Danfoss Turbocor VTT Series Page 123 Service Manual Download

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123 of 165

M-SV-VT-001-EN Rev. A

Compressor Components

Figure 156 - Rear Feed

Through Removal

Rear Bearing Sensor

Feed Through

Rear Bearing Power

Feed Through

10. Remove the four (4) screws that secure the Axial Bearing Assembly.
11. Insert four (4) 6 mm jacking screws to aid in the removal of the Axial Bearing Assembly. This will

be required due to the magnetic force keeping the assembly in place. Once the magnetic force

decreases, gently slide away the Axial Bearing Assembly away from the Compressor.

• • • CAUTION • • •

All magnetic parts should be separated and placed in individual bags that can be sealed to prevent

contamination to the parts. Metal debris can and will lead to premature failure of the Compressor

components.

Location for Jacking

Screw (4 places)

Figure 157 - Axial Bearing

Assembly Jacking Screw

Locations

NOTE

For clarity, all wire harnesses were removed from Figure 157 (Axial Bearing Assembly Jacking Screw

Locations).

Summary of Contents for Turbocor VTT Series

Page 1: ...Danfoss Turbocor Variable Twin Turbo VTT Series Compressors VTT Series Compressors Service Manual http turbocor danfoss com ...

Page 2: ...THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 3: ...ergy and Signal Flow 21 Compressor Components 25 3 1 Component Identification 25 3 2 External Components 30 3 2 1 IFV Pipe Assembly 30 3 2 1 1 Removal and Installation 30 3 2 1 2 IFV Pipe Assembly Verification 31 3 2 1 3 Torque Specifications 31 3 2 2 IFV Actuator 31 3 2 2 1 Removal and Installation 32 3 2 2 2 Programming Required 33 3 2 2 3 Calibration 34 3 2 2 4 Torque Specifications 34 3 2 3 IC...

Page 4: ...val and Installation 69 3 4 1 2 Torque Specifications 69 3 5 1 Front Bearing Power and Sensor Feed Throughs 70 3 5 1 1 Removal and Installation 70 3 6 1 Rear Bearing Power and Sensor Feed Throughs 70 3 6 1 1 Removal and Installation 71 3 7 1 VTT Service Electronics Assembly 72 3 7 1 1 Removal and Installation 73 3 7 1 2 CCM 74 3 7 1 2 1 CCM Function 74 3 7 1 2 2 CCM Connections 76 3 7 1 3 CCM CIM ...

Page 5: ...VFD Control Card 133 4 2 1 VFD Card Connections 134 4 2 2 Removal and Installation 135 4 2 3 VFD Control Card Verification 135 4 2 4 Torque Specifications 135 4 3 VFD Orifice 136 4 3 1 VFD Orifice Specifications 136 4 4 VFD Valve 137 4 4 1 VFD Valve Specifications 137 4 5 VFD Pressure Control Valve Cable 138 4 5 1 VFD Pressure Control Valve Pin Connections 138 4 5 2 VFD Pressure Control Valve Remo...

Page 6: ...4 Table 16 Expected AC Voltage Range 57 Table 17 Motor Terminal Block Torque Specifications 57 Table 18 Tower Plate Torque Specifications 59 Table 19 Motor Power Feed Through Torque Specifications 62 Table 20 Stator Thermistor R T Curve 66 Table 21 Motor Power Cover Torque Specifications 69 Table 22 Terminal to Wire Color 84 Table 23 Front Bearing Sensor Pin Verification 86 Table 24 Rear Bearing S...

Page 7: ...onnector 39 Figure 30 Pressure Temperature Sensor Harness Retaining Clips 40 Figure 31 Pressure Temperature Sensor R T Curve 41 Figure 32 Economizer Blank 42 Figure 33 EXV Revision A Only 43 Figure 34 EXV Revisions B and Later 43 Figure 35 Actuator Coil Removal 44 Figure 36 Actuator Coil Installation 44 Figure 37 Opening Valve Manually 45 Figure 38 Brazing the EXV 46 Figure 39 EXV Cable 46 Figure ...

Page 8: ...nsor Cable 85 Figure 96 Front Bearing Sensor Connections 86 Figure 97 9 Pin Connector 87 Figure 98 Feed Through Connector 87 Figure 99 Rear Bearing Sensor Cable 87 Figure 100 Rear Bearing Sensor Connections 88 Figure 101 9 Pin Connector 89 Figure 102 Feed Through Connector 90 Figure 103 Motor Temperature Sensor Cable 90 Figure 104 CCM J12 Connection 91 Figure 105 Pulse Width Modulation Amplifier R...

Page 9: ...124 Figure 159 Thrust Disk Removal 124 Figure 160 Stator Cooling Temperature Sensor 125 Figure 161 Radial Bearing Mylar Insertion 125 Figure 162 Radial Bearing Screws 126 Figure 163 Radial Bearing Assembly Jacking Screw Locations 126 Figure 164 Radial Bearing Assembly Removal 127 Figure 165 Stator View 127 Figure 166 Thrust Disk Alignment Pins 128 Figure 167 Rear Bearing Sensor Feed Through 129 Fi...

Page 10: ...vity Revisions A and B 150 Figure 198 CIM Connectivity Revisions C and Later 150 Figure 199 Active Alarm Fault Viewer 151 Figure 200 Compressor Assembly 153 Figure 201 Compressor Power Cable Removal 154 Figure 202 Strain Relief 154 Figure B1 Volute Assembly Sleeve 161 Figure B2 Long Guide Pin 162 Figure B3 Short Guide Pin 162 Figure B4 Thrust Disk Alignment Pin 163 Figure B5 Shaft Bolt Torquing Pi...

Page 11: ...itness for a particular purpose In no event shall DTC be liable for direct 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 of such damages In particular DTC is not responsible for any costs including but not limited to those incurred as a result of ...

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Page 13: ... for servicing and does not provide part numbers of single products or single components If this information is required please contact a recognized Danfoss Turbocor original equipment manufacturer OEM customer 1 2 Organization This manual is organized in the following manner Section 1 Introduction this section describes the purpose of the manual its organization conventions used in the manual and...

Page 14: ...y precautions must be observed during installation start up and service of the compressor due to the presence of pressure and voltage hazards Only qualified and trained personnel should install start up and service Danfoss Turbocor compressors Safety information is located throughout the manual to alert service personnel of potential hazards and is identified by the headings DANGER and CAUTION 1 4...

Page 15: ...Mains Input power to the VFD 2 Lock Out Tag Out LOTO the mains disconnect to ensure no accidental or unauthorized re application of the Mains Input power can occur DANGER Do not touch any components when removing the either Motor Power Cover or the VFD Cover 3 Remove the Compressor Motor Power Cover only and the VFD cover 4 Using an appropriately rated voltage meter confirm that the AC voltage is ...

Page 16: ...ould only be removed from the ESD protective bag at the last moment just before installation when the operator is ready to do the replacement The operator should avoid touching any components or connectors on the module and should hold the module by its edge or enclosure as applicable 1 8 1 ESD Protection Grounding All parts that are susceptible to damage by ESD will be marked using the following ...

Page 17: ...eplacing any VTT O ring 1 Remove each O ring to be installed from its package and inspect for defects such as blemishes abrasions cuts or punctures 2 Slight stretching of the O ring when it is rolled inside out will help to reveal some defects not otherwise visible 3 After inspection and prior to installation lubricate the O ring with a light coat of Super O Lube 4 Avoid rolling or twisting the O ...

Page 18: ...18 of 165 M SV VT 001 EN Rev A THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 19: ...ict where the Compressor is operating within the aero map with respect to surge power thus commanding the IntraFlow Valve IFV to open or close to avoid surge Refer to Figure 6 IFV Flow for an illustration of the recirculation flow Figure 6 IFV Flow 2 2 Economizer The VTT Compressors are designed with an economizer input option The following are two 2 types of economizer arrangements that can be us...

Page 20: ...ted gate bipolar transistor IGBT temperatures indicate peak power requirements which activates additional refrigerant cooling when required The VFD module is equipped with cooling fans to provide airflow along the heat sink Units have a fan mounted in the enclosure door to provide additional airflow to the unit Each fan has tachometer feedback to the VFD Control Card to confirm that the fan is ope...

Page 21: ...des SCRs 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 charges the capacitors 5 The DC bus provides DC voltage to Inverter 6 The Inverter converts the DC bus voltage into a variable frequency 3 phase simulated AC voltage to the Stator 7 The VFD provides 462 683 VDC to the DC DC Module 8 The DC DC Module provides 24 VDC to ...

Page 22: ...22 of 165 M SV VT 001 EN Rev A Compressor Fundamentals Figure 9 System Architecture and Control Interface Revisions A and B Revisions A and B ...

Page 23: ...23 of 165 M SV VT 001 EN Rev A Compressor Fundamentals Figure 10 System Architecture and Control Interface Revisions C and Later Revisions C and Later ...

Page 24: ...24 of 165 M SV VT 001 EN Rev A THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 25: ...d if applicable The most recent revision of this Compressor Major Revision C allows for the use of some customer supplied cabling for the electronics For details on the required cable type and maximum length refer to the VTT Applications Manual 3 1 Component Identification This section identifies the major parts of the Compressor No Component No Component 1 Lift Anchor Front 7 Volute Second Stage ...

Page 26: ...ification Power Side 6 8 2 4 Table 2 Compressor Component Identification Power Side No Component No Component 1 Power Cover 5 Economizer Port 2 Motor Cooling Exit Port 6 P T Sensor Suction 3 Motor Cooling Electronic Expansion Valve EXV 7 Discharge Flange 4 Motor Cooling Inlet Port 8 P T Sensor Discharge 7 ...

Page 27: ...TT Service Electronics Module 8 Motor Cooling Valve Cable 2 Front Bearing Power Cable 9 Rear Bearing Sensor Cable 3 Front Bearing Power Feed Through 10 Rear Bearing Sensor Feed Through 4 Front Bearing Sensor Feed Through 11 Rear Bearing Power Feed Through 5 Front Bearing Sensor Cable 12 Rear Bearing Power Cable 6 Suction Discharge Pressure Temperature Sensor Cable 13 Motor Temperature Sensor Cable...

Page 28: ...mponent Identification Power Side Cover Off Table 4 Compressor Component Identification Power Side Cover Off No Component No Component 1 Motor Terminal Block 5 Bus Bar 2 Spacer Bus Bar 6 Motor Power Feed Through 3 Mains Input Bracket 7 Tower Plate 4 Ground Cable Stud 2 1 5 6 4 3 ...

Page 29: ...ompressor Sensors and Cables Topside No Component No Component 1 IFV Cables 3 EXV Cable 2 Discharge P T Sensor Cable 4 Suction P T Sensor Cable Table 5 Compressor Component Identification Power Side Cables Figure 16 Compressor Sensors and Cables Topside 1 2 2 1 3 4 ...

Page 30: ... clockwise rotation 4 Remove the three 3 set screws from the IFV Actuator base where it attaches to the Bonnet Function Module 5 Remove the IFV Actuator from the Bonnet Function Module 6 Loosen all eight 8 screws from the suction and discharge side of the IFV pipe assembly IFV Pipe Assembly ICM Bolts 100 Nm 74 ft lb 4 places ICM Adapter Valve Stem Bonnet Function Module O rings 2 places Flange Scr...

Page 31: ... When power is applied to the Compressor the IFV Actuator drives the valve fully closed and then to the start position 2 A warning will be generated if the IFV Actuator is unable to adjust the IFV position IFV Pipe Installation 1 Verify all contact surfaces are clean and dry If not clean with a lint free cloth 2 Lubricate the new O rings and place them on the IFV suction and discharge side flanges...

Page 32: ...al 1 Isolate the Compressor power as described in the Electrical Isolation of the Compressor VFD section of this manual 2 Disconnect the Red power and Black signal cables from the IFV by turning the collars located on the cable ends in a counter clockwise rotation 3 Using a 2 5 mm hex bit loosen the three 3 set screws that attach the IFV Actuator to the Bonnet Function Module 4 Remove the IFV Actu...

Page 33: ...he actuator is fully inserted with the wire connection ports facing up 3 Secure the IFV Actuator to the Bonnet Function Module using the three 3 set screws and a 2 5 mm hex bit Torque to specification 4 Attach the Red power and Black signal cables to the IFV by turning the collars located on the cable ends in a clockwise rotation 5 Restore power to the Compressor Figure 20 IFV Actuator Install 3 2...

Page 34: ...ton to select 5 13 Press the Enter Edit button 14 Hold the Enter Edit button for 2 seconds to exit the programming mode 3 2 3 ICM Body The ICM attaches to the IFV Pipe Assembly The driving force from the IFV is transferred via a magnetic coupling through the stainless steel valve stem on the Bonnet Function Module This action permits the regulation of the refrigerant flow to the inlet of the first...

Page 35: ...et Function Module O ring groove 5 Install the Guide Ring into the Bonnet Function Module groove 6 Lubricate and install the two 2 lower Bonnet Function Module O rings into their respective grooves 7 Install the Bonnet Function Module and install the four 4 hex bolts finger tighten only 8 Torque the four 4 hex screws in a crisscross pattern in two 2 stages Stage 1 Tighten to 50 Nm 37 ft lb Stage 2...

Page 36: ...tor with ICM valve 5 ICM Bonnet Gasket 3 O ring for bonnet function module 6 ICM Body Table 8 Bonnet Function Module O ring Descriptions 3 2 4 IFV Cable The IFV Cable provides a connection for power and communication between the CCM and the IFV Figure 24 IFV Cable Description Nm Ft Lb In Lb IFV Set Screws 3 27 Industrial Control Motor ICM Body Bolts 100 74 885 Table 9 ICM Body Torque Specification...

Page 37: ...ated on the cable ends in a counter clockwise rotation Figure 26 J14 CCM Board Connector J14 Connector Compressor Components 3 2 4 1 Removal and Installation Figure 25 IFV Cable Connection Power Cable Red Signal Cable Black 3 Remove the Compressor Service Side Cover 4 Locate J14 IFV Valve on the CCM Board and remove the connector Refer to Figure 26 J14 CCM Board Connector 5 Remove the cable from t...

Page 38: ...se rotation 2 Route the cable from IFV Actuator to the Compressor service side and attach it to the retaining clips 3 Plug the connector into J14 IFV Valve on the CCM Board 4 Ensure the connections are tight and secure 5 Replace the Service Side Cover 6 Restore power to the Compressor IFV Cable Retaining Clip IFV Cable Retaining Clip IFV Cable Retaining Clip 3 2 4 2 Verification 1 Verify proper fu...

Page 39: ...ble Harness Removal 1 Isolate the Compressor power as described in the Electrical Isolation of the Compressor VFD section of this manual 2 Remove the Service Side Cover 3 Unplug the cable harness connector from the suction and discharge sensors 4 Unplug the cable harness connector from J8 on the CCM Refer to Figure 29 J8 CCM Board Connector Figure 29 J8 CCM Board Connector 5 Remove the cable harne...

Page 40: ...ng Clip P T Sensor Harness Retaining Clip Installation Instructions 1 Plug the cable harness connector into the suction sensor and discharge sensor 2 Route the Pressure Temperature cable to the service side and attach it to the Compressor mounting brackets 3 Plug the cable harness connector into J8 on the CCM 4 Replace the Service Side Cover 5 Restore power to the Compressor ...

Page 41: ...erature values are as expected Refer to Figure 31 Pressure Temperature Sensor R T Curve below for both the Suction and Discharge sensors 4 If either sensor is found to be out of specification refer to the High and Low Pressure Temperature Sensors section of this manual regarding the replacement steps Figure 31 Pressure Temperature Sensor R T Curve 20 0 20 40 60 80 100 120 140 30 20 10 0 10 20 30 4...

Page 42: ...ith a lint free cloth 2 Lubricate the new O ring and place it onto the Compressor housing O ring groove 3 Using the four 4 M16 screws install the Economizer Blank Finger tighten and then tighten in a crisscross pattern in two 2 stages Stage 1 Tighten to 30 Nm 22 ft lb Stage 2 Tighten to a final torque of 100 Nm 73 ft lb 4 Leak test the Compressor to the appropriate pressure and industry standards ...

Page 43: ...s then used to cool the Rotor on the return to the exit via the airgap between the Stator and Rotor There are two 2 variants of the EXV both perform the same function but are not interchangeable due to the mounting flange design The O ring is identical between the two 2 variants Figure 33 EXV Revision A Only Figure 34 EXV Revisions B and Later Torque to 70 Nm 52 ft lb 4 places Torque to 30 Nm 22 f...

Page 44: ...il Removal 4 Disconnect the liquid line connection at the EXV 5 Remove the flange screws that attach the EXV to the Compressor housing Note the orientation of the valve assembly 6 Remove the O ring from the Compressor housing Figure 36 Actuator Coil Installation CAUTION Protect the valve from heat during installation 6 Re install the actuator coil onto the EXV assembly Refer to Figure 36 Actuator ...

Page 45: ...3 Remove the ETS6 manual coil or actuator coil 4 Wrap the valve in cool wet towels to help prevent excessive heat from damaging the valve 5 Using a MAPP and AIR mixture torch NOT MAPP gas and oxygen nor an Oxy Acetylene torch heat the shipping cap on the stub end of the valve until the solder becomes liquefied While the solder is still liquefied carefully remove the cap with pliers 6 Clean the now...

Page 46: ...r head and retaining clip if removed Figure 38 Brazing the EXV 3 2 7 4 Torque Specifications Description Nm Ft Lb In Lb Flange SHCS M14x40 Revision A 70 52 620 Flange SHCS M8x25 Revisions B and later 30 22 266 Table 11 EXV Torque Specifications 3 2 8 EXV Cable The EXV Cable connects the CCM to the EXV Figure 39 EXV Cable ...

Page 47: ... the Service Side Cover 3 Remove connector J15 EEV_MOT from the CCM Figure 40 CCM J15 Connector 4 Remove the Valve Actuator from the EXV on the discharge side of Compressor 5 Route the cable out of the service side 6 Release the cable from the retaining clip located underneath the Compressor Refer to Figure 36 EXV Cable Retaining Clip for the exact location of the clip Figure 36 EXV Cable Retainin...

Page 48: ... Gray 5 wire to each of the four 4 other wires 3 2 8 3 Running Check Figure 42 Cable Pinout for Continuity Resistance Verification 1 The valve resets to 0 when power is first applied to the Compressor 2 The valve opens to 15 for two 2 minutes at Compressor startup 3 While running it is controlled based on superheat temperature as refrigerant exits the motor 3 2 9 Motor Cooling Exit Flange The moto...

Page 49: ... VT 001 EN Rev A Compressor Components Figure 44 Motor Cooling Exit Flange Revisions B and Later Figure 43 Motor Cooling Exit Flange Revision A Only Torque to 70 Nm 52 ft lb 2 places Torque to 70 Nm 52 ft lb 4 places ...

Page 50: ...to the new O ring and then fit it into the O ring groove on the Compressor housing 3 Install the Motor Cooling Exit Flange not the shipping flange and tighten the flange screws evenly in a crisscross pattern Revision A only and torque to specification 4 Leak test the Compressor to the appropriate pressure and industry standards 5 Evacuate the Compressor to the appropriate pressure and industry acc...

Page 51: ... specification 4 Leak test the Compressor to the appropriate pressure and industry standards 5 Evacuate the Compressor to the appropriate pressure and industry accepted standards 6 Charge the Compressor with refrigerant 7 Restore power to the Compressor 3 2 10 2 Torque Specifications Description Nm Ft Lb In Lb Bottom Plug M16x2 70 52 620 Table 13 Bottom Plug Torque Specifications Bottom Plug 3 2 1...

Page 52: ...connection of the cables from the VFD to the Compressor motor There are two 2 variants of this cover as shown below The most noticeable difference is there are four 4 mounting screws for the A Revision while the later revisions have six 6 mounting screws Figure 46 Motor Power Cover Revision A Figure 47 Motor Power Cover Revisions B and Later Torque to 6 Nm 53 in lb 6 places ...

Page 53: ...aling surface of the cover 3 Place the cover over the motor power side 4 Install the screws to secure the Motor Power Cover and torque to specification 5 Restore power to the Compressor 3 3 1 2 Torque Specifications Description Nm Ft Lb In Lb Power Cover SHCS M5x16 6 53 Table 14 Motor Power Cover Torque Specifications 3 3 2 Mains Input Bracket The Mains Input Bracket provides support for the condu...

Page 54: ...et Mains Input Bracket Installation 1 Place the Mains Input Bracket into position 2 Install the screws to secure the Mains Input Bracket and torque to specification 3 Insert the cables through the Mains Input Bracket and push the conduit through exposing enough threads to attach the locknut s 4 Install the locknut s 5 Connect the six 6 motor power cables two 2 cables per phase 6 Install the three ...

Page 55: ...les to the Compressor motor This is the location where the Compressor receives 3 Phase AC voltage Refer to Figure 50 Motor Terminal Block to locate the AC voltage input to the motor Figure 50 Motor Terminal Block Bus Bar Mounting Screws Torque to 5 Nm 44 ft lb 6 places Power Cable Nuts Torque to 10 Nm 8 ft lb 3 places Copper Spacer Washer Lock Washer 3 places Terminal Block to Compressor Screws To...

Page 56: ...M5 screws and washers and torque to specification 3 Install the three 3 M16 brass nuts flat washers and lock washers from the Motor Tower Feed Through 4 Install the three 3 copper bus bars onto the studs on the terminal block 5 Install the three 3 copper spacers 6 Connect the six 6 motor power cables two 2 cables per phase 7 Install the three 3 M10 nuts flat washers and lock washers on the studs a...

Page 57: ... 10 8 89 Bus Bar Mounting SHCS M5x16 5 4 44 Ground Cable Nut M10x1 5 Brass 20 15 177 Table 17 Motor Terminal Block Torque Specifications Table 16 Expected AC Voltage Range 3 3 3 3 Torque Specifications 5 If the meter does not show any reading it is possible that there is no power from the VFD Measure again but this time verify the 3 phase output at the VFD 6 If the meter still does not show any re...

Page 58: ...te 5 Remove the plate and O ring Tower Plate Installation 1 Verify all sealing and internal surfaces are clean and dry If not clean with a lint free cloth 2 Clean the O ring groove 3 Ensure no parts tools or debris are left in the Motor Tower 4 Apply Super O Lube to the new O ring and then fit it into the O ring groove on the Compressor tower 5 Place the Tower Plate over Motor Tower with the writi...

Page 59: ...1 2 3 8 10 5 7 9 4 6 Description Nm Ft Lb In Lb Tower Plate SHCS M6x30 10 7 89 Table 18 Tower Plate Torque Specifications 3 3 4 2 Torque Specifications 3 3 5 Motor Power Feed Through The Motor Power Feed Through connects the Motor Bus Bars to the internal motor leads while preventing refrigerant pressure from escaping Figure 54 Motor Power Feed Through CAUTION Disassembling the Motor Power Feed Th...

Page 60: ... motor bus bar fasteners from the Motor Power Feed Through Stud Figure 55 Motor Power Feed Through mounted 6 Remove the terminal block assembly from the Compressor housing Refer to the Motor Terminal Block section of this manual 7 Remove the Tower Plate Refer to the Tower Plate section of this manual 8 Carefully remove the internal nuts and motor cables from the Motor Power Feedthrough 9 Remove th...

Page 61: ...r Feed Throughs and torque to specification 7 Perform a final verification that the motor cables are not touching each other or the Compressor housing 8 Ensure no parts tools or debris are left in Motor Tower 9 Ensure the sealing surface of the plate is clean and free of damage or debris 10 Clean the O ring groove 11 Apply Super O Lube to the new O ring and then fit it into the O ring groove on th...

Page 62: ...inding section of the motor is similar in design to a standard 3 phase star connected Stator Stator The Stator operates as the force that drives the shaft utilizing the high voltage HV DC pulses provided to the motor windings by the Inverter located in the VFD Rotor The Rotor is an integral part of the motor shaft and is a permanent magnet design that allows the synchronous characteristic required...

Page 63: ...ual 2 Remove the Motor Power Cover 3 Remove the three 3 M10 nuts and flat washers off the top of the copper spacers 4 Remove the motor power cables CAUTION A faulty Stator can cause the Inverter to fail 5 Using a mega ohm meter set for 1000 VDC measurements connect the red mega ohm meter lead to one of the three 3 Motor Bus Bars and the black mega ohm meter lead to the Compressor housing The measu...

Page 64: ... manual 2 Remove the Motor Power Cover 3 Remove the three 3 M10 nuts and flat washers off the top of the copper spacers 4 Remove motor power cables Protect isolate the cable ends 5 Using a multimeter set for resistance measurements and place the red multimeter lead on one of the three 3 motor bus bar posts and the black multimeter lead on another motor bus bar post and record the results The measu...

Page 65: ...black 7 Using a multimeter set for resistance measurements place the red multimeter lead on pin 1 and the black multimeter lead on pin 3 of the external connector and record the measurement 8 Perform the same resistance measurement for pins 2 and 4 of the external connector If the measured value does not correspond to the expected resistance then the internal connector must be checked in order to ...

Page 66: ... 190 1721 7 20 1077 9 110 1422 9 200 1758 6 30 1116 7 120 1460 7 Table 20 Stator Thermistor R T Curve 9 Verify resistance of each circuit at the external connector to housing ground Should be open 10 If the Stator Temperature Sensor Feed Through is suspected to have a problem remove it and test as above directly at the internal connector Refer to the Stator Temperature Sensor Feed Through section ...

Page 67: ... from the feed through Refer to Figure 61 Rear Bearing Sensor Feed Through for details on the location Figure 61 Rear Bearing Sensor Feed Through Rear Bearing Sensor Feed Through 3 Use a multimeter set to resistance verify the resistance of the circuit at the feed through Resistance should be measured between Pins 10 and 11and the measured value should be within 10 of the resistance values listed ...

Page 68: ...68 of 165 M SV VT 001 EN Rev A Figure 62 Stator Cooling Temperature Sensor Pinout 5 6 7 4 8 3 9 2 1 10 11 Pin 11 Pin 10 ...

Page 69: ...ht 8 M5x16 screws that hold the Service Side Cover in place 3 Remove the Service Side Cover Service Side Cover Installation 1 Verify all contact surfaces are clean and dry If not clean with a lint free cloth 2 Place the gasket on the sealing surface of the cover 3 Place the cover over the service side 4 Install the eight 8 M5x16 screws to secure the Service Side Cover 5 Restore power to the Compre...

Page 70: ...ressor Components Figure 64 Front Bearing Sensor Feed Through 3 5 1 1 Removal and Installation Front Bearing Power and Sensor Feed Through Removal Refer to the Front Bearings section of this manual The Rear Bearing Power Feed Through supplies power from the PWM to the front radial magnetic bearing actuators while keeping refrigerant pressure from escaping The Rear Bearing Sensor Feed Through suppl...

Page 71: ...re 66 Rear Bearing Sensor Feed Through Figure 67 Rear Bearing Power Feed Through Compressor Components 3 6 1 1 Removal and Installation Rear Bearing Power and Sensor Feed Through Removal Refer to the Rear Bearings section of this manual ...

Page 72: ...ions are not interchangeable Revisions A and B use Molex style connectors Figure 68 VTT Service Electronics Revisions A and B while C Revision and later Compressors utilize a mixture of terminal block style connectors and Molex connectors Figure 69 VTT Service Electronics Revisions C and Later When necessary the two 2 styles are pictured in this section Figure 68 VTT Service Electronics Revisions ...

Page 73: ...mpressor VFD section of this manual 2 Remove the Service Side Cover 3 Disconnect the power and communications cables from the CCM and PWM 4 Disconnect all cables going to the VTT Service Electronics Assembly 5 Remove the PWM heat sink fasteners and ground wires if applicable NOTE The various connections are illustrated throughout this section 6 Remove the fasteners that secure the Service Electron...

Page 74: ... EEPROM holds the parameter settings for the particular Compressor modules The flash memory holds the firmware and data storage for the logs Compressor Components 2 Attach the Service Electronics Assembly to the main housing using two 2 screws located at the heat sink but do not tighten Be sure to include the two 2 ground wires on the left and the one 1 250 VDC ground wire on the right 3 Install t...

Page 75: ...75 of 165 M SV VT 001 EN Rev A Figure 72 CCM Revisions C and Later Figure 71 CCM Revisions A and B Compressor Components ...

Page 76: ...ion bottom left J17 CIM Communication bottom middle J7 24 V DC Out to CIM and J11 Ground bottom right J10 and J6 Bearing Sensor Cables center right J1 ST RTD bottom right J14 IFV Valve bottom right J13 Economizer EEV if available lower right J8 Suction Discharge P T sensors mid right Figure 73 CCM Electrical Connections and Test Points Revisions A and B Test Point 1 Test Point 4 Test Point 2 Test ...

Page 77: ...5 CCM CIM 24V Cable Revisions C and Later 3 7 1 3 1 Removal and Installation Removal 1 Isolate the Compressor and VFD power as described in the Electrical Isolation of the Compressor VFD section of this manual 2 Remove the Service Side Cover 3 Locate J7 on the CCM Board and unplug the connector Figure 76 CCM J7 Connector Revisions A and B Figure 77 CCM J7 Connector Revisions C and Later J7 J7 ...

Page 78: ...nector NOTE There are two 2 variants of the CIM Revisions A and B do not contain the connector numbers e g J5 The Pin 1 indicators are also not present on the A and B revisions Installation 1 Route the new cable between the CCM and CIM 2 Insert the 24 VDC connector to the CIM 3 Insert the 24 VDC connector into J7 on the CCM Board 4 Replace the covers 5 Restore power to the Compressor 3 7 1 3 2 24 ...

Page 79: ...scribed in the Electrical Isolation of the Compressor VFD section of this manual 2 Remove the Service Side Cover 3 Disconnect the 24 VDC J16 and GND J24 connectors from the CCM Board Figure 81 J16 and J24 Revisions A and B J16 Connector J24 Connector 4 Remove 24 VDC J4 and GND J7 from DC DC Board Figure 82 J4 and J 7 Revisions A and B J7 Connector J4 Connector 5 Remove the cable between the CCM an...

Page 80: ... in the Electrical Isolation of the Compressor VFD section of this manual 2 Remove the Service Side Cover 3 Disconnect the J16 connector from the CCM Board Figure 83 J16 Revisions C and Later Figure 84 J4 Revisions C and Later J16 Connector 4 Remove J4 from the DC DC Board 5 Remove the cable between the CCM and the DC DC J4 Connector ...

Page 81: ... connector on DC DC Board at 24 VDC J4 4 Secure the cables in place 5 Install the Service Side Cover 6 Restore power to the Compressor 3 7 1 4 2 DC DC CIM 24V Cable Verification After power is applied to the Compressor ensure the LEDs on the CIM are illuminated and communication is established 3 7 1 5 CCM CIM Cable The CCM CIM Cable provides a connection for communication between the CCM and the C...

Page 82: ...Status 24VDC AUX P T SENSORS COMPRESSOR INTERFACE MODULE POWER CCM CAN USB I Lock Status RS485 2 J7 1 1 1 1 1 1 1 J6 J5 J4 J3 J2 J1 J2 Connector 4 Remove the Compressor Service Side Cover 5 Disconnect the J17 connector from the CCM Board Figure 88 J17 Revisions A and B Figure 89 J17 Revisions C and Later 6 Remove the cable between the CIM and the CCM Boards J17 Connector J17 Connector ...

Page 83: ...MT and enter the User ID and Access Code 2 Open the Warnings and Faults Tool 3 Verify that the CIM Compatibility CAN Communications and VFD Communications Faults are not active 3 7 1 6 CCM VFD Cable The VFD Cable provides a connection for communication between the CCM and the VFD Figure 90 CCM VFD Cable Revisions A and B Figure 91 CCM VFD Cable Revisions C and Later 3 7 1 6 1 Removal and Installat...

Page 84: ...from the CCM 4 Open the VFD front panel 5 Remove wires from terminals 61 68 69 12 and 19 J4 Connector Figure 94 Terminal Identification 6 Remove the cable 61 68 69 39 42 50 53 54 12 13 18 19 27 29 32 33 20 37 55 Wire Color Terminal Number Black 61 Green 68 White 69 Red 12 Blue 19 Silver Screw Table 22 Terminal to Wire Color ...

Page 85: ...CAN Communications and VFD Communications Faults are not active 3 7 1 6 2 CCM VFD Cable Verification 3 7 1 7 Front Bearing Sensor Cable Figure 95 Front Bearing Sensor Cable 3 7 1 7 1 Removal and Installation Removal 1 Isolate the Compressor power as described in the Electrical Isolation of the Compressor VFD section of this manual 2 Remove the Service Side Cover 3 Remove the 9 pin connector from J...

Page 86: ... Front Bearing Sensor Pin Verification for the resistance specifications Refer to Figure 97 9 Pin Connector for the pinout 2 If the results do no match the specifications listed remove the cable and check the resistances at the feed through Refer to Figure 98 Feed Through Connector for the pinout 3 If the results still do not match the listed specifications the feed through will need to be tested ...

Page 87: ...able The Rear Bearing Sensor Cable provides shaft position information from the Rear Bearing Sensor Feed Through to the CCM The Rear Bearing Sensor Cable also receives a signal from the Stator Cooling Temperature Sensor 5 6 7 4 8 3 9 2 1 10 11 5 2 3 7 8 4 9 6 1 Figure 97 9 Pin Connector Figure 98 Feed Through Connector ...

Page 88: ...Isolation of the Compressor VFD section of this manual 2 Remove the Service Side Cover 3 Remove the 9 pin connector from J10 on the CCM Board 4 Remove the Molex connector from J1 on the CCM Board 5 Twist and pull to remove the sensor cable connection from the feed through Compressor Components Figure 100 Rear Bearing Sensor Connections ...

Page 89: ...ted for continuity Refer to the Rear Bearings section for details on how to remove the feed through 3 7 1 8 2 Rear Bearing Sensor Cable Verification Table 24 Rear Bearing Sensor Pin Verification Pins Sensor Type Resistance 6 7 Radial 2 0 Ω to 3 5 Ω 6 8 Radial 2 0 Ω to 3 5 Ω 9 1 Axial 2 0 Ω to 3 5 Ω 1 4 Axial 2 0 Ω to 3 5 Ω 2 3 Radial 2 0 Ω to 3 5 Ω 3 5 Radial 2 0 Ω to 3 5 Ω 5 2 3 7 8 4 9 6 1 Figur...

Page 90: ...o the CCM 3 7 1 9 1 Removal and Installation Removal 1 Isolate the Compressor power as described in the Electrical Isolation of the Compressor VFD section of this manual 2 Remove the Service Side Cover 3 Locate and remove the connector from MOT RTD J12 located on the top left corner of the CCM Board 5 6 7 4 8 3 9 2 1 10 11 Compressor Components Figure 102 Feed Through Connector ...

Page 91: ...oint and verify the voltages at the test points listed in Table 25 CCM Test Point Values 3 7 1 9 2 Motor Temperature Sensor Cable Verification Table 25 CCM Test Point Values Test Point Number Test Point Voltage Value DC Voltage Range TP2 24 21 6 26 4 TP5 15 13 5 16 5 TP4 5 4 5 5 5 TP1 Ground 3 7 1 10 PWM 1 The PWM Board is mounted parallel to the CCM with a heat sink connected to the Compressor ho...

Page 92: ...ulse Width Modulation Amplifier Revisions A and B Figure 106 Pulse Width Modulation Amplifier Revisions C and Later Compressor Components J11 Connector Front Bearing Power Cable Rear Bearing Power Cable J11 Connector Front Bearing Power Cable Rear Bearing Power Cable ...

Page 93: ...power connection between the DC DC and the PWM Figure 107 250V DC DC PWM Cable Revisions A and B Figure 108 250V DC DC PWM Cable Revisions C and Later 3 7 1 11 1 Removal and Installation Removal Revision A and B Cables 1 Isolate the Compressor and VFD power as described in the Electrical Isolation of the Compressor VFD section of this manual 2 Remove the Service Side Cover 3 Disconnect the J11 con...

Page 94: ...nd J6 Connector Revisions A and B 8 Disconnect the 250V DC DC ground wire from the DC DC 9 Remove the cable from the DC DC panel Removal Revisions C and Later Cables 1 Isolate the Compressor and VFD power as described in the Electrical Isolation of the Compressor VFD section of this manual 2 Remove the Service Side Cover 3 Disconnect the J11 connector from the PWM J2 Connector J6 Connector Figure ...

Page 95: ...ontaining the DC DC 6 Disconnect the 250 V J2 connector from the DC DC Figure 112 DC DC J2 Connector Revisions C and Later J11 Connector J2 Connector Installation Revisions A and B 1 Route the cable into the service side 2 Secure the ground cable to the service side 3 Insert the connector to J11 on the PWM Board 4 Secure the cable where it enters the service side ...

Page 96: ... connector to J2 on the DC DC Board 7 Close the DC DC panel 8 Restore power to the Compressor 3 7 1 11 2 Verification 250V DC DC PWM Cable Verification 1 With power applied to the Compressor using a DC voltage meter verify the 250 VDC test points on the DC DC for correct voltage Place the negative test lead on 250 VDC and the positive test lead on 250 VDC 2 Place the negative test lead in the HV t...

Page 97: ...he HV test point of the PWM and negative lead in the first pin hole of the rear PWM Bearing Power Cable 5 The measured voltage drop should be 0 33 0 46 VDC 6 Repeat in a clockwise rotation for all the outer pin holes of the rear Bearing Power Cable and the 4 pins of the front Bearing Power Cable The center pin of the rear Bearing Power Cable does not have a test value 7 Place the negative test lea...

Page 98: ...ect validation to test bearing levitation control 4 Create and save a calibration report for records and review Description Nm Ft Lb In Lb Power Cover SHCS M5x16 6 53 Service Side Cover SHCS M5x16 6 53 Power Cable Nut Brass M10x1 5 10 8 89 Service Electronics Assembly fasteners 6 53 Service Electronics ground wires at left and 250 VDC ground wire at right 6 53 Table 26 Electronics Side Torque Spec...

Page 99: ...e section in this manual 4 Disconnect the Stator temperature sensor cable from CCM J12 5 Remove the Stator temperature sensor cable from the feed through 6 Remove the Service Electronics Assembly Refer to the VTT Service Electronics Assembly section in this manual 7 Refer to the Rear Bearings section of this manual regarding access to the internal connector 8 Remove the fasteners holding the Stato...

Page 100: ...twist lock support 6 Install the four 4 M5 screws holding the Stator Temperature Sensor Feed Through to the housing and tighten in a crisscross pattern in two 2 stages Stage 1 Tighten to 3 Nm 26 in lb Stage 2 Tighten to a final torque of 6 Nm 53 in lb 7 Install the Service Electronics Assembly 8 Connect the Stator Temperature Sensor Feed Through cable to CCM J12 9 Install the Service Side Cover 10...

Page 101: ... 53 Stator Temperature Sensor Feed Through SHCS M5x20 6 53 3 7 1 13 High and Low Pressure Temperature Sensors The high and low pressure temperature sensors Figure 122 High and Low Pressure Temperature Sensors are used to signal the operating pressures and temperatures at the suction and discharge ports to the CCM These values are used to calculate pressure ratios and saturated temperatures The hig...

Page 102: ...moval and Installation Installation 1 Check and clean the threads in the compressor housing 2 Verify all contact surfaces are clean and dry If not clean with a lint free cloth 3 Apply lube to new sensor O ring 4 Insert the sensor and engage the first few threads by hand 5 Using a deep socket tighten sensor and torque to specification 6 Reconnect the sensor connector 7 Leak test the Compressor to t...

Page 103: ... Pin Location 3 Compare the compressor pressure readout to the gauge pressure value 4 The values should not be greater than the following Suction Sensor 1 7psi 12kPa Discharge Sensor 7 25psi 50kPa Running Check 1 Connect to the compressor with the SMT 2 Compare pressure and temperature readout from compressor to readings from a calibrated gauge set and thermometer placed as close to the sensor loc...

Page 104: ...e Suction Housing See Figure 126 Suction Housing Cable Clamps 6 Carefully lay the IFV Cable harness over the rear of the compressor to prevent it from being damaged 7 Remove the cable harness from the pressure temperature sensor on the Suction Housing 8 Remove the retaining clip from the Suction Housing as shown in Figure 126 Suction Housing Cable Clamps 9 Carefully lay the pressure temperature se...

Page 105: ... to gain clearance for the Volute removal A 5x5 wood block under the rear foot and a piece of 6 u channel under the front This u channel needs to be 12 long with a 12 5mm hole drilled in the center There is a threaded hole under the compressor where the Volute meets the main compressor housing Fasten the u channel to the compressor with a 12mm bolt 2 5 inches long 12 Remove the screws at the 10 o ...

Page 106: ... Suction Cover Removed 13 Install the Short Guide Pins in these positions Refer to the Short Guide Pin example in Appendix B 14 Remove the remaining screws from the Suction Cover use four 4 of the removed screws for jacking screws 15 Locate the jacking screw holes on the flange and install the four 4 removed screws Tighten them evenly in a crisscross pattern This will slowly push the Suction Cover...

Page 107: ...12x55 screws located at the 10 and 2 o clock position on the End Cap 18 Insert the Short Guide Pins in these locations Refer to Figure 131 Guide Pin Locations 19 Remove the remaining screws and use a rubber mallet to tap off the End Cap 20 Gently slide the End Cap away from the compressor housing and set aside the End Cap End Cap Screws 70 Nm 52 ft lb 12 places ...

Page 108: ...o heat up the impeller First Stage Impeller Bolt 100 Nm 74 ft lb 21 Install three 3 Shaft Bolt Torquing Pins in the three 3 holes in the Axial Bearing Assembly It will be necessary to turn the shaft bolt on the front of the compressor in order to engage the pins These pins will then hold the shaft in place for the removal of the shaft bolt Refer to the Shaft Bolt Torquing Pin example in Appendix B...

Page 109: ...ctor and cap over the end of the compressor shaft Refer to the Volute Assembly Sleeve example in Appendix B This is also shown in Figure 134 Nylon Shaft Protector and Cap Figure 136 Nylon Shaft Protector and Cap Figure 135 First Stage Impeller Removal T Spacer First Stage Impeller Bolt Shaft Cap Shaft Sleeve ...

Page 110: ... Appendix B 27 Remove the remaining screws from the Volute use four 4 of these flange screws as jacking screws to push the Volute off the housing 28 Take a 3 strap with a clevis hook on one end and attach the clevis to the lifting eye on the Volute 29 Install the jacking screws into the Volute to push it off the housing being mindful of the nylon shaft cover to ensure it doesn t slide off when you...

Page 111: ...he impeller 30 Carefully lower the Volute to the floor 31 Remove the Second Stage Impeller This will require the use of a heat gun to heat up the impeller Do not use a torch 32 Remove the eight 8 screws and remove the front touchdown bearing labyrinth seal plate with the U Spacer Figure 139 Second Stage Impeller Removal Second Stage Impeller U Spacer Touchdown Bearing Labyrinth Seal Plate Screws 3...

Page 112: ...ms for order and orientation Failure to maintain the order of the shims could result in operability problems and in some cases damage to internal components Figure 142 Shim Example 33 Once all of the eight 8 screws have been removed insert four 4 of the removed screws into the Touchdown Bearing Labyrinth Seal Plate jacking screw locations Tighten them evenly in a crisscross pattern This will slowl...

Page 113: ...chdown bearing 35 Release the internal cable tie from the bearing sensor feed through cable 36 Disconnect the internal connectors from the Front Bearing Sensor Feed Through and the Front Bearing Power Feed Through 37 Disconnect the external bearing sensor cable from the feed through 38 Remove the eight 8 M5 screws holding the feed throughs to the housing 39 Carefully remove both feed throughs from...

Page 114: ...he O ring grooves 3 Carefully insert both feed throughs into the housing Reconnect the internal connectors Figure 145 Front Bearing Sensor Feed Through Figure 146 Front Bearing Power Feed Through Notch Notch 4 Install a new internal cable tie to secure the bearing sensor feed through cable 5 Install the eight 8 M5x20 feed through screws and tighten in a crisscross pattern in two 2 stages Stage 1 T...

Page 115: ...to the new O ring and then fit it into the Volute O ring groove 14 Verify that the nylon shaft cover and cap and the Long Guide Pins are still in place 15 Carefully move the Volute into place 16 Once in place install lock washers and flat washer on all 16 screws 17 Finger tighten all 16 screws until seated and then using the pattern in Figure 146 Volute Torque Pattern torque the fasteners in two 2...

Page 116: ...ction Housing and the Volute If not clean with a lint free cloth 21 Apply Super O Lube to the new O ring and then fit it into the O ring groove on the Suction Housing 22 Insert the Short Guide Pins in the 10 o clock 2 o clock and 6 o clock positions on the Volute 23 Carefully install the Suction Housing CAUTION Be sure to locate the Short Guide Pin at 3 o clock position to ensure the IFV pipe is l...

Page 117: ...s 40 Finger tighten all 12 screws and ensure that the End Cap is seated evenly into the Compressor housing 41 Tighten the 12 M5 screws in a crisscross pattern in two 2 stages Stage 1 Tighten to 35 Nm 25 8 ft lb Stage 2 Tighten to a final torque of 70 Nm 52 ft lb 42 Install the Service Side Cover 43 Connect the motor power cables 44 Install the three 3 M10 nuts and washers on the studs above the co...

Page 118: ...cation 1 Disconnect the PWM connector from the bearing power feed through 2 Verify bearing coil resistance at the feed through pins according to Table 29 Front Bearing Coil Resistance 3 Verify that the resistance of each pin to ground is open Table 29 Front Bearing Coil Resistance Bearing Identification Feed Through Pin Identification Expected Value Front Radial Coil 1 3 2 6 3 5 Ω 2 4 2 6 3 5 Ω No...

Page 119: ...ove them from the clamp located on the Suction Housing see Figure 126 Suction Housing Cable Clamps 10 Carefully lay the IFV Cable harness over the rear of the Compressor to prevent it from being damaged 11 Remove the cable harness from the pressure temperature sensor on the Suction Housing 12 Remove the retaining clip from the Suction Housing as shown in Figure 126 Suction Housing Cable Clamps 13 ...

Page 120: ...rews from the Volute use four 4 of these flange screws as jacking screws to push the Volute off the housing 32 Take a strap rated at a minimum of 136 kg 300 lbs with a clevis hook on one end and attach the clevis to the lifting eye on the Volute 33 Install the jacking screws into the Volute to push it off the housing being mindful of the nylon shaft cover to ensure it doesn t slide out when you pu...

Page 121: ...ar underneath the shaft and gently lower the shaft onto the Stator Figure 153 Guide Pin Locations Guide Pin Locations 2 Places 3 7 2 2 Rear Bearings Rear Compressor Disassembly 1 Remove the two 2 M12x55 screws located at the 10 and 2 o clock positions on the End Cap 2 Insert the Short Guide Pins in these locations refer to the Short Guide Pin example in Appendix B Refer to Figure 153 Guide Pin Loc...

Page 122: ...sor and Rear Bearing Power Harness Rear Bearing Power Feed Through Harness Connector Rear Bearing Sensor Feed Through Connector 6 Disconnect the external bearing sensor and power cables from the feed throughs 7 Remove the eight 8 M5 screws holding the feed throughs to the housing 8 Carefully remove both feed throughs from the housing Gently pull the internal connectors through the housing 9 Remove...

Page 123: ...rce keeping the assembly in place Once the magnetic force decreases gently slide away the Axial Bearing Assembly away from the Compressor CAUTION All magnetic parts should be separated and placed in individual bags that can be sealed to prevent contamination to the parts Metal debris can and will lead to premature failure of the Compressor components Location for Jacking Screw 4 places Figure 157 ...

Page 124: ...that secure the Thrust Disk and carefully slide the Thrust Disk off the Compressor shaft CAUTION All magnetic parts MUST be separated and placed in individual bags that can be sealed to prevent contamination to the parts Metal debris can and will lead to premature failure of the Compressor components Axial Bearing Screws 30 Nm 22 ft lb 4 places Thrust Disc Screws 10 Nm 89 in lb 3 places ...

Page 125: ...d lock washer that secure the Stator Cooling Temperature Sensor Figure 160 Stator Cooling Temperature Sensor 14 Insert two 2 pieces of Mylar between the Compressor shaft and the Rear Radial Bearing Assembly Figure 161 Radial Bearing Mylar Insertion Mylar Insertion Points Stator Cooling Temperature Sensor Screw 4 Nm 35 in lb ...

Page 126: ...ly Figure 162 Radial Bearing Screws Radial Bearing Screws Torque to 30 Nm 22 ft lb 4 places Figure 163 Radial Bearing Assembly Jacking Screw Locations Jacking screw locations 4 places 16 Insert the four 4 jacking screws into the jacking screw locations as indicated in Figure 163 Radial Bearing Assembly Jacking Screw Locations ...

Page 127: ...inue this until the Radial Bearing Assembly can be removed by hand 18 While supporting the shaft carefully slide out the Radial Bearing Assembly Figure 164 Radial Bearing Assembly Removal 19 Slide a small piece of Mylar underneath the shaft and gently lower the shaft onto the Stator 20 Disconnect the internal Stator harness connector and test as described in the Stator Thermistor Resistance Verifi...

Page 128: ...ation These pins are necessary due to the magnetized shaft 6 Carefully slide the Thrust Disk into place over the Compressor shaft and align it with the inserted pins 7 Remove all of the Thrust Disk Alignment Pins Figure 166 Thrust Disk Alignment Pins Thrust Disk Alignment Pin Locations 3 places 8 Insert the three 3 M5x35 screws that secure the Thrust Disk and torque to specification 9 Carefully sl...

Page 129: ...ide the End Cap into the Compressor housing 21 Assemble all 12 of the M12x55 screws with the flat and lock washers 22 Insert the screws in the available locations 23 Remove the two 2 Short Guide Pins and insert the remaining screws 24 Finger tighten all 12 screws and ensure that the End Cap is seated evenly into the Compressor housing 25 Tighten the 12 M5 screws in a crisscross pattern in two 2 st...

Page 130: ...power feed through 2 Verify bearing coil resistance at the feed through pins according to Table 30 Rear Bearing Coil Resistance Refer to Figure 169 Rear Bearing Power Feed Through Pin Identification 3 Verify that the resistance of each pin to ground is open Table 30 Rear Bearing Coil Resistance Bearing Identification Feed Through Pin Identification Expected Value Rear Radial Coil 1 3 2 6 3 5 Ω 2 4...

Page 131: ...hrough SHCS M6x20 6 53 Rear Bearing Sensor Feed Through SHCS M6x20 6 53 Stator Temperature Sensor Feed Through SHCS M6x20 6 53 End Cap SHCS M12x55 70 52 620 Axial Bearing Assembly SHCS M8x40 30 22 266 Stator Cooling Temperature Sensor SHCS M4x20 4 35 Thrust Disk SHCS M5x35 10 7 88 Radial Bearing Assembly SHCS M8x65 30 22 266 Table 31 Internal Components Torque Specifications 3 7 2 2 3 Torque Speci...

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Page 133: ...D information refer to the VFD Service Manual Figure 170 VFD A VFD is an electronic motor controller that converts DC into a variable AC waveform output The frequency and voltage of the output are regulated to control the motor speed or torque The VFD can vary the speed of the motor in response to commands from the CCM 4 2 VFD Control Card The VFD Control Card contains most of the logic section Th...

Page 134: ...cted to the CCM via an RS 485 cable Figure 172 RS 485 and Interlock Connection Details illustrates the connection to the VFD Control Card Refer to the VTT Service Electronics Assembly section for the details on the CCM connection Figure 172 RS 485 and Interlock Connection Details 61 68 69 39 42 50 53 54 12 13 18 19 27 29 32 33 20 37 55 VFD Control Card ...

Page 135: ...ntrol wiring terminal blocks located at bottom of the VFD Control Card 5 Remove the four 4 screws that hold metal cradle in to the card holder 6 Carefully pull the card off the metal retainer bracket The VFD Control Card has a plug on the backside that connects it to the ribbon cable Installation 1 Carefully attach card to the retainer bracket Be sure that the plug on the back of card is inserted ...

Page 136: ...e VFD orifice must be fitted to the VFD VFD module at the cold plate tube refrigerant inlet This orifice controls flow of refrigerant to the VFD module Figure 173 VFD Orifice Figure 174 Cold Plate Tubes 4 3 1 VFD Orifice Specifications Inlet 12 5 mm 1 2 OD Male Outlet 9 3 mm 3 8 OD Male ...

Page 137: ...nents 4 4 VFD Valve The VFD Valve must be fitted to the VFD at the cold plate tube refrigerant outlet This valve regulates refrigerant pressure and temperature Figure 175 VFD Valve 4 4 1 VFD Valve Specifications Inlet 16 mm 5 8 in Female Outlet 16 mm 5 8 in Female ...

Page 138: ...FD Pressure Control Valve Cable The VFD Pressure Control Valve Cable connects the CIM to the VFD Pressure Control Valve Motor Figure 176 VFD Pressure Control Valve Cable 4 5 1 VFD Pressure Control Valve Pin Connections Figure 177 VFD Pressure Control Valve Pin Identification ...

Page 139: ...ol Valve Cable from the CIM at J6 VFD Cooling The numbers referenced in Figure 180 CIM Revisions A and B Wire Diagram correspond to the numbers colors listed in Figure 178 VFD Pressure Control Valve M12 Connection Figure 179 CIM Revisions A and B J6 Connection J6 Connector NOTE A figure representing CIM Revision C is not shown The order of connectivity is the same between the two 2 revisions 5 Rem...

Page 140: ... J6 on the CIM 3 Secure the cable 4 Restore power to the VFD 1 2 4 3 Figure 180 CIM Revisions A and B Wire Diagram 4 6 VFD DC DC Cable The VFD DC DC Cable passes High Voltage DC from the VFD to the DC DC Figure 181 VFD DC DC Cable 4 6 1 Removal and Installation Removal 1 Isolate the VFD power as described in the Electrical Isolation of the Compressor VFD section of this manual 2 Open the panel con...

Page 141: ...nector 4 Disconnect the HV DC Ground cable from the DC DC Board 5 Remove the cover from the VFD 6 Disconnect the cables from Regen 82 and Regen 83 J12 Test Point Figure 183 VFD Regen 82 and Regen 83 7 Disconnect the HV DC Ground cable from the VFD 8 Remove the cable Regen Screw 19 Nm 14 ft lb Regen Screw 19 Nm 14 ft lb ...

Page 142: ...nnect power to the VFD Description Nm Ft Lb In Lb and Regen Screws M5 19 14 168 Table 34 Regen Cable Torque Specifications 4 6 2 VFD DC DC Cable Verification 1 Apply power to the VTT VFD 2 Verify the LEDs on CIM are on 3 On the DC DC using an appropriately rated voltage meter verify HV DC input is correct for the applied voltage by checking at VDC J12 and VDC J13 test points 4 The measured voltage...

Page 143: ...DC converter provides the compressor with 24V DC with respect to 0V and HV 250V DC with respect to HV for the bearing PWM amplifier The DC DC Converter receives a high voltage DC supply from the VFD module Figure 184 DC DC Revisions A and B Figure 185 DC DC Revisions C and Later ...

Page 144: ... VFD section of this manual 2 Open the panel containing the DC DC Verify the HV DC input from VFD is below 5 VDC by checking at VDC J12 and VDC J13 test points on DC DC with a DC voltage meter 3 Disconnect the HV DC input cable from J1 24 VDC output cable from J4 and 250 VDC output cable from J2 Refer to Figures 186 DC DC J1 Connection and J12 J13 Test Points and 2 DC DC J2 and J4 Connections Figu...

Page 145: ...solate the VFD power as described in the Electrical Isolation of the Compressor VFD section of this manual 2 Open the panel containing the DC DC Verify the HV DC input from VFD is below 5 VDC by checking at VDC J12 and VDC J13 test points on DC DC with a DC voltage meter 3 Disconnect the HV DC input cable from J1 24 VDC output cable from J4 and 250 VDC output cable from J2 Figure 188 DC DC J1 Conn...

Page 146: ...J7 4 Close the panel 5 Restore power to the VFD 4 Remove the securing hardware holding the DC DC frame to the panel 5 Remove the DC DC from the panel OEM Module Components Figure 189 DC DC J2 and 4 Connections J4 Connector J2 Connector Installation Revisions C and Later 1 Place the DC DC in panel and secure in place 2 Connect the HV DC input cable to J1 24 VDC output cable to J4 and 250 VDC output...

Page 147: ...four 4 new M4x35 screws along with the four 4 new flat and split washers 2 Mount the fan to the DC DC in the proper direction There is an arrow on the fan housing that should be pointing towards the DC DC Refer to Figure 191 Fan Orientation 3 Using a 3 mm hex bit attach the new fan to the DC DC with the new four 4 M4x35 screws and Figure 191 DC DC Fan Orientation Direction of Airflow torque to spe...

Page 148: ...rect for the applied voltage by checking at VDC J12 and VDC J13 test points The measured voltage should be at least 1 35 x the AC input voltage 5 Verify the 24 VDC output is correct by checking Pins 4 and 5 at J4 6 Verify the 250 VDC output is correct by checking Pins 1 and 2 at J2 J10 J2 Pin 2 J2 Pin 1 J4 Pin 4 J4 Pin 5 5 1 4 Torque Specifications 4 On the DC DC using an appropriately rated volta...

Page 149: ...t present on the A and B revisions Figure 194 CIM Revision C Shown Figure 195 CIM Faceplate Revisions A and B Figure 196 CIM Faceplate Revisions C and Later Comm Reset Fault Reset Fault Status EV TX STATUS RUN TX RX RX RS485 1 I Lock STAGING VFD COOLING CAN Status 24VDC AUX P T SENSORS COMPRESSOR INTERFACE MODULE POWER CCM CAN USB I Lock Status RS485 2 Comm Reset Fault Reset Fault Status EV TX STA...

Page 150: ...150 of 165 M SV VT 001 EN Rev A OEM Module Components Figure 197 CIM Connectivity Revisions A and B Figure 198 CIM Connectivity Revisions C and Later ...

Page 151: ...nual 2 Remove all terminal connectors from the original CIM leaving all wires connected to the screw terminals 3 Remove the CIM from the DIN Rail or other mounting method 4 Remove the DIN Rail clip or other mounting method from the CIM Installation 1 If used with the original CIM install the DIN Rail clip or other mounting method on the new CIM using the original hardware 2 Mount the new CIM in pl...

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Page 153: ... VFD power as described in the Electrical Isolation of the Compressor VFD section of this manual 2 Remove the Motor Power Cover 3 Remove the M10 nuts flat washers and lock washers off the top of the copper spacers 4 Remove the motor power cables Protect isolate the cable ends 5 Remove the three 3 copper spacers 6 Remove the ground wire from the ground post 7 1 Refrigerant Containment CAUTION Isola...

Page 154: ...ct the interface cables CIM DC DC and VFD Module to the relevant connection points on the CCM and PWM 11 Remove the strain relief from the compressor housing as shown in Figure 202 Strain Relief Figure 201 Compressor Power Cable Removal Figure 202 Strain Relief Power Cable Nuts Torque to 10 Nm 8 ft lb 3 places Copper Spacer Washer Lock Washer 3 places Ground Post Torque nut to 20 Nm 15 ft lb Compr...

Page 155: ...mately 25 50 psi with a nontoxic inert gas e g helium nitrogen for shipment this will prevent moisture and foreign material from entering the compressor NOTE Blanking plates should not be removed from the new compressor until you are ready to place the new compressor in position New compressors are pressurized with helium to 50 psi Pressure should be relieved through the Schrader valve located nex...

Page 156: ...Connect the interface cables CIM DC DC and VFD Module to the relevant connection points on the CCM and PWM 22 Reinstall the Service Side Cover DANGER Ensure that electrical power is isolated from the AC mains cables before handling them Compressor Removal and Installation 23 Remove the Motor Power Cover 24 Connect the cable gland that secures the power cable conduit to the Conduit Bracket 25 Insta...

Page 157: ...ce Side Cover SHCS M5x16 6 53 Power Cable Nut Brass M10x1 5 10 8 89 Ground Screw 6 53 Ground Cable Nut M10x1 5 Brass 20 15 177 Suction Flange SHCS M20x2 5 6 5 53 Discharge Flange SHCS M20 2 5 6 5 53 Economizer Flange SHCS M16x2 20 15 177 Motor Cooling Exit Flange SHCS M14x2 10 8 89 Motor Cooling Inlet Flange 5 4 44 Base Mounting SHCS M12x1 75 20 15 177 7 3 1 Torque Specifications ...

Page 158: ...158 of 165 M SV VT 001 EN Rev A THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 159: ...tor with Display ICM Industrial Control Motor IFV IntraFlow Valve IGBT Insulated Gate Bipolar Transistor kV Kilovolt LED Light Emitting Diode LOTO Lockout Tagout MAPP Methylacetylene Propadiene Propane MOT Motor NTC Negative Temperature Coefficient º C Degrees Celsius º F Degrees Fahrenheit OEM Original Equipment Manufacturer P T Pressure Temperature PWM Pulse Width Modulation R T Resistance Tempe...

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Page 161: ... Specifications R1 5 x 4 125 A 52 25 40 022 0 013 B 0 05 A B 0 10 UNLESS OTHERWISE SPECIFIED ALL DIMENSIONS ARE IN MILLIMETERS SURFACE FINISH 6 4 TOLERANCES WHOLE No s 0 5 ONE DECIMAL PLACE 0 1 2 DECIMAL PLACES 0 05 ANGULAR 0 5 Figure B1 Volute Assembly Sleeve ...

Page 162: ...IFIED ALL DIMENSIONS ARE IN MILLIMETERS SURFACE FINISH 6 4 TOLERANCES WHOLE No s 0 5 ONE DECIMAL PLACE 0 1 2 DECIMAL PLACES 0 05 ANGULAR 0 5 Figure B2 Long Guide Pin 120 84 20 12 R1 1 50 X 35 M12 x 1 75 A B 12 15 01 A B 005 UNLESS OTHERWISE SPECIFIED ALL DIMENSIONS ARE IN MILLIMETERS SURFACE FINISH TOLERANCES WHOLE No s 0 5 ONE DECIMAL PLACE 0 1 2 DECIMAL PLACES 0 05 ANGULAR 0 5 Figure B3 Short Gu...

Page 163: ...ng Specifications Figure B4 Thrust Disk Alignment Pin 5 0 85 0 22 1 R 1 0 7 5 7 6 REF Ø5 0 x 0 8 UNLESS OTHERWISE SPECIFIED ALL DIMENSIONS ARE IN MILLIMETERS SURFACE FINISH 6 4 TOLERANCES WHOLE No s 0 5 ONE DECIMAL PLACE 0 1 2 DECIMAL PLACES 0 05 ANGULAR 0 5 ...

Page 164: ...Special Tooling Specifications Figure B5 Shaft Bolt Torquing Pin 6 0 72 1 X 15 x 2 UNLESS OTHERWISE SPECIFIED ALL DIMENSIONS ARE IN MILLIMETERS SURFACE FINISH 6 4 TOLERANCES WHOLE No s 0 5 ONE DECIMAL PLACE 0 1 2 DECIMAL PLACES 0 05 ANGULAR 0 5 ...

Page 165: ... as distinct variable speed technology specialists Today we operate from engineering and manufacturing facilities spanning across three continents Danfoss Inverter Scrolls Danfoss Turbocor Compressors Danfoss Scrolls Danfoss Optyma Condensing Units Danfoss Maneurop Reciprocating Compressors M SV VT 001 EN Rev A Danfoss DCS CC 2017 06 Our products can be found in a variety of applications such as r...

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