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M-AP-001-EN Rev. N

* Danfoss Turbocor’s commitment to excellence ensures continuous product improvements.
* Subject to change without notice.

Introduction

Acronym / Term

Definition

Shaft Orbit

The path travelled by the compressor shaft relative to the bearing magnetic centers

Shrouded Impeller

An impeller with boxed in, or “shrouded,” impeller blades, as opposed to an open impeller.

SIE

Semi-Integrated Electronics version of the compressor.

Single-Stage

Centrifugal

compressor

Type of centrifugal compressor having one impeller.

Snubbers

Capacitors responsible for eliminating electrical noise/harmonics from the DC Bus before it

reaches the IGBT

Soft-Start Board /

Soft-

Starter

The Soft-Start Board limits in-rush current by progressively increasing the conduction

angle of the SCRs. This technique is used at compressor startup while the DC capacitors are

charging up. The Soft-Start Board takes as input a 3-phase voltage source at 50/60Hz from

the input terminal and a DC voltage signal from the SCR output. In turn, it outputs pulses

to the SCR and provides power to the High-Voltage (HV) DC-DC Converter. All voltages

from the Soft-Start Board are with respect to the positive DC bus and not the compressor

ground.

SST

Saturated Suction Temperature

Surge

The condition at which the compressor cannot sustain the discharge pressure, allowing

refrigerant to temporarily and rapidly re-enter the compressor fluid path, creating a

cavitating effect. This is an undesirable situation that should be avoided.

Thrust Bearing

A bearing that absorbs the axial forces produced in a centrifugal compressor by the

refrigerant pressure differential across the impeller.

Ton

The basic unit for measuring the rate of heat transfer (12,000 BTU/H; 3.516 kw/H)

Touchdown

Bearings

Carbon races or ball bearing for the purpose of preventing mechanical interference

between the shaft and the magnetic bearings should they lose power or fail.

Twin Turbine

Two-Stage

Centrifugal

compressor

Type of centrifugal compressor having two impellers. The first-stage impeller raises the

pressure of the refrigerant vapor approximately halfway from the cooler pressure to the

condenser pressure, and the second-stage impeller raises the pressure the rest of the

way. With a two-stage compressor, an interstage economizer may be used to improve the

refrigeration cycle efficiency

TXV

Thermal Expansion Valve. A pressure-dependent refrigerant metering device that operates

independently and is controlled by temperature.

Underwriters Laboratories (www.ul.com)

Up-Trip Voltage

When the DC- bus reaches the up-trip voltage, the SCRs will be gated open continuously

VAC

Volts Alternating Current

Vaned Diffuser

An assembly of plates with curved vanes that serve to slow, compress, and reduce

refrigerant rotation as it enters the second-stage impeller

Vaneless Diffuser

Similar to a Vaned Diffuser, except that it does not possess any de-swirl vanes

VDC

Volts Direct Current

VFD

Variable Frequency Drive

Содержание Turbocor TT Series

Страница 1: ...Danfoss Turbocor Twin Turbine Centrifugal Compressors TT TG Series Compressors Applications and Installation Manual Revision N http turbocor danfoss com...

Страница 2: ...Page 2 of 108 M AP 001 EN Rev N THIS PAGE INTENTIONALLY LEFT BLANK...

Страница 3: ...C Converter 26 3 5 Magnetic Bearing System 26 3 5 1 Overview 26 3 5 2 Bearing Control System 26 4 Control Interface Wiring 28 4 1 Control Wiring Connection Guidelines 29 4 2 Interface Cable 30 4 3 Com...

Страница 4: ...1 TT300 and TT400 Sound Power Measurements 71 15 1 1 Results 71 16 Physical Data 75 16 1 Clearance 75 16 2 Center of Gravity 77 16 3 Torque Specifications 86 17 Piping Considerations 87 18 Environmen...

Страница 5: ...e 37 Table 6 2 Acceptable Frequency Range 37 Table 6 3 FLA and LRA Value Range 38 Table 6 4 Main Cable Connector Plate Hole Sizes 42 Table 13 1 Recommended Minimum Copper Tube Size 60 Table 13 2 Low L...

Страница 6: ...lve Medium Temperature Compressors Only 67 Figure 14 6 Typical Refrigeration Piping Schematic With Multiple DX Evaporators 68 Figure 14 7 Typical Refrigeration Piping Schematic Using Multiple Compress...

Страница 7: ...lines provided in this manual are AS IS with no warranty of any kind either express or implied including without limitation any implied warranties of condition uninterrupted use merchantability or fit...

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Страница 9: ...d into the following sections 1 Overview of the TT TG series compressors provides an overview of the Twin Turbo and Total Green TT and TG series compressors including an introduction to the compressor...

Страница 10: ...outcome of the procedure being performed NOTE Indicates something to be noted by the reader NOTE DANGER Indicates an essential operating or maintenance procedure practice or condition which if not str...

Страница 11: ...pressure divided by the absolute suction pressure CSA Canadian Standards Association www csa ca DC Bus High DC voltage simultaneously connected to multiple compressor components via metallic bus bars...

Страница 12: ...insufficient power to sustain safe and normal operation and is typically due to a loss of power Genlanolin A type of grease In certain climates where the dew point falls below the operating temperatur...

Страница 13: ...agnetic field and is also a parameter used to evaluate the strength of the permanent magnets of the shaft One practical application is to use this phenomenon to indirectly measure motor speed as well...

Страница 14: ...ly re enter the compressor fluid path creating a cavitating effect This is an undesirable situation that should be avoided Thrust Bearing A bearing that absorbs the axial forces produced in a centrifu...

Страница 15: ...e with refrigerant R134a The TG series compressor is for use with R1234ze E refrigerant only ASHRAE standard 34 has classified this refrigerant as R1234ze E with safety classification of A2L ASHRAE St...

Страница 16: ...below 1 C ambient if refrigerant circuit is maintained at a minimum of 1 C Saturated temperature The compressor should not be operated at an altitude higher than 3000m The compressor should be stored...

Страница 17: ...y permanent magnet synchronous motor powered by pulse width modulating PWM voltage supply The high speed variable frequency operation that affords high speed efficiency compactness and soft start capa...

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Страница 19: ...conditions The first compression element the gas encounters is the first stage impeller The centrifugal force produced by the rotating impeller results in an increase in both gas velocity and pressure...

Страница 20: ...lve opens If the temperature increases to the point where it equals a higher temperature threshold the second solenoid valve opens From the outlet of the orifices the refrigerant is directed to the he...

Страница 21: ...d leakage BMCC From IGBT Temp Sensor From SCR Temp Sensor IGBT SCR ORIFICE ORIFICE Solenoid B Solenoid A Liquid Refrigerant Inlet BMCC From Motor Cavity Temp Sensor From Motor Winding Temp Sensor Moto...

Страница 22: ...ration 2 3A Calibration Customer Chiller Control Communications Interface Diagnostic Terminal Internet RS 485 Comms to Chiller or Building Management System User Interface Serial Driver Module 15VDC 2...

Страница 23: ...controlled sequence preventing damage to components 3 4 2 Soft Start Board The Soft Start Board limits inrush current by progressively increasing the conduction angle of the SCRs This technique is us...

Страница 24: ...stationary surfaces A digital bearing controller and motor controller provide the PWM command signals to the Bearing PWM Amplifier and IGBT Inverter respectively The bearing controller also collects s...

Страница 25: ...in modules with the power electronics IGV stepper motor motor cooling solenoids rotor position sensors and pressure temperature sensors The Backplane also features on board low voltage DC DC converte...

Страница 26: ...sition commands to the 250VDC PWM signals that are applied to each bearing actuator coil Rotor position sensors are located on rings attached to the front and rear radial bearing assemblies The front...

Страница 27: ...r Touchdown Bearings Touchdown Bearings Target Sleeve Y axis Position Sensor Y axis Position Sensor Channels Fx Fy Channels Rx Ry Channel Axi 250 VDC Position Command Signals Bearing Motor Compressor...

Страница 28: ...sor Running N O Contact Compressor Running N O Contact Pressure Sensor Signal 1 5Volts Sensor 5V Sensor 0V Temperature Sensor Signal 1 5Volts Universal Analog Output Universal Analog Output Universal...

Страница 29: ...l the auxiliary expansion valve economizer Demand 0 10V Analog input from customer supplied controller to drive the compressor i e 0 max kW input with a deadband of 2VDC for the respective compressor...

Страница 30: ...le in the Spare Parts Selection Guide For RS 485 communication the maximum cable length should not exceed 100 meters 328 feet If using RS 232 communication the cable length should not exceed 15 meters...

Страница 31: ...ion and electrical noise 4 3 Compressor I O Board Mounting Details Figure 4 4 Compressor I O Board Control Interface Wiring NOTE The UL listed enclosure should protect against moisture and other corro...

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Страница 33: ...ion which are typcially deemed appropriate for Water Cooled condiitons These values allow for adjustment for compressors placed in Air Cooled applications which can have the value increased up to 1730...

Страница 34: ...5 2 Discharge Temperature Trip Settings Unit Compressor TG230 ST TG230 MT TG310 ST TG390 ST TG520 ST TT300 ST TT300 MT TT350 ST TT400 ST TT700 ST F Trip 212 194 203 194 194 212 194 203 194 194 C Trip...

Страница 35: ...ilding applications An OEMs use of Turbocor Compressors in applications other than stationary building applications e g Marine Applications is considered a non standard application and is not eligible...

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Страница 37: ...y from DTC unless otherwise stated by DTC This includes any application of a 400V compressor in a 380V application without the use of a transformer to correct the voltage going into the compressor NOT...

Страница 38: ...0 380V 60 170 66 187 60 66 TT400 400V 60 170 66 187 60 66 TT400 460V 60 150 66 165 60 66 TT400 575V 60 120 66 132 60 66 TT700 380V 60 206 66 227 60 66 TT700 400V 60 196 66 216 60 66 TT700 460V 60 170...

Страница 39: ...e and immediately before the compressor that is downstream from the line reactor Contact DTC for more information 6 4 Motor Insulation Class All TT TG Series compressors have a motor insulation Class...

Страница 40: ...and grease and paint free 4 At one point usually the entrance of the power supply panel all grounds should be connected together refer to Section 6 11 From an EMC standpoint it is best to categorize d...

Страница 41: ...eep power cables and interface cables separate Use metal cable glands for shielded cables The wire loom going to the panel door should be shielded using a metal braided hose that is connected to groun...

Страница 42: ...arried inside of a code approved electrical metallic conduit of the flexible or rigid types The mains input cable should be CSA UL or CE approved three wire with a common shield and single ground The...

Страница 43: ...perating map which is in the speed control range only As the compressor reduces speed and mechanical unloading is enabled such as the closing of the variable IGV the tolerance increases to 10 The cond...

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Страница 45: ...to the FLA rating of the particular compressor The lower limit is related to minimum pressure ratios required to effect proper motor and power electronics cooling with standard refrigerant circuit co...

Страница 46: ...e capacity will be dependent on specific operating characteristics of each compressor model Refer to the current authorized compressor selection rating software for more exact values and conditions Fi...

Страница 47: ...s related to the FLA rating of the particular compressor The lower limit is related to minimum pressure ratios required to effect proper motor and power electronics cooling with standard refrigerant c...

Страница 48: ...s related to the FLA rating of the particular compressor The lower limit is related to minimum pressure ratios required to effect proper motor and power electronics cooling with standard refrigerant c...

Страница 49: ...um SDT for compressors with an FLA less than that is lower than the upper bound of the operating envelope and depends on the FLA rating 1 The actual obtainable capacity will be dependent on specific o...

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Страница 51: ...fugal compression the minimum stable load is dependent on the pressure ratio imposed on the compressor by the chiller system All compressor performance including unloading should be determined through...

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Страница 53: ...required to start against a pressure ratio of 2 4 or greater Load balancing valve hot gas bypass the LBV is piped downstream of the check valve and is primarily used in low load conditions to keep th...

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Страница 55: ...of 108 M AP 001 EN Rev N Product Certification All TT and TG Series compressors are ETL and CE listed and have been tested in accordance with UL Standard 984 and CSA Standard C22 2 11 Product Certifi...

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Страница 57: ...e DC voltage to an adjustable three phase AC voltage Signals from the compressor controller shall determine the inverter output frequency voltage and phase thereby regulating the motor speed In case o...

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Страница 59: ...iderations that ensure oil return such as multiple risers and traps are not required In most cases larger diameter lines will result in better compressor performance and efficiency 4 For improved effi...

Страница 60: ...on Software on the Customer Service and Support Performance Tools section of the DTC web page www turbocor com The circuit must be properly designed to reflect the specified heat exchanger approach wi...

Страница 61: ...13 2 Low Lift Pump Sizing The standard TT TG control limits compressor speed and capacity below a 1 5 pressure ratio to ensure adequate motor inverter cooling When enabled the low lift option is meant...

Страница 62: ...such as hot building start up can limit the maximum capacity of the centrifugal compressor If more capacity is desired it is advisable to raise the discharge pressure temporarily to increase the pres...

Страница 63: ...ith Subcooler Evaporator Sight Glass Check Valve Expansion Valve Motor Cooling Port Suction Port Economizer Port Discharge Port Sight Glass Filter Drier Check Valve Refrigerant Pump Pressure Regulatin...

Страница 64: ...and Load Balancing Valve Motor Cooling Port Suction Port Economizer Port Discharge Port Sight Glass Sight Glass Filter Drier Filter Drier Evaporator Expansion Valve Expansion Valve Staging Valve Stag...

Страница 65: ...Piping Schematic With Flash Tank Economizer Motor Cooling Port Suction Port Economizer Port Discharge Port Sight Glass Filter Drier Evaporator Expansion Valve Sight Glass Economizer Tank Condenser wi...

Страница 66: ...al Refrigeration Piping Schematic With Sub Cooler Circuit Economizer Motor Cooling Port Suction Port Economizer Port Discharge Port Sight Glass Filter Drier Evaporator Sight Glass Expansion Valve Cond...

Страница 67: ...hematic Using Motor Cooling Pressure Regulating Valve Medium Temperature Compressors Only Motor Cooling Port Suction Port Economizer Port Discharge Port Sight Glass Filter Drier Expansion Valve Conden...

Страница 68: ...on Piping Schematic With Multiple DX Evaporators Motor Cooling Port Suction Port Economizer Port Discharge Port Sight Glass Filter Drier Filter Drier Sight Glass Expansion Valve Expansion Valve Expans...

Страница 69: ...Port Motor Cooling Port with integral strainer Suction Port Economizer Port Discharge Port Motor Cooling Port with integral strainer Suction Port Economizer Port Discharge Port Sight Glass Sight Glass...

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Страница 71: ...es while the compressor is installed on top of a building The sound data below should be used as a guide only The following sound measurements are based on a specific physical setup such as suction di...

Страница 72: ...5 7 62 6 630 60 2 58 4 630 71 8 69 8 800 65 1 64 5 800 67 7 67 2 1000 76 5 76 7 1000 70 5 70 6 1250 66 2 66 9 1250 82 3 83 0 1600 69 9 71 0 1600 72 6 73 9 2000 69 6 70 9 2000 73 3 74 7 2500 68 6 69 9...

Страница 73: ...z Linear scale dB A weighted dBA Third octave band Hz Linear scale dB A weighted dBA 160 51 65 160 55 70 200 49 61 200 50 62 250 60 70 250 61 70 315 60 68 315 62 69 400 64 71 400 65 75 500 63 65 500 6...

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Страница 75: ...144 kg TG520 318 lbs 144 kg 16 Physical Data Adequate clearance around the compressor is essential to facilitate maintenance and service Removal of the compressor top and service side covers requires...

Страница 76: ...2 8 67 TT350 TT400 TT500 O RING GROOVE OD 88 9 3 499 WIDTH 4 1 0 1614 ID 80 7 3 177 O RING GROOVE OD 33 3 1 311 TT300 TG230 41 3 1 659 TT350 TT400 TT500 TT700 WIDTH 4 1 0 1614 ID 25 1 0 988 TT300 TG2...

Страница 77: ...Page 77 of 108 M AP 001 EN Rev N Physical Data 16 2 Center of Gravity Figure 16 4a Center of Gravity...

Страница 78: ...TT400 TG390 TT700 TG520 CG LINE Length of Center of Gravity m in XL 0 257 10 13 0 249 9 81 0 247 9 74 0 251 9 87 Width of Center of Gravity m in YL 0 151 5 95 0 153 6 03 0 152 5 97 0 150 5 91 Compres...

Страница 79: ...ysical Data Compressor valve flange details are shown in Figures 16 5 through 16 14 Refer to the product specifications in the Spare Parts Selection Guide for further details Figure 16 5 Discharge Por...

Страница 80: ...Page 80 of 108 M AP 001 EN Rev N Physical Data Figure 16 6 Discharge Port Details TT350 and TG310 Figure 16 7 Discharge Port Detail TT400 and TG390 Gas Flow Gas Flow...

Страница 81: ...Page 81 of 108 M AP 001 EN Rev N Physical Data Figure 16 8 Discharge Port Detail TT700 and TG520 Gas Flow...

Страница 82: ...Page 82 of 108 M AP 001 EN Rev N Physical Data Figure 16 9 Suction Port All Models...

Страница 83: ...Page 83 of 108 M AP 001 EN Rev N Physical Data Figure 16 10 Suction Port Detail DD All Models Figure 16 11 Suction Port Detail DD TT700 and TG520 Gas Flow Gas Flow...

Страница 84: ...Page 84 of 108 M AP 001 EN Rev N Physical Data Figure 16 12 TT300 Flange Footprint Details Figure 16 13 TT350 TG310 TG390 and TT400 Flange Footprint Details...

Страница 85: ...ev N Physical Data Figure 16 14 TT700 and TG520 Flange Footprint Details Port Thread Size Hole Depth mm Torque Nm Suction M16 X 2 34 5 75 Discharge M10 X 1 5 20 22 Economizer M10 X 1 5 20 22 Table 16...

Страница 86: ...A C Bus Bars 6 4 53 DC Capacitors and Bleed Resistor 2 1 18 IGBT Mounting Screws 6 4 53 Shraeder Valves 15 11 133 Motor Cooling Body body nut E Housing and later 25 18 221 Motor Cooling Compression N...

Страница 87: ...ooling line NOTE Some applications may require alternative arrangements Contact DTC for further assistance if required CAUTION The discharge line must be fitted with a non return valve to prevent reve...

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Страница 89: ...nsate Insulation should be installed on the suction valve piping and the end cap as this is where condensation is most likely to form It is recommended to fit an End Cap insulator in a humid environme...

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Страница 91: ...cessive vibration Due to the flexibility of the compressor s isolation mounts compressor vibration during transit can fracture the motor cooling line s rigid piping DTC suggests the temporary installa...

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Страница 93: ...ould not extend from the compressor mounting rails to the base frame see Figure 20 3 and Figure 20 4 3 Check that the compressor mounting rails are level 5mm 3 16 in the lateral and longitudinal plane...

Страница 94: ...re 20 2 Mounting Base TT and TG series NOTE If isolation pads are used at the four 4 mounting base points the overall height of the compressor will change Be sure to measure accordingly based on the i...

Страница 95: ...langes to the compressor O rings must be of type EPDM also known by the compound E0740 75 for R1234ze refrigerant O ring grease must be silicone based and compatible with R1234ze CAUTION The motor coo...

Страница 96: ...ol wiring connections to the compressor I O Board Table 16 1 Control Wiring Details provides details for the module terminal connections The interface cable connects the compressor to the compressor I...

Страница 97: ...Page 97 of 108 M AP 001 EN Rev N Figure 20 6 Compressor I O Board Connections Installation Interface Cable Compressor I O Board...

Страница 98: ...rounding Improper grounding can be identified by measuring the voltage between the customer s negative terminals and the ground J1 COM or Modbus shield terminal on the compressor I O board see Figure...

Страница 99: ...e that the interlock contacts are closed The measured value should be less than 1 Figure 20 8 Interlock Circuit Tests Measure the voltage between each customer interlock terminal and the frame ground...

Страница 100: ...for 90 C 194 F minimum with a maximum current rating corresponding to the LRA value on the compressor nameplate Keep power cables and control interface cables in separate conduits Use metal cable gla...

Страница 101: ...Nut Mains Stud 3 8 16 1 5 long Compression Lug AC Input Connection Upper Nut 10 Nm 7 ft lb Jam Nut 7 Nm 62 in lb Figure 20 10 Ground Post Nuts 7 Attach the three main power cables to the compressor t...

Страница 102: ...102 of 108 M AP 001 EN Rev N 11 Seal any gaps between the cabling and the mains input bracket to minimize any dust ingress into the compressor 12 Replace the mains input cover and secure it the faste...

Страница 103: ...y panel 2 Attach the AC line wires to the line reactor output terminals as shown in 3 If a harmonic filter is being installed attach its AC line wires to the line reactor output terminals 4 Attach the...

Страница 104: ...Page 104 of 108 M AP 001 EN Rev N Appendix A Power Line Accessories Installation Figure A 1 Line Reactor Connections...

Страница 105: ...und lug to the main ground bus and tighten the nut see Figure B 2 1 Insert the load wires from the line side of the line reactor into the terminals labelled L1 L2 and L3 on the Load side of the filter...

Страница 106: ...Page 106 of 108 M AP 001 EN Rev N Figure B 1 Interconnection Layout Figure B 2 Grounding Diagram Appendix B Power Line Accessories Installation...

Страница 107: ...an select from a list of symptoms in the app that match the problems exhibited by the compressor being serviced The app will then list potential causes solutions to the problem and service literature...

Страница 108: ...distinct variable speed technology specialists Today we operate from engineering and manufacturing facilities spanning across three continents Danfoss Inverter Scrolls Danfoss Turbocor Compressors Da...

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