Danfoss Turbocor TT Series User manual

®
Service Manual - Revision H

Danfoss Turbocor® Twin-Turbine
Centrifugal Series Compressors

TT Series Compressors
http://turbocor.danfoss.com |

THIS PAGE INTENTIONALLY LEFT BLANK
Page 2 of 294 - M-SV-001-EN Rev. H 1/23/2023

Table of Contents
Table of Contents 3
Chapter 1.0 Introduction 17
1.1Application 17
1.2Purpose 19
1.3Organization 19
1.4CommitmenttoQualityandtheEnvironment 20
1.5SafetySummary 20
1.5.1DangerNotification 20
1.5.2CautionNotification 21
1.5.3Note 21
1.6Precautions 21
1.7RefrigerantType 21
1.8ElectricalIsolation 22
1.9HandlingStaticSensitiveDevices 24
1.9.1ESDProtection/Grounding 24
1.10DCBusTestHarnessInstallationandRemoval 25
1.10.1GeneralVerificationandInstallationoftheDCBusTestHarness 26
1.10.2DCBusTestHarnessInstallationforClosed-TopSoftStart 27
1.10.3DCBusTestHarnessInstallationforOpen-TopSoftStarts 30
1.10.4GeneralDCBusTestHarnessRemoval 31
1.10.5DCBusTestHarnessRemovalforClosed-TopSoftStarts 31
1.10.6DCBusTestHarnessRemovalforOpen-TopSoftStarts 31
1.11CompressorFasteners 32
1.12GeneralO-ringHandling 32
Chapter 2.0 Compressor Fundamentals 33
2.1MainFluidPath 33
2.2MotorandPowerElectronicsCooling 33
2.3CapacityControl 37
2.4CompressorEnergyandSignalFlow 38
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
M-SV-001-EN Rev. H-1/23/2023 Page 3 of 294

Chapter 4.0 Component Identification 47
4.1CompressorCovers 52
4.1.1MainsInputCover 52
4.1.1.1MainsInputCoverRemovalandInstallation 52
4.1.2TopCover 53
4.1.2.1TopCoverRemovalandInstallation 53
4.1.3ServiceSideCover 54
4.1.3.1ServiceSideCoverRemovalandInstallation 54
4.1.4CapacitorCover 55
4.1.4.1CapacitorCoverRemovalandInstallation 55
4.1.5CompressorCoverTorqueSpecifications 57
4.2CoolingAdapter 58
4.2.1CoolingAdapterRemovalandInstallation 59
4.2.2CoolingAdapterTorqueSpecifications 59
4.3CompressorInterfaceModule 60
4.3.1CompressorInterfaceModuleConnectionDescriptions 60
4.3.2CompressorInterfaceModuleVerification 62
4.3.2.1DeterminingiftheCompressorInterfaceModuleisDrainingEnergy 62
4.3.2.2CompressorInterfaceModuleCommunicationVerification 62
4.3.2.3InterlockVerification 63
4.3.3CompressorInterfaceModuleRemoval&Installation 63
4.3.3.1CompressorInterfaceModuleRemoval 63
4.3.3.2CompressorI/OBoardInstallation 64
4.4CompressorInterfaceCable 65
4.4.1CompressorInterfaceCableVerification 65
4.4.2CompressorInterfaceCableRemovalandInstallation 65
4.4.2.1CompressorInterfaceCableRemoval 65
4.4.2.2CompressorInterfaceCableInstallation 65
4.5CompressorControllerCableHarness 67
4.5.1CompressorControllerCableConnections 67
4.5.2CompressorControllerCableHarnessRemovalandInstallation 68
4.5.3CompressorControllerCableHarnessTorqueSpecifications 71
4.6SolenoidsandCoils 72
4.6.1SolenoidandCoilConnections 72
4.6.2SolenoidCoilHarness 73
4.6.2.1SolenoidCoilHarnessRemovalandInstallation 73
4.6.3SolenoidVerification 73
4.6.3.1ResistanceMeasurementofCoolingSolenoidCoils 73
4.6.3.2OutputVoltagetoSolenoidCoils 74
4.6.3.3CoolingPathBlockageInspection 74
Page 4 of 294 - M-SV-001-EN Rev. H 1/23/2023

4.6.4SolenoidandCoilRemovalandInstallation 75
4.6.4.1SolenoidandCoilRemoval 75
4.6.4.2SolenoidandActuatorInstallation 76
4.6.4.3SolenoidTorqueSpecifications 77
4.7InterstagePipe-TTH/TGH 78
4.7.1InterstagePipeRemovalandInstallation 78
4.7.1.1InterstagePipeRemoval 78
4.7.1.2InterstagePipeInstallation 78
4.7.2InterstagePipeTorqueSpecifications 79
4.8CompressorHousingEndCap 80
4.8.1CompressorHousingEndCapRemovalandInstallation 80
4.8.1.1CompressorHousingEndCapRemoval 80
4.8.1.2CompressorHousingEndCapInstallation 81
4.8.1.3CompressorHousingEndCapTorqueSpecifications 81
4.9IGV 82
4.9.1IGVConnections 82
4.9.2IGVVerification 83
4.9.2.1IGVStepperMotorVerification 83
4.9.2.2IGVOperationVerification 83
4.9.3IGVHousingRemovalandInstallation 85
4.9.3.1IGVHousingAssemblyRemoval 85
4.9.3.2IGVAssemblyRemoval 87
4.9.3.3IGVAssemblyInstallation 90
4.9.4IGVTorqueSpecifications 95
4.10MainsPlateBracket 96
4.10.1MainsPlateBracketRemovalandInstallation 96
4.10.1.1MainsPlateBracketRemoval 96
4.10.1.2MainsPlateBracketInstallation 96
4.10.1.3MainsPlateTorqueSpecifications 98
4.113-PhaseMainVoltageInputTerminalBlock 99
4.11.13-PhaseMainVoltageInputTerminalBlockVerification 100
4.11.1.13-PhaseACinputVerification 100
4.11.1.2ConnectingtheACInputCable 100
4.11.1.3Verifyingthe3-PhaseACInput 101
4.11.23-PhaseMainVoltageInputTerminalBlockRemovalandInstallation 102
4.11.2.1General3-PhaseMainVoltageInputTerminalBlockRemoval 102
4.11.2.2Specific3-PhaseMainVoltageInputTerminalBlockRemoval-TTS300/TGS230 102
4.11.2.33-PhaseMainVoltageInputTerminalBlockRemoval-TTS/TGS/TTH/TGH(Except
TTS300/TGS230) 103
4.11.2.43-PhaseMainVoltageInputTerminalBlockInstallation-TTS300/TGS230 104
4.11.2.53-PhaseMainInputTerminalBlockInstallation-TTH/TGH/TTH/TGH(ExceptTTS300/TGS230) 105
4.11.2.6General3-PhaseMainVoltageInputTerminalBlockInstallation 106
4.11.2.7TerminalBlockTorqueSpecifications 106
M-SV-001-EN Rev. H-1/23/2023 Page 5 of 294

4.12InputMainsBusBars 108
4.12.1InputMainsBusBarRemoval 108
4.12.1.1GeneralMainsBusBarRemoval 108
4.12.2InputMainsBusBarInstallation 109
4.12.2.1GeneralMainsBusBarInstallation 110
4.12.3ACBusBarTorqueSpecifications 110
4.13TerminalBlockFuseReplacement 111
4.13.1VerificationofTerminalBlockFuse 111
4.13.2TerminalBlockFuseRemovalandInstallation 111
4.13.2.1TerminalBlockFuseRemoval 111
4.13.2.2TerminalBlockFuseInstallation 112
4.14SoftStart 113
4.14.1SoftStartConnections 114
4.14.2SoftStartVerification 115
4.14.2.1VerifyingSoftStartVoltages 115
4.14.2.2VerifyingSoftStartFuses 116
4.14.3SoftStartRemovalandInstallation 117
4.14.4SoftStartRemoval(Closed-Top) 117
4.14.5SoftStartRemoval(Open-Top) 119
4.14.6SoftStartInstallation(Closed-Top) 121
4.14.7SoftStartInstallation(Open-Top) 122
4.14.8SoftStartFanRemovalandInstallation 123
4.14.9SoftStartFanRemoval 123
4.14.10SoftStartFanInstallation 124
4.14.10.1SoftStartTorqueSpecifications 125
4.15SCRDCBusBar-TTS300/TGS230 126
4.15.1SCRDCBusBarRemovalandInstallation 126
4.15.1.1SCRDCBusBarRemoval-TTS300/TGS230 126
4.15.1.2SCRDCBusBarInstallation-TTS300/TGS230 126
4.15.1.3SCRDCBusBarTorqueSpecifications 127
4.16SoftStartSCRGateCable 128
4.16.1SoftStartSCRGateCableConnections 128
4.16.2SoftStartSCRGateCableRemovalandInstallation 128
4.16.2.1SoftStartSCRGateCableRemoval 128
4.16.2.2SoftStartSCRGateCableInstallation 130
4.17SoftStartAC/DCHarness 132
4.17.1SoftStartAC/DCHarnessConnections 132
4.17.2SoftStartAC/DCHarnessRemovalandInstallation 133
4.17.2.1SoftStartAC/DCHarnessRemoval-TTS300/TGS230 133
4.17.2.2SoftStartAC/DCHarnessRemoval-TTS/TGS/TTH/TGH(ExceptTTS300/TGS230) 136
Page 6 of 294 - M-SV-001-EN Rev. H 1/23/2023

4.17.2.3SoftStartAC/DCHarnessInstallation-TTS300/TGS230 137
4.17.2.4SoftStartAC/DCHarnessInstallation-TTS/TGS/TTH/TGH(ExceptTTS300/TGS230) 138
4.17.2.5SoftStartAC/DCHarnessTorqueSpecifications 140
4.18Silicone-ControlledRectifier 141
4.18.1SCRConnections 141
4.18.2SCRVerification 142
4.18.2.1DiodesVerification-Two-HoleMount 142
4.18.2.2DiodesVerification-Four-HoleMount 143
4.18.2.3GatesVerification 144
4.18.2.4SCRTemperatureSensor 144
4.18.2.5SCRTemperatureSensorVerification 144
4.18.2.6SCRTemperatureSensorGeneralRemoval 145
4.18.2.7SCRTemperatureSensorRemoval-TTS300/TGS230 145
4.18.2.8SCRTemperatureSensorRemoval-TTS/TGS/TTH/TGHRev.FandEarlier(ExceptTTS300/TGS230) 146
4.18.2.9SCRTemperatureSensorInstallation-TTS300/TGS230 148
4.18.2.10SCRTemperatureSensorInstallation-TTS/TGS/TTH/TGHRev.FandEarlier(Except
TTS300/TGS230) 148
4.18.2.11SCRTemperatureSensorGeneralInstallation 148
4.18.2.12SCRTemperatureSensorTorqueSpecifications 148
4.18.3SCRRemovalandInstallation 149
4.18.3.1SCRGeneralRemoval 149
4.18.3.2SCRRemoval-TTS300/TGS230 149
4.18.3.3SCRRemoval-TTS/TGS/TTH/TGH(ExceptTTS300/TGS230) 150
4.18.3.4SCRInstallation-TTS300/TGS230 153
4.18.3.5SCRInstallation-TTS/TGS/TTH/TGH(ExceptTTS300/TGS230) 155
4.18.3.6SCRGeneralInstallation 156
4.18.3.7SCRTorqueSpecifications 156
4.19SCRCoolingManifold 157
4.19.1SCRCoolingManifoldGeneralRemovalSteps 157
4.19.2SCRCoolingManifoldSpecificRemovalSteps-TTS300/TGS230 157
4.19.3SCRCoolingManifoldSpecificRemovalSteps-TTS/TGS/TTH/TGH(ExceptTTS300/TGS230) 159
4.19.4SCRCoolingManifoldSpecificInstallationSteps-TTS300/TGS230 160
4.19.5SCRCoolingManifoldSpecificInstallationSteps-TTS/TGS/TTH/TGH(ExceptTTS300/TGS230) 160
4.19.6SCRCoolingManifoldGeneralInstallationSteps 162
4.19.7SCRCoolingManifoldTorqueSpecifications 162
4.20SnubberCapacitors 164
4.21DCCapacitorBusBarAssembly 165
4.21.1DCCapacitorDCBusBarConnections 166
4.21.2DCBusVoltageVerification 167
4.21.2.1BleedResistorVerification 167
4.21.2.2SnubberCapacitorVerification 167
4.21.3DCCapacitorBusBarAssemblyRemovalandInstallation 168
4.21.4DCCapacitorBusBarAssemblyGeneralRemoval 168
M-SV-001-EN Rev. H-1/23/2023 Page 7 of 294

4.21.4.1DCCapacitorBusBarAssemblyRemoval-TTS300/TGS230 168
4.21.4.2DCCapacitorBusBarAssemblyRemoval-TTS/TGS/TTH/TGH(ExceptTTS300/TGS230) 170
4.21.4.3DCCapacitorBusBarAssemblyInstallation-TTS300/TGS230 174
4.21.4.4DCCapacitorBusBarAssemblyInstallation-TTS/TGS/TTH/TGH(ExceptTTS300/TGS230) 174
4.21.5DCCapacitorBusBarAssemblyGeneralInstallationSteps 174
4.21.6DCCapacitorBusBarAssemblyTorqueSpecifications 174
4.22Inverter 176
4.22.1InverterConnections 176
4.22.2InverterVerification 176
4.22.3InverterCableHarness 177
4.22.4InverterCableHarnessRemovalandInstallation 177
4.22.4.1InverterCableHarnessRemoval 177
4.22.4.2InverterCableHarnessInstallation 178
4.22.5InverterCableHarnessTorqueSpecifications 179
4.22.6InverterRemovalandInstallation 179
4.22.6.1CompressorSpecificInverterRemovalSteps-TTS300/TGS230 179
4.22.6.2CompressorSpecificInverterRemovalSteps-TTS/TGS/TTH/TGH(ExceptTTS300/TGS230) 182
4.22.6.3CompressorSpecificInverterInstallationSteps-TTS300/TGS230 185
4.22.6.4CompressorSpecificInverterInstallationSteps-TTS/TGS/TTH/TGH(ExceptTTS300/TGS230) 187
4.22.7InverterCardReplacement 188
4.22.7.1InverterCardRemoval 188
4.22.7.2InverterControlCardInstallation 189
4.22.8InverterTorqueSpecifications 192
4.23MotorComponents 194
4.23.1Function 194
4.23.1.1Stator 194
4.23.1.2Rotor 194
4.23.2MotorProtection 194
4.23.3MotorConnections 194
4.23.4MotorVerification 195
4.23.4.1StatorInsulationVerification 195
4.23.4.2StatorResistanceVerification 195
4.23.4.3StatorThermistorResistanceVerification 195
4.23.5MotorComponentsRemovalandInstallation 196
4.23.5.1MotorBusBarRemoval 196
4.23.5.2MotorBusBarInstallation 197
4.23.5.3CopperTubeRemoval 198
4.23.5.4CopperTubeInstallation 198
4.23.5.5MotorCoverPlateRemoval 198
4.23.5.6MotorCoverPlateInstallation 199
4.23.5.7HighPowerFeedthroughRemoval 200
4.23.5.8High-PowerFeedthroughInstallation 202
4.23.5.9MotorAssemblyTorqueSpecifications 203
Page 8 of 294 - M-SV-001-EN Rev. H 1/23/2023

4.24HighVoltageDC-DCConverter 204
4.24.1DC-DCConverterFunction 204
4.24.2DC-DCConverterVerification 204
4.24.2.1InputVoltageVerification 204
4.24.2.2OutputVoltageVerification 204
4.24.2.3InputResistanceMeasurement 205
4.24.2.4OutputResistanceMeasurement 205
4.24.3DC-DCRemovalandInstallation 206
4.24.3.1DC-DCTorqueSpecifications 208
4.24.4DC-DCSupplyCableHarness 209
4.24.5DC-DCHarnessRemovalandInstallation 209
4.24.5.1DC-DCHarnessRemoval 209
4.24.5.2DC-DCHarnessInstallation 210
4.25Backplane 211
4.25.1BackplaneFunction 211
4.25.2BackplaneConnectionsandTestPoints 211
4.25.2.1LEDLocations 213
4.25.2.2BackplaneVerification 214
4.25.3BackplaneRemovalandInstallation 215
4.25.3.1BackplaneRemoval 215
4.25.3.2BackplaneInstallation 216
4.25.3.3BackplaneTorqueSpecifications 216
4.26SerialDriver 217
4.26.1SerialDriverFunction 217
4.26.2SerialDriverConnections 217
4.26.3SerialDriverVerification 217
4.26.3.1SerialDriverInputVoltage 217
4.26.3.2SerialDriverOutputVoltageVerification 218
4.26.4SerialDriverRemovalandInstallation 218
4.26.4.1SerialDriverRemoval 218
4.26.4.2SerialDriverInstallation 218
4.27BMCC 220
4.27.1BMCCConnections 220
4.27.2BMCCVerification 220
4.27.2.1BMCCPowerVerification 220
4.27.2.2BMCCCommunicationVerification 220
4.27.3BMCCBatteryandVerification 221
4.27.3.1BMCCBatterySafety 221
4.27.3.2BMCCBatteryVerification 221
4.27.4BMCCRemovalandInstallation 222
4.27.4.1BMCCRemoval 222
4.27.4.2BMCCInstallation 223
M-SV-001-EN Rev. H-1/23/2023 Page 9 of 294

4.28BearingPulseWidthModulatorAmplifier 225
4.28.1PWMFunction 225
4.28.2PWMConnections 226
4.28.3PWMVerification 226
4.28.3.1VerifyiftheBearingPWMAmplifierisDrainingEnergy 227
4.28.3.2VerifyFunctionalityoftheFiveOutputChannels 227
4.28.3.3VerifyFunctionalityoftheFiveDiodeSets 227
4.28.4PWMRemovalandInstallation 228
4.28.4.1PWMAmplifierRemoval 228
4.28.4.2PWMAmplifierInstallation 229
4.28.4.3PWMTorqueSpecifications 229
4.29MagneticBearings 230
4.29.1MagneticBearingsFunction 230
4.29.2MagneticBearingsConnections 230
4.29.3BearingVerification 230
4.29.3.1BearingCoilVerification 230
4.29.3.2BearingCurrentVerification 232
4.29.4BearingPowerFeedthroughRemovalandInstallation 233
4.29.4.1BearingPowerFeedthroughRemoval 233
4.29.4.2BearingPowerFeedthroughInstallation 234
4.29.4.3MagneticBearingTorqueSpecifications 235
4.30BearingSensors 236
4.30.1BearingSensorFunction 236
4.30.2BearingSensorConnection 236
4.30.3BearingSensorVerification 236
4.30.3.1BearingSensorResistanceVerification 236
4.30.3.2BearingSensorCableVerification 237
4.30.4BearingSensorCableRemovalandInstallation 238
4.30.5BearingSensorFeedthroughRemovalandInstallation 239
4.30.5.1BearingSensorFeedthroughRemoval 239
4.30.5.2BearingSensorFeedthroughInstallation 240
4.30.5.3BearingSensorTorqueSpecifications 241
4.31CavityTemperatureSensor 242
4.31.1CavityTemperatureSensorFunction 242
4.31.2CavityTemperatureSensorConnections 242
4.31.3CavityTemperatureSensorVerification 242
4.31.4CavityTemperatureSensorRemovalandInstallation 243
4.31.4.1CavityTemperatureSensorRemoval 243
4.31.4.2CavityTemperatureSensorInstallation 243
4.31.4.3CavitySensorTorqueSpecifications 244
4.32Pressure/TemperatureSensor 245
Page 10 of 294 - M-SV-001-EN Rev. H 1/23/2023

4.32.1Pressure/TemperatureSensorFunction 245
4.32.2Pressure/TemperatureSensorConnections 245
4.32.3Pressure/TemperatureSensorVerification 246
4.32.4Pressure/TemperatureSensorRemovalandInstallation 247
4.32.4.1SuctionPressure/TemperatureSensorRemoval 247
4.32.4.2SuctionPressure/TemperatureSensorInstallation 248
4.32.4.3DischargePressure/TemperatureSensorRemoval 248
4.32.4.4DischargePressure/TemperatureSensorInstallation 248
4.32.4.5InterstagePressure/TemperatureSensorRemoval(TTH/TGHCompressorsOnly) 249
4.32.4.6InterstagePressure/TemperatureSensorInstallation(TTH/TGHCompressorsOnly) 249
4.32.4.7Pressure/TemperatureSensorTorqueSpecifications 249
Chapter 5.0 lTroubleshooting 251
5.1AlarmandFaultIndications 251
5.1.1AlarmTypes 251
5.1.2FaultTypes 251
5.2TroubleshootingwiththeServiceMonitoringToolsSoftware 254
5.2.1CompressorFaultTroubleshooting 254
5.2.2Motor/SystemFaultsTroubleshooting 260
5.2.3BearingFaultTroubleshooting 263
5.3BearingCalibration 263
5.3.1WhentoCalibratetheBearings 263
5.3.1.1CalibrationwhenCommissioning 263
5.3.1.2RegularMaintenanceCalibration 264
5.3.1.3CalibrationwhenTroubleshooting 264
5.3.1.4BMCCChange 264
5.3.2PerformingaCalibration 264
5.3.2.1BeforePerformingaCalibration 264
5.3.2.2Calibration 264
5.3.3AfterCalibrationisComplete 265
5.3.3.1Validate 265
5.3.3.2SavetoEEPROM 266
5.3.4CreateaCalibrationReport 266
5.3.5CalibrationReportAnalysis 266
5.4SMTCompressorConnectionStatusIndications 269
5.5SystemandCompressorLevelTroubleshooting 269
5.5.1CompressorVoltageTroubleshooting 269
5.5.2DeterminingtheCauseofanEnergyDrain 271
5.5.2.1DeterminingifSerialDriverisDrainingEnergy 271
5.5.2.2DeterminingifBMCCisDrainingEnergy 271
5.5.2.3DetermineifPWMisDrainingEnergy 272
5.5.2.4DeterminingifInverterisDrainingEnergy 272
M-SV-001-EN Rev. H-1/23/2023 Page 11 of 294

5.5.2.5DeterminingifCompressorI/OBoardisDrainingEnergy 272
5.5.2.6DeterminingtheCauseofBlownSoftStartFuses(Closed-TopSoftStartOnly) 272
5.5.3TroubleshootinganOpenInterlock 273
5.5.4TroubleshootingtheInverter 273
Chapter 6.0 Maintenance 275
6.1PreventativeMaintenanceTasks 275
6.2MoisturePreventionMeasures 276
6.2.1RequiredItems 276
6.2.1.1ServiceSideDisassembly 276
6.2.1.2ServiceSideAssembly 277
6.2.1.3TopSide 278
Appendix A Acronyms/Terms 279
Appendix B Compressor Troubleshooting Flowcharts 281
Appendix C Compressor Test Sheet 287
Page 12 of 294 - M-SV-001-EN Rev. H 1/23/2023

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later
compressors
F.1 06-10-2019 15/16 UpdatedTypecodefigures
1-1and1-2.
F.2 11-10-2019 18-19,&28 UpdatedTGS490
compressorwithR515B
refrigerant.
F.2 11-10-2019 36 Removedheliumand
changedtheinertgas
pressureto15psi.
F.2 11-10-2019 98 UpdatedF4andF5fuse
description.
G 05-27-2020 All Manualupdatedtoinclude
allMajorRevisionH
changes.
H 12-23-2022 All Manualeditedand
improvedforcontentand
completeness
M-SV-001-EN Rev. H-1/23/2023 Page 13 of 294

Page 14 of 294 - M-SV-001-EN Rev. H 1/23/2023
THIS PAGE INTENTIONALLY LEFT BLANK

Proprietary Notice
Copyright,LimitationsofLiabilityandRevisionRights.
Thispage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 an opportunity for improvements while reading this manual? Email us at
[email protected] with a brief description.
*Subjecttochangewithoutnotice.
*DanfossTurbocor’scommitmenttoexcellenceensurescontinuousproductimprovements.
M-SV-001-EN Rev. H-1/23/2023 Page 15 of 294

Page 16 of 294 - M-SV-001-EN Rev. H 1/23/2023
THIS PAGE INTENTIONALLY LEFT BLANK

Chapter 1.0 Introduction
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.
1.1 Application
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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foracompletedescriptioninthenewdesign.
Figure 1-1 Old to New Type Code

M-SV-001-EN Rev. H-1/23/2023 Page 17 of 294

Figure 1-2 New Type Code


Page 18 of 294 - M-SV-001-EN Rev. H 1/23/2023

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).
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:
lAgeneraldescriptionofthecompressordesign
lAfunctionaldescriptionofthevariouscomponentsofthecompressor
lInformationregardingproceduresnecessarytodetectthesourceofaproblemwithinthe
compressor
lTheproceduresfordisassemblingandassemblingvariouscomponentsofthecompressor
lFaultandcalibrationinterpretations
lSystemtroubleshootingsuggestions
NOTE
Bearingandbearingsensorrepairsarenotcoveredinthismanualastheyarenotfieldserviceable.Compressorsrequiringsuchrepairs
mustbesentbacktothefactoryforinspectionandrepair.

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,regardlessofthecompressorrevision.
DanfossLLCdoessellvariousupgradekits(e.g.,SoftStartUpgradeKit)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.
1.3 Organization
Thismanualisorganizedinthefollowingmanner:
lSection 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
lSection 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
lSection 3: Compressor Removal and Installation–thissectiondescribesthesafepracticesof
removingandinstallingthecompressor
lSection 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
M-SV-001-EN Rev. H-1/23/2023 Page 19 of 294

lSection 5: Troubleshooting–thissectiondescribestroubleshootingusingsignalsfromthe
compressortodeterminethespecificsourceoffaultsatthesystemandcompressorlevel
lSection 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
lAppendix A: Acronyms/Terms–thissectionprovidesdefinitionsoftermsandacronymsusedin
thismanual
lAppendix B:Compressor Troubleshooting Flowcharts –thissectioncontainsflowchartstoassist
youwithcompressortroubleshooting
lAppendix 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:
lProcedures–alluserproceduresarelistedinnumericalsteps,unlessitisaone-stepprocedure.A
one-stepprocedureisshownasabullet.
lUser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.
lMonitoringProgramWindowNames–allwindownameswillbeinitalic.ExampleCompressor
Controller window.
lInternal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.
lExternalReferences–referencestoitemsnotwithinthismanualareunderlined.Example;Referto
theTTS/TGS/TTH/TGHApplicationsManualforinstallationprocedures.

1.4 Commitment to Quality and the Environment
DanfossTurbocorCompressors(DTC)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long-term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! • • •

Page 20 of 294 - M-SV-001-EN Rev. H 1/23/2023