Danfoss Turbocor TTS Series Service Manual Download

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279 of 282

M-SV-001-EN Rev. G

Component

Test Point

Expected Value

Verification Section

Measured Value

SCR Gate Resistance

Gate Terminals

>1Ω and <25Ω (all models) "4.19.2.3 Gates

Verification"

SCR Temperature Sensor

J17 Sensor connector

10KΩ @ 70°F (21°C)

"4.19.2.5 SCR Temperature

Sensor Verification"

Soft Start Fuses

<1Ω

"4.15.2.2 Verifying Soft

Start Fuses"

<1Ω

"4.15.2.2 Verifying Soft

Start Fuses"

F3 & F6

<1Ω

"4.15.2.2 Verifying Soft

Start Fuses"

F4 & F5

30-38Ω

"4.15.2.2 Verifying Soft

Start Fuses"

Solenoid Actuators

4.8 W

108Ω – 132Ω

"4.7.3 Solenoid

Verification"

9.3 W

56.25Ω – 68.75Ω

"4.7.3 Solenoid

Verification"

Stator Resistance

Phase 1:2

>0.0Ω and <1Ω

"4.24.4.2 Stator Resistance

Verification"

Phase 1:3

>0.0Ω and <1Ω

"4.24.4.2 Stator Resistance

Verification"

Phase 2:3

>0.0Ω and <1Ω

"4.24.4.2 Stator Resistance

Verification"

Stator Thermistor Resistance

+ to -

150-300Ω at 70° F (21°C)

"4.24.4.3 Stator Thermistor

Resistance Verification"

Summary of Contents for Turbocor TTS Series

Page 1: ...Danfoss Turbocor Twin Turbine Centrifugal Series Compressors TTS TGS TTH TGH Series Compressors Service Manual Revision G http turbocor danfoss com...

Page 2: ...l covers Major Revision F and later compressors If you have a Major Revision E or earlier compressor we suggest downloading Service Manual Revision E from our website since there are some steps that a...

Page 3: ...dule 63 4 5 Compressor Interface Cable 66 4 6 Compressor Controller Cable Harness 67 4 7 Solenoids and Coils 72 4 8 Interstage Pipe TTH TGH 77 4 9 Compressor Housing End Cap 78 4 10 IGV 80 4 11 Mains...

Page 4: ...f Contents Chapter 6 0 Maintenance 263 6 1 Preventative Maintenance Tasks 263 6 2 Moisture Prevention Measures 264 Appendix A Acronyms Terms 269 Appendix B Compressor Troubleshooting Flowcharts 271 Ap...

Page 5: ...4 27 SCR DC Bus Bar Torque Specifications 121 Table 4 28 Soft Start AC DC Harness Torque Specifications 133 Table 4 29 SCR Diode Values 137 Table 4 30 SCR Gate Resistance Ranges 137 Table 4 31 SCR Tem...

Page 6: ...Removing the Compressor Interface Module from the DIN Rail 66 Figure 4 20 Compressor Interface Cable 67 Figure 4 21 Compressor Controller Cable Harness Variants 68 Figure 4 22 Backplane Connections 69...

Page 7: ...0 TGS230 101 Figure 4 89 Input Terminal Block Installation TTS TGS TTH TGH Rev F and Earlier Except TTS300 TGS230 101 Figure 4 90 Input Terminal Block Installation TTS TGS TTH TGH Rev H Except TTS300...

Page 8: ...4 158 SCR Removal TTS300 TGS230 143 Figure 4 159 SCR Gate Cable and AC DC Harness Connections TTS TGS TTH TGH Rev F and Earlier Except TTS300 TGS230 143 Figure 4 160 SCR Gate Cable and AC DC Harness C...

Page 9: ...GH Except TTS300 TGS230 179 Figure 4 223 DC DC Removal TTS TGS TTH TGH Rev F and Earlier Except TTS300 TGS230 180 Figure 4 224 Motor Winding Sensor Removal 180 Figure 4 225 Inverter Removal TTS TGS TT...

Page 10: ...aring Power Feedthrough Alignment Pin 227 Figure 4 289 Bearing Power Feedthrough Torque Sequence 227 Figure 4 290 Bearing Sensor Feedthroughs 228 Figure 4 291 Bearing Sensor Pin Locations 229 Figure 4...

Page 11: ...cial incidental or consequential damages 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 damag...

Page 12: ...support Revision F and later compressors F 1 6 10 2019 15 16 Upodated Typecode figures 1 1 and 1 2 F 2 11 10 2019 18 19 28 Updated TGS490 compressor with R515B refrigerant F2 11 10 2019 36 Removed hel...

Page 13: ...R515B 19 1 8 Electrical Isolation 19 1 9 Handling Static Sensitive Devices 20 1 9 1 ESD Protection Grounding 21 1 10 DC Bus Test Harness Installation and Removal 22 1 10 1 General Verification and In...

Page 14: ...14 of 282 M SV 001 EN Rev G THIS PAGE INTENTIONALLY LEFT BLANK...

Page 15: ...adds an S for standard or H for High Lift Voltage Code Application Note T is dropped Major Revision Build Note This would change from an O to a 0 Existing New Removed Type Code Definition Product Seri...

Page 16: ...Voltage Code character 8 E 380V 50Hz D 380V 60Hz H 400V 50Hz J 400V 60Hz G 460V 60Hz F 575V 60Hz Application character 9 S Standard Application M Medium Temperature Application J Standard Temp KHK Li...

Page 17: ...of removing and installing the compressor Section 4 Compressor Components this section describes in depth component information the steps necessary to obtain measurements that verify a component is fu...

Page 18: ...r long term health hazards A Danger notification is displayed in the format shown in Figure 1 3 Danger Notification Example Figure 1 3 Danger Notification Example 1 5 2 Caution Notification A CAUTION...

Page 19: ...Mains Input Cover on page 56 4 Using an appropriately rated voltage meter confirm the absence of AC voltage DANGER Do not touch any components when removing the Mains Input Cover 5 If AC voltage is no...

Page 20: ...precautions that must be followed when providing service support in the field Service support personnel should create a safe static free environment Service personnel must use a commercially availabl...

Page 21: ...cribed in 1 8 Electrical Isolation on page 19 2 Remove the Mains Cover Refer to 4 2 1 Mains Input Cover on page 56 3 Clip the ESD strap ground clip to the compressor ground post Refer to Figure 1 9 Ma...

Page 22: ...ts are made via shrouded multimeter jacks on the opposite end of the cables Cable and personal protection are provided by inline fast acting fuses 1 4 x 1 1 4 62 milliamp 250V and current limiting 100...

Page 23: ...iagram Open Top Soft Start 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 sec...

Page 24: ...onnectors and harness so that the Top Cover can be reinstalled 6 Reinstall the Top Cover and Mains Input Cover Refer to 4 2 Compressor Covers on page 56 7 Remove ESD strap from the compressor and your...

Page 25: ...and connect to the 15VAC leads of the DC Bus Test Harness If the reading is zero isolate the three phase supply in accordance with 1 8 Electrical Isolation on page 19 When access is safe remove the f...

Page 26: ...eter lead into the DC test harness lead and the negative voltmeter lead into the DC test harness lead Refer to Table 1 3 Expected DC Bus Voltage on page 25 for the expected DC bus voltage If the DC bu...

Page 27: ...from the socket of the DC Bus Test Harness 4 Reconnect the J8 connector into the Soft Start 5 Remove ESD strap from the compressor and yourself 6 Install all covers on the compressor Refer to 4 2 Comp...

Page 28: ...icate the O ring with a light coat of Super O Lube 4 Avoid rolling or twisting the O ring when maneuvering it into place 5 Keep the position of the O ring mold line constant NOTE It is strongly sugges...

Page 29: ...29 of 282 M SV 001 EN Rev G Chapter 2 Compressor Fundamentals 2 1 Main Fluid Path 31 2 2 Motor and Power Electronics Cooling 31 2 3 Capacity Control 34 2 4 Compressor Energy and Signal Flow 34...

Page 30: ...30 of 282 M SV 001 EN Rev G THIS PAGE INTENTIONALLY LEFT BLANK...

Page 31: ...te Vapor then enters the 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 di...

Page 32: ...ion around the power electronic components In the split cooling version Solenoid 1 is opened if either the cavity temperature or the motor temperature reaches its turn on point and Solenoid 2 is opene...

Page 33: ...quid Refrigerant Inverter Temp Sensor Impeller 1st Stage Impeller 2nd Stage Radial Bearing Axial Bearing Stator Rotor Radial Bearing Solenoid E Solenoid M Motor Cavity Temp Sensor BMCC From Motor Cavi...

Page 34: ...he use of Inverter control To accomplish this the incoming 3 phase AC supply is converted to high voltage DC incorporating smoothing storage capacitors and then switched by the Inverter utilizing 3 ph...

Page 35: ...ut terminal 2 AC voltage enters the SCRs and DC voltage powers the DC bus 3 The Soft Start Board limits the in rush current at power up by controlling the SCR gates 4 DC bus voltage from the SCRs char...

Page 36: ...voltage powers the DC bus 2 DC bus voltage from the SCRs charges the capacitors Soft Start limits the in rush current at power up by controlling the SCR gates DC bus provides DC voltage to the Inverte...

Page 37: ...Module 15VDC 24VDC To Motor Cooling Solenoids To IGV Stepper Motor Compressor I O Board 0 10VDC 0 10VDC Compressor Inputs Compressor Outputs Bearing PWM Ampli er HV 17VDC 5VDC Control Feedback 15VDC 2...

Page 38: ...38 of 282 M SV 001 EN Rev G THIS PAGE INTENTIONALLY LEFT BLANK...

Page 39: ...pressor Removal and Installation 3 1 Refrigerant Containment 41 3 2 Compressor Removal 41 3 3 Compressor Installation 42 3 4 Compressor Replacement Considerations for Motor Cooling Adapter 43 3 5 Exte...

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Page 41: ...nect the compressor from the refrigerant system connections suction discharge economizer and motor cooling line taking care when removing connections that there is no residual pressure 8 Install the S...

Page 42: ...7 Confirm that the compressor and spreader bar are properly balanced between the lifting points and the lifting hoist 8 Slowly lower the compressor until it is positioned within approximately 5 mm of...

Page 43: ...rmal operation 3 4 Compressor Replacement Considerations for Motor Cooling Adapter The housing connection seal is an ISO standard O ring seal and the external pipework connection is an ORFS In additio...

Page 44: ...ed Clean flux and any excess filler from joint 5 Clean the O ring face of the sleeve ensuring no scratches or debris are present Apply a light amount of O ring lube to the face of the sleeve and assem...

Page 45: ...S230 compressors 20 15 177 Motor Cooling Body E housing and later 25 18 221 Motor Cooling Compression Nut E housing and later 11 8 97 Ground Post Top Nut 10 7 89 Ground Post Second Jam Nut 7 62 Ground...

Page 46: ...46 of 282 M SV 001 EN Rev G THIS PAGE INTENTIONALLY LEFT BLANK...

Page 47: ...d Coil Removal and Installation 75 4 8 Interstage Pipe TTH TGH 77 4 8 1 Interstage Pipe Removal and Installation 77 4 8 2 Interstage Pipe Torque Specifications 78 4 9 Compressor Housing End Cap 78 4 9...

Page 48: ...or Bus Bar Assembly Removal and Installation 158 4 22 4 DC Capacitor Bus Bar Assembly General Removal 158 4 22 5 DC Capacitor Bus Bar Assembly General Installation Steps 163 4 22 6 DC Capacitor Bus Ba...

Page 49: ...1 Bearing Sensor Function 228 4 31 2 Bearing Sensor Connection 228 4 31 3 Bearing Sensor Verification 229 4 31 4 Bearing Sensor Cable Removal and Installation 229 4 31 5 Bearing Sensor Removal and Ins...

Page 50: ...50 of 282 M SV 001 EN Rev G THIS PAGE INTENTIONALLY LEFT BLANK...

Page 51: ...onent Identification This section identifies the major parts of the compressor Figure 4 1 Compressor Components Identification Covers On Table 4 1 Compressor Components Covers On 3 11 1 2 4 5 6 7 8 9...

Page 52: ...ent No Component 1 Suction Pressure Temperature Sensor 8 Compressor Cooling Access Port Access Port 1 NOTE TTS300 TGS230 have only one access port 2 IGV Suction Port 9 Compressor Cooling Access Port 2...

Page 53: ...9 8 6 1 2 3 4 5 7 10 11 12 13 14 No Component No Component 1 PWM Amplifier 8 Suction Pressure Temperature Sensor 2 BMCC 9 Motor Cooling Solenoids 3 Serial Driver 10 Motor Cooling Connection 4 Backplan...

Page 54: ...cludes TTH TGH Table 4 4 Compressor Components Capacitor Side Excludes TTH TGH 1 3 4 2 5 6 7 No Component No Component 1 Capacitors 5 Optional Pressure Regulating Port 2 IGV Position Indicator 6 IGV M...

Page 55: ...apacitor Side TTH TGH Only 1 5 9 7 6 2 10 3 8 4 No Component No Component 1 Capacitors 6 Economizer Port 2 IGV Motor Feedthrough 7 Interstage Pipe 3 Optional Pressure Regulating Port 8 Interstage Temp...

Page 56: ...1 Ensure that no residue remains on the contact surfaces of Mains Input Cover and Top Cover 2 Place the Mains Input Cover and secure it with the M5x15 fasteners Tighten according to the sequence shown...

Page 57: ...asteners and remove the cover 2 Remove the M5x15 fasteners that secure the Top Cover and remove the cover Top Cover Installation 1 Ensure that no residue remains on the contact surfaces of Top Cover a...

Page 58: ...for the Backplane Serial Driver BMCC PWM feed throughs and cabling Figure 4 9 Service Side Cover 4 2 3 1 Service Side Cover Removal and Installation Service Side Cover Removal 1 Remove the M5x15 fast...

Page 59: ...ne with the foam side up Refer to Figure 4 12 Capacitor Nylon Nuts for this and the following step 2 Install the nylon nuts to the base of the DC Capacitor Bus Bar Assembly under the main compressor h...

Page 60: ...rding to the sequence in Figure 4 15 Capacitor Cover Torque Sequence Torque to 13 in lb on the second pass Figure 4 15 Capacitor Cover Torque Sequence 4 2 5 Compressor Cover Torque Specifications Tabl...

Page 61: ...ing Adapter TTH375 TGH285 CAUTION A filter drier must be used in conjunction with the Cooling Adapter strainer is not a replacement The strainer is used as a backup to prevent damage to the solenoid o...

Page 62: ...nd finger tighten 4 Torque the cooling 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 Tigh...

Page 63: ...Analog input to drive compressor 0 10V I LOCK Pin 3 4 Interlock safety switch must be part of a closed circuit to start compressor STATUS Pin 5 6 Output closed circuit compressor in normal operation...

Page 64: ...ons and Installation Manual for further information Jumpers JP5 LIQ LEV 1 JP6 LIQ LEV 2 For use with a voltage type level sensor with 15V supply and 0 5V signal Install jumpers between LVL pins 2a and...

Page 65: ...the compressor the BMCC is able to communicate with the user interface If the system is not able to connect verify The D9 green LED is on The cable connection between the Backplane port J7 and the CI...

Page 66: ...off on the CIM 2 Remove all external connections from the CIM 3 Using a screwdriver apply leverage toward the left while lifting the right side of the CIM See Figure 4 19 Removing the Compressor Inte...

Page 67: ...6 Remove the cable by grasping each connector J6 on CIM and J7 on Backplane and pulling away from the board connectors 4 5 2 2 Compressor Interface Cable Installation 1 Install the cable into the J6...

Page 68: ...emoval and Installation on page 112 TTH TGH Compressors To Discharge Pressure Temperature Sensor To IGV Connector To Suction Pressure Temperature Sensor To Interstage Sensor To J17 on Backplane To J18...

Page 69: ...drive connector J21 Figure 4 22 Backplane Connections 7 Disconnect the cables from the suction and discharge pressure sensors Refer to Figure 4 23 Pressure Temperature and SCR Temperature Sensor Locat...

Page 70: ...h Figure 4 26 IGV Connector Clamp 11 Remove the DC Capacitor Bus Bar Assembly Refer to 4 22 DC Capacitor Bus Bar Assembly on page 156 12 Remove the cable harness in stages so the same routing can be f...

Page 71: ...23 Pressure Temperature and SCR Temperature Sensor Locations TTS300 TGS230 on page 69 and Figure 4 25 Pressure Temperature Sensors TTH375 TGH285 for this and the following step 7 Connect the cables to...

Page 72: ...odels The size can be identified by reading the number engraved into the solenoid orifice body For solenoid identification by model reference the Spare Parts Selection Guide Solenoid actuator coils ar...

Page 73: ...10 Solenoid Coil Resistance Ranges to find the expected resistance for the left and right Compressor Cooling Coils 6 To measure the resistance across the left Compressor Cooling Solenoid Coil place t...

Page 74: ...present at one or both solenoid coils use a multimeter to test the back sides of pins 1 3 and pins 5 6 of the cooling solenoid coils WHILE they are energized Refer to Figure 4 32 Compressor Cooling So...

Page 75: ...d Tube Plungers using a six point 13mm deep socket 7 Remove the O rings from the Solenoid Tube Plungers if plungers are to be reused 8 Remove the Orifice Valves using a 15 16 socket 9 Remove the two 2...

Page 76: ...ce with standard industry practices 9 Install the Solenoid Coils in their proper location For split cooling models the coil positions are dedicated The right side coil can be identified by an R affixe...

Page 77: ...gure 4 38 Interstage Pipe Removal 4 8 1 2 Interstage Pipe Installation 1 Clean all mating surfaces 2 Obtain two 2 new O rings for the Interstage Pipe and lubricate them with O lube 3 Install the new O...

Page 78: ...10 7 89 4 9 Compressor Housing End Cap The Compressor Housing End Cap may be removed if it is damaged or if there is a refrigerant leak between the mating surfaces There are no field serviceable compo...

Page 79: ...d the O ring 4 9 1 2 Compressor Housing End Cap Installation 1 Ensure that all components and threads are clear clean and oil free 2 Clean lubricate and install the O ring into the groove in the compr...

Page 80: ...al Driver in turn uses 15VDC to control the IGV stepper motor Figure 4 41 IGV Assembly 4 10 1 IGV Connections Refer to Figure 4 42 IGV Connections for the location of the IGV connections Figure 4 42 I...

Page 81: ...feed through terminals and the IGV Housing The measured value should be open or infinity Figure 4 43 IGV Motor Feedthrough 4 10 2 2 IGV Operation Verification Some of the steps contained within this...

Page 82: ...ntage 100 Figure 4 48 IGV Open Percentage 100 7 On the Backplane there are four 4 LEDs that should light up when the IGV Motor is being driven Refer to Figure 4 50 Backplane Cool LEDs on page 83 Check...

Page 83: ...ng Assembly Removal 1 Isolate compressor power as described in Section 1 8 Electrical Isolation on page 19 2 Remove the clamp securing the IGV Connector Refer to Figure 4 52 IGV Harness Removal for th...

Page 84: ...separate the four pin Feedthrough from the IGV Housing Refer to Figure 4 54 IGV Feedthrough Removal Figure 4 54 IGV Feedthrough Removal 3 Disconnect the four 4 wires from the four pin Feed Through Not...

Page 85: ...rm shaft Refer to Figure 4 56 IGV Motor Assembly Removal Support the bottom of the IGV Motor to prevent damage to the motor shaft A light tap on the motor locating screw with a hammer may help release...

Page 86: ...Gear Removal Figure 4 59 Worm Gear Removal 10 Remove the snap ring from the worm gear shaft Refer to Figure 4 60 Large Worm Gear Bearing Removal for this and the following step 11 Remove the upper la...

Page 87: ...1 Ensure that all components and threads are clear clean and oil free 2 Install the lower small worm gear bearing into the housing This may require a very light tap with a hammer Ensure the lower wor...

Page 88: ...fully closed 7 Fit the upper large bearing to the worm gear and install the snap ring Refer to Figure 4 65 Large Worm Gear Bearing Installation Figure 4 65 Large Worm Gear Bearing Installation 8 Insta...

Page 89: ...osition of the flat surface of the shaft relative to the locating pin The flat surface should be oriented facing up ready to be inserted in the worm gear Refer to Figure 4 68 Shaft Position Figure 4 6...

Page 90: ...r Alignment on page 89 17 Clean lubricate and install the O ring on the Feed Through before connecting the wires 18 Insert the motor wires onto the Feed Through pins in accordance with Table 4 16 IGV...

Page 91: ...Operation of the IGV can also be tested using the SMT driving the IGV manually once the IGV has been mounted on the compressor 22 Clean the mating surfaces of both the compressor and IGV 23 Clean lub...

Page 92: ...roper operation and movement of the IGV assembly Refer to Figure 4 74 IGV Position Indicator to verify the position of the IGV Figure 4 74 IGV Position Indicator 4 10 4 IGV Torque Specifications Table...

Page 93: ...1 Mains Plate Bracket Removal 1 Isolate compressor power as described in Section 1 8 Electrical Isolation on page 19 2 Disconnect the mains input cables from the Terminal Block 3 Disconnect the main...

Page 94: ...S TGS TTH TGH Rev H and Earlier Except TTS300 TGS230 Figure 4 77 Mains Input Nut Installation TTS300 TGS230 Compressors Figure 4 78 Mains Input Nut Installation TTS TGS TTH TGH Rev H and Earlier Excep...

Page 95: ...series and another for all other TTS TGS TTH TGH series With the introduction of Revision H compressors all compressors except for the TTS300 TGS230 compressors have an upgraded Terminal Block design...

Page 96: ...pproved components in circuit with code compliant protection DANGER This equipment contains hazardous voltages that can cause injury or death Exercise extreme caution when working on energized circuit...

Page 97: ...s Repeat on load side of the fuses TT300 TG230 only Figure 4 82 Measuring the 3 Phase AC Input Voltage on the AC Input Terminals TTS300 TGS230 Figure 4 83 Measuring 3 Phase AC Input Voltage on AC Inpu...

Page 98: ...0 1 Remove the three 3 M6x16 fasteners that connect the Fast Acting Fuses to the SCRs Refer to Figure 4 84 Terminal Block Removal TTS300 TGS230 for this and the following four 4 steps 2 Remove the six...

Page 99: ...as an assembly On Rev H compressors the center AC Bus Bar must be removed to access a mounting fastener for the terminal block but the two 2 bus bars can remain attached 5 Remove the fasteners that se...

Page 100: ...16 3 places Terminal Block AC Bus Bar to Terminal Block Fastener M5x12 6 places Terminal Block to Compressor Fastener M5x45 2 places AC Bus Bar to SCR Fastener M8x20 3 places Terminal Block to SCR Co...

Page 101: ...e to 20 Nm 15 ft lb Refer to Figure 4 88 Terminal Block Input Pressure Screws TTS300 TGS230 Figure 4 88 Terminal Block Input Pressure Screws TTS300 TGS230 7 Continue to Section 4 12 2 6 General 3 Phas...

Page 102: ...orque the six 6 fasteners to 3 Nm 27 in lb and the three 3 M8x20 AC Bus Bar Fastners to 9 Nm 80 in lb b For Rev H compressors torque the six 6 M5x12 fastners to 2Nm 17 in lb and the three 3 M6x16 AC B...

Page 103: ...ure the AC Bus Bars to the SCRs Description Nm Ft Lb In Lb TTS300 TGS230 AC Bus Bar to SCR fastener M6x16 5 44 TTS300 TGS230 Terminal Block Mounting fastener M5x15 3 27 TTS300 TGS230 Fuse Assembly to...

Page 104: ...ure 4 92 AC DC Bus Bus Bar Connectors TTS TGS TTH TGS Rev F and earlier Except TTS300 TGH230 Figure 4 93 AC DC Bus Bus Bar Connectors TTS TGS TTH TGS Rev H Except TTS300 TGH230 4 13 2 2 Input Mains Bu...

Page 105: ...tall the top covers Refer to 4 2 Compressor Covers on page 56 5 Return the compressor to normal operation 4 13 2 3 AC Bus Bar Torque Specifications Table 4 21 AC Bus Bar Torque Specifications Descript...

Page 106: ...k Fuse Removal 1 Isolate the compressor power as described in Section 1 8 Electrical Isolation on page 19 2 Remove the 5 16 18 fastener on the line side of the fuse 3 Remove the 5 16 18 nut from the l...

Page 107: ...with Revision H compressors the Open Top Soft Start was introduced There is a significant visual difference between the two 2 variants refer to Figure 4 97 Soft Start Variants on page 107 for the visu...

Page 108: ...tartup stage After DC bus voltage is built up it starts powering the DC DC converter Both PTCs in the AC input path and blocking diodes in DC input path protect the high power side electronics from th...

Page 109: ...arness refer to 1 10 DC Bus Test Harness Installation and Removal on page 22 with power applied to the compressor verify that the expected DC bus voltage is present for the application Refer to Table...

Page 110: ...rts The Soft Start part numbers 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 t...

Page 111: ...urements place the leads on the ends of the F2 Nano fuse The reading should be less than 1 An open F2 fuse may indicate a problem with the DC DC 6 Using a multimeter set for resistance measurements pl...

Page 112: ...s to replace them 10 Install the Soft Start Refer to 4 15 6 Soft Start Installation Closed Top on page 116 11 Install the top covers Refer to 4 2 Compressor Covers on page 56 12 Return the compressor...

Page 113: ...for all TTS TGS TTH TGH compressors 4 Remove the M5x15 fasteners that secure the Soft Start mounting bracket to the compressor Refer to Figure 4 104 Closed Top Soft Start Figure 4 104 Closed Top Soft...

Page 114: ...n page 19 2 Remove the Soft Start Temperature Harness Refer to Figure 4 107 Open Top Soft Start J7 Connector Figure 4 107 Open Top Soft Start J7 Connector 3 Disconnect the Soft Start ground wire by re...

Page 115: ...ors 4 Unplug cable connectors J1 J2 and J8 from the Soft Start Figure 4 109 Open Top Soft Start Connector Removal 5 Remove the M5x20 fasteners that secure the Soft Start mounting bracket to the compre...

Page 116: ...tion 5 Install the J9 Soft Start Temperature Sensor connector Refer to Figure 4 102 Closed Top Soft Start J9 Connector on page 112 6 Connect the Soft Start ground wire and mains input ground wire onto...

Page 117: ...red Refer to the specific spare part kit instructions for adapter board usage CAUTION Use of the adapter board on Open Top Soft Starts and on Soft Starts with revision Q and later may cause the fan no...

Page 118: ...of the fan and will no longer be visible When the adapter boards are used the arrows will only be visible from the bottom side of the Soft Start Figure 4 115 Soft Start Fan Orientation 2 Install the...

Page 119: ...Start fastener M5x15 or M5x20 5 44 Soft Start Fan fastener M5x35 6 Upper Nut 5 16 18 UNC 7 62 Jam Nut 5 16 18 UNC 7 62 Lower Nut 5 16 18 UNC 20 15 177 Cover fastener M5x15 13 4 16 SCR DC Bus Bar TTS30...

Page 120: ...r should be next to the SCR Gate pins aligned with the holes identified as 3 on the SCRs Refer to Figure 4 120 SCR DC Bus Bar to SCR Alignment for this and the following step Figure 4 120 SCR DC Bus B...

Page 121: ...1 Soft Start SCR Gate Cable Closed Top Soft Starts Figure 4 122 Soft Start SCR Gate Cable Open Top Soft Starts 4 17 2 Soft Start SCR Gate Cable Removal and Installation 4 17 2 1 Soft Start SCR Gate Ca...

Page 122: ...23 Soft Start SCR Gate Cable Removal TTS300 TGS230 Figure 4 124 Soft Start SCR Gate Cable Removal at SCR TTS TGS TTH TGH Models Rev F and Earlier Except TTS300 TGS230 Figure 4 125 Soft Start SCR Gate...

Page 123: ...126 Closed Top Soft Start J8 Connector Top b For compressors with the Open Top Soft Start install the J2 connector Figure 4 127 Open Top Soft Start J2 Connector 2 Once the Cable Harness has been inst...

Page 124: ...rnesses The installed harness will vary depending on the style of DC DC Soft Start and compressor model and revision The following steps provide detail on how to replace the Soft Start AC DC Harness I...

Page 125: ...rbocor Compressors Inc Whole numbers One decimal place Two decimal places Angular Radius Chamfer 3 Radius Chamfer 3 Roughness Ra m 0 5 0 1 0 05 1 0 2 0 5 Front view Scale 1 1 PERMANENTLY MARK OR LABEL...

Page 126: ...0 J1 High Voltage AC DC Connector J1 Connector J4 Connector L1 L2 and L3 Spade Terminals 3 places J7 DC DC Trigger Signal Connector DC and DC Spade Terminals For use with potted DC DC For use with Rev...

Page 127: ...2 DC ring terminals from the DC bus bar by removing the attaching hardware Refer to Figure 4 132 DC Ring Terminal Removal TTS300 TGS230 for this and the following step 4 Disconnect the DC ring termina...

Page 128: ...equiped connector Refer to Figure 4 135 Closed Top Soft Start J1 and J7 Removal NOTE Compressors utilizing the open frame DC DC design do not utilize the J7 Trigger Signal connector b For compressors...

Page 129: ...ompressors refer to Figure 4 138 AC Input Ring and DC Spade Connector Removal TTS TGS TTH TGH Rev H Except TTS300 TGS230 on page 130 3 Disconnect the DC and DC spade terminals from the DC bus bar a Fo...

Page 130: ...page 127 5 Remove the Soft Start AC DC Harness from the Soft Start a For compressors with the Closed Top Soft Start remove the J1 and J7 if equiped connector Refer to Figure 4 135 Closed Top Soft Sta...

Page 131: ...DC connector to the DC DC Converter Refer to Figure 4 133 DC DC Connectors Open Frame on page 127 if this compressor contains the Open Frame DC DC Converter or to Figure 4 134 DC DC Connectors Potted...

Page 132: ...nput and Spade Connector Installation TTS TGS TTH TGH Rev F and Earlier Except TTS300 TGS230 b For Rev H compressors refer to Figure 4 141 AC Input and Spade Connector Installation TTS TGS TTH TGH Rev...

Page 133: ...h the AC input voltage and the DC voltage output from the SCRs the Soft Start Board generates the gate signal and outputs pulses of 0 12VDC to the SCRs to control the in rush current when power is ini...

Page 134: ...S230 on page 135 to locate the following connections to the SCRs AC input to SCR SCR Gate cables to Soft Start SCR to DC bus Figure 4 143 SCR Connections TTS300 TGS230 TTS300 TGS230 all revisions TTS...

Page 135: ...gure 4 146 SCR Terminals Two Hole Mount on page 136 and Figure 4 147 SCR Terminals Four Hole Mount on page 136 for terminal locations 4 Perform this test for each SCR 5 Install the DC Bus Bars to the...

Page 136: ...Perform this test for each SCR 6 Using a multimeter set for diode measurements place the black lead on terminal 1 of the SCR and place the red lead on terminal 3 The measured value should be between 0...

Page 137: ...e 4 30 SCR Gate Resistance Ranges 4 19 2 4 SCR Temperature Sensor This section applies to TTS TGS Revision G and earlier compressors only The TTS TGS Revision H and TTH compressors do not utilize an S...

Page 138: ...Removal TTS300 TGS230 1 If desired remove the discharge pressure temperature sensor connector Refer to 4 33 4 Pressure Temperature Sensor Removal and Installation on page 236 Figure 4 150 Discharge Pr...

Page 139: ...from under the DC Bus Bar Assembly from the discharge side of the compressor Refer to Figure 4 153 SCR Temperature Sensor Connector TTS TGS TTH TGH Rev F and Earlier Except TTS300 TGS230 Figure 4 153...

Page 140: ...e Sensor into the SCR Cooling Manifold and torque to 6 Nm 53 in lbs 2 Connect the discharge pressure temperature sensor connector if it was removed 3 Install the SCR Temperature Sensor Cable in the sa...

Page 141: ...for this and the following four 4 steps 2 For Remove the three 3 fasteners that connect the Fast Acting Fuses to the SCRs 3 Remove the six 6 Fuse to Terminal Block fasteners that secure the fuses to t...

Page 142: ...six 6 M6x16 fasteners that secure the and SCR Bus Bars to the SCRs 8 Remove the DC Bus Bars Figure 4 157 DC Bus Bar Removal TTS300 TGS230 9 Remove the two 2 M6x16 fasteners that secure each SCR to the...

Page 143: ...fer to Figure 4 159 SCR Gate Cable and AC DC Harness Connections TTS TGS TTH TGH Rev F and Earlier Except TTS300 TGS230 and Figure 4 160 SCR Gate Cable and AC DC Harness Connections TTS TGS TTH TGH Re...

Page 144: ...ar from the SCRs a For Revision F and earlier compressors remove the six 6 M8x20 DC Bus fasteners from the SCRs Refer to Figure 4 161 SCR Bus Fastener Removal TTS TGS TTH TGH Rev F and Earlier Except...

Page 145: ...to Figure 4 163 SCR Removal TTS TGS TTH TGH Rev F and Earlier Except TTS300 TGS230 b For Revision H compressors remove the two 2 M6x16 fasteners that secure each SCR to the SCR Cooling Manifold and re...

Page 146: ...nifold fasteners Figure 4 166 SCR Orientation TTS300 TGS230 5 Place the negative bus bar on the SCRs The negative bus bar should be next to the SCR Gate Connectors aligned with the holes identified as...

Page 147: ...Block Adapter then install the two 2 fasteners for each of the three 3 fuse block assemblies and torque to 4 Nm 35 in lb 14 Install the three 3 M6x16 fasteners that connect the Fast Acting Fuses to th...

Page 148: ...en to 2 Nm 18 in lb Stage 2 Tighten to a final torque of 5 Nm 44 in lb b For Revision H compressors tighten the six 6 M6x16 fasteners to 5 Nm 44 in lb Figure 4 170 SCR Torque Sequence TTS TGS TTH TGH...

Page 149: ...CR Bus Bar Bolt M6 10 7 89 SCR to SCR Cooling Manifold fastener M6x16 5 44 SCR to SCR Cooling Manifold fastener M6x16 Rev H excluding TTS300 TGS230 5 44 TTS300 TGS230 Fuse to Terminal Block fastener 4...

Page 150: ...ld Removal TTS TGS TTH TGH Except TTS300 TGS230 on page 151 4 20 2 SCR Cooling Manifold Removal TTS300 TGS230 1 Remove the Fuses Refer to 4 12 2 2 Specific 3 Phase Main Voltage Input Terminal Block Re...

Page 151: ...Voltage Input Terminal Block Removal and Installation on page 98 9 Remove the DC Bus Bars and Capacitor Assembly Refer to 4 22 3 DC Capacitor Bus Bar Assembly Removal and Installation on page 158 10 I...

Page 152: ...into the SCR cooling manifold Refer to Figure 4 175 SCR Cooling Plate O ring Installation TTS300 TGS230 Figure 4 175 SCR Cooling Plate O ring Installation TTS300 TGS230 4 Install the SCR Cooling Mani...

Page 153: ...2 Apply O Lube to a new Inverter Heat Sink O ring and place in the O ring grove in the Inverter Heat Sink Plate and install Refer to Figure 4 176 Inverter Heat Sink Plate O ring Installation TTS TGS T...

Page 154: ...itor assembly over the Inverter Refer to 4 22 3 DC Capacitor Bus Bar Assembly Removal and Installation on page 158 11 Install the Terminal Block Assembly Refer to 4 12 2 5 3 Phase Main Input Terminal...

Page 155: ...r M5X15 5 44 Ground Post Top Nut 5 16 18 UNC 10 7 89 Ground Post Second Jam Nut 5 16 18 UNC 7 62 Cover fastener M5x15 13 Snubber Capacitor fastener M6x16 7 62 Nylon Capacitor Nuts 7 62 Terminal Block...

Page 156: ...Except TTS300 TGS230 on page 157 The SCRs output 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 c...

Page 157: ...Cable Harness to DC Bus for the location of the connections listed below 1 DC to Soft Start 2 DC to Soft Start and DC DC 3 DC bus to Inverter Figure 4 181 Soft Start Cable Harness to DC Bus Snubber Ca...

Page 158: ...2 Remove the Soft Start Refer to 4 15 Soft Start on page 107 3 Remove the Snubber Capacitors Refer to Figure 4 183 Snubber Capacitor Removal TTS300 TGS230 on page 159 4 Using a multimeter set for capa...

Page 159: ...e 4 183 Snubber Capacitor Removal TTS300 TGS230 4 Remove the nylon nuts at the base of the DC Capacitor Bus Bar Assembly under the main compressor housing Refer to Figure 4 184 Capacitor Nut Removal T...

Page 160: ...Installation TTS300 TGS230 on page 163 4 22 4 2 DC Capacitor Bus Bar Assembly Removal TTS TGS TTH TGH Except TTS300 TGS230 7 Remove the six 6 DC bus fasteners from the SCRs Refer to Figure 4 186 SCR B...

Page 161: ...00 TGS230 Figure 4 188 Snubber Capacitor Removal TTS TGS TTH TGH Except TTS300 TGS230 9 Remove the nylon nuts at the base of the DC Capacitor Bus Bar Assembly under the main compressor housing Refer t...

Page 162: ...ars Refer to Figure 4 190 Capacitor Assembly Removal TTS TGS TTH TGH Rev F and Earlier Except TTS300 TGS230 and Figure 4 191 Capacitor Assembly Removal TTS TGS TTH TGH Rev H Except TTS300 TGS230 Figur...

Page 163: ...e DC Capacitor Bus Bar Assembly and torque to 7 Nm 62 in lb Refer to Figure 4 184 Capacitor Nut Removal TTS300 TGS230 on page 159 10 Connect the SCR Gate cable harness to the SCRs noting its orientati...

Page 164: ...fastener M8x20 Excludes TTS300 TGS230 compressors 9 80 Terminal Block Mounting fastener M5x45 Excludes TTS300 TGS230 compressors 4 35 Capacitor DC Bus Bar to SCR fastener M8x20 Excludes TTS300 TGS230...

Page 165: ...er Connections 4 23 2 Inverter Verification This procedure only verifies the Inverter diodes The Inverter Control Board cannot be verified in the field unless an inverter tester is used A faulty Inver...

Page 166: ...minal place the red multimeter lead on the DC terminal The measured value should be 0 275V 0 4V 10 Repeat Steps 6 through 9 for the remaining Inverter phases Figure 4 193 Inverter Diode Measurements S...

Page 167: ...are no bent or broken pin connectors 8 Remove the Inverter Cable Harness ground connection from the Backplane Refer to Figure 4 196 Harness Removal from Backplane Figure 4 196 Harness Removal from Bac...

Page 168: ...Specifications Table 4 35 Inverter Cable Harness Torque Specifications 4 23 6 Inverter Removal and Installation General Removal 1 Isolate compressor power as described in Section 1 8 Electrical Isola...

Page 169: ...lies TTS300 TGS230 for this and the following two 2 steps 3 Remove the two 2 fasteners from each of the three 3 fuse block assemblies 4 Remove the fuse assemblies along with the Mylar Figure 4 198 Fus...

Page 170: ...citor Bus Bar Assembly Removal and Installation on page 158 for this and the following step 11 Remove the nylon nuts at the base of the DC Capacitor Bus Bar Assembly under the main compressor housing...

Page 171: ...ers from the Inverter Refer to Figure 4 203 Inverter Copper Tube Removal and the note below 15 Slide out all three 3 Inverter Copper Tubes Figure 4 203 Inverter Copper Tube Removal Mylar Motor Bus Bar...

Page 172: ...re 4 204 Inverter Cable Harness Removal TTS300 TGS230 17 Disconnect all wiring connections from the DC DC Converter Refer to Figure 4 205 Open Frame DC DC and Figure 4 206 Potted DC DC for the connect...

Page 173: ...DC DC Shown 20 Disconnect the wires from the Motor Winding Sensor Refer to Figure 4 208 Motor Winding Sensor Connector Removal Figure 4 208 Motor Winding Sensor Connector Removal 21 Loosen the M5x16 f...

Page 174: ...0 M6x30 fasteners that secure the Inverter to the compressor main housing and carefully remove the Inverter and remove and discard the two 2 O rings underneath Figure 4 211 Inverter Assembly Removal T...

Page 175: ...oval Steps TTS TGS TTH TGH Except TTS300 TGS230 1 Remove the three 3 AC wires of the Soft Start AC DC cable harness from the AC Bus Bars 2 Unplug the SCR Gate cable harness from the from the SCRs noti...

Page 176: ...ers Refer to Figure 4 215 Terminal Block and AC Mains Input Bus Bar Removal TTS TGS TTH TGH Rev F and Earlier Except TTS300 TGS230 b For Revision H compressors leave the Terminal Block in place but re...

Page 177: ...Tubes Figure 4 217 Inverter Copper Tube Removal TTS TGS TTH TGH Except TTS300 TGS230 7 Loosen the M5x16 IGV Feedthrough fastener that secures the Retainer Clip and rotate the clip to allow for the co...

Page 178: ...S300 TGS230 or to Figure 4 220 Compressor Cable Harness Removal TTH TGH Only for TTH only compressors Figure 4 219 Compressor Cable Harness Removal TTS TGS TTH TGH Except TTS300 TGS230 Figure 4 220 Co...

Page 179: ...arness from the top of the Inverter Refer to Figure 4 222 Inverter Harness Removal TTS TGS TTH TGH Except TTS300 TGS230 Figure 4 222 Inverter Harness Removal TTS TGS TTH TGH Except TTS300 TGS230 NOTE...

Page 180: ...C from the Inverter Heat Sink Plate Figure 4 223 DC DC Removal TTS TGS TTH TGH Rev F and Earlier Except TTS300 TGS230 14 Disconnect the wires from the Motor Winding Sensor Refer to Figure 4 224 Motor...

Page 181: ...f the fitting Refer to Figure 4 227 SCR Manifold Return Brass Fitting Removal TTS TGS TTH TGH Except TTS300 TGS230 Figure 4 227 SCR Manifold Return Brass Fitting Removal TTS TGS TTH TGH Except TTS300...

Page 182: ...e used to ensure to ensure proper torque is obtained 8 Carefully install the Inverter on the compressor housing with the SCR temperature sensor cable if equiped run on top where the SCR cooling manifo...

Page 183: ...he Soft Start harness from the DC bus assembly noting the orientation Torque the M6 fasteners to 10 Nm 7 ft lb Refer to Figure 4 230 DC Bus Installation TTS300 TGS230 for this and the following step 1...

Page 184: ...e compressor housing groove 3 Remove 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 M...

Page 185: ...n the SCR Manifold Return Brass Fitting smaller one on top Apply O lube to each O ring before installation Refer to Figure 4 234 SCR Manifold Return Brass Fitting O ring Installation TTS TGS Except TT...

Page 186: ...xcept TTS300 TGS230 20 Connect the Snubber Capacitors and torque to 7 Nm 62 in lb Refer to 4 22 3 DC Capacitor Bus Bar Assembly Removal and Installation on page 158 21 Tighten the DC Bus Assembly to t...

Page 187: ...pressor power as described in Section 1 8 Electrical Isolation on page 19 2 Remove the Capacitor Cover Refer to 4 2 4 1 Capacitor Cover Removal and Installation on page 59 3 Disconnect the 3 phase A C...

Page 188: ...re 4 239 Seated Spring Pins 2 There are two 2 different length spring pins if any are replaced be sure to replace with the same length spring pin Refer to Figure 4 240 Spring Locations and Table 4 36...

Page 189: ...separate Be sure to hold both to avoid dropping the driver board if separation occurs If they do become separat ed carefully snap the cover back into place prior to assembly 7 For proper alignment ins...

Page 190: ...k Removal and Installation on page 98 16 Install the Soft Start Refer to 4 15 Soft Start on page 107 17 Connect all remaining cable harnesses 18 Install the Capacitor Cover Refer to 4 2 4 1 Capacitor...

Page 191: ...3 4 24 Motor Components 4 24 1 Function The motor type employed is a permanent magnet synchronous speed motor The winding section of the motor is similar in design to a standard 3 phase star connected...

Page 192: ...windings are intact 4 24 4 2 Stator Resistance Verification To verify the Stator resistance complete the following steps 1 Isolate the compressor power as described in Section 1 8 Electrical Isolation...

Page 193: ...R T Curve 1 4 24 5 Motor Assembly Removal and Installation This section contains steps that explain the removal and replacement of the Motor Bus Bars Copper Tubes Cover Plate and the High Power Feed T...

Page 194: ...ly install the three 3 M8x70 fasteners that secure the motor bus bars to the inverter output through the Copper Tubes Continue to Step 3 if the compressor contains PPS High Power Feedthroughs Continue...

Page 195: ...r to 4 24 5 Motor Assembly Removal and Installation on page 193 4 Remove the three 3 Copper Tubes Refer to Figure 4 248 Copper Tube Removal Figure 4 248 Copper Tube Removal 4 24 5 4 Copper Tube Instal...

Page 196: ...Removal 9 Remove and discard the O ring from the compressor housing 4 24 5 6 Motor Cover Plate Installation 1 Clean the mating surfaces with a lint free cloth Inspect the sealing area for any damage...

Page 197: ...ers that secure the motor bus bars to the Stainless Steel High Power Feedthroughs and torque to 15 5 Nm 11 5 ft lb Be careful not to over tighten the bolts to the power feedthroughs Continue to Step 1...

Page 198: ...hrough assembly Refer to Figure 4 253 High Power Feedthrough Removal stainless steel Figure 4 253 High Power Feedthrough Removal stainless steel O ring 3 places High Power Feedthrough 3 places Ring Te...

Page 199: ...rminals to the PPS High Power 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 7 Secure the ring te...

Page 200: ...ly Torque Specifications Table 4 38 Motor Assembly Torque Specifications High Power Feedthrough Motor Bus Bar Motor Thermistor Terminals Inverter to Motor Bus Bar fastener M8x70 Description Nm Ft Lb I...

Page 201: ...ough the Soft Start Board F1 fuse The Soft Start Board also powers the potted style DC DC Converter with 15VAC when the DC bus has reached minimum level Refer to Figure 4 258 Potted DC DC on page 204...

Page 202: ...resistance measurements place the multimeter leads on the J2 250VDC output terminals Refer to Figure 4 258 Potted DC DC on page 204 and Figure 4 259 Open Frame DC DC on page 204 The result should be...

Page 203: ...Soft Start J9 Connector b For Open Top Soft Starts disconnect the J7 connector Refer to Figure 4 107 Open Top Soft Start J7 Connector on page 114 6 Carefully cut any cable ties that may be securing th...

Page 204: ...VDC J3 and 15VAC J4 from the DC DC Converter Refer to Figure 4 258 Potted DC DC Open frame style Three 3 connectors DC Bus Input J1 250VDC Output J2 and 24VDC output J4 from the DC DC Converter Refer...

Page 205: ...ide under Refer to Figure 4 261 DC DC Rear Fastener Install Figure 4 261 DC DC Rear Fastener Install 4 Align the DC DC Converter with the mounting holes on the Inverter Heat Sink Plate by sliding the...

Page 206: ...3 Soft Start Removal and Installation on page 112 8 Install the top covers Refer to 4 2 Compressor Covers on page 56 9 Return the compressor to normal operation 4 25 4 4 DC DC Torque Specifications T...

Page 207: ...solenoids bearing sensors and pressure temperature sensors It is a means to transfer control sensor and error information between the BMCC and other compressor components The Backplane also serves as...

Page 208: ...t 2 J2 and J3 BMCC Connection Port 12 J21 IGV Motor Control Port 3 J8 Serial Driver Connection Port 13 Inverter Ground Screw 4 J7 I O Cable Connection 14 J11 and J12 Rear Bearing Sensor Cable to Groun...

Page 209: ...2 HV Test Point 6 15V Test Point 3 17HV Test Point 7 24V Test Point 4 0V Test Point 8 15V Test Point 4 26 2 1 LED Locations The Backplane LEDs are indicated in Figure 4 267 Backplane LED Locations Le...

Page 210: ...ane 5 Using a multimeter set for resistance measurements place the multimeter leads in the Backplane test points as defined in Table 4 43 Backplane Test Point Values on page 211 See Figure 4 266 Backp...

Page 211: ...fer to Figure 4 265 Backplane Connections on page 208 7 Remove the Inverter Ground fastener from the top right of the Backplane to release the Inverter cable ground ring 8 Replace the Inverter ground...

Page 212: ...Serial Driver 8 Install the Service Side Cover Refer to 4 2 3 1 Service Side Cover Removal and Installation on page 58 9 Return the compressor to normal operation 4 26 3 3 Backplane Torque Specificati...

Page 213: ...Side Cover Refer to 4 2 3 1 Service Side Cover Removal and Installation on page 58 7 Return the compressor to normal operation 4 27 3 2 Serial Driver Output Voltage Verification 1 Remove the Service...

Page 214: ...er to 4 2 3 1 Service Side Cover Removal and Installation on page 58 4 Return the compressor to normal operation 4 28 BMCC The BMCC is the central processor board of the compressor Based on sensor inp...

Page 215: ...ger tool 2 If the system is able to connect the BMCC is able to communicate with the user interface 3 If the system is not able to connect verify a The BMCC is properly connected to the Backplane b Th...

Page 216: ...rior to disposal Always refer to local requirements in your area to ensure the battery is properly disposed 4 28 3 2 BMCC Defective Battery Symptoms If the BMCC battery is good and no BMCC problems ex...

Page 217: ...Serial Driver from the Backplane and slide it slowly away from the compressor Refer to 4 27 4 Serial Driver Removal and Installation on page 213 5 Carefully disconnect the BMCC from the Backplane and...

Page 218: ...Service Side Cover on page 58 5 Return the compressor to normal operation 6 If a BMCC that is not original to the compressor is installed a calibration must be completed and saved to the EEPROM to mat...

Page 219: ...evision F and later compressor Figure 4 280 Bearing Power Feed Throughs and PWM Connection Port Impellers Z axis Position Sensor Sensor Ring Front Radial Bearing Motor Sensor Ring Rear Radial Bearing...

Page 220: ...V and 5V test points 14 If the voltages do not change the PWM is not the source or not the only source of energy drain 4 29 3 2 Verify Functionality of the Five Output Channels 1 Verify the bearing co...

Page 221: ...7 Repeat Step 6 for all 10 pin holes on both PWM connectors Figure 4 281 Connecting Leads to PWM Connector and HV and HV Test Points 8 Still set on diode measurement place the black multimeter lead o...

Page 222: ...s for the PWM and bearing feed throughs 7 Install the BMCC Refer to 4 28 4 BMCC Removal and Installation on page 217 8 Install the Serial Driver Refer to 4 27 4 Serial Driver Removal and Installation...

Page 223: ...30 3 1 Bearing Coil Verification 1 Isolate compressor power as described in Section 1 8 Electrical Isolation on page 19 2 Remove the Service Side Cover Refer to 4 2 3 1 Service Side Cover Removal and...

Page 224: ...4 30 3 2 Bearing Current Verification 1 Connect to the compressor using the SMT 2 Open the Compressor Monitor tool Refer to Figure 4 286 Compressor Monitor Tool on page 225 3 Look at the bearing sect...

Page 225: ...he cable from J9 on the Backplane 7 Remove the cable from the 9 pin connector at the Rear Bearing Sensor Feedthrough 8 Remove the ground wire from J11 on the Backplane 4 30 3 4 Bearing Sensor Cable In...

Page 226: ...2 Isolate the compressor and recover the refrigerant according to industry standards Refer to 3 1 Refrigerant Containment on page 41 3 Remove the Service Side Cover Refer to 4 2 3 1 Service Side Cove...

Page 227: ...rough Torque Sequence Figure 4 289 Bearing Power Feedthrough Torque Sequence 6 Leak test and evacuate in accordance with standard industry practices 7 Carefully install the PWM Refer to 4 29 4 PWM Rem...

Page 228: ...hroughs located above the front and rear bearing power feed throughs The bearing sensor feed throughs are connected to the bearing sensor cables which connect to J9 and J10 on the Backplane Refer to F...

Page 229: ...e Figure 4 291 Bearing Sensor Pin Locations 4 31 4 Bearing Sensor Cable Removal and Installation Refer to Figure 4 265 Backplane Connections on page 208 for connector locations in this section 4 31 5...

Page 230: ...hrough Removal 4 31 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 feed through are cl...

Page 231: ...upper guide rails Refer to Figure 4 294 BMCC Insertion Guides Figure 4 294 BMCC Insertion Guides 11 Install the Service Side Cover 4 2 3 1 Service Side Cover Removal and Installation on page 58 12 Ins...

Page 232: ...he Cavity Temperature Sensor is a 10K 77 F 25 C NTC thermistor The resistance value should correspond to the chart in Figure 4 297 Temperature vs Resistance 6 Measure the resistance of the Cavity Temp...

Page 233: ...and engage the first few threads by hand 4 Tighten the sensor to 13 Nm 10 ft lb 5 Leak test and evacuate in accordance with standard industry practices 6 Install the Backplane Refer to 4 26 3 Backplan...

Page 234: ...emperature sensor is secured to the IGV above the suction port The discharge pressure temperature sensor is secured to the compressor housing above the discharge port Refer to Figure 4 300 Pressure Te...

Page 235: ...inals 5 If the integrity of the cable is in question disconnect the compressor controller cable from the pressure temperature sensor and proceed to the next step 6 Place the leads on Terminal 1 3 of t...

Page 236: ...essure Temperature Sensor Installation 1 Check and clean the O ring housing thread and O ring sealing surface in the IGV Housing 2 Apply lube to O ring 3 Insert the sensor and engage the first few thr...

Page 237: ...rigerant Containment on page 41 3 Disconnect the sensor connector 4 Using a deep 15 16 socket remove the sensor from the Interstage Pipe Figure 4 307 Interstage Pressure Temperature Sensor Removal 4 3...

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Page 239: ...250 5 3 Bearing Calibration 250 5 3 1 When to Calibrate the Bearings 250 5 3 2 Performing a Calibration 251 5 3 3 After Calibration is Complete 252 5 3 4 Create a Calibration Report 252 5 3 5 Calibrat...

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Page 241: ...The measured temperature has exceeded the fault limit Low Suction Pressure The measured suction pressure has exceeded the fault limit Discharge Pressure The measured discharge pressure has exceeded th...

Page 242: ...Rotor may be Locked Back Electromotive Force EMF is low Winding Temperature The measured motor winding temperature has exceeded the fault limit High Suction Superheat The calculated Suction Superheat...

Page 243: ...EMF has fallen below the minimum Back EMF limit EEPROM Checksum Fault An error checksum error occurs reading the data table from the EEPROM Generator Mode Active At greater than 0 RPM and DC bus volt...

Page 244: ...ayback tool provides a method of reviewing operational conditions without a connection to the compressor It also creates a file to electronically transmit for peer review See the latest Service Monito...

Page 245: ...e insufficient system load or a sudden drop in evaporator entering air water temperature or flow Check the charge system load and entering air water conditions Review the fault log for actual suction...

Page 246: ...73 Verify the solenoid actuators Refer to 4 7 3 Solenoid Verification on page 73 Verify the Serial Driver Refer to 4 27 3 Serial Driver Verification on page 213 Verify SCR temperature sensor Refer to...

Page 247: ...erify the associated sensor and related connections Inverter Temperature Sensor Fault RFT Sensor errors occur when the sensor is providing a reading that is outside the normal readable temperature ran...

Page 248: ...ed gas is entering the compressor suction port Verify the Inverter Refer to 4 23 2 1 Inverter Verification on page 165 Verify the Stator Refer to 4 24 4 Motor Verification on page 192 Inverter Error I...

Page 249: ...ill recover when cavity temperature cools or due to a permanent demagnetization of the shaft If this fault occurs three times within a 30 minute period a Lock Out Fault will occur Compare the Back EMF...

Page 250: ...itate Only Mode Using the Compressor Monitor levitate the shaft and record the bearing forces Greater than 2A indicates an issue Manually calibrate the bearings save to EEPROM and identify if bearing...

Page 251: ...es to momentarily levitate the shaft and compares the values to tolerance limits 5 3 2 1 Before Performing a Calibration Interlock must be open RS485 or other external compressor communication connect...

Page 252: ...st calibration values overwrite stored values There is no requirement to save calibrations to EEPROM after performing a bearing calibration Comparing original factory calibration values stored in EEPR...

Page 253: ...d Action Verify the PWM Action Verify the bearings Action Verify the bearing sensors 4 Data in Report One or more of the gain values exceeds 3 0 Interpretation Bearing electrical fault or shaft is obs...

Page 254: ...date create another report Start Begin bearing calibration Could shaft run and levitate without issue prior to calibration No Yes Does shaft levitate after Save to EEPROM Yes Does shaft levitate after...

Page 255: ...ns fuses If the name plate rated voltage is present proceed to Step 4 If any of the three phases are not present isolate compressor power then replace the fuses 4 Isolate the compressor power as descr...

Page 256: ...BMCC refer to 4 28 4 BMCC Removal and Installation on page 217 and PWM refer to 4 29 4 PWM Removal and Installation on page 221 22 Re apply compressor power 23 Verify the HV and the 24 VDC test point...

Page 257: ...n 10 proceed to Step 5 5 Isolate the compressor power and wait for the LEDs on the Backplane to turn off 6 Remove the BMCC refer to 4 28 4 BMCC Removal and Installation on page 217 ensure the Inverter...

Page 258: ...C Converter high voltage input Refer to 4 25 2 1 Input Voltage Verification on page 201 Verify the DC DC Converter Refer to 4 25 2 DC DC Converter Verification on page 201 Verify the PWM Refer to 4 29...

Page 259: ...e the wire to the I LOCK neg at the J2 connector of the I O board 5 5 4 Troubleshooting the Inverter 1 Download the fault and event log 2 Review the fault and event log for any Inverter Error Signal A...

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Page 261: ...261 of 282 M SV 001 EN Rev G Chapter 6 Maintenance 6 1 Preventative Maintenance Tasks 263 6 2 Moisture Prevention Measures 264...

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Page 263: ...ges Ensure electrical terminals are tight Check for signs of hot spots discoloration on power cables Check amperages during operation are as per design Check DC bus voltage Replace DC Capacitor Bus Ba...

Page 264: ...ctric grease can be applied by Finger Small brush 6 2 1 1 Service Side Disassembly 1 Isolate the compressor power as described in Section 1 8 Electrical Isolation on page 19 of this manual 2 Allow tim...

Page 265: ...around the motor winding sensor terminals high power feed throughs and motor bus bars 3 Using a soft bristle brush remove any debris or dust from the motor winding sensor terminals high power feed th...

Page 266: ...ll three fuse assemblies Refer to 4 14 2 Terminal Block Fuse Removal and Installation on page 106 and Figure 6 4 Accessing Inside SCR to Cooling Manifold Fastener TTS TGS Compressors only Figure 6 4 A...

Page 267: ...ray on the SCR fasteners 16 Apply dielectric grease to the Bus Bar fasteners 17 Clean off any excess dielectric grease 18 Inspect all electrical connections 19 Install top covers on compressor Refer t...

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Page 269: ...ealth and environmental 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 man...

Page 270: ...270 of 282 M SV 001 EN Rev G Acronym Term Definition SMT Service Monitoring Tool VDC Volts Direct Current or Volts DC C Degrees Celsius F Degrees Fahrenheit...

Page 271: ...art Sheet 1 Is the compressor operating correctly Is the Mains voltage within range End A Yes No Yes Repair Mains voltage problem No Are the LEDs on the I O Board lit Canyou communicatewithcompressor...

Page 272: ...rcuit Is there a demand displayed Yes No Restore demand input to the compressor Has the IGV reset No Yes Wait until IGV reset Is Inverter Temp below Maximum Start Temp No Yes Refer to Section 5 5 4 Tr...

Page 273: ...late compressor Refer to Electrical Isolation 1 7 Yes No Remove the Top Cover Inspect all electronics for visible damage Are there any signs of visible damage Verify Soft Start fuses Closed Top Soft S...

Page 274: ...est all SCRs and refer to SCR Verification 4 18 2 No 15VAC present Replace Soft Start and re install Top Cover SCRs pass test No Yes No Replace all three SCRs and re install Top Cover Install DC Bus T...

Page 275: ...m Backplane leaving only the J6 IGBT cable J4 250VDC and J24 VDC inputs connected Remove Serial Driver BMCC and PWM Re apply mains power Verify the HV and 24V test points on Backplane Are voltages wit...

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Page 277: ...easurement J2 Charging or discharging 4 25 2 4 Output Resistance Measurement J3 Charging or discharging 4 25 2 4 Output Resistance Measurement J4 1M 4 25 2 4 Output Resistance Measurement Front Bearin...

Page 278: ...I Lock 2 2 to 3 7 VDC 4 4 2 3 Interlock Verification Power Off J2 Removed I Lock to I Lock 22 k 4 4 2 3 Interlock Verification Pressure Temperature Sensor Resistance 1 to 3 1 to 2 of the plug 10K 77...

Page 279: ...s F2 1 4 15 2 2 Verifying Soft Start Fuses F3 F6 1 4 15 2 2 Verifying Soft Start Fuses F4 F5 30 38 4 15 2 2 Verifying Soft Start Fuses Solenoid Actuators 4 8 W 108 132 4 7 3 Solenoid Verification 9 3...

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Page 281: ...select from a list of symptoms in the app that match the problems exhibited by the compressor being serviced The app will then list potential causes solutions to the problem and service literature to...

Page 282: ...as distinct variable speed technology specialists Today we operate from engineering and manufacturing facilities spanning across three continents Danfoss Inverter Scrolls Danfoss Turbocor Compressors...

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