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Danfoss Turbocor TT-300, Руководство по обслуживанию

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21 of 132

M-SV-001-EN Rev.E

Introduction

1. Install the DC bus test harness as described 
in the “Installation of the DC Bus Test Harness” 
section of this manual.

2. Reapply AC power to the compressor.

3. Using an appropriately rated voltmeter with 
the 1000VDC range selected, insert the positive 

voltmeter lead into the DC(+F) test harness lead, 
and the negative voltmeter lead into the DC(-) 
test harness lead. Refer to Table 2 (Expected DC 
Bus Voltage) for expected DC bus voltage.

The DC(+F) lead connects to the DC output from 
the F1 Fuse on the Soft Start Board.

4. Insert the positive voltmeter lead into the DC 
(+) test harness lead, and the negative voltmeter 
lead into the DC(-) test harness lead. Refer to 
Table 2 (Expected DC Bus Voltage) for expected 
DC bus voltage.

5. Measure the 15VAC from the Soft Start 
Board by placing the voltage meter leads into 
the 15VAC leads. The 15VAC leads connect to 
the 15VAC output from the Soft Start Board 

transformer.

The DC(+) lead connects to the DC bus input to 
the Soft Start Board.

6. When finished, isolate compressor power and 
remove the DC bus test harness.

1.9.2  DC Bus Test Harness 
Use

Table 2 - Expected DC Bus 

Voltage

Compressor Nameplate

AC Voltage

Acceptable AC Voltage Range

Expected DC Bus

Voltage Range

575 VAC

518 - 632 VAC

700 - 853 VDC

460 VAC

414 - 506 VAC

559 - 683 VDC

400 VAC

360 - 440 VAC

486 - 594 VDC

380 VAC

342 - 418 VAC

462 - 564 VDC

1. Isolate the compressor power as described 
in the “Electrical Isolation of the Compressor” 

section of this manual and remove the top side 
covers.

2. Remove the DC bus test harness from the cable 
passage.

3. Disconnect the two plugs of the DC bus test 
harness from the Soft Start Board.

4. Disconnect the two plugs of the compressor 
cable harness from the corresponding sockets of 
the DC bus test harness.

5. Reconnect the J1 and J7 connectors on the Soft 
Start Board.

6. Reinstall the top covers.

1.9.3  Removal of the DC 
Bus Test Harness

 • • • CAUTION • • •

Use your ESD wrist strap before touching the Soft Start Board or any electronic components.

Содержание Turbocor TT-300

Страница 1: ...Danfoss Turbocor Twin Turbine Centrifugal Compressors TT TG Series Compressors Service Manual http turbocor danfoss com...

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

Страница 3: ...C January 2017 All Major revision F compressor changes throughout the manual D August 2017 54 57 Added IGBT Control Card Replacement instructions E October 2017 15 97 123 124 Added R513A refrigerant...

Страница 4: ...4 of 132 M SV 001 EN Rev E THIS PAGE INTENTIONALLY LEFT BLANK...

Страница 5: ...ssor Fundamentals 22 2 1 Main Fluid Path 22 2 2 Motor and Power Electronics Cooling 22 2 3 Capacity Control 26 2 4 Compressor Energy and Signal Flow 26 Compressor Components 29 3 1 Component Identific...

Страница 6: ...ation 68 3 12 Solenoids and Actuators 68 3 12 1 Function 68 3 12 2 Connections 68 3 12 3 Verification 69 3 12 4 Removal and Installation 70 3 13 IGV 71 3 13 1 Function 71 3 13 2 Connections 71 3 13 3...

Страница 7: ...04 4 3 1 When to Calibrate the Bearings 104 4 3 2 Performing a Calibration 104 4 3 3 After Calibration is Complete 106 4 3 4 Create a Calibration Report 106 4 3 5 Calibration Report Analysis 107 4 4 C...

Страница 8: ...ndicators TT350 TT400 TT500 TT700 TG310 TG390 TG520 33 Table 9 Expected AC Voltage Range 39 Table 10 SCR Diode Values 45 Table 11 SCR Gate Resistance Ranges 45 Table 12 Backplane Test Point Values 66...

Страница 9: ...AC Input Voltage on the AC Input Terminals 38 Figure 27 Measuring 3 Phase AC Input TT300 TG230 Only 38 Figure 28 Terminal Block Bus Bars TT350 TT400 TT500 TT700 TG310 TG390 TG520 39 Figure 29 Termina...

Страница 10: ...gure 84 Front Bearing 4 Pin Orientation 86 Figure 85 Front and Rear Bearing Feed Throughs with Molex Connectors 87 Figure 86 Compressor Monitor Tool 87 Figure 87 Bearing Sensor Feed Throughs 88 Figure...

Страница 11: ...e provided AS IS without any warranty of any kind either express or implied including without limitation any implied warranties of condition uninterrupted use merchantability fitness for a particular...

Страница 12: ...12 of 132 M SV 001 EN Rev E THIS PAGE INTENTIONALLY LEFT BLANK...

Страница 13: ...his manual gives only general procedures for servicing and does not provide part numbers of single products or single components If this information is required please contact a recognized Danfoss Tur...

Страница 14: ...alified 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 i...

Страница 15: ...00 TG230 Before performing any service on the compressor electrical power must be isolated Before removing top side covers isolate the compressor power by completing the following steps 1 Turn off the...

Страница 16: ...tlines static control precautions that must be followed when providing service support in the field Service support personnel should create a safe static free environment Service personnel must use a...

Страница 17: ...tart Board clip the ESD strap ground clip to the mains plate Refer to arrow in Figure 5 Mains Plate and Ground Post 4 If you only need to remove the Service Side Cover clip the ESD strap ground to the...

Страница 18: ...ss is not designed to be left in the compressor during normal operation When checks are complete disconnect and remove the test harness Refer to Figure 8 DC Bus Harness Connection Diagram for a connec...

Страница 19: ...roximately 100k and the reading for the fuse should be 29 3 Remove the Service Side Cover 4 Install the ESD clip 5 Disconnect the J1 and J7 connectors on the Soft Start Board See Figure 9 Soft Start B...

Страница 20: ...le passage on either side of the HV DC DC Converter down into the service side See Figure 12 Cable Passage Figure 11 Connect Test Harness to Compressor Figure 12 Cable Passage DANGER The DC bus test h...

Страница 21: ...put from the Soft Start Board transformer The DC lead connects to the DC bus input to the Soft Start Board 6 When finished isolate compressor power and remove the DC bus test harness 1 9 2 DC Bus Test...

Страница 22: ...ser In the second stage impeller velocity energy is again added to the refrigerant and converted to the final discharge pressure in the discharge diffuser and volute From the second stage impeller ref...

Страница 23: ...rature or the motor temperature reaches its turn on point and solenoid 2 is opened if the Inverter or silicon controlled rectifier SCR temperature reaches its turn on point Medium temperature MT versi...

Страница 24: ...24 of 132 M SV 001 EN Rev E Compressor Fundamentals Figure 15 Compressor Motor and Power Electronics Cooling TT300 TG230 Serial Cooling...

Страница 25: ...25 of 132 M SV 001 EN Rev E Compressor Fundamentals Figure 16 Compressor Motor and Power Electronics Cooling All Models Except TT300 TG230 Serial Cooling...

Страница 26: ...operation Speed modulation is achieved by the use of Inverter control To accomplish this the incoming 3 phase AC supply is converted to high voltage DC incorporating smoothing storage capacitors and t...

Страница 27: ...C bus voltage from the SCRs charges the capacitors 5 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 Sta...

Страница 28: ...28 of 132 M SV 001 EN Rev E Compressor Fundamentals Figure 18 Compressor Energy and Control Flow Block Diagram...

Страница 29: ...upport Base 2 Cable Harness Sensor 13 Top Access Cover 3 Suction Pressure Temperature Sensor 14 Lift Anchor Rear 4 Inlet Guide Vanes IGV Suction Port 15 End Bell 5 IGV Position Indicator 16 Motor Cool...

Страница 30: ...00 TG230 No Component No Component 1 Compressor I O Board 7 Bearing Motor Compressor Controller BMCC 2 Soft Start Board 8 Bearing Pulse Width Modulation PWM Amplifier 3 Insulated Gate Bipolar Transist...

Страница 31: ...G230 No Component No Component 1 Discharge Temperature Pressure Sensor 6 Suction Temperature Pressure Sensor 2 Motor Winding Sensors 7 Inlet Guide Vanes IGV Position Indicator 3 Motor Cooling Solenoid...

Страница 32: ...tion Covers Off TT350 TT400 TT500 TT700 TG310 TT390 TT520 No Component No Component 1 Compressor I O Board 6 Serial Driver 2 Soft Start Board 7 Bearing Motor Compressor Controller BMCC 3 Insulated Gat...

Страница 33: ...50 TT400 TT500 TT700 TG310 TG390 TG520 No Component No Component 1 Discharge Temperature Pressure Sensor 5 Bearing Sensor Ring Cable 2 Motor Winding Sensors 6 Suction Temperature Pressure Sensor 3 Mot...

Страница 34: ...standards using dry nitrogen 10 Disconnect the compressor from the refrigerant system connections suction discharge economizer and motor cooling line taking care when removing connections that there i...

Страница 35: ...e compressor to appropriate pressure and industry accepted standards 19 Evacuate compressor to appropriate pressure and industry accepted standards 20 Charge the compressor with refrigerant 21 Apply p...

Страница 36: ...t be brazed into the braze sleeve 2 Remove pressure from compressor as per OEM standard procedure 3 Remove nut from connection fitting body Discard blanking disc Locate braze sleeve and clean Ensure r...

Страница 37: ...any reason clean the O ring fitting and housing threads and apply a small amount of O ring lube before reassembly The terminal block is the location where the compressor receives 3 Phase AC voltage ev...

Страница 38: ...rminals and Figure 27 Measuring 3 Phase AC Input Repeat for all AC input terminals Repeat on load side of the fuses TT300 TG230 only 4 Verify that the meter shows the expected AC measurement within th...

Страница 39: ...Range AC Input Nameplate Voltage Acceptable Voltage Range 575VAC 518 to 632VAC 460VAC 414 to 506VAC 400VAC 360 to 440VAC 380VAC 342 to 418VAC 1 Isolate the compressor power as described in the Electri...

Страница 40: ...ews from the terminal block adaptors and lift away the fuse assemblies and insulating Mylar See Figure 30 AC Input to SCRs TT300 TG230 5 Remove the screws that secure the terminal block to the casting...

Страница 41: ...Make note of the Soft Start Cable Harness locations See Figure 25 Main AC Input Terminal The Soft Start Board limits in rush current when power is applied to the compressor by progressively increasin...

Страница 42: ...If the 15VAC supply is not present at start up the DC DC converter will not function 1 Isolate the compressor power as described in the Electrical Isolation of the Compressor section of this manual 2...

Страница 43: ...position 2 Secure the screws that hold the mounting bracket to the compressor Tighten to 5Nm 3 6 ft lb 3 Connect the cable connectors to the Soft Start Board 4 Connect the Soft Start ground wire to t...

Страница 44: ...35 times that of the AC input voltage 460 900VDC See Figure 35 SCR Connections to locate the connections to the SCRs 1 AC input voltage to SCR 2 SCR Gate cables to Soft Start 3 SCR to DC bus Figure 3...

Страница 45: ...described in the Electrical Isolation of the Compressor section of this manual 2 Using needle nose pliers carefully remove the SCR gate cable harness from the SCRs 3 Using a multimeter set for resista...

Страница 46: ...igure 38 DC Bus Components Identification 5 Remove the screws that secure the SCRs to the cooling manifold 6 Lift off the SCRs from the cooling manifold and wipe clean the heat sink paste 1 Isolate th...

Страница 47: ...ure sensor into the SCR manifold 2 TT300 TG230 Only Lift the SCR manifold and route the SCR temperature sensor cable under the SCR manifold 3 TT300 TG230 Only Tighten the Inverter manifold screws 4 Co...

Страница 48: ...duce noise associated with the Inverter switching frequency Bleed resistors are used to discharge the capacitors after power is removed to allow the compressor to be serviced safely See Figure 38 DC B...

Страница 49: ...sured value should be 0 42 F to 0 52 F 1 Isolate the compressor power as described in the Electrical Isolation of the Compressor section of this manual 2 Remove the Soft Start and the Soft Start Cable...

Страница 50: ...TT400 TT500 and TT700 only 5 Remove main AC bus bars TG310 TG390 TG520 TT350 TT400 TT500 and TT700 only 6 Remove the screws that secure the DC bus bars to the SCRs TG310 TG390 TG520 TT350 TT400 TT500...

Страница 51: ...500 TT700 TG310 TG390 and TG520 only See right side of Figure 39 Soft Start Cable Harness to DC Bus 7 Install the main AC bus bars TT350 TT400 TT500 TT700 TG310 TG390 and TG520 only 8 Using needle nos...

Страница 52: ...4VDC and gating signals to the Inverter from the BMCC In return the Inverter sends current temperature error and DC bus voltage information to the BMCC via the Backplane Motor currents and voltages di...

Страница 53: ...ee Figure 44 Inverter Connections 7 Keeping the red multimeter lead on the phase 1 AC terminal place the black multimeter lead on the DC terminal The measured value should be open See Figure 44 Invert...

Страница 54: ...connect the motor bus bars to the Inverter Important Do not remove the screws that secure the Inverter to the compressor main housing 7 Unscrew the six 6 screws using a T15 Torx bit Begin on the outs...

Страница 55: ...are two 2 different length spring pins if any are replaced be sure to replace with the same length spring pin Figure 47 Long Spring Pin Locations identifies the location of the long spring pins all ot...

Страница 56: ...over the IGBT module with the connector towards motor stator output bus bar the shape of Driver Board must be aligned with IGBT Press Plate shape 7 Insert the screws into the corresponding Press Plat...

Страница 57: ...same se quence as previous step to 1 5 Nm 13 2 in lbs Figure 53 Final Torque NOTE It is recommended to verify Inverter functionality using an inverter tester prior to reassembly of the top side elect...

Страница 58: ...gerant Isolation and recovery of the refrigerant must be performed by a qualified service technician adhering to industry ASHRAE standards Figure 54 Removing the Inverter TT300 TG230 Shown 3 7 4 2 Inv...

Страница 59: ...to the total separation of the motor windings from the incoming 3 phase current by the DC conversion Therefore the bulk of protection is based on measurements taken by the Inverter and calculations d...

Страница 60: ...for resistance measurements place the red multimeter lead on one of the three motor bus bars and the black multimeter lead on another motor bus bar and record the results The measured value should be...

Страница 61: ...61 of 132 M SV 001 EN Rev E Compressor Components Figure 56 Stator Thermistor R T Curve 1...

Страница 62: ...ng PWM Amplifier DC bus voltage 460 900VDC is supplied to the HV DC DC converter through the Soft Start Board F1 fuse The Soft Start Board also powers the HV DC DC Converter with 15VAC when the DC bus...

Страница 63: ...DC DC Converter Connections The result should not be 0 0 The result can be open or 150k 4 Reverse the multimeter leads on the J1 plug terminals See Figure 57 DC DC Converter Connections The result sh...

Страница 64: ...e Inverter plate See Figure 59 HV DC DC Converter Removal 4 Plug in all connectors to the HV DC DC Converter 5 Install the Soft Start 3 10 Backplane 3 10 1 Function The Backplane is powered by 24VDC w...

Страница 65: ...ial Driver Connection Port J2 and J3 BMCC Connection Port J1 PWM Connection Port 0V Test Point 15V Test Point 24V Test Point 5V Test Point 15V Test Point J16 Motor Cooling Solenoids Control Port J17 S...

Страница 66: ...is functioning correctly NOTE The test point LEDs are ON if any voltage is present The test points must be measured to determine the actual voltage CAUTION The Inverter cable must be connected to the...

Страница 67: ...the Backplane All components that communicate with the Serial Driver are connected to the Backplane See Figure 60 Backplane Connections and Test Points 1 Remove the Service Side Cover 2 With main pow...

Страница 68: ...and or electronics cooling path The solenoid actuator coils control the opening and closing of the solenoids Solenoids are secured to the service side of the compressor housing in the upper left See F...

Страница 69: ...or Cooling Solenoid place the meter probes at Pins 1 and 3 of the cable connector See Figure 65 Motor Cooling Solenoid Cable Connector 7 To measure the resistance across the right Motor Cooling Soleno...

Страница 70: ...enoid actuator coils 6 Remove the solenoid body and cooling valve orifice 1 Lubricate a new O ring with O ring lubricant and install it on the valve 2 Insert the valve orifice and solenoid body in the...

Страница 71: ...connections 3 13 IGV 3 13 1 Function 3 13 2 Connections The IGV assembly consists of movable vanes and a motor The IGV assembly is a variable angle guiding device that is used to control the capacity...

Страница 72: ...he compressor 3 Open the Compressor Configuration tool Set the Compressor Control Mode to Manual Control by selecting Manual Control from the Compressor Control Mode drop down list 4 Open the Compress...

Страница 73: ...andards 6 Reconnect the cable at the feed through connector on the IGV Housing 7 Secure the connector clamp 8 Reconnect the suction sensor connector 4 Recover the refrigerant from the compressor 5 Dis...

Страница 74: ...to the Backplane b The I O cable connection between the Backplane and the Compressor I O Board is properly attached c The cable connection between the Compressor I O Board RS485 or RS232 and the user...

Страница 75: ...Calibration Figure 71 Compressor Interface Module Ports Figure 72 Compressor Interface Module Jumper Locations 3 15 Compressor Interface Module 3 15 1 Function 3 15 2 Connections The Compressor Interf...

Страница 76: ...when no sensor connected Refer to the Applications Manual for thermistor specifications J4 EXV 1 EXV 2 Control 15V output EXV1 Pin 6 to 9 EXV2 Pin 1 to 4 J5 Liquid Level input LIQ LEV 1 Pin 4 to 6 Liq...

Страница 77: ...he computer 3 Open the SMT software and select the Compressor Connection Manager tool See the Service Monitoring Tools User Manual for use instructions 4 Click Connect If the Compressor Connection Man...

Страница 78: ...rlock Status states Open the interlock circuit is damaged and the BMCC needs to be replaced 9 Isolate compressor power 10 Remove the J2 connector from the CIM 11 Using a multimeter for resistance meas...

Страница 79: ...sor I O Board Installation Figure 74 Bearing Control Signal Flow 3 16 Bearing Pulse Width Modulator Amplifier 3 16 1 Function The PWM Amplifier supplies current to the radial and axial magnetic bearin...

Страница 80: ...e differences The 6 pin wire connects to the rear left bearing power feed through The 4 pin wire connects to the front right bearing power feed through See Figure 75 Bearing Power Feed Throughs and PW...

Страница 81: ...kplane 2 Verify the bearing coil resistances are within specification 3 Verify the bearing sensor resistances are within specification 4 Perform a bearing calibration using the SMT To verify the diode...

Страница 82: ...ee Figure 78 Connecting Leads to PWM Connector and HV Test Point The measured voltage drop should be 0 39 0 46VDC 8 Repeat Step 5 for all 10 pin holes of both PWM connectors 9 If any of the test resul...

Страница 83: ...e 79 Removing the PWM Amplifier 7 Pull the bearing PWM amplifier from J1 of the Backplane Figure 79 Removing the PWM Amplifier 3 16 4 2 PWM Amplifier Installation 1 Check that the ground screw at the...

Страница 84: ...ft position within 0 0003 7 microns One axial Z axis and two radial X Y axis magnetic bearings are used to maintain shaft position See Figure 80 Radial Magnetic Bearings and Figure 72 Axial Magnetic B...

Страница 85: ...power 2 Remove the Service Side Cover verifying the Backplane LEDs have turned off 3 Remove the Serial Driver BMCC and PWM 4 Set multimeter for resistance checks 5 Test resistance on bearing power fee...

Страница 86: ...70 3 25 2 70 3 25 Axial Coil 3 4 5 70 6 20 TT300 TG230 only 6 00 6 70 TT400C E F TG390 only 6 00 6 70 Front Bearing Connector Front Radial Coil 1 2 2 70 3 25 4 70 5 20 3 4 2 70 3 25 4 70 5 20 Notes S...

Страница 87: ...s displayed are within the range defined in Table 15 Bearing Amperage Ranges during compressor operation Table 15 Bearing Amperage Ranges Bearing Position Force Range Axial Force 1 to 1 Amp Front X Fo...

Страница 88: ...the Bearing Sensor feed throughs located above the front and rear bearing power feed throughs See Figure 87 Bearing Sensor Feed Throughs The bearing sensor feed throughs are connected to the bearing s...

Страница 89: ...of the bearing sensor feed through is in question isolate the compressor recover the refrigerant remove the feed through and repeat the above steps directly at the internal sensor connector Figure 89...

Страница 90: ...tance between the Cavity Temperature Sensor terminals 1 and 3 See Figure 90 Cavity Temperature Sensor Terminal The Cavity Temperature Sensor is a 10K 77 F 25 C NTC thermistor The resistance value shou...

Страница 91: ...erature sensor See Figure 92 Cavity Temperature Sensor Removal 1 Skip this step for all compressors that are Major Revision E and later Apply a refrigerant safe thread sealant to the cavity temperatur...

Страница 92: ...e compressor power 2 Remove the Service Side Cover 3 Disconnect the pressure temperature cable clip SUCTION J18 or DISCHGE J19 from the Backplane board See Figure 93 Pressure Temperature Cable Termina...

Страница 93: ...of this manual 2 Isolate the compressor recover the refrigerant according to industry standards 3 Disconnect the sensor connector 4 Using a deep socket remove the sensor 1 Check and clean O ring hous...

Страница 94: ...ts will stop the compressor in 10 seconds or less See Table 18 Compressor Fault Types Table 19 Motor Fault Types and Table 20 Bearing Fault Types Table 17 Alarm Types Compressor Alarm Description Inve...

Страница 95: ...g fault type is present then the generic compressor fault is triggered This is not an actual fault only an indication that a motor or bearing fault has occurred Sensor Fault If the following measured...

Страница 96: ...s reading the data table from the EEPROM Generator Mode Active At greater than 0 RPM and DC bus voltage low Generator mode is enabled switching the Inverter to rectifier function to maintain the DC bu...

Страница 97: ...onfigure the electronic expansion valve configuration parameters and settings Logged Event and Fault Viewer Retrieve logged fault and event data history regarding the operation of a connected compress...

Страница 98: ...e root cause of fault occurrence Downloading fault and event logs every time a compressor is visited is useful for documenting compressor operational history Fault and event history can be extracted f...

Страница 99: ...0 and afterwards to a value greater than 0 Now the fault is reset and the compressor is ready to run The assumption is that the cause of the fault has been rectified A fault demanding a power cycle L...

Страница 100: ...the time of fault Results in an Instantaneous Lock Out Fault 3 Phase Over Current Fault AFT Indicates the compressor is drawing current greater than the 3 Phase Current Fault Limit Review the fault l...

Страница 101: ...and repair as necessary Cycle power to clear Lock Out Fault Active alarm Fault Viewer in SMT allows the Lock Out counter to be monitored High Winding Temperature Fault AFT Indicates the Raw Motor The...

Страница 102: ...Out Fault will occur Verify the Inverter and the Inverter cable connections See Section 3 7 3 1 If the Inverter Error fault persists after the Inverter is verified it should be replaced Review the Fau...

Страница 103: ...incoming AC phases Measure the difference in current and voltage between the phases If there is a current imbalance more than 5 between the phases verify the incoming AC power supply Review the Compr...

Страница 104: ...ted to be identical to Latest values Cycle power to the compressor ensuring the green LED on the I O board turns off This may need to be repeated multiple times Create a calibration report before any...

Страница 105: ...determine the cause of failure verify the following Ensure there are no faults present the shaft will not levitate for validation if a fault is present Ensure the RS485 at J1 on the I O board is disco...

Страница 106: ...iginal factory calibration values stored in EEPROM to the latest calibration allows determination of long term changes Saving to EEPROM permanently overwrites existing stored calibration values Stored...

Страница 107: ...tion is disconnected Action Verify the PWM Action Verify the bearings Action Verify the bearing sensors 4 Data in Report One or more of the gain values exceeds 3 0 Interpretation Bearing electrical fa...

Страница 108: ...ate shaft create a calibration report and cycle power Do not save calibration to EEPROM Create a calibration report Return compressor to normal operation No Yes No Successful Re Calibration Return com...

Страница 109: ...the nameplate rated voltage restore correct voltage 3 Verify all three phases of voltage after the mains fuses If the name plate rated voltage is present proceed to Step 4 If any of the three phases...

Страница 110: ...3 11 4 1 BMCC see Section 3 14 4 1 and PWM see Section 3 16 4 1 22 Re apply compressor power 23 Verify the HV and the 24 VDC test points on the Backplane If all voltages are within 10 proceed to Step...

Страница 111: ...n 10 the BMCC is not draining energy If any of these voltages are not within 10 proceed to Step 5 5 Isolate the compressor power and wait for the LEDs on the Backplane to turn off 6 Remove the BMCC se...

Страница 112: ...voltage input see Section 3 9 3 1 b Verify the DC DC Converter see Section 3 9 3 c Verify the PWM see Section 3 16 3 d Verify the bearings see Section 3 17 3 3 An open F2 fuse may indicate a problem w...

Страница 113: ...CC see Section 3 14 4 replace the wire to the I LOCK neg at the J2 connector of the I O board 1 Download the fault and event log 2 Review the fault and event log for any Inverter Error Signal Active f...

Страница 114: ...al terminals are tight Check for signs of hot spots discoloration on power cables Check amperages during operation are as per design Check DC bus voltage Replace DC Capacitor Assembly Energized 10 yea...

Страница 115: ...r BMCC and PWM from the Backplane Board Make sure the board assemblies do not come in contact with electric or static sources Application of Dielectric grease The dielectric grease can be applied by F...

Страница 116: ...as later replaced on Mjor Revision E compressors with a non removable red neoprene gasket Perform the following steps if the com pressor has either the black or red neoprene gaskets There is also a ne...

Страница 117: ...rag carefully wipe off any dielectric grease from the exposed power feed through pins 21 Apply a thin coating of dielectric grease to the PWM harness connectors female as shown in Figure 103 PWM Conne...

Страница 118: ...ing feed through pins and reconnect the PWM harness connectors to the appropriate feed throughs in the correct orientation 7 Reinstall Service Side Cover on compressor 5 2 1 3 Top Side 1 Remove the to...

Страница 119: ...ubricant on the SCR screws to remove any trace of moisture 12 Wipe off excess lube with a lint free rag 13 Wait for surfaces to dry completely 14 Once they are dry apply a coat of rust inhibitor spray...

Страница 120: ...120 of 132 M SV 001 EN Rev E THIS PAGE INTENTIONALLY LEFT BLANK...

Страница 121: ...e on their sole responsibility that the products comply with all the legal requirements in force in Europe Citation European Commission Directorate General for Enterprise and Industry ww ec europa eu...

Страница 122: ...in electrical power Id The part of the motor current generating torque IGBT Insulated Gate Bipolar Transistor See Inverter Impeller Rotating part of a centrifugal compressor that increases the pressur...

Страница 123: ...IGV stepper motor and optional expansion valves It contains four relays for the solenoid valves compressor status and Compressor run status SH Superheat The sensible heat added to a refrigerant thus...

Страница 124: ...pressor Troubleshooting Flowcharts This appendix contains flowcharts for Compressor Operation Troubleshooting Figure 108 and Compressor Voltage Troubleshooting Figure 109 and Figure 110 Figure 108 Com...

Страница 125: ...125 of 132 M SV 001 EN Rev E Appendix B Compressor Troubleshooting Flowcharts Figure 109 Compressor Voltage Troubleshooting Chart 1...

Страница 126: ...126 of 132 M SV 001 EN Rev E Appendix B Compressor Troubleshooting Flowcharts Figure 110 Compressor Voltage Troubleshooting Chart 2...

Страница 127: ...h Resistance TT300 TT400 C E F TG230 TG390 1 to 2 2 7 to 25 3 17 3 TT300 TT400 C E F TG230 TG390 3 to 4 2 7 to 25 3 17 3 TT350 TT400 P TT500 TT700 TG310 TG520 1 to 2 4 7 to 5 20 3 17 3 TT350 TT400 P T...

Страница 128: ...connector 0 39 0 46VDC 3 16 3 3 Lead in HV C47 lead in PWM connector 0 39 0 46VDC 3 16 3 3 Rear Bearing Feed Through Resistance All models 1 to 6 2 7 to 3 25 3 17 3 All models 2 to 5 2 7 to 3 25 3 17...

Страница 129: ...red Value F4 F5 30 38 3 4 3 2 Solenoid Actuators 4 8 W 108 132 3 12 3 9 3 W 56 25 68 75 3 12 3 Stator Resistance Phase 1 2 0 0 and 1 3 8 4 2 Phase 1 3 0 0 and 1 3 8 4 2 Phase 2 3 0 0 and 1 3 8 4 2 Sta...

Страница 130: ...130 of 132 M SV 001 EN Rev E Notes...

Страница 131: ...M SV 001 EN Rev E Scan here to download the App DanfossTurboTool App quick access to compressor troubleshooting Mobile Application TurboTool App 24 7 Access to Danfoss Turbocor compressor troubleshoot...

Страница 132: ...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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