Danfoss Turbocor Service guide

Service Manual - Revision G

Danfoss Turbocor® Twin-Turbine Centrifugal Series Compressors

TTS, TGS, TTH, TGH Series Compressors

http://turbocor.danfoss.com

This manual covers Major Revision "F" and later compressors. If you have a Major Revision "E" or earlier compressor, we suggest

downloading Service Manual Revision E from our website since there are some steps that are unique.

Table of Contents

Chapter 1.0 Introduction ........................................................................................................................................................................ 15

1.1 Application ................................................................................................................................................................................................................................................................... 15

1.2 Purpose .........................................................................................................................................................................................................................................................................16

1.3 Organization ................................................................................................................................................................................................................................................................17

1.4 Commitment to Quality and the Environment ...............................................................................................................................................................................................18

1.5 Safety Summary ......................................................................................................................................................................................................................................................... 18

1.6 Precautions ..................................................................................................................................................................................................................................................................18

1.7 Refrigerant Type .........................................................................................................................................................................................................................................................18

1.8 Electrical Isolation......................................................................................................................................................................................................................................................19

1.9 Handling Static Sensitive Devices ........................................................................................................................................................................................................................ 20

1.10 DC Bus Test Harness Installation and Removal .............................................................................................................................................................................................22

1.11 Compressor Fasteners ........................................................................................................................................................................................................................................... 27

1.12 General O-ring Handling ...................................................................................................................................................................................................................................... 27

Chapter 2.0 Compressor Fundamentals ................................................................................................................................................ 31

2.1 Main Fluid Path ........................................................................................................................................................................................................................................................... 31

2.2 Motor and Power Electronics Cooling ................................................................................................................................................................................................................31

2.3 Capacity Control......................................................................................................................................................................................................................................................... 34

2.4 Compressor Energy and Signal Flow .................................................................................................................................................................................................................. 34

Chapter 3.0 Compressor Removal and Installation .............................................................................................................................. 41

3.1 Refrigerant Containment ........................................................................................................................................................................................................................................41

3.2 Compressor Removal ............................................................................................................................................................................................................................................... 41

3.3 Compressor Installation .......................................................................................................................................................................................................................................... 42

3.4 Compressor Replacement Considerations for Motor Cooling Adapter .................................................................................................................................................43

3.5 Exterior Connection Torque Speciﬁcations ...................................................................................................................................................................................................... 45

Chapter 4.0 Compressor Components ................................................................................................................................................... 51

4.1 Component Identiﬁcation ...................................................................................................................................................................................................................................... 51

4.2 Compressor Covers ................................................................................................................................................................................................................................................... 56

4.3 Cooling Adapter ......................................................................................................................................................................................................................................................... 61

4.4 Compressor Interface Module .............................................................................................................................................................................................................................. 63

4.5 Compressor Interface Cable ..................................................................................................................................................................................................................................66

4.6 Compressor Controller Cable Harness ............................................................................................................................................................................................................... 67

4.7 Solenoids and Coils ................................................................................................................................................................................................................................................... 72

4.8 Interstage Pipe - TTH/TGH ......................................................................................................................................................................................................................................77

4.9 Compressor Housing End Cap .............................................................................................................................................................................................................................. 78

4.10 IGV ................................................................................................................................................................................................................................................................................80

4.11 Mains Plate Bracket ................................................................................................................................................................................................................................................ 93

4.12 3-Phase Main Voltage Input Terminal Block .................................................................................................................................................................................................. 95

4.13 Input Mains Bus Bars (Except TTS300/TGS230) ..........................................................................................................................................................................................103

4.14 Terminal Block Fuse Replacement ...................................................................................................................................................................................................................105

4.15 Soft Start ...................................................................................................................................................................................................................................................................107

4.16 SCR DC Bus Bar - TTS300/TGS230 ....................................................................................................................................................................................................................119

4.17 Soft Start SCR Gate Cable ...................................................................................................................................................................................................................................121

4.18 Soft Start AC/DC Harness ...................................................................................................................................................................................................................................124

4.19 Silicone-Controlled Rectiﬁer ............................................................................................................................................................................................................................133

4.20 SCR Cooling Manifold ..........................................................................................................................................................................................................................................150

4.21 Snubber Capacitors ..............................................................................................................................................................................................................................................156

4.22 DC Capacitor Bus Bar Assembly .......................................................................................................................................................................................................................156

4.23 Inverter ......................................................................................................................................................................................................................................................................165

4.24 Motor Components ..............................................................................................................................................................................................................................................191

4.25 High Voltage DC-DC Converter ........................................................................................................................................................................................................................201

4.26 Backplane .................................................................................................................................................................................................................................................................207

4.27 Serial Driver .............................................................................................................................................................................................................................................................212

4.28 BMCC .........................................................................................................................................................................................................................................................................214

4.29 Bearing Pulse Width Modulator Ampliﬁer....................................................................................................................................................................................................218

4.30 Magnetic Bearings ................................................................................................................................................................................................................................................223

4.31 Bearing Sensors .....................................................................................................................................................................................................................................................228

4.32 Cavity Temperature Sensor ................................................................................................................................................................................................................................231

4.33 Pressure/Temperature Sensor ..........................................................................................................................................................................................................................234

Chapter 5.0 Troubleshooting ...............................................................................................................................................................241

5.1 Alarm and Fault Indications .................................................................................................................................................................................................................................241

5.2 Troubleshooting with the Service Monitoring Tools Software ...............................................................................................................................................................243

5.3 Bearing Calibration .................................................................................................................................................................................................................................................250

5.4 Compressor Connection Status Indications...................................................................................................................................................................................................255

5.5 System and Compressor Level Troubleshooting ..........................................................................................................................................................................................255

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Table of Contents

Chapter 6.0 Maintenance ......................................................................................................................................................................263

6.1 Preventative Maintenance Tasks ......................................................................................................................................................................................................................263

6.2 Moisture Prevention Measures .........................................................................................................................................................................................................................264

Appendix A – Acronyms/Terms ........................................................................................................................................................... 269

Appendix B – Compressor Troubleshooting Flowcharts ................................................................................................................... 271

Appendix C – Compressor Test Sheet ................................................................................................................................................. 277

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List of Tables

Table 2-1 Compressor Fluid Paths ...............................................................................................................................................................................................................................31

Table 3-1 Exterior Connection Torque Speciﬁcations ...................................................................................................................................................................................... 45

Table 4-1 Compressor Components (Covers On) ..................................................................................................................................................................................................51

Table 4-2 Compressor Components Service Side (Excludes TTH/TGH Compressors) .............................................................................................................................52

Table 4-3 Compressor Components Service Side (TTH/TGH Only) ................................................................................................................................................................53

Table 4-4 Compressor Components Capacitor Side (Excludes TTH/TGH) .................................................................................................................................................... 54

Table 4-5 Compressor Components Capacitor Side (TTH/TGH Only) ............................................................................................................................................................55

Table 4-6 Compressor Cover Torque Speciﬁcations ............................................................................................................................................................................................. 60

Table 4-7 Cooling Adapter Torque Speciﬁcations ................................................................................................................................................................................................. 62

Table 4-8 CIM Ports and Jumpers ................................................................................................................................................................................................................................63

Table 4-9 Compressor Controller Cable Harness Torque Speciﬁcations ....................................................................................................................................................... 72

Table 4-10 Solenoid Coil Resistance Ranges ........................................................................................................................................................................................................... 73

Table 4-11 Solenoid Torque Speciﬁcations .............................................................................................................................................................................................................. 76

Table 4-12 Interstage Pipe Torque Speciﬁcations ................................................................................................................................................................................................. 78

Table 4-13 Compressor Housing End Cap Torque Speciﬁcations .................................................................................................................................................................... 79

Table 4-14 IGV Components ......................................................................................................................................................................................................................................... 80

Table 4-15 IGV Feedthrough Wiring Order .............................................................................................................................................................................................................. 84

Table 4-16 IGV Feedthrough Pin to Wire Reference .............................................................................................................................................................................................90

Table 4-17 IGV Torque Speciﬁcations.........................................................................................................................................................................................................................92

Table 4-18 Mains Plate Torque Speciﬁcations......................................................................................................................................................................................................... 95

Table 4-19 Expected AC Voltage Range ....................................................................................................................................................................................................................98

Table 4-20 Terminal Block Torque Speciﬁcations ................................................................................................................................................................................................103

Table 4-21 AC Bus Bar Torque Speciﬁcations ........................................................................................................................................................................................................105

Table 4-22 Terminal Block Fuse Torque Speciﬁcations ......................................................................................................................................................................................107

Table 4-23 Closed-Top Soft Start Connection Identiﬁcation ...........................................................................................................................................................................108

Table 4-24 Open-Top Soft Start Connection Identiﬁcation .............................................................................................................................................................................109

Table 4-25 Soft Start Fuse Details .............................................................................................................................................................................................................................112

Table 4-26 Soft Start Torque Speciﬁcations ...........................................................................................................................................................................................................119

Table 4-27 SCR DC Bus Bar Torque Speciﬁcations ...............................................................................................................................................................................................121

Table 4-28 Soft Start AC/DC Harness Torque Speciﬁcations ...........................................................................................................................................................................133

Table 4-29 SCR Diode Values ......................................................................................................................................................................................................................................137

Table 4-30 SCR Gate Resistance Ranges .................................................................................................................................................................................................................137

Table 4-31 SCR Temperature Sensor Torque Speciﬁcations ............................................................................................................................................................................141

Table 4-32 SCR Torque Speciﬁcations ......................................................................................................................................................................................................................149

Table 4-33 SCR Cooling Manifold Torque Speciﬁcations. .................................................................................................................................................................................155

Table 4-34 DC Capacitor Bus Bar Assembly Torque Speciﬁcations ...............................................................................................................................................................164

Table 4-35 Inverter Cable Harness Torque Speciﬁcations ................................................................................................................................................................................168

Table 4-36 Spring Identiﬁcation Table .....................................................................................................................................................................................................................189

Table 4-37 Inverter Torque Speciﬁcations ..............................................................................................................................................................................................................190

Table 4-38 Motor Assembly Torque Speciﬁcations .............................................................................................................................................................................................200

Table 4-39 DC-DC Torque Speciﬁcations ................................................................................................................................................................................................................206

Table 4-40 Backplane Connections ..........................................................................................................................................................................................................................208

Table 4-41 Backplane Test Points ..............................................................................................................................................................................................................................209

Table 4-42 Backplane LED Locations .......................................................................................................................................................................................................................210

Table 4-43 Backplane Test Point Values ..................................................................................................................................................................................................................211

Table 4-44 Backplane Torque Speciﬁcations .........................................................................................................................................................................................................212

Table 4-45 PWM Torque Speciﬁcations ...................................................................................................................................................................................................................222

Table 4-46 Magnetic Bearing Coil Resistance Values .........................................................................................................................................................................................224

Table 4-47 Bearing Amperage Nominal Ranges ..................................................................................................................................................................................................225

Table 4-48 Magnetic Bearing Torque Speciﬁcations ..........................................................................................................................................................................................228

Table 4-49 Bearing Sensor Coil Resistance ............................................................................................................................................................................................................229

Table 4-50 Bearing Sensor Torque Speciﬁcations ...............................................................................................................................................................................................231

Table 4-51 Cavity Sensor Torque Speciﬁcations ..................................................................................................................................................................................................233

Table 4-52 Pressure/Temperature Sensor Torque Speciﬁcations...................................................................................................................................................................237

Table 5-1 Alarm Types ...................................................................................................................................................................................................................................................241

Table 5-2 Compressor 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

Table 5-6 Compressor Status ......................................................................................................................................................................................................................................245

Table 5-7 Compressor Status 2 Faults ......................................................................................................................................................................................................................247

Table 5-8 Motor Status ..................................................................................................................................................................................................................................................248

Table 5-9 Bearing Status ...............................................................................................................................................................................................................................................250

Table 6-1 Preventative Maintenance Tasks ............................................................................................................................................................................................................263

Table 6-2 SCR Fastener Torque Speciﬁcations ......................................................................................................................................................................................................267

Table A-1 Acronyms/Terms .........................................................................................................................................................................................................................................269

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List of Figures

Figure 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

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

Figure 3-1 Compressor Power Cable Removal .......................................................................................................................................................................................................41

Figure 3-2 Compressor Mounting Fasteners...........................................................................................................................................................................................................42

Figure 3-3 Motor Cooling Fitting.................................................................................................................................................................................................................................43

Figure 4-1 Compressor Components Identiﬁcation (Covers On) ....................................................................................................................................................................51

Figure 4-2 Compressor Component Identiﬁcation - Service Side (Excludes TTH/TGH Compressors) ...............................................................................................52

Figure 4-3 Compressor Component Identiﬁcation - Service Side (TTH/TGH Only) .................................................................................................................................. 53

Figure 4-4 Compressor Component Identiﬁcation - Capacitor Side (Excludes TTH/TGH) ......................................................................................................................54

Figure 4-5 Compressor Component Identiﬁcation - Capacitor Side (TTH/TGH Only) ............................................................................................................................. 55

Figure 4-6 Top Covers Removal ...................................................................................................................................................................................................................................56

Figure 4-7 Mains Input Cover Torque Sequence ................................................................................................................................................................................................... 57

Figure 4-8 Top Cover ........................................................................................................................................................................................................................................................ 57

Figure 4-9 Service Side Cover ....................................................................................................................................................................................................................................... 58

Figure 4-10 Service Side Cover .................................................................................................................................................................................................................................... 58

Figure 4-11 Capacitor Cover ......................................................................................................................................................................................................................................... 59

Figure 4-12 Capacitor Nylon Nuts ...............................................................................................................................................................................................................................59

Figure 4-13 Relief Membrane Position ...................................................................................................................................................................................................................... 60

Figure 4-14 Recessed Holes .......................................................................................................................................................................................................................................... 60

Figure 4-15 Capacitor Cover Torque Sequence...................................................................................................................................................................................................... 60

Figure 4-16 Cooling Adapter - Excludes TTH375/TGH285 .................................................................................................................................................................................61

Figure 4-17 Cooling Adapter - TTH375/TGH285) ..................................................................................................................................................................................................61

Figure 4-18 Compressor Interface Module Ports & Jumpers ............................................................................................................................................................................ 63

Figure 4-19 Removing the Compressor Interface Module from the DIN Rail ............................................................................................................................................. 66

Figure 4-20 Compressor Interface Cable ..................................................................................................................................................................................................................67

Figure 4-21 Compressor Controller Cable Harness Variants..............................................................................................................................................................................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

Figure 4-30 Solenoid Coil Harness ..............................................................................................................................................................................................................................73

Figure 4-31 Backplane - J16 Connector .................................................................................................................................................................................................................... 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

Figure 4-36 Solenoid Actuator Coil Position ........................................................................................................................................................................................................... 76

Figure 4-37 Interstage Pipe ........................................................................................................................................................................................................................................... 77

Figure 4-38 Interstage Pipe Removal .........................................................................................................................................................................................................................77

Figure 4-39 Compressor Housing End Cap - TTS/TGS .........................................................................................................................................................................................78

Figure 4-40 Compressor Housing End Cap - TTH/TGH ........................................................................................................................................................................................78

Figure 4-41 IGV Assembly .............................................................................................................................................................................................................................................. 80

Figure 4-42 IGV Connections ........................................................................................................................................................................................................................................ 80

Figure 4-43 IGV Motor Feedthrough ..........................................................................................................................................................................................................................81

Figure 4-44 SMT Icon ....................................................................................................................................................................................................................................................... 81

Figure 4-45 Compressor Conﬁguration Tool ........................................................................................................................................................................................................... 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

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

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List of Figures

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

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

Figure 4-74 IGV Position Indicator .............................................................................................................................................................................................................................. 92

Figure 4-75 Mains Plate Bracket .................................................................................................................................................................................................................................. 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

Figure 4-79 Input Terminal Block - TTS300/TGS230 ............................................................................................................................................................................................. 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

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

Figure 4-84 Terminal Block Removal - TTS300/TGS230 ....................................................................................................................................................................................... 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

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

Figure 4-95 Terminal Block Fuse Test .......................................................................................................................................................................................................................106

Figure 4-96 Terminal Block Fuse Removal..............................................................................................................................................................................................................106

Figure 4-97 Soft Start Variants....................................................................................................................................................................................................................................107

Figure 4-98 Closed-Top Soft Start Connections ...................................................................................................................................................................................................108

Figure 4-99 Open-Top Soft Start Connections .....................................................................................................................................................................................................109

Figure 4-100 Soft Start Label Location ....................................................................................................................................................................................................................110

Figure 4-101 Soft Start Fuse Locations ...................................................................................................................................................................................................................111

Figure 4-102 Closed-Top Soft Start J9 Connector ...............................................................................................................................................................................................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

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

Figure 4-113 Open-Top-Soft Start Installation .....................................................................................................................................................................................................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

Figure 4-117 Soft Start Fan Connector ....................................................................................................................................................................................................................119

Figure 4-118 SCR DC Bus Bars ....................................................................................................................................................................................................................................119

Figure 4-119 SCR DC Bus Bar Removal - TTS300/TGS230 .................................................................................................................................................................................120

Figure 4-120 SCR DC Bus Bar to SCR Alignment ..................................................................................................................................................................................................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

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

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List of Figures

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

Figure 4-128 SCR Gate Connector Alignment ......................................................................................................................................................................................................124

Figure 4-129 Soft Start AC/DC Harness Connections - TTS300/TGS230 .....................................................................................................................................................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

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

Figure 4-142 SCR Styles ................................................................................................................................................................................................................................................134

Figure 4-143 SCR Connections - TTS300/TGS230 ................................................................................................................................................................................................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

Figure 4-146 SCR Terminals - Two Hole Mount ....................................................................................................................................................................................................136

Figure 4-147 SCR Terminals - Four Hole Mount ...................................................................................................................................................................................................136

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

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) ..........................................................144

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

Figure 4-171 SCR Cooling Manifold .........................................................................................................................................................................................................................150

Figure 4-172 Inverter Assembly Removal - TTS300/TGS230 ...........................................................................................................................................................................150

Figure 4-173 SCR Cooling Manifold Removal - TTS300/TGS230 ....................................................................................................................................................................151

Figure 4-174 SCR Cooling Manifold Removal .......................................................................................................................................................................................................152

Figure 4-175 SCR Cooling Plate O-ring 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

Figure 4-178 SCR Cooling Plate Installation - TTS/TGS/TTH/TGH (Except TTS300/TGS230) ................................................................................................................154

Figure 4-179 DC Bus Components Identiﬁcation TTS/TGS/TTH/TGH Rev. F and Earlier (Except TTS300/TGS230) .....................................................................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

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

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Figure 4-192 Inverter Connections ...........................................................................................................................................................................................................................165

Figure 4-193 Inverter Diode Measurements (Skiip 613 Shown) ....................................................................................................................................................................166

Figure 4-194 Inverter Cable Harness .......................................................................................................................................................................................................................166

Figure 4-195 Harness Removal from Inverter .......................................................................................................................................................................................................167

Figure 4-196 Harness Removal from Backplane ..................................................................................................................................................................................................167

Figure 4-197 Inverter Connector Alignment .......................................................................................................................................................................................................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 .............................................................................................................................................................................171

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

Figure 4-238 Driver Board Removal .........................................................................................................................................................................................................................188

Figure 4-239 Seated Spring Pins ...............................................................................................................................................................................................................................188

Figure 4-240 Spring Locations ...................................................................................................................................................................................................................................188

Figure 4-241 Spring Pin Identiﬁcation ....................................................................................................................................................................................................................189

Figure 4-242 Driver Board Placement .....................................................................................................................................................................................................................189

Figure 4-243 Initial Tightening Pass Sequence ....................................................................................................................................................................................................190

Figure 4-244 Connection to Stator ...........................................................................................................................................................................................................................192

Figure 4-245 Stator Thermistor R/T Curve 1 ..........................................................................................................................................................................................................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

Figure 4-254 Connection to Stator ...........................................................................................................................................................................................................................200

Figure 4-255 J3 - 24VDC Output Connector .........................................................................................................................................................................................................202

Figure 4-256 DC-DC Harness ......................................................................................................................................................................................................................................202

Figure 4-257 DC-DC Harness Routing .....................................................................................................................................................................................................................203

Figure 4-258 Potted DC-DC .........................................................................................................................................................................................................................................204

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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

Figure 4-262 Potted DC-DC - Top View ...................................................................................................................................................................................................................206

Figure 4-263 Open Frame DC-DC - Top View ........................................................................................................................................................................................................206

Figure 4-264 Backplane ................................................................................................................................................................................................................................................207

Figure 4-265 Backplane Connections ......................................................................................................................................................................................................................208

Figure 4-266 Backplane Test Points ..........................................................................................................................................................................................................................209

Figure 4-267 Backplane LED Locations - Left Side ..............................................................................................................................................................................................209

Figure 4-268 Backplane LED Locations - Right Side ...........................................................................................................................................................................................210

Figure 4-269 Removing the Backplane ...................................................................................................................................................................................................................211

Figure 4-270 Serial Driver.............................................................................................................................................................................................................................................212

Figure 4-271 Serial Driver Removal ..........................................................................................................................................................................................................................214

Figure 4-272 Insertion Guides ....................................................................................................................................................................................................................................214

Figure 4-273 BMCC .........................................................................................................................................................................................................................................................215

Figure 4-274 BMCC Case Separation .......................................................................................................................................................................................................................216

Figure 4-275 BMCC Battery Measurement ............................................................................................................................................................................................................217

Figure 4-276 BMCC Removal ......................................................................................................................................................................................................................................217

Figure 4-277 BMCC Insertion Guides .......................................................................................................................................................................................................................218

Figure 4-278 PWM ..........................................................................................................................................................................................................................................................218

Figure 4-279 Bearing Control Signal Flow .............................................................................................................................................................................................................219

Figure 4-280 Bearing Power Feed Throughs and PWM Connection Port ...................................................................................................................................................219

Figure 4-281 Connecting Leads to PWM Connector and HV- and HV+ Test Points ................................................................................................................................221

Figure 4-282 Removing the PWM Ampliﬁer .........................................................................................................................................................................................................222

Figure 4-283 PWM Ampliﬁer Installation ...............................................................................................................................................................................................................222

Figure 4-284 Bearing Connections ...........................................................................................................................................................................................................................223

Figure 4-285 Front and Rear Bearing Feed Through Connectors ..................................................................................................................................................................224

Figure 4-286 Compressor Monitor Tool ..................................................................................................................................................................................................................225

Figure 4-287 Bearing Power Feedthrough Assembly ........................................................................................................................................................................................226

Figure 4-288 Bearing Power Feedthrough Alignment Pin ...............................................................................................................................................................................227

Figure 4-289 Bearing Power Feedthrough Torque Sequence .........................................................................................................................................................................227

Figure 4-290 Bearing Sensor Feedthroughs .........................................................................................................................................................................................................228

Figure 4-291 Bearing Sensor Pin Locations ...........................................................................................................................................................................................................229

Figure 4-292 Bearing Sensor Feed Through Removal .......................................................................................................................................................................................230

Figure 4-293 Bearing Sensor 9-Pin Feedthrough Connector Torque Sequence ......................................................................................................................................230

Figure 4-294 BMCC Insertion Guides .......................................................................................................................................................................................................................231

Figure 4-295 Cavity Sensor ..........................................................................................................................................................................................................................................231

Figure 4-296 Cavity Temperature Sensor Terminal .............................................................................................................................................................................................232

Figure 4-297 Temperature vs. Resistance ...............................................................................................................................................................................................................232

Figure 4-298 Cavity Temperature Sensor Removal .............................................................................................................................................................................................233

Figure 4-299 Pressure/Temperature Sensor ..........................................................................................................................................................................................................234

Figure 4-300 Pressure/Temperature Sensor Connections (All TTS/TGS Compressors) ..........................................................................................................................234

Figure 4-301 Pressure/Temperature Sensor Locations (TTH/TGH) ...............................................................................................................................................................234

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

Figure 4-307 Interstage Pressure/Temperature Sensor Removal ..................................................................................................................................................................237

Figure 5-1 Fault Trigger Methods ..............................................................................................................................................................................................................................244

Figure 5-2 Bearing Calibration Tool ..........................................................................................................................................................................................................................251

Figure 5-3 Bearing Calibration Flow .........................................................................................................................................................................................................................254

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

Figure 6-5 SCR Fastener Dielectric Grease Application .....................................................................................................................................................................................267

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Proprietary Notice

This publication contains proprietary information to Danfoss LLC. This publication is protected under the Copyright laws of the United States of America (USA) and most other countries. This work is owned by Danfoss LLC, and was published as of the most recent revision of this publication, as indicated on the Title page of this document. This document is for the use Danfoss LLC customers and prospective customers only. Any use beyond that is prohibited.

Tests have demonstrated that equipment produced according to the guidelines provided in this manual will function properly, however Danfoss LLC cannot guarantee the equipment to work in every physical, hardware or software environment.

The guidelines provided in this manual are provided “AS-IS” without any warranty of any kind, either express or implied, including, without limitation, any implied warranties of condition, uninterrupted use, merchantability, fitness for a particular purpose.

In no event shall Danfoss LLC be liable for direct, indirect, special, incidental or consequential damages arising out of the manufacture, use, or the inability to manufacture or use information contained in this manual, even if advised of the possibility of such damages. In particular, Danfoss LLC is not responsible for any costs, including but not limited to those incurred as a result of lost profits or revenue, loss of damage or equipment, loss of computer programs, loss of data, the costs to substitute these, or any claims by third parties. In any event, the total aggregate liability for all damages of any kind and type (regardless of whether based in contract or tort) of Danfoss LLC, shall not exceed the purchase price of this product.

Danfoss LLC reserves the right to revise the publication at any time and to make changes to its contents without prior notice or any obligation to notify former or present users of such revisions or changes.

Danfoss Turbocor Compressors Inc. 1769 East Paul Dirac Drive Tallahassee, Florida 32310 USA Phone 1-850-504-4800 Fax 1-850-575-2126 http://turbocor.danfoss.com

Encounter an error or see opportunity for improvements while reading this manual? Email us at turbocor.contact@danfoss.com with a brief description.

* Subject to change without notice.

* Danfoss Turbocor’s commitment to excellence ensures continuous product improvements.

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List of Changes

Table 1-1 List of Changes

Revision Date Page Description of Change

F 05-30-2019 Redevelopment of manual to include TTH/TGH and support Revision F and

F.1 6-10-2019 15/16 Upodated Typecode figures 1-1 and 1-2.

F.2 11-10-2019 18-19

F2 11-10-2019 36 Removed helium and changed the inert gas pressure to 15 psi.

F2 11-10-2019 98 Updated F4 and F5 fuse description.

G 5-27-2020 all Manual updated to include all Major Revision H changes.

later compressors

Updated TGS490 compressor with R515B refrigerant.

& 28

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Chapter 1: Compressor Introduction

1.4 Commitment to Quality and the Environment ...............................................................................................................................18

1.5 Safety Summary ................................................................................................................................................................................ 18

1.5.1 Danger Notiﬁcation ............................................................................................................................................................................................................................................... 18

1.5.2 Caution Notiﬁcation .............................................................................................................................................................................................................................................. 18

1.5.3 Note ............................................................................................................................................................................................................................................................................. 18

1.7.1 R134a/513A .............................................................................................................................................................................................................................................................. 18

1.7.2 R1234ze .....................................................................................................................................................................................................................................................................19

1.7.3 R515B .......................................................................................................................................................................................................................................................................... 19

1.8 Electrical Isolation ............................................................................................................................................................................. 19

1.9 Handling Static Sensitive Devices .................................................................................................................................................... 20

1.9.1 ESD Protection/Grounding ................................................................................................................................................................................................................................. 21

1.10 DC Bus Test Harness Installation and Removal ............................................................................................................................. 22

1.10.1 General Veriﬁcation and Installation of the DC Bus Test Harness ......................................................................................................................................................22

1.10.2 DC Bus Test Harness Installation for Closed-Top Soft Start ...................................................................................................................................................................23

1.10.3 General DC Bus Test Harness Removal .........................................................................................................................................................................................................27

1.10.4 DC Bus Test Harness Removal for Closed-Top Soft Starts ......................................................................................................................................................................27

1.10.5 DC Bus Test Harness Removal for Open-Top Soft Starts ........................................................................................................................................................................27

1.11 Compressor Fasteners ....................................................................................................................................................................27

1.12 General O-ring Handling ................................................................................................................................................................ 27

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Chapter 1.0 Introduction

1.1 Application

Figure 1-1 Old to New Type Code

Conversion From Old Code to New Code

Product Series and Capacity

Note: The new code adds an “S” for

standard or “H” for High Lift

This section provides a brief introduction to the Service Manual including the Application, Purpose, Organization, Document Conventions used, Safety Information, and the Danfoss LLC Quality Policy.

As of May 6, 2019, the product nomenclature changed. "Figure 1-1 Old to New Type Code" maps the old structure of the Type code to the new structure. Additionally, the “Series” indicators not have an additional character in order to differentiate the standard compressors from high-lift compressors. Unless the compressor is a high-lift design, an “S” will be added (e.g., TTS350). A high lift compressor will have an “H” in the Series designation (e.g., TTH375). Throughout this manual, it shall be assumed that if a series designation contains neither an "S" or "H" (e.g., TT350) that it is not a high-lift design. Refer to "Figure 1-2 New Type Code" on page 16 for a complete description in the new design.

TT300‐E‐1‐ST‐G‐O‐CE

Existing

New

Voltage Code

Application

Note: “T” is dropped

Major Revision

Build

Note: This would change

from an “O” to a “0”

Removed*

TTS300GES1S010X0XXS123

Type Code Definition

Product Series and Capacity TTS300: TT Series 300 Aero Config TTS350: TT Series 350 Aero Config TTS400: TT Series 400 Aero Config TTS500: TT Series 500 Aero Config TTS700: TT Series 700 Aero Config TGS230: TG Series 230 Aero Config TGS310: TG Series 310 Aero Config TGS390: TG Series 390 Aero Config TGS520: TG Series 520 Aero Config TTH375: TT High Lift Series 375 Aero Config TGH285: TG High Lift Series 285 Aero

Config

Mains Plate Size

I/O Board Options

Major Revision E: Major Revision E F: Major Revision F G: Major Revision G

Voltage Code E: 380V/50Hz D: 380V/60Hz H: 400V/50Hz J: 400V/60Hz G: 460V/60Hz

F: 575V/60Hz

Factory Type

Customer

Specific

Application S: Standard Application M: Medium Temperature Application J: Standard Temp KHK Listed K: Medium Temp KHK Listed

Mains Plate Size 1: Mains Plate 2.00” 2: Mains Plate 2.48” 3: Mains Plate 3.00”

4: Mains Plate 3.50”

Accessories

I/O Board Option S: I/O Board included with 5m cable M: No I/O Board, 5m cable Included

Build 0: New Compressor C: Rebuilt Certified Compressor

Software

Options

Reserved for

Future Options

Factory Type 1: TLH Factory (CE Rated) 2: HYN Factory (CH Rated) 3: TLH Factory (NC Rated)

Customer Specific Configuration 0: Gen Covers/Plate, EN/FR/CH

Customer Engraved Nameplate X: No CPN (Standard) Y: CPN on Nameplate

Accessories Configuration 0: No accessories

Future Option X: Reserved X: Reserved

Software S123: Software Revision

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Figure 1-2 New Type Code

M : No I/O Board, 5m cable included

Build (character 12) 0 : New Compressor C : Rebuilt Certiﬁed Compressor

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

Turbocor TTS/TGS Series

Type Code

TTS300 G E S 1 S 0 1 0 X 0 X X S123

Product Series and Capacity (characters 1-6)

TTS300 : TT Series 300 Aero Conﬁg TTS350 : TT Series 350 Aero Conﬁg TTS400 : TT Series 400 Aero Conﬁg TTS500 : TT Series 500 Aero Conﬁg

TTS700 : TT Series 700 Aero Conﬁg TGS280 : TG Series 280 Aero Conﬁg TGS310 : TG Series 310 Aero Conﬁg TGS390 : TG Series 390 Aero Conﬁg TGS520 : TG Series 520 Aero Conﬁg

TTH375 : TT High Lift Series 375 Aero Conﬁg

TGH285 : TG High Lift Series 285 Aero Conﬁg

Major Revision (character 7)

E: Major Revision E

F : Major Revision F G : Major Revision G H : Major Revision H

Voltage Code (character 8)

M : Medium Temperature Application

E : 380V/50Hz D : 380V/60Hz H : 400V/50Hz

J : 400V/60Hz

G : 460V/60Hz

F : 575V/60Hz

Application (character 9)

S : Standard Application

J : Standard Temp KHK Listed

K : Medium Temp KHK Listed

Mains Plate Size (character 10)

1 : Mains Plate 2.00” 2 : Mains Plate 2.48” 3 : Mains Plate 3.00” 4 : Mains Plate 3.50”

I/O Board Option (character 11)

S : I/O Board included with 5m cable

1.2 Purpose

This Service Manual is intended to provide service procedures specific to the Danfoss Turbocor compressors. It is not intended to teach basic fundamental safety, refrigeration, electrical, or fitting skills. It is assumed persons using this manual will be appropriately certified and have detailed knowledge, experience, and skills in respect to working with high-pressure refrigerants and medium voltage electrical components to 1 Kilovolt (kV) high-power alternating current (AC) and direct current (DC).

Software (character 19-22)

S123 : Software Revision

Future Option (character 18) X : Reserved

Future Option (character 17) X : Reserved

Accessories Conﬁguration (character 16) 0 : No accessories

Customer Engraved Nameplate (character 15) X : No CPN (Standard) Y : CPN on Nameplate

Customer Speciﬁc Conﬁguration (character 14) 0 : Gen Covers/Plate, EN/FR/CH

Factory Type (character 13) 1 : TLH Factory (CE Rated) 2 : HYN Factory (CH Rated) 3 : TLH Factory (NC Rated)

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Some potential safety situations may not be foreseen or covered in this manual. Danfoss LLC expects personnel using this manual and working on Danfoss Turbocor compressors to be familiar with, and carry out, all safe work practices necessary to ensure safety for personnel and equipment.

The purpose of this manual is to provide:

• A general description of the compressor design

• A functional description of the various components of the compressor

• Information regarding procedures necessary to detect the source of a problem within the compressor

1.3 Organization

• The procedures for disassembling and assembling various components of the compressor

• Fault and calibration interpretations

• System troubleshooting suggestions

• Maintenance tasks that should be followed

This manual gives only general procedures for servicing and does not provide part numbers of single products or single components. If this information is required, please contact a recognized Danfoss Turbocor original equipment manufacturer (OEM) customer.

Additionally, this manual is written for Major revision F and later compressors. When necessary, particular revision compressors are specified, but the majority of the content remains the same, regarless of the compressor revision. Danfoss LLC does sell various upgrade kits (e.g., Soft Start Upgrade Kit) and and those kits may include retrofit cabling or other hardware that are not specifically installed on production compressors. This manual only illustrates components that were installed on production compressors. Always refer to the specific spare part kit instructions during installation.

This manual is organized in the following manner:

• Section 1: Introduction – this section describes the purpose of the manual, its organization, conventions used in the manual, and a safety summary which describes the use of Danger, Caution, and Notes symbols

• Section 2: Compressor Fundamentals – this section identifies the parts of the compressor and provides fundamental knowledge of the role each component plays in the main fluid path, motor-cooling system, and in the energy and signal flow

• Section 3: Compressor Removal and Installation – this section describes the safe practices of removing and installing the compressor

• Section 4: Compressor Components – this section describes in depth component information, the steps necessary to obtain measurements that verify a component is functional and the steps necessary to replace a compressor component

• Section 5: Troubleshooting – this section describes troubleshooting using signals from the compressor to determine the specific source of faults at the system and compressor level

• Section 6: Maintenance – this section contains a table containing a list of tasks that should be performed on a regular basis to maintain optimal performance of the system

• Appendix A: Acronyms/Terms – this section provides definitions of terms and acronyms used in this manual

• Appendix B: Compressor Troubleshooting Flowcharts – this section contains flowcharts to assist you with compressor troubleshooting

• Appendix C: Compressor Test Sheet – this section contains a sheet with test points, expected values, and the section in the manual associated with a particular test

The following conventions are used in this manual:

• Procedures – all user procedures are listed in numerical steps, unless it is a one-step procedure. A one-step procedure is shown as a bullet.

• User Action Required (software) – if a user is required to take action in a software procedure, the action will be shown in bold. Example; When the Login window opens, type in your name and password.

• Monitoring Program Window Names – all window names will be in italic. Example Compressor Controller window.

• Internal References – references to sections within this manual are encapsulated in quotes. Example, Isolate the compressor power as described in the “Electrical Isolation of the Compressor" section of this manual.

• External References – references to items not within this manual are underlined. Example; Refer to the Installation and Operation Manual for installation procedures.

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1.4 Commitment to Quality and the Environment

Danfoss Turbocor Compressors is dedicated to leading through innovation and to satisfying our customers with the best quality, value, and on-time delivery of high-efficiency oil-free centrifugal compressors.

We are committed to controlling our impact on the environment demonstrated through setting goals focused on continual improvement and complying with all relevant legislation, regulation, and other requirements to protect the environment.

1.5 Safety Summary

Safety precautions must be observed during installation, start-up, and service of the compressor due to the presence of pressure and voltage hazards. Only qualified and trained personnel should install, start up, and service Danfoss Turbocor compressors. Safety information is located throughout the manual to alert service personnel of potential hazards and is identified by the headings DANGER and

CAUTION.

1.5.1 Danger Notification

A DANGER notification signifies an essential operation or maintenance procedure, practice, or condition which, if not strictly observed, could result in injury to or death of personnel or longterm health hazards. A Danger notification is displayed in the format shown in "Figure 1-3 Danger Notification Example".

Figure 1-3 Danger Notification Example

• • • DANGER • • •

1.5.2 Caution Notification

A CAUTION notification signifies an essential operation or maintenance procedure, practice, or condition which, if not strictly observed, could result in damage to or destruction of equipment or potential problems in the outcome of the procedure being performed. A Caution notification is displayed in the format shown in "Figure 1-4 Caution Notification Example".

Figure 1-4 Caution Notification Example

1.5.3 Note

A NOTE provides additional information such as a tip, comment, or other useful, but not imperative information. A Note is displayed in the format shown in "Figure 1-5 Note Example".

Figure 1-5 Note Example

1.6 Precautions

Consideration for personal safety and equipment safety is very important. This chapter contains various sections that cover safety precautions and methods that must be followed when servicing the compressor. Prior to servicing the compressor, carefully read this chapter to ensure familiarity of both personal and equipment safety.

1.7 Refrigerant Type

1.7.1 R134a/513A

TTS and TTH series compressors are totally oil-free and optimized for use with refrigerants R134a. The TTS and TTH are also compatible with R513A.

• • • CAUTION • • •

NOTE

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1.7.2 R1234ze

TGS and TGH series compressors are totally oil-free and optimized for use with refrigerant R1234ze only.

ASHRAE standard 34 has classified this refrigerant as “R1234ze(E) with safety classification of A2L.” ASHRAE Standard 34, 2010 Addendum 1 contains the change to the standard.

1.7.3 R515B

TGS490 compressors can be used with refrigerant R515B which has an ASHRAE Standard 34 safety classification of A1.

Table 1-2 Refrigerant Used with Danfoss Turbocor

Compressor Refrigerant

TTS Series R134a/R513A

TGS Series R1234ze, R515B (TGS490 only)

TTH Series R134a/R513A

TGH Series R1234ze

Do not use recycled refrigerant as it may contain oil, which can aﬀect system reliability. The refrigerant should be pure and stored in virgin containers.

1.8 Electrical Isolation

Before servicing the Compressor, isolate the compressor power by completing the following steps:

NOTE

• • • DANGER • • •

• This equipment contains hazardous voltages that can cause serious injury or death. Only qualiﬁed and trained personnel should work on Danfoss LLC equipment.

• Always wear appropriately-rated safety equipment when working around equipment and/or components energized with high voltage.

• Removing the Mains Input Cover will expose the technician to a high voltage hazard of up to 632 VAC. Ensure the Mains Input power is turned oﬀ and locked out before removing the Mains Input Cover.

1. Turn off the Mains Input power to the compressor.

2. Lock Out/Tag Out (LOTO) the mains disconnect to ensure no accidental or unauthorized re-

application of the Mains Input power can occur.

NOTE

The Mains Input fast-acting fuses are installed in the power panel for all compressor models except the TT300/TG230.

3. Remove the Mains Cover only. Refer to "4.2.1 Mains Input Cover" on page 56.

4. Using an appropriately-rated voltage meter, confirm the absence of AC voltage.

• • • DANGER • • •

Do not touch any components when removing the Mains Input Cover.

5. If AC voltage is not present, reinstall the Mains Input cover and wait at least 20 minutes before

removing either the Mains Input or Top Side Cover. If AC voltage still exists, go back to Step 2 to determine why the compressor voltage is not isolated.

6. Remove the Top Cover, taking particular care not to touch ANY components underneath. Refer

to "4.2.2 Top Cover" on page 57.

7. Using an appropriately-rated voltage meter, check the DC Bus Bars for DC voltage level. If the

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Figure 1-6 DC Bus Voltage Test Points

voltage is above 5 volts direct current (VDC), wait five (5) minutes and recheck until voltage is below 5 VDC. Refer to "Figure 1-6 DC Bus Voltage Test Points".

Place Positive (+) Meter Lead Here

TTS300 Revision G Shown

1.9 Handling Static Sensitive Devices

Figure 1-7 ESD Susceptible Caution Label

Place Negative (-) Meter Lead Here

Place Positive (+) Meter Lead Here

Place Negative (-) Meter Lead Here

TTS350 Revision H Shown

Active electronic components are susceptible to damage when exposed to static electrical charges. Damage to such components may lead to outright failure or reduction in service life. Since the presence of static charges is not always evident, it is essential that service personnel follow static control procedures at all times when handling sensitive electronic components.

This section outlines static control precautions that must be followed when providing service support in the field. Service support personnel should create a safe, static-free environment.

Service personnel must use a commercially available service kit for handling static-sensitive devices. The kit typically includes:

• Ground cord assembly

• Alligator clip

• Grounding wrist strap

• Wrist strap tester

If a safe, static control environment cannot be created for a specific reason, the operator will ensure that electrostatic discharge (ESD) items and personnel are at the same electrical potential as the equipment.

The electronic modules should only be removed from the ESD protective bag at the last moment, just before installation when the operator is ready to do the replacement.

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The operator should avoid touching any components or connectors on the module and should hold the module by its edge or enclosure, as applicable.

1.9.1 ESD Protection/Grounding

All parts that are susceptible to damage by ESD will be marked using the following label. Refer to "Figure 1-8 ESD Label". Please follow the instructions below to ensure safety and to protect the parts from ESD damage.

Figure 1-8 ESD Label

1. Isolate the compressor power as described in "1.8 Electrical Isolation" on page 19.

2. Remove the Mains Cover. Refer to "4.2.1 Mains Input Cover" on page 56.

3. Clip the ESD strap ground clip to the compressor ground post. Refer to "Figure 1-9 Mains Plate

Figure 1-9 Mains Plate and Ground Post

and Ground Post".

4. If you need to remove the Soft Start, clip the ESD strap ground clip to the mains plate. Refer to

"Figure 1-9 Mains Plate and Ground Post".

5. If you only need to remove the Service Side Cover, clip the ESD strap ground clip to the cover

screw hole that is part of the compressor housing. Refer to "Figure 1-10 Compressor Grounding Points".

Figure 1-10 Compressor Grounding Points

Ground Post

Mains Plate

Ground Points

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1.10 DC Bus Test Harness Installation and Removal

A DC bus test harness must be used when testing the voltages of the compressor’s power electronics. The DC bus test harness is not designed to be left in the compressor during normal operation. When checks are complete, disconnect and remove the test harness. There are two (2) different Soft Start versions referenced within these instructions. The steps below are organized based on which Soft Start is installed on the compressor. To identify the installed Soft Start, refer to "4.15 Soft Start" on page 107.

All versions of the DC Bus Test Harness have male/female plugs to allow piggyback connection to the required voltage measurement points on the Soft-Start. Refer to "Figure 1-11 DC Bus Test Harness Diagram (Closed-Top Soft Start)" for an example of the harness. Voltage measurements are made via shrouded multimeter jacks on the opposite end of the cables. Cable and personal protection are provided by inline fast-acting fuses (1/4 x 1 1/4, 62 milliamp 250V) and current-limiting 100kΩ 3W resistors.

Figure 1-11 DC Bus Test Harness Diagram (Closed-Top Soft Start)

Resistor, 100K, 3W, 5% tolerance (5 places)

Fuse, Fast acting, 0.062A, 1/4x1 1/4 (5 places)

Figure 1-12 DC Bus Test Harness Diagram (Open-Top Soft Start)

Resistor, 100K, 3W, 5% tolerance (2 places)

Fuse, Fast acting, 0.062A, 1/4x1 1/4 (2 places)

• • • CAUTION • • •

Before using the DC bus test harness, integrity of the fuses/resistors in the harness and cable must be checked.

1.10.1 General Verification and Installation of the DC Bus Test Harness

1. Isolate the compressor power as described in "1.8 Electrical Isolation" on page 19.

1 2 3

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• • • CAUTION • • •

Use your ESD wrist strap before touching the Soft Start Board or any electronic components.

2. Use an ESD strap and attach it the compressor housing while installing the Test Harness.

3. Remove the Service Side Cover. Refer to "4.2.3 Service Side Cover" on page 58.

Use your ESD wrist strap before touching the Soft Start Board or any electronic components.

This would be a good time to perform a visual inspection of the top-side electronics to determine if there is any visual damage present. Also at this time, it is suggested to verify the integrity of the fuses if you have a Closed-Top Soft Start.

4. Confirm the integrity of the fuses and resistors in the DC bus test harness by using a

multimeter set to resistance. Check each cable individually. Refer to "Figure 1-11 DC Bus Test Harness Diagram (Closed-Top Soft Start)" and "Figure 1-12 DC Bus Test Harness Diagram (OpenTop Soft Start)"for harness fuse and resistor locations. The reading for the resistor should be approximately 100kΩ and the reading for the fuse should be 29Ω.

5. Continue to the appropriate section below based on the particular Soft Start.

1.10.2 DC Bus Test Harness Installation for Closed-Top Soft Start

1. Disconnect the J1 and J7 connectors on the Soft Start Board. Refer to "Figure 1-13 Soft Start

(Closed Top)".

Figure 1-13 Soft Start (Closed Top)

• • • CAUTION • • •

NOTE

2. Connect the two (2) plugs of the compressor cable harness into the corresponding sockets of

the DC bus test harness. Refer to "Figure 1-14 Connect DC Bus Test Harness (Closed-Top Soft Start)" for this and the following step.

Figure 1-14 Connect DC Bus Test Harness (Closed-Top Soft Start)

Multimeter Jacks

To J7 on Soft Start

To J1 on Soft Start

To harness for J1

To harness for J7

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Figure 1-15 DC Bus Test Harness Connection Diagram (Closed-Top Soft Start)

ORIGINAL CONNECTIONS

Soft Start

(Top Side)

CONNECTIONS WITH DC BUS TEST HARNESS

Soft Start

(Top Side)

Harness to DC Bus and AC Line

Harness to DC-DC Converter

Harness to DC Bus and AC Line

Figure 1-16 Cable Passage

Harness to DC-DC Converter

00.0

Volt

Meter

3. Connect the two (2) plugs of the DC bus test harness into the Soft Start. Refer to "Figure 1-13 Soft Start (Closed Top)".

4. Route the cables through the cable passage on either side of the DC-DC Converter, down into the service side. Refer to "Figure 1-16 Cable Passage" on page 24.

NOTE

• For clarity purposes, several components have been removed from "Figure 1-16 Cable Passage"

• If the main housing has two cable passages, either passage can be used

Cable Passage

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5. Carefully adjust the connectors and harness so that the Top Cover can be reinstalled.

6. Reinstall the Top Cover and Mains Input Cover. Refer to "4.2 Compressor Covers" on page 56.

7. Remove ESD strap from the compressor and yourself.

Table 1-3 Expected DC Bus Voltage

Compressor Nameplate AC Voltage

575 VAC 518-632 VAC 700-853 VDC

460 VAC 414-506 VAC 559-683 VDC

400 VAC 360-440 VAC 486-594 VDC

380 VAC 342-418 VAC 462-564 VDC

8. Reapply AC power to the Compressor.

9. Using an appropriately-rated voltmeter with the 1000VDC range selected, insert the positive voltmeter lead into the DC (+F) test harness lead, and the negative voltmeter lead into the DC (-) test harness lead. If the voltage corresponds to "Table 1-3 Expected DC Bus Voltage", the DC bus voltage is correct and HV DC (F1) fuse on the Soft Start is intact. This would imply that the Soft Start and Silicon-Controlled Recifiers (SCRs) are functioning correctly; proceed to Step 12. If voltage reads 0, go to Step 10.

Acceptable AC Voltage Range Expected DC Bus Voltage Range

10. Leaving the DC(-) test lead in place, relocate the positive (+) test lead to DC(+). If DC voltage is consistent with "Table 1-3 Expected DC Bus Voltage", this would imply that the Soft Start and SCRs are working correctly, but the HV DC fuse (F1) on the Soft Start is an open circuit, refer to "4.25 High Voltage DC-DC Converter" on page 201 to verify the DC-DC Converter.

11. If the DC voltage is not present or is not consistent with "Table 1-3 Expected DC Bus Voltage", the incoming AC voltage should be verified to be between the acceptable AC Voltage Range listed in "Table 1-3 Expected DC Bus Voltage". Additionally the F2, F3, F4, F5, and F6 fuses need to be verified as well as the SCR Diodes and SCR Gates. Refer to "4.19 Silicone-Controlled Rectifier" on page 133 for testing details.

12. Reset multimeter scaling to read 15VAC and connect to the 15VAC leads of the DC Bus Test Harness. If the reading is zero, isolate the three-phase supply in accordance with "1.8 Electrical Isolation" on page 19. When access is safe, remove the four (4) fasteners that hold the Soft Start in position, and check fuses F2, F3, F4, F5, & F6 for continuity. If any fuse is found to be an open circuit, replace it and return to Step 6.

13. If the 15VAC is not present, replace the Soft Start (refer to "4.15.3 Soft Start Removal and Installation" on page 112). If the 15VAC is correct, proceed to the next step.

14. When finished, remove the DC Bus Test Harness. Refer to Section 5 – Removal of the DC Bus Test Harness.

The DC bus test harness is not designed to be left in the compressor during normal operation. When checks are complete, disconnect and remove the test harness.

1.10.2.1 DC Bus Test Harness Installation for Open-Top Soft Starts

1. Disconnect the J8 connector from the Soft Start. Refer to "Figure 1-17 J8 Soft Start Connection (Open Top)".

Figure 1-17 J8 Soft Start Connection (Open Top)

2. Connect the plug of the compressor cable harness into the corresponding socket of the DC bus test harness. Refer to "Figure 1-18 Connect DC Bus Test Harness (Open-Top Soft Start)" and "Figure 1-19 DC Bus Test Harness Connection Diagram (Open-Top Soft Start)" for this and the following step.

3. Connect the plug of the DC bus test harness into the Soft Start.

• • • DANGER • • •

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Figure 1-18 Connect DC Bus Test Harness (Open-Top Soft Start)

Multimeter jacks

Figure 1-19 DC Bus Test Harness Connection Diagram (Open-Top Soft Start)

ORIGINAL CONNECTIONS

Soft Start

(Top Side)

CONNECTIONS WITH DC BUS TEST HARNESS

Soft Start

(Top Side)

Harness to DC Link

To J8 on Soft Start

1 2 3

To harness for J8

00.0

Volt

Meter

4. Route the cables through the cable passage beside the DC-DC Converter, down into the service side. Refer to "Figure 1-16 Cable Passage" on page 24.

NOTE

When checks are complete, disconnect and remove the test harness. If the main housing has two cable passages, wither passage can be used.

5. Reinstall the Top Cover and Mains Input Cover. Refer to "4.2 Compressor Covers" on page 56.

6. Reapply AC power to the Compressor.

7. Insert the positive voltmeter lead into the DC (+) test harness lead, and the negative voltmeter lead into the DC (-) test harness lead. Refer to "Table 1-3 Expected DC Bus Voltage" on page 25 for the expected DC bus voltage. If the DC bus voltage is not present, or if it is outside the “Expected DC Bus Voltage” range shown in "Table 1-3 Expected DC Bus Voltage" on page 25, verify proper incoming AC input, verify SCR Gates, and verify SCR Diodes. If incoming AC power is correct, and the SCRs pass the diode and gate tests, replace the Soft Start.

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NOTE

There are no replaceable fuses present in the Open-Top Soft Start.

8. When finished, remove the DC Bus Test Harness. Refer to "1.10.3 General DC Bus Test Harness Removal".

1.10.3 General DC Bus Test Harness Removal

1. Isolate the compressor power as described in "1.8 Electrical Isolation" on page 19.

Use your ESD wrist strap before touching the Soft Start Board or any electronic components.

2. Use an ESD strap and attach it the compressor housing while installing the Test Harness.

3. Continue to the appropriate section below based on the particular Soft Start.

1.10.4 DC Bus Test Harness Removal for Closed-Top Soft Starts

1. Remove the DC bus test harness from the cable passage.

2. Disconnect the two (2) plugs of the DC Bus Test Harness from the Soft Start.

3. Disconnect the two (2) plugs of the compressor cable harness from the corresponding sockets of the DC Bus Test Harness.

4. Reconnect the J1 and J7 connectors into the Soft Start.

5. Remove ESD strap from the compressor and yourself.

6. Install all covers on the compressor. Refer to "4.2 Compressor Covers" on page 56.

7. Return the compressor to normal operation.

• • • CAUTION • • •

1.10.5 DC Bus Test Harness Removal for Open-Top Soft Starts

1. Remove the DC Bus Test Harness from the cable passage.

2. Disconnect the plug of the DC Bus Test Harness from the Soft Start.

3. Disconnect the plug of the compressor cable harness from the socket of the DC Bus Test Harness.

4. Reconnect the J8 connector into the Soft Start.

5. Remove ESD strap from the compressor and yourself.

6. Install all covers on the compressor. Refer to "4.2 Compressor Covers" on page 56.

7. Return the compressor to normal operation.

8. Disconnect the two (2) plugs of the compressor cable harness from the corresponding sockets of the DC bus test harness.

9. Reconnect the J1 and J7 connectors onto the Soft Start.

10. Install top covers on compressor. Refer to "4.2 Compressor Covers" on page 56.

1.11 Compressor Fasteners

Only replace fasteners with exact replacements. Failure to do so could lead to fastener corrosion and/or failure.

1.12 General O-ring Handling

Various O-rings are utilized throughout the TT and TG compressors to contain the refrigerant. Prior to the removal of any component utilizing an O-ring, the refrigerant must be properly recovered per industry-standard procedures. Upon O-ring replacement, a leak test should be performed. The following O-ring-specific steps are required when replacing any compressor O-ring:

1. Remove each O-ring to be installed from its package and inspect for defects such as blemishes, abrasions, cuts, or punctures.

2. Slight stretching of the O-ring when it is rolled inside out will help to reveal some defects not otherwise visible.

• • • CAUTION • • •

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3. After inspection and prior to installation, lubricate the O-ring with a light coat of Super-O-Lube.

4. Avoid rolling or twisting the O-ring when maneuvering it into place.

5. Keep the position of the O-ring mold line constant.

NOTE

It is strongly suggested that anytime an O-ring is removed, that a new O-ring is used in its place.

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Chapter 2: Compressor Fundamentals

2.2 Motor and Power Electronics Cooling .............................................................................................................................................31

2.3 Capacity Control ................................................................................................................................................................................ 34

2.4 Compressor Energy and Signal Flow ...............................................................................................................................................34

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+ 252 hidden pages

Danfoss Turbocor Service guide

Specifications and Main Features

Frequently Asked Questions

User Manual

Chapter 1.0 Introduction

1.1 Application

1.2 Purpose

1.3 Organization

1.4 Commitment to Quality and the Environment

1.5 Safety Summary

1.5.1 Danger Notification

1.5.2 Caution Notification

1.5.3 Note

1.6 Precautions

1.7 Refrigerant Type

1.7.1 R134a/513A

1.7.2 R1234ze

1.7.3 R515B

1.8 Electrical Isolation

1.9 Handling Static Sensitive Devices

1.9.1 ESD Protection/Grounding

1.10 DC Bus Test Harness Installation and Removal

1.10.1 General Verification and Installation of the DC Bus Test Harness

1.10.2 DC Bus Test Harness Installation for Closed-Top Soft Start

1.10.3 General DC Bus Test Harness Removal

1.10.4 DC Bus Test Harness Removal for Closed-Top Soft Starts

1.10.5 DC Bus Test Harness Removal for Open-Top Soft Starts

1.11 Compressor Fasteners

1.12 General O-ring Handling