Danfoss Turbocor TTS Series, Service Manual

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3 of 282
M-SV-001-EN Rev. G
Table of Contents
Chapter 1.0 Introduction ........................................................................................................................................................................ 15
1.1 Application ...................................................................................................................................................................................................................................................................15
1.2 Purpose .........................................................................................................................................................................................................................................................................16
1.3 Organization ................................................................................................................................................................................................................................................................17
1.4 Commitment to Quality and the Environment ...............................................................................................................................................................................................18
1.5 Safety Summary .........................................................................................................................................................................................................................................................18
1.6 Precautions ..................................................................................................................................................................................................................................................................18
1.7 Refrigerant Type .........................................................................................................................................................................................................................................................18
1.8 Electrical Isolation......................................................................................................................................................................................................................................................19
1.9 Handling Static Sensitive Devices ........................................................................................................................................................................................................................20
1.10 DC Bus Test Harness Installation and Removal .............................................................................................................................................................................................22
1.11 Compressor Fasteners ...........................................................................................................................................................................................................................................27
1.12 General O-ring Handling ......................................................................................................................................................................................................................................27
Chapter 2.0 Compressor Fundamentals ................................................................................................................................................ 31
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
Chapter 3.0 Compressor Removal and Installation .............................................................................................................................. 41
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 Exterior Connection Torque Specifications ......................................................................................................................................................................................................45
Chapter 4.0 Compressor Components ................................................................................................................................................... 51
4.1 Component Identification ......................................................................................................................................................................................................................................51
4.2 Compressor Covers ...................................................................................................................................................................................................................................................56
4.3 Cooling Adapter .........................................................................................................................................................................................................................................................61
4.4 Compressor Interface Module ..............................................................................................................................................................................................................................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 Plate Bracket ................................................................................................................................................................................................................................................93
4.12 3-Phase Main Voltage Input Terminal Block ..................................................................................................................................................................................................95
4.13 Input Mains Bus Bars (Except TTS300/TGS230) ..........................................................................................................................................................................................103
4.14 Terminal Block Fuse Replacement ...................................................................................................................................................................................................................105
4.15 Soft Start ...................................................................................................................................................................................................................................................................107
4.16 SCR DC Bus Bar - TTS300/TGS230 ....................................................................................................................................................................................................................119
4.17 Soft Start SCR Gate Cable ...................................................................................................................................................................................................................................121
4.18 Soft Start AC/DC Harness ...................................................................................................................................................................................................................................124
4.19 Silicone-Controlled Rectifier ............................................................................................................................................................................................................................133
4.20 SCR Cooling Manifold ..........................................................................................................................................................................................................................................150
4.21 Snubber Capacitors ..............................................................................................................................................................................................................................................156
4.22 DC Capacitor Bus Bar Assembly .......................................................................................................................................................................................................................156
4.23 Inverter ......................................................................................................................................................................................................................................................................165
4.24 Motor Components ..............................................................................................................................................................................................................................................191
4.25 High Voltage DC-DC Converter ........................................................................................................................................................................................................................201
4.26 Backplane .................................................................................................................................................................................................................................................................207
4.27 Serial Driver .............................................................................................................................................................................................................................................................212
4.28 BMCC .........................................................................................................................................................................................................................................................................214
4.29 Bearing Pulse Width Modulator Amplifier....................................................................................................................................................................................................218
4.30 Magnetic Bearings ................................................................................................................................................................................................................................................223
4.31 Bearing Sensors .....................................................................................................................................................................................................................................................228
4.32 Cavity Temperature Sensor ................................................................................................................................................................................................................................231
4.33 Pressure/Temperature Sensor ..........................................................................................................................................................................................................................234
Chapter 5.0 Troubleshooting ...............................................................................................................................................................241
5.1 Alarm and Fault Indications .................................................................................................................................................................................................................................241
5.2 Troubleshooting with the Service Monitoring Tools Software ...............................................................................................................................................................243
5.3 Bearing Calibration .................................................................................................................................................................................................................................................250
5.4 Compressor Connection Status Indications...................................................................................................................................................................................................255
5.5 System and Compressor Level Troubleshooting ..........................................................................................................................................................................................255