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Danfoss Turbocor TTS Series

Danfoss Turbocor TTS Series
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Danfoss Turbocor® Twin-Turbine
Centrifugal Series Compressors
TTS, TGS, TTH, TGH Series Compressors
Service Manual - Revision G
http://turbocor.danfoss.com
®

Table of Contents

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Danfoss Turbocor TTS Series Specifications

General IconGeneral
Motor TypePermanent Magnet Synchronous Motor (PMSM)
LubricationOil-free
RefrigerantR-134a, R-1234ze(E)
Power Supply380 V, 60 Hz
Variable Speed DriveIntegrated
Compressor TypeOil-free, centrifugal

Summary

Chapter 1: Compressor Introduction

1.1 Application

Explains product nomenclature changes and series indicators for compressors.

1.2 Purpose

Details the manual's purpose and required expertise for service procedures.

1.5 Safety Summary

Highlights critical safety precautions for installation, start-up, and service.

1.8 Electrical Isolation

Provides steps to safely isolate compressor power before maintenance.

1.9 Handling Static Sensitive Devices

Outlines precautions for handling ESD-sensitive components.

1.10 DC Bus Test Harness Installation and Removal

Procedures for installing and removing the DC bus test harness for diagnostics.

Chapter 2: Compressor Fundamentals

2.1 Main Fluid Path

Describes the two-stage centrifugal compressor's primary refrigerant flow.

2.2 Motor and Power Electronics Cooling

Explains liquid refrigerant flow for cooling motor and power electronics.

2.3 Capacity Control

Details how capacity is controlled via speed modulation and inlet guide vanes.

2.4 Compressor Energy and Signal Flow

Outlines the distribution of power and signals through compressor components.

Chapter 3: Compressor Removal and Installation

3.1 Refrigerant Containment

Details procedures for safe refrigerant isolation and recovery before component removal.

3.2 Compressor Removal

Provides step-by-step instructions for safely removing the compressor.

3.3 Compressor Installation

Outlines procedures for installing a new compressor, including connections and torque specs.

3.5 Exterior Connection Torque Specifications

Lists torque specifications for various exterior connections on the compressor.

Chapter 4: Compressor Components

4.1 Component Identification

Identifies major compressor components with numbered diagrams for easy reference.

4.2 Compressor Covers

Explains the function and removal/installation of protective covers for internal components.

4.3 Cooling Adapter

Describes the adapter connecting the liquid feed line for motor and power electronics cooling.

4.15 Soft Start

Covers the two variants of Soft Starts and their function in managing in-rush current during startup.

4.19 Silicone-Controlled Rectifier (SCR)

Explains the SCRs' role in converting AC to DC voltage for the Inverter.

4.22 DC Capacitor Bus Bar Assembly

Describes the assembly including bus bars, capacitors, and bleed resistors.

4.23 Inverter

Details the Inverter's function in converting DC bus voltage to AC output for the motor.

4.25 High Voltage DC-DC Converter

Explains the function and variants of the DC-DC converter used for power supply.

4.26 Backplane

Describes the Backplane's role in power distribution and communication among compressor components.

4.28 BMCC

Details the BMCC as the central processor controlling bearing and motor systems.

4.30 Magnetic Bearings

Explains how magnetic bearings levitate the shaft and maintain position using electromagnets.

4.31 Bearing Sensors

Describes bearing sensors that provide shaft orbit information.

4.33 PressureTemperature Sensor

Describes sensors used to monitor operating pressures and temperatures for calculations.

Chapter 5: Troubleshooting

5.1 Alarm and Fault Indications

Explains how alarms and faults indicate compressor conditions beyond normal limits.

5.2 Troubleshooting with the Service Monitoring Tools Software

Guides on using SMT software for viewing compressor status and troubleshooting procedures.

5.3 Bearing Calibration

Details procedures for performing bearing calibration during commissioning, maintenance, or troubleshooting.

5.5 System and Compressor Level Troubleshooting

Covers troubleshooting voltage issues and energy drains at system and compressor levels.

5.5.1 Compressor Voltage Troubleshooting

Steps to verify AC input voltage and identify potential issues.

5.5.2 Determining the Cause of an Energy Drain

Procedures to identify which component is causing an energy drain.

5.5.3 Troubleshooting an Open Interlock

Steps to diagnose and bypass an open interlock circuit.

5.5.4 Troubleshooting the Inverter

Guidance on troubleshooting Inverter faults, including checking for active errors.

Chapter 6: Maintenance

6.1 Preventative Maintenance Tasks

Identifies tasks for regular maintenance to ensure optimal system performance.

6.2 Moisture Prevention Measures

Recommends steps to prevent condensate infiltration in electrical connections.

Appendix A - AcronymsTerms

AcronymsTerms

Provides definitions for acronyms and terms used throughout the manual.

Appendix B - Compressor Troubleshooting Flowcharts

Compressor Operation Troubleshooting Flowchart (Sheet 1)

Provides a flowchart for diagnosing compressor operational issues.

Compressor Voltage Troubleshooting Flowchart (Sheet 1)

Step-by-step guide for troubleshooting compressor voltage issues.

Appendix C - Compressor Test Sheet

Compressor Test Sheet

Contains test points, expected values, and verification sections for components.

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