooler Sight Glass Pressure Regulating Valve Filter Drier Evaporator Check Valve Staging Valve ...

Page 68: ...ion Piping Schematic With Multiple DX Evaporators Motor Cooling Port Suction Port Economizer Port Discharge Port Sight Glass Filter Drier Filter Drier Sight Glass Expansion Valve Expansion Valve Expansion Valve Evaporator Evaporator Evaporator Condenser with Subcooler Check Valve Staging Valve ...

Page 69: ... Port Motor Cooling Port with integral strainer Suction Port Economizer Port Discharge Port Motor Cooling Port with integral strainer Suction Port Economizer Port Discharge Port Sight Glass Sight Glass Filter Drier Filter Drier EXV Sight Glass Staging Valve Staging Valve Staging Valve Staging Valve Sight Glass Sight Glass Check Valve Check Valve Load Balance Valve Condenser with Subcooler Evaporat...

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Page 71: ...ces while the compressor is installed on top of a building The sound data below should be used as a guide only The following sound measurements are based on a specific physical setup such as suction discharge piping evaporator and condensers as well as specific pressure ratios Any OEM system design would not necessarily match these conditions OEMs are responsible for their system sound level measu...

Page 72: ...65 7 62 6 630 60 2 58 4 630 71 8 69 8 800 65 1 64 5 800 67 7 67 2 1000 76 5 76 7 1000 70 5 70 6 1250 66 2 66 9 1250 82 3 83 0 1600 69 9 71 0 1600 72 6 73 9 2000 69 6 70 9 2000 73 3 74 7 2500 68 6 69 9 2500 72 8 74 3 3150 72 3 73 6 3150 75 3 76 7 4000 71 3 72 3 4000 74 6 75 8 Table 15 4 Sound Power Measurements Table 15 5 Sound Pressure Calculation Operation Mode Sound Power A Scale dBA Sound Power...

Page 73: ...Hz Linear scale dB A weighted dBA Third octave band Hz Linear scale dB A weighted dBA 160 51 65 160 55 70 200 49 61 200 50 62 250 60 70 250 61 70 315 60 68 315 62 69 400 64 71 400 65 75 500 63 65 500 62 66 630 78 79 630 76 79 800 80 81 800 78 80 1000 83 82 1000 82 83 1250 82 81 1250 81 81 1600 77 76 1600 75 74 2000 77 76 2000 75 74 2500 75 74 2500 76 76 3150 75 75 3150 75 76 4000 72 71 4000 73 73 ...

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Page 75: ...s 144 kg TG520 318 lbs 144 kg 16 Physical Data Adequate clearance around the compressor is essential to facilitate maintenance and service Removal of the compressor top and service side covers requires a minimum clearance of 24 600mm and 16 406mm respectively 16 1 Clearance Figure 16 1 Suction Front View All Models NOTE If insulators are used at the four 4 mounting base points the overall height o...

Page 76: ...0 2 8 67 TT350 TT400 TT500 O RING GROOVE OD 88 9 3 499 WIDTH 4 1 0 1614 ID 80 7 3 177 O RING GROOVE OD 33 3 1 311 TT300 TG230 41 3 1 659 TT350 TT400 TT500 TT700 WIDTH 4 1 0 1614 ID 25 1 0 988 TT300 TG230 33 1 1 30 TT350 TT400 TT500 TT700 TG310 TG390 TG520 150 5 91 TT350 TT400 TT500 TG310 174 0 6 57 TT300 3 4 1 1 4 0 9 2 3 4 3 3 7 8 787 6 31 00 TG310 TG390 TG520 ...

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

Page 78: ...0 TT400 TG390 TT700 TG520 CG LINE Length of Center of Gravity m in XL 0 257 10 13 0 249 9 81 0 247 9 74 0 251 9 87 Width of Center of Gravity m in YL 0 151 5 95 0 153 6 03 0 152 5 97 0 150 5 91 Compressor Weight Including I O Cable and Mounting Bumpers Kg lb 125 5 277 134 1 296 132 7 293 135 4 299 Compressor Total Weight Kg lb 123 2 272 131 8 291 130 5 288 133 2 294 ...

Page 79: ...hysical 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 80: ...Page 80 of 108 M AP 001 EN Rev N Physical Data Figure 16 6 Discharge Port Details TT350 and TG310 Figure 16 7 Discharge Port Detail TT400 and TG390 Gas Flow Gas Flow ...

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

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

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

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

Page 85: ...Rev N Physical Data Figure 16 14 TT700 and TG520 Flange Footprint Details Port Thread Size Hole Depth mm Torque Nm Suction M16 X 2 34 5 75 Discharge M10 X 1 5 20 22 Economizer M10 X 1 5 20 22 Table 16 3 Screw Hole Specifications ...

Page 86: ...2 A C Bus Bars 6 4 53 DC Capacitors and Bleed Resistor 2 1 18 IGBT Mounting Screws 6 4 53 Shraeder Valves 15 11 133 Motor Cooling Body body nut E Housing and later 25 18 221 Motor Cooling Compression Nut E Housing and later 11 8 97 Cover Plate 13 10 115 Hermetic Feed Through 22 16 195 Motor Cooling Brass Orifice 7 5 62 Motor Cooling Plunger 4 3 35 TT300 Mains Termination 31 23 274 Check figure bel...

Page 87: ...cooling line NOTE Some applications may require alternative arrangements Contact DTC for further assistance if required CAUTION The discharge line must be fitted with a non return valve to prevent reverse flow into the discharge port which can cause damage to compressor components All pipe work should be carried out in accordance with industry standards Brazing without the use of nitrogen will res...

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Page 89: ...ensate 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 External copper piping should be braced to minimize the transfer of vibration to the compressor 18 1 Humidity 18 2 Vibration 18 Environmental Considerations ...

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Page 91: ...xcessive vibration Due to the flexibility of the compressor s isolation mounts compressor vibration during transit can fracture the motor cooling line s rigid piping DTC suggests the temporary installation of an anti vibration bracket between the compressor s base frame and mounting rail during transit as shown in Figure 19 1 19 1 Vibration 19 Shipping Considerations Figure 19 1 Anti Vibration Bra...

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Page 93: ...hould not extend from the compressor mounting rails to the base frame see Figure 20 3 and Figure 20 4 3 Check that the compressor mounting rails are level 5mm 3 16 in the lateral and longitudinal planes The compressor should be carefully inspected for visible signs of damage Check for loose bolts and damage to covers or outer casing Damage should first be reported to the carrier not DTC DTC Custom...

Page 94: ...ure 20 2 Mounting Base TT and TG series NOTE If isolation pads are used at the four 4 mounting base points the overall height of the compressor will change Be sure to measure accordingly based on the insulator used 1 If isolation pads are used install four 4 pads in accordance with the footprint dimensions given in Figure 20 2 2 Mount the compressor onto the isolation pads Ensure the compressor mo...

Page 95: ...flanges to the compressor O rings must be of type EPDM also known by the compound E0740 75 for R1234ze refrigerant O ring grease must be silicone based and compatible with R1234ze CAUTION The motor cooling line should be channeled from the liquid line see Figure 20 5 The motor cooling line requires the installation of a service valve not included to enable refrigerant isolation during compressor s...

Page 96: ...rol wiring connections to the compressor I O Board Table 16 1 Control Wiring Details provides details for the module terminal connections The interface cable connects the compressor to the compressor I O board To connect the cable 1 Plug the cable connector into connector J6 on the compressor I O board For RS 485 communication the total length of the interface cable and control wiring can be exten...

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

Page 98: ...grounding Improper grounding can be identified by measuring the voltage between the customer s negative terminals and the ground J1 COM or Modbus shield terminal on the compressor I O board see Figure 20 7 If the measured voltage is not zero determine the source of the voltage The most likely cause of voltage is insufficient insulation of the external circuit In case of uncertainty of the groundin...

Page 99: ...re 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 the interlock contacts are open and closed In either contact state if the measured voltage is not zero verify the source of the voltage Do not connect the interlock terminals until the voltage...

Page 100: ...d for 90 C 194 F minimum with a maximum current rating corresponding to the LRA value on the compressor nameplate Keep power cables and control interface cables in separate conduits Use metal cable glands for shielded cables to ensure good grounding If you are installing a DTC line reactor or EMI or harmonic filter in the mains input circuit refer to the applicable installation instructions 1 Rele...

Page 101: ...m Nut Mains Stud 3 8 16 1 5 long Compression Lug AC Input Connection Upper Nut 10 Nm 7 ft lb Jam Nut 7 Nm 62 in lb Figure 20 10 Ground Post Nuts 7 Attach the three main power cables to the compressor terminals see Figure 20 10 Continue to Step 8 for TT300 TG230 compressors For all other TT TG compressors continue to Step 9 NOTE The bore size of the Terminal Block Adapter is 18mm therefore the maxi...

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

Page 103: ...ly panel 2 Attach the AC line wires to the line reactor output terminals as shown in 3 If a harmonic filter is being installed attach its AC line wires to the line reactor output terminals 4 Attach the ground wire to the mounting block on the panel wall Ensure there is good electrical mechanical contact between the ground wire and the panel wall 5 Secure the AC line cable to the main supply panel ...

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

Page 105: ...ound lug to the main ground bus and tighten the nut see Figure B 2 1 Insert the load wires from the line side of the line reactor into the terminals labelled L1 L2 and L3 on the Load side of the filter Tighten the terminal screws 2 Attach the ground lug to the main ground bus and tighten the nut 1 If a Harmonic Filter is to be installed follow the manufacturers instructions 2 Connection of a Harmo...

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

Page 107: ...can select from a list of symptoms in the app that match the problems exhibited by the compressor being serviced The app will then list potential causes solutions to the problem and service literature to reference for further information The app provides the correct operating parameters for key components no need to keep reference documents on hand You no longer need to keep hundreds of pages of p...

Page 108: ...s distinct variable speed technology specialists Today we operate from engineering and manufacturing facilities spanning across three continents Danfoss Inverter Scrolls Danfoss Turbocor Compressors Danfoss Scrolls Danfoss Optyma Condensing Units Secop Compressors for Danfoss Danfoss Maneurop Reciprocating Compressors M AP 001 EN Rev N Copyright Danfoss Turbocor Compressors Inc 2018 12 Our product...

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Danfoss TG230 Series, Installation Manual

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