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Turbocor TT Series
Danfoss Turbocor TT Series User Manual
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Service
Manual
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Revision
H
Danfoss
Turbocor®
Twin-Turbine
Centrifugal
Series
Compressors
TT
Series
Compressors
http://turbocor.danfoss.com
|
2
Table of Contents
default chapter
3
Table of Contents
3
Chapter 1.0 Introduction
17
Application
17
Purpose
19
Organization
19
Commitment to Quality and the Environment
20
Safety Summary
20
Danger Notification
20
Caution Notification
21
Note
21
Precautions
21
Refrigerant Type
21
Electrical Isolation
22
Handling Static Sensitive Devices
24
ESD Protection/Grounding
24
DC Bus Test Harness Installation and Removal
25
General Verification and Installation of the DC Bus Test Harness
26
DC Bus Test Harness Installation for Closed-Top Soft Start
27
DC Bus Test Harness Installation for Open-Top Soft Starts
30
General DC Bus Test Harness Removal
31
DC Bus Test Harness Removal for Closed-Top Soft Starts
31
DC Bus Test Harness Removal for Open-Top Soft Starts
31
Compressor Fasteners
32
General O-Ring Handling
32
Chapter 2.0 Compressor Fundamentals
33
Main Fluid Path
33
Motor and Power Electronics Cooling
33
Capacity Control
37
Compressor Energy and Signal Flow
38
Chapter 3.0 Compressor Removal and Installation
41
Refrigerant Containment
41
Compressor Removal
41
Compressor Installation
42
Compressor Replacement Considerations for Motor Cooling Adapter
43
Exterior Connection Torque Specifications
45
Chapter 4.0 Component Identification
47
Compressor Covers
52
Mains Input Cover
52
Mains Input Cover Removal and Installation
52
Top Cover
53
Top Cover Removal and Installation
53
Service Side Cover
54
Service Side Cover Removal and Installation
54
Capacitor Cover
55
Capacitor Cover Removal and Installation
55
Compressor Cover Torque Specifications
57
Cooling Adapter
58
Cooling Adapter Removal and Installation
59
Cooling Adapter Torque Specifications
59
Compressor Interface Module
60
Compressor Interface Module Connection Descriptions
60
Compressor Interface Module Verification
62
Determining if the Compressor Interface Module Is Draining Energy
62
Compressor Interface Module Communication Verification
62
Interlock Verification
63
Compressor Interface Module Removal & Installation
63
Compressor Interface Module Removal
63
Compressor I/O Board Installation
64
Compressor Interface Cable
65
Compressor Interface Cable Verification
65
Compressor Interface Cable Removal and Installation
65
Compressor Interface Cable Removal
65
Compressor Interface Cable Installation
65
Compressor Controller Cable Harness
67
Compressor Controller Cable Connections
67
Compressor Controller Cable Harness Removal and Installation
68
Compressor Controller Cable Harness Torque Specifications
71
Solenoids and Coils
72
Solenoid and Coil Connections
72
Solenoid Coil Harness
73
Solenoid Coil Harness Removal and Installation
73
Solenoid Verification
73
Resistance Measurement of Cooling Solenoid Coils
73
Output Voltage to Solenoid Coils
74
Cooling Path Blockage Inspection
74
Solenoid and Coil Removal and Installation
75
Solenoid and Coil Removal
75
Solenoid and Actuator Installation
76
Solenoid Torque Specifications
77
Interstage Pipe - TTH/TGH
78
Interstage Pipe Removal and Installation
78
Interstage Pipe Removal
78
Interstage Pipe Installation
78
Interstage Pipe Torque Specifications
79
Compressor Housing End Cap
80
Compressor Housing End Cap Removal and Installation
80
Compressor Housing End Cap Removal
80
Compressor Housing End Cap Installation
81
Compressor Housing End Cap Torque Specifications
81
Igv
82
IGV Connections
82
IGV Verification
83
IGV Stepper Motor Verification
83
IGV Operation Verification
83
IGV Housing Removal and Installation
85
IGV Housing Assembly Removal
85
IGV Assembly Removal
87
IGV Assembly Installation
90
IGV Torque Specifications
95
Mains Plate Bracket
96
Mains Plate Bracket Removal and Installation
96
Mains Plate Bracket Removal
96
Mains Plate Bracket Installation
96
Mains Plate Torque Specifications
98
3-Phase Main Voltage Input Terminal Block
99
3-Phase Main Voltage Input Terminal Block Verification
100
3-Phase AC Input Verification
100
Connecting the AC Input Cable
100
Verifying the 3-Phase AC Input
101
3-Phase Main Voltage Input Terminal Block Removal and Installation
102
General 3-Phase Main Voltage Input Terminal Block Removal
102
Specific 3-Phase Main Voltage Input Terminal Block Removal - TTS300/TGS230
102
3-Phase Main Voltage Input Terminal Block Removal - TTS/TGS/TTH/TGH (Except TTS300/TGS230)
103
3-Phase Main Voltage Input Terminal Block Installation - TTS300/TGS230
104
3-Phase Main Input Terminal Block Installation - TTH/TGH/TTH/TGH (Except TTS300/TGS230)
105
General 3-Phase Main Voltage Input Terminal Block Installation
106
Terminal Block Torque Specifications
106
Input Mains Bus Bars
108
Input Mains Bus Bar Removal
108
General Mains Bus Bar Removal
108
Input Mains Bus Bar Installation
109
General Mains Bus Bar Installation
110
AC Bus Bar Torque Specifications
110
Terminal Block Fuse Replacement
111
Verification of Terminal Block Fuse
111
Terminal Block Fuse Removal and Installation
111
Terminal Block Fuse Removal
111
Terminal Block Fuse Installation
112
Soft Start
113
Soft Start Connections
114
Soft Start Verification
115
Verifying Soft Start Voltages
115
Verifying Soft Start Fuses
116
Soft Start Removal and Installation
117
Soft Start Removal (Closed-Top)
117
Soft Start Removal (Open-Top)
119
Soft Start Installation (Closed-Top)
121
Soft Start Installation (Open-Top)
122
Soft Start Fan Removal and Installation
123
Soft Start Fan Removal
123
Soft Start Fan Installation
124
Soft Start Torque Specifications
125
SCR DC Bus Bar - TTS300/TGS230
126
SCR DC Bus Bar Removal and Installation
126
SCR DC Bus Bar Removal - TTS300/TGS230
126
SCR DC Bus Bar Installation - TTS300/TGS230
126
SCR DC Bus Bar Torque Specifications
127
Soft Start SCR Gate Cable
128
Soft Start SCR Gate Cable Connections
128
Soft Start SCR Gate Cable Removal and Installation
128
Soft Start SCR Gate Cable Removal
128
Soft Start SCR Gate Cable Installation
130
Soft Start AC/DC Harness
132
Soft Start AC/DC Harness Connections
132
Soft Start AC/DC Harness Removal and Installation
133
Soft Start AC/DC Harness Removal - TTS300/TGS230
133
Soft Start AC/DC Harness Removal - TTS/TGS/TTH/TGH (Except TTS300/TGS230)
136
Soft Start AC/DC Harness Installation - TTS300/TGS230
137
Soft Start AC/DC Harness Installation - TTS/TGS/TTH/TGH (Except TTS300/TGS230)
138
Soft Start AC/DC Harness Torque Specifications
140
Silicone-Controlled Rectifier
141
SCR Connections
141
SCR Verification
142
Diodes Verification - Two-Hole Mount
142
Diodes Verification - Four-Hole Mount
143
Gates Verification
144
SCR Temperature Sensor
144
SCR Temperature Sensor Verification
144
SCR Temperature Sensor General Removal
145
SCR Temperature Sensor Removal - TTS300/TGS230
145
SCR Temperature Sensor Removal - TTS/TGS/TTH/TGH Rev. F and Earlier (Except TTS300/TGS230)
146
SCR Temperature Sensor Installation - TTS300/TGS230
148
SCR Temperature Sensor Installation - TTS/TGS/TTH/TGH Rev. F and Earlier
148
Tts300/Tgs230)
148
SCR Temperature Sensor General Installation
148
SCR Temperature Sensor Torque Specifications
148
SCR Removal and Installation
149
SCR General Removal
149
SCR Removal - TTS300/TGS230
149
SCR Removal - TTS/TGS/TTH/TGH (Except TTS300/TGS230)
150
SCR Installation - TTS300/TGS230
153
SCR Installation - TTS/TGS/TTH/TGH (Except TTS300/TGS230)
155
SCR General Installation
156
SCR Torque Specifications
156
SCR Cooling Manifold
157
SCR Cooling Manifold General Removal Steps
157
SCR Cooling Manifold Specific Removal Steps - TTS300/TGS230
157
SCR Cooling Manifold Specific Removal Steps - TTS/TGS/TTH/TGH (Except TTS300/TGS230)
159
SCR Cooling Manifold Specific Installation Steps - TTS300/TGS230
160
SCR Cooling Manifold Specific Installation Steps - TTS/TGS/TTH/TGH (Except TTS300/TGS230)
160
SCR Cooling Manifold General Installation Steps
162
SCR Cooling Manifold Torque Specifications
162
Snubber Capacitors
164
DC Capacitor Bus Bar Assembly
165
DC Capacitor DC Bus Bar Connections
166
DC Bus Voltage Verification
167
Bleed Resistor Verification
167
Snubber Capacitor Verification
167
DC Capacitor Bus Bar Assembly Removal and Installation
168
DC Capacitor Bus Bar Assembly General Removal
168
DC Capacitor Bus Bar Assembly Removal - TTS300/TGS230
168
DC Capacitor Bus Bar Assembly Removal - TTS/TGS/TTH/TGH (Except TTS300/TGS230)
170
DC Capacitor Bus Bar Assembly Installation - TTS300/TGS230
174
DC Capacitor Bus Bar Assembly Installation - TTS/TGS/TTH/TGH (Except TTS300/TGS230)
174
DC Capacitor Bus Bar Assembly General Installation Steps
174
DC Capacitor Bus Bar Assembly Torque Specifications
174
Inverter
176
Inverter Connections
176
Inverter Verification
176
Inverter Cable Harness
177
Inverter Cable Harness Removal and Installation
177
Inverter Cable Harness Removal
177
Inverter Cable Harness Installation
178
Inverter Cable Harness Torque Specifications
179
Inverter Removal and Installation
179
Compressor Specific Inverter Removal Steps - TTS300/TGS230
179
Compressor Specific Inverter Removal Steps - TTS/TGS/TTH/TGH (Except TTS300/TGS230)
182
Compressor Specific Inverter Installation Steps - TTS300/TGS230
185
Compressor Specific Inverter Installation Steps - TTS/TGS/TTH/TGH (Except TTS300/TGS230)
187
Inverter Card Replacement
188
Inverter Card Removal
188
Inverter Control Card Installation
189
Inverter Torque Specifications
192
Motor Components
194
Function
194
Stator
194
Rotor
194
Motor Protection
194
Motor Connections
194
Motor Verification
195
Stator Insulation Verification
195
Stator Resistance Verification
195
Stator Thermistor Resistance Verification
195
Motor Components Removal and Installation
196
Motor Bus Bar Removal
196
Motor Bus Bar Installation
197
Copper Tube Removal
198
Copper Tube Installation
198
Motor Cover Plate Removal
198
Motor Cover Plate Installation
199
High Power Feedthrough Removal
200
High-Power Feedthrough Installation
202
Motor Assembly Torque Specifications
203
High Voltage DC-DC Converter
204
DC-DC Converter Function
204
DC-DC Converter Verification
204
Input Voltage Verification
204
Output Voltage Verification
204
Input Resistance Measurement
205
Output Resistance Measurement
205
DC-DC Removal and Installation
206
DC-DC Torque Specifications
208
DC-DC Supply Cable Harness
209
DC-DC Harness Removal and Installation
209
DC-DC Harness Removal
209
DC-DC Harness Installation
210
Backplane
211
Backplane Function
211
Backplane Connections and Test Points
211
LED Locations
213
Backplane Verification
214
Backplane Removal and Installation
215
Backplane Removal
215
Backplane Installation
216
Backplane Torque Specifications
216
Serial Driver
217
Serial Driver Function
217
Serial Driver Connections
217
Serial Driver Verification
217
Serial Driver Input Voltage
217
Serial Driver Output Voltage Verification
218
Serial Driver Removal and Installation
218
Serial Driver Removal
218
Serial Driver Installation
218
Bmcc
220
BMCC Connections
220
BMCC Verification
220
BMCC Power Verification
220
BMCC Communication Verification
220
BMCC Battery and Verification
221
BMCC Battery Safety
221
BMCC Battery Verification
221
BMCC Removal and Installation
222
BMCC Removal
222
BMCC Installation
223
Bearing Pulse Width Modulator Amplifier
225
PWM Function
225
PWM Connections
226
PWM Verification
226
Verify if the Bearing PWM Amplifier Is Draining Energy
227
Verify Functionality of the Five Output Channels
227
Verify Functionality of the Five Diode Sets
227
PWM Removal and Installation
228
PWM Amplifier Removal
228
PWM Amplifier Installation
229
PWM Torque Specifications
229
Magnetic Bearings
230
Magnetic Bearings Function
230
Magnetic Bearings Connections
230
Bearing Verification
230
Bearing Coil Verification
230
Bearing Current Verification
232
Bearing Power Feedthrough Removal and Installation
233
Bearing Power Feedthrough Removal
233
Bearing Power Feedthrough Installation
234
Magnetic Bearing Torque Specifications
235
Bearing Sensors
236
Bearing Sensor Function
236
Bearing Sensor Connection
236
Bearing Sensor Verification
236
Bearing Sensor Resistance Verification
236
Bearing Sensor Cable Verification
237
Bearing Sensor Cable Removal and Installation
238
Bearing Sensor Feedthrough Removal and Installation
239
Bearing Sensor Feedthrough Removal
239
Bearing Sensor Feedthrough Installation
240
Bearing Sensor Torque Specifications
241
Cavity Temperature Sensor
242
Cavity Temperature Sensor Function
242
Cavity Temperature Sensor Connections
242
Cavity Temperature Sensor Verification
242
Cavity Temperature Sensor Removal and Installation
243
Cavity Temperature Sensor Removal
243
Cavity Temperature Sensor Installation
243
Cavity Sensor Torque Specifications
244
Pressure/Temperature Sensor
245
Pressure/Temperature Sensor Function
245
Pressure/Temperature Sensor Connections
245
Pressure/Temperature Sensor Verification
246
Pressure/Temperature Sensor Removal and Installation
247
Suction Pressure/Temperature Sensor Removal
247
Suction Pressure/Temperature Sensor Installation
248
Discharge Pressure/Temperature Sensor Removal
248
Discharge Pressure/Temperature Sensor Installation
248
Interstage Pressure/Temperature Sensor Removal (TTH/TGH Compressors Only)
249
Interstage Pressure/Temperature Sensor Installation (TTH/TGH Compressors Only)
249
Pressure/Temperature Sensor Torque Specifications
249
Chapter 5.0 Ltroubleshooting
251
Alarm and Fault Indications
251
Alarm Types
251
Fault Types
251
Troubleshooting with the Service Monitoring Tools Software
254
Compressor Fault Troubleshooting
254
Motor/System Faults Troubleshooting
260
Bearing Fault Troubleshooting
263
Bearing Calibration
263
When to Calibrate the Bearings
263
Calibration When Commissioning
263
Regular Maintenance Calibration
264
Calibration When Troubleshooting
264
BMCC Change
264
Performing a Calibration
264
Before Performing a Calibration
264
Calibration
264
After Calibration Is Complete
265
Validate
265
Save to EEPROM
266
Create a Calibration Report
266
Calibration Report Analysis
266
SMT Compressor Connection Status Indications
269
System and Compressor Level Troubleshooting
269
Compressor Voltage Troubleshooting
269
Determining the Cause of an Energy Drain
271
Determining if Serial Driver Is Draining Energy
271
Determining if BMCC Is Draining Energy
271
Determine if PWM Is Draining Energy
272
Determining if Inverter Is Draining Energy
272
Determining if Compressor I/O Board Is Draining Energy
272
Determining the Cause of Blown Soft Start Fuses (Closed-Top Soft Start Only)
272
Troubleshooting an Open Interlock
273
Troubleshooting the Inverter
273
Chapter 6.0 Maintenance
275
Preventative Maintenance Tasks
275
Moisture Prevention Measures
276
Required Items
276
Service Side Disassembly
276
Service Side Assembly
277
Top Side
278
Appendix A Acronyms/Terms
279
Appendix B Compressor Troubleshooting Flowcharts
281
Appendix C Compressor Test Sheet
287
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Danfoss Turbocor TT Series Specifications
General
Brand
Danfoss
Model
Turbocor TT Series
Category
Air Compressor
Language
English
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