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Danfoss Turbocor Twin-Turbine TTS Series, Applications And Installation Manual

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Danfoss Turbocor Twin-Turbine TTS Series Applications And Installation Manual Download Page 1

Danfoss Turbocor® 

Twin-Turbine

 

Centrifugal Compressors

TTS/TGS/TTH/TGH Compressors

Applications and Installation Manual - Revision Q

http://turbocor.danfoss.com

 ® 

Summary of Contents for Turbocor Twin-Turbine TTS Series

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

Page 2: ...ev Q List of Changes Revision Date Page Description of Change P 06 12 2019 Redevelopment of manual to include TTH TGH compressors P 1 12 12 2019 Update to include TG490 and Medium Temp Q 04 06 2020 Ma...

Page 3: ...n Pressure Limits 37 5 5 Standards Compliance 37 Chapter 6 0 Electrical Specifications 39 6 1 Supply Voltage and Frequency 39 6 2 Compressor Current Limit and Operating Range Settings 39 6 3 Disconnec...

Page 4: ...cations 75 15 1 TTS300 and TTS400 Sound Power Measurements 75 Chapter 16 0 Physical Data 79 16 1 Clearance 79 16 2 Torque Specifications 92 Chapter 17 0 Piping Considerations 93 Chapter 18 0 Environme...

Page 5: ...ceptable Frequency Range 39 Table 6 3 FLA and LRA Value Range 40 Table 6 4 Main Cable Connector Plate Hole Sizes 44 Table 13 1 Recommended Minimum Copper Tube Size 61 Table 13 2 Low Lift Pump Sizing 6...

Page 6: ...ation Piping Schematic Using Motor Cooling Pressure Regulating Valve TTH TGH Medium Temperature Compressors Only 70 Figure 14 7 Typical Refrigeration Piping Schematic With Multiple DX Evaporators 71 F...

Page 7: ...Figure 20 7 Interlock and Motor Speed Connections 104 Figure 20 8 Interlock Circuit Tests 105 Figure 20 9 Typical Electrical Connections 106 Figure 20 10 Ground Post Nuts 106 Figure 20 11 Compressor A...

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Page 9: ...indirect special 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...

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Page 11: ...to the following sections 1 Overview of the TTS TGS series compressors provides an overview of the Twin Turbo and Total Green TTS and TGS series compressors including an introduction to the compressor...

Page 12: ...h if not strictly observed could result in serious damage or destruction of equipment WARNING CAUTION Indicates an essential operating or maintenance procedure practice or condition which if not stric...

Page 13: ...itions Compression Ratio The absolute discharge pressure divided by the absolute suction pressure CSA Canadian Standards Association www csa ca DC Bus High DC voltage simultaneously connected to multi...

Page 14: ...ent power to sustain safe and normal operation and is typically due to a loss of power Genlanolin A type of grease In certain climates where the dew point falls below the operating temperature of some...

Page 15: ...ic field and is also a parameter used to evaluate the strength of the permanent magnets of the shaft One practical application is to use this phenomenon to indirectly measure motor speed as well as es...

Page 16: ...st Bearing A bearing that absorbs the axial forces produced in a centrifugal compressor by the refrigerant pressure differential across the impeller Ton The basic unit for measuring the rate of heat t...

Page 17: ...re of the Type Code to the new structure Additionally the Series indicators not have an additional character in order to differentiate the standard compressors from high lift compressors Unless the co...

Page 18: ...m Temp KHK Listed Mains Plate Size character 10 1 Mains Plate 2 00 2 Mains Plate 2 48 3 Mains Plate 3 00 4 Mains Plate 3 50 I O Board Option character 11 S I O Board included with 5m cable M No I O Bo...

Page 19: ...the top side power electronics to ensure there are no signs of oxidation or any other signs of moisture or condensation Ensure all covers are in place and secured The Danfoss Turbocor compressors hav...

Page 20: ...ics portion manages the refrigerant compression process from the suction to the discharge including the inlet guide vane assembly Motor The motor portion contains a direct drive high efficiency perman...

Page 21: ...load conditions The first compression element the gas encounters is the first stage impeller The centrifugal force produced by the rotating impeller results in an increase in both gas velocity and pre...

Page 22: ...over The orifices cause the refrigerant to expand thereby lowering its temperature Both valves open in response to the temperature sensed in the motor and inverter From the outlet of the orifices the...

Page 23: ...or Cavity Temp Sensor From Motor Winding Temp Sensor Motor Rotor cooling gas and leakage BMCC From Inverter Temp Sensor Inverter SCR ORIFICE ORIFICE Solenoid E Solenoid M Liquid Refrigerant Inlet BMCC...

Page 24: ...trol Overview Refer to Figure 3 6 Compressor Control System Functional Block Diagram which shows a functional block diagram of the compressor control and monitoring system Refer to Figure 3 8 Magnetic...

Page 25: ...acitors are charging up The soft start function and the variable speed drive combined limit the inrush current at startup Backplane 2 3A Calibra on Front Radial Bearing Rear Radial Bearing Axial Beari...

Page 26: ...erall pressure ratio and thereby reduces the lift enabling the compressor to reduce speed unload 3 4 7 Motor Bearing Control The magnetic bearing system physically supports a rotating shaft while enab...

Page 27: ...ow except for the alarm LED which is green red Table 3 1 Backplane LEDs describe the LEDs functions Table 3 1 Backplane LEDs 3 4 13 High Voltage DC DC Converter DC DC converters supply and electricall...

Page 28: ...Y and Z axes The rotor position along the Z or axial axis is read by measuring the distance between the sensor and a target sleeve mounted on the rotor The rear sensor ring contains sensors that read...

Page 29: ...XV Phase 2B EXV 2 Economizer or load balancing valve Level Sensor 15V Sensor Signal 1 5Volts Level Sensor 0V Level Sensor 15V Sensor Signal 1 5Volts Level Sensor 0V Level Sensor 1 Evaporator Level Sen...

Page 30: ...d REF Shield REF 120 PLC COM NETB NETA MODBUS Retain Termination Jumper in Last Board Remove Termination Jumper in All Intermediate Boards Termination Resistor should only be included if one is not in...

Page 31: ...rsal analog output manually controlled as a percentage of total voltage written through Modbus This can be configured for 0 5V or 0 10V via on board jumpers Entering Chilled Water Temp Analog input in...

Page 32: ...must not be grounded as this would create a ground loop Refer to Figure 4 2 Modbus Grounding Diagram on page 30 4 2 Interface Cable The cable that carries the I O communication to the compressor is 5...

Page 33: ...should be mounted in a dry area free from vibration and electrical noise Figure 4 4 Compressor I O Board 4 3 1 Compressor I O Board Mounting Instructions 1 Tilt the I O Board as shown in Figure 4 5 Co...

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Page 35: ...Trip Limit It is also controlled by a Pressure Ratio alarm limit monitoring the ratio between the Discharge and Suction Pressures Table 5 1 Discharge Pressure Alarm and Trip Settings In the TGS230 TT...

Page 36: ...00 compressor allows for adjustment of this setting Compressors which are placed in Air Cooled applications can have this value increased up to 4 8 NOTE Pressure ratio must be calculated using absolut...

Page 37: ...nditions 5 5 Standards Compliance It is the responsibility of the Original Equipment Manufacturer OEM to ensure that proper safety protocols are in place and that the chiller system has been designed...

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Page 39: ...TS TGS Compressor Nomenclature section of this manual for details on the compressor voltage availability Table 6 2 Acceptable Frequency Range 6 2 Compressor Current Limit and Operating Range Settings...

Page 40: ...0 400V 40 106 44 117 40 44 TGS230 460V 40 99 44 110 40 44 TGS230 575V 40 79 44 88 40 44 TGS310 380V 50 150 55 165 50 55 TGS310 400V 50 150 55 165 50 55 TGS310 460V 50 135 55 145 50 55 TGS390 380V 50 1...

Page 41: ...t be done using the FLA of the affected compressor to the next highest amp but in any event should be a minimum of FLA x 1 25 Fast acting fuses must be installed as close as possible and immediately b...

Page 42: ...ation of the line reactor should be according to Figure 20 9 Typical Electrical Connections on page 106 The rule of selecting the Line Reactor is PReactor_Rated kW FLA A URated V 1 73 0 9 1 25 1000 6...

Page 43: ...ground in accordance with relevant electrical codes and standards such as NEC Section 250 in the U S or its equivalent for other countries Special filtering and measuring may be required in installati...

Page 44: ...tion of 45 W Model 380V 400V 460V 575V TTS300 TGS230 2 5 2 5 2 5 2 5 TTS350 TGS310 2 5 2 5 3 N A TTS400 TGS390 2 5 2 5 3 3 TGS490 2 5 2 5 3 N A TTS700 TGS520 2 5 2 5 3 N A TTH375 TGH285 2 5 2 5 3 N A...

Page 45: ...en operating conditions This tolerance band is valid for the area of the operating map which is in the speed control range only As the compressor reduces speed and mechanical unloading is enabled such...

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Page 47: ...ating is lower than that shown 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...

Page 48: ...and TGS230 Medium Temperature Compressor 1 1 The actual obtainable capacity will be dependent on specific operating characteristics of each compressor model Refer to the current authorized compressor...

Page 49: ...er than that shown 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 wit...

Page 50: ...than that shown 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 s...

Page 51: ...LA settings The maximum SDT for compressors with an FLA less than that is lower than the upper bound of the operating envelope and depends on the FLA rating 1 The actual obtainable capacity will be de...

Page 52: ...settings The maximum SDT for compressors with an FLA less than that is lower than the upper bound of the operating envelope and depends on the FLA rating 1 The actual obtainable capacity will be depen...

Page 53: ...e nature of centrifugal compression the minimum stable load is dependent on the pressure ratio imposed on the compressor by the chiller system All compressor performance including unloading should be...

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Page 55: ...staging valve must be injected downstream of the main EXV in order to de superheat the gas prior to entering the suction of the compressor CAUTION If the staging valve is used as load balancing valve...

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Page 57: ...7 of 114 M AP 001 EN Rev Q Chapter 11 0 Product Certification All TTS TGS TTH TGH Series compressors are ETL and CE listed and have been tested in accordance with UL Standard 984 and CSA Standard C22...

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Page 59: ...ed by position sensors to provide real time repositioning of the rotor shaft controlled by onboard digital electronics 12 4 Capacity Control The compressor shall have a Variable Frequency Drive VFD fo...

Page 60: ...e 12 6 1 Ancillary Devices A check valve shall be installed on the discharge port of all compressors to protect against backflow of refrigerant during coast down It is recommended that the valve be lo...

Page 61: ...larly at low compression ratios 5 Take all necessary precautions to prevent any possibility of liquid floodback to the compressor This means consideration during the ON and OFF cycles particularly in...

Page 62: ...The circuit must be properly designed to reflect the specified heat exchanger approach with minimized pressure drops across the liquid side and expansion side Piping design including expansion device...

Page 63: ...t port is fitted with a 5 8 flare adapter NOTE Danfoss LLC highly recommends the insulation of the suction and inter stage pipe as well as the bottom of the compressor for MT applications to prevent i...

Page 64: ...pressure ratio due to high evaporator load conditions such as hot building start up can limit the maximum capacity of the centrifugal compressor If more capacity is desired it is advisable to raise t...

Page 65: ...er with Subcooler Evaporator Sight Glass Check Valve Expansion Valve Motor Cooling Port Suction Port Economizer Port Discharge Port Sight Glass Filter Drier Check Valve Refrigerant Pump Pressure Regul...

Page 66: ...oling Port Suction Port Economizer Port Discharge Port Sight Glass Sight Glass Filter Drier Filter Drier Evaporator Expansion Valve Expansion Valve Staging Valve Staging Valve Load Balancing Valve Loa...

Page 67: ...Economizer Motor Cooling Port Suction Port Economizer Port Discharge Port Sight Glass Filter Drier Evaporator Expansion Valve Sight Glass Economizer Tank Condenser with Subcooler Filter Drier Expansio...

Page 68: ...tic With Closed Type Economizer Motor Cooling Port Suction Port Economizer Port Discharge Port Sight Glass Filter Drier Evaporator Sight Glass Expansion Valve Condenser with Subcooler S Solenoid Valve...

Page 69: ...lating Valve TTS300 TGS230 Medium Temperature Compressors Only Motor Cooling Port Suction Port Economizer Port Discharge Port Sight Glass Filter Drier Expansion Valve Condenser with Subcooler Sight Gl...

Page 70: ...egulating Valve TTH TGH Medium Temperature Compressors Only Motor Cooling Port Suction Port Economizer Port Discharge Port Sight Glass Filter Drier Condenser with Subcooler Pressure Regulating Valve F...

Page 71: ...DX Evaporators Motor Cooling Port Suction Port Economizer Port Discharge Port Sight Glass Filter Drier Filter Drier Sight Glass Expansion Valve Expansion Valve Expansion Valve Evaporator Evaporator Ev...

Page 72: ...t Discharge Port Motor Cooling Port with integral strainer Suction Port Economizer Port Discharge Port Motor Cooling Port with integral strainer Suction Port Economizer Port Discharge Port Sight Glass...

Page 73: ...amage to the compressor NOTE All TGH TTH compressors MUST include an economizer flash or plate style If an economizer is not provided significant instability should be expected and the operating range...

Page 74: ...r Port Discharge Port Sight Glass Sight Glass Filter Drier Filter Drier Condenser with Subcooler Filter Drier Filter Drier Filter Drier Expansion Valve Expansion Valve Sight Glass Sight Glass Check Va...

Page 75: ...TTS400 Compressor presents the results of sound pressure calculations for various distances while the compressor is installed on top of a building Disclaimer The sound data below should be used as a g...

Page 76: ...315 68 7 62 0 315 69 9 63 4 400 66 9 62 3 400 66 6 62 2 500 71 5 68 6 500 65 7 62 6 630 60 2 58 4 630 71 8 69 8 800 65 1 64 5 800 67 7 67 2 1000 76 5 76 7 1000 70 5 70 6 1250 66 2 66 9 1250 82 3 83 0...

Page 77: ...A weighted dBA Third octave band Hz Linear scale dB A weighted dBA 160 51 65 160 55 70 200 49 61 200 50 62 250 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 63...

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Page 79: ...1 02 788mm 20 4 518mm 19 17 487mm 318 lbs 144 kg 135 6 kg 299 lbs 133 4 kg 294 lbs TTH375 TGH285 36 7 932mm 23 2 590mm 19 17 487mm 400 lbs 181 kg 166 kg 366 lbs 163 7 kg 361 lbs 16 1 Clearance Adequat...

Page 80: ...nt view Scale 1 2 MOTOR COOLING FITTING SIZE 1 2 SWEAT CONNECTION Discharge Port 229 7 9 04 TT300 TG230 220 2 8 67 TT350 TT400 TT500 TT700 TG310 TG520 O RING GROOVE OD 88 9 3 49 WIDTH 4 1 0 16 ID 80 7...

Page 81: ...TH TGH Suction Side View Figure 16 5 TTH TGH Service Side View Front view Scale 1 2 79 996 3 15 8 5 0 9 6 3 3 5 705 5 27 78 4 8 7 2 3 1 9 1 8 484 35 19 07 560 55 22 07 272 49 10 73 2 0 3 1 8 3 1 7 5 1...

Page 82: ...ischarge Side View Front view Scale 1 1 150 5 9 300 11 81 360 14 17 3 1 6 1 1 2 4 4 4 8 7 2 3 1 9 1 8 220 8 66 589 56 23 21 O RING GROOVE OD 88 9 3 499 WIDTH 4 1 0 1614 ID 80 7 3 177 O RING GROOVE OD...

Page 83: ...TTH TGH Compressors Figure 16 9 Center of Gravity Top View Excluding TTH TGH Compressors 150 66 5 93 8 7 3 4 3 4 4 2 9 0 4 4 1 1 4 3 220 2 8 67 3 8 1 1 5 Z L 2 2 7 1 8 9 4 167 6 57 787 30 98 Rear view...

Page 84: ...or Side View Figure 16 11 TTH TGH Center of Gravity Top View Left view Scale 1 2 2 8 9 7 5 1 1 4 1 705 7 27 78 2 4 1 0 5 9 4 9 Z L Center of Gravity view Scale 1 2 182 3 7 18 484 35 19 07 1 5 0 5 9 1...

Page 85: ...ection Guide for further details Figure 16 12 Discharge Port Detail TTS300 and TGS230 Description Parameter TTS300 TGS230 TGS490 TTS350 TGS310 TTS400 TGS390 TTS700 TGS520 TTH375 TGH285 CG LINE Length...

Page 86: ...86 of 114 M AP 001 EN Rev Q Figure 16 13 Discharge Port Detail TTS350 and TGS310 Figure 16 14 Discharge Port Detail TTS400 and TGS390 Gas Flow Gas Flow...

Page 87: ...87 of 114 M AP 001 EN Rev Q Figure 16 15 Discharge Port Detail TTS700 TGS490 and TGS520 Figure 16 16 Discharge Port Detail TTH375 and TGH285 Gas Flow 72 075 2 84 36 1 41 2 65 1 90...

Page 88: ...88 of 114 M AP 001 EN Rev Q Figure 16 17 Suction Port All Models...

Page 89: ...89 of 114 M AP 001 EN Rev Q Figure 16 18 Suction Port Detail DD All Models Excluding TTS700 and TGS520 Figure 16 19 Suction Port Detail DD TTS700 TGS490 and TGS520 Gas Flow Gas Flow...

Page 90: ...90 of 114 M AP 001 EN Rev Q Figure 16 20 TTS300 and TGS230 Flange Footprint Details Figure 16 21 TTS350 TGS310 TTS400 TGS390 TTH375 and TGH285 Flange Footprint Details...

Page 91: ...ead Spec Thread Depth mm Recommended Torque Nm Suction M16 34 5 75 Discharge M10 20 32 Economizer M10 20 32 WARNING Refer to the manufacturer fastener specifications and torque as required but do not...

Page 92: ...r and Sensor Feedthroughs 5 4 44 Cavity Sensor E Housing and Later 13 10 115 SCR Mounting Screws 7 5 62 A C Bus Bars 6 4 53 DC Capacitors and Bleed Resistor 2 1 18 IGBT Mounting Screws 6 4 53 Shraeder...

Page 93: ...n of a sight glass and full flow liquid dryer in the motor cooling line NOTE Some applications may require alternative arrangements Contact Danfoss LLC for further assistance if required CAUTION The d...

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Page 95: ...nsate Insulation should be installed 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 environme...

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Page 97: ...ue to the flexibility of the compressor s isolation mounts compressor vibration during transit can fracture the motor cooling line s rigid piping Danfoss LLC suggests the temporary installation of an...

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Page 99: ...compressor 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...

Page 100: ...ng base points the overall height of the compressor will change Be sure to measure accordingly based on the insulator used 1 If isolation pads are used install four 4 pads in accordance with the footp...

Page 101: ...anking plates Isolation and recovery of the refrigerant must be performed by a qualified technician Always wear proper safety equipment when handling refrigerants Refer to Figure 20 5 Motor Cooling Co...

Page 102: ...trol Wiring Details on page 31 provides details for the module terminal connections CAUTION Incorrect wiring of the terminals can severely damage the module and other components The interface cable co...

Page 103: ...103 of 114 M AP 001 EN Rev Q Figure 20 6 Compressor I O Board Connections Interface Cable Compressor I O Board...

Page 104: ...shield terminal on the compressor I O board refer to Figure 20 7 Interlock and Motor Speed Connections If the measured voltage is not zero 0 determine the source of the voltage The most likely cause o...

Page 105: ...l Connections on page 106 20 7 Power Wiring This section describes the connection of the power wiring to the compressor Figure 20 9 Typical Electrical Connections on page 106 shows a typical schematic...

Page 106: ...minals on page 107 Continue to Step 8 for TT300 TG230 compressors For all other TTS TGS compressors continue to Step 9 Figure 20 10 Ground Post Nuts 8 The three 3 compression lugs on the TTS300 TGS230...

Page 107: ...ssor 12 Replace the mains input cover and secure it the fasteners Seal Bracket Opening TTS300 TGS230 Compressors All TTS TGS TTH TGH Models Prior to Revision H Except TTS300 TGS230 Upper Nut Jam Nut M...

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Page 109: ...panel using approved methods e g cable gland A 1 2 AC Line Cable Connection to Compressor Terminal 1 Feed the AC line cable through the opening in the side of the main supply panel 2 Attach the AC lin...

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Page 111: ...de Connection 1 Insert the load wires instead of the line side of the line reactor into the terminals labeled L1 L2 and L3 on the Load side of the filter Tighten the terminal screws 2 Attach the groun...

Page 112: ...112of114 M AP 001 EN Rev Q Figure B 2 Grounding Diagram Grounding Diagram Filter Ground Lug Short Heavy Braided Cable Main Ground Bus...

Page 113: ...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 referen...

Page 114: ...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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