Danfoss Turbocor TTS Series Applications And Installation Manual Download

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Chapter 19.0 Shipping Considerations

19.1 Vibration

When shipping the compressor as an integral part of a chiller unit, precautions should be taken to protect the

compressor motor cooling line from excessive vibration. Due to the flexibility of the compressor’s isolation mounts,

compressor vibration during transit can fracture the motor cooling line’s rigid piping. Danfoss LLC Applications

suggests the temporary installation of an anti-vibration bracket between the compressor’s base frame and

mounting rail during transit, as shown in Figure 19-1 Anti-Vibration Bracket.

Figure 19-1 Anti-Vibration Bracket

M-AP-001-EN Rev. S-9/8/2021 Page 113 of 136

Summary of Contents for Turbocor TTS Series

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

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Page 3: ...Main Fluid Path 25 3 2 Motor Cooling 26 3 3 Inlet Guide Vanes 29 3 4 Compressor Control Overview 30 3 4 1 Motor Drive System 30 3 4 2 Soft Start 31 3 4 3 Bearing Motor Compressor Controller 31 3 4 4...

Page 4: ...ance 43 Chapter 6 0 Electrical Specifications 45 6 1 Supply Voltage and Frequency 45 6 2 Voltage Sag Immunity 45 6 3 Compressor Current Limit and Operating Range Settings 45 6 4 Disconnects 47 6 5 Mot...

Page 5: ...es 73 Chapter 13 0 System Design Guidelines 75 13 1 General Requirements 75 13 2 Economizer Option 76 13 3 Motor Electronics Cooling Requirements 76 13 4 Electrical Requirements 77 13 5 Application Sp...

Page 6: ...20 2 Rigging Requirements 115 20 3 Unit Placement 115 20 4 Mounting Base 116 20 5 Piping Connections 117 20 6 Control Wiring 118 20 6 1 Control Wiring Connections 118 20 6 2 Circuit Grounding 119 20...

Page 7: ...clude TTH TGH compressors P 1 12 12 2019 Update to include TG490 and Medium Temp Q 04 06 2020 Major Revision H upgrade R 02 01 2021 Includes High SST and general review update S 07 29 2021 Complete re...

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Page 9: ...s 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 res...

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Page 11: ...LLC compressors are familiar with and carry out all safe work practices necessary to ensure safety for personnel and equipment 1 1 Scope This manual is designed for use with Bearing Motor Compressor...

Page 12: ...Conditioning Heating and Refrigeration Institute www ari org www ahrinet org ANSI American National Standards Institute ASHRAE American Society of Heating Refrigeration and Air Conditioning Engineers...

Page 13: ...nd loudness dBA Sound level measurement that has been adjusted based on how the human ear perceives sounds in the air DC Bus High DC voltage simultaneously connected to multiple compressor components...

Page 14: ...eration and is typically due to a loss of power Harmonics Harmonics are multiples of the fundamental frequency distortions found in electrical power subjected to continuous disturbances HFC Hydrofluor...

Page 15: ...magnetic bearings Line Reactor A transformer like device designed to introduce a specific amount of inductive reactance into a circuit When this occurs it limits the change in current in the line whic...

Page 16: ...se in temperature results in a rise in resistance ohms ODF Outside Diameter Flare OEM Original Equipment Manufacturer PCB Printed Circuit Board PLC Programmable Logic Controller Pressure Ratio See Com...

Page 17: ...the compressor cannot sustain the discharge pressure allowing refrigerant to temporarily and rapidly re enter the compressor fluid path creating a cavitating effect This is an undesirable situation t...

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

Page 19: ...Additionally the Series indicators not have an additional character in order to differentiate the standard compressors from high lift compressors Unless the compressor is a high lift design an S will...

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

Page 21: ...all chiller system components exposed to refrigerant should be approved by their manufacturer for use with that refrigerant 2 3 Environment The compressor should not be operated at an altitude higher...

Page 22: ...exposed metals For outdoor installations a weather proof enclosure with vents is recommended to house the compressor l TTS TGS TTH TGH compressors can operate below 1 C ambient if refrigerant circuit...

Page 23: ...nent magnet synchronous motor powered by pulse width modulating PWM voltage supply The high speed variable frequency operation that affords high speed efficiency compactness and soft start capability...

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Page 25: ...ge impeller The centrifugal force produced by the rotating impeller results in an increase in both gas velocity and pressure The high velocity gas discharging from the impeller is directed to the seco...

Page 26: ...electromechanical components refer to Figure 3 3 Compressor Cooling Circuit TGS230 TTS300 and Figure 3 4 Compressor Cooling Circuit TTS300 Split Cooling TGS310 TTS350 TGS390 TGS490 TTS400 TTS700 and...

Page 27: ...GS230 use a split cooling method where the motor and electronics portions are cooled separately by refrigerant liquid Figure 3 3 Compressor Cooling Circuit TGS230 TTS300 Table 3 3 Compressor Cooling C...

Page 28: ...plit Cooling TGS310 TTS350 TGS390 TGS490 TTS400 TTS700 and TGS520 No Description No Description 1 From Motor Winding Temp Sensor 7 From Inverter Temp Sensor 2 BMCC 8 SCR 3 Solenoid M 9 Motor Rotor Coo...

Page 29: ...peller 2nd Stage 14 Inverter Temp Sensor 7 Radial Bearing 15 PRV pressure regulating valve 8 Stator Rotor 3 3 Inlet Guide Vanes The Inlet Guide Vane IGV assembly is a variable angle guiding device tha...

Page 30: ...ard l BMCC l Bearing PWM Amplifier l Backplane l Serial Driver l HV DC DC Converter Figure 3 6 Compressor Control System Functional Block Diagram 3 4 1 Motor Drive System Normally AC power to the comp...

Page 31: ...rrent at startup 3 4 3 Bearing Motor Compressor Controller The hardware and software for the compressor controller and the bearing motor controller physically reside in the BMCC The BMCC is the centra...

Page 32: ...Serial Driver module performs serial to parallel conversion on the stepper motor drive signals from the BMCC The module also contains four normally open relays under BMCC control Two of the relays dr...

Page 33: ...nd magnetic bearing PWM Amplifier respectively 3 5 Magnetic Bearing System 3 5 1 Overview A rotating shaft under changing load conditions will experience forces in both radial and axial directions In...

Page 34: ...al bearing assemblies The front sensor ring contains sensors that read the rotor position along the X Y and Z axes The rotor position along the Z or axial axis is read by measuring the distance betwee...

Page 35: ...ry point for control wiring from the chiller plant to the compressor Refer to Figure 4 1 Typical Control Wiring Figure 4 2 Modbus Grounding Diagram for the proper Compressor I O Board connectivity Fig...

Page 36: ...izer Input from a level sensor to control the auxiliary expansion valve economizer Demand 0 10V Analog input from customer supplied controller to drive the compressor i e 0 max kW input with a deadban...

Page 37: ...or connected to the Entering Chilled Water analog input LEAVE Install the jumper if there is no temperature sensor connected to the Leaving Chilled Water analog input JP5 JP6 Jumpers J5 and J6 are use...

Page 38: ...ther end An extension cable is available from your local supplier An optional 10 meter 32 8 ft cable is also available in the Spare Parts Selection Guide NOTE If an I O extension cable is used heat sh...

Page 39: ...ry area free from vibration and electrical noise NOTE The UL listed enclosure should protect against moisture and other corrosive elements Figure 4 4 Compressor I O Board 4 3 1 Compressor I O Board Mo...

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Page 41: ...arm Fault kPa g PSIG kPa g 2 PSIG3 TGS230ST 1239 180 1299 188 TGS230MT 1116 162 1176 171 TGS310 1240 180 1300 189 TGS490 1240 180 1300 189 TGS390 876 127 926 134 TGS520 876 127 926 134 TGH285 1510 218...

Page 42: ...TGS230MT TGS310 TGS490 TGS390 TGS520 TGH285 TTS300ST TTS300MT TTS350 TTS400 TTS700 TTH375 Alarm 4 4 5 2 5 2 3 5 3 5 6 3 4 4 5 2 3 5 3 5 6 3 Fault 5 2 5 2 5 5 5 5 4 4 6 5 5 2 5 2 5 5 4 4 6 5 The TGS23...

Page 43: ...ise ships floating platforms Danfoss Turbocor compressors are produced for civilian use and are not intended for safety critical systems Misapplication of a Turbocor compressor will not be covered und...

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Page 45: ...inal rated voltage defined on the compressor nameplate will result in voiding of the compressor warranty from Danfoss LLC unless otherwise stated by Danfoss LLC This includes any application of a 400V...

Page 46: ...400V 50 210 55 231 50 55 TGS490 460V 50 180 55 198 50 55 TGS520 380V 50 149 55 165 50 55 TGS520 400V 50 142 55 158 50 55 TGS520 460V 50 123 55 137 50 55 TGS520 575V 50 99 55 110 50 55 TGH285 380V 50 1...

Page 47: ...poor power factor and higher full load current Refer to Figure 20 9 Typical Electrical Connections for interconnection details 6 5 Motor Insulation Class All TTS TGS TTH TGH Series compressors have a...

Page 48: ...use of the nature of your application and or installation an alternative component with the same attenuation characteristics must be used to maintain compliance with the EMC Directive It is the respon...

Page 49: ...ions The rule of selecting the Line Reactor is PReactor_Rated kW LRA A URated V 1 73 0 9 1000 6 11 Harmonic Current Filtering IEEE 519 If it is necessary to provide additional current harmonic reducti...

Page 50: ...rate Use metal cable glands for shielded cables l The wire loom going to the panel door should be shielded using a metal braided hose that is connected to ground at both ends l Electrical panel must h...

Page 51: ...ground The cable must be rated for 90 C 194 F minimum at the maximum applicable current It is recommended that the cable be double jacketed e g teck cable type Refer to Table 6 4 Main Cable Connector...

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Page 53: ...2 Tolerance of Performance Ratings The CPR rating conditions are based on flange to flange and do not take into effect any line pressure drops or piping inconsistent with the guidance in the manual C...

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Page 55: ...s where operation at SST condition limits above those specified and rated for a particular variant but operation may be limited by the maximum ambient temperature around the compressor the saturated d...

Page 56: ...wn and is related to the FLA rating of the particular compressor The lower limit is related to minimum pressure ratios required to effect proper motor and power electronics cooling with standard refri...

Page 57: ...ated to the FLA rating of the particular compressor The lower limit is related to minimum pressure ratios required to effect proper motor and power electronics cooling with standard refrigerant circui...

Page 58: ...ated to the FLA rating of the particular compressor The lower limit is related to minimum pressure ratios required to effect proper motor and power electronics cooling with standard refrigerant circui...

Page 59: ...ted to the FLA rating of the particular compressor The lower limit is related to minimum pressure ratios required to effect proper motor and power electronics cooling with standard refrigerant circuit...

Page 60: ...d to the FLA rating of the particular compressor The lower limit is related to minimum pressure ratios required to effect proper motor and power electronics cooling with standard refrigerant circuit c...

Page 61: ...to the FLA rating of the particular compressor The lower limit is related to minimum pressure ratios required to effect proper motor and power electronics cooling with standard refrigerant circuit com...

Page 62: ...d to the FLA rating of the particular compressor The lower limit is related to minimum pressure ratios required to effect proper motor and power electronics cooling with standard refrigerant circuit c...

Page 63: ...to the FLA rating of the particular compressor The lower limit is related to minimum pressure ratios required to effect proper motor and power electronics cooling with standard refrigerant circuit com...

Page 64: ...to the FLA rating of the particular compressor The lower limit is related to minimum pressure ratios required to effect proper motor and power electronics cooling with standard refrigerant circuit com...

Page 65: ...ted to the FLA rating of the particular compressor The lower limit is related to minimum pressure ratios required to effect proper motor and power electronics cooling with standard refrigerant circuit...

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Page 67: ...the minimum stable load is dependent on the pressure ratio imposed on the compressor by the chiller system All compressor performance including unloading should be determined through use of the relev...

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Page 69: ...he main EXV in order to desuperheat the gas prior to entering the suction of the compressor CAUTION If the staging valve is used as a LBV there are two major risks l Check valve chattering if the bypa...

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

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Page 73: ...by regulating the motor speed In case of power failure the compressor shall be capable of allowing for a normal de levitation and shutdown Compressor speed shall be reduced as condensing temperature a...

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Page 75: ...e and efficiency EXV capacity should be selected accordingly Thermal expansion valves TXVs are not recommended due to the general inability of these devices to adequately cover the operating spectrum...

Page 76: ...age www turbocoroem com The circuit must be properly designed to reflect the specified heat exchanger approach with minimized pressure drops across the liquid side and expansion side Piping design inc...

Page 77: ...h the compressor and must be installed external to the compressor between the main suction line and the motor electronics cooling outlet port adjacent to the inter stage port The valve has a Solder OD...

Page 78: ...sed compressor speed and capacity at pressure ratios below 1 5 To ensure adequate cooling for extended operation with pressure ratios below 1 5 the chiller system must provide the subcooled refrigeran...

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

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

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

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

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

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

Page 86: ...ng Schematic Using Motor Cooling Pressure Regulating Valve TTH TGH Medium Temperature Compressors Only NOTE l Service valves are optional l Closed type economizer shown open type can also be used Page...

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

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

Page 89: ...damage to the compressor NOTE All TGH TTH compressors MUST include an active economizer flash or plate style when operated at pressure ratios above 2 0 If an economizer is not active at pressure ratio...

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

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

Page 92: ...00 76 5 76 7 1000 70 5 70 6 1250 66 2 66 9 1250 82 3 83 0 1600 69 9 71 0 1600 72 6 73 9 2000 69 6 70 9 2000 73 3 74 7 2500 68 6 69 9 2500 72 8 74 3 3150 72 3 73 6 3150 75 3 76 7 4000 71 3 72 3 4000 74...

Page 93: ...ear scale dB A weighted dBA 160 51 65 160 55 70 200 49 67 200 50 62 350 60 70 250 61 70 315 60 68 315 62 69 400 64 71 400 65 75 500 63 65 500 62 66 630 78 79 630 76 79 800 80 81 800 78 80 1000 83 82 1...

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Page 95: ...3 kg 315 lbs 132 kg 291 lbs TTS400 TGS390 788 mm 31 02 518 mm 20 4 487 mm 19 17 142 kg 312 lbs 130 6 kg 288 lbs TTS700 TGS520 788 mm 31 02 518 mm 20 4 487 mm 19 17 144 kg 318 lbs 132 kg 294 lbs TTH375...

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

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

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

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

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

Page 101: ...th of Center of Gravity m in YL 151 mm 5 95 153 1 mm 6 03 152 mm 5 97 150 mm 5 91 159 9 mm 6 29 Height of Center of Gravity m in ZL 215 mm 8 464 227 1 mm 8 94 227 mm 8 94 227 mm 8 94 241 05 mm 9 49 Co...

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

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

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

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

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

Page 107: ...d Torque Nm Suction M16 34 5 75 Discharge M10 20 32 Economizer M10 20 32 CAUTION Refer to the manufacturer fastener specifications and torque as required but do not exceed the torque values listed in...

Page 108: ...6 4 53 DC Capacitors and Bleed Resistors 2 1 18 Inverter Mounting Fasteners 6 4 53 Schaeder Valves 13 10 115 Motor Cooling Body Body Nut E Housing and Later 25 18 221 Motor Cooling Compression Nut E...

Page 109: ...in the motor cooling line NOTE Some applications may require alternative arrangements Contact Danfoss LLC Applications for further assistance if required CAUTION The discharge line must be fitted wit...

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Page 111: ...on the suction valve piping and the end cap as this is where condensation is most likely to form It is recommended to fit an End Cap insulator in a humid environment NOTE The End Cap insulator is not...

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Page 113: ...the flexibility of the compressor s isolation mounts compressor vibration during transit can fracture the motor cooling line s rigid piping Danfoss LLC Applications suggests the temporary installation...

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Page 115: ...to protect it from damage Two eyebolts one at each end are provided for compressor rigging A spreader bar should be used to safely position the compressor into its final location refer to Figure 20 1...

Page 116: ...d longitudinal planes NOTE If isolation pads are used at the four mounting base points the overall height of the compressor will change Be sure to measure accordingly based on the insulator used 1 If...

Page 117: ...uipment on the unit are compatible with the appropriate refrigerant DANGER The motor cooling line should be channeled from the liquid line Figure 20 5 Motor Cooling Connection and Access Port The moto...

Page 118: ...rear of the compressor This connection is a 1 2 inch O ring face seal connection Figure 20 5 Motor Cooling Connection and Access Port 5 Perform a leak test evacuation and charge according to industry...

Page 119: ...Connections 20 6 2 Circuit Grounding Improper grounding or voltage in circuits connected to the compressor I O board can lead to component failures In particular the interlock and analog output circui...

Page 120: ...n the compressor I O board Figure 20 7 Interlock and Motor Speed Connections 20 6 3 Voltage Free Contacts Prior to connecting the interlock terminals of the compressor I O board measure the resistance...

Page 121: ...with a common shield and single ground It is recommended that the cable be double jacketed for example a teck cable type The cable must be rated for 90 C 194 F minimum with a maximum current rating co...

Page 122: ...mains input bracket 3 Fasten the cable gland to the bracket with the locknut 4 Feed the AC input cable through the cable gland 5 Attach the ground cable to the ground post on the compressor housing 6...

Page 123: ...nals for the descriptions of the items shown in Figure 20 11 Compressor AC Input Terminals and Figure All TTS TGS TTH TGH Models Revision H Except TTS300 TGS230 Table 20 2 Compressor AC Input Terminal...

Page 124: ...of the Terminal Block Adapter TTS300 and TGS230 only is 18 mm therefore the maximum wire diameter must not exceed that size 10 Tighten the gland nut to secure the cable to the mains input bracket 11 S...

Page 125: ...the panel wall Ensure there is good electrical mechanical contact between the ground cable and the panel wall 5 Secure the AC line cable to the main supply panel using approved methods e g cable gland...

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Page 127: ...e B 2 Grounding Diagram NOTE A short heavy stranded conductor from the filter chassis to the main ground bus is recommended for top performance A battery braid litz wire or flexible welding cable with...

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

Page 129: ...ap Lift 2 Use an appropriately sized hex wrench to turn the setting screw Turn three 3 complete revolutions counterclockwise Figure C 2 Hex Wrench 3 Remove the Schrader valve cap and then the Schrader...

Page 130: ...mponents of the valve do not point the flame towards the center body portion of the valve Refer to Figure C 4 Brazing Connections Figure C 4 Brazing Connections 8 Once cooled Re install the Schrader v...

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

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Page 133: ...Turbocor Training class Scan the code to see our schedule and register today 78 years of combined service and applications knowledge Practical classroom courses Hands on compressor demonstrations Serv...

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Page 135: ...he app that match the problems exhibited by the compressor being serviced The app will then list potential causes solutions to the problem and service literature to reference for further information T...

Page 136: ...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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