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Turbocor TTS Series
Danfoss Turbocor TTS Series User Manual
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This manual co
vers Major Revision "F" and lat
er compressors. If y
ou have a Major Re
vision "E" or earlier compressor
, we suggest
downloading Service Manual Revision E from our websit
e since there are some steps tha
t are unique.
1
3
Table of Contents
Table of Contents
3
Chapter 1: Compressor Introduction
13
Application
15
Purpose
16
Organization
17
Commitment to Quality and the Environment
18
Precautions
18
Refrigerant Type
18
Danger Notification
18
Caution Notification
18
Note
18
R134A/513A
18
Safety Summary
18
Electrical Isolation
19
R1234Ze
19
R515B
19
Handling Static Sensitive Devices
20
ESD Protection/Grounding
21
DC Bus Test Harness Installation and Removal
22
General Verification and Installation of the DC Bus Test Harness
22
DC Bus Test Harness Installation for Closed-Top Soft Start
23
Compressor Fasteners
27
General O-Ring Handling
27
General DC Bus Test Harness Removal
27
DC Bus Test Harness Removal for Closed-Top Soft Starts
27
DC Bus Test Harness Removal for Open-Top Soft Starts
27
Chapter 2: Compressor Fundamentals
29
Figure 2-1 Compressor Fluid Paths
31
Main Fluid Path
31
Motor and Power Electronics Cooling
31
Table 2-1 Compressor Fluid Paths
31
Figure 2-2 Cooling Inlet Adapter
32
Figure 2-3 Split Cooling Path - TTH375/TGH285
33
Figure 2-4 Split Cooling Path - (TTS/TGS (Except TTS300/TGS230 Serial Cooling)
33
Capacity Control
34
Compressor Energy and Signal Flow
34
Figure 2-5 Serial Cooling Path - TTS300/TGS230
34
Figure 2-6 Compressor Energy and Signal Flow Connections
36
Figure 2-7 Compressor Energy and Control Flow Block Diagram - TTS/TGS Compressors
37
Chapter 3: Compressor Removal and Installation
39
Chapter 3: Compressor Removal and Installation
41
Compressor Removal
41
Figure 3-1 Compressor Power Cable Removal
41
Refrigerant Containment
41
Compressor Installation
42
Figure 3-2 Compressor Mounting Fasteners
42
Compressor Replacement Considerations for Motor Cooling Adapter
43
Figure 3-3 Motor Cooling Fitting
43
Exterior Connection Torque Specifications
45
Table 3-1 Exterior Connection Torque Specifications
45
Chapter 4: Compressor Components
47
Component Identification
51
Figure 4-1 Compressor Components Identification (Covers On)
51
Figure 4-9 Service Side Cover
51
Table 4-1 Compressor Components (Covers On)
51
Figure 4-2 Compressor Component Identification - Service Side (Excludes TTH/TGH Compressors)
52
Figure 4-273 BMCC
52
Figure 4-278 PWM
52
Table 4-2 Compressor Components Service Side (Excludes TTH/TGH Compressors)
52
Figure 4-3 Compressor Component Identification - Service Side (TTH/TGH Only)
53
Table 4-3 Compressor Components Service Side (TTH/TGH Only)
53
Figure 4-4 Compressor Component Identification - Capacitor Side (Excludes TTH/TGH)
54
Table 4-4 Compressor Components Capacitor Side (Excludes TTH/TGH)
54
Figure 4-37 Interstage Pipe
55
Figure 4-5 Compressor Component Identification - Capacitor Side (TTH/TGH Only)
55
Table 4-5 Compressor Components Capacitor Side (TTH/TGH Only)
55
Compressor Covers
56
Figure 4-6 Top Covers Removal
56
Mains Input Cover
56
Figure 4-7 Mains Input Cover Torque Sequence
57
Figure 4-8 Top Cover
57
Top Cover
57
Figure 4-10 Service Side Cover
58
Service Side Cover
58
Figure 4-11 Capacitor Cover
59
Figure 4-12 Capacitor Nylon Nuts
59
Capacitor Cover
59
Table 4-6 Compressor Cover Torque Specifications
60
Figure 4-13 Relief Membrane Position
60
Figure 4-14 Recessed Holes
60
Figure 4-15 Capacitor Cover Torque Sequence
60
Compressor Cover Torque Specifications
60
Cooling Adapter
61
Figure 4-16 Cooling Adapter - Excludes TTH375/TGH285
61
Figure 4-17 Cooling Adapter - TTH375/TGH285)
61
Table 4-7 Cooling Adapter Torque Specifications
62
Cooling Adapter Removal and Installation
62
Cooling Adapter Torque Specifications
62
Compressor Interface Module
63
Figure 4-18 Compressor Interface Module Ports & Jumpers
63
Compressor Interface Module Connection Descriptions
63
Compressor Interface Module Verification
65
Table 4-8 CIM Ports and Jumpers
63
Compressor Interface Cable
66
Figure 4-19 Removing the Compressor Interface Module from the DIN Rail
66
Compressor Interface Module Removal & Installation
66
Compressor Controller Cable Harness
67
Figure 4-20 Compressor Interface Cable
67
Compressor Interface Cable Verification
67
Compressor Interface Cable Removal and Installation
67
Figure 4-21 Compressor Controller Cable Harness Variants
68
Compressor Controller Cable Connections
68
Compressor Controller Cable Harness Removal and Installation
68
Figure 4-22 Backplane Connections
69
Figure 4-23 Pressure/Temperature and SCR Temperature Sensor Locations - TTS300/TGS230
69
Figure 4-24 Pressure/Temp and SCR Temp Sensor Locations - TTS/TGS
70
Figure 4-25 Pressure/Temperature Sensors - TTH375/TGH285
70
Figure 4-26 IGV Connector Clamp
70
Figure 4-27 Cable Passage
71
Figure 4-28 Cooling Valve Bodies
72
Figure 4-29 Compressor Cooling Solenoid Coils
72
Compressor Controller Cable Harness Torque Specifications
72
Solenoid and Coil Connections
72
Table 4-10 Solenoid Coil Resistance Ranges
73
Figure 4-30 Solenoid Coil Harness
73
Figure 4-31 Backplane - J16 Connector
73
Solenoid Coil Harness
73
Solenoid Verification
73
Figure 4-32 Compressor Cooling Solenoid Coil Cable Connector
74
Figure 4-33 Backplane - Cool Leds and +24V Test Points
74
Figure 4-34 Solenoid Cooling Path - TTS300/TGS230
74
Figure 4-35 Solenoid Component Removal
75
Solenoid and Coil Removal and Installation
75
Table 4-11 Solenoid Torque Specifications
76
Figure 4-36 Solenoid Actuator Coil Position
76
Solenoids and Coils
72
Table 4-9 Compressor Controller Cable Harness Torque Specifications
72
Figure 4-38 Interstage Pipe Removal
77
Interstage Pipe Removal and Installation
77
Interstage Pipe - TTH/TGH
77
Compressor Housing End Cap
78
Figure 4-39 Compressor Housing End Cap - TTS/TGS
78
Figure 4-40 Compressor Housing End Cap - TTH/TGH
78
Interstage Pipe Torque Specifications
78
Table 4-13 Compressor Housing End Cap Torque Specifications
79
Compressor Housing End Cap Removal and Installation
79
Table 4-12 Interstage Pipe Torque Specifications
78
Figure 4-41 IGV Assembly
80
Figure 4-42 IGV Connections
80
IGV Connections
80
Figure 4-43 IGV Motor Feedthrough
81
Figure 4-44 SMT Icon
81
Figure 4-45 Compressor Configuration Tool
81
IGV Verification
81
Figure 4-46 Control Mode
82
Figure 4-47 Compressor Monitor Tool
82
Figure 4-48 IGV Open Percentage - 100
82
Figure 4-49 IGV Open Percentage - 0
82
Figure 4-50 Backplane Cool Leds
83
Figure 4-51 Backplane +15V Test Point
83
Figure 4-52 IGV Harness Removal
83
IGV Housing Removal and Installation
83
Table 4-15 IGV Feedthrough Wiring Order
84
Figure 4-53 IGV Housing Removal
84
Figure 4-54 IGV Feedthrough Removal
84
Figure 4-55 Set Screw Removal
85
Figure 4-56 IGV Motor Assembly Removal
85
Figure 4-57 Locking Collar Tool
85
Figure 4-58 Locking Collar Removal
86
Figure 4-59 Worm Gear Removal
86
Figure 4-60 Large Worm Gear Bearing Removal
86
Figure 4-61 IGV Throat Removal
87
Figure 4-62 Small Worm Gear Bearing Removal
87
Figure 4-63 Small Worm Gear Bearing Installation
87
Figure 4-64 IGV Position Indicator Magnet
88
Figure 4-65 Large Worm Gear Bearing Installation
88
Figure 4-66 Locking Collar Installation
89
Figure 4-67 IGV Worm Gear Alignment
89
Figure 4-68 Shaft Position
89
Table 4-16 IGV Feedthrough Pin to Wire Reference
90
Figure 4-69 IGV Motor Alignment
90
Figure 4-70 Motor Wire Position
90
Figure 4-71 IGV Motor Wires Connected
91
Figure 4-72 Feedthrough Orientation
91
Figure 4-73 IGV Housing Installation
91
Table 4-17 IGV Torque Specifications
92
Figure 4-74 IGV Position Indicator
92
IGV Torque Specifications
92
Igv
80
Table 4-14 IGV Components
80
Figure 4-75 Mains Plate Bracket
93
Mains Plate Bracket Removal and Installation
93
Figure 4-76 Ground Post Nuts
94
Figure 4-77 Mains Input Nut Installation - TTS300/TGS230 Compressors
94
Figure 4-78 Mains Input Nut Installation - TTS/TGS/TTH/TGH Rev. H and Earlier (Except TTS300/TGS230)
94
Mains Plate Bracket
93
3-Phase Main Voltage Input Terminal Block
95
Figure 4-79 Input Terminal Block - TTS300/TGS230
95
Table 4-18 Mains Plate Torque Specifications
95
Figure 4-80 Input Terminal Block - TTS/TGS/TTH/TGH Rev. H (Except TTS300/TGS230)
96
Figure 4-81 Input Terminal Block - TTS/TGS/TTH/TGH Rev. F and Earlier (Except TTS300/TGS230)
96
3-Phase Main Voltage Input Terminal Block Verification
96
Figure 4-82 Measuring the 3-Phase AC Input Voltage on the AC Input Terminals - TTS300/TGS230
97
Figure 4-83 Measuring 3-Phase AC Input Voltage on AC Input Terminals (TTS/TGS/TTH/TGH (Except TTS300/TGS230)
97
Table 4-19 Expected AC Voltage Range
98
Figure 4-84 Terminal Block Removal - TTS300/TGS230
98
3-Phase Main Voltage Input Terminal Block Removal and Installation
98
Figure 4-85 Input Terminal Block Removal - TTS/TGS/TTH/TGH Rev. F and Earlier (Except TTS300/TGS230)
99
Figure 4-86 Input Terminal Block Removal - TTS/TGS/TTH/TGH Rev. H (Except TTS300/TGS230)
100
Figure 4-87 Input Terminal Block Installation - TTS300/TGS230
100
Figure 4-88 Terminal Block - Input Pressure Screws - TTS300/TGS230
101
Figure 4-89 Input Terminal Block Installation - TTS/TGS/TTH/TGH Rev. F and Earlier (Except TTS300/TGS230)
101
Figure 4-90 Input Terminal Block Installation - TTS/TGS/TTH/TGH Rev. H (Except TTS300/TGS230)
102
Figure 4-91 Input Mains Bus Bar Examples
103
Input Mains Bus Bars (Except TTS300/TGS230)
103
Table 4-20 Terminal Block Torque Specifications
103
Figure 4-92 AC/DC Bus Bus Bar Connectors - TTS/TGS/TTH/TGS Rev. F and Earlier (Except TTS300/TGH230)
104
Figure 4-93 AC/DC Bus Bus Bar Connectors - TTS/TGS/TTH/TGS Rev. H (Except TTS300/TGH230)
104
Figure 4-94 Terminal Block Fuse
105
Verification of Terminal Block Fuse
105
Figure 4-95 Terminal Block Fuse Test
106
Figure 4-96 Terminal Block Fuse Removal
106
Terminal Block Fuse Removal and Installation
106
Table 4-21 AC Bus Bar Torque Specifications
105
Terminal Block Fuse Replacement
105
Figure 4-97 Soft Start Variants
107
Soft Start
107
Table 4-22 Terminal Block Fuse Torque Specifications
107
Figure 4-98 Closed-Top Soft Start Connections
108
Soft Start Connections
108
Table 4-24 Open-Top Soft Start Connection Identification
109
Figure 4-99 Open-Top Soft Start Connections
109
Soft Start Verification
109
Figure 4-100 Soft Start Label Location
110
Figure 4-101 Soft Start Fuse Locations
111
Table 4-25 Soft Start Fuse Details
112
Figure 4-102 Closed-Top Soft Start J9 Connector
112
Soft Start Removal and Installation
112
Soft Start Removal (Closed-Top)
112
Figure 4-103 Ground Location
113
Figure 4-104 Closed-Top Soft Start
113
Figure 4-105 Soft Start Lift
113
Figure 4-106 Closed-Top Soft Start Connector Removal
114
Figure 4-107 Open-Top Soft Start J7 Connector
114
Figure 4-108 Ground Location
114
Soft Start Removal (Open-Top)
114
Figure 4-109 Open-Top Soft Start Connector Removal
115
Figure 4-110 Open-Top Soft Start Removal
115
Figure 4-111 Closed-Top-Soft Start Installation
116
Figure 4-112 Ground Stud Location
116
Soft Start Installation (Closed-Top)
116
Figure 4-113 Open-Top-Soft Start Installation
117
Soft Start Installation (Open-Top)
117
Soft Start Fan Removal and Installation
117
Soft Start Fan Removal
117
Figure 4-114 Soft Start Without Adapter
118
Figure 4-115 Soft Start Fan Orientation
118
Figure 4-116 Soft Start Fan Installation
118
Soft Start Fan Installation
118
Table 4-23 Closed-Top Soft Start Connection Identification
108
Figure 4-117 Soft Start Fan Connector
119
Figure 4-118 SCR DC Bus Bars
119
SCR DC Bus Bar - TTS300/TGS230
119
Table 4-26 Soft Start Torque Specifications
119
Figure 4-119 SCR DC Bus Bar Removal - TTS300/TGS230
120
Figure 4-120 SCR DC Bus Bar to SCR Alignment
120
SCR DC Bus Bar Removal and Installation
120
Figure 4-121 Soft Start SCR Gate Cable (Closed-Top Soft Starts)
121
Figure 4-122 Soft Start SCR Gate Cable (Open-Top Soft Starts)
121
Soft Start SCR Gate Cable Connections
121
Soft Start SCR Gate Cable Removal and Installation
121
Figure 4-123 Soft Start SCR Gate Cable Removal - TTS300/TGS230
122
Figure 4-124 Soft Start SCR Gate Cable Removal at SCR - TTS/TGS/TTH/TGH Models Rev. F and Earlier (Except TTS300/TGS230)
122
Figure 4-125 Soft Start SCR Gate Cable Removal at SCR - TTS/TGS/TTH/TGH Models Rev. H (Except TTS300/TGS230)
122
Figure 4-126 Closed-Top Soft Start J8 Connector Top
123
Figure 4-127 Open-Top Soft Start J2 Connector
123
Soft Start SCR Gate Cable
121
Table 4-27 SCR DC Bus Bar Torque Specifications
121
Figure 4-128 SCR Gate Connector Alignment
124
Soft Start AC/DC Harness
124
Figure 4-129 Soft Start AC/DC Harness Connections - TTS300/TGS230
125
Soft Start AC/DC Harness Connections
125
Figure 4-130 Soft Start AC/DC Harness Connections - TTS/TGS/TTH/TGH (Except TTS300/TGS230)
126
Figure 4-131 AC Input Ring Terminal Removal - TTS300/TGS230
127
Figure 4-132 DC Ring Terminal Removal - TTS300/TGS230
127
Figure 4-133 DC-DC Connectors (Open Frame)
127
Soft Start AC/DC Harness Removal and Installation
127
Figure 4-134 DC-DC Connectors (Potted)
128
Figure 4-135 Closed-Top Soft Start J1 and J7 Removal
128
Figure 4-136 Open-Top Soft Start J1 and J8 Removal
129
Figure 4-137 AC Input Spade and DC Spade Connector Removal - TTS/TGS/TTH/TGH Rev. F and Earlier (Except TTS300/TGS230)
129
Figure 4-138 AC Input Ring and DC Spade Connector Removal - TTS/TGS/TTH/TGH Rev. H (Except TTS300/TGS230)
130
Figure 4-139 Soft Start AC/DC Harness Position - TTS300/TGS230
131
Figure 4-140 AC Input and Spade Connector Installation - TTS/TGS/TTH/TGH Rev. F and Earlier (Except TTS300/TGS230)
132
Figure 4-141 AC Input and Spade Connector Installation - TTS/TGS/TTH/TGH Rev. H (Except TTS300/TGS230)
133
Silicone-Controlled Rectifier
133
Table 4-28 Soft Start AC/DC Harness Torque Specifications
133
Figure 4-142 SCR Styles
134
Figure 4-143 SCR Connections - TTS300/TGS230
134
SCR Connections
134
Figure 4-144 SCR Connections - TTS/TGS/TTH/TGH Rev. F and Earlier (Except TTS300/TGS230)
135
Figure 4-145 SCR Connections - TTS/TGS/TTH/TGH Rev. H (Except TTS300/TGS230)
135
SCR Verification
135
Figure 4-146 SCR Terminals - Two Hole Mount
136
Figure 4-147 SCR Terminals - Four Hole Mount
136
Table 4-29 SCR Diode Values
137
Table 4-30 SCR Gate Resistance Ranges
137
Figure 4-148 SCR Temperature Sensor Assembly
137
Figure 4-149 J17 Connector
137
Figure 4-150 Discharge Pressure/Temperature Sensor Connector Removal - TTS300/TGS230
138
Figure 4-151 SCR Temperature Sensor Connector - TTS300/TGS230
138
Figure 4-152 SCR Temperature Sensor Removal -TTS300/TGS230
139
Figure 4-153 SCR Temperature Sensor Connector - TTS/TGS/TTH/TGH Rev. F and Earlier (Except TTS300/TGS230)
139
Figure 4-154 Discharge Pressure/Temperature Sensor Connector Removal - TTS/TGS/TTH/TGH (Except TTS300/TGS230)
139
Figure 4-155 SCR Temperature Sensor Removal - TTS/TGS/TTH/TGH Rev. F and Earlier (Except TTS300/TGS230)
140
Table 4-31 SCR Temperature Sensor Torque Specifications
141
SCR Removal and Installation
141
Figure 4-156 Fuse Block Assemblies - Two Hole Mount - TTS300/TGS230
142
Figure 4-157 DC Bus Bar Removal - TTS300/TGS230
142
Figure 4-158 SCR Removal - TTS300/TGS230
143
Figure 4-159 SCR Gate Cable and AC/DC Harness Connections - TTS/TGS/TTH/TGH Rev. F and Earlier (Except TTS300/TGS230)
143
Figure 4-160 SCR Gate Cable and AC/DC Harness Connections - TTS/TGS/TTH/TGH Rev. H (Except TTS300/TGS230)
143
Figure 4-161 SCR Bus Fastener Removal - TTS/TGS/TTH/TGH Rev. F and Earlier (Except TTS300/TGS230)
144
Figure 4-162 SCR Bus Fastener Removal - TTS/TGS/TTH/TGH Rev. H (Except TTS300/TGS230)
145
Figure 4-163 SCR Removal - TTS/TGS/TTH/TGH Rev. F and Earlier (Except TTS300/TGS230)
145
Figure 4-164 SCR Removal - TTS/TGS/TTH/TGH Rev. H (Except TTS300/TGS230)
145
Figure 4-165 SCR Heat Sink Paste Application - TTS300/TGS230
146
Figure 4-166 SCR Orientation - TTS300/TGS230
146
Figure 4-167 Bus Bar Installation - TTS300/TGS230
147
Figure 4-168 Bus Bar Locations - TTS300/TGS230
147
Figure 4-169 SCR Thermal Paste Application - TTS/TGS/TTH/TGH (Except TTS300/TGS230)
148
Figure 4-170 SCR Torque Sequence - TTS/TGS/TTH/TGH Rev. F and Earlier (Except TTS300/TGS230)
148
Table 4-32 SCR Torque Specifications
149
Figure 4-172 Inverter Assembly Removal - TTS300/TGS230
150
SCR Cooling Manifold General Removal
150
SCR Cooling Manifold Removal - TTS300/TGS230
150
Figure 4-173 SCR Cooling Manifold Removal - TTS300/TGS230
151
SCR Cooling Manifold Removal - TTS/TGS/TTH/TGH (Except TTS300/TGS230)
151
Figure 4-174 SCR Cooling Manifold Removal
152
Figure 4-175 SCR Cooling Plate O-Ring Installation - TTS300/TGS230
152
SCR Cooling Manifold Installation - TTS300/TGS230
152
Figure 4-176 Inverter Heat Sink Plate O-Ring Installation - TTS/TGS/TTH/TGH (Except TTS300/TGS230)
153
Figure 4-177 SCR Manifold Return Brass Fitting O-Ring Installation - TTS/TGS/TTH/TGH (Except TTS300/TGS230)
153
SCR Cooling Manifold Installation - TTS/TGS/TTH/TGH (Except TTS300/TGS230)
153
Figure 4-178 SCR Cooling Plate Installation - TTS/TGS/TTH/TGH (Except TTS300/TGS230)
154
SCR Cooling Manifold General Installation
154
Table 4-33 SCR Cooling Manifold Torque Specifications
155
Figure 4-171 SCR Cooling Manifold
155
SCR Cooling Manifold Torque Specifications
155
SCR Cooling Manifold
150
DC Capacitor Bus Bar Assembly
156
Figure 4-179 DC Bus Components Identification TTS/TGS/TTH/TGH Rev. F and Earlier (Except TTS300/TGS230)
156
Snubber Capacitors
156
Figure 4-180 DC Bus Components Identification TTS/TGS/TTH/TGH Rev. H (Except TTS300/TGS230)
157
Figure 4-181 Soft Start Cable Harness to DC Bus
157
DC Capacitor DC Bus Bar Connections
157
DC Bus Voltage Verification
158
DC Capacitor Bus Bar Assembly Removal and Installation
158
DC Capacitor Bus Bar Assembly General Removal
158
Figure 4-182 DC Bus Bar and Soft Start Harness Removal - TTS300/TGS230
159
Figure 4-183 Snubber Capacitor Removal - TTS300/TGS230
159
Figure 4-184 Capacitor Nut Removal - TTS300/TGS230
159
Figure 4-185 Capacitor Assembly Removal - TTS300/TGS230
160
Figure 4-186 SCR Bus Bar Removal - TTS/TGS/TTH/TGH Rev. F and Earlier (Except TTS300/TGS230)
160
Figure 4-187 SCR Bus Bar Removal - TTS/TGS/TTH/TGH Rev. H (Except TTS300/TGS230)
161
Figure 4-188 Snubber Capacitor Removal - TTS/TGS/TTH/TGH (Except TTS300/TGS230)
161
Figure 4-189 Capacitor Nut Removal - TTS/TGS/TTH/TGH (Except TTS300/TGS230)
161
Figure 4-190 Capacitor Assembly Removal - TTS/TGS/TTH/TGH Rev. F and Earlier (Except TTS300/TGS230)
162
Figure 4-191 Capacitor Assembly Removal - TTS/TGS/TTH/TGH Rev. H (Except TTS300/TGS230)
162
DC Capacitor Bus Bar Assembly General Installation Steps
163
Table 4-34 DC Capacitor Bus Bar Assembly Torque Specifications
164
DC Capacitor Bus Bar Assembly Torque Specifications
164
Figure 4-192 Inverter Connections
165
Inverter Connections
165
Inverter Verification
165
Figure 4-193 Inverter Diode Measurements (Skiip 613 Shown)
166
Inverter Cable Harness
166
Inverter Cable Harness Removal and Installation
166
Figure 4-194 Inverter Cable Harness
167
Figure 4-195 Harness Removal from Inverter
167
Figure 4-196 Harness Removal from Backplane
167
Inverter Cable Harness Installation
167
Table 4-35 Inverter Cable Harness Torque Specifications
168
Figure 4-197 Inverter Connector Alignment
168
Inverter Removal and Installation
168
Figure 4-198 Fuse Block Assemblies - TTS300/TGS230
169
Figure 4-199 Terminal Block Removal - TTS300/TGS230
169
Figure 4-200 Soft Start Harness Removal
170
Figure 4-201 DC Bus Bar Removal
170
Figure 4-202 DC Bus Bar Mylar Removal - TTS300/TGS230
170
Figure 4-203 Inverter Copper Tube Removal
171
Figure 4-204 Inverter Cable Harness Removal - TTS300/TGS230
172
Figure 4-205 Open-Frame DC-DC
172
Figure 4-206 Potted DC-DC
172
Figure 4-207 DC-DC Removal (Potted DC-DC Shown)
173
Figure 4-208 Motor Winding Sensor Connector Removal
173
Figure 4-209 Retainer Clip Rotation
173
Figure 4-210 Compressor Cable Harness Removal - TTS300/TGS230
174
Figure 4-211 Inverter Assembly Removal - TTS300/TGS230
174
Figure 4-212 SCR Cooling Manifold Removal - TTS300/TGS230
175
Figure 4-213 SCR Connections - TTS/TGS/TTH/TGH Rev. F and Earlier (Except TTS300/TGS230)
175
Figure 4-214 SCR Connections - TTS/TGS/TTH/TGH Rev. H (Except TTS300/TGS230)
176
Figure 4-215 Terminal Block and AC Mains Input Bus Bar Removal - TTS/TGS/TTH/TGH Rev. F and Earlier (Except TTS300/TGS230)
176
Figure 4-216 Input Terminal Block Removal - TTS/TGS/TTH/TGH Rev. H (Except TTS300/TGS230)
177
Figure 4-217 Inverter Copper Tube Removal - TTS/TGS/TTH/TGH (Except TTS300/TGS230)
177
Figure 4-218 Retainer Clip Rotation
178
Figure 4-219 Compressor Cable Harness Removal - TTS/TGS/TTH/TGH (Except TTS300/TGS230)
178
Figure 4-220 Compressor Cable Harness Removal - TTH/TGH Only
178
Figure 4-221 SCR Manifold Removal - TTS/TGS/TTH/TGH (Except TTS300/TGS230)
179
Figure 4-222 Inverter Harness Removal - TTS/TGS/TTH/TGH (Except TTS300/TGS230)
179
Figure 4-223 DC-DC Removal - TTS/TGS/TTH/TGH Rev. F and Earlier (Except TTS300/TGS230)
180
Figure 4-224 Motor Winding Sensor Removal
180
Figure 4-225 Inverter Removal - TTS/TGS/TTH/TGH (Except TTS300/TGS230)
180
Figure 4-226 Inverter O-Ring Removal - TTS/TGS/TTH/TGH (Except TTS300/TGS230)
181
Figure 4-227 SCR Manifold Return Brass Fitting Removal - TTS/TGS/TTH/TGH (Except TTS300/TGS230)
181
Figure 4-228 SCR Cooling Plate O-Ring Installation - TTS300/TGS230
182
Figure 4-229 Inverter Fastener Locations - TTS300/TGS230
182
Figure 4-230 DC Bus Installation - TTS300/TGS230
183
Figure 4-231 Terminal Block Installation - TTS300/TGS230
184
Figure 4-232 Inverter Fastener Locations - TTS/TGS/TGH (Except TTS300/TGS230)
184
Figure 4-233 Inverter Heat Sink Plate O-Ring Installation - TTS/TGS (Except TTS300/TGS230)
185
Figure 4-234 SCR Manifold Return Brass Fitting O-Ring Installation - TTS/TGS (Except TTS300/TGS230)
185
Figure 4-235 SCR Cooling Plate Installation - TTS/TGS/TTH/TGH (Except TTS300/TGS230)
185
Figure 4-236 DC Bus Capacitor Assembly Installation - TTS/TGS/TTH/TGH (Except TTS300/TGS230)
186
Figure 4-237 Driver Board Fasteners
187
Inverter Card Replacement
187
Figure 4-238 Driver Board Removal
188
Figure 4-239 Seated Spring Pins
188
Figure 4-240 Spring Locations
188
Table 4-36 Spring Identification Table
189
Figure 4-241 Spring Pin Identification
189
Figure 4-242 Driver Board Placement
189
Table 4-37 Inverter Torque Specifications
190
Figure 4-243 Initial Tightening Pass Sequence
190
Inverter Torque Specifications
190
Inverter
165
Motor Components
191
Function
191
Motor Protection
191
Figure 4-244 Connection to Stator
192
Motor Connections
192
Motor Verification
192
Figure 4-245 Stator Thermistor R/T Curve 1
193
Motor Assembly Removal and Installation
193
Figure 4-246 Motor Bus Bar Removal - PPS Feedthroughs
194
Figure 4-247 Motor Bus Bar Removal - Stainless-Steel Feedthroughs
194
Figure 4-248 Copper Tube Removal
195
Figure 4-249 Motor Cover Plate Removal
196
Figure 4-250 Thermistor Connector Removal
196
Figure 4-251 Cover Plate Torque Sequence
197
Figure 4-252 High-Power Feedthrough (PPS)
198
Figure 4-253 High-Power Feedthrough Removal (Stainless Steel)
198
Table 4-38 Motor Assembly Torque Specifications
200
Figure 4-254 Connection to Stator
200
High Voltage DC-DC Converter
201
DC-DC Converter Function
201
DC-DC Converter Verification
201
Figure 4-255 J3 - 24VDC Output Connector
202
Figure 4-256 DC-DC Harness
202
DC-DC Supply Cable Harness
202
Figure 4-257 DC-DC Harness Routing
203
DC-DC Harness Removal and Installation
203
Figure 4-258 Potted DC-DC
204
Figure 4-259 Open Frame DC-DC
204
Figure 4-260 DC-DC Converter Removal
205
Figure 4-261 DC-DC Rear Fastener Install
205
Table 4-39 DC-DC Torque Specifications
206
Figure 4-262 Potted DC-DC - Top View
206
Figure 4-263 Open Frame DC-DC - Top View
206
Backplane
207
Figure 4-264 Backplane
207
Backplane Function
207
Table 4-40 Backplane Connections
208
Figure 4-265 Backplane Connections
208
Backplane Connections and Test Points
208
Table 4-41 Backplane Test Points
209
Figure 4-266 Backplane Test Points
209
Figure 4-267 Backplane LED Locations - Left Side
209
Table 4-42 Backplane LED Locations
210
Figure 4-268 Backplane LED Locations - Right Side
210
Table 4-43 Backplane Test Point Values
211
Figure 4-269 Removing the Backplane
211
Backplane Removal and Installation
211
Figure 4-270 Serial Driver
212
Serial Driver Function
212
Serial Driver Connections
213
Serial Driver Verification
213
Serial Driver Removal and Installation
213
Serial Driver
212
Table 4-44 Backplane Torque Specifications
212
Bmcc
214
Figure 4-271 Serial Driver Removal
214
Figure 4-272 Insertion Guides
214
BMCC Connections
215
BMCC Verification
215
BMCC Battery and Verification
215
Figure 4-274 BMCC Case Separation
216
Figure 4-275 BMCC Battery Measurement
217
Figure 4-276 BMCC Removal
217
BMCC Removal and Installation
217
Bearing Pulse Width Modulator Amplifier
218
Figure 4-277 BMCC Insertion Guides
218
PWM Function
218
Figure 4-279 Bearing Control Signal Flow
219
Figure 4-280 Bearing Power Feed Throughs and PWM Connection Port
219
PWM Connections
219
PWM Verification
220
Figure 4-281 Connecting Leads to PWM Connector and HV- and HV+ Test Points
221
PWM Removal and Installation
221
Table 4-45 PWM Torque Specifications
222
Figure 4-282 Removing the PWM Amplifier
222
Figure 4-283 PWM Amplifier Installation
222
Figure 4-284 Bearing Connections
223
Magnetic Bearings Function
223
Magnetic Bearings Connections
223
Bearing Verification
223
Table 4-46 Magnetic Bearing Coil Resistance Values
224
Figure 4-285 Front and Rear Bearing Feed through Connectors
224
Table 4-47 Bearing Amperage Nominal Ranges
225
Figure 4-286 Compressor Monitor Tool
225
Figure 4-287 Bearing Power Feedthrough Assembly
226
Bearing Power Feedthrough Removal and Installation
226
Figure 4-288 Bearing Power Feedthrough Alignment Pin
227
Figure 4-289 Bearing Power Feedthrough Torque Sequence
227
Magnetic Bearings
223
Bearing Sensors
228
Figure 4-290 Bearing Sensor Feedthroughs
228
Bearing Sensor Function
228
Bearing Sensor Connection
228
Table 4-49 Bearing Sensor Coil Resistance
229
Figure 4-291 Bearing Sensor Pin Locations
229
Bearing Sensor Verification
229
Bearing Sensor Cable Removal and Installation
229
Bearing Sensor Removal and Installation
229
Figure 4-292 Bearing Sensor Feed through Removal
230
Figure 4-293 Bearing Sensor 9-Pin Feedthrough Connector Torque Sequence
230
Table 4-48 Magnetic Bearing Torque Specifications
228
Cavity Temperature Sensor
231
Figure 4-294 BMCC Insertion Guides
231
Figure 4-295 Cavity Sensor
231
Cavity Temperature Sensor Function
231
Figure 4-296 Cavity Temperature Sensor Terminal
232
Cavity Temperature Sensor Connections
232
Cavity Temperature Sensor Verification
232
Cavity Temperature Sensor Removal and Installation
232
Table 4-51 Cavity Sensor Torque Specifications
233
Figure 4-298 Cavity Temperature Sensor Removal
233
Table 4-50 Bearing Sensor Torque Specifications
231
Figure 4-300 Pressure/Temperature Sensor Connections (All TTS/TGS Compressors)
234
Figure 4-301 Pressure/Temperature Sensor Locations (TTH/TGH)
234
Pressure/Temperature Sensor Function
234
Pressure/Temperature Sensor Connections
234
Pressure/Temperature Sensor Verification
234
Figure 4-297 Temperature Vs. Resistance
235
Figure 4-299 Pressure/Temperature Sensor
235
Figure 4-302 Temperature Vs. Resistance
235
Figure 4-303 Pressure/Temperature Cable Terminals
235
Figure 4-304 Pressure/Temperature Sensor Pin Locations
235
Figure 4-305 Suction Pressure/Temperature Sensor Removal
236
Figure 4-306 Discharge Pressure/Temperature Sensor
236
Pressure/Temperature Sensor Removal and Installation
236
Table 4-52 Pressure/Temperature Sensor Torque Specifications
237
Figure 4-307 Interstage Pressure/Temperature Sensor Removal
237
Pressure/Temperature Sensor
234
Chapter 5: Troubleshooting
239
Default Chapter
241
Alarm and Fault Indications
241
Table 5-1 Alarm Types
241
Table 5-2 Compressor Fault Types
241
Alarm Types
241
Fault Types
241
Table 5-3 Compressor Status 2 Faults
242
Table 5-4 Motor Fault Types
243
Table 5-5 Bearing Fault Types
243
Troubleshooting with the Service Monitoring Tools Software
243
Figure 5-1 Fault Trigger Methods
244
Compressor Fault Troubleshooting
244
Table 5-6 Compressor Status
245
Table 5-7 Compressor Status 2 Faults
247
Table 5-8 Motor Status
248
Motor Faults/System Status
248
Bearing Calibration
250
Table 5-9 Bearing Status
250
Bearing Status
250
When to Calibrate the Bearings
250
Figure 5-2 Bearing Calibration Tool
251
Performing a Calibration
251
After Calibration Is Complete
252
Create a Calibration Report
252
Calibration Report Analysis
253
Figure 5-3 Bearing Calibration Flow
254
Compressor Connection Status Indications
255
System and Compressor Level Troubleshooting
255
Compressor Voltage Troubleshooting
255
Determining the Cause of an Energy Drain
257
Troubleshooting an Open Interlock
259
Troubleshooting the Inverter
259
Chapter 6.0 Maintenance
263
Preventative Maintenance Tasks
263
Table 6-1 Preventative Maintenance Tasks
263
Moisture Prevention Measures
264
Figure 6-1 Module Removal
264
Figure 6-2 Motor Cooling Valve Solenoids
265
Figure 6-3 Motor Component Dielectric Grease Application
266
Figure 6-4 Accessing Inside SCR to Cooling Manifold Fastener (TTS & TGS Compressors Only)
266
Table 6-2 SCR Fastener Torque Specifications
267
Figure 6-5 SCR Fastener Dielectric Grease Application
267
Appendix A - Acronyms/Terms
269
Table A-1 Acronyms/Terms
269
Appendix B - Compressor Troubleshooting Flowcharts
271
Appendix C - Compressor Test Sheet
277
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Danfoss Turbocor TTS Series Specifications
General
Brand
Danfoss
Model
Turbocor TTS Series
Category
Compressor
Language
English
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