What does it mean when the superheat temperature is too high on my Danfoss Air Compressor?
If the calculated superheat temperature has exceeded the alarm limit on your Danfoss Air Compressor, be aware that the difference between the fault limit and the alarm limit is the dead band for the control. The superheat alarm is always set 8°K below the fault limit.
General| Model | TT300 |
|---|---|
| Cooling Capacity | 300 kW |
| Motor Type | Permanent Magnet Synchronous Motor |
| Lubrication | Oil-free |
| Compressor Type | Centrifugal |
| Refrigerant | R134a |
Outlines copyright, liability limitations, and revision rights for the manual.
Explains the manual's purpose and intended audience.
Describes the manual's structure and section breakdown.
States the company's commitment to quality and customer satisfaction.
Provides an overview of safety precautions and hazard identification.
Explains danger notifications and their significance for safety.
Explains caution notifications and their significance for safety.
Explains the use and format of notes in the manual.
Covers general safety precautions for personnel and equipment.
Details the types of refrigerants used with the compressors.
Specifies refrigerants for TT series compressors.
Specifies refrigerants for TG series compressors.
Explains the critical steps for isolating electrical power before service.
Covers precautions for handling static-sensitive electronic components.
Details ESD protection and grounding procedures for safe handling.
Instructions for installing and removing the DC bus test harness.
Step-by-step guide for installing the DC bus test harness.
How to use the DC bus test harness to measure voltage.
Steps to disconnect and remove the DC bus test harness.
Describes the path of refrigerant through the compressor stages.
Explains how the motor and power electronics are cooled.
Details serial and split cooling methods for motor and electronics.
Explains methods used for compressor capacity control.
Outlines the flow of energy and signals within the compressor.
Identifies major compressor components and their locations.
Provides steps for removing and installing the compressor.
Safety procedure for isolating and recovering refrigerant before service.
Detailed steps for removing the compressor from its installation.
Detailed steps for installing a new or reconditioned compressor.
Specific considerations for replacing the motor cooling adapter.
Describes the terminal block where 3-phase AC voltage is supplied.
Explains the function of the main voltage input terminal block.
Details how the AC power is routed to the SCRs and Soft Start board.
Procedures for verifying the 3-phase AC input.
Steps to verify the main 3-phase AC input.
How to securely connect the AC input cable.
How to measure AC input voltage and verify readings.
Steps for removing and installing the terminal block.
Specific steps for removing the terminal block on certain models.
Specific steps for removing the terminal block on TT300/TG230 models.
Specific steps for installing the terminal block on certain models.
Specific steps for installing the terminal block on TT300/TG230 models.
Introduces the Soft Start Board and its function.
Explains the function of the Soft Start Board in limiting in-rush current.
Shows the connection points on the Soft Start Board.
Procedures for verifying Soft Start voltages and fuses.
Steps to verify the voltages related to the Soft Start Board.
Steps to test the Soft Start fuses for continuity.
Steps for removing and installing the Soft Start Board.
Detailed steps for removing the Soft Start Board.
Detailed steps for installing the Soft Start Board.
Explains the SCR module and its function in AC to DC conversion.
Describes the role of SCRs in converting AC voltage to DC for the Inverter.
Shows the connections to the SCR modules.
Procedures for verifying SCR module functionality.
Steps to verify the diodes within the SCR module.
How to verify the gate resistance of the SCRs.
How to verify the SCR temperature sensor resistance.
Steps for removing and installing SCRs and their temperature sensor.
Detailed steps for removing the SCR modules.
Steps to remove the SCR temperature sensor.
Steps to install the SCR modules.
Steps to install the SCR temperature sensor.
Describes the DC bus components and their function.
Explains the role of DC bus components like capacitors, bus bars, and resistors.
Shows the DC bus connections.
Procedures for verifying DC bus voltage, bleed resistors, and snubber capacitors.
How to verify the DC bus voltage.
Steps to verify the resistance of bleed resistors.
How to measure the capacitance of snubber capacitors.
Steps for removing and installing DC bus components.
Detailed steps for removing the DC bus assembly.
Detailed steps for installing the DC bus assembly.
Describes the Inverter (IGBT) and its function.
Explains how the Inverter generates AC output voltage for the motor.
Shows the Inverter's connection points.
Procedures for verifying Inverter diodes.
Steps to verify the Inverter diodes' functionality.
Steps for removing and installing the Inverter and IGBT Control Card.
Steps to remove the IGBT Control Card (where applicable).
Steps to install the IGBT Control Card.
Detailed steps for removing the entire Inverter assembly.
Detailed steps for installing the Inverter assembly.
Describes the motor specifications and protection.
Explains the motor's function as a permanent magnet synchronous motor.
Describes the stator's role in generating force for the shaft.
Describes the rotor's design and its synchronous characteristic.
Details motor protection mechanisms, including overheat cutouts.
Shows how to identify motor connections.
Procedures for verifying stator insulation, resistance, and thermistor.
How to test stator insulation integrity.
Steps to verify stator winding resistance.
How to verify the stator thermistor's resistance.
Describes the HV DC/DC Converter and its function.
Explains the converter's role in providing voltage to the Backplane.
Shows the input and output connections for the HV DC/DC Converter.
Procedures for verifying HV DC/DC converter input/output voltages and resistances.
How to verify the input voltage to the converter.
How to verify the output voltages from the converter.
Steps to verify input resistance of the converter.
How to measure output resistance of the converter.
Steps for removing and installing the HV DC/DC Converter.
Detailed steps for removing the HV DC/DC Converter.
Detailed steps for installing the HV DC/DC Converter.
Describes the Backplane and its role.
Explains the Backplane's function as a power and signal distribution hub.
Identifies Backplane connections and test points.
Shows the locations of status LEDs on the Backplane.
Procedures for verifying Backplane voltage and resistance.
Steps for removing and installing the Backplane.
Detailed steps for removing the Backplane.
Detailed steps for installing the Backplane.
Describes the Serial Driver and its function.
Explains the Serial Driver's role in controlling solenoids and LEDs.
Shows how the Serial Driver connects to the Backplane.
Procedures for verifying Serial Driver voltages.
How to verify input voltages to the Serial Driver.
How to verify output voltages from the Serial Driver.
Steps for removing and installing the Serial Driver.
Detailed steps for removing the Serial Driver.
Detailed steps for installing the Serial Driver.
Describes the solenoids and actuators for cooling.
Explains the function of solenoids in controlling refrigerant flow.
Shows how solenoids are secured and connected.
Procedures for verifying solenoid actuator coil resistance.
How to measure the resistance of solenoid actuator coils.
How to verify the output voltage supplied to the solenoids.
How to inspect cooling paths for blockages.
Steps for removing and installing solenoids and actuators.
Detailed steps for removing solenoids and actuators.
Detailed steps for installing solenoids and actuators.
Describes the Inlet Guide Vanes (IGV) assembly.
Explains the IGV's function in controlling compressor capacity.
Shows the IGV assembly connections.
Procedures for verifying IGV stepper motor and operation.
Steps to verify the IGV stepper motor's resistance.
How to verify IGV operation using the SMT tool.
Steps for removing and installing the IGV assembly.
Detailed steps for removing the IGV assembly.
Detailed steps for installing the IGV assembly.
Describes the Bearing Motor Compressor Controller (BMCC).
Explains the BMCC's role as the central processor.
Shows BMCC connections to the Backplane.
Procedures for verifying BMCC power supply and communication.
How to verify the BMCC's power supply voltages.
Steps to verify BMCC communication with the SMT.
Steps for removing and installing the BMCC.
Detailed steps for removing the BMCC.
Detailed steps for installing the BMCC.
Describes the Compressor Interface Module (CIM) or I/O Board.
Explains the CIM's function in user control and status reporting.
Shows the ports and jumper locations on the CIM.
Procedures for verifying CIM functionality.
How to check if the CIM is draining excessive power.
Steps to verify CIM communication with the compressor.
How to verify the system interlock circuit.
Steps for removing and installing the CIM.
Detailed steps for removing the CIM.
Detailed steps for installing the Compressor I/O Board.
Describes the Bearing PWM Amplifier.
Explains the PWM Amplifier's role in supplying current to bearing coils.
Shows the PWM connection port and feed-through differences.
Procedures for verifying PWM amplifier functionality.
How to check if the PWM Amplifier is draining energy.
How to verify the PWM's five output channels.
How to verify the functionality of the PWM's five diode sets.
Steps for removing and installing the PWM Amplifier.
Detailed steps for removing the PWM Amplifier.
Detailed steps for installing the PWM Amplifier.
Describes magnetic bearings and their function.
Explains how magnetic bearings levitate the shaft.
Shows the PWM connectors for bearing power feed throughs.
Procedures for verifying bearing coil integrity.
How to check bearing coil insulation and resistance.
How to verify bearing amperages during operation.
Describes bearing sensors and their connections.
Explains how bearing sensors provide shaft orbit information.
Shows how bearing sensors connect to the Backplane.
Procedures for verifying bearing sensor resistance.
How to verify bearing sensor resistance and ground readings.
Describes the cavity temperature sensor.
Explains the cavity sensor's role in measuring motor-cooling gas temperature.
Shows how the cavity temperature sensor connects to the Backplane.
Procedures for verifying the cavity temperature sensor.
Steps for removing and installing the cavity temperature sensor.
Detailed steps for removing the cavity temperature sensor.
Detailed steps for installing the cavity temperature sensor.
Describes the suction and discharge pressure/temperature sensors.
Explains the function of pressure/temperature sensors in monitoring compressor operation.
Shows how the pressure/temperature sensors connect to the Backplane.
Procedures for verifying pressure/temperature sensors and their cables.
Steps for removing and installing pressure/temperature sensors.
Detailed steps for removing the sensors.
Detailed steps for installing the sensors.
Explains how alarms and faults indicate operating conditions.
Lists and describes different types of compressor alarms.
Categorizes and describes critical and non-critical compressor faults.
Lists various compressor fault types and their descriptions.
Lists motor and bearing fault types.
How to use the SMT software for troubleshooting.
Detailed fault analysis using SMT tools.
Interpreting motor faults and system status messages.
Lists bearing status types and their descriptions.
Describes bearing status indicators during operation.
When and how to perform bearing calibration.
Conditions and reasons for performing bearing calibration.
Calibration for initial setup and comparison.
Calibration performed during routine maintenance.
When calibration is needed for troubleshooting.
Calibration required after BMCC replacement.
Steps involved in performing a bearing calibration.
Prerequisites before starting calibration.
The actual calibration steps and validation.
Options after calibration completion (Validate, Save, Report).
How to validate calibration data by levitating the shaft.
How to save calibration values to EEPROM.
Steps to create a calibration report.
How to interpret calibration report data.
Explains different compressor connection status indicators.
Troubleshooting at system and compressor levels.
Steps to troubleshoot compressor voltage issues.
Steps to troubleshoot compressor voltage issues.
How to identify components draining energy.
Steps to check if the Serial Driver is draining energy.
Steps to check if the BMCC is draining energy.
Steps to check if the PWM is draining energy.
Steps to check if the Inverter is draining energy.
Steps to check if the Compressor I/O Board is draining energy.
Troubleshooting steps for blown Soft Start fuses.
How to troubleshoot an open interlock circuit.
Steps to troubleshoot Inverter faults.
Lists regular maintenance tasks for optimal performance.
Recommendations to prevent condensate infiltration in electrical connections.
Lists consumables needed for moisture prevention.
Steps for disassembling the service side for maintenance.
Steps for removing solenoid coils.
Steps for applying dielectric grease.
Steps for reassembling the service side after maintenance.
Steps for top-side maintenance and component cleaning.
Glossary of product-specific acronyms and terms.
Flowchart for troubleshooting compressor operation issues.
First part of a flowchart for voltage troubleshooting.
Second part of a flowchart for voltage troubleshooting.
Table detailing test points, expected values, and verification sections.
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