Danfoss TGH285 Page 67 Applications And Installation Manual Download

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Chapter 9.0 Minimum Unloading Capacity

Due to the nature of centrifugal 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.

M-AP-001-EN Rev. S-9/8/2021 Page 67 of 136

Summary of Contents for TGH285

Page 1: ... Applications and Installation Manual Revision S Danfoss Turbocor Twin Turbine Centrifugal Compressors TTS TGS TTH TGH Compressors http turbocor danfoss com ...

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Page 3: ...1 Main Fluid Path 25 3 2 Motor Cooling 26 3 3 Inlet Guide Vanes 29 3 4 Compressor Control Overview 30 3 4 1 Motor Drive System 30 3 4 2 Soft Start 31 3 4 3 Bearing Motor Compressor Controller 31 3 4 4 Compressor Control 31 3 4 5 Capacity Control 31 3 4 6 Expansion Valve Control 31 3 4 7 Motor Bearing Control 31 3 4 8 Monitoring Functions 32 3 4 9 Abnormal Conditions 32 3 4 10 Bearing PWM Amplifier...

Page 4: ...iance 43 Chapter 6 0 Electrical Specifications 45 6 1 Supply Voltage and Frequency 45 6 2 Voltage Sag Immunity 45 6 3 Compressor Current Limit and Operating Range Settings 45 6 4 Disconnects 47 6 5 Motor Insulation Class 47 6 6 AC Input Line Power Electronic Component Protection 47 6 7 Power Line Contactor 48 6 8 CE Compliance and EMI EMC Filtering 48 6 9 Surge Protection 49 6 10 Line Reactor 49 6...

Page 5: ...ces 73 Chapter 13 0 System Design Guidelines 75 13 1 General Requirements 75 13 2 Economizer Option 76 13 3 Motor Electronics Cooling Requirements 76 13 4 Electrical Requirements 77 13 5 Application Specific Requirements 77 13 5 1 Medium Evaporating Temperature Application TGS230 TTS300 TGH285 TTH375 77 13 5 2 High Evaporating Temperature Application TGS310 TTS350 TGS490 TGS390 TTS400 TGS520 TTS70...

Page 6: ...5 20 2 Rigging Requirements 115 20 3 Unit Placement 115 20 4 Mounting Base 116 20 5 Piping Connections 117 20 6 Control Wiring 118 20 6 1 Control Wiring Connections 118 20 6 2 Circuit Grounding 119 20 6 3 Voltage Free Contacts 120 20 7 Power Wiring 121 Appendix A 125 A 1 Line Reactor Installation Instructions 125 Appendix B 127 B 1 EMI EMC Filter Installation Instructions 127 Appendix C 129 C 1 Pr...

Page 7: ...nclude TTH TGH compressors P 1 12 12 2019 Update to include TG490 and Medium Temp Q 04 06 2020 Major Revision H upgrade R 02 01 2021 Includes High SST and general review update S 07 29 2021 Complete review many small changes made Includes new TTS 575V option M AP 001 EN Rev S 9 8 2021 Page 7 of 136 ...

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Page 9: ...es arising out of the manufacture use or the inability to manufacture or use information contained in this manual even if advised of the possibility of such damages In particular Danfoss LLC is not responsible for any costs including but not limited to those incurred as a result of lost profits or revenue loss of damage or equipment loss of computer programs loss of data the costs to substitute th...

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Page 11: ...s LLC compressors are familiar with and carry out all safe work practices necessary to ensure safety for personnel and equipment 1 1 Scope This manual is designed for use with Bearing Motor Compressor Controller BMCC software Version 4 0 0 and later Table 1 1 Application Manual Applicability Manual Release Date BMCC Firmware Versions M AP 001 XX Rev E September 2013 CC 2 3 1213 M AP 001 XX Rev L O...

Page 12: ...r Conditioning Heating and Refrigeration Institute www ari org www ahrinet org ANSI American National Standards Institute ASHRAE American Society of Heating Refrigeration and Air Conditioning Engineers www ashrae org Axial Bearing Bearing that controls the horizontal movement Z axis of the motor shaft Backplane A printed circuit board PCB for the purpose of power and control signal transmission Ma...

Page 13: ...and loudness dBA Sound level measurement that has been adjusted based on how the human ear perceives sounds in the air DC Bus High DC voltage simultaneously connected to multiple compressor components via metallic bus bars including the capacitors DC DC Converter DC DC converters supply and electrically isolate the high and low DC voltages that are required by the control circuits When the compres...

Page 14: ...peration and is typically due to a loss of power Harmonics Harmonics are multiples of the fundamental frequency distortions found in electrical power subjected to continuous disturbances HFC Hydrofluorocarbon HFC 134a A positive pressure chlorine free refrigerant having zero ozone depletion potential HV High Voltage Hz Hertz IEEE Institute of Electrical and Electronic Engineers www ieee org IGV In...

Page 15: ... magnetic bearings Line Reactor 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 filters the waveform and attenuates electrical noise and harmonics associated with an inverter drive output LLC Limited Liability Company LRA Locked Rotor Ampere LVD Low voltage directive M...

Page 16: ...ase in temperature results in a rise in resistance ohms ODF Outside Diameter Flare OEM Original Equipment Manufacturer PCB Printed Circuit Board PLC Programmable Logic Controller Pressure Ratio See Compression Ratio PE Protective Earth PSIG Pounds per square in gauge PWM Pulse Width Modulation Radial Bearing Bearings that control the position of the shaft on the X and Y axis Rectifier A rectifier ...

Page 17: ...h the compressor cannot sustain the discharge pressure allowing refrigerant to temporarily and rapidly re enter the compressor fluid path creating a cavitating effect This is an undesirable situation that should be avoided 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 bearing for the purpose of preventing mechanical inter...

Page 18: ...Acronym Term Definition VDC Volts Direct Current VFD Variable Frequency Drive W Watt Page 18 of 136 M AP 001 EN Rev S 9 8 2021 ...

Page 19: ... Additionally the Series indicators not have an additional character in order to differentiate the standard compressors from high lift compressors Unless the compressor is a high lift design an S will be added e g TTS350 A high lift compressor will have an H in the Series designation e g TTH375 Throughout this manual it shall be assumed that if a series designation contains neither an S or H e g T...

Page 20: ...Figure 2 2 Compressor Nomenclature Page 20 of 136 M AP 001 EN Rev S 9 8 2021 ...

Page 21: ...n all chiller system components exposed to refrigerant should be approved by their manufacturer for use with that refrigerant 2 3 Environment The compressor should not be operated at an altitude higher than 3000 m The compressor should be stored and operated within the following ambient temperature ranges l Storage 30 C to 70 C 22 F to 158 F l Operation 1 C to 51 C 30 F to 124 F l Mains Power Appl...

Page 22: ...o exposed metals For outdoor installations a weather proof enclosure with vents is recommended to house the compressor l TTS TGS TTH TGH compressors can operate below 1 C ambient if refrigerant circuit is maintained at a minimum of 1 C Saturated temperature 2 4 Configurations of the TTS TGS TTH TGH Compressor Models The compressor motor and power assemblies are packaged in the design CAUTION It is...

Page 23: ...anent 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 l Electronics The electronics is divided into two 2 sections Power electronics located on the top of the compressor including soft start DC DC Silicon...

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Page 25: ...age 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 through a volute via a diffuser a volute is a curved funnel increasing in area ...

Page 26: ...d electromechanical components refer to Figure 3 3 Compressor Cooling Circuit TGS230 TTS300 and Figure 3 4 Compressor Cooling Circuit TTS300 Split Cooling TGS310 TTS350 TGS390 TGS490 TTS400 TTS700 and TGS520 CAUTION A minimum operating pressure ratio of 1 5 is required to maintain adequate cooling of the compressor unless the system is fitted with an appropriately selected liquid pump cooling pump...

Page 27: ...TGS230 use a split cooling method where the motor and electronics portions are cooled separately by refrigerant liquid Figure 3 3 Compressor Cooling Circuit TGS230 TTS300 Table 3 3 Compressor Cooling Circuit TGS230 TTS300 No Description No Description 1 From Motor Winding Temp Sensor 8 SCR 2 BMCC 9 Motor Rotor Cooling Gas and Leakage 3 Solenoid M 10 Cooling path re enters at the suction line of th...

Page 28: ...Split Cooling TGS310 TTS350 TGS390 TGS490 TTS400 TTS700 and TGS520 No Description No Description 1 From Motor Winding Temp Sensor 7 From Inverter Temp Sensor 2 BMCC 8 SCR 3 Solenoid M 9 Motor Rotor Cooling Gas and Leakage 4 Solenoid E 10 From Motor Cavity Temp Sensor 5 Liquid Refrigerant Inlet 11 Inverter 6 Orifice Page 28 of 136 M AP 001 EN Rev S 9 8 2021 ...

Page 29: ...mpeller 2nd Stage 14 Inverter Temp Sensor 7 Radial Bearing 15 PRV pressure regulating valve 8 Stator Rotor 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 ...

Page 30: ...oard l BMCC l Bearing PWM Amplifier l Backplane l Serial Driver l HV DC DC Converter Figure 3 6 Compressor Control System Functional Block Diagram 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 int...

Page 31: ...urrent at startup 3 4 3 Bearing Motor Compressor Controller The hardware and software for the compressor controller and the bearing motor controller physically reside in the BMCC The BMCC is the central processor of the compressor 3 4 4 Compressor Control The Compressor Controller is continuously updated with critical data from external sensors that indicate the compressor s operating status Under...

Page 32: ...e Serial Driver module performs serial to parallel conversion on the stepper motor drive signals from the BMCC The module also contains four normally open relays under BMCC control Two of the relays drive the motor cooling solenoids and the other two are used to indicate compressor fault status and running status The status relays can be wired to external control circuits 3 4 12 Backplane The Back...

Page 33: ...and magnetic bearing PWM Amplifier respectively 3 5 Magnetic Bearing System 3 5 1 Overview A rotating shaft under changing load conditions will experience forces in both radial and axial directions In order to compensate for these forces a five axis bearing system is used incorporating two radial bearings of two axes each and one thrust axial bearing Refer to Figure 3 7 Magnetic Bearing Configurat...

Page 34: ...ial 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 sleeve mounted on the rotor The rear sensor ring contains sensors that read the position along the X and Y axes Information from the position sensors is continuously fed bac...

Page 35: ...try point for control wiring from the chiller plant to the compressor Refer to Figure 4 1 Typical Control Wiring Figure 4 2 Modbus Grounding Diagram for the proper Compressor I O Board connectivity Figure 4 1 Typical Control Wiring M AP 001 EN Rev S 9 8 2021 Page 35 of 136 ...

Page 36: ...mizer Input from a level sensor to control 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 ...

Page 37: ...sor connected to the Entering Chilled Water analog input LEAVE Install the jumper if there is no temperature sensor connected to the Leaving Chilled Water analog input JP5 JP6 Jumpers J5 and J6 are used to match the characteristics of the liquid level sensors Voltage type Level Sensor If using a voltage type sensor with 15V supply and 0 5V signal install jumpers between LVL pins 2a and 3a and pins...

Page 38: ...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 NOTE If an I O extension cable is used heat shrink tubing should be applied to the mating cable connectors to maintain good conductivity and protect the connection from heat and humidity For RS 485 communication the maximum cable length should n...

Page 39: ...dry area free from vibration and electrical noise NOTE The UL listed enclosure should protect against moisture and other corrosive elements Figure 4 4 Compressor I O Board 4 3 1 Compressor I O Board Mounting Instructions 1 Tilt the I O Board as shown in Figure 4 5 Compressor I O Board Installation in order to engage it into the DIN Rail 2 Lower the I O Board until it snaps into place Figure 4 5 Co...

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Page 41: ...larm Fault kPa g PSIG kPa g 2 PSIG3 TGS230ST 1239 180 1299 188 TGS230MT 1116 162 1176 171 TGS310 1240 180 1300 189 TGS490 1240 180 1300 189 TGS390 876 127 926 134 TGS520 876 127 926 134 TGH285 1510 218 1586 229 TTS300ST 1190 173 1240 180 TTS300MT 1190 173 1240 180 TTS350 1730 251 1800 261 TTS400 1190 173 1240 180 TTS700 1190 173 1240 180 TTH375 2016 292 2116 306 In the TGS230 TTS300 compressors th...

Page 42: ...T TGS230MT TGS310 TGS490 TGS390 TGS520 TGH285 TTS300ST TTS300MT TTS350 TTS400 TTS700 TTH375 Alarm 4 4 5 2 5 2 3 5 3 5 6 3 4 4 5 2 3 5 3 5 6 3 Fault 5 2 5 2 5 5 5 5 4 4 6 5 5 2 5 2 5 5 4 4 6 5 The TGS230 TTS300 compressor allows for adjustment of this setting Compressors which are placed in Air Cooled applications can have this value increased up to 4 8 NOTE Pressure ratio must be calculated using ...

Page 43: ...uise ships floating platforms Danfoss Turbocor compressors are produced for civilian use and are not intended for safety critical systems Misapplication of a Turbocor compressor will not be covered under Danfoss LLC s Standard Warranty Terms and Conditions 5 5 Standards Compliance It is the responsibility of the Original Equipment Manufacturer OEM to ensure that proper safety protocols are in plac...

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Page 45: ...minal rated voltage defined on the compressor nameplate will result in voiding of the compressor warranty from Danfoss LLC unless otherwise stated by Danfoss LLC 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 TTS TGS Compressor Nomenclature section of this manual for detail...

Page 46: ... 400V 50 210 55 231 50 55 TGS490 460V 50 180 55 198 50 55 TGS520 380V 50 149 55 165 50 55 TGS520 400V 50 142 55 158 50 55 TGS520 460V 50 123 55 137 50 55 TGS520 575V 50 99 55 110 50 55 TGH285 380V 50 150 55 165 50 55 TGH285 400V 50 150 55 165 50 55 TGH285 460V 50 131 55 145 50 55 TGH285 575V 50 105 55 116 50 55 TTS300 380V 40 145 44 160 40 44 TTS300 400V 40 145 44 160 40 44 TTS300 460V 40 135 44 1...

Page 47: ...n poor power factor and higher full load current Refer to Figure 20 9 Typical Electrical Connections for interconnection details 6 5 Motor Insulation Class All TTS TGS TTH TGH Series compressors have a motor insulation Class H rating or better according to the NEMA UL Standard 6 6 AC Input Line Power Electronic Component Protection Most safety regulations require that upstream branch protection be...

Page 48: ...ause of the nature of your application and or installation an alternative component with the same attenuation characteristics must be used to maintain compliance with the EMC Directive It is the responsibility of the user to maintain compliance with the Directives Contact a Danfoss LLC sales representative for more details Proper installation of the EMI EMC filter can have a dramatic effect on ove...

Page 49: ...tions The rule of selecting the Line Reactor is PReactor_Rated kW LRA A URated V 1 73 0 9 1000 6 11 Harmonic Current Filtering IEEE 519 If it is necessary to provide additional current harmonic reduction beyond that provided by the standard 5 line reactor Danfoss LLC recommends the installation of a harmonic filter device in parallel with the compressor as shown in Figure 20 9 Typical Electrical C...

Page 50: ...arate Use metal cable glands for shielded cables l The wire loom going to the panel door should be shielded using a metal braided hose that is connected to ground at both ends l Electrical panel must have a dedicated ground conductor in accordance with relevant electrical safety regulations l Verify that the panel ground conductor is sized in accordance with relevant electrical safety regulations ...

Page 51: ... 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 e g teck cable type Refer to Table 6 4 Main Cable Connector Plate Hole Sizes for cable gland specifications Table 6 4 Main Cable Connector Plate Hole Sizes Model 380V 400V 460V 575V TTS300 TGS230 2 5 2 5 2 5 2 5 TTS350 TGS310 2 5 2 5 3 N A TTS400 TGS390 2 5 2...

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Page 53: ...7 2 Tolerance of Performance Ratings The CPR rating conditions are based on flange to flange and do not take into effect any line pressure drops or piping inconsistent with the guidance in the manual Compressors are guaranteed to meet the published performance ratings in the current CPR tool within the tolerance band published in CPR Higher accuracy is predicted in the speed only range and toleran...

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Page 55: ...es where operation at SST condition limits above those specified and rated for a particular variant but operation may be limited by the maximum ambient temperature around the compressor the saturated discharge temperature and the compressor power input Before offering a compressor to the market above the SST limits of each variant they must be validated by the OEM through controlled testing at ste...

Page 56: ...own and 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...

Page 57: ...lated 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...

Page 58: ...lated 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...

Page 59: ...ated 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 ...

Page 60: ...ed 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 mo...

Page 61: ... 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 more...

Page 62: ...ed 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 mo...

Page 63: ... 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 more...

Page 64: ... 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 more...

Page 65: ...ated 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 ...

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Page 67: ...n 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 M AP 001 EN Rev S 9 8 2021 Page 67 of 136 ...

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Page 69: ...the main EXV in order to desuperheat the gas prior to entering the suction of the compressor CAUTION If the staging valve is used as a LBV there are two major risks l Check valve chattering if the bypassed flow is too high this chattering will lead to bearing faults due to vibrations Please contact Danfoss LLC for further information l High suction superheat which may lead to compressor fault Stag...

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Page 71: ...on All TTS TGS TTH TGH Series compressors are ETL listed and CE marked and have been tested in accordance with UL 60335 2 34 2017 Ed 6 CSA C22 2 No 60335 2 34 2017 Ed 2 and EN 60335 2 34 2013 M AP 001 EN Rev S 9 8 2021 Page 71 of 136 ...

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Page 73: ...eby 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 energy performance through the entire range of capacity Capacity modulates infinitely as motor speed is varied across the range IGVs shall be built in to further tr...

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Page 75: ...ce and efficiency EXV capacity should be selected accordingly Thermal expansion valves TXVs are not recommended due to the general inability of these devices to adequately cover the operating spectrum of centrifugal compressors particularly at low compression ratios 5 Take all necessary precautions to prevent any possibility of liquid floodback to the compressor This means consideration during the...

Page 76: ...page www turbocoroem 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 CAUTION To prevent bypass of gas through an idle compressor the economizer refrigerant circuit should inc...

Page 77: ...th the compressor and must be installed external to the compressor between the main suction line and the motor electronics cooling outlet port adjacent to the inter stage port The valve has a Solder ODF connection with 7 8 diameter Danfoss KVP 22 set at a corresponding pressure to 0 8 C 34 F saturated temperature depending on the used refrigerant Refer to C 1 Pressure Regulating Valve Installation...

Page 78: ...ased 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 subcooled refrigerant flow specified in Table 13 2 Low Lift Pump Sizing An OEM supplied liquid refrigerant pump will be required in most circumstances designs If an adequate supply of subcooled liquid is not provided th...

Page 79: ...Figure 13 2 Centrifugal Performance Dynamics NOTE Contact Danfoss LLC Applications for compressor selection and technical advice M AP 001 EN Rev S 9 8 2021 Page 79 of 136 ...

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Page 81: ...Chapter 14 0 Sample Refrigeration Circuits Figure 14 1 Typical Refrigeration Piping Schematic NOTE Service valves are optional M AP 001 EN Rev S 9 8 2021 Page 81 of 136 ...

Page 82: ...Figure 14 2 Typical Refrigeration Piping Schematic with Staging and Load Balancing Valve NOTE Service valves are optional Page 82 of 136 M AP 001 EN Rev S 9 8 2021 ...

Page 83: ...Figure 14 3 Typical Refrigeration Piping Schematic with Flash Tank Economizer NOTE Service valves are optional M AP 001 EN Rev S 9 8 2021 Page 83 of 136 ...

Page 84: ...Figure 14 4 Typical Refrigeration Piping Schematic with Closed Type Economizer NOTE Service valves are optional Page 84 of 136 M AP 001 EN Rev S 9 8 2021 ...

Page 85: ...5 Typical Refrigeration Piping Schematic Using Motor Cooling Pressure Regulating Valve TTS300 TGS230 Medium Temperature Compressors Only NOTE Service valves are optional M AP 001 EN Rev S 9 8 2021 Page 85 of 136 ...

Page 86: ...ing Schematic Using Motor Cooling Pressure Regulating Valve TTH TGH Medium Temperature Compressors Only NOTE l Service valves are optional l Closed type economizer shown open type can also be used Page 86 of 136 M AP 001 EN Rev S 9 8 2021 ...

Page 87: ...Figure 14 7 Typical Refrigeration Piping Schematic with Multiple DX Evaporators NOTE Service valves are optional M AP 001 EN Rev S 9 8 2021 Page 87 of 136 ...

Page 88: ...4 8 Multiple Compressors Single Circuit Piping Schematic NOTE Contact Danfoss LLC for compressor selection and further technical advice NOTE Service valves are optional Page 88 of 136 M AP 001 EN Rev S 9 8 2021 ...

Page 89: ... damage to the compressor NOTE All TGH TTH compressors MUST include an active economizer flash or plate style when operated at pressure ratios above 2 0 If an economizer is not active at pressure ratios above 2 0 significant instability should be expected and the operating range of the compressor will not meet rated expectations Economizer should be deactivated below PR 2 0 NOTE Service valves are...

Page 90: ...Figure 14 10 TTH TGH Piping Schematic with Required Economizer Flash Tank and Vapor Line Solenoid NOTE Service valves are optional Page 90 of 136 M AP 001 EN Rev S 9 8 2021 ...

Page 91: ...These tables present the results of sound pressure calculations for various distances while the compressor is installed on top of a building l The sound data below should be used as a guide only l 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 nece...

Page 92: ...000 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 for TTS400 Operation Mode Sound Power A Scale dBA Sound Power Linear Scale dB 420 kW 120 Ton 88 4 89 1 525 kW 150 Ton 88 1 89 2 Table 15 5 Sound Pressure C...

Page 93: ...near scale dB A weighted dBA 160 51 65 160 55 70 200 49 67 200 50 62 350 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 71 400 73 73 M AP 001 EN Rev S 9 8 2021 Page 93 of 136 ...

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Page 95: ...43 kg 315 lbs 132 kg 291 lbs TTS400 TGS390 788 mm 31 02 518 mm 20 4 487 mm 19 17 142 kg 312 lbs 130 6 kg 288 lbs TTS700 TGS520 788 mm 31 02 518 mm 20 4 487 mm 19 17 144 kg 318 lbs 132 kg 294 lbs TTH375 TGH285 932 mm 36 7 590 mm 23 2 487 mm 19 17 181 kg 400 lbs 163 7 kg 361 lbs 16 1 Clearance Adequate clearance around the compressor is essential to facilitate maintenance and service Removal of the ...

Page 96: ...Figure 16 1 Suction View All Models Excluding TTH TGH Compressors Figure 16 2 Service Side View Excluding TTH TGH Compressors Page 96 of 136 M AP 001 EN Rev S 9 8 2021 ...

Page 97: ...Figure 16 3 Discharge Side View Excluding TTH TGH Compressors Figure 16 4 TTH TGH Suction Side View M AP 001 EN Rev S 9 8 2021 Page 97 of 136 ...

Page 98: ...Figure 16 5 TTH TGH Service Side View Figure 16 6 TTH TGH Second Stage Housing View Page 98 of 136 M AP 001 EN Rev S 9 8 2021 ...

Page 99: ...Figure 16 7 TTH TGH Discharge Side View Figure 16 8 Center of Gravity Capacitor Side View Excluding TTH TGH Compressors M AP 001 EN Rev S 9 8 2021 Page 99 of 136 ...

Page 100: ...Figure 16 9 Center of Gravity Top View Excluding TTH TGH Compressors Figure 16 10 TTH TGH Center of Gravity Capacitor Side View Page 100 of 136 M AP 001 EN Rev S 9 8 2021 ...

Page 101: ...dth of Center of Gravity m in YL 151 mm 5 95 153 1 mm 6 03 152 mm 5 97 150 mm 5 91 159 9 mm 6 29 Height of Center of Gravity m in ZL 215 mm 8 464 227 1 mm 8 94 227 mm 8 94 227 mm 8 94 241 05 mm 9 49 Compressor valve flange details are shown in Figure 16 12 Discharge Port Detail TTS300 and TGS230 through Figure 16 22 TTS700 TGS490 and TGS520 Flange Footprint Details Refer to the product specificati...

Page 102: ...Figure 16 12 Discharge Port Detail TTS300 and TGS230 Figure 16 13 Discharge Port Detail TTS350 and TGS310 Page 102 of 136 M AP 001 EN Rev S 9 8 2021 ...

Page 103: ...Figure 16 14 Discharge Port Detail TTS400 and TGS390 Figure 16 15 Discharge Port Detail TTS700 TGS490 and TGS520 M AP 001 EN Rev S 9 8 2021 Page 103 of 136 ...

Page 104: ...Figure 16 16 Discharge Port Detail TTH375 and TGH285 Figure 16 17 Suction Port All Models Page 104 of 136 M AP 001 EN Rev S 9 8 2021 ...

Page 105: ...Figure 16 18 Suction Port Detail All Models Excluding TTS700 TGS490 and TGS520 Figure 16 19 Suction Port Detail TTS700 TGS490 and TGS520 M AP 001 EN Rev S 9 8 2021 Page 105 of 136 ...

Page 106: ...Figure 16 20 TTS300 and TGS230 Flange Footprint Details Figure 16 21 TTS350 TGS310 TTS400 TGS390 TTH375 and TGH285 Flange Footprint Details Page 106 of 136 M AP 001 EN Rev S 9 8 2021 ...

Page 107: ...ed Torque Nm Suction M16 34 5 75 Discharge M10 20 32 Economizer M10 20 32 CAUTION Refer to the manufacturer fastener specifications and torque as required but do not exceed the torque values listed in Table 16 3 Screw Hole Specifications If this value is exceeded damage to compressor housing threads may occur M AP 001 EN Rev S 9 8 2021 Page 107 of 136 ...

Page 108: ...s 6 4 53 DC Capacitors and Bleed Resistors 2 1 18 Inverter Mounting Fasteners 6 4 53 Schaeder Valves 13 10 115 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 Feedthrough 22 16 195 Motor Cooling Brass Orifice 7 5 62 Motor Cooling Plunger 4 3 35 TT300 Mains Termination 31 23 274 Check figure below for...

Page 109: ...r in the motor cooling line NOTE Some applications may require alternative arrangements Contact Danfoss LLC Applications 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 ...

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Page 111: ...d 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 NOTE The End Cap insulator is not available for TGH TTH compressors 18 2 Vibration External copper piping should be braced to minimize the transfer of vibration to the compressor M AP 001 EN Rev S 9 8 2021 Page 111 of 136 ...

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Page 113: ... the flexibility of the compressor s isolation mounts compressor vibration during transit can fracture the motor cooling line s rigid piping Danfoss LLC Applications 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 Anti Vibration Bracket Figure 19 1 Anti Vibration Bracket M AP 001 EN Rev S ...

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Page 115: ... to protect it from damage Two eyebolts one at each end are provided for compressor rigging A spreader bar should be used to safely position the compressor into its final location refer to Figure 20 1 Rigging Set up 20 3 Unit Placement 1 If mounting the compressor with the Danfoss LLC mounting kit refer to 20 4 Mounting Base if not install four isolation pads in accordance with the footprint dimen...

Page 116: ...nd longitudinal planes NOTE If isolation pads are used at the four 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 pads in accordance with the footprint dimensions given in Figure 20 2 Mounting Base TTS TGS TTH TGH Series 2 Mount the compressor onto the isolation pads Ensure t...

Page 117: ...quipment on the unit are compatible with the appropriate refrigerant DANGER The motor cooling line should be channeled from the liquid line Figure 20 5 Motor Cooling Connection and Access Port The motor cooling line requires the installation of a service valve not included to enable refrigerant isolation during compressor servicing Compressors are pressurized with nitrogen to 15 psi Pressure shoul...

Page 118: ...e rear of the compressor This connection is a 1 2 inch O ring face seal connection Figure 20 5 Motor Cooling Connection and Access Port 5 Perform a leak test evacuation and charge according to industry standards Figure 20 5 Motor Cooling Connection and Access Port 20 6 Control Wiring The compressor I O board enables communication of control and status signals between the compressor controller and ...

Page 119: ... Connections 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 refer to Figure 20 7 Interlock and Motor Speed Connections Prior to connecting the control wiring to the compressor I O board check for impr...

Page 120: ...on the compressor I O board Figure 20 7 Interlock and Motor Speed Connections 20 6 3 Voltage Free Contacts Prior to connecting the interlock terminals of the compressor I O board measure the resistance across the customer s interlock terminals refer to Figure 20 8 Interlock Circuit Tests Ensure that the interlock contacts are closed The measured value should be less than 1Ω Page 120 of 136 M AP 00...

Page 121: ... with a common shield and single ground It is recommended that the cable be double jacketed for example a teck cable type The cable must be rated for 90 C 194 F minimum with a maximum current rating corresponding to the LRA value on the compressor nameplate l Keep power cables and control interface cables in separate conduits Use metal cable glands for shielded cables to ensure good grounding l If...

Page 122: ...e mains input bracket 3 Fasten the cable gland to the bracket with the locknut 4 Feed the AC input cable through the cable gland 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 refer to Figure 20 10 Ground Post Nuts 7 Attach the three main power cables to the compressor terminals refer to Figure 20 11 Compresso...

Page 123: ...inals for the descriptions of the items shown in Figure 20 11 Compressor AC Input Terminals and Figure All TTS TGS TTH TGH Models Revision H Except TTS300 TGS230 Table 20 2 Compressor AC Input Terminals No Description No Description 1 Mains Input Pressure Screw 4 Upper Jam Nut 2 AC Input Connection 5 Seal Bracket Opening 3 Mains Stud 3 8 16 1 5 long 6 Terminal Block Adapter M AP 001 EN Rev S 9 8 2...

Page 124: ... of the Terminal Block Adapter TTS300 and TGS230 only is 18 mm therefore the maximum wire diameter must not exceed that size 10 Tighten the gland nut to secure the cable to the mains input bracket 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 with the fasteners Page 124 of 136 M AP 00...

Page 125: ... the panel wall Ensure there is good electrical mechanical contact between the ground cable and the panel wall 5 Secure the AC line cable to the main supply panel using approved methods e g cable gland A 1 2 AC Line Cable Connection to Compressor Terminal 1 Feed the AC line cable through the opening in the side of the main supply panel 2 Attach the AC line wires to the line reactor output terminal...

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Page 127: ...re B 2 Grounding Diagram NOTE A short heavy stranded conductor from the filter chassis to the main ground bus is recommended for top performance A battery braid litz wire or flexible welding cable with many fine strands is recommended for best grounding performance B 1 2 Load Side Connection 1 Insert the load wires instead of the line side of the line reactor into the terminals labeled L1 L2 and L...

Page 128: ...Figure B 2 Grounding Diagram Page 128 of 136 M AP 001 EN Rev S 9 8 2021 ...

Page 129: ...Cap Lift 2 Use an appropriately sized hex wrench to turn the setting screw Turn three 3 complete revolutions counterclockwise Figure C 2 Hex Wrench 3 Remove the Schrader valve cap and then the Schrader valve Figure C 3 Schrader Valve Removal 4 Clean all connections with a sanding cloth and then apply soldering flux to the exterior of the clean copper tube Do the same to the mating copper pipe that...

Page 130: ...omponents of the valve do not point the flame towards the center body portion of the valve Refer to Figure C 4 Brazing Connections Figure C 4 Brazing Connections 8 Once cooled Re install the Schrader valve Finger tight plus a turn 3Nm Then install the Schrader valve cap 9 Leak test the cooled joint to ensure there are no leaks 10 Use an appropriately sized hex wrench to turn the setting screw Set ...

Page 131: ...2 cap Finger tight plus a turn 3Nm DANGER It is important to properly tighten the Schrader valve and the top cap This is especially important when used with flammable refrigerants M AP 001 EN Rev S 9 8 2021 Page 131 of 136 ...

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Page 133: ... Turbocor Training class Scan the code to see our schedule and register today 78 years of combined service and applications knowledge Practical classroom courses Hands on compressor demonstrations Service Monitoring Tools software applications Highly qualified and field experienced instructors of the Danfoss Turbocor Learning Center will provide you with a high level of training Attendees will be ...

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Page 135: ...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 parts catalogs and training manuals Wit...

Page 136: ...ompressors VTX1600 Compressors Highlift Compressors TGS Compressors 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 processes http turbocor danfoss com Danfoss LLC 1769 E Paul Dirac Drive Tallahassee Fl 32310 USA 1 850 504 4800 Danfoss can accept no responsibility for pos...

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