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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Chapter 2.0 Compressor Fundamentals

Compressor operation begins with a demand signal applied to the compressor. The startup sequence is configurable in the startup settings. See the OEM Programming Manual for further details.

2.1 Main Fluid Path

The compressor is a two-stage centrifugal type compressor utilizing variable speed as the principle means of capacity control with inlet guide vanes (IGVs) assisting when required. Refrigerant enters the first stage suction side of the compressor as a low-pressure, low-temperature, superheated vapor. It then passes through variable IGVs that assist compressor control at part-load conditions. Both impellers are mounted on a common shaft. Vapor passes through the first stage impeller where velocity energy is added to the refrigerant. This is converted to an intermediate pressure in the first stage volute. Vapor then enters the second stage impeller through a diffuser. In the second stage, impeller velocity energy is again added to the refrigerant and converted to the final discharge pressure in the discharge diffuser and volute. From the second stage impeller, refrigerant passes as a high pressure, superheated vapor to the system discharge line.

Figure 2-1 Compressor Fluid Paths

1 1

Table 2-1 Compressor Fluid Paths

No. Component No. Component

1 Low Pressure/Low Temperature Gas 6 High-Pressure/High Temperature Gas

2 Inlet Guide Vanes (IGVs) 7 Second-Stage Impeller

3 First-Stage Impeller 8 Vaned Diffuser

4 Volute Assembly 9 Vaneless Diffuser

5 Discharge Port 10 De-Swirl Vanes

2.2 Motor and Power Electronics Cooling

Liquid refrigerant, having at least 2⁰C (Kelvin)/ 3.6°F (Rankine) sub-cooling at connection point, must be piped to the compressor cooling inlet connection. This connection is a 1/2 inch O-ring face seal (ORFS) connection with a built-in strainer. Refer to "Figure 2-2 Cooling Inlet Adapter" for an example of the cooling inlet adapter.

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Figure 2-2 Cooling Inlet Adapter

1/2" ORFS connection with strainer

Liquid refrigerant is internally channeled to two (2) solenoid valves. These valves have integral orifices that act as expansion devices to cool the compressor motor, shaft (rotor) and power electronics. TTS300 and TGS230 compressors have these solenoids arranged so that all components are cooled in series with each other and the solenoids act as two stages of cooling capacity. The TTS350, TTS400, TTS500, TTS700, T TH375, TGS310, TGS390, TGS490, TGS520, TTH375, and TGH285 compressors have separate cooling paths for motor and power electronics. These cooling methods are identified as serial or split cooling.

Serial cooling has its return point to the inlet of the first stage impeller, thus cooling all components with refrigerant evaporating at the saturated suction temperature. In serial cooling versions, Solenoid 1 is opened if any temperature reaches its “turn on” point and Solenoid 2 is opened if any temperature reaches a second “turn on” point value. Refer to cooling circuit diagram "Figure 2-5 Serial Cooling Path

- TTS300/TGS230" on page 34.

The split cooling has the motor/shaft cooling circuit return to the first stage impeller inlet and the power electronics return to the second stage impeller inlet. This ensures a higher evaporating (cooling) temperature to minimize condensation around the power electronic components. In the split cooling version, Solenoid 1 is opened if either the cavity temperature or the motor temperature reaches its “turn on” point and Solenoid 2 is opened if the Inverter or SCR temperature reaches its “turn on” point. Refer to cooling circuit diagram "Figure 2-4 Split Cooling Path - (TTS/TGS (Except TTS300/ TGS230 Serial Cooling)" and "Figure 2-3 Split Cooling Path - TTH375/TGH285" on page 33.

Medium temperature (MT) version compressors require their motor cooling suction line to be vented externally to the main suction line through an evaporator pressure regulating (EPR) valve. This valve is required to ensure that evaporating temperatures cooling the motor and electronics do not get too cold. The EPR valve should be adjusted to maintain a minimum evaporation temperature of 1.5°C (35°F). Refer to the Applications and Installation Manual for further details.

Serial Cooling compressors can be identified by having only one 1/4 inch flare Schrader connection adjacent to the main motor cooling liquid connection, while a split cooling model will have two. These 1/4 inch flare connections access the refrigerant feeds to the components being cooled and bypass the solenoid valves. These ports may be used to inject liquid refrigerant directly to cool components and enable compressors to operate during system charging operations. A minimum pressure ratio of 1.5 and a full liquid seal at the compressor is required to ensure proper and correct compressor cooling.

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Figure 2-3 Split Cooling Path - TTH375/TGH285

High-Li� Cooling Circuit

Flow Diagram

Solenoid

Inverter

Motor Cavity

Temp. Sensor

Inverter Temp Sensor

Stator/Rotor

Inlet

(Liquid Refrigerant)

Solenoid

Impeller

Stage

Axial Bearing

Radial

Bearing

Figure 2-4 Split Cooling Path - (TTS/TGS (Except TTS300/TGS230 Serial Cooling)

Liquid

Refrigerant

Inlet

BMCC

SCR

Radial

Bearing

Impeller

Stage

From Moto r

Winding Temp.

Sensor

BMCC

Solenoid

From Moto r

Cavity Tem p.

Sensor

ORIFICE

Solenoid

ORIFICE

From Inverter

Temp. Sensor

BMCC

Inverter

From SCR

Temp. Sensor

SCR

Motor/Rotor

cooling gas and

leakage

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Figure 2-5 Serial Cooling Path - TTS300/TGS230

Liquid

Refrigerant

Inlet

2.3 Capacity Control

From Motor

Winding Temp.

Sensor

BMCC

Solenoid

From Motor

Cavity Temp.

Sensor

Solenoid

BMCC

ORIFICEORIFICE

From Inverter

Temp. Sensor

Inverter

From SCR

Temp. Sensor

SCR

Motor/Rot or

cooling gas and

leakage

Capacity control of the compressor is achieved primarily by speed modulation. When unloading, the compressor’s first action is to reduce speed to slightly above the minimum (surge) speed for the pressure ratio present at the time. Further reduction in capacity and an increase in shaft/impeller stability can be achieved by closing the IGVs. These are variable angle vanes installed in the suction inlet ahead of the first stage impeller. These guide vanes restrict the refrigerant from entering the impeller inlet, as well as imparting a “pre swirl” of the refrigerant in the direction of impeller rotation to increase energy efficiency during part load operation.

Speed modulation is achieved by the use of “Inverter” control. To accomplish this, the incoming 3-phase AC supply is converted to high voltage DC, incorporating smoothing/storage capacitors, and then switched by the Inverter, utilizing 3-phase rectifiers, to give a simulated 3-phase AC supply of variable voltage and frequency to the compressor motor.

2.4 Compressor Energy and Signal Flow

During normal operation, 3-phase power is required to be connected to the compressor at all times, even if it is not running. Power is distributed through the following components to maintain compressor operation:

• Silicon-Controlled Rectifier (SCR)

• Soft Start Board

• DC Capacitor Bus Bar Assembly

• Inverter

• Stator

• High-Voltage (HV) DC-DC Converter

• Backplane

• Bearing Motor Compressor Controller (BMCC)

• Serial Driver

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• Bearing Pulse Width Modulation (PWM) Amplifier

• Compressor I/O Board

• IGV

• Solenoid actuators

The order of power and signal flow through the compressor components is as follows. Refer to "Figure 2-6 Compressor Energy and Signal Flow Connections":

1. A 3-phase voltage source is provided to the compressor through the voltage input terminal.

2. AC voltage enters the SCRs and DC voltage powers the DC bus.

3. The Soft Start Board limits the in-rush current at power-up by controlling the SCR gates.

4. DC bus voltage from the SCRs charges the capacitors.

5. DC bus provides DC voltage to Inverter.

6. The Inverter converts the DC bus voltage into a variable frequency, 3-phase simulated AC voltage to the Stator.

7. The DC-DC Converter uses the DC bus voltage to provide 24VDC and 250VDC to the Backplane.

8. The Backplane connects and supplies low DC voltage to the service side components.

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Figure 2-6 Compressor Energy and Signal Flow Connections

TTS300 Shown

DC bus voltage from the SCRs

charges the capacitors

Soft Start limits the in-rush

current at power-up by controlling the SCR gates

Soft Start AC Output Voltage to DC-DC Converter

3-phase Voltage Input Terminal

AC voltage enters the SCRs and DC voltage powers the DC bus

DC bus provides DC voltage to the

Inverter

Soft Start AC/DC Input Voltage; DC Output Voltage to DC-DC Converter

(+) (-)

DC BUS

DC-DC converts DC bus voltage

to provide 24 VDC and 250 VDC to backplane

Backplane supplies low

DC voltage to service side components

Inverter connection

Inverter converts DC bus voltage into 3-phase simulated AC voltage to the stator

Inverter DC Bus connection

Ground

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Refer to "Figure 2-7 Compressor Energy and Control Flow Block Diagram - TTS/TGS Compressors" for a

block diagram summary of the energy and voltage signal flow through the compressor.

NOTE

TTH/TGH Compressors are very similar to "Figure 2-7 Compressor Energy and Control Flow Block Diagram - TTS/TGS Compressors".

Figure 2-7 Compressor Energy and Control Flow Block Diagram - TTS/TGS Compressors

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3-Phase

380-575VAC

50/60 Hz

EMI/EMC

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Chapter 3: Compressor Removal and Installation

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

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Chapter 3.0 Compressor Removal and Installation

3.1 Refrigerant Containment

Isolation and recovery of the refrigerant must be performed by a qualiﬁed service technician adhering to industry/ASHRAE standards.

1. Close the suction, discharge, and economizer isolating valves as appropriate.

2. Close the motor-cooling liquid line shut-off valve.

3. Use a magnet to manually open at least one of the motor cooling solenoids.

4. Connect a refrigerant recovery system to the compressor as per industry-standard procedures and transfer the refrigerant to an appropriate containment vessel.

3.2 Compressor Removal

1. Isolate the Compressor power as described in the "1.8 Electrical Isolation" on page 19 section of this manual.

Ensure that there is no secondary power source connected to the compressor before disconnecting the following cables:

2. Remove the power cables.

3. Remove the ground wire from the ground post.

Figure 3-1 Compressor Power Cable Removal

• • • CAUTION • • •

TTS350 Major Rev. F shown

4. Remove the Service Side Cover.

5. Disconnect the I/O cable from the Backplane I/O connector (J7) and remove the cable from the compressor.

6. Once the transfer of refrigerant is complete, bring the compressor back to atmospheric pressure according to industry standards using dry nitrogen.

7. Disconnect the compressor from the refrigerant system connections (suction, discharge, economizer and motor cooling line), taking care when removing connections that there is no residual pressure.

8. Install the Service Side Cover.

9. Install the Mains Input Cover.

10. Position the lifting hoist/crane with the 2-point spreader bar directly above the lifting points.

11. Using a properly rated chain/cable, connect the spreader bar to the compressor lifting points.

12. Confirm that all lifting points are secured in accordance with relevant safety procedures and standards.

13. Connect an appropriate lifting device to the eyebolts provided on each side of the compressor.

14. Remove the four (4) compressor mounting fasteners and associated hardware from the base of the compressor.

15. Lift the compressor approximately 100 mm (4”). Confirm that the compressor and spreader bar are properly balanced between the lifting points and the lifting hoist.

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16. Continue the removal of the compressor and lower to the desired location in order to remove the chains/cables.

17. Using the blanking plates and bolts provided with the new compressor, seal the compressor and charge to 15 psi with a nontoxic inert gas (e.g., nitrogen) for shipment (this will prevent moisture and foreign material from entering the compressor).

3.3 Compressor Installation

Blanking plates should not be removed from the new compressor until you are ready to place the new compressor in operation. New compressors are pressurized with nitrogen to 15 psi. Pressure should be relieved through the Schrader valve, located next to the motor cooling connection, prior to removing the blanking plates. Isolation and recovery of the refrigerant must be performed by a qualiﬁed technician. Always wear proper safety equipment when handling refrigerants.

Install new O-rings when attaching ﬂanges to the compressor.

1. Relieve the inert gas pressure through the motor cooling exit port Schrader valve.

2. Remove the suction, discharge, and economizer (if applicable) blanking plates from the compressor.

3. Remove the motor cooling inlet adapter cap. Refer to "3.4 Compressor Replacement Considerations for Motor Cooling Adapter" on page 43.

4. Ensure that all connections have protective covers to prevent foreign object damage during installation.

5. Attach the spreader bar to the two (2) lifting hooks (eye bolts) on the top of the compressor and confirm that all lifting points are secured in accordance with relevant safety procedures and standards.

6. Position an appropriate lifting hoist/crane and connect to the spreader bar.

7. Confirm that the compressor and spreader bar are properly balanced between the lifting points and the lifting hoist.

8. Slowly lower the compressor until it is positioned within approximately 5 mm (¼”) of the compressor mounts.

9. Loosely install the rubber mounts and mounting fasteners to the base of the compressor.

10. Slowly release the load from the crane so that compressor weight is supported by the compressor mounts.

11. Tighten the suction flange fasteners to 75 Nm (55 ft.lb.).

12. Tighten the discharge flange fasteners to 32 Nm (24 ft.lb.).

13. Tighten the economizer flange fasteners (if applicable) to 32 Nm (24 ft.lb.).

14. Torque the compressor mounting base fasteners to 22 Nm (16 ft.lb.).

Figure 3-2 Compressor Mounting Fasteners

NOTE

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Mounting Base Fastener, M12, 22 Nm (16 ft.lb.) (4 places)

15. Torque the motor cooling line connection (Nut) to 11 Nm (8 ft.lb.).

16. Remove the Service Side Cover.

17. Install the I/O strain relief to the compressor housing.

18. Connect the compressor I/O cable to the Backplane I/O connector (J7).

19. Install the Service Side Cover.

• • • DANGER • • •

Ensure that electrical power is isolated from the AC mains cables before handling the cables.

20. Remove the Mains Input Cover.

21. Connect the cable gland that secures the Mains Input cable conduit to the Mains Input bracket.

22. Install the Mains Input ground wire to the ground post and torque the top nut to 10 Nm (7 ft.lb.).

23. Attach the AC mains cables to the terminals and torque to specification.

• TTS300/TGS230 Compressors - 20 Nm (15 ft.lb.)

• All Compressors (excluding TT300/TG230) - 21 Nm (15 ft.lb.)

24. Install the Mains Input Cover. Refer to "4.2.1 Mains Input Cover" on page 56.

25. Leak test and evacuate in accordance with standard industry practices.

26. Return the compressor to normal operation.

3.4 Compressor Replacement Considerations for Motor Cooling Adapter

The housing connection seal is an ISO standard O-ring seal and the external pipework connection is an ORFS. In addition, the line size has been standardized at 1/2 inch for all models and the fitting includes a built-in (removable) strainer.

The current fitting consists of 1) body (including both O-rings), 2) strainer, 3) blanking disc, 4) 1/2” braze sleeve, steel (all for connecting 1/2 inch copper tube) and 5) nut. Body to compressor housing thread is M16 x 1.5. Refer to "Figure 3-3 Motor Cooling Fitting".

Figure 3-3 Motor Cooling Fitting

O-ring

Body

Adapter Body Connection thread M16x1.5 25 Nm (18 ft.lb.)

O-ring

Strainer

Nut Inside thread 13/16 UN-2A 11 Nm (8 ft.lb.)

Blanking Disk

Braze Sleeve

Tube connection thread is 13/16-16 UN-2A. Strainer recess is Ø 9.5.

Flexible Line

1. If the connection is a flexible hose to 3/8 or 1/2 inch flare, the entire hose will require replacement with the current style.

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2. Isolate the compressor and recover the refrigerant according to industry standards. Refer to "3.1 Refrigerant Containment" on page 41.

3. Source appropriate OEM specified and procured flexible line.

4. Remove the nut from the connection fitting body. Discard the blanking disc, nut, and braze sleeve.

5. Before installation of the OEM supplied flexible line, inspect the O-ring face to ensure it is clean and free from scratches or other damage. Lightly smear O-ring lube on the O-ring face of the line and install using two (2) wrenches; one to hold body of fitting and one to tighten the nut. This is done to prevent over torqueing the fitting in the compressor housing.

Flexible lines are not supplied by Danfoss LLC. Selection of appropriate hose and ﬁtting is the responsibility of OEM/installer. This information is readily available from various sources.

NOTE

Rigid 1/2 inch copper connection

1. If the connection is 1/2 inch rigid copper, a length of 1/2 inch copper must be brazed into the braze sleeve.

2. Isolate the compressor and recover the refrigerant according to industry standards. Refer to "3.1 Refrigerant Containment" on page 41.

3. Remove the nut from the connection-fitting body. Discard the blanking disc. Locate the braze sleeve and clean. Ensure removal of all oil and surface debris. Braze as per the OEM standard process for copper/steel joint.

4. Place an appropriate length of 1/2 inch copper tube into the braze sleeve. Pretreat/flux joint area as per the OEM standard procedure. Braze the pipe to the sleeve ensuring the nut can be fitted after brazing or otherwise position as required. Clean flux and any excess filler from joint.

5. Clean the O-ring face of the sleeve ensuring no scratches or debris are present. Apply a light amount of O-ring lube to the face of the sleeve and assemble to the fitting. Tighten the nut using two (2) wrenches; one to hold body of fitting and one to tighten the nut. This is done to prevent over torqueing the fitting in the compressor housing

Rigid 3/8 inch copper connection - TTS300/TGS230

• If the connection is 3/8 inch rigid copper, a length of 1/2 inch copper must be brazed into the braze sleeve as described above. A transition fitting should be brazed to connect the 3/8 to 1/2 inch tubes. Follow the procedure as noted above in Rigid 1/2 Copper Connection section.

Important

• It should be noted that the inclusion of a strainer within the connection body is intended as a last resort backup only to prevent ingress of debris that may block solenoid orifices or restrict motor and power electronics cooling. It is not a substitute for a correctly sized full-flow filter drier. A filter drier must be installed in all instances. If it is found that a filter drier is not installed, and the fitting is changed due to a field replacement of the compressor, a filter drier must be included in the line modification.

• If it is required to remove the fitting from the housing for any reason, clean the O-ring, fitting and housing threads, and apply a small amount of O-ring lube before reassembly.

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3.5 Exterior Connection Torque Specifications

Table 3-1 Exterior Connection Torque Specifications

Description Thread Depth (mm)Nm Ft.Lb. In.Lb.

Power Cable Nut (excluding TTS300/TGS230 compressors) - 21 15 186

Input Pressure Screws (TTS300/TGS230 compressors) - 20 15 177

Motor Cooling Body, E-housing and later - 25 18 221

Motor Cooling Compression Nut, E-housing and later - 11 8 97

Ground Post, Top Nut - 10 7 89

Ground Post, Second (Jam) Nut - 7 - 62

Ground Post, Lower Nut - 20 15 177

Suction Flange Fastener 34.5 75 55 664

Discharge Flange Fastener 20 32 24 283

Economizer Flange Fastener 20 32 24 283

Schrader Valve - 15 11 133

Base Mounting Bolt 24 22 16 195

Cover Fastener - 1.5 - 13

Compressor Mounting Fastener - 14 10 124

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Chapter 4: Compressor Components

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

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

4.2.1 Mains Input Cover ..................................................................................................................................................................................................................................................56

4.2.2 Top Cover...................................................................................................................................................................................................................................................................57

4.2.3 Service Side Cover..................................................................................................................................................................................................................................................58

4.2.4 Capacitor Cover ...................................................................................................................................................................................................................................................... 59

4.2.5 Compressor Cover Torque Speciﬁcations ...................................................................................................................................................................................................... 60

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

4.3.1 Cooling Adapter Removal and Installation ................................................................................................................................................................................................... 62

4.3.2 Cooling Adapter Torque Speciﬁcations ..........................................................................................................................................................................................................62

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

4.4.1 Compressor Interface Module Connection Descriptions ........................................................................................................................................................................ 63

4.4.2 Compressor Interface Module Veriﬁcation ...................................................................................................................................................................................................65

4.4.3 Compressor Interface Module Removal & Installation ............................................................................................................................................................................. 66

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

4.5.1 Compressor Interface Cable Veriﬁcation .......................................................................................................................................................................................................67

4.5.2 Compressor Interface Cable Removal and Installation ............................................................................................................................................................................67

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

4.6.1 Compressor Controller Cable Connections .................................................................................................................................................................................................. 68

4.6.2 Compressor Controller Cable Harness Removal and Installation ........................................................................................................................................................ 68

4.6.3 Compressor Controller Cable Harness Torque Speciﬁcations ................................................................................................................................................................ 72

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

4.7.1 Solenoid and Coil Connections ......................................................................................................................................................................................................................... 72

4.7.2 Solenoid Coil Harness ........................................................................................................................................................................................................................................... 73

4.7.3 Solenoid Veriﬁcation .............................................................................................................................................................................................................................................73

4.7.4 Solenoid and Coil Removal and Installation................................................................................................................................................................................................. 75

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

4.8.1 Interstage Pipe Removal and Installation ......................................................................................................................................................................................................77

4.8.2 Interstage Pipe Torque Speciﬁcations.............................................................................................................................................................................................................78

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

4.9.1 Compressor Housing End Cap Removal and Installation ........................................................................................................................................................................ 79

4.10.1 IGV Connections ................................................................................................................................................................................................................................................... 80

4.10.2 IGV Veriﬁcation .....................................................................................................................................................................................................................................................81

4.10.3 IGV Housing Removal and Installation ........................................................................................................................................................................................................ 83

4.10.4 IGV Torque Speciﬁcations .................................................................................................................................................................................................................................92

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

4.11.1 Mains Plate Bracket Removal and Installation .......................................................................................................................................................................................... 93

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

4.12.1 3-Phase Main Voltage Input Terminal Block Veriﬁcation .......................................................................................................................................................................96

4.12.2 3-Phase Main Voltage Input Terminal Block Removal and Installation ............................................................................................................................................ 98

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

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

4.14.1 Veriﬁcation of Terminal Block Fuse ..............................................................................................................................................................................................................105

4.14.2 Terminal Block Fuse Removal and Installation ........................................................................................................................................................................................106

4.15.1 Soft Start Connections .....................................................................................................................................................................................................................................108

4.15.2 Soft Start Veriﬁcation ........................................................................................................................................................................................................................................109

4.15.3 Soft Start Removal and Installation.............................................................................................................................................................................................................112

4.15.4 Soft Start Removal (Closed-Top) ...................................................................................................................................................................................................................112

4.15.5 Soft Start Removal (Open-Top) .....................................................................................................................................................................................................................114

4.15.6 Soft Start Installation (Closed-Top) ..............................................................................................................................................................................................................116

4.15.7 Soft Start Installation (Open-Top) ................................................................................................................................................................................................................117

4.15.8 Soft Start Fan Removal and Installation ....................................................................................................................................................................................................117

4.15.9 Soft Start Fan Removal.....................................................................................................................................................................................................................................117

4.15.10 Soft Start Fan Installation .............................................................................................................................................................................................................................118

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

4.16.1 SCR DC Bus Bar Removal and Installation .................................................................................................................................................................................................120

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

4.17.1 Soft Start SCR Gate Cable Connections .....................................................................................................................................................................................................121

4.17.2 Soft Start SCR Gate Cable Removal and Installation .............................................................................................................................................................................121

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

4.18.1 Soft Start AC/DC Harness Connections .....................................................................................................................................................................................................125

4.18.2 Soft Start AC/DC Harness Removal and Installation .............................................................................................................................................................................127

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

4.19.1 SCR Connections ................................................................................................................................................................................................................................................134

4.19.2 SCR Veriﬁcation ...................................................................................................................................................................................................................................................135

4.19.3 SCR Removal and Installation........................................................................................................................................................................................................................141

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

4.20.1 SCR Cooling Manifold General Removal ...................................................................................................................................................................................................150

4.20.2 SCR Cooling Manifold Removal - TTS300/TGS230 .................................................................................................................................................................................150

4.20.3 SCR Cooling Manifold Removal - TTS/TGS/TTH/TGH (Except TTS300/TGS230) ..........................................................................................................................151

4.20.4 SCR Cooling Manifold Installation - TTS300/TGS230 ............................................................................................................................................................................152

4.20.5 SCR Cooling Manifold Installation - TTS/TGS/TTH/TGH (Except TTS300/TGS230) .....................................................................................................................153

4.20.6 SCR Cooling Manifold General Installation ..............................................................................................................................................................................................154

4.20.7 SCR Cooling Manifold Torque Speciﬁcations. ..........................................................................................................................................................................................155

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

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

4.22.1 DC Capacitor DC Bus Bar Connections ......................................................................................................................................................................................................157

4.22.2 DC Bus Voltage Veriﬁcation ............................................................................................................................................................................................................................158

4.22.3 DC Capacitor Bus Bar Assembly Removal and Installation .................................................................................................................................................................158

4.22.4 DC Capacitor Bus Bar Assembly General Removal ................................................................................................................................................................................158

4.22.5 DC Capacitor Bus Bar Assembly General Installation Steps ...............................................................................................................................................................163

4.22.6 DC Capacitor Bus Bar Assembly Torque Speciﬁcations .......................................................................................................................................................................164

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

4.23.1 Inverter Connections ........................................................................................................................................................................................................................................165

4.23.2 Inverter Veriﬁcation ...........................................................................................................................................................................................................................................165

4.23.3 Inverter Cable Harness .....................................................................................................................................................................................................................................166

4.23.4 Inverter Cable Harness Removal and Installation ..................................................................................................................................................................................166

4.23.5 Inverter Cable Harness Installation .............................................................................................................................................................................................................167

4.23.6 Inverter Removal and Installation................................................................................................................................................................................................................168

4.23.7 Inverter Card Replacement ............................................................................................................................................................................................................................187

4.23.8 Inverter Torque Speciﬁcations ......................................................................................................................................................................................................................190

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

4.24.1 Function ................................................................................................................................................................................................................................................................191

4.24.2 Motor Protection ................................................................................................................................................................................................................................................191

4.24.3 Motor Connections ...........................................................................................................................................................................................................................................192

4.24.4 Motor Veriﬁcation ..............................................................................................................................................................................................................................................192

4.24.5 Motor Assembly Removal and Installation...............................................................................................................................................................................................193

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

4.25.1 DC-DC Converter Function .............................................................................................................................................................................................................................201

4.25.2 DC-DC Converter Veriﬁcation ........................................................................................................................................................................................................................201

4.25.3 DC-DC Supply Cable Harness .......................................................................................................................................................................................................................202

4.25.4 DC-DC Harness Removal and Installation .................................................................................................................................................................................................203

4.26.1 Backplane Function ..........................................................................................................................................................................................................................................207

4.26.2 Backplane Connections and Test Points ...................................................................................................................................................................................................208

4.26.3 Backplane Removal and Installation...........................................................................................................................................................................................................211

4.27.1 Serial Driver Function .......................................................................................................................................................................................................................................212

4.27.2 Serial Driver Connections ...............................................................................................................................................................................................................................213

4.27.3 Serial Driver Veriﬁcation ..................................................................................................................................................................................................................................213

4.27.4 Serial Driver Removal and Installation .......................................................................................................................................................................................................213

4.28.1 BMCC Connections............................................................................................................................................................................................................................................215

4.28.2 BMCC Veriﬁcation ..............................................................................................................................................................................................................................................215

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4.28.3 BMCC Battery and Veriﬁcation ......................................................................................................................................................................................................................215

4.28.4 BMCC Removal and Installation ...................................................................................................................................................................................................................217

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

4.29.1 PWM Function .....................................................................................................................................................................................................................................................218

4.29.2 PWM Connections .............................................................................................................................................................................................................................................219

4.29.3 PWM Veriﬁcation ................................................................................................................................................................................................................................................220

4.29.4 PWM Removal and Installation .....................................................................................................................................................................................................................221

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

4.30.1 Magnetic Bearings Function ..........................................................................................................................................................................................................................223

4.30.2 Magnetic Bearings Connections ..................................................................................................................................................................................................................223

4.30.3 Bearing Veriﬁcation ...........................................................................................................................................................................................................................................223

4.30.4 Bearing Power Feedthrough Removal and Installation .......................................................................................................................................................................226

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

4.31.1 Bearing Sensor Function .................................................................................................................................................................................................................................228

4.31.2 Bearing Sensor Connection ...........................................................................................................................................................................................................................228

4.31.3 Bearing Sensor Veriﬁcation ............................................................................................................................................................................................................................229

4.31.4 Bearing Sensor Cable Removal and Installation .....................................................................................................................................................................................229

4.31.5 Bearing Sensor Removal and Installation .................................................................................................................................................................................................229

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

4.32.1 Cavity Temperature Sensor Function .........................................................................................................................................................................................................231

4.32.2 Cavity Temperature Sensor Connections ..................................................................................................................................................................................................232

4.32.3 Cavity Temperature Sensor Veriﬁcation .....................................................................................................................................................................................................232

4.32.4 Cavity Temperature Sensor Removal and Installation ..........................................................................................................................................................................232

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

4.33.1 Pressure/Temperature Sensor Function ....................................................................................................................................................................................................234

4.33.2 Pressure/Temperature Sensor Connections .............................................................................................................................................................................................234

4.33.3 Pressure/Temperature Sensor Veriﬁcation ...............................................................................................................................................................................................234

4.33.4 Pressure/Temperature Sensor Removal and Installation ....................................................................................................................................................................236

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Chapter 4.0 Compressor Components

This section provides compressor component locations and functional descriptions, verification and troubleshooting methods, cable connection identification, and steps necessary to replace a component.

4.1 Component Identification

This section identifies the major parts of the compressor.

Figure 4-1 Compressor Components Identification (Covers On)

Table 4-1 Compressor Components (Covers On)

No. Component No. Component

1 Top Cover 7 Service Side Cover

2 Mains Input Cover 8 Rear Support Base

3 Lift Anchor (Front) 9 Compressor I/O Board

4 Cable Harness (Sensor) 10 Compressor I/O Board Cable

5 IGV Housing 11 End Cap

6 Front Support Base 12 Lift Anchor (Rear)

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

TT300 Shown

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

No. Component No. Component

1 Suction Pressure/Temperature Sensor 8 Compressor Cooling Access Port Access

2 IGV Suction Port 9 Compressor Cooling Access Port #2

3 PWM Amplifier 10 Motor-Cooling Connection

4 BMCC 11 DC-DC Converter

5 Serial Driver 12 Soft Start

6 Backplane 13 Inverter

7 Motor-Cooling Solenoids 14 Fast-Acting Fuses (TTS300/TGS230 only)

Port #1 (NOTE: TTS300/TGS230 have only one access port)

(not available on TTS300/TGS230 compressors) NOT SHOWN

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

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

No. Component No. Component

1 PWM Amplifier 8 Suction Pressure/Temperature Sensor

2 BMCC 9 Motor-Cooling Solenoids

3 Serial Driver 10 Motor-Cooling Connection

4 Backplane 11 DC-DC Converter

5 Compressor Cooling Access Port 12 Soft Start Board

6 IGV Suction Port 13 Inverter

7 Compressor Cooling Access Port 14 AC Mains Bus Bars

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

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

No. Component No. Component

1 Capacitors 5 Optional Pressure Regulating Port

2 IGV Position Indicator 6 IGV Motor Feedthrough

3 Economizer Port 7 Discharge Temperature/Pressure Sensor

4 Discharge Port

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

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

No. Component No. Component

1 Capacitors 6 Economizer Port

2 IGV Motor Feedthrough 7 Interstage Pipe

3 Optional Pressure Regulating Port 8 Interstage Temperature/Pressure Sensor

4 Suction Temperature/Pressure Sensor 9 Discharge Port

5 Suction Port 10 Interstage Temperature/Pressure Sensor

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4.2 Compressor Covers

Figure 4-6 Top Covers Removal

The compressor covers provide protection to the internal components as well as protection for anyone that might be near the compressor while the mains power is applied and while the capacitors contain a dangerous electrical charge.

Mains Input Cover

Top Cover

Care must be taken in removal and installation of the covers to prevent the fasteners from falling in to the power electronic compartment. Dropping cover fasteners can cause a short circuit, cause energized components to explode, and cause damage to the power electronic parts of the compressor. After properly positioning the covers, carefully install the fasteners to minimize the risk of them falling into the power electronic areas.

4.2.1 Mains Input Cover

4.2.1.1 Mains Input Cover Removal and Installation

Mains Input Cover Removal

1. Remove the M5x15 fasteners that secure the Mains Input Cover and remove the cover.

Mains Input Cover Installation

1. Ensure that no residue remains on the contact surfaces of Mains Input Cover and Top Cover.

2. Place the Mains Input Cover and secure it with the M5x15 fasteners. Tighten according to the sequence shown in "Figure 4-7 Mains Input Cover Torque Sequence" on page 57.

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• • • CAUTION • • •

Figure 4-7 Mains Input Cover Torque Sequence

Mains Cover Fastener, M5x15

4 places)

3. Follow the sequence twice. The first time, only tighten the fasteners half way down to allow for adjustment. Tighten the # 4 fastener only once and be sure to not overtighten. Torque to 13 in.lb. on the second pass.

4.2.2 Top Cover

4.2.2.1 Top Cover Removal and Installation

Top Cover Removal

1. Remove the Mains Input Cover by releasing the M5x15 fasteners and remove the cover.

2. Remove the M5x15 fasteners that secure the Top Cover and remove the cover.

Top Cover Installation

1. Ensure that no residue remains on the contact surfaces of Top Cover and casting sides.

2. Place the Top Cover and secure it with the M5x15 fasteners according to the sequence shown in "Figure 4-8 Top Cover". Follow the sequence twice. The first time, only tighten the fasteners half way down to allow for adjustments. Torque to 13 in.lb. on the second pass.

Figure 4-8 Top Cover

Top Cover Fastener, Torque to 1.5 Nm (13 in.lb.) (9 places)

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3. Ensure that no residue remains on the contact surfaces of the Mains Input Cover and casting sides.

4. Place the new Mains Input Cover and secure it with the M5x15 fasteners. Tighten according to the sequence shown in "Figure 4-7 Mains Input Cover Torque Sequence".

5. Follow the sequence twice. The first time, only tighten the fasteners half way down to allow for adjustment. Torque to 13 in.lb. on the second pass. Tighten the # 4 fastener only once and use caution as to not overtighten.

4.2.3 Service Side Cover

The Service Side Cover provides protection for the Backplane, Serial Driver, BMCC, PWM, feed throughs, and cabling.

Figure 4-9 Service Side Cover

4.2.3.1 Service Side Cover Removal and Installation

Figure 4-10 Service Side Cover

Service Side Cover Removal

1. Remove the M5x15 fasteners that secure the Service Side Cover and remove the cover.

Service Side Cover Installation

1. Ensure that no residue remains on the contact surfaces of the Service Side Cover and compressor housing sides.

2. Place the Service Side Cover and secure it with the M5x15 fasteners according to the sequence shown in "Figure 4-10 Service Side Cover".

3. Follow the sequence twice. The first time, only tighten the fasteners half way down to allow for adjustment. Torque to 13 in.lb. on the second pass.

Service Side Cover Fastener, M5x15 (6 places)

5 3

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4.2.4 Capacitor Cover

The Capacitor Cover provides protection for the capacitors.

Figure 4-11 Capacitor Cover

4.2.4.1 Capacitor Cover Removal and Installation

Capacitor Cover Removal

1. Remove the M5x15 fasteners that secure the Top Cover and Capacitor Cover to each other.

2. Remove the fasteners that secure the Capacitor Cover. Remove the cover.

3. Remove the nylon nuts under the capacitor assembly, then remove the capacitor relief membrane.

Figure 4-12 Capacitor Nylon Nuts

Capacitor Cover Installation

1. Install the capacitor relief membrane with the foam side up. Refer to "Figure 4-12 Capacitor Nylon Nuts" for this and the following step.

2. Install the nylon nuts to the base of the DC Capacitor Bus Bar Assembly, under the main compressor housing and torque to 7 Nm (62 in.lb.).

Nylon nut (4 places)

Foam Side Up

3. Place the Capacitor Cover and secure it with the M5x15 fasteners from the Top Cover.

4. Place the Capacitor Cover on the compressor and loosely secure it with the M5X15 fasteners. The bottom of the cover should rest just above the Relief Membrane. Refer to "Figure 4-13 Relief Membrane Position" on page 60. Additionally, the cover should line up and sit in the recessed holes in the compressor housing. Refer to "Figure 4-14 Recessed Holes".

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Figure 4-13 Relief Membrane Position

Figure 4-14 Recessed Holes

Relief membrane should be visible when Capacitor Cover is installed

5. Place the long M5x20 fastener and flat washer in position number three (3) shown in "Figure 4-15 Capacitor Cover Torque Sequence". Use the remaining M5x15 fasteners to secure the cover. Tighten all fasteners according to the sequence in "Figure 4-15 Capacitor Cover Torque Sequence". Torque to 13 in.lb. on the second pass.

Figure 4-15 Capacitor Cover Torque Sequence

Capacitor Cover Fastener, M5x15 (5 places)

4.2.5 Compressor Cover Torque Specifications

Table 4-6 Compressor Cover Torque Specifications

Description Nm Ft.Lb. In.Lb.

Capacitor Cover Fastener, M5x20

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Cover Fastener, M5x15 1.5 - 13

Cover Fastener, M5x20 (#3 on Capacitor Cover) 1.5 - 13

4.3 Cooling Adapter

To provide cooling for the motor and power electronics, a liquid feed line is connected to the compressor via the Cooling Adapter. This adapter contains a strainer to collect any debris that may be present.

• • • CAUTION • • •

A ﬁlter/drier must be used in conjunction with the Cooling Adapter strainer is not a replacement. The strainer is used as a backup to prevent damage to the solenoid oriﬁces should any debris get past the ﬁlter/drier.

Figure 4-16 Cooling Adapter - Excludes TTH375/TGH285

Braze Sleeve

Nut Inside thread 13/16 UN-2A 11 Nm (8 ft.lb.)

Figure 4-17 Cooling Adapter - TTH375/TGH285)

Strainer

O-ring

Adapter Body Connection thread M16x1.5 25 Nm (18 ft.lb.)

O-ring

Nut Inside thread 13/16 UN-2A 11 Nm (8 ft.lb.)

Braze Sleeve

Adapter Body Connection thread M16x1.5 25 Nm (18 ft.lb.)

O-ring

Strainer

O-ring

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4.3.1 Cooling Adapter Removal and Installation

Cooling Adapter Removal

1. Isolate the compressor and recover the refrigerant according to industry standards. Refer to "3.1 Refrigerant Containment" on page 41.

2. Hold the Adapter Body with a 15/16" flare nut wrench while loosening the Connection Nut with another 15/16" flare nut wrench.

3. Remove the line away from the Adapter Body.

4. Remove the Adapter Body with a 15/16" flare nut wrench.

5. Remove O-ring from the compressor housing if it does not come out with the Adapter Body.

Cooling Adapter Installation

1. Verify the threads in the compressor housing are clean and free of debris (do not use compressed gas to clean the threads as this may blow the debris into the compressor).

2. Clean and lubricate the O-ring. Install onto the cooling adapter body.

3. Insert the cooling adapter body into the compressor and finger tighten.

4. Torque the cooling adapter body to the compressor housing to 25 Nm (18 ft.lb.).

5. Install the screen inside the cooling adapter.

6. Install the braze sleeve and nut minus the O-ring. Tighten the nut finger tight against the Cooling Adapter. This will allow for the measurement and fitting of the liquid line. Once the measuring and fitting of the liquid line has been completed, unscrew the nut from the cooling adapter body and complete the brazing of the liquid line to the braze sleeve.

7. Once the Cooling Adapter assembly has cooled, install the O-ring into the Cooling Adapter and the finger tighten the nut. Torque the nut to 11 Nm (8 ft.lb.).

8. Leak test and evacuate compressor in accordance with standard industry practices."

A magnet may need to be placed on the motor cooling solenoids if evacuation cannot be performed directly to the liquid line.

9. Return the compressor to normal operation.

4.3.2 Cooling Adapter Torque Specifications

Table 4-7 Cooling Adapter Torque Specifications

Description Nm Ft.Lb. In.Lb.

Adapter Body Connection 25 18 221

Nut 11 8 97

NOTE

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4.4 Compressor Interface Module

D1 D2 D3 D4 D5 D6 D7 D8

The Compressor Interface Module (CIM), also referred to as the Compressor I/O Board, allows the user to control the compressor and allows the compressor to return status and sensor information to the user. See "Figure 4-18 Compressor Interface Module Ports & Jumpers" for I/O board connection locations.

Figure 4-18 Compressor Interface Module Ports & Jumpers

Table 4-8 CIM Ports and Jumpers

JP2

JP7

No. Component No. Component

J1 RS-485 Communication Port JP1 Analog Output Voltage

J2 Input/Output JP2 MODBUS Terminator

J3 Input/Output JP3 Entry

J4 EXV1 and EXV2 Control JP4 Leave

J2 J3JP1

J8J5

JP3

JP4

JP5

JP6

J5 Liquid Level Input JP5 LIQ LEV1

J6 RS232 I/O Cable Connection JP6 LIQ LEV2

J7 RS232 External Communication Port JP7 J7 Power

J8 External Sensor Inputs

4.4.1 Compressor Interface Module Connection Descriptions

J1 – RS-485 external communication port

• Jumper JP2 required at end of Modbus line

J2 – Input/output

• DEMAND – Pin 1 & 2 – Analog input to drive compressor (0-10V)

• I/LOCK – Pin 3 & 4 – Interlock safety switch: must be part of a closed circuit to start compressor

• STATUS – Pin 5 & 6 – Output; closed circuit: compressor in normal operation; open circuit: compressor in alarm condition.

• SPEED – Pin 7 & 8 – compressor motor speed output (0-5V = 10,000 RPM/volt)

No longer available for compressors running BMCC ﬁrmware versions CC3.0 and later.

NOTE

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• LIQT – Pin 9 & 10 – Liquid temperature sensor input

• Refer to the Applications and Installation Manual for thermistor specifications

J3 – Input/output

• RUN – Pin 1 & 2 – compressor running indicator output. Normally Open, closes when RPM reaches specified RPM set in BMCC

• ANALOG – Pin 3 & 4 – Output dependent on BMCC setting. 0-5V or 0-10V set by jumper JP1

• ENTRY – Pin 5 & 6 – Entering chilled fluid temperature sensor input

– Use ENTRY jumper when no sensor connected

– Refer to the Applications and Installation Manual for thermistor specifications

• LEAVE – Pin 7 & 8 – Leaving chilled fluid temperature sensor input

– Use LEAVE jumper when no sensor connected

– Refer to the Applications and Installation Manual for thermistor specifications

J4 – EXV 1 & EXV 2 Control – 15V output

• EXV1 – Pin 6 to 9

• EXV2 – Pin 1 to 4

J5 – Liquid Level input

• LIQ LEV 1 – Pin 4 to 6 – Liquid level sensor driving the electronic expansion valve1 (EXV1)

• LIQ LEV 2 – Pin 1 to 3 – Liquid level sensor driving the electronic expansion valve2 (EXV2)

• Refer to the Applications and Installation Manual for further information

• Jumpers JP5 (LIQ LEV 1) & JP6 (LIQ LEV 2)

– For use with a voltage-type level sensor (with 15V supply and 0-5V signal)

» Install jumpers between LVL pins 2a and 3a, and Pins 2b and 3b

» Connect the sensor leads to the “+,” “S,“ and “-“ terminals on the Compressor I/O Board

(consult vendor documentation for sensor lead identification)

– For use with a resistive-type float sensor

» Install jumpers between LVL Pins 1a and 2a, and Pins 1b and 2b

» Connect the sensor leads to the “-” and “S” terminals on the Compressor I/O Board

– When using Superheat Control (no sensor connected)

» Install jumpers between LVL pins 2a and 3a, and Pins 2b and 3b

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J6 – RS-232 I/O Cable connection

• Communication port with Backplane

J7 – RS-232 external communication port

• Use Jumper JP7 only to supply power at the 9-pin connector

J8 – External sensor inputs

• Spare T: External temperature sensor input

– Refer to the Applications and Installation Manual for thermistor specifications

• Spare P: External pressure sensor input

– Refer to the Applications and Installation Manual for pressure sensor specifications

– Refer to the OEM Programming Manual for software implications

D1 to D8 – EXV LED indicators

• Red: 2 sets of 4 LEDs for EXV 1 & EXV 2

D9 – Power LED

• Green: ON: compressor is on (i.e., Compressor I/O Board and BMCC are properly connected to the Backplane)

4.4.2 Compressor Interface Module Verification

4.4.2.1 Determining if the Compressor Interface Module is Draining Energy

1. Identify if the D9, green light-emitting diode (LED) is on.

2. Remove the Service Side Cover.

3. Measure the Backplane +5V and +15V test point voltages.

4. Remove all external connections to the I/O board.

5. Measure the Backplane +5V and +15V test point voltages.

6. Isolate compressor power and wait for the Backplane LEDs to turn off.

7. Disconnect the compressor I/O cable from the J6 connector on the CIM.

8. Apply power to the compressor.

9. Measure the Backplane +5V and +15V test point voltages.

10. If voltages do not change, I/O board is not draining energy.

4.4.2.2 Compressor Interface Module Communication Verification

1. Connect the CIM to a computer.

2. Confirm serial port to be used by the computer.

3. Open the Service Monitor Tool (SMT) software and select the Compressor Connection Manager tool. See the Service Monitoring Tools User Manual for use instructions.

4. Click Connect.

• If the Compressor Connection Manager is able to connect to the compressor, the BMCC is able to communicate with the user interface.

• If the system is not able to connect, verify:

– The D9, green LED is on.

– The cable connection between the Backplane (port J7) and the CIM (port J6) is properly

attached.

– The cable connection between the CIM (at port J1 if using RS485 communication or at

port J7 if using RS232 communication) and the user’s computer is properly attached.

– The BMCC is properly connected to the Backplane.

5. If all connections are properly attached and you still cannot connect to the compressor with the SMT, confirm computer serial port, then use the Search function in the Compressor Connection Manager to determine the correct baud rate and slave address of the compressor. Refer to the Service Monitoring Tools User Manual for use instructions.

6. If you can still not connect to the compressor, verify the Backplane and the BMCC.

4.4.2.3 Interlock Verification

1. Ensure the compressor interface cable is properly attached to the Backplane and to the CIM and the BMCC is properly attached to the Backplane.

2. Remove the J2 connector from the I/O board.

3. Using a multimeter set for DC voltage, measure the voltage between I/LOCK+ and I/LOCK-.

• The voltage should be 2.2 - 3.7VDC.

4. Install the J2 connector to the CIM.

5. Ensure the circuit connected to I/LOCK+ and I/LOCK- on the CIM (port J2) is closed.

6. Measure the voltage at I/LOCK- to the common ground point.

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• The measured value at I/LOCK- should be 0VDC.

– If the measured value is not 0VDC, locate and remove the source of the voltage.

7. Open the SMT Compressor Monitor tool.

8. With the system interlock circuit remaining closed, verify the Compressor Interlock Status states “Closed.”

• If the Compressor Interlock Status states “Open,” the interlock circuit is damaged and the BMCC needs to be replaced.

9. Isolate compressor power.

10. Remove the J2 connector from the CIM.

11. Using a multimeter for resistance measurement. Place the meter probes on I/LOCK+ and I/ LOCK-.

• Resistance should be < 22.2kΩ; if not, the interlock circuit is damaged and the BMCC needs to be replaced.

• Refer to "5.5.3 Troubleshooting an Open Interlock" on page 259 for further details.

4.4.3 Compressor Interface Module Removal & Installation

Ensure there is no secondary power source connected to the Compressor I/O Board before disconnecting the I/O cable.

4.4.3.1 Compressor Interface Module Removal

1. Isolate compressor power and wait for the D9 LED to turn off on the CIM.

2. Remove all external connections from the CIM.

3. Using a screwdriver, apply leverage toward the left while lifting the right side of the CIM. See "Figure 4-19 Removing the Compressor Interface Module from the DIN Rail".

4. Repeat the procedure for the other mounting foot to disengage the CIM from the DIN rail.

• • • DANGER • • •

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

Cross Section of

Interface Module Housing

DIN Rail

4.4.3.2 Compressor I/O Board Installation

1. Install the left foot of the replacement board into the rail and press the right side of the board down until it engages the rail.

2. Reconnect all external connections and wiring on the CIM.

3. Return the compressor to normal operation.

4.5 Compressor Interface Cable

The Compressor Interface Cable connects the compressor to the CIM. Refer to "Figure 4-20 Compressor Interface Cable" on page 67 for an overall view of the cable installation.

The Rear Bearing Sensor Cable has been removed for clarity.

NOTE

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Figure 4-20 Compressor Interface Cable

Compressor Interface Cable

4.5.1 Compressor Interface Cable Verification

If any communication problems exist, verify the integrity of the cable assembly. This can be accomplished by performing a continuity test at each corresponding pin.

Grommet

Notch for cable

4.5.2 Compressor Interface Cable Removal and Installation

4.5.2.1 Compressor Interface Cable Removal

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

2. Wait for the green light (D9) on the CIM to turn off.

3. Remove the Service Side Cover. Refer to "4.2.3.1 Service Side Cover Removal and Installation" on page 58.

4. Use a flat-blade screwdriver to disengage the connector screw from the backplane.

5. Disengage the connector thumbscrew from the CIM.

6. Remove the cable by grasping each connector (J6 on CIM and J7 on Backplane) and pulling away from the board connectors.

4.5.2.2 Compressor Interface Cable Installation

1. Install the cable into the J6 connector on the CIM and the J7 connector on the Backplane.

2. Tighten the connectors to secure the cable.

3. Ensure the cable is routed properly and that the grommet is properly positioned in the compressor housing notch.

4. Install the Service Side Cover. Refer to "4.2.3 Service Side Cover" on page 58.

5. Return the compressor to normal operation.

4.6 Compressor Controller Cable Harness

The Compressor Controller Cable Harness passes signals from the sensors on the compressor to the Backplane. The following steps provide detail on how to replace the Compressor Controller Cable Harness. Prior to removal, note the location of the harness routing as this will minimize the installation time of the new harness.

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4.6.1 Compressor Controller Cable Connections

Figure 4-21 Compressor Controller Cable Harness Variants

All TTS/TGS Rev. G and Earlier Compressors

To Suction Pressure/ Temperature Sensor

All TTS/TGS Rev. H Compressors

To Suction Pressure/ Temperature Sensor

To IGV Connector

To Discharge Pressure/ Temperature Sensor

To SCR Temperature Sensor

To J19 on Backplane

To J18 on Backplane

To J21 on Backplane

To J17 on Backplane

To J18 on Backplane

To J19 on Backplane

To J21 on Backplane

To Interstage Sensor

TTH/TGH Compressors

To Suction Pressure/ Temperature Sensor

To IGV Connector

4.6.2 Compressor Controller Cable Harness Removal and Installation

Compressor Controller Cable Harness Removal

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

2. Remove the Service Side Cover. Refer to "4.2.3.1 Service Side Cover Removal and Installation" on page 58.

3. Remove the Soft Start. Refer to "4.15.3 Soft Start Removal and Installation" on page 112.

To Discharge Pressure/ Temperature Sensor

To J17 on Backplane

To J21 on Backplane

To J19 on Backplane

To J18 on Backplane

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4. Remove the Terminal Block Assembly (excluding TTS300/TGS230 compressors). Refer to "4.12.2 3-Phase Main Voltage Input Terminal Block Removal and Installation" on page 98.

5. Remove the DC Bus Bar and Capacitor Assembly. Refer to "4.22.3 DC Capacitor Bus Bar Assembly Removal and Installation" on page 158.

6. Refer to "Figure 4-22 Backplane Connections" and remove the following connectors from the Backplane:

• Pressure/temperature sensor connectors (J17, J18, and J19)

• IGV motor drive connector (J21)

Figure 4-22 Backplane Connections

All TTH/TGH compressors and all TTS/TGS Major Rev H and later compressors do not contain an SCR Temperature Sensor.

J17 J18 J19

J21

7. Disconnect the cables from the suction and discharge pressure sensors. Refer to "Figure 4-23 Pressure/Temperature and SCR Temperature Sensor Locations - TTS300/TGS230", "Figure 4-25 Pressure/Temperature Sensors - TTH375/TGH285", and "Figure 4-25 Pressure/Temperature Sensors - TTH375/TGH285" on page 70 for this and the following step.

NOTE

Figure 4-23 Pressure/Temperature and SCR Temperature Sensor Locations - TTS300/TGS230

Cable Harness

TTS300 Rev. F Shown

Suction Sensor

SCR Temperature Sensor Cable

Discharge Sensor

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Figure 4-24 Pressure/Temp and SCR Temp Sensor Locations - TTS/TGS

Cable Harness

TTS350 Rev. F Shown

Suction Sensor

Figure 4-25 Pressure/Temperature Sensors - TTH375/TGH285

Cable Harness

Suction Sensor

SCR Temperature Sensor Cable

Discharge Sensor

Interstage Sensor

Figure 4-26 IGV Connector Clamp

8. Disconnect the SCR Manifold Sensor connector.

9. Loosen the M5x16 fastener securing the IGV Connector Clamp and rotate the clamp out of the way. Refer to "Figure 4-26 IGV Connector Clamp".

10. Remove the harness connector from the IGV Feedthrough.

Cable Clip

11. Remove the DC Capacitor Bus Bar Assembly. Refer to "4.22 DC Capacitor Bus Bar Assembly" on page 156.

12. Remove the cable harness in stages so the same routing can be followed for the installation.

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Compressor Controller Cable Harness Installation

1. Route the cable harness through the hole in the main compressor housing at the service side. Refer to "Figure 4-27 Cable Passage" on page 71

Figure 4-27 Cable Passage

Cable Passage

2. Route the cable harness between the DC-DC Converter and the Inverter. Lay the harness over the Inverter Plate.

3. Bend the cable harness under the Mains Terminal Block and route it toward the capacitor side of the compressor.

4. Install the harness onto the IGV Feedthrough.

5. Rotate the clamp over the IGV connector and torque the M5x16 fastener to 25 Nm (18 ft.lb.) Refer to "Figure 4-26 IGV Connector Clamp".

6. Connect the SCR Manifold Sensor connector (excluding TTH compressors). Refer to "Figure 4-23 Pressure/Temperature and SCR Temperature Sensor Locations - TTS300/TGS230" on page 69 and "Figure 4-25 Pressure/Temperature Sensors - TTH375/TGH285" for this and the following step.

7. Connect the cables to the suction and discharge pressure sensors.

8. Insert the molded rubber grommet in the notch in the main compressor housing.

9. Install the four (4) Backplane connectors (J17, J18, J19, and J21).

• Soft Start interface connector (J22)

• Pressure/temperature sensor connectors (J17, J18, and J19)

• IGV motor drive connector (J21)

10. Install the DC Capacitor Bus Bar Assembly. Refer to "4.22 DC Capacitor Bus Bar Assembly" on page 156.

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

12. Return the compressor back to normal operation.

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4.6.3 Compressor Controller Cable Harness Torque Specifications

Table 4-9 Compressor Controller Cable Harness Torque Specifications

Description Nm Ft.Lb. In.Lb.

IGV Feedthrough Fastener, M5x16 25 18 221

Cover Fastener, M5x15 1.5 - 13

Cover Fastener, M5x20 1.5 - 13

4.7 Solenoids and Coils

The solenoids pass the high-pressure liquid refrigerant to the low pressure motor and/or electronics cooling path.

4.7.1 Solenoid and Coil Connections

Solenoids are secured to the service side of the compressor housing in the upper left. Refer to "Figure 4-28 Cooling Valve Bodies".

Figure 4-28 Cooling Valve Bodies

Solenoid orifice size will vary between compressor models. The size can be identified by reading the number engraved into the solenoid orifice body. For solenoid identification by model, reference the Spare Parts Selection Guide.

Solenoid actuator coils are secured to the solenoids by nuts hand tightened at the back of each actuator. Refer to "Figure 4-29 Compressor Cooling Solenoid Coils".

Power is supplied to the Coils through the Backplane from the Serial Driver and controlled by signals from the BMCC to the Serial Driver. The cable is connected to J16 on the Backplane. Refer to "Figure 4-31 Backplane - J16 Connector" on page 73.

Figure 4-29 Compressor Cooling Solenoid Coils

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4.7.2 Solenoid Coil Harness

Figure 4-30 Solenoid Coil Harness

4.7.2.1 Solenoid Coil Harness Removal and Installation

For details, refer to "4.7.4.1 Solenoid and Coil Removal" on page 75 and "4.7.4.2 Solenoid and Actuator Installation" on page 76.

4.7.3 Solenoid Verification

When actuator coils are removed from the solenoids, they must be replaced in the same location. Incorrect installation can result in damage to compressor components.

4.7.3.1 Resistance Measurement of Cooling Solenoid Coils

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

2. Remove the Service Side Cover. Refer to "4.2.3.1 Service Side Cover Removal and Installation" on page 58.

3. Disconnect the Compressor-Cooling Solenoid Coil Connector (J16) from the Backplane.

4. Set the multimeter for resistance measurement.

5. Observe the voltage and power specification indicated on the side of the Compressor-Cooling Coils and refer to "Table 4-10 Solenoid Coil Resistance Ranges" to find the expected resistance for the left and right Compressor-Cooling Coils.

6. To measure the resistance across the left Compressor-Cooling Solenoid Coil, place the meter probes at Pins 1 and 3 of the cable connector. Refer to "Figure 4-32 Compressor Cooling Solenoid Coil Cable Connector" on page 74.

7. To measure the resistance across the right Compressor-Cooling Coil, place the meter probes at Pins 5 and 6 of the cable connector. Refer to "Figure 4-32 Compressor Cooling Solenoid Coil Cable Connector" on page 74.

• • • CAUTION • • •

Figure 4-31 Backplane - J16 Connector

Table 4-10 Solenoid Coil Resistance Ranges

Model Voltage Power Resistance

TTS300 starting at 142035030, TTS350, TTS500, TTS700, T TH375, TGS230, TGS310, TGS390, TGS490, TGS520, & TGH375

TTS300 prior to 142035030 24V 4.8W 108Ω – 132Ω

J16

24V 9.3W 56.25Ω – 68.75Ω

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Figure 4-32 Compressor Cooling Solenoid Coil Cable Connector

4.7.3.2 Output Voltage to Solenoid Coils

1. Remove the Service Side Cover. Refer to "4.2.3.1 Service Side Cover Removal and Installation" on page 58.

2. The compressor must be running and make a call to enable the cooling solenoid coils for the LEDs to turn on. The SMT Cooling Mode will indicate "inverter," "motor," or "motor and inverter" when the software is sending the signal to the coils.

3. To ensure the Serial Driver is providing power to the solenoids, look for the Cool-L and Cool-H LEDs on the Backplane. Refer to "Figure 4-33 Backplane - Cool LEDs and +24V Test Points".

4. To determine if 24VDC is present at one or both solenoid coils, use a multimeter to test the back sides of pins 1 & 3 and pins 5 & 6 of the cooling solenoid coils WHILE they are energized. Refer to "Figure 4-32 Compressor Cooling Solenoid Coil Cable Connector".

1 2 3

4 5 6

Figure 4-33 Backplane - Cool LEDs and +24V Test Points

+24 Test Point

4.7.3.3 Cooling Path Blockage Inspection

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

2. Isolate the compressor and recover the refrigerant according to industry standards. Refer to "3.1 Refrigerant Containment" on page 41.

3. Remove the actuators, solenoids, and orifices.

4. Remove the Liquid Line connection from the compressor and inspect the strainer.

5. Ensure that the cooling paths are clean, as shown in "Figure 4-34 Solenoid Cooling Path

- TTS300/TGS230".

Cool-L & Cool-H LEDs

Figure 4-34 Solenoid Cooling Path - TTS300/TGS230

Cooling Paths

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4.7.4 Solenoid and Coil Removal and Installation

On current TTS350, T TS400, TTS500, TTS700, TGS310, TGS390, TGS490, TGS520, and certain T TS300 models, the solenoid valve bodies may have diﬀerent oriﬁce sizes due to the split-cooling conﬁguration. It is important to not get the left and right confused when removing and installing these solenoid bodies. See "Figure 4-29 Compressor Cooling Solenoid Coils" on page 72.

Removal of the compressor solenoids will release refrigerant. Isolation and recovery of the refrigerant must be performed by a qualiﬁed service technician adhering to industry/ASHRAE standards.

4.7.4.1 Solenoid and Coil Removal

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

2. Isolate the compressor and recover the refrigerant according to industry standards. Refer to "3.1 Refrigerant Containment" on page 41.

There is no need to recover the refrigerant if only the solenoid coils are being removed.

3. Remove the Service Side Cover. Refer to "4.2.3.1 Service Side Cover Removal and Installation" on page 58.

4. Disconnect the Solenoid Coil J16 connector from the Backplane. Refer to "Figure 4-31 Backplane - J16 Connector" on page 73.

5. Remove the Solenoid Retaining Nuts and the Beveled Washers, then remove the Solenoid Coils. Refer to "Figure 4-35 Solenoid Component Removal" for this and the following four (4) steps.

6. Remove the Solenoid/Tube Plungers using a six-point 13mm deep socket.

7. Remove the O-rings from the Solenoid Tube/Plungers if plungers are to be reused.

8. Remove the Orifice Valves using a 15/16" socket.

9. Remove the two (2) O-rings from the Orifice Valves if the valves are to be reused.

NOTE

• • • CAUTION • • •

NOTE

Figure 4-35 Solenoid Component Removal

Solenoid Actuator Coils (2 places)

Beveled Washer (2 places)

Small O-ring (2 places)

Large O-ring (2 places)

Orifice Valve (2 places)

Solenoid/Tube Plunger (2 places)

Solenoid Retaining Nut (2 places)

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4.7.4.2 Solenoid and Actuator Installation

1. Ensure that all components and threads are clear, clean, and oil free.

2. Lubricate the small and large new O-rings with O-ring lubricant and install them on the Orifice Valve.

3. Insert the Orifice Valves into the compressor housing and engage the first few threads by hand.

4. Tighten the Orifice Valves with a 15/16" socket and torque to 7 Nm (62 in.lb.).

5. Lubricate the O-rings for the Solenoid Tube/Plungers with O-ring lubricant and install them on the Solenoid Tube/Plungers.

6. Insert the Solenoid Tube/Plungers into the Orifice Valves and engage the first few threads by hand.

7. Tighten the Solenoid/Tube Plungers using a six-point 13mm deep socket and torque to 4 Nm (35 in.lb.).

8. Leak test and evacuate compressor in accordance with standard industry practices.

9. Install the Solenoid Coils in their proper location. For split cooling models, the coil positions are dedicated. The right-side coil can be identified by an “R” affixed to the coil. The left-side coil can be identified by an “L” affixed to the coil. Refer to "Figure 4-36 Solenoid Actuator Coil Position".

Figure 4-36 Solenoid Actuator Coil Position

Motor Cooling

10. Install the Beveled Washers and Solenoid Retaining Nuts to secure the Solenoid Actuator Coils.

Only hand tighten the Solenoid Retaining Nuts. Do not use pliers to install.

11. Reconnect the Solenoid Coils to J16 on the Backplane.

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

13. Return the compressor to normal operation.

4.7.4.3 Solenoid Torque Specifications

Table 4-11 Solenoid Torque Specifications

Electronics Cooling

Install on left side

• • • CAUTION • • •

Install on right side

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Description Nm Ft.Lb. In.Lb.

Solenoid Tube/Plunger 4 - 35

Orifice Valve 7 - 62

Cover Screw, M5x15 1.5 - 13

4.8 Interstage Pipe - TTH/TGH

The Interstage Pipe may be removed if it is damaged or if there is a refrigerant leak between the mating surfaces.

Figure 4-37 Interstage Pipe

4.8.1 Interstage Pipe Removal and Installation

4.8.1.1 Interstage Pipe Removal

1. Isolate compressor power.

2. Isolate the compressor and recover the refrigerant according to industry standards. Refer to "3.1 Refrigerant Containment" on page 41.

3. Disconnect the Interstage P/T Sensor harness.

4. Disconnect the pipe connected to the Economizer port.

5. Remove the four (4) M10x40 fasteners (2 per side) and remove the Interstage Pipe.

6. Remove the O-rings from the flanges.

Figure 4-38 Interstage Pipe Removal

P/T Sensor

O-ring (2 places)

Interstage Pipe Fastener, M10x40 (4 places)

4.8.1.2 Interstage Pipe Installation

1. Clean all mating surfaces.

2. Obtain two (2) new O-rings for the Interstage Pipe and lubricate them with O-lube.

3. Install the new O-rings into the grooves of the Housing Extension and the Second Stage

4. Carefully line up the Interstage Pipe and insert a fastener into each flange.

5. Install the remaining two (2) fasteners finger tight.

6. Torque all four (4) M10x40 fasteners evenly to 32 Nm (24 ft.lb.).

7. Connect the Economizer flange and torque the M10x30 fasteners to 32 Nm (24 ft.lb.).

8. Lubricate the new P/T Sensor O-ring and install into the Interstage Pipe. Torque to 10 Nm (7

9. Connect the Sensor Harness.

10. Leak test and evacuate compressor in accordance with standard industry practices.

Economizer Port

Suction Housing.

ft.lb.).

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A magnet may need to be placed on the motor cooling solenoids if evacuation cannot be performed directly to the liquid line.

11. Return the compressor to normal operation.

4.8.2 Interstage Pipe Torque Specifications

Table 4-12 Interstage Pipe Torque Specifications

Description Nm Ft.Lb. In.Lb.

Interstage Pipe Fastener, M10x40 32 24 283

Economizer Flange Fastener, M10x30 32 24 283

P/T Sensor 10 7 89

4.9 Compressor Housing End Cap

The Compressor Housing End Cap may be removed if it is damaged or if there is a refrigerant leak between the mating surfaces.

There are no field-serviceable components inside of the Compressor Housing End Cap. After the assembly of the compressor, its function is to prevent refrigerant from escaping. It also contains an eyebolt to allow for installation and removal of the compressor.

Figure 4-39 Compressor Housing End Cap - T TS/TGS

NOTE

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

Compressor Housing End Cap Fastener, M10x40 (12 places)

Compressor Housing End Cap Fastener, M10x40 (8 places)

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4.9.1 Compressor Housing End Cap Removal and Installation

4.9.1.1 Compressor Housing End Cap Removal

1. Isolate compressor power.

2. Isolate the compressor and recover the refrigerant according to industry standards. Refer to "3.1 Refrigerant Containment" on page 41.

3. Remove the Interstage Pipe (TTH/TGH compressors only). Refer to "4.8.1 Interstage Pipe Removal and Installation" on page 77.

4. Remove the End Cap.

a. For TTS/TGS compressors remove the eight (8) M10x40 fasteners that secure the

Compressor Housing End Cap to the compressor housing and remove the End Cap. Refer to "Figure 4-39 Compressor Housing End Cap - TTS/TGS" on page 78.

b. For TTH/TGH compressors, remove the 10 M10x40 fasteners that secure the Compressor

Housing End Cap to the compressor housing and remove the End Cap. Refer to "Figure 4-40 Compressor Housing End Cap - TTH/TGH" on page 78.

5. Remove and discard the O-ring.

4.9.1.2 Compressor Housing End Cap Installation

1. Ensure that all components and threads are clear, clean, and oil free.

2. Clean, lubricate, and install the O-ring into the groove in the compressor housing.

3. Carefully line up the Compressor Housing End Cap and loosely install several of the M10x40 fasteners to hold the end cap in place. Refer to "Figure 4-39 Compressor Housing End Cap TTS/TGS" and "Figure 4-40 Compressor Housing End Cap - TTH/TGH".

4. Install the remaining fasteners and torque fasteners in a crisscross pattern to 32 Nm (24 ft.lb.).

5. Install the Interstage Pipe (TTH/TGH compressors only). Refer to "4.8.1 Interstage Pipe Removal and Installation" on page 77.

6. Leak test and evacuate compressor in accordance with standard industry practices.

7. Return the compressor back to normal operation.

4.9.1.3 Compressor Housing End Cap Torque Specifications

Table 4-13 Compressor Housing End Cap Torque Specifications

Description Nm Ft.Lb. In.Lb.

Compressor Housing End Cap Fastener, M10x40 32 24 283

Interstage Pipe Fastener, M10x40 32 24 283

Economizer Flange Fastener, M10x30 32 24 283

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4.10 IGV

Figure 4-41 IGV Assembly

4.10.1 IGV Connections

The IGV assembly consists of movable vanes and a motor. The IGV assembly is a variable-angle guiding device that is used to control the capacity at low-load conditions. The IGV position can vary between approximately 0% (closed/perpendicular to flow) and 100% (open/parallel to flow). The vane angle is determined by the BMCC and controlled by the Serial Driver. The Serial Driver, in turn, uses +15VDC to control the IGV stepper motor.

Refer to "Figure 4-42 IGV Connections" for the location of the IGV connections.

Figure 4-42 IGV Connections

Table 4-14 IGV Components

No. Component

1 The IGV assembly is bolted to the compressor housing.

2 The compressor controller cable is held to the IGV Motor feed through by the cable clip.

3 The compressor controller cable continues on to the suction pressure/temperature sensor.

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4 The suction pressure/temperature sensor is connected to the IGV Housing.

5 IGV Position Indicator.

4.10.2 IGV Verification

4.10.2.1 IGV Stepper Motor Verification

1. Isolate compressor power..

2. Disconnect the IGV Motor Cable from the suction pressure/temperature sensor and the IGV Motor power feedthrough. Refer to "Figure 4-43 IGV Motor Feedthrough" for this and the following step.

3. Measure the resistance between terminals 1 and 2, and 3 and 4 of the IGV Motor feed through. The measured value should be between 46Ω and 59Ω.

4. Measure the resistance between the IGV Motor feed through terminals and the IGV Housing. The measured value should be open or infinity.

Figure 4-43 IGV Motor Feedthrough

4.10.2.2 IGV Operation Verification

Some of the steps contained within this section require the use of the SMT. Refer to the Service Monitor Tool Manual regarding the proper usage of the SMT.

1. Remove the Service Side Cover. Refer to "4.2.3.1 Service Side Cover Removal and Installation" on page 58.

2. Open the SMT installed on your computer and connect to the compressor. Refer to "Figure 4-44 SMT Icon".

Figure 4-44 SMT Icon

3. Open the Compressor Configuration tool. Refer to "Figure 4-45 Compressor Configuration Tool".

Figure 4-45 Compressor Configuration Tool

Cable Clip

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4. Set the Compressor Control Mode to Manual Control by selecting Manual Control from the

Figure 4-46 Control Mode

5. Open the Compressor Monitor tool. Refer to "Figure 4-47 Compressor Monitor Tool".

Figure 4-47 Compressor Monitor Tool

6. In the IGV Open Percentage parameter box, input 110%. Refer to "Figure 4-48 IGV Open

Compressor Control Mode drop-down list. Refer to "Figure 4-46 Control Mode".

Percentage - 100%".

Figure 4-48 IGV Open Percentage - 100%

7. On the Backplane, there are four (4) LEDs that should light up when the IGV Motor is being driven. Refer to "Figure 4-50 Backplane Cool LEDs" on page 83.

The LEDs will not remain illuminated once the requested position has been achieved..

8. In the IGV Open Percentage parameter box, input 0%. Refer to "Figure 4-49 IGV Open Percentage - 0%".

Figure 4-49 IGV Open Percentage - 0%

• Check that all four (4) LEDs are blinking (D13, D14, D15, and D16) and that the IGV position indicator moves toward open. Refer to "Figure 4-42 IGV Connections" on page 80 for the location of the IGV Position Indicator.

NOTE

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9. Check that all four (4) LEDs are blinking. Refer to "Figure 4-50 Backplane Cool LEDs".

Figure 4-50 Backplane Cool LEDs

10. Verify the IGV position indicator moves toward closed.

11. Measure the +15V test point on the Backplane to verify voltage is supplied to the Serial Driver

Figure 4-51 Backplane +15V Test Point

Cool-L & Cool-H LEDs

IGV Stepper Motor LEDs

for the IGV. Refer to "Figure 4-51 Backplane +15V Test Point".

+15V Test Point

4.10.3 IGV Housing Removal and Installation

Removal of the IGV mounting fasteners will release refrigerant. Isolation and recovery of the refrigerant must be performed by a qualiﬁed service technician adhering to industry/ASHRAE standards.

4.10.3.1 IGV Housing Assembly Removal

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

2. Remove the clamp securing the IGV Connector. Refer to "Figure 4-52 IGV Harness Removal" for this and the following step.

3. Disconnect the IGV Motor Cable and Suction Sensor connector.

Figure 4-52 IGV Harness Removal

TTS300 Major Rev F shown

Cable Harness

IGV Motor Feedthrough

• • • CAUTION • • •

Suction Sensor

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Figure 4-53 IGV Housing Removal

4.10.3.2 IGV Assembly Removal

4. Isolate the compressor and recover the refrigerant according to industry standards. Refer to "3.1 Refrigerant Containment" on page 41.

5. Remove the 12 M10x40 fasteners that secure the IGV Housing Assembly to the compressor housing and pull the housing away from the compressor. See "Figure 4-53 IGV Housing Removal".

IGV Housing Fastener,

M10x40

(12 places)

1. Remove the IGV Housing Assembly.

2. Remove the four (4) M5x16 fasteners and separate the four-pin Feedthrough from the IGV Housing. Refer to "Figure 4-54 IGV Feedthrough Removal".

Figure 4-54 IGV Feedthrough Removal

3. Disconnect the four (4) wires from the four-pin Feed Through. Note and record position of wire colors to their corresponding pins. Expected: 1 = Red, 2 = Gray, 3 = Yellow, and 4 = Black. Refer to "Table 4-15 IGV Feedthrough Wiring Order".

The colors associated with each pin could vary, so be sure to identify those on the respective compressor.

Table 4-15 IGV Feedthrough Wiring Order

IGV Feedthrough O-ring

NOTE

Color Pin #

Red 1

Gray 2

Yellow 3

Black 4

IGV Feedthrough

Cable Clip

IGV Feedthrough M5x16 fastener (4 places)

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4. Using a Stepper Motor Driver, turn the worm shaft and Vane Drive assembly to position the motor shaft so that locking set screw is aligned with the hole shown in "Figure 4-55 Set Screw Removal". Use needle-nose pliers or similar tool to turn the worm gear if a Stepper Motor Driver is not available.

5. Remove the set screw completely using a 2.5 mm hex bit to release the motor from the worm gear.

Figure 4-55 Set Screw Removal

The set screw may be diﬃcult to release as it will have threadlocker applied. For proper engagement into the set screw, do not use a ball-end hex wrench.

6. Remove the IGV Motor assembly by pulling away from worm shaft. Refer to "Figure 4-56 IGV Motor Assembly Removal". Support the bottom of the IGV Motor to prevent damage to the motor shaft. A light tap on the motor locating screw with a hammer may help release the motor shaft from the worm gear.

Figure 4-56 IGV Motor Assembly Removal

NOTE

M5x8 Set Screw

Figure 4-57 Locking Collar Tool

7. Slide the Locking Collar Tool (P/N 100246) into the housing and over the worm shaft. Ensure the drive pins are engaged in the Locking Collar. Refer to "Figure 4-57 Locking Collar Tool".

Locking Collar Tool, P/N 100246

Locking Collar

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Figure 4-58 Locking Collar Removal

The Locking Collar contains a left-hand thread. To remove, turn clockwise when viewing from the motor end.

Figure 4-59 Worm Gear Removal

8. Turn the Locking Collar clockwise to remove. Refer to "Figure 4-58 Locking Collar Removal".

Drive Pin Holes

Locking Collar

NOTE

9. Remove the worm gear by rotating the IGV Throat clockwise by hand or rotate the worm shaft by hand. Refer to "Figure 4-59 Worm Gear Removal".

Rotate IGV Throat clockwise to expel worm shaft

10. Remove the snap ring from the worm gear shaft. Refer to "Figure 4-60 Large Worm Gear Bearing Removal" for this and the following step.

11. Remove the upper (large) bearing from the worm gear.

Figure 4-60 Large Worm Gear Bearing Removal

Worm Gear

Large Worm Gear Bearing

Large Worm Gear Snap Ring

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12. Remove the four (4) M6x55 fasteners that retain the IGV Throat assembly and lift the entire assembly from the IGV Housing. Refer to "Figure 4-61 IGV Throat Removal" on page 87.

Figure 4-61 IGV Throat Removal

IGV Throat M6x55 fastener (4 places)

IGV Throat

13. Inspect the IGV Housing assembly for residue/contamination or foreign objects.

14. Remove the small lower worm gear bearing from the housing. Perform this step by pushing the bearing out from the port below the bearing. Refer to "Figure 4-62 Small Worm Gear Bearing Removal".

Figure 4-62 Small Worm Gear Bearing Removal

Push from this end

4.10.3.3 IGV Assembly Installation

Fitting incorrect IGV components for the speciﬁc compressor model will result in physical damage to the compressor.

1. Ensure that all components and threads are clear, clean, and oil free.

2. Install the lower (small) worm gear bearing into the housing. This may require a very light tap with a hammer. Ensure the lower worm gear bearing is fully seated into the housing. Refer to "Figure 4-63 Small Worm Gear Bearing Installation"

Figure 4-63 Small Worm Gear Bearing Installation

Small Lower Worm Gear Bearing

• • • CAUTION • • •

Bearing to fully seat into housing

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3. Ensure the IGV position indicator magnet is in place in the IGV Throat assembly. Refer to "Figure 4-64 IGV Position Indicator Magnet".

Figure 4-64 IGV Position Indicator Magnet

4. Place the IGV Throat assembly into the IGV Housing orientating the IGV Throat threads directly below the IGV Motor Mount.

5. Add one (1) drop of threadlocker (Loctite 243 blue or equivalent) to the IGV Throat fastener threads and install. Torque to 5 Nm (44 in.lb.).

6. Rotate the outer ring of the drive assembly and ensure that the guide vanes move freely. The assembly must rotate over a span where the vanes are open (perpendicular to gas flow) and fully closed.

7. Fit the upper (large) bearing to the worm gear and install the snap ring. Refer to "Figure 4-65 Large Worm Gear Bearing Installation".

Figure 4-65 Large Worm Gear Bearing Installation

Magnet

Large Worm Gear Bearing

Large Worm Gear Snap Ring

Worm Gear

8. Install the worm gear into the housing by “screwing” the worm gear along the IGV Throat Gear. Locate the worm gear shaft into the bottom (small) bearing.

9. Place the threaded Locking Collar on the four (4) pins of the Collar tool and install into the housing.

NOTE

Ensure the ﬂat side of the collar is against the tool.

10. Turn the Locking Collar counter clockwise and torque to 5 Nm (44 in.lb.). Refer to "Figure 4-66 Locking Collar Installation" on page 89.

NOTE

Locking collar is a left-hand thread. Turn counter-clockwise when viewed from motor end to tighten (do not use threadlocker on collar).

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Figure 4-66 Locking Collar Installation

11. Rotate the worm gear by hand until the set screw hole in the worm gear is visible through the

Figure 4-67 IGV Worm Gear Alignment

Drive Pin Holes

Locking Collar

access hole in the casting. Verify that the worm gear turns freely. Do not install the set screw at this time. Refer to "Figure 4-67 IGV Worm Gear Alignment".

Worm Gear Aligned

Figure 4-68 Shaft Position

12. Insert the IGV Motor wires through the Feed Through hole.

13. Check the position of the flat surface of the shaft relative to the locating pin. The flat surface should be oriented facing up, ready to be inserted in the worm gear. Refer to "Figure 4-68 Shaft Position".

Check locating

Flat surface of the shaft facing UP

14. Install the motor into the housing and align the motor shaft flat surface with worm gear adapter.

15. Ensure the motor locating pin is aligned with the notch in the housing flange. Refer to "Figure 4-69 IGV Motor Alignment" on page 90.

pin position

• • • CAUTION • • •

Check that wiring is clear of housing and edges of motor.

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Figure 4-69 IGV Motor Alignment

Align locating pin with notch

Gap=0.5mm

16. Put one (1) drop of threadlocker (Loctite 243 blue or equivalent) on the threads of the small set screw. While pushing in, on the backside of the motor, secure the worm gear to the flat surface of the motor shaft using a 2.5 mm hex bit. Rock the motor backwards and forwards while tightening to ensure full and correct engagement of the screw. Torque the set screw to 5Nm (44 in.lb.). Refer to "Figure 4-67 IGV Worm Gear Alignment" on page 89.

17. Clean, lubricate, and install the O-ring on the Feed Through before connecting the wires.

18. Insert the motor wires onto the Feed Through pins in accordance with "Table 4-16 IGV Feedthrough Pin to Wire Reference". Also reference your notes from removal.

The colors associated with each pin could vary, so be sure to refer to notes taken during removal.

Table 4-16 IGV Feedthrough Pin to Wire Reference

19. Position the wires as shown in "Figure 4-70 Motor Wire Position" and "Figure 4-71 IGV Motor Wires Connected".

Figure 4-70 Motor Wire Position

NOTE

All Except TT300N

Color Pin Number

Red 1

Gray 2

Yellow 3

Black 4

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Figure 4-71 IGV Motor Wires Connected

20. Install the Feed Through using the four (4) M5x16 fasteners and install the IGV Motor Cable Retainer Clip under one of the fasteners. Tighten only three (3) of the fasteners to 5Nm (44 in.lb.) while leaving the fourth fastener with the retainer clip slightly loose. Refer to "Figure 4-72 Feedthrough Orientation".

Figure 4-72 Feedthrough Orientation

21. If available, test the motor operation with a stepper motor driver. Operation of the IGV can

22. Clean the mating surfaces of both the compressor and IGV.

23. Clean, lubricate, and install the IGV Housing O-ring.

24. Re-install the IGV on the compressor and finger-tighten the fasteners.

25. Tighten the fasteners in a crisscross pattern to 22 Nm (16 ft.lb.).

Figure 4-73 IGV Housing Installation

Notch in feedthrough should align with roll pin in the compressor housing

Do not tighten Retainer Clip until the harness is installed

also be tested using the SMT driving the IGV manually (once the IGV has been mounted on the compressor).

IGV Housing Fastener, M10x40 (12 places)

26. Leak test and evacuate compressor in accordance with standard industry practices.

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27. Plug in the Feed Through and Suction Pressure Temperature Sensor Harness.

28. Torque the remaining Feed Through fastener (the one securing the Motor Harness Retainer

29. Return the compressor back to normal operation.

30. Test run the compressor to verify proper operation and movement of the IGV assembly. Refer

All IGV assemblies are fully open when the Position Indicator is in the top position.

Figure 4-74 IGV Position Indicator

4.10.4 IGV Torque Specifications

Table 4-17 IGV Torque Specifications

Clip) to 5Nm (44 in.lb.).

to "Figure 4-74 IGV Position Indicator" to verify the position of the IGV.

NOTE

Description Nm Ft.Lb. In.Lb.

IGV Housing Fastener, M10x40 22 16 195

IGV Feedthrough Fastener, M5x16 5 - 44

IGV Motor Setscrew, M5x8 5 - 44

IGV Throat Fastener, M6x55 5 - 44

Locking Collar 5 - 44

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4.11 Mains Plate Bracket

Figure 4-75 Mains Plate Bracket

TTS350 Rev. F Shown

The Mains Plate is used to secure the mains cables. The Mains Plate is identical across all versions of the compressors. However, the ground post on the TTS300/TGS230 compressors is located directly behind the Mains Plate, whereas the ground post for all other compressor models goes through the Mains Plate and into the compressor housing. The illustrations in this section are of the TTS350 and all removal and installation steps of the various TTS/TTH/TGS/TGH compressors are the same.

Mains Cover

Upper Nut 5/16" - 18 UNC

Lock Washer

Jam Nut 5/16" - 18 UNC

Lower Nut - 5/16" - 18 UNC

4.11.1 Mains Plate Bracket Removal and Installation

4.11.1.1 Mains Plate Bracket Removal

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

2. Disconnect the mains input cables from the Terminal Block.

3. Disconnect the main input ground cable and Soft Start ground wire from the ground post.

4. Remove the cable gland that secures the mains input cable conduit to the Mains Plate.

5. Remove the two (2) M6x16 fasteners that secure the Mains Plate. Refer to "Figure 4-75 Mains Plate Bracket" on page 93.

6. Remove the Mains Plate.

Mains Plate Mounting M6x16 Fastener (2 places)

5/16"-18X1.5" Set Cup Point Screw

4.11.1.2 Mains Plate Bracket Installation

1. Install the Mains Plate using the M6x16 fasteners and torque to 7 Nm (62 in.lb.).

2. Install the cable gland.

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3. Install the Soft Start ground wire on top of the lower nut and torque the jam nut to 7 Nm (62 in.lb). Install the ground cable for the mains on top of the jam nut and torque the upper nut to 10 Nm (7 ft.lb.) Refer to "Figure 4-76 Ground Post Nuts".

Figure 4-76 Ground Post Nuts

Upper Nut - 10 Nm (7 ft.lb.)

Lock Washer

Jam Nut - 7 Nm (62 in.lb.)

Lower Nut - 20 Nm (15 ft.lb.)

4. Install the mains input cables to the Terminal Block and torque to 20 Nm (15 ft.lb.) for TTS300/ TGS230 compressors and torque all others to 21 Nm (15 ft.lb.). Refer to "Figure 4-77 Mains Input Nut Installation - TTS300/TGS230 Compressors" and "Figure 4-78 Mains Input Nut Installation - TTS/TGS/TTH/TGH Rev. H and Earlier (Except TTS300/TGS230)".

Figure 4-77 Mains Input Nut Installation - TTS300/TGS230 Compressors

Mains Input Pressure Screw, 11/16 x 16 - 20 Nm (15 ft.lb.) (3 places)

Figure 4-78 Mains Input Nut Installation - TTS/TGS/TTH/TGH Rev. H and Earlier (Except TTS300/TGS230)

Mains Input Nut, 3/8 x 16 - 21 Nm (15 ft.lb.) (3 places)

NOTE

The TTS300/TGS230 series compressors do not utilize cable lugs. Because of this, torque speciﬁcations will vary depending on the type of cabling. it is recommended to contact the manufacturer of the cabling used for the appropriate torque speciﬁcation.

5. Install the top covers. Refer to "4.2 Compressor Covers" on page 56.

6. Return the compressor to normal operation.

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4.11.1.3 Mains Plate Torque Specifications

Table 4-18 Mains Plate Torque Specifications

Description Nm Ft.Lb. In.Lb.

Mains Plate Mounting Screw, M6x16 7 - 62

Cover Fastener, M5x15 1.5 - 13

Upper Nut, 5/16" - 18 UNC 10 7 89

Jam Nut, 5/16" - 18 UNC 7 - 62

Lower Nut, 5/16" - 18 UNC 20 15 177

Mains Input Nut, 3/8" - 16 UNC (excludes TT300/TG230 compressors) 21 15 186

4.12 3-Phase Main Voltage Input Terminal Block

The Terminal Block is the location where the compressor receives 3-Phase AC voltage, even when not running. All compressors must be fitted with class T fast-acting fuses to protect the solid-state Inverter. Danfoss Turbocor control does NOT directly measure 3-phase power values. All 3-phase voltage information displayed in the SMT is calculated from DC bus voltage and motor power as measured by the Inverter. The input voltage varies between 380-575VAC at a frequency of 50/60Hz.

There are two (2) different configurations of the Terminal Blocks, one for the TTS300/TGS230 series and another for all other TTS/TGS/TTH/TGH series. With the introduction of Revision H compressors, all compressors, except for the TTS300/TGS230 compressors, have an upgraded Terminal Block design.

Refer to "Figure 4-79 Input Terminal Block - TTS300/TGS230" for TTS300/TGS230 compressors. For all other compressors that are Revision G and earlier, refer to "Figure 4-81 Input Terminal Block - TTS/TGS/ TTH/TGH Rev. F and Earlier (Except TTS300/TGS230)" on page 96 and for all other compressors that are Revision H, refer to "Figure 4-80 Input Terminal Block - TTS/TGS/TTH/TGH Rev. H (Except TTS300/ TGS230)" on page 96.

Figure 4-79 Input Terminal Block - TTS300/TGS230

Mylar

Fuse Assembly

Terminal Block

M-SV-001-EN Rev. G

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Figure 4-80 Input Terminal Block - TTS/TGS/TTH/TGH Rev. H (Except TTS300/TGS230)

AC Bus Bars

Terminal Block

Figure 4-81 Input Terminal Block - TTS/TGS/TTH/TGH Rev. F and Earlier (Except TTS300/TGS230)

AC Bus Bars

4.12.1 3-Phase Main Voltage Input Terminal Block Verification

4.12.1.1 3-Phase AC input Verification

The compressor requires a 3-phase power source with UL-approved or CE-approved components in circuit with code-compliant protection.

• This equipment contains hazardous voltages that can cause injury or death. Exercise extreme

caution when working on energized circuits.

• Always wear safety glasses when working around components energized by high voltage. Faulty

components can explode and cause serious eye injuries.

4.12.1.2 Connecting the AC Input Cable

1. Isolate compressor power.

2. Ensure the AC cables are securely fastened to the input Terminal Block.

• • • DANGER • • •

Terminal Block

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3. If the cables cannot be securely fastened to the input terminal, the Terminal Block is damaged and needs to be replaced.

4.12.1.3 Verifying the 3-Phase AC Input

1. Turn ON the AC input power.

2. Set the multimeter for AC voltage measurements.

3. Place the meter probe on one phase of the AC input terminals and the other meter probe on another phase of the AC input terminals as shown in "Figure 4-82 Measuring the 3-Phase AC Input Voltage on the AC Input Terminals - TTS300/TGS230" and "Figure 4-83 Measuring 3-Phase AC Input Voltage on AC Input Terminals (TTS/TGS/TTH/TGH (Except TTS300/TGS230)". Repeat for all AC input terminals. Repeat on load side of the fuses (TT300/TG230 only).

Figure 4-82 Measuring the 3-Phase AC Input Voltage on the AC Input Terminals - TTS300/TGS230

Figure 4-83 Measuring 3-Phase AC Input Voltage on AC Input Terminals (TTS/TGS/TTH/TGH (Except TTS300/TGS230)

TTS350 Rev. F Shown

4. Verify that the meter shows the expected AC measurement within the range as indicated in "Table 4-19 Expected AC Voltage Range" on page 98. The acceptable AC input voltage range is +/-10% of the nameplate AC input voltage.

5. If the meter does not show any reading, it is possible there is no power from the AC source. Ensure the AC power source is turned ON and try again. If there is no power on the load side of the fuses (TTS300/TGS230 only), isolate the power and check the fuses.

6. If the measured values correspond to the specified values for all phases, the AC input voltage is okay.

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Table 4-19 Expected AC Voltage Range

AC Input

Nameplate Voltage

575VAC 518 to 632VAC

460VAC 414 to 506VAC

400VAC 360 to 440VAC

380VAC 342 to 418VAC

Acceptable Voltage Range

4.12.2 3-Phase Main Voltage Input Terminal Block Removal and Installation

4.12.2.1 General 3-Phase Main Voltage Input Terminal Block Removal

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

2. Disconnect the mains input cables from the Terminal Block.

3. For TT300/TG230 compressors, continue to Section "4.12.2.2 Specific 3-Phase Main Voltage Input Terminal Block Removal - TTS300/TGS230"; for all others, continue to Section "4.12.2.3 3-Phase Main Voltage Input Terminal Block Removal - TTS/TGS/TTH/TGH Rev. F and Earlier (Except TTS300/TGS230)" on page 99.

4.12.2.2 Specific 3-Phase Main Voltage Input Terminal Block Removal - TTS300/TGS230

1. Remove the three (3) M6x16 fasteners that connect the Fast Acting Fuses to the SCRs. Refer to "Figure 4-84 Terminal Block Removal - TTS300/TGS230" for this and the following four (4) steps.

2. Remove the six (6) Fuse to Terminal Block fasteners that secure the fuses to the Terminal Block Adapter.

3. Remove the fuses.

4. Remove the insulating Mylar.

5. Remove the Terminal Block fasteners that secure the Terminal Block to the compressor housing and remove the Terminal Block.

Figure 4-84 Terminal Block Removal - TTS300/TGS230

AC Bus Bar to SCR Fastener, M6x16, (3 places)

Terminal Block Fastener, M5x15, (3 places)

6. Continue to Section "4.12.2.4 3-Phase Main Voltage Input Terminal Block Installation - TTS300/ TGS230" on page 100.

Fuse to Terminal Block Fastener (6 places)

Fuse Assembly (3 places)

Mylar

Terminal Block

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4.12.2.3 3-Phase Main Voltage Input Terminal Block Removal - TTS/TGS/TTH/TGH Rev. F and Earlier (Except TTS300/ TGS230)

1. Disconnect the three (3) connectors of the Soft Start AC/DC harness from the bus bars.

2. Remove the three (3) fasteners that secure the AC Bus Bars to the SCRs. For Revision F and earlier compressors, refer to "Figure 4-85 Input Terminal Block Removal - TTS/TGS/TTH/TGH Rev. F and Earlier (Except TTS300/TGS230)" and for Revision H compressors, refer to "Figure 4-86 Input Terminal Block Removal - TTS/TGS/TTH/TGH Rev. H (Except TTS300/TGS230)" on page 100 for this and the following three (3) steps.

3. Remove the six (6) fasteners that secure the three (3) AC Bus Bars to the Terminal Block.

4. Remove the AC Bus Bars.

NOTE

If the terminal block is being removed to access other components, it is not necessary to remove the AC Bus Bars from the terminal block on Rev F and earlier compressors - the terminal block and bus bars can be removed as an assembly. On Rev H compressors, the center AC Bus Bar must be removed to access a mounting fastener for the terminal block but the two (2) bus bars can remain attached.

5. Remove the fasteners that secure the Terminal Block to the casting and remove the Terminal Block.

a. Rev F and ealier compressors use two (2) M5x45 fasteners that attach the Terminal Block to

the compressor housing.

b. Rev H compressors use three fasteners; it uses the same two (2) as listed above and there

is an additional M6x16 fastener that is located at the back center of the Terminal Block (under the center AC Bus Bar). This fastener secures the Terminal Block to the SCR Cooling Plate.

6. Remove the two (2) spacers if the Terminal Block is to be replaced with a new one.

7. Continue to Section "4.12.2.5 3-Phase Main Input Terminal Block Installation - TTH/TGH/TTH/ TGH (Except TTS300/TGS230)" on page 101.

Figure 4-85 Input Terminal Block Removal - TTS/TGS/TTH/TGH Rev. F and Earlier (Except TTS300/TGS230)

AC Bus Bars

AC Bus Bar to Terminal Block Fastener

Mains Input Nut, 3/8 x 16, (3 places)

Terminal Block to Compressor Fastener, M5x45, (2 places)

Terminal Block

AC Bus Bar to SCR Fastener, M8x20, (3 places)

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Figure 4-86 Input Terminal Block Removal - TTS/TGS/TTH/TGH Rev. H (Except TTS300/TGS230)

Mains Input Nut, 3/8 x 16, (3 places)

AC Bus Bar to Terminal Block Fastener, M5x12 (6 places)

Terminal Block to Compressor Fastener, M5x45, (2 places)

4.12.2.4 3-Phase Main Voltage Input Terminal Block Installation - TTS300/TGS230

AC Bus Bar to SCR Fastener, M8x20, (3 places)

AC Bus Bars

Terminal Block

Terminal Block to SCR Cooling Plate Fastener, M6x16, (2 places)

Figure 4-87 Input Terminal Block Installation - TTS300/TGS230

AC Bus Bar to SCR

Fuse Assembly to Terminal Block Fastener (6 places)

Terminal Block Mounting Fastener, M5x15 - 3 Nm (27 in.lb.) (3 places)

Mylar

AC Bus Bar to SCR Fastener M6x16 - 5 Nm (44 in.lb.) (3 places)

Fuse

Fuse Assembly

Terminal Block Adapter

Terminal Block

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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

Chapter 2.0 Compressor Fundamentals

2.1 Main Fluid Path

2.2 Motor and Power Electronics Cooling

2.3 Capacity Control

2.4 Compressor Energy and Signal Flow

Chapter 3.0 Compressor Removal and Installation

3.1 Refrigerant Containment

3.2 Compressor Removal

3.3 Compressor Installation

3.4 Compressor Replacement Considerations for Motor Cooling Adapter

3.5 Exterior Connection Torque Specifications

Chapter 4.0 Compressor Components

4.1 Component Identification

4.2 Compressor Covers

4.2.1 Mains Input Cover

4.2.2 Top Cover

4.2.3 Service Side Cover

4.2.4 Capacitor Cover

4.2.5 Compressor Cover Torque Specifications

4.3 Cooling Adapter

4.3.1 Cooling Adapter Removal and Installation

4.3.2 Cooling Adapter Torque Specifications

4.4 Compressor Interface Module

4.4.1 Compressor Interface Module Connection Descriptions

4.4.2 Compressor Interface Module Verification

4.4.3 Compressor Interface Module Removal & Installation

4.5 Compressor Interface Cable

4.5.1 Compressor Interface Cable Verification

4.5.2 Compressor Interface Cable Removal and Installation

4.6 Compressor Controller Cable Harness

4.6.1 Compressor Controller Cable Connections

4.6.2 Compressor Controller Cable Harness Removal and Installation

4.6.3 Compressor Controller Cable Harness Torque Specifications

4.7 Solenoids and Coils

4.7.1 Solenoid and Coil Connections

4.7.2 Solenoid Coil Harness

4.7.3 Solenoid Verification

4.7.4 Solenoid and Coil Removal and Installation

4.8 Interstage Pipe - TTH/TGH

4.8.1 Interstage Pipe Removal and Installation

4.8.2 Interstage Pipe Torque Specifications

4.9 Compressor Housing End Cap

4.9.1 Compressor Housing End Cap Removal and Installation

4.10 IGV

4.10.1 IGV Connections

4.10.2 IGV Verification

4.10.3 IGV Housing Removal and Installation

4.10.4 IGV Torque Specifications

4.11 Mains Plate Bracket

4.11.1 Mains Plate Bracket Removal and Installation

4.12 3-Phase Main Voltage Input Terminal Block