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Danfoss Turbocor TT Series, Service Manual

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4.24.3 DC-DC Removal and Installation

Removal

1. Isolate the compressor power as described in Section 1.8 Electrical Isolation on page 22.

2. Remove the Soft Start. Refer to Section 4.14.3 Soft Start Removal and Installation on page 117.

3. Remove the connectors from the DC-DC.

l

Potted style - Four (4) connectors (DC Bus Input (J1), 250VDC (J2), 24VDC (J3), and 15VAC (J4)) from
the DC-DC Converter. Refer to Figure 4-229 Potted DC-DC on page 206.

l

Open frame style - Three (3) connectors (DC Bus Input (J1), 250VDC Output (J2), and 24VDC output
(J4)) from the DC-DC Converter. Refer to Figure 4-230 Open Frame DC-DC on page 206.

Figure 4-229 Potted DC-DC

Figure 4-230 Open Frame DC-DC

4. Loosen the M3x10 fasteners that are located next to the Inverter. Refer to Figure 4-231 DC-DC

Converter Removal on page 207 for this and the next two (2) steps.

5. Remove the M3x10 fasteners that are located on the front side of the DC-DC Converter.

6. Lift the DC-DC Converter on the front side and slide it clear of the rear fasteners. If reusing, store the

DC-DC Converter in an anti-static bag.

7. After the removal of the DC-DC Converter, completely remove the remainder of the M3x10 fasteners.

Page 206 of 294 - M-SV-001-EN Rev. H 1/23/2023

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Summary of Contents for Turbocor TT Series

Page 1: ...Service Manual Revision H Danfoss Turbocor Twin Turbine Centrifugal Series Compressors TT Series Compressors http turbocor danfoss com...

Page 2: ...THIS PAGE INTENTIONALLY LEFT BLANK Page 2 of 294 M SV 001 EN Rev H 1 23 2023...

Page 3: ...op Soft Start 27 1 10 3 DC Bus Test Harness Installation for Open Top Soft Starts 30 1 10 4 General DC Bus Test Harness Removal 31 1 10 5 DC Bus Test Harness Removal for Closed Top Soft Starts 31 1 10...

Page 4: ...3 2 3 Interlock Verification 63 4 3 3 Compressor Interface Module Removal Installation 63 4 3 3 1 Compressor Interface Module Removal 63 4 3 3 2 Compressor I O Board Installation 64 4 4 Compressor In...

Page 5: ...cations 95 4 10 Mains Plate Bracket 96 4 10 1 Mains Plate Bracket Removal and Installation 96 4 10 1 1 Mains Plate Bracket Removal 96 4 10 1 2 Mains Plate Bracket Installation 96 4 10 1 3 Mains Plate...

Page 6: ...7 Soft Start Installation Open Top 122 4 14 8 Soft Start Fan Removal and Installation 123 4 14 9 Soft Start Fan Removal 123 4 14 10 Soft Start Fan Installation 124 4 14 10 1 Soft Start Torque Specifi...

Page 7: ...4 18 3 1 SCR General Removal 149 4 18 3 2 SCR Removal TTS300 TGS230 149 4 18 3 3 SCR Removal TTS TGS TTH TGH Except TTS300 TGS230 150 4 18 3 4 SCR Installation TTS300 TGS230 153 4 18 3 5 SCR Installa...

Page 8: ...TH TGH Except TTS300 TGS230 182 4 22 6 3 Compressor Specific Inverter Installation Steps TTS300 TGS230 185 4 22 6 4 Compressor Specific Inverter Installation Steps TTS TGS TTH TGH Except TTS300 TGS230...

Page 9: ...e Removal and Installation 215 4 25 3 1 Backplane Removal 215 4 25 3 2 Backplane Installation 216 4 25 3 3 Backplane Torque Specifications 216 4 26 Serial Driver 217 4 26 1 Serial Driver Function 217...

Page 10: ...lation 234 4 29 4 3 Magnetic Bearing Torque Specifications 235 4 30 Bearing Sensors 236 4 30 1 Bearing Sensor Function 236 4 30 2 Bearing Sensor Connection 236 4 30 3 Bearing Sensor Verification 236 4...

Page 11: ...2 1 Compressor Fault Troubleshooting 254 5 2 2 Motor System Faults Troubleshooting 260 5 2 3 Bearing Fault Troubleshooting 263 5 3 Bearing Calibration 263 5 3 1 When to Calibrate the Bearings 263 5 3...

Page 12: ...eshooting the Inverter 273 Chapter 6 0 Maintenance 275 6 1 Preventative Maintenance Tasks 275 6 2 Moisture Prevention Measures 276 6 2 1 Required Items 276 6 2 1 1 Service Side Disassembly 276 6 2 1 2...

Page 13: ...1 1 and 1 2 F 2 11 10 2019 18 19 28 Updated TGS490 compressor with R515B refrigerant F 2 11 10 2019 36 Removed helium and changed the inert gas pressure to 15 psi F 2 11 10 2019 98 Updated F4 and F5 f...

Page 14: ...Page 14 of 294 M SV 001 EN Rev H 1 23 2023 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 15: ...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 resp...

Page 16: ...Page 16 of 294 M SV 001 EN Rev H 1 23 2023 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 17: ...onally the Series indicators 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...

Page 18: ...Figure 1 2 New Type Code Page 18 of 294 M SV 001 EN Rev H 1 23 2023...

Page 19: ...s not provide part numbers of single products or single components If this information is required please contact a recognized Danfoss Turbocor original equipment manufacturer OEM customer Additionall...

Page 20: ...ibed in the Electrical Isolation of the Compressor section of this manual l External References references to items not within this manual are underlined Example Refer to the TTS TGS TTH TGH Applicati...

Page 21: ...ust be followed when servicing the compressor Prior to servicing the compressor carefully read this chapter to ensure familiarity of both personal and equipment safety 1 7 Refrigerant Type Turbocor co...

Page 22: ...dels except the TTS300 TGS230 3 Remove the Mains Cover only Refer to Section 4 1 1 Mains Input Cover on page 52 4 Using an appropriately rated voltage meter confirm the absence of AC voltage DANGER Do...

Page 23: ...Figure 1 6 DC Bus Voltage Test Points NOTE Refer to the applicable service procedure as that may require the covers to remain off M SV 001 EN Rev H 1 23 2023 Page 23 of 294...

Page 24: ...ter If a safe static control environment cannot be created for a specific reason the operator will ensure that electrostatic discharge ESD items and personnel are at the same electrical potential as t...

Page 25: ...page 52 Figure 1 10 Compressor Grounding Points 1 10 DC Bus Test Harness Installation and Removal A DC bus test harness must be used when testing the voltages of the compressor s power electronics The...

Page 26: ...gram Closed Top Soft Start Figure 1 12 DC Bus Test Harness Diagram Open Top Soft Start CAUTION Before using the DC bus test harness integrity of the fuses resistors in the harness and cable must be ch...

Page 27: ...26 for harness fuse and resistor locations The reading for the resistor should be approximately 100k and the reading for the fuse should be 29 5 Continue to the appropriate section below based on the...

Page 28: ...er down into the service side Refer to Figure 1 16 Cable Passage NOTE l For clarity purposes several components have been removed from Figure 1 16 Cable Passage Figure 1 16 Cable Passage 5 Carefully a...

Page 29: ...is not consistent with Table 1 2 Expected DC Bus Voltage the incoming AC voltage should be verified to be between the acceptable AC Voltage Range listed in Table 1 2 Expected DC Bus Voltage Additiona...

Page 30: ...o the corresponding socket of the DC bus test harness Refer to Figure 1 18 Connect DC Bus Test Harness Open Top Soft Start and Figure 1 19 DC Bus Test Harness Connection Diagram Open Top Soft Start fo...

Page 31: ...as described in 1 8 Electrical Isolation CAUTION Use your ESD wrist strap before touching the Soft Start Board or any electronic components 2 Use an ESD strap and attach it the compressor housing whi...

Page 32: ...ng replacement a leak test should be performed The following O ring specific steps are required when replacing any compressor O ring 1 Remove each O ring to be installed from its package and inspect f...

Page 33: ...he second stage impeller through a diffuser In the second stage impeller velocity energy is again added to the refrigerant and converted to the final discharge pressure in the discharge diffuser and v...

Page 34: ...ller inlet This ensures a higher evaporating cooling temperature to minimize condensation around the power electronic components In the split cooling version Solenoid One 1 is opened if either the cav...

Page 35: ...l Bearing 2 Liquid Refrigerant Inlet 10 Axial Bearing 3 Solenoid E 11 Impeller 1st Stage 4 Inverter 12 Motor Cavity Temp Sensor 5 SCR 13 BMCC 6 Impeller 2nd Stage 14 Inverter Temp Sensor 7 Radial Bear...

Page 36: ...No Description No Description 1 From Motor Winding Temp Sensor 8 SCR Manifold 2 BMCC 9 Motor Rotor Cooling Gas 3 Solenoid M 10 From Motor Cavity Temp Sensor 4 Solenoid E 11 E Schrader Valve 5 Liquid...

Page 37: ...Capacity Control Capacity control of the compressor is achieved primarily by speed modulation When unloading the compressor s first action is to reduce speed to slightly above the minimum surge speed...

Page 38: ...essor Controller BMCC l Serial Driver l Bearing Pulse Width Modulation PWM Amplifier l Compressor I O Board l IGV l Solenoid actuators The order of power and signal flow through the compressor compone...

Page 39: ...Figure 2 6 Compressor Energy and Signal Flow Connections M SV 001 EN Rev H 1 23 2023 Page 39 of 294...

Page 40: ...ry of the energy and voltage signal flow through the compressor NOTE TTH TGH Compressors are very similar to Figure 2 7 Compressor Energy and Control Flow Block Diagram TT Series Compressors Figure 2...

Page 41: ...rical Isolation on page 22 CAUTION Ensure that there is no secondary power source connected to the compressor before disconnecting the following cables 2 Remove the AC power cables from the Mains Inpu...

Page 42: ...hen attaching flanges to the compressor 1 Relieve the inert gas pressure through the motor cooling exit port Schrader valve 2 Remove the suction discharge and economizer if applicable blanking plates...

Page 43: ...the AC mains cables to the terminals and torque to specification l TTS300 TGS230 Compressors 20 Nm 15 ft lb l All Compressors excluding TT300 TG230 21 Nm 15 ft lb 24 Install the Mains Input Cover Ref...

Page 44: ...n the compressor housing NOTE Flexible lines are not supplied by Danfoss LLC Selection of appropriate hose and fitting is the responsibility of OEM installer This information is readily available from...

Page 45: ...low filter drier A filter drier must be installed in all instances If it is found that a filter drier is not installed and the fitting is changed due to a field replacement of the compressor a filter...

Page 46: ...Page 46 of 294 M SV 001 EN Rev H 1 23 2023 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 47: ...able 4 1 Compressor Components Covers On No Component No Component 1 Top Cover 7 Service Side Cover 2 Mains Input Cover 8 Rear Support Base 3 Lift Anchor Front 9 Compressor I O Board 4 Compressor Cont...

Page 48: ...ooling Access Port Access Port 1 NOTE TTS300 TGS230 have only one access port 2 IGV Suction Port 9 Compressor Cooling Access Port 2 not available on TTS300 TGS230 compressors NOT SHOWN 3 PWM Amplifier...

Page 49: ...nent 1 PWM Amplifier 8 Compressor Cooling Access Port 2 BMCC 9 Suction Pressure Temperature Sensor 3 Serial Driver 10 Cooling Inlet Adapter 4 Backplane 11 DC DC Converter 5 Motor Cooling Solenoids 12...

Page 50: ...Capacitor Side Excludes TTH TGH No Component No Component 1 Capacitors 5 Optional Medium Temp application Cooling Path Pressure Regulating Port 2 Economizer Port 6 IGV Motor Feedthrough 3 IGV Position...

Page 51: ...Component 1 Capacitors 6 Optional Medium Temp application Cooling Path Pressure Regulating Port 2 Interstage Pipe 7 IGV Motor Feedthrough 3 Interstage Temperature Pressure Sensor 8 Suction Temperature...

Page 52: ...ment Dropping cover fasteners can cause a short circuit cause energized components to fail catastrophically and cause damage to the power electronic parts of the compressor After properly positioning...

Page 53: ...4 1 2 Top Cover 4 1 2 1 Top Cover Removal and Installation Top Cover Removal 1 Isolate compressor power as described in Section 1 8 Electrical Isolation on page 22 2 Remove the Mains Input Cover by r...

Page 54: ...econd pass Tighten the 4 fastener only once and use caution as to not overtighten 6 Return the compressor to normal operation 4 1 3 Service Side Cover The Service Side Cover provides protection for th...

Page 55: ...vice Side Cover Torque Sequence 4 1 4 Capacitor Cover The Capacitor Cover provides protection for the capacitors Figure 4 11 Capacitor Cover 4 1 4 1 Capacitor Cover Removal and Installation Capacitor...

Page 56: ...ts 3 Place the Capacitor Cover and secure it with the M5x15 fasteners from the Top Cover 4 Place the Capacitor Cover on the compressor and loosely secure it with the M5X15 fasteners The bottom of the...

Page 57: ...r Torque Sequence Torque to 13 in lb on the second pass 6 Install the top covers Refer to Section 4 1 Compressor Covers on page 52 7 Return the compressor to normal operation Figure 4 15 Capacitor Cov...

Page 58: ...collect any debris that may be present CAUTION A filter drier must be used in conjunction with the Cooling Inlet Adapter strainer The strainer is used as a backup to prevent damage to the solenoid ori...

Page 59: ...adapter body to the compressor housing to 25 Nm 18 ft lb 5 Install the screen inside the cooling adapter 6 Install the braze sleeve and nut minus the O ring Tighten the nut finger tight against the Co...

Page 60: ...munication Port JP1 Analog Output Voltage J2 Input Output JP2 MODBUS Terminator J3 Input Output JP3 Entry J4 EXV1 and EXV2 Control JP4 Leave J5 Liquid Level Input JP5 LIQ LEV1 J6 Compressor Interface...

Page 61: ...for thermistor specifications J4 EXV 1 EXV 2 Control 15V output 200mA maximum each l EXV1 Pin 6 to 9 l EXV2 Pin 1 to 4 J5 Liquid Level input l LIQ LEV 1 Pin 4 to 6 Liquid level sensor l LIQ LEV 2 Pin...

Page 62: ...Apply power to the compressor 9 Measure the Backplane 5V and 15V test point voltages 10 If voltages do not change I O board is not draining energy 4 3 2 2 Compressor Interface Module Communication Ve...

Page 63: ...Compressor Interlock Status states Open the interlock circuit is damaged and the BMCC needs to be replaced 9 Isolate compressor power 10 Remove the J2 connector from the CIM 11 Using a multimeter for...

Page 64: ...oard Installation 1 Install the left foot of the replacement board into the rail and press the right side of the board down until it engages the rail 2 Reconnect all external connections and wiring on...

Page 65: ...Cable Removal 1 Isolate compressor power 2 Wait for the green light D9 on the CIM to turn off 3 Remove the Service Side Cover Refer to Section 4 1 3 1 Service Side Cover Removal and Installation on p...

Page 66: ...t is properly positioned in the compressor housing notch 4 Install the Service Side Cover Refer to Section 4 1 3 1 Service Side Cover Removal and Installation on page 54 5 Return the compressor to nor...

Page 67: ...llowing steps provide detail on how to replace the Compressor Controller Cable Harness Prior to removal note the location of the harness routing as this will minimize the installation time of the new...

Page 68: ...n 4 21 3 DC Capacitor Bus Bar Assembly Removal and Installation on page 168 6 Refer to Figure 4 22 Backplane Connections and remove the following connectors from the Backplane l Pressure temperature s...

Page 69: ...CR Temperature Sensor Locations TTS300 TGS230 Figure 4 24 Pressure Temp and SCR Temp Sensor Locations TTS TGS Except TTS300 TGS230 Figure 4 25 Pressure Temperature Sensor Locations TTH375 TGH285 M SV...

Page 70: ...he cable harness under the Mains Terminal Block and route it toward the capacitor side of the compressor 4 Install the harness onto the IGV Feedthrough 5 Rotate the clamp over the IGV connector and to...

Page 71: ...r covers Refer to Section 4 1 Compressor Covers on page 52 13 Return the compressor back to normal operation 4 5 3 Compressor Controller Cable Harness Torque Specifications Table 4 9 Compressor Contro...

Page 72: ...ading the number engraved into the solenoid orifice body For solenoid identification by model reference the Spare Parts Selection Guide Solenoid actuator coils are secured to the solenoids by nuts tig...

Page 73: ...page 54 3 Disconnect the Compressor Cooling Solenoid Coil Connector J16 from the Backplane 4 Set the multimeter for resistance measurement Refer to Table 4 10 Solenoid Coil Resistance Ranges on page 7...

Page 74: ...Cool L and Cool H LEDs on the Backplane Refer to Figure 4 33 Backplane Cool LEDs and 24V Test Points 4 To determine if 24VDC is present at one or both solenoid coils use a multimeter to test the back...

Page 75: ...inment on page 41 NOTE There is no need to recover the refrigerant if only the solenoid coils are being removed 3 Remove the Service Side Cover Refer to Section 4 1 3 1 Service Side Cover Removal and...

Page 76: ...15 16 socket and torque to 7 Nm 62 in lb 5 Apply O ring lubricant to the o rings on the plunger assemblies 6 Check that the plunger moves freely by exercising action of spring by hand 10 cycles 7 Ins...

Page 77: ...onnect the Solenoid Coils to J16 on the Backplane 13 Install the Service Side Cover Refer to Section 4 1 Compressor Covers on page 52 14 Return the compressor to normal operation 4 6 4 3 Solenoid Torq...

Page 78: ...stage Pressure Temperature P T Sensor harness Refer to Figure 4 38 Interstage Pipe Removal for this and the following steps 4 Disconnect the pipe connected to the Economizer port 5 Remove the four 4 M...

Page 79: ...ring and install into the Interstage Pipe Torque to 10 Nm 7ft lb 11 Connect the Sensor Harness 12 Leak test and evacuate compressor in accordance with standard industry practices NOTE A magnet may ne...

Page 80: ...Housing End Cap TTH TGH 4 8 1 Compressor Housing End Cap Removal and Installation 4 8 1 1 Compressor Housing End Cap Removal 1 Isolate compressor power 2 Isolate the compressor and recover the refrig...

Page 81: ...gure 4 39 Compressor Housing End Cap TTS TGS on page 80 and Figure 4 40 Compressor Housing End Cap TTH TGH on page 80 4 Install the remaining fasteners and torque fasteners in a crisscross pattern to...

Page 82: ...trol the IGV stepper motor Figure 4 41 IGV Assembly 4 9 1 IGV Connections Refer to Figure 4 42 IGV Connections for the location of the IGV connections Figure 4 42 IGV Connections Table 4 14 IGV Compon...

Page 83: ...4 9 2 2 IGV Operation Verification Some of the steps contained within this section require the use of the SMT Refer to the Service Monitoring Tool Manual regarding the proper usage of the SMT 1 Remov...

Page 84: ...g driven Refer to Figure 4 50 Backplane IGV LEDs on page 85 l Check that all four 4 LEDs are blinking D13 D14 D15 and D16 and that the IGV position indicator ball moves toward open Refer to Figure 4 4...

Page 85: ...stallation CAUTION Removal of the IGV mounting fasteners will release refrigerant Isolation and recovery of the refrigerant must be performed by a qualified service technician adhering to industry ASH...

Page 86: ...s Refer to Section 3 1 Refrigerant Containment on page 41 5 Remove the 12 M10x40 fasteners that secure the IGV Housing Assembly to the compressor housing and pull the housing away from the compressor...

Page 87: ...e on the respective compressor 4 Remove the IGV Motor assembly by pulling away from worm shaft Refer to Figure 4 56 IGV Motor Assembly Removal on page 88 Support the bottom of the IGV Motor to prevent...

Page 88: ...ged in the Locking Collar Refer to Figure 4 57 Locking Collar Tool Figure 4 57 Locking Collar Tool 8 Turn the Locking Collar clockwise to remove Refer to Figure 4 58 Locking Collar Figure 4 58 Locking...

Page 89: ...following step 11 Remove the upper large bearing from the worm gear Figure 4 60 Large Worm Gear Bearing 12 Remove the four 4 M6x55 fasteners that retain the IGV Throat assembly and lift the entire ass...

Page 90: ...fully seated into the housing Refer to Figure 4 62 Small Worm Gear Bearing 3 Ensure the IGV position indicator magnet is in place in the IGV Throat assembly Refer to Figure 4 63 IGV Position Indicator...

Page 91: ...sible through the access hole in the casting Verify that the worm gear turns freely Do not install the set screw at this time Refer to Figure 4 64 IGV Worm Gear Alignment Figure 4 64 IGV Worm Gear Ali...

Page 92: ...he flat of the motor shaft Torque the set screw to 5Nm 44 in lb Refer to Figure 4 64 IGV Worm Gear Alignment on page 91 17 Clean lubricate and install the O ring on the Feedthrough before connecting t...

Page 93: ...he fasteners to 5Nm 44 in lb while leaving the fourth fastener with the retainer clip slightly loose Refer to Figure 4 69 Feedthrough Orientation Figure 4 69 Feedthrough Orientation 21 If available te...

Page 94: ...re Sensor Harness 28 Torque the remaining Feedthrough fastener the one securing the Motor Harness Retainer Clip to 5 Nm 44 in lb 29 Return the compressor back to normal operation 30 Test run the compr...

Page 95: ...Torque Specifications Description Nm Ft Lb In Lb IGV Housing Fastener M10x40 22 16 195 IGV Feedthrough Fastener M5x16 5 44 IGV Motor Setscrew M5x8 5 44 IGV Throat Fastener M6x55 5 44 Locking Collar 5...

Page 96: ...t ground cable and Soft Start ground wire from the ground post 4 Remove the lower nut from the ground post 5 Remove the cable gland that secures the mains input cable conduit to the Mains Plate 6 Remo...

Page 97: ...hers to 21 Nm 15 ft lb Refer to Figure 4 74 Mains Input Installation TTS300 TGS230 Compressors and Figure 4 75 Mains Input Nut Installation TTS TGS TTH TGH Except TTS300 TGS230 Figure 4 74 Mains Input...

Page 98: ...s on page 52 8 Return the compressor to normal operation 4 10 1 3 Mains Plate Torque Specifications Table 4 17 Mains Plate Torque Specifications Description Nm Ft Lb In Lb Mains Plate Mounting Screw M...

Page 99: ...t voltage varies between 380 575VAC at a frequency of 50 60Hz There are three 3 different configurations of the Terminal Blocks l For TTS300 TGS230 compressors Refer to Figure 4 76 Input Terminal Bloc...

Page 100: ...proved components in the circuit with code compliant protection DANGER l This equipment contains hazardous voltages that can cause injury or death Exercise extreme caution when working on energized ci...

Page 101: ...side of the fuses TT300 TG230 only Figure 4 79 Measuring the 3 Phase AC Input Voltage on the AC Input Terminals TTS300 TGS230 Figure 4 80 Measuring 3 Phase AC Input Voltage on AC Input Terminals TTS T...

Page 102: ...s continue to Section 4 11 2 3 3 Phase Main Voltage Input Terminal Block Removal TTS TGS TTH TGH Except TTS300 TGS230 on page 103 4 11 2 2 Specific 3 Phase Main Voltage Input Terminal Block Removal TT...

Page 103: ...om the terminal block on Rev F and earlier compressors the terminal block and bus bars can be removed as an assembly On Rev H compressors the center AC Bus Bar must be removed to access a mounting fas...

Page 104: ...3 Nm 27 in lb 2 Place the Mylar insulator in the center section of Terminal Block 3 Including the Soft Start AC Ring terminals L1 L2 L3 Secure the three 3 Fuse Assemblies Bus Bar side to the SCRs usin...

Page 105: ...k Input Pressure Screws TTS300 TGS230 7 Continue to Section 4 11 2 6 General 3 Phase Main Voltage Input Terminal Block Installation on page 106 4 11 2 5 3 Phase Main Input Terminal Block Installation...

Page 106: ...hree 3 M6x16 AC Bus Bars to SCR fasteners to 5 Nm 44 in lb 4 Reconnect the three 3 terminals of the Soft Start cable harness to the AC Bus Bars 5 Install the mains input cables to the Terminal Block a...

Page 107: ...8x20 excludes TTS300 TGS230 compressors 9 80 Mains Input Pressure Screw 11 16 16 UNC TTS300 TGS230 compressors only 20 15 177 Cover Fastener M5x15 1 5 13 Upper Nut 5 16 18 UNC 10 7 89 Jam Nut 5 16 18...

Page 108: ...ng a Remove the connectors of the Soft Start AC DC Harness from the bus bars and lift away the Soft Start AC DC Harness b Remove the three 3 M8x20 fasteners that secure the AC Bus Bars to the SCRs c R...

Page 109: ...osition b Loosely install the six 6 fasteners that secure the three 3 AC Bus Bars to the Terminal Block c Loosely install the three 3 M8x20 fasteners that secure the AC Bus Bars to the SCRs d Torque t...

Page 110: ...stall the top covers Refer to Section 4 1 Compressor Covers on page 52 5 Return the compressor to normal operation 4 12 3 AC Bus Bar Torque Specifications Table 4 20 AC Bus Bar Torque Specifications D...

Page 111: ...on the load side Refer to Figure 4 92 Terminal Block Fuse Test The resistance should be no greater than 2 Figure 4 92 Terminal Block Fuse Test 4 Continue for the remaining two 2 fuses 5 Replace any fu...

Page 112: ...the 5 16 18 fastener on the line side of the fuse and torque to 20 Nm 15 ft lb 4 Install the top covers Refer to Section 4 1 Compressor Covers on page 52 5 Return the compressor to normal operation Ta...

Page 113: ...gnal For Closed Top Soft Starts the 3 phase AC voltage is passed through 1 4A fast acting fuses to two 2 onboard transformers that reduce the primary voltage to a secondary 15VAC Both transformers pas...

Page 114: ...Top Soft Start Connection Identification No Component 1 J9 Soft Start Temperature Sensor connector 2 J5 Thermostatic Fan Control connector 3 J7 DC DC Trigger Signal connector 4 J1 High Voltage AC DC...

Page 115: ...Installation and Removal on page 25 with power applied to the compressor verify that the expected DC bus voltage is present for the application Refer to Table 1 2 Expected DC Bus Voltage on page 29 l...

Page 116: ...mbers and revisions are identified by a label on the side of the Soft Start mounting bracket The Soft Start revision follows immediately after the 6 digit part number Refer to Figure 4 97 Soft Start L...

Page 117: ...it board or fan Table 4 24 Soft Start Fuse Details Fuse Amperage Resistance Circuit Class Comments F1 2A Less than 1 HV DC to DC Fast Acting F2 0 25A Less than 1 Transformer Secondary 15V AC to DC DC...

Page 118: ...rom the ground post on the compressor housing at the 3 phase connection point Refer to Figure 4 100 Ground Location Figure 4 100 Ground Location 4 Remove the M5x15 fasteners that secure the Soft Start...

Page 119: ...fer to Figure 4 103 Closed Top Soft Start Connector Removal Figure 4 103 Closed Top Soft Start Connector Removal 7 Remove the Soft Start assembly and place it in a safe location 4 14 5 Soft Start Remo...

Page 120: ...removing the nut and mains input ground wire from the ground post on the compressor housing at 3 phase connection point Refer to Figure 4 105 Ground Location Figure 4 105 Ground Location 4 Unplug cabl...

Page 121: ...ft Start assembly and place it in a safe location 4 14 6 Soft Start Installation Closed Top 1 Place the Soft Start over the AC Bus Bars board side up with the fan toward the IGV 2 Install connectors J...

Page 122: ...g washer and nut then torque the top nut to 7 Nm 62 in lb Figure 4 109 Ground Stud Location 7 Install the top covers Refer to Section 4 1 Compressor Covers on page 52 8 Return the compressor to normal...

Page 123: ...n Top Soft Starts and on Soft Starts with revision Q and later may cause the fan not to start leading to Soft Start over temperature faults Not incorporating the adapter board on Soft Starts with revi...

Page 124: ...is installed on Open Top Soft Starts the fan arrows will be located on the bottom right corner of the fan and will no longer be visible When the adapter boards are used the arrows will only be visible...

Page 125: ...nstall the top covers Refer to Section 4 1 Compressor Covers on page 52 5 Return the compressor to normal operation 4 14 10 1 Soft Start Torque Specifications Table 4 25 Soft Start Torque Specificatio...

Page 126: ...bed in Section 1 8 Electrical Isolation on page 22 2 Using a 10 mm wrench socket remove the bolts that secure the and SCR DC Bus Bars to the DC Capacitor Bus Bars Refer to Figure 4 116 SCR DC Bus Bar...

Page 127: ...to the Capacitor DC Bus Bar 6 Torque the six 6 M6x16 SCR DC Bus Bar fasteners to 5 Nm 44 in lb 7 Hold the two 2 M6x20 Bus Bar bolts with a wrench and torque the M6 nuts to 10 Nm 7 ft lb 8 Install the...

Page 128: ...nd Installation 4 16 2 1 Soft Start SCR Gate Cable Removal 1 Isolate the compressor power as described in Section 1 8 Electrical Isolation on page 22 2 Remove the six 6 Soft Start SCR Gate Cable conne...

Page 129: ...igure 4 121 Soft Start SCR Gate Cable Removal at SCR TTS TGS TTH TGH Models Rev F and Earlier Except TTS300 TGS230 Figure 4 122 Soft Start SCR Gate Cable Removal at SCR TTS TGS TTH TGH Models Rev H Ex...

Page 130: ...ith the Open Top Soft Start install the J2 connector Figure 4 124 Open Top Soft Start J2 Connector 2 Once the Cable Harness has been installed onto the Soft Start the cable should be routed toward the...

Page 131: ...gure 4 125 SCR Gate Connector Alignment 4 Install the top covers Refer to Section 4 1 Compressor Covers on page 52 5 Return the compressor to normal operation M SV 001 EN Rev H 1 23 2023 Page 131 of 2...

Page 132: ...provide detail on how to replace the Soft Start AC DC Harness Not all harness variations are shown here but the major differences that impact removal and installation are described in this manual Ple...

Page 133: ...art and or the Open Frame DC DC to gain better access for this procedure 4 17 2 1 Soft Start AC DC Harness Removal TTS300 TGS230 1 Isolate compressor power as described in Section 1 8 Electrical Isola...

Page 134: ...g terminal from the DC bus bar by removing the attaching hardware Figure 4 129 DC Ring Terminal Removal TTS300 TGS230 5 Remove the DC DC Connections If the DC DC is the potted style remove connectors...

Page 135: ...osed Top Soft Start J7 Trigger Signal connector 7 Remove the Soft Start AC DC Harness from the Softstart a For compressors with the Closed Top Soft Start remove the J1 and J7 if equipped connector Ref...

Page 136: ...ev H compressors refer to Figure 4 135 AC Input Ring and DC Spade Connector Removal TTS TGS TTH TGH Rev H Except TTS300 TGS230 on page 137 3 Disconnect the DC and DC spade terminals from the DC bus ba...

Page 137: ...e 4 132 Closed Top Soft Start J1 and J7 Removal on page 135 NOTE Compressors utilizing the open frame DC DC design do not utilize the J7 Trigger Signal connector b For compressors with the Open Top So...

Page 138: ...verter Refer to Figure 4 131 DC DC Connectors Potted on page 135 9 Install the top covers Refer to Section 4 1 Compressor Covers on page 52 10 Return the compressor to normal operation 4 17 2 4 Soft S...

Page 139: ...TTS TGS TTH TGH Rev H Except TTS300 TGS230 5 Install the L1 L2 and L3 terminals to the AC Bus Bars a For Revision F and earlier compressors refer to Figure 4 137 AC Input and Spade Connector Installa...

Page 140: ...on 4 17 2 5 Soft Start AC DC Harness Torque Specifications Table 4 27 Soft Start AC DC Harness Torque Specifications Description Nm Ft Lb In Lb AC Bus Bar to SCR fastener M5x16 5 44 Soft Start DC DC t...

Page 141: ...ed to the compressor This is used while the DC capacitors are charging up The DC bus voltage output from the SCRs is approximately 1 35 times that of the AC input voltage 460 900VDC There are two 2 di...

Page 142: ...Electrical Isolation on page 22 2 Remove the DC Bus Bars from the SCRs Refer to Section 4 21 3 DC Capacitor Bus Bar Assembly Removal and Installation on page 168 3 Using a multimeter set for diode me...

Page 143: ...lock Removal and Installation on page 102 4 Remove the Capacitor Assembly Refer to Section 4 21 3 DC Capacitor Bus Bar Assembly Removal and Installation on page 168 5 Using a multimeter set for diode...

Page 144: ...0 and Figure 4 141 SCR Connections TTS TGS TTH TGH Rev F and Earlier Except TTS300 TGS230 3 Using a multimeter set for resistance measurements place the leads on the two 2 gate terminals The value sho...

Page 145: ...re Sensor Removal TTS300 TGS230 for TT300 TG230 compressors and for all other TT TG compressors continue to Section 4 18 2 8 SCR Temperature Sensor Removal TTS TGS TTH TGH Rev F and Earlier Except TTS...

Page 146: ...Start AC wires from the AC Bus Bars 2 Remove the Terminal Block and AC Bus Bars as an assembly Refer to Section 4 11 2 3 3 Phase Main Voltage Input Terminal Block Removal TTS TGS TTH TGH Except TTS300...

Page 147: ...Sensor Connector Removal TTS TGS TTH TGH Except TTS300 TGS230 6 Remove the SCR Temperature Sensor from the SCR Cooling Manifold Refer to Figure 4 152 SCR Temperature Sensor Removal TTS TGS TTH TGH Rev...

Page 148: ...perature sensor connector if it was removed 3 Install the SCR Temperature Sensor Cable in the same location It should be on top of the SCR Cooling Manifold and next to the Inverter Refer to Figure 4 1...

Page 149: ...use Block Assemblies TTS300 TGS230 for this and the following four 4 steps 2 Remove the three 3 fasteners that connect the fast acting fuses to the SCRs 3 Remove the six 6 Fuse to Terminal Block faste...

Page 150: ...Continue to Section 4 18 3 4 SCR Installation TTS300 TGS230 on page 153 4 18 3 3 SCR Removal TTS TGS TTH TGH Except TTS300 TGS230 1 Remove the Soft Start Refer to Section 4 14 3 Soft Start Removal and...

Page 151: ...inals and bus bars Refer to Section 4 11 2 3 Phase Main Voltage Input Terminal Block Removal and Installation on page 102 4 Remove the Snubber Capacitors from the Inverter Refer to Section 4 20 Snubbe...

Page 152: ...68 7 Remove the SCRs a For Revision F and earlier compressors remove the 12 M6x16 fasteners that secure the SCRs to the SCR Cooling Manifold and remove the SCRs Refer to Figure 4 160 SCR Removal TTS T...

Page 153: ...e is free of any contaminants 3 Spread a thin and uniform coat of Dow Corning Silicone Heat Sink paste or equivalent entirely over the bottom of each SCR surface Refer to Figure 4 162 SCR Heat Sink Pa...

Page 154: ...bus bar aligned with holes identified as 2 on the diodes 8 The curved section of the bus bar should be installed upwards Refer to Figure 4 164 Bus Bar Installation TTS300 TGS230 9 Insert and finger t...

Page 155: ...ept TTS300 TGS230 1 Clean the contact surfaces of SCR Cooling Manifold 2 If the SCRs are to be reused clean their mounting surface backside to ensure the surface is free of any contaminants 3 Spread a...

Page 156: ...top covers Refer to Section 4 1 Compressor Covers on page 52 4 Return the compressor to normal operation 4 18 3 7 SCR Torque Specifications Table 4 31 SCR Torque Specifications Description Nm Ft Lb In...

Page 157: ...art Refer to Section 4 14 3 Soft Start Removal and Installation on page 117 5 For TTS300 TGS230 compressors continue to Section 4 19 2 SCR Cooling Manifold Specific Removal Steps TTS300 TGS230 and for...

Page 158: ...moval of the SCR Cooling Manifold 7 Carefully peel back the foam to gain access to the two 2 M6x20 fasteners Remove the two 2 SCR Cooling Manifold fasteners and remove the assembly Refer to Figure 4 1...

Page 159: ...r 4 M6x35 SCR Cooling Manifold fasteners that secure the SCR Cooling Manifold to the Inverter Heat Sink Plate Refer to Figure 4 171 SCR Cooling Manifold Removal for this and the following step 5 Remov...

Page 160: ...21 4 3 DC Capacitor Bus Bar Assembly Installation TTS300 TGS230 on page 174 7 Install the Terminal Block and torque the M5x15 fasteners to 3 Nm 27 in lb Refer to Section 4 11 2 3 Phase Main Voltage In...

Page 161: ...lation Refer to Figure 4 174 SCR Manifold Return Brass Fitting O ring Installation TTS TGS TTH TGH Except TTS300 TGS230 Figure 4 174 SCR Manifold Return Brass Fitting O ring Installation TTS TGS TTH T...

Page 162: ...mains input cables to the Terminal Block and torque to 21 Nm 15 ft lb 4 19 6 SCR Cooling Manifold General Installation Steps 1 Install the Soft Start Refer to Section 4 14 3 Soft Start Removal and In...

Page 163: ...9 80 Capacitor DC Bus Bar to SCR fastener M8x20 excludes TTS300 TGS230 compressors 9 80 Mains Input Pressure Screw 11 16 16 UNC TTS300 TGS230 compressors only 20 15 177 Mains Input Nut 3 8 16 UNC excl...

Page 164: ...4 20 Snubber Capacitors Refer to Section 4 21 DC Capacitor Bus Bar Assembly on page 165 for details on the Snubber Capacitors Page 164 of 294 M SV 001 EN Rev H 1 23 2023...

Page 165: ...t DC voltage to the bus bars The DC capacitors serve as energy storage and filter out the voltage ripple associated with the operation of the rectifier circuit and any voltage unbalance in the 3 phase...

Page 166: ...TGS230 4 21 1 DC Capacitor DC Bus Bar Connections Refer to Figure 4 178 Soft Start Cable Harness to DC Bus on page 167 for the location of the connections listed below 1 DC to Soft Start 2 DC to Soft...

Page 167: ...or from one side of the capacitor 3 Bend the bleed resistor back slightly until it no longer contacts the DC bus CAUTION A faulty bleed resistor can be the result of a faulty DC capacitor 4 Using a mu...

Page 168: ...emove the Soft Start Refer to Section 4 14 3 Soft Start Removal and Installation on page 117 3 Continue to Section 4 21 4 1 DC Capacitor Bus Bar Assembly Removal TTS300 TGS230 for TTS300 TGS230 compre...

Page 169: ...Capacitor Nut Removal TTS300 TGS230 5 Carefully lift the DC Bus Bars and capacitors out as an assembly Do not remove the bleed resistors or capacitors from the bus bars Refer to Figure 4 182 Capacitor...

Page 170: ...s AC Bus Bars as described in Section 4 12 1 Input Mains Bus Bar Removal on page 108 2 Remove the six 6 DC bus fasteners from the SCRs Refer to Figure 4 183 SCR Bus Bar Removal TTS TGS TTH TGH Rev F a...

Page 171: ...r capacitors from the Inverter noting the leg orientation of one leg is longer than the other Refer to Figure 4 185 Snubber Capacitor Removal TTS TGS TTH TGH Except TTS300 TGS230 Figure 4 185 Snubber...

Page 172: ...ors out as an assembly Do not remove the bleed resistors Balance Board or capacitors from the bus bars Refer to Figure 4 187 Capacitor Assembly Removal TTS TGS TTH TGH Rev F and Earlier Except TTS300...

Page 173: ...7 Capacitor Assembly Removal TTS TGS TTH TGH Rev F and Earlier Except TTS300 TGS230 Figure 4 188 Capacitor Assembly Removal TTS TGS TTH TGH Rev H Except TTS300 TGS230 M SV 001 EN Rev H 1 23 2023 Page...

Page 174: ...ure 4 140 SCR Connections TTS300 TGS230 on page 141 11 Continue to Section 4 21 5 DC Capacitor Bus Bar Assembly General Installation Steps 4 21 4 4 DC Capacitor Bus Bar Assembly Installation TTS TGS T...

Page 175: ...compressors 4 35 Capacitor DC Bus Bar to SCR fastener M8x20 excludes TTS300 TGS230 compressors 9 80 Mains Input Pressure Screw 11 16 16 UNC TTS300 TGS230 compressors only 20 15 177 Mains Input Nut 3...

Page 176: ...des The Inverter Control Board cannot be verified in the field unless an inverter tester is used A faulty Inverter may also appear as an Inverter Error fault 1 Isolate the compressor power as describe...

Page 177: ...he meter being used The main idea is that the values be consistent between phases Figure 4 190 Inverter Diode Measurements Skiip 613 Shown 4 22 3 Inverter Cable Harness Figure 4 191 Inverter Cable Har...

Page 178: ...Figure 4 193 Harness Removal from Backplane 9 Cut any cable ties securing the Inverter Cable Harness and pull through the compressor housing passage 4 22 4 2 Inverter Cable Harness Installation 1 Inse...

Page 179: ...ctrical Isolation on page 22 2 Isolate the compressor and recover the refrigerant according to industry standards Refer to Section 3 1 Refrigerant Containment on page 41 3 Disconnect the mains input w...

Page 180: ...TS300 TGS230 Figure 4 196 Inverter Cable Harness Removal TTS300 TGS230 7 Remove the DC DC from the Inverter Heat Sink Plate Refer to Section 4 24 3 DC DC Removal and Installation on page 206 8 Disconn...

Page 181: ...e Inverter to the compressor main housing and carefully remove the Inverter and remove and discard the two 2 O rings underneath Figure 4 198 Inverter Assembly Removal TTS300 TGS230 NOTE The SCRs do no...

Page 182: ...S230 14 Remove the Terminal Block and AC Mains input Bus Bars Refer to Section 4 11 2 3 Phase Main Voltage Input Terminal Block Removal and Installation on page 102 15 Remove the Snubber Capacitors an...

Page 183: ...ific Removal Steps TTS TGS TTH TGH Except TTS300 TGS230 on page 159 20 Remove the Inverter cable harness from the top of the Inverter Refer to Figure 4 202 Inverter Harness Removal TTS TGS TTH TGH Exc...

Page 184: ...re 4 204 Inverter Removal TTS TGS TTH TGH Except TTS300 TGS230 Figure 4 204 Inverter Removal TTS TGS TTH TGH Except TTS300 TGS230 24 Remove and discard the large Inverter O ring from the compressor ho...

Page 185: ...age 185 Figure 4 206 SCR Manifold Return Brass Fitting Removal TTS TGS TTH TGH Except TTS300 TGS230 4 22 6 3 Compressor Specific Inverter Installation Steps TTS300 TGS230 1 Clean O ring groove in the...

Page 186: ...ll the Inverter on the compressor housing with the SCR temperature sensor cable if equipped run on top where the SCR cooling manifold meets the Inverter Cooling Manifold 8 Torque the M6x30 Inverter fa...

Page 187: ...the backing material from the Inverter Cooling Manifold of the new Inverter Use caution to not damage the bottom sealing surface of the Inverter 4 Install the 18 M6x30 fasteners into the Inverter ass...

Page 188: ...Refer Section to 4 1 Compressor Covers on page 52 7 Return the compressor to normal operation 4 22 7 Inverter Card Replacement This section details the steps to remove and install the Inverter Contro...

Page 189: ...N Do not move or touch any spring pins unless they are not in proper alignment Damage or misalignment of spring pins can cause failure of the entire Inverter module 4 22 7 2 Inverter Control Card Inst...

Page 190: ...d Table 4 35 Spring Identification for the locations of the long and short spring pins For an example of the difference between the two 2 different spring pin lengths refer to Figure 4 214 Spring Pin...

Page 191: ...to hold both to avoid dropping the driver board if separation occurs If they do become separated carefully snap the cover back into place prior to assembly 7 For proper alignment insert two 2 of the f...

Page 192: ...o Section 4 14 Soft Start on page 113 16 Connect all remaining cable harnesses 17 Install the top covers Refer to Section 4 1 Compressor Covers on page 52 18 Return the compressor to normal operation...

Page 193: ...s Bar to SCR fastener M8x20 excludes TTS300 TGS230 compressors 9 80 Mains Input Pressure Screw 11 16 16 UNC TTS300 TGS230 compressors only 20 15 177 Mains Input Nut 3 8 16 UNC excludes TTS300 TGS230 c...

Page 194: ...ion based on incoming 3 phase currents and voltage conditions are inadequate to protect the motor and electronics in the event of mishap due to the total separation of the motor windings from the inco...

Page 195: ...oft Start Refer to Section 4 14 3 Soft Start Removal and Installation on page 117 3 Remove the Copper Tubes that connect the motor bus bars to the Inverter 4 Using a multimeter set for resistance meas...

Page 196: ...ectrical Isolation on page 22 2 Remove the Soft Start Refer to Section 4 14 3 Soft Start Removal and Installation on page 117 3 Remove the Motor Bus Bars If the feedthrough is a PPS style hold the Hig...

Page 197: ...3 M10x16 fasteners and lockwashers that secure the motor bus bars to the PPS High Power Feedthroughs and torque to14 Nm 10 ft lb Be careful not to over tighten the bolts to the power feedthroughs Con...

Page 198: ...nstall the three 3 Copper Tubes and torque the M8x70 Motor Bus Bar fasteners to 14 Nm 10 in lb 2 Install the three 3 Motor Bus Bars Refer to Section 4 23 5 Motor Components Removal and Installation on...

Page 199: ...e insulation if necessary in order to remove the Cover Plate 8 Lift the Cover Plate slightly to prevent breaking the connections and carefully unplug the lower thermistor connectors Refer to Figure 4...

Page 200: ...with standard industry practices 7 Connect the two 2 connectors to the thermistor sensor feedthrough 8 Install the Motor Bus Bars Refer to Section 4 23 5 2 Motor Bus Bar Installation on page 197 9 In...

Page 201: ...and ring terminal connections from the feedthrough in order to be able to release feedthrough assembly Refer to Figure 4 225 High Power Feedthrough Removal PPS Figure 4 225 High Power Feedthrough Remo...

Page 202: ...ower Feedthroughs using the M10x16 fasteners from the inside 6 Once the M10x16 fasteners are finger tight torque them to 14 Nm 10 ft lb Continue to Step 9 CAUTION Hold the high power feedthrough using...

Page 203: ...ble 4 37 Motor Assembly Torque Specifications Description Nm Ft Lb In Lb Soft Start Mounting fastener M5X15 5 44 Cover Plate fastener M8x25 18 13 159 High Power Feedthrough both styles 22 16 195 Inver...

Page 204: ...osed Top Soft Start Board also powers the potted style DC DC Converter with 15VAC when the DC bus has reached minimum level Refer to Figure 4 229 Potted DC DC on page 206 andFigure 4 230 Open Frame DC...

Page 205: ...Isolation on page 22 2 Unplug all connectors to the DC DC Converter 3 Using a multimeter set for resistance measurements place the multimeter leads on the J2 250VDC output terminals Refer to Figure 4...

Page 206: ...ut J2 and 24VDC output J4 from the DC DC Converter Refer to Figure 4 230 Open Frame DC DC on page 206 Figure 4 229 Potted DC DC Figure 4 230 Open Frame DC DC 4 Loosen the M3x10 fasteners that are loca...

Page 207: ...e Inverter Heat Sink Plate Do not tighten at this time leave enough space under the fasteners to allow the DC DC Converter to slide under Refer to Figure 4 232 DC DC Rear Fastener Install Figure 4 232...

Page 208: ...on page 117 8 Install the top covers Refer to Section 4 1 Compressor Covers on page 52 9 Return the compressor to normal operation 4 24 3 1 DC DC Torque Specifications Table 4 38 Table 4 39 DC DC Torq...

Page 209: ...move the Soft Start Temperature Harness Connector The two 2 different Soft Start variants have a change in these connectors Both are approximately in the same location a For Closed Top Soft Starts dis...

Page 210: ...he 24VDC and 250VDC output from the DC DC Refer to Figure 4 229 Potted DC DC on page 206 andFigure 4 230 Open Frame DC DC on page 206 for further details 5 Connect the two 2 motor thermistor connectio...

Page 211: ...en the BMCC and other compressor components The Backplane also serves as the source of power to the parts connected to it It features on board low voltage DC DC converters for converting 5V 15V 15V an...

Page 212: ...nd either may be used 5 J24 Input of 24VDC from DC DC 15 J23 Cavity Temperature Sensor Input 6 J4 Input of 250VDC From DC DC 16 J10 Front Bearing Sensor Input 7 J16 Motor Cooling Solenoids Control Por...

Page 213: ...15V Test Point 3 17HV Test Point 7 24V Test Point 4 0V Test Point 8 15V Test Point 4 25 2 1 LED Locations The Backplane LEDs are indicated in Figure 4 240 Backplane LED Locations Left Side and Figure...

Page 214: ...easurements place the multimeter leads in the Backplane test points as defined in Figure 4 239 Backplane Test Points on page 213 Table 4 42 Backplane Test Point Values on page 215 3 Isolate compressor...

Page 215: ...ve the Serial Driver Refer to Section 4 26 4 Serial Driver Removal and Installation on page 218 4 Remove the BMCC Refer to Section 4 27 BMCC on page 220 5 Remove the PWM Refer to Section 4 28 4 PWM Re...

Page 216: ...und fastener from top right of the Backplane 6 Connect the Inverter ground ring to the Inverter Ground Screw and torque the fastener at top right of the Backplane to 3 Nm 27 in lb 7 Install the Bearin...

Page 217: ...Section 4 1 3 1 Service Side Cover Removal and Installation on page 54 2 With main power on using a multimeter set for DC voltage measurements verify the voltage on the Backplane 15V and 24V test poin...

Page 218: ...n valve is connected to the I O board the LEDs on the I O board will flicker as the external expansion valve is reset 5 Install the Service Side Cover Refer to Section 4 1 3 1 Service Side Cover Remov...

Page 219: ...e J8 connector on the Backplane 3 Install the Service Side Cover Refer to Section 4 1 3 1 Service Side Cover Removal and Installation on page 54 4 Return the compressor to normal operation M SV 001 EN...

Page 220: ...ve the BMCC from the Backplane 5 Turn ON the AC input power and measure the voltages at the 15V 15V and 5V test points The measured voltages should be similar to those measured when the BMCC is instal...

Page 221: ...can be locally sourced at most stores that sell coin type batteries DANGER Please follow the safety warnings listed in this section Please observe the following safety warnings l Verify the battery i...

Page 222: ...ompressor power 2 Remove the Service Side Cover Refer to Section 4 1 3 1 Service Side Cover Removal and Installation on page 54 3 Verify the LEDs on the Backplane have turned off 4 Carefully disconnec...

Page 223: ...are set to the lowest amperage limits and must be configured to meet the system requirements 1 Align the two 2 lower insertion guides of the BMCC so that they are on the inside of the two 2 upper ins...

Page 224: ...iginal to the compressor is installed a calibration must be completed and saved to the EEPROM to match the BMCC to the compressor Refer to Section 5 3 Bearing Calibration on page 263 Page 224 of 294 M...

Page 225: ...ring coils as commanded by the BMCC In return the PWM passes feedback from the current sensor for the bearing coils to the BMCC Refer to Figure 4 252 Bearing Control Signal Flow on page 226 The Backpl...

Page 226: ...ion of a Major Revision F and later compressor 4 28 3 PWM Verification NOTE l A faulty PWM Amplifier may be the result of a bearing failure and may cause a failure of the Potted DC DC resulting in a b...

Page 227: ...4 29 3 Bearing Verification on page 230 3 Verify the voltages at the HV 17HV and 5V Backplane test points are within the expected voltage ranges shown in Table 4 42 Backplane Test Point Values on pag...

Page 228: ...makes contact with the clip in the pin hole Refer to Figure 4 253 Connecting Leads to PWM Connector and HV and HV Test Points The measured voltage drop should be 0 39 0 46VDC 9 Repeat for all 10 pin...

Page 229: ...e PWM to the main compressor housing with three M5x10 fasteners Torque to 4 5 Nm 40 in lb 7 Ensure the heat sink of the PWM is firmly seated against the main compressor housing 8 Connect the two 2 con...

Page 230: ...er at the bearing power feedthroughs Refer to Figure 4 255 Bearing Connections Figure 4 255 Bearing Connections 4 29 3 Bearing Verification 4 29 3 1 Bearing Coil Verification CAUTION Do not attempt to...

Page 231: ...isolate the compressor recover the refrigerant according to industry standards remove the feedthrough and repeat the above steps directly at the internal bearing cluster block Table 4 45 Magnetic Bea...

Page 232: ...essor Monitor Tool on page 233 5 Click on the Shaft Levitation Status icon to levitate the shaft 6 Look at the Bearing Advanced section and verify that the bearing amperages displayed are within the r...

Page 233: ...mpressor power as described in Section 1 8 Electrical Isolation on page 22 2 Isolate the compressor and recover the refrigerant according to industry standards Refer to Section 3 1 Refrigerant Contain...

Page 234: ...16 fasteners that secure the feedthrough Figure 4 259 Rear Bearing Power Feedthrough Assembly 9 Remove the Feedthrough NOTE Small pliers such as needle nose may be required to remove the feedthrough 4...

Page 235: ...ully install the BMCC Refer to Section 4 27 BMCC on page 220 10 Carefully install the Serial Driver Refer to Section 4 26 4 Serial Driver Removal and Installation on page 218 11 Install the Service Si...

Page 236: ...efer to Figure 4 262 Bearing Sensor Feedthroughs Figure 4 262 Bearing Sensor Feedthroughs 4 30 3 Bearing Sensor Verification 4 30 3 1 Bearing Sensor Resistance Verification 1 Isolate compressor power...

Page 237: ...Bearing Power Feedthroughs or Bearing Sensor Cables This section provides verification details should a compressor experience a bearing fault type where other verification testing and troubleshooting...

Page 238: ...ure proper functionality 21 Return the compressor to normal operation 4 30 4 Bearing Sensor Cable Removal and Installation Refer to Figure 4 238 Backplane Connections on page 212 for connector locatio...

Page 239: ...Refer to the locating keys on the plug and slots in the connector The Rear locating key should be at the top of the J9 Backplane clip Gently squeeze the connector retainers to snap the connectors in p...

Page 240: ...Left Shown 4 30 5 2 Bearing Sensor Feedthrough Installation 1 Using a lint free cloth clean the mating surface on the compressor housing 2 Verify that the new O rings and 9 pin feedthrough are clean I...

Page 241: ...tion above 9 Install the Service Side Cover Refer to Section 4 1 3 1 Service Side Cover Removal and Installation on page 54 10 Return the compressor to normal operation 4 30 5 3 Bearing Sensor Torque...

Page 242: ...it for the LEDs on the Backplane to turn off 4 Disconnect the Cavity Temperature Sensor Cable J23 from the Backplane 5 Set multimeter for resistance measurements 6 Measure the resistance between the C...

Page 243: ...Using a 15 16 wrench or slotted socket remove the Motor Cavity Sensor Figure 4 269 Cavity Temperature Sensor Removal 4 31 4 2 Cavity Temperature Sensor Installation 1 Clean the mating surface with a l...

Page 244: ...ecifications Table 4 50 Cavity Sensor Torque Specifications Description Nm Ft Lb In Lb Inverter and Backplane Ground fastener M5x25 3 27 Backplane Mounting fastener M5x25 3 27 PWM Mounting heatsink fa...

Page 245: ...rature Sensor 4 32 2 Pressure Temperature Sensor Connections The suction pressure temperature sensor is secured to the IGV above the suction port The discharge pressure temperature sensor is secured t...

Page 246: ...er Removal and Installation on page 54 3 Disconnect the pressure temperature cable clip SUCTION J18 or DISCHGE J19 or INTER J17 from the Backplane board Refer to Figure 4 274 Pressure Temperature Cabl...

Page 247: ...ware to a calibrated gauge Discharge and Interstage pressure reading should be within 50 kPa 7 25 psig Suction pressure reading should be within 17 kPa 2 5 psig Figure 4 275 Pressure Temperature Senso...

Page 248: ...1 Isolate the compressor power as described in Section 1 8 Electrical Isolation on page 22 2 Recover the refrigerant according to industry standards 3 Disconnect the sensor connector 4 Using a deep 15...

Page 249: ...l 4 32 4 6 Interstage Pressure Temperature Sensor Installation TTH TGH Compressors Only 1 Check and clean O ring housing thread and O ring sealing surface in the compressor housing 2 Apply O lube to O...

Page 250: ...Page 250 of 294 M SV 001 EN Rev H 1 23 2023 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 251: ...easured Inverter Temperature has exceeded the Inverter Cooling Control Fault limit starting the Fault Delay timer Inverter Temperature The measured Inverter temperature has exceeded the alarm limit Le...

Page 252: ...is not an actual fault only an indication that a motor or bearing fault type has occurred Sensor Fault If the following measured temperatures in C or pressures in kPa abs are surpassed a sensor fault...

Page 253: ...eeds the fault limit DC Bus Overvoltage Fault The measured DC bus voltage has exceeded the Maximum DC Bus Voltage limit while RPM is 0 Motor High Current Fault The motor current has exceeded Maximum M...

Page 254: ...T software 5 2 1 Compressor Fault Troubleshooting When troubleshooting a compressor fault detailed analysis of this data should be made in conjunction with a compressor recording file if possible to d...

Page 255: ...5 9 Bearing Status on page 263 Table 5 6 Compressor Status Compressor Status Description Trigger Method Troubleshooting High Inverter Temperature Fault AFT Consequence l Indicates the Inverter cooling...

Page 256: ...ion pressure and other conditions that are recorded at the time of fault High Discharge Pressure Fault AFT Consequence l Results in an Instantaneous Lock Out Fault pre CC4 0 0 Recommendation l Suggest...

Page 257: ...loads and water air flow l Review the fault log for suction and discharge pressures and other conditions that are recorded at the time of fault Bearing Motor Fault Active INS l If a Motor Fault type...

Page 258: ...ndication of faults recorded at time of lock out fault Determine cause of the faults and repair as necessary l Cycle power to clear Lock Out Fault Active alarm Fault Viewer in SMT allows the Lock Out...

Page 259: ...d therefore must have an error in the reading or functional problem with the sensor l Verify the associated sensor and related connections Inverter Temperature Sensor Fault RFT l Sensor errors occur w...

Page 260: ...tart Verification on page 115 l All 3 phase voltage information displayed in the SMT is calculated from DC bus voltage as measured by the Inverter verify the Inverter and its connections Refer to Sect...

Page 261: ...T is calculated from DC bus voltage as measured by the Inverter l Typically this fault is recorded when power to the compressor is removed l Measure and compare the incoming main AC voltage to the com...

Page 262: ...es to the displayed readings in the Compressor Monitor Tool and Fault and Event Log details to determine conditions related to the fault l Typically this fault is recorded when power to the compressor...

Page 263: ...PWM refer to Section 4 28 3 PWM Verification on page 226 bearing sensors refer to Section 4 30 3 Bearing Sensor Verification on page 236 and bearings refer to Section 4 29 3 Bearing Verification on p...

Page 264: ...1 4 BMCC Change If a replacement BMCC is installed in a compressor a calibration must be performed saved to EEPROM and repeated to match the BMCC to the specific compressor 5 3 2 Performing a Calibrat...

Page 265: ...libration process prematurely l Ensure Interlock is open 5 3 3 After Calibration is Complete The message Calibration Complete appears when all SMT calibration steps are complete regardless of the resu...

Page 266: ...nges 5 3 4 Create a Calibration Report The calibration report compares current bearing calibration values to stored values There is no requirement to perform a bearing calibration before creating a ca...

Page 267: ...al fault or shaft is obstructed l Action Verify the bearings l Action Verify the bearing sensors Refer to Figure 1 3 Bearing Calibration Flow on page 1 6 Data in Report The difference between the Late...

Page 268: ...Figure 5 3 Bearing Calibration Flow Page 268 of 294 M SV 001 EN Rev H 1 23 2023...

Page 269: ...voltage after the mains fuses l If the name plate rated voltage is present proceed to Step 4 l If any of the three phases are not present isolate compressor power then replace the fuses 4 Isolate the...

Page 270: ...n on page 22 20 Wait for the LEDs on the Backplane to turn off 21 Remove all connectors from the Backplane leaving only the J6 Inverter cable J4 250VDC and J24 24VDC inputs connected 22 Remove the Ser...

Page 271: ...Driver is draining energy l If any of these voltages are not within 10 another component is draining energy 5 5 2 2 Determining if BMCC is Draining Energy 1 Remove the Service Side Cover Refer to Sect...

Page 272: ...nsor Verification on page 236 13 Re apply the compressor power 14 Test the Backplane voltages at the HV 17HV 24V 15 5 and 15 VDC test points l If all voltages are within 10 the PWM is draining energy...

Page 273: ...ge 117 5 5 3 Troubleshooting an Open Interlock 1 Verify the interlock Refer to Section 4 3 2 3 Interlock Verification on page 63 2 Ensure there is no external power applied on the interlock circuit 3...

Page 274: ...Page 274 of 294 M SV 001 EN Rev H 1 23 2023 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 275: ...are tight P Check for signs of hot spots discoloration on power cables P Check amperages during operation are as per design P Check DC bus voltage P Replace DC Capacitor Bus Bar Assembly Refer to Sect...

Page 276: ...ables l Lint free cloth or clean rags l Soft bristle brush l Small wire brush l Dielectric grease Danfoss LLC part 901982 or equivalent l Dielectric grease spray NOTE The Danfoss LLC part 901982 Diele...

Page 277: ...30 Note actuator position before removal 6 Dry off any condensate around the solenoids Figure 6 2 Motor Cooling Valve Solenoids 7 Remove any debris or dust from Backplane Board and solenoids using a s...

Page 278: ...moval and Installation on page 54 6 2 1 3 Top Side 1 Remove the top covers from the compressor Refer to Section 4 1 Compressor Covers on page 52 2 Dry off any condensate around the motor winding senso...

Page 279: ...protection and is a key indicator of a product s compliance with legislation The CE marking is affixed by manufacturers to their products By placing CE marking on a product manufacturers declare on t...

Page 280: ...ition RTC Real Time Clock SCR Silicone Controlled Rectifier SMT Service Monitoring Tools Software VDC Volts Direct Current or Volts DC C Degrees Celsius F Degrees Fahrenheit Page 280 of 294 M SV 001 E...

Page 281: ...ration Troubleshooting Figure B 1 Compressor Operation Troubleshooting Flowchart Sheet 1 and Compressor Voltage Troubleshooting Figure B 3 Compressor Voltage Troubleshooting Flowchart Sheet 1 Figure B...

Page 282: ...Figure B 2 Compressor Operation Troubleshooting Flowchart Sheet 2 Page 282 of 294 M SV 001 EN Rev H 1 23 2023...

Page 283: ...Figure B 3 Compressor Voltage Troubleshooting Flowchart Sheet 1 M SV 001 EN Rev H 1 23 2023 Page 283 of 294...

Page 284: ...Figure B 4 Compressor Voltage Troubleshooting Flowchart Sheet 2 Page 284 of 294 M SV 001 EN Rev H 1 23 2023...

Page 285: ...Figure B 5 Compressor Voltage Troubleshooting Flowchart Sheet 3 M SV 001 EN Rev H 1 23 2023 Page 285 of 294...

Page 286: ...Page 286 of 294 M SV 001 EN Rev H 1 23 2023 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 287: ...or discharging 4 24 2 4 Output Resistance Measurement J3 Potted J4 Open Frame Charging or discharging 4 24 2 4 Output Resistance Measurement J4 Potted 1M 4 24 2 4 Output Resistance Measurement Front B...

Page 288: ...to 2 of the plug 10K 77 F 25 C 4 31 3 Cavity Temperature Sensor Verification PWM Diode Lead in HV lead in PWM connector 0 39 0 46VDC 4 28 3 3 Verify Functionality of the Five Diode Sets Lead in HV C4...

Page 289: ...on 9 3 W 56 25 68 75 4 6 3 Solenoid Verification Stator Resistance Phase 1 2 0 0 and 1 4 23 4 2 Stator Resistance Verification Phase 1 3 0 0 and 1 4 23 4 2 Stator Resistance Verification Phase 2 3 0 0...

Page 290: ...Page 290 of 294 M SV 001 EN Rev H 1 23 2023 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 291: ...hat 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 p...

Page 292: ...Page 292 of 294 M SV 001 EN Rev H 1 23 2023 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 293: ...urbocor 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 Servi...

Page 294: ...mpressors 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 sup...

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